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Carrier 48EZ(N)-A User's Manual

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1. ris SCHEMATIC 1 IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT tf 208 230 1 60 2 SEE PRICE PAGES FOR THERMOSTATS at 3 USE 15 DEG COPPER CONDUCTORS FOR FIELD INSTALLATION ak BK BK 4 SEE INSTALLATION INSTRUCTIONS FOR PROPER HEATING AND LN Bk PAR yoy COOLING CONNECTIONS FOR YOUR UNIT INDOOR FAN MOTOR SG T PLUGS DO NOT DISCONNECT UNDER LOAD DO 5 ON SMALL MODELS 151 AND 152 WIRED 7 Hy CF IN SERIES LARGE BASE MODELS HAVE LS1 ONLY BK KE com 6 INDUCER CAPACITOR AND WIRING ON CERTAIN MODELS ONLY ym IF IS PRESENT YELLOW WIRES FROM IGC AND IDM CONNECT ON SAME SIDE OF CAP2 BLD 7 THIS FUSE 15 MANUFACTURED BY LITTELFUSE P N 257003 COMPRESSOR PLU 8 THIS FUSE 15 NANUFACTURED BY LITTELFUSE P N 257005 BK LEGEND N DR DEFROST BOARD RELAY BK
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3. 3D UNIT COMPONENT ARRANGEMENT L3 SIE TA USE COPPER CONDUCTORS ONLY e L 12 BK FIELD SUPPL 208 230 VAC 60 HZ 3PH COMPRESSOR INDOOR FAN CONTROL BOX AREA 11 SECTION SECTION LS1 LARGE 23 13 LS2 SWALL 166 TRAN CCH e ou E ox IF USED 23 T is cr 110 e BK BK 11 CAP 2 DB OFM 6 BK O O BK BKY Ro Y COMP z P ud GAS F SECTION ne 151 BK 23 SMALL FS CABINET T3 BL T1 T3 y COMP 11C BK gt 23 6 1 4 IGC T7 L1 CR CH 156 11 O BK CH FO 12 BR Y Y 23 BIN CAP2 Jel exem SEE NOTE 7 SEE NOTE 5 2 COM IFB R SA SECONDARY 24 2 n a ns 01 e IFB Fuse a SEE NOTE 6 x id P2 1 PC R RT FUSE 5 t R OP1 7 R 777 P2 2 C O BR Qc FS m BL T STAT 1 FS m OP1 8 0 O Orc 9 P2 4 R O R 5 Sa R R OP1 1 R 55 v4 R vo w OP1 6 W2 Quee 0 ty 5 DB C EX ES 1 2 4 Q Gad 6 OP1 4 6 IF USED 5 BK BR DB C W T OP1 6 W Q 9 0 9 Oc ER zi lt 4 x R1 W Eo DH 1 5 er BR OI 2 y 1 y W SEE NOTE 10 __ 8 1
4. 29 esi Em 927 166 9 9 222 198 W42 Do esi 4o enig M01 VN VN VN VN VN VN VN VN VN esi mm ES 864 059 791 Do 9c c ke 61 2 esi 4o xoelg Lv LY 26 ve Le VN esi 079 LEZ 818 188 696 920 2911 Do 6c Sc 0c 81 2 est 40 YBIH pew 29 Sv Ov 96 66 06 est Em RES 277 224 299 692 078 216 6001 VN VN VN VN 62 92 22 02 8 Sune T da peu 2987 29 42 65 96 ce 1009 08 62 9 9 789 PLL 168 LEG W49 Do 8c Sc 0c est IS Sv 6 9 est Em 927 166 9 9 222 198 W42 Do 9c 42 est 4o enig mol VN VN VN VN VN VN 95 9v 07 est 864 059 ysl W49 60 80 90 0 vo ro 43385 55 211 16 TVNH31X3 YOLOW 3SIH 09 748 HUN L 19
5. 0 Bulsuas Aq pinbr ay 5 Z or e 4 y e Aq 44 ainseay NN buibjeu5 v6 1 726 84 81 01 61 9 01 61 090 66 21 LOL 8L SOL 6L 601 oz 211 oz 870 ewe west Uer we _ we 62 vL 28 SL 99 SLL Ly soL ainssald aunssald 2216 4 pasinbay 2 4 juerquiy 0 gt 10 eur pasinbay 2 4 pasinbay 6 8 Z 11 9 SL vL 42 9c 9 vc 6 8 9 S 9 or oocc A08019 31 Fig 16 Cooling Charging Table Subcooling 48EZ MAINTENANCE To ensure continuing high performance and to minimize the possibility of premature equipment failure periodic maintenance must be performed on this equipment This combination heating cooling unit should be inspected at least once each year by a qualified service person To troubleshoot cooling or heating of units refer to Tables 12 13 and 14 NOTE Consult your local dealer about the availability of a maintenance
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8. A10207L Fig 14 Cont 208 230 1 60 Ladder Wiring Diagram Unit 48EZ A 28 CONNECTION WIRING DIAGRAM NOTES 1 IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED SCHEMATIC THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT IF USED 2 SEE PRICE PAGES FOR THERMOSTATS 208 230 3 60 3 USE 75 DEG COPPER CONDUCTORS FOR FIELD INSTALLATION BK DB 4 SEE INSTALLATION INSTRUCTIONS FOR PROPER HEATING AND COOLING aeria aul s 5 THIS FUSE IS MANUFACTURED BY LITTELFUSE 257003 BK CEHO BK OFM COLO
9. do 9r Lv 9v Sb vv ev Lv Ot 2621 798 5061 0861 9202 2902 VN VN Le 0 62 82 82 4o peu 1 89 738 VN VN 6S 29 99 vs 55 19 09 1009 0 1851 2271 2161 5961 1091 2791 9691 9541 VN VN VN VN VN VN VN VN 4o VN VN VN VN VN VN VN VN 09 VOLL bebe 2611 8121 4961 1971 VN VN VN VN VN VN VN VN VN 4o enig MO VN VN VN VN VN VN VN VN VN ost 0801 QELL 2211 vec 5921 LLEL 1981 ZOvL 12 02 VN VN VN VN VN VN VN 4o yori 9 96 VN VN VN VN VN VN VN 2081 206 1661 0 02 2022 6922 9022 bez 12 02 61 VN VN VN VN VN do 9 9 9 56 VN VN VN VN VN 64L 7981 5061 0861 9202 2902 22 92 92 Gz ve ve 4o peu 0608579 738 6t 8v Sb 22 ev Lv Ot 6 1099 SE 1851 2271 2161 5961 1091 2 91 9691 9541 ve ze Le 62 62 82 22 92 9 65 29 SG es 25 05 9r
10. 48EZ N A Comfort 13 SEER Single Packaged HYBRID HEAT Dual Fuel System with Puron R 410A Refrigerant Single and Three Phase 2 5 Nominal Tons Sizes 24 60 turn to the experts f Installation Instructions NOTE Read the entire instruction manual before starting the installation NOTE Installer Make sure the Owner s Manual and Service Instructions are left with the unit after installation TABLE OF CONTENTS PAGE SAFETY CONSIDERATIONS 1 2 INTRODUCTION eperera skopert EEP ooo pee 2 RECEIVING AND INSTALLATION 2 13 Check Equipment nna 2 Identify Unit ooh eee E ens 2 Inspect Shipment 2 cece eee eee eee es 2 Provide Unit Support 2 Roof Curb t eR tile Cee ee 2 Slab 2 Field Fabricate Ductwork 6 Provide Clearances 4 2 eer ee 6 Rig and Place Unit 6 Connect Condensate Drain 7 Install Flue 2 2 22 2 4 4 7 Install Gas Piping se 7 Install Duct Connections 9 Configuring Units for Downflow Vertical Discharge 9 Install Electrical Connections 12 High Voltage Connections 12 Special Procedures for 208 V Operation 12 Control V
11. 07387 7907 81 GEJE v 098 0101 8 1 27 9 691 258 09 1 02 802 08 090 070 724 2238 MET nS 1 A X 99 81 SOILSIYILIVYYHI LINA WA NI ALIAYY9 30 8314342 WH NT LHOI3H LINN LM LINN 191819313 8 6 2 4330 2 221 8 L X L 4N 11611 776 131100 NIVNQ 09450 imensions Fig 2 48EZ A24 36 Unit D 07 lt 9210067 387 TAN 1 MAA 3965 2561 179961 Ly 26 1 fag ye BIC ANINI SYD 8 1 1 8 5 61 98 1 Jed DIR BAL 7181 9LL oo oo 891 8 6 9 E DNINUO NIN340 e 1910 0v Nun Bu 114405 8 1 51 I WA NI C1 NI SNOISNAWIO Q3SINOHdNOO 38AVW 3ONVNHOJU3d WALSAS N3HL N31SAS TIVM 87702 ZL 5531 030V ld SI LINN JI S3ONVISIQO WDNININ anv Lona 777791210 31150440 3015 EEPE LINN S1N3A3UIQ03H JIN 303 143013 quse 3015 AYINI 83404 71015 593009 1102 dYA3 CNN S3HONI SNIOIAH3S ONY NOLIVH3dO 3ONVHVY3TO AMLIN3 1081802 310H VIO 2 22 u AHIN3 304 OM 14 9 82 8 211 1NOHJ 9 G221 91 8 87 Vd 55122 91315313 TANYd 338018 8 1 7 8
12. 1 Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit If the skid is not available use a spreader bar of sufficient length to protect the unit from damage 2 Attach shackles clevis pins and straps to the base rails of the unit Be sure materials are rated to hold the weight of the unit See Fig 5 3 Attach a clevis of sufficient strength in the middle of the straps Adjust the clevis location to ensure unit is lifted level with the ground After the unit is placed on the roof curb or mounting pad remove the top skid Step 6 Connect Condensate Drain NOTE When installing condensate drain connection be sure to comply with local codes and restrictions Model 48EZ A disposes of condensate water through a 3 4 in NPT fitting which exits through the compressor access panel See Fig 2 and 3 for location Condensate water can be drained directly onto the roof in rooftop installations where permitted or onto a gravel apron in ground level installations Install a field supplied condensate trap at end of condensate connection to ensure proper drainage Make sure that the outlet of the trap is at least 1 in 25 mm lower than the drain pan condensate connection to prevent the pan from overflowing See Fig 6 Prime the trap with water When using a gravel apron make sure it slopes away from the unit If the installation requires draining the condensate water a
13. I6C BR OR Er C SEE NOTE 11 2 Y Y NES Lw NON SEE NOTE 4 SEE NOTE 8 IFB HIGH C SEE NOTE 4 R w COM GY GAS HEAT Q ed ry IFB P1 2 ECON ae 1 a cet Tah HARNESS p f 2 Y X Pm 3 5 4 BR 5 BK Ly 2 6 OY SEE NOTE 9 COM C 8 0 A10208L Fig 15 Cont 208 230 3 60 Ladder Wiring Diagram Unit 48EZ A 30 072 2120092308 au uey S y 6 lt lt lt enjeA ay uey 5 pasnseaw au PPY 8 Buioooqns 10 pinbi7 ay ay 650126 peay abseyosig 10559 05 ay jo ainssald paunseeui ay ay Bulpuodsaiio9 anjeA Y 9 e 99 991 G ay pue ezis ay uo peseq e qej y ui au 0 1949Y Y y 3 991 os Buisues ay
14. 36 7 OUTDOOR COIL INDOOR COIL gt Metering Position gt gt J 3 LCS 5 a 5 e lt x gt gt SEU o D Wi rT Position LEGEND HPS High Pressure Switch LCS Loss of Charge Switch 20 AccuraterMetering Device Arrow indicates direction of flow C03011 Fig 25 Typical Heat Pump Operation Cooling Mode SN OUTDOOR COIL INDOOR COIL mum f TXV in Bypass Position A 3 Ly 5 Los Fm 5 5 HPS T Oei 8 XU Metering Position LEGEND HPS High Pressure Switch LCS Loss of Charge Switch Q3 3 Device Arrow indicates direction of flow C03012 Fig 26 Typical Heat Pump Operation Heating Mode WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage This system uses Puron R 410A refrigerant which has higher operating pressures than R 22 and other r
15. mm IN mm IN mm IN mm Small 10 254 32 4 822 30 6 778 TI Num zs Large 14 356 1 42 2 1072 CPRFCURB013A00 14 356 1116 NOTES 1 Roof curb must be set up for unit being installed 2 Seal strip must be applied as required to unit being installed 3 Roof curb is made of 16 gauge steel 4 Attach ductwork to curb flanges of duct rest on curb 5 Insulated panels 1 in 25 4 mm thick fiberglass 1 16 density IMPORTANT Do not install large base pan HYBRID HEAT units onto curb check the Y distance in the product literature dimensional drawing the small base pan common curb The center of gravity on a large base to ensure that Y is greater than 14 in 356 mm Do not install any large pan HYBRID HEAT unit could overhang the curb causing an unsafe base pan unit onto the common curb with a Y dimension center of condition Before installing any large base pan unit onto the common gravity less than 14 in 356 mm Fig 4 Roof Curb Dimensions 48EZ A A CAUTION NOTICE TO RIGGERS A PRUDENCE AVIS AUX MANIPULATEUR ACCESS PANELS MUST BE IN PLACE WHEN RIGGING PANNEAUX D ACCES DOIT ETRE EN PLACE POUR MANIPULATION Use top skid as spreader bar Utiliser la palette du haut comme barre de r partition MINIMUM HEIGHT 36 914 4 mm HAUTEUR MINIMUM UNIT HEIGHT HAUTEUR D UNITE SEE DETAIL A VOIR DETAIL A SEAL STRIP MUSTBEIN BANDE SCELLANT DOIT ETRE PLACE BEFORE
16. 2 Remove pipe plug on manifold See Fig 11 and connect manometer Turn on gas supply to unit 3 Record number of seconds for gas meter test dial to make one revolution 4 Divide number of seconds in Step 3 into 3600 number of seconds in one hr A07679 Fig 11 Burner Assembly 5 Multiply result of Step 4 by the number of cubic feet cu ft shown for one revolution of test dial to obtain cubic feet cu ft of gas flow per hour 6 Multiply result of Step 5 by Btu heating value of gas to obtain total measured input in Btuh Compare this value with heating input shown in Table 3 Consult the local gas supplier if the heating value of gas is not known 15 48EZ A EXAMPLE Assume that the size of test dial is 1 cu ft one revolution takes 32 sec and the heating value of the gas is 1050 Btu ft Proceed as follows 1 32 sec to complete one revolution 2 3600 32 112 5 3 112 5 x 1 112 5 ft of gas flow hr 4 112 5 x 1050 118 125 Btuh input If the desired gas input is 115 000 Btuh only a minor change in the manifold pressure is required Observe manifold pressure and proceed as follows to adjust gas input 1 Remove regulator cover screw over plastic adjustment screw on gas valve See Fig 12 2 Turn plastic adjustment screw clockwise to increase gas input or turn plastic adjustment screw counterclockwise to decrease input See Fig 12 Manifold pressure must be between 3 2 and
17. on tags stickers and labels attached to the equipment and any other safety precautions that might apply Training for operators of the lifting equipment should include but not be limited to the following 1 Application of the lifter to the load and adjustment of the lifts to adapt to various sizes or kinds of loads 2 Instruction in any special operation or precaution 3 Condition of the load as it relates to operation of the lifting kit such as balance temperature etc Follow all applicable safety codes Wear safety shoes and work gloves Inspection Prior to initial use and at monthly intervals all rigging shackles clevis pins and straps should be visually inspected for any damage evidence of wear structural deformation or cracks Particular attention should be paid to excessive wear at hoist hooking points and load support areas Materials showing any kind of wear in these areas must not be used and should be discarded 4 WARNING UNIT FALLING HAZARD Failure to follow this warning could result in personal injury or death Never stand beneath rigged units or lift over people 4 WARNING PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury death or property damage When straps are taut the clevis should be a minimum of 36 in 914 mm above the unit top cover Rigging Lifting of Unit See Fig 5 Lifting holes are provided in base rails as shown in Fig 2 and 3
