CARRIER Package Units(both Units Combined) Manual L1001389

User Manual: CARRIER CARRIER Package Units(both units combined) Manual CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides

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Installation Instructions

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

PAGE

SAFETY CONSIDERATIONS ......................... 1

INTRODUCTION ................................... 2

RECEIVING AND INSTALLATION ................. 2-14

Check Equipment .................................. 2

Identify Unit .................................... 2

Inspect Shipment ................................. 2

Provide Unit Support ............................... 2

Roof Curb ...................................... 2

Slab Mount ..................................... 2

Field Fabricate Ductwork ............................ 2

Provide Clearances ................................. 3

Rig and Place Unit ................................. 7

Connect Condensate Drain ........................... 8

Install Flue Hood ................................... 8

Install Gas Piping .................................. 8

Install Duct Connections ............................. 9

Configuring Units for Downflow (Vertical)

Discharge ...................................... 9

Install Electrical Connections ........................ 13

High-Voltage Connections ........................ 13

Special Procedures for 208-V Operation .............. 13

Control Voltage Connections ....................... 13

Balance Point Setting Thermidistat or Hybrid Heat

Thermostat .................................... 14

Transformer Protection ........................... 14

PRE-START-UP ................................... 14

START-UP ..................................... 15-19

Check for Refrigerant Leaks ......................... 15

Unit Sequence of Operation ......................... 15

Start-Up Heating and Make Adjustments ............... 15

Checking Heating Control ......................... 16

Check Gas Input ................................ 16

Adjust Gas Input ................................ 16

Check Burner Flame ............................. 17

Start-Up Cooling and Make Adjustments ............... 18

Checking Cooling Control Operation ................ 18

Checking and Adjusting Refrigerant ................. 18

Indoor Airflow and Airflow Adjustments ............. 18

Continuous Fan Operation ........................ 19

MAINTENANCE ................................ 29-35

Air Filter ........................................ 29

Indoor Blower and Motor ........................... 29

Flue Gas Passageways .............................. 30

Limit Switch ..................................... 30

Burner Ignition ................................... 30

Main Burners .................................... 30

Outdoor Coil, Indoor Coil, & Condensate Drain Pan ...... 30

A0g033

Fig. 1 - Unit 48VT-A

Outdoor Fan ..................................... 31

Electrical Controls and Wiring ....................... 31

Refrigerant Circuit ................................. 31

Gas Input ........................................ 32

Indoor Airflow ................................... 32

Check Defrost Thermostat ........................... 32

Puron® Items .................................... 32

TROUBLESHOOTING .............................. 35

START-UP CHECKLIST ............................ 35

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-BI49.1 and .2 Natural Gas and Propane

Installation codes, and Canadian Electrical Code CSA C22A

Recognize safety information. This is the safety-alert symbol /_.

When you see this symbol on the unit and in instructions or manu-

als, be alert to the potential for personal injury. Understand these

signalwords:DANGER,WARNING,andCAUTION.These

wordsareusedwiththesafety-alertsymbol.DANGERidentifies

themostserioushazardswhichwill result in severe personal iniury

or death. WARNING signifies hazards which could result in per-

sonal injury or death. CAUTION is used to identify unsafe practic-

es which may result in minor personal injury or product and prop-

erty damage. NOTE is used to highlight suggestions which will

result in enhanced installation, reliability, or operation.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

iniury or death.

Before installing or servicing system, always turn off main

power to system. There may be more than one disconnect

switch. Turn off accessory heater power switch if

applicable. TAG THE DISCONNECT SWITCH WITH A

SUITABLE WARNING LABEL.

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury, death or property damage.

A qualified installer or agency must use only

factory-authorized kits or accessories when modifying this

product.

CUT HAZARD

Failure to follow this caution may result in personal iniury.

When removing access panels (see Fig. 19) or performing

maintenance functions inside your unit, be aware of sharp

sheet metal parts and screws. Although special care is taken

to reduce sharp edges to a minimum, be extremely careful

when handling parts or reaching into the unit.

INTRODUCTION

The 48VT-A unit (see Fig. 1) is a fully self-contained,

combination Category I gas heating/electric heating and cooling

unit designed for outdoor installation (See Fig. 2 and 3 for unit

dimensions). All unit sizes have return and discharge openings for

both horizontal and downflow configurations, and are factory

shipped with all downflow duct openings covered. Units may be

installed either on a rooftop, a cement slab, or directly on the

ground, if local codes permit (See Fig. 4 for roof curb dimensions).

Models with an N in the fifth position of the model number are

dedicated Low NOx units designed for California installations.

These models meet the California maximum oxides of nitrogen

(NOx) emissions requirements of 40 nanograms/joule or less as

shipped from the factory and must be installed in California Air

Quality Management Districts or any other regions in North

America where a Low NOx rule exists.

RECEIVING AND INSTALLATION

Step 1-- Check Equipment

IDENTIFY UNIT

The unit model number and serial number are stamped on the unit

information plate. Check this information against shipping papers.

INSPECT SHIPMENT

Inspect for shipping damage before removing packaging materials.

If unit appears to be damaged or is torn loose from its anchorage,

have it examined by transportation inspectors before removal.

Forward claim papers directly to transportation company.

Manufacturer is not responsible for any damage incurred in transit.

Check all items against shipping list. Immediately notify the

nearest equipment distribution office if any item is missing. To

prevent loss or damage, leave all parts in original packages until

installation.

If the unit is to be mounted on a curb in a downflow application,

review Step 9 to determine which method is to be used to remove

the downflow panels before rigging and lifting into place. The

panel removal process may require the unit to be on the ground.

Step 2 -- Provide Unit Support

For hurricane tie downs, contact distributor for details and PE

(Professional Engineering) Certificate if required.

ROOF CURB

Install accessory roof curb in accordance with instructions shipped

with curb (See Fig. 4). Install insulation, cant strips, roofing, and

flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is

critical for a water tight seal. Install gasketing material supplied

with the roof curb. Improperly applied gasketing also can result in

air leaks and poor unit performance.

Curb should be level to within 1/4 in. (6 mm). This is necessary for

unit drain to function properly. Refer to accessory roof curb

installation instructions for additional information as required.

Installation on older "G" series roof curbs.

Two accessory kits are available to aid in installing anew "G"

series unit on an old "G" roof curb.

1. Accessory kit number CPADCURB001A00, (small chassis)

and accessory kit number CPADCURB002A00, (large

chassis) includes roof curb adapter and gaskets for the

perimeter seal and duct openings. No additional

modifications to the curb are required when using this kit.

2. An alternative to the adapter curb is to modify the existing

curb by removing the outer horizontal flange and use

accessory kit number CPGSKTKIT001A00 which includes

spacer blocks (for easy alignment to existing curb) and

gaskets for the perimeter seal and duct openings. This kit is

used when existing curb is modified by removing outer

horizontal flange.

UNIT/STRUCTURAL DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Ensure there is sufficient clearance for saw blade when cutting

the outer horizontal flange of the roof curb so there is no

damage to the roof or flashing.

SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4

in. (102 mm) thick with 2 in. (51 mm) above grade. The slab

should be flush on the compressor end of the unit (to allow

condensate drain installation) and should extend 2 in. (51 mm) on

the three remaining sides of the unit. Do not secure the unit to the

slab except when required by local codes.

Step 3-- Field Fabricate Ductwork

Secure all ducts to roof curb and building structure on vertical

discharge units. Do not connect ductwork to unit. For horizontal

applications, unit is provided with flanges on the horizontal

openings. All ductwork should be secured to the flanges. Insulate

and weatherproof all external ductwork, joints, and roof openings

withcounterflashingandmasticinaccordancewithapplicable

codes.

Ductspassingthroughanunconditionedspacemustbeinsulated

andcoveredwithavaporbarrier.

If aplenumreturnisusedonaverticalunit,thereturnshouldbe

ductedthroughtheroofdecktocomplywithapplicablefirecodes.

Readunitratingplateforanyrequiredclearancesaroundductwork.

Cabinetreturn-airstaticshallnotexceed-.25IN.W.C.

Step 4-- Provide Clearances

The required minimum operating and service clearances are shown

in Fig. 2 and 3.

IMPORTANT: Do not restrict outdoor airflow. An air restriction

at either the outdoor-air inlet or the fan discharge may be

detrimental to compressor life.

The condenser fan pulls air through the condenser coil and

discharges it through the top grille. Be sure that the fan discharge

does not recirculate to the condenser coil. Do not locate the unit in

either a corner or under an overhead obstruction. The minimum

clearance under a partial overhang (such as a normal house

overhang) is 48-in. (1219 mm) above the unit top. The maximum

horizontal extension of a partial overhang must not exceed 48-in.

(1219 mm).

Do not place the unit where water, ice, or snow from an overhang

or roof will damage or flood the unit. Do not install the unit on

carpeting or other combustible materials. The unit may be installed

on wood flooring or on Class A, B, or C roof covering materials.

sl>I_-Jl_-_

_l i, r

is i • x

o__o_ _ _ o_

F-

s /i

N...............................................i .........

°Ki'

_ o _

k_ SNo_

Fig. 2 - 48VT-A24-30 Unit Dimensions

<\ii

A09416

-ii _,__

> Q

0 , _

i_,,<,

[_J

i_ 'ii_ -

.....................,;_;.............................

o_>

Fig. 3 - 48VT-A36-60 []nit Dimensions

A09417

HVACunitI

baserails

Anchor screw j

Flashing field

supplied _

Gasket

j Roofcurb

Wood nailer*

/Roofcurb*

Insulation

/(field supplied)

Roofing material

field supplied

Cant strip _/ t

A09090

ROOF CURB DETAIL

SMALL CURB A09418

F A

LARGE CURB A09415

A09419

B C D F

IN. (mm)* IN. (mm) IN. (mm) IN. (mm)

UNIT SIZE

Small

Large

NOTES:

CATALOG

NUMBER

CPRFCURB010A00

CPRFCURB011A00

CPRFCURB012A00

CPRFCURB013A00

IN. (mm)

11 (279)

14 (356)

11 (279)

14 (356)

10 (254)

14 (356)

16 (406) 47.8

(1214)

1. Roof curb must be set up for unit being installed.

2. Seal strip must be applied, as required, to unit being installed.

3. Roof curb is made of 16-gauge steel.

4. Attach ductwork to curb (flanges of duct rest on curb).

5. Insulated panels: 1-in. (25.4 mm) thick fiberglass 1 lb. density.

IMPORTANT: Do not install large base pan HYBRID HEAT

units onto the small base pan (common curb). The center of gravity

on a large base pan HYBRID HEAT unit could overhang the curb

causing an unsafe condition. Before installing any large base pan

unit onto the common curb, check the "Y" distance in the product

Fig. 4 - Roof Curb Dimensions

IN. (mm)

32.4 (822)

43.9

(1116)

2.7 (69)

G H

IN. (mm) IN. (mm)

30.6 (778)

46.1 (1170)

42.2 (1072)

literature dimensional drawing to ensure that "Y" is greater than 14

in. (356 ram). Do not install any large base pan unit onto the

common curb with a "Y" dimension (center of gravity) less than 14

in. (356 mm).

JMINIMUM HEIGHT: 36" (9!4.4 ram)

HAUTEUR MINIMUM

DUCTS

SEE DE,TAIL A

VOIB DETAIL A

UNIT HEIGHT

HAUTEUR D'UNITEJ"

DETAIL A

VOIR DIETAIL A

SEAL STRIP MUST BE IN BANDE SCELLANT BOIT ETRE

PLACE BEFORE PLACING EN PL,_C E AVANT DE PLACER

UNIT ON ROOF CURB L=U NITE SUR LA BASE DE TOIT

50CY502286 2,0

A09051

24 30 36

Unit Unit

Ib kg Ib kg Ib kg Ib

Rigging 374 170 366 166 Rigging 448 203 494

Weight Weight

42 48 60

kg Ib kg Ib kg

224 514 233 548 249

NOTE: See dimensional drawing for corner weight distribution.

Fig. 5 -48VT-A Suggested Rigging

Step 5 -- Rig and Place Unit Inspection

PERSONAL INJURY OR PROPERTY DAMAGE

HAZARD

Failure to follow this warning could result in personal

iniury, death or property damage.

When installing the unit on a rooftop, be sure the roof will

support the additional weight.

Rigging and handling of this equipment can be hazardous for

many reasons due to the installation location (roofs, elevated

structures, etc.).

Only trained, qualified crane operators and ground support staff

should handle and install this equipment.

When working with this equipment, observe precautions in the

literature, on tags, stickers, and labels attached to the equipment,

and any other safety precautions that might apply.

Training for operators of the lifting equipment should include, but

not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the

lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting

kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work

gloves.

Prior to initial use, and at monthly intervals, all rigging shackles,

clevis pins, and straps should be visually inspected for any

damage, evidence of wear, structural deformation, or cracks.

Particular attention should be paid to excessive wear at hoist

hooking points and load support areas. Materials showing any kind

of wear in these areas must not be used and should be discarded.

UNIT FALLING HAZARD

Failure to follow this warning could result in personal

iniury or death.

Never stand beneath rigged units or lift over people.

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal

iniury/death or property damage.

When straps are taut, the clevis should be a minimum of 36

in. (914 mm) above the unit top cover.

Ri_gin_/Liftin_ of Unit (See Fi_. 5)

Lifting holes are provided in base rails as shown in Fig. 2 and 3.

1. Leave top shipping skid on the unit for use as a spreader bar

to prevent the rigging straps from damaging the unit. If the

skid is not available, use a spreader bar of sufficient length

to protect the unit from damage.

2. Attach shackles, clevis pins, and straps to the base rails of

the unit. Be sure materials are rated to hold the weight of the

unit (See Fig. 5).

3. Attach a clevis of sufficient strength in the middle of the

straps. Adjust the clevis location to ensure unit is lifted level

with the ground.

After the unit is placed on the roof curb or mounting pad, remove

the top skid.

Step 6-- Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Model 48VT-A disposes of condensate water through a 3/4 in.

