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1. Figure 23 Temperature Sensor Resistance Charts 39 INSTALLATION PERFORMANCE CHECK LIST ATTENTION INSTALLERS Itis your responsibility to know this product better than your customer This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product Safety should always be the deciding factor when installing this product and us ing common sense plays an important role as well Pay attention to all safety warnings and any other special notes highlighted in the manual Improper installation of the furnace or failure to follow safety warnings could result in serious injury death or property damage These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Please read all instructions carefully before starting the installation Return these instructions to the customer s package for future reference INSTALLATION ADDRESS CITY UNIT MODEL UNIT SERIAL Unit Installed Minimum clearances per Figure 1 page 5 INSTALLER NAME CITY STATE Has the owner s information been reviewed with the customer NO Has the Literature Package been left YES with the unit
2. 3OVJH3LNI AX3 NOILONS EISE diN3 L NOILONS Hooaino 5 2 HOLIMS 7109 34nSS34d HOLIMS 3ufiSSdHd MOT 541 HOLIMS SYNSSAYd SdH ONISIM OO IN3931 YOLOW Hoodino dei Agoz uo eoejd pue de Agoz 104 AjUO SJaPOW 2 802 10 9 ejejd ees uonoojojd ju911n91910 pue 104 10 5 s10jonpuoo goen jueuiea2e doi 104 oj SYOA 061 jeu SWa sAs uo JON s10jonpuoo 1eddoo esn Ajddns 104 2 Buraas JOBUUODSIG L SALON 9uj2e 3 ser abexded UOL c 19Z9dd 1994 WNV4H9VIQ ONIAIM ue Aq 914194 8 epis eysoddo uo jeuiuuo yoeqAbbid wb ST Fo ZS E o 5 5 SF O o ae Sz SF De LL 35 REFRIGERANT CHARGING A WARNING These units are shipped fully charged with R 410A refrigerant and ready for installation When a system is installed according to these instructions no refrigerant charging is required If repairs make it necessary for evacuation and charging it should only be done by qualified trained personnel thoroughly fam
3. 29 Electrical Information 30 Figure 12 Two Stage Hot Surface Ignition amp Blower Control Board 30 Figure 13 VSHE Blower Control Board 30 Figure 14 Interface Board in Control Panel 31 Table 17 Interface Board Operating Codes 31 Figure 15 Inverter Assembly 32 Figure 16 R6GI Typical Heat Exchanger Assy 33 Figure 17 Wiring Diagram 2 3 amp 4 34 Figure 18 Wiring Diagram 5 Ton 35 REFRIGERANT 36 Alternate Procedure for Charging Air Conditioner In Cooling EE 36 Application Notes on the Use of Charging Charts 36 Figure 19 Charging Chart for 2 Ton Units ar Figure 20 Charging Chart for Ton Units 37 Figure 21 Charging Chart for 4 Ton Units 38 Figure 22 Charging Chart for 5 Ton Units 38 Figure 23 Temperature Sensor Resistance LO jc oo Lo ed odd 39 INSTALLATION PERFORMANCE CHECK LIST 40 IMPORTANT SAFETY INFORMATION Please read allinstructions before servicing this equipment Pay attention to all safety warnings and any other special notes highlighted in the manual Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored WARNING indicates a potentially hazardous situation that if not avoided
4. WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Nevertest for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life A AVERTISSEMENT RISQUE D INDENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourrait d entrainer des blessures graves la mort ou des dommages mat riels Ne jamais utiliser une flamme nue por v rifier la pr sence des fuites de gaz Pour la v rification de tous les joints utiliser plut t une solution savonneuse commerciale fabriqu e sp cifiquement pur la d tection des fuites de gaz Unincendie ou uneexplosion peutentrainer des dommages mat riels des blessures ou la mort Afterthe gas piping to the unitis complete all connections mustbetestedforgas leaks This includes pipe connections at the main gas valve emergency shutoff valve and other gas connectors A soap and water solution can be applied on each joint or union using a small paintbrush If any bubbling is observed the connection is not sealed adequately and mustbe retightened Repeatthe tightening and soap check process until bubbling ceases f pressure testing the gas supply lines at pressures greater than 1 2 psig 14 inches WC the unit must
5. ELECTRICAL SYSTEM Electrical connections tight Line voltage polarity correct Is the thermostat level Is the heat anticipator setting correct e We Encourage C Professionalism US A eren ENERGY PARTNER Residential Furnaces Through Technician DOE 10 CFR Part 430 Certification by NATE Intertek CERTIFIED www ahridirectory org VENTING SYSTEM Is the vent hood installed YES YES Filter s secured in place YES Filter s clean YES z O Is vent hood free from restrictions EE OO z GAS SYSTEM Natural Gas Type circle one Propane ves in W C Gas pipe connections leak tested Gas Line Pressure Is there adequate fresh air supply for combustion and ventilation NO Ti m Installation Altitude Deration Percentage Furnace Input Supply Air Temperature Return Air Temperature Temperature Rise During Furnace Operation Low fire manifold pressure High fire manifold pressure REFRIGERATION SYSTEM Liquid Pressure Nominal Speed high side Suction Pressure Nominal Speed low side PROPOSITION 65 WARNING WARNING This product contains chemicals known to the state of California to cause cancer WARNING This product contains chemicals known to the state of California to cause birth defects or other reproductive harm AR CERTIFIED www ahridirectory org Unit
6. Figure 16 R6GI Typical Heat Exchanger Assembly Draft Inducer Motor Low Speed Resistor See 208V Operation Low Voltage Thermostat Connections Branch Circuit Ground Connection Branch Circuit High Voltage Connection Dual Vent Pressure Switch 2 Stage Gas Valve Hot Surface Igniter 33 ELp 221 1 seoejdeu 9980112 HOLINOI MOTA SLIHM 9 SALON 33S MoO18 SNOILO3NNOO ASVLIOA 91315 MOTISA TOHLNOOD Svo Av13 330 Ymg Svo 59715 2 YOLOW HOSN3S 3INV T4 aad 137OIA SS3NHVH u3MO 18 o 71009 1V3H IOHLNOO H3MO 18 n 2 4 5 5 H3MOd 09 1 0 2 802 OL 7 91915 aN3931 HOLIMS 3ufiSSdHd 541 HOLIMS 55 SdH HOLOVINOO MOTI3A p 3dlH lS HANS WNIAYSL NOTAT 31IHM 301 5 696 TISHS HOSS3HdWOO MOTI3A YOLOVSY dW31 NOILONS 2 dWAL 7100 L dW31 1100 dal 39HVHOSIG dW31 YOOGLNO Uu 1NO TIOH 3INV 14 MOTI3A il quvog 3OVJH3 LNI AX3 diN3 L NOLLOnS lt 7 NOILONS YVHOSIG 5 52 ER HOLIMS 7109 34nSS34d 34
7. The installer must comply with all local codes and regulations which govern the installation of this type of equipment Local codes and regulations take precedence over any recommendations contained in these instructions Consult local building codes and the National Electrical Code ANSI Cl for special installation requirements This equipment contains liquid and gaseous refrigerant under high pressure Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment Air Ducts must be installed in accordance with the standards of the National Fire Protection Association Standards for Installation of Air Conditioning and Ventilation Systems NFPA 90A Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems NFPA 90B these instructions and all applicable local codes Consult Table 12 page 27 Table 13 page 27 amp Table 14 page 27 and the rating plate for the proper circulating air flow and temperature rise It is important that the duct system be designed to provide the correct flow rates and external pressure rise An improperly designed duct system can result in nuisance shutdowns and comfort or noise issues This unit is designed for outdoor installations only and should be located in a position as shown on page 5 Use only with the type of gas approved for this unit Refer to the unit rating plate Provide adequate co
8. COMBUSTION AIR amp VENTING REQUIREMENTS WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed with each individual appliance connected to the venting system being placed in operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in the venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is
9. See Figure 6 Heating Configurations This gas pack is factory configured for two stage gas heating operation with a two stage heating thermostat Connectthe low voltage thermostat White amp Brown wires to W1 amp W2 between the unit low voltage terminal board and thermostat sub base See Figure 6 To operate with a single stage heat thermostat only connect the low voltage thermostat White wire between W1 on the unit low voltage terminal board and thermostat sub base Reposition the automatic heat staging jumper located on the ignition control module from OFF to ON to set a 10 minute time delay before the gas furnace will automatically move to high heat operation NOTE When low fire on the gas valve is energized the furnace operates in low fire mode at a lower blower speed and the timer begins its delay function If the room thermostat is not satisfied before the timer activates the furnace will stage to high fire The inducer motor and blower will ramp to a higher speed until the thermostat is satisfied Configuring the Variable Speed Blower The variable speed blower has been designed to give the installer maximum flexibility for optimizing system performance efficiency and comfort It is equipped with a microprocessor controlled variable speed motor that is pre programmed to deliver optimum airflow in a variety of conditions and system configurations Because the blower can be configured in many ways it is important to read
10. de energized 19 11 The inducer motor is de energized after a 30 second post purge 12 The circulating air blower will remain energized for approximately 120 150 seconds after the demand for heat is no longer present 13 Abnormal Conditions If a limit switch opens during heating operation the gas valve is de energized immediately The control de energizes the induced draft motor and runs the indoor blower motor continuously while the limit switch is open Cooling Mode Before the first start after power up and between cycles there will always be a 5 minute re start delay imposed With a for cooling and before the compressor is turned on the outdoor fan will run for 1 minute to assure that the outdoor temperature measurement is close to that of the ambient air The compressor will then ramp up to a speed selected by the capacity control scheme The unit is a true variable speed unit Normally the compressor will operate at one of 5 speeds in cooling each predetermined for a balance of optimum efficiency and capacity The outdoor fan motor and indoor blower will also operate at multiple speeds following the compressor For cooling mode the speeds used will depend on several factors including Whether first or second stage operation is called for by the thermostat which must be two stage capable Outdoor ambient temperature The length of time the equipment has been operating during the current cycl
