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

PAGE

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

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

RECEIVING AND INSTALLATION ................. 2-13

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

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

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

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

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

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

Ground Mount .................................. 2

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

Provide Clearances ................................. 2

Rig and Place Unit ................................. 4

Connect Condensate Drain ........................... 6

Install Flue Hood ................................... 7

Install Gas Piping .................................. 7

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

Configuring Units for Downflow (Vertical)

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

Install Electrical Connections ........................ 10

High-Voltage Connections ........................ 10

Special Procedures for 208-V Operation .............. 11

Control Voltage Connections ....................... 11

Easy Select TM . .................................. 11

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

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

START-UP ..................................... 14-21

Check for Refrigerant Leaks ......................... 14

Unit Sequence of Operation ......................... 14

48XP Sequence of Operation ...................... 14

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

Check Heating Control ........................... 15

Check Gas Input ................................ 15

Adjust Gas Input ................................ 15

Check Burner Flame ............................. 16

Airflow and Temperature Rise ...................... 16

Heating Sequence of Operation ..................... 16

Limit Switches ................................. 16

Rollout Switch ................................. 17

Start-Up Cooling & Make Adjustments ................ 17

Checking Cooling Control Operation ................ 17

Checking & Adjusting Refrigerant Charge ............ 21

Indoor Airflow and Airflow Adjustments ............. 21

MAINTENANCE ................................ 22-25

Air Filter ........................................ 22

Evaporator Blower and Motor ........................ 22

Flue Gas Passageways .............................. 22

C99088

Fig. 1 - Unit 48XP

Combustion Air Blower ............................ 23

Limit Switch ..................................... 23

Burner Ignition ................................... 23

Main Burners .................................... 23

Condenser Coil, Evaporator Coil, & Condensate

Drain Pan ....................................... 23

Condenser Fan ................................... 24

Electrical Controls and Wiring ....................... 24

Refrigerant Circuit ................................. 24

Gas Input ........................................ 24

Evaporator Airflow ................................ 24

Puron® Items .................................... 25

TROUBLESHOOTING .............................. 26

START-UP CHECKLIST ............................ 26

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)NFPA54/ANSIZ223A,andthe 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 Z_

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

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

signal words: DANGER, WARNING, and CAUTION. These

words are used with the safety-alert symbol. DANGER identifies

the most serious hazards which will result in severe personal injury

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

injury 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. Turn off accessory heater power

switch if applicable.

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

A qualified installer or agency must use only

factory-authorized kits or accessories when modifying this

product.

INTRODUCTION

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

Category I gas heating/electric 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 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 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.

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.

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.

GROUND MOUNT

The unit may be installed either on a slab or placed directly on the

ground, if local codes permit. Place the unit on level ground

prepared with gravel for condensate discharge.

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

with counter flashing and mastic in accordance with applicable

codes.

Ducts passing through an unconditioned space must be insulated

and covered with a vapor barrier.

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 clearances are shown

in Fig. 2 and 3. Adequate combustion, ventilation and condenser

air must be provided in accordance with section 9.3, Air for

Combustion and Ventilation, of the National Fuel Gas Code

NFPA54/ANSI Z223.1 or applicable provisions of local building

code. In Canada, follow section 8 of Can/CSA-BI49.1

Installation Codes or applicable provisions of local building code.

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.

I

m_

I

d_

798 5

[S 44]

FIELD ENTRY_

SERVICE PORTS i

19 O[O 15] NPT

X 220 DEER

_83 0

[32 72]

LEFT SIDE VIEW

It

406 5

[16 DOE

OUTDOOR

106 o

[4 17]

@ t

INDOOR COIL TOP VIEW

[4700]

FULL LOUVER

[168]

_3265

[1285]

_724

[285]

COMPRESSOR, 8LOWER, GAS PARTITIO

& ELECTRICAL ACCESS PANEL

12263

[A828]

FRONT VIEW

D

_UTDOOR COIL

UNIT

_8XPO2_04O/OGO

_SXPO3OO4O/OGO

_SXP036060/090

ELECTRICAL

CHARACTERISTICS

208 230 I 60

208 230 i 60, 2081230 3 60

208 230 i 60, 208/230 3 60

UNIT WT UNIT HEIGHT

LBS KG "A"

340 154 940,313702]

344 156

368 167

CENTER OF GRAVITY MM/IN

Y Z

368 B[i_5] 40641160]

55881220] 38741i53] 4470[176]

50801200] 55561i4 O] 44701176]

CORNER WEIGHT LBS/KG

"1 .... 2.... 3.... 4"

024 51123 68131 102146 119/54

030 52123 69/31 103/a7 120155

036 55124 74133 110150 129158

REQ_RED CLEARANCES TO COMBUSTIBLE MATL. MILLIMETERS [IN]

TO_ OF UNIT ............................ 3556 [1400]

DUCT SIDE OF UNIT ......................................... 508 [200]

SIDE OPPOSETE DUCTS..................................... 3556 [1400]

BOTTOM OF UNIT .............................. O0 [OOO]

FLUE PANEL .............................................. 9i44 [3600]

805

[317]

1533

[604]

t

NEC. REQUIRED CLEARANCES.

MILLIMETERS [IN]

BETWEEN UNITS, POWER ENTRY SIDE ........................ 10668 [4200]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE ....... 9140 [36 ODE

UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, DOWER ENTRY SIDE ................... i0668 [4200]

REQ_RED CLEARANCE FOR OPERATION AND SERVICINO MILLIMETERS [IN]

EVAP COIL ACCESS SIDE ....................... 91_ O [3600]

POWER ENTRY SIDE ........................................ 91_0 [3600]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP ........................................... 12192 [_800]

SIDE OPPOSITE DUCTS..................................... 9140 [3600]

DUCT PANEL ............................ 304 8 [1200]*

_MINIMUM DISTANCES:IF UNIT IS PLACED LESS THAN 3048 [1200] FROM WALL

SYSTEM,THEN SYSTEM PERFORMANCE MAYBE COMPROMISED

DIMENSIONS IN [] ARE IN INCHES

_I156

[455]

i238

[487]

3130

[1232]

222[088] DEA

t

456 R

[1796]

a68

[184]

52 8

[208]

1222

[48_]

[020]

NPT

L GAS ENTRY

RIGHT SIDE VIEW

L1177

[463]

898

[353]

m_:_RN

INING

iL__

[21 67]

!496

[983] [98B]

REARVIEW

o>

2

48XP500006

ml

I

m_

&

.=.

t_

_°

860

[339]

4066

[1601]

t

Y

1[ OUTBOOR

[i1

10906

[4294]

FIELD ENTRY

SERVECE PORT

FULL LOUVER EL

11231

[4422]

LEFT SIDE VIEW

INDOOR6OIL _. \N

TOP VIEW

• _ FULL LOUVER

[284]

_X_ \

COMPRESSOR, BLOWER, GAS SECTION _

& ELECTRICAL ACCESS PANEL

FRONT VIEW

805

[317]

733

[682]

[i1 t

ELECTRICAL

UNIT CHARACTERISTICS

48XP042060/090 208 230 1 60, 208/230 3 60

48XP048090/!15/i30 208 230 1 60, 208/R30 3 60

48XPO6009B/!lS!130 208 230 1 60, 208/230 3 60

UNIT WT UNIT HEIGHT CENTER OF GRAVITY MM/IN

LBS KG "A" X Z

412 181 1091714298: 4953[195] NB721180]

462 210 I1425[4498: 4953[195] 4476[176] 4572[180]

507 230 119331469B: 533412/0] 5BBB[ROO] 4420[176]

CORNER WEIGHT LBS/KG

"i .... 2 .... 3 .... 4"

042 62/28 82/37 124156 144/65

048 69/31 92/42 139/63 16R/73

060 76135 101146 152/69 178180

REO_PED CLEARANCES TO COMBUSTIBLE MATL.

MILLIMETERS [IN]

TOP OF UNET ............................................. 3596 [1400]

DUCT SEDE OF UNET ......................................... 508 [200]

SIDE OPPOSITE DUCTS ..................................... 3556 [1400]

BOTTOM OF UNET............................................ OO [OOO]

FLUE PANEL ............................... 914 4 [36 O0]

NEC. REQUIRED CLEARANCES.