NPT fitting which exits through the compressor access panel (See

Fig. 2 and 3for location).

Condensate water can be drained directly onto the roof in rooftop

installations (where permitted) or onto a gravel apron in ground

level installations. Install a field-supplied condensate trap at end

of condensate connection to ensure proper drainage. Make sure that

the outlet of the trap is at least 1 in. (25 mm) lower than the

drain-pan condensate connection to prevent the pan from

overflowing (See Fig. 6). Prime the trap with water. When using a

gravel apron, make sure it slopes away from the unit.

If the installation requires draining the condensate water away

from the unit, install a 2-in. (51 mm) trap at the condensate

connection to ensure proper drainage (See Fig. 6). Make sure that

the outlet of the trap is at least 1 in. (25 mm) lower than the

drain-pan condensate connection. This prevents the pan from

overflowing.

Prime the trap with water. Connect a drain tube - using a minimum

of 3/4-in. PVC or 3/4-in. copper pipe (all field-supplied) - at the

outlet end of the 2-in. (51 mm) trap. Do not undersize the tube.

Pitch the drain tube downward at a slope of at least 1-in. (25 mm)

for every 10 fl (3 m) of horizontal run. Be sure to check the drain

tube for leaks.

l-in. (25 ram) rain.

TRAP

@1 mm) min.

A09052

Fig. 6 - Condensate Trap

Step 7 -- Install Flue Hood

The flue assembly is secured and shipped in the return air duct.

Remove duct cover to locate the assembly (See Fig. 8).

NOTE: Dedicated low NOx models MUST be installed in

California Air Quality Management Districts where a Low NOx

rule exists.

These models meet the California maximum oxides of nitrogen

(NOx) emissions requirements of 40 nanograms/joule or less as

shipped from the factory.

NOTE: Low NOx requirements apply only to natural gas

installations.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury or death.

The venting system is designed to ensure proper venting.

The flue hood assembly must be installed as indicted in this

section of the unit installation instructions.

Install the flue hood as follows:

1. This installation must conform with local building codes

and with the National Fuel Gas Code (NFGC) NFPA 54 /

ANSI Z223A, (in Canada, CAN/CGA BI49A, and

B149.2) latest revision. Refer to Provincial and local

plumbing or wastewater codes and other applicable local

codes.

2. Remove flue hood from shipping location (inside the return

section of the blower compartment-see Fig. 8). Remove the

return duct cover to locate the flue hood. Place flue hood

assembly over flue panel. Orient screw holes in flue hood

with holes in the flue panel.

3. Secure flue hood to flue panel by inserting a single screw on

the top flange and the bottom flange of the hood.

Step 8-- Install Gas Piping

The gas supply pipe enters the unit through the access hole

provided. The gas connection to the unit is made to the l/2-in.

(12.7 mm) FPT gas inlet on the gas valve.

Install a gas supply line that runs to the heating section. Refer to

Table 2 and the NFGC for gas pipe sizing. Do not use cast-iron

pipe. It is recommended that a black iron pipe is used. Check the

local utility for recommendations concerning existing lines. Size

gas supply piping for 0.5 IN. W.C. maximum pressure drop. Never

use pipe smaller than the l/2-in. (12.7 mm) FPT gas inlet on the

unit gas valve.

For natural gas applications, the gas pressure at unit gas connection

must not be less than 4.0 IN. W.C. or greater than 13 IN. W.C.

while the unit is operating. For propane applications, the gas

pressure must not be less than 11.0 IN. W.C. or greater than 13 IN.

W.C. at the unit connection.

A l/8-in. (3.2 mm) NPT plugged tapping, accessible for test gauge

connection, must be installed immediately upstream of the gas

supply connection to the gas valve.

When installing the gas supply line, observe local codes pertaining

to gas pipe installations. Refer to the NFGC NFPA 54/ANSI

Z223.1 latest edition (in Canada, CAN/CGA B149.1).

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed

plumber or gas fitter.

2. When flexible connectors are used, the maximum length

shall not exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoff valves

are used, they shall be T-handle valves.

4. The use of copper tubing for gas piping is NOT approved

by the state of Massachusetts.

In the absence of local building codes, adhere to the following

pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.

(6.35 mm) for every 15 ft (4.6 m) of length to prevent traps.

Grade all horizontal runs downward to risers. Use risers to

connect to heating section and to meter.

2. Protect all segments of piping system against physical and

thermal damage. Support all piping with appropriate straps,

hangers, etc. Use a minimum of one hanger every 6 ft (1.8

m). For pipe sizes larger than 1/2 in., (12.7 mm) follow

recommendations of national codes.

3. Apply joint compound (pipe dope) sparingly and only to

male threads of joint when making pipe connections. Use

only pipe dope that is resistant to action of liquefied

petroleum gases as specified by local and/or national codes.

Never use Teflon tape.

4. Install sediment trap in riser leading to heating section (See

Fig. 7). This drip leg functions as a trap for dirt and

condensate,

TEE

NIPPLE

CAP

C99020

Fig. 7 - Sediment Trap

5. Install an accessible, external, manual main shutoff valve in

gas supply pipe within 6 fl (1.8 m) of heating section.

6. Install ground-joint union dose to heating section between

unit manual shutoff and external manual main shut-off

valve.

7. Pressure test all gas piping in accordance with local and

national plumbing and gas codes before connecting piping

to unit.

NOTE: Pressure test the gas supply system after the gas supply

piping is connected to the gas valve. The supply piping must be

disconnected from the gas valve during the testing of the piping

systems when test pressure is in excess of 0.5 psig. Pressure test the

gas supply piping system at pressures equal to or less than 0.5 psig.

The unit heating section must be isolated from the gas piping

system by dosing the external main manual shutoff valve and

slightly opening the ground-joint union.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury,

death and/or property damage.

-Connect gas pipe to unit using a backup wrench to avoid

damaging gas controls.

-Never purge a gas line into a combustion chamber. Never

test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of

leaks to check all connections.

-Use proper length of pipe to avoid stress on gas control

manifold.

-If a flexible connector is required or allowed by authority

having jurisdiction, black iron pipe shall be installed at

furnace gas valve and extend a minimum of 2 in. (51 mm)

outside furnace casing.

-If codes allow a flexible connector, always use a new

connector, do not use a connector which has previously

serviced another gas appliance.

8. Check for gas leaks at the field-installed and

factory-installed gas lines after all piping connections have

been completed. Use a commercially available soap solution

made specifically for the detection of leaks (or method

specified by local codes and/or regulations).

Step 9-- Install Duct Connections

The unit has duct flanges on the supply- and return-air openings

on the side and bottom of the unit. For downshot applications, the

ductwork connects to the roof curb (See Fig. 2 and 3 for

connection sizes and locations).

Configuring Units for Downflow (Vertical) Discharge

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury

or death.

Before installing or servicing system, always turn off main

power to system. There may be more than one disconnect

switch. Tag the disconnect switch with a suitable warning

label.

1. Open all electrical disconnects before starting any servace

work.

2. Remove horizontal (metal) duct covers to access vertical

(downflow) discharge duct knockouts in unit basepan. (See

Fig. 8.)

3. Using Fig. 9 as a guide, proceed to cut out the downflow

duct panels.

4. Drill 1/2 in. (13 mm) diameter or larger holes in all four

corners of duct panels.

NOTE: On large chassis units remove sheet metal shields on

panels by using a crew driver to shear off retainers and discard.

5. On left and side supply duct opening side with keyhole or

single bladed hacksaw cut out panel along "V" groove.

6. On right side, with keyhole or single blade hacksaw, with

teeth facing up and starting from the front and moving to

the rear, cut along "V" groove.

7. Now with three sides cut, flex panel up and down to re-

move.

8. Replace side access panel and duct cover.

9. After completing unit conversion, perform all safety checks

and power up unit.

Alternate Method

1. Open all electrical disconnects and install lockout tag before

starting any service work.

2. Remove horizontal (metal) ductcovers to access vertical

(downflow) discharge duct knockouts in unit basepan. (See

Fig. 8.)

3. Leave top shipping crate on unit during this method.

4. Tip unit over on the front side (access panels) so the bottom

of the base pan is accessible.

5. Drill two holes diagonally opposed, of suitable size to ac-

commodate jigsaw or reciprocating saw. (See Fig. 9.)

NOTE: On large chassis units remove sheet metal shields on

panels by using a screw driver to shear off retainers and discard.

[]NIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the

unit being installed.

When cutting duct panels, do not contact or damage any

internal components (heat exchanger, electric heat). Do not

use a saw blade that protrudes more than 1 in. (25 mm) into

unit.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Collect ALL screws that were removed. Do not leave screws

on rooftop as permanent damage to the roof may occur.

6. Using a suitable saw cut along "V" groove and remove duct

panels.

7. Tip unit back onto its base and replace duct covers.

8. After completing unit conversion, perform all safety checks

and power up unit.

NOTE: The design and installation of the duct system must be in

accordance with the standards of the NFPA for installation of

nonresidence-type air conditioning and ventilating systems, NFPA

90A or residence-type, NFPA 90B; and/or local codes and

ordinances.

Adhere to the following criteria when selecting, sizing, and

installing the duct system:

1. Units are shipped for horizontal duct installation (by

removing duct covers).

2. Select and size ductwork, supply-air registers, and

return-air grilles according to American Society of Heating,

Refrigeration and Air Conditioning Engineers (ASHRAE)

recommendations.

3. Use flexible transition between rigid ductwork and unit to

prevent transmission of vibration. The transition may be

screwed or bolted to duct flanges. Use suitable gaskets to

ensure weather tight and airtight seal.

4. All units must have field-supplied filters or accessory filter

rack installed in the return-air side of the unit.

Recommended sizes for filters are shown in Table 1.

5. Size all ductwork for maximum required airflow (either

heating or cooling) for unit being installed. Avoid abrupt

duct size increases or decreases or performance may be

affected.

Table 1 - Physical Data - Unit 48VT-A

Unit Size 24040 24060 30040 30060 36060 36090

Nominial Capacity -ton 2 2 2.5 2.5 3 3

Shipping Weight (Ib) 354 354 346 346 426 426

(kg) 161 161 157 157 193 193

Compressor Quantity 1

Type Scroll

Refrigerant R- 41 OA

Refrigerant Quantity (Ib) 11.1 11.1 10.3 10.3 9.9 9.9

Quantity (kg) 5.0 5.0 4.7 4.7 4.5 4.5

Refrigerant Metering Device Indoor TXV, Outdoor Dual Accuraters

Orofice OD (in) 0.032 (2) 0.032 (2) 0.037 (2) 0.037 (2) 0.038 (2) 0.038 (2)

(mm) 0.81 (2) 0.81 (2) 0.94 (2) 0.94 (2) 0.97 (2) 0.97 (2)

Outdoor Coil

Rows... Fins/in, 2...21 2...21 2...21 2...21 2...21 2...21

face area (sq. ft.) 13.6 13.6 13.6 13.6 13.6 13.6

Outdoor Fan

Nominal Airflow (cfm) 2500 2500 2700 2700 31 O0 31 O0

Diameter (in.) 24 24 24 24 26 26

Diameter (mm) 610 610 610 610 660 660

Motor hp (rpm) 1/10 (810) 1/10 (810) 1/5 (810) 1/5 (810) 1/5 (810) 1/5 (810)

Indoor Coil

Rows... Fins/in, 3...17 3...17 3...17 3...17 3...17 3...17

face area (sq. ft.) 3.7 3.7 3.7 3.7 4.7 4.7

Indoor Blower

Nominal Airflow (cfm) 800 800 1000 1000 1200 1200

Size (in.) lOx 10 lOx 10 lOx 10 lOx 10 11 x 10 11 x 10

Size (mm) 254 x 254 254 x 254 254 x 254 254 x 254 279 x 254 279 x 254

Motor hp 1/2 1/2 1/2 1/2 3/4 3/4

Furnace Section*

Burner Orifice

Natural Gas Qty...Drill Size 2...44 2...38 2...44 2...38 2...38 3...38

Propane Gas Qty...Drill Size 2...55 2...53 2...55 2...53 2...53 3...53

High Pressure Switch (psig)

Cutout 650 +/- 15

Reset (Auto) 420 +/- 25

Loss- of- Charge/Low Pressu re Switch (psig)

Cutout 20 +/- 5

Reset (Auto) 45 +/- 10

Return Air Filtersl-$

disposable (in) 20x20x1 20x24x1 24x30x1

(mm) 508x508x25 508x610x25 610x762x25

*Based on altitude of 0 to 2000 ft (0-610 m).

1-Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of

300 ft/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.

:l: If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity.

UnitSize

NominialCapacity- ton

ShippingWeight(Ib)

(kg)

CompressorQuantity

Type

Refrigerant

RefrigerantQuantity(Ib)

Quantity(kg)

RefrigerantMeteringDevice

OroficeOD(in)

(mm)

OutdoorCoil

Rows...Fins/in,

facearea(sq.ft.)

OutdoorFan

NominalAirflow(cfm)

Diameter(in.)

Diameter(mm)

Motorhp

Motor(rpm)

IndoorCoil

Rows...Fins/in,

facearea(sq.ft.)

IndoorBlower

NominalAirflow(cfm)

Size(in.)

