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Installation, Start-Up, and Operating Instructions

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1. i R A S A Gasket around duct ue Insulated Gasket around Insulated deck pan outer edge deck Long Return opening BXC 00076 UNIT SIZE ODS CATALOG NUMBER c 48XP024 036 CPRFCURBOO6A00 8 203 11 279 161 2 419 28 3 4 730 CPRFCURBO007A00 14 356 11 279 161 2 419 28 3 4 730 48XP042 060 CPRFCURBO008A00 8 203 16 3 16 411 17 3 8 441 40 1 4 1022 CPRFCURBO009A00 14 356 16 3 16 411 17 3 8 441 40 1 4 1022 NOTES 1 Roof curb must be set up for unit being installed 2 Seal strip must be applied as required to unit being installed 3 Dimensions in are in millimeters 4 Roof curb is made of 16 gage steel 5 Table lists only the dimensions per part number that have changed 6 Attach ductwork to curb flanges of duct rest on curb 7 Insulated panels 1 in thick fiberglass 1 Ib density 8 Dimensions are in inches 9 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 00070 CORNER WEIGHTS LARGE CABINET CORNER WEIGHTS SMALL CABINET Unit 24 30 36 TotalWeight 350 350 388 9 Corner Weight 1 70 70 78 Corner Weight 2 54 54 60 3 Corner We
2. BES SIS S O a C03027 BLOWER HOUSING 2 SETSCREWS HIDDEN C99085 Fig 23 Removal of Motor and Blower Wheel dimensional size and type as originally installed See Table 1 for recommended filter sizes Inspect air filter s at least once each month 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 NN C99086 Fig 24 Burner Rack Removed 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 WARNING Before cleaning the blower motor and wheel disconnect gas supply turn off and tag electrical power to the unit Failure to adhere to this warning could cause personal injury or death Cleaning the Blower Motor and Wheel 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
3. Defective compressor Replace and determine cause Insufficient line voltage Determine cause and correct Blocked condenser Determine cause and correct Defective run start capacitor overload or start relay Determine cause and replace Defective thermostat Replace thermostat Faulty condenser fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Dirty air filter Unit undersized for load Replace filter Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak repair and recharge Leaking valves in compressor Replace compressor Excessive head pressure Air in system Recover refrigerant evacuate system and recharge Condenser coil dirty or restricted Clean coil or remove restriction Dirty air filter Replace filter Dirty condenser coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant evacuate system and recharge Condenser air restricted or air short cycling Determine cause and correct Head pressure too low Low refrigerant charge Check for leaks repair and recharge Compressor valves leaking Restriction in liquid tube Replace compressor Remove restriction Excessive suction pressure High heat load
4. SIGNALS IM THE STRUCTURE OR THIS 15 A UL REQUIREMENT FAULT 2 0 Fig 19 208 230 3 60 Wiring Diagram Units 48XP 17 Table 5 Heating Inputs GAS SUPPLY PRESSURE MANIFOLD INPUT Natural Propanet IN WG BTUH ORIFICES Natural Propanet 40 000 2 4 0 13 0 4 0 13 0 3 5 3 5 60 000 2 4 0 13 0 4 0 13 0 3 5 3 5 90 000 3 4 0 13 0 4 0 13 0 3 5 3 4 115 000 3 4 0 13 0 4 0 3 5 3 7 130 000 When a unit is converted to propane different size orifices must be used See separate natural to propane conversion kit instructions 1 Based on altitudes from sea level to 2000 ft above sea level For altitudes above 2000 ft reduce input rating 4 percent for each additional 1000 ft above sea level In Canada from 2000 ft above sea level to 4500 ft above sea level de rate the unit 10 percent e GAS HEATING MODE natural gas with a heating value of 1050 Btu f at 0 65 specific 1 Thermostat closes circuit R to W W1 The unit de gravity or propane gas with a heating value of 2500 Btu f at livers the selected gas heat airflow The IGC will 1 5 specific gravity control a 45 sec blower delay and a 45 sec For elevations above 2000 ft reduce input 4 percent for each Off delay 1000 ft above sea level When gas supply being used has a different heating value or specific gravity refer to national and local codes or contact Step
5. 580 530 490 460 430 400 360 325 300 280 11 2 1 610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 Capacity of pipe in cu ft of gas per hr for gas pressure of 0 5 psig or less Pressure drop of 0 5 in wg based on a 0 60 specific gravity gas Refer to Table National Fire Protection Association NFPA 54 T This length includes an ordinary number of fittings unit is operating For propane applications the gas pressure must not be less than 7 0 in wg or greater than 13 in wg at the unit connection An 1 8 plugged tapping accessible for test gage connec tion must be installed immediately upstream of the gas supply connection to the gas valve When installing the gas supply line observe local codes pertaining to gas pipe installations Refer to the NFGC ANSI Z223 1 1988 NFPA latest edition in Canada CAN CGA B149 1 2 86 In the absence of local building codes adhere to the following pertinent recommendations 1 Avoid low spots in long runs of pipe Grade all pipe 1 4 in in every 15 ft 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 For pipe sizes larger than 1 2 in follo
6. HEATING amp COOLING 48XP N 024 060 Single Packaged Gas Heating Electric Cooling Units With Puron R 410A Refrigerant Visit www carrier com Installation Start Up and Operating Instructions NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY 8 09 4 1 INTRODUCTION 5r notetur 2 RECEIVING AND INSTALLATION cm 2 CHECK EQUIPMENT 5 rotten trt rh 2 IDENTIFY UNIT M 2 5 e instant ra ino eter tree enn 2 PROVIDE UNIT SUPPOR P ii iernare aeS ESEA 2 ROOK CURBS 2 SLAB MOUNT einni anaana 2 GROUND 2 FIELD FABRICATE 254 2 50 0 0 2 RIG AND PLACE UNIP os ecce 6 CONNECT CONDENSATE 01 000 7 INSTALE BLUE HOOD reet 7 INSTALL GAS PIPING tret rrr A meses 8 INSTALL DUCT CONNECTIONS 9 CONFIGURING UNITS FOR DOWNFLOW VERTI CAL DISCHARGE tenet risiini 10 INSTALL ELECTRICAL CONNECTIONS 10 HIGH VOLTAGE 11 SPECIAL PROCEDURES FOR 208 OPERATION 11 CONTROL VOLTAGE CONNECT
7. 20 508 19 3 489 17 6 447 48XP030 040 060 208 230 1 60 350 159 39 02 991 1 20 508 19 3 489 17 6 447 48XP036 060 090 208 230 1 60 208 230 3 60 388 176 41 02 1041 9 20 0 508 14 0 355 6 13 0 330 2 Fig 2 48XP024 036 Unit Dimensions 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 tile or other combustible materials The unit may be installed on wood flooring or on Class A B or C roof covering materials 355 8 3421 355 8 14 011 13 49 14 011 86 0 3 391 RETURN SUPPLY 2 171 406 6 16 01 D OPTIONAL OPTIONAL 1 RETURN SUPPLY 406 6 AIR AIR 16 011 OPENING OPENING il t T L fl COND COIL 4 I 80 5 s LA es i um im 115 8al OPENING OPENING Y m EVAP COIL j 173 5 EpzzzzzzzzEp zzzzzpz z 6 831 t KETT 14 631 COND COIL x 03 48 C rin O taen DEM TOP VIEW REAR VIEW REQUIRED CLEARANCE FOR OPERATION AND SERVICING REQUIRED CLEARANCE TO COMBUSTIBLE MATL in mm in mm EVAP COIL ACCESS SIDE sss 36 00 914 0 TOP OF UNIT tt rer ecu 14 00 355 6 POWER ENTRY SIDE niat attinenti nn cens 36 00 914 0 DUCT SIDE OF UNIT 2 00 50 8 EX
8. ASHRAE recommen dations 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 s l ensure weather tight and airtight seal 4 units must have field supplied filters or accessory filter SUPPLY RETURN rack installed in the return air side of the unit Recommended DUCT DUCT sizes for filters are shown in Table 1 OPENING OPENING C99011 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 Fig 9 Supply and Return Duct Opening 6 Adequately insulate and weatherproof all ductwork located outdoors Insulate ducts passing through unconditioned space and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association SMACNA and Air Conditioning Contractors of America ACCA minimum installation standards for heating and air conditioning systems Secure all ducts to building structure 7 Flash weatherproof and vibration isolate all openings in building structure in accordance with local codes and good building practices Step 10 INSTALL ELECTRICAL CONNECTIONS WARNING The unit cabinet must have an uninterrupted unbroken electrical ground to minimize the possib
9. Detecting oil generally indicates a refrigerant leak WARNING System under pressure Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid personal injury or death 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 f 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 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 result ing in higher overall system efficienc
