CARRIER Package Units(both Units Combined) Manual L0912143

User Manual: CARRIER CARRIER Package Units(both units combined) Manual CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides

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Installation Instructions

EQUIPMENT OPERATION HAZARD

Failure to follow this caution may result in improper unit

operation.

OAT sensor must be field installed. See Accessory

Installation for more details.

EQUIPMENT OPERATION HAZARD

Failure to follow this caution may result in improper unit

operation.

This Infinity TM unit is designed for use with an Infinity User

Interface.

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

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

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

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

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

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

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

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

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

Slab Mount ..................................... 3

Provide Clearances ................................. 3

Rig and Place Unit ................................. 3

Inspection ...................................... 3

Rigging/Lifting of Unit ............................ 9

Select and Install Ductwork ........................... 9

Configuring Units for Downflow (Vertical) Discharge . . . 10

Provide for Condensate Disposal ..................... 11

Install Flue Hood .................................. 11

Install Gas Piping ................................. 12

Install Electrical Connections ........................ 13

High-Voltage Connections ........................ 13

Routing Power Leads Into Unit ..................... 13

Connecting Ground Lead to Ground Screw ........... 13

Routing Control Power Wires ..................... 13

Accessory Installation ............................ 13

Special Procedures for 208-v Operation .............. 14

PRE-START-UP ................................... 16

START-UP ..................................... 16-27

Unit Start-Up and Troubleshooting ................... 16

Sequence of Operation ............................. 21

Check for Refrigerant Leaks ......................... 26

Start-Up Adjustments .............................. 26

A09032

Fig. 1 - Unit 48XL-A

Checking Cooling and Heating Control Operation ...... 26

Checking and Adjusting Refrigerant Charge ........... 26

Refrigerant Charge .............................. 27

No Charge ..................................... 27

Low Charge Cooling ............................. 27

To Use Cooling Charging Charts .................... 27

Non-Communicating Emergency Cooling/Heating Mode .. 27

MAINTENANCE ................................ 29-30

Air Filter ........................................ 29

Indoor Fan and Motor .............................. 29

Inducer Blower ................................... 29

Limit Switch ..................................... 29

Burner Ignition ................................... 29

Main Burners .................................... 29

Inducer Pressure Switch ............................ 30

Outdoor Coil, Indoor Coil, and Condensate Drain Pan ..... 30

Outdoor Fan ..................................... 30

Electrical Controls and Wiring ....................... 30

Refrigerant Circuit ................................. 31

Indoor Airflow ................................... 31

Pressure Switches ................................. 31

Loss-of-Charge Switch ............................ 31

High-Pressure Switches ............................ 31

Copeland Scroll Compressor (Puron cR)Refrigerant) ........ 31

Refrigerant System ................................ 31

Refrigerant .................................... 31

Compressor Oil ................................. 31

Servicing Systems on Roofs with Synthetic Materials .... 31

Liquid-Line Filter Drier .......................... 32

Puron (R-410A) Refrigerant Charging ............... 32

TROUBLESHOOTING .............................. 32

FINAL CHECKS ................................... 33

CARE AND MAINTENANCE ........................ 33

START-UP CHECKLIST ............................ 37

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service maintenance,

or use can cause explosion, fire, electrical shock, or other

conditions which may cause death, personal injury, or property

damage. Consult a qualified installer, service agency, or your

distributor or branch for information or assistance. The qualified

installer or agency must use factory-authorized kits or accessories

when modifying this product. Refer to the individual instructions

packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions

included in literature and attached to the unit. consult local

building codes, the current editions of the National Fuel Gas Code

(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code

(NEC) NFPA 70.

In Canada refer to the current editions of the National Standards of

Canada CAN/CSA-BI49.1 and .2 Natural Gas and Propane

Installation codes, and Canadian Electrical Code CSA C22.1

Recognize safety information. This is the safety-alert symbol /_.

When you see this symbol on the unit and in instructions or manu-

als, be alert to the potential for personal injury. Understand these

signal words: DANGER, WARNING, and CAUTION. These

words are used with the safety-alert symbol. DANGER identifies

the most serious hazards which will result in severe personal injury

or death. WARNING signifies hazards which could result in per-

sonal injury or death. CAUTION is used to identify unsafe practic-

es which may result in minor personal injury or product and prop-

erty damage. NOTE is used to highlight suggestions which will

result in enhanced installation, reliability, or operation.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

iniury or death.

Before installing or servicing system, always turn off main

power to system and tag disconnect. 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).

CUT HAZARD

Failure to follow this caution may result in personal iniury.

When removing access panels or performing maintenance

functions inside your unit, be aware of sharp sheet metal

parts and screws. Although special care is taken to reduce

sharp edges to a minimum, be extremely careful when

handling parts or reaching into the unit.

INTRODUCTION

The 48XL-A 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 rooftop, or

on cement slab (See Fig. 4 for roof curb dimensions). 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

Check Equipment

IDENTIFY UNIT

The unit model number and serial number are printed on the unit

informative plate. Check this information against shipping papers.

INSPECT SHIPMENT

Inspect for shipping damage before removing packaging material.

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 distributor office if any item is missing. To prevent loss or

damage, leave all parts in original packages until installation.

If the unit is to be mounted on a curb in a downflow application,

review "Configuring Units for Downflow Discharge" to determine

which method is to be used to remove the downflow panels before

rigging and lifting into place. The panel removal process may

require the unit to be on the ground.

Provide Unit Support

IMPORTANT: The unit must be secured to the curb by installing

screws through the bottom of the curb flange and into the unit base

rails. When installing large base units onto the common curb, the

screws must be installed before allowing the full weight of the unit

to rest on the curb. A minimum of six screws are required for large

base units. Failure to secure unit properly could result in an

unstable unit. See Warning near Rigging/Lifting information and

accessory curb instructions for more details.

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. (6.35 m) (See Fig. 2). This is

necessary for unit drain to function properly. Refer to accessory

roof curb installation instructions for additional information as

required.

MAXIMUM ALLOWABLE

B DIFFERENCE in. (mm)

A-B B-C A-C

1/4 (6.35) 1/4 (6.35) 1/4 (6.35)

A07925

Fig. 2- []nit Leveling Tolerances

Installation on older "G" series roof curbs.

Two accessory kits are available to aid in installing a new "G"

series unit on an old "G" roof curb.

1. Accessory kit number CPADCURB001A00, (small chassis)

and accessory kit number CPADCURB002A00, (large

chassis) includes roof curb adapter and gaskets for the

perimeter seal and duct openings. No additional

modifications to the curb are required when using this kit.

2. An alternative to the adapter curb is to modify the existing

curb by removing the outer horizontal flange and use

accessory kit number CPGSKTKIT001A00 which includes

spacer blocks (for easy alignment to existing curb) and

gaskets for the perimeter seal and duct openings. This kit is

used when existing curb is modified by removing outer

horizontal flange.

UNIT/STRUCTURAL DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Ensure there is sufficient clearance for saw blade when cutting

the outer horizontal flange of the roof curb so there is no

damage to the roof or flashing.

,_,_ --== __

/_,Ir/OPTIONA i--"Y_"_-_- )PTIONALjl II

RETURN SUPPLY

illlt ._5_--X "%\ j_,

AIR AIR

IBR 11II

Illll /il \i ./-L. / x , II II

,ill /t I W2,_I t II,

,HI I_ I I! _,L_s'j ] II,

Hfl' 1 _"L--_/ HH

Ill, t,4 ) /z ,,

IIHI @..G i/j IIII

(50.atom)

-EVARCOIL COND. COIL

A07926

Fig. 3 - Slab Mounting Detail

SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4

in. (102 mm) thick with 2 in. (51 mm) above grade. The slab

should extend approximately 2 in. (51 mm) 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.

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. (1219 mm) above the unit top. The maximum horizontal

extension of a partial overhang must not exceed 48 in. (1219 mm).

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. (102 mm) above the highest expected water

and runoff levels. Do not use unit if it has been under water.

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 shackles,

clevis pins, and straps should be visually inspected for any

damage, evidence of wear, structural deformation, or cracks.

Particular attention should be paid to excessive wear at hoist

hooking points and load support areas. Materials showing any kind

of wear in these areas must not be used and should be discarded.

UNIT FALLING HAZARD

Failure to follow this warning could result in personal

iniury or death.

Never stand beneath rigged units or lift over people.

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal

iniury/death or property damage.

When straps are taut, the clevis should be a minimum of 36

in. (914 mm) above the unit top cover.

