Carrier 48XL Infinity Instruction Manual

Browse online or download Instruction Manual for Split-system air conditioners Carrier 48XL Infinity. Carrier 48XL Infinity Instruction manual User Manual

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®
Turn to the Expertg
Installation Instructions
EQUIPMENT OPERATION HAZARD
Failure to follow this caution may result in improper unit
operation.
OAT sensor must be field installed. See Accessory
Installation for more details.
EQUIPMENT OPERATION HAZARD
Failure to follow this caution may result in improper unit
operation.
This Infinity TM unit is designed for use with an Infinity User
Interface.
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS ......................... 2
INTRODUCTION ................................... 2
RECEIVING AND INSTALLATION ................. 2-12
Check Equipment .................................. 2
Identify Unit .................................... 2
Inspect Shipment ................................. 2
Provide Unit Support ............................... 2
Roof Curb ...................................... 2
Slab Mount ..................................... 3
Provide Clearances ................................. 3
Rig and Place Unit ................................. 3
Inspection ...................................... 3
Rigging/Lifting of Unit ............................ 9
Select and Install Ductwork ........................... 9
Configuring Units for Downflow (Vertical) Discharge . . . 10
Provide for Condensate Disposal ..................... 11
Install Flue Hood .................................. 11
Install Gas Piping ................................. 12
Install Electrical Connections ........................ 13
High-Voltage Connections ........................ 13
Routing Power Leads Into Unit ..................... 13
Connecting Ground Lead to Ground Screw ........... 13
Routing Control Power Wires ..................... 13
Accessory Installation ............................ 13
Special Procedures for 208-v Operation .............. 14
PRE-START-UP ................................... 16
START-UP ..................................... 16-27
Unit Start-Up and Troubleshooting ................... 16
Sequence of Operation ............................. 21
Check for Refrigerant Leaks ......................... 26
Start-Up Adjustments .............................. 26
A09032
Fig. 1 - Unit 48XL-A
Checking Cooling and Heating Control Operation ...... 26
Checking and Adjusting Refrigerant Charge ........... 26
Refrigerant Charge .............................. 27
No Charge ..................................... 27
Low Charge Cooling ............................. 27
To Use Cooling Charging Charts .................... 27
Non-Communicating Emergency Cooling/Heating Mode .. 27
MAINTENANCE ................................ 29-30
Air Filter ........................................ 29
Indoor Fan and Motor .............................. 29
Inducer Blower ................................... 29
Limit Switch ..................................... 29
Burner Ignition ................................... 29
Main Burners .................................... 29
Inducer Pressure Switch ............................ 30
Outdoor Coil, Indoor Coil, and Condensate Drain Pan ..... 30
Outdoor Fan ..................................... 30
Electrical Controls and Wiring ....................... 30
Refrigerant Circuit ................................. 31
Indoor Airflow ................................... 31
Pressure Switches ................................. 31
Loss-of-Charge Switch ............................ 31
High-Pressure Switches ............................ 31
Copeland Scroll Compressor (Puron cR)Refrigerant) ........ 31
Refrigerant System ................................ 31
Refrigerant .................................... 31
Compressor Oil ................................. 31
Servicing Systems on Roofs with Synthetic Materials .... 31
Liquid-Line Filter Drier .......................... 32
Puron (R-410A) Refrigerant Charging ............... 32
TROUBLESHOOTING .............................. 32
FINAL CHECKS ................................... 33
CARE AND MAINTENANCE ........................ 33
START-UP CHECKLIST ............................ 37
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Summary of Contents

Page 1 - Installation Instructions

®Turn to the ExpertgInstallation InstructionsEQUIPMENT OPERATION HAZARDFailure to follow this caution may result in improper unitoperation.OAT sensor

Page 2 - SAFETY CONSIDERATIONS

2. Avoid abrupt duct size increases and reductions. Abruptchange in duct size adversely affects air performance.IMPORTANT: Use flexible connectors bet

Page 3

_5 -OI,,,,_, Cut along'V" groovesDrillplacesI IReturn Duct PanelsFlex up & downto removecota,oo0_I li I... _-"-..Jl., I I E I X