10. is Me D 8 8 8 o YN 1 Set DIP Switches Set the dip switches back of ON OFF DELAY Thermidistat Control Board appropriately for specific Sa sa System being installed WHT 2 Thermidistat Control Configurations AUXI See Thermidistat Control Installation Instructions for detailed description d Option 5 Variable Speed Indoor Motor Set to ON Option 7 Super Dehumidify Set to ON 4 Option 17 Select Programmable or non programmable mode 0600009000000 24 3 Set desired humidity level on fron of Thermidistat HEATER MOTOR O 50 to 55 RH recommended For dehumidification in cooling both dhu and cool must be displayed 12 PIN CONNECTOR C01034G ECM ID BLOWER MOTOR QUICK REFERENCE GUIDE TROUBLESHOOTING Use the Troubleshooting Guides See Tables 10 12 if problems occur with these units START UP CHECKLIST 277 AIR CONDITIONER WITH 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 Puron refrigerant cylinders manufactured prior to March 1 1999 have a dip tube that allows liquid to flow out of cylinder in upright position Cylinders manufactured March 1 1999 and later DO NOT have a dip tube and MUST be positione
11. 1250 048 115 1600 130 5 1750 090 1250 5 060 115 1600 130 1800 Table 9 COIL PRESSURE DROP wg UNIT STANDARD CFM SCFM SIZE 700 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 024 0 005 0 007 0 010 0 012 0 015 0 007 0 010 0 012 0 015 0 018 0 021 0 024 036 0 019 0 023 0 027 0 032 0 037 0 042 0 047 042 0 014 0 017 0 020 0 024 0 027 0 031 0 035 0039 0 043 048 m 0 027 0 032 0 036 0 041 0 046 0 052 0 057 0 063 0068 060 0 029 0 032 0 036 0 040 0 045 0 049 0 053 WARNING The ability to properly perform maintenance on this equip ment 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 User s Manual FAILURE TO HEED THIS WARNING COULD RESULT IN SERI OUS PERSONAL INJURY AND POSSIBLE DAMAGE TO THIS EQUIPMENT WARNING Failure to follow these warnings could result in serious personal injury 1 First turn off gas supply to the unit Then turn off electrical power to the unit before performing any maintenance or service on the unit Use extreme caution when removing panels and parts As with any m
12. 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 for heating above room temperature and operates in Cooling mode when temperature control is set to call for cooling below room temperature IMPORTANT Three phase scroll compressor units 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 el evated noise levels and the difference between compressor suction and discharge pressures may be dramatically lower than normal CHECKING AND ADJUSTING REFRIGERANT CHAR GEThe refrigerant system is fully charged with R 410A refriger ant 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 ther mometer a sling psychrometer and a gauge manifold are required when using the superheat 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 20 CAUTION When evaluating the
13. 990 930 855 024 COOLING DEHUMIDIFY 715 670 715 695 645 795 775 745 COOLING 1010 920 825 1105 1030 930 1255 1160 1050 030 COOLING DEHUMIDIFY 890 845 795 890 865 825 1010 980 925 COOLING 1110 1025 970 1235 1175 1115 1400 1355 1280 036 COOLING DEHUMIDIFY 990 960 910 990 975 940 1125 1110 1085 Table 9B 48XP Cooling Dry Coil ECM Airflow Large Cabinet CFM ADJUST T PIN SELECT LO PIN NOM PIN HI PIN SIZE EXTERNAL STATIC PRESSURE RANG 0 1 1 0 0 1 1 0 0 1 1 0 COOLING 1100 1225 1410 042 COOLING DEHUMIDIFY 980 980 1125 COOLING 1260 1400 1610 048 COOLING DEHUMIDIFY 1120 1120 1290 COOLING 1575 1750 2010 060 COOLING DEHUMIDIFY 1400 1400 1610 Table 9C 48XP Gas Heating ECM Airflow Small Cabinet EASY SELECT BOARD SETTING CFM 700 800 1100 1250 Unit Static Size Brossure 0 0 0 4 0 4 0 7 0 7 1 0 0 0 0 4 0 4 0 7 0 7 1 0 0 0 0 4 0 4 0 7 0 7 1 0 0 0 0 4 0 4 0 7 0 7 1 0 Gas Heat Size T 040 855 770 710 060 1020 890 835 56 040 880 840 805 060 1030 970 910 060 1035 995 955 090 1170 1110 1025 21 Table 9D 48XP Gas Heating ECM Airflow Large Cabinet TM BS AED SETTING CFH 1000 1250 1600 1750 1800 External Hs 0 0 1 0 0 0 1 0 0 0 1 0 0 0 1 0 0 0 1 0 Gas Heat Size 060 1000 090 1250 090
14. Check for source and eliminate Compressor valves leaking Replace compressor Refrigerant overcharged Recover excess refrigerant Suction pressure too low Dirty air filter Replace Filter Low refrigerant charge Check for leaks repair and recharge Metering device or low side restricted Remove source of restriction Insufficient evaporator airflow Increase air quantity Check filter replace if necessary Temperature too low in conditioned area Reset thermostat Outdoor ambient below 55 F Install low ambient kit Field installed filter drier restricted 29 Replace Table 11 Troubleshooting Guide Heating CAUSE REMEDY Burners will not ignite Water in gas line Drain Install drip leg No power to furnace Check power supply fuses wiring or circuit breaker No 24 v power supply to control circuit Check transformer 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 Broken thermostat wire Run continuity check Replace wire if necessary Misaligned spark electrodes Check flame ignition and sense electrode positioning Adjust as necessary No gas at main burners 1 Check gas line for air Purg
15. FLASHES 6 REMOVE JI WHEN USING THERMIDISTAT HUMIDISTAT AND 12 ROLLOUT SWITCH FAULT 7 FLASHES DEHUMIDIFICATION MODE INTERNAL CONTROL FAULT 8 FLASHES T REMOVE J2 R TEMPORARY ONE HOUR AUTOMATIC RESET FAULT NOTE 9 9 FLASHES 8 0 BE WIRED IN ACCORDANCE WITH NEC AND LOCAL CODES 1 PAUSE ERROR CODE DISPLAY t ERROR CONES 9 THIS CODE INDICATES AN INTERNAL PROCESSOR FAULT THAT WILL RESET ITSELF IN ONE HOUR FAULT CAN BE CAUSED BY STRAY RF GAS SECTION SHALL NUMERIGAL SEQUENCE SIGNALS IN THE STRUCTURE OR NEARBY THIS 15 A UL REQUIREMENT FAULT 48GP 500258 3 0 Fig 18 208 230 1 60 Wiring Diagram Unit 48XP 16 C01035 5 208 230 3 60 T FIELD t SUPPLY YEL POWER _ E oui EQUIP GND FOR 042 060 UNITS ONLY COMP Ario SPLICE EQUIPMENT CO TERMINAL CHARKED FLAME SENSOR TERMINAL UNMARKED SPLICE Gue GAS VALVE RELAY HIGH PRESSURE SWITCH HS HALL EFFECT SENSOR FIELD CONTROL WIRING HIGH VOLTAGE TRANSFORMER FIELD POWER WIRING IGNITOR ACCESSORY OR OPTIONAL INTEGRATED CONTROL Pag INDUCED DRAFT MOTOR 10 INDICATE COMMON POTENTIAL INTEGRATED GAS UMIT WOT TO REPRESENT WIRING Eur BR BLOWER RELAY INDOOR MOTOR RELAY CONTACTOR LON PRESSURE SHITCH CAP CAPACITOR COMP COMPRESSOR moror GAIN GAS TAA MOTOR CR COMBUSTION RELAY QUADRUPLE TERMINAL Li ITCH TRANSFORMER
16. FULL UNIT MODEL NUMBER AC HP Size ENTER AVAILABLE HEATSETTINGS ENTER AVAILABLE AIRFLOW HEAT AIR PIN CONNECTION System Type SETTING ENTER AVAILABLE SIZES SIZE PIN CONNECTION SETTING AC HP Comfort HP Eff TYPE PIN CONNECTION SETTING AC HP CFM Adjust ADJUST PIN CONNECTION SETTING DELAY PIN CONNECTION SETTING ES ED B 0 0 or 0 90 for gas electric models On Off Delay CONTINOUS FAN PIN CONNECTION SETTING ENH Lo Med Hi 01999 Copyright 2005 CARRIER Corp 7310 W Morris St Indianapolis 46231 48XP3si aaa MN Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 1 4 PC 101 Catalog No 534 80239 Printed in U S A Form 48 351 Pg 32 5 04 Replaces 48 251
17. Gas HIGH PRESSURE SWITCH psig SCENE Cut out Reset Auto 420 25 LOSS OF CHARGE LOW PRESSURE SWITCH a Liquid Line psig j Cut out 45 10 Reset auto RETURN AIR FILTERS 1 20 x 24 1 20 24 1 20 24 1 20 24 x 1120 x 24 1 20 x 24 x 1 24 x 80 x 1 24 x 80 x 1 Based on altitude of to 2000 ft T 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 wg 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 WARNING Never stand beneath rigged units or lift over people Failure to follow this warning may cause personal injury or death WARNING Never exceed 200 Ibs per bracket lifting force Failure to follow this warning may cause personal injury or death WARNING Accessory lifting kit is only to be used with Small Packaged units which have a composite unit base with molded rigging holds Failure to follow this warning may cause personal injury or death Step 6 CONNECT CONDENSATE DRAIN
18. 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 ground level installations Install a field supplied condensate trap at end of condensate connection to ensure proper drainage Make sure that the outlet of the trap is at least 1 in 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 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 trap Do not undersize the tube Pitch the drain tube downward at a slope of at least 1 in for every 10 ft of horizontal run Be sure to check the drain tube for leaks Step 7 INSTALL FLUE HOOD The flue hood assembly is shipped
19. PL2 8 TO TRANS Co ORN BRN TO CONT PL2 9 GROUNDED T BRN HS THRU STANDOFF SECI BRN BRN SEGI FIELD THERMOSTAT BRN K BLK L BLU BLU PLI i gay 7 BRN 16C COMMON PLI 4 MN BRN IMR C PL3 I 6 BRN 1 PLT vig vio PLI 8 PL3 3 8 PLI 9 RED ORN PL3 4 3 3 PLI 10 BRN WHT PL3 5 4 10 ORN BLU 5 UNIT COMPONENT ARRANGEMENT at PL3 T 5 OUTDOOR FAN zm 8 CM SECTION ORN TYPE ORN oRN 3 EQUIP GRA 10 GND BLU GE BLU 0 vio 12 PL3 13 compressor Fan e MIO vio WHT Q1 SECTION SECTION TRAN 123 a BLK 102 BLK Gey Ee ts 4 a QU 16 WHT DELAY WHT 16C x DISCONNECT NOTES HCF PER NEC 1 1F ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED AV ERROR MODE ED INDICATIO IT MUST BE REPLACED WITH TYPE 90 DEGREE C WIRE OR SPLICE BOX NORMAL OPERATION ON 115 EQUIVALENT HARDWARE FAILURE OFF 2 SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES ICM FAN ON OFF DELAY MODIFIED FLASH 3 USE 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION HS LIMIT SWITCH FAULT 2 FLASHES 4 REPLACE LOW VOLTAGE FUSES WITH NO GREATER THAN 5 AMP FUSES 152 5 04 MODELS 48GP024 036 HAS 151 AND 152 IN SERIES MOUNTING PANEL ABOVE IGNITION LOCKOUT FAULT 5 FLASHES ON MODELS HAS EST ONLY MGV INDOOR BLOWER INDUCER SWITCH FAULT