MILLIMETERS [IN]

BETWEEN UNITS, POWER ENTRY SIDE ....................... 10668 [a20O]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIBE .......... 9140 [3600]

UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE .................... 10668 [4200]

REO_RED CLEARANCE FOR OPERATION AND ,SERVICING

MILLIMETERS [IN]

EVAP COIL ACCESS SEDE .................................. 9140 [3600]

ROWER ENTRY SEDE ............................ 914 O [3600]

(EXCEPT FOR NEC REQUIREMENTS)

oNIT TOP ....................................... 12192 [4800]

SIDE OPPOSITE DUCTS ..................................... 9140 [3600]

DUCT PANEL .............................................. 3048 [1200]_

_MINIMUM DESTANCES:ZF UNIT IS PLACED LESS THAN 3048 [1200] FROM WALL

SYSTEM,THEN SYSTEM PERFORMANCE MAYBE COMPROMISED

DIMENSIONS IN [] ARE IN INCHES

_1i63

[458]

28 61113] BIA N 0

POWER ENTRY\ \

f

506

[19 93]

466

[i 84]

526

[R07]

i422

[SGO] RIGHT SIDE VIEW

[016]

872

[343]

SUPPLY

DUCT .. .

[i3 83] [1383]

REAR VIEW

>

g

48XP500009

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) _'_v

*Gasketing .._

/Wood \

Flashing.field II1_1 tl

II_s_n (f!eld I

I Roofing mate_al ll_i!_ II supplied)

\ f'_'dsuPP'ied-- - tl_iill IL

_, /IS_!II II-_Uuctwork /

\ _li II ,i_,dsupp,ed/

Roof Curb for Small Cabinet

Note A:When unit mounting screw is used

retainer bracket must also be used.

Roof Curb for Large Cabinet

Note A:When unit mounting screw is used

retainer bracket must also be used.

Supply opening

(BxC)

445/16"

R/A

\,\

Insulated

S/A

-'---'--GaSkec,tua_Ound. /_

Gasket around

deck pan outer edge

\

A B C

UNIT SIZE IN. (MM) IN. (MM) IN. (MM)

8 (203) 11 (279) 16-1/2 (419)

48XP024-036 14 (356) 11 (279) 16-1/2 (419)

48XP042-060 8 (203) 16-3/16 (411) 17-3/8 (441)

14 (356) 16-3/16 (411) 17-3/8 (441)

CATALOG

NUMBER

CPRFCURB006A00

CPRFCURB007A00

CPRFCURB008A00

CPRFCURB009A00

NOTES:

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

C00076

D

IN, (MM)

28-3/4 (730)

28-3/4 (730)

40-1/4 (1022)

40-1/4 (1022)

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 mm) thick fiberglass 1 lb (.45 kg) density.

d. When unit mounting screw is used (see Note A), a retainer bracket must be used as well. This bracket must also be used when required by code for hurricane or seismic

conditions. This bracket is available through Micrometl.

Fig. 4 - Roof Curb Dimensions

Unit

Rigging

Weight

SMALL CABINET

024 030 036

Ib kg Ib kg Ib kg

351 159 355 161 379 172

LARGE CABINET

042 048 060

Unit Ib kg Ib kg Ib kg

Rigging 427 194 477 216 522 237

Weight

NOTE: See dimensional drawing for corner weights.

Fig. 5 - 48XP Rigging Weights

BASEPAN SLOT (BELOW HANDHOLDS)

BEFORE RIGGING

DUCTS

SEAL STRIP MUST BE IN

PLACE BEFORE PLACING

UNIT ON ROOF CURB

UNIT 48XP A B

in. in. mm

024 22.0 14.50 368.3

030 22.0 14.50 368.3

036 22.0 15.30 388.6

042 20.0 21.25 539.8

048 21.5 16.3 414.0

060 23.5 16.3 414.3

mm

558.5

558.5

558.5

508.0

546.1

596.9

Fig. 6 - Suggested Rigging

C99015

Step 5 -- Rig and Place Unit

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.

Use spreader bars or crate top when rigging the unit. The 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

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.

When a field-fabricated support is used, be sure that the support is

level and properly supports the unit. Lifting point should be

directly over the center of gravity for the unit.

UNIT FALLING HAZARD

Failure to follow this warning could result in personal

iniury or death.

Never stand beneath rigged units or lift over people.

PERSONAL INJURY HAZARD

Failure to follow this warning could result in personal

iniury or death.

Never exceed 200 lb (91 kg) per bracket lifting force.

PERSONAL INJURY HAZARD

Failure to follow this warning could result in personal

iniury/death.

Accessory lifting kit is only to be used with Small Packaged

units which have a composite unit base with molded rigging

holds.

Step 6-- Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Model 48XP disposes of condensate water through a 3/4 in. NPT

fitting which exits through the compressor access panel (See Fig. 2

and 3 for location).

Condensate water can be drained directly onto the roof in rooftop

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

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. 7). 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. 7). Make sure that

the outlet of the trap is at least 1 in. 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 l-in. (25 mm)

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

tube for leaks.

1" (25 mm) MIN.

._L TRAP

OUTLET Z

_..'__-j__ 2"(51 mm)M IN.

A08001

Fig. 7 -Condensate Trap

Step 7-- Install Flue Hood

The flue hood assembly is shipped in the return section of the

indoor blower compartment (See Fig. 9). Remove the return duct

cover to locate the assembly.

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.

PERSONAL INJURY AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury

or death and unit component damage.

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.

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 mm) in every 15 ft (5 m) 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 (2 m).

For pipe sizes larger than 1/2 in., 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.

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 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 screw on

the right side and the left side 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.

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 plugged tapping, accessible for test gage

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 NFPA 54/ANSI Z223.1, in

Canada CAN/CSA-BI49.1 and B149.2 latest editions. In the

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*

Burner Orifice No. (Qty._Drill Size) Natural Gas

Burner Orifice No. (Qty._Drill Size) Propane Gas

HIGH-PRESSURE SWITCH (psig)

Cut-out Reset (Auto)

LOSS-OF-CHARGE /LOW-PRESSURE SWITCH

(Liquid Line) (psig) Cut-out

Reset (auto)

RETURN-AIR FILTERS Throwawayt

(in.)

(mm)

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

Table 1 - Physical Data -Unit 48XP

024040 024060 030040 030080 036080

2 2 2-1/2 2-1/2 3

388 388 392 392 416

176 176 178 178 189

Scroll

1

036090 042060 042090

3 3-1/2 3-1/2

416 464 464

189 210 210

7.3 7.3 8.0 8.0 9.5 9.5 10.7 10.7

3.3 3.3 3.6 3.6 4.3 4.3 4.9. 4.9

TXV

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

11.95 11.95 11.95 11.95 13.7 13.7 15.4 15.4

2350 2350 2350 2350 2800 2800 2800 2800

22 22 22 22 22 22 22 22

559 559 559 559 559 559 559 559

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...15 3...15 3...15 4...15 4...15 3...15 3...15

3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7

770 770 960 960 1150 1150 1400 1400

10x10 10x10 10x10 10x10 1lx10 1lx10 1lx10 1lx10

254x254 254x254 254x254 254x254 279x254 279x254 279x254 279x254

1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4

2...44 2...38 2...44 2...38 2...38 3...38 2...38 2...38

2...50 2...46 2...50 2...46 2...46 3...46 2...46 2...46

650 +/-15

420 +/-25

20 +/-5

45 +/-10

20x24x1 24x30x1

508x610x25 610x762x25

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 060115 060130

NOMINAL CAPACITY (ton) 4 4 4 5 5 5

SHIPPING WEIGHT (Ib) 512 512 512 559 559 559

(kg) 232 232 232 254 254 254

COMPRESSORS Scroll

Quantity 1

REFRIGERANT (R-410A) Quantity (Ib) 11.25 11.25 11.25 13.2 13.2 13.2

(kg) 5.1 5.1 5.1 6.0 6.0 6.0

REFRIGERANT METERING DEVICE T; IV

CONDENSER COIL Rows...Fins/in. 2...21 2...21 2...21 2...21 2...21 2...21

Face Area (sq ft) 17.4 17.4 17.4 19.3 19.3 19.3

CONDENSER FAN

Nominal Cfm 3300 3300 3300 3300 3300 3300

Diameter (in.) 22 22 22 22 22 22

(mm) 559 559 559 559 559 559

Motor Hp (Rpm) 1/4 (1100) 1/4 (1100) 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 4...17 4...17