18. 1 8 1 1 18786111 ly y 01 1102 8000110 v TANYd 84055384802 305 1 41 722111 8 1 77 4330 2 22 8 L X L d N L 6L 9 8 1371110 NIVUQ 19706011 99901 3015 AYINI 83404 553273805 43080089 MI mm ems 33H10 SYM 31382802 NO 32018 ANY LINN a eee 1 1078161 96777 3018 AYINI 83404 53273515 03084008980 ANY LINN 4 o 9 9901 qp ao ets tem etn 3015 AYINI 83404 SLINA N33Ml3Q 1 TWN S3HONI SSONVHY3TO Gl 4 P v1 977 Utt 33NV4 107181 1 AX 10701077 LINN 30 1108 91I E 19 666 1910 31150440 3015 2 187061 2 3o 3015 Lond 2 LINN 30 401 NN S3HONI W32INONOO3 1d32X3 5 011480 UYN SIBLISNENOO OL GSYINOSY 0311 15 1 AYOLOVS 17 LNYA3138 VIVO 318 1 TIY 3100 Z 6L vLL 6 19 6 eri z ev o se 67581 9202 8902 0 1 9101 060 09V N 2387 PW esee PES ON INGO 751107999 PIJE 6 Zell 11 0 2 802 0 6 8 061 611 060 87 27387 31v EIE 1441 MENTENI 811 78512 Lole serji 5 06 8 708 6 19 0 2 802 009 060 090 29 238 7901140 1001120 M 5 9 81
19. 3 lt lt SPLICE MARKED GND GROUND PRIMARY 53 FACTORY WIRING HPS HIGH PRESSURE SWITCH 208 230V FIELD CONTROL WIRING I IGNITOR FIELD POWER WIRING IGC INTERGRATED GAS UNIT CONTROLLER Y ACCESSORY OR OPTIONAL IFB INDOOR FAN BOARD 12345 WERING IDM INDUCED DRAFT MOTOR TRAN TO INDICATE COMMON INDOOR FAN MOTOR WIRING 605 LOW GAS PRESSURE SWITCH WHEN USED SECONDARY BR BL BK LPS PRESSURE SWITCH 9 CONTACTOR PRIMARY LIMIT SWITCH 0 CAP 1 CAPACITOR COMP LS2 SECONDARY LIMIT SWITCH L Bn CAP 2 CAPACITOR INDUCER MGV GAS VALVE R CCH CRANK CASE HEATER OFM OUTDOOR FAN MOTOR jy COMP COMPRESSOR MOTOR PRS PRESSURE SWITCH SEE NOTE A CR COMBUSTION RELAY RS ROLLOUT SWITCH DB DEFROST BOARD RVS REVERSING VALVE DFT DEFROST TEMPERATURE TRANSFORNER SWITCH T STAT THERMOSTAT R SEE NOTE 7 COLOR CODE e AS BR BROWN 2l GY GRAY T Pe 6 GREEN R 1 0 ORANGE R gt A Mu W TSTAT YELLOW 1 E ys R R BR LOW BK 7 TA Y vur RN G 6 4 GAS HEAT h INDOOR BLOWER T 8L CI 24 CONNECTIONS 4 t w HIGH E Go Mice Y 0 Y 12 12 9 J2 et qz W qu d NOTE 8 Gb R RED R DLs m v EFROST BOARD DB BR at DR CTD ap C2 BL ea T 151 152 P2 BR T Y amp Y qa T
20. 3 8 IN W C REGULATOR COVER SCREW SY PLASTIC ADJUSTMENT SCREW ON OFF SWITCH 28 KES REGULATOR SPRING PROPANE WHITE NATURAL SILVER pe GAS PRESSURE LL REGULATOR INLET ll ADJUSTMENT PRESSURETAP s ISS MANIFOLD PRESSURE TAP 07751 Fig 12 Single Stage Gas Valve A WARNING FIRE AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and or property damage Unsafe operation of the unit may result if manifold pressure is outside this range 3 Replace regulator cover screw on gas valve See Fig 12 4 Turn off gas supply to unit Remove manometer from pressure tap and replace pipe plug on gas valve See Fig 11 Turn on gas to unit and check for leaks Measure Manifold Pressure Propane Units Refer to propane kit installation instructions for properly checking gas input NOTE For installations below 2 000 ft 610 m refer to the unit rating plate for proper propane conversion kit For installations above 2 000 ft 610 m contact your distributor for proper propane conversion kit Check Burner Flame With control access panel see Fig 18 removed observe the unit heating operation Watch the burner flames to see if they are light blue and soft in appearance and that the flames are approximately the same for each burner Propane will have blue flame See Fig 10 Refer to the Maintenance
21. 4 consecutive limit switch faults LED 4 flashes Inadequate airflow to unit Check the operation of the indoor evaporator fan motor and that supply air temperature rise agrees with range on unit nameplate information Ignition lockout LED 5 flashes Unit unsuccessfully attempted ignition for 15 minutes Check ignitor and flame sensor electrode spacing gaps etc Ensure that fame sense and ignition wires are properly terminated Verify that unit is obtaining proper amount of gas Pressure Switch Fault LED 6 flashes Open pressure switch Verify wiring connections to pressure switch and inducer motor Verify pressure switch hose is tightly connected to both inducer housing and pressure switch Verify inducer wheel is properly attached to inducer motor shaft Verify inducer motor shaft is turn ing Rollout switch fault LED 7 flashes Rollout switch has opened Rollout switch will automatically reset but IGC will continue to lockout unit Check gas valve operation Ensure that induced draft blower wheel is properly secured to motor shaft Inspect heat exchanger Reset unit at unit disconnect Internal control fault Microprocessor has sensed an error in the software If error code is not cleared by resetting unit power replace the LED 8 flashes or hardware IGC Temporary 1 hr auto reset Electrical interference impeding IGC softwar Reset 24 v to control board or turn thermostat of
22. 91 VN 56 Le 62 82 22 92 do enig VN 59 09 29 SG 55 19 6t Lv 2201 2201 6811 9521 1821 6821 W42 0 82 22 92 Gz ve ve 4o yori 55 19 9r Lv Sp vv t ev Lv 2081 206 1661 0 02 2022 6522 9022 vez 0 62 82 82 22 92 92 Gz Gz do UBIH pe vs 25 19 09 9r Lv 9v Sb 2621 7981 5061 0861 9202 2902 VN VN VN ve ze Le 4o peu 23 87 VN VN VN v9 29 09 65 29 SG 1099 SE 1851 2271 2161 5961 1091 2791 9691 9541 VN VN VN VN VN VN VN VN VN VN VN VN VN VN VN VN VN VN VOLL 4611 8121 4961 vOv L 2971 VN VN VN VN VN VN VN VN VN 4o enig MO VN VN VN VN VN VN VN VN VN 0801 951 2211 beck 5921 LLEL 1981 ZOvL 6 0 80 L0 90 90 20 ro 0102 43385 35NVH TINA COM aunss3ud OILVLS TVNH31X3 YOLOW 3SIH 09 PZ7V ZASP HUN jejuozrrog 3009 V ZA8v 24 V ZA8v 802 10 0
23. Check Equipment IDENTIFY UNIT The unit model number and serial number are stamped on the unit information plate Check this information against shipping papers INSPECT SHIPMENT Inspect for shipping damage before removing packaging materials If unit appears to be damaged or is torn loose from its anchorage have it examined by transportation inspectors before removal Forward claim papers directly to transportation company Manufacturer is not responsible for any damage incurred in transit Check all items against shipping list Immediately notify the nearest equipment distribution office if any item is missing To prevent loss or damage leave all parts in original packages until installation If the unit is to be mounted on a curb in a downflow application review Step 9 to determine which method is to be used to remove the downflow panels before rigging and lifting into place The panel removal process may require the unit to be on the ground Step 2 Provide Unit Support For hurricane tie downs contact distributor for details and PE Professional Engineering Certificate if required ROOF CURB Install accessory roof curb in accordance with instructions shipped with curb See Fig 4 Install insulation cant strips roofing and flashing Ductwork must be attached to curb IMPORTANT The gasketing of the unit to the roof curb is critical for a water tight seal Install gasketing material supplied with the roof curb Improperl
24. GAS HEAT SUPPLY AIR PRESSURES GAS INLET PRESSURE IN W C GAS MANIFOLD PRESSURE IN W C REFRIGERANT SUCTION PSIG SUCTION LINE TEMP REFRIGERANT DISCHARGE PSIG LIQUID TEMPT VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS GAS HEAT TEMPERATURE RISE TEMPERATURE RISE See Literature RANGE MEASURED TEMPERATURE RISE Measured at suction inlet to compressor t Measured at liquid line leaving condenser Copyright 2010 Carrier Corp 7310 W Morris St Indianapolis IN 46231 Edition Date 09 10 Catalog No 4822 085 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces 48EZ 07SI 41
25. LGPS WHEN USED NS BR Gs 9 PRS IF USED W i Pin T M HPS BI e BL o f e di D 91 sv BR Co Sm pat FS 69 Y o BR 0 0 BR GH 5n 3 c BR rh DIP SWITCH SETTINGS DEFAULT 30 MINUTES 60 MINUTES 90 MINUTES 120 MINUTES 9 123 122161123 123 123 sr JUMPERED TEST PINS USE METAL OBJECT OFF FIELD SPEED UP CYCLE F DEFAULT 1 MOMENTARILY SHORT PINS AND RELEASE TO BYPASS 2 SHORT POR 59 SEC CAND RELEASE FOR FORCED DEFROST Sho kof teh THE COMPRESSOR WILL SHUT OFF FOR 30 SEC ON DEFROST H DEFROST WILL TERMINATE IN 30 SEC IF DFT OPEN INITIATION AND TERMINATION IN THE QUIET SHIFT ON DEFROST WILL TERMINATE NORMALLY IF DFT IS CLOSED A10207C Fig 14 208 230 1 60 Connection Wiring Diagram Unit 48EZ A 27 LADDER WIRING DIAGRAM 48EZ DANGER ELE
26. Lv VOLL bebe 2611 8121 4961 vOv L 1971 9 SE Le 0 62 82 22 4o enig S9 9 09 89 99 vs 25 05 0801 951 2211 beck 5921 LLEL LSEL ZOvL 6 0 8 0 L0 90 90 vo 20 ro 0102 43335 35NVH TINA COM aunss3ud OILVLS TVNH31X3 YyOLOW 3SIH 09 7 748 HUN 8 jejuozrrog 3405 23 02 61 VN VN VN VN VN VN VN 4o yori 95 VN VN VN VN VN VN VN 7281 8961 2902 0 12 2612 9822 6552 60 Love 12 02 61 VN VN VN VN VN do 9 ZE 95 VN VN VN VN VN 59 1 0981 8881 LvGL 2861 2102 5902 8802 LELZ 22 12 12 12 02 02 02 4o peu 06009Vv N Z38 Ly Ov 0 6 9 16 Ze 9 SE 1099 SE 091 6891 0271 6921 1641 728 8981 2681 2261 W42 82 22 92 92 Gz ve ve 4o os 8v Lv 9t Sb vv ev ev Lv 8991 2091 9291 8
27. PLACING PLACE AVANT DE PLACER UNIT ON ROOF CURB L UNIT SUR LA BASE DE TOIT DETAIL A VOIR DETAIL A 50CY502286 2 0 A09051 RIGGING WEIGHTS SMALL CABINET RIGGING WEIGHTS LARGE CABINET 24 30 36 42 48 60 b kg ib kg ib kg Bn Ib kg Ib kg Ib kg Rigging Rigging Wahi 359 163 373 169 379 172 Wahi 461 209 482 219 507 230 NOTE See dimensional drawing for corner weights Fig 5 48EZ A Suggested Rigging Step 3 Field Fabricate Ductwork Secure all ducts to roof curb and building structure on vertical discharge units Do not connect ductwork to unit For horizontal applications unit is provided with flanges on the horizontal openings All ductwork should be secured to the flanges Insulate and weatherproof all external ductwork joints and roof openings with counter flashing and mastic in accordance with applicable codes 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 See unit rating plate for any required clearances around ductwork Cabinet return air static shall not exceed 25 IN W C Step 4 Provide Clearances The required minimum operating and service clearances are shown in Fig 2 and 3 IMPORTANT Do not restrict outdoor airflow An air restriction at either the outdoor air inlet or the fan discharge may be detrimental to compr
28. Provide a drip loop before running wires through panel Secure and strain relief all wires so that they do not interfere with operation of unit A gray wire is standard on 3 phase unit for connection to an economizer Balance Point Setting Thermidistat or Hybrid Thermostat BALANCE POINT TEMPERATURE The balance point temperature is a setting which affects the operation of the heating mode This is a field selected input temperature range 5 to 55 F 15 to 12 C where the Thermidistat or dual fuel thermostat will monitor outdoor air temperature and decide whether to enable or disable the heat pump If the outdoor temperature is above the balance point the heat pump will energize first to try to satisfy the indoor temperature demand If the heat pump does not make a sufficient improvement within a reasonable time period i e 15 minutes then the gas furnace will come on to satisfy the indoor temperature demand If the outdoor temperature is below the balance point the heat pump will not be allowed to operate i e locked out and the gas furnace will be used to satisfy the indoor temperature There are three separate concepts which are related to selecting the final balance point temperature Read each of the following carefully to determine the best balance point in a hybrid installation 1 Capacity Balance Temperature This is a point where the heat pump cannot provide sufficient capacity to keep up with the indoor temper
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30. and Condensate Drain Pan Inspect the outdoor coil indoor coil and condensate drain pan at least once each year The coils are easily cleaned when dry therefore inspect and clean the coils either before or after each cooling season Remove all obstructions including weeds and shrubs that interfere with the airflow through the condenser coil Straighten bent fins with a fin comb If coated with dirt or lint clean the coils with a vacuum cleaner using the soft brush attachment Be careful not to bend the fins If coated with oil or grease clean the coils with a mild detergent and water solution Rinse coils with clear water using a garden hose Be careful not to splash water on motors insulation wiring or air filter s For best results spray outdoor coil fins from inside to outside the unit On units with an outer and inner condenser coil be sure to clean between the coils Be sure to flush all dirt and debris from the unit base Inspect the drain pan and condensate drain line when inspecting the coils Clean the drain pan and condensate drain by removing all foreign matter from the pan Flush the pan and drain tube with clear water Do not splash water on the insulation motor wiring or 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 33 48EZ A BLOWER HOUSING 2 S
31. at least twice during each heating and cooling season or whenever the filter s becomes clogged with dust and or lint Indoor Blower and Motor NOTE All motors are prelubricated Do not attempt to lubricate these motors For longer life operating economy and continuing efficiency clean accumulated dirt and grease from the blower wheel and motor annually 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect and tag electrical power to the unit before cleaning and lubricating the blower motor and wheel Cleaning the Blower Motor and Wheel 1 Remove and disassemble blower assembly as follows a Remove blower access panel see Fig 18 b Disconnect 5 pin plug and 4 pin plug from indoor blower motor Remove capacitor if required c On all units remove blower assembly from unit Remove screws securing blower to blower partition and slide assembly out Be careful not to tear insulation in blower compartment d Ensure proper reassembly by marking blower wheel and motor in relation to blower housing before disassembly Loosen setscrew s that secures wheel to motor shaft Remove screws that secure motor mount brackets to housing and slide motor and motor mount out of housing 2 Remove and clean blower wheel as follows a Ensure proper reassembly by marking wheel orientation b Lift wheel from housing When handling and or cleaning blower wheel
