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Installation, Start-Up, and Operating Instructions

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1. LLL cm ees 82 738 o ee eher 030 wais 353 as 359 59 e oo Gm 1495 na 1070 9 99 88 boh ERE E MM M k 1230 1145 1080 977 re Ee ae M xm 389 38a sem Cim 1398 ia7 128i 1205 ima 104 20 036 Watts sis so 489 474 459 443 48 Gm 19r 1426 1er 07 6 an ee ERARA Lake 605 593 583 Cim 1484 1410 1330 1243 1147 1044 9360 Watts os sos sos seas see 54 52 43 354 ETE cm nE nz zx SE HE ED RR was 7 7o era es 604 sr S50 s3 Gm ie 1688 16 0 1566 1492 1999 1279 righ Was rer ra ze p Cem er 3e 637 1s 559 su sa so 042 Med Watts 591 578 573 568 Cim 1554 1523 1496 1467 1432 1387 1332 1269 048 060 755 77 719 899 ers 63 67 62 55 sez 556 ne Due EE Lem wi m m Dm 9 19 73 17 3624 1591 1438 se 9 1 158 1779 8 ws i97 Watts
2. w5 Ttt ritu t c c s 1 7 a a HKD rae A M om F YEL 3H He z 4 POWER p dm 4 BL s tu p COMP n m 7 BLU i OUN s d SEE NOTE gt mm FOUN GRD BL AAA t GRN YEL FOR 042 060 ONLY 15 YEL 3e iFM 071 072 AP wi 9 YEL or Be D tee ma 24v SPLICE BOY PRIMART LAST OF MORE 1 38 230 CTCL GRW EP cans bo Mw D 5 o p RED ty SECONDARY W100 GRN YEL Gay 2v THERMIDISTAT 1 t xia 1 BLK 5 je YEL p yd RED yt Fa td iss MB d TF E RED HF 26 BR MGV wab SES FLAME SC 45 BR WEG GRN YEL W43 BR 18 BR GROUNDED THRU STAMOOFT a COOLING FAN LOGIC Toke 4624 T 6 030 068 UNITS EMERGITLD REATIMG FAN LOGIC 45 Tas oom an EMERGITED 06 ERERGITID One t CM is UNIT COMPONENT ARRANGEMENT Titkimad UMMAELCD Eae ME 9 sur KIGA PATSSUAE SWITCH Oiane D Doe y ft 1 M CHIESE DIP SWITCH SETTINGS arial Qu T NOI TO ACPACSCAT OMIM TA ICE 30 NUI bo wINUICS ja HCM ERES QUT DOOM FAN it CLOVER ALAT o OUfpOON S MSOR fu lt PLUG COMM TOR CAMNNCASE 9 MAE TM M a ALLA RYS REVIAS ING VALVE SOLENOID 5500 Tial O LAT 5 OUTDOOR 510504 CONSEC 10w a bitR
3. 1000 1200 1200 1400 1400 10 X 10 10 X 10 10 X 10 11 X 10 11X 10 1 4 1 2 1 2 1 2 1 2 3 38 3 46 610 15 420 25 20 5 45 10 1 Required filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airliow or the heating airttow velocity of 300 fUminute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in wg 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 in FPT gas inlet on the unit gas valve For natural gas applications the gas pressure at unit gas connection must not be less than 4 0 in wg or greater than 13 in wg while the unit is operating For propane applications the gas pressure must not be less than 7 0 in wg or greater than 3 in wg
4. or dual fuel thermostat must be used 1 Tighten all screws around bumer compartment No gas at main burners Incomplete combustion resuits in 2 Cracked heat exchanger Replace Poor flame characteristics Aldehyde odors carbon monoxide sooting 3 Unit over tired Reduce input change orifices or flame floating flame adjust gas line or manifold pressure 4 Check burner alignment 31 Table 13 Troubleshooting Guide LED Error Codes SYMPTOM Hardware failure LED OFF Loss of power to control module IGC High limit switch opens during heat Fan ON OFF delay modified exchanger warm up period before delay expires LEDT FLASH Limit switch opens within three minutes after biower off delay timing in Heating mode Limit switch faults LED 2 flashes High temperature limit switch is open Flame sense fault The IGC sensed flame that should not be LED 3 flashes present 4 consecutive limit switch faults LED 4 flashes inadequate airflow to unit Ignition lockout Unit unsuccessfully attempted ignition for LED 5 fiashes 15 minutes Induced draft motor fault IGC does not sense that induced draft LED 6 flashes motor is operating Rollout switch fault LED 7 flashes Rollout switch has opened Roliout control fault Microprocessor has sensed an error in the LED 8 flashes software or hardware Redundant Safety Circuit ae Software Mattunction REMEDY
5. 6 Remove ignitor and sensor wires at the ignitor module 7 Remove the mounting screw that attaches the burner rack to the unit base See Fig 28 8 Slide the burner rack out of the unit See Fig 26 and 29 9 To reinstall reverse the procedure outlined above OUTDOOR COIL INDOOR COIL AND CONDENSATE DRAIN Inspect the Outdoor coil Indoor coil and condensats drain 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 outdoor coil Straighten bent fins with a fin comb If coated with dirt or lint clean the coils with a vacuum cleaner using the soft brush attachment Be careful not to bend the fins If coated with oil or grease clean the coils with a mild detergent and water solution Rinse coils with clear water using a garden hose Be careful not to splash water on motors insulation wiring or air filter s For best results spray outdoor coil fins from inside to outside the unit On units with an outer and inner outdoor coil be sure to clean between the coils Be sure to flush all dirt and debris from the unit base Inspect the drain and condensate drain line when inspecting the coils Clean the drain and condensate drain line by removing all foreign matter from the drain Flush the drain and drain tube with clear water Do not sp
6. Check 5 amp fuse on IGC power to unit 24 circuit breaker and transformer Units without a 24 circuit breaker have an intemal overioad in the 24 v transformer If the overload trips allow 10 min utes for automatic reset Ensure unit ts fired on rate ensure temperature rise is correct Ensure unit s external static pressure is within application guidelines Check the operation of the indoor fan motor Ensure that the supply air temperature rise is accordance with the range on the unit nameplate Reset unit if problem persists replace control board Check operation of indoor fan motor and that supply air temperature rise agrees with on unit nameplate information 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 Check for proper voltage motor is operating check the speed sensor plug IGC Terminal J2 connection Proper connection PIN 1 White PIN 2 Red PIN 3 Black 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 Il error code is not cleared by resetting unit power replace the IGC Internat processor fault that will reset itsett in 1 hour Fault can be caused by stray RF signals in the s
7. Fig 5 48JZ Corner Weights Step 5 RIG AND PLACE UNIT CAUTION When installing the unit on a rooftop be sure the roof will support the additional weight Use spreader bars or crate top when rigging the unit The units must be rigged for lifting See Fig 6 Refer to Table 1 for operating weight Use extreme caution to prevent damage when moving the unit Unit must remain in an upright position during ail rigging and moving operations The unit must be level for proper condensate drainage therefore the ground level pad or accessory roof curb must be level before setting the unit in place When a field fabricated support is used be sure that the support is level and properly supports the unit Lifting point should be directly over the center of gravity for the unit Step 6 CONNECT CONDENSATE DRAIN NOTE When installing condensate drain connection be sure to comply with local codes and restrictions Model 4872 disposes of condensate water through a 3 4 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 I in lower than the drain condensate connection to prevent the drain from o
8. and ground leads into the control box 2 Connect ground lead to chassis ground connection Tabie 3 Electrical Data Unit 482 VOLTAGE RANGE COMPRESSOR 208 230 1 60 187 253 253 253 V PH HZ 253 253 3 Locate the black and yellow wires connected to the line side of the contactor 4 Connect L to black wire on connection 11 of the compressor contactor 5 Connect L2 to yellow wire on connection 23 of the compres sor 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 Before making any wiring changes make sure the gas supply is switched off first Then switch off the power supply to the unit and install lock out tag Electrical shock can cause serious injury or death CONTROL VOLTAGE CONNECTIONS NOTE This unit must be installed with either a Thermidistat or Dual fuel thermostat for proper system operation Do not use any type of power stealing thermostat no Common C connection at Stat Unit control problems may res
9. in mm Ol Git i6 xo 14 355 6 Ductsideof unit 2 50 8 Side opposite ducts 44 355 6 Bottomof unit ee ls 0 50 12 7 Flus panal lt 22 07 zo Ro ee a oi Ron s 36 914 4 NEC REQ D CLEARANCES in mm Between units power entry side 42 1066 8 Unit and ungrounded surfaces power entry side 36 914 Unit and block or concrete walls and other grounded surfaces control box side lr 42 1065 8 M5 14 381 28 6 1 13 Di POWER 22 2 0 881 DIA HOLI CONTROL ENTRY 123 0 14 84 456 2 yala 1191 302 12 351 19 0 0 75 AP T in 2 0 OMPALSSOR BLOW R GAS SECTION FLUE HOOD 12 7 0 501 rH ii ELECTRICAL ACCESS PANEL 1 84 GAS DM 52 8 12 4 0 203 iE 4226 3 12 081 18 28 22 2 02 023 14 831 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW UNIT ELECTRICAL CHARACTERISTICS 208 230 1 60 48 12024 040 483Z030 040 060 48 JZ036 060 090 208 230 1 60 208 230 3 60 UNIT WEIGHT e 515 M76 37020403 206589 153 9874 C99017 UNIT HEIGHT kg z 141 0 35 02 889 5 22 0 558 8 14 5 368 3 16 0 406 4 17 6 447 0 37 02 940 3 22 0 558 8 16 5 419 1 Fig 2 48JZ024 036 Unit Dimensions Step 3 FIELD FABRICATE DUCTWORK Secure all ducts to roof curb and buil