Face Area (sq ft) 4.7 4.7 4.7 5.7 5.7 5.7

EVAPORATOR BLOWER

Nominal Airflow (Cfm) 1400 1400 1400 1710 1710 1710

Size (in.) 1lx10 1lx10 1lx10 1lx10 1lx10 1lx10

(mm) 279x254 279x254 279x254 279x254 279x254 279x254

Motor (hp) 3/4 (1075) 3/4 (1075) 3/4 (1075) 1.0 (1040) 1.0 (1040) 1.0 (1040)

FURNACE SECTION*

Burner Orifice No. (Qty...Drill Size) Natural Gas 3...38 3...33 3...31 3...38 3...33 3...31

Burner Orifice No. (Qty._Drill Size) Propane Gas 3...46 3...42 3...41 3...46 3...42 3...41

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 heating airflow velocity of

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

Table2- MaximumGas Flow Capacity*

NOMINAL INTERNAL LENGTH OF PIPE, FT (m)t

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

SIZE (IN,) (IN,) (3) (8) (9) (12) (15) (18) (21) (24) (27) (30) (38) (48) (53) (81)

1/2 .822 175 120 97 82 73 88 81 57 53 50 44 40 -- --

3/4 .824 380 250 200 170 151 138 125 118 110 103 93 84 77 72

1 1.049 880 485 375 320 285 280 240 220 205 195 175 180 145 135

11/4 1.380 1400 950 770 800 580 530 490 480 430 400 380 325 300 280

11/2 1.810 2100 1480 1180 990 900 810 750 890 850 820 550 500 480 430

* 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.

IN

TEE

NIPPLE

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.

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 nfininmm of 2 in. (51 ram) 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

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.Openallelectricaldisconnectsbeforestartinganyservice

work.

2.Removehorizontal(metal)ductcoverstoaccessvertical

(downflow)dischargeductknockoutsinunitbase.

3.Useascrewdriverandhammertoremovethepanelsinthe

bottomoftheunitbase(SeeFig.9& 10).

IIi'

SUPPLY RETURN

DUCT DUCT

OPENING OPENING

Fig. 9 - Supply and Return Duct Opening

C99011

VERTICAL DUCT COVERS

Fig. 10 - Vertical Duct Cover Removed

C99012

4. If unit ductwork is to be attached to vertical opening flanges

on the unit base (jackstand applications only), do so at this

time.

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.

5. It is recommended that the base insulation around the

perimeter of the vertical return-air opening be secured to

the base with aluminum tape. Applicable local codes may

require aluminum tape to prevent exposed fiberglass.

6. Cover both horizontal duct openings with the provided

duct covers. Ensure opening is air- and watertight.

7. After completing unit conversion, perform all safety checks

and power up unit.

NOTE: The design and installation of the duct system nmst 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.

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

building structure.

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

building structure in accordance with local codes and good

building practices.

10

Step 10 -- Install Electrical Connections

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal injury

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 could 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.

HIGH-VOLTAGE CONNECTIONS

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 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 and Fig. 11 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 leads into the

control box.

2. Connect ground lead to chassis ground connection.

3. Connect L1 to pressure lug connection 11 of the compressor

contactor.

4. Connect L2 to pressure lug connection 23 of the

compressor contactor.

LOW-VO LTAG E

POWER LEADS-

(SEE UNIT

WIRING LABEL)

HIGH VOLTAGE r

POWER LEADS I¢_ """

(SEE UNIT WIRING

LABEL) Lc_

mmm

GND

CONTROL BOX

O-

O-

O_

O-

O=

SPLICE BOX

FIELD-SUPPLIED

FUSED DISCONNECT

YZL£Y)--D.i Z-,,'_

GR._(e_)_. i-¢n_

_J

RE DZR2,1>.i-f_

BREC_)_ i"(-€3

,THERMOSTAT

(TYPICAL)

LEGEND

Field Control-Voltage Wiring

Field High-Voltage Wiring .......

A08476

Fig. ll - High and Control-Voltage Connections

Three-phase units:

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

the control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the lines

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 13 of

the compressor contactor.

6. Connect field wire L3 to Blue wire from compressor.

SPECIAL PROCEDURES FOR 208-V OPERATION

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal injury

or death.

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.

ELECTRICAL SHOCK FIRE/EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury

or death and property damage.

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.

11

Useno.18AmericanWireGage(AWG)color-coded,insulated

(35Cminimum)wirestomakethecontrolvoltageconnections

betweenthethermostatandtheunit.If thethermostatislocated

morethan100ft (30m)fromtheunit(asmeasuredalongthe

controlvoltagewires),useno.16AWGcolor-coded,insulated(35

Cminimum)wires.

Locatethesixlowvoltagethermostatleadsin24voltsplicebox.

SeeFig.11forconnectiondiagram.Runthelow-voltageleads

fromthethermostat,throughthecontrolwiringinletholegrommet

(Fig.2and3),andintothelow-voltagesplicebox.Provideadrip

loopbeforerunningwiresthroughpanel.Secureandstainreliefall

wiressothattheydonotinterferewithoperationofunit.

Easy Select TM -48XP

EASY SELECT TM CONFIGURATION TAPS FOR 48XP

Easy Select taps are used by the installer to configure a system. The

ECM motor uses the selected taps to modify its operation to a

pre-programmed table of airflows.

The unit must be configured to operate properly with system

components with which it is installed. To successfully configure a

basic system (see information printed on circuit board label located

next to select pins), move the 6 select wires to the pins which

match the components used (See Fig. 12).

a. GAS HEAT/CFM-SELECT GAS HEAT INPUT SIZE

Factory selected gas heat size should correspond to unit

label.

b. AC/HP SIZE- SELECT SYSTEM SIZE INSTALLED

Factory selected air conditioner size should correspond

to capacity of unit installed. Installer should verify air

conditioner size to ensure that airflow delivered falls

within proper range for the size unit installed. This

applies to all operational modes.

c. SYSTEM TYPE--SELECT SYSTEM TYPE

INSTALLED

Factory selected on 48XP for AC-Air conditioner.

For Gas Heat/Electric Cool Unit-AC must be selected.

d. AC/HP CFM ADJUST-SELECT NOMINAL, LOW,

OR HIGH AIRFLOW

The AC/HP CFM Adjust select is factory set to the

NOM tap. The CFM Adjust selections NOM/LO will

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

provides 10 percent airflow below nominal unit size

selected. Adjust selection options are provided to adjust

airflow supplied to meet individual installation needs for

such things as noise, comfort, and humidity removal

(See Fig. 12, D as indicated).

e. ON/OFF DELAY- SELECT DESIREDTIME DELAY

PROFILE

Four motor operation delay profiles are provided to

customize and enhance system operation (See Fig. 12, E

as indicated).

Selection options are:

(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 and 45 sec off delay.

(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

cool-down in conjunction with the airflow in

heating mode.

12

9 PIN CONNECTOR

ICM PRINTED CIRCUIT BOARD '_--_

SEC1

r"m

HEATER/MOTOR

AUX1 HUM1

AUX2 HUM2

24VAC

GRY ==_

12 PIN CONNECTOR

C01039

Fig. 12 - Detail of SPP Printed-Circuit Board

(3.) A no delay option used for servicing unit or when

a thermostat is utilized to perform delay functions

in cooling mode. In heating mode IGC will control

45 sec on delay with no airflow and 45 sec off

delay.

(4.) ENH- Not recommended for 48XP

f. CONTINUOUS FAN--SELECT DESIRED FAN

SPEED WHEN THERMOSTAT IS SET ON

CONTINUOUS FAN

(1.) LO speed-Factory setting, 50 percent cooling

mode airflow.

