Carrier INFINITY 48XL User Manual
Installation Instructions
EQUIPMENT OPERATION HAZARD
OAT sensor must be field installed. See Accessory
Installation for more details.
EQUIPMENT OPERATION HAZARD
This Infinity TM unit is designed for use with an Infinity User
Interface.
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS ......................... 2
INTRODUCTION ................................... 2
RECEIVING AND INSTALLATION ................. 2-12
Check Equipment .................................. 2
Identify Unit .................................... 2
Inspect Shipment ................................. 2
Provide Unit Support ............................... 2
Roof Curb ...................................... 2
Slab Mount ..................................... 2
Ground Mount .................................. 2
Provide Clearances ................................. 7
Rig and Place Unit ................................. 7
Inspection ...................................... 8
Introduction ..................................... 8
Use of Rigging Bracket ............................ 8
Select and Install Ductwork ........................... 8
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units .......................... 9
Provide for Condensate Disposal ..................... 10
Install Flue Hood .................................. 10
Install Gas Piping ................................. 10
Install Electrical Connections ........................ 11
High-Voltage Connections ........................ 11
Routing Power Leads Into Unit ..................... 12
Connecting Ground Lead to Ground Screw ........... 12
Routing Control Power Wires ..................... 12
Accessory Installation ............................ 12
Special Procedures for 208-v Operation .............. 12
PRE-START-UP ................................... 15
START-UP ..................................... 15-26
Unit Start-Up and Troubleshooting ................... 15
Sequence of Operation .......................... 20-24
Check for Refrigerant Leaks ......................... 25
Start-Up Adjustments .............................. 25
Checking Cooling and Heating Control Operation ...... 25
Checking and Adjusting Refrigerant Charge ........... 25
®
Turn to the Expertg
A05307
Fig. 1 - Unit 48XL
Refrigerant Charge .............................. 26
No Charge ..................................... 26
Low Charge Cooling ............................. 26
To Use Cooling Charging Charts .................... 26
Non-Communicating Emergency Cooling/Heating Mode .. 26
MAINTENANCE ................................ 28-30
Air Filter ........................................ 28
Indoor Fan and Motor .............................. 28
Inducer Blower ................................... 28
Limit Switch ..................................... 28
Burner Ignition ................................... 28
Main Burners .................................... 28
Inducer Pressure Switch ............................ 28
Outdoor Coil, Indoor Coil, and Condensate Drain Pan ..... 29
Outdoor Fan ..................................... 29
Electrical Controls and Wiring ....................... 29
Refrigerant Circuit ................................. 29
Indoor Airflow ................................... 29
Pressure Switches ................................. 29
Loss-of-Charge Switch ............................ 28
High-Pressure Switches ............................ 29
Copeland Scroll Compressor (Puron cR)Refrigerant) ........ 30
Refrigerant System ................................ 30
Refrigerant .................................... 30
Compressor Oil ................................. 30
Servicing Systems on Roofs with Synthetic Materials .... 30
Liquid-Line Filter Drier .......................... 30
Puron (R-410A) Refrigerant Charging ............... 30
TROUBLESHOOTING ........................... 30-31
FINAL CHECKS ................................... 32
CARE AND MAINTENANCE ........................ 32
START-UP CHECKLIST ............................ 36
SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due
to mechanical and electrical components. Only trained and
qualified personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance flmctions,
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on this
equipment, observe precautions in the literature, on tags, and on
labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. Installation must be in compliance with
local and national building codes. Wear safety glasses, protective
clothing, and work gloves. Have fire extinguisher available. Read
these instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit.
Recognize safety information. This is the safety-alert symbol /_.
When you see this symbol on the unit and in instructions or manu-
als, be alert to the potential for personal iniury. Understand these
signal words: DANGER, WARNING, and CAUTION. These
words are used with the safety-alert symbol. DANGER identifies
the most serious hazards which will result in severe personal iniury
or death. WARNING signifies hazards which could result in per-
sonal iniury or death. CAUTION is used to identify unsafe practic-
es which may result in minor personal injury or product and prop-
erty damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
Always install furnace to operate within the intended temperature
rise range with a duct system which has an external static pressure
within the allowable range, as specified in "Indoor Airflow Adjust-
ments" section of these instructions. See furnace rating plate.
ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Before installing or servicing system, always turn off main
power to system and tag disconnect. There may be more
than one disconnect switch. Turn off accessory heater power
switch if applicable.
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal
iniury or equipment damage.
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 48XL packaged unit is a fully self-contained combination
Category I gas heating/electric air conditioner designed for outdoor
installation (See Fig. 1). Standard units are shipped in a
horizontal-discharge configuration for installation on a
ground-level slab or directly on the ground if local codes permit.
Standard units can be converted to downflow (vertical) discharge
configurations for rooftop applications.
Models with an N in the fifth position of the model number are
dedicated Low NOx units designed for California installations.
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory and must be installed in California Air
Quality Management Districts or any other regions in North
America where a Low NOx rule exists.
NOTE: Low NOx requirements apply only to natural gas
installations.
RECEIVING AND INSTALLATION
Check Equipment
IDENTIFY UNIT
The unit model number and serial number are printed on the unit
informative 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 office if any item is missing. To prevent loss or
damage, leave all parts in original packages until installation.
Provide Unit Support
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate, if required.
ROOF CURB
Install accessory roof curt) in accordance with instructions shipped
with curt) (See Fig. 4). Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curt) is
critical for a water tight seal. Install gasketing material supplied
with the roof curt). Improperly applied gasketing also can result in
air leaks and poor unit performance.
Curb should be level to within 1/4 in. (6.35 m) (See Fig. 2). This is
necessary for unit drain to function properly. Refer to accessory
roof curt) installation instructions for additional information as
required.
MAXIMUM ALLOWABLE
DIFFERENCE in. (ram)
A-B
1/4 (6.35)
Fig. 2 - Unit Leveling Tolerances
SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of 4
in. (102 mm) thick with 2 in. (51 mm) above grade. The slat)
should extend approximately 2 in. (51 mm) beyond the casing on
all 4 sides of the unit (See Fig. 3). Do not secure the unit to the slat)
except when required by local codes.
RETURr SUPPLY
lUll .,_ lY/i_ \ \'\1 .,_ dill
m_ _E_ dlII
III1|OPENIN,_ i _, f--_OPENING 1111
IIII| tlil _ _z_ ( 't [ _III
IIIII Ill[ I_J'/_ _ _II jlII
IIIII Ill| IIll _<s'_ I!,I tlii
_ Hiv-'_ \ -- JbJ/.... illl
IIIII N I/ "_ //I IIII
IIIII _'_ A' ) /_ IIII
IIIII N?',.q / // IIII
2" _
(50.Smm)
#-- -2=_--__-----_/
/
EVAR COIL COND. COIL
Fig. 3 - Slab Mounting Detail
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.
B-C A-C
1/4 (6.35) 1/4 (6.35)
. j, .
/
A07925
A07926
ase
/ ,,Screw.__._
/ (NOTE A) -_'l
/ *Gasketing .._ r_ j
/ \
Flashing field Ill_l II
I supplied _ JJU_ilt"_ Ro°f curb*
Roofing material U_ I[ supphed)
fieldsupplied-- ll_ii
..............................798 6 ......................