11. etc NOTE Deration is necessary to compensate for low atmospheric pressure at high altitudes For altitudes between 5 000 and 10 000 feet above sea level the unit can be converted by adjusting the furnace manifold pressure See Table 5 for the correct manifold pressure settings when using natural gas LP Propane Gas Conversion WARNING This unit was equipped at the factory for use with natural gas only A special kit supplied by the manufacturer is required to convert the unit to operate on LP propane gas Failure to use the proper conversion kit can cause fire explosion property damage carbon monoxide poisoning personal injury or death MPORTANT NOTE When converting this low NOx unit from natural gas to propane LP gas it is necessary to remove the NOx baffles Conversion of this equipment to LP Propane gas must be made by qualified service personnel using approved factory parts Conversion to LP can be accomplished by replacing the natural gas orifices with the appropriate LP Propane orifices and then adjusting the manifold pressure page 18 Conversion to LP Propane sea level and high altitude is detailed in the installation instructions provided with the conversion kit Please follow the instructions provided in each kit Approved conversion kits are The United States LP Propane Gas Sea Level and High Altitude Conversion Kit is for LP propane conversion in the United States at altitudes between ze
12. 1 Connect the gauge manifold to the liquid and vapor service valves See Figure 5 page 10 2 Start the system in cooling mode Allow the system to run 15 minutes to stabilize 3 Record the liquid refrigerant pressure in psig at the service valve 4 Record the liquid refrigerant line temperature in F at the service valve 36 5 Using the temperature value recorded determine the corresponding liquid refrigerant pressure from the curve inthe appropriate charging chart See Figure 19 Figure 20 page 37 amp Figure 22 page 38 6 If the pressure measured in step 3 is less than the required liquid refrigerant pressure determined in step 5 then refrigerant needs to be added 7 1f the pressure measured in step 3 is greater than the required liquid refrigerant pressure determined in step 5 then the system is over charged 8 Add or remove charge from the system depending on the measurements recorded Allow the system to stabilize for 15 minutes before taking the next readings Application Notes on the Use of Charging Charts This equipments cooling system contains refrigerant under high pressure always use safe practices when servicing the unit Always review the factory literature and safety warnings prior to servicing These units are shipped from the factory with the proper amount and type of refrigerant Always inspect the unit rating label to determine the units information prior to working on the system Do not mix
13. HOILSIS3H LHLON das uiv t SNOLLO3NNOO 39V110A 913913 HOLINOI MOTI3A 9 ALON 33S HOSN3S 314 D 554 4IMOT4 caso 1009 1V3H quvog OH NOO H3MO l8 z O a Br 000 DHUM Y1 SEN GND ejduiexe 10 Aq 5 51 syou9 y Jed eum jo Jaquinu Sau Buisojous 95 9419 e e OSL snid ep 5 5 xne sed ON E sjnajonpuoo sep 72 jueJnoo 19dn09 ZH 09 0 12euuoo pue y20 q 015159 Pal pessed q eq 1snui 101616 Agoz 104 OVA 0 2 802 eur YOLOVLNOO 3dlHlS MOTISA MOTISA AlddNS ama 09 1 062 802 OL ovig MS iovis H9014 TWNIWY SL 431114 3NIT MOTI3A MOTI3A 18 0018 Tel 1SOd H3A00 ag MIIA 301 TIAHS HOSSSYdWOO 3unss3ud NOILONS 055 dW31 NOILONS 7 eit 7100 dN31 SDYVHOSIG LA JOHLNOO ama MOTI3A 4 2
14. It is recommended that the area to be conditioned be completely insulated and vapor sealed Y Check the electrical supply and verify the power supply is adequate for unit operation Consideration should be given to availability of electric power service access noise and shade If there is any question concerning the power supply contact the local power company All units are securely packed at the time of shipment and upon arrival should be carefully inspected for damage prior to installing the equipment at the job site Verify coil fins are straight If necessary comb fins to remove flattened or bent fins Claims for damage apparent or concealed should be filed immediately with the carrier Please consult your dealer for maintenance information and availability of maintenance contracts Read all instructions before installing the unit Locating the Equipment Survey the job site to determine the best location for the packaged unit The unit should be located with consideration of minimizing the length of the supply and return ducts Consideration should also be given to the accessibility of fuel electric power service access noise and shade Select a solid level position preferably on a concrete slab slightly above the grade level and parallel to the home DO NOT PLACE UNIT UNDER THE HOME Overhead obstructions poorly ventilated areas and areas subject to accumulation of debris should be avoided Do not place the unit
15. Mode 27 Gas Information CAPACITY OF BLACK IRON GAS PIPE CU FT PER HOUR FOR NATURAL GAS SPECIFIC GRAVITY 0 60 DIAMETER IN 10 20 30 40 50 60 70 80 Input To Furnace Btu hr Cubic Feet Per Hour Required Heating Value of Gas Btu Cu Ft NOTE The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace To determine the cubic feet per hour of gas flow required by the furnace divide the input rate of the furnace by the heating value from gas supplier of the gas Table 15 Gas Pipe Capaacities GAS FLOW RATES GAS FLOW RATES CUBIC FEET PER HOUR CUBIC FEET PER HOUR TIME FOR CUBIC FEET PER TIME FOR CUBIC FEET PER ONE REVOLUTION REVOLUTION OF GAS METER ONE REVOLUTION REVOLUTION OF GAS METER emos _ 273 545 265 529 257 514 250 500 243 86 ____20 10 90 237 474 462 225 450 220 439 214 429 ____50 10 60 1 120 419 205 409 2 28 Table 16 Gas Flow Rates FOR YOUR SAFETY READ POUR VOTRE SECURITE LIRE AVANT L EMPLOI WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life ATTENTION L inobservation de ces instructions peut entrainer un ince
16. Park Quincy MA 02269 or American Gas Association 400 N Capitol N W Washington DC 20001 or www NFPA org CANADA NSCNGPIC Fora copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario M9W 1R3 Canada Safety US NFGC NFPA 54 1999 ANSI Z223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 and 2 00 National Standard of Canada NSCNGPIC GENERAL INFORMATION This Single Package Gas Heating Electric Cooling Units are designed only for outdoor rooftop or ground level installations and can be readily connected to the duct system of a home This unit has been tested for capacity and efficiency in accordance with AHRI Standards and will provide many years of safe and dependable comfort providing it is properly installed and maintained With regular maintenance this unit will operate satisfactorily year after year Abuse improper use and or improper maintenance can shorten the life of the appliance and create unsafe hazards To achieve optimum performance and minimize equipment failure it is recommended that periodic maintenance be performed on this unit The ability to properly perform maintenance on this equipment requires certain tools and mechanical skills Before you install this unit The cooling load of the area to be conditioned must be calculated and a system ofthe proper capacity selected
17. Pressure Opens 650 15 psig See Figure 8 amp Switch recloses 460 15 psig Figure 9 Low Pressure Switch Ambient Air Temp Opens 20 5 psig recloses 35 5 psig Thermistor 10KO 25 C Fig 10 Thermistor 10KO 25 C Fig 10 IFB LP1 LP2 IFB OUTDOOR TEMP BLK IFB DISCHARGE TEMP RED Compressor Discharge Temp Low Line Voltage at Inverter Line Overcurrent at Inverter Line Voltage Sampling Error Inverter Loss of Communication Inverter Internal Inverter Heat Sink Sensor Failure Loss of Communication Inverter Internal Loss of Communication IFB to Inverter Override High Compressor Current Override High Line Current Override High Inverter Heat Sink Temp Outdoor Fan Motor Fault Low Pressure Switch Open High Compressor Discharge Temperature Interface Board Software Error Sensor Failure Suction Line Temperature Sensor Failure Compressor Discharge Temperature Sensor Failure Ambient Temperature Sensor Failure Coil Temp 1 Defrost Sensor Failure Suction Pressure Transducer Blower Motor Fault Blower Communication Fault Cooling Low Ambient Lockout a ua nu un J Table 7 Interface Board Diagnostic Codes 24 Coil Saturation Temp Thermistor 10KO 2 25 C Fig
18. and follow all instructions carefully A CAUTION To avoid personal injury or property damage make certain that the motor leads cannot come into contact with any uninsulated metal components of the unit Upon initial start up the variable speed blower must be checked sothatthe factory settings match the unit with the system climatic conditions and other system options With the blower installed and configured properly the furnace will gradually change speed in response to changes in system variables such as thermostat settings duct static filters etc The variable speed blower is configured by setting the eight dip switches for heating and cooling operation located on the blower control board See Figure 13 page 30 for dip switch location NOTES For change in blower speed selection to take effect system power must be cycled off then restored after 10 seconds Specialattention mustbe givento dip switch location 1 The blower control board provides four separate programs one for each specific unit tonnage and is designed to automatically identify the motor horsepower installed in that specific unit 1 2 HP motor for 2 amp 3 ton models and 1 HP motor for 4 amp 5 Ton models Dip switch 1 ofthe blower control board is factory setfor the specific unit tonnage where this dip switch determines the following 0 OFF position 2 Ton with 1 2 HP motor 1 ON position 3 Ton with 1 2 HP motor 0 OFF position 4 Ton w
19. codes NOTE Make sure the two supports beneath the unit have been removed Figure 3 Ground Level Installation Horizontal to Downflow Conversion The unitis shipped ready for horizontal duct connections If down flow ducts are required the unit must be converted following the steps below for both the supply and return ducts 1 Remove both horizontal duct caps 2 Locate the ductcap insidethe duct openings and remove the screw holding it in place 3 Lift the cap out ofthe unit Hint The cap can be pushed up from the bottom by reaching through the fork slot 4 Cover the horizontal duct openings with the horizontal duct caps removed earlier in step 1 The insulation will be on the indoor side 5 Fasten the cover with screws to seal 6 Remove and discard the two wood supports beneath the unit Condensate Drain Condensate is removed from the unit through the 3 4 female pipe fitting Figure 5 located on the front side of the unit Install a 2 inch condensate trap in the drain line of thesame size and prime with water When connecting rigid drain line hold the female fitting with a wrench to prevent twisting Do not over tighten Refer to local codes and restrictions for proper condensate disposal requirements ACCESSORY ROOF CURB Condensate Drain Fi