(2.) MED speed-Move connector to MED, 65 percent

cooling mode airflow.

(3.) HI speed-Move connector to HI, 100 percent

cooling mode airflow (See Fig. 12, F as indicated).

g. LOW-VOLTAGE CIRCUIT FUSING AND

REFERENCE

The low-voltage circuit is fused by a board-mounted

5-amp automotive fuse placed in series with the

transformer SEC2 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

marked with ground symbol.

h. BASIC UNIT 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

rated ARI performance is required, or if system

enhancements such as super dehumidify are not needed.

(1.) HEAT-Factory selected to match heat input size.

(2.) AC/HP Size-Factory selected to match system size,

please verify.

(3.) SYSTEM TYPE-Factory selected on 48XP system

AC-AIR CONDITIONER.

(4.) AC/HP CFM ADJUST-Select NOM.

(5.) ON/OFF DELAY-Factory selected 0/90 profile.

(Do Not Use ENH profile for Gas Packaged Units)

(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 selected to match system size,

please verify.

(3.) SYSTEM TYPE-Factory selected on 48XP system

AC-AIR CONDITIONER.

(4.) AC/HP CFM ADJUST-Select NOM.

(5.) ON/OFF DELAY-Select :'0/0" profile.

(6.) CONTINUOUS FAN-Select desired fan speed

when thermostat is set to continuous fan.

(7.) DEHUMIDIFY MODE-Remove J1 jumper to

activate.

NOTE: J1 jumper should only be removed when a Thermidistat,

humidistat or capable zoning control is installed.

(8.) LOW VOLTAGE CONNECTIONS-Make

connections as shown in ELECTRICAL

CONNECTIONS section.

(9.) CONFIGURE THERMIDISTAT-Follow

Thermidistat (or capable zoning system)

installation instructions for Super Dehumidify

operation.

ACCESSORY INSTALLATION

a. AUXILIARY TERMINALS 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 is energized (See Fig. 12). During Super

dehumidify mode, the G signal is not present 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 CONNECTIONS

The AUXI and AUX2 terminals are not always

energized during blower operations, as described above.

When using an electronic 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.

HUM 1FI

(c)

HUM 2[7

(G)

c. HUMIDIFIER/HUMIDISTAT CONNECTIONS Easy

Select Board terminals HUM1 and HUM2 are provided

for direct connection to the low-voltage control of a

humidifier through a standard humidistat (See Fig. 12).

These terminals are energized with 24-v. when G

thermostat signal is present (See Fig. 13 & 14).

Alternately, the 24-v. signal may be sourced from the W

and C on the 9 pin connector. When using a

Thermidistat Control, Zone Comfort Plus or Comfort

Zone II, the 24-v. signal may be sourced directly from

the Thermidistat HUM terminal (See Fig. 12, 13 & 14).

d. DEHUMIDIFY CAPABILITY WITH STANDARD

HUMIDISTAT CONNECTION

Latent capacities for this unit are better than average

systems. If increased latent capacity is an application

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 of selected cooling airflow. To

activate this mode, remove jumper 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

required.

HUMIDISTAT

24-VAC _ TO HUMIDIFIER

J

HUMIDIFIER WIRING

Fig. 13 -Humidifier Wiring -48XP

A95317

EASY SELECTIq

BOARD TERMINALF]

BLOCK

J1

REMovEJ

JUMPER

1

IHUMIDISTAT

I

l

A95316

Fig. 14 -Humidistat Wiring for De-Humidify Mode -48XP

TRANSFORMER PROTECTION

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

a 30-sec. overload or shorted secondary condition.

13

PRE-START-UP

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury,

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 startu _:

1. Remove access panel.

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. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

4. Verify the following conditions:

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal injury,

death or property damage.

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.

a. Make sure gas line is free of air. Before lighting the unit

for the first time, perform the following with the gas

valve in the "OFF" position:

If the gas supply pipe was not purged before connecting

the unit, it will be full of air. It is recommended that the

ground joint union be loosened, and the supply line be

allowed to purge until the odor of gas is detected. Never

purge gas lines into a combustion chamber. Immediately

upon detection of gas odor, retighten the union. Allow 5

minutes to elapse, then light unit.

b. Make sure that condenser-fan blade is correctly

positioned in fan orifice. Leading edge of condenser-fan

blade should be 1/2 in. (13 mm) maximum from fan

orifice.

c. Ensure fan hub is 1/8 in. (3 mm) maximum from motor

housing (See Fig. 15).

d. Make sure that air filter(s) is in place.

e. Make sure that condensate drain trap is filled with water

to ensure proper drainage.

f. Make sure that all tools and miscellaneous loose parts

have been removed.

1/8" (3 mm) MAX BETWEEN MOTOR SHAFT

MOTORAND FAN HUB

A08474

Fig. 15 -Fan Blade Clearance

START-UP

Step 1-- 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 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. Evacuate and recover refrigerant from refrigerant system if

additional leaks are not found.

5. Charge unit with R-410A refrigerant, using a volume tric-

charging cylinder or accurate scale. Refer to unit rating plate

for required charge.

Step 2 -- Unit Sequence of Operation

48XP Sequence of Operation

a. CONTINUOUS FAN

(1.) Thermostat closes circuit R to G-The Blower runs

at continuous fan airfow.

b. COOLING 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

to O-The unit delivers single speed cooling

airflow.

c. COOLING MODE-DEHUMIDIFICATION

(1.) If indoor temperature is above temperature set

point and humidity is above humidity set point,

14

thermostat or Thermidistat closes circuits Rto G, R

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 DEHUMIDIFY

OPERATION (SEE QUICK REFERENCE GUIDE)

NOTE: The indoor control used, such as a Thermidistat, must be

capable of providing Super Dehumidify operation mode and

control must be configured as outlined in its installation

instructions. Consult indoor control literature to determine if

control is capable of providing Super Dehumidify inputs and for

configuration instruction.

(1.) If the indoor temperature is below the temperature

set point and the humidity is above the humidity

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

(24-v.), the motor will deliver airflow at the full

cooling or cooling plus dehumidify mode

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 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 "On" delay and a 45 sec.

"Off"' delay.

Step 3 -- 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.

Make sure that burner orifices are properly aligned. Unstable

operation may occur when the burner orifices in the manifold are

misaligned.

Follow the lighting instructions on the heating section operation

label (located inside the burner or blower access door) to start the

heating section.

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

gas piping has been checked for leaks.

CHECK HEATING CONTROL

Start and check the unit for proper cooling control operation as

follows (see furnace lighting instructions located inside burner or

blower 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. After a call for heating, the main burner should light within

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,

this sequence is repeated. If the burners do not light within

15 minutes 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.

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 1050 Btu/ft 3 at 0.65

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

Btu/ft 3 at 1.5 specific 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 from 2001 ft (610 m) to 4500 ft (1372 m) above

sea leval reduce input 10%.

• 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 determine the required orifice size.

UNIT 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 misdirection of burner flame. Replace with correct sized

orifices.

ADJUST 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 Units)

Minor adjustment to the gas flow can be made by changing the

manifold pressure. The manifold pressure must be maintained

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.

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. 16) 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 3 into 3600 (number of

seconds in one hr).

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.

6. Multiply result of Step 5 by 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).

15

MANIFOLD PIPE PLUG

C99019

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.

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 Pressure (Propane Units)

The main burner orifices on a propane gas unit are sized for the

unit rated input when the manifold pressure reading matches the

level specified in Table 3.

Proceed as follows to adjust gas input on a propane gas unit:

1. Turn off gas to unit.

2. Remove pipe plug on manifold and connect manometer

(See Fig. 16).

3. Turn on gas to unit.

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

BURNER

MAN IFOLD

C99021

Fig. 17 -Monoport Burner

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 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.

16

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

ments

UNIT DAMAGE HAZARD

Failure to follow this warning could result in unit component

damage.

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 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 the time selected on the Easy

Select board.

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).

