Carrier 50XZ024, 50XZ036, 50XZ042, 50XZ048, 50XZ060 Installation, Start-up And Service Instructions Manual

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Page 1

50XZ 024–060

Single-Packaged Heat Pump Units

with Puron® (R-410A) Refrigerant

Installation, Start-Up,

and Service Instructions

NOTE: Read the entire instruction manual before starting the

installation. This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS.....................................................2

Introduction ....................................................................................2

Receiving and Installation..............................................................2

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

IDENTIFY UNIT................................................................2

INSPECT SHIPMENT........................................................2

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

ROOF CURB.......................................................................2

SLAB MOUNT ...................................................................2

GROUND MOUNT ............................................................2

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

Rig and Place Unit....................................................................3

INSPECTION......................................................................3

INSTALLATION ................................................................4

Select and Install Ductwork .....................................................5

CONVERTING HORIZONTAL DISCHARGE UNITS TO

DOWNFLOW (VERTICAL) DISCHARGE UNITS.........7

Provide for Condensate Disposal.............................................7

Install Electrical Connections...................................................8

HIGH-VOLTAGE CONNECTIONS..................................8

ROUTING POWER LEADS INTO UNIT........................9

CONNECTING GROUND LEAD TO GROUND LUG ..9

ROUTING CONTROL POWER WIRES (24-V)..............9

Easy Select™—50XZ .........................................................9

50XZ Sequence Of Operation...........................................17

SPECIAL PROCEDURES FOR 208-V OPERATION ...17

PRE-START-UP ..........................................................................18

START-UP...................................................................................18

50XZ: Start-Up .......................................................................18

Check for Refrigerant Leaks..................................................19

Start-Up Adjustments..............................................................19

CHECKING COOLING AND HEATING CONTROL OP-

ERATION..........................................................................19

CHECKING AND ADJUSTING REFRIGERANT

CHARGE...........................................................................19

REFRIGERANT CHARGE..............................................20

NO CHARGE....................................................................20

LOW CHARGE COOLING .............................................20

TO USE COOLING CHARGING CHARTS ..................20

INDOOR AIRFLOW AND AIRFLOW ADJUST-

MENTS..............................................................................20

Defrost Control .......................................................................20

Quiet Shift..........................................................................20

Defrost................................................................................20

MAINTENANCE.........................................................................22

Air Filter..................................................................................23

Indoor Blower and Motor.......................................................23

Outdoor Coil, Indoor Coil, and Condensate Drain Pan........23

Outdoor Fan............................................................................24

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

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

Indoor Airflow........................................................................24

Metering Devices–TXV & Accurater Piston.........................24

Pressure Switches....................................................................25

Loss of Charge Switch ...........................................................25

High-Pressure Switch..............................................................25

Copeland Scroll Compressor (Puron Refrigerant).................26

Refrigerant System..................................................................26

Refrigerant .........................................................................26

Compressor Oil..................................................................26

Servicing Systems on Roofs with Synthetic Materials....26

Liquid Line Filter Drier ....................................................26

Puron (R-410A) Refrigerant Charging .............................26

System Information.................................................................26

Loss of Charge Switch......................................................26

Check Defrost Thermostat ................................................26

TROUBLESHOOTING ...............................................................27

Start-Up Checklist........................................................................27

NOTE TO INSTALLER — READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY before installing this unit. Also, make sure the Owner’s Manual and Service Instructions are left with the unit after installation.

Fig. 1—Unit 50XZ

C99064

Visit www.carrier.com

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4 Tab 5a 5a

PC101CatalogNo.535–00114 PrintedinU.S.A.Form50XZ-2SIPg18–03Replaces:50XZ-1SI

Page 2

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electric shock, or other occurrences, which could cause serious injury or death or damage your property. Consult a qualified installer or service agency for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when modifying this product.

Recognize safety information. This is the safety-alert symbol . When you see this symbol on the product or in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words — DANGER, WARNING, CAUTION, and NOTE. Danger identifies the most serious hazards, which will result in severe personal injury or death. Warning indicates a condition that could cause serious personal injury or death. Caution is used to identify unsafe practices, which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

1. The power supply (volts, phase, and hertz) must correspond to that specified on unit rating plate.

2. The electrical supply provided by the utility must be sufficient to handle load imposed by this unit.

3. This installation must conform with local building codes and with NEC (National Electrical Code). Refer to provincial and local plumbing or waste water codes and other applicable local codes.

Before performing service or maintenance operations on system, turn off main power to unit. Turn off accessory heater power switch if applicable. Electrical shock could cause severe injury or death.

Puron (R-410A) systems operate at higher pressures than standard R-22 systems. DO not use R-22 service equipment or components on Puron (R-410A) equipment. Ensure service equipment is rated for Puron (R-410A)

INTRODUCTION

The 50XZ heat pump is fully self-contained and designed for outdoor installation. (See Fig. 1) Standard units are shipped in a horizontal-discharge configuration for installation on a groundlevel slab. Standard units can be converted to downflow (vertical) discharge configurations for rooftop applications.

RECEIVING AND INSTALLATION

Step 1—Check Equipment

IDENTIFY UNIT The unit model number and serial number are stamped on the unit

identification plate. Check this information against shipping papers.

INSPECT SHIPMENT Inspect for shipping damage while unit is still on shipping pallet.

If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest Carrier Air Conditioning office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

Step 2—Provide Unit Support

ROOF CURB Install accessory roof curb in accordance with instructions shipped

with curb (See Fig. 5). Install insulation, cant strips, roofing, and flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing also can result in air leaks and poor unit performance.

Curb should be level to within 1/4 in. (See Fig. 6). This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required.

SLAB MOUNT Place the unit on a solid, level concrete pad that is a minimum of

4 in. thick with 2 in. above grade (See Fig. 7). The slab should extend approximately 2 in. beyond the casing on all 4 sides of the unit. Do not secure the unit to the slab except when required by local codes.

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

ground if local codes permit. Place the unit on level ground prepared with gravel for condensate discharge.

Step 3—Provide Clearances

The required minimum service clearances are shown in Figs. 2 and

3. Adequate ventilation and outdoor air must be provided. The outdoor fan draws air through the outdoor coil and discharges it through the top fan grill. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in.

IMPORTANT: Do not restrict outdoor airflow. An air restriction at either the outdoor-air inlet or the fan discharge may be detrimental to compressor life.

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. Slab-mounted units should be at least 4 in. above the highest expected water and runoff levels. Do not use unit if it has been under water.

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Step 4—Rig and Place Unit

Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.)

Only trained, qualified crane operators and ground support staff should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.

Follow all applicable safety codes. Wear safety shoes and work gloves.

INSPECTION Prior to initial use, and at monthly intervals, all rigging brackets

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. Brackets or straps showing any kind of wear in these areas must not be used and should be discarded.

Fig. 2—50XZ024-036 Unit Dimensions

UNIT ELECTRICAL CHARACTERISTICS

UNIT WEIGHT

UNIT HEIGHT

IN. (MM)

”A”

CENTER OF GRAVITY

IN. (MM)

lb kg X Y Z

50XZ024 208/230-1-60 350 159 39.02 (991.1) 20.0 (508.0) 19.3 (489.0) 17.6 (447.0) 50XZ030 Not Available At This Time ” ” ” ” ” ” 50XZ036 208/230-1-60,208/230-3-60 373 169 41.02 (1041.9) 20.0 (508.0) 14.0 (355.6) 13.0 (330.2)

C00160

Required Clearance for Operation and Service

Page 4

INSTALLATION

1. Remove unit from shipping carton. Leave top shipping skid on the unit as a spreader bar to prevent the rigging straps from damaging the unit. If the wood skid is not available, use a spreader bar of sufficient length to protect unit from damage.

2. Position the lifting bracket assembly around the base of the unit. Be sure the strap does not twist.

3. Place each of the 4 metal lifting brackets into the rigging holds in the composite unit base.

4. Thread lifting bracket strapping around bottom perimeter of unit as follows:

a. Open lever of tension buckle (ratchet type). b. Feed strapping through tension buckle as shown in Fig. 8. c. Pull strapping through tension buckle unit taut.

Fig. 3—50XZ 042-060 Unit Dimensions

UNIT ELECTRICAL CHARACTERISTICS

UNIT WEIGHT

UNIT HEIGHT

IN. (MM)

”A”

CENTER OF GRAVITY

IN. (MM)

lb kg X Y Z

50XZ042 Not Available At This Time ” ” ” ” ” ” 50XZ048 208/230-1-60, 208/230-3-60 463 210 44.98 (1142.5) 19.5 (495.3) 17.6 (447.6) 18.0 (457.2) 50XZ060 208/230-1-60, 208/230-3-60 499 226 46.98 (1193.3) 21.0 (533.4) 20.0 (508.0) 17.6 (442.0)

C00161

Page 5

d. Snap lever down to lock strap in tension buckle. To release

strapping, squeeze safety latch, lift lever, and pull webbing outward.

5. Tighten the tension buckle until it is taut. Lifting brackets must be secure in the rigging holds.

6. Attach field-supplied clevis or hook of sufficient strength to hole in the lifting bracket. (See Fig. 9)

7. Attach the 2 safety straps directly to the clevis or hook at the 4 rigging brackets. DO NOT attach the safety straps to the lifting brackets. (See Fig. 9)

8. Position lifting point directly over the unit’s center of gravity.

9. Lift unit. When unit is directly over the roof curb, remove the 2 safety straps. Lower the equipment onto the roof curb.

10. After the unit is placed on the roof curb or mounting pad, remove the top crating. On 50XZ060 units only, 2 wire ties fastened to the outdoor coils and reversing valve/accumulator assembly must be cut. Remove the left and front louver panels and corner post to access wire ties. The wire tie to be cut on the left is located approximately 4 in. down the tube sheet. The wire tie to be cut on the right is located approximately 6 in. down the tube sheet.

