Carrier Infinity 48DU-030, Infinity 48DU-024, Infinity 48DU-036, Infinity 48DU-042, Infinity 48DU-048 Installation Instruction

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Installation Instructions

IMPORTANT: OAT sensor must be field installed. See

Accessory Installation for more details.

IMPORTANT: This Infinity _ unit is designed for use with an Infinity User Interface.

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

Page

SAFETY CONSIDERATIONS ........................ 2

INTRODUCTION .................................. 2

RECEIVING AND INSTALLATION ................ 2-12

Check Equipment ................................. 2

Identify Unit ................................... 2

Inspect Shipment ................................ 2

Provide Unit Support .............................. 2

Roof Curb ..................................... 2

Slab Mount .................................... 2

Ground Mount ................................. 2

Provide Clearances ................................ 7

Rig and Place Unit ................................ 7

Inspection ..................................... 8

Introduction .................................... 8

Use of Rigging Bracket ........................... 8

Select and Install Ductwork .......................... 8

Converting Horizontal Discharge Units to Downflow

(Vertical) Discharge Units ......................... 9

Provide for Condensate Disposal .................... 10

Install Flue Hood ................................. 10

Install Gas Piping ................................ 10

Install Electrical Connections ....................... 11

High- Voltage Connections ....................... 11

Routing Power Leads Into Unit .................... 12

Connecting Ground Lead to Ground Screw . ......... 12

Routing Control Power Wires .................... 12

Accessory Installation ........................... 12

Special Procedures for 208-v Operation ............. 12

PRE-START-UP .................................. 15

START-UP .................................... 15-25

Unit Start-Up and Troubleshooting .................. 15

Sequence of Operation ......................... 19-24

Check for Refrigerant Leaks ........................ 24

Start-Up Adjustments ............................. 24

Checking Cooling and Heating Control Operation ..... 25

Checking and Adjusting Refrigerant Charge .......... 25

Refrigerant Charge ............................. 25

No Charge .................................... 25

Low Charge Cooling ............................ 25

To Use Cooling Charging (;harts ................... 25

Non-Comnmnicating Emergency Cooling/Heating Mode . 25

MAINTENANCE ............................... 27-29

Air Filter ....................................... 27

Indoor Fan and Motor ............................. 27

Inducer Blower .................................. 27

Limit Switch .................................... 27

Turn to the Expertd

C99001

Fig. 1 - Unit 48DU

Burner Ignition .................................. 27

Main Burners ................................... 27

Inducer Pressure Switch ........................... 27

Outdoor Coil. Indoor Coil, and Condensate Drain Pan .... 28

Outdoor Fan .................................... 28

Electrical Controls and Wiring ...................... 28

Refrigerant Circuit ................................ 28

Indoor Airflow . ................................. 28

Pressure Switches ................................ 28

Loss-of-Charge Switch ........................... 28

High-Pressure Switches ........................... 28

Copeland Scroll Compressor (Puron _: Refrigerant) ....... 29

Refrigerant System ............................... 29

Refrigerant ................................... 29

Compressor Oil ................................ 29

Servicing Systems on Roofs with Synthetic Materials ... 29

Liquid-Line Filter Drier ......................... 29

Puron (R-410A) Refrigerant Charging .............. 29

TROUBLESHOOTING .......................... 29-31

FINAL CHECKS .................................. 31

CARE AND MAINTENANCE ....................... 31

START-UP CHECKLIST ........................... 35

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 functions, such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on this

equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety

precautions that may apply.

Followallsafetycodes.Installationmustbeincompliancewith localandnationalbuildingcodes.Wearsafetyglasses,protective

clothing,andworkgloves.Havefireextinguisheravailable.Read theseinstructionsthoroughlyandfollowallwarningsorcautions

includedinliteratureandattachedtotheunit. Recognizesafetyinformation.Thisisthesafety-alertsymbol_.

Whenyouseethissymbolontheunitandininstructionsormanuals, bealerttothepotentialforpersonalinjury.Understandthesesignal

words:DANGER.WARNING,andCAUTION.Thesewordsare usedwiththesafety-alertsymbol.DANGERidentifiesthemostse-

rioushazardswhichwillresultinseverepersonalinjuryordeath. WARNINGsignifieshazardswhichcould result in personal injury

or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage.

NOTE is used to highlight suggestions which will result in en- hanced installation, reliability, or operation.

Always install furnace to operate within the intended temperature rise range with a duct system which has an external static pressure

within the allowable range, as specified in "Indoor Airflow Adjust- ments" section of these instructions. See furnace rating plate.

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. There may be more than one disconnect

switch. Turn off accessory heater power switch if applicable.

UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury

or equipment damage. Puron (R-410A) systems operate at higher pressures than

standard R-22 systems. DO NOT use R-22 service equipment or components on Puron (R-410A) equipment.

Ensure service equipment is rated for Puron {R-410A).

INTRODUCTION

The 48DU packaged unit is a fully self-contained combination Category I gas heating/electric air conditioner designed for outdoor installation (See Fig. 1). Standard units are shipped in a

horizontal-discharge configuration for installation on a ground-level slab or directly on the ground if local codes permit.

Standard units can be converted to downflow (vertical) discharge configurations for rooftop applications.

Models with an N in the fifth position of the model number are dedicated Low NOx units designed for California installations.

These models meet the California maximum oxides of nitrogen (NOx) emissions requirements of 40 nanograms/joule or less as

shipped from the factory and must be installed in California Air Quality Management Districts or any other regions in North

America where a Low NOx rule exists.

NOTE: Low NOx requirements apply only to natural gas installations.

RECEIVING AND INSTALLATION

INSPECT SHIPMENT

Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have

it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items

against shipping list. Immediately notify the nearest Carrier office if any item is missing. To prevent loss or damage, leave all parts in

original packages until installation. 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. 4). 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. (See Fig. 2). This is necessau for unit drain to function properly. Refer to accessory roof curb

installation instructions for additional information as required.

MAXIMUMALLOWABLE

DIFFERENCE(in,)

B A-B B-C A-C

1/4 1/4 1/4

C99065

Fig. 2 - Unit Leveling Tolerances

SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4 in. thick with 2 in. above grade. The slab should extend

approximately 2 in. beyond the casing on all 4 sides of the unit (See Fig. 3). Do not secure the unit to the slab except when required by

local codes.

EVAR COIl COND COIL

Fig. 3 - Slab Mounting Detail

C99096

Step 1--Check Equipment IDENTIFY UNIT

The unit model number and serial number are printed on the unit informative plate. Check this information against shipping papers.

GROUND MOUNT The unit may be installed either on a slab or placed directly on the

ground if local codes permit. Place the unit on level ground prepared with gravel for condensate discharge.

Roof Curb for Small Cabinet

Note A: When unit mounting screw is used,

retainer bracket must also be used,

Roof Curb for Large Cabinet

Note A: When unit mounting screw is used,

retainer bracket must also be used,

R/A

Support

Long

Support

UNIT SIZE

024-030

036-060

NOTES:

[. Roof curb must be set up for unit being installed.

2. Seat strip must be applied, as required, to unit being installed.

3. Dimensions are in inches.

4. Dimension in ( )are in millimeters.

5. Roof curb is made of 16 gauge steel.

6. Attach ductwork to curb (flanges of duct rest on curb).

7. Inadated panels: I in. thick fiberglass 1 lb. density. S. When unit mounting screw is used (see Note A). a retainer bracket must be used as well. This bracket must also be used when required by code for hurricane or seismic

conditions. This bracket is available through Micrometl.

ODS CATALOG A B

NUMBER IN. (MM) IN. (MM)

CPRFCURB008A00 8 (203) 11 (279) CPRFCURB00FA00 14 (356) 11 (279)

CPRFCURB008A00 8 (203) 16-3/16 (411) CPRFCURB009A00 14 (356) 16-3/16 (411)

Fig. 4 - Roof Curb Dimensions

IN. (MM)

16-1/2 (419) 16-1/2 (419)

17-3/8 (441) 17-3/8 (441)

IN. (MM)

28-3/4 (730)

28-3/4 (730) 40-1/4 (1022) 40-1/4 (1022)

insulated deck pan

_Gasket around _

Gasket around

outer edge \

IN. (MM)

30-3/8 (771)

30-3/8 (771) 41-15/16 (1065) 41-15/16 (1065)

duct

\\,\

IN. (MM)

44-5/16 (1126) 44-5/16 (1126)

44-7/16 (1129) 44-7/16 (1129)

S/A

IN. (MM)

45-15/16 (1167) 45-15/16 (1167)

46 - 1/16 (1169) 46-1/16 (1169)

A05308

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RIGHTSIDEVIEW REAR VIEW

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O38O9O ji01/45 B

042050 ji11150 3

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S _T_:_4 I_{'_ S ¸STEM PERFORI,O[_¢__'8; ¢O41_ROITS[_

o> o_ s

UNIT SIZE NOMINAL CAPACITY (ton)

OPERATING WEIGHT 0b,) COMPRESSORS

Quantity

REFmGERANT: PURON (R-410A)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Size

Part Number

OUTDOOR COiL

Rows.Sins/in. Face Area (sq ft)

OUTDOOR FAN

Nominal Cfm Diameter (in,)

Motor Hp (Rpm)

INDOOR COiL

Rows..,Fins/in. Face Area (sq ft)

INDOOR FAN

Nominal Airflow (Cfm) Comfort

Efficiency Max

Furnace (gas ht,) airflow-Low Stage Furnace (gas ht,) airflow-High Stage

Size (in,)

Motor HP (RPM)

FURNACE SECTION* Burner Orifice No, (Qty,.,Drill Size)

Natural Gas

HiGH = PRESSURE SWITCH (peig)

Cut-out

Reset (Auto)

HIGH=PRESSURE SWITCH 2 (psi9)

(Compressor Solenoid) Cut-out

Reset (Auto)

LOSS-OF-CHARGE / LOW-PRESSURE SWITCH

(Liquid Lh_e) (psig) Cut-out

Reset (auto)

RETURN=AIR FILTERS (in.)1-

Throwaway

Contimled next page,

Table 1--Physical Data - Unit 48DU

024040 024060 030040 030060 036060 036090 042060 042090

2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2

398 401 403 408 485 493 507 515

2-Stage Scroll

10.1 10.1 11.3 11.3 9,5 9,5 13.8 13.8

TXV

2Ton 2Ton 3Ton 3Ton 3Ton 3Ton 4Ton 4Ton

EA36YD129 EA36YD129 EA36YD139 EA36YD139 EA36YD139 EA36YD139 EA36YD149 EA36YD149

2.,,21 2.,,21 2.,,21 2.,,21 2.,,21 2.,,21 2.,,21 2.,,21

13.8 13.8 15.3 15.3 17.5 17.5 19.4 19.4

2700 2700 2700 2700 2800 2800 2800 2800

22 22 22 22 22 22 22 22

I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825)

3.,,17 3.,,17 3.,,17 3.,,17 3.,,17 3.,,17 3.,,17 3.,,17 3,7 3,7 3,7 3,7 4,7 4,7 4,7 4,7

Variable based on Comfort Rollback(see UserlnterMceinstructionsfor moreinformaion).

7OO 8OO 475 844

10xl0

1/2

2.,,44 3.,,44 2.,,44 3.,,44 3.,,44 3.,,38 3.,,44 3.,,38

90x24x1 90x24x1 90x24x1 90x24x1 94x30x1 94x30x1 94x36x1 94x36x1

700 875 875 1050 1050 800 1000 1000 1200 1200 727

1120

10x10

1/2

475 844

10x10

1/2

727

1120

10x10

1/2

870 ±10

470 ± 25

585 ±15 455 ±15

25 ± 5 55 ± 5

745

1120

11x10

3/4

11x10

875 1410

3/4

1225 1400

745

1120

11x10

3/4

1225 1400

875

1410

11x10

3/4

Table 1--Physical Data (Can't) - Unit 48DU

UNIT SIZE NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS

Quantity

REFRIGERANT," PURON (R=41OA)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Size

Part Number

OUTDOOR FAN

Nominal Cfm Diameter (in.) Motor Hp (Rpm)

OUTDOOR COIL

Rows..,Fins/in. Face Area (sq ft)

INDOOR COIL

Rows._Fins/in. Face Area (sq ft)

INDOOR FAN

Nominal Airflow (Cfm) Comfort Efficiency

Max Furnace (gas ht.) airflow-Low Stage

Furnace (gas ht.) airflow-High Stage Size (In.)

