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Carrier 48XL Air Conditioner User Manual

1. W DER y res rC CONNECIION WIRING DIAGRAM LADDER WIRING DIAGRAM re y FIELD SUPPLY li I USE COPPER CONDUCTORS ONLY Gry L2 UNIT COMPONENT ARRANGEMENT 208 230 VAC 8K FIELD SUPPLY 208 230 VAC 60 HZ 1PH w L 4 sas GUTDOOR FAW Ore 60HZ 1PH Y CONT avs Y 11 e E O E Ll COMPRESSOR INDOOR FAN el 1 section section LS z ray 11 Ea cr Nha COMP K KCONTROL onno Boat Toa IF USED 3 I Gara Loew a ae HCF Y BL s asc SPLICE BOX cape
2. CAP C IF USED CCH 1108k 1iX Ri a 2 nm a II amp _ PL2 1 Oi 5 2 L2 2 o E PL2 2 em 2 8 REMOTE SPARKER CONTROL i as S PL2 l ss e e 2 E 115 3 1 ES gt E o SPARKER 3 230V TRANS SEE NOTES Ll CO B AAA ell L2 R YY z RI 4 o U ee FLAME 24V com Hg Bey w LoPS LP KIT ace s SENSOR WHEN USED E i PL Y PRESSURE SWITCH I PLI 4 Q a A o as ust g PL6 v v v e y 3 PL1 8 REMOTE SPARKER SELECT MODELS center BL SAS VALVE eh PLi 10 OB 1513 AU PLI 3 GY cI AOC B8R Dht1 5 c PL1 12 GY 0 PL3 4 BL ul r33 CC 6 PL3 2 FG PLTA FA poup USER INTERFACE they 8 PLT C w PAR piro TAY PLT A E PL1 8 O R D RVS S PLI AO RYS PL1 2 Bk IPS bno aR PL1 1 C PL2 4 10 TO ef PS a O J 2 N HPS ES 3 PL3 1 a 2 B mes Cs 2 jir PL3 2 CL A E 2 an PLS 1 OOO E s br Ocon a z Lor ns 2 O BL aii aR Oco D sooty tE AR Gd OCT or z Le 2 O 3 PL6 4 a6 65 OAT PL6 5 O ak OAT troig aT usai 7 ak 4 8 060 ONLY n ae ee o e s bs 48DU 500003 s any 48XL sI IU MG OET STI synduy sey seyd ASUS TXgp oneUIIyS SUMM LT SH
3. RETURN 7 AR A FROM POWER SOURCE DISCONNECT PER NEO NEC NATIONAL ELECTRICAL CODE A06091 Fig 11 Typical Installation GROUND SCREW IN SPLICE BOX SINGLE PHASE Li CONNECTIONS TO DISCONNECT PER NEC L NOTE Use copper wire only LEGEND NEC National Electrical Code Field Wiring Splice Connections A06299 Fig 12 Line Power Connections Board Furnace Board i Fig 13 Control Plate User Infinity Furnace Infinity HP AC Interface Board Board Outdoor Air Thermistor Supplied with IU FIELD CONNECTION REQUIRED BLACK WIRES HUMIDIFIER 1 svac A Outdoor Coil Thermistor FACTORY CONNECTED FACTORY WIRES PROVIDED FOR FIELD CONNECTION OF UTILITY CURTAILMENT LEGEND Factory Wiring sua Field Wiring mus Fig 14 Control Voltage Wiring Connections 14 A06306 A06301 PRE START UP 44 WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death and or property damage ELECTRICAL SHOCK 1 Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured Do not remove compressor terminal cover un
4. INTRODUCTION The lifting rigging bracket is engineered and designed to be installed only on Small Packaged Products This bracket is to be used to rig lift a Small Packaged Product onto roofs or other elevated structures 44 WARNING PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury death or property damage Rigging brackets for one unit use only When removing a unit at the end of its useful life use a new set of brackets USE OF RIGGING BRACKET Field Installation of Rigging 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 Remove 4 screws in unit corner posts Yon Attach each of the 4 metal rigging brackets under the panel rain lip See Fig 7 Use the screws removed in step 2 above to secure the brackets to the unit 44 WARNING PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury death or property damage Rigging bracket MUST be under the rain lip to provide adequate lifting 4 WARNING PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury death or property damage Do not strip screws when re securing the unit If a screw is stripped replace the stripped one wit
5. 28 Outdoor Coil Indoor Coil and Condensate Drain Pan 29 Outdoor Fane sv iaa eaten es tA eee BEES eh B45 29 Electrical Controls and Wiring 29 Refrigerant CIU occ etoile go eae OFA wah A Bho 29 Indoor AOW lt i 52 y y sn eee CR Rae os Gee CE ha Sa 29 Pressure SWitches r u pus a ade Ree oe hb Rae ee Racy 29 Loss of Charge Switch _ 28 High Pressure Switches e TE IND 29 Copeland Scroll Compressor Puron Refrigerant 30 Refrigerant System 0 0 0 eee eee ees 30 REMigerant isis a oe gig ewe ew io 30 Compressor OIl seis ao ee la Ra GRA 30 Servicing Systems on Roofs with Synthetic Materials 30 Liquid Line Filter Drier zs aca s saa smua Qs 30 Puron R 410A Refrigerant Charging 30 TROUBLESHOOTING 000 000 0005 30 31 FINAL CHECKS wo cae rt is be wee 532 CARE AND MAINTENANCE 32 START UP CHECKLIST cantara os ide eatin lea v 36 SAFETY CONSIDERATIONS Installation and servicing of this equipment can be hazardous due to mechanical and electrical components Only trained and qualified personnel should install repair or service this equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on this equipment observe precautions in the literature on tags and on l
6. 48XL Infinity 15 SEER Single Packaged Air Conditioner and Gas Furnace System With Puron R 410A Refrigerant Single Phase 2 to 5 Nominal Tons Sizes 024 060 Turn to the Experts Installation Instructions 4 WARNING EQUIPMENT OPERATION HAZARD OAT sensor must be field installed See Accessory Installation for more details 4 WARNING EQUIPMENT OPERATION HAZARD This Infinity unit is designed for use with an Infinity User Interface NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS PAGE SAFETY CONSIDERATIONS 2 INTRODUCTION a Seg ed betwee sia aly ee ein pw 2 RECEIVING AND INSTALLATION 2 12 Check Equipment isis esate beats tel Pas 2 Identify Unit auqa E AA tence suu k 2 Inspect SAP A AE E te yE eigen 2 Provide Unit Support 1 0 6 0 eee eee eee 2 ROOF CUIDY u a ai taka oe dete mous 2 Slab Mounts 5 204 vetoed ert 82 etal E ESIR BIRS aes 2 Ground Mount tered ty eee tek seeded Cas t e 2 Provide Clearances sroine ee eee eens ZA Rigiand Place Unit mc Eire 7 TaSpe Chon ia ade 8 IntroduetiON aayqa a a uakis u ea aea 8 Use of Rigging Bracket 8 Select and Install Ductwork 8 Converting Horizontal Discharge Units to Downflow Vertical Discharge Units _ 1 9 Provide for Condensate Disposal 10 Install Flue Ho
7. 61 0 1 2 622 175 120 97 82 73 66 61 57 53 50 44 40 3 4 824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 1 1 4 1 380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280 1 1 2 1 610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 Capacity of pipe in cu ft of gas per hr for gas pressure of 0 5 psig or less Pressure drop of 0 5 IN W C based on a 0 60 specific gravity gas Refer to Table NFPA 54 ANSI Z223 1 T This length includes an ordinary number of fittings ROUTING POWER LEADS INTO UNIT Use only copper wire between disconnect and unit The high voltage leads should be in a conduit until they enter the duct panel conduit termination at the duct panel must be watertight Run the high voltage leads through the power entry knockout on the power entry side panel See Fig 5 and 6 for location and size For single phase units connect leads to the black and yellow wires CONNECTING GROUND LEAD TO GROUND SCREW Connect the ground lead to the chassis using the ground screw on the control plate near the inducer switch See Fig 13 ROUTING CONTROL POWER WIRES For detailed instruction on the low voltage connections to the User Interface UD refer to the UI installation guide Form a drip loop with the control leads before routing them into the unit Route the low voltage control
8. PRESSURE SWITCH PROTECTION REFRIGERANT The unit is equipped with high and low pressure switches If the control senses the opening of a high or low pressure switch it will respond as follows 1 De energize the compressor contactor HPS1 amp LPS or the compressor solenoid contactor HPS2 Keep the outdoor fan operating for 15 minutes Display the appropriate fault codes SY N E After a 15 minute delay if there is still a call for cooling and the LPS or HPS is reset the compressor contactor is energized 5 If LPS or HPS has not closed after a 15 minute delay the outdoor fan is turned off If the open switch closes anytime after the 15 minute delay then resume operation with a call for cooling 6 If LPS or HPS trips 3 consecutive cycles the unit operation is locked out for 4 hours 7 In the event of a high pressure switch trip or high pressure lockout check the refrigerant charge outdoor fan operation and outdoor coil for airflow restrictions 8 In the event of a low pressure switch trip or low pressure lockout check the refrigerant charge and indoor airflow CONTROL FAULT If the HP AC control board has failed the control will flash the appropriate fault code See Table 5 The control board should be replaced BROWN OUT PROTECTION If the line voltage is less than 187v for at least 4 seconds the appropriate compressor contactor and fan relay are de energized Compressor and fan operation are not al
9. 11 LS2 Gv BR 11 c HI MED ST cow Ke BR I FS gt a as SOS z GAS SECTION amp EN po bd s 2 AD FIELD SPLICE LEGEND Se o a a Z SPLICE ICAA y Y FURNACE CONTROL BOARD a FIELD CONTROL WIRING 3 2 FIELD POWER WIRING E RSC REMOTE SPARKER 2 e CONTROL 151311 3 CONT CONTACTOR B a g CAP CAPACITOR JEAN GYWR E o SPARKER COMP COMPRESSOR MOTOR El PRE E gn CS COMPRESSOR SOLENOID somone CCH CRANK CASE HEATER L1 Comnen B K Y real 2 EQUIP EQUIPMENT SEE NOTES R ER FS FLAME SENSOR gt z RU sec 2 OND GROUND 1 ME ZA SC Ti HPS HIGH PRESSURE SWITCH mx e z AM gme e LoPS iS KIT Me TRAN TRANSFORMER Di SENSOR WHEN USED 1 IGNITOR i 2 IDM INDUCER DRAFT MOTOR zy 5 IDR INDUCER RELAY PRESSURE SWITCH l IFM INDOOR FAN MOTOR a o 5 LPS LOW PRESSURE SWITCH LS LIMIT SWITCH BL Y 5 2 SY GAS VALVE I I V 8 2 OFM OUTDOOR FAN MOTOR E ROLLOUT SWITCH vs VR L2 oo con five d z RYS REVERSING VALVE SOLENOID y 11 DJ PLI 6 2 OCT OUTDOOR COIL a RU a YL vo m neo saa 2 P PRESSURE SHITCH a l rani EA cw Pe uverio gt es Q mz E SELECT MODELS 5 LLS LIQUID LINE SOLENOID as vi OT TV ue CONTROL BOARD aw SONLI ae 15 BL GAS VALVE we lt UI USER INTERFACE I BR acing 3 othe eQ PL1 10 oa 15131 LT COLOR CODE BLACK BK ORANGE Q ES TS Dr lo SLP LE aE ro Za PLt 3 a DO as O JUSTA pin e suq me saor P eo e A PINK e YELLOW Y KODES is em mE THE m PL3 4 a O GR
10. 610 m Input rate must be within 2 of rating plate input 1 Determine the correct gas input rate a The rated gas inputs shown in Table 4 are for altitudes from sea level to 2000 ft 610 m above sea level These inputs are based on natural gas with a heating value of 1050 Btu ft3 at 65 specific gravity IN THE U S A The input rating for altitudes above 2 000 ft 610 m must be reduced by 4 percent for each 1 000 ft 305 m above sea level For installations below 2 000 ft 610 m refer to the unit rating plate For installations above 2 000 ft 610 m multiply the input by on the rating plate by the derate multiplier in Table 6 for the correct input rate Table 5 Altitude Derate Multiplier for U S A Altitude ft m Percent of Derate Dorato Muliplier 0 610 0 1 00 610 918 8 12 0 90 915 1219 12 16 0 86 1220 1524 16 20 0 82 1524 1829 20 24 0 78 1829 2134 24 28 0 74 2134 2438 28 32 0 70 2139 2743 32 36 0 66 2744 3048 36 40 0 62 Derate multiplier factors are based on midpoint altitude for altitude range IN CANADA The input rating for altitudes from 2 000 610 m to 4 500 ft 1372 m above sea level must be derated 10 percent by an authorized Gas Conversion Station or Dealer EXAMPLE 90 000 Btuh Input Furnace Installed at 4300 ft 1372 m Furnace Input Rate Derate Multiplier Furnace Input Rate at Sea Level x Factor at Installation Altitude 9
11. Burner Orifice No Qty Drill Size Natural Gas 2 44 3 44 2 44 3 44 3 44 3 38 3 44 3 38 HIGH PRESSURE SWITCH psig Cut out 670 10 Reset Auto 470 25 HIGH PRESSURE SWITCH 2 psig cal haa Solenoid 565 15 beater 455 15 Reset Auto LOSS OF CHARGE LOW PRESSURE SWITCH Liquid Line psig Cut out 23 5 Reset auto 55 45 RETURN AIR FILTERS Throwaway in 20x24x1 24x30x1 24x36x1 mm 508x610x25 610x762x25 610x914x25 Continued next page Table 1 Physical Data Con t Unit 48XL UNIT SIZE 048090 048115 048130 060090 060115 060130 NOMINAL COOLING CAPACITY ton 4 4 4 5 5 5 NOMINAL HEATING CAPACITY Btu 90 000 115 000 130 000 90 000 115 000 130 000 OPERATING WEIGHT Ib 521 521 521 572 572 572 kg 236 236 236 259 259 259 COMPRESSORS 2 Stage Scroll Quantity 1 REFRIGERANT PURON R 410A Quantity Ib 15 3 15 3 15 3 15 8 15 8 15 8 kg 6 9 6 9 6 9 7 2 7 2 7 2 REFRIGERANT METERING DEVICE TXV Size 4 Ton 4 Ton 4 Ton 5 Ton 5 Ton 5 Ton Part Number EA36YD149 EA36YD149 EA36YD149 EA36YD159 EA36YD159 EA36YD159 OUTDOOR FAN Nominal Cfm 3300 3300 3300 3300 3300 3300 Diameter in 22 22 22 22 22 22 mm 559 559 559 559 559 559 Motor Hp Rpm 1 4 1100 1 4 1100 1 4 1100 1 3 1110 1 3 1110 1 3 1110 OUTDOOR COIL Rows Fins in 2 21 2 21 2 21 2 21 2 21 2 21 Face Area sq ft 19 4 19 4 19 4 23 3 23
12. Compressors are internally spring mounted Do not loosen or remove compressor holddown bolts 6 Each unit system has two Schrader type ports one low side Schrader fitting located on the suction line and one high side Schrader fitting located on the compressor discharge line Be sure that caps on the ports are tight START UP Unit Start Up and Troubleshooting NOTE Always check high and low voltage supply to the unit components Check the integrity of the plug receptacle connections and unit wiring harness prior to assuming a component failure A LED Description LEDs built into Infinity control boards provide installer or service person information concerning operation and or fault condition of the unit controls and ECM motor This information is also available at the system UI in text with basic troubleshooting instructions Careful use of information displayed will reduce the need for extensive manual troubleshooting Both the furnace and heat pump HPyair conditioner AC boards have an amber LED and a green LED On the HP AC board these are located near the System Communications connector ABCD lower right corner of the HP AC board as installed in the unit On the furnace board these are located at the upper right side adjacent to the fuse above the terminal block The amber LED is the System Status LED labeled STATUS The green LED labeled COMM is used as an indicator of system communications status See Fig 15 and 1
13. Table 3 shows the temperature rise in each gas heating mode Refer to these tables to determine the desired heating airflow for the system being installed NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly Airflow can be changed using the UI See UI installation instructions for more detail NOTE Once the compressor has started and then has stopped it should not be started again until 4 minutes have elapsed The cooling cycle remains on until the room temperature drops to point that is slightly below the cooling control setting of the UI AIR CONDITIONER SEQUENCE OF OPERATION COOLING OPERATION With a call for first stage cooling the outdoor fan and low stage compressor are energized If low stage cannot satisfy cooling demand high stage cooling is energized by the UI After second stage is satisfied the unit returns to low stage operation until first stage is satisfied or until second stage is required again When both first stage and second stage cooling are satisfied the compressor will shut off NOTE When two stage unit is operating at low stage system vapor suction pressure will be higher than a standard single stage system or high stage operation NOTE Outdoor fan motor will continue to operate for one minute after compressor shuts off when outdoor ambient is greater than or equal to 100 F 38 C UTILITY INTERFACE WITH INFINITY CONTROL The utility
