The URL can be used to link to this page

REVIEWED BLD2024-0676+Manufacturer_Specifications_and_Installation_Instructions+5.20.2024_9.30.57_AM+426739948VL-K ComfortTM 13.4 SEER2 Single -Packaged Air Conditioner and Gas Furnace System with Puron® (R-410A) Refrigerant Single Phase 2-5 Nominal Tons (Sizes 24-60) Three Phase 3-5 Nominal Tons (Sizes 36-60) Installation Instructions IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy. NOTE: Read the entire instruction manual before starting the installation. NOTE: Installer: Make sure the Owner's Manual and Service Instructions are left with the unit after installation. Table of Contents Safety Considerations ....................................... 1 Introduction...............................................2 Receiving and Installation ................................... 2 Pre-Start-up..............................................13 Start-up.................................................14 Maintenance.............................................42 Troubleshooting..........................................46 Start-up Checklist.........................................46 A09033 Fig. 1— Unit 48VL (Low NOx Model Available) Safety Considerations Improper installation, adjustment, alteration, service maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory -authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. consult local building codes, the current editions of c 000� 4=00- 1-NNWR==EWM=W� (9) Turn to the experts the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code (NEC) NFPA 70. In Canada refer to the current editions of the National Standards of Canada CAN/CSA-B149.1 and 2 Natural Gas and Propane Installation codes, and Canadian Electrical Code CSA C22.1 Recognize safety information. This is the safety -alert symbol As. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these signal words: DAN- GER, WARNING, and CAUTION. These words are used with the safe- ty -alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to iden- tify unsafe practices which may 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. CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury and/or death. Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous gas that can be fatal when inhaled. Follow all installation, maintenance, and service instructions. See additional information below regarding the installation of a CO Alarm. Most states is the USA and jurisdictions in Canada have laws that require the use of Carbon Monoxide (CO) alarms with fuel burning products. Examples of fuel burning products are furnaces, boilers, space heaters, generators, water heaters, stoves/ranges, clothes dryers, fireplaces, incinerators, automobiles, and other internal combustion engines. Even if there are no laws in your jurisdiction requiring a CO Alarm, it's highly recommended that whenever any fuel burning product is used in or around the home or business that the dwelling be equipped with a CO Alarm(s). The Consumer Product Safety Commission recommends the use of CO Alarm(s). The CO Alarm(s) must be installed, operated, and maintained according to the CO Alarm manufacturer's instructions. For more information about Carbon Monoxide, local laws, or to purchase a CO Alarm only, please visit the following website https://www.kidde.com ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable. 48VL-K: Installation Instructions Receiving and Installation FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or unit damage. A qualified installer or agency must use only factory -authorized kits or accessories when modifying this product. FIRE, INJURY, OR DEATH HAZARD Failure to follow this warning could result in property damage, personal injury, or death. This unit was manufactured to operate with natural gas. When fuel supply is liquid propane gas (LP), this unit MUST be converted with a factory approved LP conversion kit. See rating plate for approved conversion kits. PERSONAL INJURY AND PROPERTY DAMAGE HAZARD For continued performance, reliability, and safety, the only approved accessories and replacement parts are those specified by the equipment manufacturer. The use of non -manufacturer approved parts and accessories could invalidate the equipment limited warranty and result in fire risk, equipment malfunction, and failure. Please review manufacturer's instructions and replacement part catalogs available from your equipment supplier. Introduction This unit (see Fig. 1) is a fully self-contained, combination Category I gas heating/electric cooling unit designed for outdoor installation (See Fig. 3 and Fig. 4 for unit dimensions). All unit sizes have return and discharge openings for both horizontal and downflow configurations, and are factory shipped with all downflow duct openings covered. Units may be installed either on a rooftop or on a cement slab. (See Fig. 5 for roof curb dimensions). In gas heating mode, this unit is designed for a minimum continuous return -air temperature of 55°F (13°C) db and a maximum continuous return -air temperature of 80OF (27°C) db. Failure to follow these return -air temperature limits may affect reliability of heat exchangers, motors, and other components. Models with a N in the fifth position of the model number are dedicated that are 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. If the unit gasketing or insulation must be replaced, ensure the material used is compliant with the two agency requirements listed. 1. Insulation and adhesives shall meet NFPA 90.1 requirements for flame spread and smoke generation. 2. Cabinet insulation shall meet ASHRAE Standard 62.2. Step 1 - Check Equipment Identify Unit The unit model number and serial number are stamped on the unit information plate. Check this information against shipping papers. Inspect Shipment Inspect for shipping damage before removing packaging materials. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest equipment distribution office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation. If the unit is to be mounted on a curb in a downflow application, review Step 9 to determine which method is to be used to remove the downflow panels before rigging and lifting into place. The panel removal process may require the unit to be on the ground. Step 2 - Provide Unit Support For hurricane tie downs, contact distributor for details and PE (Professional Engineering) Certificate if required. Roof Curb Install accessory roof curb in accordance with instructions shipped with curb (See Fig. 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 water tight 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. (6 mm). This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required. Installation on older "G" series roof curbs. Two accessory kits are available to aid in installing a new "G" series unit on an old "G" roof curb. 1. Accessory kit number CPADCURI3001A00, (small chassis) and accessory kit number CPADCURI3002A00, (large chassis) includes roof curb adapter and gaskets for the perimeter seal and duct openings. No additional modifications to the curb are required when using this kit. 2. An alternative to the adapter curb is to modify the existing curb by removing the outer horizontal flange and use accessory kit number CPGSKTKITOOIA00 which includes spacer blocks (for easy alignment to existing curb) and gaskets for the perimeter seal and duct openings. This kit is used when existing curb is modified by removing outer horizontal flange. UNITS/STRUCTURAL DAMAGE HAZARD Failure to follow this caution may result in property damage. Ensure there is sufficient clearance for saw blade when cutting the outer horizontal flange of the roof curb so there is no damage to the roof or flashing. Slab Mount Place the unit on a solid, level pad that is at least 2 in. (51 mm) above grade. The pad should extend approximately 2 in. (51 mm.) beyond the casing on all 4 sides of the unit. (See Fig. 2.) Do not secure the unit to the pad except when required by local codes. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 48VL-K: Installation Instructions ( is hrommis 1�m I f------ 7------- EVAP.COIL COND. A07926 Fig. 2 — Slab Mounting Details Step 3 — Field Fabricate Ductwork Secure all ducts to roof curb and building structure on vertical discharge units. Do not connect ductwork to unit. For horizontal applications, unit is provided with flanges on the horizontal openings. All ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes. Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier. If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes. Read unit rating plate for any required clearances around ductwork. Cabinet return -air static shall not exceed -.25 IN. W.C. Step 4 — Provide Clearances IMPORTANT: The unit must be secured to the curb by installing screws through the bottom of the curb flange and into the unit base rails. When installing large base units onto the common curb, the screws must be installed before allowing the full weight of the unit to rest on the curb. A minimum of six screws are required for large base units. Failure to secure unit properly could result in an unstable unit. See Warning near Rigging/Lifting information and accessory curb instructions for more details. The required minimum operating and service clearances are shown in Fig. 3 and Fig. 4. Adequate combustion, ventilation and condenser air must be provided. 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. The condenser fan pulls air through the condenser coil and discharges it through the top grille. Be sure that the fan discharge does not recirculate to the condenser coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48-in. (1219 mm) above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48-in. (1219 mm). Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slab -mounted units should be at least 2 in. (51 mm) above the highest expected water and runoff levels. Do not use unit if it has been under water. Step 5 — Rig and Place Unit PERSONAL INJURY OR PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury, death or property damage. When installing the unit on a rooftop, be sure the roof will support the additional weight. Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.). Only trained, qualified crane operators and ground support staff should handle and install this equipment. When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply. Training for operators of the lifting equipment should include, but not be limited to, the following: 1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads. 2. Instruction in any special operation or precaution. 3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc. Follow all applicable safety codes. Wear safety shoes and work gloves. Inspection Prior to initial use, and at monthly intervals, all rigging shackles, clevis pins, and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Materials showing any kind of wear in these areas must not be used and should be discarded. PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury/death or property damage. When straps are taut, the clevis should be a minimum of 36 in. (914 mm) above the unit top cover. UNIT FALLING HAZARD Failure to follow this warning could result in personal injury or death. Never stand beneath rigged units or lift over people. Rigging/Lifting of Unit (See Fig. 6) UNIT FALLING HAZARD Failure to follow this warning could result in personal injury or death. Large base units must be secured to common curb before allowing full weight of unit to rest on curb. Install screws through curb into unit base rails while rigging crane is still supporting unit. Lifting holes are provided in base rails as shown in Fig. 3 and Fig. 4. 1. Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage. 2. Attach shackles, clevis pins, and straps to the base rails of the unit. Be sure materials are rated to hold the weight of the unit (See Fig. 6). 3. Attach a clevis of sufficient strength in the middle of the straps. Adjust the clevis location to ensure unit is lifted level with the ground. After the unit is placed on the roof curb or mounting pad, remove the top skid. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. m LOUVER PANEL / - 12325,-13/i64] [ -5/8 828.7 DRAIN OUTLET X /7/8�'1922.2N DEEP LEFT SIDE VIEW I� j1�,111A� jJJJJJJI TOP VIEW [66."I 1 [1193.831 LOUVER PANEL -4-v2 1114.31 ELECTRICAL ACCESS PANEL [28.61 POW[C r41 3. 8" 122.21 DIAL [281 CONTRO CENTER OF GRAVITY IN/MM CORNER WEIGHT -B/KG REWIRED CLEARANCES TO COMBUSTIBLE MARL INCHES [NMI TOP OF UNIT.... .,,, .. .1d [355.61 DUCT SIDE OF UNIT .... .. .... .. 2 [50.8I SIDE OPPOSITE DUCTS ..................... ..... ..14 [355.6] BOTTOM OF UNIT...........................................0 [0.0] ELECTRICAL PANEL ........................................ 36 [914.4I NEC. REWIRED CLEARANCES. INCHES [MMI BETWEEN UNITS, POWER ENTRY SIDE ........................ 4, [1066.SI UNIT AND UNGROUNDED SURFACES. POWER ENTRY SIDE ......... 36 [914.0I UNIT AND BLOCK ORCONCRETE WALLS AND OTHER GROUNDED SURFACES, POWER ENTRY SIDE .................... 42 11066. 81 REWIRED CLEARANCE FIR OPERATION AND SERVICIND INCHES [MMI E VAP COIL ACCESS SIDE..................................36 [914.OI POWER ENTRY SIDE........................................42 11066.81 (EXCEPT FOR NEC REOUIREMENTSI UNIT TOP ................................................ 48 SIDE OPPOSITE DUCTS.....................................36 DUCT PANEL .............................................. [[1219.2I 9141 12 [304..08I- MINIMUM DISTANCES:IF UNIT IS PLACED LESS THAN 12 [304.8] FROM WALL SYSTEM MIT HEN SYSTEM 11R FOHMANCE MAYBE COMPROMISED. DIMENSIONS IN 11 ARE IN MILLIMETERS LOUVER PANEL LOUVER PANEL SUPPLY RETURN CG 15-7/8 DUCT DUCT 1403. OPENING OPENING 3-5/8 14-5/16 "Z„ 19-15/15-5/8 192.11 1363.61 [506.4]16 [396.9] 7-5,16 0-3/16 [166.7] C8 8,8 COMPRESSOR LOWER d-13/16 3/16 PANEL •'X^ PANEL 1122.2] [4.8] 111" 111. 71 N. P.T 3-5/8 2-1/16 GAS ENTRY [87.3] 9-7/8 21-112 9-7/8 48-3/16 152.41 [250. 81 1549.31 1250.81 [1224.0I 1-13/16 FRONT VIEW [46.II RIGHT SIDE VIEW REAR VIEW SD5773-4 A A OD G r rn n1 n1 0 rn c n 0 co 17 5 8 13-1. 13-9/16 13-15/i6 6 [35401 [344.51 [354.0] 187.31 2[11/46 RE SUPPLY ° �4.OPiIONAL______ OPTIONAL 1 ail RETURN H'hy "M SUPPLY 15-15/16 [d15 AIR OPENING AIR EKING 1 _�- REOUIRPD CLEARANCES TO LOMBIGRBLE NIATL. INCHES [MAR] OUTDOOR COIL n TOP OFUNIi............................................. DUCT SIDE OF UNIT ..................................... 14 [355 61 ..2 [50,SI 3 3/16 3-3/16 SIDE OPPOSITE DUCTS ..................... BOTTOM OF UNIT .......................... ..14 [355.6I .. 0 [0.0] ELECTRICAL PANEL ........................................ 36 [914.4I NEC. REQUIRED CLEARANCES BETWEEN UNITS, POWER ENTRY SIDE ..... ... .........d2 INCHES IMMI [10fi 6. 8] UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE.........36 [91 d.0] UNIT AND BLOCK OA CONCRETE WALLS AND OTHER ® �L fi 3 GROUNDED SURFACES, POWER ENTRY SIDE...,. ..42 11066.81 [173.01 0] REDUIRED CLEARANCE FOR OPERATION AND SESEWINGO INCHES IMMI INDOOR COIL TOP VIEW UTDOOR COIL POWER ENTAYASI DES SIDE ............d2 1906681 (EXCEPT FOR NEC REQUIREMENTS) UNIT iOP................................................48 SIDE OPPOSITE DUC iB..................................... [1219.1 11 36 [91d.6I DUCT PANEL ............................... ...12 [30d.8I- I +MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12 [304.8] FROM WALL 2 AT 11193.81 4-1/2 [114.3] SYSTEM NEW SYSTEM PERFORMANCE MAYBE COMPROMISED, [50.8] DIMENSIONS IN 11 ARE IN MILLIMETERS LOUVER PANEL 1-1/e 128.6]DIA K.o POWER ENTRY LOUVER PANEL LOUVER PANEL ELECTRICAL ACCESS PANEL 7/8' 122. 2] DIA. HOLE „A, CONTROL ENTRY d-7/8 I123.8I ° may} C 1 21 [557/8 5.6] 16-1/4 2 11 .09 15-7/8 [403.2] SUPPLY DUCT OPENING RETURN DUCT OPENING ° 42-15/16 [1090.61 LOUVER PANEL 3-11/16 [93. 7] [d12. i] [d47. 7112-1/8 I308. 01 6-5/8 0 °b .� • • 0 . E= °6 11G& 31 .8 6.6 DRAIN OUTLET-"'M 5-9/16 ° BLOWER 1/2" [12.71 IN P.T 3/d" [19.11N.P.T. 72-15/16 [141.3] % 7/8" [22.2] DEEP [328.61 "X" PANEL GAS ENTRY 3/I6 3-3/8 COMPRESSOR 2-1/16 [4. 81 [81.31 44-118 PANEL 48-3/16 152.41 13-7/8 13-5/8 73-7/8 11122.4] 11224.01 1-13116 1352.41 [346.11 [352. 41 LEFT SIDE VIEW FRONT VIEW 146.01 RIGHT SIDE VIEW REAR VIEW SD5773-4 A 48VL-K: Installation Instructions T F HVAC unit HVAC unit base rails basepan Anchor screw \ Sealing Screw Bracket to Gasket Unit Base Rail \ / Roofcurb Hold Down Bracket - Provided with Curb Wood nailer* Flashing field supplied Roofcurb* Insulation Roofing material (field supplied) field supplied Cant strip / field supplied, �j LARGE CURB SMALL/COMMON CURB � I I I SMALL SUPPLY BASE AIR UNIT I I� I I I I I I I I I II I I I I I I I I I I I I LARGE I RETURN I BASE I AIR UNIT I I I I I I I 1---------------1 -----� UNIT PLACEMENT ON COMMON CURB SMALL OR LARGE BASE UNIT A180216 UNIT CATALOG A B (small / common (large C D E F G H SIZE NUMBER IN. base) base) IN. IN. IN. IN. IN. (mm) IN. (mm) (mm) IN. (mm)* IN. (mm)* (mm) (mm) (mm) (mm) Small or Large CPRFCURB011 B00 14 (356) 10 (254) 14 (356) 16 (406) 47.8 (1214) (822) 2 7 (69) 30.6 (778) 46.1 (1170) Large CPRFCURB013B00 (356) 14 (356) (1116) 42.2 (1072) Part Number CPRCURB01113100 can be used on both small and large basepan units. The cross supports must be located based on whether the unit is a small basepan or a large basepan. NOTES: 1. Roof curb must be set up for unit being installed. 2. Seal strip must be applied, as required, to unit being installed. 3. Roof curb is made of 16-gauge steel. 4. Attach ductwork to curb (flanges of duct rest on curb). 5. Insulated panels: 1-in. (25.4 mm) thick fiberglass 1 lb. density. Fig. 5 — Roof Curb Dimensions Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 48VL-K: Installation Instructions A CAUTION - NOTICE TO RIGGERS A PRUDENCE - AVIS AUX MANIPULATEUR ACCESS PANELS MUST BE IN PLACE WHEN RIGGING. PANNEAUX D'ACCES DOIT ETRE EN PLACE POUR MANIPULATION. Use top skid as spreader bar. / Utiliser la palette du haut comme barre de r6partition SEE VOIR DETAIL MINIMUM HEIGHT. 36" (914.4 mm) HAUTEUR MINIMUM UNIT HEIGHT HAUTEUR D'UNITE DETAIL A VOIR DETAIL A SEAL STRIP MUST BE IN BANDE SCELLANT DOIT @TRE PLACE BEFORE PLACING EN PLACE AVANT DE PLACER UNIT ON ROOF CURB L'UNITt SUR LA BASE DE TOIT 50CY502286 2.0 A09051 SMALL CABINET LARGE CABINET 24 30 36 42 48 Unit Unit Ib kg Ib kg Ib kg Ib kg Ib kg Rigging 339 154 348 158 Rigging 394 179 428 194 481 218 WeightIli NOTE: See dimensional drawing for corner weights. Fig. 6 — Unit Suggested Rigging Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 7 48VL-K: Installation Instructions Table 1- Physical Data UNIT SIZE 24040 24060 30040 30060 36060 36090 42060 42090 NOMINAL CAPACITY (ton) 2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 SHIPPING WEIGHT lb. 339 339 348 348 394 394 428 428 SHIPPING WEIGHT (kg) 154 154 158 158 179 179 194 194 COMPRESSOR / QUANTITY Scroll / 1 REFRIGERANT (R-410A) Quantity lb. 6.4 6.4 6.0 6.0 5.75 5.75 6.0 6.0 Quantity (kg) 2.9 2.9 2.7 2.7 2.6 2.6 2.7 2.7 REFRIGERANT METERING DEVICE Orifice ORIFICE ID in. / mm .059 / 1.5 .059 / 1.5 .063 / 1.60 .063 / 1.60 .070 / 1.78 .073 / 1.85 .073 /1.85 OUTDOOR COIL Rows ... Fins/in. 1..21 1...21 1...21 1...21 1...21 1...21 1...21 1...21 Face Area (sq ft) 11.9 11.9 13.6 13.6 13.6 13.6 13.6 13.6 OUTDOOR FAN Nominal CFM 2500 2500 3200 3200 3500 3500 3500 3500 Diameter in. 24 24 24 24 26 24 26 26 Diameter (mm) 609.6 609.6 609.6 609.6 660.4 609.6 660.4 660.4 Motor Hp (Rpm) 1/12 (810) 1/12 (810) 1/5 (810) 1/5 (810) 1/2 (810) 1/2 (810) 3/4 (810 3/4 (810) INDOOR COIL Rows ... Fins/in. 3...17 3...17 3...17 3...17 2...17 2...17 3...17 3...17 Face Area (sq ft) 3.7 3.7 3.7 3.7 5.6 5.6 4.7 4.7 INDOOR BLOWER Nominal Cooling Airflow (CFM) 750 750 950 950 1150 1150 1350 1350 Size in. 10x10 10x10 10x10 10x10 11x10 11x10 11x10 11x10 Size (mm.) 254x254 254x254 254254 254254 279.4x254 279.4254 279.4x254 279.4x254 Motor HP (RPM) 1/2 (1050) 1/2 (1050) 1/2 (1050) 1/2 (1050) 3/4 (1000) 3/4 (1000) 1/2 (1050) 1/2 (1050) FURNACE SECTION Burner Orifice No. (Qty...Drill Size) Natural Gas (Factory Installed) 2...44 3...44 2...44 3...44 3...44 3...38 3...44 3...38 Propane Gas 2...55 3...55 2...55 3...55 3...55 3...53 3...55 3...53 HIGH-PRESSURE SWITCH 650 +/- 15 (psig) Cut-out Reset (Auto) 420 +/- 25 LOSS -OF -CHARGE / LOW-PRESSURE SWITCH (Liquid Line) (psig) cut-out Reset NA (auto) 1 each 24xl6xl 1 each 24xl4xl RETURN -AIR FILTERSt t 610x406x25 610x356x25 Throwaway Size in. 2 each 20xl2xl 24xl8xl 24xl6xl (mm) 508x305x25 610x457x25 610x406x25 *. Based on altitude of 0 to 2000 ft (0-610 m). t. Required filter sizes shown are based on the larger of the AHRI (Air Conditioning Heating and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 to 350 ft/minute for throwaway type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C. $. If using accessory filter rack refer to the filter rack installation instructions for correct filter sizes and quantity Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 48VL-K: Installation Instructions Table 1-Physical Data (Continued) UNIT SIZE 48090 48115 48130 NOMINAL CAPACITY (ton) 4 4 4 SHIPPING WEIGHT lb 481 481 481 SHIPPING WEIGHT kg 218 218 218 COMPRESSOR / QUANTITY Scroll / 1 REFRIGERANT (R-410A) Quantity lb 9.0 9.0 9.0 Quantity (kg.) 4.1 4.1 4.1 REFRIGERANT METERING DEVICE Orifice ORIFICE ID in./mm .080 / 2.03 OUTDOOR COIL Rows ... Fins/in. 1...21 1...21 1...21 Face Area (sq ft) 23.3 23.3 23.3 OUTDOOR FAN Nominal CFM 3500 3500 3500 Diameter in. 26 26 26 Diameter (mm) 660.4 660.4 660.4 Motor Hp (Rpm) 1/5 (810) 1/5 (810) 1/5 (810) INDOOR COIL Rows ... Fins/in. 3...17 3...17 3...17 Face Area (sq ft) 5.6 5.6 5.6 INDOOR BLOWER Nominal Cooling Airflow (CFM) 1600 1600 1600 Size in. 11x10 11x10 11x10 Size (mm) 279.4x254 279.4254 279.4x254 Motor HP (RPM) 1.0(1075) 1.0(1075) 1.0(1075) FURNACE SECTION Burner Orifice No. (Qty...Drill Size) Natural Gas (Factory Installed) 3...38 3...33 3...31 Propane Gas 3...53 3...51 3...49 HIGH-PRESSURE SWITCH 650 +/- 15 (psig) Cut-out Reset (Auto) 420 +/- 25 LOSS -OF CHARGE / LOW-PRESSURE SWITCH (Liquid Line) (psig) cut-out Reset N/A (auto) RETURN -AIR FILTERS Throwawayf tin. 1 each 24xl6xl mm 610x406x25 24xl 8xl 610x457x25 *. Based on altitude of 0 to 2000 ft (0-610 m). f. Required filter sizes shown are based on the larger of the AHRI (Air Conditioning Heating and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 to 350 ft/minute for throwaway type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C. $. If using accessory filter rack refer to the filter rack installation instructions for correct filter sizes and quantity. Step 6 - Connect Condensate Drain NOTE: When installing condensate drain connection be sure to comply with local codes and restrictions. This unit disposes of condensate water through a 3/4 in. NPT fitting which exits through the base on the evaporator coil access side. See Fig. 3 and Fig. 4 for location. Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a field -supplied 2-in. (51 mm) condensate trap at the end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. (25 mm) lower than the drain -pan condensate connection to prevent the pan from overflowing (See Fig. 7). Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit. Connect a drain tube using a minimum of 3/4-in. PVC or 3/4-in. copper pipe (all field -supplied) at the outlet end of the 2-in. (51 mm) trap. Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1-in. (25 mm) for every 10 ft (3.1 m) of horizontal run. Be sure to check the drain tube for leaks. TRAP OUTLET 1-in. (25 mm) min. -----' 2-in. (51 mm) mm. A09052 Fig. 7 - Condensate Trap Step 7 - Install Flue Hood The flue assembly is secured and shipped in the return air duct. Remove duct cover to locate the assembly (See Fig. 9). NOTE: Dedicated low NOx models MUST be installed in California Air Quality Management Districts where a Low NOx rule exists. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 48VL-K: Installation Instructions These models meet the California maximum oxides of nitrogen (NOx) emissions requirements of 40 nanograms/joule or less as shipped from the factory. NOTE: Low NOx requirements apply only to natural gas installations. 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 indicted in this section of the unit installation instructions. Install the flue hood as follows: 1. This installation must conform with local building codes and with NFPA 54/ANSI Z223.1 National Fuel Gas Code (NFGC), (in Canada, CAN/CGA B 149.1, and B 149.2) latest revision. Refer to Provincial and local plumbing or wastewater codes and other applicable local codes. 2. Remove flue hood from shipping location (inside the return section of the blower compartment -see Fig. 9). Remove the return duct cover to locate the flue hood. Place flue hood assembly over flue panel. Orient screw holes in flue hood with holes in the flue panel. 3. Secure flue hood to flue panel by inserting a single screw on the top flange and the bottom flange of the hood. Step 8 - Install Gas Piping The gas supply pipe enters the unit through the access hole provided. The gas connection to the unit is made to the 1/2-in. (12.7 mm) FPT gas inlet on the gas valve. Install a gas supply line that runs to the heating section. Refer to the NFGC for gas pipe sizing. Do not use cast-iron pipe. It is recommended that a black iron pipe is used. Check the local utility for recommendations concerning existing lines. Size gas supply piping for 0.5 IN. W.C. maximum pressure drop. Never use pipe smaller than the 1/2-in. (12.7 mm) FPT gas inlet on the unit gas valve. For natural gas applications, the gas pressure at unit gas connection must not be less than 4.0 IN. W.C. or greater than 13 IN. W.C. while the unit is operating. For propane applications, the gas pressure must not be less than 11.0 IN. W.C. or greater than 13 IN. W.C. at the unit connection. A 1/8-in. (3.2 mm) NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the gas valve. When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1 latest edition (in Canada, CAN/CGA B 149.1). NOTE: In the state of Massachusetts: 1. Gas supply connections MUST be performed by a licensed plumber or gas fitter. 2. When flexible connectors are used, the maximum length shall not exceed 36 in. (915 mm). 3. When lever handle type manual equipment shutoff valves are used, they shall be T-handle valves. 4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts. In the absence of local building codes, adhere to the following pertinent recommendations: 1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in. (6.35 mm) for every 15 ft (4.6 m) of length to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter. 2. Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one hanger 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 tape. 4. Install sediment trap in riser leading to heating section (See Fig. 8). This drip leg functions as a trap for dirt and condensate. 5. Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft (1.8 m) of heating section. 6. Install ground joint union close to heating section between unit manual shutoff and external manual main shut-off valve. 7. Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit. TEE NIPPLE CAP C99020 Fig. 8 - Sediment Trap 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. Table 2 - Gas Flow Capacity* NOMINAL INTERNAL LENGTH OF PIPE FT (m)t IRON PIPE SIZE (IN.) DIAMETER (IN.) 10 (3) 20 (6) 30 (9) 40 (12) 50 (15) 60 (18) 70 (21) 80 (24) 90 (27) 100 (30) 125 (38) 150 (46) 175 (53) 200 (61) 1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 - - 3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 1-1/4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280 1-1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 *. Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5-IN. W.C. (based on a 0.60 specific gravity gas). Refer to Table 2 and National Fuel Gas Code NFPA 54/ANSI Z223.1. f. This length includes an ordinary number of fittings. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 10 48VL-K: Installation Instructions FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. - Connect gas pipe to unit using a backup wrench to avoid damaging gas controls. - Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. - Use proper length of pipe to avoid stress on gas control manifold. - If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe shall be installed at furnace gas valve and extend a minimum of 2 in. (51 mm) outside furnace casing. - If codes allow a flexible connector, always use a new connector. Do not use a connector which has previously serviced another gas appliance. 8. Check for gas leaks at the field -installed and factory -installed gas lines after all piping connections have been completed. Use a commercially available soap solution (or method specified by local codes and/or regulations). Step 9 — Install Duct Connections The unit has duct flanges on the supply- and return -air openings on the side and bottom of the unit. For downshot applications, the ductwork connects to the roof curb (See Fig. 3 and Fig. 4 for connection sizes and locations). Configuring Units for Downflow (Vertical) Discharge ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch. 1. Open all electrical disconnects before starting any service work. 2. Remove horizontal (metal) duct covers to access vertical (downflow) discharge duct knockouts in unit basepan. (See Fig. 9.) PROPERTY DAMAGE HAZARD Failure to follow this caution may result in property damage. Collect ALL screws that were removed. Do not leave screws on rooftop as permanent damage to the roof may occur. 3. For single-phase models only, on the discharge side only, remove the insulation covering the downshot (plastic) knockout. Insulation is held in place with aluminum tape. Please note that large chassis units have 2 pieces of insulation, and only the piece over the downshot knockout needs to be removed. Discard insulation. 4. To remove the downshot (plastic) knockouts for both supply and returns, break front and right side connecting tabs with a screwdriver and hammer. Push cover down to break rear and left side tabs. These plastic knockouts are held in place with tabs similar to an electrical knockout. Discard plastic knockout covers. 