Carrier 48XP024040300 User Manual CENTRAL PACKAGE Manuals And Guides L0907192
CARRIER Package Units(both units combined) Manual L0907192 CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides
User Manual: Carrier 48XP024040300 48XP024040300 CARRIER CENTRAL PACKAGE - Manuals and Guides View the owners manual for your CARRIER CENTRAL PACKAGE #48XP024040300. Home:Heating & Cooling Parts:Carrier Parts:Carrier CENTRAL PACKAGE Manual
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® Turn to the Expertg 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 SAFETY CONSIDERATIONS ......................... INTRODUCTION ................................... RECEIVING AND INSTALLATION ................. Check Equipment .................................. Identify Unit .................................... Inspect Shipment ................................. Provide Unit Support ............................... Roof Curb ...................................... Slab Mount ..................................... Ground Mount .................................. Field Fabricate Ductwork ............................ Provide Clearances ................................. Rig and Place Unit ................................. Connect Condensate Drain ........................... Install Flue Hood ................................... Install Gas Piping .................................. Install Duct Connections ............................. Configuring Units for Downflow (Vertical) Discharge ...................................... Install Electrical Connections ........................ High-Voltage Connections ........................ Special Procedures for 208-V Operation .............. Control Voltage Connections ....................... Easy Select . .................................. Transformer Protection ........................... PRE-START-UP ................................... START-UP ..................................... Check for Refrigerant Leaks ......................... Unit Sequence of Operation ......................... 48XP Sequence of Operation ...................... Start-Up Heating & Make Adjustments ................ Check Heating Control ........................... Check Gas Input ................................ Adjust Gas Input ................................ Check Burner Flame ............................. Airflow and Temperature Rise ...................... Heating Sequence of Operation ..................... Limit Switches ................................. Rollout Switch ................................. Start-Up Cooling & Make Adjustments ................ Checking Cooling Control Operation ................ Checking & Adjusting Refrigerant Charge ............ Indoor Airflow and Airflow Adjustments ............. MAINTENANCE ................................ Air Filter ........................................ Evaporator Blower and Motor ........................ Flue Gas Passageways .............................. TM PAGE 1 2 2-13 2 2 2 2 2 2 2 2 2 4 6 7 7 9 9 10 10 11 11 11 14 14 14-21 14 14 14 15 15 15 15 16 16 16 16 17 17 17 21 21 22-25 22 22 22 C99088 Fig. 1 - Unit 48XP Combustion Air Blower ............................ Limit Switch ..................................... Burner Ignition ................................... Main Burners .................................... Condenser Coil, Evaporator Coil, & Condensate Drain Pan ....................................... Condenser Fan ................................... Electrical Controls and Wiring ....................... Refrigerant Circuit ................................. Gas Input ........................................ Evaporator Airflow ................................ Puron® Items .................................... TROUBLESHOOTING .............................. START-UP CHECKLIST ............................ SAFETY Improper installation, 23 23 23 23 23 24 24 24 24 24 25 26 26 CONSIDERATIONS 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 packaged with the kits or accessories when installing. instructions 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 Z223A, andthe (NEC) NFPA 70. In Canada refer to the current editions National Electrical of the National Code 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 Z_ nearest equipment distribution prevent loss installation. or damage, Step 2 -- Provide For hurricane leave if any item is missing. packages Engineering) contact distributor Certificate for details ROOF CURB Install accessory signal words with curb (See Fig. 4). Install insulation, cant strips, flashing. Ductwork must be attached to curb. the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor erty damage. NOTE is used result in enhanced installation, personal injury or product and propto highlight suggestions which will reliability, roof curb in accordance IMPORTANT: critical The for a water Failure to follow injury or death. result in personal mm) warning damage. could SHOCK HAZARD result AND A qualified installer or agency must use factory-authorized kits or accessories when modifying product. slab, or directly on the ground, combination for outdoor if local codes Models with an N in the fifth position of the model number are dedicated Low NOx units designed for California installations. 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 Step 1 -- Check IDENTIFY AND INSTALLATION Equipment 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 while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before Forward claim papers directly to transportation Manufacturer is not responsible for any damage incurred Check all items against shipping list. Immediately also can result in information removal. company. in transit. notify thick with as required. pad that is a minimum 2 in. (51 mm) The unit may be installed above either grade. of 4 The on a slab or placed directly if local codes permit. Place the unit with gravel for condensate discharge. Field Fabricate slab on level on the ground Ductwork flashing and mastic in accordance Ducts passing through an unconditioned and covered with a vapor barrier. permit (See Fig. 4 for roof curb dimensions). These for additional by local codes. with counter codes. only this 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 cement is 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 INTRODUCTION a rooftop, supplied Secure all ducts to roof curb and building structure on vertical discharge units. Do not connect ductwork to unit. For horizontal in personal The 48XP unit (see Fig. 1) is a fully self-contained, Category I gas heating/electric cooling unit designed curb material gasketing slab except when required GROUND MOUNT Step 3 -- Failure to follow this injury, death or property to the roof gasketing applied and 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 ground, prepared ELECTRICAL POISONING unit shipped roofing, air leaks and poor unit performance. in. (102 Before installing or servicing system, always turn off and tag lockout main power to system. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable. FIRE, EXPLOSION, CARBON MONOXIDE of the Install Place the unit on a solid, level concrete could with instructions 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 or operation. HAZARD this warning seal. with the roof curb. Improperly installation instructions SLAB MOUNT ELECTRICALSHOCK gasketing tight and PE if required. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these words: DANGER, WARNING, and CAUTION. These are used with the safety-alert symbol. DANGER identifies To until Unit Support tie downs, (Professional office all parts in original the with space must applicable be insulated If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes. A minimum clearance is not required around ductwork. Cabinet return-air static shall not exceed -.25 IN. W.C.. Step 4 -- Provide Clearances The required minimum operating and service in Fig. 2 and 3. Adequate combustion, air must be provided in accordance Combustion and Ventilation, of the clearances NFPA54/ANSI Z223.1 or applicable provisions code. In Canada, follow section 8 of Installation Codes or applicable IMPORTANT: Do provisions not restrict outdoor at either the outdoor-air detrimental to compressor inlet life. or are shown ventilation and condenser with section 9.3, Air for National Fuel Gas Code the of local building Can/CSA-BI49.1 of local building airflow. fan code. An air restriction discharge may be 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 overhang) horizontal (1219 under a partial overhang (such as a normal house is 48-in. (1219 mm) above the unit top. The maximum extension of a partial overhang must not exceed 48-in. 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. 106 o [4 17] 208 _SXPO3OO4O/OGO _SXP036060/090 CORNER "1 .... It 406 [16 UNIT ELECTRICAL CHARACTERISTICS UNIT _8XPO2_04O/OGO 230 I 60 WT LBS KG 340 154 208 230 i 60, 2081230 3 60 344 156 208 230 i 60, 208/230 3 60 368 167 REQ_RED WEIGHT LBS/KG 2 .... 3.... 