14. 3 23 3 INDOOR COIL Rows Fins in 3 17 3 17 g 17 4 17 4 17 4 17 Face Area sq ft 5 7 5 7 5 7 5 7 5 7 5 7 INDOOR FAN Nominal Airflow Cfm Comfort Variable based on Comfort Roll back see User Interface instructions for more information Efficiency 1400 1400 1400 1750 1750 1750 Max 1600 1600 1600 2000 2000 2000 Furnace gas ht airflow Low Stage 815 1215 1255 845 1215 1258 Furnace gas ht airflow High Stage 1385 1885 1875 1300 1910 1920 Size in 11x10 11x10 11x10 11x10 11x10 11x10 mm 279x254 279x254 279x254 279x254 279x254 279x254 Motor HP RPM 3 4 3 4 3 4 1 1 1 FURNACE SECTION Burner Orifice No Qty Drill Size Natural Gas 3 38 3 33 3 31 3 38 3 33 3 31 HIGH PRESSURE SWITCH psig Cut out 670 10 Reset Auto 470 25 HIGH PRESSURE SWITCH 2 psig Compressor Solenoid Cut out 565 15 Reset Auto 455 215 LOSS OF CHARGE LOW PRESSURE SWITCH Liquid Line psig Cut out 23 5 Reset auto 65 25 RETURN AIR FILTERS Throwaway in T 24x36x1 mm 610x914x25 Based on altitude of 0 to 2000 ft 0 to 610 m TRecommended 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 pressur
15. 8 m of heating section 6 Install ground joint union close to heating section between unit manual shutoff and external manual main shut off valve 10 a a TEE OUT NIPPLE CAP gt Fig 10 Sediment Trap 7 Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit C99020 NOTE Pressure test the gas supply system after the gas supply piping is connected to the gas valve The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0 5 psig Pressure test the gas supply piping system at pressures equal to or less than 0 5 psig The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground joint union 44 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in fire explosion personal injury death and or property damage e Connect gas pipe to unit using a backup wrench to avoid damaging gas controls e Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections Use proper length of pipe to avoid stress on gas control manifold If a flexible connector is required or
16. CONDITIONER OPERATIONS The unit time delays include e Five minute time delay to start cooling operation when there is a call from the thermostat or user interface To bypass this feature momentarily short and release Forced Detrost pins e Five minute compressor recycle delay on return from a brown out condition e Two minute time delay to return to standby operation from last valid communication with Infinity only e One minute time delay of outdoor fan at termination of cooling mode when outdoor ambient is greater than or equal to 100 F 38 C There is no time delay between air conditioner staging from low to high and from high to low capacity the compressor will change from low to high and from high to low capacity as demand dictates Table 3 Air Delivery and Temperature Rise at Rated Heating Input Rated Heating Input Btu hr Heating Rise Range F C Heating Rise Either Stage F C Unit Efficiency Comtort High St Low St High Sta Low Sta 9 age Om eee ig gs ew Stage High Stage Low Stage High Stage Low Stage 48XL N 024040 20 50 15 45 35 30 40 35 40 000 26 000 48XL N 030040 11 28 8 25 19 17 22 19 48XL N 030060 a 48XL N 036080 80 000 39 000 e E F 40 50 48XL N 042060 22 28 48XL N 036090 48XL N 042090 35 65 35 65 50 55 48XL N 048090 80999 981990 19 36 19 36 28 81 48XL N 0
17. Furnace Board features a gas component test system to help diagnose a system problem in the case of a gas component failure To initiate the component test procedure ensure that there are no UI inputs to the control the ABCD connector can be removed from the Infinity control board for this operation and all time delays have expired Turn on setup switch SW1 6 NOTE The component test feature will not operate if the control is receiving any UI signals or until all time delays have expired The component test sequence is as follows 1 The control turns the inducer motor ON and keeps it ON through step 3 N After waiting 10 seconds the control turns the igniter ON for 15 seconds then OFF 3 The control then turns the indoor fan motor on for 15 seconds then OFF 4 After shutting the blower motor OFF the control runs the inducer for 10 seconds then turns it OFF NOTE operating The EAC terminals are energized when the blower is After the component test is completed one or more status codes 11 25 or 41 will flash See component test section or Status Code Label for explanation of status codes NOTE To repeat component test turn setup switch SW1 6 to OFF and then back ON Check for Refrigerant Leaks Locate and repair refrigerant leaks and charge the unit as follows 1 Use both high and low pressure ports to relieve system pressure and reclaim remaining refrigerant 2 Repair leak following accepted pract
18. SETSCREW TIGHTNESS AAS A ee sss O III START UP ELECTRICAL SUPPLY VOLTAGE COMPRESSOR AMPS INDOOR EVAPORATOR FAN AMPS TEMPERATURES OUTDOOR CONDENSER AIR TEMPERATURE DB RETURN AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB GAS HEAT SUPPLY AIR PRESSURES GAS INLET PRESSURE IN WG GAS MANIFOLD PRESSURE _______ IN WG REFRIGERANT SUCTION PSIG SUCTION LINE TEMP REFRIGERANT DISCHARGE PSIG DISCHARGE TEMPt 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 amp CONNECTED Measured at suction inlet to compressor tMeasured at liquid line leaving condenser Copyright 2008 Carrier Corp e 7310 W Morris St e Indianapolis IN 46231 Printed in U S A Edition Date 08 08 Catalog No 48XL 04SI Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces 48XL 3S 36
19. and indoor air flow Control Fault 45 Outdoor unit control board has failed Control board needs to be replaced Brown Out 230 46 Line voltage lt 187v for at least 4 seconds Compressor and fan operation v not allowed until voltage gt 190v Verify line voltage There is no 230v at the contactor when indoor unit is powered and cooling No 230v at Unit 47 heating demand exists Verify the disconnect is closed and 230v wiring is connected to the unit Outdoor Air Temp 53 Outdoor air sensor not reading or out ot range Ohm out sensor and check Sensor Fault wiring RAA se 55 Coil sensor not reading or out of range Ohm out sensor and check wiring Thermistors Out of 56 Improper relationship between coil sensor and outdoor air sensor Ohm out Range sensors and check wiring Low Stage Ther Compressor voltage sensed then disappears while cooling or heating de 71 mand exists Possible causes are internal compressor overload trip or start mal Cutout ae relay not releasing if installed r Compressor voltage sensed then disappears while cooling or heating de High Stage Ther f A 72 mand exists Possible causes are internal compressor overload trip or start mal Cutout 3 relay not releasing if installed Contactor Shorted 73 Compressor voltage sensed when no demand for compressor operation exists Contactor may be stuck closed or there is a wiring error No 230V at Com 74 Compressor voltage not sensed when compressor should be starting Con
20. hood with holes in the flue panel 3 Secure flue hood to flue panel by inserting a single screw on the top and the bottom of the hood 1 25 mm MIN TRAP OUTLET y 2 51 mm MIN A0800 Fig 9 Condensate Trap Install Gas Piping The gas supply pipe enters the unit through the access hole provided The gas connection to the unit is made to the 1 2 in FPT gas inlet on the gas valve Install a gas supply line that runs to the heating section Refer to Table 2 and the current edition of NFGC in the U S and the current NSCNGPIC in Canada Do not use cast iron pipe It is recommended that a black iron pipe is used Check the local utility for recommendations concerning existing lines Size gas supply piping for 0 5 IN W C maximum pressure drop Never use pipe smaller than the 1 2 in FPT gas inlet on the unit gas valve For natural gas applications the gas pressure at unit gas connection must not be less than 4 0 IN W C or greater than 13 IN W C while the unit is operating For propane applications refer to propane conversion kit instructions A 1 8 in NPT plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the gas valve and downstream of manual equipment shutoff valve When installing the gas supply line observe local codes pertaining to gas pipe installations Refer to the NFPA 54 ANSI Z223 1 2006 in Canada CAN CSA B149 1 N
21. 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 amp Troubleshooting and Table 5 as well as the UI instructions for additional information Additional Troubleshooting information can be found in Table 10 MAJOR COMPONENTS 2 STAGE HP AC BOARD The two stage HP AC control board controls the following functions Low and high stage compressor operation Outdoor fan motor operation Reversing valve operation 30 Detrost operation Low ambient cooling Crankcase heater operation Compressor external protection Pressure switch monitoring refrigerant Time delays FURNACE BOARD The furnace board controls the following functions Indoor blower operation Gas valve Inducer motor Remote sparker module Pressure switch monitoring gas SYSTEMS COMMUNICATION FAILURE If communication with the Infinity Control is lost with the UL the controls will flash the appropriate fault codes Check the wiring to the UL indoor and outdoor units MODEL PLUG The HP AC control board must have a valid model plug to operate If a valid model plug is not detected it will not operate and the control will flash the appropriate fault code shown in Table 5
22. load or increase unit size Ul temperature set too low Reset Ul setting Low refrigerant charge Locate leak repair and recharge Air in system Recover refrigerant evacuate system and re charge Outdoor coil dirty or restricted Clean coil or remove restriction Excessive head pressure Dirty air filter Replace filter Dirty indoor or outdoor coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant evacuate system and re charge Indoor or outdoor air restricted or air short cycling Determine cause and correct Head pressure too low Low refrigerant charge Check for leaks repair and recharge Restriction in liquid tube Remove restriction Excessive suction pressure High heat load Check for source and eliminate Reversing valve hung up or leaking internally Replace valve Refrigerant overcharged Recover excess refrigerant Suction pressure too low Dirty air filter Replace filter Low refrigerant charge Check for leaks repair and recharge Metering device or low side restricted Remove source of restriction Insufficient coil airflow Check filter replace if necessary Temperature too low in conditioned area Reset Ul setting Outdoor ambient below 55 F 13 C Verify low ambient cooling enabled in Ul Filter drier restricted Replace IF
23. maintenance on this equipment other than those procedures recommended in the Owner s Manual 44 WARNING ELECTRICAL SHOCK HAZARD Failure to follow these warnings could result in personal injury or death 1 Turn off electrical power to the unit before performing any maintenance or service on this unit Use extreme caution when removing panels and parts Never place anything combustible either on or in contact with the unit y CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in equipment damage or improper operation Errors made when reconnecting wires may cause improper and dangerous operation Label all wires prior to disconnecting when servicing The minimum maintenance requirements for this equipment are as follows 1 Inspect air filter s each month Clean or replace when necessary N Inspect indoor coil drain pan and condensate drain each cooling season for cleanliness Clean when necessary 3 Inspect indoor fan motor and wheel for cleanliness each cooling season Clean when necessary 4 Check electrical connections for tightness and controls for proper operation each cooling season Service when necessary 5 Check for restrictions on inducer outlet Clean flue hood 6 Inspect burner compartment before each heating season for rust corrosion soot or excessive dust 7 Inspect all accessories Perform any service or maintenance to the accessories as recommended in
24. power is restored if the UI is still calling for gas heating The amber LED light will flash code 12 during the 90 second period after which the LED will be ON continuously as long as no faults are detected After the 90 second period the unit will respond to the UI normally GAS HEAT MODE AND ADJUSTMENTS When the UI calls for gas heat the Infinity furnace board performs a self check verifies the pressure switch is open and starts the inducer on high speed 1 Inducer Pre purge Period When the inducer motor comes up on high speed the pressure switch closes and the Infinity ignition control on the furnace board begins a 15 second pre purge period If the pressure switch fails to remain closed the inducer will remain running After the pressure switch re closes the Infinity ignition control will begin a 15 second pre purge period N Trial For Ignition Sequence The spark igniter will spark for 3 seconds The main gas valve relay contact closes to energize the gas valve on low stage After 5 seconds the igniter is de energized and a 2 second flame proving period begins NOTE The unit always lights on high speed inducer and low stage gas valve operation 3 Flame Proving When the burner flame is proved at the flame proving sensor the furnace control determines what heating stage to run based on feedback from the UI If the UI is asking for low stage gas heat the ignition control will change the inducer speed to low spe
25. pressor tactor may be stuck open or there is a wiring error Low Stage Ther 81 Thermal cutout occurs in three consecutive low high stage cycles Low mal Lockout stage locked out for 4 hours or until 24v power recycled High Stage Ther 82 Thermal cutout occurs in three consecutive high low stage cycles High mal Lockout stage locked out for 4 hours or until 24v power recycled Low Pressure 83 Low pressure switch trip has occurred during 3 consecutive cycles Unit Lockout operation locked out for 4 hours or until 24v power recycled High Pressure 84 High pressure switch trip has occurred during 3 consecutive cycles Unit Lockout operation locked out for 4 hours or until 24v power recycled INFINITY CONTROLLED LOW AMBIENT COOLING NOTE When this unit is operating below 55 F 13 C outdoor temperature provisions must be made for low ambient operation This unit is capable of low ambient cooling down to O F 18 C ONLY when using the Infinity control A low ambient kit is not required and the outdoor fan motor does not need to be replaced for Infinity controlled low ambient operation Low ambient cooling must be enabled in the UI set up Fan may not begin to cycle until about 40 F 4 C OAT Fan will cycle based on coil and outdoor air temperature Infinity controlled low ambient mode operates as follows e In high stage fan is off when outdoor coil temp is lt outdoor air temperature plus 3 F 1 7 C or outd