5. Set unit on roof curb. 6. Verify that the downshot ducts are aligned with the downshot knockout areas. 7. Re -install horizontal (metal) covers as needed to seal unit. Ensure openings are air and watertight. NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence -type air conditioning and ventilating systems, NFPA 90A or residence -type, NFPA 90B; and/or local codes and ordinances. Horizontal Duct Covers A09076 EMS A09077 Fig. 9 — Supply and Return Duct Opening Adhere to the following criteria when selecting, sizing, and installing the duct system: 1. Units are shipped for horizontal duct installation (by removing duct covers). 2. Select and size ductwork, supply -air registers, and return -air grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations. 3. Use flexible transition between rigid ductwork and unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure weather -tight and airtight seal. 4. All units must have field -supplied filters or accessory filter rack installed in the return -air side of the unit. Recommended sizes for filters are shown in Table 1. 5. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases or performance may be affected. 6. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 11 48VL-K: Installation Instructions use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors of America (ACCA) minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure. 7. Flash, weatherproof, and vibration isolate all openings in building structure in accordance with local codes and good building practices. Step 10 — Install Electrical Connections ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. The unit cabinet must have an uninterrupted, unbroken electrical ground. This ground may consist of an electrical wire connected to the unit ground screw in the control compartment, or conduit approved for electrical ground when installed in accordance with NFPA 70 (NEC) (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes. 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 NFPA 70 (NEC) (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. 6. Route field power supply(s) away from areas that could be damaged by lawn and garden equipment or other accidental damage. High -Voltage Connections When routing power leads into unit, use only copper wire between disconnect and unit. The high voltage leads should be in a conduit until they enter the duct panel; conduit termination at the duct panel must be watertight. The unit must have a separate electrical service with a field -supplied, waterproof disconnect switch mounted at, or within sight from, the unit. Refer to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing. The field -supplied disconnect switch box may be mounted on the unit over the high -voltage inlet hole when the standard power and low -voltage entry points are used (See Fig. 3 and Fig. 4 for acceptable location). NOTE: Field supplied disconnect switch box should be positioned so that it does not cover up any of the unit gas combustion supply air louvers. See unit wiring label (Fig. 14 - Fig. 19) and Fig. 10 for reference when making high voltage connections. Proceed as follows to complete the high -voltage connections to the unit. Single phase units: 1. Run the high -voltage (L1, L2) and ground lead into the control box. 2. Connect ground lead to chassis ground connection. 3. Locate the black and yellow wires connected to the line side of the contactor (if equipped). 4. Connect field L1 to black wire on connection 11 of the compressor contactor. 5. Connect field wire L2 to yellow wire on connection 23 of the compressor contactor. Three-phase units: 1. Run the high -voltage (L1, L2, L3) and ground lead into the control box. 2. Connect ground lead to chassis ground connection. 3. Locate the black and yellow wires connected to the line side of the contactor (if equipped). 4. Connect field L1 to black wire on connection 11 of the compressor contactor. 5. Connect field wire L3 to yellow wire on connection 13 of the compressor contactor. 6. Connect field wire L2 to blue wire from compressor. Special Procedures for 208-v Operation ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Make sure the power supply to the unit is switched OFF and install lockout tag before making any wiring changes. With disconnect switch open, move black wire from transformer (3/16 in. [4.8mm]) terminal marked 230 to terminal marked 208. This retaps transformer to primary voltage of 208 vac. ELECTRICAL SHOCK FIRE/EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death and property damage. Before making any wiring changes, make sure the gas supply is switch off first. Then switch off the power supply to the unit and install lockout tag. Control Voltage Connections Do not use any type of power -stealing thermostat. Unit control problems may result. Use no. 18 American Wire Gage (AWG) color -coded, insulated (35°C minimum) wires to make the control voltage connections between the thermostat and the unit. If the thermostat is located more than 100 ft (30.5 m) from the unit (as measured along the control voltage wires), use no. 16 AWG color -coded, insulated (35°C minimum) wires. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 12 48VL-K: Installation Instructions Standard Connection Pre -Start-up Run the low -voltage leads from the thermostat, through the inlet hole, and into unit low -voltage splice box. Locate six (seven for 3-phase) 18-gage wires leaving control box. These low -voltage connection leads can be identified by the colors red, green, yellow, brown, blue, and white (See Fig. 10). A gray wire is standard on 3-phase units for connection to an economizer. Ensure the leads are long enough to be routed into the low -voltage splice box (located below right side of control box). Route leads through hole in bottom of control box and make low -voltage connections (See Fig. 10). Secure all cut wires, so that they do not interfere with operation of unit. 0— — —— HIGH VOLTAGE POWER LEADS o— — — — —� — — POWER (SEE UNIT WIRING SUPPLY LABEL) o— — — — - — — 3-PHASE SHOWN 1-PHASE USESTWO POWER ' LEADS EQUIP GR FIELD -SUPPLIED FUSED DISCONNECT iOL BOX LOW -VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL) SPLICE BOX o- WHT�N� LJ o- o- GRN(G) G THERMOSTAT o- RED(R)_ (TYPICAL) o- BRN(C) —J o- BLU.DH) GRA(Y2) _phase Only A09053 Fig. 10 — High- and Control -Voltage Connections Heat Anticipator Setting (Electro-Mechanical Thermostats only) The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance. Set the heat anticipator, using an ammeter between the W and R terminals to determine the exact required setting. NOTE: For thermostat selection purposes, use 0.18 amp for the approximate required setting. Failure to make a proper heat anticipator adjustment will result in improper operation, discomfort to the occupants of the conditioned space, and inefficient energy utilization; however, the required setting may be changed slightly to provide a greater degree of comfort for a particular installation. Transformer Protection The transformer is of the energy -limiting type, however a direct short will likely blow a secondary fuse. If an overload or short is present, correct overload condition and check for blown fuse on Indoor Fan board or Integrated Gas Controller. Replace fuse as required with correct size and rating. ENVIRONMENTAL, FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in 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 plug is in place and secured. 3. Do not remove compressor plug until all electrical sources are disconnected and tagged. 4. Relieve and recover all refrigerant from system before touching or disturbing compressor plug 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: -Shut off electrical power to unit and install lockout tag. -Relieve and reclaim all refrigerant from system using both high- and low-pressure ports. -Cut component connecting tubing with tubing cutter and remove component from unit. -Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame. 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 access panels (see Fig. 22). 2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with unit. Make the following inspections: a. Inspect for shipping and handling damage, such as broken lines, loose parts, disconnected wires, etc. b. Inspect all field- and factory -wiring connections. Be sure that connections are completed and tight. c. Ensure wires do not touch refrigerant tubing or sharp sheet metal edges. d. Inspect coil fins. If damaged during shipping and handling, carefully straighten fins with a fin comb. FIRE, EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death or property damage. Do not purge gas supply into the combustion chamber. Do not use a match or other open flame to check for gas leaks. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 13 48VL-K: Installation Instructions 4. Verify the following conditions: a. Make sure gas line is free of air. Before lighting the unit for the first time, perform the following with the gas valve in the OFF position: NOTE: If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is recommended that the ground joint union be loosened, and the supply line be allowed to purge until the odor of gas is detected. Never purge gas lines into a combustion chamber. Immediately upon detection of gas odor, retighten the union. Allow 5 minutes to elapse, then light unit. b. Ensure fan hub is positioned correctly with respect to motor housing. c. Make sure that air filter(s) is in place. d. Make sure that condensate drain trap is filled with water to ensure proper drainage. e. Make sure that all tools and miscellaneous loose parts have been removed. Start-up FIRE, INJURY, OR DEATH HAZARD Failure to follow this warning could result in property damage, personal injury, or death. Do not bypass any of the safety controls in the unit, including but not limited to the main limit switch, rollout or burner rollout switch, and pressure switch/pressure transducer. Step 1 — Check for Refrigerant Leaks EXPLOSION HAZARD Failure to follow this warning could result in death, serious personal injury, and/or property damage. Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion. Proceed as follows to locate and repair a refrigerant leak and to charge the unit: 1. Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high- and low-pressure ports. 2. Repair leak following accepted practices. NOTE: Install a filter drier whenever the system has been opened for repair. 3. Add a small charge of Puron (R-410A) refrigerant vapor to system and leak -test unit. 4. Recover refrigerant from refrigerant system and evacuate to 500 microns if no additional leaks are found. 5. Charge unit with Puron (R-410A) refrigerant, using an accurate scale. Refer to unit rating plate for required charge. Step 2 — Start-up Heating and Make 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. Make sure that burner orifices are properly aligned. Unstable operation my occur when the burner orifices in the manifold are misaligned. Follow the lighting instructions on the heating section operation label (located on the inside of the control access panel) to start the heating section. NOTE: Make sure that gas supply has been purged, and that all gas piping has been checked for leaks. Fig. 11 — Burner Assembly FOLD Fig. 12 — Monoport Burner Check Heating Control A07679 C99021 Start and check the unit for proper heating control operation as follows (see furnace lighting instructions located on the inside of the control access panel): 1. Place room thermostat SYSTEM switch in the HEAT position and the fan switch is placed in AUTO position. 2. Set the heating temperature control of the thermostat above room temperature. 3. The induced -draft motor will start. 4. On a call for heating, the main burner should light within 5 sec. of the spark being energized. If the burners do not light, there is a 22-sec. delay before another 5-sec. try. If the burners still do not light, this sequence is repeated. For 3-phase models if the burners do not light within 15 minutes from the initial call for heat, there is a lockout. For single phase models, if the burners do not light on the 4th ignition attempt, there is a lockout. To reset the control, break the 24-v power to W. 5. For 3-phase models the evaporator fan will turn on 45 sec. after the flame has been established. The evaporator fan will turn off 45 sec. after the thermostat has been satisfied. For single phase models the evaporator fan will turn on 30 sec. after the flame has been established. The evaporator fan will turn off 90 sec. After the thermostat has been satisfied. Please note that the integrated gas Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 14 48VL-K: Installation Instructions unit controller (IGC) has the capability to automatically reduce the evaporator "ON" delay and increase the evaporator "OFF" delay in the event of high duct static and/or partially -clogged filter. Check Gas Input Check gas input and manifold pressure after unit start-up (See Table 5). If adjustment is required proceed as follows: • The rated gas inputs shown in Table 5 are for altitudes from sea level to 2000 ft (610 m) above sea level. These inputs are based on natural gas with a heating value of 1025 Btu/ft3 at 0.60 specific gravity, or propane gas with a heating value of 2500 Btu/ft3 at 1.5 specific gravity. IN THE U.S.A.: The input rating for altitudes above 2,000 ft (610 m) must be reduced by 4% for each 1,000 ft (305 m) above see level. For installations below 2,000 ft (610 m), refer to the unit rating plate. For installations above 2,000 ft (610 m). multiply the input on the rating plate by the derate multiplier in Table 3 for correct input rate. Table 3 — Altitude Derate Multiplier for U.S.A.. Derate Multiplier Altitude ft (m) Percent of Derate Factort 0-2000 0 1.00 (0-610) 2001-3000 8-12 0.90 (610-914) 3001-4000 12-16 0.86 (915-1219) 4001-5000 16-20 0.82 (1220-1524) 5001-6000 20-24 0.78 (1524 -1829) 6001-7000 24-28 0.74 (1829-2134) 7001-8000 28-32 0.70 (2134-2438) 8001-9000 32-36 0.66 (2439-2743) 9001-10,000 36-40 0.62 (2744-3048) *. In Canada see Canadian Altitude Adjustment. j . Derate multiplier factors are based on midpoint altitude for altitude range. IN CANADA: The input rating for altitudes from 2,000 (610 m) to 4,500 ft (1372 m) above sea level must be derated 10% by an authorized Gas Conversion Station or Dealer. EXAMPLE: 90,000 Btu/hr Input Furnace Installed at 4300 ft. Furnace Input Rate at X Derate Multiplier __ Furnace Input Rate at Sea Level Factor Installation Altitude 90,000 X 0.90 = 81,000 When the gas supply being used has a different heating value or specific gravity, refer to national and local codes, or contact your distributor to determine the required orifice size. UNIT DAMAGE HAZARD Failure to follow this caution may result in reduced unit and/or component life. Do Not redrill an orifice. Improper drilling (burrs, out -of -round holes, etc.) can cause excessive burner noise and misdirection of burner flame. If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Adjust Gas Input The gas input to the unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure. Measuring the gas flow at the meter is recommended for natural gas units. The manifold pressure must be measured to determine the input of propane gas units. Measure Gas Flow (Natural Gas Units) Minor adjustment to the gas flow can be made by changing the manifold pressure. The manifold pressure must be maintained between 3.2 and 3.8 IN. W.C. ON/OFF SWITCH REGULATOR COVERSCREW PLASTIC ADJUSTMENT SCREW REGULATOR SPRING (PROPANE - WHITE) NATURAL - SILVER) INLET ADJUSTMENT PRESSURETAP 11 MANIFOLD PRESSURE TAP A07751 Fig. 13 — Single -Stage Gas Valve If larger adjustments are required, change main burner orifices following the recommendations of national and local codes. NOTE: All other appliances that use the same meter must be turned off when gas flow is measured at the meter. Proceed as follows: 1. Turn off gas supply to unit. 2. Remove pipe plug on manifold (See Fig.11) and connect manometer. Turn on gas supply to unit. 3. Record number of seconds for gas meter test dial to make one revolution. 