HVAC unit

base rails

Anchor screw /

Flashing field

Roofing material

HVAC unit

basepan

_ Sealing

Gasket

Roofcurb

_Wood nailer*

/Roofcurb*

Insulation

/(field supplied)

'Provided with roofcurb

ROOF CURB DETAIL

A09090

Dashed lines show cross support

location for large basepan units

SMALL/COMMON CURB A09413

SMALL

BASE

UNIT

LARGE

BASE

UNIT

LARGE CURB

UNIT PLACEMENT ON

COMMON CURB

SMALL OR LARGE BASE UNIT

A09094

UNIT CATALOG A B (small /common

SIZE NUMBER IN, base)

(mm) IN, (mm)*

Small CPRFCURB01OAOO (279)

or 14 10 (254)

Large CPRFCURB011AOO (356)

CPRFCURB012AOO (279)

Large 14 (356)

B (large CD E F

base) IN, IN, IN, IN,

IN, (mm)* (mm) (mm) (mm) (mm)

32.4

(822)

16 47.8

14 (356) (406) (1214) 2.7 (69)

CPRFCURB013A00 (356)

NOTES:

1. Roof curb must be set up for unit being installed,

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

3. Roof curb is made of 1d-gauge steel.

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

5. Insulated panels: 1-in. (25.4 mm) thick fiberglass 1 lb. density.

Fig. 4 - Roof Curb Dimensions

43.9

(1116)

A09414

G H

IN. (mm) IN. (mm)

30.6 (778)

46.1 (1170)

42.2 (1072)

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iiiii_ . !i_

................." ' LiT_

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Fig. 5 - 48XL-A24-30 Unit Dimensions

A09521

ill

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Fig. 6 - 48XL-A36-60 Unit Dimensions

A09522

UNIT SIZE

NOMINAL COOLING CAPACITY (ton)

NOMINAL HEATING CAPACITY (Btu)

SHIPPING WEIGHT (Ib)

(kg)

COMPRESSORS

Quantity

REFRIGERANT: PURON (R-410A)

Quantity (Ib)

(kg)

REFRIGERANT METERING DEVICE

Size

OUTDOOR COIL

Rows...Fins/in.

Face Area (sq if)

OUTDOOR FAN

Nominal Cfm

Diameter (in.)

(mm)

Motor Hp (Rpm)

INDOOR COIL

Rows...Fins/in.

Face Area (sq if)

INDOOR FAN

Nominal Airflow (Cfm)

Comfort

Efficiency

Max

Furnace (gas ht.) airflow-Low Stage

Furnace (gas ht.) airflow-High Stage

Size (in.)

(ram)

Motor HP

24040 36090 42060 42090

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

40,000 90,000 60,000 90,000

426 530 544 552

193 240 247 250

Table 1 - Physical Data -Unit 48XL-A

24060 30040 30060 36060

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

60,000 40,000 60,000 60,000

431 433 438 522

196 196 199 237

2-Stage Scroll

10.1 10.1 11.3 11.3 9.5 9.5 13.8 13.8

4.6 4.6 5.1 5.1 4.3 4.3 6.3 6.3

2Ton

2...21

13.6

2700

559

1/8 (825)

3...17

3.7

700

800

475

844

10x10

254x254

1/2

2Ton

2...21

13.6

2700

559

1/8 (825)

3...17

3.7

3Ton

2...21

15.3

2700

559

1/8 (825)

3...17

3.7

3Ton

2...21

15.3

2700

559

1/8 (825)

3...17

3.7

TXV

3Ton

2...21

17.5

2800

559

1/8 (825)

3...17

4.7

3Ton

2...21

17.5

2800

559

1/8 (825)

3...17

4.7

4Ton

2...21

19.4

2800

559

1/8 (825)

3...17

4.7

Variable based on Comfort Rol! back (see User Interface instructions for more information).

700

800

727

1120

10x10

254x254

1/2

875

1000

475

844

10x10

254x254

1/2

875

1000

727

1120

10x10

254x254

1/2

1050

1200

745

1120

11x10

279x254

3/4

1050

1200

875

1410

11x10

279x254

3/4

1225

1400

745

1120

11x10

279x254

3/4

4Ton

2...21

19.4

2800

559

1/8 (825)

3...17

4.7

1225

1400

875

1410

11x10

279x254

3/4

FURNACE SECTION*

Burner Orifice No. (Qty...Drill Size)

Natural Gas (Factory installed) 2...44 3...44 2...44 3...44 3...44 3...38 3...44 3...38

Propane Gas 2...55 3...55 2...55 3...55 3...55 3...53 3...55 3...53

HIGH-PRESSURE SWITCH (psig)

Cut-out 670 -+10

Reset (Auto) 470 -+25

HIGH-PRESSURE SWITCH 2 (psig)

(Compressor Solenoid) 565 -+ 15

Cut-out 455 -+ 15

Reset (Auto)

LOSS-OF-CHARGE /

LOW- PRESSURE SWITCH

(Liquid Line) (psig)

Cut-out 23 -+5

Reset (auto) 55 -+5

RETURN-AIR FILTERS Throwawayt

(in.) 20x24x1 24x30x1 24x36x1

(mm) 508x610x25 610x762x25 610x914x25

Continued next page.

UNIT SIZE

NOMINAL COOLING CAPACITY (ton)

NOMINAL HEATING CAPACITY (Btu)

SHIPPING WEIGHT (Ib)

(kg)

COMPRESSORS

Quantity

REFRIGERANT: PURON (R-410A)

Quantity (Ib)

(kg)

REFRIGERANT METERING DEVICE

Size

OUTDOOR FAN

Norninal Cfrn

Diameter (in.)

(mm)

Motor Hp (Rpm)

OUTDOOR COIL

Rows...Fins/in.

Face Area (sq ft)

INDOOR COIL

Rows...Fins/in.

Face Area (sq ft)

INDOOR FAN

Norninal Airflow (Cfrn)

Comfort

Efficiency

Max

Furnace (gas ht.) airflow-Low Stage

Furnace (gas ht.) airflow-High Stage

Size (in.)

(mm)

Motor HP (RPM)

FURNACE SECTION*

Burner Orifice No. (Qty...Drill Size)

Natural Gas (Factory Installed)

Propane Gas

HIGH-PRESSURE SWITCH (psig)

Cut-out

Reset (Auto)

HIGH-PRESSURE SWITCH 2 (psig)

(Cornpressor Solenoid)

Cut-out

Reset (Auto)

LOSS-OF-CHARGE /

LOW- PRESSURE SWITCH

(Liquid Line) (psig)

Cut-out

Reset (auto)

RETURN-AIR FILTERS Throwawayt (in.)

(ram)

Table 1--Physical Data (Con't) - Unit 48XL-A

48090 48115 48130 60090

4445

90,000 115,000 130,000 90,000

558 558 558 609

253 253 253 276

2-Stage Scroll

60115 60130

5 5

115,000 130,000

609 609

276 276

15.3 15.3 15.3 15.8 15.8 15.8

6.9 6.9 6.9 7.2 7.2 7.2

TXV

4Ton 4Ton 4Ton 5Ton 5Ton 5Ton

3300 3300 3300 3300 3300 3300

22 22 22 22 22 22

559 559 559 559 559 559

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 Comforf Rollback(see Userlnterfaceinstructionsfor moreinformation).

1400 1400 1400 1750 1750

1600 1600 1600 2000 2000

1255

1875

11x10

279x254

3/4

845

1300

11x10

279x254

1215

1910

11x10

279x254

1215

1885

11x10

279x254

3/4

815

1385

11x10

279x254

3/4 1

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

3...53 3...51 3...49 3...53 3...51 3...49

670 ± 10

470 ± 25

565 ± 15

455 ± 15

23 ± 5

55 ± 5

24x36x1

610x914x25

1750

2000

1255

1920

11x10

279x254

*Based on altitude of 0 to 2000 ft (0 to 610 m).

1-Recommended filter sizes for field-installed air filter grilles mounted on the wall or ceiling of the conditioned structure. Required 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/minute for throwaway type or 450

ft/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.

CAUTION - NOTICE TO RIGGERS

PRUDENCE - AViS AUX MANIPULATEUR

ACCESS PANELS MUST BE iN PLACE WHEN RIGGING.

PANNEAUX D'ACCES DOlT ETRE EN PLACE POUR MANiPULATiON.

Use top skid as spreader bar. /Utiliser la palette du haut comme barre de r6partition

jJ ..... MiNiMUM HEIGHT: 36" (9!4.4 turn)

JHAUTEUR MINIMUM

DUCTS

UNIT HEIGHT

HAUTEUR D'UNITE

SEAL STRIP MUST BE IN BANDE SCELLANT BOIT ETRE

PLACE BEFORE PLACING EN PL,_C E AVANT DE PLACER

UNIT ON ROOF CURB L:U NtTE SUR LA BASE DE TOtT

SEE DETAIL A

VOIR DETAIL A

CABINET

Small

DETAIL A

VOIR DIETAIL A

MODEL

48XL-A24

48XL-A30

5ocY5o2286 2,0

A09079

RIGGING WEIGHT

Ib kg

426 193

433 196

Large

NOTE: See dimensional drawing for corner weight distribution.