26. the accessory instructions Air Filter IMPORTANT Never operate the unit without a suitable air filter in the return air duct system Always replace the filter with the same dimensional size and type as originally installed See Table 1 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean cleanable type at least twice during each cooling season and twice during the heating season or whenever the filter becomes clogged with dust and lint Indoor Fan and Motor NOTE All motors are pre lubricated Do not attempt to lubricate these motors For longer life operating economy and continuing efficiency clean accumulated dirt and grease from the blower wheel and motor annually Inducer Blower NOTE All motors are pre lubricated Do not attempt to lubricate these motors Clean periodically to assure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during the heating season For the first heating season inspect blower wheel bi monthly to determine proper cleaning frequency Limit Switch Remove unit access panel to gain access to the limit switch The limit switch is located above the indoor blower housing NOTE On small chassis units a second limit switch is located beside the indoor blower housing Burner Ignition Unit is equipped with a direct spark ignition 100 percent lockout system Ignition module is located in the con
27. 0 000 x 0 90 81 000 b When the gas supply being used has a different heating value or specific gravity refer to national and local codes or contact your distributor to determine the required orifice size 2 Adjust manifold pressure to obtain low stage input rate See Fig 19 a Turn off gas supply 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 e Remove regulator adjustment cap from low stage gas valve pressure regulator See Fig 19 and turn low stage adjusting screw 3 16 or smaller flat tipped screwdriver counterclockwise out to decrease rate and clockwise in to increase input rate REGULATOR COVER SCREW PLASTIC ADJUST SCREW ON OFF SWITCH REGULATOR SPRING 1 2 NPT INLET HIGH STAGE GAS PRESSURE REGULATOR ADJUSTMENT LOW STAGE GAS PRESSURE REGULATOR ADJUSTMENT INLET PRESSURE TAP MANIFOLD PRESSURE TAP A04167 Fig 19 Redundant Automatic Gas Control Valve NOTE DO NOT set low stage manifold pressure less than 1 4 IN W C or more than 2 0 IN W C for natural gas If manifold pressure is outside this range change main burner orifices f Re install low stage regulator adjustment cap g Leave manometer connected NOTE If orifice hole appears damaged or it is s
28. 1 0 520 7 20 5 421 6016 6 48XL036090 208 230 493 223 6 1142 5 44 98 553 4121 0 520 7 20 5 421 6116 6 48XL042060 2087230 507 229 0 1193 3 46 98 553 4121 0 520 1120 5 421616 6 481042090 2081230 515 033 6 1193 3046 98 553 4121 0 520 1020 5 421 6116 6 48XL048090 208 230 1 60 521 236 3 1193 3 46 981 495 3 19 5 539 8 21 3 457 2 18 0 48XL048115 208 230 1 521 236 3 1193 3146 98 495 3 19 5 539 8 21 3 457 2 18 0 48XL048130 208 230 521 236 3 1193 3146 98 495 3 19 5 539 8 21 3 457 2 18 0 48XL 060090 208 230 1 60 572 259 5 1294 9 50 98 553 4 21 0 508 0 20 0 447 0 17 6 48XL060115 208 230 1 60 572 259 5 1294 9 50 98 553 4 21 0 508 0 20 0 447 0 17 6 48XL060130 208 230 1 60 572 259 5 1294 9 50 98 553 4 21 0 508 0 20 0 447 0 17 6 CORNER WEIGHT LBS KG REQUIRED CLEARANCES TO COMBUSTIBLE MATL A B c D MILLIMETERS INJ TOP OF UNIT ocios 355 6 14 00 036060 100 45 4 112 50 8 91 41 3 182 82 DUCT SIDE OF UNIT 50 8 2 003 SIDE OPPOSITE DUCTS 1355 6 114 00 036090 101 45 8 114 51 1 92 41 1 185 83 BOTTOM OF UNIT vee 12 1 10 50 ELECTRIC HEAT PAREL O O O I I I al Ia 12 9144 36 00 042060 111 50 3 79 35 8 136 61 1 181 82 NEC REQURED CLEARANCES MILLIMETERS IN 042090 113 51 31 81 36 7 138 62 6 184 83 BETWEEN UNITS POWER ENTRY SIDE oo 1066 8 42 00 UNIT ANO UNGROUNDED SURFACES POWER ENTRY SIDE 914 0 36 00 04
29. 32 403 112 107 102 92 2778 44 42 39 33 413 114 109 104 94 2847 45 43 40 34 423 116 111 106 96 2916 46 44 41 35 433 117 112 107 97 2985 47 45 42 36 443 119 114 109 99 3054 48 46 43 37 453 121 116 111 101 3123 49 47 44 38 463 122 117 112 102 3192 50 47 45 39 473 124 119 114 104 3261 51 48 46 40 483 126 121 116 106 3330 52 49 47 41 493 127 122 117 107 3399 53 50 47 42 503 129 124 119 109 3468 54 51 48 43 513 130 125 120 110 3537 55 52 49 44 523 132 127 122 112 3606 56 53 50 44 533 133 128 123 113 3675 56 54 51 45 50DU500166 2 0 A08423 Fig 23 Cooling Charging Table Subcooling 27 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 44 WARNING PERSONAL HAZARD Failure to follow this warning could result in personal injury or death and possible unit component damage INJURY AND UNIT 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
30. 6 Heating Inputs HEATING INPUT BTU HR UMBER OE GAS SUPPLY a ae IN W C MANIFOLD s ulii IN W C ORIFICES I High Stage Low Stage Min Max High Stage Low Stage 40 000 26 000 2 4 0 13 0 3 2 3 8 1 4 2 0 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 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 Table 7 ECM Wet Coil Pressure Drop IN W C UNIT STANDARD CFM SCFM SIZE 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 024 0 005 0 007 0 010 0 012 0 015 3 u E E x 030 0 007 0 010 0 012 0 015 0 018 0 021 0 024 E u 036 0019 0023 0027 0032 0037 0 042 0 047 E 042 0 014 0 017 0 020 0 024 0 027 0 031 0 035 0 039 0 043 048 0 027 0 032 0036 0 041 0 046 0 052 0 057 0 063 0 068 060 0 029 0 032 0 036 0 040 0 045 0 049 0 053 Table 8 Fil
31. 60090 48XL N 048115 30 60 30 60 45 50 48XL N 060115 119009 Z31090 17 33 17 33 25 28 48XL N 048130 35 65 35 65 50 55 48XL N 060130 lick 84 500 19 36 19 36 28 31 Airflow delivery values for external static pressure values of up to 1 IN W C Table 4 Heat Pump Air Conditioner Board Status Codes AMBER LED OPERATION FAULT FLASH POSSIBLE CAUSE AND ACTION CODE Standby no call for unit operation None on ei ne Normal operation Rapid con Unit being controlled by standard thermostat inputs instead of Infin Standard Ther y rit I d 3 Emergency Mode tinuous ity Control Only high stage operation is available This operating mostat Control f ee flashing mode should be used in emergency situations only Low Stage Cool Heat Operation None 1 pause Normal operation High Stage Cool Heat Operation None 2 pause Normal operation System ibn 19 Communication with Ul lost Check wiring to Ul indoor and outdoor units nications Failure I Control does not detect a model plug or detects an invalid model plug Unit vale Model Flug will not operate without correct model plug High Pressure 31 High pressure switch trip Check refrigerant charge outdoor fan operation Switch Open and coils for airflow restrictions Low Pressure s Switch Open 32 Low pressure switch trip Check refrigerant charge
32. 8 Status Codes will be displayed on the STATUS LED using the following protocol The number of short flashes indicates first digit of code The number of long flashes indicates second digit of code Ww N e A short flash is 0 25 seconds on A long flash is 1 second on J The time between flashes is 0 25 seconds 5 The time between last short flash and first long flash is 1 second 6 The LEDs will be off for 2 5 seconds before repeating code 7 If multiple status codes are active concurrently the highest priority status code is displayed B Control Start Up and Troubleshooting On power up green COMM LEDs will be turned off until successful system communications are established this should happen within 10 seconds Once communications with Ul are successful both COMM LEDs will be lit and held on At the same time amber STATUS LEDs will be lit and held continuously on until a request for operating mode is received The STATUS LED will be on any time unit is in idle mode System Communications If at any time communications are not successful for a period exceeding 2 minutes the Infinity control will only allow 15 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 troubles
33. 8090 115 52 2 86 39 0 138 62 6 182 82 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE 1066 8 42 00 048115 115 52 2 86 39 0 138 62 6 182 82 REQUIRED CLEARANCE FOR OPERATION AND SERVICING i 048130 115 52 2 86 39 0 138 62 6 182 82 EVAP COIL ACCESS SIDE 0 060090 126 57 2 91 41 3 153 69 202 91 POMER ENTRY S OE REQUIREMENTS ki UNIT TOP o Be 6 0 060115 126 57 2 91 41 3 153 69 4 202 91 SIDE OPPO 6 0 DUCT PANE 2 0018 1 126 57 1744 3 41537 4 191 117 1 beca basal a Wu Q 2 MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 304 8 12 00 FROM WALL 14 61 SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISED 928 611 133 K O POWER ENTRY G22 210 88 HOLE CONTROL ENTRY COMPRESSOR BLOWER ELECTRIC HEAT amp ELECTRICAL ACCESS PANEL 1226 3 48 28 FRONT VIEW 1 84 52 6 2 07 142 2 5 601 Fig 6 48XL036 060 Unit Dimensions 12 110 5 N P T GAS ENTRY RIGHT SIDE VIEW DIMENSIONS IN J ARE IN INCHES RETURN DUCT OPENING SUPPLY DUCT OPENING REAR VIEW A07900 Table 1 Physical Data Unit 48XL UNIT SIZE 024040 024060 030040 030060 036060 036090 042060 042090 NOMINAL COOLING CAPACITY ton 2 2 2 1 2 2 1 2 3 3 3 1 2 3 1 2 NOMINAL HEATING CAPACITY Btu 40 000 60 000 40 000 60 000 60 000 90 000 60 000 90 000 OPERATING WEIGHT Ib 3
34. 96 401 403 408 485 493 507 515 kg 180 182 183 185 220 224 230 234 COMPRESSORS 2 Stage Scroll Quantity 1 REFRIGERANT PURON R 410A Quantity Ib 10 4 10 4 11 3 11 3 9 5 9 5 13 8 13 8 kg 46 46 5 1 5 1 4 3 4 3 6 3 6 3 REFRIGERANT METERING DEVICE TXV Size 2 Ton 2 Ton 3 Ton 3 Ton 3 Ton 3 Ton 4 Ton 4 Ton Part Number EA36YD129 EA36YD129 EA36YD139 EA36YD139 EA36YD139 EA36YD139 EA36YD149 EA36YD149 OUTDOOR COIL Rows Fins in 22 2 21 2 21 2 21 2 21 2 21 2 21 2 21 Face Area sq ft 13 6 13 6 15 3 15 3 17 5 17 5 19 4 19 4 OUTDOOR FAN Nominal Cfm 2700 2700 2700 2700 2800 2800 2800 2800 Diameter in 22 22 22 22 22 22 22 22 mm 559 559 559 559 559 559 559 559 Motor Hp Rpm 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 INDOOR COIL Rows Fins in 3 17 3 17 3 17 3 17 3 17 3 17 3 17 3 17 Face Area sq ft 3 7 3 7 3 7 3 7 4 7 4 7 4 7 4 7 INDOOR FAN Nominal Airflow Ctm Comfort Variable based on Comfort Roll back see User Interface instructions for more information Efficiency 700 700 875 875 1050 1050 1225 1225 Max 800 800 1000 1000 1200 1200 1400 1400 Furnace gas ht airflow Low Stage 475 727 475 727 745 875 745 875 Furnace gas ht airflow High Stage 844 1120 844 1120 1120 1410 1120 1410 Size in 10x10 10x10 10x10 10x10 11x10 11x10 11x10 11x10 mm 254x254 254x254 254x254 254x254 279x254 279x254 279x254 279x254 Motor HP RPM 1 2 1 2 1 2 1 2 3 4 3 4 3 4 3 4 FURNACE SECTION
35. A LEGEND o Y FURNACE CONTROL BOARD FIELD SPLICE SPLICE g FACTORY WIRING 7 FIELD CONTROL WIRING 1 FIELD POWER WIRING w BR ts HI MED BR 1 F N aS Ir GAS SECTION Y A Y y IDM 4 RSC REMOTE SPARKER CONTROL mii 4 3 2 1 al 9 p a H CONT CONTACTOR m CAP CAPACITOR COMP COMPRESSOR MOTOR cs COMPRESSOR SOLENOID CCH CRANK CASE HEATER EQUIP EQUIPMENT FS FLAME SENSOR GND GROUND 10161 HPS HIGH PRESSURE SWITCH BK aa TRAN TRANSFORMER IGNITOR TOM INDUCER DRAFT MOTOR IFM INDOOR FAN MOTOR LPS LOW PRESSURE SWITCH Ls LIMIT SWITCH SY GAS VALVE BR OFM OUTDOOR FAN MOTOR V RS ROLLOUT SWITCH RYS REVERSING VALVE SOLENOID OCT OUTDOOR COIL THERMISTOR OAT OUTDOOR AIR THERMOSTOR PS PRESSURE SWITCH LLS LIQUID LINE SOLENOID UE USER INTERFACE RS isi ORANGE Q COLOR CODE BLACK BK 0 o WHITE W YELLOW Y Es dp SS Ese lt M avom LINE VOLTAGE FACTORY i LOW vOLTAGE FIELD LOW VOLTAGE FACTORY BR ed wm LINE VOLTAGE FIELD INTERNAL CIRCUIT Fests HEE E 8 8L T BOARD WIRING k NO
36. EEN ell a m E PL3 4 BL omar INE VOLTAGE FACTORY mt 6 a Pe u pul e Wa u nn j STORY ae I mom INE VOLTAGE F TELD En m a ean oer BHK 6 PLI A PN USER INTERFACE STATUS SHIFT 3 60060 WIR IO m us nen ELE PLT C NOTES a el Ri DRAR If ANY OF THE ORIGINAL WIRE FURNJSHED IS REPLACED PES A TA IT MUST BE REPLACED WITH TYPE 90 C OR EQUIVALENT yan L 67 EE O USE 15 C COPPER CONDUCTORS FOR FIELD INSTALLATIONS SI i y VI 1 ue CHANU ATURE BY LH tunt pasto O Ly aa ou ES MANUFACTURED BY LITTLEFUSE OPTIONAL CONN NLY Ra ia MODEL 024 030 LST AND LS2 ARE IN SERIES I FACTORY WIRES PROVIDED NOT CONNECTED imss en Q Ps kes x MODELS 036 960 HAVE LSI ONLY e ES ce a PO PO 3 TO BE WIRED IN ACCORDANCE WITH NEC AND WHEN USED PL2 2 R z LOCAL CODES Y na bla E BLOWER ON DELAY FOR GAS HEATING IS 30 SECONDS I S a E OTO ES 2 BLOWER OFF DELAY FOR GAS HEATING IS 120 SECONDS FLAME Bl curs era PS z DEFAULT WITH FIELD SELECTABLE DELAYS OF 90 120 WiC sensor gjy atl REMOTES S sns P e So O O a Oco E 150 OR 180 SECONDS AVAILABLE rH SPARR E coy ais 2 ac A con BLOWER OFF DELAY FOR COOLING IS 90 SECONDS S i 2 CONT 2 6 1 R PE S IGNITION LOCKOUT OCCURS AFTER FOUR CONSECUTIVE B O 00 Elan gt oct UNSUCCESSFUL TONTT ION ATTEMPTS CONTROL WILL GAS VALVE AUT NERE ENE i GY j Om um com nes Eee o 3 OAT LiouTo IKE Sol Eroro SPARRER 5 K a e Q Pa z ne sb eee oe Ue 18DU
37. M does not run Blower wheel not secured to shaft Properly tighten blower wheel to shaft Insufficient voltage at motor Determine cause and correct Power connectors not properly sealed Connectors should snap easily do not force IFM operation is intermittent Water dripping into motor Verify proper drip loops in connector wires Connectors not firmly sealed Gently pull wires individually to be sure they are crimped into the housing Table 10 Troubleshooting Chart Con t Gas Furnace Operation SYMPTOM CAUSE REMEDY Burners will not ignite 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 over current protection that requires a cool down peri od to reset Mis wired or loose connections Check all wiring and wire nut connections Misaligned spark electrodes Check flame ignition and sense electrode posi 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 attempt ing to light unit 2 Check gas valve nducer pressure switch not closing 1 Check pressure switch wires connections and tubing Repair or replace if necessary Ina
38. NG ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death For vertical supply and return units tools or parts could drop into ductwork therefore install a 90 degree turn in the return ductwork between the unit and the conditioned space If a 90 degree elbow cannot be installed then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space Units with electric heaters require 90 degree elbow in supply duct When designing and installing ductwork consider the following 1 All units should have field supplied filters or accessory filter rack installed in the return air side of the unit Recommended sizes for filters are shown in Table 1 2 Avoid abrupt duct size increases and reductions Abrupt change in duct size adversely affects air performance a EL RIGGING WEIGHT ib kg Small 48XL 024 420 191 Small 48XL 030 427 194 48XL 036 515 234 48XL 042 587 244 Large 48XL 048 543 246 48XL 060 594 269 NOTE See dimensional drawing for corner weight distribution Corner weights shown on drawing are based on unit only weights and do not include packaging A06298 D ACCESS PANEL C A06296 Fig 7 Suggested Rigging IMPORTANT Use flexible connectors between ductwork and unit to prevent transmission of vibration Use suitable gaskets to ensure weather tight a