20. condensation Do not install the unit such that exhaust from the vent termination is directed into window wells stairwells under decks or in alcoves or similarly recessed areas The vent termination must not be located above any public walkways CIRCULATING AIR SUPPLY WARNING Do not allow combustion products to enter the return air ductwork or the circulating air supply Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death All return ductwork must be secured to the unit with sheet metal screws All return ductwork must be adequately sealed and all joints must be taped When return air is provided through the bottom of the unit the joint between the unit and the return air plenum must be air tight The roof curb or cement pad on which the unit is mounted must provide sound physical support of the unit with no gaps cracks or sagging between the unit and the curb or pad Return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert stove etc Doing so may result in fire explosion carbon monoxide poisoning personal injury or property damage Air Ducts This unit is designed only for use with a supply and return duct Air ducts should be installed in accordance with the standards of the National Fire Protec
21. control panel cover before applying power Overcurrent protection must be provided at the branch circuit distribution panel and sized as shown on the unit rating label and according to applicable local codes See the unit rating plate for maximum circuit ampacity and maximum overcurrent protection limits A wiring diagram is located on the inside cover of the control access panel of the outdoor unit The installer should become familiar with the wiring diagram Figure 17 amp Figure 18 before making any electrical connections to the outdoor unit For 208Volt Operation Only Units are shipped from the factory wired for 240 volt transformer operation For 208V operation remove the lead from the transformer terminal marked 240V and connect it to the terminal marked 208V Theinducer motorlow speed resistor mustbe by passed for 208 Volt operation Remove the insulated quick connect from one side ofthe resistor block and connect to piggyback terminal on opposite side to complete motor circuit Thermostat Low Voltage Connections This Gas Electric unit is designed to operate with a 24 VAC Class II control circuit The control circuit wiring must comply with the current provisions of the NEC ANSI NFPA 70 and with applicable local codes having jurisdiction Thermostat connections should be made in accordance with the instructions supplied with the thermostat These units use a special variable speed compressor to achieve a high level o
22. different refrigerants or charge the unit with a refrigerant not listed on the unit rating label The charging charts Figure 19 Figure 20 page 37 amp Figure 22 page 38 are valid for a variety of indoor return air conditions and are most highly influenced by the outdoor ambient temperature outdoor fan operation and the unit operating voltage Before referencing the charts always make sure that the compressor circuit is energized on nominal speed Y1 amp Y2 energized and has stable operation As can be seen in the charging charts the ideal system sub cooling can vary over the range of operation Always reference the charts to determine the ideal amount of sub cooling for a given liquid pressure Units charged to other values will not perform at the rated unit efficiency EER inspecta systems operation using quality instruments match the measured liquid temperature to the units chart The measured liquid pressure reading should be within 396 of the value shown for most installations DO NOT use the charts for operating under first stage cooling For systems that are operating with more then a 596 deviation inspect the unit for leaks Always use safe and environmentally sound methods for refrigerant handling When repairing system leakages always utilize a nitrogen inert gas to protect the refrigerant system and pressure check the repair before re charging Always replace the filter dryers when performing any repa
23. in a confined space or recessed area where discharge air from the unit could re circulate back through the condenser coil Sufficient clearance for unobstructed airflow through the louvered control access panel and outdoor coil must be maintained in order to achieve rated performance See Figure 1 for minimum clearance requirements Aclearance of atleast 36 inches from the blower access panel and from the louvered control access panel is recommended for servicing and maintenance Where accessibility clearances are greater than clearances to combustibles accessibility clearances must take preference The hot condenser air must be discharged up and away from the home If practical place the air conditioner and its ducts in an area where they will be shaded from the afternoon sun when the heat load is greatest Heating Load This unit should be sized to provide the design heating load requirement Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods For installations above 2 000 ft the unit should have a sea level input rating large enough that it will meet the heating load after deration for altitude 36 UNOBSTRUCTED ES z u m OO oF O AMENS Minimum Required Clearances to Combustibles Figure 1 Clearance Requirements
24. ise crm 2 4 crw ise crm Rise so 1025 0 0 o 675 se 1150 66 o o o 0 1200 54 1550 57 1 o rzo0 s 1550 57 0 0 0 1 850 48 1075 57 1 0 0 1 925 53 1200 63 1250 50 1650 54 1 0 0 1250 50 1650 54 0 01 1 01 875 46 1125 55 1 0 1 0 975 50 1300 58 0 0 1 0 1300 47 1750 52 1 0 t 0 1300 47 1750 52 0 011 1 925 44 1175 53 1 0 1 1 1 1000 48 1350 56 1 44 rend 50 1 0 1 1 1375 44 1800 50 0 1 0 0 950 42 1225 51 1 1 0 0 1050 46 1375 55 0 1 0 0 1450 42 1850 48 1 1 0 0 1450 42 1850 48 11000 40 1275 49 1 t 0 1 1 1100 44 1400 54 0 1 of 1 1475 40 1900 47 1 1 0 1 1475 40 11900 47 0 1 4 o 1025 39 1325 47 1 1 1 0 1150 42 1450 52 0 1 1 0 1525 39 1950 46 1 1 t 0 11525 39 1950 46 1 1 11 1050 1375 45 1 1 1 1 1200 41 1500 51 1 1575 2000 45 1 Switch 1 selects blower program in conjunction with motor horsepower 0 2 4 1 3 5 2 Recommended CFM s Factory settings and temperature rises are highlighted in bold Use of any other setting may result in nuisance trips 3 Temperature rises in tables are approximate Actual temperature rises may vary Table 14 Airflow Settings CFM amp Rise F for Heating
25. of the humidistat to the R terminal of the low voltage field connection board amp the other side to the DEHUM terminal located on the blower control board Wire the humidistat to close on rise in humidity For dehumidification the Dehum input on the VSHE board can be used to control this function If the Dehum input is active and the unit is operating in second stage cooling the following will happen The suction line temperature sensor is used for coil temperature The blower CFMis 75 of cooling value for the operating speed If coil temperature is less than 37 F for 30 seconds then blower CFM is set to 85 of cooling value If coil temperature rises above 37 F for 5 minutes then blower runs at 75 of cooling value If coil temperature is less than 35 F for 30 seconds then blower CFM is set to 100 of cooling value If coil temperature rises to between 35 and 37 F for 5 minutes then blower CFM is set to 85 of cooling value If coil temperature rises above 37 F for 5 minutes then blower CFM is set to 75 of cooling value Delay Override When performing startup tests or troubleshooting the 5 minutes startup delay can be skipped by shorting the two J4 Test pins indicated in Figure 14 for about 1 second while the compressor is off and waiting to start NOTE This will also clear the faults stored in memory Fan Only Mode 1 On a call for fan only operation the thermostat applies 24 VAC to the G terminal on the f
26. operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Codes 9 After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appliance to their previous conditions of use AVERTISSEMENT RISQUE D EMPOISONNEMENT AU MONOXYDE DE CARBONED Le non respect des consignes suivantes portant sur chacun des appareils raccord s au syst me d vacuation mis en service pourrait entrainer l empoisennement au monoxyde de carbone ou la mort Les consignes suivantes doivent tre observ es pour chaque appareil raccord au systeme d vacuation mis en service si les autres appareils raccord s au syst me ne sont pas en service 1 Sceller toute ouverture non utilis e de la syst me d vacuation 2 S assurer que la syst me d vacuation pr sente des dimensions et une pente horizontale conformes la norme ANSI Z223 1 NFPA 54 intitul e National Fuel Gas Code ou aux codes d installation CSA B149 1 ainsi qu aux pr sentes instructi
27. system must be designed so that the return air supply to the furnace is equal to the return air supply under normal indoor return air applications Air Filter Requirements WARNING Never operate the unit without a filter in place Dust and lint could accumulate on internal parts resulting in loss of efficiency equipment damage and possible fire This unit is not supplied with air filter s and has no factory equipped means for accommodating internal filter s A suitable air filter must be installed upstream of the evaporator coil of the return air system Refer to Table 1 for recommended filter sizes Allreturnairmustpassthroughthe filters before entering the evaporator coil It is important that all filters be kept clean and replaced frequently to ensure proper operation of unit Dirty or clogged filters will reduce the efficiency of the unit and result in unit shutdowns Airfilter pressure drop must not exceed 0 08 inches WC Horizontal and downflow Installations require the air filter system be installed in the return air ductwork NOTE TOINSTALLER After installing or replacing the filtration system for this unit add the following statement on or adjacent to the filter service panel Replace filter s installed in your system only with the same dimensional size filters that are being replaced NOMINAL APPROXIMATE COOLING AIR FLOW FILTER AREA FILTER SIZE TONS RANGE CFM SQ IN IN X IN