4" UNIT HEIGHT CENTER OF GRAVITY "A" 368 40641160] 55881220] 38741i53] 4470[176] 50801200] 55561i4 68131 102146 119/54 030 52123 69/31 103/a7 120155 TO _ OF UNIT ............................ DUCT SIDE OF UNIT ......................................... SIDE OPPOSETE DUCTS..................................... BOTTOM OF UNIT .............................. FLUE PANEL .............................................. 036 55124 74133 110150 129158 NEC. REQUIRED CLEARANCES. MILLIMETERS [IN] 10668 [4200] 9140 [36 ODE ....... i0668 @ t _MINIMUM DISTANCES:IF INDOOR COIL _UTDOOR 12192 [_800] 9140 [3600] 304 8 [1200]* UNIT IS PLACED LESS THAN 3048 [1200] FROM WALL SYSTEM,THEN SYSTEM PERFORMANCE MAYBE COMPROMISED DIMENSIONS I MILLIMETERS [IN] 91_ O [3600] 91_0 [3600] EVAP COIL ACCESS SIDE ....................... POWER ENTRY SIDE ........................................ (EXCEPT FOR NEC REQUIREMENTS) UNIT TOP ........................................... SIDE OPPOSITE DUCTS..................................... DUCT PANEL ............................ t D [4200] CLEARANCE FOR OPERATION AND SERVICINO OUTDOOR 1533 [604] 44701176] MILLIMETERS [IN] 3556 [1400] 508 [200] 3556 [1400] O0 [OOO] 9i44 [3600] BETWEEN UNITS, POWER ENTRY SIDE ........................ UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES, DOWER ENTRY SIDE ................... REQ_RED O] CLEARANCES TO COMBUSTIBLE MATL. 51123 805 [317] Z B[i_5] 024 5 DOE MM/IN Y 940,313702] IN [] ARE IN INCHES COIL TOP VIEW m_ I 798 [S 5 44] [4700] [455] FIELD ENTRY_ SERVICE PORTS i _I156 FULL LOUVER 222[088] DEA d_ i238 [487] t 456 R [1796] INING m_:_RN 3130 [1232] i [020] [168] _3265 [1285] 19 O[O 15] NPT X 220 DEER _83 [32 0 72] LEFT SIDE VIEW o> 2 COMPRESSOR, 8LOWER, GAS PARTITIO & ELECTRICAL ACCESS PANEL 12263 [A828] _724 [463] a68 [184] NPT 52 8 [208] L FRONT VIEW 898 [353] [21 67] GAS ENTRY 1222 [48_] [285] L__ L1177 !496 [98B] [983] RIGHT SIDE VIEW REAR VIEW 48XP500006 WT UNIT HEIGHT CENTER OF GRAVITY "A" Z KG 230 1 60, 208/230 3 60 412 181 1091714298: 4953[195] 48XP048090/!15/i30 208 230 1 60, 208/R30 3 60 462 210 I1425[4498: 4953[195] 4476[176] 4572[180] 48XPO6009B/!lS!130 208 230 1 60, 208/230 3 60 507 230 119331469B: 533412/0] 5BBB[ROO] 4420[176] "i .... REO_PED 2 .... 3 .... 4" CLEARANCES TO COMBUSTIBLE MATL. 82/37 124156 144/65 69/31 92/42 139/63 16R/73 TOP OF UNET ............................................. DUCT SEDE OF UNET ......................................... SIDE OPPOSITE DUCTS ..................................... BOTTOM OF UNET............................................ FLUE PANEL ............................... 76135 101146 152/69 178180 NEC. REQUIRED CLEARANCES. 042 62/28 048 060 NB721180] MILLIMETERS [IN] 3596 [1400] 508 [200] 3556 [1400] OO [OOO] 914 4 [36 O0] MILLIMETERS [IN] 10668 [a20O] 9140 [3600] BETWEEN UNITS, POWER ENTRY SIDE ....................... UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIBE .......... UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES, POWER ENTRY SIDE .................... REO_RED t 805 [317] 733 [682] 1[ OUTBOOR _MINIMUM [i1 INDOOR 6OIL _. I \N [i1 10668 t [4200] CLEARANCE FOR OPERATION AND ,SERVICING MILLIMETERS [IN] 9140 [3600] 914 O [3600] EVAP COIL ACCESS SEDE .................................. ROWER ENTRY SEDE ............................ (EXCEPT FOR NEC REQUIREMENTS) oNIT TOP ....................................... SIDE OPPOSITE DUCTS ..................................... DUCT PANEL .............................................. Y ml MM/IN X LBS 208 CORNER WEIGHT LBS/KG 4066 [1601] UNIT ELECTRICAL CHARACTERISTICS UNIT 48XP042060/090 860 [339] 12192 9140 3048 [4800] [3600] [1200]_ DESTANCES:ZF UNIT IS PLACED LESS THAN 3048 [1200] FROM WALL SYSTEM,THEN SYSTEM PERFORMANCE MAYBE COMPROMISED DIMENSIONS [] IN ARE IN INCHES TOP VIEW m_ & 10906 [4294] _1i63 [458] FIELD ENTRY SERVECE PORT .=. 28 61113] BIA N 0 POWER ENTRY\ \ t_ • _ _° FULL LOUVER FULL LOUVER EL f 506 [19 _X_ BLOWER, & ELECTRICAL 11231 [4422] . . . \ COMPRESSOR, LEFT SIDE VIEW SUPPLY DUCT 93] GAS SECTION _ ACCESS [284] PANEL 466 [i 84] i422 [SGO] FRONT VIEW [016] 526 [R07] [i3 83] [1383] 872 [343] RIGHT SIDE VIEW REAR VIEW 48XP500009 > g J base\ iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_i!i!ii!ii!ii!ii!ii!i!!_!!_!!_!!_!i _i!_iii_ii_ii_ii_ii_ii_ii_ii_ii_i!!!!!_!!_!!i!i!i!ii!ii!iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii!i!i!i!iiiiiiiiiiiiiiiiii_i_l_l ...... J Screw / (NOTE A) *Gasketing / _ _'_v .._ Wood \ Flashing. field II1_1 tl II_s_n I Roofing \ f'_'dsuPP'ied -- _, \ (f!eld I ll_i!_ II mate_al IL - tl_iill /IS_!II _li supplied) II-_Uuctwork / II ,i_,dsupp,ed/ Roof Curb for Small Cabinet Roof Curb for Note A:When unit mounting screw is used retainer bracket must also be used. Large Cabinet Note A:When unit mounting screw is used retainer bracket must also be used. Supply opening (BxC) 445/16" R/A S/A \, \ Insulated deck pan -'---'-- GaSkec,tua_Ou nd. / _ Gasket around outer edge \ C00076 CATALOG NUMBER A IN. (MM) B IN. (MM) CPRFCURB006A00 8 (203) 11 (279) 16-1/2 (419) 28-3/4 CPRFCURB007A00 14 (356) 11 (279) 16-1/2 (419) 28-3/4 UNIT SIZE 48XP024-036 CPRFCURB008A00 48XP042-060 8 (203) 14 (356) CPRFCURB009A00 16-3/16 16-3/16 C IN. (MM) (411) (411) 17-3/8 17-3/8 D IN, (441) (441) (MM) (730) (730) 40-1/4 (1022) 40-1/4 (1022) NOTES: 1. Roof curb must be set up for unit being installed. 2. Seal 3. Roof strip 4. Attach 5. Insulated d. When curb must ductwork panels: unit conditions. be applied, is made to curb 1-in. mounting This as required, of 16-gauge (flanges (25 mm) screw bracket to unit being installed. steel. of duct thick is used is available rest on curb). fiberglass (see Note through 1 lb (.45 A), a retainer kg) density. bracket must be used as well. This bracket Micrometl. Fig. 4 - Roof Curb Dimensions must also be used when required by code for hurricane or seismic Unit SMALL CABINET 030 024 Ib Rigging Weight kg 351 Ib 159 NOTE: See dimensional 036 kg 355 Unit Ib 161 042 kg 379 Rigging Weight 172 LARGE CABINET 048 060 Ib kg Ib kg Ib kg 427 194 477 216 522 237 drawing for corner weights. Fig. 5 - 48XP Rigging Weights DUCTS SEAL STRIP MUST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB BASEPAN SLOT (BELOW BEFORE RIGGING HANDHOLDS) C99015 U NIT 48XP A B in. 22.0 22.0 22.0 20.0 21.5 23.5 024 030 036 042 048 060 in. 14.50 14.50 15.30 21.25 16.3 16.3 mm 558.5 558.5 558.5 508.0 546.1 596.9 Fig. 6 - Suggested mm 368.3 368.3 388.6 539.8 414.0 414.3 Rigging Step 5 -- Rig and Place Unit Rigging and handling many reasons due structures, etc.). Only trained, should handle When working of this equipment to the installation can be hazardous location (roofs, for elevated PERSONAL qualified crane operators and ground support staff this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply. Use spreader bars or crate top when rigging the unit. The all rigging and moving operations. The unit must be level for proper condensate drainage; therefore, the ground-level pad or accessory roof curb must be level before setting the unit in place. a field-fabricated support is used, be sure that the support is and properly supports the unit. Lifting point should be directly UNIT over the center of gravity FALLING Failure to follow iniury or death. Never stand beneath for the unit. Failure to follow iniury or death. Never exceed result in personal Step 6 -NOTE: comply Model Connect When Condensate installing with local codes 48XP disposes condensate drain connection be sure to and restrictions. of condensate fitting which exits through and 3 for location). Condensate Drain water through the compressor water can be drained directly a 3/4 in. NPT access panel (See Fig. 2 onto the roof in rooftop 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 this warning INJURY could Accessory lifting kit is only to be used with Small Packaged units which have a composite unit base with molded rigging holds. could result in personal units or lift over people. overflowing (See Fig. 7). Prime the trap with water. When gravel apron, make sure it slopes away from the unit. If the installation requires draining from the unit, install a 2-in. (51 connection the outlet condensate PERSONAL warning installations (where permitted) or onto a gravel apron in groundlevel installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make HAZARD rigged HAZARD this units must be rigged for lifting (See Fig. 6). Refer to Table 1 for operating weight. Use extreme caution to prevent damage when moving the unit. Unit must remain in an upright position during When level INJURY to follow iniury/death. and install this equipment. with Failure HAZARD this warning Prime could 200 lb (91 kg) per bracket result in personal lifting force. using a the condensate water away mm) trap at the condensate to ensure proper drainage (See Fig. 7). Make sure that of the trap is at least 1 in. lower than the drain-pan connection. This prevents the pan from overflowing. 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) outlet end of the 2-in. (51 mm) trap. Do not undersize Pitch the drain tube downward at a slope of at least l-in. - at the the tube. (25 mm) for every 10 ft (3 m) of tube for leaks. the drain horizontal run. Be sure to check 1" (25 mm) absence of local building recommendations: MIN. ._L TRAP OUTLET Z _..'__-j__ 1. Avoid 2"(51 mm)M IN. heating Trap flue hood assembly is shipped in the return indoor blower compartment cover to locate the assembly. (See Fig. 9). Remove Dedicated MUST low NOx models Quality Management Districts be installed section of the the return duct in California Air where a Low NOx rule exists. These models meet the California maximum oxides emissions requirements of 40 nanograms/joule of nitrogen (NOx) or less as shipped from the factory. NOTE: Low installations. PERSONAL NOx requirements INJURY AND UNIT apply only DAMAGE to natural gas HAZARD Failure to follow this warning could result in personal or death and unit component damage. injury The venting system is designed to ensure proper venting. The flue hood assembly must be installed as indicated in this section of the unit installation instructions. Install the flue hood 1. This as follows: installation must conform with local building codes and with the National Fuel Gas Code (NFGC), NFPA 54/ANSI Z223.1 (in Canada, CAN/CSA B149.1, 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. 9). Place vent cap assembly over flue panel. Orient screw holes in vent cap with holes in the flue panel. 3. Secure flue hood to flue panel by inserting a single the right side and the left side of the hood. screw on 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. FPT gas inlet on the manual shutoff or 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. 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 7.0 IN. W.C. or greater than 13 IN. W.C. at the unit connection. An l/8-in. NPT connection, must supply connection plugged tapping, accessible be installed immediately to the gas valve. 2. Protect thermal Step 7 -- Install Flue Hood The for upstream test of the adhere to the following pertinent low spots in long runs of pipe. Grade all pipe 1/4 in. (6 mm) in every 15 ft (5 m) to prevent traps. Grade horizontal runs downward to risers. Use risers to connect A08001 Fig. 7 - Condensate codes, gage gas When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1, in Canada CAN/CSA-BI49.1 and B149.2 latest editions. In the section and to meter. all segments damage. all to of piping Support system all piping against physical with appropriate and straps, hangers, etc. Use a minimum of one hanger every 6 ft (2 m). For pipe sizes larger than 1/2 in., follow recommendations of national codes. 3. Apply joint compound (pipe dope) male threads of joint when making sparingly and only to 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. Table UNIT SIZE 48XP NOMINAL CAPACITY (ton) SHIPPING WEIGHT (Ib) (kg) COMPRESSORS Quantity REFRIGERANT (R-410A) Quantity (Ib) (kg) REFRIGERANT METERING DEVICE CONDENSER COIL Rows...Fins/in. Face Area (sq ft) CONDENSER FAN Nominal Cfm Diameter (in.) (me) Motor Hp (Rpm) EVAPORATOR COIL Rows...Fins/in. Face Area (sq ft) EVAPORATOR BLOWER Nominal Airflow (Cfm) Size (in.) (me) Motor (hp) FURNACE SECTION* 1 - Physical 024040 2 388 176 Data 024060 2 388 176 - Unit 030040 2-1/2 392 178 48XP 030080 2-1/2 392 178 036090 3 416 189 042060 3-1/2 464 210 042090 3-1/2 464 210 9.5 4.3 9.5 4.3 10.7 4.9. 10.7 4.9 036080 3 416 189 Scroll 1 7.3 3.3 7.3 3.3 8.0 3.6 8.0 3.6 TXV 2...21 11.95 2...21 11.95 2...21 11.95 2...21 11.95 2...21 13.7 2...21 13.7 2...21 15.4 2...21 15.4 2350 22 559 2350 22 559 2350 22 559 2350 22 559 2800 22 559 2800 22 559 2800 22 559 2800 22 559 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 3...15 3.7 3...15 3.7 3...15 3.7 3...15 3.7 4...15 3.7 4...15 3.7 3...15 3.7 3...15 3.7 770 10x10 254x254 1/2 770 10x10 254x254 1/2 960 10x10 254x254 1/2 960 10x10 254x254 1/2 1150 1 lx10 279x254 3/4 1150 1 lx10 279x254 3/4 1400 1 lx10 279x254 3/4 1400 1 lx10 279x254 3/4 2...44 2...38 2...44 2...38 2...38 3...38 2...38 2...38 Burner Orifice No. (Qty._Drill Size) Natural Gas 2...50 2...46 2...50 2...46 2...46 3...46 2...46 2...46 Burner Orifice No. (Qty._Drill Size) Propane Gas HIGH-PRESSURE SWITCH (psig) 650 +/-15 420 +/-25 Cut-out Reset (Auto) LOSS-OF-CHARGE / LOW-PRESSURE SWITCH 20 +/-5 (Liquid Line) (psig) Cut-out 45 +/-10 Reset (auto) RETURN-AIR FILTERS Throwawayt 20x24x1 24x30x1 (in.) 508x610x25 610x762x25 (mm) *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.. Table 1 - Physical Data - Unit 48XP (Continued) UNIT SIZE 48XP 048090 048115 048130 060090 NOMINAL CAPACITY (ton) 4 4 4 5 SHIPPING WEIGHT (Ib) 512 512 512 559 (kg) 232 232 232 254 COMPRESSORS Scroll Quantity 1 REFRIGERANT (R-410A) Quantity (Ib) 11.25 11.25 11.25 13.2 (kg) 5.1 5.1 5.1 6.0 REFRIGERANT METERING DEVICE T; IV CONDENSER COIL Rows...Fins/in. 2...21 2...21 2...21 2...21 Face Area (sq ft) 17.4 17.4 17.4 19.3 CONDENSER FAN Nominal Cfm 3300 3300 3300 3300 Diameter (in.) 22 22 22 22 (mm) 559 559 559 559 Motor Hp (Rpm) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100) EVAPORATOR COIL Rows...Fins/in. 4...15 4...15 4...15 4...17 Face Area (sq ft) 4.7 4.7 4.7 5.7 EVAPORATOR BLOWER Nominal Airflow (Cfm) 1400 1400 1400 1710 Size (in.) 1lx10 1lx10 1 lx10 1 lx10 (mm) 279x254 279x254 279x254 279x254 Motor (hp) 3/4 (1075) 3/4 (1075) 3/4 (1075) 1.0 (1040) FURNACE SECTION* Burner Orifice No. (Qty...Drill Size) Natural Gas 3...38 3...33 3...31 3...38 Burner Orifice No. (Qty._Drill Size) Propane Gas 3...46 3...42 3...41 3...46 HIGH-PRESSURE SWITCH (psig) Cut-out 650 +/-15 Reset (Auto) 420 +/-25 LOSS-OF-CHARGE / LOW-PRESSURE SWITCH (Liquid Line) (psig) 20 +/-5 Cut-out Reset (auto) 45 +/-10 RETURN-AIR FILTERS Throwaway'[" (in.) 24x30x1 (mm) 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 300 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.. 060115 5 559 254 060130 5 559 254 13.2 6.0 13.2 6.0 2...21 19.3 2...21 19.3 3300 22 559 1/4 (1100) 3300 22 559 1/4 (1100) 4...17 5.7 4...17 5.7 1710 1 lx10 279x254 1.0 (1040) 1710 1 lx10 279x254 1.0 (1040) 3...33 3...42 3...31 3...41 heating airflow velocity of Table 2- Maximum Gas NOMINAL IRON PIPE, SIZE (IN,) 1/2 3/4 1 11/4 11/2 INTERNAL DIAMETER (IN,) .822 .824 1.049 1.380 1.810 Flow Capacity* LENGTH 10 (3) 175 380 880 1400 2100 20 (8) 120 250 485 950 1480 30 (9) 97 200 375 770 1180 40 (12) 82 170 320 800 990 50 (15) 73 151 285 580 900 OF PIPE, 80 (18) 88 138 280 530 810 70 (21) 81 125 240 490 750 FT (m)t 80 (24) 57 118 220 480 890 90 (27) 53 110 205 430 850 100 (30) 50 103 195 400 820 125 (38) 44 93 175 380 550 150 (48) 40 84 180 325 500 175 (53) -77 145 300 480 200 (81) -72 135 280 430 * Capacity of pipe in cuft 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 Z223.1. 1-This length includes an ordinary number of fittings. 4. Install sediment trap in riser leading to heating section (See Fig. 8). This drip leg functions as a trap for dirt and condensate. FIRE IN 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. TEE -Use proper length of pipe to avoid stress on gas control manifold. NIPPLE -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 nfininmm of 2 in. (51 ram) outside furnace casing. CAP C99020 Fig. 8 - Sediment Trap 5. Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft (2 m) of heating section. 6. Install ground-joint union close 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 closing the external main manual shutoff valve and slightly opening the ground-joint union. -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 factoryinstalled gas lines after all piping connections have been completed. Use soap-and-water solution (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 and tag lockout main power to system, There may be more than one disconnect switch, 1.Open allelectrical disconnects before starting anyservice work. 2.Remove horizontal (metal) ductcovers toaccess vertical (downflow) discharge ductknockouts inunitbase. 3.Useascrewdriver andhammer toremove thepanels inthe bottom oftheunitbase (See Fig.9& 10). PROPERTY Failure DAMAGE HAZARD to follow this caution may result in property Collect ALL screws that were removed. on rooftop as permanent damage 5. It is recommended perimeter that of the vertical to the roof may occur. the base insulation return-air opening the base with aluminum tape. Applicable require aluminum tape to prevent exposed 6. damage. Do not leave screws around the be secured local codes fiberglass. to may Cover both horizontal duct openings with the provided duct covers. Ensure opening is air- and watertight. 7. After completing unit conversion, and power up unit. perform all safety checks NOTE: The design and installation of the duct system nmst be in accordance with the standards of the NFPA for installation of nonresidence-type 90A or ordinances. I I Adhere to the following installing the duct system: i' RETURN DUCT OPENING SUPPLY DUCT OPENING 1. Units C99011 Fig. 9 - Supply and Return air conditioning residence-type, are removing Duct Opening shipped and ventilating NFPA 90B; criteria when for and/or horizontal systems, local selecting, duct NFPA codes sizing, and and installation (by duct covers). 