48XL-A36

48XL-A42

48XL-A48

48XL-A60

Fig. 7-Suggested Rigging

522

544

558

609

237

247

253

276

Ri_in_/Liftin_ of Unit (See Fi_. 7)

UNIT FALLING HAZARD

Failure to follow this warning could result in personal

iniury or death.

Large base units must be secured to common curb before

allowing full weight of unit to rest on curb. Install screws

through curb into unit base rails while rigging crane is still

supporting unit.

Lifting holes are provided in base rails as shown in Fig. 5 and 6.

1. Leave top shipping skid on the unit for use as a spreader bar

to prevent the rigging straps from damaging the unit. If the

skid is not available, use a spreader bar of sufficient length

to protect the unit from damage.

2. Attach shackles, clevis pins, and straps to the base rails of

the unit. Be sure materials are rated to hold the weight of the

unit (See Fig. 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.

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

the top skid.

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.

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal

iniury or death.

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.

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.

(610 mm) from electric heater element.

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

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

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.

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

and vibration-isolate duct openings in wall or roof

according to good construction practices.

6. Read unit rating plate for any required clearances around

ductwork.

Configuring Units for Downflow (Vertical) Discharge

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Before installing or servicing system, always turn off main

power to system and install lockout tag. There may be

more than one disconnect switch.

1. Open all electrical disconnects before starting any service

work.

2. Remove horizontal (metal) duct covers to access vertical

(downflow) discharge duct knockouts in unit basepan. (See

Fig. 8.)

3. []sing Fig. 9 as a guide, proceed to cut out the downflow

duct panels.

4. Drill 1/2 in. (13 mm) diameter or larger holes in all four

corners of duct panels.

NOTE: On large chassis units remove sheet metal shields on

panels by using a screw driver to shear off retainers and discard.

5. On left and side supply duct opening side with keyhole or

single bladed hacksaw cut out panel along "V" groove.

6. On right side, with keyhole or single blade hacksaw, with

teeth facing up and starting from the front and moving to

the rear, cut along "V" groove.

7. Now with three sides cut, flex panel up and down to re-

move.

8. Replace side access panel and duct cover.

9. After completing unit conversion, perform all safety checks

and power up unit.

Alternate Method

1. Open all electrical disconnects and install lockout tag before

starting any service work.

2. Remove horizontal (metal) ductcovers to access vertical

(downflow) discharge duct knockouts in unit basepan. (See

Fig. 8.)

3. Leave top shipping crate on unit during this method.

4. Tip unit over on the front side (access panels) so the bottom

of the base pan is accessible.

5. Drill two holes diagonally opposed, of suitable size to ac-

commodate jigsaw or reciprocating saw. (See Fig. 9.)

NOTE: On large chassis units remove sheet metal shields on

panels by using a screw driver to shear off retainers and discard.

[]NIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the

unit being installed.

When cutting duct panels, do not contact or damage any

internal components (heat exchanger, electric heat). Do not

use a saw blade that protrudes more than 1 in. (25 mm) into

unit.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Collect ALL screws that were removed. Do not leave screws

on rooftop as permanent damage to the roof may occur.

6. Using a suitable saw cut along "V" groove and remove duct

panels.

7. Tip unit back onto its base and replace duct covers.

8. After completing unit conversion, perform all safety checks

and power up unit.

Basepan

Downflow

(Vertical)

Supply

Knockout

Horizontal Duct Covers

i t

A09076

Basepan

Downflow

Return

Knockout

Fig. 8 - Supply and Return Duct Opening

A09077

_5 -O

,,,,_, Cut along

'V" grooves

Drill

places

I I

Return Duct Panels

Flex up & down

to remove

cota,oo0_I li I

..... _-"-..Jl., I I E I X I I I Cut along"V"

vgrooves _ r_, I A I _. I _ I i.J _ grooveteeth

"141'VI .li7 ,ac,ng up

I ___'_.... C)'--' _Drill 3 places

I ,I

Supply Duct Panels

Drill 2 places

Cut along

i i "V" grooves

Return & Supply Duct Panels from

Underside of Base (Alternate Method)

A09420

Fig. 9-Vertical (Downflow) Discharge Duct Knockouts

The design and installation of the duct system must be in

accordance with the standards of the NFPA for installation of

nonresidence-type air conditioning and ventilating systems, NFPA

90A or residence-type, NFPA 90B; and/or local codes and

ordinances.

Adhere to the following criteria when selecting, sizing, and

installing the duct system:

1. Units are shipped for horizontal duct installation (by

removing duct covers).

2. Select and size ductwork, supply-air registers, and

return-air grilles according to American Society of Heating,

Refrigeration and Air Conditioning Engineers (ASHRAE)

recommendations.

3. Use flexible transition between rigid ductwork and unit to

prevent transmission of vibration. The transition may be

screwed or bolted to duct flanges. Use suitaMe gaskets to

ensure weather-tight and airtight seal.

4. All units must have field-supplied filters or accessory filter

rack installed in the return-air side of the unit.

Recommended sizes for filters are shown in Table 1.

5. Size all ductwork for maximum required airflow (either

heating or cooling) for unit being installed. Avoid abrupt

duct size increases or decreases or performance may be

affected.

6. Adequately insulate and weatherproof all ductwork located

outdoors. Insulate ducts passing through unconditioned

space, and use vapor barrier in accordance with latest issue

of Sheet Metal and Air Conditioning Contractors National

Association (SMACNA) and Air Conditioning Contractors

of America (ACCA) minimum installation standards for

heating and air conditioning systems. Secure all ducts to

building structure.

7. Flash, weatherproof, and vibration isolate all openings in

building structure in accordance with local codes and good

building practices.

Provide for Condensate Disposal

NOTE: Ensure that condensate-water disposal methods comply

with local codes, restrictions, and practices.

The units dispose of condensate through a 3/4 -in. NPT female

fitting that exits on the compressor end of the unit. Condensate

water can be drained 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. (25 mm) 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. (51 mm) 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. (25 mm) lower than the unit

drain-pan condensate connection to prevent the pan from

overflowing. Connect a drain tube 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. (51 mm) trap (See Fig. 10). Do not

undersize the tube. Pitch the drain tube downward at a slope of at

least 1 in. for every 10 ft. (3 m) of horizontal run. Be sure to check

the drain trough for leaks. Prime the trap at the beginning of the

cooling season start-up.

Install Flue Hood

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury or death.

The venting system is designed to ensure proper venting.

The flue hood assembly must 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), NFPA

54/ANSI Z223.1 (in Canada, CAN/CSA B149.1, and

B149.2) or 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.Securefluehoodto flue panel by inserting a single screw on

the top and the bottom of the hood.

l-in. (25 ram)rain.

TRAP

ram) rain.

A09052

Fig. 10 -Condensate Trap

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 l/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. W.C. maximum pressure drop. Never use pipe

smaller than the l/2-in. FPT gas inlet on the unit gas valve.

For natural gas @plications, the gas pressure at unit gas connection

nmst not be less than 4.0 IN. W.C. or greater than 13 IN. W.C.

while the unit is operating. For propane @plications, refer to

propane conversion kit instructions.

A l/8-in. (3.2 ram) 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 NFPA 54/ANSI Z223.1-2006

(in Canada, CAN/CSA 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 in. (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 @proved

by the state of Massachusetts.

In the absence of local building codes, adhere to the following

pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.

(6.35 ram) for every 15 ft (4.6 m) of length to prevent traps.

Grade all horizontal runs downward to risers. Use risers to

connect to heating section and to meter.

2. Protect all segments of piping system against physical and

thermal damage. Support all piping with @propriate straps,

hangers, etc. Use a nfininmm of one hanger every 6 ft. (1.8

m). For pipe sizes larger than 1/2 in., follow

recommendations of national codes.

3. Apply joint compound (pipe dope) sparingly and only to

male threads of joint when making pipe connections. Use

only pipe dope that is resistant to action of liquefied

petroleum gases as specified by local and/or national codes.

Never use Teflon t@e.

4. Install sediment trap in riser leading to heating section (See

Fig. 11). 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 fl (1.8 m) of heating section.

6. Install ground-joint union close to heating section between

unit manual shutoff and external manual main shut off

valve.

7. Pressure test all gas piping in accordance with local and

national plumbing and gas codes before connecting piping

to unit.

NOTE: Pressure test the gas supply system after the gas supply

piping is connected to the gas valve. The supply piping nmst 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 nmst be isolated from the gas piping

system by closing the external main manual shutoff valve and

slightly opening the ground-joint union.

