Carrier Heating System 48PG03 16 User Manual

48PG03-16  
Gas Heating/Electric Cooling Units  
with PURON® (R-410A) Refrigerant  
User’s Information Manual  
NOTE TO INSTALLER:  
CONTENTS  
Page  
This manual should be left with the equipment owner.  
DETERMINE TYPE OF UNIT CONTROL . . . . . . . . . . . . . . 1  
TO LIGHT UNIT (Units with Electro-Mechanical  
Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
TO LIGHT UNIT (Units with ComfortLink™  
WARNING: If the information in this manual  
is not followed exactly, a fire or explosion  
may result causing property damage, per-  
sonal injury or loss of life.  
Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5  
TO SHUT UNIT OFF (Units with  
Electro-Mechanical Control). . . . . . . . . . . . . . . . . . . . . . . 5  
TO SHUT UNIT OFF (Units with ComfortLink  
— Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8  
MAINTAINING YOUR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
ROUTINE MAINTENANCE AND CARE FOR  
— WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
• Do not touch any electrical switch; do  
not use any phone in your building.  
• Immediately call your gas supplier  
from a neighbor’s phone. Follow the  
gas supplier’s instructions.  
THE EQUIPMENT OWNER. . . . . . . . . . . . . . . . . . . . . . . 8,9  
Air Filter(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Alarm Status (Units with ComfortLink Control) . . . . . . 8  
Integrated Gas Controller (IGC) . . . . . . . . . . . . . . . . . . . . . 9  
Combustion Area and Vent System . . . . . . . . . . . . . . . . . 9  
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Evaporator, Condenser, and  
Combustion Fan Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Indoor Fan, Belt, and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . 9  
Indoor Fan Shaft Bearings (Sizes 03-14). . . . . . . . . . . . . 9  
Indoor Fan Shaft Bearings (Size 16) . . . . . . . . . . . . . . . . . 9  
Refrigerant Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Evaporator and Condenser Coils. . . . . . . . . . . . . . . . . . . . 9  
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Condenser Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Electrical Controls and Wiring. . . . . . . . . . . . . . . . . . . . . . . 9  
Unit Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
REGULAR DEALER MAINTENANCE. . . . . . . . . . . . . . . . 10  
BEFORE YOU CALL FOR SERVICE CHECK FOR  
SEVERAL EASILY SOLVED PROBLEMS. . . . . . . . . . 10  
IN CASE OF TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
• If you cannot reach your gas supplier,  
call the fire department.  
— Installation and service must be per-  
formed by a qualified installer, service  
agency or the gas supplier.  
Improper installation, adjustment, alteration, ser-  
vice or maintenance can cause injury or property  
damage. Refer to this manual. For assistance or  
additional information consult a qualified installer,  
service agency, or the gas supplier.  
DETERMINE TYPE OF UNIT CONTROL  
The procedures used to light or shut off the unit depend on  
the type of unit control. This section will help determine the  
control type of the unit.  
Before performing recommended maintenance, be sure  
main power switch to unit is turned off and lockout tag is  
installed. Electrical shock could cause personal injury.  
Electro-Mechanical Control — These units may be  
controlled directly by a thermostat, or indirectly by a third-  
party control that connects to the thermostat inputs. For direct  
thermostat control, use the Electro-Mechanical Control  
procedures in this book. For units with third-party controls  
connected to the thermostat inputs, refer to the third-party con-  
trol instructions for procedures to ensure complete unit shut off.  
Your combination heating/cooling unit is equipped with di-  
rect spark ignition and induced draft power combustion blower.  
ComfortLink Control — These units have a factory-  
installed Carrier ComfortLink control. A Scrolling Marquee  
display is located on the front of the unit control box behind the  
control box and compressor access door. These units may be  
controlled directly by a thermostat, directly by a space temper-  
ature sensor, or indirectly through other Carrier Comfort  
Network® (CCN) communication devices. To ensure complete  
unit shut off, use the ComfortLink Control procedures in this  
book.  
Burners will light automatically. Do not attempt to light by  
hand; personal injury may result.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 111 Catalog No. 04-53480006-01 Printed in U.S.A. Form 48PG-5SO Pg 1 8-05 Replaces: 48PG-4SO  
Book 1  
4
Tab 1a 6a  
 
MAIN  
ON  
OFF  
LOCK-OUT  
G
TA  
STEP 1  
STEP 2  
STEP 3  
STEP 4  
STEP 5  
STEP 6  
STEP 7  
STEP 9  
STEP 8  
STEP 10  
Fig. 2 — To Light Unit (Units with Electro-Mechanical Control)  
3
 