32. be sure not to disturb balance weights clips on blower wheel vanes c Remove caked on dirt from wheel and housing with a brush Remove lint and or dirt accumulations from wheel and housing with vacuum cleaner using soft brush attachment Remove grease and oil with mild solvent d Reassemble wheel into housing e Reassemble motor into housing Be sure setscrews are tightened on motor shaft flats and not on round part of shaft Reinstall blower into unit Reinstall capacitor 32 Connect 5 pin plug and 4 pin plug to indoor blower motor g Reinstall blower access panel see Fig 18 3 Restore electrical power to unit Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles Integrated Gas Unit Controller IGC Auto Transformer 24 fuses used on 460 volt units only Hidden Interface Fan Board IFB Induced Draft Motor Fan Partition Rollout ollou Mountin Collector Bracket B Inducer Burner Mounting Switch Blower Rack SUE Housing few 09193 Fig 17 Blower Housing and Flue Collector CONTROL BLOWER BIET ACCESS COMPRESSOR PANEL ACCESS PANEL 09207 Fig 18 Unit Access Panels Induced Draft combustion air Blower Assembl The induced draft blower assembly consists of the inducer motor the blower housing and the induced draft blower wheel Cl
33. controller IGC The indoor evaporator fan motor is energized 45 sec after flame is established When the thermostat is satisfied and W is de energized the burners stop firing and the indoor evaporator fan motor shuts off after a 45 sec time off delay Please note that the IGC has the capability to automatically reduce the indoor fan motor on delay and increase the indoor fan motor off delay in the event of high duct static and or partially clogged filter NOTE An LED light emitting diode indicator is provided on the control board to monitor operation The control board is located by removing the burner access panel see Fig 18 During normal operation the LED is continuously on Step 3 Start up Heating and Make Adjust ments CAUTION UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the unit being installed Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Make sure that burner orifices are properly aligned Unstable operation my occur when the burner orifices in the manifold are misaligned Follow the lighting instructions on the heating section operation label located on the inside of the control access panel to start the
34. lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a refrigerant leak c Leak test all refrigerant tubing connections using electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected see the Check for Refrigerant Leaks section d Inspect all field and factory wiring connections Be sure that connections are completed and tight e Ensure wires do not touch refrigerant tubing or sharp sheet metal edges f Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 4 WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury death or property damage Do not purge gas supply into the combustion chamber Do not use a match or other open flame to check for gas leaks Use a commercially available soap solution made specifically for the detection of leaks to check all connections 48 2 4 Verify the following conditions a Make sure gas line is free of air Before lighting the unit for the first time perform the following with the gas valve in the OFF position NOTE 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 Ne
35. run start capacitor overload start relay Determine cause and replace One leg of 3 phase power dead Replace fuse or reset circuit breaker Determine cause Three phase scroll compressor makes excessive noise and there may be a low pressure differential Scroll compressor is rotating in the wrong direction Correct the direction of rotation by reversing the 3 phase power leads to the unit Compressor cycles other than normally satisfying thermostat Refrigerant overcharge or undercharge Recover refrigerant evacuate system and recharge to capacities shown on nameplate Defective compressor Replace and determine cause Insufficient line voltage Determine cause and correct Blocked Outdoor Determine cause and correct Defective run start capacitor overload or start relay Determine cause and replace Defective thermostat Replace thermostat Faulty Outdoor fan motor or capacitor Replace Damaged reversing valve Determine cause and correct Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak repair and recharge Mechanical damage in compressor Replace compressor Air in system Recov
36. section for information on burner removal Normal Operation An LED light emitting diode indicator is provided on the integrated gas unit controller IGC to monitor operation The IGC is located by removing the control access panel see Fig 18 During normal operation the LED is continuously on See Table 5 for error codes Airflow and Temperature Rise The heating section for each size unit is designed and approved for heating operation within the temperature rise range stamped on the unit rating plate Table 7 shows the approved temperature rise range for each heating input and the air delivery cfm at various temperature rises for a given external static pressure The heating operation airflow must produce a temperature rise that falls within the approved range Refer to Indoor Airflow and Airflow Adjustments section to adjust heating airflow when required Limit Switches Normally closed limit switch LS completes the control circuit Should the leaving air temperature rise above the maximum allowable temperature the limit switch opens and the control circuit breaks Any interruption in the control circuit instantly closes the gas valve and stops gas flow to the burners The blower motor continues to run until LS resets When the air temperature at the limit switch drops to the low temperature setting of the limit switch the switch closes and completes the control circuit The direct spark ignition system cycles and the
37. supply and return air grilles are open free from obstructions and adjusted properly WARNING ELECTRICAL SHOCK AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death Before making any indoor wiring adjustments shut off gas supply Then disconnect electrical power to the unit and install lockout tag before changing blower speed This unit has independent fan speeds for gas heating and cooling In addition this unit has the field selectable capability to run two different cooling fan speeds A normal cooling fan speed 350 400 CFM Ton and an enhanced dehumidification fan speed As low as 320 CFM Ton for use with either a dehumidistat or a thermostat that supports dehumidification This unit is factory set up for use with a single cooling fan speed The cooling speed is marked LOW on the interface fan board IFB See Fig 13 factory shipped settings are noted in Table 7 There are 3 additional speed tap wires available for use in either gas heating or cooling For color coding on the indoor fan motor leads see Table 6 The additional 3 speed tap wires are shipped loose with vinyl caps and are located in the control box near the interface fan board IFB See Fig 13 Gas Heating Fan Speed Set up To change the gas heating speed 1 Remove the vinyl cap off of the desired speed tap wire Refer to Table 6 for color coding Table 7 shows the temperature rise associated w
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39. 16 967 3015 AMLNG YIMOd 930 4 5 QIANNOYONN QNY LINN 1959901 er 3415 AMIN3 83404 SLINA 8334138 INN S3HONI SSONVHV3TIO DAN 63 LINN 30 01109 187666171 751204 31150440 301 187051 30 391 1204 1975561 30 401 NN SIHONI 318115 8 09 OL 83719080293 031 1 15 1 3 116 303 LNVA3138 DE AYINI 1041403 3l0H WIG 127221 8 1 AUIN3 43404 0 W VIO 9 82 8 1 1 866111 158611 ly 9L L 1 1102 4000100 dOL 2611 9 9 1432 3 501140 318Vl 17 3100 009 6 060 090 92 2397 766 osje vL e c2 8 cc 062 802 0795 76719760 1 81 6 92 8 75 062 902 0 S 090 0v0 0 V N 2397 6 55 67105750187 LE v oLjo v2 8 2G 062 002 061090 000172 18 2138 Nuni3s 114405 99781 3505 SUM 7 90 gl 52696 71 7 095 0101 8 1 27 97991 216 09 062 802 1 062 902 005 8 060 090 9 27387 J Y 907 gl S es 71 77096 0101 8 1 2 17591 sec 09 8 062 902 1 062 802 005 090 070
40. 2 38 2 44 2 38 2 38 3 38 2 38 3 38 Propane GasQty Drill Size 2 55 2 53 2 55 2 53 2 53 3 53 2 53 3 53 psig Cut out 650 15 Reset Auto 420 25 LOSS OF CHARGE LOW PRESSURE SWITCH Liquid Line psig Cut out 20 5 Reset auto 45 10 RETURN AIR FILTERS 1 Throwaway 20x20x1 20x24x1 24x30x1 mm 508x508x25 508x610x25 610x762x25 Based on altitude of 0 to 2000 ft 0 610 m TRequired filter sizes shown are based on the larger of the AHRI Air Conditioning Heating and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 IN W C t If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity 10 Table 1 Physical Data Unit 48EZ A Cont d UNIT SIZE 48EZ 48090 48115 48130 60090 60115 60130 NOMINAL CAPACITY ton 4 4 4 5 5 5 OPERATING WEIGHT Ib 482 482 482 507 507 507 kg 219 219 219 230 230 230 COMPRESSORS Scroll Quantity 1 410A Quantity Ib 9 6 12 3 kg 4 4 5 6 TXV OUTDOOR ORIFICE in qty 0 046 2 0 052 2 mm 1 2 1 3 OUTDOOR COIL Rows Fins in 2 21 2 21 2 21 2 21 2 21 2 21 Face Area sq ft 13 6 13 6 13 6 17 5 17 5 17 5 Nominal Cf
41. 2 02 61 61 81 21 21 91 4 16 9 se ve Le Le 8811 1221 8221 ELEL 2951 LLL SvGL W42 22 12 02 61 61 81 11 21 91 4o peu _ 090zvv N zag8v 6 9 9 ce ve Le Le 08 1066 62 6911 2821 8951 9091 W42 22 Gz ve 12 02 61 81 4o 9r 9v t Lv 6 16 9 SE 126 726 2201 5601 0 11 v6LL 2821 W42 62 22 92 ve 22 12 02 61 enig 265 Lv vv Lv 6 9 9 ve 198 868 996 9101 901 9211 9621 6 0 8 0 L0 90 90 20 ro 0102 43335 35NVH TINA COM aunss3ud OILVLS TVNH31X3 YyOLOW 3SIH 09 7 8 HUN oS1eqosiq pejuozrrog 3009 V ZA8v 22 V ZA8v 22 Gz ve 22 12 12 12 4o yori 9r 9v ev Lv 6 9 9 ZE 2081 206 1661 0 02 2022 6922 9022 vez 22 92 Gz ve ve
42. 208 V Operation 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Make sure the power supply to the unit is switched OFF before making any wiring changes Tag the disconnect switch with a suitable warning label With disconnect switch open move black wire from transformer 3 16 in terminal marked 230 to terminal marked 200 This retaps transformer to primary voltage of 208 vac A WARNING ELECTRICAL SHOCK AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death Before making any wiring changes make sure the gas supply is switched off first Then switch off the power supply to the unit and install lockout tag 12 Control Voltage Connections Do not use any type of power stealing thermostat Unit control problems may result Use no 18 American Wire Gage AWG color coded insulated 35 C minimum wires to make the control voltage connections between the thermostat and the unit If the thermostat is located more than 100 ft 30 5 m from the unit as measured along the control voltage wires use no 16 AWG color coded insulated 35 C minimum wires Locate the seven eight on 3 phase low voltage thermostat leads in 24 volt splice box See Fig 9 for connection diagram Run the low voltage leads from the thermostat through the control wiring inlet hole grommet Fig 2 and 3 and into the low voltage splice box
43. 61 81 91 VN 4o peu 070059 738 VN vS 9v ev 9 ve ze 05 VN 1009 0 Lov 295 859 7 008 188 796 5201 8801 VN VN VN Le Gz 61 11 4o VN VN VN 99 Sv Lv 16 ve Le 825 999 eel 288 46 VN VN VN VN VN VN Le 92 4o enig MO VN VN VN VN VN VN SG Lv Lv Gly 279 859 T7 W49 60 80 90 90 vo zo ro 0102 43385 35NVH TINA COMU aunssaud 211716 TVNH31X3 YOLOW 3SIH 09 PZ7V ZASh HUN jejuozrrog 3009 V ZA8v 20 V ZA8v Le 82 22 92 Gz ve 4o 9 09 99 es 19 8v Sb t ev 0121 4 6581 20v L 9 2191 0891 0591 Le 0 62 82 92 Gz ve ve do 09 98 vs 25 05 9r 9v ev OL 8021 892 9121 Vn 681 9 9 9091 VN VN VN 96 ve Le 62 82 4o peu 0609 v N Z38 VN VN VN
44. APACITOR COMP 152 SECONDARY LIMIT SV TCH TRAN CAP 2 CAPACITOR INDUCER MGV MAIN GAS VALVE ap CCH CRANK CASE HEATER OFM OUTDOOR FAN MOTOR SECONDARY BK COMP COMPRESSOR MOTOR PRS PRESSURE SWITCH NR 2 CR COMBUSTION RELAY RS ROLLOUT SWITCH 58 DEFROST BOARD RYS REVERSING VALVE Lar 0 DFT DEFROST TEMPERATURE SAT SUPPLY AR TEMPERATURE SWITCH TRAN _ TRANSFORME QE ECON EM R R1 ECON RELAY 4 Sa a6 25 aoe ae ae ECON Cr C SEE NOTE 5 ir R e B B 11 24 R 2 lt FB FUSE w nA i G GY COM BR e 2 Y R eav 1 C R BR lt i BR T STAT COM TO lt 5 R lt ppt a v Y nn 37 SER NOTE 11 BK 8 6 6 4 DH BL vesp m INDOOR BLOWER IGC 24V CONNECTIONS cH SEE NOTE 4 LK 3 0 Y Hi TDD 5 lar J2 SEE SEE NOTE 10 W Y aT SEE NOTE 6 4 BOS GO samp R R am USE aL RS EFROST BOARD DB BR R cm 8 465 LGPS WHEN USED BL s y 4 BR 151 152 490 00 R ora cs Y 0 HCD m i 5 PRS W 2 EV DOES P B bah Q 2 en aH MGV P3 HPS LPS Gi ZON E 5 Bk oo KO BL BR CDO at FS o BR 097 OBR rh DIP SWITCH SETTINGS DEFAULT Cc BR 30 MINUTES 60 MINUTES 90 MINUT
45. CTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING USE COPPER CONDUCTORS ONLY 2 18 UNIT COMPONENT ARRANGEMENT oat Us 1PH 11 STU T E IF USED 23 C 23 Seeon 151 LARGE POE AREA 110 uszcsmatty 169 DB m TFB DR 6 US ka Q BK O4At O 4 BK e BK 157 HCF OF1 OF2 Y 77 2 ap COMP BK CAP C IFM MGV Hro E 151 R SMALL FS 1 COMP CABINET 110 BK ae 23 IFM 6 166 ODE L1 CR CM Ie 11 FO V v EDT i L2 BR Y O Y 2 23 CAP2 SEE NOTE 8 ee T i SEE NOTE 6 PRIMARY 208 230V BK _ LEB R 2 SEE NOTE 7 24VAC R DB de I FUSE 516 3 1 5AMP P3 2 3A RT FUSE P2 1 R O R 9 P2 2 C O BR Lx FS LPs es xe P2 5 Y O ev Q Y ene 7 0 P2 3 W O 04 1 8 0 nu Q BL 029 BL n if 2 4 R 5 1 RSs R OP1 1 R RS NOTE N Q v4 R v gt r W OP1 6 W2 2 Pi 152 na 01 Ge 6 1 4 6 22 1 5 BK 5 5 BR 08 0 65 LOPS PRS RYS w op1 6 w Q NaF 9 NI 6t BR MGV DH BL OP1 5 Y2 DH Y ze 6 IGC OR C 777 BR YO Low cd IFB HIGH 9 BR C COM GAS HEAT hr IFB P1 2
46. E 1 If indoor temperature is above temperature set point thermostat closes circuits R to G R to Y and to O The unit delivers cooling airflow c HEAT PUMP HEATING MODE Outdoor temperature above balance point setpoint of thermostat 1 On a call for heating terminals and of the Hybrid thermostat are energized The Y signal is sent to the Defrost Board DB terminal The DB has a built in five minute anti short cycle timer which will not allow the compressor to restart before the time delay has expired 2 T2 energizes the compressor contactor via the High Pressure Switch HPS and Low Pressure Switch LPS The compressor and outdoor fan start Thermostat energizes the Interface Fan Board terminal The blower motor is energized through contacts of the IFB 3 When the thermostat removes the and calls the compressor contactor and outdoor fan are de energized The evaporator motor is de ener gized after a 90 sec delay d GAS HEATING MODE Outdoor temperature below balance point setpoint of thermostat Heating Sequence of Operation See Fig 15 and 16 and unit wiring label On a call for heating terminal W of the thermostat is energized starting the induced draft motor When the pressure switch senses that the induced draft motor is moving sufficient combustion air the burner sequence begins This function is performed by the integrated gas unit
47. ES 120 MINUTES ON 3011 2 3 123160123 123 123 WE on or SHE COMPRESSOR WILL SHUT OFF FOR GROUNDED 30 SEC ON DEFROST INITIATION AND THRU STANDOFF z THE QUIET SHIFT Y DEFAULT SPEED JUMPERED TEST PINS USE METAL OBJECT CI UL 1 MOMENTARILY SHORT PINS AND RELEASE TO BYPASS 1 STCLES MINUTES COMPRESSOR OFF DELAY 2 SHORT FOR 5 SEC AND RELEASE FOR FORCED DEFROST SEE NOTE 8 y 3 PERMANENT SHORT WILL BE IGNORED 2 DEFROST WILL TERMINATE IN 30 SEC IF DFT OPEN Y DEFROST WILL TERMINATE NORMALLY IF DFT IS CLOSED A10208C Fig 15 208 230 3 60 Connection Wiring Diagram Unit 48EZ A 29 48EZ LADDER WIRING DIAGRAM DANGER E ECTRICAL SHOCK HAZARD DISCONNECI POWER BEFORE SERVICING
48. ETSCREWS HIDDEN 99085 Fig 19 Removal of Motor and Blower Wheel 07680 Fig 20 Burner Rack Removed FEEDER TUBE STUB TUBE Y We DEFROST THERMOSTAT 99029 Fig 21 Defrost Thermostat Location 07680 Fig 22 Burner Rack Removed Outdoor Fan CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in damage to unit components Keep the outdoor fan free from all obstructions to ensure proper cooling operation Never place articles on top of the unit 1 Remove 6 screws holding outdoor grille and motor to top cover 2 Turn motor grille assembly upside down on top cover to expose the fan blade 3 Inspect the fan blades for cracks or bends 4 If fan needs to be removed loosen the setscrew and slide the fan off the motor shaft 5 When replacing fan blade position blade back to the same position as before 6 Ensure that setscrew engages the flat area on the motor shaft when tightening 7 Replace grille Electrical Controls and Wiring Inspect and check the electrical controls and wiring annually Be sure to turn off the gas supply and then the electrical power to the unit Remove access panels see Fig 18 to locate all the electrical controls and wiring Check all electrical connections for tightness Tighten all screw connections If any discolored or burned connections are noticed disassemble the con
49. L INTERNAL LENGTH OF PIPE pM DIAMETER PIPE 10 20 30 40 50 60 70 80 90 100 125 150 175 200 SIZE IN 3 1 64 91 12 2 152 183 213 244 27 4 80 5 384 46 0 53 3 61 0 172 522 175 120 97 82 73 66 61 57 53 50 44 40 3 4 824 360 250 200 170 151 138 125 118 103 93 84 77 72 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 185 1 1 4 1 380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280 T 1 2 1 510 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 Capacity of pipe in cu ft of gas per hr for gas pressure of 0 5 psig or less Pressure drop of 0 5 IN W C based on a 0 60 specific gravity gas Refer to Table 2 and National Fire Protection Association NFPA 54 ANSI This length includes an ordinary number of fittings Z223 1 Table 3 Heating Inputs A PPLY PRE RE IN W C HEATING INPUT NUMBER OF GAS SU SSURE IN W C MANIFOLD PRESSURE Naturalt Propane t IN W C BTUH ORIFICES Min Max Min Max NaturalT Propane t 40 000 2 4 0 13 0 11 0 13 0 3 2 3 8 10 0 11 0 60 000 2 4 0 13 0 11 0 13 0 3 2 3 8 10 0 11 0 90 000 3 4 0 13 0 11 0 13 0 3 2 3 8 10 0 11 0 115 000 3 4 0 13 0 11 0 13 0 3 2 3 8 10 0 11 0 130 000 3 4 0 13 0 11 0 13 0 3 2 3 8 10 0 11 0 When unit is convert
50. R CODE 6 THIS FUSE IS MANUFACTURED BY LITTELFUSE P N 257005 FIELD 7 INDUCER CAPACITOR AND WIRING ON CERTAIN MODELS ONLY BK BK Ye Y BK BLACK CAP2 IS PRESENT YELLOW WIRES FROM IGC AND IDM CONNECT SUPPLY 1 CAP1 BL BLUE ON SAME SIDE OF CAP2 Hea I BR e BR BR BROWN 8 REMOVE YELLOW SPLICE WIRE WHEN ECONOMIZER AND ECONOMIZER 2 1 CF rh GY GRAY RELAYS ARE USED AND CONNECT TO RELAY R AS SHOWN 6 GREEN 9 WHEN ECONOMIZER AND ECONOMIZER RELAYS ARE USED BK ATT 8 ORANGE CONNECT THE YELLOW AND BLACK WIRES TO RELAY AS SHOWN RELAY PINK KIT REQUIRED WITH ECONOMIZER AND HEAT PUMP DUAL FUEL UNITS BL R RED 10 WHEN ECONOMIZER AND ECONOMIZER RELAYS ARE USED VIOLET INSTALL WIRES AS SHOWN ONTO THE COILS OF RELAY AND RELAY R1 11 DEHUNIDIFICATION FEATURE CANNOT BE USED WHEN ECONOMIZER 15 EQUIP_GN Y WHITE LEGEND COMPRESSOR PLUG ECONOMIZER ES BK FIELD SPLICE EQUIP EQUIPMENT Y N TERMINAL MARKED FS FLAME SENSOR TERMINAL UNMARKED GND GROUND SIY 5 SPLICE IF USED HPS HIGH PRESSURE SWITCH BK d L SPLICE MARKED 1 FACTORY WIRING Toc INTERGRATED GAS UNIT CONTROLLER BK PRIMARY FIELD CONTROL WIRING IFB INDOOR FAN BOARD Y CON 39 FIELD POWER WIRING IDM INDUCED DRAFT MOTOR 208 230V ACCESSORY OR OPTIONAL INDOOR FAN MOTOR WIRING LGPS LOW GAS PRESSURE SWITCH WHEN USED Y St PRIMARY LIMIT SWITCH 2345 CONTACTOR CAP 1 C
51. Use only copper conductor for connections between field supplied electrical disconnect switch and unit DO NOT USE ALUMINUM WIRE Be sure that high voltage power to unit is within operating voltage range indicated on unit rating plate On 3 phase units ensure phases are balanced within 2 percent Consult local power company for correction of improper voltage and or phase imbalance Insulate low voltage wires for highest voltage contained within conduit when low voltage control wires are in same conduit as high voltage wires Do not damage internal components when drilling through any panel to mount electrical hardware conduit etc High Voltage Connections When routing power leads into unit use only copper wire between disconnect and unit The high voltage leads should be in a conduit until they enter the duct panel conduit termination at the duct panel must be watertight The unit must have a separate electrical service with a field supplied waterproof disconnect switch mounted at or within sight from the unit Refer to the unit rating plate NEC and local codes for maximum fuse circuit breaker size and minimum circuit amps ampacity for wire sizing The field supplied disconnect switch box may be mounted on the unit over the high voltage inlet hole when the standard power and low voltage entry points are used See Fig 2 and 3 for acceptable location NOTE Field supplied disconnect switch box should be positioned so t
52. VN S9 v9 29 09 65 29 vOv L 8991 2091 9291 8 91 VN VN VN VN VN VN VN VN VN do enig MO VN VN VN VN VN VN VN VN VN 2201 2201 681 9821 1821 6881 W42 92 Gz 12 12 02 02 4o yori 9v ev Lv Ot 9 ZE 9 7281 8961 2902 2612 9822 6552 Love 22 92 92 Gz ve ve do UBIH pe 6v Lv 9v Sb ev ev Lv 59 1 0981 8881 1761 2861 2102 5902 8802 LELZ 82 22 22 92 92 92 4o peu SLLOSV N Z38 55 19 19 6 9r Lv 9t Sb 1009 0 091 6891 0221 6941 1621 vcl 8981 2681 2261 VN VN ve Le 0 62 esi VN VN 09 69 29 99 vs es 25 6rEL vOv L 8991 2091 9291 8 91 VN VN VN VN VN VN VN VN 4o enig MO VN VN VN VN VN VN VN VN 09 2201 2201 6811 9821 1821 Lye 6851 Svy 6 0 80 L0 90 90 20 ro 0102 43385 TINA COM aunss3ud OILVLS TVNH31X3 YOLON 3SIH 09 PZV ZASh HUN o amp 1eqosiq pue ejuozuo
53. ace with proper unit or add additional unit Restricted airflow Clean or replace filter Remove any restriction Limit switch cycles main burners Check rotation of blower temperature rise of unit Adjust as neces sary Poor flame characteristics Incomplete combustion results in Aldehyde odors carbon monoxide sooting flame floating flame 1 Tighten all screws around burner compartment 2 Cracked heat exchanger Replace 3 Unit over fired Reduce input change orifices or adjust gas line or manifold pressure 4 Check burner alignment 5 Inspect heat exchanger for blockage Clean as necessary Table 14 Troubleshooting Guide LED Error Codes SYMPTOM CAUSE REMEDY No Power or Hardware fail ure LED OFF Loss of power to control module IGC Check 5 amp fuse son IGC power to unit 24 v circuit breaker and transformer Units without a 24 v circuit breaker have an internal overload in the 24 v transformer If the overload trips allow 10 minutes for automatic reset Limit switch faults LED 2 flashes High temperature limit switch is open Check the operation of the indoor evaporator fan motor Ensure that the supply air temperature rise is in accordance with the range on the unit nameplate Clean or replace filters Flame sense fault LED 3 flashes The IGC sensed flame that should not be present Reset unit If problem persists replace control board
54. ade The slab should be flush on the compressor end of the unit to allow condensate drain installation and should extend 2 in 51 mm on the three remaining sides of the unit Do not secure the unit to the slab except when required by local codes Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier 0 6210097385 A3 LNOYS 1487 MIJA 3016 10772211 1178981 1870521 6961 870621 4 9118 87 8 1 6 8 5 12 8 1 6 LA N 8771 07901 553224 438018 as mom os 85 T8220 91 l 21 1799 gti 91 6 9 an 11726 6 901 41 8 9 6 9 1 340 lona P ONINAdO 1900 2 1135 Alddn WA NI C1 NI SNOISNINIQ GASTWOUdNOD 38AVN 3ONVNHOJU3d WALSAS N31S4S TIVM 8770 ZL 5531 039714 SI LINN JI S3ONVISIQO WAWININ 13NYd Lond 0440 3415 777401 LINN 1038 QIN 1432 3 9 77771015 AYINI 8304 0 7161 9 7773015 300V 1102 avAi NW S3HONI 6 3ONVHY3 TO aauino3d EAEE va 7771015 AMINA 43404 5323515 GIGNNOYS 83 10 STIVA 11382N02 YO 2019 ANY LINN 0
55. ator 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 10x10 ft 3x3 m area 2 Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run offs and protect drop cloth from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately under component s to be serviced and prevent lubricant run offs through the louvered openings in the unit base 4 Perform required service 5 Remove and dispose of any oil contaminated material per local codes PURON R 410A QUICK REFERENCE GUIDE Liquid Line Filter Drier This filter drier is specifically designed to operate with Puron Use only factory authorized components Filter drier must be replaced whenever the refrigerant system is opened When removing a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system Puron R 410A Refrigerant Charging Refer to unit information plate and charging chart Some R 410A refrigerant cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder in upright position For cylinders equipped with a dip tube charge Puron units with cylinder in upright position and a commercial meterin
56. ature demand because of declining outdoor temperature At or below this point the furnace is needed to maintain proper indoor temperature 2 Economic Balance Temperature Above this point the heat pump is the most cost efficient to operate and below this point the furnace is the most cost efficient to operate This can be somewhat complicated to determine and it involves knowing the cost of gas and electricity as well as the efficiency of the furnace and heat pump For the most economical operation the heat pump should operate above this temperature assuming it has sufficient capacity and the furnace should operate below this temperature 3 Comfort Balance Temperature When the heat pump is operating below this point the indoor supply air feels uncomfortable i e too cool This is purely subjective and will depend on the homeowner s idea of comfort Below this temperature the gas furnace should operate in order to satisfy the desire for indoor comfort Transformer Protection The transformer is of the energy limiting type It is set to withstand a 30 sec overload or shorted secondary condition If an overload or short is present correct overload condition and check for blown fuse on gas control board or Interface Fan Board Replace fuse as required with correct size and rating PRE START UP 4 WARNING FIRE EXPLOSION ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death or pr
