Carrier Infinity 48DU-030 User manual

Turn to the Expertd
Installation Instructions
IMPORTANT: OAT sensor must be field installed. See
Accessory Installation for more details.
IMPORTANT: This Infinity _unit is designed for use with an
Infinity User Interface.
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
Page
SAFETY CONSIDERATIONS ........................ 2
INTRODUCTION .................................. 2
RECEIVING AND INSTALLATION ................ 2-12
Check Equipment ................................. 2
Identify Unit ................................... 2
Inspect Shipment ................................ 2
Provide Unit Support .............................. 2
Roof Curb ..................................... 2
Slab Mount .................................... 2
Ground Mount ................................. 2
Provide Clearances ................................ 7
Rig and Place Unit ................................ 7
Inspection ..................................... 8
Introduction .................................... 8
Use of Rigging Bracket ........................... 8
Select and Install Ductwork .......................... 8
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units ......................... 9
Provide for Condensate Disposal .................... 10
Install Flue Hood ................................. 10
Install Gas Piping ................................ 10
Install Electrical Connections ....................... 11
High- Voltage Connections ....................... 11
Routing Power Leads Into Unit .................... 12
Connecting Ground Lead to Ground Screw . ......... 12
Routing Control Power Wires .................... 12
Accessory Installation ........................... 12
Special Procedures for 208-v Operation ............. 12
PRE-START-UP .................................. 15
START-UP .................................... 15-25
Unit Start-Up and Troubleshooting .................. 15
Sequence of Operation ......................... 19-24
Check for Refrigerant Leaks ........................ 24
Start-Up Adjustments ............................. 24
Checking Cooling and Heating Control Operation ..... 25
Checking and Adjusting Refrigerant Charge .......... 25
Refrigerant Charge ............................. 25
No Charge .................................... 25
Low Charge Cooling ............................ 25
To Use Cooling Charging (;harts ................... 25
Non-Comnmnicating Emergency Cooling/Heating Mode . 25
MAINTENANCE ............................... 27-29
Air Filter ....................................... 27
Indoor Fan and Motor ............................. 27
Inducer Blower .................................. 27
Limit Switch .................................... 27
C99001
Fig. 1 - Unit 48DU
Burner Ignition .................................. 27
Main Burners ................................... 27
Inducer Pressure Switch ........................... 27
Outdoor Coil. Indoor Coil, and Condensate Drain Pan .... 28
Outdoor Fan .................................... 28
Electrical Controls and Wiring ...................... 28
Refrigerant Circuit ................................ 28
Indoor Airflow . ................................. 28
Pressure Switches ................................ 28
Loss-of-Charge Switch ........................... 28
High-Pressure Switches ........................... 28
Copeland Scroll Compressor (Puron _: Refrigerant) ....... 29
Refrigerant System ............................... 29
Refrigerant ................................... 29
Compressor Oil ................................ 29
Servicing Systems on Roofs with Synthetic Materials ... 29
Liquid-Line Filter Drier ......................... 29
Puron (R-410A) Refrigerant Charging .............. 29
TROUBLESHOOTING .......................... 29-31
FINAL CHECKS .................................. 31
CARE AND MAINTENANCE ....................... 31
START-UP CHECKLIST ........................... 35
SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due to
mechanical and electrical components. Only trained and qualified
personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions, such
as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. When working on this
equipment, observe precautions in the literature, on tags, and on
labels attached to or shipped with the unit and other safety
precautions that may apply.

Followallsafetycodes.Installationmustbeincompliancewith
localandnationalbuildingcodes.Wearsafetyglasses,protective
clothing,andworkgloves.Havefireextinguisheravailable.Read
theseinstructionsthoroughlyandfollowallwarningsorcautions
includedinliteratureandattachedtotheunit.
Recognizesafetyinformation.Thisisthesafety-alertsymbol_.
Whenyouseethissymbolontheunitandininstructionsormanuals,
bealerttothepotentialforpersonalinjury.Understandthesesignal
words:DANGER.WARNING,andCAUTION.Thesewordsare
usedwiththesafety-alertsymbol.DANGERidentifiesthemostse-
rioushazardswhichwillresultinseverepersonalinjuryordeath.
WARNINGsignifieshazardswhichcould result in personal injury
or death. CAUTION is used to identify unsafe practices which may
result in minor personal injury or product and property damage.
NOTE is used to highlight suggestions which will result in en-
hanced installation, reliability, or operation.
Always install furnace to operate within the intended temperature
rise range with a duct system which has an external static pressure
within the allowable range, as specified in "Indoor Airflow Adjust-
ments" section of these instructions. See furnace rating plate.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. Turn off accessory heater power switch if applicable.
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury
or equipment damage.
Puron (R-410A) systems operate at higher pressures than
standard R-22 systems. DO NOT use R-22 service
equipment or components on Puron (R-410A) equipment.
Ensure service equipment is rated for Puron {R-410A).
INTRODUCTION
The 48DU packaged unit is a fully self-contained combination
Category I gas heating/electric air conditioner designed for outdoor
installation (See Fig. 1). Standard units are shipped in a
horizontal-discharge configuration for installation on a
ground-level slab or directly on the ground if local codes permit.
Standard units can be converted to downflow (vertical) discharge
configurations for rooftop applications.
Models with an N in the fifth position of the model number are
dedicated Low NOx units designed for California installations.
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory and must be installed in California Air
Quality Management Districts or any other regions in North
America where a Low NOx rule exists.
NOTE: Low NOx requirements apply only to natural gas
installations.
RECEIVING AND INSTALLATION
Step 1--Check Equipment
IDENTIFY UNIT
The unit model number and serial number are printed on the unit
informative plate. Check this information against shipping papers.
INSPECT SHIPMENT
Inspect for shipping damage while unit is still on shipping pallet. If
unit appears to be damaged or is torn loose from its anchorage, have
it examined by transportation inspectors before removal. Forward
claim papers directly to transportation company. Manufacturer is
not responsible for any damage incurred in transit. Check all items
against shipping list. Immediately notify the nearest Carrier office
if any item is missing. To prevent loss or damage, leave all parts in
original packages until installation.
Step 2--Provide Unit Support
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate, if required.
ROOF CURB
Install accessory roof curb in accordance with instructions shipped
with curb (See Fig. 4). Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a water tight seal. Install gasketing material supplied with the
roof curb. Improperly applied gasketing also can result in air leaks
and poor unit performance.
Curb should be level to within 1/4 in. (See Fig. 2). This is necessau
for unit drain to function properly. Refer to accessory roof curb
installation instructions for additional information as required.
3MAXIMUMALLOWABLE
DIFFERENCE(in,)
B A-B B-C A-C
1/4 1/4 1/4
C99065
Fig. 2 - Unit Leveling Tolerances
SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of 4
in. thick with 2 in. above grade. The slab should extend
approximately 2 in. beyond the casing on all 4 sides of the unit (See
Fig. 3). Do not secure the unit to the slab except when required by
local codes.
7
EVAR COIl COND COIL
Fig. 3- Slab Mounting Detail
C99096
GROUND MOUNT
The unit may be installed either on a slab or placed directly on the
ground if local codes permit. Place the unit on level ground prepared
with gravel for condensate discharge.

Roof Curb for Small Cabinet
Note A: When unit mounting screw is used,
retainer bracket must also be used,
Roof Curb for Large Cabinet
Note A: When unit mounting screw is used,
retainer bracket must also be used,
UNIT SIZE
024-030
036-060
E
Long
Support
Support
A
R/A
\\\\\ _Gasket around _
duct
S/A
/2
/
insulated
deck pan Gasket around
outer edge \ \
\\,\
NOTES:
ODS CATALOG A B
NUMBER IN. (MM) IN. (MM)
CPRFCURB008A00 8 (203) 11 (279)
CPRFCURB00FA00 14 (356) 11 (279)
CPRFCURB008A00 8 (203) 16-3/16 (411)
CPRFCURB009A00 14 (356) 16-3/16 (411)
[. Roof curb must be set up for unit being installed.
C
IN. (MM)
16-1/2 (419)
16-1/2 (419)
17-3/8 (441)
17-3/8 (441)
D
IN. (MM)
28-3/4 (730)
28-3/4 (730)
40-1/4 (1022)
40-1/4 (1022)
E
IN. (MM)
30-3/8 (771)
30-3/8 (771)
41-15/16 (1065)
41-15/16 (1065)
F
IN. (MM)
44-5/16 (1126)
44-5/16 (1126)
44-7/16 (1129)
44-7/16 (1129)
A05308
G
IN. (MM)
45-15/16 (1167)
45-15/16 (1167)
46 - 1/16 (1169)
46-1/16 (1169)
2. Seat strip must be applied, as required, to unit being installed.
3. Dimensions are in inches.
4. Dimension in ( )are in millimeters.
5. Roof curb is made of 16 gauge steel.
6. Attach ductwork to curb (flanges of duct rest on curb).
7. Inadated panels: I in. thick fiberglass 1 lb. density.
S. When unit mounting screw is used (see Note A). a retainer bracket must be used as well. This bracket must also be used when required by code for hurricane or seismic
conditions. This bracket is available through Micrometl.
Fig. 4 - Roof Curb Dimensions

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UNIT SIZE
NOMINAL CAPACITY (ton)
OPERATING WEIGHT 0b,)
COMPRESSORS
Quantity
REFmGERANT: PURON (R-410A)
Quantity (lb.)
REFRIGERANT METERING DEVICE
Size
Part Number
OUTDOOR COiL
Rows.Sins/in.
Face Area (sq ft)
OUTDOOR FAN
Nominal Cfm
Diameter (in,)
Motor Hp (Rpm)
INDOOR COiL
Rows..,Fins/in.
Face Area (sq ft)
INDOOR FAN
Nominal Airflow (Cfm)
Comfort
Efficiency
Max
Furnace (gas ht,) airflow-Low Stage
Furnace (gas ht,) airflow-High Stage
Size (in,)
Motor HP (RPM)
FURNACE SECTION*
Burner Orifice No, (Qty,.,Drill Size)
Natural Gas
HiGH =PRESSURE SWITCH (peig)
Cut-out
Reset (Auto)
HIGH=PRESSURE SWITCH 2 (psi9)
(Compressor Solenoid)
Cut-out
Reset (Auto)
LOSS-OF-CHARGE /
LOW-PRESSURE SWITCH
(Liquid Lh_e) (psig)
Cut-out
Reset (auto)
RETURN=AIR FILTERS (in.)1-
Throwaway
Contimled next page,
Table 1--Physical Data - Unit 48DU
024040 024060 030040 030060 036060 036090 042060 042090
2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2
398 401 403 408 485 493 507 515
2-Stage Scroll
10.1 10.1 11.3 11.3 9,5 9,5 13.8 13.8
TXV
2Ton 2Ton 3Ton 3Ton 3Ton 3Ton 4Ton 4Ton
EA36YD129 EA36YD129 EA36YD139 EA36YD139 EA36YD139 EA36YD139 EA36YD149 EA36YD149
2.,,21 2.,,21 2.,,21 2.,,21 2.,,21 2.,,21 2.,,21 2.,,21
13.8 13.8 15.3 15.3 17.5 17.5 19.4 19.4
2700 2700 2700 2700 2800 2800 2800 2800
22 22 22 22 22 22 22 22
I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825) I/8 (825)
3.,,17 3.,,17 3.,,17 3.,,17 3.,,17 3.,,17 3.,,17 3.,,17
3,7 3,7 3,7 3,7 4,7 4,7 4,7 4,7
7OO
8OO
Variable based on Comfort Rollback(see UserlnterMceinstructionsfor moreinformaion).
700 875 875 1050 1050
800 1000 1000 1200 1200
475
844
10x10
1/2
727
1120
10x10
1/2
745
1120
11x10
3/4
875
1410
11x10
3/4
475
844
10xl0
1/2
727
1120
10x10
1/2
1225
1400
745
1120
11x10
3/4
1225
1400
875
1410
11x10
3/4
2.,,44 3.,,44 2.,,44 3.,,44 3.,,44 3.,,38 3.,,44 3.,,38
870 ±10
470 ± 25
585 ±15
455 ±15
25 ± 5
55 ± 5
90x24x1 90x24x1 90x24x1 90x24x1 94x30x1 94x30x1 94x36x1 94x36x1

UNIT SIZE
NOMINAL CAPACITY (ton)
OPERATING WEIGHT (lb.)
COMPRESSORS
Quantity
REFRIGERANT," PURON (R=41OA)
Quantity (lb.)
REFRIGERANT METERING DEVICE
Size
Part Number
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
Motor Hp (Rpm)
OUTDOOR COIL
Rows..,Fins/in.
Face Area (sq ft)
INDOOR COIL
Rows._Fins/in.
Face Area (sq ft)
INDOOR FAN
Nominal Airflow (Cfm)
Comfort
Efficiency
Max
Furnace (gas ht.) airflow-Low Stage
Furnace (gas ht.) airflow-High Stage
Size (In.)
Motor HP (RPM)
FURNACE SECTION*
Burner Orifice No, (Qty,.,DriH Size}
Natural Gas
HmGH-PRESSURE SWITCH (psig)
Cut-out
Reset (Auto)
HmGH=PRESSURE SWITCH 2 (psi9)
(Compressor Solenoid)
Cut-out
Reset (Auto)
LOSS=OF=CHARGE /
LOW=PRESSURE SWITCH
(Liquid Line) (psig)
Cut-out
Reset (auto)
RETURN-AIR FILTERS (in.)f
Throwaway
Based on altitude of 0 to 2000 ft.
Table 1--Physical Data (Can't) - Unit 48DU
048090 048115 048130
4445
521 521 521 572
2-Stage Scroll
1
15.3 15.3 15.3 15.8
TXV
4 Ton 4 Ton 5 Ton
EA36YD149 EA36YD149
060090 060115 080130
5 5
572 572
15.8 15.8
4Ton 5Ton 5Ton
EA36YD149 EA36YD159 EA36YD159 EA36YD159
3300 3300 3300 3300 3300 3300
22 22 22 22 22 22
1/4 (1100) 1/4 (1100) 1/4 (1100) 1/3 (1110) 1/3 (1110) 1/3 (1110)
2,.,21 2._21 2._21 2..,21 2..,21 2...21
19.4 19.4 19.4 23.3 23.3 23.3
3..,17 3.,.17 3.,.17 4..,17 4..,17 4.,.17
5.7 5.7 5.7 5.7 5.7 5.7
Variable based on Comfort Rollback(see Userlnterfaceinstructionsfor moreinformation),
1400 1400 1400 1750
1600 1600 1600 2000
1215
1885
11x10
8/4
1255
1875
11x10
3/4
845
1300
11x10
1
815
1385
11x10
3/4
1750 1750
2000 2000
1215
1910
11x10
1
3...33 3...31
1255
1920
11x10
1
3...38 3...33 3...31 3...38
670 ± 10
470 ± 25
565 ± 15
455 ±15
25 ± 5
55 ± 5
24x36x1 24x36x1 24x36x1 24x38x1 24x36x1 24x36x1
fRequired filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/min
ute for throwaway type or 450 ftiminute for high capacity type. Air filter pressure drop for non standard filters illust not exceed 0,08 in, we.
Step 3--Provide Clearances
The required minimum service clearances are shown in Fig. 5 and
6. Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 48 in.
above the unit top. The maximum horizontal extension of a partial
overhang must not exceed 48 in.
IMPORTANT: Do not restrict outdoor airflow. An air restriction at
either the outdoor-air inlet or the fan discharge may be detrimental
to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab-mounted units
should be at least 4 in. above the highest expected water and runoff
levels. Do not use unit if it has been under water.
Step 4_Rig and Place Unit
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated structures.
etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment, and
any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.

n
INSPECTION
Prior to initial use, and at monthly intervals, all rigging brackets and
straps should be visually inspected for any damage, evidence of
wear, structural deformation, or cracks. Particular attention should
be paid to excessive wear at hoist hooking points and load support
areas. Brackets or straps showing any kind of wear in these areas
must not be used and should be discarded.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Befnre installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. Turn off accessory heater power switch if applicable.
Tag disconnect switch with a suitable warning label.
UNIT FALLING HAZARD
Failure to fnllow this warning could result in personal injury
or death.
Never stand beneath rigged units or lift over people.
INTRODUCTION
The lifting/rigging bracket is engineered and designed to be
installed only on Small Packaged Products.
This bracket is to be used to rigdift a Small Packaged Product onto
roofs or other elevated structures.
PROPERTY DAMAGE HAZARD
Failure to fnllow this warning could result in personal
injury/death or property damage.
Rigging brackets for one unit use only, When removing a
unit at the end of its useful life, use a new set of brackets.
USE OF RIGGING BRACKET
Field Installation of Ri_in_ Bracket
1. If applicable, remove unit from shipping carton. Leave top
shipping skid on the unit for use as a spreader bar to prevent
the rigging straps from damaging the unit. If the skid is not
available, use a spreader bar of sufficient length to protect the
unit from damage.
2. Remove 4 screws in unit corner posts.
3. Attach each of the 4 metal rigging brackets under the panel
rain lip (See Fig. 7). Use the screws removed in step 2 above
to secure the brackets to the unit.
PROPERTY DAMAGE HAZARD
Failure to fnllow this warning could result in personal
injury/death or property damage.
Rigging bracket MUST be under the rain lip to provkle
adequate lifting.
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or prnperty damage.
Do not strip screws when re-securing the unit. If a screw is
stripped, replace the stripped one with a larger diameter screw
(included).
Ri_in_/Liftin_ of Unit
1. Bend top of brackets down approximately 30 degrees from
the corner posts.
2. Attach straps of equal length to the rigging brackets at
opposite ends of the unit. Be sure straps are rated to hold the
weight of the unit (See Fig. 7).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level
with the ground.
4. After unit is securely in place detach rigging straps. Remove
corner posts, screws, and rigging brackets then reinstall
screws.
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
When straps are taut, the clevis should be a minimum of 36
inches above the unit top cover.
After the unit is placed on the roof curb or mounting pad, remove
the top crating.
Step 5--Select and Install Ductwork
The design and installation of the duct system must be in accordance
with the standards of the NFPA for installation of non-residence
type air conditioning and ventilating systems. NFPA 90A or
residence type. NFPA 90B and/or local codes and ordinances.
Select and size ductwork, supply- air registers, and return air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply- and return-air openings on
the side of the unit.
PERSONAL AND PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal injury,
death and/or property damage.
For vertical supply and return units, tools or parts could drop
into ductwork, therefore, install a 90 degree turn in the return
ductwork between the unit and the conditioned space. If a 90
degree elbow cannot be installed, then a grille of sufficient
strength and density should be installed to prevent objects
from falling into the conditioned space. Units with electric
heaters require 90 degree elbow in supply duct.
When designing and installing ductwork, consider the following:
1. All units should have field- supplied filters or accessory filter
rack installed in the return-air side of the unit.
Recommended sizes for filters are shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.

MiNiMUMHEIGHT: 36'
DETAILA
SEEDETAIL AJr
UNiTHEIGHT
J
RIGGING
CABINET MODEL WEIGHT A B C D
48DU-024 420 90 90 83 155
Small 48DU-030 427 92 92 85 158
48DU-036 515 106 119 97 193
48DU-042 537 118 84 144 192
Large 48DU-048 543 120 90 144 189
48DU-060 594 130 95 159 210 Y
.
Fig. 7 - Suggested Rigging
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather tight and airtight seal. When electric heat is installed,
use fireproof canvas (or similar heat resistant material) connector
between ductwork and unit discharge connection. If flexible duct is
used. insert a sheet metal sleeve inside duct. Heat resistant duct
connector (or sheet metal sleeve) must extend 24-in. from electric
heater element.
3. Size ductwork for max possible air flow (See Table 1).
4. Seal, insulate, and weatherproof all external ductwork. Seal,
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.
A05161B /
©XC
A07113
CONVERTING HORIZONTAL DISCHARGE UNITS TO
DOWNFLOW (VERTICAL) DISCHARGE UNITS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. Turn off accessory heater power switch if applicable.
1. Open all electrical disconnects and install lockout tag before
starting any service work.
2. Remove side duct covers to access bottom return and supply
knockouts.
NOTE: These panels are held in place with tabs similar to an
electrical knockout.
3. Use a screwdriver and hammer to remove the panels in the
bottom of the composite unit base.
4. Ensure the side duct covers are in place to block off the
horizontal air openings (See Fig. 8).

Step6--ProvideforCondensateDisposal
NOTE:Ensurethatcondensate-waterdisposalmethodscomply
withlocalcodes,restrictions,andpractices.
Theunitsdisposeofcondensatethrougha3/4-in.NPTfemale
fittingthatexitsonthecompressorendof the unit. Condensate water
can be drained directly onto the roof in rooftop installations (where
permitted) or onto a gravel apron in ground level installations.
Install a field-supplied condensate trap at end of condensate
connection to ensure proper drainage. Make sure that the outlet of
the trap is at least 1 in. lower than the drain-pan condensate
connection to prevent the pan from overflowing. Prime the trap with
water. When using a gravel apron, make sure it slopes away from the
unit.
If the installation requires draining the condensate water away from
the unit, install a field-supplied 2-in. trap at the condensate
connection to ensure proper drainage. Condensate trap is available
as an accessory or is field-supplied. Make sure that the outlet of the
trap is at least 1 in. lower than the unit drain-pan condensate
connection to prevent the pan from overflowing. Connect a drain
trough using a minimum of field-supplied 3/4 -in. PVC or
field-supplied 3/4 -in. copper pipe at outlet end of the 2 -in. trap
(See Fig. 9). Do not undersize the tube. Pitch the drain trough
downward at a slope of at least 1 in. for every 10 ft. of horizontal run.
Be sure to check the drain trough for leaks. Prime the trap at the
beginning of the cooling season start-up.
Step 7--Install Flue Hood
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
The venting system is designed to ensure proper venting. The
flue hood assembly nmst be installed as indicated in this
section of the unit installation instructions.
Install the flue hood as follows:
1. This installation must conform with local building codes and
with the National Fuel Gas Code (NFGC), ANSI Z223.1 (in
Canada, CAN/CGA B149.1, and B149.2) or NFPA
(National Fire Protection Association) latest revision. Refer
to provincial and local plumbing or wastewater codes and
other applicable local codes.
2. Remove flue hood from shipping location (inside the return
section of the blower compartment-See Fig. 8). Remove the
return duct cover to locate the flue hood. Remove two screws
on flue panel. Place flue hood assembly over flue panel.
Orient screw holes in flue hood with holes in the flue panel.
3. Secure flue hood to flue panel by inserting a single screw on
the top and the bottom of the hood.
SUPPLY
DUC,T
OPENING
RETURN
DUCT
OPENING
Fig, 8 - 48DU with Duct Covers On
C99011
10
1" (25rnm) MIN
Fig. 9 - Condensate Trap
C99013
Step 8---Install Gas Piping
The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2-in. FPT
gas inlet on the gas valve.
Install a gas supply line that runs to the heating section. Refer to
Table 2 and the current edition of NFGC in the U.S. and the current
NSCNGPIC in Canada. Do not use cast-iron pipe. It is
recommended that a black iron pipe is used. Check the local utility
for recommendations concerning existing lines. Size gas supply
piping for 0.5 in. wc maximum pressure drop. Never use pipe
smaller than the 1/2-in. FPT gas inlet on the unit gas valve.
For natural gas applications, the gas pressure at unit gas connection
must not be less than 4.0 in. wc or greater than 13 in. wc while the
unit is operating. For propane applications, refer to propane
conversion kit instructions.
A 1/8-in. NPT plugged tapping, accessible for test gauge
connection, must be installed immediately upstream of the gas
supply connection to the gas valve and downstream of manual
equipment shutoff valve.
When installing the gas supply line, observe local codes pertaining
to gas pipe installations. Refer to the NFGC ANSI Z223.1-2005
NFPA latest edition (in Canada, CAN/CGA B149.1).
NOTE:In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 ram).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T-handle valves.
4. The use of copper tubing for gas piping is NOT approved by
the state of Massachusetts.
In the absence of local building codes, adhere to the following
pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.
for every 15 ft of length to prevent traps. Grade all horizontal
runs downward to risers. Use risers to connect to heating
section and to meter.
2. Protect all segments of piping system against physical and
thermal damage. Support all piping with appropriate straps,
hangers, etc. Use a minimum of one hanger every 6 ft. For
pipe sizes larger than 1/2 in., follow recommendations of
national codes.
3. Apply joint compound (pipe dope) sparingly and only to
male threads of joint when making pipe connections. Use
only pipe dope that is resistant to action of liquefied
petroleum gases as specified by local and/or national codes.
Never use Teflon tape.
4. Install sediment trap in riser leading to heating section (See
Fig. 10). This drip leg functions as a trap for dirt and
condensate.
5. Install an accessible, external, manual main shutoff valve in
gas supply pipe within 6 ft of heating section.
6. Install ground-joint union close to heating section between
unit manual shutoff and external manual main shut off valve.

NOMINAL INTERNAL
IF{ON PiPE DIAMETER
SIZE (IN.) (iN.) 10 20 100 125 150 175 200
1/2 _622 175 120 50 44 40
3/4 _824 360 250 103 93 84 77 72
1 1.049 680 465 195 175 160 145 135
1-1/4 1.380 1400 950 400 360 325 300 280
1-1/2 1.610 2!00 1460 620 550 500 460 430
Table 2--MaxhnumGas Flow Capacity*
LENGTH OF PIPE (FT)t
30 40 50 60 70 80 90
97 82 73 66 61 57 53
200 170 151 138 125 118 1!0
375 320 285 260 240 220 205
770 600 580 530 490 460 430
1180 990 900 810 750 690 650
Capacity of pipe in cu ft of gas per hr for gas presalre of 0.5 psig or tess. Pressure drop of 0,5 in, we (based on a 0.60 specific gravity gas). Refer to Table, National Fire Protec
tion Association NFPA 54.
This length includes an ordinary number of fittings.
IN
OUT_
_¢_ CAP
C99020
Fig. 10 -Sediment Trap
7. Pressure test all gas piping in accordance with local and
national plumbing and gas codes before connecting piping
to unit.
NOTE: Pressure test the gas supply system after the gas supply
piping is connected to the gas valve. The supply piping must be
disconnected from the gas valve during the 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.
Step 9---Install Electrical Connections
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, ANSI/NFPA American
National Standards Institute/National Fire Protection
Association (latest edition) (in Canada, Canadian Electrical
Code CSA C22.1) and local electrical codes.
HIGH-VOLTAGE CONNECTIONS
The unit must have a separate electrical service with a
field-supplied, waterproof disconnect switch mounted at. or within
sight from, the unit. Refer to the unit rating plate, NEC and local
codes for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing (See Table 3 for electrical data).
The field-supplied disconnect may be mounted on the unit over the
high-voltage inlet hole (See Fig. 5 and 6).
Operation of unit on improper line voltage constitutes abuse and
may cause unit damage that could affect warranty.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in fire, explosion,
personal injury, death and/or property damage.
• Connect gas pipe to unit using a backup wrench to avoid
damaging gas controls.
• Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections.
• Use proper length of pipe to avoid stress on gas control
manifold.
• If a flexible connector is required or allowed by authority
having jurisdiction, black iron pipe shall be installed at
furnace gas valve and extend a minimum of 2 in. outside
furnace casing.
•If codes allow a flexible connector, always use a new
connector. Do not use a connector which has previously
serviced another gas appliance.
8. Check for gas leaks at the field-installed and
factory-installed gas lines after all piping connections have
been completed. Use soap-and-water solution (or method
specified by local codes and/or regulations).
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the unit
being installed.
1. Make all electrical connections in accordance with NEC
ANSI/NFPA (latest edition) and local electrical codes
governing such wiring. In Canada. all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part i and applicable local
codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high-voltage power to unit is within operating
voltage range indicated on unit rating plate.
4. Insulate low-voltage wires for highest voltage contained
within conduit when low-voltage control wires are in same
conduit as high-voltage wires.
5. Do not damage internal components when drilling through
any panel to mount electrical hardware, conduit, etc.
11

ROUTINGPOWERLEADSINTOUNIT
Useonlycopperwirebetweendisconnectandunit.Thehigh
voltageleadsshouldbeinaconduituntiltheyentertheductpanel;
conduitterminationattheductpanelnmstbewatertight.Runthe
high-voltageleadsthroughthepowerentryknockoutonthepower
entrysidepanel.SeeFig.5and6forlocationandsize.For
single-phaseunits,connectleadstotheblackandyellowwires.
CONNECTINGGROUNDLEADTOGROUNDSCREW
Connectthegroundleadtothechassisusingthegroundscrewon
thecontrolplateneartheinducerswitch(SeeFig.13).
ROUTINOCONTROLPOWERWIRES
FordetailedinstructiononthelowvoltageconnectionstotheUser
Interface(UI),refertotheUIinstallationguide.
Formadrip-loopwiththecontrolleadsbeforeroutingthemintothe
unit.Routethelowvoltagecontrolleadsthroughgrommeted.
low-voltageholeprovidedintounit(SeeFig.5and6).Connectuser
interfaceleadstounitcontrolpowerleadsasshowninFig.14.
Theunittransformersupplies24-vpowerforcompletesystem
includingaccessoryelectricalheater.Transformerisfactorywired
for230-voperation.Ifsupplyvoltageis208-v.rewiretransformer
primaryasdescribedinSpecialProceduresfor208-vOperation
section.
Thefurnaceboardisfusedbyaboard-mountedautomotivefuse
placedinserieswithtransformerSEC1andRcircuit.TheCcircuit
oftransformercircuitisreferencedtochassisgroundthrougha
printedcircuitrunatSEC2andgasvalvegroundingwire.Checkto
be surecontrolboardis mountedsecurelyusingboth
factory-installedscrews.
ACCESSORYINSTALLATION
A.OutdoorAirThermistor(OAT)
NOTE:THE INSTALLATIONOF AN OUTDOOR
TEMPERATURESENSORUSINGTHE INFINITY
CONTROLBOARDOATTERMINALSISREQUIRED.
MANY INFINITYFEATURES(AUTOHUMIDITY
CONTROL,COMFORTROLLBACK,ETC.)WILLBE
LOSTIFTHEOATISNOTCONNECTED.
For detailed mounting instructions for the OAT sensm; please
refer to TSTATXXSEN01-B installation instructions (catalog
no. 63TS-TA13); Procedures 1 through 3.
The OAT input is used to supply outdoor temperature data for
system level functions and for temperature display on User Interface
(UI). Using two wires of the field-supplied thermostat wire cable.
wire the ends of the two black OAT pigtails. Wire the opposite ends
of these two wires to the OAT provided with the UI. There is no
polarity to be observed.
NOTE: Mis-wiring OAT inputs will not cause damage to either
Infinity control or thermistor. If the thermistor is wired incorrectly,
no reading will appear at UI. Re-wire thermistor correctly for
normal operation.
B. Humidifier Connections
The furnace control board terminal marked HUM is provided for
low voltage (24-vac) control of a humidifier. No humidistat is
required as UI monitors indoor humidity.
When commanded to operate humidifier, the unit control will
energize the HUM output to turn humidifier on and de-energize
HUM output to turn humidifier off. Wire HUM and COM terminals
directly to humidifier as shown in Fig. 14.
C. Electronic Air Cleaner
Electronic Air Cleaner terminals are provided on the Infinity
Control Board (EAC-1 and EAC-2). While these terminals can be
used to power a 230V EAC. it is recomnmnded that any EAC be
installed per the EAC installation instructions and connected
separately to a standard 115V or 230V outlet with an airflow sensor
to control operation of the EAC.
SPECIAL PROCEDURES FOR 208-V OPERATION
Be sure unit disconnect switch is open.
Disconnect the yellow primary lead from the transformer. See unit
wiring label (See Fig. 16).
Connect the yellow primary lead to the transformer terminal labeled
200-v.
INDOOR
THERMOSTAT
FROM
POWER __ _
SOURCE
Fig. 11 -Typical Installation
DISCONNECT
PER NEC
C99061
12

SINGLE-PHASE
CONNECTIONS
TO DISCONNECT
PER NEC
GROUND SCREW
(IN SPLICE BOX)
GROUND
LEAD
L1 ....... /Z_,===BLK--
L2
NOTE: Use copper wire only.
LEGEND
NEC - National Electrical Code
Field Wiring
_}( Splice Connections
Fig. 12 - Line Power Connections
A06299 I
HP/AC
Board
Board
Splice Box
i :
Fig. 13 -Control Plate
A06306
13

User Infinity Furn_c_ Infinity HPiAC
interface Board Board
I
|
|
|
LEGEND
Factory Wiring
OutdoorAirThermistor
(Supplied with IU)
FIELD CONNECTION
REQUIRED
(BLACK WIRES)
OCT
Outdoor Coil Thermistor
FACTORY CONNECTED
FACTORY WIRES PROVIDED
FOR FIELD CONNECTION
OF UTILITY CURTAILMENT
Fig. 14 - Control Voltage Wiring Connections A08301
UNIT V=PH_HZ
SIZE
024 208/230 1 60
030 208/230 1 60
036 208/230 1 60
042 208/230 1 60
048 208/230 1 60
060 208/230 1 60
VOLTAGE
RANGE
Min Max
187 253
187 253
187 253
187 253
187 253
187 253
Table 3--Electrical Data = Unit 48DU
OUTDOOR
COMPRESSOR FAN MOTOR
FLA
0.9
0.9
0.9
0.9
1.5
1.9
INDOOR FAN
MCA
18.0/18.0
22.8/22.8
28.5/28.5
28.5/28.5
34.7/34.7
4&1/4&1
RLA LRA
10.3 52.0
14.1 70.0
16.7 82.0
16.7 96.0
2! .2 96.0
25.6 118.0
MOTOR
FLA
4.3
4.3
6.8
6.8
6.8
9.1
POWER SUPPLY
MOCP
25/25
35/35
45/45
45/45
50/50
60/60
LEGEND
FLA Full Load Amps
LRA Locked Rotor Amps
MCA -- Minimum Circuit Amps
MOCP Maximum Overcurrent Protection
RLA Rated Load Amps
NOTES:
1. in compliance with NEC (National Electrical Code) requirements
for multimotor and combination load equipment (refer to NEC
Articles 430 and 440), the overcurrent protective de'ice for the
unit shall be Power Supply fuse. The CGA (Canadian Gas
Association) units may be fuse or circuit breaker
2. Minimum wire size is based on 60 C copper wire. Ifother than
60 C wire is used, or if length exceeds wire length in table,
determine size from NEC.
3. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply volt-
age is greater than 2%. Use the following formula to determine
the percentage of voltage imbalance
% Voltage imbalance
= 100x max vol_avera e volta e
average voltage
Heater capacity (kW) based on heater voltage of 208v & 240v.
-k I1power distibution voltage to unit varies from rated heater
voltage, heater kW will vary accordingly.
EXAMPLE: Supply voltage is 230-3-60.
A B C AB = 228 v
BC = 231 v
AC = 227 v
Average Voltage = 228 + 231 + 227
3
=686
3
= 229
Determine maximum deviation from average voltage.
(AB) 229 - 228 = 1 v
(BC) 231 - 229 = 2 v
(AC) 229- 227 = 2 v
Maximum deviation is 2 v.
Determine percent of ,voltage imbalance
2
% Voltage Imbalance = 100 x --
229
= 0.8%
This amount of phase imbalance is satisfactory as it is below the
maximum allowable 2%.
IMPORTANT: If the supply voltage phase imbalance is
more than 2%, contact your local electdc utility company
immediately.
14

PRE- START- UP
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death and/or property damage.
1. Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
2. Do not operate compressor or provide any electric power
to unit unless compressor terminal cover is in place and
secured.
3. Do not remove compressor terminal cover until all
electrical sources are disconnected and tagged.
4. Relieve and recover all refrigerant from system before
touching or disturbing anything inside terminal box if
refrigerant leak is suspected around compressor terminals.
5. Never attempt to repair soldered connection while
refrigerant system is under pressure.
6. Do not use torch to remove any component. System
contains oil and refrigerant under pressure.
7. To remove a component, wear protective goggles and
proceed as follows:
a. Shut off gas supply to unit.
b. Shut off electrical power to unit and install lockout
tag.
c. Relieve and reclaim all refrigerant from system
using both high- and low-pressure ports.
d. Cut component connecting tubing with tubing
cutter and remove component from unit.
e. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to flame.
Use the Start-Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial start-up:
1. Remove all access panels.
2. Read and follow instructions on all DANGER, WARNING,
CAUTION. and INFORMATION labels attached to, or
shipped with unit.
3. Make the following inspections:
a. Inspect for shipping and handling damages, such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections and on
unit base. Detecting oil generally indicates a refrigerant
leak. Leak test all refrigerant tubing connections using
electronic leak detector, or liquid-soap solution. If a
refrigerant leak is detected, see following Check for
Refrigerant Leaks section.
c. Inspect all field- and factory-wiring connections. Be
sure that connections are completed and tight.
d. Ensure wires do not touch refrigerant tubing or sharp
sheet metal edges.
e. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.
4. Verify the following conditions:
a. Make sure gas line is free of air. Before lighting the unit
for the first time, perform the following tasks with the gas
valve in the OFF position.
NOTE: If the gas supply pipe was not purged before connecting the
unit. it will be full of air. It is recommended that the ground joint
union be loosened, and the supply line be allowed to purge until the
odor of gas is detected. Never purge gas lines into a combustion
chamber. Immediately upon detection of gas odor, retighten the
union. Allow 5 minutes to elapse, then light unit.
5.
6.
b. Make sure that condenser-fan blade is correctly
positioned in fan orifice. Top 1/3 of condenser fan blade
should be within fan orifice venturi.
c. Ensure fan hub is positioned correctly with respect to
motor housing (See Fig. 23).
d. Make sure that air filter(s) is in place.
e. Make sure that condensate drain trap is filled with water
to ensure proper drainage.
f. Make sure that all tools and miscellaneous loose parts
have been removed.
Compressors are internally spring mounted. Do not loosen
or remove compressor holddown bolts.
Each unit system has two Schrader-type ports, one low-side
Schrader fitting located on the suction line, and one
high-side Schrader fitting located on the compressor
discharge line. Be sure that caps on the ports are tight.
START-UP
Step l--Unit Start-Up and Troubleshooting
NOTE: Always check high- and low-voltage supply to the unit
components. Check the integrity of the plug receptacle connections
and unit wiring harness prior to assuming a component failure.
A. LED Description
LEDs built into Infinity control boards provide installer or service
person information concerning operation and/or fault condition of
the unit controls and ECM motor. This information is also available
at the systenr UI in text with basic troubleshooting instructions.
Careful use of information displayed will reduce the need for
extensive manual troubleshooting.
Both the furnace and heat pump (HP)/air conditioner (AC) boards
have an amber LED and a green LED. On the HP/AC board, these
are located near the System Communications connector (ABCD)
(lower right corner of the HP/AC board as installed in the unit). On
the furnace board, these are located at the upper right side, adjacent
to the fuse. above the terminal block. The amber LED is the System
Status LED, labeled STATUS. The green LED, labeled COMM, is
used as an indicator of system communications status (See Fig. 15
and 17).
Status Codes will be displayed on the STATUS LED using the
following protocol:
1. The number of short flashes indicates first digit of code.
2. The number of long flashes indicates second digit of code.
3. A short flash is 0.25 seconds on. A long flash is 1 second on.
4. The time between flashes is 0.25 seconds.
5. The time between last short flash and first long flash is 1
second.
6. The LEDs will be off for 2.5 seconds before repeating code.
7. If multiple status codes are active concurrently, the highest
priority status code is displayed.
B. Control Start-Up and System Communications
Troubleshooting
On power up, green COMM LEDs will be turned off until
successful system communications are established (this should
happen within 10 seconds). Once communications with UI are
successful, both COMM LEDs will be lit and held on. At the same
time. amber STATUS LEDs will be lit and held continuously on
until a request for operating mode is received. The STATUS LED
will be on any time unit is in idle mode.
If, at any time. communications are not successful for a period
exceeding 2 minutes, the Infinity control will only allow emergency
heating or cooling operation using a common thermostat and the
terminal strip connections on the two control boards (See
15

Non-CommunicatingEmergencyCooling/HeatingMode)and
willdisplayStatusCode16,SystemCommunicationFault,on
amberSTATUSLED.Nofurthertroubleshootinginformationwill
beavailableatUIuntilcommunicationsarere-established.
IfeitherCOMMLEDdoesnotlightwithinpropertimeperiodand
statuscodesarenotdisplayed;
1.Checksystemtransformerhigh-andlow-voltagetobesure
thesystemispowered.
2.CheckABCDconnectiononbothboards.
3.Checkfuseonfurnaceboardtobesureitisnotblown.Iffuse
isopen,checksystemwiringbeforereplacingittobesurea
shortdoesnotcauseafailureofreplacementfuse.
IfCOMMLEDdoesnotlightwithinpropertimeperiodandstatus
codeisdisplayed:
1.ChecksystemwiringtobesureUI ispoweredand
connectionsaremadeAtoA,BtoB,etc.andwiringisnot
shorted.Miswiringor shortingof the ABCD
communicationswiringwill not allowsuccessful
communications.
NOTE:Shortingormiswiringlow-voltagesystemwiringwillnot
causedamagetounitcontrolorUIbutmaycauselowvoltagefuse
toopen.
C.Indoor Fan Motor Troubleshooting
The indoor fan is driven by an ECM motor consisting of two parts:
the control module and the motor winding section. Do not assume
motor or module is defective if it will not start. Use the designed-in
LED information aids and follow troubleshooting steps described
below before replacing motor control module or entire motor.
Motor control module is available as a replacement part.
VERIFY MOTOR WINDING SECTION
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
After disconnecting power from the ECM motor, wait at least
5 minutes before removing the control section. Internal
capacitors require time to discharge.
Before proceeding to replace a motor control module:
1. Check motor winding section to be sure it is functional.
2. Remove motor control module section and unplug winding
plug. Motor shaft should turn freely, resistance between any
two motor leads should be similar and resistance between
any motor lead and unpainted motor end should exceed
100,000 ohms.
3. Failing any of these tests, entire ECM motor must be
replaced.
4. Passing all of the tests, motor control module alone can be
replaced.
MOTOR TURNS SLOWLY
1. Low static pressure loading of blower while access panel is
removed will cause blower to run slowly. Particularly at low
airflow requests. This is normal, do not assume a fault exists.
2. Recheck airflow and system static pressure using UI service
screens with access panel in place.
NOTE: Blower motor faults will not cause a lockout of blower
operation. The fan coil control will attempt to run the blower motor
as long as UI maintains a demand for airflow. The control will not
operate electric heaters while a fault condition exists. The control
communicates with the motor at least once every five seconds, even
when the motor is idle. If, during operation, the control does not
communicate with the motor for more than 25 seconds, the motor
will shut itself down and wait for communications to be
reestablished.
D. Furnace Control Troubleshooting
Furnace control faults indicated by flashing codes on the amber
system STATUS LED can be resolved using troubleshooting
information provided below. Codes are listed in order of their
priority, highest to lowest. Though multiple faults can exist at any
time. only the highest priority code will be displayed on STATUS
LED. Clearing the indicated fault when multiple faults exist will
cause the next highest priority Status Code to be flashed. All
existing faults, as well as a fault history, can be viewed at UI.
STATUS CODE CONTINUOUS OFF
Check for 230 VAC at L1 and L2, and 24 VAC at SEC-1 and
SEC-2.
STATUS CODE CONTINUOUS ON
Control has 24 VAC power.
STATUS CODE 11 - NO PREVIOUS CODE
Stored status codes are erased automatically after 72 hours.
STATUS CODE 12 - BLOWER ON AFTER POWER UP
(230 VAC or 24 VAC) Blower runs for 90 seconds if unit is powered
up during a call for heat (R-W/W1 closed) or (R-W/W1 opens)
during blower on-delay period.
STATUS CODE 13 - LIMIT CIRCUIT LOCKOUT
Lockout occurs if a limit or flame rollout switch is open longer than
3 minutes or 10 successive limit trips occurred during high heat.
Control will auto reset after three hours. Refer to status code 33.
STATUS CODE 14 -IGNITION LOCKOUT
Control will auto reset after three hours. Refer to status code 34.
STATUS CODE 15 - BLOWER MOTOR LOCKOUT
Indicates the blower failed to reach 250 RPM or the blower failed
to communicate within 30 seconds after being turned ON in two
successive heating cycles. Control will auto reset after 3 hours. Refer
to status code 41.
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Fig. 15 - Detail of Furnace Board
A06026
16

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Fig. 16 - Wiring Schematic-48DU Single Phase
A06310
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17

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0
O0 l
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O0
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flquld Lille Sole*xoid
* SUPPLIED BY UTILITY PROVIDER
Fig. 17 - 2-Stage HP/AC Control Board
A05247
STATUS CODE 21 - GAS HEATING LOCKOUT
Control will NOT auto reset. Check for mis-wired gas valve or
defective control (valve relay).
STATUS CODE 22 - ABNORMAL FLAME-PROVING
SIGNAL
Flame is proved while gas valve is de-energized. Inducer will run
until fault is cleared. Check for leaky gas valve or stuck-open gas
valve.
STATUS (:ODE 23 - PRESSURE SWITCH DID NOT OPEN
Check for obstructed pressure tubing or pressure switch stuck
closed.
STATUS CODE 24 - SECONDARY VOLTAGE FUSE IS OPEN
Check for short circuit in secondary voltage (24VAC) wiring.
STATUS CODE 25 - INVALID MODEL SELECTION OR
SETUP ERROR
Indicates either the model plug is missing or incorrect. If code
flashes 4 times on power-up, control is defaulting to model
selection stored in memory. Check for proper model plug number
and resistance values per wiring diagram.
STATUS CODE 31, 32 - PRESSURE SWITCH OR RELAY DID
NOT CLOSE OR REOPENED
Control relay may be defective. If open longer than five minutes,
inducer shuts off for 15 minutes before retry. If open during blower
on-delay period, blower will come on for the selected blower
off-delay. Check for excessive wind, restricted vent, defective
inducer motor, defective pressure switch, lower inducer voltage
(230VAC), inadequate combustion air supply, disconnected or
obstructed pressure tubing, or low inlet gas pressure (if LGPS used).
STATUS (:ODE 33 -LIMIT CIRCUIT FAULT
Indicates a limit or flame rollout switch is open. Blower will run for
4 minutes or until open switch remakes, whichever is longer. If open
longer than 3 minutes, code changes to lockout 13. If open less than
3 minutes status code 33 continues to flash until blower shuts off.
Check for loose blower wheel, restricted vent, excessive wind, dirty
filter or restricted duct system, defectNe switch or connections, or
inadequate combustion air supply (flame roll-out switch open).
STATUS CODE 34 -IGNITION PROVING FAILURE
Control will try three more times before lockout 14 occurs. If flame
signal lost during blower on-delay period, blower will come on for
the selected blower off-delay. Check for oxide buildup on flame
sensor (clean with fine steel wool), proper flame sense microamps
(.5 microamps D.C. min.. 4.0-6.0 nominal), manual valve shutoff.
low inlet gas pressure, control ground continuity, gas valve
defective or turned off, flame sensor must not be grounded.
inadequate flame carryover or rough ignition, or green/yellow wire
must be connected to unit sheet metal.
STATUS CODE 41 - BLOWER MOTOR FAULT
Indicates the blower failed to reach 250 RPM or the blower failed
to communicate within the prescribed time limits. Thirty seconds
after being turned ON or ten seconds during steady - state operation.
STATUS CODE 45 - CONTROL CIRCUITRY LOCKOUT
Auto reset after one hour lockout due to gas valve relay stuck open,
flame sense circuit failure, or software check error. Reset power to
clear lockout. Replace control if status code repeats.
E. HP/AC Control Troubleshooting
See Table 5for HP/AC control board status codes and
troubleshooting information.
STATUS CODE 53, OUTDOOR AIR TEMPERATURE SENSOR
FAULT - DETAILED DESCRIPTION
If an OAT sensor is found at power-up, input is constantly checked
to be within a valid temperature range. If sensor is found to be open
or shorted at any time after initial validation, Status Code 53 will be
displayed at amber STATUS LED.
Check for faults in wiring connecting sensor to OAT terminals.
Using an Ohm meter, check resistance of thermistor for a short or
open condition.
If thermistor is shorted or open, replace it to return the system to
normal operation. If fault is in the wiring connections, correcting the
fault will clear the code and return the system to normal operation.
NOTE: If fault condition is an open thermistor or a wiring problem
that appears to be an open thermistor and the power to the unit is
18

cycledoff.thefaultcodewillbeclearedonthenextpower-upbut
thefaultwillremainandsystemoperationwillnotbeasexpected.
Thisisbecauseon power-up, the unit control cannot discern the
difference between an open sensor or ira sensor is not installed.
Step 2--Sequence of Operation
The 48DU packaged unit is designed for installation with a
communicating UI. This unit will not respond to commands
provided by a common thermostat except under certain emergency
situations described in Step 1--Start-Up and Troubleshooting.
The UI uses temperature, humidity and other data supplied from
indoor and outdoor system components to control heating or
cooling system for optimum comfort. The unit will be commanded
by UI to supply airflow. The unit will operate the indoor blower at
requested airflow for most modes.
INDOOR AIRFLOW ADJUSTMENTS
The nominal requested airflow for air conditioner operations will be
350 cfm per ton of nominal cooling capacity as defined by unit size.
Actual airflow request will be adjusted from nominal using indoor
and outdoor temperature and indoor humidity data to optimize the
system operation for occupant comfort and system efficiency. Refer
to UI literature for further system control details.
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airflow is 350 to 450
cfm for each 12.000 Btuh of rated cooling capacity. For
heating operation, the airflow must produce a temperature rise
that falls within the range stamped on the unit rating plate.
For gas heat operations, Table 4 shows the temperature rise in each
gas heating mode. Refer to these tables to determine the desired
heating airflow for the system being installed.
NOTE: Be sure that all supply-and return-air grilles are open. free
from obstructions, and adjusted properly.Airflow can be changed
using the UI. See UI installation instructions for more detail.
NOTE: Once the compressor has started and then has stopped, it
should not be started again until 4 minutes have elapsed. The
cooling cycle remains "on" until the room temperature drops to
point that is slightly below the cooling control setting of the UI.
AIR CONDITIONER SEQUENCE OF OPERATION
COOLING OPERATION
With a call for first stage cooling, the outdoor fan, and low stage
compressor are energized. If low-stage cannot satisfy cooling
Unit
48DU (-,N)024040
48DU (-,N)030040
48DU (-,N)030060
48DU (-,N)036060
48DU (-,N)042060
48DU (-,N)036090
48DU (-,N)042090
48DU (-,N)048090
48DU (-,N)060090
48DU (-,N)048115
48DU (-,N)060115
48DU(-,N)048130
48DU (-, N)060130
_,irflowdelivery valuestor
demand, high-stage cooling is energized by the UI. After second
stage is satisfied, the unit returns to low-stage operation until first
stage is satisfied or until second stage is required again. When both
first stage and second stage cooling are satisfied, the compressor will
shut off.
NOTE: When two-stage unit is operating at low-stage, system
vapor (suction) pressure will be higher than a standard
single-stage system or high-stage operation.
NOTE: Outdoor fan motor will continue to operate for one
minute after compressor shuts off. when outdoor ambient is
greater than or equal to 100°F.
UTILITY INTERFACE WITH INFINITY CONTROL
The utility curtailment relay should be connected to factory
supplied pigtails (PINK. connected to R, VIOLET connected to
Y2 on the control board) located in the low voltage splice box
(See Fig. 13, 14 and 16). This input allows a power utility device
to interrupt compressor operation during peak load periods.
When the utility sends a signal to shut the system down, the UI
will display "Curtailment Active".
COMPRESSOR OPERATION
When the compressor is operating in low stage, the modulating
ring is deactivated, allowing two internal bypass ports to close off
33% of the scroll compression area so the system operates at part
load capacity. The 24-volt solenoid coil is de-energized in
low-stage operation.
When the compressor is operating at high stage, the modulating
ring is activated, sealing the bypass ports, which allows the
compressor to operate at full load capacity. The 24-volt solenoid
coil is energized in high stage operation.
CRANKCASE HEATER OPERATION (IF APPLICABLE)
The crankcase heater is energized during off cycle below 65W
outdoor air temperature.
OUTDOOR FAN MOTOR OPERATION
The outdoor unit control energizes the outdoor fan any time the
compressor is operating. The outdoor fan remains energized if a
pressure switch or compressor overload should open. Outdoor fan
motor will continue to operate for one minute after the
compressor shuts off when the outdoor ambient is greater than or
equal to 100'_F.
TIME DELAYS-AIR CONDITIONER OPERATIONS
The unit time delays include:
• Five minute time delay to start cooling operation when
there is a call from the thermostat or user interface. To
bypass this feature, momentarily short and release
Forced Defrost pins.
Table 4--Air Delivel T arid Temperature Rise at Rated Heating Input
Rated Heating Input (Btu/hr) Heating Rise Range (°F) Heating Rise (Either Stage, °F)
"Efficiency .... Comfort"
High Stage Low Stage High Stage Low Stage High Stage Low Stage High Stage Low Stage
40,000 26,000
60,000 39,000
90,000 58,500
115,000 75,000
130,000 84,500
_xternai _atio pressure values of u
20 - 50
25 - 55
35 - 65
30 - 60
35 - 65
to 1 in. wc,
15-45
25 - 55
35 - 65
30 - 60
35 - 65
35 30
40
5O
45
5O
4O 35
5O
55
5O
55
19

Table5--HEAT PUMP/AIR CONDITIONER BOARD STATUS CODES
AMBER
LED
OPERATION FAULT POSSIBLE CAUSE AND ACTION
FLASH
CODE
Standby no call for unit opera- On solid,
tion None no flash Normal operation.
Standard Ther- Rapid, con- Unit being controlled by standard thermostat inputs instead of Infin-
Emergency Mode mostat Control tinuous ity Control. Only high stage operation is available. This operating
flashing mode should be used in emergency situations only.
Low Stage Cool/Heat Operation None 1, pause Normal operation.
High Stage Coot/Heat Opera-
tion None 2, pause Normal operation.
System Commu- 16 Communication with UI lost. Check wiring to UI, indoor and outdoor
nications Failure units.
Invalid Model 25 Control does not detect a model plug or detects an invalid model
Plug plug. Unit will not operate without correct model plug.
High-Pressure 31 High-pressure switch trip. Check refrigerant charge, outdoor fan
Switch Open operation and coils for airflow restrictions.
Low-Pressure 32 Low-pressure switch trip. Check refrigerant charge and indoor air
Switch Open flow.
Outdoor unit control board has failed. Control board needs to be
Control Fault 45 replaced.
Brown Out 46 Line voltage < 187v for at least 4 seconds. Compressor and fan
(230 v) operation not allowed until voItage>190v. Verify line voltage.
There is no 230v at the contactor when indoor unit is powered and
No 230v at Unit 47 cooling/heating demand exists. Verify the disconnect is closed and
230v wiring is connected to the unit.
Outdoor Air Outdoor air sensor not reading or out of range. Ohm out sensor
Temp Sensor 53 and check wiring.
Fault
Outdoor Coil 55 Coii sensor not reading or out of range. Ohm out sensor and check
Sensor Fault wiring.
Thermistors Out 56 Improper relationship between colt sensor and outdoor air sensor.
of Range Ohm out sensors and check wiring.
Compressor voltage sensed, then disappears while cooling or heat-
Low Stage Ther-
mal Cutout 71 ing demand exists. Possible causes are internal compressor over-
Ioad trip or start relay not releasing (if installed).
Compressor voltage sensed, then disappears while cooling or heat-
High Stage Ther-
mal Cutout 72 ing demand exists. Possible causes are internal compressor over-
Ioad trip or start relay not releasing (if installed).
Contactor Compressor voltage sensed when no demand for compressor op-
73 eration exists. Contactor may be stuck closed or there is awiring
Shorted error.
No 230V at 74 Compressor voltage not sensed when compressor should be start-
Compressor ing. Contactor may be stuck open or there is awiring error.
Low Stage Ther- 81 Thermal cutout occurs in three consecutive low/high stage cycles.
mal Lockout Low stage locked out for 4 hours or untiI 24v power recycled.
High Stage Ther- 82 Thermal cutout occurs in three consecutive high/tow stage cycles.
mal Lockout High stage locked out for 4 hours or until 24v power recycled.
Low-Pressure Low-pressure switch trip has occurred during 3 consecutive
83 cycles. Unit operation locked out for 4 hours or untiI 24v power
Lockout recycled.
High-pressure switch trip has occurred during 3 consecutive
High- Pressure
Lockout 84 cycles. Unit operation locked out for 4 hours or untiI 24v power
recycled.
• Five minute compressor recycle delay on return from a
brown-out condition.
• Two minute time delay to return to standby operation
from last valid communication (with Infinity only).
• One minute time delay of outdoor fan at termination of
cooling mode when outdoor ambient is greater than or
equal to 100°1=.
• There is no time delay between air conditioner staging
from low to high and from high to low capacity; the
compressor will change from low to high and from high
to low capacity as demand dictates.
INFINITY CONTROLLED LOW AMBIENT COOLING
NOTE:When this unit is operating below 55°F outdoor
temperature, provisions must be made for low ambient operation.
This unit is capable of low ambient cooling ONLY when using the
Infinity control. A low ambient kit is not required, and the outdoor
fan motor does not need to be replaced for Infinity controlled low
ambient operation. Low ambient cooling must be enabled in the
UI set-up. Fan may not begin to cycle until about 40 °F OAT. Fan
will cycle based on coil and outdoor air temperature. Infinity
controlled low ambient mode operates as follows:
2O