Step 5—Select and Install Ductwork

The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of non-residence type air conditioning and ventilating systems, NFPA 90A or residence-type, NFPA 90B and/or local codes and ordinances.

Select and size ductwork, supply-air registers, and return air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations.

The unit has duct flanges on the supply- and return-air openings on the side of the unit.

When designing and installing ductwork, consider the following:

For vertical supply and return units, tools or parts could drop into ductwork and cause serious injury or death. Install a 90 degree turn in the return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Units with electric heaters require 90 degree elbow in supply duct.

1. All units should 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.

2. Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.

IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weather tight and airtight seal. When electric heat is installed, use fireproof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must extend 24-in. from electric heater element.

3. Size ductwork for cooling air quantity (cfm). The minimum air quantity for proper electric heater operation is listed in Table 2. Heater limit switches may trip at air quantities below those recommended.

4. Seal, insulate, and weatherproof all external ductwork. Seal, insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems.

Fig. 4—Corner Weights

CORNER WEIGHTS (SMALL CABINET) CORNER WEIGHTS (LARGE CABINET)

Model 50XZ

Unit 24 30 36

Model 50XZ

Unit 42 48 60

Total Weight 350

Not

Available

373 Total Weight

Not

Available

463 499

Corner Weight 1 70 “ 75 Corner Weight 1 “ 98 107 Corner Weight 2 54 “ 58 Corner Weight 2 “ 61 70 Corner Weight 3 84 “ 90 Corner Weight 3 “ 127 136 Corner Weight 4 141 “ 150 Corner Weight 4 “ 177 186

C00071

Page 6

Fig. 5—Roof Curb Dimensions

UNIT SIZE ODS CATALOG NUMBER

IN. (MM)

50XZ024-036

CPRFCURB006A00 8 (203) 11(279) 161/2 (419) 28-3/4 (730) CPRFCURB007A00 14 (356) 11(279) 161/2 (419) 28-3/4 (730)

50XZ042-060

CPRFCURB008A00 8 (203) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022) CPRFCURB009A00 14 (356) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022)

NOTES:

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

2. Seal strip must be applied, as required, to unit being installed.

3. Dimensions in ( ) are in millimeters.

4. Roof curb is made of 16-gage steel.

5. Table lists only the dimensions, per part number, that have changed.

6. Attach ductwork to curb (flanges of duct rest on curb).

7. Insulated panels: 1-in. thick fiberglass 1 lb. density.

8. Dimensions are in inches.

9. When unit mounting screw is used (see Note A), a retainer bracket must be used as well. This bracket must also be used when required by code for hurricaneor seismic conditions. This bracket is available through Micrometl.

C00076

Gask et around

outer edge

Insulated deck pan

Gask et around

duct

S/A

R/A

HVAC unit

base

*Gask eting

outer flange

Flashing field

supplied

Roofing material

field supplied

Cant str ip

field supplied

*Provided with roofcurb

Roof

Duct wo rk

field supplied

Insulation (field

supplied)

Roofcurb*

Wood nailer*

Gask eting

inner flange*

Scre w

(NO TE A)

Roof Curb for Small Cabinet

Note A: When unit mounting scre w is used,

retainer bra cke t must also be used.

HVAC unit

base

*Gask eting

outer flange

Flashing field

supplied

Roofing material

field supplied

Cant str ip

field supplied

*Provided with roofcurb

Roof

Duct wo rk

field supplied

Insulation (field

supplied)

Roofcurb*

Wood nailer*

Gask eting

inner flange*

Scre w

(NOTE A)

Roof Curb for Large Cabinet

Note A: When unit mounting scre w is used,

retainer bra cket must also be used.

B Ty p.

Supply opening (B x C)

Long

Support

/16"

Return opening

(B X C)

Insulated deck pan

Short

Support

C Typ.

Page 7

5. Secure all ducts to building structure. Flash, weatherproof, and vibration-isolate duct openings in wall or roof according to good construction practices.

CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DISCHARGE UNITS

Before performing service or maintenance operations on system, turn off main power to unit. Turn off accessory heater power switch if applicable. Electrical shock could cause serious injury or death.

1. Open all electrical disconnects before starting any service work.

2. Remove horizontal duct covers to access bottom return and supply knock out panels.

3. Use a screwdriver and hammer to remove the panels in the bottom of the unit base.

NOTE: These panels are held in place with tabs similar to an electrical knockout.

4. Reinstall the horizontal duct covers (Fig. 11) to block off the horizontal air openings.

NOTE: Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.

Step 6—Provide for Condensate Disposal NOTE: Ensure that condensate-water disposal methods comply

with local codes, restrictions, and practices. The 50XZ units dispose of condensate through a 3/4 in. NPT

female fitting that exits on the compressor end of the unit. Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.

Fig. 6—Unit Leveling Tolerances

C99065

MAXIMUM ALLOWABLE

DIFFERENCE (in.)

A-B B-C A-C

1/4 1/4 1/4

Fig. 7—Slab Mounting Detail

C99096

OPTIONAL

RETURN

AIR

OPENING

OPTIONAL

SUPPLY

AIR

OPENING

EVAP. COIL COND. COIL

Fig. 8—Threading Belt

C99067

HANDHOLD

FEED

HOOK

Page 8

If the installation requires draining the condensate water away from the unit, install a field-supplied 2 -in. trap at the condensate connection to ensure proper drainage. Condensate trap is available as an accessory or is field-supplied. Make sure that the outlet of the trap is at least 1 in. lower than the unit drain-pan condensate connection to prevent the pan from overflowing. Connect a drain trough using a minimum of field-supplied 3/4-in. PVC or fieldsupplied 3/4-in. copper pipe at outlet end of the 2-in. trap. (See Fig.

12) Do not undersize the tube. Pitch the drain trough downward at a slope of at least 1 in. every 10 ft. of horizontal run. Be sure to check the drain trough for leaks. Prime the trap at the beginning of the cooling season start-up.

Step 7—Install Electrical Connections

The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of an electrical wire connected to the unit ground lug in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA American National Standards Institute/National Fire Protection Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes. Failure to adhere to this warning could result in serious injury or death.

Failure to follow these precautions could result in damage to the unit being installed:

1. Make all electrical connections in accordance with NEC ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate. On 3-phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.

4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are in same conduit as high-voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

HIGH-VOLTAGE CONNECTIONS The unit must have a separate electrical service with a field-

supplied, waterproof disconnect switch mounted at, or within sight from the unit. Refer to the unit rating plate, NEC and local codes

Fig. 9—Suggested Rigging

UNIT MAXIMUM SHIPPING WEIGHT A B

Size lb kg in. mm. in. mm.

50XZ024 372 169 19.0 482.6 18.25 463.6

50XZ030

Not Yet

Available

“ ““““

50XZ036 395 179 20.0 508 19.0 482.6

50XZ042

Not Yet

Available

“ ““““

50XZ048 485 220 20.0 508 21.25 539.8 50XZ060 521 236 21.0 533.4 20.0 508.0

C99075

PLACE RIGGING BRACKET ASSEMBLY IN 4 RIGGING HOLES AND INSTALL TIE DOWN STRAP AROUND PERIMETER OF UNIT AND THROUGH SPACE IN BRACKET ASSEMBLY

INSTALL SAFETY STRAPS TO RIGGING CLEVIS AT 4 RIGGING BRACKETS

TIGHTEN STRAPPING SECURELY WITH TENSION BUCKLE

SEE DETAIL A

DETAIL A

SCALE 0.250

914-137" (36"-54")

“A”

“B”

Page 9

for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing (See Table 3 for electrical data).

The field-supplied disconnect may be mounted on the unit over the high-voltage inlet hole (See Figs. 2 and 3).

If the unit has an electric heater, a second disconnect may be required. Consult the Installation, Start-Up, and Service Instructions provided with the accessory for electrical service connections.

Operation of unit on improper line voltage constitutes abuse and may cause unit damage that could affect warranty.

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. Run the high-voltage leads through the power entry knockout on the power entry side panel. (See Fig. 2 and 3 for location and size) When the leads are inside the unit, run leads up the high-voltage raceway to the line wiring splice box (See Fig. 13 through 17). For singlephase units, connect leads to the black and yellow wires; for 3-phase units, connect the leads to the black, yellow, and blue wires.

CONNECTING GROUND LEAD TO GROUND LUG Refer to Fig. 16 and 17. Connect the ground lead to the chassis

using the ground lug in the wiring splice box. ROUTING CONTROL POWER WIRES (24-V)

Form a drip-loop with the thermostat leads before routing them into the unit. Route the thermostat leads through grommeted, low-voltage hole provided in unit into unit control power splice box. (See Fig. 2 and 3) Connect thermostat leads to unit control power leads as shown in Fig. 16.

The unit transformer supplies 24-v power for complete system including accessory electrical heater. An automatic-reset circuit breaker (See Fig. 18) is provided in the 24-v circuit; see the caution label on the transformer or Fig. 19. Transformer is factory wired for 230-v operation. If supply voltage is 208-v, rewire transformer primary as described in Special Procedures for 208-v Operation section.

EASY SELECT™—50XZ

EASY SELECT™ CONFIGURATION TAPS FOR 50XZ

Easy Select™ taps are used by the installer to configure a system. The ECM motor uses the selected taps to modify its operation to

Table 1—Physical Data—Unit 50XZ

UNIT SIZE 50XZ024 50XZ030 50XZ036 50XZ042 50XZ048 50XZ060

NOMINAL CAPACITY (ton) 2

Not Yet

Available

Not Yet

Available

OPERATING WEIGHT (lb.) 350 “ 373 “ 463 499

COMPRESSOR QUANTITY 1

TYPE SCROLL COMPRESSOR

REFRIGERANT R-410A

REFRIGERANT METERING DEVICE

Indoor-TXV

Outdoor-Accurater

Refrigerant (R-410A) Quantity (lb.) 7.5 “ 9.5 “ 12.5 14.0

METERING DEVICE

TXV “ TXV “ TXV TXV

ORIFICE OD (in.) 0.035 (2) “ 0.038 (2) “

0.038 (Left OD Coil)

0.046 (Right OD Coil)

0.042 (Left OD Coil)

0.052 (Right OD Coil)

OUTDOOR COIL

Rows... Fins/in.

face area (sq. ft.)