39. OTE In the state of Massachusetts 1 Gas supply connections MUST be performed by a licensed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 in 915 mm 3 When lever handle type manual equipment shutoff valves are used they shall be T handle valves 4 The use of copper tubing for gas piping is NOT approved by the state of Massachusetts In the absence of local building codes adhere to the following pertinent recommendations 1 Avoid low spots in long runs of pipe Grade all pipe 1 4 in 6 35 mm for every 15 ft 4 6 m of length to prevent traps Grade all horizontal runs downward to risers Use risers to connect to heating section and to meter N Protect all segments of piping system against physical and thermal damage Support all piping with appropriate straps hangers etc Use a minimum of one hanger every 6 ft 1 8 m For pipe sizes larger than 1 2 in follow recommendations of national codes 3 Apply joint compound pipe dope sparingly and only to male threads of joint when making pipe connections Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and or national codes Never use Teflon tape 4 Install sediment trap in riser leading to heating section See Fig 10 This drip leg functions as a trap for dirt and condensate 5 Install an accessible external manual main shutoff valve in gas supply pipe within 6 ft 1
40. S00095 0zr90V T f f IT mg UTILITY RELAY UTILITY SIGNAL OPEN RELAY SUPPLIED BY UTILITY PROVIDER O PETRO n TPP o k om s Liquid Line Solenoid A05247 Fig 18 2 Stage HP AC Control Board STATUS CODE 21 GAS HEATING LOCKOUT Control will NOT auto reset Check for mis wired gas valve or defective control valve relay STATUS CODE 22 ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for leaky gas valve or stuck open gas valve STATUS CODE 23 PRESSURE SWITCH DID NOT OPEN Check for obstructed pressure tubing or pressure switch stuck closed STATUS CODE 24 SECONDARY VOLTAGE FUSE IS OPEN Check for short circuit in secondary voltage 24VAC wiring STATUS CODE 25 INVALID MODEL SELECTION OR SETUP ERROR Indicates either the model plug is missing or incorrect If code flashes 4 times on power up control is defaulting to model selection stored in memory Check for proper model plug number and resistance values per wiring diagram STATUS CODE 31 32 PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED Control relay may be defective If open longer than five minutes inducer shuts off for 15 minutes before retry If open during blower on delay period blower will come on for the selected bl
41. TES IF ANY OF THE ORIGINAL WIRE FURNISHED IS REPLACED TT MUST BE REPLACED WITH TYPE 90 C OR EQUIVALE USE 75 C COPPER CONDUCTORS FOR FIELD INSTALLATIONS REPLACE LOW VOLTAGE FUSE WITH 3 AMP FUSE ONLY MANUFACTURED BY LITTLEFUSE P N 257003 MODEL 024 030 LS1 AND LSZ ARE IN SERIES WHEN USED MODELS 036 060 HAVE LS ONLY TO 8E URED IN ACCORDANCE WITH NEC AND gt 5 l l OPTIONAL FACTORY I snap RY SWITCH Y LOCAL CODES BLOWER ON DELAY FOR GAS HEATING IS 30 SECONDS WiC e o ty BLOWER OFF DELAY FOR GAS HEATING IS 120 SECONDS cH BL of ULT WITH FIELD SELECTABLE DELAYS OF 90 120 UTILITY CURTAILMENT Y SPLICES FOR OAT PROVIDED IN LOW VOLTAGE CONNECTION 60x CONNECTION ONLY WIRES PROVIDED NOT CONNECTED iy af 2 OR 180 SECONDS AVAILABLE BR 00 BLOWER OFF DELAY FOR COOLING IS 90 SECONDS IGNETION LOCKOUT OCCURS AFTER FOUR CONSECUTIVE GAS VALVE UNSUCCESSFUL IGNITION ATTEMPTS CONTROL WILL GY i AUTO RESET AFTER THREE HOURS i j SPARKER L1 I USE COPPER CONDUCTORS ONLY G DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING T lt lo K FIELD SUPPLY 208 230 VAC 60 HZ 1PH Y COMP CONT PP ws ek E BL ilja Q8y09_3v dH
42. abels attached to or shipped with the unit and other safety precautions that may apply Follow all safety codes Installation must be in compliance with local and national building codes Wear safety glasses protective clothing and work gloves Have fire extinguisher available Read hese instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit Recognize safety information This is the safety alert symbol A When you see this symbol on the unit and in instructions or manu als be alert to the potential for personal injury Understand these signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in per sonal injury or death CAUTION is used to identify unsafe practic es which may result in minor personal injury or product and prop erty damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation Always install furnace to operate within the intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in Indoor Airflow Adjust ments section of these instructions See furnace rating plate 44 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal i
43. allowed by authority 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 serviced another gas appliance 8 Check for gas leaks at the field installed and factory installed gas lines after all piping connections have been completed Use a commercially available soap solution made specifically for the detection of leaks or method specified by local codes and or regulations Install Electrical Connections 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death The unit cabinet must have an uninterrupted unbroken electrical ground This ground may consist of an electrical wire connected to the unit ground screw in the control compartment or conduit approved for electrical ground when installed in accordance with NEC NFPA 70 National Fire Protection Association latest edition in Canada Canadian Electrical Code CSA C22 1 and local electrical codes HIGH VOLTAGE CONNECTIONS The unit must have a separate electrical service with a field supplied waterproof disconnect switch mounted at or within sight from the unit Refer to the unit rating plate NEC and local codes for maximum fuse circuit breaker size and minimum circuit amps ampacity for wire sizing The fi
44. and condensate drain pan at least once each year The coils are easily cleaned when dry therefore inspect and clean the coils either before or after each cooling season Remove all obstructions including weeds and shrubs that interfere with the airflow through the condenser coil Straighten bent fins with a fin comb If coated with dirt or Hnt clean the coils with a vacuum cleaner using the soft brush attachment Be careful not to bend the fins If coated with oil or grease clean the coils with a mild detergent and water solution Rinse coils with clear water using a garden hose Be careful not to splash water on motors insulation wiring or air filter s For best results spray condenser coil fins from inside to outside the unit On units with an outer and inner condenser coil be sure to clean between the coils Be sure to flush all dirt and debris from the unit base Inspect the drain pan and condensate drain line when inspecting the coils Clean the drain pan and condensate drain by removing all foreign matter from the pan Flush the pan and drain trough with clear water Do not splash water on the insulation motor wiring or air filter s If the drain trough is restricted clear it with a plumbers snake or similar probe device Outdoor Fan 7 CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in damage to unit components Keep the outdoor fan free from all obstructions to ensure proper coolin
45. contactor is energized If the thermal protector has not re set the outdoor fan is turned off If the call for cooling continues the control will energize the compressor contactor every 15 minutes If the thermal protector closes at the next 15 minute interval check the unit will resume operation If the thermal cutout trips for three consecutive cycles then unit operation is locked out for 4 hours and the appropriate fault code is displayed NO 230V AT COMPRESSOR If the compressor voltage is not sensed when the compressor should be starting the contactor may be stuck open or there is a wiring error The control will flash the appropriate fault code Check the contactor and control box wiring TROUBLESHOOTING UNIT FOR PROPER SWITCHING BETWEEN LOW amp HIGH STAGES Check the suction pressures at the service valves Suction pressure should be reduced by 3 10 when switching from low to high capacity NOTE The liquid pressures are very similar between low and high stage operation so liquid pressure should not be used for troubleshooting Compressor current should increase 20 45 when switching from low to high stage The compressor solenoid when energized in high stage should measure 24vac COMPRESSOR INTERNAL RELIEF The compressor is protected by an internal pressure relief IPR which relieves discharge gas into compressor shell when differential between suction and discharge pressures exceeds 550 625 psi The compressor is a
46. ctions using electronic leak detector or liquid soap solution If a refrigerant leak is detected see following Check for Refrigerant Leaks section c Inspect all field and factory wiring connections Be sure that connections are completed and tight d Ensure wires do not touch refrigerant tubing or sharp sheet metal edges e Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 4 Verify the following conditions a Make sure gas line is free of air Before lighting the unit for the first time perform the following tasks with the gas valve in the OFF position NOTE Ifthe gas supply pipe was not purged before connecting the unit it will be full of air It is recommended that the ground joint union be loosened and the supply line be allowed to purge until the odor of gas is detected Never purge gas lines into a combustion chamber Immediately upon detection of gas odor retighten the union Allow 5 minutes to elapse then light unit b Make sure that condenser fan blade is correctly positioned in fan orifice Top 1 3 of condenser fan blade should be within fan orifice venturi c Ensure fan hub is positioned correctly with respect to motor housing See Fig 24 d Make sure that air filter s is in place e Make sure that condensate drain trap is filled with water to ensure proper drainage f Make sure that all tools and miscellaneous loose parts have been removed 5
47. curtailment relay should be connected to factory supplied pigtails PINK connected to R VIOLET connected to Y2 on the control board located in the low voltage splice box See Fig 13 14 and 16 This input allows a power utility device to interrupt compressor operation during peak load periods When the utility sends a signal to shut the system down the UI will display Curtailment Active COMPRESSOR OPERATION When the compressor is operating in low stage the modulating ring is deactivated allowing two internal bypass ports to close off 33 of the scroll compression area so the system operates at part load capacity The 24 volt solenoid coil is de energized in low stage operation When the compressor is operating at high stage the modulating ring is activated sealing the bypass ports which allows the compressor to operate at full load capacity The 24 volt solenoid coil is energized in high stage operation CRANKCASE HEATER OPERATION IF APPLICABLE The crankcase heater is energized during off cycle below 65 F 18 C outdoor air temperature OUTDOOR FAN MOTOR OPERATION The outdoor unit control energizes the outdoor fan any time the compressor is operating The outdoor fan remains energized if a pressure switch or compressor overload should open Outdoor fan motor will continue to operate for one minute after the compressor shuts off when the outdoor ambient is greater than or equal to 100 F 38 C TIME DELAYS AIR
48. d supplied Roof Roof Previded with roof curb Roof Curb for Small Cabinet Note A When unit mounting screw is used retainer bracket must also be used E f Provided with roof curb Roof Curb for Large Cabinet Note A When unit mounting screw is used retainer bracket must also be used 3 SN xtrm_ _ k4 4 F Gasket around EY 0 duct ee n Insulated Gasket around Insulated deck pan outer edge deck pan Long Support Y A05308 UNIT SIZE CATALOG A B c D E F G NUMBER IN MM IN MM IN MM IN MM IN MM IN MM IN MM wae CPRFCURBO006A00 8 203 11 279 16 1 2 419 28 3 4 730 30 3 8 771 44 5 16 1126 45 15 16 1167 CPRFCURBO007A00 14 356 11 279 16 1 2 419 28 3 4 730 30 3 8 771 44 5 16 1126 45 15 16 1167 saeoke CPRFCURBOO8A00 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 CPRFCURBOO9A00 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 NOTES 1 Roof curb must be set up for unit being installed Seal strip must be applied as required to unit being installed Roof curb is made of 16 gauge steel Attach ductwork to curb flanges of duct rest on curb Insulated panels 1 in 25
49. dequate heating 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 Replace with proper unit or add additional unit Restricted airflow Clean or replace filter Remove any restriction Limit switch cycles main burners Check rotation of blower temperature rise of unit Adjust as necessary Poor flame characteristics ncomplete combustion results in Aldehyde odors carbon monoxide sooting flame floating flame 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 UP CHECKLIST Remove and Store in Job File I Preliminary Information MODEL NO 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 ECK 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
50. door air sensor indicates gt 10 F 12 C cooler than the coil sensor the sensors are out of range If the sensors are out of range the control will flash the appropriate fault code as shown in Table 5 The thermistor comparison is not performed during low ambient cooling operation FAILED THERMISTOR DEFAULT OPERATION Factory defaults have been provided in the event of failure of outdoor air thermistor and or coil thermistor 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 If the OCT sensor should fail low ambient cooling will not be allowed Detrost will occur at each time interval during heating operation but will terminate after 5 minutes If there is a thermistor out of range error defrost will occur at each time interval during heating operation but will terminate after 5 minutes Refer to the Troubleshooting Chart Table 10 for additional troubleshooting information OCT Thermistor must be secured tight on the liquid tube A06311 Fig 26 Outdoor Coil Thermistor OCT Attachment FINAL CHECKS IMPORTANT Before leaving job be sure to do the following 1 Ensure that all wiring is routed away from tubing and sheet metal edges to prevent rub through or wire pinching N Ensure that all wiring and tubing is secure in unit before adding panels and covers Securel
