Page 1: Table Of Contents
....... . Fig. 1 - - Unit 48DU Rig and Place Unit .
Page 2: Safety Considerations
INTRODUCTION approximately 2 in. beyond the casing on all 4 sides of the unit (See The 48DU packaged unit is a fully self- -contained combination Fig. 3). Do not secure the unit to the slab except when required by Category I gas heating/electric air conditioner designed for outdoor local codes.
Page 3 HVAC unit HVAC unit base base Gask eting inner flange* Scre w Scre w Gask eting (NO TE A) (NO TE A) inner flange* *Gask eting *Gask eting outer flange outer flange Wood nailer* Wood nailer* Flashing field Flashing field supplied supplied Roof curb*...
Page 6 Table 1—Physical Data - - Unit 48DU UNIT SIZE 024040 024060 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY (ton) 2 ---1/2 2 ---1/2 3 ---1/2 3 ---1/2 OPERATING WEIGHT (lb.) 2 ---Stage Scroll COMPRESSORS Quantity REFRIGERANT: PURON (R --- 410A) 10.1...
Page 7: Provide Clearances
Table 1—Physical Data (Con’t) - - Unit 48DU UNIT SIZE 048090 048115 048130 060090 060115 060130 NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) 2- -Stage Scroll COMPRESSORS Quantity REFRIGERANT: PURON (R- - 410A) 15.3 15.3 15.3 15.8 15.8 15.8 Quantity (lb.)
Page 8: Inspection
INSPECTION WARNING Prior to initial use, and at monthly intervals, all rigging brackets and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should PROPERTY DAMAGE HAZARD be paid to excessive wear at hoist hooking points and load support Failure to follow this warning could result in personal areas.
Page 9: Converting Horizontal Discharge Units To Downflow (Vertical) Discharge Units
DETAIL A06298 RIGGING MODEL CABINET WEIGHT 48DU- -024 Small 48DU- -030 48DU- -036 48DU- -042 Large 48DU- -048 48DU- -060 A06296 Fig. 7 - - Suggested Rigging IMPORTANT: Use flexible connectors between ductwork and CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DISCHARGE UNITS unit to prevent transmission of vibration.
Page 10: Provide For Condensate Disposal
6 ft of heating section. Return Duct Cover 6. Install ground- -joint union close to heating section between unit manual shutoff and external manual main shut off valve. Supply Duct Cover A06320 Fig. 8 - - 48DU with Duct Covers On...
Page 11: Install Electrical Connections
Table 2—Maximum Gas Flow Capacity* NOMINAL INTERNAL LENGTH OF PIPE (FT)† IRON PIPE DIAMETER SIZE (IN.) (IN.) .622 — — .824 1.049 1- - 1/4 1.380 1400 1- - 1/2 1.610 2100 1460 1180 *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. wg (based on a 0.60 specific gravity gas). Refer to Table, National Fire Protec- tion Association NFPA 54.
Page 12: Routing Power Leads Into Unit
ROUTING POWER LEADS INTO UNIT For detailed mounting instructions for the OAT sensor, please refer to TSTATXXSEN01- -B installation instructions (catalog Use only copper wire between disconnect and unit. The high no. 63TS- -TA13); Procedures 1 through 3. voltage leads should be in a conduit until they enter the duct panel; conduit termination at the duct panel must be watertight.
Page 13 GROUND SCREW (IN SPLICE BOX) GROUND LEAD SINGLE-PHASE CONNECTIONS TO DISCONNECT PER NEC NOTE: Use copper wire only. LEGEND NEC – National Electrical Code Field Wiring Splice Connections A06299 Fig. 12 - - Line Power Connections A06306 Fig. 13 - - Control Plate...
Page 14 Infinity Furnace A06301 Fig. 14 - - Control Voltage Wiring Connections Table 3—Electrical Data - - Unit 48DU VOLTAGE OUTDOOR INDOOR FAN COMPRESSOR POWER SUPPLY UNIT RANGE FAN MOTOR MOTOR V- - PH- - HZ SIZE MOCP 208/230–1–60 10.3 52.0 18.0/18.0...
Page 15: Pre- -Start- -Up
PRE- -START- -UP b. Make sure that condenser- -fan blade is correctly positioned in fan orifice. Top 1/3 of condenser fan blade WARNING should be within fan orifice venturi. c. Ensure fan hub is positioned correctly with respect to motor housing (See Fig. 23). FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD d.
Page 16 Non- -Communicating Emergency Cooling/Heating Mode) and communicate with the motor for more than 25 seconds, the motor will display Status Code 16, System Communication Fault, on will shut itself down and wait for communications to be amber STATUS LED. No further troubleshooting information will reestablished.
Page 17 A06310 Fig. 16 - - Wiring Schematic- -48DU Single Phase...
Page 18 UTILITY RELAY Liquid Line Solenoid UTILITY SIGNAL OPEN RELAY SUPPLIED BY UTILITY PROVIDER A05247 Fig. 17 - - 2- -Stage HP/AC Control Board STATUS CODE 21 - - GAS HEATING LOCKOUT STATUS CODE 34 - - IGNITION PROVING FAILURE Control will NOT auto reset. Check for mis- -wired gas valve or Control will try three more times before lockout 14 occurs.
Page 19: Sequence Of Operation
Step 2—Sequence of Operation NOTE: When two- -stage unit is operating at low- -stage, system The 48DU packaged unit is designed for installation with a vapor (suction) pressure will be higher than a standard communicating UI. This unit will not respond to commands single- -stage system or high- -stage operation.
