Carrier Air Compressor 48A2 User Manual

48A2,A3,A4,A5020-060  
Single-Package Rooftop  
Gas Heating/Electric Cooling Units  
with COMFORTLINK™ Controls and Scroll Compressors  
User’s Information Manual  
NOTE TO INSTALLER  
TO LIGHT UNIT  
This manual should be left with the equipment owner.  
DANGER  
1. Do not turn off the electrical power to unit without  
first turning off the gas supply.  
2. Before attempting to start the gas heating section,  
familiarize yourself with all the procedures that must  
be followed.  
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  
• Do not try to light any appliance.  
3. 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.  
If you do not follow these instructions exactly, a fire or  
explosion may result, causing property damage, injury, or  
loss of life.  
• 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.  
• If you cannot reach your gas sup-  
plier, call the fire department.  
See Fig. 1 and 2 for location of gas valve. Refer to Fig. 3  
while performing the following steps.  
1. Disable unit operation by using the scrolling marquee.  
The scrolling marquee is located in the control box at the  
compressor end of the unit.  
— Installation and service must be per-  
formed by a qualified installer, service  
agency or the gas supplier.  
ESCAPE  
a. Push the  
is shown.  
key unit a blank display screen  
b. Push the  
lit.  
key until the SERVICE TEST LED is  
c. Push the ENTER key. The display will show  
STOP.  
WARNING  
NOTE: Items in the Configuration and Service  
Test modes are password protected. The display  
will flash PASS and WORD when required. Use  
the ENTER and arrow keys to enter the 4 digits of  
the password. The default password is 1111.  
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.  
ENTER  
or  
d. Push the  
key again. The NO/YES display  
key to toggle the display to  
will flash.  
e. Push the  
ENTER  
YES and then push  
. The unit will be  
WARNING  
locked off from heating, cooling or any operation.  
The controls will still function and the display will  
still operate.  
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.  
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.  
Your combination heating/cooling unit is equipped with  
direct spark ignition and induced draft power combustion  
blower.  
4. Remove the gas section panels.  
5. Move the switch on the gas valve to the OFF position and  
wait 5 minutes.  
WARNING  
NOTE: If this is the first installation of the unit, the gas  
flue hoods must be installed before operating unit. These  
must be installed for the unit to run properly.  
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.  
Catalog No. 04-53480052-01 Printed in U.S.A. Form 48A-5SO Pg 1 3-08 Replaces: 48A-3SO  
Book 1  
Tab 1a  
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a48-925tf  
MODE  
Run Status  
Service Test  
Temperature  
a30-2239ef  
Pressures  
Setpoints  
Inputs  
Alarm Status  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
a48-924tf  
STEP 1  
STEP 2  
STEP 3  
a48-3767tf  
STEP 4  
STEP 5  
a48-3768tf  
STEP 6  
STEP 7  
MODE  
Run Status  
Service Test  
Temperature  
a30-2239ef  
Pressures  
Setpoints  
Inputs  
Alarm Status  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
a48-931tf  
a48-930tf  
STEP 8  
STEP 9  
STEP 10  
Fig. 3 — To Light Unit  
3
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6. Move the switch on the gas valve to the ON position.  
7. Replace the gas section access panels.  
ENTER  
and arrow keys to enter the 4 digits of the  
password. The default password is 1111.  
8. Turn on the electrical supply to the units.  
9. Open the field-installed manual gas valve.  
10. Using the scrolling marquee, enable the unit to run using  
the following procedure:  
ENTER  
or  
d. Push the  
key again. The NO/YES display  
key to toggle the display to  
will flash.  
e. Push the  
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.  
a. Push the ESCAPE key unit a blank display screen  
is shown.  
b. Push the  
lit.  
key until the SERVICE TEST LED is  
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.  
ENTER  
c. Push the  
STOP.  
key. The display will show  
d. Push the ENTER key again. The NO/YES display  
will flash.  
4. Remove the gas section panels.  
5. Move the switch on the gas valve to the OFF position and  
wait 5 minutes before doing any service in the section or  
on the piping.  
e. Push the  
or  
key to toggle the display to  
ENTER  
NO and then push  
normal operation and exit Service Test mode.  
. The unit will return to  
6. Replace gas section access panels.  
7. If unit is being shut down because of a malfunction, call  
11. To test the operation of the gas section, use the scrolling  
marquee Service Test routine to energize the gas outputs  
and to turn on the gas. Refer to 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 CV (constant volume)  
units with a space temperature sensor, make sure that the  
set points are at the normal heat set points.  