2...21

12.3

“

2...21

13.6

“

2...21

17.2

2...21

19.4

OUTDOOR FAN

Nominal Airflow (CFM)

Diameter

Motor HP (RPM)

2350

1/8 (825)

“

2800

1/8 (825)

“

3300

1/4 (1100)

3300

1/4 (1100)

INDOOR COIL

Rows... Fins/in.

face area (sq. ft.)

3...15

3.7

“

4...15

3.7

“

4...15

4.7

4...15

5.7

INDOOR BLOWER

Nominal Airflow (CFM)

Size (in.)

Motor (HP)

790

10x10

1/2

“

1100

11x10

3/4

“

1400

11x10

3/4

1750

11x10

1.0

HIGH-PRESSURE SWITCH (psig)

Cutout

Reset (Auto)

610±15 420±25

LOSS-OF-CHARGE/LOW-PRESSURE SWITCH

(Liquid Line) (psig)

Cutout

Reset (Auto)

20±5

45±10

RETURN-AIR FILTERS (in.)*

throwaway

20x20x1 “ 20x24x1 “ 24x30x1 24x30x1

* Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute for throwaway type or 450 ft/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 in. wg.

Table 2—Minimum Airflow for Reliable Electric Heater Operation (Cfm)

SIZE 50XZ024 50XZ030 50XZ036 50XZ042 50XZ048 50XZ060

AIRFLOW (CFM) 750 1025 1250 1285 1710 1800

Page 10

a pre-programmed table of airflows. The unit must be configured to operate properly with system components with which it is installed. To successfully configure a basic system (see information printed on circuit board label located next to select pins), move the 6 select wires to the pins which match the components used.

a. AUX HEAT kW/CFM—SELECT HEATER RANGE

FOR SIZE OF ELECTRIC HEATER INSTALLED Installer must select the auxiliary heat airflow approved for

application with kW size heater installed. If no heater is installed, this step can be skipped. Each select pin is

marked with a range of heaters for which airflow (also marked), is approved. For increased comfort, select the narrowest kW range matching the heater size, for example, 0–10 for 10–kW heater. This airflow must be greater than the minimum for CFM for electric heater application with the size system installed for safe and continuous operation. (See Tables 4A, 4B, 4C,5&6forairflow delivery and minimum CFM.) Note that airflow marked is the airflow which will be supplied in emergency heat mode and heating mode on air conditioners when electric heat is the primary heating source. In heat pump heating mode when electric heaters are energized, the ECM will run the higher

Fig. 10—Typical Installation

C00063

INDOOR THERMOSTAT

DISCONNECT PER NEC*

FROM POWER SOURCE

RETURN AIR

TOP COVER

*NEC - NATIONAL ELECTRICAL CODE

Fig. 11—50XZ with Duct Covers On

C00092

Duct Covers

Page 11

of heat pump heating airflow and electric heater airflow to ensure safe heater operation. The factory selection is the largest heater range approved (See Fig. 20, A as indicated).

b. AC/HP SIZE—SELECT SYSTEM SIZE INSTALLED

The factory setting for air conditioner or heat pump size is the size which matches the model of packaged unit installed. Installer should verify air conditioner or heat pump size to ensure that airflow delivered falls within

proper range for the size unit installed. This applies to all operational modes with the exception of electric heat modes (See Fig. 20, B as indicated).

c. SYSTEM TYPE—SELECT SYSTEM TYPE IN-

STALLED The type of system will be factory selected (see below for

details): (1.) AC-Air conditioner (2.) HP-COMFORT—Heat Pump Comfort provides ap-

proximately 315 CFM per ton for higher normal

Fig. 12—Condensate Trap

C99013

1” (25mm) MIN.

2” (50mm) MIN.

TRAP OUTLET

Table 3—Electrical Data—50XZ

UNIT 50XZ

SIZE

V-PH-HZ

VOLTAGE

RANGE

COMPRESSOR

ODFM

FLA

IDFM

FLA

ELECTRIC HEAT SINGLE POINT POWER SUPPLY

Min Max RLA LRA Nominal Kw* FLA UNIT MCA MAX FUSE OR CKT BKR MOCP

024 208/230–1–60 187 253 13.5 61.0 0.9 4.3

-/-

3.8/5.0

5.4/7.2

7.5/10.0

-/-

18.1/20.8 26/30

36.1/41.7

22.1/22.1

44.6/48.1

54.6/59.6

67.2/74.2

30/30 60/60

— —

—

— 70/70 80/80

030 208/230–1–60 187 253 15.9 73.0 0.9 4.3

-/-

3.8/5.0

5.4/7.2

7.5/10.0

11.3/15.0

-/-

18.1/20.8 26/30

36.1/41.7

54.2/62.5

25.1/25.1

47.6/51.1

57.6/62.6

70.2/77.2

92.8/103.2

30/30

— — — —

— 60/70 70/80 80/90

100/110

036

208/230–1–60 187 253 16.9 83.0 0.9 6.8

-/-

3.8/5.0

5.4/7.2

7.5/10.0

11.3/15.0

-/-

18.1/20.8 26/30

36.1/41.7

54.2/62.5

28.8/28.8

51.4/54.9

61.3/66.3

74.0/80.9

96.5/107.0

35/35

— — — —

— 70/70 80/80 90/90

100/110

208/230–3–60 187 253 12.2 77.0 1.6 6.8

-/-

3.8/5.0

7.5/10.0

11.3/15.0

-/-

10.4/12.0

20.8/24.1

31.3/36.1

23.7/23.7

36.7/38.7

49.7/53.7

62.7/68.8

30/30 50/50 60/60

—

— 70/80

042

208/230–1–60 187 253 22.4 105.0 0.9 6.8

-/-

3.8/5.0

5.4/7.2

7.5/10.0

11.3/15.0

15.0/20.0

-/-

18.1/20.8 26/30

36.1/41.7

54.2/62.5

72.2/83.3

35.7/35.7

58.3/61.7

68.2/73.2

80.8/87.8

103.4/113.8

126.0/139.9

45/45

— — — — —

— 80/80 90/90

100/100 125/125 150/150

208/230–3–60 187 253 15.4 88.0 0.9 6.8

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

10.4/12.0

20.8/24.1

31.3/36.1

41.6/48.0

27.0/27.0

40.0/42.0

53.0/57.0

66./72.1

78.9/86.9

35/35 60/60

— — —

—

— 70/70 80/80

90/100

048

208/230–1–60 187 253 21.3 109.0 1.6 6.8

-/-

3.8/5.0

5.4/7.2

7.5/10.0

11.3/15.0

15.0/20.0

-/-

18.1/20.8 26/30

36.1/41.7

54.2/62.5

72.2/83.3

35.0/35.0

57.6/61.1

67.5/72.5

80.2/87.1

102.7/113.2

125.3/139.2

45/45

— — — — —

— 80/80 90/90

100/100 125/125 150/150

208/230–3–60 187 253 14.7 91.0 1.6 6.8

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

10.4/12.0

20.8/24.1

31.3/36.1

41.6/48.0

26.8/26.8

39.8/41.8

52.8/56.8

65.9/71.9

78.7/86.7

35/35 60/60

— — —

—

— 70/70 80/80 90/90

060

208/230–1–60 187 253 26.9 145.0 1.5 9.1

-/-

3.8/5.0

5.4/7.2

7.5/10.0

11.3/15.0

15.0/20.0

-/-

18.1/20.8 26/30

36.1/41.7

54.2/62.5

72.2/83.3

44.2/44.2

66.8/70.3

76.7/81.7

89.4/96.3

111.9/122.4

134.5/148.4

60/60

— — — — —

—

90/100 100/110 110/125 150/150 150/175

208/230–3–60 187 253 17.6 123.0 1.5 9.1

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

10.4/12.0

20.8/24.1

31.3/36.1

41.6/48.0

32.6/32.6

45.6/47.6

58.7/62.7

71.7/77.7

84.6/92.6

40/40 60/60

— — —

—

— 70/70 80/80 90/90

Page 12

heating air delivery temperature and provides approximately 350 CFM per ton cooling airflow for good humidity removal.

(3.) HP-EFF (Factory Selected for 50XZ)— Heat Pump

Efficiency provides same airflow for heating and cooling modes to increase overall HP efficiency; approximately 350 CFM per ton.

d. AC/HP CFM ADJUST—SELECT NOMINAL, LOW, OR

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

High-Hi (NOM for 060) tap. The CFM Adjust selections NOM/LO will regulate airflow supplied for all operational modes, except non-heat pump heating modes. HI provides 15 percent airflow over nominal unit size selected and LO provides 10 percent airflow below nominal unit size selected. CFM Adjust selection options are provided to adjust airflow supplied to meet individual installation needs for such things as noise, comfort, and humidity removal (See Fig. 20, D as indicated).

e. ON/OFF DELAY—SELECT DESIRED

TIME DELAY PROFILE Four motor operation delay profiles are provided to cus-

tomize and enhance system operation (See Fig. 20, E as indicated). Selection options are:

(1.) The standard 90 sec off delay (Factory Setting) at 100

percent airflow in cooling or heat pump heating mode.

(2.) A 30 sec cooling delay with no airflow, 90 sec off

delay at 100 percent airflow profile is used when it is desirable to allow system coils time to heat-up/cooldown in conjunction with the airflow in cooling or heat pump heating mode.