20. STALLED Factory selected on 48XP for AC Air conditioner For Gas Heat Electric Cool Unit AC must be selected AC HP ADJUST SELECT NOMINAL LOW 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 12 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 indi cated e ON OFF DELAY SELECT DESIRED TIME DELAY PROFILE Four motor operation delay profiles are provided to cus tomize 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 9 ICM PRINTED CIRCUIT BOARD SEC1 SEC2 EASY SELECT GAS 1 09 060 040 1250 1100 800 ED d AC HP SIZE 036 030 024 018 LU B 1 1 1 SYSTEM HP COMFORT HP EFF 1 5 RN B AC HP CFM ADJUST A
21. TOP VIEW REQ D CLEARANCES TO COMBUSTIBLE MATL in mm uso ox ox Ro ee 14 355 6 Duct side of unit 2 2 50 8 Side opposite dUCIS s o os ira oo oo 14 355 6 Bottom of unit 2 o d ok odo hoo 0 50 12 7 NEC REQ D CLEARANCES in mm system then the system performance may be compromised 2240 LEGEND Unit and block or concrete walls and other grounded CG Center of Gravity surfaces control box side 42 1066 8 COND Condenser EVAP Evaporator NEC National Electrical Code REQ D Required Note Dimensions are in in mm 7 uni Fuss FIELD ENTRY SERVICE PORTS 23 0 28 6 1 13 DIA POWER ENTRY 22 2 0 88 DIA HOLE CONTROL ENTRY 4 123 0 4 84 2 451 j 17 96 347 2 HE 13 67 208 g l DRAIN OUTLET 42 1 19 0 0 75 N P T 1 68 x 22 0 DP OMPRESSOR BLOWER GAS SECTION FLUE HOOD 46 8 Le 12 7 0 50 326 5 amp ELECTRICAL ACCESS PANEL 1 84 GAS ENTRY 12 85 52 8 t 201 pi 2 851 1226 3 12 081 831 0 48 281 122 2 132 72 4 811 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW C99017 UNIT WEIGHT UNIT HEIGHT CENTER OF GRAVITY UNIT ELECTRICAL CHARACTERISTICS IN MM IN MM Ib kg A X Y 2 48 024 040 060 208 230 1 60 350 159 39 02 991 1
22. air recirculation To check switch 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 inter changed 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 tech niques Refrigerants present additional safety hazards WARNING Wear safety glasses and gloves when handling refrigerants Keep torches and other ignition sources away from refriger ants and oils Failure to follow this warning can cause a fire serious injury or death The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll The scroll compressor has no dynamic suction or discharge valves and it is more tolerant of stresses caused by debris liquid slugging and flooded starts The compressor is equipped with an anti rotational device and an internal pressure relief port The anti rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector The pressure relief port is a safety device designed to protect against extreme high pressure The relief port has an operating r
23. air tempera ture rise above the maximum 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 Step 4 START UP COOLING AND MAKE ADJUST MENTS CAUTION Failure to adhere to the following Start Up procedures may cause unit damage Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Do not operate the compressor when the outdoor temperature is below 55 F unless accessory low ambient kit is installed Do not ra
24. checked for leaks manifold pressure The manifold pressure must be maintained CHECK HEATING CONTROL between 34 and 3 6 in wg If larger adjustments are required change main burner orifices following the recommendations of Start and check the unit for proper heating control operation as national and local codes 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 NOTE 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 Set the heating temperature control of the thermostat above room temperature 2 Remove pipe plug on manifold See Fig 16 and connect manometer Turn on gas supply to unit 3 The induced draft motor will start 3 Record number of seconds for gas meter test dial to make one 4 After a call for heating the main burner should light within 5 revolution 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 4 Divide number of seconds in Step 3 into 3600 number of seconds in one hour minutes from the initial call for heat there is a lockout To 5 Multiply result of Step 4 by the number of cu ft shown for one reset t
25. 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 attach ment Remove grease and oil with mild solvent 24 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
26. cover See Fig 24 to the heat exchanger assembly Inspect the heat exchangers 4 Clean all surfaces as required using a wire brush COMBUSTION AIR BLOWER Clean periodically to assure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during the heating season For the first heating season inspect blower wheel bi monthly 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 mount ing 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
27. dehumidify are the same The following system configuration is recommended for maximum 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 11 jumper should only be removed when a Thermidis tat humidistat or capable zoning control is installed 8 LOW VOLTAGE CONNECTIONS Make tions as shown in ELECTRICAL CONNECTIONS section 9 CONFIGURE THERMIDISTAT Follow Thermi distat or capable zoning system installation in structions for Super Dehumidify operation ACCESSORY INSTALLATION a AUXILIARY TERMINALS The AUX and HUM terminals on the Easy Select Board are tied directly to the terminal and provide 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 informa tion ELECTRONIC AI
28. o POWER SUPPLY SIZE V PH HZ 48XP Min Max RLA LRA FLA FLA MCA 2 024 208 230 1 60 187 253 13 5 61 0 08 43 22 0 22 0 30 30 030 208 230 1 60 187 253 15 9 73 0 08 43 25 0 25 0 30 30 en 208 230 1 60 187 253 16 9 83 0 0 8 6 8 28 7 28 7 35 35 208 230 3 60 187 253 12 2 77 0 0 8 6 8 22 9 22 9 30 30 m 208 230 1 60 187 253 224 105 0 0 8 6 8 35 6 35 6 45 45 208 230 3 60 187 253 15 4 88 0 08 68 26 9 26 9 35 35 m 208 230 1 60 187 253 21 3 109 0 1 6 6 8 35 0 35 0 45 45 208 230 3 60 187 253 14 7 91 0 1 6 6 8 26 8 26 8 35 35 m 208 230 1 60 187 253 27 0 145 0 1 6 9 1 44 5 44 5 60 60 208 230 3 60 187 253 19 2 137 0 1 6 9 1 33 3 33 3 40 40 EXAMPLE Supply voltage is 460 3 60 LEGEND E d d 4 LRA C US 452 464 455 Minimum Circuit Amps Average Voltage E MOCP Maximum Overcurrent Protection RLA Rated Load Amps 1871 BKR Circuit Breaker 3 457 NOTES 1 In compliance with NEC National Electrical Code requirements for multimotor and combination load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be Power Supply fuse Canadian units may be fuse or circuit breaker 2 Minimum wire size is based on 60 C copper wire If other than 60 C wire is used or if length exceeds wire length in table determine size from NEC 3 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greate
29. required Subcooling 8 Add Charge if the measured temperature is higher than the table value 68 70 72 74 76 77 79 81 83 85 87 89 91 93 95 97 99 2 2 2 2 2 2 2 3 3 3 3 24 38 45 52 60 68 76 84 92 00 09 318 27 36 345 354 364 374 384 394 04 414 24 34 44 54 64 74 84 94 04 101 103 105 107 108 110 112 114 116 118 119 121 123 124 126 127 2 2 4 4 4 4 4 4i 4 4i 4 5 514 524 534 50 2500174 E 55 99091 Fig 22 Unit Access Panel 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 23 Required Subcooling F 71 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 Required Liquid Line Temperature for a Specific Subcooling R 410A Required Subcooling C Pressure kPa a e Now o NX P on as baa a o J N N J wo NNN oan e 103 105 107 109 bh
30. serious injury or death Airflow can be changed by changing the selection pins on the Easy Select circuit board MAINTENANCE To ensure continuing high performance and to minimize the possibility of premature equipment failure periodic maintenance must be performed on this equipment This combination heating cooling unit should be inspected at least once each year by a qualified service person To troubleshoot cooling or heating of units refer to Tables 10 11 and 12 NOTE Consult your local dealer about the availability of a maintenance contract Table 8 Pressure Drop In wg CFM 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 20 X 20 X 1 0 05 0 07 0 08 0 10 0 12 0 13 0 14 0 15 20X24X1 0 09 0 10 0 11 0 13 0 14 0 15 0 16 24X30X 1 0 07 0 08 0 09 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 Table 9A 48XP Cooling Dry Coil ECM Airflow Small Cabinet CFM ADJUST UNIT PIN SELECT LO PIN NOM PIN HI PIN SIZE EXTERNAL STATIC PRESSURE RANGE 00 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 07 10 COOLING 800 725 2 885 805 730
31. that may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Proce dures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch me tering device coil accumulator or reversing valve Synthetic Roof Precautionary Procedure 1 Cover extended roof working area with an impermeable polyethylene plastic drip cloth or tarp Cover an approximate 10 X 10 ft area 2 Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run offs and protect drop cloth from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately under component s to be serviced and prevent lubricant run offs through the louvered openings in the unit base 4 Perform required service 5 Remove and dispose of any oil contaminated material per local codes LIQUID LINE FILTER DRIER This filter drier is specifically designed to operate with Puron Use only factory authorized components Filter drier must be replaced whenever the refrigerant system is opened When removing a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system PURON R 410A REFRIGERANT CHARGING Refe