28. value 2 Remove the regulator cap Turn the high fire adjusting screw clockwise to increase the pressure or counterclockwise to reduce the pressure See Figure 9 page 23 for adjusting screw locations 3 Replace the regulator cap after adjustments are complete OPERATING SEQUENCE The operating sequences for the heating cooling and fan modes are described below Refer to the field and furnace wiring diagrams Figure 17 page 34 amp Figure 18 page 35 Heating Mode 1 On a call for 1st stage heat the thermostat closes and applies 24 VAC to terminal W1 on the control board 2 Safety Circuit Proving The control board verifies continuity through the 24VAC limit control circuit If the high temperature limit switch and flame roll out switch are closed and both the high and low vent pressure switches are open the control board will then begin pressure switch proving If an open limit is detected the control board will energize the indoor blower motor and operate it continuously while the limit switch circuit is open All other system functions will be inoperable until the limit circuit closes While the limit circuit is open the control will display Open Limit Switch Fault See Table 9 page 25 3 The furnace control checks for continuity 24 VAC across the pressure switch If either the high or low pressure switch is closed the heat mode sequence will not continue If either remains closed the control will display a Pressur
29. 10 TEMP YEL Thermistor 10KO IFB SUCTION TEMP 25 C Fig 10 BLU IFB COIL 2 Suction Temp IFB Interface Board Table 8 Instrumentation List TROUBLESHOOTING HEATING MODE If the furnace fails to operate check the following s the thermostat operating properly Are the blower compartment door s in place Is the furnace disconnect closed Has the circuit breaker tripped or the control board fuse burned open Is the gas turned on Are any manual reset switches open Is the filter dirty or plugged Is the flame sensor coated Remove and clean with steel wool Do not use emery cloth or sandpaper Are all the LED s on the furnace and motor control boards constantly ON If not refer to Table 9 amp Table 10 page 25 to determine fault condition IMPORTANT NOTE The furnace will lock out after 5 failed attempts for ignition and will try again every hour if the call for heat remains DIAGNOSTIC DESCRIPTION GREEN LED RED LED Control Fault No Power Off Off L1 Neutral Polarity Fault Flash Flash 1 Hour Lockout Alternating Flash Normal Operation On Flash Pressure Switch Closed Fault Pressure Switch Open Fault Open Limit Switch Fault Motor Fault DIAGNOSTIC DESCRIPTION YELLOW LED Low Flame Sensor Signal Continuous Flash Flame Present Table 9 Furnace Control Board Fault Conditions DIAGNOSTIC DESCRIPTION Control Fault No Power VAR
30. Based on velocity of 300 ft min for disposable filters APPROX RECOMMENDED Table 1 Air Filter Requirements Unconditioned Spaces All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation Use insulation with an outer vapor barrier Refer to local codes for insulation material requirements Acoustical Duct Work Certain installations may require the use of acoustical lining inside the supply duct work Acoustical insulation must be in accordance with the current revision of the Sheet Metal and Air Conditioning Contractors National Association SMACNA application standard for duct liners Duct lining must be UL classified batts or blankets with a fire hazard classification of FHC 25 50 or less Fiber duct work may be used in place of internal duct liners if the fiber duct work is in accordance with the current revision of the SMACNA construction standard on fibrous glass ducts Fibrous duct work and internal acoustical lining must be NFPA Class 1 air ducts when tested per UL Standard 181 for Class 1 ducts UNIT INSTALLATION Packaging Removal Remove the shipping carton and User s Manual from the equipment Take care not to damage the coil or cabinet when removing the carton For rooftop installations remove and discard the two supports attached beneath the unit Rigging amp Hoisting A WARNING To avoid the risk of property damage personal injury or d
31. DE INDICATION Inverter Power Module Overcurrent General Inverter Drive Fault High Compressor Current Current Sampling Error Inverter High Inverter Heat Sink Temperature High DC Bus Voltage Inverter Low DC Bus Voltage Inverter nu un Instrumentation The 20 SEER iQ Drive split air conditioner includes instrumentation as listed in Table 8 All items listed are connected to the interface board except for the high pressure switch Refer to Figure 12 page 30 amp Figure 13 page 30 Figure 14 page 31 Figure 15 page 32 Figure 17 page 34 amp Figure 18 page 35 The five temperature sensors are color coded so that the color of the wire insulation matches the color of the connector base on the left side of the circuit board All temperature sensors are 10k ohm thermistors The resistances of these sensors when disconnected from the interface board may be checked against Figure 23 page 39 for troubleshooting purposes The charts show the thermistor resistance temperature curve broken into two parts for ease of use Low Ambient Cooling System control will modulate to allow safe operation in low outdoor temperatures by controlling blower CFM compressor speed and fan speed until an outdoor temperature is less than 50 F Unit is then disabled and remains locked out until temperature has increased to gt 55 F Code 29 is displayed to indicate low cooling lockout High
32. I M 20 De Humidification 20 Delay 20 Fan Only 20 EQUIPMENT MAINTENANCE 20 Cleaning of Heat Exchanger 21 OF BIImfe ianiai 22 TROUBLESHOOTING COOLING 24 Diagnostic eser recante eec 24 aeo EL busta ied 24 Low Ambient Cooling 24 TROUBLESHOOTING HEATING MODE 24 REPLACEMENT 25 HEATING COMPONENT FUNCTIONS 25 OPTIONAL FURNACE CONTROL BOARD GONNEGCTIONG iaa ht naa aka tha na seg 25 FIGURES amp TABLES niin NEE Eege 26 Figure 10 Unit Dimensions 26 Table 11 Center of Gravity amp Shipping Weights 26 Diis Dala e 27 Table 12 Nominal Heating Airflow Rates amp Temperature Rises F 27 Table 13 Airflow Settings for Cooling Mode 27 Table 14 Airflow Settings CFM amp Rise F for Heating Mode 27 Gas Information 28 Table 15 Gas Pipe Capaacities 28 Table 16 Gas Flow Rates 28 Figure 11 Gas Valve Label
33. IABLE Normal Operation Motor Fault Communications Fault SPEED FURNACES Table 10 Motor Control Board Fault ConditionS REPLACEMENT PARTS Replacement parts are available through all Nordyne distributors Please have the complete model and serial number of the unit when ordering replacement parts Electrical Blower Control Boards Pressure Switches Compressors Reactor Contactors Relays Gas Valves Temperature Limit Switches Ignition Control Boards Thermistors e Ignitors Flame Sensors Thermostats Inverters Transformers Motors Blower Motor Fan Motor Inducer Blower Motor Components Blower Assembly Electronic Expansion Valves Burner Manifold Fan Grille Burners Orifices Filter Driers Cabinet Panels Gaskets Coil Heat Exchanger HEATING COMPONENT FUNCTIONS Flame Roll Out Control The flame roll out control acts to verify that the burner flame is being drawn into the heat exchanger tubes If the burner flame is not being drawn into the heat exchanger tubes the roll out control will open within several seconds and the integrated control diagnostic light will flash one time The circulating air blower will continue to operate while the flame roll out control is open See Figure 16 page 33 Flame Sensor The flame sensor acts to prove that flame has carried over from the ignitor to the left most burner If no flame is sensed the unitwillbe shut down a
34. R DE GAZ Ne pas tenter d allumer aucun appareil Ne toucher aucun interrupteur lectrique n utiliser aucun t l phone dans le b timent Evacuer l immeuble imm diatement Appeler imm diatement le fournisseur de gaz en employant le t l phone d un voisin Respecter la lettre les instructions du fournisseur de gaz Si personne ne r pond appeler le service des incendies DO NOT DESTROY THIS MANUAL KEEP IN A SAFE PLACE FOR FUTURE REFERENCE TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION 3 REQUIREMENTS amp CODES 4 GENERAL 5 Before you install this 5 Locating the EGITIGFLuuouicsccon cras 5 ig cup cp Es ETT 5 COMBUSTION AIR amp VENTING REQUIREMENTS 6 General lo e OE ease vent T 7 CIRCULATING AIR 8 min ES 8 Air Filter 8 9 Acoustical DUCE aia 9 UNIT INSTALLATION 9 9 PUI HDI i 9 Clearances to Combustible Materials 9 Cl 60 EE 9 TE 9 Horizontal to Downflow Conversion 10 G
35. R6GI PPG2GI 20 SEER 81 AFUE INSTALLATION INSTRUCTIONS Multi Stage Variable Speed Inverter Driven System with Gas Heating Electric Cooling SE ee Premium Model Shown WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Installation and service must be performed by a qualified installer service agency or the gas supplier Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department A AVERTISSEMENT RISQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourrait entrainer des blessures graves la mort ou des dommages mat riels L installation et l entretien doivent tre effectu s par un installateur qualifi un organisme de service ou le fournisseur de gazstaller service agency or the gas supplier Ne pas entreposer ni utiliser de l essence ni d autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ni de tout autre appareil QUE FAIRE S IL Y A UNE ODEU
36. SETTINGS 3 TON CFM SETTINGS 4TON CFM SETTINGS 5 TON CFM SETTINGS COOLING COOLING COOLING COOLING BLOWER RECOMMENDED BLOWER RECOMMENDED BLOWER RECOMMENDED BLOWER RECOMMENDED SELECTOR AIRFLOW SELECTOR AIRFLOW SELECTOR AIRFLOW SELECTOR AIRFLOW SETTING HIGH CFM SETTING HIGH CFM SETTING HIGH CFM SETTING HIGH CFM ko s 650 1 680 710 740 70 1101110101 800 230 860 e 1 t o o o 920 1110 950 980 111 0 11 1 1010 1 4 4 0 0 1040 Io 1070 1 1 1 150 NOTES Dip switch positions 0 OFF 1 ON 1 Switch 1 selects blower program in conjunction with motor horsepower 0 2 or 4 Ton 1 3 or 5 Ton 2 Recommended factory settings are highlighted in bold Table 13 Airflow Settings for Cooling Mode Ou z HEATING TON CFMSETTINGS 3TONCFMSETTINGS eating 4TONCFMSETTINGS Hearing 5 TON SETTINGS BLOWER Low HIGH BLOWER Low HIGH BLOWER Low HIGH BLOWER Low HIGH SELECTOR HEAT SELECTOR ugar HEAT SELECTOR Hear HEAT SELECTOR HEAT SETTING SETTING SETTING SETTING 64 800 80 000 81 000 100 000 97 200 120 000 97 200 120 000 2 s cew nise crm mise en 2 4 crw ise crm rise n 2 3 4 crm
37. TING COOLING THERMOSTAT WIRE GAUGE Table 4 Thermostat Wire Gauge THERMOSTAT TERMINAL STRIP 6 Blower Auto or Continuous ON BLACK ____ 24VAC Common D OPTIONAL SEE NOTE gt Diagnostics 2 WHITE Mont gt 15 Stage Heat RED gt 24VAC 2 BLUE gt 2 Stage Coo NOT USED NOT USED 4 KO YELLOW 4 I 157 Stage Cool 3 BROWN LE 2 Stage Heat DEHUM To Blower Control Board Optional NOTE For use with compatible thermostats only Refer to the thermostat manual for detailed installation and programming instructions Figure 6 Two Stage Heating Two Stage Cooling Configuration 12 Heat Cool Thermostat 2 Stage Heat 2 Stage Cool Thermostat Recommended For highest efficiency a 2 Stage Heating Cooling thermostat is recommended for this unit A 2 Stage Cool thermostat is required for control of the special variable speed compressor A 2 Stage Heat thermostat will allow the gas heat to operate at a more efficient low heat condition until there is a demand for higher heat output to the conditioned space Single Stage Heat 2 Stage Cool Thermostat Optional A 2 Stage Cool thermostat is required for control of the special variable speed compressor A single stage Heat thermost