10. 30 REMEDY Call power company Replace fuse or reset circuit breaker Replace component Determine cause and correct Check wiring diagram and rewire correctly Lower thermostat setting below room temperature Check wiring and repair or replace Determine cause after allowing tima for overload to cool and close Replace compressor Determine cause and replace Replace fuse or reset circuit breaker Determine cause Recover refrigerant evacuate system and recharge to capacities shown on nameplate Replace and determine cause Determine cause and correct Determine cause and Correct Determine cause and replace Replace thermostat Replace Locate restriction and remove Replace liiter Decrease load or increase unit size Reset thermostat Locata leak repair and recharge Recover refrigerant evacuate system and recharge Clean coil or remove restriction Replace filter Clean coil Recover excess refrigerant Recover refrigerant evacuate system and recharge Determine cause and correct Check for leaks repair and recharge Replace compressor Remove restriction Check tor source and eliminate Recover excess refrigerant Replace Filter Check for leaks repair and recharge Remove source of restriction increase air quantity Check filler repiace if necessary Reset thermostat Install low ambient kit Replace Table 12 Troubleshooting Guide Heating SYMPTOM CAUSE REMED
11. CLEARANCE TO COMBUSTIBLE MATL TOP OF UNIT DUCT SIDE OF UNIT SIDE OPPOSITE DUCTS BOTTOM OF UNIT FLUE PANEL NEC REQUIRED CLEARANCES BETWEEN UNITS POWER ENTRY SIDE UNIT AND UNGROUNDED SURFACES POW UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE 115 4 4 54 42 00 1066 8 36 00 914 0 42 00 1066 8 MILLIMETERS a 28 6 1 131 DIA X O POWER ENTRY 22 2 10 881 OIA HOLE CORTROL WIRY 08 1 SECTION 12 1 19 30 GAS ENTRY 3 0 10 201 RIGHT SIDE VIEW C99074 CENTER OF GRAVITY UNIT ELECTRICAL CHARACTERISTICS UNIT eee ur MM IN MM b M A 2 48J2042 060 090 208 230 1 60 208 230 3 60 380 172 16 6 421 6 SJZO4 G MS 130 206 230 1 60 208 230 360 409 186 4098110409 215 546 155 422 18 0 4572 822060 090 115 130 208 230 1 60 208030 460 504 229 4810911 23545969 163128 17 5 470 Fig 3 48J2042 060 Unit Dimensions Step 4 PROVIDE CLEARANCES The required minimum operating and service clearances are shown in Fig 2 and 3 Adequate combustion ventilation and outdoor coil 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
12. E A CAUTION _ Errors made when reconnecting wires may cause improper and dangerous operation Label all wires prior to disconnec tion when servicing SUCTION UME TEMPERAT IRE CEG Ft WARNING Before cleaning the blower motor and wheel tum off gas supply Then turn off and tag electrical power to the unit Failure to adhere to this warning could cause serious injury or Fig 20 Cooling Charging Chart 48JZ024 Units death 2 Inspect indoor coil outdoor coil drain pan and condensate The minimum maintenance requirements for this equipment are as drain each cooling season for cleanliness Clean when neces follows sary 1 Inspect air filter s each month Clean or replace when 3 Inspect blower motor and wheel for cleanliness at the begin necessary Certain geographical locations may require more ning of each heating and cooling season Clean when neces frequent inspections sary For first heating and cooling season inspect blower 21 Table 10 Wet Coil Air Delivery Horizontal and Downflow Discharge Unit 48JZ024 060 Deduct 10 percent for 208 Volts 230 VOLT External Static Pressure in wg Unit Motor Speed oo ot o2 03 o4 os os 07 oe o 10 wats 279 282 280 27 26 Du om we rur a a 024 E mil cm 96 sss 797 zo ee EE pw ee 3p Bop e 794 vos
13. Maximum Gas Flow Capacity NOMINAL INTERNAL LENGTH OF PIPE IRON PIPE SIZE DIAMETER IN m 2 1 2 x 9 75 5 4 4 Lm pm pum pam cre pee pes o or pate tetr 1049 680 465 37S 320 285 260 240 220 205 195 175 160 145 1385 1400 880 770 00 seo 530 490 460 430 400 360 325 300 i610 2100 1460 1180 900 900 810 750 690 650 620 550 500 460 Capacity of pipe in cu ft ot 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 54 t This length includes an ordinary number of fittings 5 Install an accessible external manual main shutoff valve in NOTE Pressure test the gas supply system after the gas supply gas supply pipe within 6 ft of heating section piping is connected to the gas valve The supply piping must be 6 Install ground joint union close to heating section between disconnected from the gas valve during the testing of the piping unit manual shutoff and external manual main shut off valve 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 externa main manual shutoff valve and slightly ope
14. Switch Fault 7 Flashes rise that falls within the approved range internal Control Fault 8 Flashes Refer to indoor Airflow and Airflow Adjustments section to adjust Temporary one hour automatic 9 Flashes i A reset fault See note 2 heating airflow when required NOTES HEATING SEQUENCE OF OPERATION HEAT PUMP There 3 sec pause between error code displays B If more than one error code exists all applicable error codes will be Heat Pump Heating Sequence of Operation Outdoor tempera displayed in numerical sequence d ture above balance point setpoint of Thermidistat option 11 This chart is on the wiring diagram located inside the burner access panel See Fig 15 16 amp 17 four Fault can be caused by siray FE eagnais in the structure er nearty Thi On a call for heating terminals Y and G of the Thermidis B When WI is Seide the burners will remain on for a minimum of 60 tat or Dual Fuel thermostat are energized The Y signal is sent seconds to the Defrost Board DB terminal Y The DB has a built in five minute anti short cycle timer which will not allow the compressor LIMIT SWITCHES to restart before the time delay has expired T2 energizes the Normally closed limit switch LS The limit switch is normally compressor contactor via the High Pressure Switch HPS and closed and opens on sensing excessive temperature rise in the heat Low Pressure Switch LPS The compressor and outdoor fan start exch
15. WARNING Before cleaning the blower motor and wheel tum off gas supply Then turn off and tag electrical power to the unit Failure to adhere to this warning could cause serious injury or death Cleaning the Blower Motor and Wheel 1 Remove and disassemble blower assembly as follows a Remove unit access and internal blower panels b Disconnect motor lead from blower relay BR Disconnect yellow lead from terminal L2 of the contactor 030 60 Hz COOLING CHARGING CHART For Use with Units Using R410a Refrigerant 042 60 Hz COOLING CHARGING CHART For use with units using R410a Retrigerant SUCTION LUNE TEMPERATURE PEG 8 1 H 3 IC LION C SUN PBI BUC HON LINE Co0083 00085 Fig 21 Cooling Charging Chart 4842030 Units Fig 23 Cooling Charging Chart 48JZ042 Units 038 60 Hz COOLING CHARGING CHART For Use with Units Using R410a Retrigerant 048 60Hz COOLING CHARGING CHART For use with units using R410a Refrigerant LILILLIT AZ LLL Pee eee See T R DA AE G ON AEE E T R P E ESL BEHER ED SR ar 0 79 8 BUCTION LINE 3 H H 3 E i 1 i MARC TION SATEEN HOR Co0086 Fig 22 Cooling Charging Chart 48JZ036 Units Fig 24 Cooling Charging Chart 4842048 Units c On all units remove blower assembly from unit Remove screws securing blower to blower partition and slide a Ensure proper reassembly by marking w
16. air side of the unit Recommended sizes for filters are shown in Table 1 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 A WARNING The unit cabinet must have an uninterrupted unbroken electrical ground to minimize the possibility 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 Electrical Code ANSI NFPA 70 latest edition and local electrical codes In Canada follow Canadian Electrical Code CSA Canadian Standards Association C22 1 and local electrical codes Failure to adhere to this warning could result in serious injury or death CAUTION Failure to follow these precautions could result in damage to the unit being installed t Make all electrical connections in accordance with NEC 70 latest edition and local electrical codes governing such wiring n 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
17. at the unit connection An 1 8 NPT 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 NFPA 54 latest edition in Canada CAN CGA 149 1 latest edition 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 follow recommendations of national codes 3 Apply joint compound pipe dope sparingly and only to male threads of joint when making pipe connections Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and or national codes Never use Teflon tape 4 Install sediment trap in riser leading to heating section See Fig 8 This drip leg functions as a trap for dirt and condensate Table 1 Physical Data Unit 48 7 Continued UNIT SIZE 48JZ 048090 048115 048130 060090 060115 060130 NOMINAL CAPACITY ton paa cup n T rl e
18. d PRIMART ose H GAS SECT O8 CONDARY 24V t 20 TO E fuc a This TO Taass to cont DIP SWITCH SETTINGS FARTI 18 J 60 MIAUTCS 96 1 126 MA SCLCCTIBLE OFT TICA CF 8011 CTCL WE COMPRESSION WILL F FOA D SCC Qu THAT ION Ti am Tat QUSET 5010 E gt oe ioa JWPfatb TES Ping usc METAL FIELD SPEED Wo CICLI A MOMLATARILT SHORT PIMS 4x6 RELEASE TO SOR Off OCLAT P wOtI FOR 5 SCC AD RIAEASL FOR FORCED INfBOST uORT BILL BE 14040 Ov SCORNCCT PCR AEC DEFROST mul CERHIMATE am 28 SiC If DFT OLFEDSO PELL CEAMIMATE MORAALI F OFT 15 CLOSED Gnd T mobi FLD Lime WIR 5i Unit nei S Coni C IC Ca TS Wat ioo LOGRO Foul Ab spica rat t ILE Y v OM MOM AYDOMATIC MUSEE FANT UOTE 91 Y SICON PavSt OL IPEA CODE 3 if woke Due Mn malt DISPLAFED amp quw 5096 4811509004 11 0 Fig 17 208 230 1 60 ICM FIOP Wiring Diagram Unit 48JZ 16 C01101 Table 5 Heating Inputs GAS SUPPLY PRESSURE MANIFOLD HEATING NUMBER IN WG PRESSURE GBINCER IN WG 90 000 115 000 130 000 t When a unit is converted to propane different size orifices must be used Se
19. for medium or high speed in the field For 208 230V For color coding on the 208 230V motor leads see Table 8 To change the speed of the blower motor remove the fan motor speed leg lead from the blower relay BM on the IGC This wire Table 8 Color Coding for 208 230 V Motor Leads 3 SPEED 2 SPEED black high speed black high speed blue medium speed red low speed red low speed is attached to terminal BM for single and 3 phase units To change the speed remove and replace with lead for desired blower motor speed Insulate the removed lead to avoid contact with chassis parts 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 qualified service person To troubleshoot cooling or heating components of units refer to Tables 11 12 and 13 NOTE Consult your local dealer about the availability of a maintenance contract 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 INJURY OR DEATH AND POSSIBLE DAMAGE TO THI