2. Select and size ductwork, supply-air registers, and return-air grilles according to American Society of Heating, Refrigeration and Air Conditioning recommendations. Engineers (ASHRAE) 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 ensure weather tight and airtight seal. gaskets 4. All units must have field-supplied filters or accessory rack installed in the return-air side of the Recommended sizes for filters are shown in Table 1. to filter unit. 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. 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) n_ininmm installation standards for heating and air conditioning systems. Secure all ducts to VERTICAL DUCT COVERS building 7. Flash, C99012 Fig. 10 - Vertical 4. If unit ductwork Duct Cover is to be attached on the unit base (jackstand time. to vertical applications building building Removed opening only), flanges do so at this 10 structure. weatherproof, structure practices. and vibration-isolate in accordance all openings with local codes in and good Step 10 -- Install Electrical Connections HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING r I¢_ LABEL) ELECTRICALSHOCK " " " Lc_ HAZARD Failure to follow this warning or death. could result in personal injury mmm FIELD-SUPPLIED FUSED DISCONNECT GND 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. CONTROL BOX OO- YZL£Y)--D.i Z-,,'_ ,THERMOSTAT (TYPICAL) GR._(e_) _. i-¢n_ LOW-VO LTAG E POWER LEADS(SEE UNIT WIRING LABEL) _J O_ RE DZR2, 1>.i-f_ O- BREC_) _ i"(-€3 O= SPLICE UNIT COMPONENT DAMAGE LEGEND HAZARD Failure to follow this caution could result in damage being installed. 1. Make all electrical NFPA 70 governing connections C22.1 connections in accordance 2. Use Canadian only Field Control-Voltage Wiring Field High-Voltage Wiring ....... to the unit A08476 Fig. ll with NEC Three-phase (latest edition) and local electrical codes such wiring. In Canada, all electrical must be in accordance with CSA standard Electrical Code local codes. Refer to unit wiring copper conductor field-supplied electrical NOT USE ALUMINUM 1. Part 1 and applicable for connections switch - High and Control-Voltage Run the high-voltage the control box. ground and unit. DO 4. Connect field compressor 3. Be sure operating 3-phase that high-voltage power to unit is within voltage range indicated on unit rating plate. On units, ensure phases are balanced within 2 percent. Consult local power company for correction improper voltage and/or phase imbalance. as high-voltage 5. Do not damage internal through any panel to mount etc. HIGH-VOLTAGE 6. Connect of SPECIAL components when electrical hardware, on connection to the lines 11 of the wire on connection 13 of field wire L3 to Blue wire from compressor. PROCEDURES FOR 208-V OPERATION Failure to follow or death. separate electrical disconnect switch service mounted with at, a or HAZARD this warning could result in personal injury Make sure the power supply to the unit is switched OFF before making any wiring changes. With disconnect switch open, move yellow wire from transformer (3/16 in.) terminal marked 230 to terminal marked 208. This retaps transformer to primary voltage of 208 vac. to the unit rating plate for and minimum circuit amps for wire sizing. entry points wire connected drilling conduit, 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 to black wires connection. contactor. ELECTRICALSHOCK within sight from, the unit. Refer maximum fuse/circuit breaker size (ampacity) LI ground leads into wires. CONNECTIONS The unit must have a field-supplied, waterproof, lead to chassis 5. Connect field wire L2 to yellow the compressor contactor. 4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are in same conduit (L1, L2, L3) and ground 3. Locate the black and yellow side of the contactor. between Connections units: 2. Connect diagram. disconnect WIRE. BOX are used (See Fig. 2 and 3 for acceptable location). See unit wiring label and Fig. 11 for reference when making high voltage connections. Proceed as follows to complete the high voltage Single connections phase ELECTRICAL to the unit. 2. Connect ground (L1, L2) and ground lead to chassis 3. Connect L1 to pressure contactor. ground lug connection 4. Connect L2 to pressure compressor contactor. leads into the HAZARD iniury 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. connection. 11 of the compressor CONTROL lug FIRE/EXPLOSION Failure to follow this warning could result in personal or death and property damage. units: 1. Run the high-voltage control box. SHOCK connection 23 of VOLTAGE CONNECTIONS the Do not use any type of power-stealing problems may result. 11 thermostat. Unit control Useno.18American WireGage (AWG) color-coded, insulated (35Cminimum) wirestomake thecontrol voltage connections between thethermostat andtheunit.If thethermostat is located morethan100ft (30m)fromtheunit(asmeasured along the control voltage wires), useno.16AWGcolor-coded, insulated (35 Cminimum) wires. Locate thesixlowvoltage thermostat leads in24voltsplice box. SeeFig.11forconnection diagram. Runthelow-voltage leads fromthethermostat, through thecontrol wiringinletholegrommet (Fig.2 and3),andintothelow-voltage splice box.Provide adrip loopbefore running wiresthrough panel. Secure andstain reliefall wires sothattheydonotinterfere withoperation ofunit. Easy Select EASY TM SELECT - 9 PIN CONNECTOR ICM PRINTED CIRCUIT BOARD '_--_ r"m SEC1 48XP CONFIGURATION TM TAPS FOR 48XP Easy Select taps are used by the installer to configure ECM motor uses the selected taps to modify pre-programmed table of airflows. a system. The its operation to a The unit must be configured to operate properly with system components with which it is installed. To successfully configure a basic system (see information next to select pins), match the components printed on circuit board move the 6 select wires used (See Fig. 12). a. GAS HEAT/CFM-SELECT Factory label. b. AC/HP Factory selected SIZE- to capacity conditioner to the pins SYSTEM air conditioner correspond SYSTEM 12 PIN CONNECTOR C01039 Fig. 12 - Detail (4.) ENH- SPEED WHEN CONTINUOUS The AC/HP CFM Adjust select is factory set to the NOM tap. The CFM Adjust selections NOM/LO will Four motor customize operation and enhance as indicated). Selection options delay profiles system are provided operation for circuit 5-amp automotive transformer SEC2 to 50 percent FAN cooling to MED, 65 percent FUSING AND is fused by a board-mounted fuse placed in series with the and the R circuit. The C circuit of the transformer is referenced to chassis ground through a printed circuit run at SEC1 connected to metal standoff (See Fig. 12, E marked h. BASIC with ground UNIT symbol. CONFIGURATION The following basic configuration of the indoor motor will provide ARI rated performance of the 48XP. This BASIC CONFIGURATION should be used when the and 45 sec off delay. rated ARI performance (2.) A 30 sec cooling delay with no airflow/90 sec off delay at 100 percent airflow profile is used when it is desirable to allow system coils time to with the airflow setting, CIRCUIT The low-voltage DELAY are: cool-down in conjunction heating mode. IS SET ON g. LOW-VOLTAGE REFERENCE (1.) The standard 90 sec off delay (Factory Setting) at 100 percent airflow in cooling mode. In heating mode, IGC will control 45 sec on delay with no airflow DESIRED THERMOSTAT FAN (3.) HI speed-Move connector to HI, 100 percent cooling mode airflow (See Fig. 12, F as indicated). (See Fig. 12, D as indicated). DESIREDTIME for 48XP (2.) MED speed-Move connector cooling mode airflow. 10 percent airflow below nominal unit size Adjust selection options are provided to adjust SELECT Board FAN--SELECT (1.) LO speed-Factory mode airflow. regulate airflow supplied for all operational modes, except non-heat pump heating modes. HI provides 15 percent airflow over nominal unit size selected and LO e. ON/OFF DELAYPROFILE Not recommended f. CONTINUOUS LOW, airflow supplied to meet individual installation needs such things as noise, comfort, and humidity removal Printed-Circuit in cooling mode. In heating mode IGC will control 45 sec on delay with no airflow and 45 sec off delay. TYPE NOMINAL, of SPP (3.) A no delay option used for servicing unit or when a thermostat is utilized to perform delay functions This Factory selected on 48XP for AC-Air conditioner. For Gas Heat/Electric Cool Unit-AC must be selected. provides selected. GRY ==_ correspond INSTALLED d. AC/HP CFM ADJUST-SELECT OR HIGH AIRFLOW HUM2 HEATER/MOTOR of unit installed. Installer should verify air size to ensure that airflow delivered falls TYPE--SELECT AUX2 SIZE to unit SIZE INSTALLED size should within proper range for the size unit installed. applies to all operational modes. c. SYSTEM which GAS HEAT INPUT SELECT HUM1 24VAC gas heat size should selected AUX1 label located enhancements is required, (1.) HEAT-Factory selected (2.) AC/HP Size-Factory please verify. in (3.) SYSTEM AC-AIR (4.) AC/HP (5.) ON/OFF are not needed. to match heat input size. selected TYPE-Factory CONDITIONER. DELAY-Factory