32. x 30 x 1 24 x 30x 1 Throwaway Based on altitude of to 2000 ft t 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 wg 1 25mm MIN TRAP OUTLET Y 1 This installation must conform with local building codes and with the National Fuel Gas Code NFGC ANSI Z223 1 in Canada CAN CGA B149 1 and B149 2 or NFPA National Fire Protection Association latest revision Refer to Provin 4 2 50mm MIN cial and local plumbing or wastewater codes and other C99013 Fig 7 Condensate Trap 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 instal lations CAUTION 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 to prevent personal injury or product damage Install the flue hood as follows applicable local codes 2 Remove flue hood from shipping location inside the return section of the blower comp
33. 10 Troubleshooting Guide Cooling CAUSE REMEDY Compressor and condenser fan will not start Compressor will not start but condenser fan runs Power Failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat contactor transformer or control relay Replace component Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly Thermostat setting too high Faulty wiring or loose connections in compressor circuit Lower thermostat setting below room temperature Check wiring and repair or replace Compressor motor burned out seized or internal overload open Determine cause Replace compressor Defective run start capacitor overload start relay Determine cause and replace One leg of 3 phase power dead Replace fuse or reset circuit breaker Determine cause Three phase scroll compressor makes excessive noise and there may be a low pressure differential Scroll compressor is rotating in the wrong direction Correct the direction of rotation by reversing the 3 phase power leads to the unit Shut down unit to allow pressures to equalize Compressor cycles other than normally satisfying thermostat Refrigerant overcharge or undercharge Recover refrigerant evacuate system and recharge to capacities shown on nameplate
34. 3 START UP HEATING AND MAKE ADJUST MENTS your distributor to determine the required orifice size CAUTION These units are designed to consume the rated gas inputs using the fixed orifices at specified manifold pressures as CAUTION Failure to adhere to the following Start Up procedures may cause unit damage 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 shown in Table 5 DO NOT RE DRILL THE ORIFICES UNDER ANY CIRCUMSTANCES or personal injury or property or product damage may occur Do not jumper any safety devices when operating the unit 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 Make sure that burner orifices are properly aligned Unstable operation may occur when the burner orifices in the manifold are misaligned 4 2 gas flow at the meter is recommended for natural gas units The Follow the lighting instructions on the heating section operation manifold pressure must be measured to determine the input of label located inside the burner or blower access door to start the propane gas units heating Measure Gas Flow Natural Gas Units NOTE Make sure that gas supply has been purged and that all Minor adjustment to the gas flow can be made by changing the gas piping has been
35. AND COMPLETELY Also make sure the User s Manual and Replacement Guide are left with the unit after installation The furnace is NOT to be used for temporary heating of buildings or structures under construction NUS o 57 2 WZ C99088 Fig 1 Unit 48XP SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical components Only trained and qualified personnel should install repair or service air conditioning equipment Untrained personnel can perform basic maintenance functions of cleaning coils and filters All other operations should be performed by trained service personnel When working on air conditioning equipment observe precautions in the literature tags and labels attached to the unit and other safety precautions that may apply Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguisher available for all brazing operations Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No 534 80239 Tab 1 Printed U S A Form 48XP 3SI Pg 1 5 04 Replaces 48XP 2SI WARNING Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning fire or an exp
36. ATE TECHNICIAN 1 PRE START UP Insert checkmark in box as each item is completed VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK GAS PIPING FOR LEAKS WHERE APPLICABLE CHECK THAT INDOOR EVAPORATOR AIR FILTER IS CLEAN AND IN PLACE VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS 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 1 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 IN WG GAS MANIFOLD PRESSURE IN WG REFRIGERANT SUCTION PSIG SUCTION LINE TEMP REFRIGERANT DISCHARGE PSIG DISCHARGE TEMPT VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS GAS HEAT TEMPERATURE RISE TEMPERATURE RISE See Literature RANGE MEASURED TEMPERATURE RISE EASY SELECT Measured at suction inlet to compressor Heat Settings TMeasured at liquid line leaving condenser IV EASY SELECT SETTINGS
37. CEPT FOR NEC REQUIREMENTS SIDE OPPOSITE DUCTS 14 00 355 6 UNIE TOR 36 00 914 0 BOTTOM OF UNIT 22 22 otaran tn 0 50 12 7 SIDE OPPOSITE DUCTS 36 00 914 0 DUCT PANEL 12 00 304 8 36 00 914 4 MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 12 00 304 8 FROM WALL SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISE NEC REQUIRED CLEARANCES in mm BETWEEN UNITS POWER 42 00 1066 8 UNIT AND UNGROUNDED SURFACES POWER ENTRY SIDE 36 00 914 0 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY 42 00 1066 8 j j pe 1193 9 115 4 1990561 47 001 4 541 F ERRA um x gt T x 28 6 1 13 DIA POWER ENTRY 22 2 0 88 DIA HOLE CONTROL ENTRY 506 1 119 93 DRAIN OUTLET 42 1 46 8 19 0 0 75 N P T 11 681 COMPRESSOR BLOWER GAS SECTION eee 184 12 1 0 50 x 20 0 0 87 DP 329 0 amp ELECTRICAL ACCESS PANEL i L GAS ENTRY 000 E 63 142 4 1123 1 12 89 t s 28 5 611 44 22 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW C99074 UNIT WEIGHT UNIT HEIGHT CENTER OF GRAVITY UNIT ELECTRICAL CHARACTERISTICS IN MM I
38. For first heating and cooling season inspect blower wheel bi monthly to determine proper cleaning frequency Check electrical connections for tightness and controls for proper operation each heating and cooling season Service when necessary ROLLOUT Required Subcooling oF oC Outdoor Ambient Temperature Model Size ii i ud psig 024 10 3 5 7 98 54 9 4 5 2 9 5 8 6 47 189 93 52 amp 8 49 8 6 48 78 43 7 39 196 17 6 9 8 16 8 9 3 16 5 9 2 15 4 8 6 14 3 7 9 203 12 8 7 1 127 73 127 71 126 7 126 7 210 17 5 9 7 169 9 4 16 6 9 2 157 87 148 82 217 EU 231 Charging Procedure o o e 66 1 Measure Discharge line pressure by attaching a gauge to the service port 2 Measure the Liquid line temperature by attaching a temperature sensing device to it 3 Insulate the temperature sensing device so that the Outdoor Ambient doesn t affect the reading 4 Refer to the required Subcooling in the table based on the model size and the Outdoor Ambient temperature 5 Interpolate if the Outdoor ambient temperature lies in between the table values Extrapolate if the temperature lies beyond the table range 6 Find the Pressure Value in the table corresponding to the the measured Pressure of the Compressor Discharge line 7 Read across from the Pressure reading to obtain the Liquid line temperature for a
39. IONS 11 Easy Select M 48 XD sees 11 TRANSFORMER 14 PRE START UP a 14 START UP om EE A 15 CHECK FOR REFRIGERANT LEAKS 15 Unit Sequence of Operation serene 15 48XP Sequence of Operation sss 15 START UP HEATING AND MAKE ADJUSTMENTS 18 CHECK HEATING CONTROL e 18 START UP COOLING AND MAKE ADJUSTMENTS 19 CHECKING COOLING CONTROL OPERATION 19 MAINTENANCE AIR FILTER EVAPORATOR BLOWER AND 24 FLUE GAS PASSAGEWAY S tenen 24 COMBUSTION AIR 24 LIMIT 406 atas etesetn eene BURNER IGNITION MAINUBURINERS rrt ERI hr ert e CONDENSER COIL EVAPORATOR COIL AND CONDENSATE DRAIN PAN htt 25 CONDENSER FAN 25 ELECTRICAL CONTROLS AND WIRING 25 REFRIGERANT CIRCUIT n 25 GAS INPUT ee miren rati 25 EVAPORATOR 2 4 4 4 25 PURONQG ITEMS nt tnnt 25 TROUBLESHOOTING ritratto 27 START UP CHECKLIST 5 27 NOTE TO INSTALLER Before the installation READ THESE INSTRUCTIONS CAREFULLY
40. LD 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 wg 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 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI American National Standards Institute Z223 1 or applicable provisions of local building code In Canada follow sections 7 2 7 3 or 7 4 or Can CGA Canadian Gas Association B149 Installation Codes or applicable provisions of local building code A CAUTION Do not restrict condenser airflow An air restriction at either the outdoor air inlet or the fan discharge can be detrimental to compressor life The c