20. inspecting the electrical controls and wiring replace the access panel Start the unit and observe at least one complete gt mp e Sla lt lt o e 4089345 Quiet Shift Speedup Pins SO GD CESO130076 00 Defrost interval DIP switches 99442 Fig 30 Defrost Control Board 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 electricul 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 HEAT PUMP SYSTEM ITEMS Defrost Control QUIET SHIFT Quiet Shift is a field selectable defrost mode which will eliminate occasional noise that could be heard at the start of defrost cycle and restarting of heating cycle It is selected by placing DIP switch 3 on defrost board in ON position When Quiet Shift switch is placed in ON position and a defrost is initiated the following sequence of operation will occur Revers ing valve will energize outdoor fan will turn off compressor will turn off for 30 sec and then turn back on to complete defrost At the start of heating after conclusion of defrost reversing valve will de energize compressor will turn off for another 30
21. into outdoor coil At the end of of the feeder tubes there is a 3 8 in OD stub tube approximately 3 in long See Fig 31 The defrost thermostat should be located on stub tube Note that there is only 1 stub tube used with liquid header and on most units it is the bottom circuit REFRIGERANT CIRCUIT Annually inspect all refrigerant tubing connections and the unit base for oil accumulations Detecting oil generally indicates a refrigerant leak A WARNING System under pressure Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid serious 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 27 GAS INPUT The gas input does not require checking unless improper heating performance is suspected If a problem exists refer to the Start Up section INDOOR AIRFLOW The heating and or cooling airflow does not require checking unless improper performance is suspected problem exists be sure that all supply and return air grilles ar
22. lubricants are known to cause long term damage to some synthetic roofing materials 28 Exposure even if immediately cleaned up may cause embrittle ment leading to cracking to occur in one year or more When performing any service that may risk exposure of compressor oi to the roof take appropriate precautions to protect roofing Proce dures which risk oi 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 cioth 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 base 4 Perform required service 5 Remove and dispose of any oil contaminated material per local codes BI FLOW FILTER DRIER This bi flow filter drier is specifically designed to operate with Puron Use only factory authorized components This filter drier must be replaced whenever the refrigerant system is opened When remo
23. sec and the outdoor fan will stay off for 40 sec before starting in the Heating mode Defrost The defrost control is a time temperature control which includes a 26 field selectable time period DIP switch 1 and 2 on the board between defrost cycles of 30 60 90 or 120 minutes factory set at 30 minutes To initiate a forced defrost two options are available depending on the status of the defrost thermostat If defrost thermostat is closed speedup pins J1 must be shorted by placing a flat head screw driver in between for 5 sec and releasing to observe a complete defrost cycle When the Quiet Shift switch is selected compressor will be turned off for two 30 sec intervals during this complete defrost cycle as explained previously When Quiet Shift switch is in factory default OFF position a normal and complete defrost cycle will be observed If defrost thermostat is in open position and speedup pins are shorted with a flat head screw driver for 5 sec and released a short defrost cycle will be observed actual length is dependent upon the selected Quiet Shift position When Quiet Shift switch is in ON position the length of defrost is minute 30 sec compressor otf period followed by 30 sec of defrost with pressor operation On return to heating operation compressor will again turn off for an additional 30 sec and the outdoor fan for 40 sec When the Quiet Shift is in OFF position only a brief 30 sec cycle wi
24. sizes and locations CONFIGURING UNITS FOR DOWNFLOW VERTICAL DIS CHARGE WARNING Before performing service or maintenance operations the system turn off main power to unit and install lock out tag Electrical shock could cause serious injury or death 1 Open all electrical disconnects before starting any service work 2 Remove horizontal duct covers to access bottom retum and supply knockout panels 3 Use a screwdriver and hammer to remove the panels in the bottom of the unit base See Fig 9 amp 10 1 l SUPPLY RETURN DUCT DUCT OPENING OPENING C99011 Fig 9 Supply and Return Duct Opening C99012 Fig 10 Vertical Duct Cover Removed 4 If unit ductwork is to be attached to vertical opening flanges on the unit base jackstand applications only do so at this time CAUTION Collect ALL screws that were removed Do not leave screws on rooftop as permanent damage to the roof may occur 5 It is recommended that the base insulation around the perim eter of the vertical return air opening be secured to the base with aluminum tape Applicable local codes may require aluminum tape to prevent exposed fiberglass 6 Cover both horizontal duct openings with the provided duct covers Ensure opening is air and watertight 7 After completing unit conversion perform all safety checks and power up unit NOTE The design and installation of the duct system must be in ac
25. 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 fifth position available on single phase only of the model number are dedicated Low NOx units designed for California installations NOTE Low NOx requirements apply only to natural gas instal lations 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 NOTE Jn order for this unit to run as designed you must install with either Carrier s Thermidistat control or Dual fuel thermo stat We recommend the Thermidistai control if using variable speed blower motors 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 Ensure electrical power supply provided for unit matches the requirements listed on the unit rating plate INSPECT SHIPMENT Inspect for shipping damage while unit is stiil on shipping pallet If unit appears to be damaged or is torn l
26. 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 electrical 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 CO m m ate oe UNIT WIRING POWER LABEL om j LILJ T mE U ISCONNECT CONTROL BOX THERMOSTAT LOW VOLTAGE THERMIDISTAT POWER LEADS SEE UNIT WIRING LABEL SPLICE BOX FIELD CONTROL VOLTAGE WIRING FIELD HIGH VOLTAGE WIRING 01110 Fig 11 High and Control Voitage Connections Single phase units 1 Run the high voltage L1 L2
27. 2 7 3 7 4 or Can CGA Canadian Gas Association B149 Installation Codes or applicable provisions of local building code Ftashing field supplied Insulation fieid Rooting material supplied lield supplied Duct work Cant strip field supplied field supplied Root Curb for Small Cabinet Note When unit mounting screw iS used retainer bracket must also be used UNIT SIZE ODS CATALOG NUMBER CPRFCURBOO6A00 48J2024 036 48J2042 060 NOTES 1 Roof curb must be set up for unit being installed 2 Seal strip must b 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 gt Dimensions are in inches Seismic conditions This bracket is available through Micrometi CPRFCURBO07A00 14 356 16 1 2 419 CPRFCURBOOBA00 8 203 16 3 16 411 17 3 8 441 CPRFCURBOO9AO0 14 356 16 3 16 411 Flashing field 2 supplied E Rootcurb Insulation field Rooting material supplied tieid supplied Duct work Cant strip 4 field supptied field supplied Provided with roofcurb Roof Curb for Large Cabinet Note A When unit mounting screw is used retainer bracket must also be used insulated Gasket around deck pan
28. 3 Replace cover screw cap on gas valve manifold pressure The manifold pressure must be maintained between 3 4 and 3 6 in wg larger adjustments are required change main burner orifices following the recommendations of national and local codes 4 Turn off gas supply to unit Remove manometer frorn 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 NOTE All other appliances that use the same meter must be turned off when gas flow is measured at the meter Proceed as follows level specified in Table 5 1 Turn off gas supply to unit Proceed as follows to adjust gas input on a propane gas unit 2 Remove pipe plug on manifold See Fig 13 and connect 1 Tum off gas to unit manometer Turn on gas supply to unit 2 Remove pipe plug on manifold and connect manometer See 3 Initiate a call for Gas Heating Fig 13 4 Record number of seconds for gas meter test dial to make one 3 Turn on gis to unit revolution 4 Initiate a call for Gas Heating 5 Divide number of seconds in Step 3 into 3600 number of 5 Remove cover screw over regulator adjustment screw on gas seconds in one hour valve 6 Multiply result of Step 4 by the number of cu ft shown for one 6 Adjust regulator adjustment screw to the correct manifold revolution o