TEE

NIPPLE

CAP

Fig. 11 -Sediment Trap

C99020

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in fire, explosion,

personal iniury, 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 nfininmm of 2 in. (51 ram)

outside furnace casing.

• If codes allow a flexible connector, always use a new

connector. Do not use a connector which has previously

serviced another gas appliance.

8. Check for gas leaks at the field-installed and

factory-installed gas lines after all piping connections have

been completed. Use a commercially availaMe soap solution

made specifically for the detection of leaks (or method

specified by local codes and/or regulations).

Table2- MaximumGas Flow Capacity*

NOMINAL INTERNAL LENGTH OF PIPEft (m)'{"

IRON PIPE DIAMETER 10 20 30 40 50 60 70 80 90 100 125 150 175 200

SIZE (IN.) (IN.) (3.0) (6.1) (9.1) (12.1) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0)

1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 -- --

3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135

1 - 1/4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280

1 - 1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

*Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5-IN. W.C. (based on a 0.60 specific gravity gas). Refer to Table,

NFPA 54/ANSI Z223,1.

1-This length includes an ordinary number of fittings.

Install Electrical Connections

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

iniury or death.

The unit cabinet must have an uninterrupted, unbroken

electrical ground. This ground may consist of an electrical

wire connected to the unit ground screw in the control

compartment, or conduit approved for electrical ground

when installed in accordance with NEC, NFPA 70 National

Fire Protection Association (latest edition) (in Canada,

Canadian Electrical Code CSA C22.1) and local electrical

codes.

HIGH-VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a

field-supplied, waterproof disconnect switch mounted at, or within

sight from, the unit. Refer to the unit rating plate, NEC and local

codes for maximum fuse/circuit breaker size and minimum circuit

amps (ampacity) for wire sizing.

The field-supplied disconnect 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.

conduit termination at the duct panel must be watertight. Run the

high-voltage leads through the power entry knockout on the

power entry side panel. See Fig. 5 and 6 for location and size. For

single-phase units, connect leads to the black and yellow wires.

CONNECTING GROUND LEAD TO GROUND SCREW

Connect the ground lead to the chassis using the ground screw on

the control plate near the inducer switch (See Fig. 13).

ROUTING CONTROL POWER WIRES

For detailed instruction on the low voltage connections to the User

Interface (UI), refer to the UI installation guide.

Form a drip-loop with the control leads before routing them into

the unit. Route the low voltage control leads through grommeted,

low-voltage hole provided into unit (See Fig. 5 and 6). Connect

user interface leads to unit control power leads as shown in Fig. 15.

The unit transformer supplies 24-v power for complete system

including accessory electrical heater. Transformer is factory wired

for 230-v operation. If supply voltage is 208-v, rewire transformer

primary as described in Special Procedures for 208-v Operation

section.

The furnace board is fused by a board-mounted automotive fuse

placed in series with transformer SEC1 and R circuit. The C circuit

of transformer circuit is referenced to chassis ground through a

printed circuit run at SEC2 and gas valve grounding wire. Check to

be sure control board is mounted securely using both

factory-installed screws.

ACCESSORY INSTALLATION

A. Outdoor Air Temperature Sensor (OAT)

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

NFPA 70 (latest edition) and local electrical codes

governing such wiring. In Canada, all electrical

connections must be in accordance with CSA standard

C22.1 Canadian Electrical Code Part 1 and applicable

local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between

field-supplied electrical disconnect switch and unit. DO

NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within

operating voltage range indicated on unit rating plate.

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.

ROUTING POWER LEADS INTO UNIT

Use only copper wire between disconnect and unit. The high

voltage leads should be in a conduit until they enter the duct panel;

EQUIPMENT OPERATION HAZARD

The installation of an outdoor air temperature sensor (OAT)

using the Infinity control board OAT terminals is required.

Many Infinity features (auto humidity control, comfort

rollback, etc.) will be lost if the OAT is not connected.

For detailed mounting instructions for the OAT sensor,

please refer installation instructions shipped with the OAT.

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.

Whencommandedto operatehumidifier,theunitcontrolwill

energizetheHUMoutputtoturnhumidifieronandde-energize

HUMoutputto turnhumidifieroff.WireHUMandCOM

terminalsdirectlytohumidifierasshowninFig.15.

C. ElectronicAirCleaner

ElectronicAir CleanerterminalsareprovidedontheInfinity

ControlBoard(EAC-IandEAC-2).Whiletheseterminalscanbe

usedtopowera230VEAC,it isrecommendedthatanyEACbe

installedpertheEACinstallationinstructionsandconnected

separatelytoastandard115Vor230Voutletwithanairflow

sensortocontroloperationoftheEAC.

SPECIALPROCEDURESFOR208-VOPERATION

Besureunitdisconnectswitchisopen.

Disconnecttheblackprimaryleadfromthetransformer.Seeunit

wiringlabel(SeeFig.17and18).

Connecttheblackprimaryleadtothetransformerterminallabeled

208-v.

INDOOR

THERMOSTAT

RETURN

FROM

POWER

SOURCE---- --

DISCONNECT

_:x.. PER NEC*

GAS LINE

Fig. 12 - Typical Installation

*NEC -NATIONAL ELECTRICAL CODE

A09075

SINGLE-PHASE

CONNECTIONS

TO DISCONNECT

PER NEC

GROUNDSCREW

(IN SPLICE BOX)

GROUND

LEAD

L1 -_BLKm

L2 ........

NOTE: Use copper wire only.

LEGEND

NEC - National Electrical Code

Field Wiring

Z_ Splice Connections

Fig. 13 - Line Power Connections

A06299

HP/AC

BOARD

FURNACE BOARD

User

interface

Fig. 14 -Control Plate

Infinity Furnace

Board

HUM

.[1

LEGEND

| Factory Wiring

Infinity HP/AC

Board

[

OAT

OCT

mY2

mY1

Outdoor Air Thermistor

(Supplied with IU)

FIELD CONNECTION

REQUIRED

(BLACK WIRES)

:t:

Outdoor Coil Thermistor

FACTORY CONNECTED

_m m

FACTORY WIRES PROVIDED

FOR FIELD CONNECTION

OF UTILITY CURTAILMENT

Fig. 15 -Control Voltage Wiring Connections

AO910S

A06301

PRE-START-UP

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

ENVIRONMENTAL HAZARD

Failure to follow this warning could result in personal

iniury or death and/or property damage.

1. Follow recognized safety practices and wear protective

goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power

to unit unless compressor ternfinal cover is in place and

secured.

3. Do not remove compressor ternfinal cover until all

electrical sources are disconnected and tagged.

4. Relieve and recover all refrigerant from system before

touching or disturbing anything inside ternfinal box if

refrigerant leak is suspected around compressor

ternfinals.

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. (See Fig. 25.)

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 nfinutes 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. 28).

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 nfiscellaneous loose parts

have been removed.

5. Compressors are internally spring mounted. Do not loosen

or remove compressor holddown bolts.

6. 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

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 assunfing 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 system 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 Conmmnications 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. 16 and 19).

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

Oil.

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 conmmnications are established (this should

happen within 10 seconds). Once conmmnications 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 nfinutes, 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-Communicating Emergency Cooling/Heating

Mode) and will display Status Code 16, System Communication

Fault, on amber STATUS LED. No further troubleshooting

information will be available at UI until communications are

re-established.

If either COMM LED does not light within proper time period and

status codes are not displayed;

1. Check system transformer high- and low-voltage to be sure

the system is powered.

2. Check ABCD connection on both boards.

3. Check fuse on furnace board to be sure it is not blown. If

fuse is open, check system wiring before replacing it to be

sure a short does not cause a failure of replacement fuse.

If COMM LED does not light within proper time period and status

code is displayed:

1. Check system wiring to be sure UI is powered and

connections are made A to A, B to B, etc. and wiring is not

shorted. Miswiring or shorting of the ABCD

communications wiring will not allow successful

communications.

NOTE: Shorting or miswiring low-voltage system wiring will

not cause damage to unit control or UI but may cause low voltage

fuse to open.

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

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

iniury or death.

After disconnecting power from the ECM motor, wait at

least 5minutes 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.

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Fig. 16 -Detail of Furnace Board

A06026

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Fig. 17 -Wiring Schematic-48XL-A Single Phase Gas Inputs 040, 060, 090 kBtu/hr

A09080

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Fig. 18 - Wiring Schematic-48XL-A Single Phase Gas Inputs 115, 130 kBtu/hr

A09081

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UTILITY RELAY *

OPEN RELAY

* SUPPLIED BY UTILITY PROVIDER

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Liquid Line Solenoid

A05247

Fig. 19 -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 CODE 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 CODE 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, defective switch or

connections, or inadequate combustion air supply (flame roll-out

switch open).

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 42 - INDUCER MOTOR FAULT

Indicates inducer motor hasn't started within a prescribed time

limit. Check inducer motor and wiring.