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.  
WARNING  
If the main burners fail to light or the blower fails 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.  
MAINTAINING YOUR UNIT  
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 SHUT UNIT OFF  
WARNING  
To ensure proper functioning of the unit, the flow of com-  
bustion and ventilating air must not be obstructed from reach-  
ing the unit. Clearance of at least 4 ft on flue and condenser  
sides and 6 in. on all other sides is required.  
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.  
ROUTINE MAINTENANCE AND CARE  
FOR THE EQUIPMENT OWNER  
Failure to follow these procedures can result in serious  
fire or personal injury.  
Consider the following information before maintaining or  
servicing equipment:  
Refer to Fig. 4 while performing the following steps:  
WARNING  
1. Disable unit operation by using the scrolling marquee.  
The scrolling marquee is located in the control box at the  
compressor end of the unit.  
1. TURN OFF GAS SUPPLY AND THEN ELECTRI-  
CAL POWER TO YOUR UNIT BEFORE SERVIC-  
ING OR PERFORMING MAINTENANCE.  
2. Do not turn off electrical power to this unit without  
first turning off the gas supply.  
a. Push the ESCAPE key unit a blank display screen  
is shown.  
3. 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.  
b. Push the  
lit.  
key until the SERVICE TEST LED is  
ENTER  
c. Push the  
STOP.  
key. The display will show  
NOTE: Items in the configuration and Service Test  
modes are password protected. The display will  
flash PASS and WORD when required. Use the  
Failure to follow these procedures can result in serious  
fire or personal injury.  
4
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a48-925tf  
MODE  
Run Status  
Service Test  
Temperature  
a30-2239ef  
Pressures  
Setpoints  
Inputs  
Alarm Status  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
a48-924tf  
STEP 1  
STEP 2  
STEP 3  
a48-3767tf  
STEP 4  
a48-3768tf  
STEP 5  
STEP 6  
Fig. 4 — To Shut Unit Off  
5
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Air Filter(s) — Air filter(s) should be checked monthly  
and changed when necessary. Units may have either 2-in. or  
4-in. thick filters. For units with 2-in. thick filters, all filters will  
be 20 x 24 x 2-in. size. For units with 4-in. thick filters, half the  
filters will be 20 x 24 x 4-in. size and half will be 20 x 20 x  
4-in. size. The filter access panel is located at the end of the unit  
opposite of the condenser section. The access door is labeled to  
indicate that it is the filter access door.  
To replace or inspect filters:  
1. Loosen the 3 latches securing the filter access door and  
open door.  
Indoor-Fan Motor, Outdoor-Fan Motor, and  
Combustion Fan Motor — Lubrication is not recom-  
mended. 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 — The bearings should be greased  
with Shell Alvania no. 2 grease or equivalent. The bearings  
will need to be greased annually, dependent on fan usage. Do  
not grease more than once a year.  
Evaporator and Condenser Coils — Cleaning of  
the coils should be done by qualified service personnel.  
Contact your dealer for the required annual maintenance.  
2. Remove the bolt securing the inner access panel, located  
behind the filter access door, using care not to lose the  
bolt.  
3. Remove the inner access panel.  
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.  
4. Slide the black plastic filter retainer towards you and  
remove.  
5. Remove filters by pulling toward you and away from the  
filter track.  
6. A filter removal rod is shipped taped to the partition  
located near the bottom filter track. The filter removal rod  
will aid in the removal of filters beyond the reach of the  
service person.  
Compressor — All compressors are factory supplied with  
a normal charge of the correct type of refrigeration-grade oil in  
them and should not require additional oil.  
Condenser Fan  
WARNING  
7. Inspect or replace filters.  
8. Return filters to filter tracks. Note direction of airflow  
arrows on filter frame.  
Do not poke sticks, screwdrivers, or any other object into  
revolving fan blades. Severe bodily injury may result.  
9. Reinstall the black plastic filter retainer.  
10. Place the filter removal rod back on the partition for  
future use.  
11. Reinstall inner panel.  
12. Reinstall bolt securing the inner panel.  
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 con-  
trols are difficult to check without proper instrumentation. If  
there are any discrepancies in the operating cycle, contact your  
dealer and request service.  
13. Close filter access panel and tighten latches.  
If you have difficulty in locating your air filter or if you  
have questions concerning proper filter maintenance, contact  
your dealer for instructions. 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 with steam or hot water and a mild deter-  
gent. Do not use throwaway filters in place of cleanable filters.  