Motor HP (RPM)

FURNACE SECTION* Burner Orifice No, (Qty,.,DriH Size}

Natural Gas

HmGH-PRESSURE SWITCH (psig)

Cut-out

Reset (Auto)

HmGH=PRESSURE SWITCH 2 (psi9)

(Compressor Solenoid)

Cut-out

Reset (Auto)

LOSS=OF=CHARGE / LOW=PRESSURE SWITCH

(Liquid Line) (psig)

Cut-out

Reset (auto)

RETURN-AIR FILTERS (in.)f

Throwaway

Based on altitude of 0 to 2000 ft.

fRequired filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/min ute for throwaway type or 450 ftiminute for high capacity type. Air filter pressure drop for non standard filters illust not exceed 0,08 in, we.

048090 048115 048130

4 4 4 5

521 521 521 572

2-Stage Scroll

15.3 15.3 15.3 15.8

4Ton 5Ton 5Ton

EA36YD149 EA36YD159 EA36YD159 EA36YD159

3300 3300 3300 3300 3300 3300

22 22 22 22 22 22

1/4 (1100) 1/4 (1100) 1/4 (1100) 1/3 (1110) 1/3 (1110) 1/3 (1110)

2,.,21 2._21 2._21 2..,21 2..,21 2...21

19.4 19.4 19.4 23.3 23.3 23.3

3..,17 3.,.17 3.,.17 4..,17 4..,17 4.,.17

5.7 5.7 5.7 5.7 5.7 5.7

Variable based on Comfort Rollback(see Userlnterfaceinstructionsfor moreinformation),

1400 1400 1400 1750 1600 1600 1600 2000

815

1385

11x10

3/4

3...38 3...33 3...31 3...38

24x36x1 24x36x1 24x36x1 24x38x1 24x36x1 24x36x1

4 Ton 4 Ton 5 Ton

EA36YD149 EA36YD149

1215 1885

11x10

8/4

1255 1875

11x10

3/4

670 ± 10 470 ± 25

565 ± 15 455 ±15

060090 060115 080130

5 5

572 572

15.8 15.8

TXV

1750 1750 2000 2000

845

1300

11x10

25 ± 5 55 ± 5

1215 1910

11x10

3...33 3...31

1255 1920

11x10

Step 3--Provide Clearances The required minimum service clearances are shown in Fig. 5 and

6. Adequate ventilation and outdoor air must be provided. The outdoor fan draws air through the outdoor coil and discharges it

through the top fan grille. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a

corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in.

above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in.

IMPORTANT: Do not restrict outdoor airflow. An air restriction at either the outdoor-air inlet or the fan discharge may be detrimental

to compressor life. Do not place the unit where water, ice, or snow from an overhang

or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slab-mounted units

should be at least 4 in. above the highest expected water and runoff levels. Do not use unit if it has been under water.

Step 4_Rig and Place Unit Rigging and handling of this equipment can be hazardous for many

reasons due to the installation location (roofs, elevated structures. etc.).

Only trained, qualified crane operators and ground support staff should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.

Training for operators of the lifting equipment should include, but not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work gloves.

INSPECTION Prior to initial use, and at monthly intervals, all rigging brackets and

straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should

be paid to excessive wear at hoist hooking points and load support areas. Brackets or straps showing any kind of wear in these areas must not be used and should be discarded.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Befnre installing or servicing system, always turn off main

power to system. There may be more than one disconnect

switch. Turn off accessory heater power switch if applicable.

Tag disconnect switch with a suitable warning label.

UNIT FALLING HAZARD

Failure to fnllow this warning could result in personal injury

or death.

Never stand beneath rigged units or lift over people.

INTRODUCTION The lifting/rigging bracket is engineered and designed to be

installed only on Small Packaged Products. This bracket is to be used to rigdift a Small Packaged Product onto

roofs or other elevated structures.

PROPERTY DAMAGE HAZARD

Failure to fnllow this warning could result in personal

injury/death or property damage. Rigging brackets for one unit use only, When removing a

unit at the end of its useful life, use a new set of brackets.

USE OF RIGGING BRACKET

Field Installation of Ri_in_ Bracket

1. If applicable, remove unit from shipping carton. Leave top shipping skid on the unit for use as a spreader bar to prevent

the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage.

2. Remove 4 screws in unit corner posts.

3. Attach each of the 4 metal rigging brackets under the panel rain lip (See Fig. 7). Use the screws removed in step 2 above

to secure the brackets to the unit.

PROPERTY DAMAGE HAZARD

Failure to fnllow this warning could result in personal

injury/death or property damage. Rigging bracket MUST be under the rain lip to provkle

adequate lifting.

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal injury/death or prnperty damage.

Do not strip screws when re-securing the unit. If a screw is stripped, replace the stripped one with a larger diameter screw

(included).

Ri_in_/Liftin_ of Unit

1. Bend top of brackets down approximately 30 degrees from the corner posts.

2. Attach straps of equal length to the rigging brackets at opposite ends of the unit. Be sure straps are rated to hold the

weight of the unit (See Fig. 7).

3. Attach a clevis of sufficient strength in the middle of the straps. Adjust the clevis location to ensure unit is lifted level

with the ground.

4. After unit is securely in place detach rigging straps. Remove corner posts, screws, and rigging brackets then reinstall

screws.

UNIT FALLING HAZARD Failure to follow this warning could result in personal

injury/death or property damage. When straps are taut, the clevis should be a minimum of 36

inches above the unit top cover.

After the unit is placed on the roof curb or mounting pad, remove the top crating.

Step 5--Select and Install Ductwork The design and installation of the duct system must be in accordance

with the standards of the NFPA for installation of non-residence type air conditioning and ventilating systems. NFPA 90A or

residence type. NFPA 90B and/or local codes and ordinances. Select and size ductwork, supply- air registers, and return air grilles

according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations. The unit has duct flanges on the supply- and return-air openings on

the side of the unit.

PERSONAL AND PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

For vertical supply and return units, tools or parts could drop into ductwork, therefore, install a 90 degree turn in the return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Units with electric heaters require 90 degree elbow in supply duct.

When designing and installing ductwork, consider the following:

1. All units should have field- supplied filters or accessory filter rack installed in the return-air side of the unit.

Recommended sizes for filters are shown in Table 1.

2. Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.

DETAILA

MiNiMUMHEIGHT: 36'

UNiTHEIGHT

SEEDETAIL AJr

CABINET MODEL WEIGHT A B C D

Small

Large 48DU-048 543 120 90 144 189

IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to

ensure weather tight and airtight seal. When electric heat is installed, use fireproof canvas (or similar heat resistant material) connector

between ductwork and unit discharge connection. If flexible duct is used. insert a sheet metal sleeve inside duct. Heat resistant duct

connector (or sheet metal sleeve) must extend 24-in. from electric heater element.

3. Size ductwork for max possible air flow (See Table 1).

4. Seal, insulate, and weatherproof all external ductwork. Seal,

5. Secure all ducts to building structure. Flash, weatherproof,

48DU-024 420 90 90 83 155 48DU-030 427 92 92 85 158

48DU-036 515 106 119 97 193 48DU-042 537 118 84 144 192

48DU-060 594 130 95 159 210

insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and

Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors Association

(ACCA) minimum installation standards for residential heating and air conditioning systems.

and vibration-isolate duct openings in wall or roof according to good construction practices.

RIGGING

Fig. 7 - Suggested Rigging

A05161B /

CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DISCHARGE UNITS

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. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.

1. Open all electrical disconnects and install lockout tag before starting any service work.

2. Remove side duct covers to access bottom return and supply knockouts.

NOTE: These panels are held in place with tabs similar to an electrical knockout.

3. Use a screwdriver and hammer to remove the panels in the bottom of the composite unit base.

4. Ensure the side duct covers are in place to block off the horizontal air openings (See Fig. 8).

A07113

Step6--ProvideforCondensateDisposal NOTE:Ensurethatcondensate-waterdisposalmethodscomply

withlocalcodes,restrictions,andpractices. Theunitsdisposeofcondensatethrougha3/4-in.NPTfemale

fittingthatexitsonthecompressorendof the unit. Condensate water

can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations.

Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain-pan condensate

connection to prevent the pan from overflowing. Prime the trap with water. When using a gravel apron, make sure it slopes away from the

unit.

If the installation requires draining the condensate water away from the unit, install a field-supplied 2-in. trap at the condensate connection to ensure proper drainage. Condensate trap is available

as an accessory or is field-supplied. Make sure that the outlet of the trap is at least 1 in. lower than the unit drain-pan condensate

connection to prevent the pan from overflowing. Connect a drain trough using a minimum of field-supplied 3/4 -in. PVC or

field-supplied 3/4 -in. copper pipe at outlet end of the 2 -in. trap (See Fig. 9). Do not undersize the tube. Pitch the drain trough

downward at a slope of at least 1 in. for every 10 ft. of horizontal run. Be sure to check the drain trough for leaks. Prime the trap at the

beginning of the cooling season start-up. Step 7--Install Flue Hood

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury

or death.

The venting system is designed to ensure proper venting. The flue hood assembly nmst be installed as indicated in this

section of the unit installation instructions.

Install the flue hood as follows:

1. This installation must conform with local building codes and with the National Fuel Gas Code (NFGC), ANSI Z223.1 (in

Canada, CAN/CGA B149.1, and B149.2) or NFPA (National Fire Protection Association) 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. 8). Remove the

return duct cover to locate the flue hood. Remove two screws on flue panel. Place flue hood assembly over flue panel.

Orient screw holes in flue hood with holes in the flue panel.

3. Secure flue hood to flue panel by inserting a single screw on the top and the bottom of the hood.

SUPPLY DUC,T OPENING

Fig, 8 - 48DU with Duct Covers On

RETURN DUCT

OPENING

C99011

1" (25rnm) MIN

C99013

Fig. 9 - Condensate Trap

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. FPT gas inlet on the gas valve.

Install a gas supply line that runs to the heating section. Refer to Table 2 and the current edition of NFGC in the U.S. and the current

NSCNGPIC in Canada. Do not use cast-iron pipe. It is recommended that a black iron pipe is used. Check the local utility

for recommendations concerning existing lines. Size gas supply piping for 0.5 in. wc maximum pressure drop. Never use pipe

smaller than the 1/2-in. 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. wc or greater than 13 in. wc while the unit is operating. For propane applications, refer to propane

conversion kit instructions.

A 1/8-in. NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the gas valve and downstream of manual

equipment shutoff valve. When installing the gas supply line, observe local codes pertaining

to gas pipe installations. Refer to the NFGC ANSI Z223.1-2005 NFPA latest edition (in Canada, CAN/CGA B149.1).

NOTE:In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 ram).

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. for every 15 ft 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. 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. 10). This drip leg functions as a trap for dirt and

condensate.

5. Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft of heating section.

6. Install ground-joint union close to heating section between unit manual shutoff and external manual main shut off valve.

Table 2--MaxhnumGas Flow Capacity*

NOMINAL INTERNAL

IF{ON PiPE DIAMETER

SIZE (IN.) (iN.) 10 20 100 125 150 175 200

1/2 _622 175 120 50 44 40

3/4 _824 360 250 103 93 84 77 72

1 1.049 680 465 195 175 160 145 135 1-1/4 1.380 1400 950 400 360 325 300 280 1-1/2 1.610 2!00 1460 620 550 500 460 430

Capacity of pipe in cu ft of gas per hr for gas presalre of 0.5 psig or tess. Pressure drop of 0,5 in, we (based on a 0.60 specific gravity gas). Refer to Table, National Fire Protec

tion Association NFPA 54.

This length includes an ordinary number of fittings.

30 40 50 60 70 80 90

97 82 73 66 61 57 53 200 170 151 138 125 118 1!0 375 320 285 260 240 220 205 770 600 580 530 490 460 430

1180 990 900 810 750 690 650

LENGTH OF PIPE (FT)t

Step 9---Install Electrical Connections

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

OUT_

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

_¢_ 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

compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA American

National Standards Institute/National Fire Protection Association (latest edition) (in Canada, Canadian Electrical

Code CSA C22.1) and local electrical codes.

HIGH-VOLTAGE CONNECTIONS

to unit.

NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig. Pressure test the gas supply piping system at pressures equal to or less than 0.5 psig. The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground-joint union.

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 (See Table 3 for electrical data). The field-supplied disconnect may be mounted on the unit over the

high-voltage inlet hole (See Fig. 5 and 6). Operation of unit on improper line voltage constitutes abuse and

may cause unit damage that could affect warranty.

FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in fire, explosion,

personal injury, death and/or property damage.

• Connect gas pipe to unit using 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.

• 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. 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 soap-and-water solution (or method specified by local codes and/or regulations).

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit being installed.

1. Make all electrical connections in accordance with NEC ANSI/NFPA (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 i and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO

NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate.