41. M to i M 8 8 8 x gt gt p HEATER MOTOR HY O 12 PIN CONNECTOR 01039 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 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 LOW VOLTAGE CIRCUIT FUSING AND REFER ENCE The low voltage circuit is fused by a board mounted 5 amp automotive fuse placed in series with the trans former SEC2 and the R circuit The C circuit of the transformer is referenced to chassis ground through a printed circuit run at SECI connected to metal standoff marked with ground symbol 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 requir
42. N MM Ib kg A X Y 7 48 042 060 090 208 230 1 60 208 230 3 60 440 200 42 98 1091 7 21 533 4 20 5 520 7 16 6 421 6 48 048 090 115 130 208 230 1 60 208 230 3 60 463 210 0 44 98 1142 5 19 5 495 3 21 3 539 8 18 0 457 2 48 060 090 115 130 208 230 1 60 208 230 3 60 499 226 46 98 1193 3 21 533 4 20 508 17 6 447 0 Fig 3 48XP042 060 Unit Dimensions Gasketing outer flange Flashing field supplied Roofing material field supplied Cant strip field supplied Gasketing inner flange Wood nailer 2 Roofcurb Insulation field supplied Duct wo rk field supplied Provided with roofcurb Roof Curb for Small Cabinet Note A When unit mounting screw is used retainer bracket must also be used Supply opening Bx inner Screw NOTE A Gasketing outer flange Flashing field supplied Roofing materal field supplied Cant strip field supplied Gask eting Duct wo rk flange Wood nailer Roofcurb Insulation field supplied field supplied Provided with roofcu Roof Curb for rb Large Cabinet Note A When unit mounting screw is used retainer bracket must also be used
43. PRIMARY mi gy COOLING FAN LOGIC 4 1 30 ENERGIZED DE ENERGIZED HEATING FAN LOGIC 9 SECONDARY Sg GR EL 74 24V BRN 45 T T 45 BR BR ENERGIZED DE ENERGIZED mu 24V SPLICE BOX TO SECI SEE NOTESS Za x3 uo ne sah MGV FLAME SEN GROUNDED THRU STANDOFF FIELD THERMOSTAT BLK P OAL ko BL COMMON UNIT COMPONENT ARRANGEMENT COMPRESSOR inpoor SECTION SECTION WOTES 1 1 ANT OF THE ORIGINAL WIRES FURNISHED ARE REPLACED IT MUST BE REPLACED WITH 90 DEGREE C WIRE OR MAL OPERATION pica 115 EQUIVALENT HAROWARE FAILURE or 2 SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES ON OFF DELAY MODIFIED 3 USE 7 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION BUE LCD A REPLACE LOW VOLTAGE FUSES WITH MO GREATER THAM 5 ANP FUSES LIMIT SWITCH FAULTS 5 0 MODELS 48GP024 036 HAS LSI AND 152 IN SERIES MOUNTING PANEL ABOVE IGNITION LOCKOUT FAULT ON MODELS 48GP042 060 HAS LSI ONLT INDOOR BLOWER INDUCER SWITCH FAULT G REMOVE JI WHEN USING THERMIDISTAT HUMIDISTAT AND ROLLOUT SWITCH FAULT DEHUMIDIFICATION MODE INTERNAL CONTROL FAULT T RENOVE J2 8 FLASHES OHE RESET 91 9 FLASHES 8 10 BE WIRED IN ACCORDANCE WITH NEC AND LOCAL CODES 1 WU TSPLAT e iou ommon coms MS mE
44. R 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 c HUMIDIFIER HUMIDISTAT CONNECTIONS Easy Select M Board terminals 1 and 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 thermo stat signal is present See Fig 13 amp 14 Alternately the 24 v signal may be sourced from the W and C on the 9 pin connector When using a Thermidistat M 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 amp 14 HUMIDISTAT TRANSFORMER PROTECTION The transformer is of the energy limiting type It is set to withstand a 30 sec overload or shorted secondary condition PRE START UP WARNING Failure to observe the following warnings could result in serious personal injury 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 co
45. S HALL EFFECT SENSOR BLU 5 FIELD CONTROL WIRING HV TRAN HIGH VOLTAGE TRANSFORMER COOLING FAN LOGIC FIELD POWER WIRING 1 1681708 ACCESSORY OR OPTIONAL ICM INTEGRATED CONTROL e WIRING MOTOR E CORR IDM INDUCED DRAFT MOTOR 2 4 5 POTENTIAL ONLY IFM INDOOR FAN MOTOR ENERGIZED DE ENERGIZED 8 NOT TO REPRESENT wiring 16C INTEGRATED GAS UNIT LK 14 4 CONTROLLER HEATING FAN LOGIC YEL e YEL BR BLOWER RELAY IMR INDOOR MOTOR RELAY PRIMARY C CONTACTOR LPS 108 PRESSURE SWITCH 14 3 CAP CAPACITOR DIKIT SWITCH 0 45 T T 45 230V lt VAL W BR Cow 000 230 COMP COMPRESSOR MOTOR 000 OUIDOOR FAN MOTOR LK VIO CR COMBUSTION RELAY gr QUADRUPLE TERMINAL RS ROLLOUT SWITCH Yt TRAN TRANSFORMER 1DM CAP 3 TRANI o gt RN Y SECONDARY REI 24 24V C BRN BRN TO FIELD R SPLICE CM BL LI 24V SPLICE BOX BR L2 12 ICM BOARD Sa RED Te IMR IGC TO KE SEC2 RED ORN TO SECI WHT W PL2 1 PL PLN Dh 5 SEE NOTES RED R FURT 5 PL2 2 RS BLU FU R RED Cr RS PL2 3 RS BLU CDoG WI IH F2 54 LS vio 4 IMR n LSI 152 N LS VIO 3 10 E OMEA P P CS t Wi GWR MGV HHH WHT T SAFETY r GRA T GV PL2 6 BRN a GV FLAME SEN E 1 FS Eko o TEL o 12 1 GRN YEL a GRN 6 4 c BRN
46. 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 Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 4 Verify the following conditions CAUTION Do not purge gas supply into the combustion chamber Do not use a match or other open flame to check for gas leaks Failure to follow this warning could result in an explosion causing personal injury or death 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 maximum from fan orifice c Ensure fan hub is 1 8 in maximum from motor housing See Fig 15 MOTOR FAN GRILLE 12 1 8 MAX BETWEEN MOTOR SHAFT MOTOR AND FAN HUB C99009 Fig 15 Fan Blade Clearance d Make sure tha
47. ader 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 Table 1 Physical Data Unit 48 UNIT SIZE 48XP 024040 024060 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY ton 2 2 2 1 2 2 1 2 3 3 3 1 2 3 1 2 OPERATING WEIGHT Ib 350 350 350 350 388 388 440 440 COMPRESSORS Scroll Quantity 1 REFRIGERANT R 410A 7 3 7 3 80 80 95 9 5 10 7 10 7 REFRIGERANT METERING DEVICE TXV 2 2 21 2 21 2 21 2 21 2 21 2 21 2 21 2 21 522 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 Pani 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 Se ean 3 15 3 15 3 15 3 15 4 15 4 15 3 15 3 15 1 37 37 37 37 37 37 37 37 AMO OR 770 770 960 960 1150 1150 1400 1400 Sean 10x10 10x10 10x10 10x10 11x10 11x10 11x10 11x10 Mm 1 2 1 2 1 2 1 2 3 4 3 4 3 4 3 4 FURNACE SECTION a 41 Size gt 44 2 44 2 44 2 44 2 38 3 38 2 38 2 38 atura as Burner Orifice Qty Drill Size 2 50 290 Post mono 9 46 Pe Propane
48. ange between 550 and 625 psi differential pressure The Copeland scroll compressor uses Mobil 3MA POE oil This is the only oil allowed for oil recharge 26 CAUTION This system uses Puron R 410A refrigerant which has higher operating pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gauge set hoses and recovery system must be designed to handle Puron If you are unsure consult the equipment manufacturer Failure to use Puron compatible servicing equipment or replacement components may result in property damage or injury REFRIGERANT SYSTEM This information covers the refrigerant system of the 48XP including the compressor oil needed servicing systems on roofs containing synthetic materials the filter drier and refrigerant charging Compressor Oil The compressor in this system uses a polyolester POE oil Mobil 3MA POE This oil is extremely hygroscopic meaning it absorbs water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere SERVICING SYSTEMS ON ROOFS WITH SYNTHETIC MATERIALS POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials Exposure even if immediately cleaned up may cause embrittle ment leading to cracking to occur in one year or more When performing any service
49. artment 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 1 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 wg maximum pressure drop Never use pipe smaller than the 1 2 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 wg or greater than 13 in wg while the Table 2 Maximum Gas Flow Capacity NOMINAL INTERNAL LENGTH OF PIPE ea DIAMETER 10 20 30 40 50 60 70 80 90 100 125 150 175 200 12 622 175 120 97 8 73 66 61 57 53 50 44 40 3 4 824 360 250 200 170 181 188 125 118 110 103 98 84 77 72 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 11 4 1 380 1400 950 770 600
50. at the base insulation around the perim system turn off main power to unit Electrical shock could eter of the vertical return air opening be secured to the base cause serious injury or death with aluminum tape Applicable local codes may require aluminum tape to prevent exposed fiberglass 1 Open all electrical disconnects before starting any service work 6 Cover both horizontal duct openings with the provided duct covers Ensure opening is air and watertight 2 Remove horizontal metal duct covers to access vertical P 5 downflow discharge duct knockouts in unit base 7 After completing unit conversion perform all safety checks and power up unit 3 Use a screwdriver and hammer to remove the panels in the P P bottom of the unit base See Fig 9 amp 10 NOTE The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence type air conditioning and ventilating systems NFPA 90A or residence type NFPA 90B and or local codes and Ls ordinances Adhere to the following criteria when selecting sizing installing the duct system 1 Units are shipped for horizontal duct installation by removing 5 lo duct covers e 2 Select and size ductwork supply air registers and return air o grilles according to American Society of Heating Refrigera f tion and Air Conditioning Engineers