Page 4 - LARGE CURB

3.Securefluehoodto flue panel by inserting a single screw onthe top and the bottom of the hood.l-in. (25 ram)rain.TRAPram) rain.A09052Fig. 10 - Conden

Page 5 - 2 _ X i_)XS

Table2- MaximumGas Flow Capacity*NOMINAL INTERNAL LENGTH OF PIPE ft (m)'{"IRON PIPE DIAMETER 10 20 30 40 50 60 70 80 90 100 125 150 175 200S

Page 6 - <_°i i

Whencommandedto operatehumidifier,theunitcontrolwillenergizetheHUMoutputtoturnhumidifieronandde-energizeHUMoutputto turnhumidifieroff.WireHUMandCOMter

Page 7

HP/ACBOARDFURNACE BOARDUserinterfacem1|||I.Fig. 14 - Control PlateInfinity FurnaceBoardHUM.[1LEGEND| Factory WiringInfinity HP/ACBoard[OATBOCTBmOmY2mY

Page 8

PRE-START-UPFIRE, EXPLOSION, ELECTRICAL SHOCK ANDENVIRONMENTAL HAZARDFailure to follow this warning could result in personaliniury or death and/or pro

Page 9 - CAUTION - NOTICE TO RIGGERS

emergency heating or cooling operation using a commonthermostat and the terminal strip connections on the two controlboards (See Non-Communicating Eme

Page 10 - []NIT COMPONENT DAMAGE HAZARD

z:>ooi--<Jzo<<::z::o::z::<ci--w<c_9z>._s%(ZDZcls,_3<N<i<:<0<9z4S5NP/AC CON[ROL BOARD88% IFig. 17 - Wiring Schemati

Page 11 - Return Duct Panels

zzz0z>wLxaz2<N=<ico<wwz_c_ FURNACECONTROL BOAR1)Fig. 18 - Wiring Schematic-48XL-A Single Phase Gas Inputs 115, 130 kBtu/hrA0908119

Page 12 - Install Gas Piping

SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service maintenance,or use can cause explosion, fire, electrical shock, or otherco

Page 13 - EQUIPMENT OPERATION HAZARD

OOOODO00[] []O0m mUTILITY RELAY *10OPEN RELAY* SUPPLIED BY UTILITY PROVIDER@?f,?o000O00r-qLiquid Line SolenoidA05247Fig. 19 - 2-Stage HP/AC Control Bo

Page 14

openorshortedat any time after initial validation, Status Code 53will be displayed at amber STATUS LED.Check for faults in wiring connecting sensor to

Page 15 - FURNACE BOARD

UnitTable 3 - Air Delivery and Temperature Rise at Rated Heating InputRated Heating Input (Btu/hr) Heating Rise Range OF (°C) Heating Rise Either Stag

Page 16 - START-UP

INFINITY CONTROLLED LOW AMBIENT COOLINGNOTE: When this unit is operating below 55°F (13°C) outdoortemperature, provisions must be made for low ambient

Page 17

CARBONMONOXIDEPOISONINGHAZARDFailureto follow this warning could result in personaliniury and/or death.If the manifold pressure and/or gas rate is not

Page 18

a.129sec.to complete one revolutionb. 3600/129 = 27.9c. 27.9 x 2 = 55.8 ft3 of gas flow/hr.d. 55.8 x 1050 = 58,590 Btuh input.In this example, the non

Page 19

BURNERFLAMEBURNERMANIFOLDFig. 22 - Monoport BurnerC99021LIMIT SWITCHESNormally closed limit switch (LS) completes the control circuit.Should the leavi

Page 20 - UTILITY RELAY *

HEATING INPUT(BTU/HR)*Low Stage26,00039,00058,50075,00084,500NUMBER OFORIFICES23333Table 6 - Heating InputsGAS SUPPLY PRESSURE (IN. W.C.)NaturalMANIFO