51. ds of the two black OAT pigtails Wire the opposite ends of these two wires to the OAT provided with the UI There is no polarity to be observed NOTE Mis wiring OAT inputs will not cause damage to either Infinity control or thermistor If the thermistor is wired incorrectly no reading will appear at UI Re wire thermistor correctly for normal operation B Humidifier Connections The furnace control board terminal marked HUM is provided for low voltage 24 vac control of a humidifier No humidistat is required as UI monitors indoor humidity When commanded to operate humidifier the unit control will energize the HUM output to turn humidifier on and de energize HUM output to turn humidifier off Wire HUM and COM terminals directly to humidifier as shown in Fig 14 C Electronic Air Cleaner Electronic Air Cleaner terminals are provided on the Infinity Control Board EAC 1 and EAC 2 While these terminals can be used to power a 230V EAC it is recommended that any EAC be installed per the EAC installation instructions and connected separately to a standard 115V or 230V outlet with an airflow sensor to control operation of the EAC SPECIAL PROCEDURES FOR 208 V OPERATION Be sure unit disconnect switch is open Disconnect the black primary lead from the transformer See unit wiring label See Fig 16 and 17 Connect the black primary lead to the transformer terminal labeled 208 v USER S INTERFACE
52. e blower failed to reach 250 RPM or the blower failed to communicate within 30 seconds after being turned ON in two successive heating cycles Control will auto reset after 3 hours Refer to status code 41 HHH S Q0 00 i de ied cva awe SN a 08 8 E Se e ray Blo E ql wo Ol ssh E ls F poge pone B BBHHBBBU sm E o Jas rg ml je Lo A06026 Fig 15 Detail of Furnace Board 16 T BI 14 13 060 090 OFO sindur sey seuq ABUS IX8F 3D8tt u5S SULIAA OT 6Lr90V CONNECTION WIRING DIAGRAM DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING LADDER WIRING DIAGRAM b UNIT COMPONENT ARRANGEMENT ELN GUTOOGR FAN o 60HZ 1PH A gt P Rs 7 COMPRESSOR INDOOR FAN igi S fe SECTION SECTION FORT H CONTROL mC CONTROL BOARD oaro TEM TRAN CONT lt ES gt gt icap HEF wwe 13 BL UTA SPLICE 80x CAP2 es 10m Ls2 E OO
53. e drop for non standard filters must not exceed 0 08 IN W C Provide Clearances The required minimum service clearances are shown in 5 and 6 Adequate ventilation and outdoor air must be provided The outdoor fan draws air through the outdoor coil and discharges it through the top fan grille Be sure that the fan discharge does not recirculate to the outdoor coil Do not locate the unit in either a corner or under an overhead obstruction The minimum clearance under a partial overhang such as a normal house overhang is 48 in above the unit top The maximum horizontal extension of a partial overhang must not exceed 48 in 1219 mm IMPORTANT Do not restrict outdoor airflow An air restriction at either the outdoor air inlet or the fan discharge may be detrimental to compressor life Do not place the unit where water ice or snow from an overhang or roof will damage or flood the unit Do not install the unit on carpeting or other combustible materials Slab mounted units should be at least 4 in 102 mm above the highest expected water and runoff levels Do not use unit if it has been under water Rig and Place Unit Rigging and handling of this equipment can be hazardous for many reasons due to the installation location roofs elevated structures etc Only trained qualified crane operators and ground support staff should handle and install this equipment When working with this equipment observe precautions in the literature on ta
54. eable polyethylene plastic drip cloth or tarp Cover an approximate 10 X 10 ft 3x3 m area N Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run offs and protect drop cloth from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately under component s to be serviced and prevent lubricant run offs through the louvered openings in the unit base 4 Perform required service 5 Remove and dispose of any oil contaminated material per local codes LIQUID LINE FILTER DRIER The filter drier is specifically designed to operate with Puron Use only factory authorized components Filter drier must be replaced whenever the refrigerant system is opened When removing a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system PURON R 410A REFRIGERANT CHARGING Refer to unit information plate and charging chart Some R 410A refrigerant cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder in upright position For cylinders equipped with a dip tube charge Puron units with cylinder in upright position and a commercial metering device in manifold hose Charge refrigerant into suction line TROUBLESHOOTING LED DESCRIPTION LEDs built into Infinity control boards provide
55. ects and install lockout tag before starting any service work 2 Remove side duct covers to access bottom return and supply knockouts NOTE These panels are held in place with tabs similar to an electrical knockout 3 Use a screwdriver and hammer to remove the panels in the bottom of the composite unit base 4 Ensure the side duct covers are in place to block off the horizontal air openings See Fig 8 Supply Duct Cover A06320 Fig 8 48XL with Duct Covers On Provide for Condensate Disposal NOTE Ensure that condensate water disposal methods comply with local codes restrictions and practices The units dispose of condensate through a 3 4 in NPT female fitting that exits on the compressor end of the unit Condensate water can be drained directly onto the roof in rooftop installations where permitted or onto a gravel apron in ground level installations Install a field supplied condensate trap at end of condensate connection to ensure proper drainage Make sure that the outlet of the trap is at least 1 in 25 mm lower than the drain pan condensate connection to prevent the pan from overflowing Prime the trap with water When using a gravel apron make sure it slopes away from the unit If the installation requires draining the condensate water away from the unit install a field supplied 2 in 51 mm trap at the condensate connection to ensure proper drainage Condensate trap is available as an accessory or is
56. ed and keep the gas valve energized on low stage If the UI is asking for high stage gas heat the ignition control will maintain running the inducer on high speed and energize the gas valve s high stage relay to increase gas flow If the burner flame is not proved within 2 seconds the control will close the gas valve and repeat the ignition sequence up to 3 more Trials For Ignition before going to Ignition Lockout Lockout will reset automatically after 3 hours by momentarily interrupting 230 VAC power or by interrupting 24 VAC power at SEC1 or SEC2 to the furnace board If flame is proved when there should be no flame present control will lock out of Gas Heating mode and operate the inducer motor until flame is no longer proved 4 Blower On Delay If the burner flame is proven approximately 37 seconds after the gas valve is opened the Indoor Blower is turned on to the appropriate speed for the gas heating stage Simultaneously the humidifier terminal HUM and electronic air cleaner terminal EAC 1 are energized throughout the heating cycle NOTE EAC 2 terminal is common with L2 and will have 115VAC to ground when unit is powered 5 Blower Off Delay When the call for gas heat is satisfied the gas valve is de energized stopping the flow of gas to the burners and de energizing the HUM terminal The inducer motor will remain on for a 4 second post purge period The indoor blower and air cleaner terminal EAC 1 will remain energiz
57. ed for 90 120 150 or 180 seconds depending on selection of blower off delay selected in the UD The factory set default is 120 second blower OFF delay CHECK GAS INPUT NATURAL GAS 44 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in component damage Do not redrill an orifice Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flame If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size 44 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage DO NOT bottom out gas valve regulator adjusting screws This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures N N 44 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury and or death If the manifold pressure and or gas rate is not properly adjusted on HI and LO stages excess carbon monoxide can be produced 4 WARNING FIRE AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and or property damage Unsafe operation of the unit may result if manifold pressure is outside of the ranges listed in Table 6 Gas input rates on rating plate are for installations at altitudes up to 2000 tt
58. eld 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 4 CAUTION UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the unit being installed 1 Make all electrical connections in accordance with NEC NFPA 70 latest edition and local electrical codes governing such wiring In Canada all electrical connections must be in accordance with CSA standard C22 1 Canadian Electrical Code Part 1 and applicable local codes Refer to unit wiring diagram Use only copper conductor for connections between field supplied electrical disconnect switch and unit DO NOT USE ALUMINUM WIRE Be sure that high voltage power to unit is within operating voltage range indicated on unit rating plate Insulate low voltage wires for highest voltage contained within conduit when low voltage control wires are in same conduit as high voltage wires Do not damage internal components when drilling through any panel to mount electrical hardware conduit etc 11 Table 2 Maximum Gas Flow Capacity NOMINAL INTERNAL LENGTH OF PIPE ft m t IRON PIPE DIAMETER 10 20 30 40 50 60 70 80 90 100 125 150 175 200 SIZE IN IN 3 0 6 1 9 1 12 1 15 2 18 3 21 3 24 4 27 4 30 5 38 1 45 7 53 3
59. field supplied Make sure that the outlet of the trap is at least 1 in 25 mm lower than the unit drain pan condensate connection to prevent the pan from overflowing Connect a drain trough using a minimum of field supplied 3 4 in PVC or field supplied 3 4 in copper pipe at outlet end of the 2 in 51 mm trap See Fig 9 Do not undersize the tube Pitch the drain trough downward at a slope of at least 1 in for every 10 ft 3 m of horizontal run Be sure to check the drain trough for leaks Prime the trap at the beginning of the cooling season start up Install Flue Hood 44 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The venting system is designed to ensure proper venting The flue hood assembly must be installed as indicated in this section of the unit installation instructions Install the flue hood as follows 1 This installation must conform with local building codes and with the National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 in Canada CAN CSA B149 1 and B149 2 or latest revision Refer to provincial and local plumbing or wastewater codes and other applicable local codes N Remove flue hood from shipping location inside the return section of the blower compartment See Fig 8 Remove the return duct cover to locate the flue hood Remove two screws on flue panel Place flue hood assembly over flue panel Orient screw holes in flue
60. flow based on gas furnace output and unit cooling capacity Infinity Furnace Infinity HP AC Board Board Outdoor Air Thermistor Supplied with IU FIELD CONNECTION REQUIRED BLACK WIRES Standard 4 Wire Thermostat Outdoor Coil Thermistor FACTORY CONNECTED FACTORY WIRES PROVIDED FOR FIELD CONNECTION OF UTILITY CURTAILMENT LEGEND Jumped Wires summa Field Wiring m mm A06302 Fig 22 Non Communicating Emergency Cooling Heating Wiring Connections Required Subcooling F C Required Liquid Line Temperature for a Specific Subcooling R 410A Outdoor Ambient Temperature Required Subcooling CF Required Subcooling C Model Size 7524 seg seg 9505 105 41 Cora 5 to 15 25 jong 3 6 8 14 024 15 5 8 6 15 6 87 15 7 8 7 15 8 8 8 15 9 8 9 174 56 51 46 36 1200 13 11 8 2 030 168 9 3 16 4 9 1 16 2 9 156 8 7 15 83 181 59 54 49 39 1248 15 12 9 4 036 14 7 7 13 9 7 7 139 7 7 13 8 7 7 13 7 7 6 188 61 56 51 41 1296 16 13 10 5 042 19 2 10 7 19 1 10 6 19 1 10 6 18 9 10 5 18 7 10 4 195 63 58 53 43 1344 17 14 12 6 048 21 116 20 8 11 5 20 7 11 5 20 4 11 3 20 2 11 2 f 202 65 60 55 45 1393 18 16 13 7 060 16 2 9 16 6 9 2 16 8 9 3 17 3 9 6 17 8 9 9 209 67 62 57 47 1441 20 17 14 9 216 69 64 59 49 1489 21 18 15 10 223 71 66 61 51 1537 22 19 16 11 Charging Procedure 230 73 68 63 53 1586 23 20 17 12 1 Measure D
61. for additional information as required MAXIMUM ALLOWABLE B DIFFERENCE in mm A B B C A C 1 4 6 35 1 4 6 35 1 4 6 35 A07925 Fig 2 Unit Leveling Tolerances SLAB MOUNT Place the unit on a solid level concrete pad that is a minimum of 4 in 102 mm thick with 2 in 51 mm above grade The slab should extend approximately 2 in 51 mm beyond the casing on all 4 sides of the unit See Fig 3 Do not secure the unit to the slab except when required by local codes ip i i aay t RETURN y 144 AIR AA o EVAP COIL COND COIL A07926 Fig 3 Slab Mounting Detail GROUND MOUNT The unit may be installed either on a slab or placed directly on the ground if local codes permit Place the unit on level ground prepared with gravel for condensate discharge 2 HVAC unit HVAC unit base base 9 inner flange Screw Gasketing Screw NOTE A gt nro NOTE A F Gasketing Gasketing outer flange vo outer flange l E H Wood nailer E Wood nailer Flashing field Flashing field supplied Roof curb supplied Roof curb Insulation field Insulation field Roofing material supplied Roofing mateial supplied field supplied field supplied Ductwork Ductwork Cant strip field supplied Cant strip field supplied field supplied fiel
62. for the various operating conditions Accurate pressure gauge and temperature sensing devices are required Connect the pressure gauge to the service port on the suction line Mount the temperature sensing device on the suction line and insulate it so that the outdoor ambient does not affect the reading Indoor air CFM must be within the normal operating range of the unit Take the liquid line temperature and read the manifold pressure gauges Refer to the chart to determine what the liquid line temperature should be NOTE If the problem causing the inaccurate readings is a refrigerant leak refer to Check for Refrigerant Leaks section NON COMMUNICATING EMERGENCY COOLING HEATING MODE 4 WIRE THERMOSTAT This mode of operation is provided only in the case where the UI has failed or is otherwise unavailable If communications cannot be established with the UI the Infinity furnace board will enable the standard thermostat input terminals to allow simple thermostatic control of the 48XL unit For control with a standard thermostat disconnect the ABCD connectors from both control boards and using No 18 AWG color coded insulated type 90 C minimum or equivalent wire make the connections between the standard thermostat the furnace board and the HP AC board per Fig 22 Recommend the use of interconnecting wire with 105C 600V 2 64 insulation The Infinity control will respond to cooling and heating demands with the maximum safe air