57. aused by a dirty outdoor coil failed fan motor or outdoor air recirculation To check switch 1 Turn off all power to unit 2 Disconnect leads on switch 3 Apply ohm meter leads across switch You should have continuity on a good switch Copeland Scroll Compressor Puron Refrigerant The compressor used in this product is specifically designed to operate with Puron R 410A refrigerant and cannot be interchanged The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting techniques Refrigerants present additional safety hazards A WARNING EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death and or property damage Wear safety glasses and gloves when handling refrigerants Keep torches and other ignition sources away from refrigerants and oils The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll The scroll compressor has no dynamic suction or discharge valves and it is more tolerant of stresses caused by debris liquid slugging and flooded starts The compressor is equipped with an internal pressure relief port The pressure relief port is a safety device designed to protect against extreme high pressure The relief port has an operating range between 550 and 625 psig differential pressure
58. be less than 4 0 IN W C or greater than 13 IN W C while the unit is operating For propane applications the gas pressure must not be less than 11 0 IN W C or greater than 13 IN W C at the unit connection 48EZ A A 1 8 in 3 2 mm NPT plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the gas valve When installing the gas supply line observe local codes pertaining to gas pipe installations Refer to the NFGC NFPA 54 ANSI Z223 1 latest edition in Canada CAN CGA 149 1 NOTE In the state of Massachusetts 1 Gas supply connections MUST be performed by a licensed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 in 915 mm 3 When lever handle type manual equipment shutoff valves are used they shall be T handle valves 4 The use of copper tubing for gas piping is NOT approved by the state of Massachusetts In the absence of local building codes adhere to the following pertinent recommendations 1 Avoid low spots in long runs of pipe Grade all pipe 1 4 in 6 35 mm for every 15 ft 4 6 m of length to prevent traps Grade all horizontal runs downward to risers Use risers to connect to heating section and to meter 2 Protect all segments of piping system against physical and thermal damage Support all piping with appropriate straps hangers etc Use a minimum of one hanger eve
59. contract WARNING PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and unit component damage The ability to properly perform maintenance this equipment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the Owner s Manual 4 WARNING ELECTRICAL SHOCK AND EXPLOSION HAZARD Failure to follow these warnings could result in personal injury or death 1 Turn off electrical power to the unit and install a lockout tag before performing any maintenance or service on this unit 2 Use extreme caution when removing panels and parts Never place anything combustible either on or in contact with the unit Should overheating occur or the gas supply fail to shut off turn off external main manual gas valve to the unit Then shut off electrical supply CAUTION CUT HAZARD Failure to follow this caution may result in personal injury When removing access panels see Fig 18 or performing maintenance functions inside your unit be aware of sharp sheet metal parts and screws Although special care is taken to reduce sharp edges to a minimum be extremely careful when handling parts or reaching into the unit CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in improper
60. ean periodically to assure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during the heating season For the first heating season inspect blower wheel bimonthly to determine proper cleaning frequency To inspect blower wheel remove draft hood assembly Shine a flashlight into opening to inspect wheel If cleaning is required remove induced draft blower assembly as follows 1 Remove control access panel See Fig 18 2 Remove the 5 screws that attach induced draft blower as sembly to the flue collector box cover 3 Slide the assembly out of the unit See 20 Clean the blower wheel If additional cleaning is required continue with Steps 4 and 5 4 To remove blower wheel remove 2 setscrews 5 To remove inducer motor remove screws that hold the inducer motor to the blower housing 6 To reinstall reverse the procedure outlined above Flue Gas Passageways To inspect the flue collector box and upper areas of the heat exchanger 1 Remove the induced draft blower assembly according to directions in the Induced Draft Blower Assembly section 2 Remove the 11 screws holding the flue collector box cover See Fig 17 to the heat exchanger assembly Inspect the heat exchangers 3 Clean all surfaces as required using a wire brush Limit Switch Remove blower access panel see Fig 18 Limit switch is located on the fan partition Burner Ignition Unit is equipped with a direct spark ignitio
61. ed to propane different size orifices must be used See separate natural to propane conversion kit instructions TBased on altitudes from sea level to 2000 ft 610 m above sea level In U S A for altitudes above 2000 ft 610 m reduce input rating 4 percent for each addi tional 1000 ft 305 above sea level In Canada from 2000 ft 610 above sea level to 4500 ft 1372 above sea level derate the unit 10 percent 11 48 2 Step 10 Install Electrical Connections A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death The unit cabinet must have an uninterrupted unbroken electrical ground This ground may consist of an electrical wire connected to the unit ground screw in the control compartment or conduit approved for electrical ground when installed in accordance with NEC NFPA 70 National Fire Protection Association latest edition in Canada Canadian Electrical Code CSA C22 1 and local electrical codes CAUTION UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the unit being installed 1 Make all electrical connections in accordance with NEC NFPA 70 latest edition and local electrical codes governing such wiring In Canada all electrical connections must be in accordance with CSA standard C22 1 Canadian Electrical Code Part 1 and applicable local codes Refer to unit wiring diagram
62. efrigerants 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 Refrigerant System This information covers the refrigerant system of the 48EZ A including the compressor oil needed servicing systems on roofs containing synthetic materials the filter drier and refrigerant charging Compressor Oil If additional oil is needed use Uniqema RL32 3MAF If this oil is not available use Copeland Ultra 32CC or Mobil Artic EAL22CC This oil is extremely hygroscopic meaning it absorbs water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere 37 48EZ Servicing Systems on Roofs and with Synthetic materials POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials Exposure even if immediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service that may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch metering device coil accumul
63. er refrigerant evacuate system and recharge Frosted coil with incorrect defrost operation Check defrost time settings Reset as necessary Check defrost temperature switch Replace as nec essary Outdoor coil dirty or restricted Clean coil or remove restriction Excessive head pressure Dirty air filter Replace filter Dirty Indoor or Outdoor coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant evacuate system and recharge Indoor or Outdoor air restricted or air short cycling Determine cause and correct Head pressure too low Low refrigerant charge Check for leaks repair and recharge Compressor IPR leaking Replace compressor Restriction in liquid tube Remove restriction Excessive suction pressure High heat load Check for source and eliminate Compressor IPR leaking Replace compressor Refrigerant overcharged Recover excess refrigerant Reversing valve hung up or leaking internally Replace valve Suction pressure too low Dirty air filter Replace Filter Low refrigerant charge Check for leaks repair and recharge Metering device or low side restricted Remove source of restriction Insufficient Indoor airflow Increase air quantity Check filter replace if neces sary Temperature too low in conditioned area Reset thermos
64. es 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 35 48 2 C99097 Fig 24 Refrigerant Circuit 2 Disconnect leads on switch 3 Apply ohm meter leads across switch You should have continuity on a good switch NOTE Because these switches are attached to refrigeration system under pressure it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists If switch must be removed remove and recover all system charge so that pressure gauges read 0 psi Never open system without breaking vacuum with dry nitrogen High Pressure Switch The high pressure switch is located in the discharge line and protects against excessive condenser coil pressure It opens at 650 psig High pressure may be c
65. essor life The condenser fan pulls air through the condenser coil and discharges it through the top grille Be sure that the fan discharge does not recirculate to the condenser coil Do not locate the unit in either a corner or under an overhead obstruction The minimum clearance under a partial overhang such as a normal house overhang is 48 in 1219 mm above the unit top The maximum horizontal extension of a partial overhang must not exceed 48 in 1219 mm Do not place the unit where water ice or snow from an overhang or roof will damage or flood the unit Do not install the unit on carpeting or other combustible materials The unit may be installed on Class A B or C roof covering materials Slab mounted units should be at least 4 in 102 mm above the highest expected water and runoff levels Do not use unit if it has been under water Step 5 Rig and Place Unit 4 WARNING PERSONAL INJURY OR PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury death or property damage When installing the unit on a rooftop be sure the roof will support the additional weight Rigging and handling of this equipment can be hazardous for many reasons due to the installation location roofs elevated structures etc Only trained qualified crane operators and ground support staff should handle and install this equipment When working with this equipment observe precautions in the literature
66. f then on again LED 9 flashes eet igen inte tersniee oware Fault will automatically reset itself in one 1 hour WARNING A the IGC must be replaced be sure to ground yourself to dissipate any electrical charge that my be present before handling new control board The IGC is sensitive to static electricity and my be damaged if the necessary precautions are not taken IMPORTANT Refer to Table 12 Troubleshooting Guide Heating for additional troubleshooting analysis LEGEND IGC Integrated Gas Unit Controller LED Light Emitting Diode 40 START UP CHECKLIST Remove and Store in Job Files I PRELIMINARY INFORMATION MODEL NO SERIAL NO DATE TECHNICIAN II PRESTART UP Insert check mark in box as each item is completed VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK GAS PIPING FOR LEAKS WHERE APPLICABLE CHECK THAT INDOOR EVAPORATOR AIR FILTER IS CLEAN AND IN PLACE VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS START UP ELECTRICAL SUPPLY VOLTAGE COMPRESSOR AMPS INDOOR EVAPORATOR FAN AMPS TEMPERATURES OUTDOOR CONDENSER AIR TEMPERATURE DB RETURN AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB HEAT PUMP SUPPLY AIR
67. fety information This is the safety alert symbol When you see this symbol on the unit and in instructions manu als be alert to the potential for personal injury Understand these signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in per sonal injury or death CAUTION is used to identify unsafe practic 1 48EZ es which may result in minor personal injury or product and erty damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing or servicing system always turn off main power to system and install lockout tag There may be more than one disconnect switch Turn off accessory heater power switch if applicable 4 WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or property damage qualified installer or agency must use only factory authorized kits or accessories when modifying this product CAUTION CUT HAZARD Failure to follow this caution may result in personal injury When removing access panels see Fig 18 or per