Page 21 - 100°F (38°C)

infinity Furnace infinityHP/ACBoard BoardStandard4..WireThermostatOutdoorAirThermistor(Suppliedwith IU)FIELDCONNECTIONREQUIRED(BLACKWIRES)OutdoorCoilT

Page 22

MAINTENANCETo ensure continuing high performance, and to minimize thepossibility of premature equipment failure, periodic maintenancemust be performed

Page 23

Installation on older "G" series roof curbs.Two accessory kits are available to aid in installing a new "G"series unit on an old &

Page 24 - CARBONMONOXIDEPOISONINGHAZARD

Bh werAccessCompressor PanelAccess PanelFig. 25 - Unit Access PanelsControlAccessPanelA09479IntegratedGas Unit(IGC)Auto Transformerfuses used on 460(H

Page 25

infinity TopA"A06035UNIT SIZE "A" DIM. IN. (MM)24 1 (26)30 1 (26)36 1 (26)42 1 (26)48 11/32 (9)60 9/16 (14)Fig. 28 - Outdoor Fan Blade

Page 26 - MANIFOLD

Synthetic Roof Precautionary Procedure1. Cover extended roof working area with an inapermeablepolyethylene (plastic) drip cloth or tarp. Cover anappro

Page 27 - (610x762x25)

the call for cooling continues, the control will energize thecompressor contactor every 15 nfinutes. If the thermal protectorcloses (at the next 15 nf

Page 28 - 50DU500166 REV 3.0 ]

AIR CONDITIONER WITH PURONREFRIGERATION SECTION QUICK-REFERENCE GUIDEPuron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure t

Page 29 - Main Burners

Table 9 - Troubleshooting Chart - CoolingSYMPTOMCompressor and outdoor fanwill not startCompressor will not start but condenser fanrunsCompressor cycl

Page 30 - Outdoor Fan

SYMPTOMBurners will not igniteInadequate heatingPoor flame characteristicsTable lO--Troubleshooting Chart - Gas Furnace 0CAUSEWater in gas lineNo powe

Page 31 - ENVIRONMENTAL HAZARD

I. PRELIMINARY INFORMATIONMODEL NO.:SERIAL NO.:DATE:TECHNICIAN:START-UP CHECKLIST(Remove and Store in Job Files)II. PRESTART-UP (Insert check mark in

Page 32 - TROUBLESHOOTING

Copyright 2009 Carrier Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 08/09Manufacturer reserves the right to cha

Page 33 - CARE AND MAINTENANCE

HVAC unitbase railsAnchor screw /Flashing fieldRoofing materialHVAC unitbasepan_ SealingGasketRoofcurb_Wood nailer*/ Roofcurb*Insulation/(field suppli

Page 34 - AIR CONDITIONER WITH PURON

[]o_tt l=1... £3£ 3 ... 3 ';_2 _ X i_)XS... o= _2 X:>=S[]© _,__777Ill _ _=iiiii_ . !i_..." ' LiT_]] ,_sS &apos

Page 35 - Excessive head pressure

illiiiil...'_i'_i'_i__i_i_i_iiiiu_oc>Lc;ilL_7o=:E:<_°i io_< ..._ _,_oFig. 6 - 48X

Page 36

UNIT SIZENOMINAL COOLING CAPACITY (ton)NOMINAL HEATING CAPACITY (Btu)SHIPPING WEIGHT (Ib)(kg)COMPRESSORSQuantityREFRIGERANT: PURON (R-410A)Quantity (I

Page 37 - START-UP CHECKLIST

UNIT SIZENOMINAL COOLING CAPACITY (ton)NOMINAL HEATING CAPACITY (Btu)SHIPPING WEIGHT (Ib)(kg)COMPRESSORSQuantityREFRIGERANT: PURON (R-410A)Quantity (I

Page 38 - Catalog No:48XL-06SI

CAUTION - NOTICE TO RIGGERSPRUDENCE - AViS AUX MANIPULATEURACCESS PANELS MUST BE iN PLACE WHEN RIGGING.PANNEAUX D'ACCES DOlT ETRE EN PLACE POUR M

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