Refrigerant Circuit — The refrigerant circuit is difficult  
to check for leaks without the proper equipment. If inadequate  
cooling is suspected, contact your local 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 im-  
proper performance if allowed to build up.  
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.  
CAUTION  
If your unit makes any unusual or especially loud noises  
during heating, shut down the heating section and call your  
dealer.  
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, the  
flue collector box, and the flue collector box cover. When  
finished, the gas controls assembly must be reinstalled for  
proper operation. Also, the flue collector box cover must be  
replaced correctly so that a proper seal is maintained. Refer to  
unit installation instructions for correct procedure. Contact  
your dealer for the required periodic maintenance.  
See Fig. 1 and 2 and proceed as follows to inspect the com-  
bustion area and power-venting system of your unit.  
1. Turn off gas supply to your unit.  
2. Turn off electrical power to your unit.  
3. Remove gas section access panels.  
4. 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.  
Fans and Belts — Periodically check the condition of  
the fan wheels and housings, and belt tension. When service is  
necessary, call your dealer.  
5. When you have completed your inspection, follow the To  
Light Unit section in this manual to restore your unit to  
operation.  
6
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6. Observe unit heating operation. Watch the burner flame  
to see if it is bright blue. If you observe a suspected mal-  
function or if the flame is not bright blue, call your dealer.  
Complete service instructions can be found in the unit  
Controls, Start-Up, Operation, Service and Troubleshooting  
literature.  
WARNING  
BEFORE YOU CALL FOR SERVICE,  
CHECK FOR PROBLEMS  
Components in heat section may be hot after unit has been  
started. When observing flame, be careful not to get close  
to or touch heating components. Serious personal injury  
may result.  
THAT CAN BE EASILY SOLVED  
If insufficient heating or cooling is suspected:  
(
) Check for sufficient airflow. Check the air filter for dirt.  
Check for blocked return 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:  
7. Replace gas section access panels.  
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.  
(
) If using a thermostat, check to be sure that your thermo-  
stat temperature set point is above the indoor temperature dur-  
ing the heating season, or below the indoor temperature during  
the cooling season. Be sure the thermostat mode is in the  
proper AUTO, HEAT, or COOL mode and not in the OFF  
mode.  
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:  
(
) Check scrolling marquee to be sure unit is not in Service  
Test mode and that unit has not been disabled. Check set points  
are properly set.  
1. Inspection of all flue product passages — including the  
burners, heat exchanger, and flue collector box.  
2. Inspection of all combustion and ventilation-air passages  
and openings.  
3. Close inspection of all gas pipes leading to and inside  
your unit.  
4. Inspection and if required, cleaning of the condenser and  
evaporator coils.  
5. Inspection and if required, cleaning of the condensate  
drain pan.  
6. Inspection and cleaning of blower wheel housing and  
motor.  
7. Inspection of all supply and return-air ducts for leaks, ob-  
structions, and insulation integrity. Any problems found  
should be resolved at the time of inspection.  
8. Inspection of the unit base for cracks, gaps, etc., which  
may cause a hazardous condition.  
(
) Is the electrical supply switch ON? Are any fuses blown  
or has the circuit breaker tripped?  
) During the heating season, check the external manual  
(
shutoff 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. Remove the gas section  
access panels.  
(
) During the heating season, check the switch 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 no safety hazards  
are present, 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  
valuable time through knowledgeable preparation for the  
service call.  
9. Inspection of the unit casing for signs of deterioration.  
10. Inspection of all electrical wiring and components to  
ensure proper connection.  
11. Inspection for leaks in the refrigerant circuit. Pressure-  
check to determine appropriate refrigerant charge.  
IN CASE OF TROUBLE  
12. Inspection of fan wheels and housings, belt tension, and  
fan motor shaft bearings.  
If, after performing the above checks, unit performance is  
unsatisfactory, shut off the unit and call your dealer.  
13. Operational check of the unit to determine working  
conditions. Repair or adjustment should be made at the  
time of inspection.  
Your servicing dealer may offer an economical service con-  
tract that covers seasonal inspections. Ask for further details.  
Dealer’s Name _____________________________________  
Telephone No. _____________________________________  
Unit Model _______________________________________  
Unit Serial Number _________________________________  
7
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Copyright 2008 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Catalog No. 04-53480052-01  
Printed in U.S.A.  
Form 48A-5SO  
Pg 8  
3-08  
Replaces: 48A-3SO  
Book 1  
Tab 1a  
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