51. d upside down to allow liquid to flow Recovery cylinder service pressure rating must be 400 psig DOT 4 400 or DOT BW400 Puron systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose Manifold sets should be 750 psig high side and 200 psig low side with 520 psig low side retard Use hoses with 750 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 Only use factory specified liquid line filter driers with rated working pressures no less than 600 psig 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 Puron liquid line filter drier is required on every unit Do not use an R 22 TXV Never open system to atmosphere while it is under a vacuum When system must be opened for service break vacuum with dry nitrogen and replace filter driers Always replace filter drier after opening system for service Do not vent Puron into the atmosphere Observe all warnings cautions and bold text Do not leave Puron suction line driers in place for more than 72 hrs 28 Table
52. e as necessary NOTE After purging gas line of air wait at least 5 minutes for any gas to dissipate before attempting to light unit 2 Check gas valve Inadequate heating Dirty air filter Clean or replace filter as necessary Gas input to furnace too low Check gas pressure at manifold match with that on unit nameplate Unit undersized for application Replace with proper unit or add additional unit Restricted airflow Clean or replace filter Remove any restriction Blower speed too low Use faster speed tap if available or install alternate motor Limit switch cycles main burners Check rotation of blower thermostat heat anticipator settings temperature rise of unit Adjust as necessary Poor flame characteristics Incomplete combustion results in Aldehyde odors carbon monoxide sooting flame floating flame 30 1 Tighten all screws around burner compartment 2 Cracked heat exchanger Replace 3 Unit over fired Reduce input change orifices or adjust gas line or manifold pressure 4 Check burner alignment SYMPTOM Table 12 Troubleshooting Guide LED Error Codes CAUSE REMEDY Hardware failure LED OFF Loss of power to control module IGC Check 5 amp fuse on IGC power to unit 24 v circuit breaker and transformer Units without a 24 v circuit breaker have an internal overload in the 24 v transformer If the overload trips allow 10 mi
53. e motor shaft 5 When replacing fan blade position blade so the hub is 1 8 in away from the motor end 1 8 in of motor shaft will be visible See Fig 15 25 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 determining proper control operation REFRIGERANT CIRCUIT Annually inspect all refrigerant tubing connections and the unit base for oil accumulations
54. echanical equipment personal injury can result from sharp edges etc Never place anything combustible either on or in contact with the unit 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 CAUTION Errors made when reconnecting wires may cause improper and dangerous operation Label all wires prior to disconnec tion when servicing The minimum maintenance requirements for this equipment are as follows 22 INDUCED DRAFT MOTOR MOUNT Ones gt 600000900000 oooooooo 565995 1 SWITCH COLLECTOR BLOWER BURNER MOUNTING BOX HOUSING RACK SCREW C99022 Fig 21 Blower Housing and Flue Collector Box Inspect air filter s each month Clean or replace when necessary Certain geographical locations may require more frequent inspections Inspect indoor coil outdoor coil drain pan and condensate drain each cooling season for cleanliness Clean when neces sary Inspect blower motor and wheel for cleanliness at the begin ning of each heating and cooling season Clean when neces sary
55. ed 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 48XP system AC AIR CONDITIONER 4 AC HP ADJUST Select NOM 13 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 Su perDehumidify does not require an outdoor temperature sensor The following configuration is recommended for maximum cooling dehumidifying comfort This configura tion will improve the comfort provided by the air condi tioning 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 de humidification by reducing airflow to a minimum The actual super dehumidify command from Thermidistat control to the indoor unit is a Y signal without a signal in addition to dehumidify signal The indoor unit responds to this combination by reducing the airflow to a minimum All other characteristics of cool to
56. el 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 14 contains oil and refrigerant under pressure To remove a component wear protective goggles and proceed as fol lows a Shut off gas supply and then electrical power to unit b Relieve and recover 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 neces sary Oil can ignite when exposed to torch flame Proceed as follows to inspect and prepare the unit for initial startup 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
57. er screw over regulator adjustment screw on gas valve 5 Adjust regulator adjustment screw to the correct manifold pressure as specified in Table 5 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 19 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 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 6 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
58. for any damage incurred in transit Check all items against shipping list Immediately notify the nearest distributor if any item is missing To prevent loss or damage leave all parts in original packages until installation Step 2 PROVIDE UNIT SUPPORT ROOF CURB Install accessory roof curb in accordance with instructions shipped with curb See Fig 4 for roof curb dimensions 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 watertight seal Install gasketing material supplied with the roof curb Improperly applied gasketing can also result in air leaks and poor unit performance Curb should be level to within 1 4 in 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 thick with 2 in above grade The slab should be flush on the compressor end of the unit to allow condensate drain installation and should extend 2 in 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 FIE
59. 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 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 L1 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 WARNING Make sure that 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 200 This retaps transformer to primary voltage of 208 vac Electrical shock can cause personal injury or death WARNING Before making wiring changes make sure the gas supply is switched off first Then switch off the power supply to the unit Electrical shock can cause personal injury or death CONTROL VOLTAGE CONNECTIONS Do not use any type of power stealing thermostat Unit control problems may result Use no 18 American Wire Gage AWG color coded insulated 35 C minimum wires to make the control voltage connectio
60. h 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 CONDENSER FAN CAUTION Keep the condenser fan free from all obstructions to ensure proper cooling operation Never place articles on top of the unit Damage to unit may result 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 th
61. he control break the 24 v power to W revolution of test dial to obtain cu ft of gas flow per hour 5 The evaporator fan will turn on 45 sec after the flame has 6 Multiply result of Step 5 by Btu heating value of gas to obtain been established The evaporator fan will turn off 45 sec after total measured input in Btuh Compare this value with heating the thermostat has been satisfied input shown in Table 5 Consult the local gas supplier if the CHECK GAS INPUT heating value of gas is not known Check gas input and manifold pressure after unit start up See EXAMPLE Assume that the size of test dial is 1 cu ft one Table 5 If adjustment is required proceed as follows revolution takes 32 sec and the heating value of the gas is 1050 3 The rated gas inputs shown in Table 5 are for altitudes from sea Btu ft Proceed as follows level to 2000 ft above sea level These inputs are based on 1 32 sec to complete one revolution 18 Table 6 Air Delivery at Indicated Temperature Rise and Rated Heating Input HEATING TEMPERATURE RISE F INPUT BTUH 20 25 30 35 40 45 50 55 60 65 70 40 000 1500 1200 1000 857 750 667 600 545 500 60 000 2250 1800 1500 1286 1125 1000 900 818 750 692 90 000 2250 1929 1688 1500 1350 1227 1125 1038 964 115 000 2464 2156 1917 1725 1568 1438 1327 1232 130 000 ES 2786 2438 2167 1950 1778 1625 1500 NOTE Dashed areas do not fal