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 4 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

openorshortedat 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

cycled off, the fault code will be cleared on the next power-up but

the fault will remain and system operation will not be as expected.

This is because on power-up, the unit control cannot discern

the difference between an open sensor or if a sensor is not

installed.

Sequence of Operation

The 48XL-A 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.

[]NIT 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 3 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 nfinutes 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

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

nfinute after compressor shuts off, when outdoor ambient is greater

than or equal to 100°F (38°C).

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. 17, 18 and 19). 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 65°F

(18 ° C) 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 nfinute after the compressor

shuts off when the outdoor ambient is greater than or equal to

100°F (38°C).

TIME DELAYS-AIR CONDITIONER OPERATIONS

The unit time delays include:

• Five nfinute 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.

• Five nfinute compressor recycle delay on return from a

brown-out condition.

• Two nfinute time delay to return to standby operation from last

valid conmmnication (with Infinity only).

• One nfinute time delay of outdoor fan at ternfination of cooling

mode when outdoor ambient is greater than or equal to 100°F

(38°C).

• 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.

Unit

Table 3 - Air Delivery and Temperature Rise at Rated Heating Input

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

"Efficiency .... Comfort"

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

20 - 50 15-45 35 30 40

40,000 26,000 (11-28) (8-25) (19) (17) (22)

Low Stage

48XL(-,N)A24040 35

48XL(-,N)A30040 (19)

48XL(-,N)A30060 25 - 55 25 - 55 40 50

48XL(-,N)A36060 60,000 39,000

48XL(-,N)A42060 (14-31) (14-31) (22) (28)

48XL(-,N)A36090

48XL(-,N)A42090 35 - 65 35 - 65 50 55

48XL(-,N)A48090 90,000 58,500 (19-36) (19-36) (28) (31)

48XL(-,N)A60090

48XL(-,N)A48115 115,000 75,000 30 - 60 30 - 60 45 50

48XL(-,N)A60115 (17-33) (17-33) (25) (28)

48XL(-,N)A48130 130,000 84,500 35 - 65 35 - 65 50 55

48XL(-,N)A60130 (19-36) (19-36) (28) (31)

Airflow delivery values for external static pressure values of up to 1 IN. W.C.

Table 4 -Heat Pump/Air Conditioner Board Status Codes

AMBER LED

OPERATION FAULT FLASH POSSIBLE CAUSE AND ACTION

CODE

On solid, no

Standby - no call for unit operation None flash Normal operation.

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

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

flashing mode should be used in emergency situations only.

Low Stage Cool/Heat Operation None 1, pause Normal operation.

High Stage Cool/Heat Operation None 2, pause Normal operation.

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

nications Failure

Control does not detect a model plug or detects an invalid model plug. Unit

Invalid Model Plug 25 will not operate without correct model plug.

High-Pressure 31 High-pressure switch trip. Check refrigerant charge, outdoor fan operation

Switch Open and coils for airflow restrictions.

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

Switch Open

Control Fault 45 Outdoor unit control board has failed. Control board needs to be replaced.

Brown Out (230 46 Line voltage < 187v for at least 4 seconds. Compressor and fan operation

v) not allowed until voltage>190v. Verify line voltage.

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

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

connected to the unit.

Outdoor Air Temp 53 Outdoor air sensor not reading or out of range. Ohm out sensor and check

Sensor Fault wiring.

Outdoor Coil Sen- 55 Coil sensor not reading or out of range. Ohm out sensor and check wiring.

sor Fault

Thermistors Out of 56 Improper relationship between coil sensor and outdoor air sensor. Ohm out

Range sensors and check wiring.

Low Stage Ther- Compressor voltage sensed, then disappears while cooling or heating de-

mal Cutout 71 mand exists. Possible causes are internal compressor overload trip or start

relay not releasing (if installed).

High Stage Ther- Compressor voltage sensed, then disappears while cooling or heating de-

mal Cutout 72 mand exists. Possible causes are internal compressor overload trip or start

relay not releasing (if installed).

Contactor Shorted 73 Compressor voltage sensed when no demand for compressor operation

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

No 230V at Com- 74 Compressor voltage not sensed when compressor should be starting. Con-

pressor tactor may be stuck open or there is a wiring error.

Low Stage Ther- 81 Thermal cutout occurs in three consecutive low/high stage cycles. Low

mal Lockout stage locked out for 4 hours or until 24v power recycled.

High Stage Ther- 82 Thermal cutout occurs in three consecutive high/low stage cycles. High

mal Lockout stage locked out for 4 hours or until 24v power recycled.

Low-Pressure 83 Low-pressure switch trip has occurred during 3 consecutive cycles. Unit

Lockout operation locked out for 4 hours or until 24v power recycled.

High-Pressure 84 High-pressure switch trip has occurred during 3 consecutive cycles. Unit

Lockout operation locked out for 4 hours or until 24v power recycled.

INFINITY CONTROLLED LOW AMBIENT COOLING

NOTE: When this unit is operating below 55°F (13°C) outdoor

temperature, provisions must be made for low ambient operation.

This unit is capable of low ambient cooling down to 0°F (-18°C).

ONLY when using the Infinity control. A low ambient kit is not

required, and the outdoor fan motor does not need to be 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 (4°C).OAT. Fan will cycle based on coil

and outdoor air temperature. Infinity controlled low ambient mode

operates as follows:

• In high stage, fan is off when outdoor coil temp is <outdoor air

temperature plus 3 ° F (1.7 ° C) or outdoor fan has been ON for 30

minutes. (Fan is turned off to allow refrigerant system to

stabilize.)

• In low stage, fan is off when outdoor coil temp is <outdoor air

temperature plus 1 °F (.6°C) or outdoor fan has been ON for 30

minutes. (Fan is turned off to allow refrigerant system to

stabilize.)

• In high stage and low stage, fan is on when outdoor coil temp >

outdoor air temperature plus 25 °F (13.8 ° C) or outdoor coil temp

> 80°F (27°C) or if outdoor fan has been OFF for 30 minutes.

(Fan is turned on to allow refrigerant system to stabilize.)

• Low-pressure switch is ignored for first 3 minutes during low

ambient start up. After 3 minutes, if LPS trips, then outdoor fan

motor is turned off for 10 minutes with the compressor running. If

LPS closes within 10 minutes then cooling continues with the

outdoor fan cycling per the coil temperature routine listed above

for the remainder of the cooling cycle. If the LPS does not close

within 10 minutes, then the normal LPS trip response (shut down

cooling operation and generate LPS trip error) will occur.

DEHUMIDIFICATION MODE

This Infinity system can be used to dehumidify the living space.

See UI Installation Instructions for more details.

SEQUENCE OF OPERATION-GAS HEAT

NOTE: Infinity control must be grounded for proper operation or

control will lock out.

NOTE: If a power interruption occurs during a call for heat, the

control will start a 90-second blower only ON period two seconds

after power is restored, if the UI is still calling for gas heating. The

amber LED light will flash code 12 during the 90-second period,

after which the LED will be ON continuously, as long as no faults

are detected. After the 90-second period, the unit will respond to

the UI normally.

GAS HEAT MODE AND ADJUSTMENTS

When the UI calls for gas heat, the Infinity furnace board performs

a self-check, verifies the pressure switch is open, and starts the

inducer on high speed.

1. Inducer Pre-purge Period: When the inducer motor comes

up on high speed, the pressure switch closes, and the

Infinity ignition control on the furnace board begins a 15

second pre-purge period. If the pressure switch fails to

remain closed, the inducer will remain running. After the

pressure switch re-closes, the Infinity ignition control will

begin a 15 second pre-purge period.

2. Trial-For-Ignition Sequence: The spark igniter will spark

for 3 seconds. The main gas valve relay contact closes to

energize the gas valve on low stage. After 5 seconds, the

igniter is de-energized and a 2-second flame-proving

period begins. NOTE: The unit always lights on high

speed inducer and low stage gas valve operation.

3. Flame-Proving: When the burner flame is proved at the

flame-proving sensor, the furnace control determines what

heating stage to run based on feedback from the UI. If the

UI is asking for low stage gas heat, the ignition control will

change the inducer speed to low speed and keep the gas

valve energized on low stage. If the UI is asking for high

stage gas heat, the ignition control will maintain running the

inducer on high speed and energize the gas valve's high

stage relay to increase gas flow.

If the burner flame is not proved within 2 seconds, the control will

close the gas valve and repeat the ignition sequence up to 3 more

Trials-For-Ignition before going to Ignition-Lockout. Lockout

will reset automatically after 3 hours, by momentarily interrupting

230 VAC power, or by interrupting 24 VAC power at SEC1 or

SEC2 to the furnace board.

If flame is proved when there should be no flame present, control

will lock out of Gas-Heating mode and operate the inducer motor

until flame is no longer proved.

4. Blower-On Delay: If the burner flame is proven,

approximately 37 seconds after the gas valve is opened the

Indoor Blower is turned on to the appropriate speed for the

gas heating stage.

Simultaneously, the humidifier terminal HUM and electronic air

cleaner terminal EAC-I are energized throughout the heating

cycle.

NOTE: EAC-2 terminal is common with L2 and will have

ll5VAC-to-ground when unit is powered.

5. Blower-Off Delay: When the call for gas heat is satisfied,

the gas valve is de-energized, stopping the flow of gas to

the burners, and de-energizing the HUM terminal. The

inducer motor will remain on for a 4-second post-purge

period. The indoor blower and air cleaner terminal EAC-I

will remain energized for 90, 120, 150, or 180 seconds

(depending on selection of blower-off delay selected in the

UI). The factory-set default is 120-second blower-OFF

delay.

CHECK GAS INPUT (NATURAL GAS)

UNIT DAMAGE HAZARD

Failure to follow this caution may result in component

damage.

Do not redrill an orifice. Improper drilling (burrs,

out-of-round holes, etc.) can cause excessive burner noise

and misdirection of burner flame. If orifice hole appears

damaged or it is suspected to have been redrilled, check

orifice hole with a numbered drill bit of correct size.

FIRE HAZARD

Failure to follow this warning could result in personal

iniury, death and/or property damage.

DO NOT bottom out gas valve regulator adjusting screws.

This can result in unregulated manifold pressure and result

in excess overfire and heat exchanger failures.

CARBONMONOXIDEPOISONINGHAZARD

Failureto follow this warning could result in personal

iniury and/or death.

If the manifold pressure and/or gas rate is not properly

ac[iusted on HI and LO stages, excess carbon monoxide can

be produced.

FIRE AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal

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 6.

Gas input rates on rating plate are for installations at altitudes up to

2000 ft (610 m). Input rate nmst be within - 2% of rating plate

input.

1. Determine the correct gas input rate.

a. The rated gas inputs shown in Table 6 are for altitudes

from sea level to 2000 ft (610 m) above sea level.

These inputs are based on natural gas with a heating

value of 1025 Btu/ft3 at .60 specific gravity.

IN THE U.S.A.:

The input rating for altitudes above 2,000 ft (610 m) nmst be

reduced by 4 percent for each 1,000 ft (305 m) above sea level.

For installations below 2,000 ft, (610 m) refer to the unit rating

plate.

For installations above 2,000 ft, (610 m) nmltiply the input by on

the rating plate by the derate nmltiplier in Table 5 for the correct

input rate.

Table 5 - Altitude Derate Multiplier for U.S.A*.

Derate Multiplier

Altitude ft (m) Percent of Derate Factort

0-2000

(0-610) 0 1.00

2001-3000*

(610-914) 8-12 0.90

3001-4000

(915-1219) 12-16 0.86

4001-5000

(1220-1524) 16-20 0.82

5001-6000

(1524-1829) 20-24 0.78

6001-7000

(1829-2134) 24-28 0.74

7001-8000

(2134-2436) 28-32 0.70

8001-9000

(2139-2743) 32-36 0.66

9001-10,000 36-40 0.62

(2744-3048)

In Canada see Canadian Altitude Adjustment.

J-Derate multiplier factors are based on midpoint altitude for altitude range.

IN CANADA:

The input rating for altitudes from 2,000 (610 m) to 4,500 ft (1372

m) above sea level nmst be derated 10 percent by an authorized

Gas Conversion Station or Dealer.

EXAMPLE:

90,000 Btuh Input Furnace Installed at 4300 fl (1372 m).

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. Ac[iust manifold pressure to obtain low stage input rate (See

Fig. 20).

a. Turn off gas supply to unit.

b. Remove pipe plug on manifold (See Fig. 21 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. 20) and turn

low-stage ac[iusting screw (3/16 or smaller flat-tipped

screwdriver) counterclockwise (out) to decrease rate and

clockwise (in) to increase input rate.

1/2" NPT INLET

Fig. 20 - Redundant Automatic Gas Control Valve

A04167

NOTE: DO NOT set low stage manifold pressure less than 1.4

IN. W.C. or more than 2.0 IN. W.C. for natural gas. If manifold

pressure is outside this range, change main burner orifices.

f. Re-install low stage regulator ac[iustment 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 6.

(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 1025

Btu/ft 3. Proceed as follows:

a.129sec.to complete one revolution

b. 3600/129 = 27.9

c. 27.9 x 2 = 55.8 ft3 of gas flow/hr.

d. 55.8 x 1050 = 58,590 Btuh input.

In this example, the nonfinal input rate for low stage is 58,500

Btu/hr, so the low stage manifold pressure is correctly set.

If the measured low stage rate is too low, increase the manifold

pressure to increase rate. 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. Furnace must operate within rise range listed on rating

plate.

b. Select "COMFORT" or "EFFICIENCY" mode on UI.

"COMFORT" mode will provide a warmer supply air

temperature, while "EFFICIENCY" will provide lower

gas consumption.

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

d. Measure supply and return temperatures as close to the

unit as possible. Subtract the return temperature from

the supply temperature to deternfine rise. Rise should

fall within the range specified on the rating plate.

5. Adjust manifold pressure to obtain high stage input rate

(See Fig. 20).

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. 20) 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. W.C. or more than 3.8 IN. W.C. 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 6.

(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 1025

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 nonfinal 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 deternfine 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. W.C.

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. 21).

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 (610 m), refer to the unit

rating plate for proper propane conversion kit. For installations

above 2,000 ft (610 m), contact your distributor for proper propane

conversion kit.

CHECK BURNER FLAME

With control access panel removed (See Fig. 25), 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.

22). Refer to the Maintenance section for information on burner

removal.

Fig. 21 -Burner Assembly

A0g082

BURNERFLAME

BURNER

MANIFOLD

Fig. 22 -Monoport Burner

C99021

LIMIT SWITCHES

Normally closed limit switch (LS) completes the control circuit.

Should the leaving-air temperature rise above the maximum

allowable temperature, the limit switch opens and the control

circuit "breaks." Any interruption in the control circuit instantly

closes the gas valve and stops gas flow to the burners. The blower

motor continues to run until LS resets. The furnace board STATUS

LED will display STATUS CODE 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 CODE 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-I 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.

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 an

accurate scale. Refer to unit rating plate for required charge.

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 (4°C) (unless

low-ambient operation is enabled in the UI). Do not rapid cycle

the compressor. Allow 5min. 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.

HEATING INPUT(BTU/HR)*

Low Stage

26,000

39,000

58,500

75,000

84,500

NUMBER OF

ORIFICES

Table 6 -Heating Inputs

GAS SUPPLY PRESSURE (IN. W.C.)

Natural

MANIFOLD PRESSURE (IN. W.C.)

Natural

High Stage

3.2-3.8

High Stage Min Max Low Stage

40,000 4.0 13.0 1.4 - 2.0

60,000 4.0 13.0 1.4 - 2.0

90,000 4.0 13.0 1.4 _ 2.0

115,000 4.0 13.0 1.4 _ 2.0

130,000 4.0 13.0 1.4 _ 2.0

*Cubic ft of natural gas per hour for gas pressures of .5 psig (14 IN. W.C.) or less and a pressure drop of .5 IN. W.C. (based on a .60 specific gravity gas). Ref:

Table 6.2 (b) NPFA 54 /ANSI Z223.1-2009.

Table 7-ECM Wet Coil Pressure Drop (IN. W.C.)

UNIT STANDARD CFM (SCFM)

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

24 0.005 0.007 0.010 0.012 0.015

30 0.007 0.010 0.012 0.015 0.018 0.021 0.024

36 0.019 0.023 0.027 0.032 0.037 0.042 0.047

42 0.014 0.017 0.020 0.024 0.027 0.031 0.035 0.039 0.043

48 0.027 0.032 0.036 0.041 0.046 0.052 0.057 0.063 0.068

60 0.029 0.032 0.036 0.040 0.045 0.049 0.053

Table 8 -Filter Pressure Drop Table (IN. W.C.)

FILTERSIZE CFM

in.(mm) 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

20X20X1 0.05 0.07 0.08 0.1 0.12 0.13 0.14 0.15 ...........

(508x508x25)

24X30X1 .... 0.05 0.6 0.07 0.07 0.08 0.09 0.1 ........

(610x762x25)

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

(610x914x25)

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.

REFRIGERANT CHARGE

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. 24). 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.

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.

NOTE: If the problem causing the inaccurate readings is a

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 48XL 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. 23. 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.

infinity Furnace infinityHP/AC

Board Board

Standard

4..Wire

Thermostat

OutdoorAirThermistor

(Suppliedwith IU)

FIELDCONNECTION

REQUIRED

(BLACKWIRES)

OutdoorCoilThermistor

FACTORYCONNECTED

_m m

FACTORYWIRESPROVIDED

FOR FIELDCONNECTION

OFUTILITYCURTAILMENT

Fig. 23 - Non-Communicating Emergency Cooling/Heating Wiring Connections

Required Subcooling °F(°C)

Outdoor Ambient Temperature °F(°C)

Model Size 75 (24) 85 (29) 95 (35) 105 (41) 115 (46)

24 16 (8.7) 16 (8.7) 16 (8.7) 16 (8.7) 16 (8.7)

30 17 (9.3) 10 (9) 16 (9.7) 15 (8.3) 15 (8.2)

36 14 (7.8) 14 (7.7) 14 (7.7) 14 (7.6) 14 (7.6)

42 19 (19.7) 19 (10.6) 19 (10.5) 19 (10.4) 19 (10.3)

48 21 (11.7) 21 (1%5) 20 (11.3) 20 (11.2) 20 (11.1)

60 17 (9.4) 17 (9.4} 17 (9.4) 17 (9.4) 17 (9.4)

•ce

1= Measure Discharge line pressure by attaching a gauge to the service port.

2= Measure the Liquid line temperature by attaching a temperature sensing

device to it.

3- Insulate the temperature sensing device so that the Outdoor Ambient

doesn't affect the reading.

¢- Refer to the required Subcooling in the table based on the model size and

_he Outdoor Ambient temperature.

5- interpolate if the Outdoor ambient temperature lies in between the table

values.

6- Find the Pressure Value in the table corresponding to the the measured

Pressure of the Compressor Discharge line,

7= Read across from the Pressure reading to obtain the Liquid line

Iemperature for a required Subcooling

_= Add Charge if the measured temperature is higher than the table value,

=Remove charge if the measured temperature is lower than the table value.

50DU500166 REV 3.0 ]

Pressure

(psig) 5

189 61

196 63

203 66

210 68

217 70

224 72

231 74

238 78

245 77

252 70

260 81

268 83

276 85

284 87

292 89

300 91

309 93 88

318 95 90

327 97 92

336 99 94

345 101 96

354 103 98

364 105 100

374 107 102

384 108 103

394 110 105

404 112 107

414 114 109

424 116 111

434 118 113

444 119 114

454 121 116

464 123 118

474 124 119

484 126 121

494 127 122

504 129 124

514 131 126

524 132 127

534 134 129

Required Liquid Line Temperature for a

Required Subcoolin_ !°F) Pressure

10 15 20 25 (kPa)

56 51 46 41 1303

58 53 48 43 1351

61 56 51 46 1399

63 58 53 48 1449

85 60 55 50 1496

67 62 57 52 1544

69 64 59 54 1593

71 66 61 56 1641

72 67 62 57 1689

74 69 64 59 1737

76 71 66 51 1792

78 73 68 63 1848

80 75 70 65 1903

82 77 72 67 1958

84 79 74 69 2013

86 81 76 71 2068

83 78 73 2130

85 90 75 2192

87 82 77 2254

89 84 79 2316

91 86 81 2378

93 88 83 2440

95 90 85 2509

97 92 87 2578

99 93 88 2647

100 95 90 2716

102 97 92 2785

104 99 94 2854

106 101 96 2923

108 103 98 2992

109 104 99 3061

111 106 101 3130

113 108 103 3199

114 109 104 3268

116 111 106 3337

117 112 107 3406

119 114 199 3475

121 116 111 3544

122 117 112 3612

124 119 114 3681

Specific Subcoolin_ IR-410A}

Required Subcoolin_ I°C)

A06302

Fig. 24 - Cooling Charging Table-Subcooling

3 6 811 14

16 13 11 85

17 15 12 9 6

19 16 13 10 8

20 17 14 11 9

21 18 15 13 10

22 19 16 14 11

23 20 18 15 12

24 21 19 16 13

25 22 20 17 14

26 23 21 18 15

27 25 22 19 16

29 26 23 20 17

30 27 24 21 19

31 28 25 22 20

32 29 26 23 21

33 30 27 24 22

34 31 28 26 23

35 32 29 27 24

36 33 31 28 25

37 34 32 29 26

38 35 33 30 27

39 36 34 31 28

40 38 35 32 29

41 39 36 33 39

42 40 37 34 31

44 41 38 35 32

45 42 39 36 33

46 43 40 37 34

47 44 41 38 35

48 45 42 39 36

48 46 43 40 37

49 47 44 41 38

50 48 45 42 39

51 48 46 43 40

52 49 47 44 41

53 50 47 45 42

54 51 48 46 43

55 52 49 46 44

56 53 50 47 45

56 54 51 48 45

A0gl0g

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 9 and 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 personal

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.

[]NIT 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. Clean when necessary.

3. Inspect indoor fan motor and wheel for cleanliness each

cooling season. Clean 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. Clean 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.

Air Filter

IMPORTANT: Never operate the unit without a suitable air filter

in the return-air duct system. Always replace the filter with the

same dimensional size and type as originally installed. See Table 1

for recommended filter sizes.

Inspect air filter(s) at least once each month and replace

(throwaway-type) or clean (cleanable-type) at least twice during

each cooling season and twice during the heating season, or

whenever the filter becomes clogged with dust and lint.

Indoor 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.

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.

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.

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.

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.

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 and install lockout tag.

3. Remove control access panel (See Fig. 25).

4. Disconnect gas piping at unit gas valve.

5. Remove fan partition mounting bracket (2 screws located

on the left side of control compartment on the fan partition

panel). Slide bracket forward, bottom first, to remove. (See

Fig. 26.)

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

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

the unit base (See Fig. 26).

8. Partially slide the burner rack out of the unit (see Fig. 26

and 27). Remove ignitor and sensor wires at the burner as-

sembly. Remove wires to rollout switch.

9. Slide the burner rack out of the unit (See Fig. 26 and 27).

10. To reinstall, reverse the procedure outlined above.

Bh wer

Access

Compressor Panel

Access Panel

Fig. 25 - Unit Access Panels

Control

Access

Panel

A09479

Integrated

Gas Unit

(IGC)

Auto Transformer

fuses used on 460

(Hidden)

Fan

Board (IFB)

Induced Draft

Motor

Fan Partition

Mounting

Bracket

Flue RolIout

Collector Inducer Burner Mounting Switch

Box Blower Rack Screw

Housing

Fig. 26 - Blower Housing and Flue Collector Box

A09480

A07680

Fig. 27 - Burner Rack Removed

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.

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 nfild

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 sinfilar probe device.

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. 28.

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

shaft when tightening.

7. Replace grille.

Electrical Controls and Wiring

Inspect and check the electrical controls and wiring annually. Be

sure to turn off the electrical power to the unit.

Remove access 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.

infinity Top

A06035

UNIT SIZE "A" DIM. IN. (MM)

24 1 (26)

30 1 (26)

36 1 (26)

42 1 (26)

48 11/32 (9)

60 9/16 (14)

Fig. 28 -Outdoor Fan Blade Clearance

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.

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.

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-Charge (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.

Hi_h-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.

Copeland Scroll Compressor (Puron Refrigerant)

The compressor used in this product is specifically designed to

operate with Puron (R-410A) refrigerant and cannot be

interchanged.

The compressor is an electrical, as well as mechanical, device.

Exercise extreme caution when working near compressors. Power

should be shut off, if possible, for most troubleshooting techniques.

Refrigerants present additional safety hazards.

EXPLOSION, FIRE HAZARD

Failure to follow this warning could result in personal

iniury 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. The compressor is equipped with noise reducing

shutdown device and an internal pressure-relief port. The

pressure-relief port is a safety device, designed to protect against

extreme high pressure. The relief port has an operating range

between 550 and 625 psi differential pressure.

Refrigerant System

This step covers the refrigerant system of the 48XL, including the

compressor oil needed, servicing systems on roofs containing

synthetic materials, the filter drier, and refrigerant charging.

REFRIGERANT

UNIT OPERATION, SAFETY

ENVIRONMENTAL HAZARD AND

Failure to follow this warning could result in personal

iniury 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 nmst be designed to handle

Puron. If you are unsure, consult the equipment

manufacturer.

COMPRESSOR OIL

If additional oil is needed use Uniqema RL32-3MAF. If this oil is

not available, use Copeland Ultra 32CC or Mobil Artic EAL22CC.

This oil is extremely hygroscopic, meaning it absorbs water

readily. POE oils can absorb 15 times as nmch 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. Cover extended roof working area with an inapermeable

polyethylene (plastic) drip cloth or tarp. Cover an

approximate 10 X 10 ft (3x3 m) area.

2. Cover area in front of the unit service panel with a terry

cloth shop towel to absorb lubricant spills and prevent

run-offs, and protect drop cloth from tears caused by tools

or components.

3. Place terry cloth shop towel inside unit immediately under

component(s) to be serviced and prevent lubricant run-offs

through the louvered openings in the unit base.

4. Perform required service.

5. Remove and dispose of any oil-contaminated material per

local codes.

LIQUID-LINE FILTER DRIER

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 4, as well as the UI

instructions, for additional information. Additional

Troubleshooting information can be found in Table 9 and 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 lost 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 4.

PRESSURE SWITCH PROTECTION-REFRIGERANT

The unit is equipped with high- and low-pressure switches. If the

control senses the opening of a high- or low-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 4). 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

n_ininmm of 190v. The control will flash the appropriate fault

code (See Table 4).

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. 19) 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 4. 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 nfinutes. If the thermal protector

closes (at the next 15 nfinute 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 UNIT 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 sinfilar 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

Thernfistors are electronic devices which sense temperature. As the

temperature increases, the resistance decreases. Thernfistors are

used to sense outdoor ambient (OAT) and coil temperature (OCT).

Refer to Fig. 29 for resistance values versus temperature. See Fig.

30 for OCT location.

If the outdoor ambient or coil thernfistor should fail, the HP/AC

control will flash the appropriate fault code (See Table 4).

IMPORTANT: Coil thernfistor is factory mounted. Check to

insure thernfistor is mounted properly. Outdoor air thernfistor

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

been properly installed.

THERMISTOR CURVE

9O I I I I

8o-k----4------4-----M------4-------I....

\ttttt

7o- -'_-- _------ I----- _------ T------I ....

6o- ---_- J.-- -- -- J----- _------ J----- --I....

\t t t t t

50.... '_------ 1----- _------ 1-------I ....

40- - _,__ k__ d___ J____l ....

t\ t t t t

3o.... _----_',_----_------I-------I....

20.... _ ______/'_/__ ____/ ____--I....

t t _t t

lo.... H--- t---_--_--

o ..................I...................I...................I...................I...................I,,,,,_

0 20 40 60 80 100 120

TEMPERATURE (DEG. F)

A91431

Fig. 29 - Resistance Values Versus Temperature

THERMISTOR SENSOR COMPARISON

The control continuously monitors and compares the outdoor air

temperature sensor and outdoor coil temperature sensor to ensure

proper operating conditions. The comparison is:

•In cooling mode, if the outdoor air sensor indicates -> 10 °F

(5.5 °C) warmer than the coil sensor (or) the outdoor air sensor

indicates ->20°F (II.0°C) cooler than the coil sensor, the sensors

are out of range.

>5 ° o

• In heating if the outdoor air sensor indicates _ 3. F (19.3 C)

warmer than the coil sensor (or) the outdoor air sensor indicates

->10°F (5.5°C) cooler than the coil sensor, the sensors are out of

range.

If the sensors are out of range, the control will flash the appropriate

fault code as shown in Table 4.

The thernfistor comparison is not performed during low ambient

cooling operation.

FAILED THERMISTOR DEFAULT OPERATION

Factory defaults have been provided in the event of failure of

outdoor air thernfistor and/or coil thernfistor.

If the OAT sensor should fail, low ambient cooling will not be

allowed and the one-nfinute outdoor fan off delay will not occur.

Defrost will be initiated based on coil temperature and time.

If the OCT sensor should fail, low ambient cooling will not be

allowed. Defrost will occur at each time interval during heating

operation, but will ternfinate after 5 nfinutes.

If there is a thernfistor out of range error, defrost will occur at each

time interval during heating operation, but will ternfinate after 5

nfinutes.

Refer to the Troubleshooting Chart (Table 9 and 10) for additional

troubleshooting information.

tight on the liquid

"tub

Fig. 3t) - Outdoor Coil Thermistor (OCT) Attachment

A06311

FINAL CHECKS

IMPORTANT: Before leaving job, be sure to do the following:

1. Ensure that all wiring is routed away from tubing and sheet

metal edges to prevent rub-through or wire pinching.

2. Ensure that all wiring and tubing is secure in unit before

adding panels and covers. Securely fasten all panels and

covers.

3. Tighten service valve stem caps to l/2-turn past finger

tight.

4. Leave Users Manual with owner. Explain system operation

and periodic maintenance requirements outlined in manual.

5. Fill out Start-Up Checklist located at the back of this

manual and place in customer file.

CARE AND MAINTENANCE

For continuing high performance and to nfininfize possible

equipment failure, periodic maintenance must be performed on this

equipment.

Frequency of maintenance may vary depending upon geographic

areas, such as coastal applications. See Users Manual for

information.

AIR CONDITIONER WITH PURON

REFRIGERATION SECTION QUICK-REFERENCE GUIDE

Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and replacement components are

designed to operate with Puron. Puron refrigerant cylinders are rose colored.

•Puron refrigerant cylinders manufactured prior to March 1, 1999, have adip tube that allows liquid to flow out of cylinder in upright

position. Cylinders manufactured March 1, 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid

to flow.

• Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.

• Puron systems should be charged with liquid refrigerant. Use a commercial-type metering device in the manifold hose.

• Manifold sets should be minimum 700 psig high side and 180 psig low side with 550 psig low side retard.

• Use hoses with minimum 700 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• Puron, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Only use factory-specified liquid-line filter driers with rated working pressures no less than 600 psig.

• Do not install a suction-line filter drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter driers and service valves with wet cloth when brazing.

• A Puron liquid-line filter drier is required on every unit.

• Do not use an R-22 TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, break vacuum with dry nitrogen and replace filter driers.

• Do not vent Puron into the atmosphere.

• Observe all warnings, cautions, and bold text.

• Do not leave Puron suction line driers in place for more than 72 hrs.

Table 9-Troubleshooting Chart -Cooling

SYMPTOM

Compressor and outdoor fan

will not start

Compressor will not start but condenser fan

runs

Compressor cycles (other than normally sat-

isfying) cooling/heating calls

Compressor operates continuously

Excessive head pressure

Head pressure too low

Excessive suction pressure

Suction pressure too low

IFM does not run

IFM operation is intermittent

CAUSE

Power failure

Fuse blown or circuit breaker tripped

Defective contactor, transformer, control relay, or high-

pressure, loss-of-charge or low-pressure switch

Insufficient line voltage

Incorrect or faulty wiring

UI setting too low/too high

Units have a 5-minute time delay

Faulty wiring 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 air filter

Unit 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 valve 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 conditioned area

Outdoor ambient below 55°F (13°C)

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 wiring diagram and rewire correctly

Reset UI setting

DO NOT bypass this compressor time

delay-wait for 5 minutes until time-delay

relay is de-energized

Check wiring 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 replace

Replace

Locate restriction and remove

Replace filter

Decrease load or increase unit size

Reset UI setting

Locate leak, repair, and recharge

Recover refrigerant, evacuate system, and re-

charge

Clean 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 UI 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--Troubleshooting Chart - Gas Furnace 0

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

peration

REMEDY

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 all wiring and wire nut connections

Check flame ignition and sense electrode posi-

tioning.

Adjust 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.

Adjust as necessary.

1. Tighten all screws around burner compartment

2. Cracked heat exchanger. Replace.

3. Unit over-fired. Reduce input (change orifices

or adjust gas line or manifold pressure).

4. Check burner alignment.

5. Inspect heat exchanger for blockage. Clean

as necessary.

I. PRELIMINARY INFORMATION

MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

START-UP CHECKLIST

(Remove and Store in Job Files)

II. PRESTART-UP (Insert check mark in box as each item is completed)

()VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS

( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS

( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)

( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE

( ) VERIFY THAT UNIT INSTALLATION IS LEVEL

( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

( ) MAKE SURE THAT - (If Applicable) ON A60 SIZE PURON HEAT PUMP ONLY, THE TWO WIRE TIRES FASTEN TO THE

OUTDOOR COILS AND REVERSING VALVE/ACCUMULATOR HAVE BEEN REMOVED

III. START-UP

ELECTRICAL

SUPPLY VOLTAGE

COMPRESSOR AMPS

INDOOR (EVAPORATOR) FAN AMPS

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE

RETURN-AIR TEMPERATURE

COOLING SUPPLY AIR DB

GAS HEAT SUPPLY AIR

PRESSURES

(;AS INLET PRESSURE

GAS MANIFOLD PRESSURE

REFRIGERANT SUCTION

REFRIGERANT DISCHARGE

IN. W.C.

PSIG, SUCTION LINE TEMP*

PSIG, LIQUID TEMPi-

( ) 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

1- Measured at liquid line leaving condenser.

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

Catalog No:48XL-06SI

Replaces: 48XL- 05Sl

CARRIER Package Units(both Units Combined) Manual L0912143

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