68. forming maintenance functions inside your unit be aware of sharp sheet metal parts and screws Although special care is taken to reduce sharp edges to a minimum be extremely careful when handling parts or reaching into the unit INTRODUCTION The 48EZ A unit see Fig 1 is a fully self contained combination Category I gas heating electric heating and cooling unit designed for outdoor installation See Fig 2 and 3 for unit dimensions All unit sizes have return and discharge openings for both horizontal and downflow configurations and are factory shipped with all downflow duct openings covered Units may be installed either on a rooftop or on a cement slab See Fig 4 for roof curb dimensions In gas heating mode this unit is designed for a minimum continuous return air temperature of 55 F 13 C db and a maximum continuous return air temperature of 80 F 27 C db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and other components Models with an N in the fifth position of the model number are dedicated Low NOx units designed for California installations These models meet the California maximum oxides of nitrogen NOx emissions requirements of 40 nanograms joule or less as shipped from the factory and must be installed in California Air Quality Management Districts or any other regions in North America where a Low NOx tule exists RECEIVING AND INSTALLATION Step 1
69. g device in manifold hose Charge refrigerant into suction line TROUBLESHOOTING Use the Troubleshooting Guides See Tables 12 14 if problems occur with these units START UP CHECKLIST Use Start Up checklist to ensure proper start up procedures are followed e 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 e Puron refrigerant cylinders are rose colored e Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 e Puron systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose when charging into suction line with compressor operating e Manifold sets should be minimum 700 psig high side and 180 psig low side with 550 psig low side retard e Use hoses with minimum 700 psig service pressure rating e Leak detectors should be designed to detect HFC refrigerant as with other HFCs is only compatible with POE oils e Vacuum pumps will not remove moisture from oil Do not use liquid line filter driers with rated working pressures less than 600 psig e Do not leave Puron suction line filter driers in line longer than 72 hrs Do not install a suction line filter drier in liquid line e POE oils absorb moisture rapidly Do not expose oil to atmosphere POE oils may cause damage to certain plastics and roofi
70. hat it does not cover up any of the unit gas combustion supply air louvers See unit wiring label Fig 14 and 15 and Fig 9 for reference when making high voltage connections Proceed as follows to complete the high voltage connections to the unit Single phase units 1 Run the high voltage L1 L2 and ground lead into the control box 2 Connect ground lead to chassis ground connection HIGH VOLTAGE POWER LEADS lt o SEE UNIT WIRING POWER LABEL ee ee ee EQUIP GR FIELD SUPPLIED FUSED DISCONNECT CONTROL BOX THERMOSTAT LOW VOLTAGE TYPICAL POWER LEADS SEE UNIT WIRING LABEL SPLICE BOX A09067 Fig 9 High and Control Voltage Connections 3 Locate the black and yellow wires connected to the line 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 23 of the compressor contactor Three phase units 1 Run the high voltage L1 L2 L3 and ground lead into the control box 2 Connect ground lead to chassis ground connection 3 Locate the black and yellow wires connected to the line side of the contactor 4 Connect field L1 to black wire on connection 11 of the compressor contactor 5 Connect field wire L3 to yellow wire on connection 13 of the compressor contactor 6 Connect field wire L2 to blue wire from compressor Special Procedures for
71. 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 heating control operation as follows see furnace lighting instructions located on the inside of the control access panel 1 Place room thermostat SYSTEM switch in the HEAT position and the fan switch is placed in AUTO position 2 Set the heating temperature control of the thermostat above room temperature 3 The induced draft motor will start 4 On a call for heating the main burner should light within 5 sec of the spark being energized If the burners do not light there is a 22 sec delay before another 5 sec try If the burners still do not light this sequence is repeated If the burners do not light within 15 minutes from the initial call for heat there is a lockout To reset the control break the 24 v power to W 5 The evaporator fan will turn on 45 sec after the flame has been established The evaporator fan will turn off 45 sec after the thermostat has been satisfied Please note that the 14 integrated gas unit controller IGC has the capability to automatically reduce the evaporator ON delay and in crease the evaporator OFF delay in the event of high duct static and or partially clogged filter Check Gas Input Check gas input and manifold pressure after unit start up See Table 3 If adjustment is required proceed a
72. ing performance is suspected leak test all refrigerant tubing using an electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected refer to the Check for Refrigerant Leaks section If no refrigerant leaks are found and low cooling performance is suspected refer to the Checking and Adjusting Refrigerant Charge section Gas Input The gas input does not require checking unless improper heating performance is suspected If a problem exists refer to the Start Up section Indoor Airflow The heating and or cooling airflow does not require checking unless improper performance is suspected If a problem exists be sure that all supply and return air grilles are open and free from obstructions and that the air filter is clean When necessary refer to the Indoor Airflow and Airflow Adjustments section to check the system airflow Check Defrost Thermostat The defrost thermostat is usually located on the lowest liquid leaving circuit of the left condenser coil see Fig 21 The thermostat closes at 32 F 0 C and opens at 65 F 18 C Puron Items Metering Device Thermostatic Expansion Valve amp Piston This unit uses both a hard shutoff balance port in the indoor coil and a piston in each side of the outdoor coil The TXV maintains a constant superheat at the evaporator coil exit cooling mode resulting in higher overall system efficiency Pressure Switches Pressure switch
73. io seo 2000 Pa 1 ees 7 oero ozro voro ooro soo eoo woo vevo sovo osoo soo 008 001 oo 00 ND aanssarg 39A IBIES pue V SASH 6 21461 0021 0881 S961 0802 9912 0822 azez 0882 Grtz 0552 yoelq Z38v 0941 0661 0212 9622 Srez ortz S0Sc yori 8 228 091 9091 0891 0291 0291 0141 9211 yoeig cvv Z38v 0021 0921 OZEL 6 61 6951 5191 9 v Z38v 058 006 096 0001 0501 xoelg u6iH Z38v 058 006 056 0001 0901 xoelg Z38v 60 80 90 20 ro SHIM 43385 HOLOW 5 211 15 TVNH31X3 8 238 26 CONNECTION WIRING DIAGRAM
74. ith each fan speed for a given static pressure Make sure that the speed chosen delivers a temperature rise within the rise range listed on the unit rating plate 2 Remove the current speed tap wire from the GAS HEAT terminal on the interface fan board IFB Fig 13 and place vinyl cap over the connector on the wire 3 Connect the desired speed tap wire to the GAS HEAT terminal on the interface fan board IFB Single Cooling Fan Speed Set up Dehumidification feature not used To change cooling speed 1 Remove the vinyl cap off of the desired speed tap wire Refer to Table 6 for color coding Add the wet coil pressure drop in Table 9 to the system static to determine the correct cooling airflow speed in Table 7 that will deliver the nominal cooling airflow as listed in Table 1 for each size 17 48EZ A 2 Remove the current speed tap wire from the LOW terminal on the interface fan board IFB See Fig 13 and place vinyl cap over the connector on the wire 3 Connect the desired speed tap wire to the LOW terminal on the interface fan board IFB Two Cooling Fan Speeds Set up Dehumidification feature used IMPORTANT Dehumidification control must open control circuit on humidity rise above set point Use of the dehumidification cooling fan speed requires use of either a 24 VAC dehumidistat or a thermostat which includes control of a 24 VAC dehumidistat connection In either case the dehumidificati
75. ltiplier Sea Level Factor Furnace Input Rate at Installation Altitude 90 000 X 0 90 81 000 When the gas supply being used has a different heating value or specific gravity refer to national and local codes or contact your distributor to determine the required orifice size 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in reduced unit and or component life Do Not redril an orifice Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flame If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Adjust Gas Input The gas input to the unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure Measuring the gas flow at the meter is recommended for natural gas units The manifold pressure must be measured to determine the input of propane gas units Measure Gas Flow Natural Gas Units Minor adjustment to the gas flow can be made by changing the manifold pressure The manifold pressure must be maintained between 3 2 and 3 8 IN W C If larger adjustments are required change main burner orifices following the recommendations of national and local codes NOTE other appliances that use the same meter must be turned off when gas flow is measured at the meter Proceed as follows 1 Turn off gas supply to unit
76. ly air registers and return air grilles according to American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE recommendations Use flexible transition between rigid ductwork and unit to prevent transmission of vibration The transition may be screwed or bolted to duct flanges Use suitable gaskets to ensure weather tight and airtight seal All units must have field supplied filters or accessory filter rack installed in the return air side of the unit Recommended sizes for filters are shown in Table 1 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 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 Flash weatherproof and vibration isolate all openings in building structure in accordance with local codes and good building practices Horizontal Duct Covers 09061 Basepan Downflow Vertical Supply Knockout Basepan Downflow Vertical Return Knockout 09060 Fig 8 Supply and Re
77. m 3100 3100 3100 3500 3500 3500 Diameter in 26 26 26 26 26 26 mm 660 660 660 660 660 660 Motor Hp Rpm 1 5 810 1 5 810 1 5 810 1 5 810 1 5 810 1 5 810 INDOOR COIL Rows Fins in 3 17 3 17 3 17 3 17 3 17 3 17 Face Area sq ft 4 7 4 7 4 7 5 7 5 7 5 7 INDOOR BLOWER Nominal Cooling Airflow 1600 1600 1600 1850 1850 1850 Size in 11x10 11x10 11x10 11x10 11x10 11x10 mm 279x254 279x254 279x254 279x254 279x254 279x254 Motor hp 1 0 1 0 1 0 1 0 1 0 1 0 Burner Orifice Natural Gas Qty Drill Size Factory Installed 3 38 3 33 3 31 3 38 3 33 3 31 Propane GasQty Drill Size 3 53 3 51 3 49 3 53 3 51 3 49 HIGH PRESSURE SWITCH psig Cut out 650 15 Reset Auto 420 25 055 LOW PRESSURE SWITCH Liquid Line psig Cut out 20 5 Reset auto 45 10 Throwaway in 24x36x1 mm 610x914x25 Based on altitude of 0 to 2000 ft 0 610 m TRequired filter sizes shown are based on the larger of the AHRI Air Conditioning Heating and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 IN W C t If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity Table 2 Maximum Gas Flow Capacity NOMINA
78. n 100 percent lockout system Ignition module IGC is located in the control box See Fig 17 Module contains self diagnostic LED During servicing refer to label diagram or Table 5 in these instructions for LED interpretation If lockout occurs unit may be reset by either momentarily interrupting power supply to unit or by turning selector switch to OFF position at the thermostat Main Burners At the beginning of each heating season inspect for deterioration or blockage due to corrosion or other causes Observe the main burner flames and adjust if necessary Removal of Gas Train To remove the gas train for servicing 1 Shut off main gas valve 2 Shut off power to unit and install lockout tag 3 Remove control access panel See Fig 18 4 Disconnect gas piping at unit gas valve 5 Remove fan partition mounting bracket 2 screws located on the left side of the control compartment on the fan parti tion panel Slide bracket forward bottom first to remove See Fig 17 6 Remove wires connected to gas valve Mark each wire 7 Remove the mounting screw that attaches the burner rack to the unit base See Fig 17 8 Partially slide the burner rack out of the unit see Fig 17 and 20 Remove ignitor and sensor wires at the burner as sembly Remove rollout switch wires 9 Slide the burner rack out of the unit See Fig 17 and 20 10 To reinstall reverse the procedure outlined above Outdoor Coil Indoor Coil
79. n IFB LOW speed when the DH control lead is not energized or IFB HIGH speed when the DH lead is energized see Fig 13 NOTE For heat pump operation the recommended airflow is 350 to 450 CFM for each 12 000 Btuh of rated cooling capacity Table 6 Color Coding for Indoor Fan Motor Leads Black High Speed Orange Med High Speed Red Med Speed Pink Med Low Speed Blue Low Speed GAS HEAT 0 09 0 LAT 00 LC eh A7 R9 AB A15 Mb S p mcam R3 28 24VAC R 3 AMP um G We R Fig 13 Interface Fan Board IFB 09058 18 V ZA8v Do VN VN 06 8c Sc ve 0c est do U6tH VN VN vs 05 9v v 07 86 96 est 079 2 818 188 696 9601 49 Do 6c 26 ve est 4o 55 8v vv est isis m 277 224 299 692 0 8 216 6001 Do VN VN VN VN VN VN VN 62 92 est M Jo o90rev N Z38r 29 Lv 3089 90 62 9 9 789 PLL 168 LEG W49 Do 6c esi 4o