63. g operation Never place articles on top of the unit 1 Remove 4 screws holding outdoor grille and motor to top cover N Turn motor grille assembly upside down on top cover to expose fan blade 3 Inspect the fan blades for cracks or bends 4 If fan needs to be removed loosen setscrew and slide fan off motor shaft 5 When replacing fan blade position blade according to the table shown in Fig 24 6 Ensure that set screw engages the flat area on the motor shaft when tightening 7 Replace grille igi as Infinity Top A06035 UNIT SIZE A DIM IN MM 024 1 26 030 1 26 036 1 26 042 1 26 048 11 32 9 060 9 16 14 Fig 24 Outdoor Fan Blade Clearance Electrical Controls and Wiring Inspect and check the electrical controls and wiring annually Be sure to turn off the electrical power to the unit Remove access panel to locate all the electrical controls and wiring Check all electrical connections for tightness Tighten all screw connections If any smoky or burned connections are noticed disassemble the connection clean all the parts re strip the wire end and reassemble the connection properly and securely After inspecting the electrical controls and wiring replace all the panels Start the unit and observe at least one complete cooling cycle to ensure proper operation If discrepancies are observed in operating cycle or
64. gs stickers and labels attached to the equipment and any other safety precautions that might apply Training for operators of the lifting equipment should include but not be limited to the following 1 Application of the lifter to the load and adjustment of the lifts to adapt to various sizes or kinds of loads 2 Instruction in any special operation or precaution 3 Condition of the load as it relates to operation of the lifting kit such as balance temperature etc Follow all applicable safety codes Wear safety shoes and work gloves 7 INSPECTION Prior to initial use and at monthly intervals all rigging brackets and straps should be visually inspected for any damage evidence of wear structural deformation or cracks Particular attention should be paid to excessive wear at hoist hooking points and load support areas Brackets or straps showing any kind of wear in these areas must not be used and should be discarded 44 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing or servicing system always turn off main power to system There may be more than one disconnect switch Turn off accessory heater power switch if applicable Tag disconnect switch with a suitable warning label 44 WARNING UNIT FALLING HAZARD Failure to follow this warning could result in personal injury or death Never stand beneath rigged units or lift over people
65. h a larger diameter screw included Rigging Lifting of Unit 1 Bend top of brackets down approximately 30 degrees from the corner posts 2 Attach straps of equal length to the rigging brackets at opposite ends of the unit Be sure straps are rated to hold the weight of the unit See Fig 7 3 Attach a clevis of sufficient strength in the middle of the straps Adjust the clevis location to ensure unit is lifted level with the ground 4 After unit is securely in place detach rigging straps Remove comer posts screws and rigging brackets then reinstall screws 4 WARNING UNIT FALLING HAZARD Failure to follow this warning could result in personal injury death or property damage When straps are taut the clevis should be a minimum of 36 in 914 mm above the unit top cover After the unit is placed on the roof curb or mounting pad remove the top crating Select and Install Ductwork The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of non residence type air conditioning and ventilating systems NFPA 90A or residence type NFPA 90B and or local codes and ordinances Select and size ductwork supply air registers and return air grilles according to ASHRAE American Society of Heating Refrigeration and Air Conditioning Engineers recommendations The unit has duct flanges on the supply and return air openings on the side of the unit 44 WARNI
66. he blower failed to communicate within the prescribed time limits Thirty seconds after being turned ON or ten seconds during steady state operation STATUS CODE 45 CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to gas valve relay stuck open flame sense circuit failure or software check error Reset power to clear lockout Replace control if status code repeats E HP AC Control Troubleshooting See Table 4 for HP AC control board status codes and troubleshooting information STATUS CODE 533 OUTDOOR AIR TEMPERATURE SENSOR FAULT DETAILED DESCRIPTION If an OAT sensor is found at power up input is constantly checked to be within a valid temperature range If sensor is found to be open or shorted at any time after initial validation Status Code 53 will be displayed at amber STATUS LED Check for faults in wiring connecting sensor to OAT terminals Using an Ohm meter check resistance of thermistor for a short or open condition 19 If thermistor is shorted or open replace it to return the system to normal operation If fault is in the wiring connections correcting the fault will clear the code and return the system to normal operation NOTE If fault condition is an open thermistor or a wiring problem that appears to be an open thermistor and the power to the unit is cycled off the fault code will be cleared on the next power up but the fault will remain and system operation will not be as expected T
67. he gas valve and stopping gas flow to the burners The indoor fan motor IFM continues to run until switch is reset The furnace board STATUS LED will display STATUS CODE 33 CONTINUOUS FAN MODE When continuous fan operation is requested by the Ul indoor fan motor will operate at continuous blower airflow Continuous fan operation is programmable See the UI Owner s Manual for detailed instructions Terminal EAC 1 is energized as long as the indoor fan motor is energized During a call for gas heat the Infinity control will transition the indoor fan motor to continuous blower airflow or gas heat airflow whichever is lowest The indoor fan motor will remain ON until the burners ignite then shut OFF and remain OFF for the blower ON delay allowing the heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period The indoor fan motor will revert to continuous blower airflow after the gas heating cycle is completed When the UI calls for cooling the indoor fan motor will switch to operate at cooling airflow When the call for cooling is satisfied the indoor fan motor will operate an additional 90 seconds at cooling airflow before transitioning back to continuous blower airflow When the call for continuous fan is removed the indoor blower will continue operating for an additional 5 seconds before shutting down if no other function requires blower motor operation COMPONENT TEST The Infinity
68. he manifold pressure to decrease rate NOTE Double check that User Interface is running on high stage gas heat while clocking the low stage firing rate 7 Verity proper high stage gas heat temperature rise a Furnace must operate within rise range listed on rating plate b Make sure access panel is re installed on the unit c Measure supply and return temperatures as close to the unit as possible Subtract the return temperature from the supply temperature to determine rise Rise should fall within the range specified on the rating plate NOTE Ifthe temperature rise is outside the rating plate range first check a Gas input for low and high stage gas heat operation b Derate for altitude if applicable c Return and supply ducts for excessive restrictions causing static pressures in excess of 5 IN W C d Make sure model plug is installed 8 Final Check a Turn off gas to unit b Remove manometer from pressure tap c Replace pipe plug on manifold See Fig 20 d Turn on gas to unit e Check for leaks CHECK GAS INPUT PROPANE GAS Refer to propane kit installation instructions for properly checking gas input NOTE For installations below 2 000 ft 610 m refer to the unit rating plate for proper propane conversion kit For installations above 2 000 ft 610 m contact your distributor for proper propane conversion kit CHECK BURNER FLAME With burner access panel removed observe the unit heating operat
69. his 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 UL This unit will not respond to commands provided by a common thermostat except under certain emergency situations described in Step 1 Start Up and Troubleshooting The UI uses temperature humidity and other data supplied from indoor and outdoor system components to control heating or cooling system for optimum comfort The unit will be commanded by UI to supply airflow The unit will operate the indoor blower at requested airflow for most modes INDOOR AIRFLOW ADJUSTMENTS The nominal requested airflow for air conditioner operations will be 350 cfm per ton of nominal cooling capacity as defined by unit size Actual airflow request will be adjusted from nominal using indoor and outdoor temperature and indoor humidity data to optimize the system operation for occupant comfort and system efficiency Refer to UI literature for further system control details A CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage For cooling operation the recommended airflow is 350 to 450 cfm for each 12 000 Btuh of rated cooling capacity For heating operation the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate For gas heat operations
70. hooting information will be available at UI until communications are re established If either COMM LED does not light within proper time period and status codes are not displayed 1 Check system transformer high and low voltage to be sure the system is powered 2 Check ABCD connection on both boards 3 Check fuse on furnace board to be sure it is not blown If fuse is open check system wiring before replacing it to be sure a short does not cause a failure of replacement fuse If COMM LED does not light within proper time period and status code is displayed 1 Check system wiring to be sure Ul 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 contro module or entire motor Motor control module is available as a replacement part VERIFY MOTOR WINDING SECTION A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could resul
71. ices NOTE Install a filter drier whenever the system has been opened for repair 3 Check system for leaks using an approved method 4 Evacuate refrigerant system and reclaim refrigerant if no additional leaks are found 5 Charge unit with Puron R 410A refrigerant using a volumetric charging cylinder or accurate scale Refer to unit rating plate for required charge Start Up Adjustments Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Do not operate the unit in cooling mode when the outdoor temperature is below 40 F 4 C unless low ambient operation is enabled in the UI Do not rapid cycle the compressor Allow 5 min between on cycles to prevent compressor damage CHECKING COOLING OPERATION See UI Installation Instructions for detailed system CHECKOUT CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with Puron R 410A refrigerant and is tested and factory sealed AND HEATING CONTROL NOTE Any adjustment to refrigerant charge must be done with unit operating in HIGH stage NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 410A charge The charging label and the tables shown refer to system temperatures and pressures in cooling mode only A refrigerant charging label is attached to the outside of the unit Table
72. if a suspected malfunction has occurred check each electrical component with the proper electrical instrumentation Refer to the unit wiring label when making these checks Refrigerant Circuit Inspect all refrigerant tubing connections and the unit base for oil accumulation annually Detecting oil generally indicates a refrigerant leak If oil is detected or if low performance is suspected leak test all refrigerant tubing using an electronic leak detector or liquid soap solution If a refrigerant leak is detected refer to Check for Refrigerant Leaks section If no refrigerant leaks are found and low performance is suspected refer to Checking and Adjusting Refrigerant Charge section Indoor Airflow The heating and or cooling airflow does not require checking unless improper performance is suspected If a problem exists be sure that all supply and return air grilles are open and free from obstructions and that the air filter is clean Pressure Switches Refrigerant Circuit Pressure switches are protective devices integrated into the control circuit low voltage They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit These pressure switches are specifically designed to operate with Puron R 410A systems R 22 pressure switches must not be used as replacements for the Puron R 410A system Loss of Charge Low Pressure Switch This switch is located on the liquid line and protec
73. ion Watch the burner flames to see if they are light blue and soft in appearance and that the flames are approximately the same for each burner Propane will have blue flame See Fig 21 Refer to the Maintenance section for information on burner removal MANIFOLD PIPE PLUG C99019 Fig 20 Burner Assembly BURNER FLAME MANIFOLD C9902 Fig 21 Monoport Burner LIMIT SWITCHES Normally closed limit switch LS completes the control circuit Should the leaving air temperature rise above the maximum allowable temperature the limit switch opens and the control circuit breaks Any interruption in the control circuit instantly closes the gas valve and stops gas flow to the burners and pilot The blower motor continues to run until LS resets The furnace board STATUS LED will display STATUS CODE 33 When the air temperature at the limit switch drops to the low temperature setting of the limit switch the switch closes and completes the control circuit The direct spark ignition system cycles and the unit returns to normal heating operation ROLLOUT SWITCH The function of the rollout switch is to close the main gas valve in the event of flame rollout The switch is located above the main burners When the temperature at the rollout switch reaches the maximum allowable temperature the control circuit trips closing t
74. ischarge line pressure by attaching a gauge to the service port 237 75 70 65 55 1634 24 21 19 13 2 Measure the Liquid line temperature by attaching a temperature sensing device toit 244 17 72 67 57 1682 25 22 20 14 3 Insulate the temperature sensing device so that the Outdoor Ambient doesn t affect E the reading 4 Refer to the required Subcooling in the table based on the mode size and the aer S a E E oa a 5 e Outdoor Ambient temperature 5 a7 37 7 7 7551 57 55 35 7 5 Interpolate if the Outdoor temperature lies in between the table values Extrapolate if 291 89 84 79 69 2006 32 29 26 20 the temperature lies beyond the table range 299 91 86 81 71 2061 33 30 27 22 6 Find the Pressure Value corresponding to the the measured Pressure on the 308 33 38 33 73 3153 37 31 5 53 Compresion Discharge Ine 317 95 90 85 75 2185 35 32 29 2 7 Read across from the Pressure reading to obtain the Liquid line temperature for a 326 97 92 87 77 2247 36 33 30 25 required Subcooling 335 99 9 89 79 2309 37 34 31 26 8 Add Charge if the measured temperature is higher than the liquid line temperature 344 101 96 91 81 2372 38 35 33 oF value in the table 353 102 97 92 82 2434 39 36 34 28 9 Add Charge using the service connection on the Suction line of the Compressor 363 104 99 94 84 2503 40 37 35 29 373 106 101 96 86 2571 41 39 36 30 383 108 103 98 88 2640 42 40 37 31 393 110 105 100 90 2709 43 41 38