HEATING

INPUT (BTUH)*

40,000

60,000

90,000

115,000

130,000

NUMBER OF

ORIFICES

2

2

3

3

3

Min

4.0

4.0

4.0

4.0

4.0

Table 3-Heating Inputs

GAS SUPPLY PHI-SSUHI- (IN. W.C.)

Natural Propanet

Max Min

13.0 4.0

13.0 4.0

13.0 4.0

13.0 4.0

13.0 4.0

Max

13.0

13.0

13.0

13.0

13.0

MANIFOLD PRESSURE (IN. W.C.)

Natural Propanet

3.5 3.5

3.5 3.5

3.5 3.4

3.5 3.7

3.5 3.5

* 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.

HEATING

INPUT

(BTUH) 20 25 30 35 40 45

40,000 1500 1200 1000 857 750 667

60,000 2250 1800 1500 1285 1125 1000

90,000 -- -- 2250 1929 1688 1500

115,000 -- -- -- 2464 2156 1917

130,000 -- -- -- 2786 2438 2167

NOTE: Dashed areas do not fall within the approved temperature rise range of the unit.

Table 5 - LED Indications

Table 4 -Air Delivery (CFM) at Indicated Temperature Rise and Rated Heating Input

TEMPERATURE RISE °F

50 55 60 65 70

600 545 500 -- --

900 818 750 692 --

1350 1227 1125 1038 964

1725 1568 1438 1327 1232

1950 1773 1625 1500 --

ERROR CODE

Normal Operation

Hardware Failure

Fan On/Off Delay Modified

Limit Switch Fault

Flame Sense Fault

Four Consecutive Limit Switch Faults

Ignition Lockout Fault

Induced- Draft 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 in numerical sequence.

3. This chart is on the wiring diagram located inside the burner access panel.

Table 6-Filter Pressure Drop (IN. W.C.)

FILTER SIZE CFM

in. (mm) 500 600 700 800 900 1000 1100 1200 1300 1400 1500

20X20X1 0.05 0.07 0.08 0.10 0.12 0.13 0.14 0.15 -- -- --

(508X508X25)

20X24X1 .... 0.09 0.10 0.11 0.13 0.14 0.15 0.16

(508X610x25)

24X30X1 ....... 0.07 0.08 0.09 0.10

(610X762x25)

LED INDICATION

On

Off

1 Flash

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

7 Flashes

8 Flashes

9 Flashes

1600 1700 1800 1900 2000 2100 2200 2300

0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18

17

UNIT

SIZE

024

030

036

042

048

060

Table 7 - 48XP Cooling Dry Coil ECM Airflow Small Cabinet

CFM ADJUST PIN LO PIN NOM PIN HI PIN

SELECT

UNIT EXTERNAL STATIC

SIZE PRESSURE RANGE 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

(IN. W.C.)

COOLING 800 725 - 885 805 730 990 930 855

024 COOLING 715 670 - 715 695 645 795 775 745

DEHUMIDIFY

COOLING 1010 920 825 1105 1030 930 1255 1160 1050

030 COOLING 890 845 795 890 865 825 1010 980 925

DEHUMIDIFY

COOLING 1110 1025 970 1235 1175 1115 1400 1355 1280

036 COOLING 990 960 910 990 975 940 1125 1110 1085

DEHUMIDIFY

Table 8 -48XP Cooling Dry (;oil ECM Airflow Large Cabinet

LO PIN NOM PIN HI PIN

UNIT SIZE

0.1-1.0 0.1-1.0 0.1-1.0

042

048

060

CFM ADJUST PIN

SELECT

EXTERNAL STATIC

PRESSURE RANGE (IN. W.C.)

COOLING

COOLING DEHUMIDIFY

COOLING

COOLING DEHUMIDIFY

COOLING

COOLING DEHUMIDIFY

1lO0

98O

1260

1120

1575

1400

1225

98O

1400

1120

1750

1400

EASY SELECT TM

BOARD SETTING

(CFM)

External

Static

Unit Pressure

Size (IN, W,C,)

Gas Heat

Size

040

024 060

040

030 060

060

036 090

1410

1125

1610

1290

2010

1610

Table 9 - 48XP Gas Heating ECM Airflow Small Cabinet

700 800 11oo 1250

0.0-0.4 0.4-0.7 0.7-1.0 0.0-0.4 0.4-0.7 0.7-1.0

855 770 710

880 840 805

0.0-0.4 0.4-0.7 0.7-1.0

1020 890 835

1030 970 910

1035 995 955

0.0-0.4 0.4-0.7 0.7-1.0

1170 1110 1025

600

0.005

External Static Pressure (IN. W.C.)

Gas Heat Size

060

090

090

115

130

090

115

130

0.0-1.0

1600

1600

1750

0.0-1.0

1750

Table 10 - 48XP Gas Heating ECM Airflow Large Cabinet

EASY SELECT TM BOARD SETTING (CFM) 1000 1250 1600

Unit Size 0.0-1.0 0.0-1.0

042 1000 -

- 1250

- 1250

048 - -

- 1250

060 - -

Tablell-ECMWetCoilPressureDrop(IN.W.C.)

STANDARD CFM (SCFM)

18OO

0.0-1.0

1800

700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100

0.007 0.010 0.012 0.015 ........

0.007 0.010 0.012 0.015 0.018 0.021 0.024 ......

- - 0.019 0.023 0.027 0.032 0.037 0.042 0.047 .....

- - - 0.014 0.017 0.020 0.024 0.027 0.031 0.035 0.039 0.043 - - -

..... 0.027 0.032 0.036 0.041 0.046 0.052 0.057 0.063 0.068 -

...... 0.029 0.032 0.036 0.040 0.045 0.049 0.053

18

SCII_MAT IC

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Fig. 18 - 208/230-1-60 Wiring Diagram, Unit 48XP

A08462

19

SCHEMATIC

208/230-3-60

FIELD

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HPS HiGH PRESSURE SWITCH

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_ iT _UST BE REPLACED W_TR TYPE gO DEGREE C _IRE OR

NORMAL OPERA_IO_ ITS EQUIVALENT

RARD_ARE FAILURE OFF Z SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES

FAN ONIOFF DELAY NOD{PiED _ FLASH 3USE 75 DEGREE COPPER CONDUCTORS FOR F_ELD _NSTALLAT_ON

LIMIT SWITCH FAULT ZFLASHES 4REPLACE LOW VOLTAGE FUSES W_TH NO GREATER THAN S A_P FUSES

PLANE SENSE FAULT 3 FLASHES SON _ODZLS 4RXPOZ_+O)6 HAS ISI AND LS2 _N SERIES

5 CONSECUTIVE LI_[T SWITCH FAULTS _ FLASHES ON MODELS _8XPO_2"060 HAS LS[ ONLYMOUNTING PANEL ABOVE _GNIT_ON LOCKOUT FAULT FLASHES

_NDOOR BLOWER {NRVCER SW_TCN FAULT 6 FLASHES 6REMOVE J[ WHEN USING TRER_IDISTA_I HU_IDISFAI AND

ROLLOUI SWITCH FAULT TFLASHES DEHUmIDIFICATiON MODE

iNTERNAL CONTROL FAULT B FLASHES ?REMOVE J2

TEMPORARY ONE HOUR AUTO_IATIC RESET _AULT (NOTE 9} 9 FLASHES 8TO BE WIRER IN ACCORDANCE _ITH NEC AND LOCAL CODES

[3 SECOND PAUSE BETWEEN ERROR CODE D_SPLAY 9THIS CODE INDICATES AN [NTERNAL PROCESSOR FAULT THAT W[LL

Z If _ORE THAN ONE ERROR EXISTS+ ALL APPLICABLE ERROR CODES RESET [TSELP I_ ONE HOUR FAULT CAN BE CAUSED BY STRAY RP

SHALL RE DISPLAYED {N NUMERICAL SEQUENCE SIGNALS IN THE STRUCTURE OR NEARBY THIS IS k UL REQUIREMEN_ FAULT

Fig. 19 -208/230-3-60 Wiring Diagram, []nit 48XP

!48XP500149 16,0

A08463

20

Required Subcoolin_ oF IoC) Required Liquid Line Temperature for aSpecific Subcooting (R-41OA)

Outdoor Ambient Temperature Required Subcooling (°F) Required Subcooling (°C)

Model Size 75 (24) 82 (26) 86 (29) 96 (85)

024 10.3(5.7) 9.8(5.4) 9.4(6.2) 9(5)

030 9.3 ( 5.2 ) 8.8 ( 4.9 ) 8.6 ( 4.8 ) 7.6 ( 4.3 )

036 17.6(9.8) 16.8 (9.3) 16.6 (9.2) 16.4 (6.6)

042 12.8(7.1) 12.7(7.1) 12.7(7.1) 12.6(7)

046 17.5(9.7) 16.9(9.4) 16.6(9.2) 16.7 (6.7)

060 13.7(7.6) 13(7.2) 16(7.2) 14.6 (6.1)

Charqinq Procedure

1- Meacure Di¢charge line preceure by attaching a gauge to the _ervice port.