MAIN  
ON  
MODE  
Run Status  
Service Test  
Temperature  
Pressures  
Setpoints  
Inputs  
Alarm Status  
OFF  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
LOCK-OUT  
G
TA  
STEP 1  
STEP 2  
STEP 3  
STEP 4  
STEP 5  
STEP 6  
STEP 7  
STEP 9  
STEP 8  
MODE  
Run Status  
Service Test  
Temperature  
Pressures  
Setpoints  
Inputs  
Alarm Status  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
STEP 10  
Fig. 3 — To Light Unit (Units with ComfortLink™ Control)  
4
 
Step 8 — Remove lockout tag and turn on the electrical  
supply to unit. Normal operation will automatically begin.  
Service Test mode will automatically end (exit) after a recycle  
of power.  
TO SHUT UNIT OFF  
(Units with ComfortLink™ Control)  
Step 9 — Open the shutoff valve on the gas supply piping.  
Do not turn off the electrical power to unit without first  
turning off the gas supply.  
Failure to follow these procedures can result in serious  
fire or personal injury.  
Step 10 — To test the operation of the gas section, the  
HEAT submenu of Service Test may be used. See the Controls,  
Start-Up, Operation, Service, and Troubleshooting Instructions  
for more details on use of Service Test.  
See Fig. 1 for location of gas valve. Refer to Fig. 5 while  
proceeding with the following steps.  
Step 11 — For normal operation, make sure that the set  
points are at the normal heat set points.  
Step 1 — Turn off the unit operation by using the Scrolling  
Marquee to put the unit into Service Test mode. The Scrolling  
Marquee is located on the front of the unit control box behind  
the control box and compressor access door (see Fig. 6).  
Thermostat inputs and remote network commands are ignored  
when Service Test mode is ON.  
a. A password may be required to change Service Test  
values depending on previous settings configured in the  
unit. Default password is “1111.”  
If the main burners fail to light, or the blower fails to come  
on, shut down gas heating section and call your dealer for  
service. Failure to follow these requirements could result in  
serious personal injury.  
TO SHUT UNIT OFF  
(Units with Electro-Mechanical Control)  
ESCAPE  
b. Press the  
c. Use the arrow keys to scroll the red LED on the display  
to the “Service Test” position and press  
key until a blank screen is shown.  
.
ENTER  
d. The control will display the Field Service Test Mode  
(TEST) setting. Press once to select the TEST  
Do not turn off the electrical power to unit without first  
turning off the gas supply.  
Failure to follow these procedures can result in serious  
fire or personal injury.  
ENTER  
setting for configuration. Press  
“OFF” to begin flashing.  
again for  
ENTER  
e. Use the arrow keys to change the configuration from  
See Fig. 1 for location of gas valve. Refer to Fig. 4 while  
proceeding with the following steps.  
ESCAPE  
to  
“OFF” to “ON,” then press  
save the setting.  
and  
ENTER  
Step 1 — Set room thermostat to lowest temperature setting  
and set SYSTEM switch to OFF position.  
Step 2 — Close the shutoff valve on the gas supply piping.  
Step 2 — Close the shutoff valve on the gas supply piping.  
Step 3 — Turn off the electrical power supply to the unit  
and install lockout tag.  
Step 3 — Turn off the electrical power supply to the unit  
and install lockout tag.  
Step 4 — Open the heat section access panel.  
Step 4 — Open the heat section access panel.  
Step 5 — Move ON/OFF switch on the internal gas valve  
to the OFF position.  
Step 5 — Move ON/OFF switch on the internal gas valve  
to the OFF position.  
Step 6 — Close the heat section access panel.  
Step 6 — Close the heat section access panel.  
Step 7 — If unit is being shut down because of a malfunc-  
tion, call your dealer as soon as possible.  
Step 7 — If unit is being shut down because of a malfunc-  
If unit is being shut down because the heating season has  
ended, restore electrical power to the unit to ensure operation  
of the cooling system during the cooling season.  
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 any gas control  
which has been under water.  
tion, 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 to ensure operation  
of the cooling system during the cooling season.  
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 any gas control  
which has been under water.  
5
 
MAIN  
ON  
OFF  
LOCK-OUT  
G
TA  
STEP 1  
STEP 2  
STEP 3  
STEP 5  
STEP 4  
STEP 7  
STEP 6  
Fig. 4 — To Shut Unit Off (Units with Electro-Mechanical Control)  
6
 
MAIN  
ON  
MODE  
Run Status  
Service Test  
Temperature  
Pressures  
Setpoints  
Inputs  
OFF  
Alarm Status  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
LOCK-OUT  
G
TA  
STEP 1  
STEP 2  
STEP 3  
STEP 5  
STEP 4  
STEP 7  
STEP 6  
Fig. 5 — To Shut Unit Off (Units with ComfortLink™ Control)  
7
 