29. 750 733 715 695 673 648 623 599 S7 e Dmm per ep EIL uo was amp eo 79s 72 7o m8 S Cim 2397 2559 2050 1974 190 em t Air delivery values are without air filter NOTE Deduct field supptied air filter pressure drop to obtain external static pressure available for ducting wheel bi monthly to determine proper cleaning frequency 4 Check electrical connections for tightness and controls for proper operation each heating and cooling season Service when necessary 5 Check and inspect heating section before each heating season Clean and adjust when necessary 6 Check flue hood and remove any obstructions if necessary AIR FILTER CAUTION Never operate the unit without a suitable air filter in the return air duct system Always replace the filter with the same dimensional size and type us originally installed See Tuble 1 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean cleanable type at least twice during each heating and cooling season or whenever the filter s becomes clogged with dust and or lint 22 INDOOR BLOWER AND MOTOR NOTE All motors are prelubricated Do not attempt to lubricate these motors For longer life operating economy and continuing efficiency clean accumulated dirt and grease from the blower wheel and motor annually
30. II M mOWTCOS 68 MIWPICS PO wiuylt 120 AOI WAIN GAS YALYE pra pra LOSCA MELAT A9 MOTOR CONTAC TOR OUTDOOR SEASON itoe PLUG CONNCCTON m ot CARMECASE OUADRUPLE TERMINAL 504 ROLLOUT JWI COMBUSTION PELAT AEVERS WG VALYE SOLEBOID COMFRESSON TINE DELAY QuiDOON SENSOA CONA CTION DEF 505 60480 TwCMWOSTAT DEFROST Tu iuOsIAY TWESWOSTAL MEAT AG IFICATION MODE ORME FIELD SELECTABLE OPTIONS FOR TINE PEAIOO DEFROST CYCLES MimuICS gt TRE COMPRESSOM Biti OFF FOR 30 SEC Ow DEFROST DISCONNECT IMITLATIOM AMD TCRMIBATIOH Im OUITT SHIFT ON PER ace JWwrtatCh TEST METAL OBJECT fib SPLER UP CICLE 1 MOMERTAR I T n pu 480 BILEASE TO BYPASS COPELSSOA OFF DELA 2 HORT FOR 3 SIC OC FROST 3 PURMAMCAT SHORT Will BE IGNORED Conter i us FROST VILL TCRWIMATE IM 30 SIC IF Of OMEN 1 LARGE CHASSIS LOCATION eae 1482500001 1 0 099 Fig 15 208 230 1 60 Wiring Diagram Unit 48427 natural gas with a heating value of 1050 Btu ft at 0 65 specific For elevations above 2000 ft reduce input 4 percent for each gravity or propane gas with a heating value of 2500 Btwft at 1000 ft above sea level 1 5 specific gravity 14 208 230 3 60 T zy
31. NSFORMER PROTECTION STAR To UP MAE 13 CHECK FOR REFRIGERANT LEAKS 13 START UP HEAT AND MAKE ADJUSTMENT S 13 CHECK HEATING CONTROL see 13 HEATING SEQUENCE OF OPERATION HEAT PUMP 18 HEATING SEQUENCE OF OPERATION GAS BAT oho E 18 START UP COOLING AND MAKE ADJUSTMENTS 19 COOLING SEQUENCE OF OPERATION 19 CHECKING COOLING CONTROL OPERATION NON ICM UNITS iere rare Prep eb tera shoes MAINTENANCE sse AIR FILTER esee ttetnntntne INDOOR BLOWER AND MOTOR end FLUE GAS PASSAGEWAYS eese COMBUSTION AIR BLOWER eese LIMIT SWITCH oats BURNER 1 recenter MAIN BURNERS essent OUTDOOR COIL INDOOR COIL AND CONDENSATE 25 OUTDOOR FAN ELECTRICAL CONTROLS AND WIRING 25 HEAT PUMP SYSTEM ITEMS INDOOR AIRFLOW PURON SYSTEM ITEMS TROUBLESHOOTING cssccstsssesenccassneseconsensecseesssanarseesaes START UP CHECKLIST M 28 NOTE TO INSTALLER Before the installation READ THESE INSTRUCTIONS CAREFULLY 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 Fig 1 U
32. OR AIR SENSOR SETTING TO PROPER SELECTION BASED ON BALANCE POINT PER THE THERMOSTAT INSTALLATION INSTRUCTIONS START UP ELECTRICAL SUPPLY VOLTAGE L1 L2 L2 L3 L3 L1 COMPRESSOR AMPS L1 L2 L3 COMPRESSOR AMPS C S R INDOOR FAN AMPS TEMPERATURES OUTDOOR AIR TEMPERATURE DB WB RETURN AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB GAS HEAT SUPPLY AIR PRESSURES GAS INLET PRESSURE IN WG GAS MANIFOLD PRESSURE IN WG REFRIGERANT SUCTION PSIG SUCTION LINE TEMP REFRIGERANT DISCHARGE PSIG DISCHARGE LINE TEMP _ VERIFY REFRIGERANT CHARGE USING CHARGING TABLES Measured at suction inlet to compressor T Measured ut liquid line leaving outdoor coil 33 34 35 Copyright 2001 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 48JZ1si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book x 101 Catalog 534 80083 Printed in U S A Form 482 151 Pg 36 10 01 Replaces New
33. Provin cial and local plumbing or wastewater codes and other applicable local codes 2 Remove flue hood from shipping location inside the blower compartment Place vent cap assembly over flue panel Orient Table 1 Physical Data Unit 482 UNIT SIZE 48JZ 042090 NOMINAL CAPACITY ton 2 2m m 3 83 sw 31 OPERATING WEIGHT Ib ono 380 380 COMPRESSORS od Quantity Quantity Ib Orifice ID In 0 067 0 067 0 073 0 073 AccuRater Piston Orifice OD in OUTDOOR COIL Rows Fins in Face Area sq ft OUTDOOR FAN Nominal Diameter in Motor HP Rpm INDOOR COIL Rows Fins in Face Area sq ft INDOOR BLOWER 2 17 8 5 2 17 10 3 2350 1 8 825 Standard PSC Motor 8 Nominal Airflow Cfm 10 X 10 10 X 10 Size in 1 4 1 4 Motor HP FURNACE SECTION Burner Orifice No Qty Drill Size Natural Gas Burner Orifice No Qty Drill Size Propane Gas HIGH PRESSURE SWITCH psig Cut out Reset Auto LOSS OF CHARGE LOW PRESSURE SWITCH Liquid Line psig Cut out Reset auto RETURN AIR FILTERS in t Throwaway Based on altitude of 0 to 2000 ft 1 8 825 EU 3 15 3 15 4 15 4 15 3 15 oo 3 7 3 7 3 7 3 7 4 7 20 20 1 20 20 1 20x24x1 20 24 1 20x24x1 24x 30x1 24x30x1 0 038 2 2 17 10 3 2 17 10 3 2350 22 1 8 825 2 17 10 3 Eg 17 2 17 Eg 13 5 Ps 1 8 25 1 8 di 100 1 4 1100 1 4 1100
34. S EQUIPMENT 20 OUTDOOR COIL 3 x 2 3 9 ul W l Bypass LEGEND Position HPS High Pressure Switch LCS Loss of Charge Switch TES Accurate Metering Device Arrow indicates direction of flow 00096 Fig 19 Typical Heat Pump Operation Cooling Mode Table 9 Filter Pressure Drop In wg CFM FILTER SIZE cog 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1600 1900 2000 2100 2200 2300 20 20 1 0 05 007 0 08 010 012 013 04 os 1 L 1 1 L 1 2x2X1 0 09 o1 015 93 1 zxaxi 1 097 0 08 009 010 072 013 0 14 0 15 o6 0 17 018 WARNING Failure to follow these warnings could result in serious injury or death 1 First turn off gas supply to the unit Then tum off electrical power and install lock out tag before performing any maintenance or service on the unit Use extreme caution when removing panels and parts As with any mechanical 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 024 60 Hz COOLING CHARGING CHART For use with units using R410a Refrigerant
35. ST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB PLACE RIGGING STRAPS IN BASEPAN SLOT BELOW RIGGING HOLDS BEFORE RIGGING 99015 unit MAXIMUM WEIGHT WE ow DE eR E UNIT 48JZ 18 220 5585 1450 36 157 220 5585 1530 349 155 220 5685 1530 402 182 230 5842 163 43 195 215 54641 163 526 29 285 5969 163 Fig 6 Suggested Rigging 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 surPLy DUCT 15 831 OPEN ENG 38 9 13 4i 25 4 550 5 249 6 9 83 121 67 9 33 REAR VIEW REQ D CLEARANCES FOR OPERATION AND SERVICING in mm Evaporator coil access side 36 914 Power entry side except for NEC requirements 36 914 Unit ouo Gee REESE os 48 1219 Side opposite ducts i s s se seserian nG 36 914 Dud panel 12 304 8 Minimum distances If unit is placed less than 12 in 304 8 mm from wall system then the system performance may be compromised LEGEND CG Center of Gravity COND Condenser EVAP Evaporator NEC National Electrical Code REQ D Required Note Dimensions are in in mm 158 5 GU FIELD ENTRY SERVICE PORTS a a 519 3 122 451 EVAP COIL TOP VIEW REQ D CLEARANCES TO COMBUSTIBLE MATL
36. Y Water in gas lina Drain Install drip leg Check power supply fuses wiring or circuit breaker Check transformer No 24 v power supply to control circuit NOTE Some transformers have internal over current protection that requires a cool down period to reset Mis wired or loose connections Check all wiring and wire nut connections Bumed out heat anticipator in thermostat Replace thermostat Burners will not ignite Broken thermostat wire Run continuity check Replace wire if necessary Te Check flame ignition and sense electrode positioning Misaligned spark electrodes Adjust as necessary t Check gas line for air Purge as necessary NOTE After purging gas line of air wait at least 5 minutes for any gas to dissipate before atlempt ng to light unit 2 Check gas valve Verify IGC has 24 v at amp E IGC board not allowing spark If so replace IGC Clean or replace filer as necessary Check gas pressure at manifold match with that on Gas input to furnace too low unit nameplate Unit undersized for application Replace with proper unit or add additional unit Restricted airflow Clean or replace filter Remove any restriction Inadequate heating Blower speed too low b i speed tap it available or install alternate Check rotation of blower thermostat heat anticipator settings temperature rise of unit Adjust as necessary Limit switch cycles main bumers or Verify use of proper thermostat Thermidistat
37. ad pressure too tow Excessive suction pressure Suction pressure too low Table 11 Troubleshooting Guide Cooling CAUSE Power Failure Fuse blown or circuit breaker tripped Detective thermostat contactor transformer or control relay Insufficient line voltage Incorrect or faulty wiring Thermostat setting too high Faulty wiring or loose connections in compressor circuit Compressor motor bumed seized or internal overioad open Detective run start capacitor overload start relay One leg of 3 phase power dead Refrigerant overcharge or undercharge Defective compressor Insufficient line voltage Blocked outdoor coil Detective run start capacitor overioad or start relay Defective thermostat Faulty outdoor fan motor or capacitor Restriction in refrigerant system Dirty air filter Unit undersized for load Thermostat set too low Low refrigerant charge Air in system Outdoor dirty or restricted Dirty air filter Dirty outdoor Refrigerant overcharged Air in system Outdoor coil air restricted or air short cycling Low refrigerant charge Compressor scroll plates cracked Restriction in liquid tube High heat toad Refrigerant overcharged Dirty air fitter Low retrigerant charge Metering device or low side restricted Insuificient indoor airflow Temperature too low in conditioned area Outdoor ambient below 40 F 55 F with ICM FIOP Factory installed filter drier restricted
