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Carrier 48XL - page 1
® Turn to the Expertg Installation Instructions EQUIPMENT OPERATION HAZARD OAT sensor must be field installed. See Accessory Installation for more details. EQUIPMENT OPERATION HAZARD This Infinity TM unit is designed for use with an Infinity User Interface. NOTE: Read the entire instruction manual before starting the installation. TABLE OF CONTENT ...
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Carrier 48XL - page 2
SAFETY CONSIDERATIONS Installation and servicing of this equipment can be hazardous due to mechanical and electrical components. Only trained and qualified personnel should install, repair, or service this equipment. Untrained personnel can perform basic maintenance flmctions, such as cleaning and replacing air filters. All other operations must be ...
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Carrier 48XL - page 3
ase / ,,Screw.__._ / (NOTE A) -_'l / *Gasketing .._ r_ j / _ Wood nailer* Flashing field Ill_l II I supplied _ JJU_ilt"_ Ro°f curb* II_::i!ll /I# Insulation (field Roofing material U_ I[ supphed) field supplied-- ll_ii![l IL '_ /l_!_i:ll II _ Duotwork _ill I[ field supplied/ Roof Curb for Small Cabinet Note A: When unit mounting ...
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Carrier 48XL - page 4
TOP VIEW INIT 48XL024¢140 ,SXLO2,1G#I _SXLU30040 48XL03_060 ELEGTRIG_L CHARACTERISTICS 208'230 ] 60 208,230 i 60 2GS,P30 _0 UNIT U_IT HEIGHT ,3ENTEROF GRAVlT{ M_,_/I_ LSS "_" X ' 396 _U4:_14_ 02; ¸ 8080(800_ 489 0(:_ 5) @l i81¸9 1641_(43 ¢2) 5,USO{28UJ 489G,:19 3) 4,170_176} 405 /8_ 8 I_9_ _(43 0_;' 5O8 O(20 i_) 489 Oil ...
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Carrier 48XL - page 5
'.yl $090 7 (42941 SERVICE PORT FULL LOUVER DRAIN 19,010,75] N,PT X 220[O.BT] DEEP £12.951 1_23.I 144221 LEFT SIDEVIEW [1.681 722 C284) t TOP VIEW G;%_! t FULL LOUVER mmm _ mm mm _ mm mm mm mm mmm I II i COMPRESSOR, BLOWER, ELECTRIC HEAT _ RICAL ACCESS PAN ]2263 [48,28] FRONT VIEW _H? 1 [4 611 286{113) POWER ENTRY ¢ 22210881 362,9 [14,29} ...
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Carrier 48XL - page 6
UNIT SIZE NOMINAL COOLING CAPACITY (ton) NOMINAL HEATING CAPACITY (Btu) OPERATING WEIGHT (Ib) (kg) COMPRESSORS Quantity REFRIGERANT: PURON (R-410A) Quantity (Ib) (kg) REFRIGERANT METERING DEVICE Size Part Number OUTDOOR COIL Rows...Fins/in, Face Area (sq ft) OUTDOOR FAN Nominal Cfm Diameter (in.) (ram) Motor Hp (Rpm) INDOOR COIL Rows...Fins/in, Fac ...
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Carrier 48XL - page 7
UNIT SIZE NOMINAL COOLING CAPACITY (ton) NOMINAL HEATING CAPACITY (Btu) OPERATING WEIGHT (Ib) (kg) COMPRESSORS Quantity REFRIGERANT: PURON (R-410A) Quantity (Ib) (kg) REFRIGERANT METERING DEVICE Size Part Number OUTDOOR FAN Nominal Cfm Diameter (in.) (mm) Motor Hp (Rpm) OUTDOOR COIL Rows...Fins/in, Face Area (sq ft) INDOOR COIL Rows...Fins/in, Face ...
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Carrier 48XL - page 8
INSPECTION Prior to initial use, and at monthly intervals, all rigging brackets and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Brackets or straps showing any kind of wear in these areas ...
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Carrier 48XL - page 9
36-in. (914 mm) SEE DETAIL A / UNIT HEIGHT A06298 CABINET Small Small MODEL 48XL-024 48XL-030 RIGGING WEIGHT Ib kg 420 191 427 194 A 48XL-036 515 234 48XL-042 537 244 Large 48XL-048 543 246 48XL-060 594 269 NOTE: See dimensional drawing for corner weight distribution. Corner weights shown on drawing are based on unit-only weights and do not include ...
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Carrier 48XL - page 10
Supply Duct Cover A06320 Fig. 8 - 48XL with Duct Covers On Provide for Condensate Disposal NOTE: Ensure that condensate-water disposal methods comply with local codes, restrictions, and practices. The units dispose of condensate through a 3/4 -in. NPT female fitting that exits on the compressor end of the unit. Condensate water can be drained direc ...