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

thermostat is utilized to perform delay functions.

(4.) ENH, enhanced selection, provides a 30 sec cooling on

delay with no airflow, plus 150 sec at 70 percent airflow and no off delay for added comfort. This will minimize cold blow in heat pump operation and could enhance system efficiency.

f. CONTINUOUS FAN—SELECT DESIRED FAN SPEED

WHEN THERMOSTAT IS SET ON CONTINUOUS FAN (1.) LO speed—Factory setting, 50 percent cooling mode

airflow.

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

cooling mode airflow.

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

mode airflow (See Fig. 20, F as indicated).

g. LOW-VOLTAGE CIRCUIT FUSING AND REFER-

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

5–amp automotive fuse placed in series with the transformer SEC2 and the R circuit. The C circuit of the transformer is referenced to chassis ground through a printed circuit run at SEC1 connected to metal standoff marked with ground symbol.

h. BASIC UNIT CONFIGURATION

The following basic configuration of the indoor motor will provide ARI rated performance of the System. This BASIC

CONFIGURATION should be used when the rated ARI performance is required, or if system enhancements such as super dehumidify are not needed.

(1.) AUX HEAT kW/CFM-Select the heater range for the

size of electric heater installed (skip this step if no heater is installed).

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

installed, please verify.

(3.) SYSTEM TYPE-Factory selected HP-EFF (for unit

50XZ).

Fig. 13—Electrical Data Legend

C03014

228 =1v 229 =2v 227 =2v

LEGEND

FLA — Full Load Amps LRA — Locked Rotor Amps MCA -- Minimum Circuit Amps MOCP — Maximum Overcurrent Protection RLA — Rated Load Amps

NO TES:

1. In compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NE C Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse. The CGA (Canadian Gas Association) units may be fuse or circuit break er.

2. Minimum wire size is based on 60 C copper wire. I f other than 60 C wire is used, or if length exceeds wire length in table, determine siz e from NEC..

3. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%.

Use the following formula to determine

the percentage of voltage imbalance. % Voltage imbalance

max voltage deviation from average voltage

= 100 x

average voltage

EXAMPLE: Supply voltage is 230-3-60.

AB = 228 v BC = 231 v AC = 227 v

228 + 231 + 227

Average Voltage =

686

= 229

Determine maximum deviation from average voltage.

(AB) 229 (BC) 231 -

(AC) 229 Maximum deviation is 2 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

229

= 0.8%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

Heater capacity (kW) based on heater voltage of 208v & 240v. If power distibution voltage to unit varies from rated heater voltage, heater kW will vary accordingly.

Page 13

Fig. 14—Wiring Schematics-50XZ Single Phase

C03005

Page 14

Fig. 15—Wiring Schematics-50XZ Three Phase

3 2

C03006

Page 15

(4.) AC/HP CFM ADJUST-Select HIGH for 042 & 048,

NOM for 036 & 060, and LO for 024 & 030. (5.) ON/OFF DELAY-Select 0/90 profile. (6.) CONTINUOUS FAN-Select desired fan speed when

thermostat is set to continuous fan.

i. COMFORT OPTIONS—SUPER DEHUMIDIFY (See

Quick Reference Guide) The Super Dehumidify option is possible when this unit is

installed with a field supplied Thermidistat™ control (Super Dehumidify does not require an outdoor temperature sensor). The following configuration is recommended for maximum cooling/dehumidifying comfort: This configuration will improve the comfort provided by the air conditioning system if more humidity removal is desired. While providing this improved comfort, the system will operate efficiently, but not at the published HSPF or ARI SEER

efficiency. The following system configuration is recommended for maximum heating and cooling/dehumidifying comfort (See Fig. 20–22).

(1.) AUX HEAT kW/CFM-Select the narrowest heater

range to match size of electric heater installed (skip this step if no heater is installed).

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

installed, please verify.

(3.) SYSTEM TYPE-Select system type HP-COMFORT

(for heat pump system) or AC (for air conditioner system).

Fig. 16—High and Control Voltage Wiring Connections

C01028

POWER SUPPLY

FIELD-SUPPLIED FUSED DISCONNECT

HIGH VOLT AGE POWER LEADS (SEE UNIT WIRING LABEL)

GND

CONTROL BOX

SPLICE BOX

LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)

YEL(Y) GRN(G)

RED(R) BRN(C)

THERMOSTAT (TYPICAL)

LEGEND

Field Control-Voltage Wiring Field High-Voltage Wiring

BLK(DH)

DHUM

Y G R C

WHI(W1) GRA(W2)

ORN(0)

Fig. 17—Line Power Connections

C99057

GROUND LUG

(IN SLPICE BOX)

BLU

YEL

BLK

GROUND

LEAD

SINGLE-PHASE CONNECTIONS TO DISCONNECT PER NEC

3-PHASE CONNECTIONS

LEGEND NEC – National Electrical Code

Field Wiring Splice Connections

NOTE: Use copper wire only.

Fig. 18—Control Wiring Plate

C99070

24 V Circuit Breaker

24 V olt Compartment

Page 16

(4.) AC/HP CFM ADJUST-Select NOM (Lo for 060). (5.) ON/OFF DELAY-Select ENH profile. (6.) CONTINUOUS FAN-Select desired fan speed when

thermostat is set to continuous fan. (7.) DEHUMIDIFY MODE-Remove J1 jumper to activate. (8.) LOW VOLTAGE CONNECTIONS-Make connec-

tions as shown in ELECTRICAL CONNECTIONS

section. (9.) CONFIGURE THERMIDISTAT™ (or capable zoning

system)-Following its installation instructions for Su-

per Dehumidify and Super Comfort Heat operation. This configuration provides the following comfort enhance-

ments:

(a.) A 30 sec blower on delay with 150 sec at 70

percent airflow to allow the indoor coil to warm up or cool down before the blower is asked to deliver 100 percent airflow reducing the cold blow sensation at start up in heating and allowing the indoor coil to more quickly reach wet coil operating conditions in cooling.

(b.) A no blower off delay eliminates cold blow which

may be associated with running the blower after shut down of the compressor and avoids reevaporation of condensed moisture after cooling/dehumidifying operation.

(c.) Lower airflow while the compressor is running to

reduce draft effects and increase heating air temperature and improved humidity control during cooling operation.

ACCESSORY INSTALLATION

a. ACCESSORY ELECTRIC HEATERS

Electric heaters may be installed with the 50XZ units per instructions supplied with electric heater package. See unit rating plate for factory-approved electric heater kits.

b. AUXILIARY TERMINALS

The AUX and HUM terminals on the Easy Select™ Board are tied directly to the G terminal, and provide a 24-v. signal whenever the G terminal is energized (See Fig. 20). During Super dehumidify mode, the G signal is not present and the auxiliary terminals are not energized. If the installation includes the use of the operating mode, do not use these terminals to control accessories. See Electronic Air Cleaner and Humidifier sections for further information.

c. ELECTRONIC AIR CLEANER CONNECTIONS

The AUX1 and AUX2 terminals are not always energized during blower operations, as described above. When using an electronic air cleaner with the unit, use Airflow Sensor P/N KEAAC0101AAA. The airflow sensor turns on electronic air cleaner when the blower is operating.

d. HUMIDIFIER/HUMIDISTAT CONNECTIONS

Easy Select™ Board terminals HUM1 and HUM2 are provided for direct connection to the low-voltage control of a humidifier through a standard humidistat (See Fig. 20–22). These terminals are energized with 24-v. when G thermostat signal is present. (See Fig. 20–22). Alternately, the 24-v. signal may be sourced from the W and C circuit board connections. When using a Thermidistat™ Control, Zone Comfort Plus or Comfort Zone II, the 24-v. signal may be sourced directly from the Thermidistat™ HUM terminal.

e. DEHUMIDIFY CAPABILITY WITH STANDARD

HUMIDISTAT CONNECTION Latent capacities for these units are better than average

systems. If increased latent capacity is an application requirement, the circuit board provides connection terminals for use of a standard humidistat. The unit will detect the humidistat contacts opening on increasing humidity and reduce its airflow to approximately 80 percent of nominal cooling mode airflow. This reduction will increase the system latent capacity until the humidity falls to a level which causes the humidistat to close its contacts. When the

Fig. 19—Transformer Label

C99058

TRANSFORMER CONTAINS A MANUAL RESET OVERCURRENT PROTECTOR

IT WILL NOT AUTOMATICALLY RESET DISCONNECT POWER AND INSTALL

LOCKOUT TAG PRIOR TO SERVICING THIS COMPARTMENT MUST BE CLOSED

EXCEPT WHEN SERVICING

Fig. 20—Detail of SPP Printed-Circuit Board

C01033

EASY SELECT

HEATER/MOTOR

AUX HEAT KW/CFM

0-30 1075

SEC1 SEC2

AC/HP SIZE

036 030 024 018

HP-COMFORT

HP-EFF

NOM HI

ENH

SYSTEM TYPE

AC/HP CFM ADJUST

ON/OFF DELAY

CONTINUOUS FAN

MED HI YELLO

AUX1 HUM1

AUX2

24VAC

GRY

HUM2

YEL

WHT

BLK

ORN

BLU

VIO

0-20 875

0-10 725

09030900

0-5 625

R W

Y/Y

G O C

9 PIN CONNECTOR

ICM PRINTED CIRCUIT BOARD

12 PIN CONNECTOR

Fig. 21—Humidifier Wiring for 50XZ

A95317

HUMIDISTAT

TO HUMIDIFIER

HUMIDIFIER WIRING

HUM 1

(C)

HUM 2

(G)

24-VAC

Page 17

contacts close, the airflow will return to 100 percent of selected cooling airflow. To activate this mode, remove jumper J1 and wire in a standard humidistat (See Fig. 20–22).

f. DEHUMIDIFY AND SUPER DEHUMIDIFY CAPABILI-

TIES these models are capable of responding to a signal from

indoor system control (thermostat, Thermidistat™, zoning control) to operate in comfort control modes such as Super Dehumidify Mode. Consult literature provided with indoor system control to determine if these operating modes are available, and to see control set up instructions. No special setup or wiring of unit is required.