:3:44]
FII{L:} _TR_ ¸ _
8ER,qSE PORIS _,
.......i]
TOP VIEW
INIT
48XL024¢140
,SXLO2,1G#I
_SXLU30040
48XL03_060
CORNER_EIEHT LBS KG
O24040 85/58 6 85,38 955 8 4b(6
0_4060 86¸¸¸¸390 86¸¸¸39 e 8O¸¸¸¸36¸5 i_8,0_/
0300,!O 8_395 8;',53 _, 8O¸¸¸¸36¸5 I_9/C_ 6
638,060 88¸¸¸¸39¸9 88/39 9 81/36 7 15i¸¸¸68 5
4 Hi C )
ELEGTRIG_L
CHARACTERISTICS
208'230 ] 60
208,230 i 60
2GS,P30 _0
UNIT U_IT HEIGHT ,3ENTEROF GRAVlT{ M_,_/I_
LSS "_" X '
396 _U4:_14_ 02; ¸ 8080(800_ 489 0(:_ 5)
@l i81¸9 1641_(43 ¢2) 5,USO{28UJ 489G,:19 3) 4,170_176}
405 /8_ 8 I_9_ _(43 0_;' 5O8 O(20 i_) 489 Oil9 3) 4,1,' 6(i}' 6}
4O8 /8_/ 09? ', 5 '? 5G80{_00_ 489¸O i95 44_G_ii _}
REOUIREDCLEARANCESTO COMBUS_BLE MAlL
TO_ OE U_iT ..... 585¸6 [14 00]
_CT SinE OF u_il .............. S08 [2 00]
SIDE OPPOSi_E DUCTS 555 6 [/4 00]
80TTO_ OF gNIT /2 7 [0 _0]
ELECT_iC HEA_ PANEL 9i4 4 [36 O0]
NEC. REQUIREDCLEARANCES,
8ET_EN VN:TS, POWERENTRY S]SE • • I066 8:4_ OOI
U_l[ AND UNGI_OUr,I_i)SU:_i_¢IS PO_'I_ I'/:RY S:I)i ...... 914¸0 _3_ 00]
U_i[ AN_¸ 8LOG4 OR 80r_CREIE _A_LS _ 0iHEI_
6_OUNSE8 SURF_ClS, PO_E!RENTRY S_ ........... i06_ 8:42 ,UO]
REQUIRE_CLEARANCEFOR OPERATIONAND _RVlCINO
Ev_l_ CO:L AGCiSS S:I)E .............. 914 0 3_ GO]
POWERENTR_¸ SlOE 914 0 (36 O0
(i:XC_R:¸ FO_ Ii{¢ R_OU_Ri_ENTG)
U_ll top .......................................... 9i,1¸0:3_ GO]
SIDE OPPOSITE DUCTS.............................. 9i4 0 {36 GOI
O_C[ P_r,_LL.................... 3,34 8 _12 GO]_
_MJU]KU O]S _C S [ tlHil IS [{&C [} L GS IUAN 904 8 1 00} [ROB _4i
S_'SII_,:_IE_ G_Sri_ PER[ %_A_CE _4448ECO_IfRO_IISE_
Vii LOil,]
#41Ui_IETER8 [iN]
vl ilk T( 8 [ _]
,<ILL]tdETERS [I]
ER_IN OUTLET--"
_851 O
//'/
[52 72]
LEFT SIDE VIEW
[i2 85]
[I 68]
]' ,I
[285]
FRONTVIEW RIGHTSIDEVIEW
Fig. 5 - 48XL024-030 Unit Dimensions
[4 6_]
.....1 i
ii I i_
_5505
[953]j
2496
[985]
REAR VIEW
A06608
2498
[983]
'.yl
$090 7
(42941
SERVICE PORT
FULL LOUVER
t
TOP VIEW
G;%_!