Size(mm)

Motorhp

FurnaceSection*

BurnerOrifice

NaturalGasQty...DrillSize

PropaneGasQty...DrillSize

HighPressureSwitch(psig)

Cutout

Reset(Auto)

Loss-of-Charge/LowPressure

Switch(psig)

Cutout

Reset(Auto)

ReturnAirFiltersl-$

disposable(in)

(mm)

Table 1 - Physical Data - Unit 48VT-A Cont'd)

42080 42090 48090 48115 48130 80090 80115 80130

3.5 3.5 4 4 4 5 5 5

472 472 460 460 460 506 506 506

214 214 209 209 209 230 230 230

Scroll

R- 410A

11.3 11.3 12.5 12.5 12.5 15.2 15.2 15.2

5.1 5.1 5.7 5.7 5.7 6.9 6.9 6.9

Indoor TXV, Outdoor Dual Accuraters

0.040 (2) 0.040 (2) 0.040 (2) 0.040 (2) 0.040 (2) 0.049 (2) 0.049 (2) 0.049 (2)

1.02 (2) 1.02 (2) 1.02 (2) 1.02 (2) 1.02 (2) 1.24 (2) 1.24 (2) 1.24 (2)

2...21 2...21 2...21 2...21 2...21 2...21 2...21 2...21

17.5 17.5 17.5 17.5 17.5 23.3 23.3 23.3

31 O0

660

1/5

(81o)

31 O0

660

1/5

(81o)

31 O0

660

1/5

(81o)

31 O0

660

1/5

(81o)

31 O0

660

1/5

(81o)

3500

660

1/4

(81O)

3500

660

1/4

(81O)

3500

660

1/4

(81O)

3...17 3...17 3...17 3...17 3...17 3...17 3...17 3...17

4.7 4.7 5.6 5.6 5.6 5.6 5.6 5.6

1400 1400 1600 1600 1600 1750 1750 1750

11 xlO 11 xlO 11 xlO 11 xlO 11 xlO 11 xlO 11 xlO 11 xlO

279 x 254 279 x 254 279 x 254 279 x 254 279 x 254 279 x 254 279 x 254 279 x 254

3/4 3/4 1 1 1 1 1 1

2...38 3...38 3...38 3...33 3...31 3...38 3...33 3...31

2...53 3...53 3...53 3...51 3...49 3...53 3...51 3...49

650 +/- 15

420 +/- 25

20 +/- 5

45 +/- 10

24x30x1 24x36x1

610x762x25 610x914x25

*Based on altitude of 0 to 2000 ft (0-610 m).

1-Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of

300 ft/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.

:l: If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity.

Horizontal Duct Covers

Basepan

Downflow

(Vertical)

Supply _

Knockout

A09076

Basepan

Downflow

J (Vertical)

Return

Knockout

Fig. 8 - Supply and Return Duct Opening

A09077

Cut along

"V" grooves N

I I

Return Duct Panels

I-.IE

,IAIEIxli

: I sl AI Cl ','_

Itl HI,:

I !

Supply Duct Panels

,,7_ Cut along

'V" grooves

"_4 Drill

places

Flex up & down

to remove

Cut along "V"

I groove, teeth

facing up

--Drill 3 places

Drill 2 places

Cut along

"V" grooves

Return & Supply Duct Panels from

Underside of Base (Alternate Method)

A09420

Fig. 9-Vertical (Downflow) Discharge Duct Knockouts

Table 2 -Maximum Gas Flow Capacity*

NOMINAL INTERNAL LENGTH OF PIPE, FT (m)t

IRON DIAMETER 10 20 30 40 50 80 70 80 90 100 125 150 175 200

PIPE, SIZE (IN.) (3.0) (6.1) (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (31.1) (45.7) (53.3) (61.0)

(IN.)

1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 -- --

3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135

1- 1/4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280

1- 1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

*Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5-IN. W.C. (based on a 0.60 specific gravity gas). Refer to Table 2

and the NFGC NFPA 54/ANSI Z 223.1.

1-This length includes an ordinary number of fittings.

Table 3-Heating Inputs

GAS SUPPLY PRESSURE (IN. W.C.)

HEATING INPUT

(BTUH)

NUMBER OF

ORIFICES

40,000 2

60,000 2

90,000 3

115,000 3

130,000 3

Min

4.0

Naturalt

Max

13.0

Propane*t

Min Max

11.0 13.0

MANIFOLD PRESSURE

(IN. W.C.)

Natural1-

3.2-3.8

Propane*t

10.0-11.0

*When a unit is converted to propane, different size orifices must be used. See separate, natural-to-propane conversion kit instructions.

1-Based on altitudes from sea level to 2000 ft (610 m) above sea level. In the U.S.A. for altitudes above 2000 ft (610 m), reduce input rating 4 percent for each

additional 1000 ft (305 m) above sea level. In Canada, from 2000 ft (610 m) above sea level to 4500 ft (1372 m) above sea level, derate the unit 10 percent.

6. Adequately insulate and weatherproof all ductwork located

outdoors. Insulate ducts passing through unconditioned

space, and use vapor barrier in accordance with latest issue

of Sheet Metal and Air Conditioning Contractors National

Association (SMACNA) and Air Conditioning Contractors

of America (ACCA) minimum installation standards for

heating and air conditioning systems. Secure all ducts to

building structure.

7. Flash, weatherproof, and vibration-isolate all openings in

building structure in accordance with local codes and good

building practices.

Step 10 -- Install Electrical Connections

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury

or death.

The unit cabinet must have an uninterrupted, unbroken

electrical ground. This ground may consist of an electrical

wire connected to the unit ground screw in the control

compartment, or conduit approved for electrical ground when

installed in accordance with NEC, NFPA 70 National Fire

Protection Association (latest edition) (in Canada, Canadian

Electrical Code CSA C22.1) and local electrical codes.

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit

being installed.

1. Make all electrical connections in accordance with NEC

NFPA 70 (latest edition) and local electrical codes

governing such wiring. In Canada, all electrical

connections must be in accordance with CSA standard

C22.1 Canadian Electrical Code Part 1 and applicable

local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between

field-supplied electrical disconnect switch and unit. DO

NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within

operating voltage range indicated on unit rating plate. On

3-phase units, ensure phases are balanced within 2

percent. Consult local power company for correction of

improper voltage and/or phase imbalance.

4. Insulate low-voltage wires for highest voltage contained

within conduit when low-voltage control wires are in

same conduit as high-voltage wires.

5. Do not damage internal components when drilling

through any panel to mount electrical hardware, conduit,

etc.

Hi,h-Voltage Connections

When routing power leads into unit, use only copper wire between

disconnect and unit. The high voltage leads should be in a conduit

until they enter the duct panel; conduit termination at the duct

panel must be watertight.

The unit must have a separate electrical service with a

field-supplied, waterproof disconnect switch mounted at, or within

sight from, the unit. Refer to the unit rating plate, NEC and local

codes for maximum fuse/circuit breaker size and minimum circuit

amps (ampacity) for wire sizing.

The field-supplied disconnect switch box may be mounted on the

unit over the high-voltage inlet hole when the standard power and

low-voltage entry points are used (See Fig. 2 and 3 for acceptable

location).

See unit wiring label (Fig. 15 and 16) and Fig. 10 for reference

when making high voltage connections. Proceed as follows to

complete the high-voltage connections to the unit.

Single phase units:

1. Run the high-voltage (L1, L2) and ground lead into the

control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line side

of the contactor.

4. Connect field LI to black wire on connection 11 of the

compressor contactor.

5. Connect field wire L2 to yellow wire on connection 23 of

the compressor contactor.

Three-phase units:

1. Run the high-voltage (L1, L2, L3) and ground lead into the

control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line side

of the contactor.

4. Connect field LI to black wire on connection 11 of the

compressor contactor.

5. Connect field wire L3 to yellow wire on connection 13 of

the compressor contactor.

6. Connect field wire L2 to blue wire from compressor.

Special Procedures for 208-V Operation

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury

or death.

Make sure the power supply to the unit is switched OFF before

making any wiring changes. Tag the disconnect switch with a

suitable warning label. With disconnect switch open, move

black wire from transformer (3/16 in.) terminal marked 230 to

terminal marked 200. This retaps transformer to primary

voltaye of 208 vac.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal iniury

or death.

Before making any wiring changes, make sure the gas supply

is switched off first. Then switch off the power supply to the

unit and install lockout tag.

Control Voltage Connections

Do not use any type of power-stealing thermostat. Unit control

problems may result.

Use no. 18 American Wire Gage (AWG) color-coded, insulated

(35°C minimum) wires to make the control voltage connections

between the thermostat and the unit. If the thermostat is located

more than 100 ft (30.5 m) from the unit (as measured along the

control voltage wires), use no. 16 AWG color-coded, insulated

(35 ° C minimum) wires.

Locate the seven (eight on 3-phase) low voltage thermostat leads

in 24 volt splice box. See Fig. 10 for connection diagram. Run the

low-voltage leads from the thermostat, through the control wiring

inlet hole grommet (Fig. 2 and 3), and into the low-voltage splice

box. Provide a drip loop before running wires through panel.

Secure and strain relief all wires so that they do not interfere with

operation of unit. A gray wire is standard on 3-phase unit for

connection to an economizer.

HIGH VOLTAGE |

POWER LEADS do,,. m

(SEE UNIT WIRINGI

LABEL) _

E__ --

EQUIP GR

CONTROL BOX

LOW VOLTAGE

POWER LEADS

(SEE UNIT

WIRING LABEL)

Co-

IO-

-"l O,,.

io-

1o-

io=

FIELD-SUPPLIED

FUSED DISCONNECT

_WH_..TLW_I).D.

.,,YEL_._),.,,, ,_

GROG20.

RED, R)..

.BR_C) 9.

ORN_(O_)

BLU (DH)_,,

E_ E_ D

THERMOSTAT

(TYPICAL)

3_Phast

Only

SPLICE BOX

A09067

Fig. 10 -High and Control-Voltage Connections

Balance Point Setting-Thermidistat or Hybrid

Thermostat

BALANCE POINT TEMPERATURE-The "balance point"

temperature is a setting which affects the operation of the heating

mode. This is a field-selected input temperature (range 5 to 55°F)

(-15 to 12°C) where the Thermidistat or dual fuel thermostat will

monitor outdoor air temperature and decide whether to enable or

disable the heat pump. If the outdoor temperature is above the

"balance point", the heat pump will energize first to try to satisfy

the indoor temperature demand. If the heat pump does not make a

sufficient improvement within a reasonable time period (i.e. 15

minutes), then the gas furnace will come on to satisfy the indoor

temperature demand. If the outdoor temperature is below the

"balance point", the heat pump will not be allowed to operate (i.e.

locked out), and the gas furnace will be used to satisfy the indoor

temperature. There are three separate concepts which are related to

selecting the final "balance point" temperature. Read each of the

following carefully to determine the best "balance point" in a

hybrid installation:

1. Capacity Balance Temperature: This is a point where the

heat pump cannot provide sufficient capacity to keep up

with the indoor temperature demand because of declining

outdoor temperature. At or below this point, the furnace is

needed to maintain proper indoor temperature.

2. Economic Balance Temperature: Above this point, the heat

pump is the most cost efficient to operate, and below this

point the furnace is the most cost efficient to operate. This

can be somewhat complicated to determine and it involves

knowing the cost of gas and electricity, as well as the

efficiency of the furnace and heat pump. For the most

economical operation, the heat pump should operate above

this temperature (assuming it has sufficient capacity) and the

furnace should operate below this temperature.

3. Comfort Balance Temperature: When the heat pump is

operating below this point, the indoor supply air feels

uncomfortable (i.e. too cool). This is purely subjective and

will depend on the homeowner's idea of comfort. Below

this temperature the gas furnace should operate in order to

satisfy the desire for indoor comfort.

Transformer Protection

The transformer is of the energy-limiting type. It is set to withstand

a 30-sec. overload or shorted secondary condition. If an overload

or short is present, correct overload condition and check for blown

fuse on gas control board or Interface Fan Board. Replace fuse as

required with correct size and rating.

PRE-START-UP

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal iniury,

death or property damage.

1. Follow recognized safety practices and wear protective

goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power

to unit unless compressor terminal cover is in place and

secured.

3. Do not remove compressor terminal cover until all

electrical sources are disconnected and tagged.

4. Relieve and recover all refrigerant from system before

touching or disturbing anything inside terminal box if

refrigerant leak is suspected around compressor

terminals.

5. Never attempt to repair soldered connection while

refrigerant system is under pressure.

6. Do not use torch to remove any component. System

contains oil and refrigerant under pressure.

To remove a component, wear protective goggles and

proceed as follows:

a. Shut off electrical power to unit and install lockout

tag.

b. Relieve and reclaim all refrigerant from system

using both high- and low-pressure ports.

c. Cut component connecting tubing with tubing

cutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs when

necessary. Oil can ignite when exposed to torch

flame.

Proceed as follows to inspect and prepare the unit for initial

start-up:

1. Remove access panels (see Fig. 19).

2. Read and follow instructions on all WARNING,

CAUTION, and INFORMATION labels attached to, or

shipped with, unit.

3. Make the following inspections:

a. Inspect for shipping and handling damages such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and

on unit base. Detecting oil generally indicates a

refrigerant leak.

c. Leak test all refrigerant tubing connections using

electronic leak detector, halide torch, or liquid-soap

solution. If a refrigerant leak is detected, see the Check

for Refrigerant Leaks section.

d. Inspect all field- and factory-wiring connections. Be

sure that connections are completed and tight.

e. Ensure wires do not touch refrigerant tubing or sharp

sheet metal edges.

f. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

FIRE,EXPLOSIONHAZARD

Failuretofollowthiswarningcouldresultinpersonalinjury,

deathorpropertydamage.

Donotpurgegassupplyintothecombustionchamber.Donot

useamatchorotheropenflametocheckforgasleaks.Usea

commerciallyavailablesoapsolutionmadespecificallyfor

thedetectionofleakstocheckallconnections.

4.Verifythefollowingconditions:

a.Makesuregaslineisfreeofair.Beforelightingtheunit

forthefirsttime,performthefollowingwiththegas

valveinthe"OFF"position:

NOTE:If thegassupplypipewasnotpurgedbeforeconnecting

theunit,it willbefullofair.It isrecommendedthattheground

jointunionbeloosened,andthesupplylinebeallowedtopurge

untiltheodorof gasisdetected.Neverpurgegaslinesintoa

combustionchamber.Immediatelyupondetectionof gasodor,

retightentheunion.Allow5minutestoelapse,thenlightunit.

b.Makesurethatcondenser-fanbladeiscorrectly

positionedinfanorifice.Leadingedgeofcondenser-fan

bladeshouldbe1/2in.(12mm)maximumfromfan

orifice.

c.Makesurethatairfilter(s)isinplace.

d.Makesurethatcondensatedraintrapisfilledwithwater

toensureproperdrainage.

e.Makesurethatalltoolsandmiscellaneouslooseparts

havebeenremoved.