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Carrier 48XL - page 11
IN TEE _-_ NIPPLE CAP C99020 Fig. 10 - Sediment Trap 7. Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit. NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the ...
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Carrier 48XL - page 12
Table 2 - Maximum Gas Flow Capacity* NOMINAL INTERNAL LENGTH OF PIPE ft (m)'{" IRON PIPE DIAMETER 10 20 30 40 50 60 70 80 90 100 125 150 175 200 SIZE (IN.) (IN.) (3.0) (6.1) (9.1) (12.1) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0) 1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 -- -- 3/4 .824 360 250 200 170 151 1 ...
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Carrier 48XL - page 13
USER INTERFACE TOP COVER FROM GAS LINE Fig. 11 - Typical Installation DISCONNECT PER NEC* *NEC - NATIONAL ELECTRICAL CODE A06091 SINGLE-PHASE L1 CONNECTIONS TO DISCONNECT PER NEC L2 ...... GROUND SCREW (IN SPLICE BOX) GROUND LEAD z_L_ BLKm -- _YEL_ NOTE: Use copper wire only. LEGEND NEC - National Electrical Code Field Wiring _ Splice Connections F ...
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Carrier 48XL - page 14
HP/AC Board Furnac6 Board Fig. 13 - Control Plate A06306 User interface m 1 | | | L infinity Furnace Board | Factory Wiring infinity HP/AC Board Outdoor Air Thermistor (Supplied with [U) FIELD CONNECTION REQUIRED (BLACK WIRES) OAT OCT a_Outdeor Coil Thermistor FACTORY CONNECTED FACTORY WIRES PROVIDED FOR FIELD CONNECTION OF UTiLiTY CURTAILMENT m 0 ...
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Carrier 48XL - page 15
PRE-START-UP FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal iniury or death and/or property damage. 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 te ...
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Carrier 48XL - page 16
emergency heating or cooling operation using a common thermostat and the terminal strip connections on the two control boards (See Non-Communicating Emergency Cooling/Heating Mode) and will display Status Code 16, System Communication Fault, on amber STATUS LED. No further troubleshooting information will be available at UI until communications are ...
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Carrier 48XL - page 17
I _° qf_ _° ? P P > g co DANGER: UNIT COMPONENT ARRANGEMENT OUTDOOR F_N [] SECTIO_ [] SAS TI LEGEND _F[ELD SPLICE • SPLICE FACTORY WIRING - FIEL@ COnTrOL _IRI_G FIEL@ POWE_ WIRING RSC REMOTE SPARKER CONTROL CQNT CONTACTOR CAP CAPACITOR COMP COMPRESSOR MOTOR CS COMPRESSOR SOLENO[D CCH CRANK CASE HEATER TO BE WIRED iN ACCOROANC[ WITH NEC ANO L ...
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Carrier 48XL - page 18
I =. q_ _o ? -B, r q_ T g 2 o_ DANGER: CONNECTION WIRING DIA6RAM ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING FIELD SUPPLY ------_ ,.._' L_-- _, UN]T COMPONENT ARRANGEMENT 208/230 VAC _''''_1_ OUTDOOR FA,, _ 60HE, 1PH _ _ SECTIO_ SECTION SECTIOn, I CCH I GAS SECTIO_ @ _ FZELD SPL]CE LEGEND 0 SPL]CE FACTORY WIRI ...
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Carrier 48XL - page 19
o O O O OO © D °° {] [E] [ .a O UTILITY RELAY * UTILITY SIGNAL '_ OPEN RELAY * SUPPLIED BY UTILITY PROVIDER O • 43ff] ° O0 0 d]]O oo @ IRcD @ Lql_id Ilne So lellold @ Fig. 18 - 2-Stage HP/AC Control Board A05247 STATUS CODE 21 - GAS HEATING LOCKOUT Control will NOT auto reset. Check for mis-wired gas valve or defective control (valve rel ...
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Carrier 48XL - page 20
If thermistor is shorted or open, replace it to return the system to normal operation. If fault is in the wiring connections, correcting the fault will clear the code and return the system to normal operation. NOTE: If fault condition is an open thermistor or a wiring problem that appears to be an open thermistor and the power to the unit is cycled ...
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Carrier 48XL - page 21
Unit Table 3 - Air Delivery and Temperature Rise at Rated Heating Input Rated Heating Input (Btu/hr) Heating Rise Range OF (°C) Heating Rise Either Stage, °F (°C) "Efficiency .... Comfort" High Stage Low Stage High Stage Low Stage High Stage Low Stage High Stage 20 - 50 15-45 35 30 40 40,000 26,000 (11-28) (8-25) (19) (17) (22) Low Sta ...
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Carrier 48XL - page 22
INFINITY CONTROLLED LOW AMBIENT COOLING NOTE: When this unit is operating below 55°F (13°C) outdoor temperature, provisions must be made for low ambient operation. This unit is capable of low ambient cooling down to 0°F (-18°C).ONLY when using the Infinity control. A low ambient kit is not required, and the outdoor fan motor does not need to be ...