t
FULL LOUVER
mmm _ mm mm _ mm mm mm mm mmm
_H? 1
[4 611
286{113)
POWER ENTRY
¢ 22210881
CONTROL ENTRY
UNIT ELECTRICAL
48XLOS6060 2081230-I-60
48XL036090 20B/230-1-00
48XLO42060 20B1230-I-60
4BXL042090 2O81R3O-l-GO
48XLO4809U 2081230"1=60
48XL048115 20B1230-1-60
48XL048130 2081230-I"60
48XLOUOORO 2081230-I-60
48XLOROH5 2O81D3O'l'6O
48XLODOlSO 2081230-I-60
CORNER WEIGHT LBSIND
A B C 0
CHARACTERISTICS
036060 1001454 1121508 911413 1821826
036090 1011458 _14/517 92/417 185/839
042060 1111503 79135,0 1361617 1811821
042090 1131513 81/36T 13B1620i1841835
O4BORO 115152 D B6/390 IBB/62EilBD/B26
O48115 115/522 861390 13B/620 1821826
048130 1151522 861390 13B/6261IBRIB26
000090 1261572 911413 153/694 2021916
060115 1261572 911415 153/694 _OD/916
060130 1261572 911413 1531694iROD/916
UNIT WT UNIT NEIGNT CENTER OF GRAVITY MMIIN
LBS KG "A" X Y 2
485 2200 11425(449B) 5534(210) 5DOT(DO5) 4216(166)
493 2236 I142514498) 5534(210) 520T(DOD) 4215(166)
507 2290 11933(4698) 5534(210) 5207(205) 4216(166)
515 '336 1193314098) 5534(210) 5207(205) 4210(166)
521 2363 11933(4098) 4953(195) 5398(213) 4572(180)
521 2363 11933(469B) 4953(195) 5398(213) 4572(180)
521 2363 11933(4698) 4953(195} 5398(213) 4572(180)
572 2595 12949(5098) 5534(210) 508 0(200) 4470(176)
572 259 5 12949(509B) 5534(21 O) 508 0(200) 4470(17 D)
572 2595 12949(5098) 5534(210) 5OBO{2OO) 4470(176)
TOP OF UNIT ............................................. 355.6 [14.00]
DUCT SIDE OF UNIT ......................... 508 [DO0]
SIDE OPPOSITE DUCTS ............... 3SS 6 [14 ON)
BOTTOM OR UNIT ................... 12 T [O 50]
ELECTRIC NEAT PANEL .............. 9_4 4 [36 OR]
BETWEEN UNITS, POWER ENTRY SIDE ............... 1066B [42 ON]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE ...... 9_40 [3600]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE ................... 10068 [4200]
RB_JIBED ¢f_.A,e,N_CE_ 8P_,P,A'IIONA._B 8_RVIa_
IVAP COIL ACCESS SIDE ........................... 9140 [36 ON)
POWER ENTRY SIDE ....................................... 9140 [3600]
(EXCEPT FOR NEC REOUIREMENTS)
UNIT TOP ................................................ R14O [3600]
SIDE OPPOSITE DUCTS ..................................... 9140 [3600]
DUCT PANEL .............................................. 3048 [IDOO]_
_MINIMUM DISTANCESIE UNIT IS PLACED LESS THAN 304 B [ID,O0} FROM WALL
SYSTEM,THEN SYSTEM PERFORMANCE MAYBE COMPROMISED
MILLIMETERS [IN]
MILLIMETERS [[N]
MILLIMETERS TIN)
DIMENSIONS IN [] ARE IN INCHES
FULL LOUVER
DRAIN
19,010,75] N,PT
X 220[O.BT] DEEP
1_23.I
144221
LEFTSIDEVIEW
£12.951
[1.681
722
C284)
I II i \
COMPRESSOR, BLOWER, ELECTRIC HEAT _
RICAL ACCESS PAN
]2263
[48,28]
FRONT VIEW
Fig. 6 - 48XL036-060 Unit Dimensions
362,9
[14,29}
5O6
397.1
115.G31
[1.B4]
52.0
46.6
[2.07]
142.2
[5.00]
BAS ENTRY
N,P.T.
402,0
115,831
H77
I4N3I
[0.16] _-
TC
87.2
[B.43]
RIOHTSIDE VIEW
SUPPLY RETURN
DUCT DUCT
OPENING " ' "
_ 3473
_35_.2 _ _351.2 _4
[13.B31 E13831
[13681
REARVIEW
A07900
UNIT SIZE
NOMINAL COOLING CAPACITY (ton)
NOMINAL HEATING CAPACITY (Btu)
OPERATING WEIGHT (Ib)
COMPRESSORS
Quantity
REFRIGERANT: PURON (R-410A)
Quantity (Ib)
REFRIGERANT METERING DEVICE
OUTDOOR COIL
OUTDOOR FAN
INDOOR COIL
INDOOR FAN
Nominal Airflow (Cfm)
Comfort
Efficiency
Max
Furnace (gas ht.) airflow-Low Stage
Furnace (gas ht.) airflow-High Stage
Size (in.)