50XZ SEQUENCE OF OPERATION

a. CONTINUOUS FAN

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

continuous fan airflow.

b. COOLING MODE-LOW HUMIDITY

(1.) If indoor temperature is above temperature set point

and humidity is below humidity set point, thermostat closes circuits R to G, R to Y/Y2 and R to O—The unit delivers cooling airflow.

c. COOLING MODE-DEHUMIDIFICATION

(1.) If indoor temperature is above temperature set point

and humidity is above humidity set point, thermostat or Thermidistat™ closes circuits R to G, R to O, and R to Y/Y2 and humidistat or Thermidistat™ opens R to DH—The unit delivers airflow which is approximately 80 percent of the nominal cooling airflow to increase the latent capacity of the system.

d. COOLING MODE-SUPER DEHUMIDIFY OPERATION

(see quick reference guide)

NOTE: The indoor control used, such as a Thermidistat™, must be capable of providing Super Dehumidify operation mode and control must be configured as outlined in its installation instructions. Consult indoor control literature to determine if control is capable of providing Super Dehumidify inputs and for configuration instruction.

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

point and the humidity is above the humidity set point, the Thermidistat™ closes circuit R to O, opens circuits R to DH and R to G, and cycles circuit R to Y/Y2. If circuit R to G is closed (24-v.), the motor will deliver airflow at the full cooling or cooling plus dehumidify mode requested value. If circuit R to G is open (0–v.) for super dehumidify mode, the motor delivers reduced airflow to maximize the humidity removal of the system while minimizing over cooling.

e. ELECTRIC HEATING MODE

(1.) Thermostat closes circuit R to W/W1, or W2—The

unit delivers the selected electric heat airflow. There are no on or off delays.

f. HEAT PUMP HEATING MODE

(1.) Thermostat closes circuits R to G and R to Y/Y2—The

unit delivers selected heat pump heating airflow.

g. HEAT PUMP HEATING WITH AUXILIARY

ELECTRIC HEAT (1.) Thermostat closes circuits R to G, R to Y/Y2 and R to

W/W1 or W2 (and R to O in the case of defrost).

In the event that electric heating is called for by the thermostat while the heat pump is also operating in either heating or defrost modes, the motor will modify its airflow output, if necessary, to provide an airflow which is defined as safe for the operation of the electric heater during heat pump operation. That airflow is the greater of the heat pump heating airflow and the electric heater only airflow.

h. HEATING MODE—SUPER COMFORT HEAT OPERA-

TION

NOTE: The indoor control used, such as a Thermidistat™, must be capable of providing Super Comfort Heat operation mode and control must be configured as outlined in its installation instructions. The system must be installed with appropriate outdoor temperature sensor. Consult indoor control literature to determine if control is capable and for configuration instructions. Consult indoor control instructions and sensor instructions for sensor installation details.

If the outdoor temperature is in the range of 12° to 40° F, the Thermidistat™ closes circuit R to Y/Y2 and opens circuit R to G. If circuit R to G is closed (24-v.), the motor will deliver airflow at the full heating requested value. If circuit R to G is open (0-v.) for maximum heating comfort, the motor delivers reduced airflow to maximize the temperature and minimize the draft effect of the heated air leaving the unit.

SPECIAL PROCEDURES FOR 208-V OPERATION

1. Be sure unit disconnect switch is open.

2. Disconnect the yellow primary lead (w 110) from the transformer. See unit wiring label. (See Fig. 14 or 15 and 18)

3. Connect the yellow primary lead (w110) to the transformer terminal labeled 200-v.

Fig. 22—Humidistat Wiring for De-Humidify Mode-

for 50XZ

A95316

EASY SELECT

BOARD TERMINAL

BLOCK

HUMIDISTAT

REMOVE

JUMPER

Page 18

PRE-START-UP

Failure to observe the following warnings could result in serious personal injury or death:

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compressor terminal cover until all electrical sources are disconnected.

4. Relieve and recover all refrigerant from both high- and low-pressure sides of system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals.

5. Never attempt to repair soldered connection while refrigerant system is under pressure.

6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. Shut off electrical power to unit. b. Relieve and reclaim all refrigerant from system using

both high- and low-pressure ports.

c. Cut component connecting tubing with tubing cutter and

remove component from unit.

d. Carefully unsweat remaining tubing stubs when neces-

sary. Oil can ignite when exposed to torch flame.

Use the Start-Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start-up:

1. Remove all access panels.

2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with, unit.

3. Make the following inspections: a. Inspect for shipping and handling damages such as broken

lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and on

unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections using electronic leak detector, or liquid-soap solution. If a refrigerant leak is detected, see following Check for Refrigerant Leaks section.

c. Inspect all field and factory-wiring connections. Be sure

that connections are completed and tight.

d. Inspect coil fins. If damaged during shipping and handling,

carefully straighten fins with a fin comb.

4. Verify the following conditions: a. Make sure that outdoor-fan blade is correctly positioned in

fan orifice. b. Make sure that air filter(s) is in place. c. Make sure that condensate drain pan and trap are filled with

water to ensure proper drainage. d. Make sure that – on the 060 size, only – the 2 wire ties

fastened to the outdoor coils and reversing

valve/accumulator have been removed. e. Make sure that all tools and miscellaneous loose parts have

been removed.

5. Compressors are internally spring mounted. Do not loosen or remove compressor hold-down bolts.

6. Each unit system has 2 Schrader-type ports, one low-side Schrader fitting located on the suction line, and one high-side Schrader fitting located on the compressor discharge line. Be sure that caps on the ports are tight.

START-UP

Step 1—50XZ: Start-Up

CHECKING COOLING AND HEATING CONTROL OPERATION– Start and check the unit for proper control operation as follows:

(1.) Place room thermostat SYSTEM switch or MODE

control in OFF position. Observe that blower motor starts when FAN mode is placed in FAN ON position and shuts down according to time delay selected on the Easy Select™ board (See Easy Select Section) when FAN MODE switch is placed in AUTO position.

(2.) Thermostat:

When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat, the thermostat completes the circuit between thermostat terminal R to terminals Y, O and G. These completed circuits through the thermostat connect contactor coil (C) (through unit wire Y) and ECM board (through unit wire G) across the 24-v. secondary of transformer (TRAN).

Thermidistat™ or Thermostat and Humidistat:

When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat, the thermostat completes the circuit between thermostat terminal R to terminals Y, O, DH, and G. These completed circuits through the thermostat connect contactor coil (C) (through unit wire Y) and ECM board (though unit wire G) across the 24-v. secondary of transformer (TRANS).

(3.) Place system switch or MODE control in HEAT

position. Set control above room temperature. Observe that compressor, outdoor fan, and indoor blower motors start. Observe that heating cycle shuts down according to time delay selected on the Easy Select™ board (See Easy Select Section) when control setting is satisfied.

(4.) When using an automatic changeover room thermo-

stat, place both SYSTEM or MODE control and FAN mode switches in AUTO positions. Observe that unit operates in Cooling mode when temperature control is set to “call for Cooling” (below room temperature), and unit operates in Heating mode when temperature control is set to “call for Heating” (above room temperature).

Fig. 23—Fan Blade Clearance

C99009

FAN GRILLE

MOTOR

1/8" MAX BETWEEN MOTORAND FAN HUB

MOTOR SHAFT

1/2˝

Page 19

NOTE: Once the compressor has started and then has stopped, it should not be started again until 5 minutes have elapsed. The cooling cycle remains ‘‘on’’ until the room temperature drops to point that is slightly below the cooling control setting of the room thermostat. At this point, the thermostat ‘‘breaks’’ the circuit between thermostat terminal R to terminals Y and G. These open circuits de-energize contactor coil C and ECM board. The condenser and compressor motors stop. After the time delay setting selected on the Easy Select™ board (See Easy Select Section) , the blower motor stops. The unit is in a ‘‘standby’’ condition, waiting for the next ‘‘call for cooling’’ from the room thermostat. The 5 minute compressor delay also applies to heat pump heating mode.

Step 2—Check for Refrigerant Leaks

Locate and repair refrigerant leaks and charge the unit as follows:

1. Use both high- and low-pressure ports to relieve system pressure and reclaim remaining refrigerant.

2. Repair leak following accepted practices.

NOTE: Install a bi-flow filter drier whenever the system has been opened for repair.

3. Check system for leaks using an approved method.

4. Evacuate refrigerant system and reclaim refrigerant if no additional leaks are found.

5. Charge unit with R-410A refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating plate for required charge.

Step 3—Start-Up Adjustments

Complete the required procedures given in the Pre-Start-Up section before starting the unit. Do not jumper any safety devices when operating the unit. Do not operate the unit in Cooling mode when the outdoor temperature is below 40°F (unless accessory low-ambient kit is installed). Do not rapid-cycle the compressor. Allow 5 min. between “on” cycles to prevent compressor damage.

CHECKING COOLING AND HEATING CONTROL OPERATION

Start and check the unit for proper control operation as follows:

1. Place room thermostat SYSTEM switch or MODE control in OFF position. Observe that blower motor starts when FAN mode is placed in FAN ON position and shuts down within 60 sec (030-060 size) or 30 sec (024 size) when FAN MODE switch is placed in AUTO position.

2. Place system switch or MODE control in HEAT position. Set control above room temperature. Observe that compressor, outdoor fan, and indoor blower motors start. Observe that heating cycle shuts down when control setting is satisfied.