38. alance in supply age is greater than 2 Use the following formula to determine the percentage of voltage imbalance Voltage imbalance 100x max voltage deviation from average voltage average voltage EXAMPLE Supply voltage is 230 3 60 232 v d ie BC 227 v 225 v AS 232 227 225 3 Average Voltage 684 3 228 Determine maximum deviation from average voltage AB 232 228 4 v 228 227 1 v 228 225 3v Maximum deviation is 4 v Determine percent of voltage imbalance Voltage Imbalance 100 x ade 228 1 75 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 PRE START UP WARNING Failure to observe the following warnings could result in serious injury or death 1 Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system 2 Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured 3 Do not remove compressor terminal cover until all electri cal sources are disconnected and tagged 4 Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terrni
39. anger compartment Should the leaving air temperature rise Thermidistat G energizes the Integrated Gas Control 1GC above the maximum allowable temperature the limit switch opens terminal G The blower motor is energized through the BM When the limit switch opens the IGC control circuit instantly and L2 terminals of the IGC opens the gas valve circuit and stops gas flow to the burners The When the Thermidistat removes the Y and calls the blower motor continues to run until LS resets compressor contactor and outdoor fan and evaporator motor are When the air temperature at the limit switch drops to the de energized low temperature setting of the limit switch the switch closes allows the ignition cycle to restart The electric spark ignition HEATING SEQUENCE OF OPERATION GAS HEAT system cycles and the unit returns to normal heating operation Gas Heating Sequence of Operation Outdoor temperature be AUXILIARY LIMIT SWITCH ROLLOUT low balance point setpoint of Thermidistat option 11 The function of the switch is to close the main gas valve in the See Fig 15 16 amp 17 event of flame rollout The switch is located above the main burners When the temperature at the auxiliary switch reaches the maximum allowable temperature and opens the IGC circuit opens opening the gus valve circuit and stopping gas tlow to the burners On a call for heating terminal W of the Thermidistat or Dual Fuel thermost
40. at is energized starting the induced draft motor When the hall effect sensor on the induced draft motor senses that The indoor fan motor IFM and induced draft motor continue to it has reached the required speed the burner sequence begins This run until switch is reset The IGC LED will display FAULT CODE function is performed by the integrated gas control IGC The 7 indoor fan motor is energized 45 sec after flame is established When the thermostat is satisfied and W is de energized the burners stop firing and the indoor fan motor shuts off after a 45 sec time off delay An LED light emitting diode indicator is provided on the control board to monitor operation The control board is located by removing the burner access panel During normal operation the LED is continuously on See Table 7 for error codes 18 Step 3 START UP COOLING AND MAKE ADJUST MENTS A CAUTION 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 in cooling mode when the outdoor temperature is below 40 F unless accessory low ambient kit is installed Do not rapid cycle the compressor Allow 5 minutes between on cycles to prevent compressor damage COOLING SEQUENCE OF OPERATION With the room thermostat SYSTEM switch in the COOL position and the FAN switch in the AUTO position the cooling se
41. before another 5 sec try If the burners still do not light this sequence is repeated if the burners do not light within 15 minutes from the initial call for heat there is a lockout To reset the control break the 24 v power to W 5 The indoor fan will turn on 45 sec after the flame has been established The indoor fan wiil turn off 45 sec after the thermostat has been satisfied CHECK GAS INPUT Check gas input and manifold pressure after unit start up See Table 5 If adjustment is required proceed as follows The rated gas inputs shown in Table 5 are for altitudes from sea level to 2000 ft above sea level These inputs are based on SCHEMATIC 208 230 1 60 Pa TEL SEE MOTE 4 i OR 642 060 ONLY QAN SHT 00 MIN anf TEL Last tos 1 30 MALUM eret ns 24 SPLICE BOX PRIMARY ot GAN ED SECONDARY Qu 24 2 S160 y ot SEE NOT ES t sfo 45 BR 56 Leo D GAN 44 GRN YEL GRN 1 0 W43 BR 19 BR GROUNDED THRU STANDOFF COOLING FAN tOGIC 4 T PN 030 050 ENERGIZED DE CHLAIGINN G tOGIC 45 4 M Y n Seiten FLAME SENSOA Omina FUSE S TUNER RELAY PRESSURE SviTCa 038 WIGN VOLTAGE TRABSEORIL 11104 UATERGRATED 645 mw DIP SWITCH SETTINGS wol 10 EUM L
42. blower wheel assembly out of the blower housing See Fig 28 Clean the blower wheel If additional cleaning is required continue with Steps 4 and 5 4 To remove blower remove 2 setscrews 5 To remove motor and cooling 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 then the blower door to gain access to the limit switch The limit switch is located above the indoor blower housing BURNER IGNITION Unit is equipped with a direct spark ignition 100 percent lockout system gnition module is located in the contro box Module contains self diagnostic LED During servicing refer to label diagram for LED interpretation If lockout occurs unit may be reset by either momentarily interrupting power supply to unit or by turning selector switch to OFF position at the thermostat MAIN BURNERS At the beginning of each heating season inspect for deterioration or blockage due to corrosion or other causes Observe the main burner flames and adjust if necessary CAUTION When setvicing gas train do not hit or plug orifice spuds 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 26 Disconnect gas piping at unit gas valve A Aa UC N Remove wires connected to gas valve Mark each wire 25
43. cordance with the standards of the NFPA for installation of nonresidence type air conditioning and ventilating systems NFPA 90A or residence type NFPA 90B and or local codes and ordinances Adhere to the following criteria when selecting sizing and installing the duct system Units are shipped for horizontal duct installation by removing duct covers 2 Select and size ductwork supply air registers and return air grilles according to American Society of Heating Refrigera tion and Air Conditioning Engineers ASHRAE recommen dations 3 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 4 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 5 Use flexible transition between rigid ductwork and unit to prevent transmission of vibration The transition may be screwed or bolted to duct flanges Use suitable gaskets to ensure weathertight and airtight seal 6 All units must have field supplied filters or accessory filter rack installed in the return
44. d 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 outdoor coil pressure It opens at 610 psig High pressure may be caused by a dirty outdoor coil failed fan motor or outdoor air recirculation To check switch 1 Turn off all power to unit and install lock out tag 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 retrigerant throughout the system by the interaction of a stationary and an orbiting scrofl The compres sor is equipped with an anti rotational device and an internal pressure relief port The anti
45. dicated Temperature Rise and Rated Heating Input HEATING INPUT BTUH 40 000 60 000 90 000 TEMPERATURE RISE F pue m we ee ee mo 109 zo 9 so S S9 2250 1100 150 1 6 wes 309 soo ee 759 L za 19 9 19 1500 1380 1227 1125 1038 mso esa ee i957 1725 1568 1408 13907 nexo 25 aee 1950 178 1625 1500 NOTE Dashed areas do not fall within the approved temperature rise range of the unit AIRFLOW AND TEMPERATURE RISE Table 7 LED Indications The heating section for each size unit is designed and approved for ERROR CODE LED INDICATION heating operation within the temperature rise range stamped on the Normal Operation On unit fating plate Hardware Failure oft Table 6 shows the approved temperature rise range for each Fan On Off Delay Modifled 1 Flash heating input and the air delivery CFM at various temperature Limit Switch Fault 2 Flashes rises The heating operation airflow must produce a temperature Sense Fault 3 Flashes rise that falls within the approved range Four Consecutive Limit Switch Faults 4 Flashes Table 6 shows the approved temperature rise range for each Ignitlon Lockout Fault 5 Flashes heating input and the air delivery CFM at various temperature Induced Draft Motor Fault 6 Flashes rises The heating operation airflow must produce a temperature Rollout
46. ding 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 minimum clearance is not required around ductwork Cabinet return air static shall not exceed 25 in wg SUPPLY uct OPC MING RETURN OPEN 55 3 351 2 347 3 351 2 3 48 113 53 13 871 13 83 REAR VIEW REQUIRED CLEARANCE FOR OPERATION AND SERVICING in imm EVAP COIL ACCESS SIDE 36 00 914 0 6 00 914 0 36 00 nd 00 914 0 12 00 304 8 MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 12 00 304 8 FROM WALL SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISE 1090 6 42 34 FILLO ENTE senvict 19 0 10 75 S OWPRESSOR BLOWER GAS 1 22 0 0 81 DP 3226 3 48 281 FRONT VIEW 1123 4 44 221 LEFT SIDE VIEW CLECFRICAL ACCESS PAIICL 355 8 14 01 SUPPLY OPTIONAL Ai OPC MIG OPTIONAL SUPPLY OPEMENG TOP VIEW REQUIRED