62. ight 3 84 84 94 Corner Weight 4 141 141 156 Unit 42 48 60 E Total Weight 440 463 499 Corner Weight 1 88 92 100 Corner Weight 2 68 72 78 E Corner Weight 3 106 111 120 Corner Weight 4 177 188 201 Fig 5 48XP Corner Weights 36 54 PLACE RIGGING STRAPS IN BASEPAN SLOT BELOW RIGGING HOLDS BEFORE RIGGING DUCTS SEAL STRIP MUST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB C99015 UNIT MAXIMUM SHIPPING A B WEIGHT 48XP Ib kg in mm in mm UNIT 48XP 024 372 169 22 0 558 5 14 50 368 3 030 372 169 22 0 558 5 14 50 368 3 036 410 186 22 0 558 5 15 30 388 6 042 462 210 20 0 508 0 21 25 539 8 048 485 220 21 5 546 1 16 3 414 0 060 521 236 23 5 596 9 16 3 414 3 Fig 6 Suggested Rigging Step 5 RIG AND PLACE UNIT WARNING When installing the unit on a rooftop be sure the roof will support the additional weight Failure to follow this warning may cause personal injury or death 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 spre
63. ility of personal injury if an electrical fault should occur This ground may consist of an electrical wire connected to the unit ground lug in the control compartment or conduit approved for electrical ground when installed in accordance with NEC National C99012 Electrical Code ANSI NFPA latest edition and local elec Fig 10 Vertical Duct Cover Removed trical codes In Canada follow Canadian Electrical Code CSA Canadian Standards Association C22 1 and local 4 If unit ductwork is to be attached to vertical opening flanges electrical codes Failure to adhere to this warning could result on the unit base jackstand applications only do so at this in personal injury or death time 10 CAUTION Failure to follow these precautions could result in damage to the unit being installed 1 Make all electrical connections in accordance with NEC ANSI NFPA latest edition and local electrical codes governing such wiring In Canada all electrical connec tions must be in accordance with CSA standard C22 1 Canadian Electrical Code Part 1 and applicable local codes Refer to unit wiring diagram Use only copper conductor for connections between field supplied electrical disconnect switch and unit DO NOT USE ALUMINUM WIRE Be sure that high voltage power to unit is within operating voltage range indicated on unit rating plate Do not damage internal components when drilling through any panel to mount electrica
64. in the return section of the indoor blower compartment See Fig 9 Remove the return duct cover to locate the assembly Table 1 Physical Data Unit 48XP Continued UNIT SIZE 48XP 048090 048115 048130 060090 060115 060130 NOMINAL CAPACITY ton 4 4 5 5 5 OPERATING WEIGHT Ib 463 463 463 499 499 499 COMPRESSORS Scroll Quantity 1 REFRIGERANT R 410A Quantity Ib 11 25 11 25 11 25 13 5 13 5 13 5 REFRIGERANT METERING DEVICE TXV SES 2 21 2 21 2 21 2 21 2 21 2 21 9 17 4 17 4 17 4 19 3 19 3 19 3 Face Area sq ft gr see d 3300 3300 3300 3300 3300 3300 4 22 22 22 22 22 22 Diameter Motor Hp Rpm 1 4 1100 1 4 1100 1 4 1100 1 4 1100 1 4 1100 1 4 1100 ee 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 1400 1400 1400 1710 1710 1710 Size in 11x10 11x10 11x10 11x10 11x10 11x10 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 3 38 3 3 31 3 38 3 33 3 31 3 46 3 3 41 3 46 3 42 3 41 Burner Orifice No Qty Drill Size Propane Gas HIGH PRESSURE SWITCH psig 610 15 Cut out Reset Auto 420 25 LOSS OF CHARGE LOW PRESSURE SWITCH 20 5 Liquid Line psig _ Cut out 45 10 Reset auto RETURN AIR FILTERS Unt 24 x 30 x 1 24 x 30x 1 24 x 30 x 1 24 x 30x 1 24
65. irflow b COOLING MODE 1 If indoor temperature is above temperature set point and humidity is below humidity set point thermostat closes circuits to 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 thermostat or Thermidistat closes circuits R to R to Y Y2 R to and humidistat or Thermidistat opens 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 instruc tions Consult indoor control literature to determine if control is capable of providing Super Dehumidify inputs and for configura tion 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 opens cir cuits 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 for Super Dehumidif
66. l hardware conduit etc On 3 phase units ensure phases are balanced within 2 percent Consult local power company for correction of improper voltage and or phase imbalance 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 See Table 3 for electrical data 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 HIGH VOLTAGE POWER LEADS SEE UNIT WIRING LABEL POWER SUPPLY Om m m m FIELD SUPPLIED FUSED DISCONNECT CONTROL BOX BLK DH o 2p GRN G THERMOSTAT LOW VOLTAGE TYPICAL POWER LEADS RED R SEE UNIT WIRING LABEL BRN C gt SPLICE BOX LEGEND Field Control Voltage Wiring Field High Voltage Wiring mom om om om om om 01026 Fig 11 High Control Voltage Connections Single phase units 1 Run the high voltage 11 L2 and ground leads into the control box 11 2 Connect
67. l within the approved temperature rise range of the unit 2 3600 32 112 5 3 112 5 x 1 2112 5 f 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 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 must be between 3 4 and 3 6 in wg Unsafe operation of the unit may result if manifold pressure is outside this range Personal injury or unit damage may result WARNING Unsafe operation of the unit may result if manifold pressure is outside this range Serious injury death or unit damage may result 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 5 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 cov
68. 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 CAUTION When servicing gas train do not hit or plug orifice spuds or personal injury property or product damage may occur Removal of Gas Train To remove the gas train for servicing 1 Shut off main gas valve Shut off power to unit Remove unit access panel See Fig 22 Disconnect gas piping at unit gas valve Remove wires connected to gas valve Mark each wire Remove ignitor and sensor wires at the ignitor module Roc 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 Straighten bent fins with a fin comb If coated wit
69. losion which can result in personal injury or unit damage Consult a qualified installer service agency or gas supplier for information or assistance The qualified installer or agency must use only factory authorized kits or accessories when modifying this product WARNING Before performing service or maintenance operations on unit turn off gas supply to unit Then turn off unit main power switch Electrical shock or explosion could cause serious injury or death Recognize safety information This is the safety alert symbol AN When you see this symbol in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE 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 a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instr
70. n utes for automatic reset Fan ON OFF delay modified LED FLASH High limit switch opens during heat exchanger warm up period before fan on delay expires Limit switch opens within three minutes after blower off delay timing in Heating mode Ensure unit is fired on rate ensure temperature rise is correct Ensure unit s external static pressure is within application guidelines Limit switch faults LED 2 flashes High temperature limit switch is open Check the operation of the indoor evaporator fan motor Ensure that the supply air temperature rise is in accordance with the range on the unit nameplate Flame sense fault LED 3 flashes The IGC sensed flame that should not be present Reset unit If problem persists replace control board 4 consecutive limit switch faults LED 4 flashes Inadequate airflow to unit Check operation of indoor evaporator fan motor and that supply air temperature rise agrees with range on unit nameplate information Ignition lockout LED 5 flashes Unit unsuccessfully attempted ignition for 15 minutes Check ignitor and flame sensor electrode spacing gaps etc Ensure that flame sense and ignition wires are properly terminated Verify that unit is obtaining proper amount of gas Induced draft motor fault LED 6 flashes IGC does not sense that induced draft motor is operating Check for proper voltage If motor is operating check the
71. ns between the thermostat and the unit If the thermostat is located more than 100 ft from the unit as measured along the control voltage wires use no 16 AWG color coded insulated 35 C minimum wires Remove knockout hole located in the heat section panel adjacent to the service access panel Remove the rubber grommet from the installer s packet and install grommet in the knockout opening Provide a drip loop before running wire through panel Run the low voltage leads from the thermostat through the inlet hole and into unit low voltage splice box Locate 18 gage wires leaving control box These low voltage connection leads can be identified by colors See Fig 11 Ensure the leads are long enough to be routed into the low voltage splice box located below right side of control box Route leads through hole in bottom of control box and make low voltage connections See Fig 11 Secure all cut wires so that they do not interfere with operation of unit EASY SELECT M 48XP EASY SELECT CONFIGURATION TAPS FOR 48XP Easy Select taps 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 Table 3 Electrical Data Unit 48XP UNIT COMPRESSOR MIU