Motor HP (RPM)
FURNACE SECTION*
Burner Orifice No. (Qty._Drill Size)
HIGH-PRESSURE SWITCH (peig)
Cut-out
HIGH-PRESSURE SWITCH 2 (psig)
LOSS-OF-CHARGE /
LOW- PRESSURE SWITCH
RETURN-AIR FILTERS Throwaway
(in.)€
(mm)
Continued next page.
(kg)
Size
Part Number
Rows...Fins/in,
Face Area (sq ft)
Nominal Cfm
Diameter (in.)
(ram)
Motor Hp (Rpm)
Rows...Fins/in,
Face Area (sq ft)
(ram)
Natural Gas
Reset (Auto)
(Compressor Solenoid)
Cut-out
Reset (Auto)
(Liquid Line) (psig)
Cut-out
Reset (auto)
(kg)
Table I - Physical Data - Unit 48XL
024040 024060 030040 036090 042060 042090
2 2 2-1/2 3 3-1/2 3-1/2
40,000 60,000 40,000 90,000 60,000 90,000
396 401 403 493 507 515
180 182 183 224 230 234
10.1 10.1 11.3 11.3 9.5 9.5 13.8 13.8
4.6 4.6 5.1 5.1 4.3 4.3 6.3 6.3
2 Ton 2 Ton 3 Ton 3 Ton 3 Ton 3 Ton 4 Ton 4 Ton
EA36YD129 EA36YD129 EA36YD139 EA36YD139 EA36YD139 EA36YD139 EA36YD149 EA36YD149
2...21 2...21 2...21 2...21 2...21 2...21 2...21 2...21
13.6 13.6 15.3 15.3 17.5 17.5 19.4 19.4
2700 2700 2700 2700 2800 2800 2800 2800
22 22 22 22 22 22 22 22
559 559 559 559 559 559 559 559
1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825)
3...17 3...17 3...17 3...17 3...17 3...17 3...17 3...17
3.7 3.7 3.7 3.7 4.7 4.7 4.7 4.7
Variable based on Comfort Rollback(see Userlnter_ceinstructionsfor moreinformation).
7OO
8OO
475
844
10x10
254x254
1/2
2...44 3...44 2...44 3...44 3...44 3...38 3...44 3...38
700 875 875 1050 1050 1225
800 1000 1000 1200 1200 1400
727
1120
10x10
254x254
1/2
20x24x1 24x30x1 24x36x1
508x610x25 610x762x25 610x914x25
475
844
10x10
254x254
1/2
030060 036060
2-1/2 3
60,000 60,000
408 485
185 220
2-Stage Scroll
1
TXV
727
1120
10x10
254x254
1/2
670 ±10
470 ± 25
565 ± 15
455 ± 15
745
1120
11x10
279x254
3/4
23 ± 5
55 ± 5
875
1410
11x10
279x254
3/4
745
1120
11x10
279x254
3/4
1225
1400
875
1410
11x10
279x254
3/4
UNITSIZE
NOMINAL COOLING CAPACITY (ton)
NOMINAL HEATING CAPACITY (Btu)
OPERATING WEIGHT (Ib)
COMPRESSORS
Quantity
REFRIGERANT: PURON (R-410A)
Quantity (Ib)
REFRIGERANT METERING DEVICE
Size
Part Number
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
Motor Hp (Rpm)
OUTDOOR COIL
Rows...Fins/in,
INDOOR COIL
Rows...Fins/in,
INDOOR FAN
Nominal Airflow (Cfm)
Comfort
Efficiency
Max
Furnace (gas ht.) airflow-Low Stage
Furnace (gas ht.) airflow-High Stage
Size (in.)