38. ade stainless steel cable such as drain clean out cable Attach the other end of the spring cable to a variable speed reversible drill Slowly insert and rotate the cable into the top portion of the heat exchanger Operate the drill alternating between forward and reverse working the cable in and out several times to obtain sufficient cleaning Repeat this process at each exchanger tube 14 Remove all loosened debris from the heat exchanger tubes using high pressure air and vacuum cleaner 15 Using a light check the condition of the upper and lower sections of the heat exchanger tube 16 Inspect the burners and if necessary clean them carefully with a soft wire brush and or the nozzle of a vacuumcleaner DO NOT DAMAGETHE IGNITOR OR FLAME SENSORWHILE CLEANINGTHE BURNER 17 Reinstall the burner box assembly using the four screws removed in Step 13 18 Reconnectthe wires to the flame roll out switch flame sensor and ignitor removed earlier in step 13 19 Reinstall the collector box and combustion motor removed earlier in steps 7 amp 8 Make sure the collector pan gasket seals the perimeter of the collector box when attaching it to the heat exchanger mounting panel and the combustion motor housing gasket is correctly positioned when reattaching the 4 nuts 20 Reconnect the gas piping to the gas valve inlet 21 Reconnect the wires to the gas valve terminals 22 After re installing the gas valve manifold assembly inspect the a
39. all a jumper wire across the control to defeatits function If the control reopens upon start up DO NOT reset the control without identifying and correcting the fault condition which caused the control to trip Verify that the gas line has been purged and connections are leak tight Verify that all exterior panels are replaced and securely fastened Verify that the outdoor fan turns freely Verify that the power supply branch circuit overcurrent protection is sized properly Y Verify that the thermostat is wired correctly The thermostat function switch should be set to OFF and the thermostat fan switch should be set to AUTO Start Up Procedure Check all electrical wiring for loose connections and tighten as required Check unit for return air filters and condensate trap Close all electrical disconnects to energize the system Air Circulation Leave the thermostat system mode on OFF and set the fan mode to ON Blower will run continuously Check the air delivery at the supply registers and adjust register openings for balanced air distribution Examine ductwork for leaks or obstruction if insufficient air is detected Set the thermostat fan mode to AUTO The blower will stop running NOTE When fan ON is selected the blower will operate at 5096 of selected airflow when no call for heating or cooling is present System Cooling 1 Set the thermostat s system mode to COOL and the fan mode to AUTO Lower the t
40. ancher o les gaz les plus lourds ont la tendance de se concentrer EN CAS D ODEUR DE GAZ Ne mettre en marche aucun appareil lectrique Ne toucher aucun commutateur lectrique ne pas employer le t l phone Quitter le b timent imm diatement et avertir la compagnie du gaz en utili sant le t l phone d un voisin A d faut de la compagnie du gaz avertir le service des pompiers C Enfoncer ou faire tourner le robinet gaz la main seulement Ne jamais utiliser d outils S il n est pas possible de faire tourner ou d enfoncer le robinet la main ne pas essayer de le r parer Faire appel un sp cialiste Forcer ou tenter de r parer le robinet pourrait tre l origine d une explosion ou d un incendie D Il est d conseill d utiliser cet appareil en contact prolong avec l eau Faire inspecter ou remplacer toute commande par un technicien qualifi si un des syst mes de contr le du gaz s est trouv sous l eau ES OPERATING INSTRUCTIONS EE MODE D EMPLOI STOP Read the safety information above this label Set the thermostat to the lowest setting Turn off all electrical power to the appliance The appliance s ignition device automatically lights the burner Do not try to light burner by hand Remove the control access door panel upper door if two door model 6 Move the gas control switch to the OFF position See Figure 1 7 Wait five 5 minutes to clear out any g
41. apors or these other corrosive chemicals near the vent termination Gasoline Kerosene Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents Cements glues paint removers varnishes etc Hydrochloric acid Masonry acid washing materials Plumbing Stack Air openings in the door of the unit warm air registers and return air grilles must never be restricted If the unit does notreceive an adequate supply of airfor combustion the flame roll out control located above the burners will open turning off the gas supply to the burners This safety device is a manually reset switch IMPORTANT NOTE DO NOT install jumper wires across this control to defeat its function or resetthe control without identifying and correcting the fault condition Ifthis control mustbe replaced useonly factory authorized replacement parts See the Replacement Parts List on page 25 Vent Termination This unit has been equipped with an integral venting system and designed to operate only with this venting system No additional venting shall be used This unit must be vented to the outdoors WARNING This unit is intended for outdoor installation only Do not vent the unit through a conventional venting system A vent cover assembly has been supplied with the unit and can be found sec
42. ary Small AC AHRI Standard 210 240 Certification applles only when the complete system I listed with AHRI HRAI YOUR ENVIRONMENT OUR EXPERTISE v MEMBER COMPANY NORDYNE COMPLETE COMFORT GENUINE VALUE Specifications amp illustrations subject to change without notice or incurring obligations O Fallon MO Printed in U S A 08 13 709225D Replaces 709225C
43. as Then smell for gas including near the floor If you smell gas STOP Follow B in above information If you don t smell gas go to the next step 8 Move the gas control Switch to the ON position See Figure 1 9 Replace the control access door panel upper door if two door model Figure 1 Turn on all electrical power to the appliance Turn the thermostat to a desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier RON SWITCH INTERRUPTEUR 10 14 12 10 11 12 1 ATTENTION Lire d abord la liste des mesures de s curit ci dessus 2 Mettre le thermostat la position minimale 3 Couper le courant lectrique qui m ne l appareil 4 Cet appareil m nager tant dot d un syst me d allumage automatique ne pas essayer d allumer le br leur manuellement 5 Retirer le panneau volet d acc s de commande panneau sup rieur s il s agit d un mod le deux panneaux 6 R glez l interrupteur de commande du gaz la position OFF voir Figure 1 7 Attendre cinq 5 minutes pour s assurer de la dissipation du gaz En cas d odeur ARR TER LE PROC D Suivre les instructions ci dessus Section B En l absence de toute odeur de gaz avancer l tape suivante 8 R glez l interrupteur de commande du gaz la position ON voir Figure 1 9 Remett
44. at can be used in conjunction with the automatic heat staging jumper on the ignition control board The heat staging function will automatically move the unit into high heat operation at the time interval selected OFF Low heat operation only and ON 10 minute delay from low to high heat mode See Figure 12 page 30 Connect the Red Yellow Green Blue White and Brown optional low voltage thermostat wires to terminals R Y1 1st Stage Cool G Y2 2nd Stage Cool W1 1st Stage Heat amp W2 2nd Stage Heat optional on both the thermostat sub base and unit low voltage terminal board The C terminal Black wire is the 24V common wire required on some thermostat models See Figure 17 page 34 amp Figure 18 page 35 Checking Heat Anticipator Settings Add the current draw of the system components OR Measure the current flow on the thermostat R W circuit after the circulating blower motor has started Setthe heat anticipator according to the thermostat manufacturer s instructions for heat anticipator settings Cooling Configurations This unit is designed to operate 5 stages of cooling controlled by any standard 2 stage thermostat The connection between Y1 on the thermostat and Y1 on the unit terminal strip energizes first stage cooling The connection bewteen Y2 on the thermostat and Y2 on the unit terminal strip energizes second stage cooling The additional stages are controlled by run time and outdoor temperature
45. be disconnected from the gas supply piping system to prevent damage to the gas valve If the test pressure is less than or equal to 1 2 psig 14 inches WC the unit must be isolated from the gas supply line by closing the manual shut off valve High Altitude Conversion Conversion of this unit must be performed by qualified service personnel using only approved parts All installations mustbe made in accordance with the National Fuel Gas Code and or local jurisdiction codes High altitude conversion can befield performed by asimple adjustment of manifold pressure or a change ofthe orifices if necessary depending on type of gas being utilized The changes required depend on the installation altitude and the heating value of the gas based on sea level which can be obtained from your local gas utility The heating value of gas at high altitude is always lower than the sea level heating value The heating values listed in Table 5 amp Table 6 page 16 are based on sea level values WARNING The reduction of input rating necessary for high altitude installation may only be accomplished with factory supplied orifices Do not attempt to drill out orifices in the field Improperly drilled orifices may cause fire explosion carbon monoxide poisoning personal injury or death If installing this unit above 2 000 feet the input rate must be reduced 4 per 1 000 feet of altitude Example 12 at 3 000 feet 16 at 4 000 feet
46. ces and these requirements Clearances must be in accordance with those shown in Figure 1 page 5 A suitable mounting pad Figure 3 must be provided and be separate from the building foundation The pad mustbe levelto ensure proper condensate disposal and strong enough to support the unit s weight The slab height must be a minimum of 2 bcm above grade and with adequate drainage Remove and discard the horizontal Supply and Return duct covers located on the rear of the unit Form duct attachment flanges by bending the sheet metal outward 90 degrees along the perforated lines Firmly attach ductwork directly to these flanges with screws or other approved mechanical connections and not to the Supply Return air panels to avoid damage to internal components of the equipment Once completed use approved duct sealing methods to ensure an air and watertight seal is achieved Rooftop Rooftop installations must be located according to local building codes or ordinances and these requirements The roof must be capable of handling the weight of the unit Reinforce the roof if necessary For unit weights see Table 11 page 26 The appropriate accessory roof curb must be installed prior to unit installation The roof curb must be square and level to ensure proper condensate drainage See Figure 4 page 10 Please follow all instructions provided with the kit Secure roof curb or frame to roof using acceptable mechanical methods perlocal