4. Divide number of seconds in Step 3 into 3600 (number of seconds in one hr). 5. Multiply result of Step 4 by the number of cubic feet (cu ft) shown for one revolution of test dial to obtain cubic feet (cu ft) of gas flow per hour. 6. Multiply result of Step 5 by Btu heating value of gas to obtain total measured input in Btuh. Compare this value with heating input shown in Table 5 (Consult the local gas supplier if the heating value of gas is not known). EXAMPLE: Assume that the size of test dial is 1 cu ft, one revolution takes 32 sec, and the heating value of the gas is 1050 Btu/ft3. Proceed as follows: Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 15 48VL-K: Installation Instructions 1. 32 sec. to complete one revolution. 2. 3600 , 32 = 112.5. 3. 112.5 x 1 =112.5 ft3 of gasflow/hr. 4. 112.5 x 1050 = 118,125 Btuh input. If the desired gas input is 115,000 Btuh, only a minor change in the manifold pressure is required. Observe manifold pressure and proceed as follows to adjust gas input: 1. Remove regulator cover screw over plastic adjustment screw on gas valve (See Fig. 13). 2. Turn plastic adjustment screw clockwise to increase gas input, or turn plastic adjustment screw counterclockwise to decrease input (See Fig. 13). Manifold pressure must be between 3.2 and 3.8 IN. WC. FIRE AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and/or property damage. Unsafe operation of the unit may result if manifold pressure is outside this range. 3. Replace regulator cover screw on gas valve (See Fig. 13). 4. Turn off gas supply to unit. Remove manometer from pressure tap and replace pipe plug on gas valve. (See Fig. 11.) Turn on gas to unit and check for leaks. Measure Manifold Pressure (Propane Units) Refer to propane kit installation instructions for properly checking gas input. NOTE: For installations below 2,000 ft (610 m), refer to the unit rating plate for proper propane conversion kit. For installations above 2,000 ft (610 m), contact your distributor for proper propane conversion kit. Check Burner Flame With control access panel (see Fig.22) removed, observe the unit heating operation. Watch the burner flames to see if they are light blue and soft in appearance, and that the flames are approximately the same for each burner. Propane will have blue flame (See Fig. 12). Refer to the Maintenance section for information on burner removal. Table 4 - High Altitude Compensation, Natural Gas - All Models Nameplate Rated Heating Input (Btu/hr), Natural Gas at Installation Altitude Above Sea Level, U.S.A.* Input (Btu/hr) 0 to 2000 ft (0-610 m) 2001 to 3000 W (611 to 914 m) 3001 to 4000 ft (915 to 1219 m) 4001 to 5000 ft (1220 to 1524 m) 5001 to 6000 ft (1524 to 1829 m) 40000 40000 36000 34400 32800 31200 60000 60000 54000 51600 49200 46800 90000 90000 81000 77400 73800 70200 115000 115000 103500 98900 94300 89700 127000 127000 114300 109200 104100 99100 *. hi the U.S.A., the input rating for altitudes above 2000 ft (610m) must be reduced by 4% for each 1000 ft (305 m) above sea level. hi Canada, the input rating for altitudes from 2001 to 4500 ft (611 to 1372 m) above sea level must be derated by 10% by an authorized gas conversion station or dealer. For Canadian Installations from 2000 to 4500 ft (610-1372 m), use U.S.A. column 2001 to 3000 ft (611 to 914 m). Table 5 - Heating Inputs HEATING INPUT (BTUH) NUMBER OF ORIFICES GAS SUPPLY PRESSURE (IN. W.C.) MANIFOLD PRESSURE (IN. W.C.) Natural Propane't Min Max Min Max Natural{ Propane*t 40,000 2 4.0 13.0 11.0 13.0 3.2-3.8 10.0-11.0 60,000 3 4.0 13.0 11.0 13.0 3.2-3.8 10.0-11.0 90,000 3 4.5 13.0 11.0 13.0 3.2-3.8 10.0-11.0 115,000 3 4.5 13.0 11.0 13.0 3.2-3.8 10.0-11.0 130,000 3 4.5 13.0 11.0 13.0 3.2-3.8 10.0-11.0 *. Based on altitudes from sea level to 2000 ft (610 m) above sea level. In U.S.A. for altitudes above 2000 ft (610 m), reduce input rating 4 percent for each additional 1000 ft (305 m) above sea level. In Canada, from 2000 ft (610 m) above sea level to 4500 ft (1372 m) above sea level, derate the unit 10 percent. t. When a unit is converted to propane, different size orifices must be used. See separate, natural -to -propane conversion kit instructions. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 16 48VL-K: Installation Instructions CONNECTION WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING SCHEMATIC 208/230-1-60 IF USED COf215LK, BLK BLK FIELD _ _ LlBILK 11 CAP 1 OFMSUPPLY HPOWER L2�YEL23 BLU YEL SEE NOTE 8 0 0 EQUIP GN� F BRN UNIT ONLY BLK COMP LEI GND YEL YEL N MAXIMUM WIRE C R SIZE 2 AWG S GRNNEL GND FM BLK L1 BLU BRN COM 1234 WHEN rno n �-l1SE❑ w - Jz mart Om I I I I TO IGC SEE NOTE 415 TRAN r BLK /IF USED C 24V CCH /` RED BLr�BLKtBLK— YEL i BRN V RIV i LGPS YEL i i PRESSURE LP KIT SWITCH ACCESSORY WHEN USED b MIN/ 1 LL f77BLK IDED !U CCH TOFF c� T1 zo L2 IDM L1 Yo EL0 (} IGC 0 0 O O =� P1 SEE NOTE 7 TO IFM a w �¢ m SEE NOTE 4/5 M LLL O �n( p7 ? MCOMR VN U v¢ N DEHUM FAN COOL HEAT cb C�D C C43 P2 _ _ _ IF USED, C LPS HPS —BRN C2 C1 BLUBLU BLK—(j�—E L— — — — — — Fig. 14 — 208/230-1-60 Connection Wiring Diagram —YEL-0 FS0777 ORG -01 0- BRN -777 RS - BLU BLU LS1 LS2 VIO RED , WHEN USED SEE NOTE 6 V10 J2 T-STAT BILL !7r -- DH BRN lT�r--C GRN =/TAT G RED —Tr-- R YEL -- Y --I— WHT Tt-- W A221583 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 17 48VL-K: Installation Instructions LADDER WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING LEGEND Z2S FIELD SPLICE EQUIP EQUIPMENT O TERMINAL (MARKED) FS FLAME SENSOR GND GROUND o TERMINAL (UNMARKED) HPS HIGH PRESSURE SWITCH • SPLICE I IGNITOR IDM INDUCED DRAFT MOTOR O SPLICE (MARKED) IFM INDOOR FAN MOTOR FACTORY LO VOLTAGE IGC INTERGRATED GAS UNIT CONTROLLER — — FIELD CONTROL WIRING LGPS LOW GAS PRESSURE SWITCH (WHEN USED) -- FIELD POWER WIRING LPS LS2 LOW PRESSURE SWITCH PRIMARY LIMIT SWITCH ACCESSORY OR OPTIONAL LS2 SECONDARY LIMIT SWITCH WIRING MGM MAIN GAS VALVE — FACTORY HI VOLTAGE OFM OUTDOOR FAN MOTOR C CONTACTOR OT QUADRUPLE TERMINAL CAP1 CAPACITOR, COMP RS ROLLOUT SWITCH CAP2 CAPACITOR, INDUCER (WHEN USED) TRAN TRANSFORMER CCH CRANKCASE HEATER T-STAT THERMOSTAT CHS CRANKCASE HEATER SWITCH COMP COMPRESSOR MOTOR 10 UNIT COMPONENT ARRANGEMENT OUTDOOR FAN OFM SECTION COMPRESSOR INDOOR FAN CONTROL BOX AREA SECTION LPS SECTION LS2 MFT--Nl23 23 21 C 11 HPS IFM CAP 1 PRS CAP1 HCF GABLS1 M SECTION R3 FS E HEATING FAN LOGIC 0 42 T T-90 W BLOWER W BLOWER ENERGIZED ENERGIZED DE -ENERGIZED DE -ENERGIZED COOLING FAN LOGIC 0 1 T T+60 Y BLOWER Y BLOWER ENERGIZED ENERGIZED DE -ENERGIZED DE -ENERGIZED NOTE: IF Y2 DE -ENERGIZED REMOVES CALL FOR COOLING, 0 SECOND OFF DELAY _1 USE COPPER CONDUCTORS ONLY BLK FIELD SUPPLY 1 EQUIP GND 208/230 VAC. 60 HZ. 1 PH C 021 C;11 l rILI OFM YEL IF USED BLK CAP 1 H BLU COMP BRN C YEL S R F YEL ELK C CCH IF USED /CCH\SS IGC BLK BLK�BLK YEL L; GRIN r7)i YEL L; ELK IFM SEE NOTE 8 / C—L GRWYEL SEE NOTE 8 r}7 IDM CAP 2 _'nnBRN WHEN Nfl USED LiWHEN ELK no 408 COM YEL USED T-STAT TRAN RED C BRN IGC "24VAC" "CONT' HIPSI �LP\$u I c BLK �// BLK BLU BLU Ci C2 BR //�� 3A FUSE 01r- FS IF FSSE1ED DH----' `BLU P1-6 P2-1 "DH"�7 YELL GRNIYEL Z^' G----� ` "Ti" ORN IIo-BRN GRN P2-3 "G' P1-2 BLU RS F --- P15 BLU RED P24 "R'. Ply0— P1-1 —VIO LS1 RED LS2 VIO Y----' `YEL WHEN UI Q P1-B SEE NOTE 6 ORNAKTITACCE w----� -WIT P2 6 PRESSURE /7/�\� - IC- SWITCH BRN SSORY WHEN USED P1-7 YEL NOTES: 1. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT. 2. SEE PRE -SALE LITERATURE FOR THERMOSTATS. 3. USE 75 DEGREES C COPPER CONDUCTORS FOR FIELD INSTALLATION. 4. REFER TO INSTALLATION INSTRUCTIONS FOR CORRECT SPEED SELECTION FOR IFM. 5. SEE INSTALLATION INSTRUCTIONS FOR PROPER HEATING AND COOLING CONNECTIONS FOR YOUR UNIT. 6. ON SOME MODELS LS1 AND LS2 ARE WIRED IN SERIES. ON OTHER MODELS ONLY LS1 IS USED. 7. THIS FUSE IS MANUFACTURED BY LITTLE FUSE, PM 287003. B. DO NOT DISCONNECT PLUG UNDER LOAD. 9. N.E.C. CLASS 2, 24V. IGC "24VAC CCU" GND o P1-9 GRY MGV GRNIYEL M z � BRN 1?1-3 GRNIYEL IFM V -BLU BRN "MOTOR CC INK ro SEE NOTE 415+ -ORN s - ELK BRN P2-2 "C" 48VL5004�0 REV.A 48VL500420 REV.A Fig. 15 — 208/230-1-60 Ladder Wiring Diagram Rh YEL ) Q23 ) C;23 A221584 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 18 48VL-K: Installation Instructions CONNECTION WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING SCHEMATIC 208/230-3-60 FIELD -- Ll- BLK FUSED SUPPLY p W1323 BILK BLK POWER _ _ _ L3J L-YEL CAP OFM - - - - L BLU 771 YEL L2 'R SEE NOTE 8 BRN ° EQUIP GND F GND UNIT ONLY YEL BILKYEL OMP INC MAXIMUM WIRE T3 T1 � GRN/YEL GND FM SIZE 2 AWG BLK Li T2 BRN COM 1234 WHEN CAP 2—USED m a r O m YEL BRN7-�BRN i TO IGC IDM SEE NOTE 4/5 rYE 208 230 vio TRANOM II BLK IY.L _--IF USED CCH / \ CHS FllBLK+ BLK—BLK ILK GRN BLK RMS ($TAN30FF ri7 0 a uuuul U UJT1 L2 I L1 � BRN BRN - YEL aFS ECONOMIZER PLUG IGC Y. o � YEL ORG -01 o- BRN 7 r _ ECOM� 1 7 P BL SAT O p .8 GRNNEL�7 6 1 6 L J P1 RS BLU 10 — 10 s s 3 2 1 GRY 2 YEL RED GRY 8 5 2 7 4 . BLU LS1 LS2 VIO RED yF ' -�-< BL �4 BRN SEE 7 IFM NOTE 4/5 EL BRN SEE NOTE D 5 I 5 LK /SEETO a �d �,� / VIo 5 1�9 LL OR 12 12 ¢ o28 M @R COOL HEAT N > COM DE��HI1U��M P2 U2 __FALLN a C� C,-J W C:b N W Y R G C DH ORN I I I I I I BRN - - -; T-STAT LGPS YEL RED BRN BLU T�-- DH i MGV GRY--C M BRN GRN G i ' LP KIT PRESSURE GRNlYEL nn RED �'r.-- R ACCESSORY WHEN USED SWITCH BRN C _ _ _ IF USED C r LPS HPS C1 BLK-(j� _BLK YEL Y WHT --- W GRY 0--Y2 C2 IBLU--(D—BLU A221581 Fig. 16 — 208/230-3-60 Connection Wiring Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 19 48VL-K: Installation Instructions LADDER WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING LEGEND Z2S FIELD SPLICE EQUIP EQUIPMENT O TERMINAL (MARKED) FS FLAME SENSOR GND GROUND 0 TERMINAL (UNMARKED) HPS HIGH PRESSURE SWITCH • SPLICE HUM HUMIDIFIER ACCESSORY TERMINAL IGNITOR O SPLICE (MARKED) IDM INDUCED DRAFT MOTOR — FACTORY LO VOLTAGE IFM INDOOR FAN MOTOR LLER — — FIELD CONTROL WIRING GPS LOW GASPRESTED SURENSWIIT TCCH (WHEN USED) -- FIELD POWER WIRING LIPS LOW PRESSURE SWITCH ACCESSORY OR OPTIONAL LS1 PRIMARY LIMIT SWITCH WIRING LS2 SECONDARY LIMIT SWITCH FACTORY HI VOLTAGE MGV MAIN GAS VALVE C CONTACTOR OFM OUTDOOR FAN MOTOR CAP1 CAPACITOR, COMP OT QUADRUPLE TERMINAL CAP2 CAPACITOR, INDUCER (WHEN USED) IRS ROLLOUT SWITCH CCH CRANKCASE HEATER TRAN TRANSFORMER CHS CRANKCASE HEATER SWITCH T-STAT THERMOSTAT COMP COMPRESSOR MOTOR L1 USE COPPER CONDUCTORS ONLY I I SLK FIELD SUPPLY 1 EQUIP GNO 208/230 VAC. 60 HZ. 3PH = C C;21 OFM BLu vEL C;11 BLKt BLK YEL IF USED CAP 1 c BLU COMP BEN C F Q23 T2 T3 YEL ELK T1 IGC CCH f IF USED CHS IGC CCH BLK�BLK�BLK YEL L2 GEN r"7 YEL LZ IFM SEE NOTE B L1 BLK L2 GRWYEL L1 SEE NOTE 8 ri i C'11 IDM 10 UNIT COMPONENT ARRANGEMENT gRN CAP FAN OFM 0..I wo � USED SECTION OM BRN 0 COMPRESSOR INDOOR FAN CONTROL BOX AREA SECTION SECTION LS2 IGC TRAN 23 23 21 C 11 LPS HPS 172 M GAS SECTION RS FS M HEATING FAN LOGIC 0 42 T BLOWER ENERGIZED ENERGIZED DE -ENERGIZED DE -ENERGIZED COOLING FAN LOGIC 0 1 T T+60 Y BLOWER Y BLOWER ENERGIZED ENERGIZED DE -ENERGIZED DE -ENERGIZED NOTE: IF Y2 DE -ENERGIZED REMOVES CALL FOR COOLING, 0 SECOND OFF DELAY USED T-STAT DH - - --' `BLU G----"GRN R---TL RED- Y---q� YEL - W----' `WHT C-- BEN Y2--- GRY NOTES: 1. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT. 2. SEE PRE -SALE LITERATURE FOR THERMOSTATS. 3. USE 75 DEGREES C COPPER CONDUCTORS FOR FIELD INSTALLATION. 4. REFER TO INSTALLATION INSTRUCTIONS FOR CORRECT SPEED SELECTION FOR IFM. 5. SEE INSTALLATION INSTRUCTIONS FOR PROPER HEATING AND COOLING CONNECTIONS FOR YOUR UNIT. 6. ON SOME MODELS LS1 AND LS2 ARE WIRED IN SERIES. ON OTHER MODELS ONLY LSi IS USED. 7. THIS FUSE IS MANUFACTURED BY LITTLE FUSE, PM 287003. 8. DO NOT DISCONNECT PLUG UNDER LOAD. 9. N.E.C. CLASS 2, 24V. Li BLK 26 206 COM YEL TRAIN RED 2, 4V C BRN IGC "24VAC" HIPS r /LPS I C 3A FUSE ELK �ELK�BLU-fl-fC}-BLUI Ci C2 IBR E�USSEED n P2-1 "DH" P1-6 YEL 'T1" ORN—To- - " P2G BRNI Pi-2 BLU RS Pi-5 BLU P2-4 "R" Pi-4 WO LS1 LS2 WO RED P2P2-11 Pi-1 ��// Pi B ORN WHEN USE SEE NOTE 6 P2-6 "W r-- i LGPS PRESSURE SWITCH i LP KIT ACCESSORY WHEN USED Pi-7 YEL o P1-9 GRNIEL IFM BLUTP -PNKSEE NOTE III— -RED-ORN-BLK YEL ECONOMIZER _PLUG Fig. 17 — 208/230-3-60 Ladder Wiring Diagram BRN C;13 sQ BLK �> 7 17 0 BLU BLU ECON L�� —GRY RL r 349176-201 REV. ---y:—= —RED Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 20 48VL-K: Installation Instructions CONNECTION WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING p SCHEMATIC 460-3-60 FIELD _ _ �l- L_ BLK IF USED SUPPLY pQ CONT BLK — BLK POWER ---L3JLYEL 11 21 BLK OFM Q CAP ---L2J `BLU 13 23 YEL YEL SE NOTE 8 o BRN EQUIP GND YEL F ® GND BLK YEL N UNIT ONLY - COMP GRBRN GND FM MAXIMUM WIRE T3 T1 SIZE 2 AWG BLK L1 T2 BRN COM ---- 1234 4"'. YEL IDMTO IGC N SEE NOTE 415 YEL YEL CC 4 230 I NOTE 10 BLK VIo� TRAN I J CAP 2 6 C1 /IF USED 24V J CCH / CHS RED BLKt BLK�BLK BLK �N YEL GRNNEL— BLK ORN BRN ECONOMIZER PLUG r ECOM� 7 1 7 SAT 6 I1 6 P BL L-J 10 �0 GRY B 1 B YEL 2 I 2 Y 3 3 � RED BRN BL 4 1 111 BLK---] 5 � 1�5 1 1�2 LGPS YEL i i LP KIT I PRESSURE ACCESSORY SWITCH WHEN USED T1) oBIUUUUUI U L2 IDM IGC N SEE NOTE 7 TO IFM Ia w �d D /SEE TE 4/5 / M LL 0 O �UQ ppTT M,C�,,JOJ,,,��M��R DEHUM FAN COOL HEAT N > N W 1— RED — MGV _. GRY IF USED r LPS I — —e— LU I YEL-0 0—,7, YEL o YEL ORG -01 o- BRN -;77 0 U GRNIYEL 7 RS P1 BLu J2 BRN LS1 LS2 RED WHEN USED SEE NOTE 6 VIO T-STAT BLU-- DH BRN--C GRN O--G RED-- R YEL Y WHT 0-- W GRY 0--Y2 A221579 Fig. 18 — 460-3-60 Connection Wiring Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 21 48VL-K: Installation Instructions LADDER WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING LEGEND Z2� FIELD SPLICE EQUIP EQUIPMENT O TERMINAL (MARKED) FS FLAME SENSOR GND GROUND 0 TERMINAL (UNMARKED) HPS HIGH PRESSURE SWITCH • SPLICE HUM HUMIDIFIER ACCESSORY TERMINAL I IGNITOR O SPLICE (MARKED) IDM INDUCED DRAFT MOTOR FACTORY LO VOLTAGE IFM IGC INDOOR FAN MOTOR INTERGRATED GAS UNIT CONTROLLER - - FIELD CONTROL WIRING LGPS LOW GAS PRESSURE SWITCH (WHEN USED) -- FIELD POWER WIRING LPS LOW PRESSURE SWITCH --- ACCESSORY OR OPTIONAL LS1 PRIMARY LIMIT SWITCH WIRING LS2 SECONDARY LIMIT SWITCH FACTORY HI VOLTAGE MGV MAIN GAS VALVE C CONTACTOR OFM OUTDOOR FAN MOTOR CAP1 CAPACITOR, COMP OT QUADRUPLE TERMINAL CAP2 CAPACITOR, INDUCER (WHEN USED) IRS ROLLOUT SWITCH CCH CRANKCASE HEATER TRAN TRANSFORMER CHS CRANKCASE HEATER SWITCH T-STAT THERMOSTAT COMP COMPRESSOR MOTOR 10 UNIT COMPONENT ARRANGEMENT OUTDOOR FAN OFM SECTION COMPRESSOR INDOOR FAN CONTROL BOX AREA SECTION SECTION LS2 23 23 21 C 11 FL PS] [Jr-7N HPS CAP IFM P S HCF CAP2 COMP IDM MGV GAS T3 Ti LSi SECTION RB T2 FS HEATING FAN LOGIC 0 42 T T-90 W BLOWER W BLOWER ENERGIZED ENERGIZED DE -ENERGIZED DE -ENERGIZED COOLING FAN LOGIC 0 1 T T+60 Y BLOWER Y BLOWER ENERGIZED ENERGIZED DE -ENERGIZED DE -ENERGIZED NOTE: IF Y2 DE -ENERGIZED REMOVES CALL FOR COOLING, 0 SECOND OFF DELAY NOTES: .WHEN T-STAT USED IGC ^zavnc° 'CONT' a /u� 3A FUSEE DH----' `BLU P2-1 "D ° P1-6 C) G--_FLL GRN FF --Q- RED Y - - - -I L YEL W---4�--WHT C-- SPINY2--- GRY 1. IFANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT. 2. SEE PRE -SALE LITERATURE FOR THERMOSTATS. 