Motor HP (RPM)
FURNACE SECTION*
Burner Orifice No. (Qty._Drill Size)
Natural Gas
HIGH-PRESSURE SWITCH (peig)
Cut-out
Reset (Auto)
HIGH-PRESSURE SWITCH 2 (peig)
(Compressor Solenoid)
Cut-out
Reset (Auto)
LOSS-OF-CHARGE /
LOW-PRESSURE SWITCH
RETURN-AIR FILTERS Throwaway
(in.)1-
(ram)
*Based on altitude of 0 to 2000 ft (0 to 610 m).
1-Recommended filter sizes for field-installed air filter grilles mounted on the wall or ceiling of the conditioned structure. 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. W.C.
(kg)
(mm)
Face Area (sq ft)
Face Area (sq ft)
(ram)
(Liquid Line) (psig)
Cut-out
Reset (auto)
Provide Clearances
The required minimum service clearances are shown in 5 and 6.
Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. 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. (1219 mm).
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. (102 mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.
(kg)
048090 048115 060115 060130
4 4 5 5
90,000 115,000 115,000 130,000
521 521 572 572
236 236 259 259
15.3 15.3 15.3 15.8 15.8 15.8
6.9 6.9 6.9 7.2 7.2 7.2
4Ton 4Ton 4Ton 5Ton 5Ton 5Ton
EA36YD 149 EA36YD 149 EA36YD 149 EA36YD 159 EA36YD 159 EA36YD 159
3300 3300 3300 3300 3300 3300
22 22 22 22 22 22
559 559 559 559 559 559
1/4 (1100) 1/4 (1100) 1/4 (1100) 1/3 (1110) 1/3 (1110) 1/3 (1110)
2...21 2...21 2...21 2...21 2...21 2...21
19.4 19.4 19.4 23.3 23.3 23.3
3...17 3...17 3...17 4...17 4...17 4...17
5.7 5.7 5.7 5.7 5.7 5.7
Variable based on Comfort Rollback(see Userlnterfaceinstructionsfor moreinformation).
1400 1400 1400 1750 1750
1600 1600 1600 2000 2000
815
1385
11x10
279x254
3/4
3...38 3...33 3...31 3...38 3...33 3...31
1215
1885
11x10
279x254
3/4
048130 060090
4 5
130,000 90,000
521 572
236 259
2-Stage Scroll
1
TXV
1255
1875
11x10
279x254
3/4
670 ± 10
470 ± 25
565 ± 15
455 ± 15
23 ± 5
55 ± 5
24x36xl
610x914x25
845
1300
11x10
279x254
1750
2000
1215
1910
11x10
279x254
1
1
1255
1920
11x10
279x254
1
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.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
7
Table 1--Physical Data (Con't) - Unit 48XL
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.
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
iniury/death or property damage.
Do not strip screws when re-securing the unit. If a screw is
stripped, replace the stripped one with a larger diameter
screw (included).
ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. Turn off accessory heater power switch if
applicable. Tag disconnect switch with a suitable warning
label.
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
iniury or death.
Never stand beneath rigged units or lift over people.
INTRODUCTION
The lifting/rigging bracket is engineered and designed to be
installed only on Small Packaged Products.
This bracket is to be used to rig/lift a Small Packaged Product onto
roofs or other elevated structures.
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
iniury/death or property damage.
Rigging brackets for one unit use only. When removing a
unit at the end of its useful life, use a new set of brackets.
USE OF RIGGING BRACKET
Field Installation of Ri_in_ Bracket
1. If applicable, remove unit from shipping carton. Leave top
shipping skid on the unit for use as a spreader bar to prevent
the rigging straps from damaging the unit. If the skid is not
available, use a spreader bar of sufficient length to protect
the unit from damage.
2. Remove 4 screws in unit corner posts.
3. Attach each of the 4 metal rigging brackets under the panel
rain lip (See Fig. 7). Use the screws removed in step 2
above to secure the brackets to the unit.
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
iniury/death or property damage.
Rigging bracket MUST be under the rain lip to provide
adequate lifting.
Riu_inu/Liftinu of Unit
1. Bend top of brackets down approximately 30 degrees from
the corner posts.
2. Attach straps of equal length to the rigging brackets at
opposite ends of the unit. Be sure straps are rated to hold the
weight of the unit (See Fig. 7).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level
with the ground.