CONTROL BOX  
AND COMPRESSOR  
ACCESS DOOR  
INDOOR MOTOR  
ACCESS DOOR  
OUTDOOR AIR  
SCREEN  
CONDENSER COIL  
ACCESS DOOR  
GAS SECTION  
ACCESS DOOR  
FILTER ACCESS  
DOOR  
Fig. 6 — Panel and Filter Locations (48PG03-07 Shown)  
MAINTAINING YOUR UNIT  
track. See Fig. 6 for filter access panel location. Note the direc-  
tion of flow arrows on the filter frame.  
All maintenance should be handled by skilled, experienced  
personnel. Your dealer can help you establish a standard  
procedure.  
For your safety, keep the area around the unit clear and free  
of combustible materials, gasoline and other flammable liquids  
and vapors.  
To assure proper functioning of the unit, flow of combustion  
and ventilating air must not be obstructed from reaching the  
unit. Clearance of at least 6 ft on all sides is required.  
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. When  
replacing your unit filters, always use the correct size and  
quantity as shown in Table 1. Filter tracks are field convertible  
for 2 or 4-in. thick filters. Verify airflow and duct static values,  
and related motor sizing and belt drive adjustment, if filter type  
or efficiency rating is changed from the original installation.  
Units with outdoor air capability have cleanable screens for  
the outdoor air. These screens should be checked annually and  
cleaned as necessary.  
ROUTINE MAINTENANCE AND CARE  
FOR THE EQUIPMENT OWNER  
Before proceeding with those things you might want to  
maintain yourself, please carefully consider the following:  
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.  
1. TURN OFF GAS SUPPLY AND ELECTRICAL  
POWER TO YOUR UNIT BEFORE SERVICING  
OR PERFORMING MAINTENANCE.  
Table 1 — Indoor Air Filter Data  
2. Do not turn off electrical power to this unit without  
first turning off the gas supply.  
UNIT 48PG FILTER QUANTITY  
FILTER SIZE (in.)  
3. When opening access doors 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 to a minimum,  
be extremely careful when handling parts or reaching  
into the unit.  
03-07  
08-14  
16  
4
6
8
16 x 25 x 2 or 16 x 25 x 4  
20 x 25 x 2 or 20 x 25 x 4  
20 x 20 x 2 or 20 x 20 x 4  
Alarm Status (Units with ComfortLink™ Con-  
trol) — The Scrolling Marquee display incorporates an  
Alarm Status LED that turns on to indicate an active alarm or  
alert. These alarms and alerts are in addition to those that  
are indicated by the Integrated Gas Control (IGC). The  
ComfortLink control active alarm codes and alarm history can  
be viewed with the Scrolling Marquee or other Carrier Comfort  
Network® (CCN) devices. Alarms may also be configured to  
broadcast automatically on CCN. If the unit will not operate  
Air Filter(s) — 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 filter access panel to replace or inspect the  
filters. All units have filter tracks into which the filters slide.  
Remove the filters by pulling the filter slide outward from the  
8
 