3. USE 75 DEGREES C COPPER CONDUCTORS FOR FIELD INSTALLATION. 4. REFER TO INSTALLATION INSTRUCTIONS FOR CORRECT SPEED SELECTION FOR IFM. 5. SEE INSTALLATION INSTRUCTIONS FOR PROPER HEATING AND COOLING CONNECTIONS FOR YOUR UNIT. 6. ON SOME MODELS LS1 AND LS2 ARE WIRED IN SERIES. ON OTHER MODELS ONLY LS1 IS USED. 7. THIS FUSE IS MANUFACTURED BY LITTLE FUSE, PIN 287003. 8. DO NOT DISCONNECT PLUG UNDER LOAD. 9. N.E.C. CLASS 2, 24V. 10. INDUCER CAPACITOR AND WIRING ON CERTAIN MODELS ONLY, IF CAP2 IS PRESENT, YELLOW WIRES FROM IGC 12" AND IDM Normal Operation -TV Q11 C 11 USE COPPER CONDUCTORS ONLY I I FIELD SUPPLY 1 EQUIP GND 208/230 VAC. 60 HZ. 3PH JC C;21 OFM BLU YEL 1 BLKt BLK YEL IF USED CAP 1 c BLU COMP BRN C C;13 F C;23 T2 T3 vEL BLK T1 CCH f IF USED CHS IGC BLK�BLK�BLK BLK -.0- YEL L2 GRN 14 YEL / L2 IFM SEE NOTE BT BLK Q 13 GRNIYEL L2 SEE NOTE B ri7 n IDM IDM VIO _ _ NOTE 10 BRN ' ! YEL I CAP 2 I YELL Li BLK ` 20 208 JCOM YEL TRAN -RED 2, 4 ,V C BRN HIPS\ r LPSC .BLK�I-¢BLK BLU-e-BLU C1 C2 BR �/ L IF USED FS �GRNNEL 1 -YEL M C •ORN --0I0- BRN P1-2 BLU RS 4 P7-5 P2 "R" BLU P1A vI0 LS1 LS2 P2-5 "Y"U P7 1 VIO RED �/ Pi-S ORN WREN Us� SEE NOTE 6 P2P2 I LGPS PSWITCHE I LP WHEN USED RY Pi-7 YEL o P1-9 GRY MGV r7rT-GRWYEL M (� BRN' LL (O GRNIYEL IFM 0 0 v PNK ti SEE NOTE 4/5-► -REBLUD w -ORN a -ELK N BRN I�IIIIIIIIIYIYIIIIII YEL ECONOMIZER COM PLUG r� !�3 3` 1.4 BRN j3 5 i 8 BLK BLU E 18 BLU SAT II III III _ _ ECON ��•?!� �-� f RED 349402-201 REV. - �r A221580 Fig. 19 — 460-3-60 Ladder Wiring Diagram An LED (light -emitting diode) indicator is provided on the integrated gas unit controller (IGC) to monitor operation. The IGC is located by removing the control access panel (see Fig.22). During normal operation, the LED is continuously on (See Table 6 for error codes). Airflow and Temperature Rise The heating section for each size unit is designed and approved for heating operation within the temperature -rise range stamped on the unit rating plate. Table 9 show the approved temperature rise range for each heating input, and the air delivery CFM at various temperature rises for a given external static pressure. The heating operation airflow must produce a temperature rise that falls within the approved range. For single phase units only, "High" blower speed is for high static cooling only and must not be used for gas heating speed. Refer to Indoor Airflow and Airflow Adjustments section to adjust heating airflow when required. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 22 48VL-K: Installation Instructions Heating Sequence of Operation (See Fig. 14, Fig. 15 and unit wiring label) On a call for heating, terminal W of the thermostat is energized, starting the induced -draft motor for a 5 second pre -purge. When the pressure switch senses that the induced -draft motor is moving sufficient combustion air, the burner sequence begins. This function is controlled by the integrated gas unit controller (IGC). The indoor (evaporator) —fan motor is energized 30 seconds after flame is established. When the thermostat is satisfied and W is de -energized, the burners stop firing and the indoor (evaporator) fan motor shuts off after a 90 second time -off delay. Please note that the IGC has the capability to automatically reduce the indoor fan motor on delay and increase the indoor fan motor off delay in the event of high duct static and/or a partially -clogged filter. Limit Switches Normally closed limit switch (LS) completes the control circuit. Should the leaving -air temperature rise above the maximum allowable temperature, the limit switch opens and the control circuit "breaks." Any interruption in the control circuit instantly closes the gas valve and stops gas flow to the burners. The blower motor continues to run until LS resets. When the air temperature at the limit switch drops to the low -temperature setting of the limit switch, the switch closes and completes the control circuit. The direct -spark ignition system cycles and the unit returns to normal heating operation. Table 6 — LED Indications STATUS CODE LED INDICATION Normal Operation* On No Power or Hardware Failure Off Check fuse, low voltage circuit 1 Flash Limit Switch Fault 2 Flashes Flame Sense Fault 3 Flashes Four Consecutive Limit Switch Faults 4 Flashes Ignition Lockout Fault 5 Flashes Pressure Switch Fault 6 Flashes Rollout Switch Fault 7 Flashes Internal Control Fault 8 Flashes Temporary 1 hr auto resett 9 Flashes *. LED indicates acceptable operation. Do not change ignition control board. f. This code indicates an internal processor fault that will reset itself in one hr. Fault can be caused by stray RE signals in the structure or nearby. This is a UL requirement. NOTES: 1. When W is energized the burners will remain on for a minimum of 60 sec. 2. If more than one error code exists they will be displayed on the LED in sequence. Rollout Switch The function of the rollout switch is to close the main gas valve in the event of flame rollout. The switch is located above the main burners. When the temperature at the rollout switch reaches the maximum allowable temperature, the control circuit trips, closing the gas valve and stopping gas flow to the burners. The indoor (evaporator) fan motor (IFM) and induced draft motor continue to run until switch is reset. The IGC LED will display FAULT CODE 7. Step 3 — Start-up Cooling and Make 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 compressor when the outdoor temperature is below 40°F (4.4°C) (unless accessory low -ambient kit is installed). Do not rapid -cycle the compressor. Allow 5 minutes between on cycles to prevent compressor damage. Checking Cooling Control Operation Start and check the unit for proper cooling control operation as follows: 1. Place room thermostat SYSTEM switch in OFF position. Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FAN switch is placed in AUTO position. 2. Place SYSTEM switch in COOL position and FAN switch in AUTO position. Set cooling control below room temperature. Observe that compressor, condenser fan, and evaporator blower motors start. Observe that cooling cycle shuts down when control setting is satisfied. The evaporator fan will continue to run for 90 sec. 3. When using an auto -changeover room thermostat, place both SYSTEM and FAN switches in AUTO positions. Observe that unit operates in Heating mode when temperature control is set to call for heating (above room temperature) and operates in Cooling mode when temperature control is set to call for cooling (below room temperature). 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 will be minimal. Checking and Adjusting Refrigerant Charge The refrigerant system is fully charged with Puron (R-410A) refrigerant and is tested and factory sealed. Allow system to operate a minimum of 15 minutes before checking or adjusting charge. AEXPLOSION HAZARD Failure to follow this warning could result in death, serious personal injury, and/or property damage. Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion. NOTE: Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper Puron (R-410A) charge. NOTE: Some units have fixed orifice refrigerant metering devices. There is a different charging procedure for both expansion devices. Refer to the correct procedure for your unit. The charging label and the tables shown refer to system temperatures and pressures in cooling mode only. A refrigerant charging label is attached to the inside of the compressor access panel. (See Table 8 Subcool chart for units with TXV and superheat chart for units with fixed orifice.) The chart includes the required liquid line temperature at given discharge line pressures and outdoor ambient temperatures. A superheat chart is attached to the inside of the compressor access panel for the unit with fixed metering device. Refer to the charging procedure on the label. An accurate thermocouple- or thermistor-type thermometer, and a gauge manifold are required when using the subcooling charging method for evaluating the unit charge. Do not use mercury or small dial -type thermometers because they are not adequate for this type of measurement. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 23 48VL-K: Installation Instructions UNIT DAMAGE HAZARD Failure to follow this caution may result in unit damage. When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils. Proceed as follows: 1. Remove caps from low- and high-pressure service fittings. 2. Using hoses with valve core depressors, attach low- and high-pressure gauge hoses to low- and high-pressure service fittings, respectively. 3. Start unit in Cooling Mode and let unit run until system pressures stabilize. 4. Measure and record the following: a. Outdoor ambient -air temperature ff [°C] db). b. Liquid line temperature ff [°C]). c. Discharge (high -side) pressure (psig). d. Suction (low -side) pressure (psig) (for reference only). 5. Using "Cooling Charging Charts," compare outdoor -air temperature ff [°C] db) with the discharge line pressure (prig) to determine desired system operating liquid line temperature (See Table 8). 6. Compare actual liquid line temperature with desired liquid line temperature. Using a tolerance of f 2°F (fl.l°C), add refrigerant if actual temperature is more than 2°F (1.1°C) higher than proper liquid line temperature, or remove refrigerant if actual temperature is more than 2°F (1.1°C) lower than required liquid line temperature. NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to the Check for Refrigerant Leaks section. Indoor Airflow and Airflow Adjustments UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage. For cooling operation, the recommended airflow is 350 to 450 cfin for each 12,000 Btuh of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate. NOTE: Be sure that all supply -and return -air grilles are open, free from obstructions, and adjusted properly. ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Disconnect electrical power to the unit and install lockout tag before changing blower speed. This unit has independent fan speeds for gas heating and cooling modes. Single phase models also have a dedicated continuous fan speed. All models (1 phase and 3 phase), have a field -selectable capability to run two different cooling speeds: A normal cooling fan speed (350-450 CFM/Ton) and an enhanced dehumidification fan speed (As low as 320 CFM/Ton) for use with either a dehumidistat or a thermostat that supports dehumidification. This unit is factory -set for use with a single cooling fan speed. For single phase models, the cooling speed is marked "COOL" on the IGC (See Fig. 20). For 3-phase models, the cooling speed is marked "LOW" on the interface board (IFB) (See Fig. 20). The factory -shipped settings are noted in Table 9. There are up to 3 additional speed tap wires available for use in either gas heating mode, cooling mode, or continuous fan mode (For color coding on the indoor fan motor leads, see Table 7). For single phase models, one of the additional speed tap wires is connected to the continuous fan, with the other 2 wires shipped loose in the control box near the IGC. For three phase models, the additional 3 speed tap wires are shipped loose with vinyl caps and are located in the control box near the interface fan board (IFB) (See Fig. 20). Gas Heating Fan Speed Set-up: To change the gas heating speed: 1. Remove existing speed tap wire from the "HEAT" terminal on the IGC. 2. Connect the desired speed tap wire on the "HEAT" terminal on the IGC board. Make sure that the speed chosen delivers temperature rise within the rise range listed on the unit. "High" speed is for high static cooling only, and must not be used for gas heating. "High" blower speed is for high static cooling only and must not be used for gas heating speed. Cooling Fan Speed Set-up (Dehumidification feature not used): To change cooling speed: 1. Remove existing speed tap wire from the "COOL" terminal on the IGC board. Add the wet coil pressure drop in Table 10 to the system static to determine the correct cooling airflow speed in Table 7 that will deliver the nominal cooling airflow listed in Table 1 for each size. 2. Connect the desired speed tap wire on the "COOL" terminal on the IGC board. Dehumidification Cooling Fan Speed Set-up IMPORTANT: Dehumidification control must open control circuit on humidity rise above set point. Use of the dehumidification cooling fan speed requires use of either a 24 VAC dehumidistat or a thermostat which includes control of a 24 VAC dehumidistat connection. In either case, the dehumidification control must open the control circuit on humidity rise above the dehumidification set point. 1. Move shunt jumper on IGD board to "DH" (See Fig. 20). 2. Refer to airflow table (Table 9) to determine allowable speeds for the dehumidification cooling fan speed. Speeds that are not allowed are shaded in Table 9. 3. Connect selected speed tap wire to "DHUM" terminal on the IGC board. Verify that static pressure is in the acceptable range for the speed tap to be used for dehumidification cooling. Continuous Fan Speed Set-up: To change continuous fan speed: 1. Remove existing speed tap wire from the "FAN" terminal on the IGC. 2. Connect the desired speed tap wire on the "FAN" terminal on the IGC board. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 24 48VL-K: Installation Instructions Table 7 — Color Coding for Indoor Fan Motor Leads Black = High Speed Orange = Med-High Speed Red = Med Speed Pink = Med-Low Speed Blue = Low Speed Cooling Sequence of Operation With the room thermostat SYSTEM switch in the COOL position and the FAN switch in the AUTO position, the cooling sequence of operation is as follows: 1. When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat, the thermostat completes the circuit between thermostat terminal R to terminals Y and G. 2. The normally open contacts of energized contactor (C) close and complete the circuit through compressor motor (COMP) to condenser (outdoor) fan motor (OFM). Both motors start instantly. 