START-UP

Step 11 Check for Refrigerant Leaks

Proceed as follows to locate and repair a refrigerant leak and to

charge the unit:

1. Locate leak and make sure that refrigerant system pressure

has been relieved and reclaimed from both high- and

low-pressure ports.

2. Repair leak following Refrigerant Service procedures.

NOTE: Install a bi-flow filter drier whenever the system has been

opened for repair.

3. Add a small charge of R-410A refrigerant vapor to system

and leak-test unit.

4. Recover refrigerant from refrigerant system and evacuate to

500 microns if no additional leaks are not found.

5. Charge unit with Puron (R-410A) refrigerant, using an

electronic scale. Refer to unit rating plate for required

charge.

Step 2 1 Unit Sequence of Operation

48VT-A Sequence of Operation

a. CONTINUOUS FAN

(1.) Thermostat closes circuit R to G energizing the

blower motor for continuous fan.

b. COOLING MODE

(1.) If indoor temperature is above temperature set

point thermostat closes circuits R to G, R to Y and

R to O-The unit delivers cooling airfow.

c. HEAT PUMP HEATING MODE

Outdoor temperature above balance point setpoint of

thermostat.

(1.) On a call for heating, terminals "Y" and "G" of the

Hybrid thermostat are energized. The "Y" signal is

sent to the Defrost Board (DB) terminal "Y". The

DB has a built in five minute anti-short cycle timer

which will not allow the compressor to restart

before the time delay has expired.

(2.) "T2" energizes the compressor contactor via the

High Pressure Switch (HPS) and Low Pressure

Switch (LPS). The compressor and outdoor fan

start. Thermostat "G" energizes the Interface Fan

Board terminal "G". The blower motor is energized

through contacts of the IFB.

(3.) When the thermostat removes the "Y" and "G"

calls, the compressor contactor and outdoor fan are

de-energized. The evaporator motor is de-ener-

gized after a 90 sec. delay.

d. GAS HEATING MODE

Outdoor temperature below balance point setpoint of

thermostat.

Heating Sequence of Operation

(See Fig. 15 and 16 and unit wiring label.)

On a call for heating, terminal W of the thermostat is energized,

starting the induced-draft motor. When the pressure switch senses

that the induced-draft motor is moving sufficient combustion air,

the burner sequence begins. This function is performed by the

integrated gas unit controller (IGC). The indoor (evaporator)-fan

motor is energized 45 sec after flame is established. When the

thermostat is satisfied and W is de-energized, the burners stop

firing and the indoor (evaporator) fan motor shuts off after a

45-sec time-off delay. Please note that the IGC has the capability

to automatically reduce the indoor fan motor on delay and increase

the indoor fan motor off delay in the event of high duct static

and/or partially-clogged filter.

NOTE: An LED (light-emitting diode) indicator is provided on

the control board to monitor operation. The control board is

located by removing the burner access panel (see Fig. 19). During

normal operation, the LED is continuously on.

Step 31 Start-up Heating and Make Adjust-

ments

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit

being installed.

Complete the required procedures given in the Pre-Start-Up

section before starting the unit. Do not jumper any safety

devices when operating the unit.

Complete the required procedures given in the Pre-Start-Up

section before starting the unit. Do not jumper any safety devices

when operating the unit. Make sure that burner orifices are

properly aligned. Unstable operation nay occur when the burner

orifices in the manifold are misaligned.

Follow the lighting instructions on the heating section operation

label (located on the inside of the control access panel) to start the

heating section.

NOTE: Make sure that gas supply has been purged, and that all

gas piping has been checked for leaks.

"Manifold

A07679

Fig. 11 - Burner Assembly

BURNER FLAME

°'°

C99021

Fig. 12 - Monoport Burner

Check Heating Control

Start and check the unit for proper heating control operation as

follows (see furnace lighting instructions located on the inside of

the control access panel):

1. Place room thermostat SYSTEM switch in the HEAT

position and the fan switch is placed in AUTO position.

2. Set the heating temperature control of the thermostat above

room temperature.

3. The induced-draft motor will start.

4. On a call for heating, the main burner should light within 5

sec. of the spark being energized. If the burners do not light,

there is a 22-sec. delay before another 5-sec. try. If the

burners still do not light, this sequence is repeated. If the

burners do not light within 15 nfinutes from the initial call

for heat, there is a lockout. To reset the control, break the

24-v power to W.

5. The evaporator fan will turn on 45 sec. after the flame has

been established. The evaporator fan will turn off 45 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" delay and in-

crease the evaporator "OFF" delay in the event of high duct

static and/or partially-clogged filter.

Check Gas Input

Check gas input and manifold pressure after unit start-up (See

Table 3). If adjustment is required proceed as follows:

• The rated gas inputs shown in Table 3 are for altitudes from sea

level to 2000 ft (610 m) above sea level. These inputs are based

on natural gas with a heating value of 1025 Btu/ft 3 at 0.60

specific gravity, or propane gas with a heating value of 2500

Btu/ft 3 at 1.5 specific gravity.

IN THE U.S.A.:

The input rating for altitudes above 2,000 ft (610 m) must be

reduced by 4% for each 1,000 ft (305 m) at_ove see level.

For installations below 2,000 ft (610 m), refer to the unit rating

plate.

For installations above 2,000 ft (610 m) nmltiply the input by on

the rating plate by the derate multiplier in Table 4 for correct input

rate.

Table 4 - Altitude Derate Multiplier for U.S.A.*

DERATE MULTIPLIER

ALTITUDE FT (M) PERCENT OF DERATE FACTOR1-

0-2000 0 1,00

(0-610)

2001-3000* 8-12 0,90

(610-914)

3001-4000 12-16 0,86

(315-1219)

4001-5000 16-20 0,82

(1220 - 1524)

5001-6000 20-24 0.78

(1524-1829)

6001-7000 24-28 0.74

(1829 - 2134)

7001-8000 28-32 0.70

(2134-2438)

8001-9000 32-36 0,66

(2439-2743)

9001-10,000 36-40 0.62

(2744-3048)

In Canada see Canadian Altitude Adjustment.

1-Derate multiplier factors are based on midpoint altitude for altitude range.

IN CANADA:

The input rating for altitudes from 2,000 to 4,500 fl (610 m to

1372 m) above sea level must be derated 10% by an authorized

Gas Conversion Station or Dealer.

EXAMPLE:

90,000 Btu/hr Input Furnace Installed at 4300 fl (1311 m).

Furnace Input Rate at X Derate Multiplier =Furnace Input Rate at

Sea Level Factor Installation Altitude

g0,000 X 0.g0 = 81,000

When the gas supply being used has a different heating value or

specific gravity, refer to national and local codes, or contact your

distributor to deternfine the required orifice size.

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in reduced unit

and/or component life.

Do Not redrill an orifice. Improper drilling (burrs,

out-of-round holes, etc.) can cause excessive burner noise

and nfisdirection of burner flame. If orifice hole appears

damaged or it is suspected to have been redrilled, check

orifice hole with a numbered drill bit of correct size.

Adiust Gas Input

The gas input to the unit is determined by measuring the gas flow

at the meter or by measuring the manifold pressure. Measuring the

gas flow at the meter is recommended for natural gas units. The

manifold pressure must be measured to determine the input of

propane gas units.

Measure Gas Flow (Natural Gas []nits)

Minor ac[iustment to the gas flow can be made by changing the

manifold pressure. The manifold pressure must be maintained

between 3.2 and 3.8 IN. W.C.

ON/OFF SWITCH

INLET

PRESSURE TAP

REGULATOR

PLASTIC

REGULATOR SPRING

(PROPANE - WHITE)

(NATURAL - SILVER)

GAS PRESSURE

MANIFOLD

A07751

Fig. 13 - Single-Stage Gas Valve

If larger adjustments are required, change main burner orifices

following the recommendations of national and local codes.

NOTE: All other appliances that use the same meter must be

turned off when gas flow is measured at the meter.

Proceed as follows:

1. Turn off gas supply to unit.

2. Remove pipe plug on manifold (See Fig. 11) and connect

manometer. Turn on gas supply to unit.

3. Record number of seconds for gas meter test dial to make

one revolution.

4. Divide number of seconds in Step 3into 3600 (number of

seconds in one hr).

5. Multiply result of Step 4 by the number of cubic feet (cu fl)

shown for one revolution of test dial to obtain cubic feet (cu

fl) of gas flow per hour.

6. Multiply result of Step 5by Btu heating value of gas to

obtain total measured input in Btuh. Compare this value

with heating input shown in Table 3 (Consult the local gas

supplier if the heating value of gas is not known).

EXAMPLE: Assume that the size of test dial is 1 cu fl, one

revolution takes 32 sec, and the heating value of the gas is 1050

Btu/fl 3. Proceed as follows:

1. 32 sec. to complete one revolution.

2. 3600 + 32 = 112.5.

3. 112.5 x 1 =112.5 f13of gas flow/hr.

4. 112.5 x 1050 = 118,125 Btuh input.

If the desired gas input is 115,000 Btuh, only a minor change in the

manifold pressure is required.

Observe manifold pressure and proceed as follows to adjust gas

input:

1. Remove regulator cover screw over plastic adjustment

screw on gas valve (See Fig. 13).

2. Turn plastic adjustment screw clockwise to increase gas

input, or turn plastic adjustment screw counterclockwise to

decrease input (See Fig. 13). Manifold pressure must be

between 3.2 and 3.8 IN. W.C.

FIRE AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal

iniury or death and/or property damage.

Unsafe operation of the unit may result if manifold pressure

is outside this range.

3. Replace regulator cover screw on gas valve (See Fig. 13).

4. Turn off gas supply to unit. Remove manometer from

pressure tap and replace pipe plug on gas valve. (See Fig.

11.) Turn on gas to unit and check for leaks.

Measure Manifold Pressure (Propane Units)

Refer to propane kit installation instructions for properly checking

gas input.

NOTE: For installations below 2,000 fl (610 m), refer to the unit

rating plate for proper propane conversion kit. For installations

above 2,000 fl (610 m), contact your distributor for proper propane

conversion kit.

Check Burner Flame

With control access panel (see Fig. 19) removed, observe the unit

heating operation. Watch the burner flames to see if they are light

blue and soft in appearance, and that the flames are approximately

the same for each burner. Propane will have blue flame (See Fig.

12). Refer to the Maintenance section for information on burner

removal.

Normal Operation

An LED (light-emitting diode) indicator is provided on the

integrated gas unit controller (IGC) to monitor operation. The IGC

is located by removing the control access panel (see Fig. 19).

During normal operation, the LED is continuously on (See Table 5

for error codes).

Airflow and Temperature Rise

The heating section for each size unit is designed and approved for

heating operation within the temperature-rise range stamped on the

unit rating plate.

Table 10 shows the approved temperature rise range for each

heating input, and the air delivery cfm at various temperature rises

for a given external static pressure. The heating operation airflow

must produce a temperature rise that falls within the approved

range.

Refer to Indoor Airflow and Airflow Adjustments section to adjust

heating airflow when required.

Limit Switches

Normally closed limit switch (LS) completes the control circuit.

Should the leaving-air temperature rise above the maximum

allowable temperature, the limit switch opens and the control

circuit "breaks." Any interruption in the control circuit instantly

closes the gas valve and stops gas flow to the burners. The blower

motor continues to run until LS resets.

When the air temperature at the limit switch drops to the

low-temperature setting of the limit switch, the switch closes and

completes the control circuit. The direct-spark ignition system

cycles and the unit returns to normal heating operation.

Table 5-LED Indications

STATUS CODE LED INDICATION

Normal Operation 2On

No Power Hardware Failure Off

Limit Switch Fault 2 Flashes

Flame Sense Fault 3 Flashes

Four Consecutive Limit Switch Faults 4 Flashes

Ignition Lockout Fault 5 Flashes

Pressure Switch Fault 6 Flashes

Rollout Switch Fault 7 Flashes

Internal Control Fault 8 Flashes

Temporary 1 hr auto reset I 9 Flashes

NOTES:

1.This code indicates an internal processor fault that will reset itself in one

hr. Fault can be caused by stray RF signals in the structure or nearby. This

is a UL requirement.

2, LED indicates acceptable operation. Do not change ignition control

board,

3. When W is energized the burners will remain on for a minimum of 60 sec.

4. If more than one error mode exists they will be displayed on the LED in

sequence.

Rollout Switch

The function of the rollout switch is to close the main gas valve in

the event of flame rollout. The switch is located above the main

burners. When the temperature at the rollout switch reaches the

maximum allowable temperature, the control circuit trips, closing

the gas valve and stopping gas flow to the burners. The indoor

(evaporator) fan motor (IFM) and induced draft motor continue to

run until switch is reset. The IGC LED will display FAULT CODE

Step 4 -- Start-up Cooling and Make Adjust-

ments

Complete the required procedures given in the Pre-Start-Up

section before starting the unit. Do not jumper any safety devices

when operating the unit. Do not operate the compressor when the

outdoor temperature is below 40°F (4.4°C) (unless accessory

low-ambient kit is installed). Do not rapid-cycle the compressor.

Allow 5 minutes between on cycles to prevent compressor damage.

ChecMng Cooling Control Operation

Start and check the unit for proper cooling control operation as

follows:

1. Place room thermostat SYSTEM switch in OFF position.

Observe that blower motor starts when FAN switch is

placed in ON position and shuts down when FAN switch is

placed in AUTO position.

2. Place SYSTEM switch in COOL position and FAN switch

in AUTO position. Set cooling control below room

temperature. Observe that compressor, condenser fan, and

evaporator blower motors start. Observe that cooling cycle

shuts down when control setting is satisfied. The evaporator

fan will continue to run for 90 sec.