80. nection clean all the parts re strip the wire end and reassemble the connection properly and securely After inspecting the electrical controls and wiring replace the access panels see Fig 18 Start the unit and observe at least one complete heating cycle and one complete cooling cycle to ensure proper operation If discrepancies are observed in any operating cycle or if a suspected malfunction has occurred check each electrical component with the proper electrical instrumentation Refer to the unit wiring label when making these checkouts NOTE Refer to the heating and or cooling sequence of operation in this publication as an aid in determining proper control operation Refrigerant Circuit Annually inspect all refrigerant tubing connections and the unit base for oil accumulations Detecting oil generally indicates a refrigerant leak 34 0 000000 Ld U Oy 2 gt m di 2 NS 2 Speedup Quiet Pins Shift Defrost interval DIP switches 08020 Fig 23 Defrost Control WARNING EXPLOSION PERSONAL ENVIRONMENTAL HAZARD Failure to follow this warning could result in personal injury INJURY AND death or property damage System under pressure Relieve pressure and recover all refrigerant before system repair or final unit disposal Use all service ports and open all flow control devices including solenoid valves If oil is detected or if low cool
81. ng materials Wrap all filter driers and service valves with wet cloth when brazing A factory approved liquid line filter drier is required on every unit Do NOT use an R 22 TXV Never open system to atmosphere while it is under a vacuum When system must be opened for service recover refrigerant evacuate then break vacuum with dry nitrogen and replace filter driers Evacuate to 500 microns prior to recharging Do not vent Puron into the atmosphere Observe all warnings cautions and bold text All indoor coils must be installed with a hard shutoff Puron TXV metering device 38 Table 12 Troubleshooting Guide Cooling or Heat Pump Heating Mode SYMPTOM CAUSE REMEDY Compressor and Outdoor fan will not start Power Failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat contactor transformer or control relay Replace component Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly Thermostat setting too high Lower thermostat setting below room temperature Compressor will not start but Outdoor fan runs Faulty wiring or loose connections in compressor circuit Check wiring and repair or replace Compressor motor burned out seized or internal over load open Determine cause Replace compressor Defective
82. oltage Connections 13 Balance Point Setting Thermidistat or Hybrid Heat Thermostat eem eker me wee eee es 13 Transformer Protection 13 PRE START UP aco dike SRG SO Ra ES 13 14 START SUP ONERE ee 14 17 Check for Refrigerant Leaks 14 Unit Sequence of Operation 14 Start Up Heating and Make Adjustments 14 Checking Heating 1 14 Check Gas Input iss RE 15 Adjust Gas Input 15 Check Burner Flame 16 Start Up Cooling and Make Adjustments 16 Checking Cooling Control Operation 16 Checking and Adjusting Refrigerant 17 Indoor Airflow and Airflow Adjustments 17 MAINTENANCE te Re te 9 32 38 Agr Tuer 32 Indoor Blower and Motor 32 Flue Gas 33 Limit Switcly 33 Burner Ignition 33 Main Burners e me eee eas 33 Outdoor Coil Indoor Coil amp Condensate Drain Pan 33 Outdoor 34 Electrical Controls and Wiring 34 Refrigerant Circuit sss csere esters t e me e 34 A09034 Gas Input
83. on control must open the control circuit on humidity rise above the dehumidification set point 1 Remove fan speed tap wire from the LOW terminal on the interface fan board IFB See Fig 13 2 Determine correct normal cooling fan speed for unit and application Add the wet coil pressure drop in Table 9 to the system static to determine the correct cooling airflow speed in Table 7 that will deliver the nominal cooling airflow as listed in Table 1 for each size 3 Remove the vinyl cap off of the desired speed tap wire Refer to Table 6 for color coding for the normal cooling fan speed and place desired speed tap wire on HIGH on the interface board 4 Refer to airflow tables Table 7 to determine allowable speeds for the dehumidification cooling fan speed In Table 7 speeds that are not allowed for dehumidification cooling are shaded 5 Remove the vinyl cap off of the desired speed tap wire Refer to Table 6 for color coding for the dehumidification cooling fan speed and place desired speed tap wire on the LOW connection on the interface board IFB Verify that static pressure is in the acceptable range for the speed tap to be used for dehumidification cooling 6 Use any spare vinyl plugs to cap any unused speed tap wires Continuous Fan Operation When the DEHUM feature is not used the continuous fan speed will be the same as cooling fan speed When the DEHUM feature is used the continuous fan will operate o
84. operation Errors made when reconnecting wires may cause improper and dangerous operation Label all wires prior to disconnecting when servicing The minimum maintenance requirements for this equipment are as follows 1 Inspect air filter s each month Clean or replace when necessary Certain geographical locations may require more frequent inspections 2 Inspect indoor coil outdoor coil drain pan and condensate drain each cooling season for cleanliness Clean when necessary 3 Inspect blower motor and wheel for cleanliness at the beginning of each heating and cooling season Clean when necessary For first heating and cooling season inspect blower wheel bi monthly to determine proper cleaning frequency 4 Check electrical connections for tightness and controls for proper operation each heating and cooling season Service when necessary Ensure electrical wiring is not in contact with refrigerant tubing or sharp metal edges 5 Check and inspect heating section before each heating season Clean and adjust when necessary 6 Check flue hood and remove any obstructions if necessary Air Filter IMPORTANT Never operate the unit without a suitable air filter in the return air duct system Always replace the filter with the same dimensional size and type as originally installed See Table 1 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean cleanable type
85. operty damage 1 Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system 2 Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and Secured Do not remove compressor terminal cover until all electrical sources are disconnected and tagged Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals Never attempt to repair soldered connection while refrigerant system is under pressure Do not use torch to remove any component System contains oil and refrigerant under pressure To remove a component wear protective goggles and proceed as follows a Shut off electrical power to unit and install lockout tag Relieve and reclaim all refrigerant from system using both high and low pressure ports Cut component connecting tubing with tubing cutter and remove component from unit Carefully unsweat remaining tubing stubs when necessary Oil can ignite when exposed to torch flame Proceed as follows to inspect and prepare the unit for initial start up 13 1 Remove access panels see Fig 18 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
86. ry death and or property damage Connect gas pipe to unit using a backup wrench to avoid damaging gas controls Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections Use proper length of pipe to avoid stress on gas control manifold If a flexible connector is required or allowed by authority having jurisdiction black iron pipe shall be installed at furnace gas valve and extend a minimum of 2 in 51 mm outside furnace casing If codes allow a flexible connector always use a new connector Do not use a connector which has previously serviced another gas appliance 8 Check for gas leaks at the field installed and factory installed gas lines after all piping connections have been completed Use a commercially available soap solution made specifically for the detection of leaks or method specified by local codes and or regulations IN TEE our NIPPLE CAP C99020 Fig 7 Sediment Trap Step 9 Install Duct Connections The unit has duct flanges on the supply and return air openings on the side and bottom of the unit For downshot applications the ductwork connects to the roof curb See Fig 2 and 3 for connection sizes and locations Configuring Units for Downflow Vertical Discharge A WARNING ELECTRICAL SHOCK HAZARD Failure to follow thi
87. ry 6 ft 1 8 m For pipe sizes larger than 1 2 in 12 7 mm follow recommendations of national codes 3 Apply joint compound pipe dope sparingly and only to male threads of joint when making pipe connections Use only pipe dope that is resistant to action of liquedfied petroleum gases as specified by local and or national codes Never use Teflon tape 4 Install sediment trap in riser leading to heating section See Fig 7 This drip leg functions as a trap for dirt and condensate 5 Install an accessible external manual main shutoff valve in gas supply pipe within 6 ft 1 8 m of heating section 6 Install ground joint union close to heating section between unit manual shutoff and external manual main shut off valve 7 Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit NOTE Pressure test the gas supply system after the gas supply piping is connected to the gas valve The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0 5 psig Pressure test the gas supply piping system at pressures equal to or less than 0 5 psig The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground joint union 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal inju
88. s follows The rated gas inputs shown in Table 3 are for altitudes from sea level to 2000 ft 610 m above sea level These inputs are based on natural gas with a heating value of 1025 Btu ft at 0 60 specific gravity or propane gas with a heating value of 2500 Btu ft at 1 5 specific gravity IN THE U S A The input rating for altitudes above 2 000 ft 610 m must be reduced by 446 for each 1 000 ft 305 m above sea level For installations below 2 000 ft 610 m refer to the unit rating plate For installations above 2 000 ft 610 m multiply the input by on the rating plate by the derate multiplier in Table 4 for correct input rate Table 4 Altitude Derate Multiplier for U S A DERATE MULTIPLIER ALTITUDE FT M PERCENT OF DERATE FACTORT 0 610 0 1 00 610 514 8 12 0 90 aie 1219 12 16 0 86 1220 1524 16 20 0 82 1524 1828 20 24 0 78 1929 2134 24 28 0 74 IM 28 32 0 70 2439 2743 32 36 0 66 2744 3048 36 40 0 62 Canada see Canadian Altitude Adjustment TDerate multiplier factors are based on midpoint altitude for altitude range BURNER FLAME C99021 Fig 10 Monoport Burner IN CANADA The input rating for altitudes from 2 000 to 4 500 ft 610 m to 1372 m above sea level must be derated 10 by an authorized Gas Conversion Station or Dealer EXAMPLE 90 000 Btu hr Input Furnace Installed at 4300 ft 1311 m Furnace Input Rate at X Derate Mu
89. s sse ed E ERU E Rd 35 Indoor Airflow 35 Check Defrost 35 Puron Items 35 TROUBLESHOOTING 38 START UP CHECKLIST 38 SAFETY CONSIDERATIONS Installation and servicing of this equipment can be hazardous due to mechanical and electrical components Only trained and qualified personnel should install repair or service this equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on this equipment observe precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply Follow all safety codes Wear safety glasses protective clothing and work gloves Have fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit Consult local building codes the current editions of the National Fuel Gas Code NFGC NFPA 54 ANSI 7223 1 and the National Electrical Code NEC NFPA 70 In Canada refer to the current editions of the National Standards of Canada CAN CSA B149 1 and 2 Natural Gas and Propane Installation codes and Canadian Electrical Code CSA C22 1 Recognize sa
90. s to low and high pressure service fittings respectively 3 Start unit in Cooling Mode and let unit run until system pressures stabilize 4 Measure and record the following a Outdoor ambient air temperature F C db b Liquid line temperature F c Discharge high side pressure psig d Suction low side pressure psig for reference only 5 Using Cooling Charging Charts compare outdoor air temperature F C db with the discharge line pressure psig to determine desired system operating liquid line temperature See Fig 16 6 Compare actual liquid line temperature with desired liquid line temperature Using a tolerance of 2 F 1 1 add refrigerant if actual temperature is more than 2 F 1 1 C higher than proper liquid line temperature or remove refrigerant if actual temperature is more than 2 F 1 1 C lower than required liquid line temperature NOTE If the problem causing the inaccurate readings is a refrigerant leak refer to the Check for Refrigerant Leaks section Indoor Airflow and Airflow Adjustments CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage For cooling operation the recommended airflow is 350 to 450 cfm for each 12 000 Btuh of rated cooling capacity For heating operation the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate NOTE Be sure that all
91. s warning could result in personal injury or death Before installing or servicing system always turn off main power to system and install lockout tag There may be more than one disconnect switch 1 Open all electrical disconnects before starting any service work 2 Remove horizontal metal duct covers to access vertical downflow discharge duct knockouts in unit basepan See Fig 8 CAUTION PROPERTY DAMAGE HAZARD Failure to follow this caution may result in property damage Collect ALL screws that were removed Do not leave screws on rooftop as permanent damage to the roof may occur To remove downflow return and supply knockout covers break front and right side connecting tabs with a screwdriver and hammer Push cover down to break rear and left side tabs NOTE These panels are held in place with tabs similar to an electrical knockout Reinstall horizontal duct covers Fig 8 shipped on unit from factory Insure openings are air and watertight NOTE The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence type air conditioning and ventilating systems NFPA 90 or residence type NFPA 90B and or local codes ordinances Adhere to the following criteria when selecting sizing and installing the duct system 1 Units are shipped for horizontal duct installation by removing duct covers 2 Select and size ductwork supp
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93. stalled as indicted in this section of the unit installation instructions Install the flue hood as follows 1 This installation must conform with local building codes and with the National Fuel Gas Code NFGC NFPA 54 ANSI 7223 1 Canada CAN CGA B149 1 and B149 2 latest revision Refer to Provincial and local plumbing or wastewater codes and other applicable local codes 2 Remove flue hood from shipping location inside the return section of the blower compartment see Fig 8 Remove the return duct cover to locate the flue hood Place flue hood assembly over flue panel Orient screw holes in flue hood with holes in the flue panel 3 Secure flue hood to flue panel by inserting a single screw on the top flange and the bottom flange of the hood Step 8 Install Gas Piping The gas supply pipe enters the unit through the access hole provided The gas connection to the unit is made to the 1 2 in 12 7 mm FPT gas inlet on the gas valve Install a gas supply line that runs to the heating section Refer to Table 2 and the NFGC for gas pipe sizing Do not use cast iron pipe It is recommended that a black iron pipe is used Check the local utility for recommendations concerning existing lines Size gas supply piping for 0 5 IN W C maximum pressure drop Never use pipe smaller than the 1 2 in 12 7 mm FPT gas inlet on the unit gas valve For natural gas applications the gas pressure at unit gas connection must not
94. tat Outdoor ambient below 55 F 12 8 Install low ambient kit Field installed filter drier restricted Replace Heat Outdoor coil frosted Move timer on control board to 30 minutes between defrost cycles Compressor runs but outdoor fan does not NC normally closed contacts on defrost board open Check condition of relay on board Replace if neces sary 39 48 2 A Table 13 Troubleshooting Guide Heating SYMPTOM CAUSE REMEDY Burners will not ignite Water in gas line Drain Install drip leg No power to furnace Check power supply fuses wiring or circuit breaker No 24 v power supply to control circuit Check transformer NOTE Some transformers have internal over current protection that requires a cool down period to reset Mis wired or loose connections Check all wiring and wire nut connections Misaligned spark electrodes Check flame ignition and sense electrode positioning Adjust as necessary No gas at main burners 1 Check gas line for air Purge as necessary NOTE After purging gas line of air wait at least 5 minutes for any gas to dissipate be fore attempting to light unit 2 Check gas valve Inadequate heating Dirty air filter Clean or replace filter as necessary Gas input to furnace too low Check gas pressure at manifold match with that on unit nameplate Unit undersized for application Repl
95. the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Do not operate the compressor when the outdoor temperature is below 40 F 4 4 C unless accessory low ambient kit is installed Do not rapid cycle the compressor Allow 5 minutes between on cycles to prevent compressor damage Checking Cooling Control Operation Start and check the unit for proper cooling control operation as follows 1 Place room thermostat SYSTEM switch in OFF position Observe that blower motor starts when FAN switch is 16 placed in ON position and shuts down when FAN switch is placed in AUTO position 2 Place SYSTEM switch in COOL position and FAN switch in AUTO position Set cooling control below room temperature Observe that compressor condenser fan and evaporator blower motors start Observe that cooling cycle shuts down when control setting is satisfied The evaporator fan will continue to run for 90 sec IMPORTANT Three phase scroll compressors units direction oriented Unit must be checked to ensure proper compressor 3 phase power lead orientation If not corrected within 5 minutes the internal protector will shut off the compressor The 3 phase power leads to the unit must be reversed to correct rotation When turning backwards the difference between compressor suction and discharge pressures will be near zero Checking and Adjusting Refrigerant Charge The refrigerant system is full
96. turn Duct Opening 48 2 Table 1 Physical Data Unit 48EZ A UNIT SIZE 48EZ 24040 24060 30040 30060 36060 36090 42060 42090 NOMINAL CAPACITY ton 2 2 2 1 2 2 1 2 3 3 3 1 2 3 1 2 SHIPPING WEIGHT Ib 359 359 373 373 379 379 461 461 kg 163 163 169 169 172 172 209 209 COMPRESSORS Scroll Quantity 1 410A Quantity Ib 8 3 8 3 10 2 10 2 7 9 7 9 10 0 10 0 kg 3 8 3 8 4 6 4 6 3 6 3 6 4 5 4 5 DEVICE Indoor TXV Outdoor Accurater OUTDOOR ORIFICE 0 038 Left in qty 0 032 2 0 035 2 0 037 2 0 040 Right mm 81 89 94 97 1 02 OUTDOOR COIL Rows Fins in 2 21 2 21 2 21 2 21 2 21 2 21 2 21 2 21 Face Area sq ft 11 9 11 9 11 9 11 9 11 9 11 9 13 6 13 6 Nominal Cfm 2000 2000 2700 2700 2700 2700 3100 3100 Diameter in 24 24 24 24 24 24 26 26 mm 610 610 610 610 610 610 660 660 Motor Hp Rpm 1 5 810 1 5 810 1 5 810 1 5 810 1 5 810 1 5 810 1 5 810 1 5 810 Rows Fins in 3 17 3 17 3 17 3 17 3 17 3 17 3 17 3 17 Face 54 ft 3 7 3 7 3 7 3 7 3 7 3 7 4 7 4 7 Nominal Cooling Airflow 800 800 1000 1000 1200 1200 1400 1400 Size in 10x10 10x10 10x10 10x10 11x10 11x10 11x10 11x10 mm 254x254 254x254 254x254 254x254 279x254 279x254 279x254 279x254 Motor hp 1 2 1 2 1 2 1 2 3 4 3 4 3 4 3 4 Burner Orifice Natural Gas Qty Drill Size Factory Installed 2 44
97. unit returns to normal heating operation Table 5 LED Indications STATUS CODE LED INDICATION Normal Operation On No Power or Hardware Failure Off Limit Switch Fault 2 Flashes Flame Sense Fault 3 Flashes Four Consecutive Limit Switch Faults 4 Flashes Ignition Lockout Fault 5 Flashes Pressure Switch Fault 6 Flashes Rollout Switch Fault 7 Flashes Internal Control Fault 8 Flashes Temporary 1 hr auto reset 9 Flashes NOTES 1 This code indicates an internal processor fault that will reset itself in one hr Fault can be caused by stray RF signals in the structure or nearby This is a UL requirement 2 LED indicates acceptable operation Do not change ignition control board 3 When W is energized the burners will remain on for a minimum of 60 sec 4 more than one error mode exists they will be displayed on the LED in sequence Rollout Switch The function of the rollout switch is to close the main gas valve in the event of flame rollout The switch is located above the main burners When the temperature at the rollout switch reaches the maximum allowable temperature the control circuit trips closing the gas valve and stopping gas flow to the burners The indoor evaporator fan motor IFM and induced draft motor continue to run until switch is reset The IGC LED will display FAULT CODE 7 Step 4 Start up Cooling and Make Adjust ments Complete the required procedures given in
98. ver purge gas lines into a combustion chamber Immediately upon detection of gas odor retighten the union Allow 5 minutes to elapse then light unit b Make sure that condenser fan blade is correctly positioned in fan orifice Leading edge of condenser fan blade should be 1 2 in 12 mm maximum from fan orifice c Make sure that air filter s is in place d Make sure that condensate drain trap is filled with water to ensure proper drainage e Make sure that all tools and miscellaneous loose parts have been removed START UP Step 1 Check for Refrigerant Leaks Proceed as follows to locate and repair a refrigerant leak and to charge the unit 1 Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high and low pressure ports 2 Repair leak following Refrigerant Service procedures NOTE Install a bi flow filter drier whenever the system has been opened for repair 3 Add a small charge of R 410A refrigerant vapor to system and leak test unit 4 Recover refrigerant from refrigerant system and evacuate to 500 microns if no additional leaks are not found 5 Charge unit with Puron R 410A refrigerant using an electronic scale Refer to unit rating plate for required charge Step 2 Unit Sequence of Operation 48EZ A Sequence of Operation a CONTINUOUS FAN 1 Thermostat closes circuit R to G energizing the blower motor for continuous fan b COOLING MOD
99. way from the unit install a 2 in 51 mm trap at the condensate connection to ensure proper drainage See Fig 6 Make sure that the outlet of the trap is at least 1 in 25 mm lower than the drain pan condensate connection This prevents the pan from overflowing Prime the trap with water Connect a drain tube using a minimum of 3 4 in PVC or 3 4 in copper pipe all field supplied at the outlet end of the 2 in 51 mm trap Do not undersize the tube Pitch the drain tube downward at a slope of at least 1 in 25 mm for every 10 ft 3 m of horizontal run Be sure to check the drain tube for leaks TRAP OUTLET l in 25 mm min A 2 in 51 mm min A09052 Fig 6 Condensate Trap Step 7 Install Flue Hood The flue assembly is secured and shipped in the return air duct Remove duct cover to locate the assembly See Fig 8 NOTE Dedicated low NOx models MUST be installed in California Air Quality Management Districts where a Low NOx rule exists These models meet the California maximum oxides of nitrogen NOx emissions requirements of 40 nanograms joule or less as shipped from the factory NOTE Low NOx requirements apply only to natural gas installations 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The venting system is designed to ensure proper venting The flue hood assembly must be in
100. y applied gasketing also can result in air leaks and poor unit performance Curb should be level to within 1 4 in 6 mm This is necessary for unit drain to function properly Refer to accessory roof curb installation instructions for additional information as required Installation on older G series roof curbs Two accessory kits are available to aid in installing a new G series unit on an old G roof curb 1 Accessory kit number CPADCURBO001A00 small chassis and accessory kit number CPADCURBO002A00 large chassis includes roof curb adapter and gaskets for the perimeter seal and duct openings No additional modifications to the curb are required when using this kit 2 An alternative to the adapter curb is to modify the existing curb by removing the outer horizontal flange and use accessory kit number CPGSKTKIT001A00 which includes spacer blocks for easy alignment to existing curb and gaskets for the perimeter seal and duct openings This kit is used when existing curb is modified by removing outer horizontal flange CAUTION UNIT STRUCTURAL DAMAGE HAZARD Failure to follow this caution may result in property damage Ensure there is sufficient clearance for saw blade when cutting the outer horizontal flange of the roof curb so there is no damage to the roof or flashing SLAB MOUNT Place the unit on a solid level concrete pad that is a minimum of 4 in 102 mm thick with 2 in 51 mm above gr
101. y charged with Puron R 410A refrigerant and is tested and factory sealed Allow system to operate a minimum of 15 minutes before checking or adjusting charge NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper Puron R 410A charge The charging label and the tables shown refer to system temperatures and pressures in cooling mode only A refrigerant charging label is attached to the inside of the compressor access panel see Fig 18 The chart includes the required liquid line temperature at given discharge line pressures and outdoor ambient temperatures An accurate thermocouple or thermistor type thermometer and a gauge manifold are required when using the subcooling charging method for evaluating the unit charge Do not use mercury or small dial type thermometers because they are not adequate for this type of measurement 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in unit damage When evaluating the refrigerant charge an indicated adjustment to the specified factory charge must always be very minimal If a substantial adjustment is indicated an abnormal condition exists somewhere in the cooling system such as insufficient airflow across either coil or both coils Proceed as follows 1 Remove caps from low and high pressure service fittings 2 Using hoses with valve core depressors attach low and high pressure gauge hose

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