4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are in same

conduit as high-voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

ROUTINGPOWERLEADSINTOUNIT Useonlycopperwirebetweendisconnectandunit.Thehigh

voltageleadsshouldbeinaconduituntiltheyentertheductpanel; conduitterminationattheductpanelnmstbewatertight.Runthe

high-voltageleadsthroughthepowerentryknockoutonthepower entrysidepanel.SeeFig.5and6forlocationandsize.For

single-phaseunits,connectleadstotheblackandyellowwires. CONNECTINGGROUNDLEADTOGROUNDSCREW

Connectthegroundleadtothechassisusingthegroundscrewon thecontrolplateneartheinducerswitch(SeeFig.13).

ROUTINOCONTROLPOWERWIRES FordetailedinstructiononthelowvoltageconnectionstotheUser

Interface(UI),refertotheUIinstallationguide. Formadrip-loopwiththecontrolleadsbeforeroutingthemintothe

unit.Routethelowvoltagecontrolleadsthroughgrommeted. low-voltageholeprovidedintounit(SeeFig.5and6).Connectuser

interfaceleadstounitcontrolpowerleadsasshowninFig.14. Theunittransformersupplies24-vpowerforcompletesystem

includingaccessoryelectricalheater.Transformerisfactorywired for230-voperation.Ifsupplyvoltageis208-v.rewiretransformer

primaryasdescribedinSpecialProceduresfor208-vOperation section.

Thefurnaceboardisfusedbyaboard-mountedautomotivefuse placedinserieswithtransformerSEC1andRcircuit.TheCcircuit

oftransformercircuitisreferencedtochassisgroundthrougha printedcircuitrunatSEC2andgasvalvegroundingwire.Checkto

be surecontrolboardis mountedsecurelyusingboth factory-installedscrews.

ACCESSORYINSTALLATION

A.OutdoorAirThermistor(OAT)

NOTE:THE INSTALLATIONOF AN OUTDOOR TEMPERATURESENSORUSINGTHE INFINITY

CONTROLBOARDOATTERMINALSISREQUIRED. MANY INFINITYFEATURES(AUTOHUMIDITY

CONTROL,COMFORTROLLBACK,ETC.)WILLBE LOSTIFTHEOATISNOTCONNECTED.

For detailed mounting instructions for the OAT sensm; please refer to TSTATXXSEN01-B installation instructions (catalog

no. 63TS-TA13); Procedures 1 through 3. The OAT input is used to supply outdoor temperature data for

system level functions and for temperature display on User Interface (UI). Using two wires of the field-supplied thermostat wire cable.

wire the ends of the two black OAT pigtails. Wire the opposite ends of these two wires to the OAT provided with the UI. There is no

polarity to be observed.

NOTE: Mis-wiring OAT inputs will not cause damage to either Infinity control or thermistor. If the thermistor is wired incorrectly,

no reading will appear at UI. Re-wire thermistor correctly for normal operation.

B. Humidifier Connections

The furnace control board terminal marked HUM is provided for low voltage (24-vac) control of a humidifier. No humidistat is

required as UI monitors indoor humidity. When commanded to operate humidifier, the unit control will

energize the HUM output to turn humidifier on and de-energize HUM output to turn humidifier off. Wire HUM and COM terminals

directly to humidifier as shown in Fig. 14.

C. Electronic Air Cleaner

Electronic Air Cleaner terminals are provided on the Infinity Control Board (EAC-1 and EAC-2). While these terminals can be

used to power a 230V EAC. it is recomnmnded that any EAC be installed per the EAC installation instructions and connected separately to a standard 115V or 230V outlet with an airflow sensor

to control operation of the EAC. SPECIAL PROCEDURES FOR 208-V OPERATION

Be sure unit disconnect switch is open. Disconnect the yellow primary lead from the transformer. See unit

wiring label (See Fig. 16). Connect the yellow primary lead to the transformer terminal labeled

200-v.

Fig. 11 - Typical Installation

INDOOR THERMOSTAT

FROM

POWER __ _

SOURCE

DISCONNECT PER NEC

C99061

GROUND

LEAD

GROUND SCREW

(IN SPLICE BOX)

SINGLE-PHASE CONNECTIONS

TO DISCONNECT

PER NEC

LEGEND NEC - National Electrical Code

Field Wiring

_}( Splice Connections

Fig. 12 - Line Power Connections

L1 ....... /Z_,===BLK--

NOTE: Use copper wire only.

A06299

HP/AC Board

Board

Splice Box

i :

A06306

Fig. 13 - Control Plate

User Infinity Furn_c_ Infinity HPiAC

interface Board Board

OutdoorAirThermistor

(Supplied with IU)

FIELD CONNECTION

REQUIRED

(BLACK WIRES)

| |

LEGEND

Factory Wiring

Fig. 14 - Control Voltage Wiring Connections

Table 3--Electrical Data = Unit 48DU

UNIT SIZE

V=PH_HZ

024 208/230 1 60 030 208/230 1 60 036 208/230 1 60

042 208/230 1 60 048 208/230 1 60 060 208/230 1 60

VOLTAGE

RANGE Min Max 187 253 187 253 187 253 187 253 187 253

187 253

LEGEND

FLA Full Load Amps LRA Locked Rotor Amps MCA -- Minimum Circuit Amps

MOCP Maximum Overcurrent Protection RLA Rated Load Amps

NOTES:

1. in compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC

Articles 430 and 440), the overcurrent protective de'ice for the

unit shall be Power Supply fuse. The CGA (Canadian Gas

Association) units may be fuse or circuit breaker

2. Minimum wire size is based on 60 C copper wire. Ifother than

60 C wire is used, or if length exceeds wire length in table, determine size from NEC.

3. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply volt- age is greater than 2%. Use the following formula to determine

the percentage of voltage imbalance

% Voltage imbalance

= 100x max vol_avera e volta e

Heater capacity (kW) based on heater voltage of 208v & 240v.

-k I1 power distibution voltage to unit varies from rated heater voltage, heater kW will vary accordingly.

average voltage

COMPRESSOR

RLA LRA

10.3 52.0

14.1 70.0

16.7 82.0

16.7 96.0

2! .2 96.0

25.6 118.0

OCT

Outdoor Coil Thermistor

FACTORY CONNECTED

FACTORY WIRES PROVIDED

FOR FIELD CONNECTION

OF UTILITY CURTAILMENT

OUTDOOR

FAN MOTOR

FLA

0.9

1.5

1.9

EXAMPLE: Supply voltage is 230-3-60.

A B C AB = 228 v

Determine maximum deviation from average voltage.

(AB) 229 - 228 = 1 v (BC) 231 - 229 = 2 v

(AC) 229- 227 = 2 v

Maximum deviation is 2 v. Determine percent of ,voltage imbalance

% Voltage Imbalance = 100 x --

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

INDOOR FAN

MOTOR

FLA

4.3

6.8

9.1

AC = 227 v

Average Voltage = 228 + 231 + 227

BC = 231 v

= 0.8%

POWER SUPPLY

MCA

18.0/18.0

22.8/22.8

28.5/28.5

34.7/34.7 4&1/4&1

= 686

= 229

229

MOCP

25/25 35/35 45/45

45/45 50/50 60/60

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electdc utility company immediately.

A08301

PRE- START- UP

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury

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 terminal cover is in place and

secured.

3. Do not remove compressor terminal cover until all electrical sources are disconnected and tagged.

4. Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box 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.

7. To remove a component, wear protective goggles and proceed as follows:

a. Shut off gas supply to unit.

b. Shut off electrical power to unit and install lockout

tag.

c. Relieve and reclaim all refrigerant from system

using both high- and low-pressure ports.

d. Cut component connecting tubing with tubing

cutter and remove component from unit.

e. Carefully unsweat remaining tubing stubs when

necessary. Oil can ignite when exposed to 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 all access panels.

2. Read and follow instructions on all DANGER, WARNING, CAUTION. and INFORMATION labels attached to, or shipped with unit.

3. Make the following inspections:

a. Inspect for shipping and handling damages, such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and on

unit base. Detecting oil generally indicates a refrigerant leak. Leak test all refrigerant tubing connections using

electronic leak detector, or liquid-soap solution. If a refrigerant leak is detected, see following Check for

Refrigerant Leaks section.

c. Inspect all field- and factory-wiring connections. Be

sure that connections are completed and tight.

d. Ensure wires do not touch refrigerant tubing or sharp

sheet metal edges.

e. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

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 tasks 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. Make sure that condenser-fan blade is correctly

positioned in fan orifice. Top 1/3 of condenser fan blade should be within fan orifice venturi.

c. Ensure fan hub is positioned correctly with respect to

motor housing (See Fig. 23).

d. Make sure that air filter(s) is in place.

e. Make sure that condensate drain trap is filled with water

to ensure proper drainage.

f. Make sure that all tools and miscellaneous loose parts

have been removed.

Compressors are internally spring mounted. Do not loosen or remove compressor holddown bolts.

Each unit system has two Schrader-type ports, one low-side Schrader fitting located on the suction line, and one

high-side Schrader fitting located on the compressor discharge line. Be sure that caps on the ports are tight.

START-UP

Step l--Unit Start-Up and Troubleshooting NOTE: Always check high- and low-voltage supply to the unit

components. Check the integrity of the plug receptacle connections and unit wiring harness prior to assuming a component failure.

A. LED Description

LEDs built into Infinity control boards provide installer or service person information concerning operation and/or fault condition of

the unit controls and ECM motor. This information is also available at the systenr UI in text with basic troubleshooting instructions. Careful use of information displayed will reduce the need for

extensive manual troubleshooting. Both the furnace and heat pump (HP)/air conditioner (AC) boards

have an amber LED and a green LED. On the HP/AC board, these are located near the System Communications connector (ABCD)

(lower right corner of the HP/AC board as installed in the unit). On the furnace board, these are located at the upper right side, adjacent

to the fuse. above the terminal block. The amber LED is the System Status LED, labeled STATUS. The green LED, labeled COMM, is

used as an indicator of system communications status (See Fig. 15 and 17).

Status Codes will be displayed on the STATUS LED using the following protocol:

1. The number of short flashes indicates first digit of code.

2. The number of long flashes indicates second digit of code.

3. A short flash is 0.25 seconds on. A long flash is 1 second on.

4. The time between flashes is 0.25 seconds.

5. The time between last short flash and first long flash is 1 second.

6. The LEDs will be off for 2.5 seconds before repeating code.

7. If multiple status codes are active concurrently, the highest priority status code is displayed.

B. Control Start-Up and System Communications

Troubleshooting

On power up, green COMM LEDs will be turned off until successful system communications are established (this should

happen within 10 seconds). Once communications with UI are successful, both COMM LEDs will be lit and held on. At the same

time. amber STATUS LEDs will be lit and held continuously on until a request for operating mode is received. The STATUS LED

will be on any time unit is in idle mode. If, at any time. communications are not successful for a period

exceeding 2 minutes, the Infinity control will only allow emergency heating or cooling operation using a common thermostat and the

terminal strip connections on the two control boards (See

Non-CommunicatingEmergencyCooling/HeatingMode)and willdisplayStatusCode16,SystemCommunicationFault,on amberSTATUSLED.Nofurthertroubleshootinginformationwill

beavailableatUIuntilcommunicationsarere-established. IfeitherCOMMLEDdoesnotlightwithinpropertimeperiodand

statuscodesarenotdisplayed;

1.Checksystemtransformerhigh-andlow-voltagetobesure thesystemispowered.

2.CheckABCDconnectiononbothboards.

3.Checkfuseonfurnaceboardtobesureitisnotblown.Iffuse isopen,checksystemwiringbeforereplacingittobesurea

shortdoesnotcauseafailureofreplacementfuse.

IfCOMMLEDdoesnotlightwithinpropertimeperiodandstatus codeisdisplayed:

1.ChecksystemwiringtobesureUI ispoweredand connectionsaremadeAtoA,BtoB,etc.andwiringisnot

shorted.Miswiringor shortingof the ABCD communicationswiringwill not allowsuccessful

communications.

NOTE:Shortingormiswiringlow-voltagesystemwiringwillnot causedamagetounitcontrolorUIbutmaycauselowvoltagefuse

toopen.

C.Indoor Fan Motor Troubleshooting

The indoor fan is driven by an ECM motor consisting of two parts: the control module and the motor winding section. Do not assume

motor or module is defective if it will not start. Use the designed-in LED information aids and follow troubleshooting steps described below before replacing motor control module or entire motor.

Motor control module is available as a replacement part. VERIFY MOTOR WINDING SECTION

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury

or death. After disconnecting power from the ECM motor, wait at least

5 minutes before removing the control section. Internal capacitors require time to discharge.