IMPORTANT: Three-phase, scroll compressors units are

direction oriented. Unit must be checked to ensure proper

compressor 3-phase power lead 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. When turning backwards, the difference between

compressor suction and discharge pressures will be near zero.

ChecMn_ and Adiustin_ Refrigerant Charge

The refrigerant system is fully charged with Puron® (R-410A)

refrigerant and is tested and factory sealed. Allow system to operate

a minimum of 15 minutes before checking or adjusting charge.

NOTE: Adjustment of the refrigerant charge is not required unless

the unit is suspected of not having the proper Puron® (R-410A)

charge.

The charging label and the tables shown refer to system

temperatures and pressures in cooling mode only. A refrigerant

charging label is attached to the inside of the compressor access

panel (see Fig. 19). The chart includes the required liquid line

temperature at given discharge line pressures and outdoor ambient

temperatures.

An accurate thermocouple- or thermistor-type thermometer, and a

gauge manifold are required when using the subcooling charging

method for evaluating the unit charge. Do not use mercury or small

dial-type thermometers because they are not adequate for this type

of measurement.

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

When evaluating the refrigerant charge, an indicated

adjustment to the specified factory charge must always be

very minimal. If a substantial adjustment is indicated, an

abnormal condition exists somewhere in the cooling system,

such as insufficient airflow across either coil or both coils.

Proceed as follows:

1. Remove caps from low- and high-pressure service fittings.

2. []sing hoses with valve core depressors, attach low- and

high-pressure gauge hoses to low- and high-pressure

service fittings, respectively.

3. Start unit in Cooling Mode and let unit run until system

pressures stabilize.

4. Measure and record the following:

a. Outdoor ambient-air temperature (°F (°C) db).

b. Liquid line temperature (°F (°C).

c. Discharge (high-side) pressure (psig).

d. Suction (low-side) pressure (psig) (for reference only).

5. Using "Cooling Charging Charts," compare outdoor-air

temperature(°F (°C) db) with the discharge line pressure

(psig) to determine desired system operating liquid line

temperature (See Fig. 17).

6. Compare actual liquid line temperature with desired liquid

line temperature. Using a tolerance of - 2°F (-1.1°C), add

refrigerant if actual temperature is more than 2°F (1.1°C)

higher than proper liquid line temperature, or remove

refrigerant if actual temperature is more than 2°F (1.1°C)

lower than required liquid line temperature.

NOTE: If the problem causing the inaccurate readings is a

refrigerant leak, refer to the Check for Refrigerant Leaks section.

Indoor Airflow and Airflow Adjustments

[]NIT OPERATION HAZARD

Failure to follow this caution may result in unit damage.

For cooling operation, the recommended airflow is 350 to

450 cfm for each 12,000 Btuh of rated cooling capacity. For

heating operation, the airflow must produce a temperature

rise that falls within the range stamped on the unit rating

plate.

NOTE: Be sure that all supply-and return-air grilles are open,

free from obstructions, and adjusted properly.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

iniury or death.

Before making any indoor wiring adjustments, shut off gas

supply. Then disconnect electrical power to the unit and

install lockout tag before changing blower speed.

This unit has independent fan speeds for gas heating and cooling.

In addition, this unit has the field-selectable capability to run two

different cooling fan speeds: A normal cooling fan speed (350~400

CFM/Ton) and an enhanced dehumidification fan speed (As low as

320 CFM/Ton) for use with either a dehumidistat or a thermostat

that supports dehumidification.

This unit is factory-set up for use with a single cooling fan speed.

The cooling speed is marked "LOW" on the interface fan board

(IFB) (Fig. 14) . The factory-shipped settings are noted in Table

10. There are 3 additional speed tap wires available for use in

either gas heating or cooling (For color coding on the indoor fan

motor leads, see Table 6). The additional 3 speed tap wires are

shipped loose with vinyl caps and are located in the control box,

near the interface fan board (IFB) (Fig. 14).

Gas Heating Fan Speed Set-up

To change the gas heating speed:

1. Remove the vinyl cap off of the desired speed tap wire

(Refer to Table 6 for color coding). Table 10 shows the

temperature rise associated with each fan speed for a given

static pressure. Make sure that the speed chosen delivers a

temperature rise within the rise range listed on the unit

rating plate.

2. Remove the current speed tap wire from the "GAS HEAT"

terminal on the interface fan board (IFB) (Fig.14) and place

vinyl cap over the connector on the wire.

3. Connect the desired speed tap wire to the "GAS HEAT"

terminal on the interface fan board (IFB).

Single Cooling Fan Speed Set-up (Dehumidification

feature not used)

To change cooling speed:

1. Remove the vinyl cap off of the desired speed tap wire

(Refer to Table 6 for color coding). Add the wet coil

pressure drop in Table 8 to the system static to determine the

correct cooling airflow speed in Table 10 that will deliver

the nominal cooling airflow as listed in Table 1 for each

size.

2. Remove the current speed tap wire from the "LOW"

terminal on the interface fan board (IFB) (Fig. 14) and place

vinyl cap over the connector on the wire,

3. Connect the desired speed tap wire to the "LOW" terminal

on the interface fan board (IFB).

Two Cooling Fan Speeds Set-up (Dehumidification

feature used)

IMPORTANT: Dehumidification control must open control

circuit on humidity rise above set point,

Use of the dehumidification cooling fan speed requires use of

either a 24 VAC dehumidistat or a thermostat which includes

control of a 24 VAC dehumidistat connection. In either case, the

dehumidification control must open the control circuit on humidity

rise above the dehumidification set point. Dehumidification

controls are available with the reverse logic; these must not be

used.

1. Remove fan speed tap wire from the "LOW" terminal on

the interface fan board (IFB) (Fig. 14).

2. Determine correct normal cooling fan speed for unit and

application. Add the wet coil pressure drop in Table 8 to

the system static to determine the correct cooling airflow

speed in Table 10 that will deliver the nominal cooling

airflow as listed in Table 1 for each size.

3. Remove the vinyl cap off of the desired speed tap wire

(Refer to Table 6 for color coding) for the normal cooling

fan speed and place desired speed tap wire on "HIGH" on

the interface board.

4. Refer to airflow tables (Table 10) to determine allowable

speeds for the dehumidification cooling fan speed. In Table

10, speeds that are not allowed for dehumidification cooling

are shaded.

5. Remove the vinyl cap off of the desired speed tap wire

(Refer to Table 6 for color coding) for the dehumidification

cooling fan speed and place desired speed tap wire on the

"LOW" connection on the interface board (IFB). Verify

that static pressure is in the acceptable range for the speed

tap to be used for dehumidification cooling.

6. Use any spare vinyl plugs to cap any unused speed tap

wires.

NOTE: For heat pump operation, the recommended airflow is 350

to 450 CFM for each 12,000 Btuh of rated cooling capacity.

Continuous Fan Operation

When the DEHUM feature is not used, the continuous fan speed

will be the same as cooling fan speed. When the DEHUM feature

is used, the continuous fan will operate on IFB "LOW" speed

when the DH control lead is not energized, or IFB "HIGH" speed

when the DH lead is energized (see Fig. 14).

Table 6- Color Coding for Indoor Fan Motor Leads

Black =High Speed

Orange = Med-High Speed

Red = Med Speed

Pink = Med-Low Speed

Blue = Low Speed

FILTER SIZE

in. (mm)

20X20X1

(508X508X25)

20X24X1

(506X610x25)

24X30X1

(610X762x25)

24X36X1

(610X914X25)

Unit Size 500

-o

P N

GAS

HEAT HIGH LOW COM

000o _

QC6 QC7 QC4 QC3

K2 K1

RL3 C8 R1L Q1

O D2 t'T"

°00051;o °c0

JM6 RI2

OILL C2 D6 D4 AB 5 _ F1

D5 D3 C3 ! R R[ 4

R2 R3 R5 R6

'in !

JW2

JW4

Y R U C 24VAC

SSTZ-8 iwl P1

W2 Y2/ G Y!/ C R

DH ¥

Fig. 14 - Interface Fan Board (IFB)

A09058

Table 7-Filter Pressure Drop Table (IN. W.C.)

CFM

600 600 700 600 900 1000 1100 1200 1300 1400 1600 1600 1700 1600 1900 2000 2100 2200 2300

0.05 0.07 0.08 0.1 0.12 0.13 0.14 0.15 ...........

.... 0.09 0.10 0.11 0.13 0.14 0.15 0.16 ........

-- -- -- 0.04 0.05 0.06 0.07 0.07 0.08 0.09 0.1 ........

....... 0.06 0.07 0.07 0.08 0.09 0.09 0.10 0.11 0.12 0.13 0.14 0.14

600 700

0.06 0.07

Table 8 - 48VT-A Wet Coil Pressure Drop

Standard CFM (S.C.EM)

800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

0.08 0.09 0.1

0.12 0.15 0.19 0.23 0.27

0.07 0.11 0.18 0.26 0.35

0.04 0.07 0.1 0.15 0.21

0.11 0.14 0.17 0.22 0.28

0.1 0.17 0.23 0.31 0.36

Table 9 -Wet Coil Air Delivery (CFM) - Downflow -High Speed with 1-in. (25 mm) Filter and Economizer

UNIT SIZE EXTERNAL STATIC PRESSURE (in. W.C.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

36, 42 1612 1569 1527 1481 1451 1393 1351 1317 1278 1242

48 2298 2239 2180 2110 2044 1951 1862 1777 1697 1591

60 2298 2239 2180 2110 2044 1951 1862 1777 1697 1591

Unit

48VT(-,N)A24040

48VT(-,N)A24060

48VT(-,N)A30040

Table 10 -Dry Coil Air Delivery CFM* - Horizontal and Downflow Discharge -Unit 48VT-A24-60

Heating Motor

Rise

Range Speed

30 - 60°F

(17 - 33°C)

25 - 55°F

(14 - 31°C)

30 - 60°F

(17 - 33°C)

Wire External Static Pressure (in. W.C.)

Color 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

CFM 754 650 _i _291

Heating Rise 40 46 56 NA NA NA NA NA NA

Low Blue (oF)

Heating Rise 22 26 31 NA NA NA NA NA NA

(oc)

CFM 85_ 777 675 59_

Med- Heating Rise 36 39 45 51 NA NA NA NA NA

Pink (OF)

Low Heating Rise 20 22 25 28 NA NA NA NA NA

(oc)

CFM 94_' 85_ 774 684 _6 i

Heating Rise 32 36 39 44 52 NA NA NA NA

Medium 2 Red (OF)

Heating Rise 18 20 22 25 29 NA NA NA NA

(oc)

CFM 840 759 667 _7

Med- Heating Rise 30 33 36 40 45 52 NA NA NA

High1 Orange (OF)

Heating Rise 17 18 20 22 25 29 NA NA NA

(oc)

CFM 12@_[ _1_6_: _69 88_ _[_,,,, 73:_ 640

Heating Rise ...........................................................................................................................................

High Black (OF) NA NA NA NA 31 34 37 41 47 il

Heating Rise

(oc) 21 23 26

CFM i

Heating Rise NA NA NA

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise 24 27 29 NA NA NA NA NA NA

(oc)

CFM

Heating Rise 36 38 40 43 46 50 54 NA NA

High 1 Black (OF)

Heating Rise 20 21 22 24 25 28 30 NA NA

(oc)

CFM t ,,_=it,,'t ,,_=it,,'t ,,_=it,, t,,_=it,,'

Heating Rise 41 47 55 NA NA NA NA NA NA

Low Blue (OF)

Heating Rise 23 26 31 NA NA NA NA NA NA

(oc)

CFM 973 887 823 t";--it ''

Med- Heating Rise 31 34 37 41 45 56 NA NA NA

Pink (oF)

Low 1 Heating Rise 17 19 20 23 25 31 NA NA NA

(oc)

CFM 954 881 800

Heating Rise 28 30 32 34 38 42 46 54 NA

Medium Red (OF)

Heating Rise 15 16 18 19 21 23 26 30 NA

(oc)

CFM 996 915 840

Med- Heating Rise NA NA 30 33 36 40 44 54 NA

High2 Orange (OF)

Heating Rise NA NA 17 18 20 22 24 30 NA

(oc)

CFM 'i86_

Heating Rise NA NA NA 30 31 34 37 41 48

High Black (OF)

Heating Rise NA NA NA 17 17 19 21 23 27

(oc)

NA NA NA NA 17 19

754 650 _29

NA NA NA NA NA NA

Low Blue

NA NA NA NA NA NA NA NA NA

85_ 777 675 591

Med- 52 NA NA NA NA NA NA NA NA

Pink

Low

29 NA NA NA NA NA NA NA NA

94_ 85_ 774 684 _6 _

47 52 NA NA NA NA NA NA NA

Medium 2 Red

26 29 NA NA NA NA NA NA NA

840:: 759 667

Med- 44 48 53 NA NA NA NA NA NA

High Orange

Unit

48VT(-,N)A30060

48VT(-,N)A36060

48VT(-,N)A36090

Table 10 -Dry Coil Air Delivery CFM* - Horizontal and Downflow Discharge -Unit 48VT-A24-60 (Cont)

Heating Motor

Rise

Range Speed

25 -55°F

(14 -31°C)

25 - 55°F

(14 - 31°C)

35 - 65°F Medium 2

(19 -36°C)

Wire External Static Pressure (in. W.C.)