47. e ee l 5 OPERATING WEIGHT Ib 40 40 409 54 504 504 COMPRESSORS Scroli Quantity Quantity Ib ome ee iie 12 REFRIGERANT METERING DEVICE Orifice 10 In 0 076 0 076 0 076 0 088 0 088 0 088 AccuRater Orifice OD in 0 046 2 0 052 2 0 052 2 0 052 2 tt 185 758 EH Face Area sq ft 13 5 13 5 13 5 15 4 15 4 15 4 OUTDOOR FAN Nominal Cfm 3300 3300 3300 Diameter in 25 are 22 Motor Rpm 1 4 1100 1 4 1100 1 4 1100 1 4 1100 INDOOR COIL 4 15 4 15 4 15 4 15 4 15 4 15 Rows Fins in 47 47 47 5 7 5 7 5 7 Face Area sq ft INDOOR BLOWER Standard PSC Motor 1750 1750 Nominal Alrftow 11 X 10 11X 10 Size in 1 0 1 0 Motor HP FURNACE SECTION Burner Ortflce No Qty Drill Size 3 31 Natural Gas 3 41 Burner Orifice No Qty Drill Size Propane Gas HIGH PRESSURE SWITCH psig a 610 15 Reset Auto oS LOSS OF CHARGE LOW PRESSURE SWITCH 20 5 Liquid Line psig 45 10 Cut out Reset auto RETURN AIR FILTERS in t Throwaway 24x 30x1 24 x30x1 24 x 30x 1 24x 30x1 24 x 30x 1 24 x30x1 Based on altitude of to 2000 tt 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 for high capacity type Air filter pressure drop tor non standard filters must not exceed 0 08 in wg Table 2
48. e 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 PURON SYSTEM ITEMS METERING DEVICE ACCURATER This metering device is an AccuRater Piston fixed orifice and is contained in the brass hex body in the liquid line PRESSURE SWITCHES Pressure switches are protective devices wired into control circuit low voltage They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit These pressure switches are specifically designed to operate with Puron R 410A systems R 22 pressure switches must not be used as replacements for the Puron R 410A system LOSS OF CHARGE SWITCH This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge low airflow across indoor coil dirty filters etc It opens on a pressure drop at about 20 psig If system pressure is above this switch should be closed To check switch 1 Turn off all power to unit and install lock out tag 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 an
49. e separate natural to propane conversion kit instructions Based on altitudes from sea level to 2000 ft above sea level For altitudes above 2000 ft reduce input rating 4 percent for each 1000 ft above sea level In Canada from 2000 ft above sea level to 4500 ft above sea level de rata the unit 10 percent 1 Remove cover screw over regulator adjustment screw on gas CAUTION e iss 5 alve These units are designed to consume the rated gas inputs 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 using the fixed orifices at specified manifold pressures as shown in Table 5 DO NOT RE DRILL THE ORIFICES UNDER ANY CIRCUMSTANCES ADJUST GAS INPUT pressure is outside this range Personal injury or unit damage may result The gas input to the unit is determined by measuring the gas flow at the meter by measuring the manifold pressure Measuring the gas flow at the meter is recommended for natural gas units The WARNING manifold pressure must be measured to determine the input of Unsafe operation of the unit may result if manifold pressure propane gas units is outside this range Serious injury death or unit damage Measure Gas Flow Natural Gas Units may result Minor adjustment to the g s flow can be made by changing the
50. e unit power leads 2 Reapply power to the compressor The suction and discharge pressure levels should now move to their normal start up levels NOTE When the compressor is rotating in the wrong direction the unit makes an elevated level of noise and does not provide cooling CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with R 410A refrigerant tested and factory sealed NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 410A charge The charging label and the tables shown refer to system temperatures and pressures in cooling mode only An accurate superheat thermocouple or thermistor type ther morneter 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 CAUTION When evaluating the 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 Refrigerant Charge Amount of refrigerant charge is listed on unit nameplate also refer to Table 1 Refer to Corporate GTAC 2 5 Charging Recovery Recycling and Reclamation training ma
51. etric 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 START UP HEAT AND MAKE ADJUSTMENTS CAUTION Complete the required procedures given in the Pre Start Up section before starting the unit NOTE This unit is factory equipped with natural gas orifices Do not jumper any safety devices when operating the unit Make sure that burner orifices are properly aligned Unstable operation may occur when the burner orifices in the manifold are misaligned Follow the lighting instructions on the heating section operation label located inside the burner or blower access door to start the heating section NOTE Make sure that gas supply has been purged and that all gas piping has been checked for leaks CHECK HEATING CONTROL Start and check the unit for proper cooling control operation as follows see furnace lighting instructions located inside burner or blower access panel 1 Place room thermostat SYSTEM switch in the HEAT position and the fan switch is placed in AUTO position Verify that the outdoor air sensor setting is above the outdoor temperature 2 Set the heating temperature control of the thermostat above room temperature 3 The induced draft motor will start 4 After a call for heating the main burner should light within 5 sec If the burners do not light there is a 22 sec delay
52. f test dial to obtain cu ft of gas flow per hour pressure as specified in Table 5 Turn adjusting screw 7 Multiply result of Step 5 by Btu heating value of gas to obtain clockwise to increase manifold pressure or turn adjusting total measured input in Btuh Compare this value with heating screw counterclockwise to decrease manifold pressure input shown in Table 5 Consult the local gas supplier if the 7 Replace cover screw heating value of gas is not known 8 Turn off gas to unit Remove manometer from pressure tap EXAMPLE Assume that the size of test dial is 1 ft one Replace pipe plug on gas valve then turn on gas to unit Check revolution takes 32 sec and the heating value of the gas is 1050 for leaks Btu ft Proceed as follows CHECK BURNER FLAME 1 32 sec to complete one revolution With burner access panel removed observe the unit heating 2 3600 32 112 5 operation Watch the burner flames to see if they are light blue and 3 soft in appearance and that the flames are approximately the same 3 112 5 x 1 112 5 ft of gas flow hr for each burner Propane will have blue flame with yellow tips 4 112 5 x 1050 2 118 125 Btuh input See Fig 14 Refer to the Maintenance section for information on If the desired gas input is 115 000 Btuh only a minor change in the burner removal manifold pressure is required Observe manifold pressure and proceed as follows to adjust gas input 17 Table 6 Air Delivery CFM at In
53. galas lt Carrier RE HEATING amp COOLING 48JZ N 024 060 Single Packaged Gas Heating Electric Heat Pump Units With 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 CONSIDERATIONS esee eeeeeertntnnntnnnn 1 enentnn tuens 2 RECEIVING AND INSTALLATION 2 CHECK EQUIPMENT thon etn 2 IDENTIFY 2 INSPECT PROVIDE UNIT SUPPORT ROOF CURB SLAB MOUNT GROUND MOUNT FIELD FABRICATE DUCTWORRK serere PROVIDE 4 RIG AND PLACE UNIT 6 CONNECT CONDENSATE INSTALL FLUE INSTALL GAS PIPING a INSTALL DUCT CONNECTIONS 9 CONFIGURING UNITS FOR DOWNFLOW VERTI CAL DISCHARGE sse INSTALL ELECTRICAL CONNECTIONS HIGH VOLTAGE CONNECTIONS sees SPECIAL PROCEDURES FOR 208 V OPERATION 1 1 CONTROL VOLTAGE CONNECTIONS l HEAT ANTICIPATOR SETTING TRA
54. heel orientation assembly out Be careful not to tear insulation in blower b Lift wheel from housing When handling and or cleaning compartment blower wheel be sure not to disturb balance weights clips d Ensure proper reassembly by marking blower wheel and on blower wheel vanes motor in relation to blower housing before disassembly c Remove caked on dirt from wheel and housing with a e Loosen setscrew s that secures wheel to motor shaft brush Remove lint and or dirt accumulations from wheel Remove screws that secure motor mount brackets to and housing with vacuum cleaner using soft brush attach housing and slide motor and motor mount out of housing ment Remove grease and oil with mild solvent 2 Remove and clean blower wheel as follows d Reassemble wheel into housing 23 060 50 Hz COOLING CHARGING CHART For use with units using R410a Refrigerant i H fm w v 600087 Fig 25 Cooling Charging Chart 4842060 Units INDUCED DRAFT MOTOR MOUNT o EL A B cL X 4 i E LE SWITCH VENT HOOD FLI IN SHIPPING BLOWER BURNER MOUNTING LOCATION BOX HOUSING RACK SCREW 99022 Fig 26 Blower Housing and Flue Collector Box Reassemble motor into housing Be sure setscrews are tightened on motor shaft flats and not on round part of shaft f Reinstall blower panel and unit access panel 3 Restore electrical power to un
55. ion of unit HEAT ANTICIPATOR SETTING The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance Set the heat anticipator using an ammeter between the W and R terminals to determine the exact required setting NOTE For thermostat selection purposes use 0 18 amp for the approximate required setting Failure to make a proper heat anticipator adjustment will result in improper operation discom fort to the occupants of the conditioned space and inefficient energy utilization however the required setting may be changed slightly to provide a greater degree of comfort for a particular installation TRANSFORMER PROTECTION The transformer is of the energy limiting type is set to withstand 30 sec overload or shorted secondary condition LEGEND FLA Full Load Amps LRA Locked Rotor Amps C US MCA Minimum Circuit Amps CKT BKR Circuit Breaker RLA Rated Load Amps NOTES 1 In compliance with NEC National Electrical Code requirements for muitimotor 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 60 copper wire If other than 60 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 imb
56. it 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 28 24 FRONT ACCESS ee 99091 EFH BLOWER gt HOUSING scam ttl Pt 443 2 SETSCREWS HIDDEN C99085 Fig 28 Removai of Motor and Blower Wheel 3 Remove the 12 screws hoiding the flue collector box cover See Fig 26 28 amp 29 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 rnotor and wheel as follows 1 Remove unit access panel See Fig 27 2 Remove the 7 screws that attach induced draft motor mount ing plate to blower housing See Fig 26 amp 28 Fig 29 Burner Rack Removed 3 Slide the motor and