Page 20 Table 5—HEAT PUMP/AIR CONDITIONER BOARD STATUS CODES AMBER FAULT POSSIBLE CAUSE AND ACTION OPERATION FLASH CODE Standby – no call for unit opera- On solid, None Normal operation. tion no flash Rapid, con- Unit being controlled by standard thermostat inputs instead of Infin- Standard Ther- Emergency Mode tinuous...
Page 21 230 VAC power, or by interrupting 24 VAC power at SEC1 or SEC2 In high stage, fan is off when outdoor coil temp is <outdoor to the furnace board. air temperature +3_F or outdoor fan has been ON for 30 minutes.
Page 22 Gas input rates on rating plate are for installations at altitudes up to REGULATOR COVER SCREW 2000 ft. Input rate must be within ± 2% of rating plate input. PLASTIC ADJUST SCREW 1. Determine the correct gas input rate. ON/OFF SWITCH a.
Page 23 a. Furnace must operate within rise range listed on rating NOTE:Double- -check that User Interface is running on high stage plate. gas heat while clocking the low stage firing rate. b. Select ”COMFORT” or ”EFFICIENCY” mode on UI. 7. Verify proper high stage gas heat temperature rise. ”COMFORT”...
Page 24: Check For Refrigerant Leaks
failure. To initiate the component test procedure, ensure that there BURNER FLAME are no UI inputs to the control (the ABCD connector can be removed from the Infinity control board for this operation) and all time delays have expired. Turn on setup switch SW1- -6. BURNER NOTE: The component test feature will not operate if the control is receiving any UI signals or until all time delays have expired.
Page 25: Checking Cooling And Heating Control Operation
(refer to system rating plate). standard thermostat input terminals to allow simple thermostatic LOW CHARGE COOLING control of the 48DU unit. Use Cooling Charging Chart (Fig. 22). Vary refrigerant until the For control with a standard thermostat, disconnect the ABCD conditions of the chart are met.
Page 26 Infinity Furnace A06302 Fig. 21 - - Non- -Communicating Emergency Cooling/Heating Wiring Connections Required Subcooling Required Liquid Line Temperature for a Specific Subcooling (R-410A) Outdoor Ambient Temperature Required Subcooling ( Required Subcooling ( Pressure Pressure Model Size 75 (24) 82 (28) 85 (29) 95 (35) 105 (41)
Page 27: Maintenance
MAINTENANCE Inspect air filter(s) at least once each month and replace (throwaway- -type) or clean (cleanable- -type) at least twice during To ensure continuing high performance, and to minimize the each cooling season and twice during the heating season, or possibility of premature equipment failure, periodic maintenance whenever the filter becomes clogged with dust and lint.
Page 28: Outdoor Coil, Indoor Coil, And Condensate Drain Pan
Step 8—Outdoor Coil, Indoor Coil, and Condensate Step 10—Electrical Controls and Wiring Drain Pan Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit. Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year.
Page 29: Copeland Scroll Compressor (Puron Refrigerant)
TROUBLESHOOTING Step 15—Refrigerant System LED DESCRIPTION This step covers the refrigerant system of the 48DU, including the LEDs built into Infinity control boards provide installer or service compressor oil needed, servicing systems on roofs containing person information concerning operation and/or fault condition of synthetic materials, the filter drier, and refrigerant charging.
Page 30 SYSTEMS COMMUNICATION FAILURE exists, the thermal protector is open. The control de- -energizes the compressor contactor for 15 minutes, but continues to operate If communication with the Infinity Control is lost with the UI, the outdoor fan. The control Status LED will flash the the controls will flash the appropriate fault codes.
Page 31: Final Checks
THERMISTOR SENSOR COMPARISON FINAL CHECKS The control continuously monitors and compares the outdoor air IMPORTANT: Before leaving job, be sure to do the following: temperature sensor and outdoor coil temperature sensor to ensure 1. Ensure that all wiring is routed away from tubing and proper operating conditions.
Page 32 AIR CONDITIONER WITH PURON REFRIGERATION SECTION QUICK- -REFERENCE GUIDE Puron refrigerant operates at 50- -70 percent higher pressures than R- -22. Be sure that servicing equipment and replacement components are designed to operate with Puron. Puron refrigerant cylinders are rose colored. Puron refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright position.
Page 33 Table 10—Troubleshooting Chart SYMPTOM CAUSE REMEDY Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor, transformer, control relay, or high-- Replace component pressure, loss--of--charge or low--pressure switch Insufficient line voltage Determine cause and correct Compressor and outdoor fan Incorrect or faulty wiring...
Page 34 Table 10—Troubleshooting Chart Con’t- -Gas Furnace Operation SYMPTOM CAUSE REMEDY Water in gas line Drain. Install drip leg. Check power supply fuses, wiring or circuit No power to unit breaker. Check transformer. NOTE: Some transformers have internal over-- No 24--v power supply to control circuit current protection that requires a cool--down peri- od to reset.
Page 35: Start-Up Checklist
START-UP CHECKLIST (Remove and Store in Job File) I. Preliminary Information MODEL NO.:_________________________________ SERIAL NO.:__________________________________ DATE:_______________________________________ TECHNICIAN:_________________________________ II. PRE-START-UP (Insert checkmark in box as each item is completed) ( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT ( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS ( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS ( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)
Page 36 Catalog No: 48DU- - 2SI Copyright 2006 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 8/21/06 Replaces: 48DU--- 1SI Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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