Before proceeding to replace a motor control module:

1. Check motor winding section to be sure it is functional.

2. Remove motor control module section and unplug winding plug. Motor shaft should turn freely, resistance between any

two motor leads should be similar and resistance between any motor lead and unpainted motor end should exceed

100,000 ohms.

3. Failing any of these tests, entire ECM motor must be replaced.

4. Passing all of the tests, motor control module alone can be replaced.

MOTOR TURNS SLOWLY

1. Low static pressure loading of blower while access panel is removed will cause blower to run slowly. Particularly at low

airflow requests. This is normal, do not assume a fault exists.

2. Recheck airflow and system static pressure using UI service screens with access panel in place.

NOTE: Blower motor faults will not cause a lockout of blower operation. The fan coil control will attempt to run the blower motor

as long as UI maintains a demand for airflow. The control will not operate electric heaters while a fault condition exists. The control communicates with the motor at least once every five seconds, even when the motor is idle. If, during operation, the control does not

communicate with the motor for more than 25 seconds, the motor will shut itself down and wait for communications to be

reestablished.

D. Furnace Control Troubleshooting

Furnace control faults indicated by flashing codes on the amber system STATUS LED can be resolved using troubleshooting

information provided below. Codes are listed in order of their priority, highest to lowest. Though multiple faults can exist at any time. only the highest priority code will be displayed on STATUS

LED. Clearing the indicated fault when multiple faults exist will cause the next highest priority Status Code to be flashed. All

existing faults, as well as a fault history, can be viewed at UI. STATUS CODE CONTINUOUS OFF

Check for 230 VAC at L1 and L2, and 24 VAC at SEC-1 and SEC-2.

STATUS CODE CONTINUOUS ON Control has 24 VAC power. STATUS CODE 11 - NO PREVIOUS CODE Stored status codes are erased automatically after 72 hours.

STATUS CODE 12 - BLOWER ON AFTER POWER UP (230 VAC or 24 VAC) Blower runs for 90 seconds if unit is powered

up during a call for heat (R-W/W1 closed) or (R-W/W1 opens) during blower on-delay period.

STATUS CODE 13 - LIMIT CIRCUIT LOCKOUT Lockout occurs if a limit or flame rollout switch is open longer than 3 minutes or 10 successive limit trips occurred during high heat.

Control will auto reset after three hours. Refer to status code 33. STATUS CODE 14 - IGNITION LOCKOUT

Control will auto reset after three hours. Refer to status code 34. STATUS CODE 15 - BLOWER MOTOR LOCKOUT

Indicates the blower failed to reach 250 RPM or the blower failed to communicate within 30 seconds after being turned ON in two

successive heating cycles. Control will auto reset after 3 hours. Refer to status code 41.

[555555

'8 o,_

A06026

Fig. 15 - Detail of Furnace Board

o I

icD i_ _ ___

I I

q_ z

A06310

Fig. 16 - Wiring Schematic-48DU Single Phase

O0 0

BN_

D E] O0 0

* SUPPLIED BY UTILITY PROVIDER

Fig. 17 - 2-Stage HP/AC Control Board

STATUS CODE 21 - GAS HEATING LOCKOUT Control will NOT auto reset. Check for mis-wired gas valve or

defective control (valve relay). STATUS CODE 22 - ABNORMAL FLAME-PROVING

SIGNAL Flame is proved while gas valve is de-energized. Inducer will run

until fault is cleared. Check for leaky gas valve or stuck-open gas valve.

STATUS (:ODE 23 - PRESSURE SWITCH DID NOT OPEN Check for obstructed pressure tubing or pressure switch stuck

closed. STATUS CODE 24 - SECONDARY VOLTAGE FUSE IS OPEN

Check for short circuit in secondary voltage (24VAC) wiring. STATUS CODE 25 - INVALID MODEL SELECTION OR

SETUP ERROR Indicates either the model plug is missing or incorrect. If code

flashes 4 times on power-up, control is defaulting to model selection stored in memory. Check for proper model plug number

and resistance values per wiring diagram. STATUS CODE 31, 32 - PRESSURE SWITCH OR RELAY DID

NOT CLOSE OR REOPENED Control relay may be defective. If open longer than five minutes,

inducer shuts off for 15 minutes before retry. If open during blower on-delay period, blower will come on for the selected blower off-delay. Check for excessive wind, restricted vent, defective

inducer motor, defective pressure switch, lower inducer voltage (230VAC), inadequate combustion air supply, disconnected or

obstructed pressure tubing, or low inlet gas pressure (if LGPS used). STATUS (:ODE 33 - LIMIT CIRCUIT FAULT Indicates a limit or flame rollout switch is open. Blower will run for

4 minutes or until open switch remakes, whichever is longer. If open longer than 3 minutes, code changes to lockout 13. If open less than

3 minutes status code 33 continues to flash until blower shuts off. Check for loose blower wheel, restricted vent, excessive wind, dirty

filter or restricted duct system, defectNe switch or connections, or inadequate combustion air supply (flame roll-out switch open).

@r]

flquld Lille Sole*xoid

A05247

STATUS CODE 34 - IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs. If flame

signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for oxide buildup on flame

sensor (clean with fine steel wool), proper flame sense microamps (.5 microamps D.C. min.. 4.0-6.0 nominal), manual valve shutoff.

low inlet gas pressure, control ground continuity, gas valve defective or turned off, flame sensor must not be grounded.

inadequate flame carryover or rough ignition, or green/yellow wire must be connected to unit sheet metal.

STATUS CODE 41 - BLOWER MOTOR FAULT Indicates the blower failed to reach 250 RPM or the blower failed

to communicate within the prescribed time limits. Thirty seconds after being turned ON or ten seconds during steady - state operation.

STATUS CODE 45 - CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to gas valve relay stuck open,

flame sense circuit failure, or software check error. Reset power to clear lockout. Replace control if status code repeats.

E. HP/AC Control Troubleshooting

See Table 5 for HP/AC control board status codes and troubleshooting information.

STATUS CODE 53, OUTDOOR AIR TEMPERATURE SENSOR FAULT - DETAILED DESCRIPTION

If an OAT sensor is found at power-up, input is constantly checked to be within a valid temperature range. If sensor is found to be open or shorted at any time after initial validation, Status Code 53 will be

displayed at amber STATUS LED. Check for faults in wiring connecting sensor to OAT terminals.

Using an Ohm meter, check resistance of thermistor for a short or open condition.

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

cycledoff.thefaultcodewillbeclearedonthenextpower-upbut thefaultwillremainandsystemoperationwillnotbeasexpected.

Thisisbecauseon power-up, the unit control cannot discern the

difference between an open sensor or ira sensor is not installed. Step 2--Sequence of Operation

The 48DU packaged unit is designed for installation with a communicating UI. This unit will not respond to commands provided by a common thermostat except under certain emergency

situations described in Step 1--Start-Up and Troubleshooting. The UI uses temperature, humidity and other data supplied from

indoor and outdoor system components to control heating or cooling system for optimum comfort. The unit will be commanded by UI to supply airflow. The unit will operate the indoor blower at

requested airflow for most modes. INDOOR AIRFLOW ADJUSTMENTS

The nominal requested airflow for air conditioner operations will be 350 cfm per ton of nominal cooling capacity as defined by unit size.

Actual airflow request will be adjusted from nominal using indoor and outdoor temperature and indoor humidity data to optimize the

system operation for occupant comfort and system efficiency. Refer to UI literature for further system control details.

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage. For cooling operation, the recommended airflow is 350 to 450

cfm 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.

For gas heat operations, Table 4 shows the temperature rise in each gas heating mode. Refer to these tables to determine the desired

heating airflow for the system being installed.

NOTE: Be sure that all supply-and return-air grilles are open. free from obstructions, and adjusted properly.Airflow can be changed using the UI. See UI installation instructions for more detail.

NOTE: Once the compressor has started and then has stopped, it should not be started again until 4 minutes have elapsed. The cooling cycle remains "on" until the room temperature drops to point that is slightly below the cooling control setting of the UI.

AIR CONDITIONER SEQUENCE OF OPERATION COOLING OPERATION

With a call for first stage cooling, the outdoor fan, and low stage compressor are energized. If low-stage cannot satisfy cooling

Table 4--Air Delivel T arid Temperature Rise at Rated Heating Input

Unit

48DU (-,N)024040 48DU (-,N)030040

48DU (-,N)030060 48DU (-,N)036060 48DU (-,N)042060

48DU (-,N)036090 48DU (-,N)042090

48DU (-,N)048090 48DU (-,N)060090

48DU (-,N)048115 48DU (-,N)060115

48DU(-,N)048130 48DU (-, N)060130

_,irflowdelivery valuestor

Rated Heating Input (Btu/hr) Heating Rise Range (°F) Heating Rise (Either Stage, °F)

High Stage Low Stage High Stage Low Stage High Stage Low Stage High Stage Low Stage

40,000 26,000

60,000 39,000

90,000 58,500

115,000 75,000

130,000 84,500

_xternai _atio pressure values of u

20 - 50

25 - 55

35 - 65

30 - 60

35 - 65

to 1 in. wc,

demand, high-stage cooling is energized by the UI. After second stage is satisfied, the unit returns to low-stage operation until first

stage is satisfied or until second stage is required again. When both first stage and second stage cooling are satisfied, the compressor will

shut off. NOTE: When two-stage unit is operating at low-stage, system

vapor (suction) pressure will be higher than a standard single-stage system or high-stage operation.

NOTE: Outdoor fan motor will continue to operate for one minute after compressor shuts off. when outdoor ambient is

greater than or equal to 100°F. UTILITY INTERFACE WITH INFINITY CONTROL

The utility curtailment relay should be connected to factory supplied pigtails (PINK. connected to R, VIOLET connected to

Y2 on the control board) located in the low voltage splice box (See Fig. 13, 14 and 16). This input allows a power utility device

to interrupt compressor operation during peak load periods. When the utility sends a signal to shut the system down, the UI

will display "Curtailment Active". COMPRESSOR OPERATION

When the compressor is operating in low stage, the modulating ring is deactivated, allowing two internal bypass ports to close off

33% of the scroll compression area so the system operates at part load capacity. The 24-volt solenoid coil is de-energized in

low-stage operation. When the compressor is operating at high stage, the modulating

ring is activated, sealing the bypass ports, which allows the compressor to operate at full load capacity. The 24-volt solenoid coil is energized in high stage operation.

CRANKCASE HEATER OPERATION (IF APPLICABLE) The crankcase heater is energized during off cycle below 65W

outdoor air temperature. OUTDOOR FAN MOTOR OPERATION

The outdoor unit control energizes the outdoor fan any time the compressor is operating. The outdoor fan remains energized if a pressure switch or compressor overload should open. Outdoor fan

motor will continue to operate for one minute after the compressor shuts off when the outdoor ambient is greater than or

equal to 100'_F. TIME DELAYS-AIR CONDITIONER OPERATIONS

The unit time delays include:

• Five minute time delay to start cooling operation when there is a call from the thermostat or user interface. To

bypass this feature, momentarily short and release

Forced Defrost pins.

"Efficiency .... Comfort"

15-45

25 - 55

35 - 65

30 - 60

35 - 65

35 30

4O 35

Table5--HEAT PUMP/AIR CONDITIONER BOARD STATUS CODES

AMBER

OPERATION FAULT POSSIBLE CAUSE AND ACTION

Standby no call for unit opera- On solid, tion None no flash Normal operation.

Emergency Mode mostat Control tinuous ity Control. Only high stage operation is available. This operating

Low Stage Cool/Heat Operation None 1, pause Normal operation. High Stage Coot/Heat Opera-

tion None 2, pause Normal operation.

Standard Ther- Rapid, con- Unit being controlled by standard thermostat inputs instead of Infin-

System Commu- 16 Communication with UI lost. Check wiring to UI, indoor and outdoor

nications Failure units. Invalid Model 25 Control does not detect a model plug or detects an invalid model

Plug plug. Unit will not operate without correct model plug. High-Pressure 31 High-pressure switch trip. Check refrigerant charge, outdoor fan

Switch Open operation and coils for airflow restrictions.

Low-Pressure 32 Low-pressure switch trip. Check refrigerant charge and indoor air

Switch Open flow. Control Fault 45

Brown Out 46 Line voltage < 187v for at least 4 seconds. Compressor and fan (230 v) operation not allowed until voItage>190v. Verify line voltage.

No 230v at Unit 47 cooling/heating demand exists. Verify the disconnect is closed and

Outdoor Air Temp Sensor 53

Fault

Outdoor Coil 55 Coii sensor not reading or out of range. Ohm out sensor and check Sensor Fault wiring.

Thermistors Out 56 Improper relationship between colt sensor and outdoor air sensor. of Range Ohm out sensors and check wiring.