57. k the unit for proper cooling control operation as follows 1 Place room thermostat SYSTEM switch in OFF position Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FAN switch is placed in AUTO position 2 Place SYSTEM switch in COOL position and FAN switch in AUTO position Set cooling control below room temperature Observe that compressor outdoor fan and indoor blower motors start Observe that cooling cycle shuts down when control setting is satisfied The indoor fan will continue to run for 30 sec 3 When using an auto changeover room thermostat place both SYSTEM and FAN switches in AUTO positions Observe that unit operates in Heating mode when temperature control is set to call for heating above room temperature and operates in Cooling mode when temperature control is set to call for cooling below room temperature 19 COMPRESSOR ROTATION On 3 phase units with scroll compressors it is important to be certain compressor is rotation in the proper direction To determine whether or not compressor is rotating in the proper direction 1 Connect service gages to suction and discharge pressure fittings 2 Energize the compressor 3 The suction pressure should drop and the discharge pressure should rise as is normal on any start up If the suction pressure does not drop and the discharge pressure does not rise to normal levels 1 Reverse any two of th
58. lash 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 OUTDOOR FAN CAUTION Keep the outdoor 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 outdoor motor 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 f fan needs to be removed loosen the setscrew and slide the fan off the motor shaft 5 When replacing fan blade position blade so the hub is 1 8 in away from the motor end 1 8 in of motor shaft will be visible See Fig 12 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
59. ll be observed If it is desirable to observe a complete defrost in warmer weather the defrost thermostat must be closed as follows 1 Turn off power to outdoor unit and install lock out tag 2 Disconnect outdoor fan motor lead from OF2 on control board See Fig 30 Tape to prevent grounding 3 Restart unit in Heating mode allowing frost to accumulate on outdoor coil 4 After few minutes in Heating mode liquid line temperature should drop below closing point of defrost thermostat ap proximately 30 F NOTE Unit will remain in defrost until defrost thermostat reopens at approximately 80 F coil temperature at liguid line or remainder of defrost cycle time Turn off power to outdoor and reconnect fan motor lead to OF2 on control board after above forced defrost cycle Defrost Thermostat The detrost thermostat signals heat pump that conditions are right for defrost or that conditions have changed to terminate defrost It is a thermally actuated switch clamped to outdoor coil to sense its temperature Normal temperature range is closed at 30 3 F and open at 80 5 F FEEDER TUBE J STUB TUBE DEFROST THERMOSTAT 699029 Fig 31 Defrost Thermostat NOTE The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible Check Defrost Thermostat There is a liquid header with a brass distributor and feeder tube going
60. nals 5 Never attempt to repair brazed connection while refrigerant system is under pressure 6 Do not use torch to remove any component System contains oil and refrigerant under pressure To remove component wear protective goggles and proceed as fol lows a Shut off gas supply and then electrical power to unit and install lock out tag 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 1 Remove access panel 2 Read and follow instructions on all WARNING CAUTION and INFORMATION labels attached to or shipped with unit 3 Make the following inspections a Inspect for shipping and handling damages such as broken lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a refrigerant leak c Leak test all refrigerant tubing connections using electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected see the Check for Refrigerant Leaks section d Inspect all field and factory wiring connections Be sure that connections are completed not rubbing agai
61. ning the ground joint union 7 Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit OUT NIPPLE CAP C99020 Fig 8 Sediment Trap CAUTION Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connect ing improperly routed rigid gas piping to the gas valve Use backup wrench on the square neck of the inlet side of the gas valve when making connection to avoid strain on or distortion of the gas control piping CAUTION If a flexible conductor is required or allowed by the authority having jurisdiction black iron pipe shali be installed at the gas valve and shall extend a minimum of 2 in outside the unit casing A 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 serious 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 connections
62. nit 48JZ 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 80083 ab Printed in U S A Form 482 151 Pg 1 10 01 Replaces New A WARNING Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning fire or an explosion which can result in serious injury death 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
63. nst any sharp sheet metal edges or refrigerant tubing and are 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 serious injury or death 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 outdoor fan blade is correctly positioned in fan orifice Leading edge of outdoor fan blade should be 1 2 in maximum fan orifice c Ensure fan hub is 1 8 in maximum trom motor housing See Fig 12 d Make sure that air filter s is in place e Make sure that condensate drain trap is filled with water to ensure proper drainage MOTOR FAN GRILLE 1 8 3 175mm MAX BETWEEN MOTOR AND FAN HUS MOTOR SHAFT Fig 12 Fan Blade Clearance f Make sure
64. nual and the following procedures NOTE Unit panels must be in place when unit is operating during charging procedure 1 No Charge Use standard evacuating techniques After evacu ating system weigh in the specified amount of refrigerant Refer to Table 1 2 Low Charge Cooling Using Cooling Charging Charts Fig 20 25 vary refrigerant until the conditions of the appropriate chart are met These charging charts are different from type normally used Charts are based on charging the units to the correct superheat for various operating conditions Accurate pressure gauge and temperature sensing device are required Connect the pressure gauge to the service port on the suction line Mount the temperature sensing device on the suction line and insulate it so that outdoor ambient temperature does not affect the reading Indoor air CFM must be within the normal operating range of the unit 3 Using Cooling Charging Charts Compare outdoor air tem perature F db and the suction line pressure psig and temperature with corresponding charging chart See Fig 20 25 ACCUMULATOR COMPAESSOR LEGEND HPS High Pressure Switch LCS Loss of Charge Switch 2155 Accurater Metering Device 4 Arrow indicates direction of flow Metering Position 00095 Fig 18 Typical Heat Pump Operation Heating Mode EXAMPLE Fig 20 Outdoor Temperature 85 Suction Pressure 145 psig Suction Temperat
65. oSt BOARD x IMEAMOSTAT COOLIM ort DIFROS TM XMOSTAT THE AWOSTAT CATING DL HUM DIE CATION TAAN TRANSI OMH DEFROST RELAY FiCLO SELECTABLE OPTIONS TOR Time PERIOD Qon ONEM u BETWC CM SCEROST CTCLLS nito COMPRESSOR seti Smut OFF FOR 38 SCC OV DEFROST brsconmecy DELTIATION AND TEAMUNATION EM OJICT SWIFT ON PUR ACC LCD sHtO JVUPERTD PEST PINS COSC META OBJECT w FIULO SPEED UP CICLE MOMENTANOQY SHORT PINS APA RILCASE TO BYPASS COMPAL 5508 OFF BELAT 2 8041 SIC AND R LEASC FOR FORCED DEFROST 3 PEMMANCNI SHORT RILL BC 1GNOR B IF Ant OF ORIGINAL WIES FURNI SKID ANC REPLAC O 31 OC ALPLACER 28 C WIRE 11 5 Cosivactuj SUL PRICE PLGCS TOR ToC MMOSTAl AnD USE 05 COPPAR CONDUCTORS TOR 10 PESTA LATION APES CUSCONMECT FIRE FROM ARE 2 iTw OM WIEN SPL B DISCOMMICT RCO mial f 10 awo COMNECT BLE WIRE 100 ira FON IPLLO DISCORNICE miti FlOM toC be AND CONPICE buy me aM ifu 1 TEMMINATE 1w 39 SCC IF 077 OPEN A MASS ATION DASRID ES iKOICATE COMPONENTS DEFROST WILL ur as onmes LOCATIO BAUD SAICIIAL BLOWER DEFROST WILL WOMMALLY If DET 13 CLOSED 487500002 UTTUO Fig 16 208 230 3 60 Wiring Diagram Units 48 2 Whenthe gas supply being used has a different heating value or specific gravity refe
66. oose from its anchorage have it examined by transportation inspectors before removal Forward claim papers directly to transportation company Manu facturer is not responsible 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 ail 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 SEAL STRIP MU
67. outer edge C B 11 279 16 1 2 419 28 3 4 730 28 3 4 730 40 1 4 1022 40 1 4 1022 17 3 8 441 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 Fig 4 Roof Curb Dimensions CAUTION Do not restrict outdoor coil airflow An air restriction at either the outdoor air inlet or the fan discharge can be detrimental to compressor life The outdoor fan pulls air through the outdoor coil and discharges it through the top cover Be sure that the fan discharge does not recirculate to the outdoor coil Do not locate the unit in either 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 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 C00070 CORNER WEIGHTS SMALL CABINET Comerwegn 52 605 CORNER WEIGHTS LARGE CABINET Total weight 380 409 060 Model 48 2 ComerWei3 49 980 995 Comer wema sa 48 Model 48JZ 193