to match system selected CFM ADJUST-Select (Do Not Use ENH profile 12 or if system such as super dehumidify on 48XP size, system NOM. selected 0/90 profile. for Gas Packaged Units) c. HUMIDIFIER/HUMIDISTAT (6.) CONTINUOUS FAN-Select desired fan speed when thermostat is set to continuous fan. i. COMFORT OPTIONS--SUPER DEHUMIDIFY (See Quick Reference Guide) The Super Dehumidify option is possible when this unit is installed with a field supplied Thermidistat _ control (SuperDehumidify does not require an outdoor temperature sensor). The following configuration is recommended for n_axinmm cooling/dehumidifying comfort. This configuration will improve the comfort provided by the air conditioning system if more humidity removal is desired. While providing this improved comfort, the system will operate efficiently, but not at the published ARI SEER efficiency. During cool-to-dehumidify call, it provides maximum dehumidification by reducing airflow to a n_ininmm. The actual super dehumidify command from Thermidistat control to the indoor unit is a :'Y" signal without a :'G" signal in addition to dehumidify signal. The indoor unit responds to this combination by reducing the airflow to a n_ininmm. All other characteristics of cool to dehumidify are the same. The following system configuration is recommended for n_axinmm cooling/dehumidifying comfort (See Fig. 12). (1.) HEAT-Factory selected to match gas heat size of unit installed. (2.) AC/HP Size-Factory please verify. humidifier through a standard These terminals are energized Zone II, the 24-v. the Thermidistat d. DEHUMIDIFY HUMIDISTAT signal using a Plus or Comfort may be sourced directly from HUM terminal (See Fig. 12, 13 & 14). CAPABILITY WITH STANDARD CONNECTION requirement, the ECM board provides connection terminals for use of a standard humidistat. The unit will detect the humidistat contacts opening on increasing humidity and reduce its airflow to approximately 80 percent of nominal cooling mode airflow. This reduction will increase the system latent capacity until the humidity falls to a level which causes the humidistat to close its contacts. When the contacts close, the airflow will return to 100 percent activate this mode, remove of selected jumper cooling airflow. To J1 and wire in a standard humidistat (See Fig. 14). e. DEHUMIDIFY AND SUPER DEHUMIDIFY CAPABILITIES This model unit is capable of responding to a signal from indoor system control (Thermidistat or capable zoning control) to operate in comfort control modes such as Super Dehumidify Mode. Consult literature provided with indoor system control to determine if these operating modes are available, and to see control set up instructions. No special setup or wiring of unit is (6.) CONTINUOUS FAN-Select desired fan speed when thermostat is set to continuous fan. required. J1 jumper to HUMIDISTAT NOTE: J1 jumper should only be removed when a Thermidistat, humidistat or capable zoning control is installed. HUM 1FI (c) (8.) LOW VOLTAGE CONNECTIONS-Make connections as shown in ELECTRICAL CONNECTIONS section. 24-VAC TERMINALS _ J HUM 2[7 (G) (9.) CONFIGURE THERMIDISTAT-Follow Thermidistat (or capable zoning system) installation instructions for Super Dehumidify operation. ACCESSORY INSTALLATION AUXILIARY (See Fig. 12). when G Latent capacities for this unit are better than average systems. If increased latent capacity is an application (4.) AC/HP CFM ADJUST-Select NOM. (5.) ON/OFF DELAY-Select :'0/0" profile. a. humidistat with 24-v. and C on the 9 pin connector. When Thermidistat Control, Zone Comfort selected to match system size, MODE-Remove Easy thermostat signal is present (See Fig. 13 & 14). Alternately, the 24-v. signal may be sourced from the W (3.) SYSTEM TYPE-Factory selected on 48XP system AC-AIR CONDITIONER. (7.) DEHUMIDIFY activate. CONNECTIONS Select Board terminals HUM1 and HUM2 are provided for direct connection to the low-voltage control of a HUMIDIFIER TO HUMIDIFIER WIRING A95317 Fig. 13 - Humidifier Wiring - 48XP EASY SELECTIq BOARD TERMINALF] BLOCK The AUX and HUM terminals on the Easy Select Board are tied directly to the G terminal, and provide a 24-v. signal whenever the G terminal dehumidify is energized (See Fig. 12). During mode, the G signal is not present Super and the auxiliary terminals are not energized. If the installation includes the use of this operating mode, do not use these terminals to control accessories. See Electronic Air Cleaner and Humidifier sections for further information. b. ELECTRONIC AIR CLEANER using an electronic I REMovEJ I HUMIDISTAT l JUMPER CONNECTIONS The AUXI and AUX2 terminals are not always energized during blower operations, as described When 1 J1 A95316 Fig. 14 - Humidistat above. Wiring for De-Humidify Mode - 48XP air cleaner with the unit, use Airflow Sensor (See Air Cleaner Price Pages for Part Number). The airflow sensor turns on electronic air cleaner when the blower is operating. TRANSFORMER PROTECTION The transformer is of the energy-limiting a 30-sec. overload or shorted secondary 13 type. It is set to withstand condition. PRE-START-UP a. Make sure gas line is free of air. Before lighting for the first time, perform the following valve in the "OFF" position: the unit with the gas If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is recommended that the FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD ground joint union be loosened, and the supply line be allowed to purge until the odor of gas is detected. Never Failure to follow this warning could result in personal injury, death or property damage. purge gas lines into a combustion chamber. Immediately upon detection of gas odor, retighten the union. Allow 5 1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system. minutes b. Make 2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured. positioned d. Make on all WARNING, labels attached to, or 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. 1/8" (3 mm) MOTORAND e. Inspect coil fins. If damaged during shipping and handling, carefully straighten fins with a fin comb. maximum from motor is in place. drain trap is filled with water MAX BETWEEN FAN HUB MOTOR loose parts SHAFT A08474 Fig. 15 - Fan Blade Clearance START-UP Step 1 -- Check for Refrigerant Leaks Proceed as follows charge the unit: to locate and repair a refrigerant leak and to 1. Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both highand low-pressure ports. 2. Repair NOTE: leak following Refrigerant Install a filter drier whenever Service procedures. the system has been opened for repair. 3. Add a small charge and leak-test unit. 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. sure that air filter(s) from fan f. Make sure that all tools and miscellaneous have been removed. 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. 2. Read and follow instructions CAUTION, and INFORMATION shipped with, unit. 3. Make the following inspections: edge of condenser-fan be 1/2 in. (13 mm) maximum e. Make sure that condensate to ensure proper drainage. while Proceed as follows to inspect and prepare the unit for initial startu _: 1. Remove access panel. blade is correctly c. Ensure fan hub is 1/8 in. (3 mm) housing (See Fig. 15). 4. Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals. connection then light unit. in fan orifice. Leading blade should orifice. 3. Do not remove compressor terminal cover until all electrical sources are disconnected and tagged. 5. Never attempt to repair soldered refrigerant system is under pressure. to elapse, sure that condenser-fan of R-410A 4. Evacuate and recover refrigerant additional leaks are not found. 5. Charge unit with R-410A refrigerant from refrigerant refrigerant, charging cylinder or accurate for required charge. vapor using to system system a volume tric- scale. Refer to unit rating plate Step 2 -- Unit Sequence of Operation 48XP Sequence of Operation a. CONTINUOUS FAN 4. Verify the following conditions: (1.) Thermostat closes circuit R to G-The at continuous fan airfow. b. COOLING FIRE, EXPLOSION Blower runs MODE (1.) If indoor temperature is above temperature set point and humidity is below humidity set point, thermostat closes circuits R to G, R to Y/Y2 and R HAZARD Failure to follow this warning could result in personal injury, death or property damage. to O-The airflow. Do not purge gas supply into the 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. c. COOLING unit delivers single speed cooling MODE-DEHUMIDIFICATION (1.) If indoor temperature is above temperature set point and humidity is above humidity set point, 14 if thermostat or Thermidistat closes circuits R to G, R this sequence to Y/Y2, R to O and humidistat or Thermidistat opens R to DH-The unit delivers airflow which is approximately 80 percent of the nominal cooling airflow to increase the latent capacity of the system. d. COOLING MODE-SUPER OPERATION NOTE: The indoor capable of (SEE control providing Dehumidify control must be configured instructions. Consult indoor control is capable configuration REFERENCE GUIDE) used, such