Low Stage Ther- mal Cutout 71 ing demand exists. Possible causes are internal compressor over-

High Stage Ther- mal Cutout 72 ing demand exists. Possible causes are internal compressor over-

Contactor Compressor voltage sensed when no demand for compressor op- Shorted

No 230V at 74 Compressor voltage not sensed when compressor should be start-

Compressor ing. Contactor may be stuck open or there is a wiring error.

Low Stage Ther- 81 Thermal cutout occurs in three consecutive low/high stage cycles. mal Lockout Low stage locked out for 4 hours or untiI 24v power recycled.

High Stage Ther- 82 Thermal cutout occurs inthree consecutive high/tow stage cycles. mal Lockout High stage locked out for 4 hours or until 24v power recycled.

Low-Pressure Low-pressure switch trip has occurred during 3 consecutive Lockout

High- Pressure Lockout 84 cycles. Unit operation locked out for 4 hours or untiI 24v power

LED

FLASH

CODE

flashing mode should be used in emergency situations only.

Outdoor unit control board has failed. Control board needs to be replaced.

There is no 230v at the contactor when indoor unit is powered and

230v wiring is connected to the unit. Outdoor air sensor not reading or out of range. Ohm out sensor

and check wiring.

Compressor voltage sensed, then disappears while cooling or heat-

Ioad trip or start relay not releasing (if installed). Compressor voltage sensed, then disappears while cooling or heat-

Ioad trip or start relay not releasing (if installed).

73 eration exists. Contactor may be stuck closed or there is a wiring

error.

83 cycles. Unit operation locked out for 4 hours or untiI 24v power

recycled.

High-pressure switch trip has occurred during 3 consecutive

recycled.

• Five minute compressor recycle delay on return from a brown-out condition.

• Two minute time delay to return to standby operation from last valid communication (with Infinity only).

• One minute time delay of outdoor fan at termination of cooling mode when outdoor ambient is greater than or

equal to 100°1=.

• There is no time delay between air conditioner staging from low to high and from high to low capacity; the

compressor will change from low to high and from high to low capacity as demand dictates.

INFINITY CONTROLLED LOW AMBIENT COOLING

NOTE:When this unit is operating below 55°F outdoor temperature, provisions must be made for low ambient operation. This unit is capable of low ambient cooling ONLY when using the Infinity control. A low ambient kit is not required, and the outdoor

fan motor does not need to be replaced for Infinity controlled low ambient operation. Low ambient cooling must be enabled in the

UI set-up. Fan may not begin to cycle until about 40 °F OAT. Fan will cycle based on coil and outdoor air temperature. Infinity

controlled low ambient mode operates as follows:

• Inhighstage,fanisoffwhenoutdoorcoiltempis<outdoor airtemperature+3WoroutdoorfanhasbeenONfor30 minutes.(Fanisturnedofftoallowrefrigerantsystemto

stabilize.)

• Inlowstage,fanisoffwhenoutdoorcoiltempis<outdoorair temperature+1"ForoutdoorfanhasbeenONfor30minutes.

(Fanisturnedofftoallowrefrigerantsystemtostabilize.)

• Inhighstageandlowstage,fanisonwhenoutdoorcoiltemp >outdoorairtemperature+25°Foroutdoorcoiltemp>80°F

orifoutdoorfanhasbeenOFFfor30minutes.(Fanisturned ontoallowrefrigerantsystemtostabilize.)

• Low-pressureswitchisignoredforfirst3minutesduringlow ambientstartup.After3minutes,ifLPStrips,thenoutdoor

fanmotoristurnedofffor10minuteswiththecompressor running.If LPScloseswithin10minutesthencooling continueswiththeoutdoorfancyclingperthecoil

temperatureroutinelistedabovefortheremainderofthe coolingcycle.IftheLPSdoesnotclosewithin10minutes,

thenthenormalLPStripresponse(shutdowncooling operationandgenerateLPStriperror)willoccur.

DEHUMIDIFICATIONMODE ThisInfinitysystemcanbeusedtodehumidifythelivingspace.See

UIInstallationInstructionsformoredetails. SEQUENCEOFOPERATION-GASHEAT

NOTE:Infinitycontrolmustbegroundedforproperoperationor controlwilllockout.

NOTE:Ifapowerinterruptionoccursduringacallforheat.the controlwillstarta90-secondbloweronlyONperiodtwoseconds afterpowerisrestored,iftheUIisstillcallingforgasheating.The amberLEDlightwillflashcode12duringthe90-secondperiod, afterwhichtheLEDwillbeONcontinuously,aslongasnofaults aredetected.Afterthe90-secondperiod,theunitwillrespondtothe UInormally.

GASHEATMODEANDADJUSTMENTS WhentheUIcallsforgasheat,theInfinityfurnaceboardperforms

aself-check,verifiesthepressureswitchisopen,andstartsthe induceronhighspeed.

1.InducerPre-purgePeriod:Whentheinducermotorcomes uponhighspeed,thepressureswitchcloses,andtheInfinity

ignitioncontrolonthefurnaceboardbeginsa15second pre-purgeperiod.If thepressureswitchfailstoremain

closed,theinducerwillremainrunning.Afterthepressure switchre-closes,theInfinityignitioncontrolwillbegina15

secondpre-purgeperiod.

2.Trial-For-IgnitionSequence:Thesparkigniterwillspark for3seconds.Themaingasvalverelaycontactclosesto

energizethegasvalveonlowstage.After5seconds,the igniteris de-energizedanda 2-secondflame-proving

periodbegins.NOTE:Theunitalwayslightsonhighspeed inducerandlowstagegasvalveoperation.

3.Flame-Proving:Whentheburnerflameisprovedatthe flame-provingsensor,thefurnacecontroldetermineswhat heatingstagetorunbasedonfeedbackfromtheUI.IftheUI

isaskingforlowstagegasheat,theignitioncontrolwill changetheinducerspeedtolowspeedandkeepthegasvalve

energizedonlowstage.IftheUIisaskingforhighstagegas heat,theignitioncontrolwillmaintainrunningtheinducer

onhighspeedandenergizethegasvalve'shighstagerelay toincreasegasflow.

Iftheburnerflameisnotprovedwithin2seconds,thecnntrolwill closethegasvalveandrepeattheignitionsequenceupto3more

Trials-For-IgnitionbeforegoingtoIgnition-Lockout.Lockout willresetautomaticallyafter3hours,bymomentarilyinterrupting

230VACpower,orbyinterrupting24VACpoweratSEC1orSEC2 tothefurnaceboard.

Ifflameisprovedwhenthereshouldbenoflamepresent,control willlockoutofGas-Heatingmodeandoperatetheinducermotor

untilflameisnolongerproved.

4.Blower-OnDelay: If theburnerflameis proven. approximately37secondsafterthegasvalveisopenedthe

IndoorBloweristurnedontotheappropriatespeedforthe gasheatingstage.

Simultaneously,thehumidifierterminalHUMandelectronicair cleanerterminalEAC-1areenergizedthroughouttheheatingcycle.

NOTE:EAC-2terminaliscommonwithL2andwillhave 115VAC-to-groundwhenunitispowered.

5.Blower-OffDelay:Whenthecallforgasheatissatisfied,the gasvalveisde-energized,stoppingtheflowofgastothe

burners,andde-energizingtheHUMterminal.Theinducer motorwillremainonfora4-secondpost-purgeperiod.The

indoorblowerandaircleanerterminalEAC-1willremain energizedfor90,120,150,or180seconds(dependingon

selectionofblower-offdelayselectedintheUI). The factory-setdefaultis120-secondblower-OFFdelay.

CHECKGASINPUT(NATURALGAS)

UNITDAMAGEHAZARD Failuretofollowthiscautionmayresultin component

damageduetoflanmimpingementofburnersandheat exchangers.

Do not redrillan orifice.Improperdrilling(burrs, out-of-roundholes,etc.)cancauseexcessiveburnernoise andmisdirectionofburnerflame.If orificeholeappears damagedoritissuspectedtohavebeenredrilled,checkorifice

holewithanumbereddrillbitofcorrectsize.

FIREHAZARD Failuretofollowthiswarningcouldresultinpersonalinjury,

deathand/orpropertydamage. DONOTbottomoutgasvalveregulatoradjustingscrews.

Thiscanresultinunregulatedmanifoldpressureandresultin excessoverfireandhetexchangerfailures.

CARBONMONOXIDEPOISONINGHAZARD Failuretofollowthiswarningcouldresultinpersonalinjury,

deathand/orpropertydamage. If themanifoldpressureand/orgasrateisnotproperly

adjustedonHIandLOstages,excesscarbonmonoxidecanbe produced.

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 of the ranges listed in Table 7.

Gasinputratesonratingplateareforinstallationsataltitudesupto 2000ft. Inputratemustbewithin_+2%ofratingplateinput.

1.Determinethecorrectgasinputrate. a.TheratedgasinputsshowninTable4areforaltitudes

fromsealevelto2000ftabovesealevel.Theseinputsare basedonnaturalgaswithaheatingvalueof1050Btu/ft3 at.65specificgravity.

INTHEU.S.A.: Theinputratingforaltitudesabove2,000ft.mustbereducedb,4

percentforeach1,000ft.abovesealevel. Forinstallationsbelow2,000ft.,refertotheunitratingplate.

Forinstallationsabove2,000ft.,multiplytheinputbyontherating platebythederatemultiplierinTable6forthecorrectinputrate.

Table6--AltitudeDerateMultiplierfurU.S.A.

Altitude (FQ Percent of Derate Facto_

0-2000 0 1.00

2001-3000 8-12 0.90 3001-4000 12-16 0.86 4001-5000 18-20 0.82 5001-6000 20-24 0.78

6001-7000 24-28 0.74 7001-8000 28-32 0.70 8001-9000 32-36 0.86

9001-10,000 38-40 0.82

:-Deratemultiplier fuctors are based on midpoint altitude for altitude range. IN CANADA:

The input rating for altitudes from 2,000 to 4,500 ft above sea level must be derated 10 percent by an authorized Gas Conversion Station

or Dealer. EXAMPLE:

90.000 Bhuh Input Furnace Installed at 4300 Ft. Furnace Input Rate Derate Multiplier Furnace Input Rate

at Sea Level X Factor at Installation Altitude

90,000 X 0.90 81,000

b. 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.

2. Adjust manifold pressure to obtain low stage input rate (See

Fig. 18).

a. Turn off gas supply to unit.

b. Remove pipe plug on manifold (See Fig. 19) and connect

manometer. Turn on gas supply to unit.

c. Turn gas valve switch to ON. d. Set unit to run for 20 minutes in low-stage gas heat

operation using the "INSTALLER CHECKOUT" menu on the User Interface.

e. Remove regulator adjustment cap from low stage gas

valve pressure regulator (See Fig. 18) and turn low-stage adjusting screw (3/16 or smaller flat-tipped screwdriver)

counterclockwise (out) to decrease rate and clockwise (in) to increase input rate.

DerateMultiplier

1/2" NPT INLET

A04167

Fig. 18 - Redundant Automatic Gas Control Valve

NOTE: DO NOT set low stage manifold pressure less than 1.4 in wc or more than 2.0 in wc for natural gas. If manifold pressure is outside this range, change main burner orifices.

f. Re-install low stage regulator adjustment cap.

g. Leave manometer connected.

NOTE: If orifice hole appears damaged or it is suspected to have been re-drilled, check orifice hole with a numbered drill bit of the

correct size. Never re-drill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics.

3. Verify natural gas low stage input rate. a. Turn off all other gas appliances and pilots served by the

gas meter.

b. If unit is not running, set unit to run for 20 minutes in

low-stage gas heat operation using the "INSTALLER CHECKOUT" menu on the UI.

c. Record number of seconds for gas meter to complete one

revolution.

d. Divide number of seconds in step c. into 3600 (number

of seconds in 1 hour).

e. Multiply result of step d. by the number of cubic feet

shown for one revolution of test dial to obtain cubic feet of gas flow per hour.

f. Multiply result of step f. by Btu heating value of the gas

to obtain total measured input shown in Table 4. (Consult the local gas supplier if the heating value of gas is not

known).

EXAMPLE: Assume a 90,000 high stage input unit is being installed. Assume that the size of the dial is 2 cubic ft.. one

revolution takes 129 sec., and the heating value of the gas is 1050 Btu/ft3. Proceed as follows:

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 nominal 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. If the measured low stage rate is too high, decrease the manifold pressure to decrease rate.

NOTE: Double-check that UI is running on low stage gas heat while clocking the low stage firing rate.

4. Verify proper low stage gas heat temperature rise.

a.Furnacemustoperatewithinriserangelistedonrating

plate.

b.Select"COMFORT"or"EFFICIENCY"modeonUI.