47. ch subsequent call for heat until ignition failure occurs Upon ignition failure the warm up is increased by 3 seconds on the next try If successful the timing remains fixed at this level In general whenever ignition failure occurs the warm up interval is increased by 3 seconds on the next try And if successful it remains there Minimum and maximum warm up time limits are set at 9 and 54 seconds 7 Flame Proving Ignition Low Heat Operation The furnace control must prove flame via the flame sensor 5 seconds after the high main gas valve is energized f flame is sensed burners on and the igniter cools off The yellow LED will be lit If no flame is sensed the gas valve closes immediately and the inducer continues to run on high A second trial for ignition step 6 begins If no flame is sensed on the fifth try for ignition the furnace controlis locked andthe control will display 1 Hour Lockout Fault The thermostat must be opened for at least 10 seconds to reset the furnace control after a lock out Otherwise the furnace will attempt another ignition sequence in 1 hour Low Fire Heat Stage 1 If flame is present at the end of the trial for ignition time the control leaves High main gas valve energized and inducer motor on High speed for the first 15 seconds and begins the heat blower 22 second on delay Control inputs are continuously monitored while the call for heat remains The control will always energ
48. combustion air motor flame roll out control over temperature limit switch and pressure switch 6 Remove the silicone rubber tube from the collector pan to the pressure switch 7 Remove 4 nuts securing the combustion blower to the collector pan Remove the combustion blower 8 Remove all screws securing the collector pan to the unit Remove the collector pan from the unit A CAUTION To prevent damage to the unit or internal components it is recommended that two wrenches be used when loosening or tightening nuts Do not over tighten 9 Using 2 wrenches separate the ground joint union in the gas supply piping at the unit 21 10 Remove the piping between the gas valve and the ground joint union if necessary Carefully remove the four screws inside the burner box 2 at each end securing the complete burner box assembly to the heat exchanger panel as shown in Figure 8 page 23 BE EXTREMELY CAREFUL DAMAGETHE IGNITORWHILE REMOVING THE BURNER ASSEMBLY NOTE The burner box may have hooks near the top on both ends To remove this type of burner box lift the burner box upwards and then remove the box from the unit 1 12 Remove the screw securing the NOx baffle retainer clip to the heat exchanger panel then pull the baffle straight forward to remove Repeat these steps for each additional tube assembly Keep components for reuse aftercleaning 13 Attach a round wire brush to a length of high gr
49. could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Beforeservicing disconnectallelectrical power to the equipment When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A WARNING These units are fully charged with R 410A refrigerant and ready for installation When a system is installed according to these instructions no refrigerant charging is required If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this equipment Some local codes require licensed installation service personnel to service this type of equipment Under no circumstances should the homeowner attempt to install and or service this equipment Failure to comply with this warning could result in equipment damage personal injury or death WARNING Do not place combustible material on or against the unit cabinet Do not place combustible materials including gasoline and any other flammable vapors and liquids in th
50. ctions provided with the equipment prior to performing the installation and operational checkout of the equipment Never test for gas leaks with an open flame Use a commercially available soap solution to check all connections See page 14 Installation of equipment may require brazing operations Installer must comply with safety codes and wear appropriate safety equipment safety glasses work gloves fire extinguisher etc when performing brazing operations This equipmentis NOT to be used for temporary heating of buildings or structures under construction Use caution when handling this appliance or removing components Personalinjury can occur from sharp metal edges presentin all sheet metal constructed equipment e e e e The installer should become familiar with the units wiring diagram before making any electrical connections to the unit See the unit wiring label or Figure 17 page 34 amp Figure 18 page 35 REQUIREMENTS amp CODES This equipment must be installed in accordance with instructions outlined in this manual all applicable local building codes and the current revision of the National Fuel Gas Code NFPA54 ANSI 2223 1 or the Natural Gas and Propane Installation Code CAN CGA B149 1 All electrical wiring must be completed in accordance with local state and national codes and regulations and with the National Electric Code ANSI NFPA 70 or in Canada the Canadian Electric Code Part 1 CSA C 22 1
51. d vacuation vacuent correctementtel que prescrit ci dessus rouvrirles portes et les fen tres et remettre les ventilateurs d vacuation les registres de foyers et tout autre appareil fonctionnant au gaz leur tat de fonctionnement initial General Information WARNING Installation methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes for providing sufficient combustion air to the furnace Provisions must be made during the installation of this unit that provide an adequate supply of air for combustion Instructions for determining the adequacy of an installation can be found in the current revision of the NFGC ANSI 2223 1 NFPA54 Consult local codes for special requirements These requirements are for US installations as found in the NFGC The requirements in Canada B149 1 are structured differently Consult with B149 1 and local code officials for Canadian installations WARNING Combustion air must not be drawn from a contaminated atmosphere Excessive exposure to contaminated combustion air will result in safety and performance related problems To maximize heat exchanger life the combustion air must be free of chemicals that can form corrosive acidic compounds in the combustion gases The recommended source of combustion air is to use clean air from outside DO NOT place any chemicals with flammable or caustic v
52. e The operating speed history for both the current and the previous operating cycles For example with afirst stage call in cooling if the setpoint was satisfied quickly the unit will restart the next time at a lower speed At a low or intermediate speed if the setpoint is not satisfied within 60 minutes the speed will be increased If the unit cycles off after having a speed increase the entire next cycle will be at the higher speed Also the outdoor fan will run for an extra minute after the compressor shuts off The actual current operating compressor speed can be determined by checking the 2 character display on the interface board Refer to Figure 14 page 31 Figure 15 page 32 and Table 17 page 31 The blower speeds for the various cooling stages are programmed and controlled in accordance with compressor speeds It is possible to adjust blower airflow if required by application in which case the controller will adjustall speeds according to the adjusted nominal speed The airflow is set by DIP switches on the blower control board providing one flow for second stage compressor speeds and a lower flow for first stage compressor speeds De Humidification Control If installing a humidistat install it in the return air duct as directed in the installation instructions included in the accessory kit Run the humidistat wiring through the low 20 voltage wire entrance in the packaged unit and connect one side
53. e Switch Closed with Inducer Off Fault until the fault condition clears 4 Pressure Switch Proving The control energizes the induced draft motor on High speed and waits for the high and low pressure vent switch to close If the low pressure switch does not close within 12 seconds the control will display a Pressure Switch Open with Inducer On Fault If the pressure switches do not close before 60 seconds expires the control will de energize the inducer for 5 minutes and continue to display a Pressure Switch Open with Inducer On Fault during the 5 minute inducer off period After the inducer has been off for 5 minutes the control energizes the inducer motor and restarts the 60 second pressure switch proving period 5 Pre Purge If the low pressure switch closes the control runs the inducer on high speed for a 30 second pre purge time while monitoring the thermostat call for heat limit switch circuit high and low pressure switch and flame sense 6 Igniter Warm Up When the 30 second pre purge time has elapsed the control begins the Hot Surface Ignition HSI warm up as follows Initial Power up After 30 seconds of igniter warm up the gas valve will open The igniter circuit will stay energized for 3 seconds after the gas valve opens After Initial Power up The control has a programmed adaptive ignition feature which varies the warm up period as follows If ignition is successful the warm up is reduced by 3 seconds on ea
54. e vicinity of the unit WARNING PROPOSITION 65 WARNING This product contains fiberglass wool a product known to the state of California to cause cancer Disturbing the insulation of this product during installation maintenance or repair will expose you to fiberglass wool Breathing this material may cause respiratory irritations or may cause lung cancer Fiberglass wool may also cause eye irritation skin sensitization or other allergic responses in susceptible individuals Always wear goggles disposable gloves long sleeved shirt and appropriate breathing protection when working near this insulation If contact with skin occurs wash immediately with soap and water In case of contact with eyes flush immediately with water for at least 15 minutes Contact a physician if needed WARNING The information listed below and on the next page must be followed during the installation service and operation of this unit Unqualified individuals should not attempt to interpret these instructions or install this equipment Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death Before beginning the installation verify that the unit model is correct for the job The unit model number is printed on the data label Follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly understand the instru