4. After unit is securely in place detach rigging straps. Remove
corner posts, screws, and rigging brackets then reinstall
screws.
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
iniury/death or property damage.
When straps are taut, the clevis should be a minimum of 36
in. (914 mm) above the unit top cover.
After the unit is placed on the roof curb or mounting pad, remove
the top crating.
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.
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
iniury or death.
For vertical supply and return units, tools or parts could
drop into ductwork, therefore, 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.
When designing and installing ductwork, consider the following:
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.
UNITHEIGHT
36-in. (914 mm)
SEE DETAIL
CABINET
Small
Small
Large 48XL-048 543 246
NOTE: See dimensional drawing for corner weight distribution. Corner
weights shown on drawing are based on unit-only weights and do not
include packaging.
MODEL
48XL-024
48XL-030
48XL-036 515 234
48XL-042 537 244
48XL-060 594 269
A /
RIGGING WEIGHT
Ib kg
420 191
427 194
Fig. 7 - Suggested Rigging
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.
(610 mm) from electric heater element.
3. Size ductwork for max possible air flow (See Table 1).
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.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration-isolate duct openings in wall or roof
according to good construction practices.
A06298
A
J
D
CONVERTING HORIZONTAL DISCHARGE UNITS TO
DOWNFLOW (VERTICAL) DISCHARGE UNITS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Before installing or servicing system, always turn off main
power to system and tag. There may be more than one
disconnect switch. Turn off accessory heater power switch if
applicable.
NOTE: If unit is not equipped with duct covers, accessory duct
covers are required. See pre-sale literature.
1. Open all electrical disconnects and install lockout tag before
starting any service work.
2. Remove side duct covers to access bottom return and
supply knockouts.
NOTE: These panels are held in place with tabs similar to an
electrical knockout.
3. Use a screwdriver and hammer to remove the panels in the
bottom of the composite unit base.
4. Ensure the side duct covers are in place to block off the
horizontal air openings (See Fig. 8).
ACCESS PANEL C
A06296
Supply Duct Cover
A06320
Fig. 8 - 48XL with Duct Covers On
Provide for Condensate Disposal
NOTE: Ensure that condensate-water disposal methods comply
with local codes, restrictions, and practices.
The 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. (25 mm) 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.
If the installation requires draining the condensate water away from
the unit, install a field-supplied 2-in. (51 mm) 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. (25 mm) 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 field-supplied 3/4 -in. copper pipe
at outlet end of the 2 -in. (51 mm) trap (See Fig. 9). Do not
undersize the tube. Pitch the drain trough downward at a slope of at
least 1 in. for every 10 ft. (3 m) of horizontal run. Be sure to check
the drain trough for leaks. Prime the trap at the beginning of the
cooling season start-up.
Install Flue Hood
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
The venting system is designed to ensure proper venting.
The flue hood assembly must be installed as indicated in
this section of the unit installation instructions.
Install the flue hood as follows:
1. This installation must conform with local building codes
and with the National Fuel Gas Code (NFGC), NFPA
54/ANSI Z223.1 (in Canada, CAN/CSA B149.1, and
B149.2) or latest revision. Refer to provincial and local
plumbing or wastewater codes and other @plicable local
codes.
2. Remove flue hood from shipping location (inside the return
section of the blower compartment-See Fig. 8). Remove the
return duct cover to locate the flue hood. Remove two
screws on flue panel. Place flue hood assembly over flue
panel. Orient screw holes in flue hood with holes in the flue
panel.
3. Secure flue hood to flue panel by inserting a single screw on
the top and the bottom of the hood.
1" (25 mm) MIN.
__ 2" (51 mm) MIN
A08001
Fig. 9 - Condensate Trap
Install Gas Piping
The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the l/2-in.
FPT gas inlet on the gas valve.