"COMFORT"modewillprovideawarmersupplyair temperature,while"EFFICIENCY"willprovidelower

gasconsumption.

c.Makesureaccesspanelisre-installedontheunit. d.Measuresupplyandreturntemperaturesasclosetothe

unitaspossible.Subtractthereturntemperaturefromthe supplytemperaturetodeterminerise.Rise should fall

within the range specified on the rating plate.

5. Adjust manifold pressure to obtain high stage input rate (See Fig. 18).

a. Set unit to run for 20 minutes in high-stage gas heat

operation using the "INSTALLER CHECKOUT" menu on the UI.

b. Remove regulator adjustment cap from high stage gas

valve pressure regulator (See Fig. 18) and turn high-stage adjusting screw (3/16 or smaller flat-tipped screwdriver)

counterclockwise (out) to decrease rate and clockwise (in) to increase input rate.

NOTE: DO NOT set high stage manifold pressure less than 3.2 in wc or more than 3.8 in wc for natural gas. If manifold pressure is outside this range, change main burner orifices.

c. Re-install high stage regulator adjustment cap. d. Leave manometer connected.

6. Verify natural gas high stage input rate.

a. Turn off all other gas appliances and pilots served by the

gas meter.

b. If unit is not running, set unit to run for 20 minutes in high

stage gas heat operation using the "INSTALLER CHECKOUT" menu on the UI.

c. Record number of seconds for gas meter to complete 1

revolution.

d. Divide number of seconds in step c. into 3600 (number

of seconds in 1 hour).

e. Multiply result of step d. by the number of cubic feet

shown for one revolution of test dial to obtain cubic feet of gas flow per hour.

f. Multiply result of step f. by Btu heating value of the gas

to obtain total measured input shown in Table 4. (Consult the local gas supplier if the heating value of gas is not

known).

EXAMPLE: Assume a 90,000 high stage input unit is being installed. Assume that the size of the dial is 2 cubic ft., one

revolution takes 84 sec., and the heating value of the gas is 1050 Btu/ft3. Proceed as follows:

a. 84 sec. to complete one revolution

b. 3600/84 = 42.9

c. 42.9 x 2 = 85.8 ft3 of gas flow/hr. d. 85.8 x 1050 = 90,090 Btuh input.

In this example, the nominal input rate for high stage is 90,000 Btu/hr, so the high stage manifold pressure is correctly set.

If the measured high stage rate is too low, increase the manifold pressure to increase rate. If the measured high stage rate is too high,

decrease the manifold pressure to decrease rate.

NOTE:Double-check that User Interface is running on high stage gas heat while clocking the low stage firing rate.

7. Verify proper high stage gas heat temperature rise. a. Furnace must operate within rise range listed on rating

plate.

b. Make sure access panel is re-installed on the unit.

c. Measure supply and return temperatures as close to the

unit as possible. Subtract the return temperature from the supply temperature to determine rise. Rise should fall

within the range specified on the rating plate.

NOTE: If the temperature rise is outside the rating plate range, first check:

a. Gas input for low and high stage gas heat operation.

b. Derate for altitude, if applicable.

c. Return and supply ducts for excessive restrictions

causing static pressures in excess of .5 in. wc.

d. Make sure model plug is installed.

8. Final Check

a. Turn off gas to unit

b. Remove manometer from pressure tap.

c. Replace pipe plug on manifold (See Fig. 19).

d. Turn on gas to unit.

e. Check for leaks.

CHECK GAS INPUT (PROPANE GAS) Refer to propane kit installation instructions for properly checking

gas input.

NOTE: For installations below 2.000 ft., refer to the unit rating plate for proper propane conversion kit. For installations above 2,000 ft, contact your distributor for proper propane conversion kit.

CHECK BURNER FLAME

With burner access panel 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. 20). Refer to the Maintenance section for information on burner removal.

MANIFOLD PIPE PLUG

C99019

Fig. 19 - Burner Assembly

BURNERFLAME

__ _ _RNER

C99021

Fig. 20 - Monoport Burner

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 and pilot. The blower

motor continues to run until LS resets. The furnace board STATUS LED will display STATUS (:ODE 33.

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.

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 fan

motor (IFM) continues to run until switch is reset. The furnace board STATUS LED will display STATUS (:ODE 33.

CONTINUOUS FAN MODE

When continuous fan operation is requested by the UI indoor fan motor will operate at continuous blower airflow. Continuous fan operation is programmable. See the UI Owner's Manual for detailed

instructions. Terminal EAC- 1 is energized as long as the indoor fan motor is energized.

During a call for gas heat. the Infinity control will transition the indoor fan motor to continuous blower airflow or gas heat airflow,

whichever is lowest. The indoor fan motor will remain ON until the burners ignite, then shut OFF and remain OFF for the blower-ON delay allowing the heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period.

The indoor fan motor will revert to continuous-blower airflow after the gas heating cycle is completed.

When the UI "calls for cooling", the indoor fan motor will switch to operate at cooling airflow. When the call for cooling is satisfied, the

indoor fan motor will operate an additional 90 seconds at cooling airflow before transitioning back to continuous-blower airflow.

When the call for continuous fan is removed, the indoor blower will continue operating for an additional 5 seconds before shutting down, if no other function requires blower motor operation.

COMPONENT TEST The Infinity Furnace Board features a gas component test system to

help diagnose a system problem in the case of a gas component

failure. To initiate the component test procedure, ensure that there 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 SWl-6.

NOTE: The component test feature will not operate if the control is receiving any UI signals or until all time delays have expired.

The component test sequence is as follows:

1. The control turns the inducer motor ON and keeps it ON

through step 3.

2. After waiting 10 seconds, the control turns the igniter ON for

15 seconds, then OFF.

3. The control then turns the indoor fan motor on for 15

seconds, then OFF.

4. After shutting the blower motor OFF. the control runs the inducer for 10 seconds, then turns it OFF.

NOTE: The EAC terminals are energized when the blower is operating.

After the component test is completed, one or more status codes (11, 25, or 41) will flash. See component test section or Status Code

Label for explanation of status codes.

NOTE: To repeat component test, turn setup switch SWl-6 to OFF and then back ON.

Step 3--Check for Refrigerant Leaks Locate and repair refrigerant leaks and charge the unit as follows:

1. Use both high- and low-pressure ports to relieve system pressure and reclaim remaining refrigerant.

2. Repair leak following accepted practices.

NOTE: Install a filter drier whenever the system has been opened for repair.

3. Check system for leaks using an approved method.

4. Evacuate refrigerant system and reclaim refrigerant if no additional leaks are found.

5. Charge unit with Puron (R-410A) refrigerant, using a volumetric-charging cylinder or accurate scale. Refer to unit

rating plate for required charge.

Step 4_Start-Up 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 unit in cooling mode

when the outdoor temperature is below 40°F (unless low-ambient operation is enabled in the UI). Do not rapid cycle the compressor.

Allow 5 min. between "on" cycles to prevent compressor damage. CHECKING COOLING AND HEATING CONTROL

OPERATION

See UI Installation Instructions for detailed system CHECKOUT. CHECKING AND ADJUSTING REFRIGERANT CHARGE

The refrigerant system is fully charged with Puron (R-410A) refrigerant and is tested and factory sealed.

NOTE: Any adjustment to refrigerant charge must be done with unit operating in HIGH stage.

NOTE: Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R-410A charge. 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 outside of the unit.

Table 7--Heating Inputs

HEATING INPUT (BTU/NR)*

High Stage

40,600 60,000 90,600

1!5,000

130,000

Cubit ft of natural gas per hour for gas pressures of .5 psig (14 in. we) or less and a pressure drop of .5 in. we (based on a .60 specific gravity gas). Ref: Table 12.2 ANSI Z223 2002iNFPA 54 2002.

Low Stage

26,066 39,666 58,500

75,000 84,500

NUMBEROF

ORIFICES

2 3 3 3 3

IMPORTANT: 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.

GAS SUPPLY PRESSURE (in, we) MANIFOLD PRESSURE (in, we)

Min

4.0

Natural

Max

13.0

High Stage

3.2- &8

Natural

Low Stage

1.4 - 2.0

TO USE COOLING CHARGING CHARTS

Take the liquid line temperature and read the manifold pressure gauges.

Refer to the chart to determine what the liquid line temperature should be.

REFRIGERANT CHARGE

NOTE: If the problem causing the inaccurate readings is a

The amount of refrigerant charge is listed on the unit rating plate and/or the physical data table. Refer to the Refrigeration Service

Techniques Manual. Refrigerants Section. NO CHARGE

Check for leak. Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant (refer to system rating plate).

LOW CHARGE COOLING

Use Cooling Charging Chart (Fig. 22). Vary refrigerant until the conditions of the chart are met. Note that charging charts are different from type normally used. Charts are based on charging the

units to correct subcooling for the various operating conditions. Accurate pressure gauge and temperature sensing devices are

required. Connect the pressure gauge to the service port on the suction line. Mount the temperature sensing device on the suction

line and insulate it so that the outdoor ambient does not affect the reading. Indoor air CFM must be within the normal operating range

of the unit.

refrigerant leak, refer to Check for Refrigerant Leaks section.

NON-COMMUNICATING EMERGENCY COOLING / HEATING MODE: 4-WIRE THERMOSTAT

This mode of operation is provided only in the case where the UI has failed or is otherwise unavailable. If communications cannot be

established with the UI. the Infinity furnace board will enable the standard thermostat input terminals to allow simple thermostatic

control of the 48DU unit. For control with a standard thermostat, disconnect the ABCD

connectors from both control boards and using No. 18 AWG color-coded, insulated type 90°C minimum or equivalent wire. make the connections between the standard thermostat, the furnace

board, and the HP/AC board per Fig. 21. Recommend the use of interconnecting wire with 105C, 600V, 2/64" insulation.

The Infinity control will respond to cooling and heating demands with the maximum safe airflow based on gas furnace output and unit

cooling capacity.

Table 8--ECM Wet (?oil Pressure D_)p (in. wc)

UNiT STANDARD OFN(SCFN) SUZE 800 700 800 900 1000 1100 1900 1300 1400 1500 1800 1700 1800 1900 2000 2100

094 0005 0.007 0.010 0.012 0015 030 0.007 0.010 0.012 0015 0018 0021 0024 038 0.019 0023 0027 0032 0037 0042 0047 042 0014 0017 0020 0024 0027 0031 0035 0.039 0.043 048 0027 0032 0036 0041 0046 0.052 0.057 0.063 0068 060 0029 0032 0.036 0.040 0.045 0049 0053

Table 9--Filter Pressure D_-op Table (in. wc)

FILTER SIZE

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

CFM

20X20X1 0.05 0.07 0.08 0.1 0.12 0.13 0.14 0.15

24X30X1 0.05 0.6 0.07 0.07 0.08 0.09 0.1 24X36X1 0.06 0.07 0.07 0.08 0.09 0.09 0.10 0.11 0.12 0.13 0.14 0.14

Standard

4,,Wire

Thermostat

infinity Furnace infinityHP/AC

Board Board

RUM

OCT

Outdoor Air Thermistor

(Supplied with Ig)

FIELD CONNECTION

REQUIRED

(BLACK WIRES)

OutdoorCoiUThermistor FACTORYCONNECTED

Fig. 21 - Non-Communicating Emergency Cooling/Heating Wiring Connections

Required 8ubcoo_ing °F (°¢)

' Outdoor Ambient Terr :}erature

Model Size 75/24) 85 (29) 95 (35} 105/41!