3. The set of normally open contacts on the interface fan board (IFB) are closed which energizes a circuit to the indoor fan motor (IFM). NOTE: Once the compressor has started and then stopped, it should not be started again until 5 minutes have elapsed. The cooling cycle remains on until the room temperature drops to a point that is slightly below the cooling control setting of the room thermostat. At this point, the thermostat breaks the circuit between thermostat terminal R to terminals Y and G. These open circuits deenergize contactor coil C. The condenser and compressor motors stop. After a 60-sec. delay, the blower motor stops. The unit is in a standby condition, waiting for the next call for cooling from the room thermostat. nn nnn I ° DH DH PH O PH Shunt in no Shunt in dehumidification dehumidification position position A14399 Fig. 20 — IGC Board Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 25 48VL-K: Installation Instructions Table S - Cooling Charging Chart SUPERHEAT CHARGING TABLE (SUPERHEAT -F (-C) AT COMPRESSOR SUCTION SERVICE PORT) OUTDOOR EVAPORATOR ENTERING AIR -F (-C) WB TEMP -F VC) 1 50 (101 1 52 (111 1 54 (121 56 (13) 58 M41 1 60 1161 62 (171 64 (181 66 (191 I REQUIRED SUCTION TUBE TEMPERATURE -F (-C) (MEASURED AT COMPRESSOR SUCTION SERVICE PORT) SUCTION PRESSURE AT SUCTION SERVICE PORT PSIG (kPa) SUPERHEAT TEMP'F (-C) 107 (738) 111 766 116 (800) 120 (828) 125 862 130 (897) 135 (931) 140 (966) 1( (10 0 (0) 35(1.7) 37(2.8) 39(3.9) 41(5.0) 43(6.1) 45(7.2) 47(8.3) 49(9.4) 51 2(1.1) 37(2.8) 39(3.9) 41(5.0) 43(6.1) 45(7.2) 47(8.3) 49(9.4) 51 (11) 53 4(2.2) 39(3.9) 41(5.0) 43(6.1) 45(7.2) 47(8.3) 49(9.4) 51 (11) 53 (12) 55 6(3.3) 41(5.0) 43(6.1) 45(7.2) 47(8.3) 49(9.4) 51 (11) 53 (12) 55 (13) 57 8(4.4) 43(6.1) 45(7.2) 47(8.3) 49(9.4) 51 (11) 53 (12) 55 (13) 57 (14) 59 10(5.6) 45(7.2) 47(8.3) 49(9.4) 51 (11) 53 (12) 55 (13) 57 (14) 59 (15) 61 12(6.7) 47(8.3) 49(9.4) 51 (11) 53 (12) 55 (13) 57 (14) 59 (15) 61 (16) 63 14(7.8) 49(9.4) 51 (11) 53(12). 55 (13) 57 (14) 59(15). 61 (16) 63 (17) 65 16(8.9) 51 (11) 53 (12) 55 (13) 57 (14) 59 (15) 61 (16) 63 (17) 65 (18) 67 18 (10.0) 53 (12) 55 (13) 57 (14) 59 (15) 61 (16) 63 (17) 65 (18) 67 (19) 69 20 (11.1) 55 (13) 57 (14) 59 (15) 61 (16) 63 (17) 65 (18) 67 (19) 69 (21) 71 22 (12.2) 57 (14) 59 (15) 61 (16) 63 (17) 65 (18) 67 (19) 69 (21) 71 (22) 73 24 (13.3) 59 (15) 61 (16) 63 (17) 65 (18) 67 (19) 69 (21) 71 (22) 73 (23) 75 26 14.4 61 (16) 63 (17) 65 (18) 67 (19) 69 (21) 71 (22) 73 (23) 75 (24) 77 28 (15.61 63 07) 65 08) 67 09) 69 (21) 71 (22) 73 (23) 75 (24) 77 (25) 79 1. Operate unit a minimum of 10 minutes before checking charge. 2, Measure suction pressure by attaching an accurate gauge to compressor suction side service port. 3. Measure suction side temperature by attaching an accurate thermisitor type or electronic thermometer to suction line about 10 inches from compressor. 4. Measure outdoor air dry-bulb temperature with thermometer. 5. Measure indoor air (return air) wet -bulb temperature with a sling psychrometer or electronic equivalent. 6. Using Superheat Charging Table find outdoor temperature and indoor air wet - bulb temperature. At this intersection 72 22 7423 7624 40zz 42z3 45 25 38 (21) 40 2z 43 (24) 36 20 38 21 41 23 33 (18) 36 (20) 39 (22) 31 17 34 19 37 21 28 16 31 17 35 19 26 (1a) 3c (17> 33 (1b> 24 13 27 15 31 17 22 (1z) 25 (14) 29 06) 20 (11) 23 13 27 15 17(9.4) 22 12 26 14 15(8.3) 20 11 25 1a 23 13 note superheat. Where a dash (--) appears on table do not attempt to charge unit under these conditions or refrigerant slugging may occur. In this situation refrigerant must be evacuated and weighed in. See rating plate for charge quantity. 7. Refer to Required Suction Tube Temp. table. Find superheat temperature located in step 6 and suction pressure. At this intersection note suction line temperature. 8. If unit has a higher suction line temperature than charted temperature, add refrigerant .J' J. ■ until charted temperature is reached. • 9. If unit has a lower suction line temperature than charted temperature, reclaim refrigerant until charted temperature is 50ZH500518 REV.A reached. 10. If outdoor air temperature or pressure at suction port changes, charge to new suction line temperature indicated on chart. Superheat charging table is derived from optimum performance point. (95°F [35°C] outdoor ambient and (80°F [27°C] dry bulb; 67°F [ 19°C] wet bulb indoor condition.) Where a dash (-) appears do not attempt to check charge or charge unit under these conditions using the superheat method. (Weigh in method should be used.) A150625 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 26 Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 Unit Size Heating Rise °F (°C) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue Alternate Heating CFM 640 553 454 310 --- --- --- --- --- BHP 0.07 0.08 0.08 0.09 --- --- --- --- --- --- Gas Heat Rise (°F) 47 54 NA NA NA NA NA NA NA NA Gas Heat Rise (°C) 26 30 NA NA NA NA NA NA NA NA Med Low$ Pink Heating Alternate Cooling CFM 830 758 688 607 514 393 254 --- --- --- BHP 0.12 0.13 0.13 0.13 0.14 0.14 0.15 --- --- --- G(OF) as Heat Rise 36 39 43 49 NA NA NA NA NA NA Gas Heat Rise (°C) 20 22 24 27 NA NA NA NA NA NA 24040 25-55 14 - 31 ( ) Medium** Red Cooling Alternate Heating CFM 1080 1025 969 910 852 787 718 638 541 457 BHP 0.21 0.22 0.23 0.23 0.24 0.24 0.25 0.25 0.26 0.27 Gas Heat Rise (°F) 28 29 31 33 35 38 41 47 55 NA Gas Heat Rise (°C) 15 16 17 18 19 21 23 26 31 NA Med-High Orange Alternate Cooling Alternate Heating CFM 1101 1046 993 936 878 816 749 676 599 498 BHP 0.22 0.23 0.24 0.24 0.25 0.26 0.26 0.27 0.27 0.28 Gas Heat Rise (OF) ) 27 28 30 32 34 36 40 44 50 NA Gas Heat Rise (°C) 15 16 17 18 19 20 22 24 28 NA High Black High Static Cooling Only CFM 1222 1173 1123 1072 1021 967 912 853 787 712 BHP 0.29 0.29 0.30 0.31 0.31 0.32 0.33 0.34 0.34 0.34 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 640 553 310 --- --- --- --- --- --- BHP 0.07 0.08 0.08 0.09 --- --- --- --- --- --- Gas Heat Rise (OF) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) NA NA NA NA NA NA NA NA NA NA Med Low Pink Alternate Cooling Alternate Heating CFM 830 758 688 607 514 393 254 --- --- BHP 0.12 0.13 0.13 0.13 0.14 0.14 0.15 --- --- --- Gas Heat Rise (OF) 54 NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) 30 NA NA NA NA NA NA NA NA NA 24060 25-55 14 - 31 ( ) Medium"" Red Cooling Alternate Heating CFM 1080 1025 969 910 852 787 718 638 541 457 BHP 0.21 0.22 0.23 0.23 0.24 0.24 0.25 0.25 0.26 0.27 Gas Heat Rise (OF) 41 44 46 49 52 NA NA NA NA NA Gas Heat Rise (oC) 23 24 26 27 29 NA NA NA NA NA Med-High$ Orange Heating Alternate Cooling CFM 1101 1046 993 936 878 816 749 676 599 498 BHP 0.22 0.23 0.24 0.24 0.25 0.26 0.26 0.27 0.27 0.28 Gas Heat Rise (OF) 41 43 45 48 51 55 NA NA NA NA Gas Heat Rise (oC) 23 24 25 26 28 30 NA NA NA NA High Black High Static Cooling Only CFM 1222 1173 1123 1072 1021 967 912 853 787 712 BHP 0.29 0.29 0.30 0.31 0.31 0.32 0.33 0.34 0.34 0.34 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue Alternate Heating CFM 643 552 455 348 225 --- --- --- --- --- BHP 0.09 0.10 0.11 0.11 0.11 --- --- --- --- --- Gas Heat Rise (OF) 46 54 NA NA NA NA NA NA NA NA Gas Heat Rise (oC) 26 30 NA NA NA NA NA NA NA NA Med Low$ Pink Heating Alternate Cooling CFM 817 744 673 597 516 431 325 190 --- BHP 0.14 0.15 0.15 0.16 0.17 0.17 0.18 0.18 --- --- Gas Heat Rise (OF) ) 36 40 44 50 NA NA NA NA NA NA Gas Heat Rise (oC) 20 22 25 28 NA NA NA NA NA NA 30040 25-55 ( 14 - 31 Medium Red Alternate Cooling Alternate Heating CFM 1159 1104 1045 990 937 878 821 759 693 618 BHP 0.31 0.32 0.33 0.33 0.34 0.35 0.36 0.37 0.37 0.38 Gas Heat Rise (OF) 26 27 28 30 32 34 36 39 43 48 Gas Heat Rise (oC) 14 15 16 17 18 19 20 22 24 27 Med-High" Orange Cooling Alternate Heating CFM 1201 1147 1095 1037 987 934 877 818 755 671 BHP 0.34 0.35 0.36 0.37 0.37 0.38 0.39 0.40 0.41 0.40 Gas Heat Rise (OF) ) 25 26 27 29 30 32 34 36 39 44 Gas Heat Rise (oC) 14 14 15 16 17 18 19 20 22 25 High Black High Static Cooling Only CFM 1291 1236 1181 1131 1080 1033 978 909 792 661 BHP 0.41 0.42 0.43 0.43 0.44 0.45 0.46 0.45 0.43 0.40 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 643 552 455 348 225 --- --- --- --- --- BHP 0.09 0.10 0.11 0.11 0.11 --- --- --- --- --- Gas Heat Rise (OF) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) NA NA NA NA NA NA NA NA NA NA Med Low Pink Alternate Cooling Alternate Heating CFM 817 744 673 597 516 431 325 190 --- BHP 0.14 0.15 0.15 0.16 0.17 0.17 0.18 0.18 --- --- Gas Heat Rise (OF) 55 NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) 30 NA NA NA NA NA NA NA NA NA 30060 25-55 14 - 31 ( ) Medium$ Red Heating Alternate Cooling CFM 1159 1104 1045 990 937 878 821 759 693 618 BHP 0.31 0.32 0.33 0.33 0.34 0.35 0.36 0.37 0.37 0.38 Gas Heat Rise (OF) 39 40 43 45 48 51 54 NA NA NA Gas Heat Rise (oC) 21 22 24 25 26 28 30 NA NA NA Medium -High" Orange Cooling Alternate Heating CFM 1201 1147 1095 1037 987 934 877 818 755 671 BHP 0.34 0.35 0.36 0.37 0.37 0.38 0.39 0.40 0.41 0.40 Gas Heat Rise (OF) ) 37 39 41 43 45 48 51 55 NA NA Gas Heat Rise (oC) 21 22 23 24 25 27 28 30 NA NA High Black High Static Cooling Only CFM 1291 1236 1181 1131 1080 1033 978 909 792 661 BHP 0.41 0.42 0.43 0.43 0.44 0.45 0.46 0.45 0.43 0.40 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue Alternate Cooling, Alternate Gas Heating CFM 1096 1044 994 945 892 837 780 717 664 612 BHP 0.14 0.15 0.16 0.18 0.19 0.19 0.20 0.21 0.22 0.23 Gas Heat Rise (OF) 41 43 45 47 50 53 NA NA NA NA Gas Heat Rise (oC) 23 24 25 26 28 30 NA NA NA NA Med Low$ Pink Gas Heating, Alternate Cooling CFM 1151 1103 1056 1002 953 897 845 788 729 678 BHP 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 Gas Heat Rise (OF) ) 39 40 42 45 47 50 53 NA NA NA Gas Heat Rise (oC) 22 22 23 25 26 28 29 NA NA NA 36060 25-55 (14 - 31) Medium Red Alternate Cooling, Alternate Gas Heating CFM 1299 1252 1204 1155 1106 1059 1007 959 905 844 BHP 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 Gas Heat Rise (OF) 34 36 37 39 40 42 44 47 49 53 Gas Heat Rise (oC) 19 20 21 21 22 23 25 26 27 29 Med-High** Orange Cooling, Alternate Gas Heating CFM 1382 1335 1292 1246 1202 1152 1106 1058 1007 957 BHP 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 Gas Heat Rise (OF) 32 33 35 36 37 39 40 42 44 47 Gas Heat Rise (oC) 18 19 19 20 21 22 22 23 25 26 High Black High Static Cooling Only CFM 1530 1485 1442 1398 1354 1309 1263 1217 1169 1120 BHP 0.33 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue Alternate Cooling, Alternate Gas Heating CFM 1096 1044 994 945 892 837 780 717 664 612 BHP 0.14 0.15 0.16 0.18 0.19 0.19 0.20 0.21 0.22 0.23 Gas Heat Rise (OF) 61 64 NA NA NA NA NA NA NA NA Gas Heat Rise (oC) 34 36 NA NA NA NA NA NA NA NA Med-Low Pink Alternate Cooling, Alternate Gas Heating CFM 1151 1103 1056 1002 953 897 845 788 729 678 BHP 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 Gas Heat Rise (OF) 58 61 63 NA NA NA NA NA NA NA Gas Heat Rise (oC) 32 34 35 NA NA NA NA NA NA NA 36090 35-65 19 - 36 ( ) Medium$ Red Gas Heating, Alternate Cooling CFM 1299 1252 1204 1155 1106 1059 1007 959 905 844 BHP 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 Gas Heat Rise (OF) 52 53 56 58 61 63 NA NA NA NA Gas Heat Rise (oC) 29 30 31 32 34 35 NA NA NA NA Med-High** Orange Cooling, Alternate Gas Heating CFM 1382 1335 1292 1246 1202 1152 1106 1058 1007 957 BHP 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 Gas Heat Rise (OF) 48 50 52 54 56 58 61 63 NA NA Gas Heat Rise (oC) 27 28 29 30 31 32 34 35 NA NA High Black High Static Cooling Only CFM 1530 1485 1442 1398 1354 1309 1263 1217 1169 1120 BHP 0.33 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue Alternate Heating CFM 956 899 843 786 729 676 621 558 504 435 BHP 0.13 0.13 0.14 0.15 0.16 0.16 0.17 0.18 0.18 0.19 Gas Heat Rise (OF) 47 50 53 NA NA NA NA NA NA NA Gas Heat Rise (oC) 26 28 29 NA NA NA NA NA NA NA Med Low$ Pink Heating Alternate Cooling CFM 1201 1153 1107 1060 1012 965 917 871 828 782 BHP 0.21 0.22 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 Gas Heat Rise (OF) ) 37 39 40 42 44 46 49 51 54 NA Gas Heat Rise (oC) 21 22 22 23 25 26 27 28 30 NA 42060 25-55 ( 14 - 31 Medium Red Alternate Cooling Alternate Heating CFM 1443 1402 1361 1322 1284 1243 1204 1164 1124 1084 BHP 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.42 Gas Heat Rise (OF) 31 32 33 34 35 36 37 38 40 41 Gas Heat Rise (oC) 17 18 18 19 19 20 21 21 22 23 Med-High" Orange Cooling Alternate Heating CFM 1529 1491 1451 1411 1376 1338 1300 1261 1223 1185 BHP 0.37 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 Gas Heat Rise (OF) ) 29 30 31 32 32 33 34 35 36 38 Gas Heat Rise (oC) 16 17 17 18 18 19 19 20 20 21 High Black High Static Cooling Only CFM 1604 1565 1529 1490 1455 1421 1385 1348 1310 1274 BHP 0.42 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51 0.52 Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 956 899 843 786 729 676 621 558 504 435 BHP 0.13 0.13 0.14 0.15 0.16 0.16 0.17 0.18 0.18 0.19 Gas Heat Rise (OF) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) NA NA NA NA NA NA NA NA NA NA Med Low Pink Alternate Cooling Alternate Heating CFM 1201 1153 1107 1060 1012 965 917 871 828 782 BHP 0.21 0.22 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 Gas Heat Rise (OF) 56 58 60 63 NA NA NA NA NA NA Gas Heat Rise (oC) 31 32 34 35 NA NA NA NA NA NA 42090 35-65 19 - 36 ( ) Medium$ Red Heating Alternate Cooling CFM 1443 1402 1361 1322 1284 1243 1204 1164 1124 1084 BHP 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.42 Gas Heat Rise (OF) 46 48 49 51 52 54 56 58 60 62 Gas Heat Rise (oC) 26 27 27 28 29 30 31 32 33 34 Med-High" Orange Cooling Alternate Heating CFM 1529 1491 1451 1411 1376 1338 1300 1261 1223 1185 BHP 0.37 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 Gas Heat Rise (OF) 44 45 46 47 49 50 52 53 55 57 Gas Heat Rise (oC) 24 25 26 26 27 28 29 29 30 31 High Black High Static Cooling Only CFM 1604 1565 1529 1490 1455 1421 1385 1348 1310 1274 BHP 0.42 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51 0.52 Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 641 551 462 385 289 216 163 115 --- --- BHP 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.09 --- --- Gas Heat Rise (OF) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) NA NA NA NA NA NA NA NA NA NA Med Low$ Pink Heating Alternate Cooling CFM 1437 1395 1351 1307 1265 1221 1176 1132 1084 1039 BHP 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 Gas Heat Rise (OF) ) 47 48 50 51 53 55 57 59 62 64 Gas Heat Rise (oC) 26 27 28 28 29 30 32 33 34 36 48090 35-65 19 - 36 ( ) Medium" Red Cooling Alternate Heating CFM 1771 1735 1699 1664 1627 1592 1557 1522 1486 1450 BHP 0.51 0.52 0.53 0.55 0.56 0.57 0.58 0.59 0.61 0.62 Gas Heat Rise (OF) 38 39 39 40 41 42 43 44 45 46 Gas Heat Rise (oC) 21 21 22 22 23 23 24 24 25 26 Med-High Orange Alternate Cooling Alternate Heating CFM 1928 1897 1862 1830 1796 1764 1732 1698 1620 1512 BHP 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.73 0.71 0.66 Gas Heat Rise (OF) ) 35 35 36 37 37 38 39 39 41 44 Gas Heat Rise (oC) 19 20 20 20 21 21 21 22 23 25 High Black High Static Cooling Only CFM 2212 2167 2124 2061 1976 1892 1794 1699 1567 1438 BHP 0.97 0.99 1.00 0.97 0.95 0.91 0.86 0.82 0.77 0.71 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 641 551 462 385 289 216 163 115 --- --- BHP 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.09 --- --- Gas Heat Rise (OF) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) NA NA NA NA NA NA NA NA NA NA Med Low Pink Alternate Cooling Alternate Heating CFM 1437 1395 1351 1307 1265 1221 1176 1132 1084 1039 BHP 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 Gas Heat Rise (OF) 60 NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) 33 NA NA NA NA NA NA NA NA NA 48115 30-60 17 - 33 ( ) Medium- Red Cooling Alternate Heating CFM 1771 1735 1699 1664 1627 1592 1557 1522 1486 1450 BHP 0.51 0.52 0.53 0.55 0.56 0.57 0.58 0.59 0.61 0.62 Gas Heat Rise (OF) 48 49 50 51 53 54 55 56 58 59 Gas Heat Rise (oC) 27 27 28 29 29 30 31 31 32 33 Med-High$ Orange Heating Alternate Cooling CFM 1928 1897 1862 1830 1796 1764 1732 1698 1620 1512 BHP 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.73 0.71 0.66 Gas Heat Rise (OF) 44 45 46 47 48 49 49 50 53 57 Gas Heat Rise (oC) 25 25 26 26 26 27 27 28 29 31 High Black High Static Cooling Only CFM 2212 2167 2124 2061 1976 1892 1794 1699 1567 1438 BHP 0.97 0.99 1.00 0.97 0.95 0.91 0.86 0.82 0.77 0.71 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 641 551 462 385 289 216 163 115 --- --- BHP 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.09 --- --- Gas Heat Rise (°F) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (°C) NA NA NA NA NA NA NA NA NA NA Med-Low Pink Alternate Cooling CFM 1437 1395 1351 1307 1265 1221 1176 1132 1084 1039 BHP 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 Gas Heat Rise (°F) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (°C) NA NA NA NA NA NA NA NA NA NA 48130 35-65 19 - 36 ( ) Medium" Red Cooling Alternate Heating CFM 1771 1735 1699 1664 1627 1592 1557 1522 1486 1450 BHP 0.51 0.52 0.53 0.55 0.56 0.57 0.58 0.59 0.61 0.62 Gas Heat Rise (°F) 53 54 56 57 58 59 61 62 64 65 Gas Heat Rise (°C) 30 30 31 32 32 33 34 34 35 36 Med-High$ Orange Heating Alternate Cooling CFM 1928 1897 1862 1830 1796 1764 1732 1698 1620 1512 BHP 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.73 0.71 0.66 Gas Heat Rise (OF) 49 50 51 52 53 54 55 56 58 62 Gas Heat Rise (°C) 27 28 28 29 29 30 30 31 32 35 High Black High Static Cooling Only CFM 2212 2167 2124 2061 1976 1892 1794 1699 1567 1438 BHP 0.97 0.99 1.00 0.97 0.95 0.91 0.86 0.82 0.77 0.71 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue Alternate Heating CFM 641 551 462 385 289 216 163 115 --- --- BHP 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.09 --- --- Gas Heat Rise (OF) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) NA NA NA NA NA NA NA NA NA NA Med Low$ Pink Heating Alternate Cooling CFM 1437 1395 1351 1307 1265 1221 1176 1132 1084 1039 BHP 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 Gas Heat Rise (OF) ) 47 48 50 51 53 55 57 59 62 64 Gas Heat Rise (oC) 26 27 28 28 29 30 32 33 34 36 60090 35-65 19 - 36 ( ) Medium" Red Cooling Alternate Heating CFM 1914 1881 1848 1814 1780 1748 1716 1681 1619 1512 BHP 0.62 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.71 0.66 Gas Heat Rise (OF) 35 36 36 37 38 38 39 40 41 44 Gas Heat Rise (oC) 19 20 20 21 21 21 22 22 23 25 Med-High Orange Alternate Cooling Alternate Heating CFM 1928 1897 1862 1830 1796 1764 1732 1698 1620 1512 BHP 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.73 0.71 0.66 Gas Heat Rise (OF) ) 35 35 36 37 37 38 39 39 41 44 Gas Heat Rise (oC) 19 20 20 20 21 21 21 22 23 25 High Black High Static Cooling Only CFM 2212 2167 2124 2061 1976 1892 1794 1699 1567 1438 BHP 0.97 0.99 1.00 0.97 0.95 0.91 0.86 0.82 0.77 0.71 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 641 551 462 385 289 216 163 115 --- --- BHP 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.09 --- --- Gas Heat Rise (OF) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) NA NA NA NA NA NA NA NA NA NA Med Low Pink Alternate Cooling Alternate Heating CFM 1437 1395 1351 1307 1265 1221 1176 1132 1084 1039 BHP 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 Gas Heat Rise (OF) 60 NA NA NA NA NA NA NA NA NA Gas Heat Rise (oC) 33 NA NA NA NA NA NA NA NA NA 60115 30-60 17 - 33 ( ) Medium- Red Cooling Alternate Heating CFM 1914 1881 1848 1814 1780 1748 1716 1681 1619 1512 BHP 0.62 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.71 0.66 Gas Heat Rise (OF) 45 45 46 47 48 49 50 51 53 57 Gas Heat Rise (oC) 25 25 26 26 27 27 28 28 29 31 Med-High$ Orange Heating Alternate Cooling CFM 1928 1897 1862 1830 1796 1764 1732 1698 1620 1512 BHP 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.73 0.71 0.66 Gas Heat Rise (OF) 44 45 46 47 48 49 49 50 53 57 Gas Heat Rise (oC) 25 25 26 26 26 27 27 28 29 31 High Black High Static Cooling Only CFM 2212 2167 2124 2061 1976 1892 1794 1699 1567 1438 BHP 0.97 0.99 1.00 0.97 0.95 0.91 0.86 0.82 0.77 0.71 A OD m m 0 0 Cn Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge Sizes 24-60 (Continued) Unit Size Heating Rise oF(o�) Motor Speed Tap Allowable Functions ESP (in. W.C.) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Lowt Blue CFM 641 551 462 385 289 216 163 115 --- --- BHP 0.05 0.06 0.06 0.07 0.07 0.08 0.08 0.09 --- --- Gas Heat Rise (°F) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (°C) NA NA NA NA NA NA NA NA NA NA Med-Low Pink Alternate Cooling CFM 1437 1395 1351 1307 1265 1221 1176 1132 1084 1039 BHP 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 Gas Heat Rise (°F) NA NA NA NA NA NA NA NA NA NA Gas Heat Rise (°C) NA NA NA NA NA NA NA NA NA NA 60130 35-65 19 - 36 ( ) Medium" Red Cooling Alternate Heating CFM 1914 1881 1848 1814 1780 1748 1716 1681 1619 1512 BHP 0.62 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.71 0.66 Gas Heat Rise (°F) 49 50 51 52 53 54 55 56 58 62 Gas Heat Rise (°C) 27 28 28 29 29 30 31 31 32 35 Med-High$ Orange Heating Alternate Cooling CFM 1928 1897 1862 1830 1796 1764 1732 1698 1620 1512 BHP 0.64 0.65 0.67 0.68 0.69 0.71 0.72 0.73 0.71 0.66 Gas Heat Rise (OF) 49 50 51 52 53 54 55 56 58 62 Gas Heat Rise (°C) 27 28 28 29 29 30 30 31 32 35 High Black High Static Cooling Only CFM 2212 2167 2124 2061 1976 1892 1794 1699 1567 1438 BHP 0.97 0.99 1.00 0.97 0.95 0.91 0.86 0.82 0.77 0.71 Shaded areas indicate speed/static combinations that are not permitted for dehumidification speed. * Air delivery values are without air filter and are for dry coil (See Wet Coil Pressure Drop Table). f Factory -shipped continuous fan speed $ Factory -shipped heating speed ** Factory -shipped cooling speed "NA" = Not allowed for heating speed "High Static Cooling" = Only to be used for cooling function (not allowed for heating function) NOTE: Deduct field -supplied air filter pressure drop and wet coil pressure drop to obtain static pressure available for ducting. A CD m m 0 0 Cn Table 10 - Wet Coil Pressure Drop (IN. W.C.) Unit Standard CFM (SCFM) Size 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 24 0.03 0.04 0.04 0.05 0.06 30 0.05 0.06 0.07 0.08 0.11 36 0.06 0.06 0.09 0.10 0.11 0.14 42 0.05 0.05 0.06 0.07 0.08 0.08 0.09 0.09 0.11 48 0.04 0.06 0.09 0.10 0.10 0.11 0.12 0.13 0.14 60 0.06 0.07 0.01 0.08 0.09 0.10 0.12 0.13 Table 11 - Economizer with 1-in. Filter Pressure Drop (IN. W.C.) Cooling Standard CFM (SCFM) Filter Size in. (mm) 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 Tons 600-1400 CFM 2 0 12x20xl+12x20xl - - 0.09 0.14 0.16 0.18 0.25 0.28 0.30 - - - - - - - - 2.5 (305x508x25+305x508x25) 1200-1800 CFM 16x24x1+14x24x1 3.5 - - - 0.10 0.11 0.12 0.13 0.14 0.16 0.16 - - - - (406x610x25+356x610x25) 1500-2200 CFM 3.0, 16x24x1+18x24x1 4.0, - - .08 .10 .11 .13 0.15 0.17 0.18 0.20 0.21 0.22 0.23 0.23 (406x610x25+457x610x25) 5.0 Table 12 - Filter Pressure Drop Table (IN. W.C.) Cooling Standard CFM (SCFM) Filter Size in. (mm) 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 Tons 600-1400 CFM 2.01 12x20xl+12x20xl 0.03 0.05 0.06 0.08 0.10 0.11 0.13 0.14 0.16 - - - - - - - - 2.5 (305x508x25+305x508x25) 1200-1800 CFM 16x24x1+14x24x1 3.5 - - - - - - 0.07 0.08 0.09 0.09 0.10 0.11 0.12 - - - - (406x610x25+356x610x25) 1100-2200 CFM 3.0 16x24x1+18x24x1 4.0 - .02 .02 .03 .03 0.04 0.06 0.08 0.10 0.11 0.13 0.14 0.15 (406x610x25+457x610x25) 5.0 48VL-K: Installation Instructions Maintenance To ensure continuing high performance and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 13, Table 14, Table 15, Troubleshooting Chart. NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract. PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and unit component damage. The ability to properly perform maintenance 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 Owner's Manual. ELECTRICAL SHOCK HAZARD Failure to follow these warnings could result in personal injury or death: 1. Turn off electrical power to the unit and install lock out tag before performing any maintenance or service on this unit. 2. Use extreme caution when removing panels and parts. 3. Never place anything combustible either on or in contact with the unit. UNIT OPERATION HAZARD Failure to follow this caution may result in improper operation. Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to disconnecting when servicing. ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental pollution. Remove and re -cycle all components or materials (i.e. oil, refrigerant, etc) before unit final disposal. 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. 3. Inspect blower motor and wheel for cleanliness at the beginning of each heating and cooling season. Clean when necessary. For first heating and cooling season, inspect blower wheel bi-monthly to determine proper cleaning frequency. 4. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary. 5. Ensure electric wires are not in contact with refrigerant tubing or sharp metal edges. 6. Check and inspect heating section before each heating season. Clean and adjust when necessary. 7. Check flue hood and remove any obstructions, if necessary. Air Filter IMPORTANT: Never operate the unit without a suitable air filter in the return -air duct system. Always replace the filter with the same dimensional size and type as originally installed. See Table 1 for recommended filter sizes. Inspect air filter(s) at least once each month and replace (throwaway -type) or clean (cleanable -type) at least twice during each cooling season and twice during the heating season, or whenever the filter becomes clogged with dust and lint. Indoor Blower and Motor NOTE: All motors are pre -lubricated. 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. ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Disconnect and tag electrical power to the unit before cleaning the blower motor and wheel. To clean the blower motor and wheel: 1. Remove and disassemble blower assembly as follows: a. Remove blower access panel (see Fig. 22). b. Disconnect 5 pin plug and 4 pin plug from indoor blower motor. Remove capacitor if required. c. On all units remove blower assembly from unit. Remove screws securing blower to blower partition and slide assembly out. Be careful not to tear insulation in blower compartment. d. Ensure proper reassembly by marking blower wheel and motor in relation to blower housing before disassembly. e. Loosen setscrew(s) that secures wheel to motor shaft, remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing. 2. Remove and clean blower wheel as follows: a. Ensure proper reassembly by marking wheel orientation. b. Lift wheel from housing. When handling and/or cleaning blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes. c. Remove caked -on dirt from wheel and housing with a brush. Remove lint and/or dirt accumulations from wheel and housing with vacuum cleaner, using soft brush attachment. Remove grease and oil with mild solvent. d. Reassemble wheel into housing. e. Reassemble motor into housing. Be sure setscrews are tightened on motor shaft flats and not on round part of shaft. Reinstall blower into unit. Reinstall capacitor. f. Connect 5 pin plug and 4 pin plug to indoor blower motor. g. Reinstall blower access panel (see Fig. 22). 3. Restore electrical power to unit. Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles. Induced Draft (combustion air) Blower Assembly The induced -draft blower assembly consists of the inducer motor, the blower housing, and the induced -draft blower wheel. Clean periodically to assure proper airflow and heating efficiency. Inspect blower wheel every fall and periodically during the heating Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 42 48VL-K: Installation Instructions season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency. To inspect blower wheel, remove draft hood assembly. Shine a flashlight into opening to inspect wheel. If cleaning is required, remove induced -draft blower assembly as follows: 1. Remove control access panel (See Fig. 22). 2. Remove the 5 screws that attach induced -draft blower assembly to the flue collector box cover. 3. Slide the assembly out of the unit. (See Fig. 24). Clean the blower wheel. If additional cleaning is required, continue with Steps 4 and 5. 4. To remove blower wheel, remove 2 setscrews. 5. To remove inducer motor, remove screws that hold the inducer motor to the blower housing. 6. To reinstall, reverse the procedure outlined above. Flue Gas Passageways To inspect the flue collector box and upper areas of the heat exchanger: 1. Remove the induced draft blower assembly according to directions in the Induced Draft Blower Assembly section. 2. Remove the 11 screws holding the flue collector box cover (See Fig. 21) to the heat exchanger assembly. Inspect the heat exchangers. 3. Clean all surfaces, as required, using a wire brush. Limit Switch Remove blower access panel (see Fig. 22). Limit switch is located on the fan partition. Burner Ignition Unit is equipped with a direct spark ignition 100 percent lockout system. Ignition module (IGC) is located in the control box (See Fig. 19). Module contains a self -diagnostic LED. During servicing, refer to label diagram or Table 6 in these instructions for LED interpretation. If lockout occurs, unit may be reset by either momentarily interrupting power supply to unit or by turning selector switch to OFF position at the thermostat. Main Burners At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe the main burner flames and adjust, if necessary. Removal of Gas Train To remove the gas train for servicing: 1. Shut off main gas valve. 2. Shut off power to unit and install lockout tag. 3. Remove control access panel (See Fig. 22). 4. Disconnect gas piping at unit gas valve. 5. Remove fan partition mounting bracket (2 screws located on the left side of control compartment on the fan partition panel). Slide bracket forward, bottom first, to remove. (See Fig. 21.) 6. Remove wires connected to gas valve. Mark each wire. 7. Remove the mounting screw that attaches the burner rack to the unit base (See Fig. 21). 8. Partially slide the burner rack out of the unit (see Fig. 21 and Fig. 24). Remove ignitor and sensor wires at the burner assembly. Remove wires to rollout switch. 9. Slide the burner rack out of the unit (See Fig. 21 and Fig. 24). 10. To reinstall, reverse the procedure outlined above. 