and the Alarm Status LED is on, contact the local dealer and  
request service.  
exchanger involves removing the gas controls assembly and  
the flue collector box cover and, when completed, reinstalling  
the gas controls assembly for proper operation. The flue collec-  
tor box cover must be reinstalled correctly so that a proper seal  
is maintained. Contact your dealer for the required periodic  
maintenance.  
Integrated Gas Controller (IGC) — The IGC board  
incorporates an LED that emits a flashing light to indicate an  
alarm code. If the furnace section will not operate and the LED  
is flashing a code (1 to 9 flashes in succession), contact your  
dealer and request service.  
Evaporator, Condenser, and Combustion Fan  
Motors — The indoor fan, outdoor fan, and combustion fan  
motors have permanently sealed bearings, so no field lubrica-  
tion is necessary.  
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.  
Indoor Fan, Belt, and Pulleys — Periodically check  
the condition of the fan wheel(s), pulleys, fan belt and the belt  
tension. If there is any loose part or belt wear, contact your  
dealer and request service.  
Indoor Fan Shaft Bearings (Sizes 03-14) — The  
indoor fan has permanently sealed bearings, so no field lubrica-  
tion is necessary.  
If your unit makes an especially loud noise when the main  
burners are ignited, shut down the heating section and call  
your dealer.  
Indoor Fan Shaft Bearings (Size 16) — Lubri-  
cate bearings at least every 6 months with suitable bearing  
grease. Typical lubricants are given below:  
See Fig. 1 and proceed as follows to inspect the combustion  
area and power-venting system of your unit.  
1. Turn off electrical power (install disconnect tag) and gas  
supply to your unit.  
2. Open burner compartment access panel.  
3. Using a flashlight, carefully inspect the burner areas for  
dirt, soot, or scale.  
MANUFACTURER  
LUBRICANT  
Texaco  
Mobil  
Sunoco  
Texaco  
Regal AFB-2*  
Mobilplex EP No. 1  
Prestige 42  
Multifak 2  
*Preferred lubricant because it contains rust and oxidation inhibitors.  
Refrigerant Circuits — The refrigerant circuits are dif-  
ficult to check for leaks without the proper equipment; there-  
fore, if inadequate cooling is suspected, contact your dealer for  
service.  
If dirt, soot, rust or scale accumulations are found, call your  
dealer and do not operate your heating section.  
Evaporator and Condenser Coils — Cleaning of the  
coils should only be done by qualified service personnel. Con-  
tact your dealer for the required annual maintenance.  
4. When you have completed your inspection, follow the  
start-up procedures in this manual to restore your unit to  
operation.  
5. Observe unit heating operation, and watch the burner  
flame with the access panel removed to see if it is bright  
blue. If you observe a suspected malfunction, or that the  
burner flames are not bright blue, call your dealer. See  
Fig. 7. Some yellow flame may be present due to the pan-  
el being removed.  
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 refrigerant grade oil.  
No field lubrication is necessary except possibly with repair or  
replacement of refrigerant circuit components.  
6. Close burner compartment access panel.  
Condenser Fan  
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.  
Fig. 7 — Proper Flame Appearance  
ElectricalControls and Wiring — Electrical controls  
are difficult to check without proper instrumentation; therefore,  
if there are any discrepancies in the operating cycle, contact  
your dealer and request service.  
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  
Unit Panels — After performing any maintenance or  
service on the unit, be sure all panels are securely fastened in  
place to prevent rain from entering unit cabinet and to prevent  
disruption of the correct unit airflow pattern.  
9
 
REGULAR DEALER MAINTENANCE  
BEFORE YOU CALL FOR SERVICE CHECK  
FOR SEVERAL EASILY SOLVED PROBLEMS  
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, combustion baffles, heat exchanger, flue collec-  
tor 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.  
If insufficient heating or cooling is suspected:  
(
) Check for sufficient airflow. Check the air filter for dirt.  
Check for blocked return-air or supply-air grilles. Be sure they  
are open and unobstructed. 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:  
(
) If using a thermostat, check to be sure that your thermo-  
stat temperature selector is set above the indoor temperature  
during the heating season, or below the indoor temperature  
during the cooling season. Be sure the SYSTEM switch in the  
proper HEAT or COOL position and not in the OFF position.  
4. Inspection, and if required, cleaning of the condenser and  
evaporator coils.  
5. Inspection, and if required, cleaning of the evaporator  
drain pan.  
(
) If using ComfortLink™ control, check Scrolling Mar-  
quee to be sure unit is not in SERVICE TEST mode. Check set  
points are properly set.  
(
) Is the electrical supply switch on? Are any fuses blown,  
or has the circuit breaker tripped?  
) During the heating season, check the manual gas shutoff  
6. Inspection, cleaning, and lubrication of blower wheel  
housing and motor.  
7. Inspection of all supply-air and return-air ducts for leaks,  
obstructions, and insulation integrity. Any problems  
found should be resolved at this time.  
8. Inspection of the unit base to ensure that no cracks, gaps,  
etc., exist which may cause a hazardous condition.  
9. Inspection of the unit casing for signs of deterioration.  
10. Inspection of all electrical wiring and components to  
assure proper connection.  
11. Inspection for leaks in the refrigerant circuit. Pressure-  
check to determine appropriate refrigerant charge  
12. Operational check of the unit to determine working con-  
ditions. Repair or adjustment should be made at this time.  
(
valve. Is this lever parallel with the pipe, indicating that the  
valve is open? Or is the lever at the 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.  
(
) During the heating season, check the control dial on the  
gas valve. Is it in the ON position? If it is not, be sure it has not  
been turned off for the purpose of safety. If nothing else is  
incorrect, follow the start-up procedures 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.  
13. 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 unit  
Installation, Start-Up and Service Instructions.  
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 _________________________________  
10  
 
 
Copyright 2005 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 111 Catalog No. 04-53480006-01 Printed in U.S.A. Form 48PG-5SO Pg 12 8-05 Replaces: 48PG-4SO  
Book 1  
4
Tab 1a 6a  
 

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