Install a gas supply line that runs to the heating section. Refer to
Table 2 and the current edition of NFOC in the U.S. and the current
NSCNGPIC in Canada. Do not use cast-iron pipe. It is
recommended that a black iron pipe is used. Check the local utility
for recommendations concerning existing lines. Size gas supply
piping for 0.5 IN. W.C. maximum pressure drop. Never use pipe
smaller than the l/2-in. FPT gas inlet on the unit gas valve.
For natural gas @plications, the gas pressure at unit gas connection
must not be less than 4.0 IN. W.C. or greater than 13 IN. W.C.
while the unit is operating. For propane @plications, refer to
propane conversion kit instructions.
A 1/8-in. NPT plugged t@ping, accessible for test gauge
connection, must be installed immediately upstream of the gas
supply connection to the gas valve and downstream of manual
equipment shutoff valve.
When installing the gas supply line, observe local codes pertaining
to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1-2006
(in Canada, CAN/CSA B149.1).
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 in. (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T-handle valves.
4. The use of copper tubing for gas piping is NOT @proved
by the state of Massachusetts.
In the absence of local building codes, adhere to the following
pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.
(6.35 mm) for every 15 ft (4.6 m) of length to prevent traps.
Orade all horizontal runs downward to risers. Use risers to
connect to heating section and to meter.
2. Protect all segments of piping system against physical and
thermal damage. Support all piping with @propriate straps,
hangers, etc. Use a minimum of one hanger every 6 ft. (1.8
m). For pipe sizes larger than 1/2 in., follow
recommendations of national codes.
3. Apply joint compound (pipe dope) sparingly and only to
male threads of joint when making pipe connections. Use
only pipe dope that is resistant to action of liquefied
petroleum gases as specified by local and/or national codes.
Never use Teflon t@e.
4. Install sediment trap in riser leading to heating section (See
Fig. 10). This drip leg functions as a trap for dirt and
condensate.
5. Install an accessible, external, manual main shutoff valve in
gas supply pipe within 6 ft (1.8 m) of heating section.
6. Install ground-joint union close to heating section between
unit manual shutoff and external manual main shut off
valve.
10
IN
TEE
_-_ NIPPLE
CAP
C99020
Fig. 10 - Sediment Trap
7. Pressure test all gas piping in accordance with local and
national plumbing and gas codes before connecting piping
to unit.
NOTE: Pressure test the gas supply system after the gas supply
piping is connected to the gas valve. The supply piping must be
disconnected from the gas valve during the testing of the piping
systems when test pressure is in excess of 0.5 psig. Pressure test the
gas supply piping system at pressures equal to or less than 0.5 psig.
The unit heating section must be isolated from the gas piping
system by closing the external main manual shutoff valve and
slightly opening the ground-joint union.
Install Electrical Connections
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
The unit cabinet must have an uninterrupted, unbroken
electrical ground. This ground may consist of an electrical
wire connected to the unit ground screw in the control
compartment, or conduit approved for electrical ground
when installed in accordance with NEC, NFPA 70 National
Fire Protection Association (latest edition) (in Canada,
Canadian Electrical Code CSA C22.1) and local electrical
codes.
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 for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.
The field-supplied disconnect may be mounted on the unit over
the high-voltage inlet hole (See Fig. 5 and 6).
Operation of unit on improper line voltage constitutes abuse and
may cause unit damage that could affect warranty.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in fire, explosion,
personal injury, death and/or property damage.
• Connect gas pipe to unit using abackup wrench to avoid
damaging gas controls.
• Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections.
• Use proper length of pipe to avoid stress on gas control
manifold.
• If a flexible connector is required or allowed by authority
having jurisdiction, black iron pipe shall be installed at
furnace gas valve and extend aminimum of 2 in. (51 mm)
outside furnace casing.
• If codes allow a flexible connector, always use anew
connector. Do not use a connector which has previously
serviced another gas appliance.
8. Check for gas leaks at the field-installed and
factory-installed gas lines after all piping connections have
been completed. Use a commercially available soap solution
made specifically for the detection of leaks (or method
specified by local codes and/or regulations).
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the
unit being installed.
1. Make all electrical connections in accordance with NEC
NFPA 70 (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.
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.
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.
11
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