55. eath it is the rigger s responsibility to ensure that whatever means are used to hoist the unit are safe and adequate The lifting equipment must be adequate for the load Refer to Table 11 page 26 for unit weights The unit must be lifted from the holes in the base rails using cables or chains Spreader bars are required to protect the unit and ensure even loading Keeptheunitin an upright position atall times The rigging must be located outside the units center of gravity Refer to Figure 10 page 26 amp Figure 11 page 29 for locating the center of gravity All panels must be securely in place during rigging and hoisting Clearances to Combustible Materials These units are certified as combination heating and cooling equipment for outdoor rooftop or ground level installations Units may be installed on combustible flooring or Class A B or C roofing material when used with bottom supply and return air ducts as long as the following requirements are met f using bottom discharge with return air ducts a roof curb must be installed prior to unit installation See Rigging and Hoisting section for setting of the unit Sufficient clearance for unobstructed airflow through the outdoor coil must also be maintained in order to achieve rated performance For information about locating the equipment see page 5 Ground Level Ground level installations must be located according to local building codes or ordinan
56. eighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department All gas piping must be installed in compliance with local codes and utility regulations In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 Installation Codes Some local codes require the installation of a manual main shut off valve and ground joint union external to the furnace The shut off valve should be readily accessible for service and or emergency use Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut off See Figure 7 page 16 The manifold pressure must be set to the appropriate value for your installation Refer to the Manifold Pressure Adjustment section page 18 for adjustment instructions Gas piping must never run in or through air ducts chimneys gas vents or elevator shafts Compounds used to seal joints on gas piping must be resistant to the actions of LP propane gas The main gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required An 1 8 inch NPT plugged tap must be installed in the gas line immediately upstream ofthe gas supply connection to the furnace for use when measuring the gas supply pressure The plug should be readily accessible for ser
57. f efficiency in a compact frame A 2 stage cooling 2 stage heating 24V thermostat should be used with this unit See Figure 6 page 12 24VAC control power wiring must be routed to interconnect the two stage thermostat and the the units low voltage terminal block Recommended wire gauge and wire lengths for typical thermostat connections are listed in Table 4 page 12 Eight wires must be run to the control panel R C W W2 G Y1 Y2 and L if used that originate at the thermostat Optional L provides a fault indication for some thermostats The thermostat should be mounted about 5 feet above the floor on an inside wall DO NOT install the thermostat 11 on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces sunlight or lighting fixtures and convective heat from warm air registers or electrical appliances Refer to the thermostat manufacturer s instruction sheet for detailed mounting information COPPER WIRE SIZE AWG 1 VOLTAGE DROP SUPPLY WIRE LENGTH FEET 150 100 SUPPLY CIRCUIT 50 AMPACITY 05 02 5 5 o 02 5 Wire Size based on N E C for 60 type copper conductors Table 3 Copper Wire Size RECOMMENDED T STAT WIRE LENGTH UNIT TO T STAT 2 WIRE 5 WIRE HEATING HEA
58. ff Delay Blower Interface Connection Automatic Heat Staging Used with Single Stage Heating Thermostat Only Low Voltage Control Circuit 3 Amp Fuse Figure 12 Two Stage Hot Surface Ignition amp Blower Control Board Status LED s Output Relay Red amp Green Red LED s See Table 10 Input Dehumidification tu a j mun A Terminal Ignition Control 2 ate Interface Connection Blower CFM Dipswitch Settings Inverter Blower Interface Interface Connection Connection Figure 13 VSHE Blower Control Board 30 2 Character Display Figure 14 Interface Board in Control Panel 2 CHARACTER DISPLAY CAPACITY STAGE Cooling Stage One Call Low Cooling Stage One Call Intermediate Cooling Stage One Call Low High Cooling Stage Two Call Nominal High Cooling Two Call Boost Startup Delay 5 Minutes System Powered but Idle Table 17 Interface Board Operating Codes 31 Reactor Inverter Board Interface Board Thermistors Compressor Terminal Board Contactor 5 Ton inverter assembly has additional components Contactor PTCR and Fan Terminal Block Figure 15 R6GI Inverter Assembly 2 3 amp 4 32 Hot Surface Ignition Control Board with 24V Secondary 3 Amp Fuse Protection Blower Control Board Draft Inducer Motor High Temperature Limit Auto Reset Flame Sensor Flame Roll Out Limit Manual Reset
59. gure 5 Condensate Drain amp Service Ports 10 ELECTRICAL WIRING WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failuretofollow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A AVERTISSEMENT RISQUE DE CHOC LECTRIQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourraitentrainerun fonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Un entretein incorrect pourrait entrainer un fonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Couper toute alimentation lectrique au g n rateur d air chaud avant de prod der aux travaux d entretein Au moment de l entretien des commandes tiquetez tous les fils avant de les d brancher S assurer de les raccorder correctement S assurer que l appareil fonctionne ad quatement apr s l entretien Electrical connections must be in compliance with all applicable local codes and ordinances and with the current revision of the National Electric Code ANSI NFPA 70 For Canadian installations the electrical co
60. hermostat temperature setpoint one degree below room temperature and verify the Operating Sequence page 19 Verify that the compressor and outdoor fan motor are energized NOTE System will energize Y1 and run at stage 1 intermediate speed 2 Feel the air being circulated by the indoor blower and verify that itis cooler than ambient temperature Listen for any unusual noises If unusual sounds occur determine the source of the noise and correct as necessary 3 After determining the system is operating properly wait 2 minutes then lower the thermostat temperature setpoint an additional 3 4 degrees until the system energizes Y1 amp Y2 and runs at stage 2 nominal rating speed Verify operating codes as indicated by the two digit display on the interface board See Figure 14 and Table 17 page 31 4 After the unit has run for approximately 5 minutes set the thermostat above room temperature Verify the outdoor fan and compressor stop running The indoor blower will stop after a 60 second delay System Heating 1 Set the thermostat to the lowest setting 2 Followthe procedures given on the operating instruction label in this installation instructions or attached inside the louvered control access panel 3 Setthethermostatone degree above room temperature and verify the sequence of operation See Operating Sequence section pages 19 amp 20 4 Verify that the compressor and outdoor fan motor are not energized 5 Afte
61. iliar with this equipment Some local codes require licensed installation service personnel to service this type of equipment Under no circumstances should the owner attempt to install and or service this equipment Failure to comply with this warning could result in property damage personal injury or death A CAUTION This unit uses R 410A refrigerant DO NOT use any other refrigerant in this unit Use of another refrigerant will damage the unit For charging in the field the unit should be run with a call for second stage cooling with both Y1 and Y2 outputs energized This may be accomplished by setting the thermostat to cool with a setpoint substantially lower than room temperature This will provide 60 minutes of operation at the nominal rating speed interface board display C 4 before there is a speed change to a higher speed C5 If the speed change to C5 occurs before the charging process is complete turn the system off then restart the process Refer to the charge amount listed on the units data label Alternate Procedure for Charging Air Conditioner in Cooling Mode with outdoor temperatures above 60 F Based on Subcooling While charging based on refrigerant weight shown on unit rating label is preferred this method is acceptable Use this method when the outdoor temperature is 60 F or higher to verify the correct charge in cooling mode The indoor temperature should be between 70 F and 80 F
62. intenance is important to achieve optimum performance from the system The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools If you do not possess these skills contact your dealer for maintenance Consult your local dealer aboutthe availability of maintenance contracts Routine maintenance should include the following A CAUTION The unit should never be operated without a filterinthereturnair system Replace disposable filters with the same type and size Inspect clean or replace air filters at the beginning of each heating and cooling season or more frequently if required Inspect the condensate drain and outdoor coil at the beginning of each cooling season Remove any debris Cleanthe outdoor coil and louvers as necessary using a mild detergent and water Rinse thoroughly with water Inspect the electrical connections for tightness at the beginning of each heating and cooling season The blower compartment should be cleaned monthly duringthe heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor Buildup of dirt and lint on the blower and motor can create excessive loads on the motor resulting in higher than normal operating temperatures and possible shortened service life Maintain heat exchanger and burners The unit should operate for many years without excessive scale buildup inthe heat exchanger howe