68. performing service or maintenance operations on unit turn off gas supply to unit Then tum off unit main power switch and install lock out tag Electrical shock or explosion could cause serious injury or death Recognize safety information This is the safety alert symbol A 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 instructions as a minimum for a safe installation INTRODUCTION The 4812 unit See Fig 1 is a fully self contained combination electric heat pump unit with gas fired back up heat designed for outdoor installation See Fig 2 and 3 for unit dimensions All unit
69. quence of operation is as follows 1 When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat the thermostat completes circuit between thermostat terminal to terminals Y and These completed circuits through the thermostat 2 O terminal energizes Reversing Valve RV through Defrost Board DB Nore The RV remains energized while the Thermidistat cooling mode is selected 3 Y terminal energizes DB Y After 5 minute time delay of DB terminals T1 amp T2 has expired if LPS and HPS safety switches are closed Compressor contactor is energized start ing the compressor and outdoor fan motor 4 G terminal energizes BM terminal of Integrated Gas Control IGC and the indoor motor starts NOTE Once the compressor has started and then stopped it should not be started again until 5 minutes have elapsed The cooling cycle remains on until the room temperature drops to a point that is slightly below the cooling control setting The thermostat opens the circuit between thermostat terminal R to terminals Y and These open circuits de energize contactor coil C and BM of the IGC The outdoor and compressor motors stop After a 30 sec delay the blower motor stops The unit is in a standby condition waiting for the next call for cooling from the room thermostat CHECKING COOLING CONTROL OPERATION NON ICM UNITS Start and chec
70. r to national and local codes or contact your distributor to determine the required orifice size 15 SCHEMATIC 208 230 1 60 LEGEND Ario coute Tun O Fest SEU enn SEA a nH wale CETECT 518509 FIELD COMO itia 46 re ae CONT MUR TROWCED Raf voton 10 Com fam MOTOR NM INTGGRATED GAS UNIT tX LUI CORIACTON CAPACITOR COMPETE SSOR MOTOR Combustion MELAT COMPAL 5509 Tol DELAT iO OThOST BOARD 50016 TRANSI OMEA pravi per SPLICE 80 THERMEORSTAT 2 0 m tone CEE wa laid EH COOLING FAN LOGIC CHENGI2ED OE ERLMIZED MEATING FAN LOGIC Aaf OF ME OAG BINE FURNISHED ANE REPLACED C SOL O8 M5 ERE 2 WE PDCE PAGES FOR INTRMOSIAI AWO SABANI SUSE TY OLGOLE COPPER COnCUCTORS FOM FIELD VES ERLERTION EPLICA LOM WU TAGE LUIS 0 90 gt FUSES s JI PEN USING PHEAWIDISIANA PUIGIJILI B x01 10 MORE AEC AMD LOCAL COOLS ai CO PMKUSON Oni ACSEE DISET im OMe Can CASEG Bir sinar Pe SONG THOS OB TAIS IS wL MCOUIBE MCT FAT UNIT COMPOWENT ARRANGEME OUTDOOR FAR Kc COMPRI SSOR SECTION FOR 022 060 UNITS won COMP PLA 5 Pla
71. rged 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 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 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 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 29 SYMPTOM Compressor and outdoor fan will not start Compressor will not start but outdoor fan runs Compressor cycles other than normally satistying thermostat Compressor operates continuously Excessive head pressure He
72. rotational device prevents the scroll from turning backwards and replaces the need for a cycle protec tor The pressure relief port is a safety device designed to protect against extreme high pressure The relief port has an operating range between 550 and 625 psi differential pressure The Copeland scroll compressor uses Mobil 3MA POE oil This is the only oil allowed for oil recharge REFRIGERANT SYSTEM This information covers the refrigerant system of the 4817 including the compressor oil needed servicing systems on roofs containing synthetic materials the filter drier and refrigerant charging Refrigerant A 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 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
73. that all tools and miscellaneous loose parts have been removed 5 Compressors are internally spring mounted Do not Joosen or remove compressor hold down bolts 6 Each unit has 2 schrader type ports one low side located on the suction line and one high side located on the compressor discharge line Be sure that caps on these ports are tight 7 This unit has High Flow Valves located on the compressor hot gas and suction tubes Large black plastic caps with O rings distinguish these valves These valves cannot be accessed for service in the field Ensure the plastic caps are in place and tight or the possibility of a refrigerant leak could occur MANIFOLD PIPE PLUG C99019 Fig 13 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 systern pressure has been relieved and reclaimed from both high and low pressure ports 2 Repair leak following Refrigerant Service procedures NOTE Install a bi flow filter drier suitable for use with Puron R 410A whenever the system has been opened for repair 3 Add a small charge of R 410A refrigerant vapor to system and leak test unit 4 Recover refrigerant and evacuate system to 500 Microns if additional leaks are not found 13 BURNER FLAME Fig 14 Monoport Burner 5 Charge unit with R 410A refrigerant using volum
74. tructure or nearby This is a UL Requirement WARNING AN 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 damagad if the necessary precautions are not taken IMPORTANT Refer to Table 12 Troubieshooting Guide Heating for additional troubleshooting analysis LEGEND IGC Integrated Gas Unit Controller LED Light Emitting Diode START UP CHECKLIST Remove and Store in Job File I PRELIMINARY INFORMATION MODEL NO sedare te ie breite eei intra D ee n SR Rer VER TENER AR EN UN eae eres recede nes Cd M H II PRE START UP insert checkmark in box as each item is completed I Been VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS MAKE SURE THAT ON 060 SIZE ONLY THE TWO WIRE TIES FASTENED TO THE OUTDOOR COILS AND REVERSING VALVE ACCUMULATOR ASSEMBLY HAVE BEEN REMOVED VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR AIR FILTER IS CLEAN AND IN PLACE VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS SET OUTDO
75. ult Use 18 American Wire Gage AWG color coded insulated 35 C minimum wires to make the control voltage connections between the thermostat and the unit If the thermostat is located more than 100 ft from the unit as measured along the control voltage wires use no 16 AWG color coded insulated 35 C minimum wires Dual fuel thermostat or Thermidistat M control is required for proper operation of the dual fuel heat pump unit Be sure to follow the instructions supplied with the thermostat and control Standard Connection Remove knockout hole located in the flue panel adjacent to the control access panel See Fig 2 and 3 Remove the rubber grommet from the installer s packet included with unit and install grommet in the knockout opening Provide a drip loop before running wire through panel 1 FUSE OR BKR Run the low voltage leads from the thermostat through the inlet hole and into unit low voltage splice box Locate five 18 gage wires leaving control box These low voltage connection leads can be identified by the colors red green yellow brown and white See Fig 11 Ensure the Jeads are long enough to be routed into the low voltage splice box located below right side of control box Stripped yellow wire is located in connection 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 operat
76. ure should be 70 Suction Temperature may vary 3 F 4 Using a tolerance of 3 F add refrigerant if actual temperature is more than 3 F higher than proper suction tube temperature or remove refrigerant if actual temperature is more than 3 F lower than required suction tube temperature Recheck the readings as charge is adjusted 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 CAUTION 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 10 shows both heating and cooling airflows at various external static pressures Refer to these tables to determine the airflow for the system being instailed NOTE Be sure that all supply and return air grilles are open free trom obstructions and adjusted properly 4 WARNING Before changing blower speed shut off gas supply Then disconnect electrical power to the unit Electrical shock or explosion can cause serious injury or death Airflow can be changed by changing the lead connections of the blower motor All 48JZ units are factory wired for low speed and may need to be wired
77. verflowing 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 condensate connection This prevents the drain from overtlowing 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 t in for every 10 ft of horizontal run Be sure to check the drain tube for leaks 1 25mm MIN 4 2 80mm MIN C99013 Fig 7 Condensate Trap Step 7 INSTALL FLUE HOOD The flue hood assembly is shipped screwed to the coil panel in the indoor blower compartment Remove the service access panel to locate the assembly 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 Install the flue hood as follows 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
78. ving a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system PURON R 410A REFRIGERANT CHARGING Refer to unit information plate and charging chart Some R 410A refrigerant cylinders contain a dip tube to allow liquid 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 TROUBLESHOOTING Use the Troubleshooting Guides See Tables 11 13 if problems occur with these units START UP CHECKLIST Use the Start Up Checklist to ensure proper start up procedures are followed HEAT PUMP WITH PURON 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 positioned upside down to allow liquid to flow Recovery cylinder service pressure rating must be 400 psig DOT 48 400 or DOT BW400 Puron systems should be cha

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