as a Thermidistat, Super operation mode Super Dehumidify inputs and Check GAS • pressure is required after proceed unit start-up (See as follows: The rated gas inputs shown in Table 3 are for altitudes specific (1.) If the indoor temperature is below the temperature set point and the humidity is above the humidity gas with a heating gravity, or propane Btu/ft 3 at 1.5 specific • from sea value of 1050 Btu/ft 3 at 0.65 gas with a heating value of 2500 gravity. In the U.S.A. for elevations above 2000 ft (610 mm), reduce input 4% for each 1000 ft (305 m) above sea level. In Canada for elevations will deliver airflow at the full plus dehumidify mode from 2001 ft (610 m) to 4500 sea leval reduce requested value. If circuit R to G is open (0-v.) for Super Dehumidify mode, the motor delivers reduced airflow to maximize the humidity removal of the system while minimizing over cooling. e. GAS HEATING and manifold level to 2000 ft (610 m) above sea level. These inputs are based and for set point, the Thermidistat closes circuit R to O, opens circuits R to DH and R to G, and closes circuit R to Y/Y2. If circuit R to G is closed has INPUT gas input on natural the motor or cooling do not light within fan will turn on 45 sec. after the flame Table 3). If adjustment instruction. (24-v.), cooling If the burners been established. The evaporator fan will turn off 45 sec. after the thermostat has been satisfied. CHECK must be as outlined in its installation control literature to determine if of providing 5. The evaporator DEHUMIDIFY QUICK is repeated. 15 minutes from the initial call for heat, there is a lockout. To reset the control, break the 24-v power to W. • When the gas supply specific gravity, distributor ft (1372 m) above input 10%. being used has a different refer to national to determine heating value or and local codes, or contact your the required orifice size. MODE (1.) Thermostat closes circuit R to W/WI-The unit delivers the selected gas heat airflow. The IGC will control a 45 sec. blower "Off"' delay. Step 3 -- Start-Up ments UNIT Heating UNIT "On" delay and a 45 sec. COMPONENT and Make Adjust- DAMAGE ADJUST HAZARD may result in damage that burner operation may occur misaligned. Follow the lighting label (located inside heating section. NOTE: Make orifices when the burner instructions CHECK HEATING Unstable in the manifold are section operation door) to start the access propane gas units. Measure Gas Flow (Natural has been purged, the unit and that all for leaks. thermostat SYSTEM and the fan switch 2. Set the heating room temperature. 3. The induced-draft temperature motor 4. After a call for heating, cooling instructions control located operation inside switch in is placed in AUTO control burner the All other turned off when follows: as or appliances gas flow 3. Record number one revolution. HEAT that use the same is measured meter at the meter. must be Proceed as to unit. of seconds 4. Divide number of seconds seconds in one hr). above for gas meter test dial to make in Step 3 into 3600 (number of 5. Multiply result of Step 4 by the number of cuft shown for one revolution of test dial to obtain ft 3 of gas flow per hr. will start. the main burner can be made by changing the pressure must be maintained 2. Remove pipe plug on manifold (See Fig. 16) and connect manometer. Turn on gas supply to unit. position. of the thermostat the gas flow between 3.4 and 3.6 IN. W.C.. If larger adjustments are required, change main burner orifices following the recommendations of national and local codes. 1. Turn off gas supply for proper by measuring Gas Units) Minor adjustment to the gas flow manifold pressure. The manifold CONTROL follows (see furnace lighting blower access panel): position or blower sure that gas supply room orifices INPUT 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 NOTE: has been checked Start and check aligned. on the heating the burner gas piping 1. Place are properly GAS The gas input to the unit is determined to 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. sure HAZARD Do Not redrill an orifice. Improper drilling (burrs, out-of-round holes, etc.) can cause excessive burner noise and misdirection of burner flame. Replace with correct sized orifices. Failure to follow this caution being installed. Make DAMAGE Failure to follow this caution may result in reduced unit and/or component life. should 6. Multiply light within obtain 5 sec. If the burners do not light, there is a 22-sec. delay before another 5-sec. try. If the burners still do not light, result total of Step 5 by Btu heating measured input in Btuh. value Compare of gas to this value with heating input shown in Table 3 (Consult the local gas supplier if the heating value of gas is not known). 15 4. Remove cover screw over regulator adjustment screw on gas valve. 5. Adjust regulator adjustment screw to the correct manifold pressure, as specified in Table 3. Turn adjusting screw clockwise to increase manifold pressure, or turn adjusting screw counterclockwise to decrease manifold pressure. 6. Replace cover screw. 7. Turn off gas to unit. Remove manometer from pressure tap. Replace pipe plug on gas valve, then turn on gas to unit. Check for leaks. CHECK BURNER FLAME With burner access panel 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 with yellow tips (See Fig. 17). Refer to the Maintenance section for information on burner removal. BURNER FLAME MANIFOLD PIPE PLUG C99019 BURNER Fig. 16 - Burner Assembly EXAMPLE: Assume that the size of test dial is 1 ft3, one revolution takes 32 sec., and the heating value of the gas is 1050 Btu/ft3. Proceed as follows: 1. 1.32 sec. to complete one revolution. 2. 3600 + 32 = 112.5. MAN IFOLD 3. 112.5 x 1 =112.5 ft3 of 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 cover screw over regulator adjustment screw on gas valve. 2. Turn regulator adjustment screw clockwise to increase gas input, or turn regulator adjustment screw counterclockwise to decrease input. Manifold pressure nmst be between 3.4 and 3.6 IN. W.C.. Unsafe operation of the unit may result if manifold pressure is outside this range. Personal injury or unit damage may result. 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 cover screw cap on gas valve. 4. Turn off gas supply to unit. Remove manometer from pressure tap and replace pipe plug on gas valve. Turn on gas to unit and check for leaks. Measure Manifold The main unit rated level specified Proceed Pressure (Propane Units) burner orifices on a propane gas unit are sized for the input when the manifold pressure reading matches the in Table 3. as follows to adjust gas input on a propane gas unit: 1. Turn off gas to unit. 2. Remove pipe plug (See Fig. 16). on manifold and connect manometer C99021 AIRFLOW Fig. 17 - Monoport Burner 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 4 shows the approved temperature rise range for each heating input, and the air delivery cfm at various temperature rises. 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 through the thermostat R circuit. Should the leaving-air temperature rise above the naaxinmm allowable temperature, the limit switch opens and the R control circuit "breaks." Any interruption in the R control circuit instantly closes the gas valve and stops gas flow to the burners and pilot. 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 R control circuit. The electric-spark ignition system cycles and the unit returns to normal heating operation. AUXILIARY LIMIT SWITCH (ROLLOUT) The function of the 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 auxiliary switch reaches the maximum allowable temperature, the R 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 7. 3. Turn on gas to unit. 16 Step 4 -- Start-Up ments UNIT DAMAGE Cooling 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. and Make Adjust- 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 the time selected on the Easy Select board. HAZARD Failure to follow this warning damage. could result in unit component Complete the required procedures given in the Pro-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 55°F (13°C) (unless accessory low-ambient kit is installed). Do not rapid-cycle the compressor. To prevent compressor damage allow 5 minutes between "on" cycles. CHECKING Start and follows: check COOLING the unit for CONTROL proper 3. When using an auto-changeover room thermostat, place both SYSTEM and FAN switches in AUTO positions. Observe that unit operates in Heating mode when temperature control is set to "call for heating" (above room temperature) and operates in Cooling mode when temperature control is set to "call for cooling" (below room temperature). OPERATION cooling control operation as Table NUMBER OF ORIFICES HEATING INPUT (BTUH)* 3 - Heating GAS SUPPLY Natural Max 13.0 13.0 13.0 13.0 13.0 Min 4.0 4.0 4.0 4.0 4.0 Inputs PHI-SSUHI- (IN. W.C.) Propanet Min 4.0 4.0 4.0 4.0 4.0 MANIFOLD Max 13.0 13.0 13.0 13.0 13.0 PRESSURE Natural 3.5 3.5 3.5 3.5 3.5 (IN. W.C.) Propanet 3.5 3.5 3.4 3.7 3.5 2 40,000 2 60,000 3 90,000 3 115,000 3 130,000 * 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 above sea level. For altitudes above 2000 ft, 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, de-rate the unit 10 percent. Table 4 - Air Delivery (CFM) at Indicated HEATING INPUT Temperature Rise and Rated TEMPERATURE Heating Input RISE °F (BTUH) 20 25 30 35 40 45 50 55 60 65 70 40,000 60,000 90,000 115,000 130,000 1500 2250 ---- 1200 1800 ---- 1000 1500 2250 --- 857 1285 1929 2464 2786 750 1125 1688 2156 2438 667 1000 1500 1917 2167 600 900 1350 1725 1950 545 818 1227 1568 1773 500 750 1125 1438 1625 -692 1038 1327 1500 --964 1232 -- NOTE: Dashed areas do not fall within the approved temperature rise range of the unit. Table ERROR 5 - LED Indications CODE LED Normal Operation Hardware Failure Fan On/Off Delay Modified Limit Switch Fault Flame Sense Fault Four Consecutive Limit Switch Faults Ignition Lockout Fault InducedDraft Motor Fault Rollout Switch Fault Internal Control Fault Safety Critical Code Fault NOTES: 1. There is a 3-sec. pause between error code displays. 