Color 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

CFM 74_ ;638

Heating Rise NA NA NA NA NA NA NA NA NA

Low Blue (oF)

Heating Rise NA NA NA NA NA NA NA NA NA

(oc)

CFM 973 887 823 780 [ 665 _38,,,,,[ 45_ i

Med- Heating Rise 46 50 54 NA NA NA NA NA NA

Pink (oF)

Low Heating Rise 25 28 30 NA NA NA NA NA NA

(oc)

CFM 1,O88['[ _Q23i 954 881 800 _23 [ 658",,, [563 _6_ i

Heating Rise 41 43 47 50 NA NA NA NA NA

Medium Red (OF)

Heating Rise 23 24 26 28 NA NA NA NA NA

(oc)

CFM _1_40}, 996 915 840 _[[, [687 56_ 480,,

Med- Heating Rise 39 42 45 49 53 NA NA NA NA

High2 Orange (OF)

Heating Rise 22 23 25 27 29 NA NA NA NA

(oc)

Heating Rise 37 39 41 44 46 50 55 NA NA

High 1 Black (OF)

Heating Rise 21 22 23 24 26 28 30 NA NA

(oc)

CFM 1176 1121 1079 1019 974

Heating Rise 38 40 41 44 46 48 51 54 NA

Low Blue (oF)

Heating Rise 21 22 23 24 25 27 28 30 NA

(oc)

CFM 1295 !_23_ 1182 1126 1075 1016

Med- Heating Rise 34 36 38 39 41 44 47 49 52

Pink (oF)

Low 1 Heating Rise 19 20 21 22 23 24 26 27 29

(oc)

CFM _$345 , !_28_:: !_23_ 1194 1140 1095 1027 974 !92_ "

Heating Rise 33 35 36 37 39 41 43 46 48

Medium 2 Red (OF)

Heating Rise 18 19 20 21 22 23 24 25 27

(oc)

CFM _150_ , !_452 : _4_3 ::: __i"[ _323i !_28:_:: !_23_ ! 1169 1130

Med- Heating Rise 30 31 31 33 34 35 36 38 39

High Orange (OF)

Heating Rise 16 17 17 18 19 19 20 21 22

(oc)

CFM }_ 05 [}_643

Heating Rise 26 27 28 28 29 30 31 32 33

High Black (OF)

Heating Rise 14 15 15 16 16 17 17 18 18

(oc)

CFM 1176 1121 1079 1019 974 !:"75

Heating Rise 58 61 63 NA NA NA NA NA NA

Low Blue (oF)

Heating Rise 32 34 35 NA NA NA NA NA NA

(oc)

CFM 1182 1126 1075 1016

Med- Heating Rise 53 55 58 60 63 NA NA NA NA

Pink (oF)

Low Heating Rise 29 31 32 34 35 NA NA NA NA

(oc)

CFM }_34_ , _282 _28_ 1194 1140 1095 1027 974

Heating Rise 51 53 55 57 60 62 NA NA NA

Red (oF)

Heating Rise 28 29 31 32 33 35 NA NA NA

(oc)

CFM _23 _282 ,}_28 1169 1130

Med- Heating Rise 45 47 48 50 51 53 55 58 60

High1 Orange (OF)

Heating Rise

(oc) 25 26 27 28 29 29 31 32 33

40 41 42 43 45 46 47 48 50

High Black

CFM

Heating Rise

(OF)

Heating Rise

(oc) 22 23 24 24 25 25 26 27 28

Unit

48VT(-,N)A42060

48VT(-,N)A42090

48VT(-,N)A48090

Table 10 -Dry Coil Air Delivery CFM* - Horizontal and Downflow Discharge -Unit 48VT-A24-60 (Cont)

Heating Motor

Rise

Range Speed

25 - 55°F

(14 - 31°C)

35 - 65°F

(19 - 36°C)

35 - 65°F

(19 - 36°C)

Wire External Static Pressure (in. W.C.)

Color 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

CFM 1295 1234 1182 1126 85

Heating Rise 34 36 38 39 41 44 47 49 52

Low 1 Blue (OF)

Heating Rise 19 20 21 22 23 24 26 27 29

(oc)

CFM 1345 1282 1235 1194 1140 !92_ "

Med- Heating Rise 33 35 36 37 39 41 43 46 48

Pink (oF)

Low Heating Rise 18 19 20 21 22 23 24 25 27

(oc)

CFM _150_ , !_452:1358 1323 1282 1234 1169 1130

Heating Rise 30 31 31 33 34 35 36 38 39

Medium Red (OF)

Heating Rise 16 17 17 18 19 19 20 21 22

(oc)

CFM _1_45 !_492:: _4_ _4_ 1362 1313 1278 1231 1188

Med- Heating Rise 29 30 31 31 33 34 35 36 37

High2 Orange (OF)

Heating Rise 16 17 17 17 18 19 19 20 21

(oc)

Heating Rise ................................................................................................................................................................................................................................................................................................................................................................

High Black (°F) 26 27 28 28 29 30 31 32 33 il

Heating Rise

(oc) 17 17 18 18

CFM [ 958 89_ [ 857:

Heating Rise NA NA NA NA

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise 24 25 26 27 28 29 30 31 32

(oc)

CFM _48_, _448 _ O_

Heating Rise 40 41 42 43 45 46 47 48 50

High Black (OF)

Heating Rise 22 23 24 24 25 25 26 27 28

(oc)

CFM 1430 1374 1327

Heating Rise 48 49 51 54 56 58 60 64 NA

Low Blue (OF)

Heating Rise 26 27 28 30 31 32 34 36 NA

(oc)

CFM 1445 1389 1341 1281 t_'28_ }_ , _ _072

Med- Heating Rise 47 49 51 53 55 57 60 63 NA

Pink (oF)

Low 1 Heating Rise 26 27 28 29 31 32 33 35 NA

(oc)

CFM 1558 1513 1474 1438 1404 1349

Heating Rise 41 42 42 44 45 46 47 48 50

Red (OF)

Heating Rise 23 23 24 24 25 26 26 27 28

(oc)

CFM

Med- Heating Rise NA NA NA NA NA 35 36 37 38

High Orange (OF)

Heating Rise NA NA NA NA NA 19 20 20 21

(oc)

CFM _74

Heating Rise NA NA NA NA NA NA NA 35 36

High Black (OF)

Heating Rise NA NA NA NA NA NA NA 19 20

(oc)

14 15 15 16 16

1295 1234 1182 1126

53 55 58 60 63

Low Blue

29 31 32 34 35 NA NA NA NA

1345 1282 1235 1194 1140 1,095 1,02_ _74 92_

Med- 51 53 55 57 60 62 NA NA NA

Pink

Low 28 29 31 32 33 35 NA NA NA

_15Q_ , _452;: _4_ 1358 1323 1282 1234 1169 1130

45 47 48 50 51 53 55 58 60

Medium 1 Red

25 26 27 28 29 29 31 32 33

_4_ _4_ 1362 1313 1278 1231 1188

Med- 44 46 47 48 50 52 53 55 57

High2 Orange

Medium 2

Unit

48VT(-,N)A48115

48VT(-,N)A48130

48VT(-,N)A60090

Table 10 -Dry Coil Air Delivery CFM* - Horizontal and Downflow Discharge -Unit 48VT-A24-60 (Cont)

Heating Motor

Rise

Range Speed

30 -60°F

(17 - 33°C)

35 - 65°F

(19 - 36°C)

35 - 65°F Medium 2

(19 - 36°C)

Wire External Static Pressure (in. W.C.)

Color 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

CFM 1430 1374 1327 12_; ;1223 _1_6 _1_2_ 1,O_ ;1,O_,6

Heating Rise 61 NA NA NA NA NA NA NA NA

Low Blue (oF)

Heating Rise 34 NA NA NA NA NA NA NA NA

(oc)

CFM 1445 1389 1341 1281 1236 _1_89 i _1_9 1Q2_

Med- Heating Rise 60 NA NA NA NA NA NA NA NA

Pink (oF)

Low Heating Rise 33 NA NA NA NA NA NA NA NA

(oc)

CFM 1558 1513 1474 1438 1404 1349

Heating Rise 52 53 54 56 57 59 60 NA NA

Medium 2 Red (OF)

Heating Rise 29 30 30 31 32 33 34 NA NA

(oc)

CFM _2_1 !2088,,,, _2Q65' _2Q13::: _98_i: i_785

Med- Heating Rise 41 42 42 43 44 45 46 47 49

High1 Orange (OF)

Heating Rise 23 23 23 24 24 25 26 26 27

(oc)

CFM 2_g_i: !2_40:, !2Q_::: !_68,

Heating Rise 35 36 37 38 40 41 42 44 46

High Black (OF)

Heating Rise 20 20 21 21 22 23 23 25 26

(oc)

CFM 1430 1374 1327 _1_6 _1_2_

Heating Rise NA NA NA NA NA NA NA NA NA

Low Blue (oF)

Heating Rise NA NA NA NA NA NA NA NA NA

(oc)

CFM 1445 1389 1341 1281 1236 _1_89 i _1_9 1Q2_

Med- Heating Rise NA NA NA NA NA NA NA NA NA

Pink (oF)

Low Heating Rise NA NA NA NA NA NA NA NA NA

(oc)

CFM 1558 1513 1474 1438 1404 1349

Heating Rise 57 59 60 62 64 65 NA NA NA

Medium 2 Red (OF)

Heating Rise 32 33 33 34 35 36 NA NA NA

(oc)

CFM _2Q65 _2Q13::: _98_i: i_785

Med- Heating Rise 45 46 47 48 49 50 51 52 54

High1 Orange (OF)

Heating Rise 25 26 26 27 27 28 28 29 30

(oc)

CFM _74

Heating Rise 39 40 41 42 44 45 47 49 51

High Black (OF)

Heating Rise 22 22 23 23 24 25 26 27 29

(oc)

Heating Rise 47 49 51 53 55 57 60 63 NA

Low 1 Blue (OF)

Heating Rise 26 27 28 29 31 32 33 35 NA

(oc)

CFM 1678 1635 1602 t_349

Med- Heating Rise 41 42 42 44 45 46 47 48 50

Pink (oF)

Low Heating Rise 23 23 24 24 25 26 26 27 28

(oc)

CFM 1843 1794 1753 1711 1675 1628

Heating Rise 35 36 36 37 38 39 40 41 42

Red (OF)

Heating Rise 19 20 20 20 21 22 22 23 23

(oc)

CFM

Med- Heating Rise NA NA NA NA NA 35 36 37 38

High Orange (OF)

Heating Rise NA NA NA NA NA 19 20 20 21

(oc)

CFM _74

Heating Rise NA NA NA NA NA NA NA 35 36

High Black (OF)

Heating Rise NA NA NA NA NA NA NA 19 20

(oc)

Table 10 - Dry Coil Air Delivery CFM* - Horizontal and Downflow Discharge - Unit 48VT-A24-60 (Cont)

Unit

48VT(-,N)A60115

48VT(-,N)A60130

Heating Motor

Rise

Range Speed

30 - 60°F

(17 - 33°C)

35 - 65°F

(19 - 36°C)

Wire External Static Pressure (in. W.C.)

Color 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

CFM 1445 _389;; _1_3_ ;128_ ;1236 _1_89;; _1_9 1,0_ 1,02_

Heating Rise 60 NA NA NA NA NA NA NA NA

Low Blue (OF)

Heating Rise 33 NA NA NA NA NA NA NA NA

(oc)

CFM 1678 1635 1602 !_4 _ _ !_438,,,,, !_40_ _1_3_

Mad- Heating Rise 52 53 54 56 57 59 60 NA NA

Pink (oF)

Low Heating Rise 29 30 30 31 32 33 34 NA NA

(oc)

CFM !_ 880 t 1843 1794 1753 1711 1675 1628

Heating Rise 44 45 46 47 48 50 51 52 53

Medium 2 Red (OF)

Heating Rise 25 25 26 26 27 28 28 29 30

(oc)

CFM _2_1 !2088,,,, _2Q65' _2Q13::: _98_i: i_785

Mad- Heating Rise 41 42 42 43 44 45 46 47 49

High1 Orange (OF)

Heating Rise 23 23 23 24 24 25 26 26 27

(oc)

CFM _2_61 !2409 2_g_i: !2_40 :, !2Q_:: : !_68,

Heating Rise /

High Black (°F) 35 36 37 38 40 41 42 44 46

Heating Rise

(oc) 20 20 21 21 22 23 23 25 26

CFM 1445 _$389 _1_3_ 128_ :1236 _1_89 _1_9 1,02_

Heating Rise NA NA NA NA NA NA NA NA NA

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise

(oc)

CFM

Heating Rise

(OF)

Heating Rise 25 26 26 27 27 28 28 29 30

(oc)

CFM _74

Heating Rise 39 40 41 42 44 45 47 49 51

High Black (OF)

Heating Rise 22 22 23 23 24 25 26 27 29

(oc)

Low Blue

NA NA NA NA NA NA NA NA NA

1678 1635 1602 _1558 _15_3 _4_ :_4_ 140_ _1_3_9

Mad- 57 59 60 62 64 65 NA NA NA

Pink

Low 32 33 33 34 35 36 NA NA NA

_880:1843 1794 1753 1711 1675 1628

49 50 51 52 54 55 56 57 59

Medium 2 Red

27 28 28 29 30 31 31 32 33

_2_1 _2e88:_2e_5 _2e13:::_98_:: _785

Mad- 45 46 47 48 49 50 51 52 54

High1 Orange

* Air delivery values are without air filter and are for dry coil (See 48VT-A Wet Coil Pressure Drop table).

1 Factory-shipped gas heating speed

2 Factory-shipped heat pump speed

NA - Not allowed for gas heating speed

Note: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting.

Shaded areas indicate speed/static combinations that are not permitted for dehumidification speed.

IX3

0._

<1_ q2

d_ q_p

(/)

O_ ¢'-/

CX-

r--q

Ld ::_

d_b

ZIZ

F--

q..)

dZ_

I!lll

qi!i,!iii

Fig. 15 - 208/230-1-60 Wiring Diagram, Unit 48VT-A

A09268

c/)

<a:

<=c

<a:

C/)

<a:

<=C

i_!oi

ill::i

Fig. 16 - 208/230-3-60 Wiring Diagram, [:nit 48VT-A

A09284

LI.

I g

.=_

_o °_

_ooo

0 0 _ _

Fig. 17 - Cooling Charging Table-Subcooling

A09412

MAINTENANCE

To ensure continuing high performance and to minimize the

possibility of premature equipment failure, periodic maintenance

must be performed on this equipment. This combination

heating/cooling unit should be inspected at least once each year by

a qualified service person. To troubleshoot cooling or heating of

units, refer to Tables 10, 11 and 12.