72. ondenser fan pulls air through the condenser coil and discharges it through the top cover 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 above the unit top The maximum horizontal extension of a partial overhang must not exceed 48 in 254 0 546 1 254 0 10 00 21 501 10 001 861 Il a RETURN SUPPLY 10 6 2 781 ZR G7 OPTIONAL Zs OPTIONAL If RETURN SUPPLY AIR i RET 406 4 OPENING OPENING 402 0 SPEL Ru 16 001 15 831 OPENING OPENING gt 2 I Y COND NON BENT COIL 14 631 88 3 13 48 249 6 be 550 5 2496 1 9 83 21 671 9 83 EAE REAR VIEW REQ D CLEARANCES FOR OPERATION AND SERVICING in mm Evaporator coil access 36 914 Power entry side except for NEC requirements 36 914 Unit tOD s 25554 55 Rock ETE Eo 48 1219 Side opposite duele s s kk x os oko Roo 36 914 Duct panel i 23 7 eo Ak s uo kom ar cc RU 12 304 8 FUG Panel iuo beso coo 36 914 4 Minimum distances If unit is placed less than 12 in 304 8 mm from wall COND COIL X
73. pid 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 Table 7 LED Indications ERROR CODE LED INDICATION Normal Operation On Hardware Failure Off Fan On Off Delay Modified 1 Flash Limit Switch Fault 2 Flashes Flame Sense Fault 3 Flashes Four Consecutive Limit Switch Faults 4 Flashes Ignition Lockout Fault 5 Flashes Induced Draft Motor Fault 6 Flashes Rollout Switch Fault 7 Flashes Internal Control Fault 8 Flashes Safety Critical Code Fault 9 Flashes 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 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
74. r than 2 Use the following formula to determine the percentage of voltage imbalance Voltage imbalance max voltage deviation from average voltage 100 x average voltage Determine maximum deviation from average voltage 457 452 464 457 lt 7 457 455 2 Maximum deviation is 7 v Determine percent of voltage imbalance Voltage Imbalance 100 x ne 457 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Table 4 Legend 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 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 condi tioner 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 IN
75. r to unit information plate and charging chart Some R 410A refrigerant cylinders contain a dip tube to allow liquid refrig erant to flow from cylinder in upright position For cylinders equipped with a dip tube charge Puron units with cylinder in upright position and a commercial metering device in manifold hose Charge refrigerant into suction line QUICK REFERENCE GUIDE SET UP INSTRUCTIONS FOR EASY SELECT BOARD SUPER HUMIDITY CONTROL IN COOLING EASY SELECT BOARD 9 PIN CONNECTOR 1 Configuration Taps ECM PRINTED CIRCUIT BOARD See Installation Instructions for detailed description A HEAT RANGE Set for gas heat size 090 for unit 048090 m B AC HP SIZE Set for size of outdoor unit Cooling Size CA Ji C SYSTEM TYPE Select AC for Gas Package Units D AC HP ADJUST Select NOM EASYSELECT E ON OFF DELAY Do not use ENH for this unit GAS HEAT CFM F CONTINUOUS FAN Select desired speed E d 1800 Tew 1050 000 2 Remove Jumper J1 to activate all dehumidity modes A Wo 1 1 1 3 Complete wiring and install outdoor temperature IESE sensor according to Installation Instructions M 060 048 042 036 B 0 8 a a x AC HP EFF Q Du ow 8 ole THERMIDISTAT CONTROL SETTINGS CFMADJUST E 4 NOM LO HI
76. refrigerant charge an indicated adjust ment 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 To Use Cooling Charging Charts 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 6 shows the temperature rise at various airflow rates Table 9A amp 9B show cooling airflows and Table 9C amp 9D 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 Before making any indoor wiring adjustments shut off gas supply Then disconnect electrical power to the unit Elec trical shock or explosion can cause
77. speed sensor plug IGC Terminal J2 connection Proper connection PIN 1 White PIN 2 Red PIN 3 Black Rollout switch fault LED 7 flashes Rollout switch has opened Rollout switch will automatically reset but IGC will continue to lock out unit Check gas valve operation Ensure that induced draft blower wheel is properly secured to motor shaft Reset unit at unit disconnect Rollout control fault LED 8 flashes Microprocessor has sensed an error in the software or hardware If error code is not cleared by resetting unit power replace the IGC Safety Critical fault LED 9 flashes If Safety Critical Software Redundant Variables Mismatch occurs then IGC will lockout This fault will clear after 1 hour Verify that flame sensor wire and spark ignitor wires are not touch ing or close together Ensure unit has a good ground on the IGC board WARNING If the IGC must be replaced be sure to ground yourself to dissipate any electrical charge that may be present before handling new control board The IGC is sensitive to static electricity and may be damaged if the necessary precautions are not taken IMPORTANT Refer to Table 11 Troubleshooting Guide Heating for additional troubleshooting analysis LEGEND IGC Integrated Gas Unit Controller LED Light Emitting Diode 31 START UP CHECKLIST Remove and Store in Job File Preliminary Information MODEL NO SERIAL NO D
78. t 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 4 gt p XXXXXXXX co MANIFOLD PIPE PLUG C99019 Fig 16 Burner Assembly 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 15 BURNER FLAME MANIFOLD C99021 Fig 17 Monoport Burner 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 volumetric charging cylinder or accurate scale Refer to unit rating plate for required charge Be sure to add extra refrigerant to compensate for internal volume of filter drier 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 a
79. tion while connect ing improperly routed rigid gas piping to the gas valve Use a backup wrench when making connection to avoid strain on or distortion of the gas control piping CAUTION Unless a flexible conductor is required or allowed by the authority having jurisdiction black iron pipe shall be installed at the gas valve and shall extend a minimum of 2 in outside the unit casing to prevent potential gas leaks and personal injury or property or product damage WARNING Never use a match or other open flame when checking for gas leaks Never purge gas line into combustion chamber Failure to follow this warning could result in an explosion causing personal injury or death 8 Check for gas leaks at the field installed and factory installed 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 DIS A CAUTION CHARGE Collect ALL screws that were removed Do not leave screws on rooftop as permanent damage to the roof may occur A WARNING Before performing service or maintenance operations on the 5 It is recommended th
80. uctions as a minimum for a safe installation 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 down flow 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 thirteenth 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 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 unit identification rating plate Check this information against ship ping papers and job data 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 Manu facturer is not responsible
81. ver until all electri cal sources are disconnected 4 Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals 1 5 Never attempt to repair soldered connection while refrig 24 VAC TO HUMIDIFIER erant system is under pressure HUM 2 6 Do not use torch to remove any component System G HUMIDIFIER WIRING A95317 Fig 13 Humidifier Wiring 48XP EASY SELECT BOARD TERMINAL BLOCK J1 REMOVE E JUMPER HUMIDISTAT e A95316 Fig 14 Humidistat Wiring for De Humidify Mode 48XP 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 mod
82. w recommendations of national codes 3 Apply joint compound pipe dope sparingly and only to male threads of joint when making pipe connections Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and or national codes Never use Teflon tape 4 nstall sediment trap in riser leading to heating section See Fig 8 This drip leg functions as a trap for dirt and condensate TEE OUT NIPPLE CAP C99020 Fig 8 Sediment Trap 5 Install an accessible external manual main shutoff valve in gas supply pipe within 6 ft 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 CAUTION Unstable operation may occur when the gas valve and manifold assembly are forced out of posi
83. y 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 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 610 psig High pressure may be caused by a dirty outdoor coil failed fan motor or outdoor
84. y mode the motor delivers reduced airflow to maximize the humidity removal of the system while minimizing over cooling SCHEMATIC c d Kel lame OEM 208 230 1 60 SUPPLY 1 He BR LEGEND 23 423 F FOR 042 060 Z FIELD SPLICE EQUIP EQUIPMENT BLK C UNITS ONLY CO TERMINAL MARKED FS FLAME SENSOR POWER 9 TERMINAL UNMARKED FU FUSE SPLICE GND GROUND EQUIP GND YEL CO SPLICE MARKED GVR GAS VALVE RELAY HPS HIGH PRESSURE SWITCH YEL FACTORY WIRING H

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