75. leads through grommeted low voltage hole provided into unit See Fig 5 and 6 Connect user interface leads to unit control power leads as shown in Fig 14 The unit transformer supplies 24 v power for complete system including accessory electrical heater Transformer is factory wired for 230 v operation If supply voltage is 208 v rewire transformer primary as described in Special Procedures for 208 v Operation section The furnace board is fused by a board mounted automotive fuse placed in series with transformer SEC1 and R circuit The C circuit of transformer circuit is referenced to chassis ground through a printed circuit run at SEC2 and gas valve grounding wire Check to be sure control board is mounted securely using both factory installed screws ACCESSORY INSTALLATION A Outdoor Air Thermistor OAT A CAUTION EQUIPMENT OPERATION HAZARD The installation of an outdoor temperature sensor using the Infinity control board OAT terminals is required Many Infinity features auto humidity control comfort rollback ETC will be lost if the OAT is not connected For detailed mounting instructions for the OAT sensor please refer to TSTATXXSENO1 B installation instructions catalog no 63TS TA13 Procedures 1 through 3 The OAT input is used to supply outdoor temperature data for system level functions and for temperature display on User Interface UD Using two wires of the field supplied thermostat wire cable wire the en
76. lowed until voltage is a minimum of 190v The control will flash the appropriate fault code See Table 5 230V LINE POWER DISCONNECT DETECTION If there is no 230v at the compressor contactor when the unit is powered and cooling demand exists the appropriate error code is displayed Verify that the disconnect is closed and 230v wiring is connected to the unit COMPRESSOR VOLTAGE SENSING The control board input terminals VS and L2 See Fig 18 are used to detect compressor voltage status and alert the user of potential problems The control continuously monitors the high voltage on the run capacitor of the compressor motor Voltage should be present any time the compressor contactor is energized and voltage should not be present when the contactor is de energized CONTACTOR SHORTED DETECTION If there is compressor voltage sensed when there is no demand for compressor operation the contactor may be stuck closed or there is a wiring error The control will flash the appropriate fault code COMPRESSOR THERMAL CUTOUT If the control senses the compressor voltage after start up and is then absent for 10 consecutive seconds while cooling demand exists the thermal protector is open The control de energizes the compressor contactor for 15 minutes but continues to operate the outdoor fan The control Status LED will flash the appropriate code shown in Table 5 After 15 minutes with a call for low or high stage cooling the compressor
77. lso protected by an internal overload attached to motor windings TEMPERATURE THERMISTORS Thermistors are electronic devices which sense temperature As the temperature increases the resistance decreases Thermistors are used to sense outdoor ambient OAT and coil temperature OCT Refer to Fig 25 for resistance values versus temperature See Fig 26 for OCT location If the outdoor ambient or coil thermistor should fail the HP AC control will flash the appropriate fault code See Table 5 IMPORTANT Coil thermistor is factory mounted Check to insure thermistor is mounted properly Outdoor air thermistor OAT is field mounted and connected Verify that the OAT has been properly installed THERMISTOR CURVE 90 s0 2 70 3 00 x u 50 s 40 2 30 g 20 10 0 20 40 60 80 100 120 TEMPERATURE DEG F A91431 Fig 25 Resistance Values Versus Temperature THERMISTOR SENSOR COMPARISON The control continuously monitors and compares the outdoor air temperature sensor and outdoor coil temperature sensor to ensure proper operating conditions The comparison is In cooling mode if the outdoor air sensor indicates gt 10 F 12 C warmer than the coil sensor or the outdoor air sensor indicates 20 F cooler than the coil sensor the sensors are out of range In heating if the outdoor air sensor indicates 35 F 2 C warmer than the coil sensor or the out
78. mine cause and correct neorrect or faulty wiring Check wiring diagram and rewire correctly Ul setting too low too high Reset Ul setting Units have a 5 minute time delay DO NOT bypass this compressor time delay wait for 5 minutes until time delay relay is de energized Compressor will not start but condenser fan runs Faulty wiring or circuit Loose connections in compressor Check wiring and repair or replace Compressor motor burned out seized or internal overload open Determine cause Replace compressor Defective run capacitor overload or PTC positive temperature coefficient thermistor Determine cause and replace Low input voltage 20 percent low Determine cause and correct Compressor cycles other than normally sat isfying cooling heating calls Refrigerant overcharge or undercharge Recover refrigerant evacuate system and re charge to capacities shown on rating plate Defective compressor Replace and determine cause nsufficient line voltage Determine cause and correct Blocked outdoor coil Determine cause and correct Defective run start capacitor overload or start relay Determine cause and replace Faulty outdoor fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Dirty air filter Replace filter Unit undersized for load Decrease
79. mm thick fiberglass 1 lb density nan j WN When unif mounting screw is used see Note A a retainer bracket must be used as well This bracket must also be used when required by code for hurricane or seismic conditions This bracket is available through Micromet Fig 4 Roof Curb Dimensions 798 6 131 FIELO ENTRY SERVICE PORTS 44 48XL UNIT WT UNIT HEIGHT CENTER OF GRAVITY MM IN KG 182 TOP VIEW S THAN 304 8 12 00 FROM RFORMANCE MAYBE COMPROMISED DIMENSIO IN ARE IN INCHES FULL LOUVER TITION PANEL LEFT S E VIEW FRONT VIEW RIGHT SIDE VIEW REAR VIEW A06608 Fig 5 48XL024 030 Unit Dimensions 19 0 0 75 N P T X 22 000 87 DEEP feat 1123 1 44 22 LEFT SIDE VIEW 406 6 116 01 pe 355 8 14 01 355 8 14 011 SUPPLY RETURN 41 4 1 63 UNIT ELECTRICAL UNIT WT UNIT HEIGHT CENTER OF GRAVITY MM IN CHARACTERISTICS LBS KG FAT X Y H 48XL 036060 208 230 1 60 485 220 0 1142 5 44 98 553 402
80. nd airtight seal When electric heat is installed use fireproof canvas or similar heat resistant material connector between ductwork and unit discharge connection If flexible duct is used insert a sheet metal sleeve inside duct Heat resistant duct connector or sheet metal sleeve must extend 24 in 610 mm from electric heater element 3 Size ductwork for max possible air flow See Table 1 4 Seal insulate and weatherproof all external ductwork Seal insulate and cover with a vapor barrier all ductwork passing through conditioned spaces Follow latest Sheet Metal and Air Conditioning Contractors National Association SMACNA and Air Conditioning Contractors Association ACCA minimum installation standards for residential heating and air conditioning systems 5 Secure all ducts to building structure Flash weatherproof and vibration isolate duct openings in wall or roof according to good construction practices CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW VERTICAL DISCHARGE UNITS 44 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing or servicing system always turn off main power to system and tag There may be more than one disconnect switch Turn off accessory heater power switch if applicable NOTE If unit is not equipped with duct covers accessory duct covers are required See pre sale literature 1 Open all electrical disconn
81. njury or death Before installing or servicing system always turn off main power to system and tag disconnect There may be more than one disconnect switch Turn off accessory heater power switch if applicable 4 WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage Puron R 410A systems operate at higher pressures than standard R 22 systems DO NOT use R 22 service equipment or components on Puron R 410A equipment Ensure service equipment is rated for Puron R 410A INTRODUCTION The 48XL packaged unit is a fully self contained combination Category I gas heating electric air conditioner designed for outdoor installation See Fig 1 Standard units are shipped in a horizontal discharge configuration for installation on a ground level slab or directly on the ground if local codes permit Standard units can be converted to downflow vertical discharge configurations for rooftop applications Models with an N in the fifth position of the model number are dedicated Low NOx units designed for California installations These models meet the California maximum oxides of nitrogen NOX emissions requirements of 40 nanograms joule or less as shipped from the factory and must be installed in California Air Quality Management Districts or any other regions in North America where a Low NOx tule exists NOTE Low NOx requirements apply only to natural gas installa
82. o follow this warning could result in personal injury or equipment damage This system uses Puron R 410A refrigerant which has higher operating pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gauge set hoses and recovery system must be designed to handle Puron If you are unsure consult the equipment manufacturer COMPRESSOR OIL The compressor in this system uses a polyolester POE oil Mobil 3MA POE This oil is extremely hygroscopic meaning it absorbs water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere SERVICING SYSTEMS ON ROOFS WITH SYNTHETIC MATERIALS POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials Exposure even if immediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service that may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks and replacing refrigerant components such as filter drier pressure switch metering device coil accumulator or reversing valve Synthetic Roof Precautionary Procedure 1 Cover extended roof working area with an imperm
83. od aar as e eee 10 Install Gas Piping eenig pet oi gees doors 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 rus suk et ta 15 START UP s ss a phasi a ayu wasiq 15 26 Unit Start Up and Troubleshooting 15 Sequence of Operation niria C 0 0 0 0 pik y oi eee 20 24 Check for Refrigerant Leaks 0 0 0 0 0 0 0 0 00 005 25 Start Up Adjustfmenfs 25 Checking Cooling and Heating Control Operation 23 Checking and Adjusting Refrigerant Charge 25 A05307 Fig 1 Unit 48XL Re frigerant Charge sssassvssa crat rene atada 26 AS A ib hehe ees ee ea ete ae ae ee 26 Low Charge Cooling uuu ee ween lin i Sue soar Pink 26 To Use Cooling Charging Charfs 26 Non Communicating Emergency Cooling Heating Mode 26 MAINTENANCE sS E eh 5 atu ia 28 30 Ait O i sts RN 28 Indoor Fan and Motor 0 ee eee 28 Inducer Blower voice ae a Bs ee 28 LM SWI Cheeni a sos ane ate etd Mie eo wos wah a OS 28 Burner TENOR Lk aya N a be 28 Matt Burners 20 tt ais E CE ANA eee ee 28 Inducer Pressure Switch r
84. oor fan has been ON for 30 minutes Fan is turned off to allow refrigerant system to stabilize In low stage fan is off when outdoor coil temp is lt outdoor air temperature plus 1 F 6 C or outdoor fan has been ON for 30 minutes Fan is turned off to allow refrigerant system to stabilize In high stage and low stage fan is on when outdoor coil temp gt outdoor air temperature plus 25 F 13 8 C or outdoor coil temp gt 80 F 27 C or if outdoor fan has been OFF for 30 minutes Fan is turned on to allow refrigerant system to stabilize Low pressure switch is ignored for first 3 minutes during low ambient start up After 3 minutes if LPS trips then outdoor fan motor is turned off for 10 minutes with the compressor running If LPS closes within 10 minutes then cooling continues with the outdoor fan cycling per the coil temperature routine listed above for the remainder of the cooling cycle If the LPS does not close within 10 minutes then the normal LPS trip response shut down cooling operation and generate LPS trip error will occur DEHUMIDIFICATION MODE This Infinity system can be used to dehumidify the living space See UI Installation Instructions for more details SEQUENCE OF OPERATION GAS HEAT NOTE Infinity control must be grounded for proper operation or control will lock out NOTE Ifa power interruption occurs during a call for heat the control will start a 90 second blower only ON period two seconds after
85. otor will shut itself down and wait for communications to be reestablished D Furnace Control Troubleshooting Furnace control faults indicated by flashing codes on the amber system STATUS LED can be resolved using troubleshooting information provided below Codes are listed in order of their priority highest to lowest Though multiple faults can exist at any time only the highest priority code will be displayed on STATUS LED Clearing the indicated fault when multiple faults exist will cause the next highest priority Status Code to be flashed AH existing faults as well as a fault history can be viewed at UI STATUS CODE CONTINUOUS OFF Check for 230 VAC at L1 and 12 and 24 VAC at SEC 1 and SEC 2 STATUS CODE CONTINUOUS ON Control has 24 VAC power STATUS CODE 11 NO PREVIOUS CODE Stored status codes are erased automatically after 72 hours STATUS CODE 12 BLOWER ON AFTER POWER UP 230 VAC or 24 VAC Blower runs for 90 seconds if unit is powered up during a call for heat R W W1 closed or R W W1 opens during blower on delay period STATUS CODE 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if a limit or flame rollout switch is open longer than 3 minutes or 10 successive limit trips occurred during high heat Control will auto reset after three hours Refer to status code 33 STATUS CODE 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to status code 34 STATUS CODE 15 BLOWER MOTOR LOCKOUT Indicates th
86. ower off delay Check for excessive wind restricted vent defective inducer motor defective pressure switch lower inducer voltage 230VAC inadequate combustion air supply disconnected or obstructed pressure tubing or low inlet gas pressure if LGPS used STATUS CODE 33 LIMIT CIRCUIT FAULT Indicates a limit or flame rollout switch is open Blower will run for 4 minutes or until open switch remakes whichever is longer If open longer than 3 minutes code changes to lockout 13 If open less than 3 minutes status code 33 continues to flash until blower shuts off Check for loose blower wheel restricted vent excessive wind dirty filter or restricted duct system defective switch or connections or inadequate combustion air supply flame roll out switch open STATUS CODE 34 IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for oxide buildup on flame sensor clean with fine steel wool proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal manual valve shutoff low inlet gas pressure control ground continuity gas valve defective or turned off flame sensor must not be grounded inadequate flame carryover or rough ignition or green yellow wire must be connected to unit sheet metal STATUS CODE 41 BLOWER MOTOR FAULT Indicates the blower failed to reach 250 RPM or t