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Carrier 48XL - page 23
CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal iniury and/or death. If the manifold pressure and/or gas rate is not properly adjusted on HI and LO stages, excess carbon monoxide can be produced. FIRE AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal iniury or death and/or proper ...
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Carrier 48XL - page 24
a.129 sec. to complete one revolution b. 3600/129 = 27.9 c. 27.9 x 2 = 55.8 ft3 of gas flow/hr. d. 55.8 x 1050 = 58,590 Btuh input. In this example, the nonfinal input rate for low stage is 58,500 Btu/hr, so the low stage manifold pressure is correctly set. If the measured low stage rate is too low, increase the manifold pressure to increase rate. ...
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Carrier 48XL - page 25
BURNER FLAME BURNER MANIFOLD Fig. 21 - Monoport Burner C99021 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 ...
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Carrier 48XL - page 26
HEATING INPUT(BTU/HR)* Low Stage 26,000 39,000 58,500 75,000 84,500 NUMBER OF ORIFICES 2 3 3 3 3 Table 6 - Heating Inputs GAS SUPPLY PRESSURE (IN. W.C.) Natural MANIFOLD PRESSURE (IN. W.C.) Natural High Stage 3.2-3.8 3.2-3.8 3.2-3.8 3.2-3.8 3.2-3.8 High Stage Min Max Low Stage 40,000 4.0 13.0 1.4 - 2.0 60,000 4.0 13.0 1.4 - 2.0 90,000 4.0 13.0 1.4 ...
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Carrier 48XL - page 27
infinity Furnace infinity HP/AC Board Board Standard 4=Wire Thermostat Outdoor Air Thermistor (Supplied with IU) FIELD CONNECTION REQUIRED (BLACKWIRES) Outdoor Coil Thermistor FACTORY CONNECTED _'m m FACTORY WIRES PROVIDED FOR FIELDCONNECTION OF UTiLiTY CURTAILMENT Fig. 22 - Non-Communicating Emergency Cooling/Heating Wiring Connections AO6302 ...
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Carrier 48XL - page 28
MAINTENANCE To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This packaged unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 10, Troubleshooting Chart. NOTE TO EQUIPMENT O ...
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Carrier 48XL - page 29
ELECTRICALSHOCK HAZARD Failure to follow this warning could result in personal injury or death. Disconnect and tag electrical power to the unit before cleaning and lubricating the blower motor and wheel. Outdoor Coil, Indoor Coil, and Condensate Drain Pan Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year. ...
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Carrier 48XL - page 30
670 psig shutting down the compressor, while HPS2 opens at 565, limiting the compressor to low-stage operation only. High pressure may be caused by a dirty outdoor coil, failed fan motor, or outdoor air recirculation. To check switches: 1. Turn off all power to unit. 2. Disconnect leads on switch. 3. Apply ohm meter leads across switch. You should ...
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Carrier 48XL - page 31
- Defrost operation - Low ambient cooling - Crankcase heater operation - Compressor external protection - Pressure switch monitoring (refrigerant) - Time delays FURNACE BOARD The furnace board controls the following functions: - Indoor blower operation - Gas valve - Inducer motor - Remote sparker module - Pressure switch monitoring (gas) SYSTEMS CO ...
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Carrier 48XL - page 32
THERMISTOR CURVE 9O I I I I 80- k---- 4------ 4----- _------ 4-------I .... i i i i i 7o- -'_-- q------ I----- _------ T------I .... 6o- _ _X__ J. _ _ _ .I_ _ _ __ _ _ J_ _ _ _I .... i i i i i 50 .... '_------ 1----- _------ 1-------I .... 40- - /_.__ l______/___l .... I I I I I 30 .... _-- -- _'-Z_---- _------ I----- --I .... 20 ...
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Carrier 48XL - page 33
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, 19 ...
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Carrier 48XL - page 34
Table 9 - Troubleshooting Chart SYMPTOM Compressor and outdoor fan will not start Compressor will not start but condenser fan runs Compressor cycles (other than normally sat- isfying) cooling/heating calls Compressor operates continuously Excessive head pressure Head pressure too low Excessive suction pressure Suction pressure too low IFM does not ...
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Carrier 48XL - page 35
SYMPTOM Burners will not ignite Inadequate heating Poor flame characteristics Table lO--Troubleshooting Chart Con't-Gas Furnace Operation CAUSE REMEDY Water in gas line Drain. Install drip leg. No power to unit No 24-v power supply to control circuit Mis-wired or loose connections Misaligned spark electrodes No gas at main burners Inducer pres ...
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Carrier 48XL - page 36
I. Preliminary information MODEL NO.: SERIAL NO.: DATE: TECHNICIAN: START=U P CHECKLIST (Remove and Store in Job File) 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 ...
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