024 155(86) 157(87) 158i88) 159(89) 030 168(93) 1¢4(91 ) 162{9) 156{87) 15(83) 035 14(77) 139(77) 139(77) 138(77) 137(76)

042 1182/I07) 191(106 191/106) 189/105) 187(104) 048 21_ 11_6 208(11_5} 207(115) 204(113) 202(112/ 060 162(9) 186(92) 168(93) 173(96) 178(99)

¢ harrU!,j£_Procedure

/ Meas_re Discha ge line p_ess_re by attaching a 9auge to the serv ce f_od

2 Measure the Liquid _f_e temperature by attachm_ a tempe_at_ sensi_g device to _t 3 h_su_ate _he temperature sensing device so tha_ the OuWoo_ Afl_b_e_t does1/t _ect the read_l/_

4 Refe_ to t_e _qui_ed Subcoo_i_g in the table based o_ the mode_ size an_ the Outdoor Ambient temperature

5 Interpolate ifthe O_tdoor tempem_re I_es _1/_etween _e table vak_es Fxtra_o_ate _fthe temperature _;es beyond the table ravage

6 F_n_ _e Pressure Vak_e corres_ondi_g to the the measured Fl_Ssure o_ the Compressor D_schar_e _i_e

7 Read across f_m the P_essure read_l_ to obtain the Liquid li_e tem_e_at_ _ a _equired Subcoolmg

8 A_d Cha_e if t_e measu_d temper_ure is _igher than _e I_qu_d_e temperature va_ue _nthe table

9 A_d Chal_e using the se_ce connection on the S_ct_on I_l_eof _e COm_l_ssor

Fig. 22 - Cooling Charging Table-Subcooling

FORFIELDCONNECTION

OFUTiLiTYCURTNLMENT

Required Liquid L{ne Temperature for a Spec{fic Subcoolir_g (R-410A}

uired Subcoolin_ Re luired 8ubcoolin_/°C)

{_i_) 5 10 15 25 (kPa) 3 5 8 14

174 56 51 46 36 1200 13 11 8 2 181 59 54 49 39 1248 15 12 9 4

188 61 56 51 41 1296 16 13 10 5 195 63 58 53 43 1344 I7 14 12 6

202 65 60 55 45 1393 I8 16 13 7 209 67 62 57 47 1441 20 17 14 9

216 68 84 59 49 1489 21 18 15 10 223 71 86 61 5I 1537 22 19 16 11

189 61 56 51 41 1303 16 13 11 5

196 63 58 53 43 1351 17 15 12 6 203 66 61 56 46 1399 19 16 13 8 210 68 83 58 48 1448 20 17 14 9

70 65 60 50 1496 21 18 15 10 72 67 82 52 1544 22 19 16 11 74 89 64 54 1593 23 20 18 12

76 71 66 56 1641 24 21 19 13 245 77 72 67 57 1689 25 22 25 14 252 79 74 69 59 1737 26 23 21 15 260 81 76 71 61 1792 27 25 22 16

268 83 78 73 63 1848 29 26 23 17 276 85 80 75 85 1903 30 27 24 19

284 87 82 77 87 1958 31 28 25 20 292 89 84 79 69 2013 32 29 26 21

300 91 86 81 71 2068 33 30 27 22 309 93 88 83 73 2130 34 31 28 23

318 95 90 85 75 2192 35 32 29 24 327 97 92 87 77 2254 36 33 31 25

336 99 94 89 79 2316 37 34 32 26 345 I01 96 91 81 2378 38 35 33 27 354 I03 98 93 83 2440 39 36 34 28 364 I05 100 95 85 2509 40 38 35 29

374 107 102 97 87 2578 41 39 36 30 384 I08 103 98 88 2647 42 40 37 31

394 I10 105 I00 90 2716 44 41 38 32

404 112 I07 102 92 2785 45 42 39 33 414 114 109 104 94 2854 46 43 40 34

424 116 Ill 106 96 2923 47 44 41 35 434 118 I13 108 98 2992 48 45 42 36

444 119 I14 109 99 3061 48 46 43 37 454 121 116 111 101 3135 49 47 44 38

464 123 I18 113 I03 3199 50 48 45 39 474 124 I19 114 I04 3268 51 48 46 40 484 126 I21 116 I06 3337 52 49 47 41

494 127 I22 117 I07 3406 53 50 47 42

504 I29 124 I19 109 3475 54 51 48 43 514 I31 126 I21 111 3544 55 52 49 44

524 I32 127 I22 112 3612 56 53 50 45 534 134 129 124 114 3681 56 54 51 45

FressureFressure

A06302

A06315

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 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 possible 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 serious injury

or death:

1. Turn off electrical power to the unit 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.

Inspect air filter(s) at least once each month and replace (throwaway-type) or clean (cleanable-type) at least mqce during each cooling season and twice during the heating season, or

whenever the filter becomes clogged with dust and lint. Step 2--Indoor Fan 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. Step 3--Inducer Blower NOTE: All motors are pre-lubricated. Do not attempt to lubricate

these motors. Clean periodically to assure proper airflow and heating efficiency.

Inspect blower wheel every fall and periodically during the heating season. For the first heating season, inspect blower wheel bi-monthly to determine proper cleaning frequency.

Step 4_Limit Switch Remove unit access panel to gain access to the limit switch. The limit

switch is located above the indoor blower housing. NOTE: On small chassis units, a second limit switch is located

beside the indoor blower housing. Step 5--Burner Ignition

Unit is equipped with a direct spark ignition 100 percent lockout system. Ignition module is located in the control box. Refer to

additional information in the Start-Up & Troubleshooting section for Status Code information.

Step 6---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.

UNIT OPERATION HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to

disconnecting when servicing.

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. (?lean when necessary.

3. Inspect indoor fan motor and wheel for cleanliness each cooling season. (?lean when necessary.

4. Check electrical connections for tightness and controls for proper operation each cooling season. Service when necessary.

5. Check for restrictions on inducer outlet. (?lean flue hood.

6. Inspect burner compartment before each heating season for rust. corrosion, soot or excessive dust.

7. Inspect all accessories. Perform any service or maintenance to the accessories as recommended in the accessory

instructions.

Step 1--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.

EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in equipment damage

or improper operation. When servicing gas train, do not hit or plug orifice spuds.

Removal of Gas Train

To remove the gas train for servicing:

1. Shut off main gas valve.

2. Shut off power to unit.

3. Remove unit access panel.

4. Disconnect gas piping at unit gas valve.

5. Remove wires connected to gas valve. Mark each wire.

6. Remove ignitor and sensor wires at the ignitor module.

7. Remove the mounting screw that attaches the burner rack to the unit base.

8. Slide the burner rack out of the unit.

9. To reinstall, reverse the procedure outlined above.

Step 7--Inducer Pressure Switch Inspect pressure switch connections. Inspect pressure switch tube

for cracks or restrictions. Replace if needed.

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 and lubricating the blower motor and wheel.

Step8---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.

Step 9--Outdoor Fan

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unit components.

Keep the outdoor fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the

unit.

1. Remove 4 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 according to the table shown in Fig. 23.

6. Ensure that set screw engages the flat area on the motor shaft when tightening.

7. Replace grille.

Infinity Top

A06035

UNIT SIZE "A" DIMENSION (ram)

024 26 030 26

036 26 042 26 048 9 060 14

Fig. 23 - Outdoor Fan Blade Clearance

Step 10--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 panel to locate all the electrical controls 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. Step ll--Refrigerant Circuit

Inspect all refrigerant tubing connections and the unit base for oil accumulation annually. Detecting oil generally indicates a

refrigerant leak. If oil is detected or if low 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 Check for

Refrigerant Leaks section. If no refrigerant leaks are found and low performance is suspected.

refer to Checking and Adjusting Refrigerant Charge section. Step 12--Indoor 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.

Step 13--Pressure Switches - Refrigerant Circuit Pressure switches are protective devices integrated into the 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.

Loss-of-Charue (Low Pressure) Switch This switch is located on the liquid 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 if the system

pressure drops to about 20 psig. If system pressure is above this, switch should be closed.

Hiuh-Pressure Switches (HPS & HPS2) The high-pressure switches are located on the discharge line and

protects against excessive condenser coil pressure. HPS opens at 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 have continuity on a good 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 psi. Never open system without breaking vacuum with dry nitrogen.

Step14--('opeland Scroll Compressor (Puron Refrigerant)

The compressor used in this product is specifically designed to operate with Puron (R-410A) refrigerant and cannot be

interchanged.

Tire 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.

EXPLOSION, FIRE 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.

The scroll 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. Tire compressor is equipped with an anti-rotational device and an internal pressure-relief port. The anti-rotational

device prevents the scroll from turning backwards and replaces the need for a cycle protector. The pressure-relief port is a safety device,

designed to protect against extreme high pressure. The relief port has an operating range between 550 and 625 psi differential

pressure.

The Copeland scroll compressor uses Mobil 3MA POE oil. This is the only oil allowed for oil recharge.

Step 15--Refi'igerant System

This step covers the refrigerant system of the 48DU, including the compressor oil needed, servicing systems on roofs containing synthetic materials, the filter drier, and refrigerant charging.

REFRIGERANT

UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury

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 mustbe designed to handle Puron. If vou are unsure, consult the equipment manufacturer.

COMPRESSOR OIL The compressor in this system uses a polyolester (POE) oil, Mobil

3MA POE. 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, and replacing

refrigerant components such as filter drier, pressure switch, metering device, coil, accumulator, or reversing valve.

Synthetic Roof Precautionary Procedure

1. (?over extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an

approximate 10 X 10 ft 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 The filter drier is specifically designed to operate with Puron. 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 units with cylinder in upright position and a commercial metering device in manifold

hose. Charge refrigerant into suction line.

TROUBLESHOOTING

LED DESCRIPTION LEDs built into Infinity control boards provide installer or service

person information concerning operation and/or fault condition of the unit controls and ECM motor. This information is also available

at the system UI in text with basic troubleshooting instructions. Careful use of information displayed will reduce the need for extensive manual troubleshooting. See section B in Start-Up &

Troubleshooting and Table 5, as well as the UI instructions, for additional information. Additional Troubleshooting information

can be found in Table 10. MAJOR COMPONENTS

2-STAGE HP/AC BOARD

The two-stage HP/AC control board controls the following functions:

- Low- and high-stage compressor operation

- Outdoor fan motor operation

- Reversing valve operation

- 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 COMMUNICATION FAILURE

If communication with the Infinity Control is I.st with the UI, the controls will flash the appropriate fault codes. Check the

wiring to the UI, indoor and outdoor units. MODEL PLUG

The HP/AC control board must have a valid model plug to operate. If a valid model plug is not detected, it will not operate

and the control will flash the appropriate fault code. shown in Table 5.

PRESSURE SWITCH PROTECTION-REFRIGERANT

The unit is equipped with high- and low-pressure switches. If the control senses the opening of a high- or I,w-pressure switch, it

will respond as follows:

1. De-energize the compressor contactor (HPS1 & LPS) or the compressor solenoid contactor (HPS2).

2. Keep the outdoor fan operating for 15 minutes.

3. Display the appropriate fault codes.

4. After a 15 minute delay, if there is still a call for cooling and the LPS or HPS is reset, the compressor contactor is energized.

5. If LPS or HPS has not closed after a 15 minute delay, the outdoor fan is turned off. If the open switch closes anytime

after the 15-minute delay, then resume operation with a call for cooling.

6. If LPS or HPS trips 3 consecutive cycles, the unit operation is locked out for 4 hours.

7. In the event of a high-pressure switch trip or high pressure lockout, check the refrigerant charge, outdoor fan

operation and outdoor coil for airflow restrictions.

8. In the event of a low-pressure switch trip or low pressure lockout, check the refrigerant charge and indoor airflow.

CONTROL FAULT If the HP/AC control board has failed, the control will flash the

appropriate fault code (See Table 5). The control board should be replaced.

BROWN OUT PROTECTION

If the line voltage is less than 187v for at least 4 seconds, the appropriate compressor contactor and fan relay are de-energized. Compressor and fan operation are not allowed until voltage is a

minimum of 190v. The control will flash the appropriate fault code (See Table 5).

230V LINE (POWER DISCONNECT) DETECTION If there is no 230v at the compressor contactor when the unit is

powered and cooling demand exists, the appropriate error code is displayed. Verify that the disconnect is closed and 230v wiring is

connected to the unit. COMPRESSOR VOLTAGE SENSING

The control board input terminals VS and L2 (See Fig. 17) are used to detect compressor voltage status, and alert the user of

potential problems. The control continuously monitors the high voltage on the run capacitor of the compressor motor. Voltage should be present any time the compressor contactor is energized,

and voltage should not be present when the contactor is de-energized.

CONTACTOR SHORTED DETECTION

If there is compressor voltage sensed when there is no demand for compressor operation, the contactor may be stuck closed or there

is a wiring error. The control will flash the appropriate fault code. COMPRESSOR THERMAL CUTOUT

If the control senses the compressor voltage after start-up, and is then absent for 10 consecutive seconds while cooling demand

exists, the thermal protector is open. The control de-energizes the compressor contactor for 15 minutes, but continues to operate

the outdoor fan. The control Status LED will flash the appropriate code shown in Table 5. After 15 minutes, with a call

for low or high stage cooling, the compressor contactor is energized. If the thermal protector has not re-set, the outdoor fan

is turned off. If the call for cooling continues, the control will energize the compressor contactor every 15 minutes. If the

thermal protector closes (at the next 15 minute interval), check the unit will resume operation.

If the thermal cutout trips for three consecutive cycles, then unit operation is locked out for 4 hours and the appropriate fault code

is displayed. NO 230V AT COMPRESSOR

If the compressor voltage is not sensed when the compressor should be starting, the contactor may be stuck open or there is a

wiring error. The control will flash the appropriate fault code. Check the contactor and control box wiring.