87. pressors Power should be shut off if possible for most troubleshooting techniques Refrigerants present additional safety hazards 4 WARNING EXPLOSION FIRE HAZARD Failure to follow this warning could result in personal injury or death and or property damage Wear safety glasses and gloves when handling refrigerants Keep torches and other ignition sources away from refrigerants and oils The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll The scroll compressor has no dynamic suction or discharge valves and it is more tolerant of stresses caused by debris liquid slugging and flooded starts 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 The Copeland scroll compressor uses Mobil 3MA POE oil This is the only oil allowed for oil recharge Refrigerant System This step covers the refrigerant system of the 48XL including the compressor oil needed servicing systems on roofs containing synthetic materials the filter drier and refrigerant charging REFRIGERANT 4 WARNING UNIT OPERATION AND SAFETY HAZARD Failure t
88. red low stage rate is too low increase the manifold pressure to increase rate If the measured low stage rate is too high decrease the manifold pressure to decrease rate NOTE Double check that UI is running on low stage gas heat while clocking the low stage firing rate 4 Verify proper low stage gas heat temperature rise a Furnace must operate within rise range listed on rating plate b Select COMFORT or EFFICIENCY mode on UL COMFORT mode will provide a warmer supply air temperature while EFFICIENCY will provide lower gas consumption c Make sure access panel is re installed on the unit d Measure supply and return temperatures as close to the unit as possible Subtract the return temperature from the supply temperature to determine rise Rise should fall within the range specified on the rating plate 5 Adjust manifold pressure to obtain high stage input rate See Fig 19 a Set unit to run for 20 minutes in high stage gas heat operation using the INSTALLER CHECKOUT menu on the UL b Remove regulator adjustment cap from high stage gas valve pressure regulator See Fig 19 and turn high stage adjusting screw 3 16 or smaller flat tipped screwdriver counterclockwise out to decrease rate and clockwise in to increase input rate NOTE DO NOT set high stage manifold pressure less than 3 2 IN W C or more than 3 8 IN W C for natural gas If manifold pressure is outside this range change main b
89. side retard e Use hoses with 750 psig service pressure rating e Leak detectors should be designed to detect HFC refrigerant e Puron as with other HFCs is only compatible with POE oils e Vacuum pumps will not remove moisture from oil e Only use factory specified liquid line filter driers with rated working pressures no less than 600 psig e Do not install a suction line filter drier in liquid line POE oils absorb moisture rapidly Do not expose oil to atmosphere e POE oils may cause damage to certain plastics and roofing materials e Wrap all filter driers and service valves with wet cloth when brazing A Puron liquid line filter drier is required on every unit Do not use an R 22 TXV e Never open system to atmosphere while it is under a vacuum When system must be opened for service break vacuum with dry nitrogen and replace filter driers Do not vent Puron into the atmosphere Observe all warnings cautions and bold text Do not leave Puron suction line driers in place for more than 72 hrs Ww Ww Table 9 Troubleshooting Chart SYMPTOM CAUSE REMEDY Compressor and outdoor fan will not start Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor transformer control relay or high pressure loss of charge or low pressure switch Replace component nsufficient line voltage Deter
90. t in personal injury or death After disconnecting power from the ECM motor wait at least 5 minutes before removing the control section Internal capacitors require time to discharge Before proceeding to replace a motor control module 1 Check motor winding section to be sure it is functional 2 Remove motor control module section and unplug winding plug Motor shaft should turn freely resistance between any two motor leads should be similar and resistance between any motor lead and unpainted motor end should exceed 100 000 ohms 3 Failing any of these tests entire ECM motor must be replaced 4 Passing all of the tests motor control module alone can be replaced MOTOR TURNS SLOWLY 1 Low static pressure loading of blower while access panel is removed will cause blower to run slowly Particularly at low airflow requests This is normal do not assume a fault exists N Recheck airflow and system static pressure using UI service screens with access panel in place NOTE Blower motor faults will not cause a lockout of blower operation The fan coil control will attempt to run the blower motor as long as UI maintains a demand for airflow The control will not operate electric heaters while a fault condition exists The control communicates with the motor at least once every five seconds even when the motor is idle If during operation the control does not communicate with the motor for more than 25 seconds the m
91. ter Pressure Drop Table IN W C FILTER SIZE CFM in mm 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 20X20X1 508x508x25 0 05 0 07 0 08 0 1 0 12 0 13 0 14 0 15 24X30X1 610x762x25 0 05 0 6 0 07 0 07 0 08 0 09 0 1 a 24X36X1 610x914x25 0 06 0 07 0 07 0 08 0 09 0 09 0 10 0 11 0 12 0 13 0 14 0 14 IMPORTANT When evaluating the refrigerant charge an TO USE COOLING CHARGING CHARTS indicated adjustment to the specified factory charge must always be very minimal If a substantial adjustment is indicated an abnormal condition exists somewhere in the cooling system such as insufficient airflow across either coil or both coils REFRIGERANT CHARGE The amount of refrigerant charge is listed on the unit rating plate and or the physical data table Refer to the Refrigeration Service Techniques Manual Refrigerants Section NO CHARGE Check for leak Use standard evacuating techniques After evacuating system weigh in the specified amount of refrigerant refer to system rating plate LOW CHARGE COOLING Use Cooling Charging Chart Fig 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 the units to correct subcooling
92. til all electrical sources are disconnected and tagged Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals Never attempt to repair soldered connection while refrigerant system is under pressure Do not use torch to remove any component System contains oil and refrigerant under pressure To remove a component wear protective goggles and proceed as follows a Shut off gas supply to unit Shut off electrical power to unit and install lockout tag Relieve and reclaim all refrigerant from system using both high and low pressure ports Cut component connecting tubing with tubing cutter and remove component from unit Carefully unsweat remaining tubing stubs when Oil can ignite when exposed to flame Use the Start Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start up 1 Remove all access panels 2 Read and follow instructions on all DANGER WARNING CAUTION and INFORMATION labels attached to or shipped with unit 3 Make the following inspections a Inspect for shipping and handling damages such as broken lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a refrigerant leak Leak test all refrigerant tubing conne
93. tions RECEIVING AND INSTALLATION Check Equipment IDENTIFY UNIT The unit model number and serial number are printed on the unit informative plate Check this information against shipping papers INSPECT SHIPMENT Inspect for shipping damage while unit is still on shipping pallet If unit appears to be damaged or is torn loose from its anchorage have it examined by transportation inspectors before removal Forward claim papers directly to transportation company Manufacturer is not responsible for any damage incurred in transit Check all items against shipping list Immediately notify the nearest Carrier office if any item is missing To prevent loss or damage leave all parts in original packages until installation Provide Unit Support For hurricane tie downs contact distributor for details and PE Professional Engineering Certificate if required ROOF CURB Install accessory roof curb in accordance with instructions shipped with curb See Fig 4 Install insulation cant strips roofing and flashing Ductwork must be attached to curb IMPORTANT The gasketing of the unit to the roof curb is critical for a water tight seal Install gasketing material supplied with the roof curb Improperly applied gasketing also can result in air leaks and poor unit performance Curb should be level to within 1 4 in 6 35 m See Fig 2 This is necessary for unit drain to function properly Refer to accessory roof curb installation instructions
94. trol box Refer to additional information in the Start Up amp 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 A CAUTION EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation When servicing gas train do not hit or plug orifice spuds Removal of Gas Train To remove the gas train for servicing 1 Shut off main gas valve Shut off power to unit Son Remove unit access panel Disconnect gas piping at unit gas valve a Remove wires connected to gas valve Mark each wire Remove ignitor and sensor wires at the ignitor module sD Remove the mounting screw that attaches the burner rack to the unit base 8 Slide the burner rack out of the unit 9 To reinstall reverse the procedure outlined above Inducer Pressure Switch Inspect pressure switch connections Inspect pressure switch tube for cracks or restrictions Replace if needed 44 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect and tag electrical power to the unit before cleaning and lubricating the blower motor and wheel Outdoor Coil Indoor Coil and Condensate Drain Pan Inspect the condenser coil evaporator coil
95. ts against low suction pressures caused by such events as loss of charge low airflow across indoor coil dirty filters etc It opens if the system pressure drops to about 20 psig If system pressure is above this switch should be closed High Pressure Switches HPS HPS2 The high pressure switches are located on the discharge line and protects against excessive condenser coil pressure HPS opens at 29 670 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 O 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 com
96. urner orifices c Re install high stage regulator adjustment cap d Leave manometer connected 6 Verify natural gas high stage input rate a Turn off all other gas appliances and pilots served by the gas meter b If unit is not running set unit to run for 20 minutes in high stage gas heat operation using the INSTALLER CHECKOUT menu on the UI c Record number of seconds for gas meter to complete 1 revolution d Divide number of seconds in step c into 3600 number of seconds in 1 hour e Multiply result of step d by the number of cubic feet shown for one revolution of test dial to obtain cubic feet of gas flow per hour f Multiply result of step f by Btu heating value of the gas to obtain total measured input shown in Table 4 Consult the local gas supplier if the heating value of gas is not known EXAMPLE Assume a 90 000 high stage input unit is being installed Assume that the size of the dial is 2 cubic ft one revolution takes 84 sec and the heating value of the gas is 1050 Btu ft3 Proceed as follows a 84 sec to complete one revolution b 3600 84 42 9 c 42 9 x 2 85 8 ft3 of gas flow hr d 85 8 x 1050 90 090 Btuh input In this example the nominal input rate for high stage is 90 000 Btu hr so the high stage manifold pressure is correctly set If the measured high stage rate is too low increase the manifold pressure to increase rate If the measured high stage rate is too high decrease t
97. uspected to have been re drilled check orifice hole with a numbered drill bit of the correct size Never re drill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics 3 Verify natural gas low stage input rate a Turn off all other gas appliances and pilots served by the gas meter b If unit is not running set unit to run for 20 minutes in low stage gas heat operation using the INSTALLER CHECKOUT menu on the UI c Record number of seconds for gas meter to complete one revolution d Divide number of seconds in step c into 3600 number of seconds in 1 hour e Multiply result of step d by the number of cubic feet shown for one revolution of test dial to obtain cubic feet of gas flow per hour f Multiply result of step f by Btu heating value of the gas to obtain total measured input shown in Table 4 Consult the local gas supplier if the heating value of gas is not known EXAMPLE Assume a 90 000 high stage input unit is being installed Assume that the size of the dial is 2 cubic ft one revolution takes 129 sec and the heating value of the gas is 1050 Btu ft3 Proceed as follows 23 a 129 sec to complete one revolution b 3600 129 27 9 c 27 9 x 2 55 8 ft3 of gas flow hr d 55 8 x 1050 58 590 Btuh input In this example the nominal input rate for low stage is 58 500 Btu hr so the low stage manifold pressure is correctly set If the measu
98. y fasten all panels and covers 3 Tighten service valve stem caps to 1 2 turn past finger tight 4 Leave Users Manual with owner Explain system operation and periodic maintenance requirements outlined in manual 5 Fill out Start Up Checklist located at the back of this manual and place in customer file CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure periodic maintenance must be performed on this equipment Frequency of maintenance may vary depending upon geographic areas such as coastal applications See Users Manual for information UY N AIR CONDITIONER WITH PURON REFRIGERATION SECTION QUICK REFERENCE GUIDE Puron refrigerant operates at 50 70 percent higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to operate with Puron Puron refrigerant cylinders are rose colored e Puron refrigerant cylinders manufactured prior to March 1 1999 have a dip tube that allows liquid to flow out of cylinder in upright position Cylinders manufactured March 1 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid to flow e Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 e Puron systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose e Manifold sets should be 750 psig high side and 200 psig low side with 520 psig low

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