2- Meacure the Liquid line temperature by attaching a temperature Ceneing

device to it.

3- Ineulate the temperature ceneing device _=o that the Outdoor Ambient

doe_=n'_affect the reading.

105 (41) Pre_sur,

8.6(4.7) 189

7(3.9) 196

14.3(7.9) 203

12.6(7) 210

14.8(8.2) 217

11.5(6.4) 224

231

238

245

252

260

268

276

284

4- Refer to the required Subcooling in the table baeed on the model ¢ize and 292

the Outdoor Ambient temperature. 300

5- Interpolate if the Outdoor ambient temperature lie_ in between the table 309

value€. Extrapolate if the temperature lie€ beyond the table range. 316

6- Find the Pree_ure Value in the table corre¢ponding to the the meaCured 327

Pre¢¢ure of the Compre¢eor Di¢charge line. 336

7- Read acro¢_= from the Preeeure reading to obtain the Liquid line 345

temperature for a required Subcooling 364

8- Add Charge if the meaeured temperature i¢ higher than the table value. 364

374

384

394

4O4

414

424

434

444

454

464

474

464

494

5O4

514

524

50XZ500174 ]534

5

61

63

66

68

70

72

74

76

77

79

81

83

85

87

89

91

93

95

97

99

101

103

105

107

108

110

112

114

116

118

119

121

123

124

126

127

129

131

132

134

Pre_sur_

10 15 20 26 (kPa)

56 51 46 41 1303

58 53 48 43 1351

61 66 51 46 1399

63 68 53 48 1448

66 60 55 50 1496

67 62 57 52 1544

69 64 59 54 1593

71 66 61 56 1641

72 67 62 57 1689

74 69 64 59 1737

76 71 66 61 1792

76 73 68 63 1848

80 78 70 66 1903

82 77 72 67 1956

84 79 74 69 2013

86 61 76 71 2066

88 63 78 73 2130

90 65 80 76 2192

92 67 82 77 2254

94 69 84 79 2316

96 91 86 81 2376

98 93 88 83 2440

100 95 90 86 2509

102 97 92 87 2576

103 98 96 88 2647

106 100 95 90 2716

107 102 97 92 2786

109 104 99 94 2854

111 106 101 96 2923

113 108 103 98 2992

114 109 104 99 3061

116 111 106 101 3130

118 113 108 103 3199

119 114 109 104 3266

121 116 111 106 3337

122 117 112 107 3406

124 119 114 109 3476

126 121 116 111 3544

127 122 117 112 3612

129 124 119 114 3661

3 6 8

16 13 11

17 18 12

19 16 13

20 17 14

21 18 15

22 19 16

23 20 18

24 21 19

26 22 20

26 23 21

27 25 22

29 26 23

30 27 24

31 28 25

32 29 26

33 30 27

34 31 28

36 32 29

36 33 31

37 34 32

38 35 33

39 36 34

40 38 35

41 39 36

42 40 37

44 41 38

45 42 39

46 43 40

47 44 41

46 45 42

46 46 43

49 47 44

50 48 45

51 48 46

52 49 47

53 50 47

54 51 48

55 52 49

56 63 50

56 64 51

11 14

8 5

9 6

10 8

11 9

13 10

14 11

15 12

16 13

17 14

18 15

19 16

20 17

21 19

22 20

23 21

24 22

26 23

27 24

28 25

29 26

30 27

31 28

32 29

33 30

34 31

35 32

36 33

37 34

38 35

39 36

40 37

41 38

42 39

43 40

44 41

45 42

46 43

46 44

47 45

48 45

C03027

Fig. 20 - Cooling Charging Table-Subcooling

IMPORTANT: Three-phase, scroll compressor units are To Use Cooling Charging Charts

direction-oriented. These units must be checked to ensure proper

compressor 3-phase power lead orientation. If not corrected within

5 minutes, the internal protector shuts off the compressor. The

3-phase power leads to the unit must be reversed to correct

rotation. When turning backwards, scroll compressors emit

elevated noise levels, and the difference between compressor

suction and discharge pressures may be zero.

CHECKING AND ADJUSTING REFRIGERANT CHARGE

The refrigerant system is fully charged with R-410A refrigerant,

tested, and factory-sealed.

NOTE: Adjustment of the refrigerant charge is not required unless

the unit is suspected of not having the proper R-410A charge.

An accurate superheat, 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.

Take the liquid line temperature and read the manifold pressure

gauges. Refer to the chart (See Fig. 20) to determine what the

liquid line temperature should be.

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

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 and Table 9 & 10 show heating airflows at the

selection pin ranges (depending on external static pressure). Refer

to these tables to determine the airflow for the system being

installed.

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

free from obstructions, and adjusted properly.

UNIT 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.

ELECTRICAL SHOCK 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.

Airflow can be changed by changing the selection pins on the Easy

Select circuit board.

21

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.

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 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.

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

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.

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:

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.

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 the flue collector box and upper areas of the heat

exchanger:

1. Remove the combustion blower wheel and motor assembly

according to directions in the Combustion-Air Blower

section.

2. Remove the 3 screws holding the blower housing to the flue

collector box cover (See Fig. 23).

3. Remove the 12 screws holding the flue collector box cover

(See Fig. 24) to the heat exchanger assembly. Inspect the

heat exchangers.

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

22

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. If cleaning is required, remove motor

and wheel as follows:

1. Remove unit access panel (See Fig. 22).

2. Remove the 7 screws that attach induced-draft motor

mounting plate to blower housing (See Fig. 23).

3. Slide the motor and blower 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 (See Fig. 23).

5. To remove motor and cooling fan assembly, remove 4

screws that hold blower housing to mounting plate.

6. To reinstall, reverse the procedure outlined above.

LIMIT SWITCH

Remove unit access panel. Limit switch is located on the blower

partition.

BURNER IGNITION

Unit is equipped with a direct spark ignition 100 percent lockout

system. Ignition module is located in the control box. Module

contains a self-diagnostic LED. During servicing, refer to label

diagram 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.

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 DRAFT MOTOR MOUNT

<<v

ROLLOUT

VENT HOOD FLUE SWITCH

IN SHIPPING COLLECTOR BLOWER BURNER MOUNTING

LOCATION BOX HOUSING RACK SCREW

C99022

Fig. 21 - Blower Housing and Flue Collector Box

UNIT 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 misdirection of burner flame. Replace with correct sized

orifices.

REMOVAL OF GAS TRAIN

To remove the gas train for servicing:

1. Shut off main gas valve.

2. Shut off power to unit.

3. Remove unit access panel (See Fig. 22).

4. Disconnect gas piping at unit gas valve.

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

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

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

the unit base (See Fig. 24).

8. Slide the burner rack out of the unit (See Fig. 21 and 24).

9. To reinstall, reverse the procedure outlined above.

CONDENSER COIL, EVAPORATOR COIL, AND

CONDENSATE DRAIN PAN

Inspect the condenser coil, evaporator 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.

23

FRONT

ACCESS PANEL

Fig. 22 - Unit Access Panel

C99091

ELECTRICAL SHOCK FIRE/EXPLOSION HAZARD

Failure to follow this warning could result in personal injury

or death and property damage.

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.

BLOWER

HOUSING

2 SETSCREWS

(HIDDEN)

C99085

Fig. 23 -Removal of Motor and Blower Wheel

Fig. 24 -Burner Rack Removed

CONDENSER FAN

C99086

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unit

components.

Keep the condenser fan free from all obstructions to ensure

proper cooling operation. Never place articles on top of the

unit.

1. Remove 6 screws holding condenser 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 so the hub is 1/8

in. (3 ram) away from the motor end (1/8 in. [3 ram] of

motor shaft will be visible, See Fig. 15).

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 panel to locate all the electrical controls and wiring.

Check all electrical connections for tightness. Tighten all screw

connections. If any smoky 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 panel. 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 either or both operating

cycles, 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 deternfining 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 INJURY HAZARD

Failure to follow this warning could result in personal iniury,

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 no refrigerant leaks are found and low cooling performance is

suspected, refer to the Checking and Adjusting Refrigerant Charge

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.

EVAPORATOR 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.

24

9 PIN CONNECTOR --

ECM PRINTED CIRCUIT BOARD --.___

SEC1 SEC2

C:_ C:3

EASYSELECT TM

GAS HEAT/CFM

1!&

AJ_ _° _i°° _° _0_0__

AC/PPSIZE

0;

,, SYSTEM TYPE

C ,,....._ O___ _; HPO0_ ........

,,, ACiHP CFMADJUST

Q, DH

R

,_ W_

1. Configuration Taps

(See Installation Instructions, for detailed description)

A. HEAT RANGE - Set for gas heat size (EX:090for unit 048090---)D

B. AC/HP SIZE - Set for size of outdoor unit (Cooling Size)

C. SYSTEM TYPE - Select "AC" for Gas Package UnitsN

D. AC/HP CFM ADJUST - Select "NOM"

E. ON/OFF DELAY - Do not use "ENH" for this unit

F. CONTINUOUS FAN - Select desired speed

2. Remove Jumper J1 to activate all dehumidify modes

3. Complete wiring and install outdoor temperature [B

sensor according to Installation Instructions

D._., _

E_..i I

F--_

_ Y_

ON/OFF DELAY _ G

"o o

_ _ _ E÷ _ _c

AUX1 HUM1

AOX_N_M_

O

Z12 PIN CONNECTOR

1. Set "DIP Switches" - Set the dip switches (back of [q

Thermidistat Control Board) appropriately for specific n

system being installed.

2. Thermidistat Control Configurations

(See Thermidistat Control installation Instructions for detailed description)_

* Option 5 (Variable Speed Indoor Motor) - Set to ON

* Option 7 (Super Dehumidify) - Set to ON

* Option 17 - Select Programmable or non-programmable mode.

3. Set desired humidity level on fron of Thermidistat

(50 to 55 % RH recommended). For dehumidification in

cooling, both "dhu" and "cool" must be displayed.

ECM ID Blower Motor-quick Reference Guide

J

C01034G

PURON ITEMS

METERING DEVICE (Thermostatic Expansion Valve )

This metering device is a hard shutoff, balance port TXV. The

TXV maintains a constant superheat at the evaporator exit 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 REFRIG-

ERANT)

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.

25

FIRE/EXPLOSIONHAZARD

Failuretofollowthiswarningcouldresultinpersonalinjury

ordeathand/orpropertydamage.

Wearsafetyglassesandgloveswhenhandlingrefrigerants.

Keeptorchesandotherignitionsourcesawayfrom

refrigerantsandoils.

Thescrollcompressorpumpsrefrigerantthroughoutthesystemby

theinteractionof astationaryandanorbitingscroll.Thescroll

compressorhasnodynanficsuctionordischargevalves,andit is

moretolerantof stressescausedbydebris,liquidslugging,and

floodedstarts.Thecompressorisequippedwithananti-rotational

deviceandaninternalpressurereliefport.Theanti-rotational

devicepreventsthescrollfromturningbackwardsandreplacesthe

needforacycleprotector.Thepressurereliefportisasafety

device,designedtoprotectagainstextremehighpressure.The

reliefporthasanoperatingrangebetween550and625psi

differentialpressure.

UNITOPERATIONANDSAFETYHAZARD

Failuretofollowthiswarningcouldresultinpersonalinjury

orequipmentdamage.

ThissystemusesPuron(R-410A)refrigerantwhichhas

higheroperatingpressuresthanR-22andotherrefrigerants.

Nootherrefrigerantmaybeusedinthissystem.Gaugeset,

hoses,andrecoverysystemnmstbedesignedtohandlePuron.

Ifyouareunsure,consulttheequipmentmanufacturer.

REFRIGERANTSYSTEM

Thisinformationcoverstherefrigerantsystemof the48XP,

includingthecompressoroilneeded,servicingsystemsonroofs

containingsyntheticmaterials,thefilterdrierandrefrigerant

charging.

CompressorOil

TheCopelandscrollcompressoruses3MAFPOEoil.Ifadditional

oil is needed,useUniqemaRL32-3MAF.If thisoil is not

availaMe,useCopelandUltra32CCorMobilArcticEAL22CC.

Thisoil is extremelyhygroscopic,meaningit absorbswater

readily.Thisoil isextremelyhygroscopic,meaningit absorbs

waterreadily.POEoilscanabsorb15timesasmuchwaterasother

oilsdesignedforHCFCandCFCrefrigerants.Takeallnecessary

precautionstoavoidexposureoftheoiltotheatmosphere.

SERVICINGSYSTEMSONROOFSWITHSYNTHETIC-

MATERIALS

POE(polyolester)compressorlubricantsareknowntocauselong

termdamagetosomesyntheticroofingmaterials.

Exposure,evenif immediatelycleanedup, may cause

embrittlement(leadingtocracking)tooccurinoneyearormore.

Whenperforminganyservicethatmayriskexposureof

compressoroiltotheroof,takeappropriateprecautionstoprotect

roofing.Procedureswhichriskoilleakageinclude,butarenot

limitedto,compressorreplacement,repairingrefrigerantleaks,

replacingrefrigerantcomponentssuchasfilterdrier,pressure

switch,meteringdevice,coil,accumulator,orreversingvalve.

SyntheticRoofPrecautionaryProcedure

1.Coverextendedroofworkingareawithanimpermeable

polyethylene(plastic)drip clothor tarp.Coveran

approximate10X10ft.(3X3m)area.

2.Coverareainfrontoftheunitservicepanelwithaterry

clothshoptowelto absorblubricantspillsandprevent

run-offs,andprotectdropclothfromtearscausedbytools

orcomponents.

3.Placeterryclothshoptowelinsideunitimmediatelyunder

component(s)tobeservicedandpreventlubricantrun-offs

throughthelouveredopeningsintheunitbase.

4.Performrequiredservice.

5.Removeanddisposeofanyoilcontaminatedmaterialper

localcodes.

LIQUIDLINEFILTERDRIER

ThisfilterdrierisspecificallydesignedtooperatewithPuron.Use

onlyfactory-authorizedcomponents.Filterdriermustbereplaced

whenevertherefrigerantsystemisopened.Whenremovingafilter

drier,useatubingcuttertocutthedrierfromthesystem.Donot

unsweatafilterdrierfromthesystem.Heatfromunsweatingwill

releasemoistureandcontanfinantsfromdrierintosystem.

PURON(R-410A)REFRIGERANTCHARGING

Refertounitinformationplateandchargingchart.SomeR-410A

refrigerantcylinderscontainadiptubetoallowliquidrefrigerantto

flowfromcylinderin uprightposition.Forcylindersequipped

withadiptube,chargePuronunitswithcylinderin upright

positionandacommercialmeteringdevicein manifoldhose.

Chargerefrigerantintosuction-line.

TROUBLESHOOTING

Use the Troubleshooting Guides (See Tables 12-14) if problems

occur with these units.

START-UP CHECKLIST

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

followed.

26

PURON® (R-410A) QUICK REFERENCE GUIDE

• 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 700 psig high side and 180 psig low side with 550 psig low-side retard.

• Use hoses with 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.

• If indoor unit is equipped with an R-22 TXV or piston metering device, it must be changed to a hard shutoff Puron 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.

• Do not use capillary tube coils.

• Observe all warnings, cautions, and bold text.

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

27

SYMPTOM

Compressor and condenser fan will not start.

Compressor will not start but condenser fan

runs

Table 12 -Troubleshooting Guide - Cooling

CAUSE

Power failure

Fuse blown or circuit breaker tripped

Defective contactor, transformer, or high-pressure,

loss-of-charge or low-pressure switch

Insufficient line voltage

Incorrect or faulty wiring

Thermostat setting too high

Faulty wiring or loose connections in compressor cir-

cuit

Compressor motor burned out, seized, or

internal overload 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 be a Scroll compressor is rotating in the wrong direction

low pressure differential.

Refrigerant overcharge or undercharge

Compressor cycles (other than normally sat-

isfying thermostat).

Compressor operates continuously

Excessive head pressure

Head pressure too low

Excessive suction pressure

Suction pressure too low

Defective compressor

Insufficient line voltage

Blocked condenser

Defective run/start capacitor, overload or start relay

Defective thermostat

Faulty condenser-fan motor or capacitor

Restriction in refrigerant system

Dirty air filter

Unit undersized for load

Thermostat set too low

Low refrigerant charge

Air in system

Condenser coil dirty or restricted

Dirty air filter

Dirty condenser coil

Refrigerant overcharged

Air in system

Condenser air restricted or air short-cycling

Low refrigerant charge

Restriction in liquid tube

High heat load

Refrigerant overcharged

Dirty air filter

Low refrigerant charge

Metering device or low side restricted

Insufficient evaporator airflow

Temperature too low in conditioned area

Outdoor ambient below 55°F (12.7°C)

Filter drier restricted

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 tempera-

ture

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. Shut down unit

to allow pressures to equalize.

Recover refrigerant, evacuate system, and re-

charge to capacities shown on rating plate

Replace and determine cause

Determine cause and correct

Determine cause and correct

Determine cause and replace

Replace thermostat

Replace

Locate restriction and remove

Replace filter

Decrease load or increase unit size

Reset thermostat

Locate leak, repair, and recharge

Recover refrigerant, evacuate system, and re-

charge

Clean coil or remove restriction

Replace filter

Clean coil

Recover excess refrigerant

Recover refrigerant, evacuate system, and re-

charge

Determine cause and correct

Check for leaks, repair, and recharge.

Remove restriction

Check for source and eliminate

Recover excess refrigerant

Replace filter

Check for leaks, repair and recharge

Remove source of restriction

Increase air quantity

Check filter-replace if necessary

Reset thermostat

Install low-ambient kit

Replace filter

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Table 13 - Troubleshooting Guide-Heating

SYMPTOM CAUSE REMEDY

Water in gas line Drain. Install drip leg.

No power to furnace Check power supply fuses, wiring or circuit breaker.

Check transformer.

No 20-v power supply to control circuit NOTE: Some transformers have internal over-current

protection that requires a cool-down period to reset.

Mis-wired or loose connections Check all wiring and wire nut connections

Burned-out heat anticipator in thermostat Replace thermostat

Burners will not ignite Broken thermostat wire Replace thermostat

Burned-out heat anticipator in thermostat Run continuity check. Replace wire if necessary.

Check flame ignition and sense electrode positioning. Ad-

Misaligned spark electrodes just 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

No gas at main burners to dissipate before attempting to light unit.

2. Check gas valve.

Dirty air filter Clean or replace filter as necessary

Check gas pressure at manifold match with that on unit

Gas input to furnace too low nameplate

Unit undersized for application Replace with proper unit or add additional unit

Inadequate heating Restricted airflow Clean or replace filter. Remove any restriction.

Blower speed too low Use faster speed tap if available, or install alternate motor.

Check rotation of blower, temperature rise of unit. Adjust

Limit switch cycles main burners as necessary.

1. Tighten all screws around burner compartment

Incomplete combustion results in: Aldehyde odors, carbon mon- 2. Cracked heat exchanger. Replace.

Poor flame characteristics oxide, sooting flame, floating flame 3. Unit over-fired. Reduce input (change orifices or adjust

gas line or manifold pressure).

4. Check burner alignment.

Table 14 - Troubleshooting Guide-LED Error Codes

SYMPTOM CAUSE REMEDY

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

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.

High limit switch opens during heat exchanger warm-up Ensure unit is fired on rate; ensure temperature rise is correct.

Fan ON/OFF delay modified period before fan-on delay expires. Limit switch opens

(LED/FLASH) within three minutes after blower-off delay timing in heat- Ensure unit's external static pressure is within application guide-

ing mode. lines.

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.

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

(LED 3flashes)

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.

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

Ignition lockout Unit unsuccessfully attempted ignition for 15 minutes. Ensure that fame sense and ignition wires are properly termi-

(LED 5 flashes) nated. Verify that unit is obtaining proper amount of gas.

Check for proper voltage. If motor is operating, check the speed

sensor plug/IGC Terminal J2 connection. Proper connection:

Induced-draft motor fault IGC does not sense that induced-draft motor is operat- PIN 1 - White

(LED 6 flashes) ing.* PIN 2 - Red

PIN 3 - Black

Rollout switch will automatically reset, but IGC will continue to

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

(LED 7 flashes) Rollout switch has opened, draft blower wheel is properly secured to motor shaft. Reset unit

at unit disconnect.

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

(LED 8 flashes) hardware. IGC*.

If Safety Critical Software Redundant Variables Mismatch Verify that flame sensor wire and spark ignitor wires are not

Safety Critical fault occurs then IGC will lockout (This fault will clear after 1 touching or close together. Ensure unit has a good ground on the

(LED 9 flashes) hr.) IGC board.

*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 13-Troubleshooting Guide-Heating for additional troubleshooting analysis.

LEGEND

IGC--Integrated Gas Unit Controller

LED--Light-Emitting Diode

29

I, Preliminary information

MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

START=UP CHECKLIST

(Remove and Store in Job File)

II. PRE-START-UP (insert checkmark in box as each item is completed)

VERIFYTHAT 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

( ) MAKE SURE THAT - (If Applicable) ON 060 SIZE PURON HEATPUMP ONLY, THE TWO WIRE TIES FASTEN

TO THE OUTDOOR COILS AND REVERSING VALVE/ACCUMULATOR HAVE BEEN REMOVED

ill. START-UP

ELECTRICAL

SUPPLY VOLTAGE

COMPRESSOR AMPS

INDOOR (EVAPORATOR) FAN AMPS

TEMPERATURES

OUTDOOR (CONDENSER) AiR TEMPERATURE DB

RETURN-AIR TEMPERATURE DB WB

COOLING SUPPLY AiR DB WB

HEAT PUMP SUPPLY AiR

GAS HEAT SUPPLY AiR

ELECTRIC 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.

IN, W.C.

PSIG SUCTION LINE TEMP*

PSIG DISCHARGE TEMPt

iV. EASY SELECT SETTINGS

FULL UNIT MODEL NUMBER:

ENTER AVAILABLE HEATSETTINGS

ENTER AVAILABLE AIRFLOVV HEAT AIR PIN CONNECTION

SETTING

ENTER AVAILABLE SIZES SIZE PiN CONNECTION SETTING

TYPE PIN CONNECTION SETTING

ADJUST PiN CONNECTION SETTING

DELAY PIN CONNECTION SETTING

(0/0 or 0/90 for gas/electric models)

CONTiNOUS FAN PiN CONNECTION SETTING

EASY SELECT

Heat Settings

AC HP Size

System Type

A_ HP-Comfort I HP.Eff

AC/HP CFM Adjust

Norm I Lo I Hi

On/Off Delay

0/90 I 30/90 i 0/0 I ENH

Continous Fan

_ I Med ] HI

C01999

Copyright 2009 Carrier Corp, • 7310 W, Morris St. • Indianapolis, IN 46231 Printed in U,S,A, Edition Date: 02/09

Manufacturer reserve8 the right to change, at any time, specification8 and design8 without notice and without obligations,

Catalog No: 48XP-05SI Rev. B

Replaces: 48XP-05SI

30