TROUBLESHOOTING [;NIT FOR PROPER SWITCHING BETWEEN LOW & HIGH STAGES

Check the suction pressures at the service valves. Suction pressure should be reduced by 3-10% when switching from low to high capacity.

NOTE: The liquid pressures are very similar between low and high stage operation, so liquid pressure should not be used for troubleshooting.

Compressor current should increase 20-45% when switching from low to high stage. The compressor solenoid, when

energized in high stage, should measure 24vac. COMPRESSOR INTERNAL RELIEF

The compressor is protected by an internal pressure relief (IPR) which relieves discharge gas into compressor shell when

differential between suction and discharge pressures exceeds 550

- 625 psi. The compressor is also protected by an internal overload attached to motor windings.

TEMPERATURE THERMISTORS

Thermistors are electronic devices which sense temperature. As the temperature increases, the resistance decreases. Thermistors

are used to sense outdoor ambient (OAT) and coil temperature (OCT). Refer to Fig. 24 for resistance values versus temperature. See Fig. 25 for OCT location.

If the outdoor ambient or coil thermistor should fail, the HP/AC control will flash the appropriate fault code (See Table 5).

IMPORTANT: Coil thermistor is factory mounted. Check to insure thermistor is mounted properly. Outdoor air thermistor

(OAT) is field mounted and connected. Verify that the OAT has been properly installed.

THERMISTOR CURVE

9, I I I I I

,,'__.___.__.___.___, ....

I\ I I I I I

,,.,-.---.--.---.---, ....

,,4-_.1___.__.___.___, ....

I \ I I I I

..,--,---.--.---.---. ....

I \ i i i i

301-_____-....V__ ____ _-___ I....

201------- _"_._ -----, '....

r_I..............................I...............I.............................I..............

O 20 40 60 80 10O 120

Fig. 24 - Resistance Values Versus Temperature

TEMPERATURE {DEG F)

A91431

THERMISTORSENSORCOMPARISON Thecontrolcontinuouslymonitorsandcomparestheoutdoorair

temperaturesensorandoutdoorcoiltemperaturesensortoensure properoperatingconditions.Thecomparisonis:

• Incoolingmode,if theoutdoorairsensorindicates-> 10°Fwarmerthanthecoilsensor(or)theoutdoorair

sensorindicates->20°Fcoolerthanthecoilsensor,the sensorsareoutofrange.

• Inheatingiftheoutdoorairsensorindicates>-35'_F

warmerthanthecoilsensor(or)theoutdoorairsensor

indicates->10°Fcoolerthanthecoilsensor,thesensors areoutofrange.

If thesensorsareoutof range,thecontrolwill flashthe appropriatefaultcodeasshowninTable5.

Thethermistorcomparisonisnotperformedduringlowambient coolingoperation.

FAILEDTHERMISTORDEFAULTOPERATION Factorydefaultshavebeenprovidedintheeventoffailureof

outdoorairthermistorand/orcoilthermistor. IftheOATsensorshouldfail.lowambientcoolingwillnotbe

allowedandtheone-minuteoutdoorfanoffdelaywillnotoccur. Defrostwillbeinitiatedbasedoncoiltemperatureandtime.

IftheOCTsensorshouldfail,lowambientcoolingwillnotbe allowed.Defrostwilloccurateachtimeintervalduringheating

operation,butwillterminateafter5minutes. Ifthereisathermistoroutofrangeerror,defrostwilloccurat

eachtimeintervalduringheatingoperation,butwillterminate after5minutes.

RefertotheTroubleshooting(?hart(Table10)foradditional troubleshootinginformation.

FINALCHECKS

IMPORTANT:Beforeleavingjob,besuretodothefollowing:

1.Ensurethatallwiringisroutedawayfromtubingand sheetmetaledgesto preventrub-throughor wire

pinching.

2.Ensurethatallwiringandtubingissecureinunitbefore addingpanelsandcovers.Securelyfastenallpanelsand

covers.

3.Tightenservicevalvestemcapsto1/2-turnpastfinger tight.

4.LeaveUsersManualwith owner.Explainsystem operationandperiodicmaintenancerequirementsoutlined

inmanual.

5.FilloutStart-UpChecklistlocatedatthebackofthis manualandplaceincustomerfile.

CAREANDMAINTENANCE

Forcontinuinghighperformanceandto minimizepossible equipmentfailure,periodicmaintenancemustbeperformedon

thisequipment. Frequencyofmaintenancemayvarydependingupongeographic

areas,suchascoastalapplications.SeeUsersManualfor information.

Fig. 25 - Outdoor Coil Thermistor (OCT) Attachment

A06311

AIRCONDITIONERWITHPURON

REFRIGERATIONSECTIONQUICK-REFERENCEGUIDE

Puronrefrigerantoperatesat50-70percenthigherpressuresthanR-22.Besurethatservicingequipmentandreplacementcomponentsare designedtooperatewithPuron.Puronrefrigerantcylindersarerosecolored.

• PuronrefrigerantcylindersmanufacturedpriortoMarch1,1999,haveadiptubethatallowsliquidtoflowoutofcylinderin uprightposition.CylindersmanufacturedMarch1,1999andlaterDONOThaveadiptubeandMUSTbepositionedupsidedown toallowliquidtoflow.

• Recoverycylinderservicepressureratingmustbe400psig.DOT4BA400orDOTBW400.

• Puronsystemsshouldbechargedwithliquidrefrigerant.Useacommercial-typemeteringdeviceinthemanifoldhose.

• Manifoldsetsshouldbe750psighighsideand200psiglowsidewith520psiglowsideretard.

• Usehoseswith750psigservicepressurerating.

• LeakdetectorsshouldbedesignedtodetectHFCrefrigerant.

• Puron,aswithotherHFCs.isonlycompatiblewithPOEoils.

• Vacuumpumpswillnotremovemoisturefromoil.

• Onlyusefactory-specifiedliquid-linefilterdrierswithratedworkingpressuresnolessthan600psig.

• Donotinstallasuction-linefilterdrierinliquidline.

• POEoilsabsorbmoisturerapidly.Donotexposeoiltoatmosphere.

• POEoilsmaycausedamagetocertainplasticsandroofingmaterials.

• Wrapallfilterdriersandservicevalveswithwetclothwhenbrazing.

• APuronliquid-linefilterdrierisrequiredoneveryunit.

• DonotuseanR-22TXV.

• Neveropensystemtoatmospherewhileitisunderavacuum.

• Whensystemmustbeopenedforservice,breakvacuumwithdrynitrogenandreplacefilterdriers.

• DonotventPuronintotheatmosphere.

• Observeallwarnings_eautions_andboldtext.

• DonotleavePuronsuctionlinedriersinplaceformorethan72hrs.

TablelO--TroubleshootingChart

SYMPTOM

Compreeeor and outdoor fan will not start

Compreeeor will not start but condeneer fan rune

Compressor cycles (other than normally sat- isfying) cooling/heating calls

Compressor operates continuously

Excessive head preeeure

Head preeeure too low

Exceseiv@ euction preeeure

Suction preeeur@ tOO lOW

IFM does not run

IFM operation is intermittent

CAUSE

Power failure Fuse blown or circuit breaker tripped

Defective conte.ctor, transformer, contrM relay, or high- pressure, loss-of-charge or low-pressure switch

InsufficMnt line voltage Incorrect or faulty wiring UI setting too Mw/too high

UMts have a 5-mMute time delay

Faulty wMng or circuit Loose connections in compressor

Compressor motor burned out, seized, or internal overload open

Defective run capacitor, overload, or PTC (positive

temperature coefficient) thermistor

Low input voltage (20 percent low) Refrigerant overcharge or undercharge Defective compressor

Insufficient line voltage Blocked outdoor coil

Defective run/start capacitor, overload or start relay Faulty outdoor fan motor or capacitor

Restriction in refrigerant system Dirty aMfilter

UMt undersized for load UI temperature set too low

Low refrigerant charge

Air in system

Outdoor coil dirty or restricted Dirty air filter Dirty indoor or outdoor coil

Refrigerant overcharged

Air in system

Indoor or outdoor air restricted or air short-cycling Low refrigerant charge

Restriction in liquid tube High heat load

Reversing vaMe hung up or leaking internally Refrigerant overcharged Dirty air filter

Low refrigerant charge Metering device or low side restricted

Insufficient coil airflow

Temperature too low in conditMned area

Outdoor ambient below 55°F Filter drier restricted

Blower wheel not secured to shaft Insufficient voltage at motor

Power connectors not properly sealed

Water dripping into motor

Connectors not firmly sealed

REMEDY

Call power company

Replace fuse or reset circuit breaker

Replace component

Determine cause and correct

Check wMng diagram and rewire correctly

Reset U! setting

DO NOT bypass this compressor time

delay wait for 5 minutes until time-dMay

relay is de-energized

Check wMng and repair or replace

Determine cause Replace compressor

Determine cause and replace Determine cause and correct

Recover refrigerant, evacuate system, and re-

charge to capacities shown on rating plate

Replace and determine cause Determine cause and correct Determine cause and correct

Determine cause and replace Replace

Locate restriction and remove Replace filter

Decrease load or increase unit size Reset U! setting

Locate leak, repair, and recharge Recover refrigerant, evacuate system, and re-

charge OMen coil or remove restriction

Replace filter

Clean coil

Recover excess refrigerant Recover refrigerant, evacuate system, and re-

charge

Determine cause and correct

Check for leaks, repair and recharge Remove restriction

Check for source and eliminate Replace valve Recover excess refrigerant Replace filter

Check for leaks, repair and recharge Remove source of restriction

Check filter replace if necessary Reset U! setting Verify low-ambient cooling enabled in UI

Replace Properly tighten blower wheel to shaft

Determine cause and correct Connectors should snap easily; do not force

Verify proper drip loops in connector wires Gently pull wires individually to be sure they are

crimped into the housing

SYMPTOM

Burners will not ignite

Inadequate heating

Poor flame characteristics

Table lO T_ub[eshootiug Chart Cou't-Gas Furnace Operation

CAUSE

Water in gas line

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 pressure switch not closing Dirty air filter

Gas input to unit too low

Unit undersized for application Restricted airflow

Limit switch cycles main burners

Incomplete combustion results in: Aldehyde odors,

carbon monoxide, sooting flame, floating flame

Drain, Install drip leg.

Check power supply fuses, wiring or circuit breaker,

Check transformer. NOTE: Some transformers have internal over-

current protection that requires a cool-down peri- od to reset.

Check ail wiring and wire nut connections Check flame ignition and sense electrode posi-

tioning. Adiust as necessary,

1. Check gas line for air, Purge as necessary. NOTE: After purging gas line of air, wait at least 5 minutes for any gas to dissipate before attempt- ing to light unit.

2. Check gas valve.

1. Check pressure switch wires, connections, and tubing, Repair or replace if necessary,

Clean or replace filter as necessary Check gas pressure at manifold match with that

on unit nameplate

Replace with proper unit or add additional unit

Clean or replace filter, Remove any restriction, Check rotation of blower, temperature rise of unit.

Adiust as necessary,

1. Tighten all screws around burner compartment

2. Cracked heat exchanger. Replace,

3. Unit over-fired. Reduce input (change orifices or adiust gas line or manifold pressure),

4. Check burner alignment,

5. Inspect heat exchanger for blockage. Clean as necessary,

REMEDY

START-U P CHECKLIST

(Remove and Store in Job File)

I. Preliminary mnformetion MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

II, PRE=START-UP (tneert eheckmetk 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

III, START-UP ELECTRICAL

SUPPLY VOLTAGE COMPRESSOR AMPS

INDOOR (EVAPORATOR) FAN AMPS

TEMPERATURES OUTDOOR (CONDENSER) AIR TEMPERATURE

RETURN-AIR TEMPERATURE DB

COOLING SUPPLY AIR DB GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE GAS MANIFOLD PRESSURE

REFRIGERANT SUCTION REFRIGERANT DISCHARGE

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS

GAS HEAT TEMPERATURE RISE TEMPERATURE RISE (See Literature) RANGE

MEASURED TEMPERATURE RISE ( ) VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PROPERLY

( ) VERIFY THAT OUTDOOR AIR THERMISTOR (OAT) IS PROPERLY INSTALLED & CONNECTED *Measured at suction inlet to compressor

tMeasured at liquid line leaving condenser.

IN.WG

PSIG SUCTION LINE TEMP*

PSIG DISCHARGE TEMPt

Manufacturer reserves the right to change_ at any time_ specifications and designs without notice and without obligations.

Catalo_ No: 48DU-3SI

Replaces: 48DU-2Sl

Carrier Infinity 48DU-030, Infinity 48DU-024, Infinity 48DU-036, Infinity 48DU-042, Infinity 48DU-048 Installation Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual