Instruction manual | Carrier 48XL Air Conditioner User Manual

®
Turn to the Expertg
Installation
EQUIPMENT
OPERATION
OAT sensor must be field
Installation for more details.
EQUIPMENT
This Infinity
Interface.
TM
OPERATION
Instructions
HAZARD
installed.
See
Accessory
HAZARD
unit is designed for use with an Infinity User
NOTE:
Read the entire instruction manual before starting the
installation.
TABLE
OF CONTENTS
PAGE
SAFETY CONSIDERATIONS
.........................
2
INTRODUCTION
...................................
2
RECEIVING AND INSTALLATION .................
2-12
Check Equipment ..................................
2
Identify Unit ....................................
2
Inspect Shipment .................................
2
Provide Unit Support ...............................
2
Roof Curb ......................................
2
Slab Mount .....................................
2
Ground Mount ..................................
2
Provide Clearances .................................
7
Rig and Place Unit .................................
7
Inspection ......................................
8
Introduction .....................................
8
Use of Rigging Bracket ............................
8
Select and Install Ductwork ...........................
8
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units ..........................
9
Provide for Condensate Disposal .....................
10
Install Flue Hood ..................................
10
Install Gas Piping .................................
10
Install Electrical Connections ........................
11
High-Voltage Connections ........................
11
Routing Power Leads Into Unit .....................
12
Connecting Ground Lead to Ground Screw ...........
12
Routing Control Power Wires .....................
12
Accessory Installation ............................
12
Special Procedures for 208-v Operation ..............
12
PRE-START-UP
...................................
15
START-UP .....................................
15-26
Unit Start-Up and Troubleshooting
...................
15
Sequence of Operation ..........................
20-24
Check for Refrigerant Leaks .........................
25
Start-Up Adjustments ..............................
25
Checking Cooling and Heating Control Operation ......
25
Checking and Adjusting Refrigerant Charge ...........
25
A05307
Fig. 1 - Unit 48XL
Refrigerant Charge ..............................
26
No Charge .....................................
26
Low Charge Cooling .............................
26
To Use Cooling Charging Charts ....................
26
Non-Communicating
Emergency Cooling/Heating Mode .. 26
MAINTENANCE ................................
28-30
Air Filter ........................................
28
Indoor Fan and Motor ..............................
28
Inducer Blower ...................................
28
Limit Switch .....................................
28
Burner Ignition ...................................
28
Main Burners ....................................
28
Inducer Pressure Switch ............................
28
Outdoor Coil, Indoor Coil, and Condensate Drain Pan .....
29
Outdoor Fan .....................................
29
Electrical Controls and Wiring .......................
29
Refrigerant Circuit .................................
29
Indoor Airflow ...................................
29
Pressure Switches .................................
29
Loss-of-Charge Switch ............................
28
High-Pressure Switches ............................
29
Copeland Scroll Compressor (Puron cR)Refrigerant) ........
30
Refrigerant System ................................
30
Refrigerant ....................................
30
Compressor Oil .................................
30
Servicing Systems on Roofs with Synthetic Materials ....
30
Liquid-Line Filter Drier ..........................
30
Puron (R-410A) Refrigerant Charging ...............
30
TROUBLESHOOTING
...........................
30-31
FINAL CHECKS ...................................
32
CARE AND MAINTENANCE
........................
32
START-UP CHECKLIST ............................
36
SAFETY
Installation
CONSIDERATIONS
and servicing
of this equipment
can be hazardous
due
to mechanical
and electrical
components.
Only trained and
qualified personnel should install, repair, or service this equipment.
Untrained
personnel
can perform
basic maintenance
flmctions,
such as cleaning and replacing air filters. All other operations must
be performed
by trained service
equipment,
observe precautions
labels attached to or shipped
precautions
Follow
personnel. When working
on this
in the literature, on tags, and on
with the unit and other safety
that may apply.
all safety
codes.
Installation
local and national building
clothing, and work gloves.
must
be in compliance
with
codes. Wear safety glasses, protective
Have fire extinguisher
available. Read
these instructions
thoroughly
and follow all warnings
included in literature and attached to the unit.
or cautions
Recognize
symbol
safety
information.
This is the safety-alert
/_.
When you see this symbol on the unit and in instructions
or manuals, be alert to the potential for personal iniury. 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 iniury
or death. WARNING
signifies hazards which could result in personal iniury or death. CAUTION
is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used
result in enhanced installation,
to highlight
suggestions
reliability, or operation.
which
will
NOTE:
installations.
Low
NOx
requirements
RECEIVING
apply
only
to
natural
gas
AND INSTALLATION
Check Equipment
IDENTIFY
The
UNIT
unit model
informative
number
and serial number
plate. Check
INSPECT
are printed
this information
against
on the unit
shipping
papers.
SHIPMENT
Inspect for shipping damage while unit is still on shipping pallet. If
unit appears to be damaged or is torn loose from its anchorage,
have it examined
by transportation
inspectors
before removal.
Forward
claim
papers
directly
to transportation
Manufacturer
is not responsible
for any damage incurred
company.
in transit.
Check all items against shipping
list. Immediately
notify the
nearest Carrier office if any item is missing. To prevent loss or
damage, leave all parts in original packages until installation.
Provide
For
Unit Support
hurricane
(Professional
tie downs,
contact
Engineering)
ROOF
CURB
Install
accessory
distributor
Certificate,
for details
roof curt) in accordance
with instructions
with curt) (See Fig. 4). Install insulation,
cant strips,
flashing. Ductwork must be attached to curb.
IMPORTANT:
The
for a water
gasketing
tight
seal.
of the
Always install furnace to operate within the intended temperature
rise range with a duct system which has an external static pressure
critical
within the allowable range, as specified in "Indoor Airflow Adjustments" section of these instructions.
See furnace rating plate.
air leaks and poor unit performance.
with the roof curt). Improperly
and PE
if required.
Install
unit
to the roof
gasketing
applied
shipped
roofing,
curt) is
material
gasketing
and
supplied
also can result in
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 curt) installation
instructions
for additional
information
as
required.
ELECTRICALSHOCK
Failure to follow
iniury or death.
HAZARD
this warning
could
result
in personal
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
MAXIMUM
ALLOWABLE
DIFFERENCE
if applicable.
A-B
in. (ram)
B-C
1/4 (6.35)
1/4
A-C
(6.35)
1/4
(6.35)
A07925
Fig. 2 - Unit Leveling
UNIT
OPERATION
AND SAFETY
Failure to follow this warning
iniury or equipment damage.
Puron (R-410A)
standard
R-22
systems
systems.
equipment
or components
Ensure service equipment
HAZARD
could
result
SLAB
in personal
MOUNT
Place the unit on a solid, level concrete
in. (102
operate at higher
DO NOT
use
Tolerances
mm)
thick
with
pad that is a minimum
2 in. (51 mm)
above
grade.
of 4
The
slat)
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 slat)
except when required by local codes.
pressures than
R-22
service
on Puron (R-410A)
equipment.
is rated for Puron (R-410A).
INTRODUCTION
The
48XL
Category
packaged
unit
I gas heating/electric
is a fully
self-contained
air conditioner
designed
for outdoor
installation
(See Fig.
1). Standard
units are shipped
in a
horizontal-discharge
configuration
for
installation
on
a
ground-level
slab or directly on the ground if local codes permit.
Standard units can be converted
to downflow
configurations
for rooftop applications.
Models
with
an N in the fifth position
(vertical)
of the model
RETURr
SUPPLY
.,_
lY/i_
\
\'\1
.,_
m_
_E_
III1| OPENIN,_
i
_,
f--_OPENING
IIII|
tlil _
_z_ (
't [
IIIII
Ill[
I_J'/_
_
_ II
IIIII
Ill|
_
dill
dlII
1111
_III
jlII
IIIII
IIIII
IIIII
N
I/
_'_ A'
N?',.q
IIII
II II
IIII
lUll
combination
#-/
are
EVAR
//I
/_
//
tlii
illl
-2=_--__-----_/
. j,
/
COIL
COND.
.
COIL
A07926
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.
"_
)
/
2"
_
(50.Smm)
discharge
number
IIll _ <s' _
I! ,I
Hiv-'_ \ -- JbJ/....
GROUND
Fig. 3 - Slab Mounting
MOUNT
The unit may be installed
either
Detail
on a slab or placed directly
ground
if local codes permit. Place the unit
prepared with gravel for condensate
discharge.
on
level
on the
ground
ase
/
/
,,Screw.__._
(NOTE
/
A)
-_'l
*Gasketing
/
.._
r_ j
\
_
Flashing
I
Ill_l
field
supplied
Wood
_
II
JJU_ilt"_
Ro°f
II_::i!ll/I#
Roofing
material
U_
curb*
(field
Insulation
supphed)
I[
IL
field
supplied--
ll_ii![l
'_
/l_!_i:ll
\
nailer*
II_ Duotwork
_ill
I[ field supplied/
Roof
Curb for Small
Cabinet
Roof Curb for Large Cabinet
Note A: When unit mounting screw is used,
retainer
bracket
must
also
Note A: When unit mounting screw is used,
retainer bracket must also be used.
be used.
_E
Supply opening
(BxO)
+
G
\
F
\/
R/A
S/A
................................................................
_,
_Gask_tua_Ound"/_
Insulated
Gasket around
SuppoR
deck pan
Long
Suppo_
outer
edge
N
X_
Retu'nopening
(BXC)
A05308
UNIT
CATALOG
NUMBER
A
IN. (MM)
B
IN. (MM)
CPRFCURB006A00
8 (203)
11 (279)
16-1/2
(419)
28-3/4
(730)
30-3/8
(771)
44-5/16
(1126)
45-15/16
CPRFCURB007A00
14 (356)
11 (279)
16-1/2
(419)
28-3/4
(730)
30-3/8
(771)
44-5/16
(1126)
45-15/16
CPRFCURB008A00
8 (203)
16-3/16
(411)
17-3/8
(441)
40-1/4
(1022)
41-15/16
(1065)
44-7/16
(1129)
46-1/16
(1169)
CPRFCURB009A00
14 (356)
16-3/16
(411)
17-3/8
(441)
40-1/4
(1022)
41-15/16
(1065)
44-7/16
(1129)
46-1/16
(1169)
be used
as well.
SIZE
024-030
036-060
D
IN. (MM)
C
IN. (MM)
E
IN. (MM)
F
IN.(MM)
G
IN. (MM)
(1167)
(1167)
NOTES:
1. Roof
curb
2.
Seal
strip
3.
Roof
4.
Attach
5.
Insulated
d.
When
curb
must
must
is made
ductwork
panels:
unit
conditions.
be set up for unit
be applied,
of 1d-gauge
to curb
1-in.
mounting
This
screw
installed.
to unit
being
installed.
steel.
(flanges
(25 mm)
bracket
being
as required,
of duct
thick
is used
is available
rest on curb).
fiberglass
(see Note
through
1 lb. density.
A), a retainer
bracket
must
This
bracket
Micrometl.
Fig. 4 - Roof Curb
Dimensions
must
also be used when
required
by
code
for hurricane
or seismic
UNIT
ELEGTRIG_L
CHARACTERISTICS
INIT
208'230
208,230
48XL024¢140
,SXLO2,1G#I
LSS
396
@l
405
4O8
] 60
i 60
_SXLU30040
2GS,P30
48XL03_060
CORNER_EIEHT LBS
4
Hi
6
85,38
_0
i81¸9
/8_ 8
/8_/
02; ¸
¢2)
0_;'
'?
,3ENTEROF GRAVlT{ M_,_/I_
X
8080(800_
5,USO{28UJ
5O8 O(20 i_)
5G80{_00_
'
489 0(:_ 5)
489G,:19 3)
489 Oil9 3)
489¸O i95
4,170_176}
4,1,' 6(i}' 6}
44_G_ii
_}
REOUIREDCLEARANCESTO COMBUS_BLE MAlL
KG
C
955
U_IT HEIGHT
"_"
_U4:_14_
1641_(43
I_9_ _(43
09? ', 5
)
8
TO_ OE U_iT
.....
_CT SinE OF u_il
SIDE OPPOSi_E DUCTS
80TTO_ OF gNIT
ELECT_iC HEA_ PANEL
4b(6
#41U i_IETER8
585¸6 [14
S08 [2
555 6 [/4
/2 7 [0
9i4 4 [36
..............
O24040
85/58
0_4060
86¸¸¸¸39 0
86¸¸¸39 e
8O¸¸¸¸36¸5
i_8,0_/
0300,!O
8_395
8;',53
_,
8O¸¸¸¸36¸5
I_9/C_
6
NEC. REQUIREDCLEARANCES,
638,060
88¸¸¸¸39¸9
88/39
9
81/36
15i¸¸¸68
5
8ET_EN VN:TS, POWERENTRY S]SE
•
•
U_l[ AND UNGI_OUr,I_i) SU:_i_¢IS
PO_'I_ I'/:RY S:I)i ......
U_i[ AN_¸ 8LOG4 OR 80r_CREIE _A_LS _
0iHEI_
6_OUNSE8 SURF_ClS, PO_E!RENTRY S_
...........
vl
7
[iN]
00]
00]
00]
_0]
O0]
ilk
T( 8 [ _]
I066 8:4_
OOI
914¸0 _3_ 00]
i06_
8:42
,UO]
REQUIRE_ CLEARANCEFOR OPERATIONAND _RVlCINO
,<ILL]tdETERS [I]
914 0 3_ GO]
914 0 (36 O0
Ev_l_ CO:L AGCiSS S:I)E ..............
POWERENTR_
¸ SlOE
(i:XC_R:¸ FO_ Ii{¢ R_OU_Ri_ENTG)
U_ll
top ..........................................
SIDE OPPOSITE DUCTS..............................
O_C[ P_r,_LL....................
TOP VIEW
..............................
798 6
:3:44]
_MJU]KU
O]S _C
S
9i,1¸0:3_
GO]
9i4 0 {36 GOI
3,34 8 _12 GO]_
[ tlHil
IS [{&C [} L GS IUAN 904 8 1 00} [ROB _4i
S_'SII_,:_IE_ G_Sri_ PER[ %_A_CE _4448ECO_IfRO_IISE_
......................
FII{L:} _TR_ ¸ _
8ER,qSE PORIS _,
Vii
LOil,]
.......
i]
.....
1i
[I
//'/
[4 6_]
I
i_
_5505
]' ,I
[285]
ER_IN OUTLET--"
[i2
_851
68]
ii
O
[52 72]
LEFT SIDE VIEW
2498
[983]
[953]j
2496
[985]
85]
FRONTVIEW
RIGHTSIDEVIEW
REAR VIEW
A06608
Fig. 5 - 48XL024-030
Unit Dimensions
UNIT
UNIT
WT
UNIT
NEIGNT
ELECTRICAL
CHARACTERISTICS
LBS
KG
"A"
48XLOS6060
2081230-I-60
485
2200
11425(449B)
48XL036090
20B/230-1-00
493
2236
I142514498)
48XLO42060
20B1230-I-60
507
2290
4BXL042090
2O81R3O-l-GO
515
'336
48XLO4809U
2081230"1=60
521
48XL048115
20B1230-1-60
521
48XL048130
2081230-I"60
48XLOUOORO
48XLOROH5
48XLODOlSO
036090
1011458
042060
1111503
042090
1131513
4215(166)
11933(4698)
5534(210)
5207(205)
4216(166)
1193314098)
5534(210)
5207(205)
4210(166)
2363
11933(4098)
4953(195)
5398(213)
4572(180)
2363
11933(469B)
4953(195)
5398(213)
4572(180)
521
2363
11933(4698)
4953(195}
5398(213)
4572(180)
2081230-I-60
572
2595
12949(5098)
5534(210)
508
0(200)
4470(176)
2O81D3O'l'6O
572
259
12949(509B)
5534(21
508
0(200)
4470(17
572
2595
12949(5098)
5534(210)
5
_14/517
92/417
185/839
79135,0
1361617
1811821
81/36T
13B1620i1841835
BETWEEN
UNIT
UNIT
SIDE
OF
OPPOSITE
BOTTOM
OR
O4BORO
115152 D B6/390
IBB/62EilBD/B26
O48115
115/522
13B/620
UNIT
NEAT
UNITS,
AND
AND
UNIT .........................
DUCTS ...............
POWER
UNGROUNDED
BLOCK
OR
SERVICE
_H?
G;%_!
7
(42941
SURFACES,
ENTRY
FULL LOUVER
FULL
048130
1151522
861390
13B/6261IBRIB26
000090
1261572
911413
153/694
2021916
060115
1261572
911415
153/694
_OD/916
060130
1261572
911413
1531694iROD/916
POWER
_
mm
mm
ENTRY
_
mm
mm
mm
MILLIMETERS
1066B
[42
[[N]
ON]
......
SIDE ...................
DISTANCESIE
UNIT
IS
SYSTEM,THEN
9_40
[3600]
10068
[4200]
PLACED
LESS
THAN
304
B [ID,O0}
FROM
WALL
SYSTEM
PERFORMANCE
MAYBE COMPROMISED
286{113)
POWER ENTRY
mm
ARE IN
INCHES
FULL LOUVER
22210881
CONTROL ENTRY
mmm
'.yl
TC
5O6
I
II
402,0
115,831
[0.16]
722
C284)
[1.B4]
COMPRESSOR,
BLOWER,
RICAL
ELECTRIC
ACCESS
HEAT _
52.0
46.6
[2.07]
PAN
]2263
£12.951
1_23.I
144221
LEFT SIDEVIEW
RETURN
DUCT
OPENING
DUCT
"
'
N,P.T.
BAS ENTRY
FRONT VIEW
__
87.2
RIOHT SIDE VIEW
3473
[13681
[B.43]
_35_.2
[13.B31
142.2
[5.00]
[48,28]
_
_351.2
Unit
Dimensions
_4
E13831
REARVIEW
A07900
Fig. 6 - 48XL036-060
"
H77
I4N3I
i \
[1.681
DRAIN
19,010,75] N,PT
X 220[O.BT] DEEP
SUPPLY
397.1
115.G31
362,9
[14,29}
50]
OR]
8P_,P,A'IION
A._B 8_RVIa_
DIMENSIONS IN []
LOUVER
SIDE
[O
[36
MILLIMETERS TIN)
IVAP COIL ACCESS SIDE ...........................
9140 [36 ON)
POWER ENTRY SIDE ....................................... 9140 [3600]
(EXCEPT FOR NEC REOUIREMENTS)
UNIT TOP ................................................ R14O [3600]
SIDE OPPOSITE DUCTS ..................................... 9140 [3600]
DUCT PANEL .............................................. 3048
[IDOO]_
_MINIMUM
1
[4 611
¢
mmm
SIDE ...............
T
4
1821826
t
PORT
[DO0]
[14 ON)
9_4
SURFACES,
POWER
ENTRY
CONCRETE
WALLS
AND
OTHER
RB_JIBED ¢f_.A,e,N_CE
_
$090
[14.00]
508
3SS
6
12
..............
[IN]
355.6
...................
PANEL
D)
4470(176)
MILLIMETERS
DUCT
SIDE
GROUNDED
TOP VIEW
5OBO{2OO)
UNIT .............................................
OF
1821826
ELECTRIC
t
O)
0
911413
861390
2
4216(166)
520T(DOD)
TOP
1121508
MMIIN
Y
5534(210)
CORNER WEIGHT LBSIND
A
B
C
1001454
OF GRAVITY
5DOT(DO5)
2081230-I-60
036060
CENTER
X
5534(210)
Table
UNIT SIZE
NOMINAL
COOLING
Data - Unit 48XL
024060
030040
030060
036060
036090
(ton)
2
2
2-1/2
2-1/2
3
3
(Btu)
40,000
396
180
60,000
401
182
40,000
403
183
60,000
408
185
60,000
485
220
CAPACITY
NOMINAL HEATING CAPACITY
OPERATING WEIGHT (Ib)
(kg)
I - Physical
024040
COMPRESSORS
Quantity
2-Stage
Size
Part Number
OUTDOOR COIL
Rows...Fins/in,
Face Area (sq ft)
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
(ram)
Motor Hp (Rpm)
INDOOR COIL
Rows...Fins/in,
Face Area (sq ft)
INDOOR FAN
Airflow
042090
3-1/2
3-1/2
90,000
493
224
60,000
507
230
90,000
515
234
9.5
4.3
13.8
6.3
13.8
6.3
Scroll
1
REFRIGERANT: PURON (R-410A)
Quantity (Ib)
(kg)
REFRIGERANT METERING DEVICE
Nominal
Comfort
042060
10.1
4.6
10.1
4.6
11.3
5.1
11.3
5.1
9.5
4.3
2 Ton
2 Ton
3 Ton
3 Ton
3 Ton
3 Ton
4 Ton
4 Ton
EA36YD129
EA36YD129
EA36YD139
EA36YD139
EA36YD139
EA36YD139
EA36YD149
EA36YD149
2...21
13.6
2...21
13.6
2...21
15.3
2...21
15.3
2...21
17.5
2...21
17.5
2...21
19.4
2...21
19.4
2700
22
559
1/8 (825)
2700
22
559
1/8 (825)
2700
22
559
1/8 (825)
2700
22
559
1/8 (825)
2800
22
559
1/8 (825)
2800
22
559
1/8 (825)
2800
22
559
1/8 (825)
2800
22
559
1/8 (825)
3...17
3.7
3...17
3.7
3...17
3.7
3...17
3.7
3...17
4.7
3...17
4.7
3...17
4.7
3...17
4.7
TXV
(Cfm)
Variable
based
on Comfort
Rollback(see
Userlnter_ceinstructionsfor
moreinformation).
Efficiency
7OO
700
875
875
1050
1050
1225
1225
Max
8OO
800
1000
1000
1200
1200
1400
1400
475
727
475
727
745
875
745
875
844
1120
844
1120
1120
1410
1120
1410
10x10
254x254
10x10
254x254
10x10
254x254
10x10
254x254
11x10
279x254
11x10
279x254
11x10
279x254
11x10
279x254
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
2...44
3...44
2...44
3...44
3...44
3...38
3...44
3...38
Furnace (gas ht.) airflow-Low
Furnace (gas ht.) airflow-High
Stage
Stage
Size (in.)
(ram)
Motor HP (RPM)
FURNACE SECTION*
Burner Orifice No. (Qty._Drill Size)
Natural Gas
HIGH-PRESSURE
Cut-out
Reset (Auto)
SWITCH
(peig)
670 ±10
470 ± 25
HIGH-PRESSURE SWITCH 2 (psig)
(Compressor Solenoid)
Cut-out
565 ± 15
455 ± 15
Reset (Auto)
LOSS-OF-CHARGE
/
LOW- PRESSURE SWITCH
(Liquid Line) (psig)
Cut-out
23 ± 5
55 ± 5
Reset (auto)
RETURN-AIR
FILTERS Throwaway
(in.)€
(mm)
Continued next page.
20x24x1
508x610x25
24x30x1
610x762x25
24x36x1
610x914x25
Table
UNIT
SIZE
NOMINAL
COOLING
NOMINAL
HEATING
OPERATING
WEIGHT
Data (Con't)
- Unit 48XL
048115
048130
060090
060115
(ton)
4
4
4
5
5
5
(Btu)
90,000
521
236
115,000
521
236
130,000
521
236
90,000
572
259
115,000
572
259
130,000
572
259
15.8
7.2
15.8
7.2
CAPACITY
CAPACITY
1--Physical
048090
(Ib)
(kg)
COMPRESSORS
Quantity
2-Stage
060130
Scroll
1
REFRIGERANT: PURON (R-410A)
Quantity (Ib)
(kg)
REFRIGERANT METERING DEVICE
Size
15.3
6.9
15.3
6.9
15.3
6.9
15.8
7.2
4Ton
4Ton
4Ton
5Ton
5Ton
EA36YD 149
EA36YD 149
EA36YD 149
EA36YD 159
EA36YD 159
EA36YD 159
3300
22
559
3300
22
559
3300
22
559
3300
22
559
3300
22
559
3300
22
559
1/4 (1100)
1/4 (1100)
1/4 (1100)
1/3 (1110)
1/3 (1110)
1/3 (1110)
2...21
19.4
2...21
19.4
2...21
19.4
2...21
23.3
2...21
23.3
2...21
23.3
3...17
5.7
3...17
5.7
3...17
5.7
4...17
5.7
4...17
5.7
4...17
5.7
TXV
Part Number
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
(mm)
Motor Hp (Rpm)
OUTDOOR COIL
Rows...Fins/in,
Face Area (sq ft)
INDOOR COIL
Rows...Fins/in,
Face Area (sq ft)
INDOOR FAN
Nominal Airflow (Cfm)
Comfort
Variable
based on Comfort
5Ton
Rollback(see
Userlnterfaceinstructionsfor
moreinformation).
Efficiency
1400
1400
1400
1750
1750
1750
Max
1600
1600
1600
2000
2000
2000
815
1215
1255
845
1215
1255
1385
1885
1875
1300
1910
1920
11x10
279x254
11x10
279x254
11x10
279x254
11x10
279x254
11x10
279x254
11x10
279x254
3/4
3/4
3/4
1
1
1
3...38
3...33
3...31
3...38
3...33
3...31
Furnace
(gas ht.) airflow-Low
Furnace
(gas ht.) airflow-High
Stage
Stage
Size (in.)
(ram)
Motor HP (RPM)
FURNACE SECTION*
Burner Orifice No. (Qty._Drill
Natural Gas
HIGH-PRESSURE
Cut-out
Reset (Auto)
Size)
SWITCH
(peig)
670 ± 10
470 ± 25
HIGH-PRESSURE
SWITCH
(Compressor Solenoid)
Cut-out
Reset (Auto)
LOSS-OF-CHARGE
LOW-PRESSURE
2 (peig)
565 ± 15
455 ± 15
/
SWITCH
(Liquid Line) (psig)
Cut-out
Reset (auto)
RETURN-AIR
(in.)1(ram)
23 ± 5
55 ± 5
FILTERS
Throwaway
24x36xl
610x914x25
*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.
Provide
The
Clearances
required
Rig and Place Unit
minimum
Adequate
service
ventilation
outdoor
fan
draws
and
air
under
in.
or
under
a partial
above
partial
unit
overhang
IMPORTANT:
at
either
Do
the
detrimental
Do
or
not
roof
carpeting
top.
outdoor-air
will
or
the
unit
damage
other
should
be at least
and runoff
levels.
coil
The
it
clearance
is 48
extension
Rigging
structures,
Only
of
a
When
working
air restriction
fan
discharge
may
not
be
ice,
the
unit.
combustible
4 in. (102 mm)
Do not use unit
or snow
from
Do
install
materials.
not
Slab-mounted
above the highest
expected
if it has been under water.
unit
on
water
with
tags,
safety
for
operators
Instruction
Condition
gloves.
7
all
equipment.
this
and
equipment,
and
precautions
of the
of the
to adapt
3.
Follow
can
be
location
hazardous
(roofs,
for
elevated
ground
observe
labels
that
lifting
precautions
attached
might
support
to
the
staff
in
the
equipment,
apply.
equipment
should
include,
but
to, the following:
2.
kit,
operators
this
stickers,
other
be limited
units
equipment
installation
crane
install
1. Application
an overhang
the
and
on
Training
An
this
the
qualified
handle
any
of
to
etc.).
should
and
due
trained,
literature,
mm).
handling
reasons
lifts
water,
flood
and
many
does not
in either
a
overhang)
airflow.
the
The
discharges
minimum
horizontal
outdoor
or
and
house
48 in. (1219
inlet
provided.
6.
life.
where
or
be
in 5 and
the fan discharge
locate
the unit
maximum
restrict
to compressor
place
outdoor
as a normal
exceed
shown
must
obstruction.
The
not
not
air
the
(such
must
are
Be sure that
coil. Do not
an overhead
overhang
the
outdoor
through
through
the top fan grille.
recirculate
to the outdoor
corner
clearances
such
lifter
to various
in any
of the
special
load
as balance,
applicable
safety
to
the load,
sizes
operation
codes.
adjustment
of the
of loads.
or precaution.
as it relates
temperature,
and
or kinds
to operation
of the lifting
etc.
Wear
safety
shoes
and
work
INSPECTION
Prior to initial use, and at monthly
intervals, all rigging brackets
and straps should be visually inspected
for any damage, evidence
of wear, structural
deformation,
or cracks. Particular
should be paid to excessive wear at hoist hooking points
attention
and load
support areas. Brackets or straps showing any kind of wear in these
areas must not be used and should be discarded.
PROPERTY
DAMAGE
HAZARD
Failure to follow this warning
iniury/death
or property damage.
could
result
in personal
Do not strip screws when re-securing
the unit. If a screw is
stripped,
replace the stripped one with a larger diameter
screw (included).
ELECTRICALSHOCK
Failure to follow
iniury or death.
Riu_inu/Liftinu
HAZARD
this warning
could
result
of Unit
1. Bend top of brackets
in personal
down
approximately
30 degrees
from
the corner posts.
2. Attach
Before installing or servicing system, always turn off main
power to system.
There may be more than one disconnect
switch.
Turn
off accessory
heater
power
switch
if
applicable. Tag disconnect
switch with a suitable warning
label.
opposite
weight
straps
of equal
length
to the rigging
brackets
at
ends of the unit. Be sure straps are rated to hold the
of the unit (See Fig. 7).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level
with the ground.
4. After unit is securely
corner posts,
screws.
UNIT
FALLING
this warning
could
result
Failure to follow this warning
iniury/death
or property damage.
could
straps. Remove
brackets
then
reinstall
in personal
rigged
units or lift over people.
INTRODUCTION
installed
rigging
UNIT
Never stand beneath
lifting/rigging
and
HAZARD
Failure to follow
iniury or death.
The
in place detach rigging
screws,
bracket
is engineered
only on Small Packaged
This bracket is to be used to rig/lift
roofs or other elevated structures.
and
designed
to
be
FALLING
HAZARD
result
in personal
When straps are taut, the clevis should be a minimum
in. (914 mm) above the unit top cover.
of 36
Products.
a Small Packaged
Product
onto
After the unit is placed
the top crating.
on the roof curb or mounting
Select and Install
Ductwork
pad, remove
The design
and installation
of the duct system
must be
accordance
with the standards
of the NFPA for installation
PROPERTY
DAMAGE
HAZARD
Failure to follow
this warning
iniury/death
or property damage.
non-residence
could
result
in personal
Rigging brackets
for one unit use only. When removing
unit at the end of its useful life, use a new set of brackets.
USE OF RIGGING
Field
Installation
a
air
conditioning
type,
NFPA
Select and size ductwork,
supply-air
and
90B
ventilating
and/or
registers,
local
systems,
codes
and return
and
air grilles
according
to
ASHRAE
(American
Society
of
Heating,
Refrigeration,
and Air Conditioning
Engineers) recommendations.
The unit has duct flanges
on the side of the unit.
BRACKET
of Ri_in_
type
NFPA 90A or residence
ordinances.
in
of
on the supply-
and return-air
openings
Bracket
1. If applicable, remove unit from shipping carton. Leave top
shipping skid on the unit for use as a spreader bar to prevent
the rigging straps from damaging the unit. If the skid is not
available, use a spreader bar of sufficient length to protect
the unit from damage.
2. Remove
rain lip (See Fig. 7). Use
above to secure the brackets
PROPERTY
DAMAGE
bracket
lifting.
MUST
under
removed
the panel
in step
2
OPERATION
to follow
this
HAZARD
warning
could
result
in personal
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.
HAZARD
Failure to follow
this warning
iniury/death
or property damage.
Rigging
adequate
brackets
the screws
to the unit.
Failure
iniury
4 screws in unit corner posts.
3. Attach each of the 4 metal rigging
ELECTRICAL
be under
could
result
in personal
When
designing
and installing
ductwork,
consider
1. All units should have field-supplied
filter rack installed
in the return-air
the rain lip to provide
Recommended
sizes for filters are shown
the following:
filters
side
or accessory
of the unit.
in Table
2. Avoid abrupt duct size increases
and reductions.
change in duct size adversely affects air performance.
1.
Abrupt
36-in. (914 mm)
UNITHEIGHT
A/
SEE DETAIL
A06298
A
RIGGING WEIGHT
CABINET
MODEL
Small
48XL-024
Ib
420
kg
191
Small
48XL-030
427
194
48XL-036
515
234
48XL-042
48XL-048
537
543
244
246
48XL-060
594
269
Large
J
NOTE: See dimensional drawing for corner weight distribution. Corner
weights shown on drawing are based on unit-only
weights and do not
include packaging.
D
ACCESS
PANEL
C
A06296
Fig. 7 - Suggested
IMPORTANT:
unit to prevent
ensure
Use
weather
installed,
connector
flexible
transmission
tight
and
airtight
use fireproof canvas
between
ductwork
flexible
duct is used,
resistant
duct connector
insert
connectors
of vibration.
seal.
between
ductwork
Use suitable
When
and
gaskets
to
heat
is
electric
a sheet metal
sleeve
(or sheet metal sleeve)
for max possible
4. Seal, insulate, and weatherproof
insulate and cover with a vapor
through conditioned
Air
Conditioning
(SMACNA)
inside
duct.
must extend
Heat
24-in.
air flow (See Table 1).
all external ductwork. Seal,
barrier all ductwork
passing
spaces. Follow
Contractors
and Air Conditioning
latest Sheet Metal and
National
Association
Contractors
(ACCA)
minimum
installation
standards
heating and air conditioning
systems.
5. Secure
all ducts
CONVERTING
HORIZONTAL
DOWNFLOW
(VERTICAL)
DISCHARGE
DISCHARGE
UNITS
TO
UNITS
(or similar heat resistant material)
and unit discharge
connection.
If
(610 mm) from electric heater element.
3. Size ductwork
Rigging
to building
and vibration-isolate
duct
according to good construction
structure.
Failure to follow
iniury or death.
this
HAZARD
warning
could
result
in personal
Before installing or servicing system, always turn off main
power to system and tag.
There may be more than one
disconnect switch. Turn off accessory heater power switch if
applicable.
residential
NOTE:
covers
in
SHOCK
Association
for
Flash,
openings
practices.
ELECTRICAL
weatherproof,
wall
or
If unit is not equipped
are required.
See pre-sale
1. Open all electrical
roof
starting
supply
NOTE:
electrical
disconnects
any service
2. Remove
side
with duct covers,
accessory
duct
literature.
and install lockout
tag before
work.
duct
covers
to
access
bottom
return
and
knockouts.
These panels
knockout.
are held in place
with tabs similar
3. Use a screwdriver
and hammer to remove
bottom of the composite unit base.
the panels
4. Ensure
to block
the side duct covers
horizontal
air openings
are in place
(See Fig. 8).
to an
in the
off the
3. Secure flue hood to flue panel by inserting
the top and the bottom
a single screw on
of the hood.
1" (25 mm) MIN.
__
2" (51 mm) MIN
A08001
Fig. 9 - Condensate
Install
Supply
Duct
Cover
A06320
Fig. 8 - 48XL
Provide
for Condensate
NOTE:
Ensure
with local codes,
with Duct Covers
that condensate-water
Gas Piping
The gas
provided.
supply pipe enters
The gas connection
the unit through
the access hole
to the unit is made to the l/2-in.
FPT gas inlet on the gas valve.
On
Install a gas supply line that runs to the heating section. Refer to
Table 2 and the current edition of NFOC in the U.S. and the current
Disposal
restrictions,
Trap
disposal
methods
comply
and practices.
NSCNGPIC
recommended
in Canada.
Do not use cast-iron
pipe.
It is
that a black iron pipe is used. Check the local utility
The units dispose of condensate
through a 3/4 -in. NPT female
fitting that exits on the compressor
end of the unit. Condensate
for recommendations
concerning
existing lines. Size gas supply
piping for 0.5 IN. W.C. maximum
pressure drop. Never use pipe
water can be drained directly
(where
permitted)
or onto
smaller
onto the roof in rooftop installations
a gravel
apron in ground
level
installations.
Install a field-supplied
condensate
condensate
connection
to ensure proper drainage.
trap at end of
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.
field-supplied
at outlet
undersize
than the l/2-in.
For natural
FPT gas inlet on the unit gas valve.
gas @plications,
the gas pressure
propane
A
conversion
1/8-in.
NPT
equipment
When
line, observe
Refer to the NFPA
B149.1).
2. When
flexible
MUST
connectors
HAZARD
could
result
in personal
connect
B149.2)
plumbing
codes.
2. Remove
must
conform
the National
Z223.1
(in
with
panel.
panel.
hangers,
local
building
to the following
to heating
section
and to meter.
etc. Use a minimum
of one hanger
sizes
larger
than
of national codes.
every
1/2
6 ft. (1.8
in.,
follow
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
codes
petroleum gases as specified
Never use Teflon t@e.
or latest revision.
Refer to provincial
and local
or wastewater
codes and other @plicable
local
flue hood
from shipping
on flue panel.
Orient
adhere
@proved
2. Protect all segments of piping system against physical and
thermal damage. Support all piping with @propriate straps,
Fuel Gas Code (NFGC),
NFPA
Canada,
CAN/CSA
B149.1,
and
location
section of the blower compartment-See
return duct cover to locate the flue
screws
is NOT
valves
as follows:
installation
and with
54/ANSI
codes,
shutoff
low spots in long runs of pipe. Grade all pipe 1/4 in.
m).
For
pipe
recommendations
1. This
length
(6.35 mm) for every 15 ft (4.6 m) of length to prevent traps.
Orade all horizontal
runs downward
to risers. Use risers to
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
by a licensed
the maximum
4. The use of copper tubing for gas piping
by the state of Massachusetts.
1. Avoid
this warning
pertaining
Z223.1-2006
be performed
are used,
In the absence of local building
pertinent recommendations:
Failure to follow
injury or death.
gauge
of the gas
of manual
local codes
54/ANSI
3. When lever handle type manual equipment
are used, they shall be T-handle
valves.
Install Flue Hood
POISONING
test
shall not exceed 36 in. (915 mm).
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.
MONOXIDE
for
In the state of Massachusetts:
1. Gas supply connections
plumber or gas fitter.
end of the 2 -in. (51 mm) trap (See Fig. 9). Do not
the tube. Pitch the drain trough downward at a slope of at
accessible
valve.
the gas supply
to gas pipe installations.
(in Canada, CAN/CSA
NOTE:
t@ping,
be installed immediately
upstream
to the gas valve and downstream
shutoff
installing
kit instructions.
plugged
connection,
must
supply connection
Connect
a drain
trough
using
a minimum
of
3/4 -in. PVC or field-supplied
3/4 -in. copper pipe
CARBON
at unit gas connection
must 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
Place flue
screw holes
hood
(inside
4. Install sediment
Fig. 10). This
condensate.
the return
Fig. 8). Remove the
hood. Remove
two
assembly
over
flue
national
trap in riser leading
to heating
section
(See
as a trap
for dirt
and
leg
functions
external,
pipe within
manual
main shutoff
6 ft (1.8 m) of heating
10
valve in
section.
6. Install ground-joint
union close to heating section
unit manual shutoff
and external manual main
valve.
in flue hood with holes in the flue
codes.
drip
5. Install an accessible,
gas supply
by local and/or
between
shut off
Install
IN
Electrical
ELECTRICAL
CAP
C99020
7. Pressure
national
to unit.
Trap
test all gas piping in accordance
with local and
plumbing
and gas codes before connecting
piping
HIGH-VOLTAGE
NOTE:
piping
Pressure
is connected
disconnected
systems
unit
piping
system
to the gas valve.
from
the gas valve
when test pressure
gas supply
The
test the gas supply
system
heating
section
system
by closing
the
slightly
opening
The supply
during
is in excess
at pressures
must
external
the ground-joint
after the gas supply
piping
the testing
must
be
of the piping
of 0.5 psig. Pressure
test the
equal to or less than 0.5 psig.
be isolated
main
from
manual
the gas piping
shutoff
valve
and
union.
this
HAZARD
warning
could
result
in personal
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.
NIPPLE
Fig. 10 - Sediment
SHOCK
Failure to follow
iniury or death.
TEE
_-_
Connections
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.
FIRE OR EXPLOSION
HAZARD
Failure to follow this warning could result in fire, explosion,
personal injury, death and/or property damage.
• Connect gas pipe to unit using a backup wrench to avoid
damaging gas controls.
UNIT
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.
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.
having jurisdiction, black iron pipe shall be installed at
furnace gas valve and extend a minimum of 2 in. (51 mm)
outside furnace casing.
• If codes allow a flexible connector, always use a new
connector. Do not use a connector which has previously
5. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit,
etc.
serviced another gas appliance.
been completed.
Use a commercially
available
made specifically
for the detection
of leaks
specified by local codes and/or regulations).
HAZARD
2. Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
• If a flexible connector is required or allowed by authority
gas
leaks
at
the
field-installed
gas lines after all piping connections
DAMAGE
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.
• Never purge a gas line into a combustion chamber. Never
8. Check
for
factory-installed
COMPONENT
and
have
soap solution
(or method
11
Table
2- Maximum
Gas
NOMINAL
IRON PIPE
SIZE (IN.)
INTERNAL
DIAMETER
Flow Capacity*
10
20
30
40
50
60
(IN.)
(3.0)
(6.1)
(9.1)
(12.1)
(15.2)
(18.3)
.622
LENGTH OF PIPE ft (m)'{"
70
80
90
(21.3)
(24.4)
100
(27.4)
125
(30.5)
150
(38.1)
175
(45.7)
200
(53.3)
(61.0)
--
--
3/4
1
.824
1.049
175
360
680
120
250
465
97
200
375
82
170
320
73
151
285
66
138
260
61
125
240
57
118
220
53
110
205
50
103
195
44
93
175
40
84
160
77
145
72
135
1 - 1/4
1 - 1/2
1.380
1.610
1400
2100
950
1460
770
1180
600
990
580
900
530
810
490
750
460
690
430
650
400
620
360
550
325
500
300
460
280
430
1/2
*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.
NFPA 54/ANSI Z223,1.
1- This length includes an ordinary
ROUTING
Use
POWER
only
voltage
conduit
copper
LEADS
wire
number
of fittings.
INTO UNIT
between
disconnect
and unit.
The
high
leads should be in a conduit until they enter the duct panel;
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
the control plate near the inducer switch (See Fig. 13).
ROUTING
For detailed
Interface
CONTROL
POWER
instruction
on the low voltage
screw on
connections
to the User
guide.
low-voltage
hole provided into unit (See Fig. 5 and 6). Connect
user interface leads to unit control power leads as shown in Fig. 14.
transformer
supplies 24-v
accessory electrical heater.
for 230-v operation.
primary as described
section.
The furnace
board
power for complete
system
Transformer
is factory wired
If supply voltage is 208-v, rewire transformer
in Special Procedures
for 208-v
Operation
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
be sure
control
board
factory-installed
screws.
ACCESSORY
A. Outdoor
and gas valve grounding wire. Check to
is mounted
securely
using
both
Air Thermistor
(OAT)
no
OPERATION
of an outdoor temperature
sensor using the
board OAT terminals
is required.
Many
control
For detailed
mounting
instructions
please refer to TSTATXXSEN01-B
Procedures
will
Humidifier
The
appear
If the thermistor
at UI.
Re-wire
damage
is wired
thermistor
to either
incorrectly,
correctly
for
furnace
is provided
for
Connections
control
board
terminal
low voltage (24-vac)
control
required as UI monitors indoor
When
commanded
to operate
marked
HUM
of a humidifier.
humidity.
humidifier,
No
the unit
humidistat
control
is
will
energize the HUM output to turn humidifier on and de-energize
HUM
output
to turn humidifier
off. Wire HUM
and COM
terminals
C.
directly
Electronic
Electronic
Air
to humidifier
as shown
in Fig. 14.
Air Cleaner
Cleaner
terminals
are provided
on
the
Infinity
Control Board (EAC-I
and EAC-2).
While these terminals can be
used to power a 230V EAC, it is recommended
that any EAC be
installed
per the EAC installation
instructions
and connected
separately
to a standard
II5V
or 230V outlet with an airflow
sensor
to control
SPECIAL
operation
PROCEDURES
Be sure unit disconnect
rollback,
for the OAT sensor,
installation instructions
1 through
OAT inputs will not cause
or thermistor.
operation.
B.
HAZARD
Infinity features (auto humidity
control, comfort
ETC.) will be lost if the OAT is not connected.
data for
on User
to be observed.
Mis-wiring
reading
Connect
208-v.
The installation
Infinity
control
no. 63TS-TAI3):
is no polarity
NOTE:
wiring
EQUIPMENT
(catalog
There
Disconnect
INSTALLATION
to supply outdoor
temperature
and for temperature
display
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.
normal
WIRES
(UI), refer to the UI installation
The OAT input is used
system
level functions
Infinity
Form a drip-loop
with the control leads before routing them into
the unit. Route the low voltage control leads through grommeted,
The unit
including
W.C. (based on a 0.60 specific gravity gas). Refer to Table,
3.
12
of the EAC.
FOR 208-V
switch
the black primary
OPERATION
is open.
lead
from the transformer.
See unit
label (See Fig. 16 and 17).
the black primary
lead
to the transformer
terminal
labeled
USER
INTERFACE
TOP
COVER
DISCONNECT
PER
NEC*
FROM
GAS LINE
*NEC
- NATIONAL
ELECTRICAL
CODE
A06091
Fig. 11 - Typical
Installation
GROUND SCREW
(IN SPLICE BOX)
GROUND
LEAD
SINGLE-PHASE
CONNECTIONS
TO DISCONNECT
PER NEC
z_L_
L1
BLKm
-- _YEL_
L2 ......
NOTE: Use copper wire only.
LEGEND
NEC - National Electrical Code
Field Wiring
_
Splice Connections
A06299
Fig. 12 - Line Power
13
Connections
HP/AC
Board
Furnac6
Board
A06306
Fig. 13 - Control
User
interface
Plate
infinity HP/AC
Board
infinity Furnace
Board
OAT
Outdoor Air Thermistor
(Supplied with [U)
FIELD CONNECTION
REQUIRED
(BLACK WIRES)
m
1
OCT
|
|
|
a_Outdeor
Coil Thermistor
FACTORY CONNECTED
L
m
0
m
Y2
m
Y1
m
w1
m
|
FACTORY WIRES PROVIDED
FOR FIELD CONNECTION
OF UTiLiTY CURTAILMENT
C
R
Factory Wiring
A06301
Fig. 14 - Control
Voltage
Wiring
14
Connections
PRE-START-UP
joint
union
until
the odor
be loosened,
combustion
retighten
FIRE,
HAZARD
EXPLOSION,
ELECTRICAL
Failure to follow
this warning
could
iniury or death and/or property damage.
1. Follow
goggles
recognized
safety practices
when checking or servicing
result
not
remove
electrical
sources
compressor
c. Ensure
protective
system.
cover
until
refrigerant
ternfinals.
leak
is
suspected
around
5. Never
attempt
to repair soldered
refrigerant system is under pressure.
6. Do not
contains
7. To remove a component,
proceed as follows:
wear
a. Shut off gas supply
b. Shut off electrical
lockout tag.
protective
all
6. Each
with respect
to
(See Fig. 24).
sure that air filter(s)
is in place.
drain trap is filled with water
loose parts
system
has
two
Do not loosen
Schrader-type
ports,
one
System
Unit Start-Up
NOTE:
and
and Troubleshooting
Always
check
high-
and low-voltage
supply
to the unit
components.
Check the integrity of the plug receptacle
and unit wiring harness prior to assunfing a component
A. LED
LEDs
Description
built into Infinity
person information
the unit controls
from system
ports.
connections
failure.
available
control
concerning
and ECM
at the
system
boards
provide
installer
or service
operation
and/or fault condition
of
motor.
This information
is also
UI in text
with
basic
troubleshooting
d. Cut component
connecting
tubing with tubing
cutter and remove component
from unit.
instructions.
Careful use of information
displayed
need for extensive manual troubleshooting.
e. Carefully
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
unsweat
necessary.
remaining
tubing
stubs when
Oil can ignite when exposed
to flame.
are located
Use the Start-Up
Checklist supplied
proceed
as follows
to inspect and
at the end of this book and
prepare the unit for initial
start-up:
1. Remove
all access
panels.
shipped
3. Make
with unit.
the following
connections.
and tight.
d. Ensure wires do not touch refrigerant
sheet metal edges.
e. Inspect
handling,
coil fins. If damaged
carefully
4. Verify the following
straighten
during
tubing
shipping
and
lighting the unit
tasks with the
gas valve in the OFF position.
If the gas supply
pipe was not purged
before
of system
connecting
that the ground
communications
status
on the STATUS
LED
using
1. The number
of short flashes indicates
first digit of code.
of long flashes
second
5. The time between
second.
indicates
on. A long
flashes
the
digit of code.
flash is 1 second
is 0.25 seconds.
last short flash
and first long
6. The LEDs will be off for 2.5 seconds
7. If multiple
Be
and
(ABCD)
Oil.
see
or sharp
connector
the
as installed in the unit).
at the upper right side,
2. The number
4. The time between
conditions:
the unit, it will be full of air. It is recommended
as an indicator
3. A short flash is 0.25 seconds
fins with a fin comb.
a. Make sure gas line is free of air. Before
for the first time, perform the following
is used
Status Codes will be displayed
following
protocol:
refrigerant leak. Leak test all refrigerant tubing
connections
using electronic leak detector, or
c. Inspect all field- and factory-wiring
sure that connections
are completed
reduce
(See Fig. 15 and 18).
inspections:
liquid-soap
solution. If a refrigerant leak is detected,
following Check for Refrigerant Leaks section.
Conmmnications
will
adjacent to the fuse, above the terminal block. The amber LED is
the System Status LED, labeled STATUS. The green LED, labeled
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
on unit base. Detecting oil generally indicates a
near the System
(lower right corner of the HP/AC board
On the furnace board, these are located
COMM,
2. Read and follow instructions on all DANGER,
WARNING,
CAUTION,
and INFORMATION
labels attached
to, or
NOTE:
correctly
fan blade
START-UP
to unit and install
c. Relieve and reclaim all refrigerant
using both high- and low-pressure
then light unit.
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.
to unit.
power
a
odor,
blade is correctly
fan hub is positioned
unit
into
of gas
5. Compressors
are internally spring mounted.
or remove compressor
holddown bolts.
while
goggles
to purge
gas lines
f. Make sure that all tools and nfiscellaneous
have been removed.
compressor
use torch to remove any component.
oil and refrigerant under pressure.
to elapse,
e. Make sure that condensate
to ensure proper drainage.
before
box if
connection
detection
5 nfinutes
housing
d. Make
and tagged.
4. Relieve and recover all refrigerant
from system
touching
or disturbing
anything
inside ternfinal
upon
sure that condenser-fan
motor
ternfinal
are disconnected
purge
positioned
in fan orifice. Top 1/3 of condenser
should be within fan orifice venturi.
in personal
and wear
refrigerant
line be allowed
Never
Immediately
the union. Allow
2. Do not operate compressor
or provide any electric power
to unit unless compressor
ternfinal cover is in place and
secured.
3. Do
chamber.
b. Make
SHOCK
and the supply
of gas is detected.
priority
status
power
up,
are active
before
repeating
concurrently,
code.
the highest
status code is displayed.
B. Control
Start-Up
Troubleshooting
On
codes
flash is 1
green
and
COMM
System
LEDs
will
Communications
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.
will be on any time unit is in idle mode.
The STATUS
If, at any time, communications
are not successful
exceeding
2 nfinutes,
the Infinity
control
will
15
LED
for a period
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
the system is powered.
2. Check ABCD connection on both boards.
to be sure
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
Failure to follow
iniury or death.
HAZARD
this warning
as long as UI maintains
a demand
operate
while
electric
heaters
communicates
with
the motor
even when the motor
not communicate
motor will shut
for airflow.
The
a fault condition
at least
is idle. If, during
once
control
exists.
every
operation,
will not
The control
five
seconds,
the control
does
with the motor for more than 25 seconds, the
itself down and wait for communications
to be
reestablished.
D. Furnace
Furnace
system
Control
Troubleshooting
control faults indicated by flashing codes on the amber
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
STATUS
faults, as well as a fault history,
CODE CONTINUOUS
Check for 230
SEC-2.
STATUS
Control
STATUS
VAC
at UI.
at L1 and L2, and 24 VAC
CODE CONTINUOUS
at SEC-1
and
ON
has 24 VAC power.
CODE
11 - NO PREVIOUS
Stored status codes
STATUS
can be viewed
OFF
CODE
are erased
CODE
automatically
12 - BLOWER
after 72 hours.
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
occurs
if a limit or flame
than 3 minutes or 10 successive limit
heat. Control will auto reset after three
33.
STATUS
Control
CODE
14 - IGNITION
LOCKOUT
rollout
switch
is open
longer
trips occurred
during high
hours. Refer to status code
LOCKOUT
will auto reset after three hours. Refer to status code 34.
STATUS
CODE
Indicates
the blower
15 - BLOWER
failed
MOTOR
LOCKOUT
to reach 250 RPM
to communicate
within 30 seconds
successive
heating cycles. Control
Refer to status code 41.
or the blower
failed
after being turned ON in two
will auto reset after 3 hours.
could result in personal
gqRNSA
After disconnecting power from the ECM motor, wait at
least 5 minutes before removing the control section. Internal
capacitors require time to discharge.
Before proceeding to replace a motor control module:
1. Check motor winding section to be sure it is functional.
2. Remove motor control module section and unplug winding
plug. Motor shaft should turn freely, resistance between any
two motor leads should be similar and resistance between
any motor lead and unpainted motor end should exceed
100,000 ohms.
ojt
a>-
T°
3. Failing any of these tests, entire ECM motor must be
replaced.
r_VCZ]
4. Passing all of the tests, motor control module alone can be
replaced.
MOTOR TURNS SLOWLY
D
_
_O
=
RN4
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
A06026
Fig. 15 - Detail of Furnace
16
Board
CONNECTION WIRING DIAGRAM
LADDER WIRING DIAGRAM
DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING
FIELD
UNIT COMPONENTARRANGEMENT
SECTIO_
OUTDOOR
F_N
[]
208,_3o
60HZ,IPH
SUPPLY
VAC
I
_'I"M
_
i,,,,_
-
[]
I
_°
qf_
SAS
TI
LEGEND
_F[ELD
_°
•
?
SPLICE
SPLICE
FACTORY WIRING
- FIEL@ COnTrOL _IRI_G
FIEL@
POWE_
WIRING
RSC
REMOTE
SPARKER
CQNT
CONTACTOR
CAP
COMP
CAPACITOR
COMPRESSOR
MOTOR
CS
COMPRESSOR
SOLENO[D
CCH
CRANK
HEATER
CASE
CONTROL
P
P
PLI 1(c)
TO BE WIRED iN ACCOROANC[ WITH NEC ANO
LOCAL CODES
8LOWER-O_ DELAY FOR GAS _EATING iS 3O SECONDS¸
_LOWER-OYF OELAY FOR GAS H[ATING IS 120 SECONOS
D_AULT WITH Fi[LD SELECTABLE D[LAYS OF gO, 120,
150, OR 180 SECONDS AVAILABLE
8LOWER-OFF OEL_Y _OR COOLING IS 9O SECONDS
co_
COM
_
IGNITION LOCKOUT OCCURS AFTER FOUR CONSECUTIVE,
UNSUCCESSFUL IGNITION ATTEMPTS CONTROL W_LL
AUTO R[S[T AFTER THREE HOURS¸
DUSO0003 111_.
>
g
co
CONNECTION WIRING DIA6RAM
LADDER WIRING DIAGRAM
DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING
FIELD
UN]T
COMPONENT
OUTDOORFA,,
SECTIO_
ARRANGEMENT
60HE,
------_
SUPPLY
208/230
_
VAC
1PH
,.._'
L_--
DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING
_,
L1
_
_''''_1_
_
USE
B_
IELD
COPPER
CONDUCTORS
208/230
SUPPY
VAC,
ONLY
60
mz,
Y
PH
_
CONT
SECTIOn,
SECTION
I
23
I
I
11
=.
q_
ICCH I
GAS SECTIO_
@
L2
_
0
FZELD SPL]CE
SPL]CE
FACTORY
FIELD
FIELD
_o
RSC
?
CONTACTOR
CAP
co_P
CAPACITOR
COMPRESSOR
CS
r
COMPRESSOR
CCH
EQUIP
FS
G_,D
SOLENOID
CRANK CASE
HEATER
EQUIPMENT
FLAME SENSOR
GROUND
HPS
TRAN
q_
WIRING
CONTROL WIRING
POWER WIRING
REMOTE SPARKER
CONTROL
CONT
-B,
LEGEND
HIGH PRESSURE
TRANSFORMER
SEE NOTES_
SWITCH
T
PL1-51C
PL>4
UI
PL3
I _!L
PL>_
GI
PL3 2
SER INTERFACE
PLT C
NOTES;
IF
IT
USE
ANY OE THE ORIGinAL
WIRE
FURNISHED
MUST BE REPLACED
WFH
TYPE
90 C OR
T_C
COPPER
REPLACE
LOW
VOLTAGE
(MANUFACTURED
MODEL DR4-DSD,
MODELS
TO BE
LOCAL
D36
WIRED
CODES
RLOWER-ON
CONDUCTORS
FUSE
FOR
WITH
BY LITTLEFUSE,
LSI AND LS2
D6D,
iN
DELAY
RAVE
LSI
ACCORDANCE
_OR
GAS
FIELD
R AMP
iS REPLACED,
EQUIVALENT
INSTALLATIONS
IT
_ITN
REC
HEATING
iS
OFF
DELAY
FOR
COOLING
IGNITION
LOCKOUT
OCCURS
AEPER
UNSUCCESSFUL
[GNIHON
ATTEMPTS
AUTO RESET AFTER THREE HOURS
IS
90
PLi
l(C)
I
AND
BD
SECONDS
BLOWER
OFF DELAY
FOR GAS
HEATING
IS IDO
DEFAUL_
_ITR
EIELD
DELECTABLE
DELAYS OF
ISD, OR 180 SECONDS
AVAILABLE
BLOWER
I
I
J:USE ONLY
P/N 257003)
ARE IN SERIES
ONLY
SECONDS
DO, 120,
GOM
CO_
SECONDS
FOUR CONSECUTIVE.
CONTROL
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UTILITY
RELAY
UTILITY
OPEN
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* SUPPLIED
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SIGNAL
RELAY
BY UTILITY
@
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Ilne
So
lellold
PROVIDER
A05247
Fig. 18 - 2-Stage
STATUS
Control
CODE 21 - GAS HEATING
will NOT
defective
control
STATUS
SIGNAL
Flame
auto reset.
22
while
until fault is cleared.
valve.
STATUS
Check
closed.
Check
for short circuit
25
pressure
SWITCH
tubing
or
will run
voltage
INVALID
Indicates
either the model plug
flashes 4 times on power-up,
switch
FUSE
(24VAC)
MODEL
gas
stuck
IS OPEN
wiring.
SELECTION
OR
is missing or incorrect.
If code
control
is defaulting
to model
selection stored in memory. Check for proper
and resistance values per wiring diagram.
STATUS CODE 31, 32 - PRESSURE
NOT CLOSE OR REOPENED
model
SWITCH
plug number
(230VAC),
obstructed
OR RELAY
DID
vent, defective
inducer voltage
inadequate
combustion
air supply, disconnected
or
pressure tubing,
or low inlet gas pressure (if LGPS
used).
STATUS
CODE 33 - LIMIT
CIRCUIT
for loose blower
wheel,
FAULT
restricted
filter
or restricted
duct
system,
combustion
CODE 34 - IGNITION
defective
air supply
PROVING
vent,
excessive
switch
(flame
or
roll-out
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,
must be connected to unit sheet metal.
STATUS
CODE 41 - BLOWER
Indicates
the blower
to communicate
within
after being
operation.
Auto
failed
turned
MOTOR
ON
or
ten
CODE 45 - CONTROL
reset after one hour lockout
wire
FAULT
to reach 250 RPM
the prescribed
or green/yellow
or the blower
time limits.
seconds
CIRCUITRY
Thirty
during
failed
seconds
steady-state
LOCKOUT
due to gas valve relay stuck open,
flame sense circuit failure, or software check error. Reset power
clear lockout. Replace control if status code repeats.
E. HP/AC
See
Control
Table
4
for
troubleshooting
STATUS
SENSOR
HP/AC
control
board
status
If an OAT sensor is found
at power-up,
will be displayed
at amber STATUS
Check
in wiring
19
codes
and
information.
CODE
53,
OUTDOOR
AIR
FAULT - DETAILED
DESCRIPTION
for faults
Using an Ohm
open condition.
to
Troubleshooting
TEMPERATURE
input is constantly
to be within a valid temperature
range. If sensor
open or shorted at any time after initial validation,
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
dirty
connections,
or inadequate
switch open).
STATUS
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
inducer motor, defective
pressure switch, lower
Board
STATUS
DID NOT OPEN
or pressure
VOLTAGE
in secondary
-
Inducer
for leaky gas valve or stuck-open
CODE 24 - SECONDARY
STATUS
CODE
SETUP ERROR
gas valve
FLAME-PROVING
gas valve is de-energized.
Check
Control
wind,
for mis-wired
ABNORMAL
CODE 23 - PRESSURE
for obstructed
STATUS
LOCKOUT
Check
(valve relay).
CODE
is proved
HP/AC
meter,
checked
is found to be
Status Code 53
LED.
connecting
check resistance
sensor
to OAT terminals.
of thermistor
for a short
or
If thermistor
is shorted
or open,
replace
it to return
normal operation.
If fault is in the wiring
the fault will clear the code and return
the system
connections,
the system
to
correcting
to normal
The
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
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 l--Start-Up
The UI uses temperature,
indoor
cooling
and Troubleshooting.
humidity
and other data supplied
from
and outdoor
system
components
to control
heating or
system for optimum comfort. The unit will be commanded
by UI to supply airflow. The unit will operate
requested airflow for most modes.
INDOOR
AIRFLOW
The nominal
the indoor
blower
at
airflow
operations
WITH
curtailment
INFINITY
relay
should
CONTROL
be
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
COMPRESSOR
33% of the scroll compression
load capacity.
The 24-volt
low-stage
operation.
for occupant
comfort and system
for further system control details.
area so the system operates at part
solenoid
coil is de-energized
in
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.
coil is energized in high stage operation.
CRANKCASE
HEATER
The
heater
crankcase
OPERATION
is energized
to follow
this caution
FAN MOTOR
DELAYS-AIR
ambient
is greater
heating
airflow for the system
NOTE:
free
from
changed
detail.
obstructions,
using
adjusted
grilles
properly.
the UI. See UI installation
Airflow
instructions
Once the compressor
should
not
be started
cooling
cycle
remains
point that is slightly
has started
until
:'on"
below
AIR CONDITIONER
COOLING
again
are open,
can
until
the room
the cooling
SEQUENCE
have
elapsed.
temperature
control
setting
from
it
The
to
of the UI.
OF OPERATION
OPERATION
a call for first stage
cooling,
compressor
are energized.
demand, high-stage
cooling
the outdoor
If low-stage
is energized
fan, and low stage
cannot satisfy cooling
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
will shut off.
NOTE:
When
stage cooling
two-stage
unit is operating
vapor (suction) pressure will be higher
system or high-stage
operation.
NOTE:
minute
Outdoor
after compressor
are satisfied,
fan motor
will
the compressor
at low-stage,
than a standard
continue
shuts off, when outdoor
system
single-stage
to operate
ambient
from a
time delay of outdoor
ambient
operation
from last
only).
fan at termination
is greater
of cooling
than or equal to 100°F
air conditioner
to high and from high to low capacity;
be
drops
this feature,
pins.
(38°C).
for more
and then has stopped,
4 minutes
Defrost
delay on return
(with Infinity
• There is no time delay between
low to high
dictates.
NOTE:
With
and
return-air
recycle
when there is a
To bypass
condition.
mode when outdoor
being installed.
Be sure that all supply-and
operation
or user interface.
short and release Forced
valid communication
rise in each
the desired
to
OPERATIONS
• Two minute time delay to return to standby
• One minute
For gas heat operations, Table 3 shows the temperature
gas heating mode. Refer to these tables to determine
than or equal
include:
• Five minute compressor
brown-out
65°F
overload should open. Outdoor fan
for one minute after the compressor
CONDITIONER
call from the thermostat
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.
below
OPERATION
shuts off when the outdoor
100°F
(38°C).
momentarily
off cycle
energizes the outdoor fan any time the
The outdoor fan remains energized
if a
pressure switch or compressor
motor will continue to operate
may result in unit damage.
solenoid
air temperature.
The outdoor unit control
compressor
is operating.
HAZARD
The 24-volt
(IF APPLICABLE)
during
• Five minute time delay to start cooling
Failure
factory
OPERATION
The unit time delays
OPERATION
to
When the compressor
is operating
in low stage, the modulating
ring is deactivated,
allowing two internal bypass ports to close off
TIME
UNIT
connected
Fig. 13, 14 and 16). This input allows a power utility device to
interrupt compressor
operation during peak load periods. When the
utility sends a signal to shut the system down, the UI will display
"Curtailment
Active".
OUTDOOR
for air conditioner
optimize
the system operation
efficiency. Refer to UI literature
utility
(18 ° C) outdoor
ADJUSTMENTS
requested
INTERFACE
supplied pigtails (PINK, connected to R, VIOLET connected
to Y2
on the control board) located in the low voltage splice box (See
operation.
NOTE:
UTILITY
for one
is greater
than or equal to 100°F (38°C).
20
and from
high
staging
the compressor
to low capacity
from low
will change
as demand
Table
3 - Air
Delivery
Rated Heating Input (Btu/hr)
and
Temperature
Rise
at Rated
Low Stage
48XL(-,N)024040
48XL(-,N)030040
40,000
26,000
48XL(-,N)030060
48XL(-,N)036060
48XL(-,N)042060
60,000
48XL(-,N)036090
48XL(-,N)042090
48XL(-,N)048090
48XL(-,N)060090
High Stage
Input
Heating Rise Either Stage, °F (°C)
Unit
High Stage
Heating
Heating Rise Range OF (°C)
"Efficiency ....
High Stage
Low Stage
Low Stage
Comfort"
High Stage
Low Stage
20 - 50
15-45
35
30
40
(11-28)
(8-25)
(19)
(17)
(22)
35
(19)
25 - 55
25 - 55
40
50
(14-31)
(14-31)
(22)
(28)
35 - 65
(19-36)
35 - 65
(19-36)
50
(28)
55
(31)
39,000
90,000
58,500
48XL(-,N)048115
48XL(-,N)060115
115,000
75,000
30 - 60
(17-33)
30 - 60
(17-33)
45
(25)
50
(28)
48XL(-,N)048130
48XL(-,N)060130
130,000
84,500
35 - 65
(19-36)
35 - 65
(19-36)
50
(28)
55
(31)
Airflow delivery values for external static pressure values of up to 1 IN. W.C.
Table
OPERATION
4 - Heat
FAULT
On solid, no
flash
None
Emergency
Standard
Thermostat Control
Low Stage Cool/Heat
High Stage Cool/Heat
Operation
Operation
Conditioner
Board
Status
AMBER LED
FLASH
CODE
Standby - no call for unit operation
Mode
Pump/Air
Rapid, continuous
flashing
Codes
POSSIBLE
CAUSE AND ACTION
Normal operation.
Unit being controlled
by standard
thermostat
inputs instead of Infinity Control.
Only high stage operation
is available.
This operating
mode should be used in emergency
situations
only.
None
1, pause
Normal operation.
None
2, pause
Normal operation.
System Communications
Failure
16
Invalid Model Plug
25
Control does not detect a model plug or detects an invalid model plug.
will not operate without correct model plug.
High-Pressure
Switch Open
Low-Pressure
31
High-pressure
switch trip. Check refrigerant
and coils for airflow restrictions.
32
Low-pressure
45
Outdoor unit control board has failed.
46
Line voltage < 187v for at least 4 seconds. Compressor
not allowed until voltage>190v.
Verify line voltage.
No 230v at Unit
47
There is no 230v at the contactor when indoor unit is powered and cooling/
heating demand exists. Verify the disconnect is closed and 230v wiring is
connected to the unit.
Outdoor Air Temp
Sensor Fault
Outdoor Coil Sensor Fault
53
Outdoor air sensor not reading or out of range. Ohm out sensor and check
wiring.
55
Coil sensor not reading or out of range. Ohm out sensor and check wiring.
Thermistors
Range
56
Improper relationship between coil sensor and outdoor
sensors and check wiring.
Low Stage Thermal Cutout
71
Compressor voltage sensed, then disappears while cooling or heating demand exists. Possible causes are internal compressor overload trip or start
relay not releasing (if installed).
High Stage Thermal Cutout
72
Compressor voltage sensed, then disappears while cooling or heating demand 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 Compressor
74
Compressor voltage not sensed when compressor should
tactor may be stuck open or there is a wiring error.
Low Stage Thermal Lockout
81
Thermal cutout occurs in three consecutive low/high stage cycles.
stage locked out for 4 hours or until 24v power recycled.
Low
High Stage Thermal Lockout
82
Thermal cutout occurs in three consecutive high/low stage cycles.
stage locked out for 4 hours or until 24v power recycled.
High
Low-Pressure
Lockout
83
Low-pressure
switch trip has occurred during 3 consecutive
operation locked out for 4 hours or until 24v power recycled.
cycles.
High-Pressure
Lockout
84
High-pressure
switch trip has occurred during 3 consecutive
operation locked out for 4 hours or until 24v power recycled.
cycles.
Switch Open
Control Fault
Brown Out
v)
(230
Out of
Communication
21
with UI lost. Check wiring to UI, indoor and outdoor
units.
Unit
charge, outdoor fan operation
switch trip. Check refrigerant charge and indoor air flow.
Control board needs to be replaced.
and fan operation
air sensor. Ohm out
be starting. Con-
Unit
Unit
INFINITY
CONTROLLED
LOW
AMBIENT
COOLING
period
This
unit
is capable
(-18°C).ONLY
is not
for
ambient
begin
on
must
to cycle until
and
ambient
ambient
and the outdoor
Infinity
cooling
coil
low
cooling
when using the Infinity
required,
replaced
of
fan motor
in the UI set-up.
air temperature.
mode operates
plus
minutes.
ambient
outdoor
coil temp
is turned
air
fan has been ON for 30
off to allow
refrigerant
system
to
coil temp is <outdoor
air
stabilize.)
• In low stage, fan is off when outdoor
temperature
plus 1 °F (.6°C)
minutes.
(Fan
is turned
or outdoor
fan has been ON for 30
off to allow
refrigerant
system
to
outdoor
air temperature
> 80°F
(27°C)
(Fan is turned
or if outdoor
ambient
switch
If flame
start up. After
motor is turned
outdoor
3 minutes,
10 minutes
fan cycling
during
low
if LPS trips, then outdoor
fan
for the remainder
then cooling
per the coil temperature
of the cooling
within
10 minutes,
cooling
operation
continues
and generate
control
If a power
amber
must be grounded
interruption
is restored,
occurs
blower
during
if the UI is still calling
After
the 90-second
period,
[]NIT
The
period,
as long as no faults
the unit will respond
to
MODE
1. Inducer
up on
Infinity
second
Pre-purge
Period:
When
high speed, the pressure
2. Trial-For-Ignition
pre-purge
Sequence:
is
de-energized
and
present,
control
the inducer
on to the appropriate
terminal
energized
motor
speed
for the
HUM and electronic
air
throughout
the heating
with
Delay:
When
L2
and will
motor will remain
The indoor blower
remain
energized
stopping
the flow of gas to
the HUM terminal.
The
on for a 4-second
post-purge
and air cleaner terminal EAC-I
for 90,
120,
150,
or 180
seconds
on selection of blower-off
delay selected in the
factory-set
default is 120-second
blower-OFF
GAS INPUT
DAMAGE
(NATURAL
GAS)
HAZARD
this caution
may
Do
an
Improper
not
redrill
orifice.
result
in component
drilling
(burrs,
burner noise
hole appears
to have been redrilled,
drill bit of correct size.
check
The spark igniter
a 2-second
HAZARD
Failure to follow this warning
could
iniury, death and/or property damage.
result
in personal
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.
period.
will spark
flame-proving
22
have
the call for gas heat is satisfied,
Failure to follow
damage.
FIRE
for 3 seconds.
The main gas valve relay contact closes to
energize the gas valve on low stage. After 5 seconds, the
igniter
Lockout
interrupting
at SEC1 or
the inducer motor comes
switch
closes, and the
ignition control on the furnace board begins a 15
pre-purge
period.
If the pressure switch fails to
a 15 second
high
furnace board performs
is open, and starts the
remain closed, the inducer will remain running.
After the
pressure switch re-closes,
the Infinity ignition control will
begin
be no flame
is common
damaged
or it is suspected
orifice hole with a numbered
AND ADJUSTMENTS
When the UI calls for gas heat, the Infinity
a self-check,
verifies the pressure switch
inducer on high speed.
the gas valve's
out-of-round
holes, etc.) can cause excessive
and misdirection
of burner flame. If orifice
the UI normally.
GAS HEAT
what
or
two seconds
for gas heating.
at the
determines
when unit is powered.
(depending
UI).
The
delay.
space.
operation
the 90-second
the LED will be ON continuously,
are detected.
will
a call for heat, the
only ON period
LED light will flash code 12 during
after which
inducer
period.
CHECK
for proper
is proved
and operate
the gas valve is de-energized,
the burners, and de-energizing
(shut down
HEAT
terminal
5. Blower-Off
LPS trip error) will occur.
OF OPERATION-GAS
will start a 90-second
after power
EAC-2
ll5VAC-to-ground
MODE
NOTE:
Infinity control
control will lock out.
NOTE:
NOTE:
with the
the living
flame
control
cycle.
listed above
LPS trip response
This Infinity system can be used to dehumidify
See UI Installation
Instructions
for more details.
SEQUENCE
If
on high
Delay:
If the burner
flame
is proven,
37 seconds after the gas valve is opened the
Indoor Blower is turned
gas heating stage.
cycle. If the LPS does not close
then the normal
DEHUMIDIFICATION
running.
routine
there should
Simultaneously,
the humidifier
cleaner
terminal
EAC-I
are
system to stabilize.)
for first 3 minutes
when
4. Blower-On
approximately
coil temp
off for 10 minutes with the compressor
LPS closes within
is proved
will lock out of Gas-Heating
mode
until flame is no longer proved.
fan has been OFF for 30 minutes.
is ignored
the burner
the furnace
Trials-For-Ignition
before going to Ignition-Lockout.
will reset automatically
after 3 hours, by momentarily
230 VAC power, or by interrupting
24 VAC power
SEC2 to the furnace board.
coil temp >
plus 25 °F (13.8 ° C) or outdoor
on to allow refrigerant
• Low-pressure
outdoor
lights
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
stabilize.)
• In high stage and low stage, fan is on when
sensor,
inducer on high speed and energize
stage relay to increase gas flow.
low
is <outdoor
always
valve energized on low stage. If the UI is asking for high
stage gas heat, the ignition control will maintain running the
as follows:
3 ° F (1.7 ° C) or outdoor
(Fan
Low
Fan may not
controlled
unit
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
kit
Fan will cycle based
Infinity
The
When
flame-proving
to be
operation.
NOTE:
and low stage gas valve operation.
3. Flame-Proving:
0°F
not need
be enabled
• In high stage, fan is off when
temperature
does
low
(4°C).OAT.
to
A low ambient
controlled
about 40°F
outdoor
control.
down
begins.
speed inducer
NOTE:
When this unit is operating
below 55°F (13°C) outdoor
temperature,
provisions
must be made for low ambient operation.
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
CARBON
MONOXIDE
POISONING
HAZARD
Failure
to follow
this warning
could result in personal
iniury
and/or
required
orifice
2. Adjust manifold
Fig. 19).
death.
size.
pressure
a. Turn off gas supply
If the manifold
pressure
and/or gas rate is not properly
adjusted on HI and LO stages, excess carbon monoxide can
be produced.
to obtain
low stage input rate (See
to unit.
b. Remove pipe plug on manifold (See Fig. 20) 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.
FIRE
AND UNIT
DAMAGE
e. Remove
HAZARD
Failure to follow
this warning
could
iniury or death and/or property damage.
result
in personal
Unsafe operation of the unit may result if manifold
is outside of the ranges listed in Table 6.
Gas input rates on rating plate are for installations
2000 ft (610 m).
input.
1. Determine
Input
rate must be within
regulator
valve pressure
adjustment
regulator
cap from low stage gas
(See Fig. 19) and turn
low-stage
adjusting screw (3/16 or smaller flat-tipped
screwdriver)
counterclockwise
(out) to decrease rate and
pressure
clockwise
at altitudes
up to
- 2% of rating
plate
(in) to increase
input rate.
the correct gas input rate.
a. The rated gas inputs shown
1/2"
in Table 4 are for altitudes
NPT
iNLET
from sea level to 2000 ft (610 m) above sea level.
These inputs are based on natural gas with a heating
value of 1050 Btu/ft3 at .65 specific gravity.
IN THE U.S.A.:
The input rating for altitudes above 2,000 ft (610 m) must
reduced by 4 percent for each 1,000 ft (305 m) above sea level.
For installations
plate.
below
Altitude
ft, (610
m) refer to the unit
rating
1/2'
For installations
the rating plate
input rate.
Table
2,000
be
5 - Altitude
ft (m)
Derate
Percent
Multiplier
for U.S.A.
Derate Multiplier
Factor*
of Derate
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
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
36-40
0.62
9001-10,000
(2744-3048)
90,000
X
pressure
X
0.90
=
81,000
is outside
this range, change
f. Re-install
Gas Control
check orifice
Never
correct
size.
aligned
orifice hole is essential
3. Verify natural
less than 1.4
gas.
If manifold
orifices.
adjustment
cap.
connected.
If orifice hole appears
been re-drilled,
Valve
pressure
main burner
low stage regulator
g. Leave manometer
re-drill
damaged
or it is suspected
hole with a numbered
an orifice.
for proper
to have
drill bit of the
A burr-free
and squarely
flame characteristics.
gas low stage input rate.
a. Turn off all other gas appliances
the gas meter.
and pilots
served by
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
one revolution.
of seconds
d. Divide number of seconds
of seconds in 1 hour).
for gas meter to complete
in step c. into 3600 (number
e. Multiply result of step d. by the number of cubic feet
shown for one revolution
of test dial to obtain cubic feet
of gas flow per hour.
f. Multiply
result of step f. by Btu heating
value of the gas
to obtain total measured input shown in Table 4.
(Consult the local gas supplier if the heating value of
at 4300 ft (1372 m).
Furnace Input Rate
at Installation
Automatic
or more than 2.0 IN. W.C. for natural
EXAMPLE:
Installed
TAP
DO NOT set low stage manifold
The input rating for altitudes from 2,000 (610 m) to 4,500 ft (1372
m) above sea level must be derated 10 percent by an authorized
Gas Conversion
Station or Dealer.
Derate Multiplier
Factor
PDAE_'/FOLDE
IN. W.C.
IN CANADA:
Btuh Input Furnace
_
NOTE:
:'Derate multiplier factors are based on midpoint altitude for altitude range,
Furnace Input Rate
at Sea Level
Altitude
J
Fig. 19 - Redundant
NOTE:
5001-6000
(1524-1829)
OUTLET
A04167
above 2,000 ft, (610 m) multiply the input by on
by the derate multiplier in Table 6 for the correct
0-2000
(0-610)
90,000
NPT
gas is not known).
EXAMPLE:
Assume
a 90,000
installed.
Assume
that the size
high stage input unit is being
of the dial is 2 cubic ft., one
revolution
takes 129 sec., and the heating
Btu/ft3.
Proceed as follows:
23
value of the gas is 1050
a.129sec.
to complete
b. 3600/129
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.
one revolution
= 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
NOTE:
the manifold
pressure
Double-check
while clocking
to decrease
a. Furnace
plate.
that UI is running
within
b. Select "COMFORT"
a. Furnace must operate within rise range listed on rating
plate.
on low stage gas heat
low stage gas heat temperature
must operate
7. Verify proper high stage gas heat temperature rise.
rate.
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:
the low stage firing rate.
4. Verify proper
NOTE: Double-check that User Interface is running on high stage
gas heat while clocking the low stage firing rate.
rise.
rise range listed on rating
or "EFFICIENCY"
mode
on UI.
"COMFORT"
mode will provide a warmer supply air
temperature,
while "EFFICIENCY"
will provide lower
a. Gas input for low and high stage gas heat operation.
gas consumption.
c. Make sure access panel is re-installed
d. Measure supply
unit as possible.
the supply
fall within
5.
Adjust
b. Derate for altitude, if applicable.
on the unit.
c. Return and supply ducts for excessive restrictions
causing static pressures in excess of .5 IN. W.C.
and return temperatures
as close to the
Subtract the return temperature
from
temperature
to deternfine rise. Rise should
the range specified on the rating plate.
manifold
pressure
to obtain
high
stage
input
d. Make sure model plug is installed.
8. Final Check
rate
a. Turn off gas to unit
(See Fig. 19).
b. Remove manometer from pressure tap.
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
valve pressure
NOTE:
adjustment
regulator
c. Replace pipe plug on manifold (See Fig. 20).
d. Turn on gas to unit.
e. Check for leaks.
cap from high stage gas
CHECK GAS INPUT (PROPANE GAS)
(See Fig. 19) and turn
high-stage
adjusting screw (3/16 or smaller flat-tipped
screwdriver)
counterclockwise
(out) to decrease rate and
Refer to propane kit installation instructions for properly checking
gas input.
clockwise
(in) to increase
DO NOT
set high stage manifold
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.
IN.W.C.
or more
pressure
is outside
input rate.
pressure
than 3.8 IN. W.C. for natural
this range, change
c. Re-install
6. Verify natural
gas.
If manifold
main burner orifices.
high stage regulator
d. Leave manometer
less than 3.2
adjustment
cap.
CHECK
connected.
With
gas high stage input rate.
a. Turn off all other gas appliances
the gas meter.
BURNER
burner
FLAME
access
panel
removed,
observe
the
unit
heating
operation.
Watch the burner flames to see if they are light blue and
soft in appearance,
and that the flames are approximately
the same
and pilots served by
for each burner. Propane will have blue flame (See Fig. 21). Refer
to the Maintenance
section for information
on burner removal.
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
revolution.
of seconds
d. Divide number of seconds
of seconds in 1 hour).
for gas meter to complete
in step c. into 3600
1
(number
e. Multiply result of step d. by the number of cubic feet
shown for one revolution of test dial to obtain cubic feet
of gas flow per hour.
f. Multiply result of step f. by Btu heating value of the gas
to obtain total measured input shown in Table 4.
(Consult the local gas supplier
gas is not known).
EXAMPLE:
Assume a 90,000
installed.
Assume that the size
a. 84 sec. to complete
value of
high stage input unit is being
of the dial is 2 cubic ft., one
revolution
takes 84 sec., and the heating
Btu/ft3. Proceed as follows:
b. 3600/84
if the heating
value
of the gas is 1050
one revolution
= 42.9
MANIFOLD
PIPE PLUG
c. 42.9 x 2 = 85.8 ft3 of gas flow/hr.
d. 85.8 x 1050
= 90,090
099019
Fig. 20 - Burner
Btuh input.
24
Assembly
BURNER
FLAME
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
BURNER
failure.
To initiate
the component
test procedure,
ensure
that there
are no UI inputs to the control (the ABCD
connector
removed from the Infinity control board for this operation)
time delays have expired. Turn on setup switch SWl-6.
NOTE:
The component
is receiving
MANIFOLD
The component
through
2. After
Fig. 21 - Monoport
LIMIT
closes the gas valve and stops gas flow to the burners and pilot.
The blower motor continues
to run until LS resets. The furnace
STATUS
When
the
air
low-temperature
completes
the
LED will display
temperature
STATUS
at the
limit
CODE
switch
33.
drops
to the
setting of the limit switch, the switch closes and
control circuit. The direct-spark
ignition
system
cycles and the unit returns
ROLLOUT
waiting
10 seconds,
to normal
The function of the rollout
the event of flame rollout.
heating
switch is to close the main gas valve in
The switch is located above the main
fan operation
is requested
by the UI indoor
EAC-I
is energized
fan
for
as long as the
ignite, then shut OFF and remain
OFF for the
delay allowing the heat exchangers
to heat up more
then restarts
indoor
When
at the end of the blower-ON
fan motor
after the gas heating
will
revert
delay period.
to continuous-blower
airflow
cycle is completed.
the UI "calls for cooling",
When
airflow
before
transitioning
the call for continuous
The
EAC
turns
fan motor
back
will switch
to continuous-blower
fan is removed,
terminals
the component
Check
Locate
the
indoor
fan
are energized
test is completed,
motor
when
the indoor
blower
will continue operating
for an additional 5 seconds before shutting
down, if no other function requires blower motor operation.
ON
on
for 15
runs the
the blower
one or more
See component
of status codes.
for Refrigerant
is
status
test section
test, turn setup
2. Repair
NOTE:
codes
or Status
switch
SWl-6
to
Leaks
and repair refrigerant
leaks and charge
leak following
the unit as follows:
accepted
system
practices.
Install a filter drier whenever
the system
has been opened
for repair.
3. Check
system
4. Evacuate
additional
for leaks using an approved
refrigerant
system
leaks are found.
method.
and reclaim
refrigerant
5. Charge
unit with Puron
(R-410A)
refrigerant,
volumetric-charging
cylinder
or accurate scale.
unit rating plate for required charge.
Start-Up
if no
using a
Refer to
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 5 min. between
"on" cycles to prevent
compressor
damage.
CHECKING
OPERATION
COOLING
See UI Installation
the indoor
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.
then
NOTE:
To repeat component
OFF and then back ON.
fan
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
turns the igniter
then OFF.
(11, 25, or 41) will flash.
Code Label for explanation
FAN MODE
detailed instructions.
Terminal
indoor fan motor is energized.
quickly,
After
furnace
motor will operate at continuous
blower airflow. Continuous
operation
is programmable.
See the UI Owner's
Manual
the burners
blower-ON
the control
then OFF.
1. Use both high- and low-pressure
ports to relieve
pressure and reclaim remaining
refrigerant.
motor (IFM) continues
to run until switch is reset. The
board STATUS LED will display STATUS CODE 33.
continuous
it ON
operating.
operation.
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
When
control
NOTE:
SWITCH
CONTINUOUS
ON and keeps
4. After shutting the blower motor OFF, the control
inducer for 10 seconds, then turns it OFF.
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
board
motor
step 3.
seconds,
Burner
if the control
is as follows:
turns the inducer
for 15 seconds,
3. The
will not operate
or until all time delays have expired.
test sequence
1. The control
C99021
test feature
any UI signals
can be
and all
CHECKING
AND
Instructions
HEATING
for detailed
AND ADJUSTING
Any adjustment
unit operating
NOTE:
unless
charge.
25
to refrigerant
with
charge
of the refrigerant
is suspected
The charging
CHARGE
Puron
(R-410A)
must be done with
stage.
Adjustment
the unit
temperatures
charging
in HIGH
CHECKOUT.
REFRIGERANT
The refrigerant
system
is fully charged
refrigerant and is tested and factory sealed.
NOTE:
system
CONTROL
of not
charge
having
label and the tables
and pressures
label is attached
in cooling
to the outside
the
is not required
proper
shown
mode
only.
of the unit.
R-410A
refer to system
A refrigerant
6 - Heating
Table
HEATING
INPUT(BTU/HR)*
Inputs
GAS SUPPLY PRESSURE
Natural
NUMBER OF
ORIFICES
(IN. W.C.)
MANIFOLD
High Stage
3.2-3.8
PRESSURE
Natural
(IN. W.C.)
High Stage
Low Stage
Min
Max
40,000
26,000
2
4.0
13.0
Low Stage
60,000
39,000
3
4.0
13.0
3.2-3.8
1.4 - 2.0
90,000
58,500
3
4.0
13.0
3.2-3.8
1.4 _ 2.0
115,000
75,000
3
4.0
13.0
3.2-3.8
1.4 _ 2.0
130,000
84,500
3
4.0
13.0
3.2-3.8
1.4 _ 2.0
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.
7 - ECM
Table
Wet
Coil
Pressure
Drop
(IN.
W.C.)
UNIT
SIZE
600
700
800
900
1000
024
0.005
0.007
0.010
0.012
0.015
0.007
0.010
0.012
0.015
0.018
0.021
0.024
0.019
0.023
0.027
0.032
0.037
0.042
0.047
0.014
0.017
0.020
0.024
0.027
0.031
0.035
0.039
0.043
0.027
0.032
0.036
0.041
0.046
0.052
0.029
0.032
0.036
030
036
042
STANDARD CFM (SCFM)
1200
1300
1400
1500
1100
O48
060
Table
FILTERSIZE
in.(mm)
20X20X1
(508x508x25)
24X30X1
24X36X1
(610x914x25)
600
700
800
900
1000
1100
1200
0.05
0.07
0.08
0.1
0.12
0.13
0.14
0.15
0.05
0.6
0.07
0.07
0.08
0.09
0.1
0.06
0.07
0.07
0.08
.......
IMPORTANT:
indicated
Drop Table (IN. W.C.)
CFM
1300 1400 1500 1600 1700
When
adjustment
evaluating
to the specified
the
refrigerant
factory
charge
charge,
must always
0.10
0.11
0.12
0.13
0.14
0.14
........
0.09
an
TO USE COOLING
be
Take
CHARGE
is listed on the unit rating
data table. Refer to the Refrigeration
Refrigerants
Section.
plate
Service
NO CHARGE
Use
standard
evacuating
evacuating
system, weigh in the specified
(refer to system rating plate).
LOW
CHARGE
techniques.
amount
After
of refrigerant
the liquid
0.09
CHARGING
refrigerant
CHARTS
line temperature
If the
and read the manifold
what
the liquid
causing
leak, refer to Check
NON-COMMUNICATING
HEATING
MODE: 4-WIRE
line temperature
the inaccurate
for Refrigerant
readings
EMERGENCY
THERMOSTAT
COOLING
established
with
the UI, the Infinity
suction line. Mount the temperature
sensing device on the suction
line and insulate it so that the outdoor ambient does not affect the
The
operating
interconnecting
Infinity
a standard
from both
insulated
/
wire with 105C,
control
disconnect
the
thermostatic
the
ABCD
control boards and using No. 18 AWG
type 90°C minimum
or equivalent
wire,
will respond
with the maximum
safe airflow
unit cooling capacity.
26
thermostat,
will enable
simple
make the connections
between the standard thermostat,
board, and the HP/AC board per Fig. 22. Recommend
connectors
color-coded,
with
board
to allow
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
the normal
control
furnace
terminals
For
be within
is a
Leaks section.
Use Cooling Charging
Chart (Fig. 23). 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
must
pressure
This mode of operation
is provided only in the case where the UI
has failed or is otherwise unavailable.
If communications
cannot be
standard thermostat input
control of the 48XL unit.
COOLING
reading. Indoor air CFM
range of the unit.
0.053
2300
problem
leak.
0.049
2200
NOTE:
for
0.068
0.045
2100
REFRIGERANT
Check
0.063
0.040
2000
to determine
and/or the physical
Techniques Manual,
0.057
2100
1900
Refer to the chart
should be.
charge
2000
1800
gauges.
of refrigerant
1900
...........
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.
The amount
1800
8 - Filter Pressure
500
....
(610x762x25)
1700
1600
the furnace
the use of
600V, 2/64" insulation.
to cooling
based
and heating
on gas furnace
demands
output
and
infinity Furnace
Board
infinityHP/AC
Board
OutdoorAir Thermistor
(Suppliedwith IU)
FIELD CONNECTION
REQUIRED
(BLACKWIRES)
Standard
4=Wire
Thermostat
OutdoorCoil Thermistor
FACTORYCONNECTED
_'m
m
FACTORYWIRESPROVIDED
FOR FIELDCONNECTION
OF UTiLiTY CURTAILMENT
AO6302
Fig. 22 - Non-Communicating
Emergency
Cooling/Heating
Required Subcooling °F (°C)
Wiring
Connections
Required Liquid Line Temperature for a Specific Subcooling (R-410A)
Outdoor Ambient Temperature
Required Subeoolin9 (°F)
Pressure
Model Size
024
030
036
15.5(8.6)
16.8(93)
14(7.7)
15.6(8.7)15.7(8.7)15.8(8.8)15.9(8.9)
16,4(9.I)
I6.2(9)
156(8,7)
13.9(7.7)
13.9(7.7)
13.8(7.7)
042
048
oe°
19.2( 10.7 ) 19.1 ( 10.6 ) 19.1( 10.6 ) 18.9 ( 10.5) 18.7( 10.4 )
21(11.6)
20.8(11.5) 20,7(11.5)
20,4(11,3) 20.2(11.2)
16.2(9)
16.6(9.2)
16.8(9.3)
17.3(9.6)
17.8(9.9)
Required Subcooling (°C)
Pressure
174
I81
188
56
59
61
5I
54
56
46
49
51
36
39
41
1200
1248
1296
13
15
16
I1
I2
13
8
9
10
2
4
5
Char in Procedure
195
202
209
216
223
230
63
65
67
69
71
73
58
60
62
64
66
68
53
55
57
59
61
63
43
45
47
49
51
53
1344
1393
1441
1489
1537
1586
17
18
20
2I
22
23
14
16
17
18
19
20
12
13
14
15
16
17
6
7
9
10
11
12
1- Measure Dischargeline pressure by attaching a gaugeto the service port.
2- Measurethe Liquid line temperature by attaching a temperature sensingdevice to it,
237
244
75
77
70
72
65
67
55
57
I834
1882
24
25
21
22
I9
20
I3
14
259
267
275
283
291
299
81
83
85
87
89
91
76
78
80
82
84
86
71
73
75
77
79
81
61
63
65
67
69
71
1786
1841
1896
1951
2008
2061
27
28
29
31
32
33
24
26
27
28
29
30
22
23
24
25
28
27
16
17
18
19
20
22
308
317
326
335
344
353
93
95
97
99
101
102
88
90
92
94
96
97
83
85
87
89
9I
92
73
75
77
79
81
82
2123
2185
2247
2309
2372
2434
34
35
36
37
38
39
31
32
33
34
35
36
28
29
30
31
33
34
23
24
25
26
27
28
363
373
383
104
106
108
99
101
103
94
96
98
84
86
88
2503
2571
2640
40
41
42
37
39
40
35
36
37
29
30
31
393
403
413
423
433
443
110
112
114
116
117
119
105
107
109
111
112
114
100
102
104
106
107
109
90
92
94
96
97
99
2709
2778
2847
2916
2985
3054
43
44
45
46
47
48
4I
42
43
44
45
46
38
39
40
41
42
43
32
33
34
35
36
37
453
463
473
121
I22
124
116
117
119
111
112
114
101
102
104
3123
3192
3261
49
50
51
47
47
48
44
45
46
38
39
40
483
493
503
513
523
533
126
127
129
130
132
133
121
122
124
125
127
128
116
117
119
120
122
123
106
107
109
110
112
113
3330
3399
3468
3537
3606
3675
52
53
54
55
56
56
49
50
51
52
53
54
47
47
48
49
50
51
41
42
43
44
44
45
15(8,3)
13.7(7.6)
3- insulatethe temperaturesensing device so that the Outdoor Ambient doesn't affect
the reading,
4- Referto the required Subcooiingin the table based on the model size and the
OutdoorAmbient temperature.
5- Interpolateif the Outdoortemperature lies in betweenthe table values, Extrapolateif
the temperature lies beyondthe table range.
6- Findthe PressureValue correspondingto the the measured Pressureon the
CompressorDischargeline.
7- Read acrossfrom the Pressure readingto obtain the Liquid line temperature for a
required SubcooIing.
8- Add Charge if the measuredtemperature is higherthan the liquid line temperature
value in the table.
9- Add Charge using the serviceconnection on the Suctionline of the Compressor,
50DU500166- 2,0
AO8423
Fig.
23
- Cooling
Charging
Table-Subcooling
27
Air Filter
MAINTENANCE
To ensure continuing high performance, and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment. This packaged unit should
be inspected at least once each year by a qualified service person.
To troubleshoot unit, refer to Table 10, Troubleshooting Chart.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
IMPORTANT:
Never
in the return-air duct
same dimensional size
for recommended filter
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
PERSONAL
HAZARD
INJURY
AND
UNIT
DAMAGE
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.
operate the unit without a suitable air filter
system. Always replace the filter with the
and type as originally installed. See Table 1
sizes.
Fan and Motor
NOTE: All motors are pre-lubricated.
these motors.
Do not attempt to lubricate
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.
these motors.
Do not attempt to lubricate
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
ELECTRICAL
SHOCK
Failure to follow
injury or death:
Remove unit access panel to gain access to the limit switch. The
limit switch is located above the indoor blower housing.
HAZARD
these warnings
could
result
1. Turn off electrical power to the unit before
any maintenance
or service on this unit.
2. Use extreme
caution
3. Never place anything
with the unit.
when removing
combustible
panels
in personal
NOTE:
On small chassis units, a second limit switch is located
beside the indoor blower housing.
performing
Burner
and parts.
either on or in contact
Ignition
[]nit 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.
[]NIT OPERATION
HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
EQUIPMENT
Errors made when reconnecting wires may cause improper
and dangerous
operation. Label all wires prior to
disconnecting when servicing.
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.
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.
Removal of Gas Train
To remove the gas train for servicing:
1. Shut off main gas valve.
2. Shut off power to unit.
3. Remove unit access panel.
4. Disconnect gas piping at unit gas valve.
5. Remove wires connected to gas valve. Mark each wire.
6. Remove ignitor and sensor wires at the ignitor module.
7. Remove the mounting screw that attaches the burner rack to
the unit base.
8. Slide the burner rack out of the unit.
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.
9. To reinstall, reverse the procedure outlined above.
Inducer
Pressure
Switch
Inspect pressure switch connections. Inspect pressure switch tube
for cracks or restrictions. Replace if needed.
28
ELECTRICALSHOCK
HAZARD
Failure
to follow
this warning
could result
injury
in personal
or death.
Disconnect
and tag electrical
power to the unit
cleaning and lubricating the blower motor and wheel.
before
infinity Top
A06035
Outdoor Coil, Indoor
Drain Pan
Coil, and Condensate
Inspect the condenser
coil, evaporator
pan at least once each year.
UNIT SIZE
coil, and condensate
drain
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
Electrical
detergent and water solution. Rinse coils with clear water, using a
garden hose. Be careful not to splash water on motors, insulation,
Remove
condenser coil, be sure to clean between
all dirt and debris from the unit base.
Inspect
the drain
pan and condensate
coil fins
and inner
the coils. Be sure to flush
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,
"plumbers snake" or similar probe device.
Outdoor
clear
it with
a
Fan
1 (26)
1 (26)
036
1 (26)
042
1 (26)
048
11/32 (9)
060
Inspect
For best results, spray condenser
the unit. On units with an outer
DIM. IN. (MM)
030
9/16 (14)
Fig. 24 - Outdoor
cleaner, using the soft brush attachment.
Be careful not to bend the
fins. If coated with oil or grease, clean the coils with a mild
wiring, or air filter(s).
from inside to outside
"A"
024
Controls
and check
Fan Blade
Clearance
and Wiring
the electrical
sure to turn off the electrical
controls
power
access panel to locate
and wiring
annually.
Be
to the unit.
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
end and reassemble the connection properly and securely.
the wire
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
each
electrical
component
instrumentation.
checks.
Refer
Refrigerant
malfunction
with
the
to the unit wiring
has occurred, check
proper
electrical
label when making
these
Circuit
Inspect all refrigerant tubing connections
and the unit base for oil
accumulation
annually.
Detecting
oil generally
indicates
a
refrigerant
UNIT
OPERATION
HAZARD
Failure to follow this caution may result in damage to unit
components.
refrigerant
solution.
Keep the outdoor fan free from all obstructions to ensure
proper cooling operation, Never place articles on top of the
unit,
Refrigerant
2. Turn
4 screws
motor/grille
expose
3. Inspect
holding
assembly
outdoor
upside
grille
down
the fan blades
for cracks
cover
to
or bends.
loosen setscrew
5. When
position
replacing
table shown
fan blade,
blade
that set screw
grille.
engages
The
according
to the
the flat area on the motor
is suspected,
leak test all
Leaks section.
and low performance
is suspected,
Refrigerant
Charge section.
Airflow
heating
and/or
cooling
airflow
does
not
require
checking
unless improper performance
is suspected.
If a problem exists, be
sure that all supplyand return-air
grilles are open and free from
obstructions,
and that the air filter is clean.
Pressure
and slide fan off
in Fig. 24.
shaft when tightening.
7. Replace
on top
to top
fan blade.
4. If fan needs to be removed,
motor shaft.
6. Ensure
and motor
or if low performance
tubing using an electronic leak detector, or liquid-so@
If a refrigerant
leak is detected,
refer to Check for
If no refrigerant leaks are found
refer to Checking and Adjusting
Indoor
1. Remove
cover.
leak.
If oil is detected
Pressure
Switches
switches
- Refrigerant
are protective
devices
Circuit
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
Loss-of-Chame
This
switch
suction
airflow
(R-410A)
(Low Pressure)
is located
system.
Switch
on the liquid
line and protects
pressure drops to about
switch should be closed.
20 psig. If system
Hi_h-Pressure
(HPS & HPS2)
The
29
Switches
high-pressure
protects
against
low
pressures
caused by such events as loss of charge, low
across indoor coil, dirty filters, etc. It opens if the system
against
switches
excessive
are located
condenser
pressure
is above
on the discharge
coil pressure.
HPS
this,
line and
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
injury or death and/or property damage.
Wear safety glasses and gloves when
Keep torches
and other
ignition
refrigerants
and oils.
result
handling
sources
in personal
System
OPERATION
Synthetic Roof Precautionary Procedure
1. Cover extended roof working area with an in,permeable
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
local codes.
material per
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
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
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, accunmlator, or reversing valve.
LIQUID-LINE
The Copeland scroll compressor uses Mobil 3MA POE oil.
This is the only oil allowed for oil recharge.
OIL
The compressor in this system uses a polyolester (POE) oil, Mobil
3MA POE. This oil is extremely hygroscopic, meaning it absorbs
water readily. POE oils can absorb 15 times as much water as other
oils designed for HCFC and CFC refrigerants. Take all necessary
precautions to avoid exposure of the oil to the atmosphere.
SERVICING SYSTEMS ON ROOFS WITH SYNTHETIC
MATERIALS
refrigerants.
away from
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 an anti-rotational
device and an internal pressure-relief port. The anti-rotational
device prevents the scroll from turning backwards and replaces the
need for a cycle protector. The pressure-relief port is a safety
device, designed to protect against extreme high pressure. The
relief port has an operating range between 550 and 625 psi
differential pressure.
Refrigerant
COMPRESSOR
AND SAFETY
Failure to follow this warning
iniury or equipment damage.
could
HAZARD
result
in personal
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.
LEDs built into Infinity control boards provide installer or service
person information concerning operation and/or fault condition of
the unit controls and ECM motor. This information is also
available at the system UI in text with basic troubleshooting
instructions. Careful use of information displayed will reduce the
need for extensive manual troubleshooting. See section B in
Start-Up & Troubleshooting
and Table 5, as well as the UI
instructions,
for
additional
information.
Additional
Troubleshooting information can be found in Table 10.
MAJOR COMPONENTS
2-STAGE HP/AC BOARD
The two-stage
functions:
HP/AC
control
board
controls
- Low- and high-stage compressor operation
- Outdoor fan motor operation
- Reversing valve operation
3O
the following
- Defrost
COMPRESSOR
operation
- Low ambient
- Crankcase
cooling
- Pressure
external
potential
problems.
The control continuously
monitors
the high
voltage on the run capacitor of the compressor
motor. Voltage
protection
switch monitoring
(refrigerant)
should be present any time the compressor
contactor
and voltage
should
not be present
when
the
- Time delays
FURNACE
BOARD
The furnace
board
- Indoor
blower
the following
CONTACTOR
functions:
operation
SHORTED
If there is compressor
compressor
operation,
- Inducer
a wiring
motor
sparker
- Pressure
switch monitoring
module
COMMUNICATION
FAILURE
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
will flash the appropriate
PRESSURE
SWITCH
The unit is equipped
1. De-energize
compressor
with high-
in Table 5.
switches.
or low-pressure
If the
switch,
it
& LPS) or the
for 15 minutes.
fault codes.
delay, if there is still a call for cooling
HPS
is
reset,
the
compressor
and
contactor
is
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
delay, then resume
operation
with a call
cycles, the unit operation
8. In the event of a low-pressure
appropriate
replaced.
BROWN
check the refrigerant
control
fault code
If the
should
compressor
be starting,
voltage
is not sensed when the compressor
the contactor may be stuck open or there is a
wiring
Check
error.
The
the contactor
control will flash the appropriate
and control box wiring.
TROUBLESHOOTING
board
switch
charge
has failed,
trip or low pressure
and indoor
the control
(See TaMe 5). The control
is less than
(POWER
DISCONNECT)
PROPER
SWITCHING
STAGES
capacity.
The
stage
liquid
pressures
operation,
current
COMPRESSOR
are very
so liquid
pressure
similar
between
should
low and
not be used
for
will
board
for at least
flash the
should
be
4 seconds,
the
DETECTION
increase
20-45%
INTERNAL
when
solenoid,
switching
when
from
energized
in
RELIEF
to motor windings.
Thermistors
temperature
If the outdoor
displayed.
connected
insure
and 230v
wiring
is
THERMISTORS
are electronic devices which sense temperature.
As the
increases,
the resistance
decreases.
Thermistors
are
used to sense outdoor ambient
Refer to Fig. 25 for resistance
26 for OCT location.
control
is closed
should
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
If there is no 230v at the compressor
contactor when the unit is
powered and cooling demand exists, the appropriate
error code is
Verify that the disconnect
to the unit.
FOR
code.
Check the suction pressures at the service valves.
Suction pressure
should be reduced by 3-10%
when switching
from low to high
TEMPERATURE
187v
UNIT
& HIGH
fault
airflow.
(See Table 5).
230V LINE
LOW
Compressor
appropriate
compressor
contactor and fan relay are de-energized.
Compressor
and fan operation
are not allowed until voltage is a
minimum
of 190v.
The control will flash the appropriate
fault
code
NO 230V AT COMPRESSOR
attached
voltage
check the unit will resume
If the thermal cutout trips for three consecutive
cycles, then unit
operation is locked out for 4 hours and the appropriate fault code is
low to high stage.
The compressor
high stage, should measure 24vac.
OUT PROTECTION
If the line
interval),
troubleshooting.
FAULT
If the HP/AC
thermal protector
has not re-set, the outdoor fan is turned off. If
the call for cooling
continues,
the control
will energize
the
compressor
contactor every 15 minutes.
If the thermal protector
high
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.
CONTROL
fault code.
CUTOUT
code shown in Table 5. After 15 minutes, with a call for low or
high stage cooling, the compressor
contactor is energized.
If the
NOTE:
6. If LPS or HPS trips 3 consecutive
is locked out for 4 hours.
lockout,
will flash the appropriate
THERMAL
compressor
contactor for 15 minutes, but continues to operate the
outdoor fan.
The control Status LED will flash the appropriate
BETWEEN
after the 15-minute
for cooling.
The control
displayed.
the appropriate
or
voltage sensed when there is no demand for
the contactor may be stuck closed or there is
closes (at the next 15 minute
operation.
and low-pressure
of a high-
fan operating
4. After a 15 minute
the LPS
energized.
shown
the compressor
contactor (HPS1
solenoid contactor (HPS2).
2. Keep the outdoor
3. Display
fault code,
PROTECTION-REFRIGERANT
control senses the opening
will respond as follows:
DETECTION
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
(gas)
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.
control
error.
COMPRESSOR
- Remote
MODEL
is energized,
contactor
is
de-energized.
controls
- Gas valve
SYSTEMS
SENSING
The control board input terminals VS and L2 (See Fig. 18) are
used to detect compressor
voltage status, and alert the user of
heater operation
- Compressor
VOLTAGE
ambient
or coil thermistor
will flash the appropriate
IMPORTANT:
thermistor
Coil thermistor
is mounted
(OAT) is field mounted
been properly installed.
31
(OAT) and coil temperature
(OCT).
values versus temperature.
See Fig.
should
fail,
the HP/AC
fault code (See Table 5).
is factory
properly.
and connected.
mounted.
Outdoor
Verify
Check
to
air thermistor
that the OAT has
THERMISTOR
9O
I
CURVE
I
I
I
80- k----4------4----_------4-------I
....
\
i
i
i
i
i
7o- -'_-- q------
I----- _------
T------I ....
6o-_ _X__
J._ _ _ .I_
_ _ __ _ _ J__ _ _I....
\i
i
i
i
i
50....
'_------ 1----- _------ 1-------I ....
40- /_.__
l______/___l
....
I\
I
I
I
I
30.... _----_'-Z_---_------I------I
....
20....
_ ______/'_._/__ ____/ ____--I....
I
I
_
I
I
lo....
H--t---_--_--
o ..................
I...................
I...................
I...................
I...................
I,,-,_
0
20
40
60
80
TEMPERATURE
100
"tub
120
(DEG. F)
\
A91431
Fig. 25 - Resistance
THERMISTOR
The control
temperature
SENSOR
Values
• In cooling
conditions.
mode,
The comparison
if the outdoor
g
warmer
than the coil sensor
indicates
-> 20 °F cooler than the coil sensor,
A06311
Fig. 26 - Outdoor
indicates
(or) the outdoor
the sensors
-> 10 °F
air sensor
IMPORTANT:
are out of
if the outdoor
air sensor
indicates
1. Ensure
>
_ 35 o F (_,_o C)
2. Ensure
than the coil sensor (or) the outdoor
air sensor
indicates
-> 10°F
(-12°C)
the sensors
are out
cooler than the coil sensor,
adding
covers.
The thermistor
FAILED
Factory
outdoor
comparison
will flash the appropriate
is not performed
THERMISTOR
DEFAULT
defaults
have been
air thermistor and/or
during
low ambient
is routed
OPERATION
provided
in the event
coil thermistor.
of failure
Troubleshooting
information.
Chart
(Table
10)
valve
for
away from tubing
and sheet
rub-through
or wire pinching.
and tubing
is secure
and covers.
service
CARE
of
Securely
fasten
caps
to l/2-turn
stem
in unit before
all panels
past
and
finger
AND
located
file.
at the back
of this
MAINTENANCE
For continuing
high
performance
and to minimize
possible
equipment
failure, periodic maintenance
must be performed on this
equipment.
Frequency
areas,
such
information.
after 5 minutes.
If there is a thermistor out of range error, defrost will occur
time interval during heating operation,
but will terminate
minutes.
Refer to the
troubleshooting
that all wiring
panels
job, be sure to do the following:
5. Fill out Start-Up
Checklist
manual and place in customer
If the OCT sensor should fail, low ambient cooling will not be
allowed.
Defrost will occur at each time interval during heating
but will terminate
Attachment
4. Leave Users Manual with owner. Explain system operation
and periodic maintenance
requirements
outlined in manual.
operation.
If the OAT sensor should fail, low ambient cooling will not be
allowed and the one-minute
outdoor fan off delay will not occur.
Defrost will be initiated based on coil temperature
and time.
operation,
that all wiring
3. Tighten
tight.
of range.
If the sensors are out of range, the control
fault code as shown in Table 5.
(OCT)
CHECKS
Before leaving
metal edges to prevent
warmer
cooling
Coil Thermistor
FINAL
range.
• In heating
F
is:
air sensor
(-12°C)
o
tight on the liquid
COMPARISON
continuously
monitors and compares the outdoor air
sensor and outdoor coil temperature
sensor to ensure
proper operating
J
_
Versus Temperature
at each
after 5
additional
32
of maintenance
as
coastal
may vary depending
applications.
See
upon
Users
geographic
Manual
for
AIR CONDITIONER
REFRIGERATION
SECTION
WITH PURON
QUICK-REFERENCE
Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing
designed to operate with Puron. Puron refrigerant cylinders are rose colored.
• Puron refrigerant
position.
cylinders manufactured
Cylinders
manufactured
GUIDE
equipment
and replacement
• Puron
cylinder
systems
• Manifold
service
should
March 1, 1999 and later DO NOT have a dip tube and MUST
sets should
pressure
be charged
be positioned
• Leak detectors
• Puron,
• Vacuum
rating must be 400 psig. DOT 4BA400
with liquid refrigerant.
upside down
should
pressure
be designed
will not remove
• Only use factory-specified
moisture
filter driers with rated working
rapidly.
Do not expose
and service
• A Puron liquid-line
filter drier is required
• Do not use an R-22
TXV.
• Never
to atmosphere
must be opened
• Do not vent Puron
• Observe
pressures
valves
materials.
with wet cloth when brazing.
on every unit.
while it is under
a vacuum.
for service, break vacuum
with dry nitrogen
into the atmosphere.
all warnings,
cautions,
• Do not leave Puron suction
no less than 600 psig.
oil to atmosphere.
to certain plastics and roofing
• Wrap all filter driers
• When system
with POE oils.
from oil.
filter drier in liquid line.
• POE oils may cause damage
open system
device in the manifold
rating.
moisture
liquid-line
• Do not install a suction-line
• POE oils absorb
metering
to detect HFC refrigerant.
as with other HFCs, is only compatible
pumps
or DOT BW400.
Use a commercial-type
be 750 psig high side and 200 psig low side with 520 psig low side retard.
• Use hoses with 750 psig service
are
prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright
to flow.
• Recovery
components
and bold text.
line driers in place for more than 72 hrs.
33
and replace
filter driers.
hose.
to allow liquid
Table
9-
Troubleshooting
SYMPTOM
Chart
CAUSE
REMEDY
Power failure
Fuse blown or circuit breaker tripped
Compressor and outdoor fan
will not start
Defective contactor, transformer, control relay, or highpressure, loss-of-charge
or low-pressure switch
Replace component
Insufficient line voltage
Determine cause and correct
Incorrect or faulty wiring
Check wiring diagram and rewire correctly
UI setting too low/too high
Reset UI setting
Units
have
a 5-minute
time
DO NOT bypass this compressor time
delay-wait for 5 minutes until time-delay
relay is de-energized
delay
Faulty wiring or circuit
Loose connections in compressor
Compressor
runs
will not start but condenser
fan
Check wiring and repair or replace
Compressor motor burned out, seized, or
internal overload open
Compressor
operates continuously
Low input voltage (20 percent low)
Determine cause and correct
Refrigerant
Recover refrigerant, evacuate system, and recharge to capacities shown on rating plate
overcharge
or undercharge
Insufficient line voltage
Blocked outdoor coil
Replace and determine cause
Determine cause and correct
Determine cause and correct
Defective run/start capacitor, overload or start relay
Determine cause and replace
Faulty outdoor fan motor or capacitor
Restriction in refrigerant system
Replace
Locate restriction and remove
Dirty air filter
Unit undersized for load
Replace filter
Decrease load or increase
UI temperature
set too low
Reset UI setting
Low refrigerant
charge
Locate leak, repair, and recharge
Recover refrigerant, evacuate system, and recharge
Clean coil or remove restriction
Outdoor coil dirty or restricted
Dirty air filter
Recover excess
pressure
Air in system
Indoor or outdoor air restricted
Head pressure too low
Excessive suction pressure
Check for leaks, repair and recharge
Remove restriction
High heat load
Reversing valve hung up or leaking internally
Check for source and eliminate
Refrigerant
Recover excess refrigerant
overcharged
charge
Metering device or low side restricted
Insufficient coil airflow
Temperature
IFM does not run
or air short-cycling
too low in conditioned
area
Replace valve
Replace filter
Check for leaks, repair and recharge
Remove source of restriction
Check filter-replace
if necessary
Reset UI setting
Outdoor ambient below 55°F (13°C)
Filter drier restricted
Verify low-ambient
Replace
Blower wheel not secured to shaft
Insufficient voltage at motor
Properly tighten blower wheel to shaft
Determine cause and correct
Power connectors
Connectors
not properly sealed
Water dripping into motor
IFM operation
refrigerant
Recover refrigerant, evacuate system, and recharge
Determine cause and correct
Low refrigerant charge
Restriction in liquid tube
Dirty air filter
Low refrigerant
Suction pressure too low
unit size
Replace filter
Clean coil
Dirty indoor or outdoor coil
Refrigerant overcharged
head
Replace compressor
Determine cause and replace
Air in system
Excessive
Determine cause
Defective run capacitor, overload, or PTC (positive
temperature coefficient) thermistor
Defective compressor
Compressor cycles (other than normally satisfying) cooling/heating calls
Call power company
Replace fuse or reset circuit breaker
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
is intermittent
Connectors
cooling enabled in UI
not firmly sealed
34
Table
lO--Troubleshooting
SYMPTOM
Chart
Con't-Gas
Furnace
CAUSE
REMEDY
Water in gas line
Drain. Install drip leg.
No power to unit
Check power supply fuses, wiring or circuit
breaker.
No 24-v power supply to control circuit
Check transformer.
NOTE: Some transformers have internal overcurrent protection that requires a cool-down period to reset.
Mis-wired
Check all wiring and wire nut connections
or loose connections
Burners will not ignite
Inadequate
heating
Misaligned spark electrodes
Check flame ignition and sense electrode
tioning.
Adjust as necessary.
No gas at main burners
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 attempting to light unit.
2. Check gas valve.
Inducer pressure switch not closing
1. Check pressure switch wires, connections,
and tubing. Repair or replace if necessary.
Dirty air filter
Clean or replace filter as necessary
Gas input to unit too low
Check gas pressure at manifold match with that
on unit nameplate
Unit undersized for application
Restricted airflow
Replace with proper unit or add additional
posi-
unit
Clean or replace filter. Remove any restriction.
Check rotation of blower, temperature
Adjust as necessary.
Limit switch cycles main burners
Poor flame characteristics
Operation
Incomplete combustion results in: Aldehyde odors,
carbon monoxide, sooting flame, floating flame
35
rise of unit.
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.
START=U P CHECKLIST
(Remove and Store in Job File)
I. Preliminary information
MODEL NO.:
SERIAL NO.:
DATE:
TECHNICIAN:
II. PRE-START-UP (insert checkmark in box as each item is completed)
VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS
CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS
CHECK GAS PiPiNG FOR LEAKS (WHERE APPLICABLE)
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
ill. START-UP
ELECTRICAL
SUPPLY VOLTAGE
COMPRESSOR AMPS
INDOOR (EVAPORATOR) FAN AMPS
TEMPERATURES
OUTDOOR (CONDENSER) AIR TEMPERATURE
RETURN-AIR TEMPERATURE
DB
COOLING SUPPLY AIR
DB
GAS HEAT SUPPLY AiR
DB
WB
WB
PRESSURES
GAS INLET PRESSURE
IN.WG
GAS MANIFOLD PRESSURE
IN.WG
REFRIGERANT SUCTION
PSIG SUCTION LINE TEMP*
REFRIGERANT DISCHARGE
PSIG DISCHARGE 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.
Copyright
2008 Carrier Corp. •
Manufacturer
reserves
7310 W. Morris St. •
the right to change,
Indianapolis,
IN 46231
at any time, specifications
and designs
Printed in U.S.A.
without
Edition
notice and without
3d
Date: 08/08
obligations,
Catalog No:48XL-O4Sl
Replaces:
48XL-3SI
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