3. When using an automatic changeover room thermostat, place both SYSTEM or MODE control and FAN mode switches in AUTO positions. Observe that unit operates in Cooling mode when temperature control is set to “call for Cooling” (below room temperature), and unit operates in Heating mode when temperature control is set to “call for Heating” (above room temperature).

IMPORTANT: Three-phase, scroll compressors are 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 may be dramatically lower than normal.

CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with R-410A refrigerant

and is tested and factory sealed. NOTE: Adjustment of the refrigerant charge is not required

unless the unit is suspected of not having the proper R-410A charge. The charging label and the tables shown refer to system temperatures and pressures in Cooling mode, only. A refrigerant charging label is attached to the outside of the service access door. If charge level is suspect in Heating mode, reclaim all refrigerant

Fig. 24—Typical Heat Pump Operation, Cooling Mode

C03011

COMPRESSOR

ACCUMULATOR

OUTDOOR COIL

INDOOR COIL

LCS

LEGEND

HPS – High Pressure Switch LCS – Loss of Charge Switch

Accurater

Metering De vice

Arrow indicates direction of flo w

TXV in Metering

Position

Bypass

Position

HP S

Page 20

and charge to nameplate amount. (This information may be obtained from the physical data table also.) 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 outside of the service access door. If charge level is suspect in Heating mode, reclaim all refrigerant and charge to nameplate amount. (This information may be obtained from the physical data table also.)

IMPORTANT: 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.

REFRIGERANT CHARGE The amount of refrigerant charge is listed on the unit nameplate

and/or the physical data table. Refer to the Refrigeration Service Techniques Manual, Refrigerants Section.

NO CHARGE Check for leak. Use standard evacuating techniques. After evacu-

ating system, weigh in the specified amount of refrigerant (refer to system data plate).

LOW CHARGE COOLING Use Cooling Charging Chart (Fig. 27). Vary refrigerant until the

conditions of the chart are met. Note that charging charts are different from type normally used. Charts are based on charging the units to correct subcooling for the various operating conditions. Accurate pressure gauge and temperature sensing devices are required. Connect the pressure gauge to the service port on the suction line. Mount the temperature sensing device on the suction line and insulate it so that the outdoor ambient does not affect the reading. Indoor air CFM must be within the normal operating range of the unit.

TO USE COOLING CHARGING CHARTS Take the liquid line temperature and read the manifold pressure

gauges. Refer to the chart to determine what the liquid line temperature should be. NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to Check for Refrigerant Leaks section.

INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS

For heating and cooling operation, the recommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For units with optional electric heat, the airflow must not be reduced below the levels stated in Table 2.

Tables 4A & 4B show both heating and cooling airflows. Refer to these tables to determine the airflow for the system being installed.

NOTE: Be sure that all supply-and return-air grilles are open, free from obstructions, and adjusted properly.

Airflow can be changed by changing the set up pins on the Easy Select™ board.

Unit 50XZ utilizes state of the art ECM (Electronic Computated Motor) ID Blower Motors.

Step 4—Defrost Control

QUIET SHIFT Quiet Shift is a field-selectable defrost mode, which will eliminate

occasional noise that could be heard at the start of defrost cycle and restarting of heating cycle. It is selected by placing DIP switch 3 (on defrost board) in ON position.

When Quiet Shift switch is placed in ON position, and a defrost is initiated, the following sequence of operation will occur. Reversing valve will energize, outdoor fan will turn off, compressor will turn off for 30 sec and then turn back on to complete defrost. At the start of heating after conclusion of defrost reversing valve will de-energize, compressor will turn off for another 30 sec, and the outdoor fan will stay off for 40 sec, before starting in the Heating mode.

DEFROST The defrost control is a time/temperature control which includes a

field-selectable time period (DIP switch 1 and 2 on the board) between defrost cycles of 30, 60, 90, or 120 minutes (factory set at 30 minutes).

To initiate a forced defrost, two options are available depending on the status of the defrost thermostat.

Fig. 25—Typical Heat Pump Operation, Heating Mode

C03012

COMPRESSOR

ACCUMULATOR

OUTDOOR COIL

INDOOR COIL

LCS

LEGEND

HPS – High Pressure Switch LCS – Loss of Charge Switch

Accurater

Metering De vice

Arrow indicates direction of flo w

TXV in Bypass Position

Metering

Position

HP S

Page 21

If defrost thermostat is closed, speedup pins (J1) must be shorted by placing a flat head screw driver in between for 5 sec and releasing, to observe a complete defrost cycle. When the Quiet Shift switch is selected, compressor will be turned off for two 30 sec intervals during this complete defrost cycle, as explained previously. When Quiet Shift switch is in factory default OFF position, a normal and complete defrost cycle will be observed.

If defrost thermostat is in open position, and speedup pins are shorted (with a flat head screw driver) for 5 sec and released,a short defrost cycle will be observed (actual length is dependent upon the selected Quiet Shift position). When Quiet Shift switch is in ON position, the length of defrost is 1 minute (30 sec compressor off period followed by 30 sec of defrost with compressor operation). On return to heating operation, compressor will

Table 4A—50XZ Cooling & Heating Dry Coil ECM Airflow

Small Cabinet

UNIT SIZE

CFM ADJUST

PIN SELECT

LO PIN NOM PIN HI PIN

EXTERNAL STATIC

PRESSURE RANGE

0.0–0.39 0.4–0.69 0.7–1.0 0.0–0.39 0.4–0.69 0.7–1.0 0.0–0.39 0.4–0.69 0.7–1.0

024

COOLING † 800 725 – 885 805 730 990 930 855

COOLING

DEHUMIDIFY

715 670 – 715 695 645 795 775 745

HEAT PUMP

COMFORT

720 660 – 790 745 685 890 850 785

030

COOLING † 1010 920 825 1105 1030 930 1255 1160 1050

COOLING

DEHUMIDIFY

890 845 795 890 865 825 1010 980 925

HEAT PUMP

COMFORT

945 850 765 1020 965 895 1140 1105 995

036

COOLING † 1110 1025 970 1235 1175 1115 1400 1355 1280

COOLING

DEHUMIDIFY

990 960 910 990 975 940 1125 1110 1085

HEAT PUMP

COMFORT

1035 975 910 1160 1080 1020 1305 1275 1220

†

Heat Pump Efficiency

and

Cooling

pin selections deliver equal airflow

Table 4B—50XZ Cooling & Heating Dry Coil ECM Airflow

Large Cabinet

UNIT SIZE

CFM ADJUST

PIN SELECT

LO PIN NOM PIN HI PIN

EXTERNAL STATIC

PRESSURE RANGE

0.1–1.0 0.1–1.0 0.1–1.0

042

COOLING † 1100 1225 1410

COOLING

DEHUMIDIFY

980 980 1125

HEAT PUMP

COMFORT

990 1100 1265

048

COOLING † 1260 1400 1610

COOLING

DEHUMIDIFY

1120 1120 1290

HEAT PUMP

COMFORT

1135 1260 1450

060

COOLING † 1575 1750 2010

COOLING

DEHUMIDIFY

1400 1400 1610

HEAT PUMP

COMFORT

1415 1575 1810

†

Heat Pump Efficiency

and

Cooling

pin selections deliver equal airflow

Table 4C—ECM WET COIL PRESSURE DROP (in. wg)

UNIT SIZE

STANDARD CFM (SCFM)

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100

024 0.005 0.007 0.010 0.012 0.015 ––––––––––– 030 – 0.007 0.010 0.012 0.015 0.018 0.021 0.024 –––––––– 036 – – – 0.019 0.023 0.027 0.032 0.037 0.042 0.047 –––––– 042 ––––0.014 0.017 0.020 0.024 0.027 0.031 0.035 0.039 0.043 – – – 048 ––––––0.027 0.032 0.036 0.041 0.046 0.052 0.057 0.063 0.068 – 060 –––––––––0.029 0.032 0.036 0.040 0.045 0.049 0.053

Page 22

again turn off for an additional 30 sec and the outdoor fan for 40 sec. When the Quiet Shift is in OFF position, only a brief 30 sec cycle will be observed.

If it is desirable to observe a complete defrost in warmer weather, the defrost thermostat must be closed as follows.

1. Turn off power to outdoor unit.

2. Disconnect outdoor fan motor lead from OF2 on control board. (See Fig. 28) Tape to prevent grounding.

3. Restart unit in Heating mode, allowing frost to accumulate on outdoor coil.

4. After a few minutes in Heating mode, liquid line temperature should drop below closing point of defrost thermostat (approximately 30°F).

NOTE: Unit will remain in defrost until defrost thermostat reopens at approximately 80°F coil temperature at liquid line or remainder of defrost cycle time.

5. Turn off power to outdoor and reconnect fan motor lead to OF2 on control board after above forced defrost cycle.

MAINTENANCE

To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This heat pump unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 7. NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.

The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment, other than those procedures recommended in the User’s Manual. FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND POSSIBLE DAMAGE TO THIS EQUIPMENT.

Failure to follow these warnings could result in serious injury or death:

1. Turn off electrical power to the unit before performing any maintenance or service on this unit.

2. Use extreme caution when removing panels and parts. As with any mechanical equipment, personal injury can result from sharp edges.

3. Never place anything combustible either on, or in contact with, the unit.

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.

2. Inspect indoor coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.

Table 5—FILTER PRESSURE DROP TABLE (In. wg)

FILTER SIZE

CFM

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

20X20X1 0.05 0.07 0.08 0.10 0.12 0.13 0.14 0.15 ——————————— 20X24X1 ————0.09 0.10 0.11 0.13 0.14 0.15 0.16 ———————— 24X30X1 ————— — —0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18

Table 6—ELECTRIC HEAT PRESSURE DROP TABLE

Small Cabinet: 024-036CFM

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

5kw 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07

7.5 kw 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.03 0.05 0.07 0.08 0.09 10 kw 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07 0.09 0.10 0.11 15 kw 0.00 0.00 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 20 kw 0.00 0.00 0.02 0.04 0.06 0.08 0.09 0.11 0.13 0.15 0.17 0.19

ELECTRIC HEAT PRESSURE DROP TABLE

Large Cabinet: 042-060

CFM

1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500

5kw 0.00 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12

7.5 kw 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 10 kw 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 15 kw 0.00 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 20 kw 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16

Page 23

3. Inspect blower motor and wheel for cleanliness each cooling season. Clean when necessary.

4. Check electrical connections for tightness and controls for proper operation each cooling season. Service when necessary.

Step 1—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) at least twice during each cooling season and twice during the heating season, or whenever the filter becomes clogged with dust and lint.

Step 2—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.

Disconnect and tag electrical power to the unit before cleaning and lubricating the blower motor and wheel. Failure to adhere to this warning could cause personal injury or death.

Step 3—Outdoor Coil, Indoor Coil, and Condensate Drain Pan

Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year.

The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere with the airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using the soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent-and-water solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring, or air filter(s). For best results, spray condenser coil fins from inside to outside the unit. On units with an outer and inner condenser coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.

Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain trough with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain trough is restricted, clear it with a “plumbers snake” or similar probe device.

Fig. 26—50XZ Balance Point Worksheet

C03008

Balance Point Worksheet

Outdoor Air Temp (Deg F)

Building Heat Loss (1000 BTUH)

Unit Integrated Heating Capacity (x1000 BTUH)

024 036 048 060

-10 0 10 17 20 30 40 47 50 60

Based on Entering Indoor Air of 70 Deg. F and Rated CFM

Page 24

Step 4—Outdoor Fan

Keep the condenser fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit. Damage to unit may result.

1. Remove 6 screws holding outdoor grille and motor to top cover.

2. Turn motor/grille assembly upside down on top cover to expose fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen setscrew and slide fan off motor shaft.

5. When replacing fan blade, position blade so that the hub is 1/8 in. away from the motor end (1/8 in. of motor shaft will be visible). (See Fig. 23)

6. Ensure that setscrew engages the flat area on the motor shaft when tightening.

7. Replace grille.

Step 5—Electrical Controls and Wiring

Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit.

Remove access panel to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete cooling cycle to ensure proper operation. If discrepancies are observed in 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.

Step 6—Refrigerant Circuit

Inspect all refrigerant tubing connections and the unit base for oil accumulation annually. Detecting oil generally indicates a refrigerant leak.

If oil is detected or if low performance is suspected, leak-test all refrigerant tubing using an electronic leak detector, or liquid-soap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section.

If no refrigerant leaks are found and low performance is suspected, refer to Checking and Adjusting Refrigerant Charge section.

Step 7—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 Indoor Airflow and Airflow Adjustments section to check the system airflow.

Step 8—Metering Devices–TXV & Accurater Piston

This unit uses 2 types of metering devices. The outdoor metering device is a fixed orifice and is contained in the brass hex-body in the liquid line feeding the outdoor coils. The indoor metering device is a TXV type device.

Fig. 27—Cooling Charging Table-Subcooling

C03027

(psig)

5 101520

(kPa)

36811

189 61 56 51 46 1303 13 13 11 8

203 66 61 56 51 1399 13 16 13 10

10.3 (5.7) 9.8 (5.4) 9.4 (5.2) 9 (5) 8.6 (4.7)

210 68 63 58 53 1448 13 17 14 11

NA NA NA NA NA

217 70 65 60 55 1496 13 18 15 13

17.6 (9.8) 16.8 (9.3) 16.5 (9.2) 15.4 (8.6) 14.3 (7.9)

224 72 67 62 57 1544 13 19 16 14

NA NA NA NA NA

231 74 69 64 59 1593 13 20 18 15

17.5 (9.7) 16.9 (9.4) 16.6 (9.2) 15.7 (8.7) 14.8 (8.2)

238 76 71 66 61 1641 13 21 19 16

13.7 (7.6) 13 (7.2) 13 (7.2) 14.5 (8.1) 11.5 (6.4)

245 77 72 67 62 1689 13 22 20 17 252 79 74 69 64 1737 13 23 21 18 260 81 76 71 66 1792 13 25 22 19 268 83 78 73 68 1848 13 26 23 20 276 85 80 75 70 1903 13 27 24 21 284 87 82 77 72 1958 13 28 25 22 292 89 84 79 74 2013 13 29 26 23 300 91 86 81 76 2068 13 30 27 24 309 93 88 83 78 2130 13 31 28 26 318 95 90 85 80 2192 13 32 29 27 327 97 92 87 82 2254 13 33 31 28 336 99 94 89 84 2316 13 34 32 29 345 101 96 91 86 2378 13 35 33 30 354 103 98 93 88 2440 13 36 34 31 364 105 100 95 90 2509 13 38 35 32 374 107 102 97 92 2578 13 39 36 33 384 108 103 98 93 2647 13 40 37 34 394 110 105 100 95 2716 13 41 38 35 404 112 107 102 97 2785 13 42 39 36 414 114 109 104 99 2854 13 43 40 37 424 116 111 106 101 2923 13 44 41 38 434 118 113 108 103 2992 13 45 42 39 444 119 114 109 104 3061 13 46 43 40 454 121 116 111 106 3130 13 47 44 41 464 123 118 113 108 3199 13 48 45 42 474 124 119 114 109 3268 13 48 46 43 484 126 121 116 111 3337 13 49 47 44 494 127 122 117 112 3406 13 50 47 45 504 129 124 119 114 3475 13 51 48 46 514 131 126 121 116 3544 13 52 49 46 524 132 127 122 117 3612 13 53 50 47 534 134 129 124 119 3681 13 54 51 48

Required Liquid Line Temperature for

Required Subcooling Deg F (Deg C)

Model Size

a Specific Subcooling (R-410A)

Charging Procedure

7- Read across from the Pressure reading to obtain the Liquid line temperature for a required Subcooling

6- Find the Pressure Value in the table corresponding to the the measured Pressure of the Compressor Discharge line.

5- Interpolate if the Outdoor ambient temperature lies in between the table values. Extrapolate if the temperature lies beyond the table range.

1- Measure Discharge line pressure by attaching a gauge to the service port.

2- Measure the Liquid line temperature by attaching a temperature sensing device to it. 3- Insulate the temperature sensing device so that the Outdoor Ambient doesn’t affect

the reading. 4- Refer to the required Subcooling in the table based on the model size and the

Outdoor Ambient temperature.

8- Add Charge if the measured temperature is higher than the table value. 9- Add Charge using the service connection on the Suction line of the Compressor.

024 030 036 042 048 060

Outdoor Ambient Temperature

75 (24) 82 (28) 85 (29) 95 (35) 105 (41)

Pressure

196

1351

Required Subcooling (Deg F) Required Subcooling (Deg C)

63 58

53 48 13

15 12

Page 25

Step 9—Pressure Switches

Pressure switches are protective devices wired into control circuit (low voltage). They shut off compressor if abnormally high or low

pressures are present in the refrigeration circuit. These pressure switches are specifically designed to operate with Puron (R-410A) systems. R-22 pressure switches must not be used as replacements for the Puron (R-410A) system.

Step 10—Loss of Charge Switch

This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge, low airflow across indoor coil, dirty filters, etc. It opens on a pressure drop at about 20 psig. If system pressure is above this, switch should be closed. To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have continuity on a good switch.

NOTE: Because these switches are attached to refrigeration system under pressure, it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists. If switch must be removed, remove and recover all system charge so that pressure gauges read 0 psi. Never open system without breaking vacuum with dry nitrogen.

Step 11—High-Pressure Switch

The high-pressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 610 psig.

High pressure may be caused by a dirty outdoor coil, failed fan motor, or outdoor air recirculation.

Fig. 28—Defrost Control

A99442

OF2

CESO130076–00

OF1

QUIET

SHIFT

120

INTERVAL TIMER

OFF

DFT

O R W

Y C

T2 C C O

DFT

T1 Y

SPEEDUP

Speedup Pins

Defrost interval DIP switches

Quiet Shift

Fig. 29—Refrigerant Circuit

C99097

Page 26

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.

Step 12—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.

Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils. Failure to follow this warning can cause a fire, serious injury, or death.

The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll. The scroll compressor has no dynamic suction or discharge valves, and it is more tolerant of stresses caused by debris, liquid slugging, and flooded starts. The compressor is equipped with an anti-rotational device and an internal pressure relief port. The anti-rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector. The pressure relief port is a safety device, designed to protect against extreme high pressure. The relief port has an operating range between 550 and 625 psi differential pressure.

The Copeland scroll compressor uses Mobil 3MA POE oil. This is the only oil allowed for oil recharge.

Step 13—Refrigerant System

This step covers the refrigerant system of the 50XZ, including the compressor oil needed, servicing systems on roofs containing synthetic materials, the filter drier and refrigerant charging.

REFRIGERANT

This system uses Puron (R-410A) refrigerant which has higher operating pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Gauge set, hoses, and recovery system must be designed to handle Puron. If you are unsure consult the equipment manufacturer. Failure to use Puron compatible servicing equipment or replacement components may result in property damage or injury.

COMPRESSOR OIL The compressor in this system uses a polyolester (POE) oil, Mobil

3MA POE. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere.

SERVICING SYSTEMS ON ROOFS WITH SYNTHETIC MATERIALS

POE (polyolester) compressor 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, accumulator, or reversing valve.

Synthetic Roof Precautionary Procedure

1. Cover extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an approximate 10 X 10 ft. area.

2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components.

3. Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant run-offs through the louvered openings in the unit base.

4. Perform required service.

5. Remove and dispose of any oil contaminated material per local codes.

LIQUID LINE FILTER DRIER The biflow 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 metering device in manifold hose. Charge refrigerant into suction-line.

Step 14—System Information

LOSS OF CHARGE SWITCH The loss of charge switch is a protective device wired into control

circuit (low voltage). It shuts off the compressor if abnormally low pressures are present in the refrigeration circuit.

CHECK DEFROST THERMOSTAT There is a liquid header with a brass distributor and feeder tube

going into outdoor coil. At the end of 1 of the feeder tubes, there is a 3/8-in. OD stub tube approximately 3 in. long. (See Fig. 30) The defrost thermostat should be located on stub tube. Note that there is only 1 stub tube used with liquid header, and on most units it is the bottom circuit.

The defrost thermostat signals heat pump that conditions are right for defrost or that conditions have changed to terminate defrost. It is a thermally actuated switch clamped to outdoor coil to sense its temperature. Normal temperature range is closed at 30° ± 3°F and open at 80° ± 5°F.

Page 27

NOTE: The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible.

TROUBLESHOOTING

Refer to the Cooling and Heating Troubleshooting Chart (Table 7) for troubleshooting information.

START-UP CHECKLIST

Fig. 30—Defrost Thermostat

C99029

FEEDER TUBE

STUB TUBE

DEFROST THERMOST AT

Page 28

HEAT PUMP WITH PURON

REFRIGERATION SECTION-QUICK REFERENCE GUIDE

Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and replacement components are

designed to operate with Puron. Puron refrigerant cylinders are rose colored.

• Puron refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright position. Cylinders manufactured March 1, 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid to flow.

• Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.

• Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose.

• Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard.

• Use hoses with 750 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• Puron, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Only use factory specified liquid-line filter driers with rated working pressures no less than 600 psig.

• Do not install a suction-line filter drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter driers and service valves with wet cloth when brazing.

• A Puron liquid-line filter drier is required on every unit.

• Do not use an R-22 TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, break vacuum with dry nitrogen and replace filter driers.

• Do not vent Puron into the atmosphere.

• Observe all warnings, cautions, and bold text.

• Do not leave Puron suction line driers in place for more than 72 hrs.

Page 29

ECM ID BLOWER MOTOR-QUICK REFERENCE GUIDE

C01034

EASY SELECT

HEATER/MOTOR

AUX HEAT KW/CFM

0-30

1075

SEC1 SEC2

AC/HP SIZE

036 030 024 018

HP-COMFORT

HP-EFF

NOM HI

ENH

SYSTEM TYPE

AC/HP CFM ADJUST

ON/OFF DELAY

CONTINUOUS FAN

MED HI YELLO

AUX1 HUM1

AUX2

24VAC

GRY

HUM2

YEL

WHT

BLK

ORN

BLU

VIO

0-20 875

0-10 725

09030900

0-5

625

R W

Y/Y

G O C

QUICK REFERENCE GUIDE

SET-UP INSTRUCTIONS FOR WARMER HEATING TEMPERATURES

AND SUPER HUMIDITY CONTROL IN COOLING

A. AUX HEAT - Set for heater size (Ex: 0-10 for 10 kw) B. AC/HP SIZE - Set for size of outdoor unit C. SYSTEM TYPE - Select "HP COMFORT" D. AC/HP CFM ADJUST - Select "LO" E. ON/OFF DELAY - Select "ENH" F. CONTINUOUS FAN - Select desired speed

2. Remove Jumper J1 to activate all dehumidify modes.

3. Complete wiring and install outdoor temperature sensor according to Installation Instructions.

1. Configuration Taps (See Installation Instructions, for detailed description.)

• Option 5 (Variable Speed Motors) - set to ON

• Option 7 (Super Dehumidify) - set to ON

• Option 12 (Heaters during Defrost) - setting "2" is suggested for all heaters

• Option 16 - Heat pump systems set to ON for warmer heat below 40° F.

• Option 17 - Select programmable or non-programmable mode.

2. Thermidistat Control Configurations (See Thermidistat™ Control Installation Instructions for detailed description.)

3. Set desired humidity level on front of Thermidistat (50 to 55% RH recommended). For dehumidification in cooling, both "dhu" and "cool" must be displayed.

1. Set "DIP Switches" - Set the dip switches (back of Thermidistat Control Board) appropriately for specific system being installed.

EASY SELECT BOARD

THERMIDISTAT™ CONTROL SETTINGS

9 PIN CONNECTOR

ICM PRINTED CIRCUIT BOARD

12 PIN CONNECTOR

Page 30

Table 7—Troubleshooting Chart

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,

control relay, defrost board, or high pressure or lossof-charge/low pressure switch

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

Units have a 5-minute time delay

DO NOT bypass this compressor time delay–wait for 5 minutes until time-delay relay is deenergized

Compressor will not start but condenser fan runs

Faulty wiring or loose connections in compressor circuit

Check wiring and repair or replace

Compressor motor burned out, seized, or internal overload open

Determine cause. Replace compressor

Defective run capacitor, overload, or PTC (positive temperature coefficient) thermistor

Determine cause and replace

One leg of 3-phase power dead

Replace fuse or reset circuit breaker. Determine cause

Low input voltage (20 percent low) Determine cause and correct

Three-phase scroll compressor (size 030060 units) 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 coil 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

Frosted coil with incorrect defrost operation

Check defrost time settings

Reset as necessary

Check defrost temperature switch

Replace as necessary Air in system

Recover refrigerant, evacuate system,

and recharge 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 (Heat) Indoor air restricted or recirculating Determine cause and correct Indoor or outdoor air restricted or air short-cycling Determine cause and correct

(Continued next page)

Page 31

Table 7—Troubleshooting Chart (Cont’d)

SYMPTOM CAUSE REMEDY

Head pressure too low

Low refrigerant charge Check for leaks, repair and recharge Restriction in liquid tube Remove restriction

Excessive suction pressure

(Heat) Outdoor coil frosted

Move timer on control board to 30 minutes

between defrost cycles (Cool) High Heat load Check for source and eliminate Reversing valve hung up or leaking internally Replace valve Refrigerant overcharged Recover excess refrigerant

Suction pressure too low

(Cool) Dirty air filter Replace filter (Heat) Outdoor coil frosted

Move timer on control board to 30 minutes

between defrost cycles Low refrigerant charge Check for leaks, repair and recharge Metering device or low side restricted Remove source of restriction

(Cool) Insufficient coil airflow

Increase air quantity

Check filter–replace if necessary (Cool) Temperature too low in conditioned area Reset thermostat (Cool) Outdoor ambient below 40°F Install low-ambient kit Filter-drier restricted Replace

Compressor runs but outdoor fan does not

NC (normally closed) contacts on defrost board open

Check condition of relay on board

Replace if necessary

IFM does not run

Blower wheel not secured to shaft Properly tighten blower wheel to shaft Insufficient voltage at motor Determine cause and correct Power connectors not properly sealed Connectors should snap easily; do not force

IFM operation is intermittent

Water dripping into motor Verify proper drip loops in connector wires Connectors not firmly sealed

Gently pull wires individually to be sure they are

crimped into the housing

IFM–Indoor Fan Motor

Page 32

C01999

START-UP CHECKLIST

(Remove and Store in Job File)

I. Preliminar y Information

MODEL NO.:_________________________________ SERIAL NO.:__________________________________ DATE:_______________________________________ TECHNICIAN:_________________________________

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

( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT ( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS ( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS ( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE) ( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE ( ) VERIFY THAT UNIT INSTALLATION IS LEVEL ( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS ( ) MAKE SURE THAT - ON 060 SIZE PURON HEATPUMP, ONLY-THE TWO WIRE TIES FASTEN TO THE OUTDOOR COILS AND REVERSING VALVE/ACCUMULATOR HAVE BEEN REMOVED.

III. START-UP ELECTRICAL

SUPPLY VOLTA GE __________________________________ COMPRESSOR AMPS_________________________________ INDOOR (EVAPORATOR) FAN AMPS___________

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE ___________DB RETURN-AIR TEMPERATURE ___________DB ___________WB COOLING SUPPLY AIR ___________DB ___________WB HEAT PUMP SUPPLY AIR ___________ GAS HEAT SUPPLY AIR ___________ ELECTRIC HEAT SUPPLY AIR ___________

PRESSURES

GAS INLET PRESSURE ___________IN.WG GAS MANIFOLD PRESSURE ___________IN.WG REFRIGERANT SUCTION ___________PSIG SUCTION LINE TEMP*___________ REFRIGERANT DISCHARGE ___________PSIG DISCHARGE TEMP†___________ ( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS GAS HEAT TEMPERATURE RISE TEMPERATURE RISE (LITERATURE) RANGE___________ MEASURED TEMPERATURE RISE___________ *Measured at suction inlet to compressor †Measured at liquid line leaving condenser.

IV. EASY SELECT SETTINGS

FULL UNIT MODEL NUMBER:___________ ENTER AVAILABLE HEATSETTINGS ENTER AVAILABLE AIRFLOW HEAT AIR PIN CONNECTION SETTING___________ ENTER AVAILABLE SIZES SIZE PIN CONNECTION SETTING___________ TYPE PIN CONNECTION SETTING___________ ADJUST PIN CONNECTION SETTING___________ DELAY PIN CONNECTION SETTING___________ (0/0 or 0/90 for gas/electric models) CONTINOUS FAN PIN CONNECTION SETTING___________

EASY SELECT

Heat Settings

AC HP Size

System Type

AC HP-Comf ort HP.Eff

AC/HP CFM Adjust

Norm Lo Hi

On/Off Delay

⁄90

⁄0 ENH

Continous Fan

Lo Med Hi

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4 Tab 5a 5a

PC101CatalogNo.535–00114 PrintedinU.S.A.Form50XZ-2SIPg 32 8–03Replaces:50XZ-1SI