2. If more than one error code exists, all applicable error codes will be displayed 3. This chart is on the wiring diagram located inside the burner access panel. Table 6 - Filter in numerical Pressure Drop FILTER SIZE in. (mm) 20X20X1 (508X508X25) 20X24X1 (508X610x25) 24X30X1 (610X762x25) INDICATION On Off 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes 9 Flashes sequence. (IN. W.C.) CFM 500 600 700 800 900 1000 1100 1200 1300 1400 1500 0.05 0.07 0.08 0.10 0.12 0.13 0.14 0.15 -- -- -- 0.09 0.10 0.11 0.13 0.14 0.15 0.16 0.07 0.08 0.09 0.10 .... ....... 17 1600 1700 1800 1900 2000 2100 2200 2300 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 Table CFM ADJUST PIN SELECT EXTERNAL STATIC PRESSURE RANGE UNIT SIZE 030 036 Cooling Dry Coil ECM 042 048 060 Cabinet HI PIN 0.0-0.39 0.4-0.69 0.7-1.0 0.0-0.39 0.4-0.69 0.7-1.0 0.0-0.39 0.4-0.69 0.7-1.0 800 725 - 885 805 730 990 930 855 715 670 - 715 695 645 795 775 745 1010 920 825 1105 1030 930 1255 1160 1050 890 845 795 890 865 825 1010 980 925 1110 1025 970 1235 1175 1115 1400 1355 1280 990 960 910 990 975 940 1125 1110 1085 Table EASY SELECT BOARD SETTING Small NOM PIN Table 8 - 48XP Cooling CFM ADJUST PIN SELECT EXTERNAL STATIC PRESSURE RANGE (IN. W.C.) COOLING COOLING DEHUMIDIFY COOLING COOLING DEHUMIDIFY COOLING COOLING DEHUMIDIFY UNIT SIZE Airflow LO PIN (IN. W.C.) COOLING COOLING DEHUMIDIFY COOLING COOLING DEHUMIDIFY COOLING COOLING DEHUMIDIFY 024 7 - 48XP 9 - 48XP Dry (;oil ECM Airflow Gas Heating Large Cabinet LO PIN NOM PIN HI PIN 0.1-1.0 0.1-1.0 0.1-1.0 1 lO0 98O 1260 1120 1575 1400 1225 98O 1400 1120 1750 1400 1410 1125 1610 1290 2010 1610 ECM Airflow Small Cabinet TM Unit Size 024 030 036 700 (CFM) External Static Pressure (IN, W,C,) Gas Heat Size 040 060 040 060 060 090 0.0-0.4 800 0.4-0.7 0.7-1.0 Table EASY Unit SELECT Size TM BOARD External 042 048 060 10 - 48XP 11 oo 0.0-0.4 0.4-0.7 0.7-1.0 855 770 710 880 840 805 Gas Heating SETTING (CFM) Static Pressure (IN. W.C.) Gas Heat Size 060 090 090 115 130 090 115 130 ECM Airflow 1250 0.0-0.4 0.4-0.7 0.7-1.0 1020 890 835 1030 1035 970 995 910 955 Large 0.0-0.4 0.4-0.7 0.7-1.0 1170 1110 1025 Cabinet 1000 1250 1600 0.0-1.0 0.0-1.0 0.0-1.0 1000 - 1250 1250 - 1600 - 1250 - 1750 18OO 0.0-1.0 0.0-1.0 1750 1600 1800 Tablell-ECMWetCoilPressureDrop(IN.W.C.) UNIT SIZE 024 030 036 042 048 060 STANDARD CFM (SCFM) 600 0.005 700 0.007 0.007 ..... ...... 800 0.010 0.010 - 900 0.012 0.012 0.019 - 1000 0.015 0.015 0.023 0.014 1100 ........ 0.018 0.027 0.017 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 0.021 0.032 0.020 0.027 0.024 0.037 0.024 0.032 0.042 0.027 0.036 ...... 0.047 0.031 0.041 0.029 ..... 0.035 0.046 0.032 0.039 0.052 0.036 0.043 0.057 0.040 0.063 0.045 0.068 0.049 0.053 18 BLN SCII_MAT IC YEL F_ELD 208/230-_-60 _YEL SUPPLY ___Y__ _ _ _ OFM // LEGEND _FIELD SPLICE O TERM_NAL_MAREED} o TERMINAL (UNMARNEDI @ SPLICE O SPL_CE {MARKED} FACTORYWIRING F_ELN CONTROLW_RINO E_ELD POMERWIRING ACCESSORY OR OPTIONAL W_RING TO _NR_CATECOMMON POTENTIAL ONLY: NOT TO REPRESENTMIRING BR B CAP COMB CR OLOMENREtAY CONTACTOR CAPACITOR COMPRESSOR MOTOR COMBNSTION RELAY E_NIP EQUIPMENT POWER F ELANE SENSOR FU FUSE MEN GROUND GVR GAS VALVE RELAY NPS NIGH PRESSURESM_TC_ US HALL EFFECT SENSOR HV TRANHIGH VOLTAGETRANSFORMER I IBNITON IBM INTEGRATEDCONTROl MOTOR _DM _NDUCEDDRAFT MOTOR IFM INDOORFAN MOTOR [MD _NTEGRATEU GAS UNIT CONTROLLER kPS LOW PRESSURE SM_TDH LS L_M]T SWlTC_ MGV MAIN GAS VALVE OFM OUTDOORFAN _OTOR QT QUADRUPLETERMINAL ENERG ZED RS ROLLOUTSM[TC_ TRAM TRANSEORNER EQU]PGND / _:EL_(_/LU YEI COMP @ IFM YEL DE-ENERG ZED _DM TRAN[ 24V SECONDARY REg_ IGC .................................. BLK @ 24V SPLICE BOX IBM BOARD RED ORN Jz BB GRA BLK@>-5 REDI PLR-2 AMP _ _ WHT ........... PL2 CED / /,_ ,_>PLR"3 ;R SEE NOTE IO C_ ] _ WHT _MEAI C_D °AUTO PLR-6 YEL_>_ z_ YE _B3 PL2 7 GRN_> I CZD ORN+_ I P[2-9 I C3[7 ON F [ ELD TI ERMOSTAT _ PL28 BRN/_ BRN I BRN PLI I GRN YEL I COMMON WIlT BLN_ RED 8RN PNN ORN UNIT COMPONENT ARRANGEMENT GRA OUTDOOR FAN SECT ON ORN EQUIP GND k I B[U v_o SECTION :APE vlo BIN BLK WET WHT _ _DISCONNECT PER NEC COMP MOUNTING PANEL ABOVE INDOOR BLOWER C s R GAS SECTION _ NORNALOPERATIO_ _ _AR_MARE FAIlUrE OF_ FA_ O_/OFF DELAYMODIFIED I _LAS_ L_M_T S_TC_ _A_tT R RLAS_ES FLAMESENSERAULT 3 _tASNES S CONSECUTIVEtlMIT SWlTC_ _AUtTS 4 _t_S_ES EGN_EON LOCEOUT_AU_T S ELAS_ES _NDUCERSWlTD_ _AULT 6 _tAS_ES ROLLOUTSMITD_ FAULT 7 ELAS_ES EN_ERNALCONTROLEAN[T 8 ELASNES TEMPORARY ONE _OU_AUTOMATIC_ESET EANLT_NOTE9} 9 ELASNES B SECOND_A_SE BETWEENERRORCODE_ISRtAY 2 _F MORET_AN ONE ERROREXISTS, ALL APPLICABLEERRORCODES S_ALL BE DISRtAYED IN NUMERICAtSEQUENCE NOTES: i1[ ANYo_ T1_£ORIGINAL WIRESFURNISDED ARE REPLACED, IT MUSTBE REPLACEDWITR TYPE 9O _EMREED MIREOR ITS EQUIVALENT 2 SEE _RICE _AGES _OR TI_[RNOSTAT ANDSUEBASES SUSE ;5 DEGREECOPPERCORRUPTORS FOR F_ELR E_STALLAfEON 4 REPLACELOWVOLTAGEFUSES M_TRNOGREATERTHAN5 A_P FUSES¸ S ON MODE_S4BGPR24 0_ HASLS] _ND LSE _N SER_ES ON_ODELS 48GPO4R060 _AS LSE O_LY 6_E_OVE J_ MHENUSING THER_R_STAT/ HU_R_STAT ANR DEHR_O_F_CAT_ON_ORE _RE_OVE J_ B TO 8E W_RER_ ACCORRA_CE MET_ NEC A_DLOCALCODES¸ _T_S CODE_D_CA_ES A_ [_1ER_AL PROCESSOREA_LT T_ATWILL RESET _TSELF _N ONE_OUR FAUtT CAN 6E CENSERBY STRAY_E S_GNELS _ THE STRUCTURE OR _EARBY TIHS IS A Ut REQUIREMENT EAUtT [OT_[S FUSE [S MANUFACTURED B_ LITTEtEUSE, R/N RS_OOS A08462 Fig. 18 - 208/230-1-60 Wiring 19 Diagram, Unit 48XP SCHEMATIC 208/230-3-60 FIELD BLK SUPPLY YEL fEL O\Ti__ __ __]_2_ EQU POWER ,[/ 8LU tP_GND C OFM BLN BLH OR +iL LEGEND _P_ELD Q SPLICE TERNINAL {MAR_ED) TERMINAL SPLICE (UNMARKED) C],SPLICE (MARKED) --FACTORY -- -- FIELD WIRING CONTROL WIRENG R CONPRESSOR CR COMBUSTION COOLING BLK YEL E EC_ IDW PL4+4 ENROOR FAN MOTOR INTEGRATED GAS UNIT CONTROLLER LOW PRESSURE SWETCH L{N{T SWITCH MAiN GAS VALVE RELAY _R_AN OUTDOOR FAN MOTOR QUADRUPLE TERMINAL ROLLORT SWITCH IRANSFORmE R PRIMARY LOGIC YE T130 TRANI _ W BR ENERGIZED LOGIC --RED IGC CR BOX -RED BR --ORN-- JR I_ PLB'B 5 --_L__2_ )>-RED PL?-3 -vv_ OFF L-- _ // / / T BRA_ I NOTE I0 _._EE -SEE NOTE_5 RE] AMP SEE NOTE lOJ +RN-- -f+2+- PL2-1 OFF .E_T meT-GNU" YE L_ {_ -WHT [------ oT +- -BLH SPLICE I II R4V SECONDARY W BR DE-ENERGIZED 24V I DM YEL DE-ENERGIZED PAN _FN --GRN-YEL_ tFM IGC OFM OT _ HEATING ONLY EGNITOR ENTEGRATED CONTROL _OTOR iNDUCER DRAFT MOTOR LPS LS NOV FAN UNITS + ++ SENSOR GAS VALVE RELAY HiGH PRESSURE SWITCH HALL EFFECT SENSOR H{GH VOLTAGE TRANSFORMER MOTOR & G ENERGIZED FLAME FUSE GROUND BLOWER RELAY CONFACTOR CAPACITOR COMP FS GVR HPS HS HV TRAN INDICATE COMMON POTENTIAL ONLY: NOT TO REPRESENT WIRING CAP EQUIPMENT FU GND --FIELD POWER WIRING ---- ACCESSORY OR OPTIONAL WIRING --TO EQUIP 042-060 MGV _--WHT _HEAT -----SRA _ YEL OAUTO PLZ-R FLAME _COOL TCI Y_ _--YEL --Y 123 C_I>-- o_ BR_ H_ --BRN TOTRANS _--BRN TO CONT ;ROUNDED IHRU STANDOFF C_13--- .J -_o _RN-YEL GRN---)>-- I I AUTO 0-- PL?