NOTE: Consult your local dealer about the availability of a

maintenance contract.

PERSONAL INJURY AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury

or death and unit component damage.

The ability to properly perform maintenance on this

equipment requires certain expertise, mechanical skills, tools

and equipment. If you do not possess these, do not attempt to

perform any maintenance on this equipment, other than those

procedures recommended in the Owner's Manual.

ELECTRICALSHOCK HAZARD

Failure to follow these warnings could result in personal

iniury or death:

1. Turn off electrical power to the unit and install a lockout

tag before performing any maintenance or service on this

unit.

2. Use extreme caution when removing panels and parts.

3. Never place anything combustible either on or in contact

with the unit.

4. Should overheating occur or the gas supply fail to shut

off, turn off external main manual gas valve to the unit.

Then shut off electrical supply.

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper

operation.

Errors made when reconnecting wires may cause improper

and dangerous operation. Label all wires prior to

disconnecting when servicing.

The minimum maintenance requirements for this equipment are as

follows:

1. Inspect air filter(s) each month. Clean or replace when

necessary. Certain geographical locations may require more

frequent inspections.

2. Inspect indoor coil, outdoor coil, drain pan, and condensate

drain each cooling season for cleanliness. Clean when

necessary.

3. Inspect blower motor and wheel for cleanliness at the

beginning of each heating and cooling season. Clean when

necessary. For first heating and cooling season, inspect

blower wheel bi-monthly to determine proper cleaning

frequency.

4. Check electrical connections for tightness and controls for

proper operation each heating and cooling season. Service

when necessary. Ensure electrical wiring is not in contact

with refrigerant tubing or sharp metal edges.

5. Check and inspect heating section before each heating

season. Clean and adjust when necessary.

6. Check flue hood and remove any obstructions, if necessary.

Air Filter

IMPORTANT: Never operate the unit without a suitable air filter

in the return-air duct system. Always replace the filter with the

same dimensional size and type as originally installed. (See Table 1

for recommended filter sizes.)

Inspect air filter(s) at least once each month and replace

(throwaway-type) or clean (cleanable-type) at least twice during

each heating and cooling season or whenever the filter(s) becomes

clogged with dust and/or lint.

Indoor Blower and Motor

NOTE: All motors are prelubricated. Do not attempt to lubricate

these motors.

For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease from the blower wheel and

motor annually.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal injury

or death.

Disconnect and tag electrical power to the unit before cleaning

the blower motor and wheel.

Cleaning the Blower Motor and Wheel

1. Remove and disassemble blower assembly as follows:

a. Remove blower access panel (see Fig. 19).

b. Disconnect 5pin plug and 4 pin plug from indoor

blower motor. Remove capacitor if required.

c. On all units, remove blower assembly from unit.

Remove screws securing blower to blower partition and

slide assembly out. Be careful not to tear insulation in

blower compartment.

d. Ensure proper reassembly by marking blower wheel and

motor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor shaft.

Remove screws that secure motor mount brackets to

housing, and slide motor and motor mount out of

housing.

2. Remove and clean blower wheel as follows:

a. Ensure proper reassembly by marking wheel orientation.

b. Lift wheel from housing. When handling and/or

cleaning blower wheel, be sure not to disturb balance

weights (clips) on blower wheel vanes.

c. Remove caked-on dirt from wheel and housing with a

brush. Remove lint and/or dirt accumulations from

wheel and housing with vacuum cleaner, using soft

brush attachment. Remove grease and oil with mild

solvent.

d. Reassemble wheel into housing.

e. Reassemble motor into housing. Be sure setscrews are

tightened on motor shaft flats and not on round part of

shaft. Reinstall blower into unit. Reinstall capacitor.

f. Connect 5pin plug and 4 pin plug to indoor blower

motor.

g. Reinstall blower access panel (see Fig. 19).

3. Restore electrical power to unit. Start unit and check for

proper blower rotation and motor speeds during heating and

cooling cycles.

Integrated

Gas Unit

(IGC)

Auto Transformer

fuses used on 460

(Hidden)

Board (IFB)

Draft

Motor

Fan Partition Flue RoIIout

Mounting Collector Indu Burner Mounting Switch

Bracket Box Blower Rack Screw

Housing

Fig. 18 -Blower Housing and Flue Collector Box

A09199

Compressor

Access Panel

Blower

Access

Panel

Fig. 19 -Unit Access Panels

Control

Access

Panel

A09214

Induced Draft (combustion air) Blower Assembly

The induced-draft blower assembly consists of the inducer motor,

the blower housing, and the induced-draft blower wheel.

Clean periodically to assure proper airflow and heating efficiency.

Inspect blower wheel every fall and periodically during the heating

season. For the first heating season, inspect blower wheel

bimonthly to determine proper cleaning frequency.

To inspect blower wheel, remove draft hood assembly. Shine a

flashlight into opening to inspect wheel. If cleaning is required,

remove induced-draft blower assembly as follows:

1. Remove control access panel (See Fig. 19).

2. Remove the 5screws that attach induced-draft blower as-

sembly to the flue collector box cover.

3. Slide the assembly out of the unit. (See Fig. 20). Clean the

blower wheel. If additional cleaning is required, continue

with Steps 4 and 5.

4. To remove blower wheel, remove 2 setscrews.

5. To remove inducer motor, remove screws that hold the

inducer motor to the blower housing.

6. To reinstall, reverse the procedure outlined above.

Flue Gas Passageways

To inspect the flue collector box and upper areas of the heat

exchanger:

1. Remove the induced draft blower assembly according to

directions in the Induced Draft Blower Assembly section.

2. Remove the 11 screws holding the flue collector box cover

(See Fig. 18) to the heat exchanger assembly. Inspect the

heat exchangers.

3. Clean all surfaces, as required, using a wire brush.

Limit Switch

Remove blower access panel (see Fig. 19). Limit switch is located

on the fan partition.

Burner Ignition

Unit is equipped with a direct spark ignition 100 percent lockout

system. Ignition module (IGC) is located in the control box (See

Fig. 18). Module contains a self-diagnostic LED. During

servicing, refer to label diagram or Table 5 in these instructions for

LED interpretation.

If lockout occurs, unit may be reset by either momentarily

interrupting power supply to unit or by turning selector switch to

OFF position at the thermostat.

Main Burners

At the beginning of each heating season, inspect for deterioration

or blockage due to corrosion or other causes. Observe the main

burner flames and adjust, if necessary.

Removal of Gas Train

To remove the gas train for servicing:

1. Shut off main gas valve.

2. Shut off power to unit and install lockout tag.

3. Remove control access panel (See Fig. 19).

4. Disconnect gas piping at unit gas valve.

5. Remove fan partition mounting bracket (2 screws located

on the left side of control compartment on the fan partition

panel). Slide bracket forward, bottom first to remove. (See

Fig. 18).

6. Remove wires connected to gas valve. Mark each wire.

7. Remove ignitor and sensor wires at the ignitor module.

8. Remove the mounting screw that attaches the burner rack to

the unit base (See Fig. 18).

9. Slide the burner rack out of the unit (See Fig. 18 and 21).

10. To reinstall, reverse the procedure outlined above.

Outdoor Coil, Indoor Coil, and Condensate Drain Pan

Inspect the outdoor coil, indoor coil, and condensate drain pan at

least once each year. The coils are easily cleaned when dry;

therefore, inspect and clean the coils either before or after each

cooling season. Remove all obstructions, including weeds and

shrubs, that interfere with the airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint,

clean the coils with a vacuum cleaner, using the soft brush

attachment. Be careful not to bend the fins. If coated with oil or

grease, clean the coils with a mild detergent-and-water solution.

Rinse coils with clear water, using a garden hose. Be careful not to

splash water on motors, insulation, wiring, or air filter(s). For best

results, spray outdoor coil fins from inside to outside the unit. On

units with an outer and inner condenser coil, be sure to clean

between the coils. Be sure to flush all dirt and debris from the unit

base.

Inspect the drain pan and condensate drain line when inspecting

the coils. Clean the drain pan and condensate drain by removing all

foreign matter from the pan. Flush the pan and drain tube with

clear water. Do not splash water on the insulation, motor, wiring, or

airfilter(s).Ifthe drain tube is restricted, clear it with a "plumbers

snake" or similar probe device. Ensure that the auxiliary drain port

above the drain tube is also clear.

BLOWER

HOUSING

2 SETSCREWS

(HIDDEN)

C99085

Fig. 20 - Removal of Motor and Blower Wheel

Fig. 21 -Burner Rack Removed

FEEDERTUBE

STUB TUBE

A07680

DEFROST

THERMOSTAT

Fig. 22 - Defrost Thermostat Location

C99029

Outdoor Fan

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unit

components.

Keep the outdoor fan free from all obstructions to ensure

proper cooling operation. Never place articles on top of the

unit.

1. Remove 6 screws holding outdoor grille and motor to top

cover.

2. Turn motor/grille assembly upside down on top cover to

expose the fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen the setscrew and slide the

fan off the motor shaft.

5. When replacing fan blade, position blade back to the same

position as before.

6. Ensure that setscrew engages the flat area on the motor shaft

when tightening.

7. Replace grille.

Electrical Controls and Wiring

Inspect and check the electrical controls and wiring annually. Be

sure to turn off the gas supply, and then the electrical power to the

unit.

Remove access panels (see Fig. 19) to locate all the electrical

controls and wiring. Check all electrical connections for tightness.

Tighten all screw connections. If any discolored or burned

connections are noticed, disassemble the connection, clean all the

parts, re-strip the wire end and reassemble the connection properly

and securely.

After inspecting the electrical controls and wiring, replace the

access panels (see Fig. 19). Start the unit, and observe at least one

complete heating cycle and one complete cooling cycle to ensure

proper operation. If discrepancies are observed in any operating

cycle, or if a suspected malfunction has occurred, check each

electrical component with the proper electrical instrumentation.

Refer to the unit wiring label when making these checkouts.

NOTE: Refer to the heating and/or cooling sequence of operation

in this publication as an aid in determining proper control

operation.

Refrigerant Circuit

Annually inspect all refrigerant tubing connections and the unit

base for oil accumulations. Detecting oil generally indicates a

refrigerant leak.

EXPLOSION, PERSONAL

ENVIRONMENTAL HAZARD INJURY AND

Failure to follow this warning could result in personal injury,

death or property damage.

System under pressure. Relieve pressure and recover all

refrigerant before system repair or final unit disposal. Use all

service ports and open all flow-control devices, including

solenoid valves.

If oil is detected or if low cooling performance is suspected,

leak-test all refrigerant tubing using an electronic leak-detector,

halide torch, or liquid-soap solution. If a refrigerant leak is

detected, refer to the Check for Refrigerant Leaks section.

If norefrigerantleaksarefoundandlowcoolingperformanceis

suspected,refertotheCheckingandAdjustingRefrigerantCharge

section.

Gas Input

The gas input does not require checking unless improper heating

performance is suspected. If a problem exists, refer to the Start-Up

section.

Indoor Airflow

The heating and/or cooling airflow does not require checking

unless improper performance is suspected. If a problem exists, be

sure that all supply- and return-air grilles are open and free from

obstructions, and that the air filter is clean. When necessary, refer to

the Indoor Airflow and Airflow Adjustments section to check the

system airflow.

Check Defrost Thermostat

The defrost thermostat is usually located on the lowest liquid

leaving circuit of the left condenser coil (see Fig. 22). The

thermostat closes at 32°F (0°C) and opens at 65°F (18°C).

Puron Items

Metering Device (Thermostatic Expansion Valve &

Piston)

This unit uses both a hard shutoff, balance port TXV in the indoor

coil and a piston in each side of the outdoor coil. The TXV

maintains a constant superheat at the evaporator coil exit (cooling

mode) resulting in higher overall system efficiency.

Pressure Switches

Pressure switches are protective devices wired into control circuit

(low voltage). They shut off compressor if abnormally high or low

pressures are present in the refrigeration circuit. These pressure

switches are specifically designed to operate with Puron (R-410A)

systems. R-22 pressure switches must not be used as replacements

for the Puron (R-410A) system.

Loss of Charge Switch

This switch is located on the liquid line and protects against low

suction pressures caused by such events as loss of charge, low

airflow across indoor coil, dirty filters, etc. It opens on a pressure

drop at about 20 psig. If system pressure is above this, switch

should be closed. To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have

continuity on a good switch.

NOTE: Because these switches are attached to refrigeration

system under pressure, it is not advisable to remove this device for

troubleshooting unless you are reasonably certain that a problem

exists. If switch must be removed, remove and recover all system

charge so that pressure gauges read 0 psi. Never open system

without breaking vacuum with dry nitrogen.

High-Pressure Switch

The high-pressure switch is located in the discharge line and

protects against excessive condenser coil pressure. It opens at 650

psig.

High pressure may be caused by a dirty outdoor coil, failed fan

motor, or outdoor air recirculation. To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have

continuity on a good switch.

Copeland Scroll Compressor (Puron Refrigerant)

The compressor used in this product is specifically designed to

operate with Puron (R-410A) refrigerant and cannot be

interchanged.

The compressor is an electrical (as well as mechanical) device.

Exercise extreme caution when working near compressors. Power

should be shut off, if possible, for most troubleshooting techniques.

Refrigerants present additional safety hazards.

EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury

or death and/or property damage.

Wear safety glasses and gloves when handling refrigerants.

Keep torches and other ignition sources away from

refrigerants and oils.

The scroll compressor pumps refrigerant throughout the system by

the interaction of a stationary and an orbiting scroll. The scroll

compressor has no dynamic suction or discharge valves, and it is

more tolerant of stresses caused by debris, liquid slugging, and

flooded starts. The compressor is equipped with an internal

pressure relief port. The pressure relief port is a safety device,

designed to protect against extreme high pressure. The relief port

has an operating range between 550 and 625 psi differential

pressure.