11. Check all connections for leaks. FIRE, EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death or property damage. Do not purge gas supply into the combustion chamber. Do not use a match or other open flame to check for gas leaks. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. 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. Integrated Gas Unit Controller (IGC) Auto Transformer fuses used on 460 volt units only. (Hidden) — Interface Fan Board (IFB) Induced Draft Motor Fan Partition Flue / / Mounting Collector Rollout Bracket Box Inducer Burner Mounting Switch Blower Rack Screw Housing Fig. 21 — Blower Housing and Flue Collector Box A170031 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 43 48VL-K: Installation Instructions Filter Access Panel For Accessory Filter Rack Access Panel Blower Access Panel Fig. 22 — Unit Access Panels BLOWER HOUSING 2 SETSCREWS (HIDDEN) Fig. 23 — Removal of Motor and Blower Wheel Fig. 24 — Burner Rack Removed Outdoor Fan UNIT OPERATION HAZARD 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 as shown in Fig. 25. 6. Ensure that setscrew engages the flat area on the motor shaft when tightening. 7. Replace grille. Electrical Controls and Wiring Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit. Remove access panels (see Fig. 22) to locate all the electrical controls A14456 and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, re -strip the wire end and reassemble the connection properly and securely. After inspecting the electrical controls and wiring, replace 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 checks. C99085 A07680 Failure to follow this caution may result in damage to unit components. Keep the condenser fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 44 48VL-K: Installation Instructions FAN C R11 I F MOTOR SHAFT Max Distance Between Top of Fan Grille and Bottom of Fan Blade Ao85o5 Size «A» IN. mm 24 9.0 228 30 8.0 203 36 7.6 193 42 7.6 193 48 7.6 193 60 7.6 193 Fig. 25 — Fan Blade Position Refrigerant Circuit Annually inspect all refrigerant tubing connections. EXPLOSION, SAFETY AND ENVIRONMENTAL HAZARD Failure to follow this warning could result in personal injury, death or property damage. System under pressure. Relieve pressure and recover all refrigerant before system repair or final unit disposal. Use all service ports and open all flow -control devices, including solenoid valves. If low cooling 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 the Check for Refrigerant Leaks section. If no refrigerant leaks are found and low cooling performance is suspected, refer to the Checking and Adjusting Refrigerant Charge section. Gas Input The gas input does not require checking unless improper heating performance is suspected. If a problem exists, refer to the Start -Up section. Evaporator Airflow The heating and/or cooling airflow does not require checking unless improper performance is suspected. If a problem exists, be sure that all supply- and return -air grilles are open and free from obstructions, and that the air filter is clean. When necessary, refer to the Indoor Airflow and Airflow Adjustments section to check the system airflow. Puron Items The indoor metering device is either a TXV or orifice type device depending on size. 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. Low Pressure Switch (if used) This switch is located on the suction 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 at 50 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. Apply ohm meter leads across switch. You should have continuity on a closed 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 psig. Never open system without breaking vacuum with dry nitrogen. High -Pressure Switch The high-pressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 650 psig. High pressure may be caused by a dirty outdoor coil, failed fan motor, or outdoor air recirculation. To check switch: 1. Turn off all power to unit. 2. Disconnect leads on switch. Apply ohm meter leads across switch. You should have continuity on a closed switch. 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. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 45 48VL-K: Installation Instructions FIRE/EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death and/or property damage. Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils. For models that have a scroll compressor, the 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 a noise reducing shutdown device and an internal pressure relief port. The pressure relief port is a safety device, designed to protect against extreme high pressure. The relief port has an operating range between 550 (26.34 kPa) and 625 psig (29.93 kPa) differential pressure. EXPLOSION, ENVIRONMENTAL SAFETY HAZARD Failure to follow this warning could result in personal injury, death or equipment damage. 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 (R-410A). If you are unsure, consult the equipment manufacturer. Refrigerant System This information covers the refrigerant system including the compressor oil needed, servicing systems on roofs containing synthetic materials, the filter drier and refrigerant charging. Compressor Oil The Copeland scroll compressor uses 3MAF POE oil. If additional oil is needed, use Uniqema RL32-3MAF. If this oil is not available, use Copeland Ultra 32 CC or Mobil Arctic EAL22 CC. 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. (3.1 in X 3.1 m) area. 2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components. 3. Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant run-offs through the louvered openings in the unit base. 4. Perform required service. 5. Remove and dispose of any oil contaminated material per local codes. Liquid Line Filter Drier This filter drier is specifically designed to operate with Puron (R-410A). 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 (R-410A) units with cylinder in upright position and a commercial metering device in manifold hose. Charge refrigerant into suction -line. Troubleshooting Use the Troubleshooting Guides (See Table 13, Table 14, and Table 15) if problems occur with these units. Start-up Checklist Use Start -Up checklist to ensure proper start-up procedures are followed. My Learning Center is your central location for professional residential HVAC training resources that help strengthen careers and businesses. We believe in providing high quality learning experiences both online and in the classroom. Access My Learning Center with your HVACpartners credentials at www.MLCtraining.com. Please contact us at mylearning@carrier.com with questions. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 46 48VL-K: Installation Instructions Table 13 — Troubleshooting Chart SYMPTOM CAUSE REMEDY Compressor and condenser fan will not start. Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor, transformer, or high-pressure, loss -of -charge or 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 temperature setting below room temperature Compressor will not start but condenser fan runs Faulty wiring or loose connections in compressor ci rcu it Check wiring and repair or replace Compressor motor burned out, seized, or Determine cause internal overload open Replace compressor Defective run/start capacitor, overload, start relay Determine cause and replace One leg of 3-phase power dead Replace fuse or reset circuit breaker Determine cause Low input voltage Determine cause and correct Three-phase scroll compressor makes excessive noise, and there may be a low pressure differential. Scroll compressor is rotating in the wrong direction Correct the direction of rotation by reversing the 3-phase power leads to the unit. Shut down unit to allow pressures to equalize. Compressor cycles (other than normally satisfying thermostat) Refrigerant overcharge or undercharge Recover refrigerant, evacuate system, and recharge to capacities shown on rating plate Defective compressor Replace and determine cause Insufficient line voltage Determine cause and correct Blocked outdoor coil Determine cause and correct Defective run/start capacitor Determine cause and replace Faulty outdoor fan motor or capacitor Replace 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 temperature set too low Reset thermostat Low refrigerant charge Locate leak, repair, and recharge 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 condenser coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant, evacuate system, and recharge Condenser air restricted or air short -cycling Determine cause and correct Head pressure too low Low refrigerant charge Check for leaks, repair, and recharge. Restriction in liquid tube Remove restriction Excessive suction pressure Refrigerant overcharged Recover excess refrigerant Suction pressure too low Dirty air filter Replace filter Low refrigerant charge Check for leaks, repair and recharge Metering device or low side restricted Remove source of restriction Insufficient evaporator airflow Increase air quantity Check filter —replace if necessary Temperature too low in conditioned area Reset thermostat Outdoor ambient below 55 (13 ) Install low -ambient kit Filter drier restricted Replace filter Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 47 48VL-K: Installation Instructions Table 14 — Troubleshooting Guide —Heating SYMPTOM CAUSE REMEDY Water in gas line Drain. Install drip leg. No power to furnace Check power supply fuses, wiring or circuit breaker. Check transformer. No 24-v power supply to control circuit NOTE: Some transformers have internal over -current protection that requires a cool -down period to reset. Burners will not ignite Mis-wired or loose connections Check all wiring and wire nut connections Misaligned spark electrodes Check flame ignition and sense electrode positioning. Adjust as necessary. 1. Check gas line for air. Purge as necessary. NOTE: After No gas at main burners purging gas line of air, wait at least 5 minutes for any gas to dissipate before attempting to light unit. 2. Check gas valve. Dirty air filter Clean or replace filter as necessary Gas input to furnace too low Check gas pressure at manifold match with that on unit nameplate Inadequate heating Unit undersized for application Replace with proper unit or add additional unit Restricted airflow Clean or replace filter. Remove any restriction. Limit switch cycles main burners Check rotation of blower, temperature rise of unit. Adjust as necessary. 1. Tighten all screws around burner compartment 2. Cracked heat exchanger. Replace. Poor flame characteristics Incomplete combustion results in: Aldehyde odors, 3. Unit over -fired. Reduce input (change orifices or adjust gas line carbon monoxide, sooting flame, floating flame or manifold pressure). 4. Check burner alignment. 5. Inspect heat exchanger for blockage. Clean as necessary. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 48 48VL-K: Installation Instructions Table 15 — Troubleshooting Guide —LED Status Codes SYMPTOM CAUSE REMEDY Check 5-amp fuse son IGC*, power to unit, 24-v circuit breaker, No Power or Hardware failure Loss of power to control module (IGC)*. and transformer. Units without a 24-v circuit breaker have an (LED OFF) internal overload in the 24-v transformer. If the overload trips, allow 10 minutes for automatic reset. Check fuse, low voltage circuit Fuse is blown or missing or short circuit in secondary Replace fuse if needed. Verify no short circuit in low voltage (24 (LED 1 flash) (24VAC) wiring. VAC wiring). Limit switch faults Check the operation of the indoor (evaporator) fan motor. Ensure (LED 2 flashes) High temperature limit switch is open. that the supply -air temperature rise is in accordance with the range on the unit nameplate. Clean or replace filters. Flame sense fault (LED 3 flashes) The IGC* sensed flame that should not be present. Reset unit. If problem persists, replace control board. 4 consecutive limit switch faults Check the operation of the indoor (evaporator) fan motor and (LED 4 flashes) Inadequate airflow to unit. that supply -air temperature rise agrees with range on unit nameplate information. Ignition lockout fault Check ignitor and flame sensor electrode spacing, gaps, etc. (LED 5 flashes) Unit unsuccessfully attempted ignition for 15 minutes. Ensure that fame sense and ignition wires are properly terminated. Verify that unit is obtaining proper amount of gas. Verify wiring connections to pressure switch and inducer motor. Pressure Switch fault Verify pressure switch hose is tightly connected to both inducer (LED 6 flashes) Open pressure switch. housing and pressure switch. Verify inducer wheel is properly attached to inducer motor shaft. Verify inducer motor shaft is turning. Rollout switch will automatically reset, but IGC' will continue to Rollout switch fault Rollout switch has opened. lockout unit. Check gas valve operation. Ensure that (LED 7 flashes) induced -draft blower wheel is properly secured to motor shaft. Inspect heat exchanger. Reset unit at unit disconnect. Internal control fault Microprocessor has sensed an error in the software If error code is not cleared by resetting unit power, replace the (LED 8 flashes) or hardware. IGC*. Temporary 1 hr auto reset' Electrical interference impeding IGC software Reset 24-v. to control board or turn thermostat off, then on again. (LED 9 flashes) Fault will automatically reset itself in one (1) hour. *WARNING 8 : If the IGC must be replaced, be sure to ground yourself to dissipate any electrical charge that my be present before handling new control board. The IGC is sensitive to static electricity and my be damaged if the necessary precautions are not taken. IMPORTANT: Refer to Table 14-Troubleshooting Guide -Heating for additional troubleshooting analysis. LEGEND IGC—Integrated Gas Unit Controller LED —Light -Emitting Diode Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 49 48VL-K: Installation Instructions Start -Up Checklist (Remove and Store in Job Files) L PRELIMINARY INFORMATION MODEL NO.: SERIAL NO.: DATE: TECHNICIAN: H. PRESTART-UP (Insert check mark in box as each item is completed) (; ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT ( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS ( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS ( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE) ( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE ( ) VERIFY THAT UNIT INSTALLATION IS LEVEL ( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS ( ) INSPECT TUBING III. START-UP ELECTRICAL SUPPLY VOLTAGE COMPRESSOR AMPS INDOOR (EVAPORATOR) FAN AMPS TEMPERATURES OUTDOOR (CONDENSER) AIR TEMPERATURE DB RETURN -AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB GAS HEAT SUPPLY AIR PRESSURES GAS INLET PRESSURE IN. W.C. GAS MANIFOLD PRESSURE IN. W.C. REFRIGERANT SUCTION PSIG,SUCTION LINE TEMP* REFRIGERANT DISCHARGE PSIG, ( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTSC GAS HEAT TEMPERATURE RISE TEMPERATURE RISE (See Literature) RANGE MEASURED TEMPERATURE RISE * Measured at suction inlet to compressor tMeasured at liquid line leaving condenser. LIQUID TEMP - © 2022 Carrier. All rights reserved. Edition Date: 11/22 Replaces:48VL-17SI Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 50