-T .... SEN E L---o [ SECT ON -- _--BRN I I -- FIELD-THERMOSTAT _7_B PLI L KHPs_BL H---_BL U_)_BL U-- BRR -- _ BRN -- COMMON .... UNIT SECTION OUTDOOR EAR COMPONENT ARRANGEMENT E_->_ [] EQU GND SECTION ..... E.... , SECTION _ND_OOR FAN >_GC BRR-- I CONTROL EII_ -GRA ORN -ORN BLU -BLU v_o -VIO BOX -BLN [_ -WHT Wilt NOTES:I_F _ E MOUNTING _NDOOR c s R GAS ss£ SECTION PANEL BLOWER ABOVE ANy OF iT _UST THE ORIGINAL BE REPLACED WIRES FURNISHED ARE REPLACRD, W_TR TYPE gO DEGREE C _IRE OR RARD_ARE FAILURE FAN ONIOFF DELAY NOD{PiED NORMAL SWITCH OPERA_IO_ LIMIT FAULT PLANE SENSE FAULT OFF _ FLASH Z FLASHES 3 FLASHES Z SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES 3USE 75 DEGREE COPPER CONDUCTORS FOR F_ELD _NSTALLAT_ON ITS EQUIVALENT 4REPLACE LOW VOLTAGE FUSES W_TH NO GREATER THAN S A_P FUSES SON _ODZLS 4RXPOZ_+O)6 HAS ISI AND LS2 _N SERIES _GNIT_ON 5 CONSECUTIVE LOCKOUT LI_[T FAULT SWITCH FAULTS {NRVCER SW_TCN FAULT ROLLOUI SWITCH FAULT iNTERNAL CONTROL FAULT TEMPORARY ONE HOUR AUTO_IATIC RESET _AULT (NOTE 9} [ 3 SECOND PAUSE BETWEEN ERROR CODE D_SPLAY _ 6 T B 9 ON MODELS _8XPO_2"060 HAS LS[ ONLY 6REMOVE J[ WHEN USING TRER_IDISTA_I HU_IDISFAI AND DEHUmIDIFICATiON MODE ?REMOVE J2 8TO BE WIRER IN ACCORDANCE _ITH NEC AND LOCAL CODES 9THIS CODE INDICATES AN [NTERNAL PROCESSOR FAULT THAT W[LL Z If _ORE THAN ONE ERROR EXISTS+ ALL APPLICABLE SHALL RE DISPLAYED {N NUMERICAL SEQUENCE FLASHES FLASHES FLASHES FLASHES FLASHES ERROR CODES RESET [TSELP I_ ONE HOUR FAULT CAN BE CAUSED BY STRAY RP SIGNALS IN THE STRUCTURE OR NEARBY THIS IS k UL REQUIREMEN_ FAULT !48XP500149 16,0 A08463 Fig. 19 - 208/230-3-60 Wiring 20 Diagram, []nit 48XP Required Subcoolin_ Outdoor Model oF IoC) Ambient Required Temperature Required Liquid Line Temperature Subcooling for a Specific Subcooting (°F) (R-41OA) Required Subcooling (°C) Size 75 (24) 024 82 (26) 10.3(5.7) 86 (29) 9.8(5.4) 96 (85) 9.4(6.2) 105 (41) 9(5) Pre_sur, 5 10 15 20 26 Pre_sur_ (kPa) 3 6 8 11 14 189 61 56 51 46 41 1303 16 13 11 8 5 7(3.9) 196 63 58 53 48 43 1351 17 18 12 9 6 16 17 13 14 10 11 8 9 8.6(4.7) 030 9.3 ( 5.2 ) 8.8 ( 4.9 ) 8.6 ( 4.8 ) 036 042 17.6(9.8) 12.8(7.1) 16.8 (9.3) 12.7(7.1) 16.6 (9.2) 12.7(7.1) 16.4 (6.6) 12.6(7) 14.3(7.9) 12.6(7) 203 210 66 68 61 63 66 68 51 53 46 48 1399 1448 19 20 17.5(9.7) 16.9(9.4) 16.6(9.2) 16.7 (6.7) 14.8(8.2) 217 70 66 60 55 50 1496 21 18 15 13 10 13.7(7.6) 13(7.2) 16(7.2) 14.6 (6.1) 11.5(6.4) 224 72 67 62 57 52 1544 22 19 16 14 11 231 74 69 64 59 54 1593 23 20 18 15 12 238 76 71 66 61 56 1641 24 21 19 16 13 245 77 72 67 62 57 1689 26 22 20 17 14 252 79 74 69 64 59 1737 26 23 21 18 15 260 81 76 71 66 61 1792 27 25 22 19 16 268 83 76 73 68 63 1848 29 26 23 20 17 276 85 80 78 70 66 1903 30 27 24 21 19 284 87 82 77 72 67 1956 31 28 25 22 20 292 300 89 91 84 86 79 61 74 76 69 71 2013 2066 32 33 29 30 26 27 23 24 21 22 309 93 88 63 78 73 2130 34 31 28 26 23 316 95 90 65 80 76 2192 36 32 29 27 24 327 336 97 92 67 82 77 2254 36 33 31 28 25 99 94 69 84 79 2316 37 34 32 29 26 345 364 101 96 91 86 81 2376 38 35 33 30 27 103 98 93 88 83 2440 39 36 34 31 28 364 105 100 95 90 86 2509 40 38 35 32 29 374 107 102 97 92 87 2576 41 39 36 33 30 384 108 103 98 96 88 2647 42 40 37 34 31 394 110 106 100 95 90 2716 44 41 38 35 32 4O4 112 107 102 97 92 2786 45 42 39 36 33 414 114 109 104 99 94 2854 46 43 40 37 34 424 116 111 106 101 96 2923 47 44 41 38 35 434 118 113 108 103 98 2992 46 45 42 39 36 444 119 114 109 104 99 3061 46 46 43 40 37 454 121 116 111 106 101 3130 49 47 44 41 38 464 123 118 113 108 103 3199 50 48 45 42 39 474 124 119 114 109 104 3266 51 48 46 43 40 464 494 126 127 121 122 116 117 111 112 106 107 3337 3406 52 53 49 50 47 47 44 45 41 42 5O4 129 124 119 114 109 3476 54 51 48 46 43 514 131 126 121 116 111 3544 55 52 49 46 44 524 132 127 122 117 112 3612 56 63 50 47 45 534 134 129 124 119 114 3661 56 64 51 48 45 046 060 Charqinq 1- Meacure Procedure Di¢charge line preceure 2- Meacure the Liquid device to it. by attaching line temperature 3- Ineulate the temperature doe_=n'_affect the reading. ceneing value€. if the Outdoor Extrapolate in the ambient 8- Add Charge Ambient lie_ in between the to obtain temperature Outdoor port. Ceneing on the model ¢ize and the table table range. in the table corre¢ponding Di¢charge line. if the meaeured 50XZ500174 table baeed lie€ beyond 7- Read acro¢_= from the Preeeure reading temperature for a required Subcooling to the _ervice a temperature _=o that the temperature if the temperature 6- Find the Pree_ure Value Pre¢¢ure of the Compre¢eor a gauge by attaching device 4- Refer to the required Subcooling the Outdoor Ambient temperature. 5- Interpolate 7.6 ( 4.3 ) to the the the Liquid i¢ higher than the meaCured line table value. ] C03027 IMPORTANT: Three-phase, direction-oriented. compressor 5 minutes, 3-phase suction scroll units must be checked to ensure proper 3-phase power lead orientation. If not corrected within the internal protector shuts off the compressor. The power rotation. elevated These Fig. 20 - Cooling Charging Table-Subcooling compressor units are To Use Cooling Charging leads When noise The refrigerant unit and the pressures be scroll difference reversed to correct compressors between emit compressor REFRIGERANT is fully charged with CHARGE R-410A refrigerant, tested, and factory-sealed. NOTE: Adjustment the unit is suspected An accurate of the refrigerant of not having superheat, charge the proper thermocouple- is not required R-410A or unless charge. 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 adequate for this type of measurement. UNIT DAMAGE the liquid line temperature and read the manifold gauges. Refer to the chart (See Fig. 20) to determine liquid line temperature should be. NOTE: If the refrigerant leak, refer to the Check problem causing INDOOR AIRFLOW the inaccurate for Refrigerant AND AIRFLOW pressure what readings the is a Leaks section. ADJUSTMENTS may be zero. AND ADJUSTING system must backwards, levels, and discharge CHECKING to the turning Take Charts because they are not 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. Table 4 shows the temperature rise at various airflow rates. Table 7 & 8 show cooling airflows at the selection to these installed. pin ranges (depending on external static pressure). tables to determine the airflow for the system Refer being NOTE: and Table Be sure that all supply- free from obstructions, 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. airflows 9 & 10 show and return-air and adjusted ELECTRICAL SHOCK Failure to follow or death. this warning heating grilles are open, properly. HAZARD could result in personal iniury Before making any indoor wiring adjustments, shut off gas supply. Then disconnect electrical power to the unit. Airflow can be changed Select circuit board. 21 by changing the selection pins on the Easy AIR FILTER 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 12, 13 and 14. NOTE: Consult your local dealer about the availability of a maintenance contract. NOTE: 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. EVAPORATOR BLOWER AND MOTOR NOTE: All motors are prelubricated. Do not attempt to lubricate these motors. PERSONAL Failure INJURY AND UNIT to follow this warning or death and unit component DAMAGE HAZARD could result in personal injury 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 For longer life, operating economy, and continuing efficiency, clean accumulated dirt and grease from the blower wheel and motor annually. CLEANING THE BLOWER MOTOR AND WHEEL 1. Remove and disassemble blower assembly as follows: a. Remove unit access panel. b. Disconnect motor lead from blower relay (BR). Disconnect yellow lead from terminal L2 of the contactor. 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: HAZARD Failure to follow these warnings could result in personal iniury or death: 1. Turn off electrical power to the unit 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. 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. 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 Failure to follow operation. HAZARD this caution may result in improper 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. 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. f. Reinstall unit access panel. 3. Restore electrical power to unit. Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles. FLUE GAS PASSAGEWAYS To inspect exchanger: 1. Remove according section. 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. 2. Remove collector 3. Remove flue collector box the combustion to directions 6. Check flue hood and remove any obstructions, if necessary. 22 in wheel the areas of the heat and motor Combustion-Air the blower housing assembly Blower to the flue box cover (See Fig. 23). the 12 screws holding 4. Clean all surfaces, each heating and upper blower the 3 screws holding (See Fig. 24) to the heat heat exchangers. 4. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary. 5. Check and inspect heating section before season. Clean and adjust when necessary. the the flue collector exchanger as required, assembly. using a wire brush. box cover Inspect the COMBUSTION-AIR BLOWER Clean periodically to assure proper airfow 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. and wheel as follows: 1. Remove is required, remove motor unit access panel (See Fig. 22). 2. Remove the mounting 3. Slide If cleaning 7 screws that plate to blower the motor attach housing and blower induced-draft motor (See Fig. 23). wheel assembly out of the blower housing (See Fig. 23). Clean the blower wheel. If additional cleaning is required, continue with Steps 4 and 5. 4. To remove blower, remove 2 setscrews 5. To remove motor and cooling screws that hold blower housing 6. To reinstall, fan assembly, remove to mounting plate. reverse the procedure LIMIT SWITCH Remove unit access panel. Limit (See Fig. 23). switch outlined 4 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 condenser 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 air filter(s). If the 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. INDUCED above. is located DRAFT MOTOR MOUNT <
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