"13

-N

-_!:2:D-

Speedup

Pins Quiet

Shift Defrost interval

DIP switches

Fig. 23 - Defrost Control

A08020

Fig. 24 - Refrigerant Circuit

C99097

OUTDOOR COIL

LEGEND

HPS - High Pressure Switch

LCS - Loss of Charge Switch

_ Accurater_'Metering Device

[-_ Arrow indicates direction of flow

Bypass

Position

TXV in Meterin

Position

r-q

LCS

Fig. 25 - Typical Heat Pump Operation, Cooling Mode

"__N DOO R COIL

C03011

OUTDOOR COIL

LEGEND

HPS - High Pressure Switch

LCS - Loss of Charge Switch

_ _i_ Accurate¢_Meteiing Device

[] Arrow indicates direction of flow

Mete@g

Position

TXV in Bypass

Position

:[:='1

LCS

Fig. 26 - Typical Heat Pump Operation, Heating Mode

INDOOR COIL

C03012

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could result in personal iniury

or equipment damage.

This system uses Puron (R-410A) refrigerant which has

higher operating pressures than R-22 and other refrigerants.

No other refrigerant may be used in this system. Gauge set,

hoses, and recovery system nmst be designed to handle Puron.

If you are unsure, consult the equipment manufacturer.

Refrigerant System

This information covers the refrigerant system of the 48VT-A

including the compressor oil needed, servicing systems on roofs

containing synthetic materials, the filter drier and refrigerant

charging.

Compressor Oil

If additional oil is needed use Uniqema RL32-3MAF. If this oil is

not available, use Copeland Ultra 32CC or Mobil Artic EAL22CC.

This oil is extremely hygroscopic, meaning it absorbs water

readily. POE oils can absorb 15 times as nmch water as other oils

designed for HCFC and CFC refrigerants. Take all necessary

precautions to avoid exposure of the oil to the atmosphere.

Servicing Systems on Roofs and with Synthetic materials

POE (polyolester) compressor lubricants are known to cause long

term damage to some synthetic roofing materials.

Exposure, even if immediately cleaned up, may cause

embrittlement (leading to cracking) to occur in one year or more.

When performing any service that may risk exposure of

compressor oil to the roof, take appropriate precautions to protect

roofing. Procedures which risk oil leakage include, but are not

limited to, compressor replacement, repairing refrigerant leaks,

replacing refrigerant components such as filter drier, pressure

switch, metering device, coil, accumulator, or reversing valve.

Synthetic Roof Precautionary Procedure

1. Cover extended roof working area with an in, permeable

polyethylene (plastic) drip cloth or tarp. Cover an

approximate 10xl0 fl (3x3 m) area.

2. Cover area in front of the unit service panel with a terry

cloth shop towel to absorb lubricant spills and prevent

run-offs, and protect drop cloth from tears caused by tools

or components.

3. Place terry cloth shop towel inside unit immediately under

component(s) to be serviced and prevent lubricant run-offs

through the louvered openings in the unit base.

4. Perform required service.

5. Remove and dispose of any oil contaminated material per

local codes.

Liquid Line Filter Drier

This filter drier is specifically designed to operate with Puron. Use

only factory-authorized components. Filter drier must be replaced

whenever the refrigerant system is opened. When removing a filter

drier, use a tubing cutter to cut the drier from the system. Do not

unsweat a filter drier from the system. Heat from unsweating will

release moisture and contaminants from drier into system.

Puron (R-410A) Refrigerant Charging

Refer to unit information plate and charging chart. Some R-410A

refrigerant cylinders contain a dip tube to allow liquid refrigerant to

flow from cylinder in upright position. For cylinders equipped

with a dip tube, charge Puron units with cylinder in upright

position and a commercial metering device in manifold hose.

Charge refrigerant into suction-line.

TROUBLESHOOTING

Use the Troubleshooting Guides (See Tables 10-12) if problems

occur with these units,

START-UP CHECKLIST

Use Start-Up checklist to ensure proper start-up procedures are

followed.

PURON® (R-410A) QUICK REFERENCE GUIDE

H "

• Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and replacement

components are designed to operate with Puron

• Puron refrigerant cylinders are rose colored.

• Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.

• Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose when

charging into suction line with compressor operating

Manifold sets should be minimum 700 psig high side and 180 psig low side with 550 psig low-side retard.

Use hoses with minimum 700 psig service pressure rating.

Leak detectors should be designed to detect HFC refrigerant.

Puron, as with other HFCs, is only compatible with POE oils.

Vacuum pumps will not remove moisture from oil.

Do not use liquid-line filter driers with rated working pressures less than 600 psig.

Do not leave Puron suction line filter driers in line longer than 72 hrs.

Do not install a suction-line filter drier in liquid line.

POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

POE oils may cause damage to certain plastics and roofing materials.

Wrap all filter driers and service valves with wet cloth when brazing.

A factory approved liquid-line filter drier is required on every unit.

Do NOT use an R-22 TXV.

Never open system to atmosphere while it is under a vacuum.

When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter

driers. Evacuate to 500 microns prior to recharging.

• Do not vent Puron into the atmosphere.

• Observe all warnings, cautions, and bold text.

• All indoor coils must be installed with a hard shutoff Puron TXV metering device.

Table11-Troubleshooting Guide - Cooling or Heat Pump Heating Mode

SYMPTOM

Compressor and Outdoor fan will not

start.

Compressor will not start but Outdoor

fan runs.

CAUSE

Power Failure

Fuse blown or circuit breaker tripped

Defective thermostat, contactor, transformer, or control

relay

Insufficient line voltage

Incorrect or faulty wiring

Thermostat setting too high

Faulty wiring or loose connections in compressor circuit

Compressor motor burned out, seized, or internal over-

load open

Defective run/start capacitor, overload, start relay

One leg of 3-phase power dead

Three-phase scroll compressor makes

excessive noise, and there may Scroll compressor is rotating in the wrong direction

be a low pressure differential.

Refrigerant overcharge or undercharge

Compressor cycles (other than normally

satisfying thermostat).

Compressor operates continuously.

Excessive head pressure.

Head pressure too low.

Excessive suction pressure.

Suction pressure too low.

Compressor runs but outdoor fan does

not

Defective compressor

Insufficient line voltage

Blocked Outdoor

Defective run/start capacitor, overload or start relay

Defective thermostat

Faulty Outdoor-fan motor or capacitor

Damaged reversing valve

Restriction in refrigerant system

Dirty air filter

Unit undersized for load

Thermostat set too low

Low refrigerant charge

Mechanical damage in compressor.

Air in system

Frosted coil with incorrect defrost operation

Outdoor coil dirty or restricted

Dirty air filter

Dirty Indoor or Outdoor coil

Refrigerant overcharged

Air in system

Indoor or Outdoor air restricted or air short-cycling

Low refrigerant charge

Compressor IPR leaking

Restriction in liquid tube

High heat load

Compressor IPR leaking

Refrigerant overcharged

Reversing valve hung up or leaking internally

Dirty air filter

Low refrigerant charge

Metering device or low side restricted

Insufficient Indoor airflow

Temperature too low in conditioned area

Outdoor ambient below 55°F (12.8°C)

Field-installed filter-drier restricted

(Heat) Outdoor coil frosted

NC (normally closed) contacts on defrost board open

REMEDY

Call power company.

Replace fuse or reset circuit breaker.

Replace component.

Determine cause and correct.

Check wiring diagram and rewire correctly.

Lower thermostat setting below room temperature.

Check wiring and repair or replace.

Determine cause Replace compressor.

Determine cause and replace.

Replace fuse or reset circuit breaker. Determine

cause.

Correct the direction of rotation by reversing the

3-phase power leads to the unit.

Recover refrigerant, evacuate system, and recharge

to capacities shown on nameplate.

Replace and determine cause.

Determine cause and correct.

Determine cause and replace.

Replace thermostat.

Replace.

Determine cause and correct

Locate restriction and remove.

Replace filter.

Decrease load or increase unit size.

Reset thermostat.

Locate leak, repair, and recharge.

Replace compressor.

Recover refrigerant, evacuate system, and recharge.

Check defrost time settings, Reset as necessary

Check defrost temperature switch, Replace as nec-

essary

Clean coil or remove restriction.

Replace filter.

Clean coil.

Recover excess refrigerant.

Recover refrigerant, evacuate system, and recharge.

Determine cause and correct.

Check for leaks, repair, and recharge.

Replace compressor.

Remove restriction.

Check for source and eliminate.

Replace compressor.

Recover excess refrigerant.

Replace valve

Replace Filter.

Check for leaks, repair, and recharge.

Remove source of restriction.

Increase air quantity. Check filter -- replace if neces-

sary.

Reset thermostat.

Install low-ambient kit.

Replace.

Move timer on control board to 30 minutes between

defrost cycles

Check condition of relay on board Replace if neces-

sary

Table 12 - Troubleshooting Guide-Heating

SYMPTOM CAUSE

Water in gas line

No power to furnace

No 24-v power supply to control circuit

Burners will not ignite Mis-wired or loose connections

Misaligned spark electrodes

No gas at main burners

Dirty air filter

Gas input to furnace too low

Unit undersized for application

Inadequate heating Restricted airflow

Limit switch cycles main burners

Incomplete combustion results in: Aldehyde odors,

carbon monoxide, sooting flame, floating flame

Poor flame characteristics

REMEDY

Drain. Install drip leg.

Check power supply fuses, wiring or circuit breaker.

Check transformer.

NOTE: Some transformers have internal over-current protection

that requires a cool-down period to reset.

Check all wiring and wire nut connections

Check flame ignition and sense electrode positioning.

Adjust as necessary.

1. Check gas line for air. Purge as necessary. NOTE: After purging

gas line of air, wait at least 5 minutes for any gas to dissipate be-

fore attempting to light unit.

2. Check gas valve.

Clean or replace filter as necessary

Check gas pressure at manifold match with that on unit nameplate

Replace with proper unit or add additional unit

Clean or replace filter. Remove any restriction.

Check rotation of blower, temperature rise of unit. Adjust as neces-

sary.

1. Tighten all screws around burner compartment

2. Cracked heat exchanger. Replace.

3. Unit over-fired. Reduce input (change orifices or adjust gas line

or manifold pressure).

4. Check burner alignment.

5. Inspect heat exchanger for blockage. Clean as necessary.

Table 13 -Troubleshooting Guide-LED Status Codes

SYMPTOM CAUSE REMEDY

Check 5-amp fuse son IGC*, power to unit, 24-v circuit breaker,

No Power Hardware failure and transformer. Units without a 24-v circuit breaker have an

(LED OFF) Loss of power to control module (IGC)*. internal overload in the 24-v transformer. If the overload trips,

allow 10 minutes for automatic reset.

Limit switch faults Check the operation of the indoor (evaporator) fan motor, Ensure

(LED 2 flashes) High temperature limit switch is open. that the supply-air temperature rise is in accordance with the

range on the unit nameplate. Clean or replace filters.

Flame sense fault The IGC* sensed flame that should not be present. Reset unit. If problem persists, replace control board.

(LED 3 flashes)

4 consecutive limit switch Check the operation of the indoor (evaporator) fan motor and that

faults Inadequate airflow to unit. supply-air temperature rise agrees with range on unit nameplate

(LED 4 flashes) information.

Ignition lockout Check ignitor and flame sensor electrode spacing, gaps, etc.

(LED 5 flashes) Unit unsuccessfully attempted ignition for 15 minutes. Ensure that fame sense and ignition wires are properly terminated.

Verify that unit is obtaining proper amount of gas.

Verify wiring connections to pressure switch and inducer motor.

Pressure Switch motor fault Verify pressure switch hose is tightly connected to both inducer

(LED 6 flashes) Open pressure switch, housing and pressure switch, Verify inducer wheel is properly

attached to inducer motor shaft. Verify inducer motor shaft is turn-

ing.

Rollout switch will automatically reset, but IGC will continue to

Rollout switch fault lockout unit. Check gas valve operation. Ensure that induced-draft

(LED 7 flashes) Rollout switch has opened, blower wheel is properly secured to motor shaft. Inspect heat

exchanger. Reset unit at unit disconnect.

Internal control fault Microprocessor has sensed an error in the software If error code is not cleared by resetting unit power, replace the

(LED 8 flashes) or hardware. IGC*.

Temporary I hr auto reset Reset 24-v. to control board or turn thermostat off, then on again.

(LED 9 flashes) Electrical interference impeding IGC software Fault will automatically reset itself in one (1) hour.

*WARNING .!_ : If the IGC must be replaced, be sure to ground yourself to dissipate any electrical charge that my be present before handling new control

board. The IGC is sensitive to static electricity and my be damaged if the necessary precautions are not taken.

IMPORTANT: Refer to Table 12-Troubleshooting Guide-Heating for additional troubleshooting analysis.

LEGEND

IGC--Integrated Gas Unit Controller

LED--Light-Emitting Diode

I. PRELIMINARY INFORMATION

MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

START-UP CHECKLIST

(Remove and Store in Job Files)

II. PRESTART-UP (Insert check mark in box as each item is completed)

()VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS

( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS

( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)

( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE

( ) VERIFY THAT UNIT INSTALLATION IS LEVEL

( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

III. START-UP

ELECTRICAL

SUPPLY VOLTAGE

COMPRESSOR AMPS

INDOOR (EVAPORATOR) FAN AMPS

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE

RETURN-AIR TEMPERATURE DB

COOLING SUPPLY AIR DB

HEAT PUMP SUPPLY AIR

GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE

GAS MANIFOLD PRESSURE

REFRIGERANT SUCTION

REFRIGERANT DISCHARGE

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS

GAS HEAT TEMPERATURE RISE

TEMPERATURE RISE (See Literature) RANGE

MEASURED TEMPERATURE RISE

*Measured at suction inlet to compressor

1- Measured at liquid line leaving condenser.

IN. W.C.

PSIG, SUCTION LINE TEMP*

PSIG, LIQUID TEMPi-

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

Catalog No: 48VT-06SI

Replaces: 48VT- 05Sl

CARRIER Package Units(both Units Combined) Manual L1001389

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