63. irto the refrigeration system After completing the repairs evacuatethe system to 350 500 microns and weigh in the refrigerant to the amount specified on the unit rating label D o 5 D 0 a 5 5 S 5 Liquid Pressure psig Remove refrigerant when above curve o Co Add refrigerant when below curve 100 Liquid Temperature F Figure 19 Charging Chart for 2 Ton Units Remove refrigerant when above curve Add refrigerant when below curve 100 Liquid Temperature F Figure 20 Charging Chart for 3 Ton Units 37 Remove refrigerant when above curve D a D a a 5 2 S 5 Add refrigerant when below curve 80 90 100 Liquid Temperature F Figure 21 Charging Chart for 4 Ton Units Remove refrigerant when above curve Liquid Pressure psig Co eo Add refrigerant when below curve 100 Liquid Temperature F Figure 22 Charging Chart for 5 Ton Units 38 170 160 150 140 130 LL m 120 Deg F 110 100 90 80 70 Temperature vs Resistance for All Thermistors Part 1
64. it control opens If the unit operates for more than four minutes with no return air set the thermostat below room temperature shut off power to the unit and replace the over temperature limit control Verifying Burner Operation WARNING Uninsulated live components are exposed when louvered control access panel is removed 1 Remove the louvered control access panel and verify there is power to the unit 2 Set thermostat above room temperature and observe the ignition sequence NOTE The burner flame should carry over immediately between all burners without lifting off curling or floating The flames should be blue without yellow tips Make sure the flame is drawn into the center of the heat exchanger tube In a properly adjusted burner assembly the flame bends down and to the right at the end of the heat exchanger tube The end of the flame will be out of sight around the bend 3 After validating flame characteristics set the thermostat below room temperature and verify the burner flame extinguishes completely Manifold Pressure Adjustment The manifold pressure must be set to the appropriate value for your installation To adjust the manifold pressure 1 Obtain the required manifold pressure setting Use Table 5 for natural gas or Table 6 page 16 for LP propane gas NOTE The values listed in the tables are based on sea level values At higher altitudes the heating value of gas is lower than the sea level heating
65. ith 1 HP motor 1 ON position 5 Ton with 1 HP motor Selecting Cooling Airflow Dip Switches 5 6 7 amp 8 The COOLING airflow is selected by setting dip switches 5 6 7 amp 8 onthe blower control board Table 12 page 27 lists the recommended airflow values CFM and switch settings for each nominal system capacity All airflows for other modes of operation are determined by these basic settings For maximum capacity generally a selection near the middle or top of the CFM range for that nominal capacity is used NOTES The CFM values listed in Table 13 amp Table 14 page 27 are not dependent on duct static pressure The motor automatically compensates within the limits of the motor for changes in duct static pressure If coil icing occurs the basic cooling airflow selected may be too low Verify the selected setting is within the range shown in Table 13 and the system is properly charged If icing continues raise the selected airflow to the next higher tap For maximum dehumidification and energy efficiency select an airflow near the middle or bottom of the CFM range for that nominal capacity The 2 stage cooling feature of the unit requires modulating the airflow The unit will automatically adjust the airflow to the appropriate rate when the unit capacity changes Selecting Heating Airflow Dip Switches 2 3 amp 4 The HEATING airflow is selected by setting dip switches 1 2 3 amp 4 on the blower c
66. ize the gas valve on High fire with the inducer on High speed for the first 15 seconds of any heating cycle After this 15 second period the control switches the gas valve to Low fire and inducer to Low speed if no second stage W2 demand is present 8 Blower Start Up After flame is proven the furnace control energizes the circulating air blower after 22 seconds The blower will then ramp up to the airflow selected for heating 9 High Heat Staging with 2 Stage Heat Thermostat Unit will always start in High heat operation See step 7 for start up sequence After the initial 15 second start up sequence is satisfied the control will move to Low heat and wait for a W2 call from a 2 stage thermostat After a second stage heat demand is present W2 energized the gas valve will open to High heat mode increasing the flow of gas to the burners while the inducer and blower motor ramp to high speed Single Stage Heat Thermostat with Automatic Heat Staging Automatic heat staging allows the unit to operate as a two stage gas furnace with the use of a single stage heating thermostat With the ignition control AUTO HEAT STAGE jumper repositioned from the OFF position to the ON position the gas furnace will automatically switch to High heat mode of operation after a 10 minute delay The induced draft motor and blower motor will both ramp to high speed See Figure 12 page 30 10 When the thermostat has been satisfied gas valve is
67. ld Assembly 2 STAGE GAS VALVE Model VR9205Q High Input Lo Input ON OFF Adjusting a Switch Screw crew Manifold pressure Tap Inlet Pressure Tap Figure 9 HI amp LO Input Adjusting Screws 23 TROUBLESHOOTING COOLING MODE Diagnostic Display The interface board located inside the control panel has a two character display which provides information regarding operational status and fault history When 24VAC control power is provided to the board the display will show some combination of characters In orderto diagnose a problem with the unit orto determine its operationalstatus remove the control panel cover then observe the 2 character lighted display on the interface board Refer to Table 7 The display will alternate between an operating code as shown in Table 17 page 31 and a list of the codes for up to the last 20 different faults or warnings When this list is being displayed each fault or warning code in memory will be displayedfor5 seconds If one ofthe stored coded conditions occurs again no repeat entry will be made Thus the fault codes in the list are not necessarily displayed in order of occurrence Fault codes are retained through loss of power The fault code list in memory can be cleared by shorting the J4 Test pins briefly when the compressoris off NOTE This action may also have other consequences See Delay Override on page 20 DISPLAY CO
68. lete one revolution 5 Convert the time per revolution to cubic feet of gas per hour using Table 16 page 28 6 Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btu per hour See Example Example Time for 1 revolution of a gas meter with a 1 cubic foot dial 40 seconds From Table 16 read 90 cubic feet gas per hour Local heating value of the gas obtained from gas supplier 1 040 Btu per cubic foot Input rate 1 040 x 90 93 600 Btuh 7 Adjust the manifold pressure if necessary See Manifold Pressure Adjustment instructions For additional information about elevations above 2 000 feet see page 15 18 Verifying Over Temperature Limit Control Operation 1 Verify the louvered control access panelis in place and that there is power to the unit 2 Block the return airflow to the unit by installing a close off plate in place of or upstream of the filter 3 Set the thermostat above room temperature and verify the units operating sequence page 19 NOTE The over temperature limit control should turn off the gas valve within approximately four minutes exact time depends on the efficiency of the close off when blocking the return air The circulating air and combustion blowers should continue to run when the over temperature limit control switch opens 4 Remove the close off plate immediately after the over temperature lim
69. lignment of the burners with the heat exchanger tubes The center of the burners should be aligned with the center of the tubes 23 Follow the operating instructions found on the right side of the door and in the User s Manual to return the unit to operation 22 Cleaning of Burners If the burners require cleaning follow the steps below 1 Shut off the gas supply to the unit either at the meter or at a manual valve in the supply piping 2 Turn off all power to the unit and set the thermostat to the lowest temperature setting 3 Remove the louvered control access panel from the unit 4 Turn the gas control knob to the OFF position See Figure 11 page 29 for gas valve shut off instructions 5 Disconnect the wires from the gas valve ignitor and flame sensor A CAUTION To prevent damage to the unit or internal components it is recommended that two wrenches be used when loosening or tightening nuts Do not over tighten 6 Using two wrenches separate the ground joint union in the gas supply piping at the unit 7 Remove the piping between the gas valve and the ground joint union if applicable 8 Carefully remove the four screws inside the burner box 2 at each end securing the complete burner box assembly to the heat exchanger panel as shown in Figure 8 page 23 BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITOR WHILE REMOVING THE BURNER ASSEMBLY NOTE The burner box may have hooks near the top on both e
70. mbustion and ventilation air to the unit See pages 6 7 Provide adequate clearances around the combustion air intake louvers See Figure 1 page 5 Combustion products must be discharged outdoors Connect this unit to an approved vent system only as specified on page 7 Additional codes listed below are for reference purposes only and do not necessarily have jurisdiction over local or state codes Local codes and regulations take precedence over any recommendations contained in these instructions Always consult with local authorities before installing any gas appliance Combustion amp Ventilation Air US National Fuel Gas Code NFGC Air for Combustion and Ventilation CANADA Natural Gas and Propane Installation Codes NSCNGPIC Venting Systems and Air Supply for Appliances Duct Systems e USand CANADA Air Conditioning Contractors Association ACCA Manual Q Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE Fundamentals Handbook Electrical Connections US National Electrical Code NEC ANSI NFPA 70 CANADA Canadian Electrical Code CSA C22 1 Gas Piping amp Gas Pipe Pressure Testing US NFGC and National Plumbing Codes CANADA NSCNGPIC General Installation US Current edition of the NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch
71. must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the CSA C22 1 Electrical Code Use the grounding lug provided in the control box next to the terminal block for grounding the unit Line Voltage The line voltage to the unit should be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the unit A properly sized branch circuit and electrical disconnect must be located within sight of and readily accessible to the unit This switch shall be capable of electrically de energizing the outdoor unit See unit data label for proper incoming field wiring Any other wiring methods must be acceptable to authority having jurisdiction Use only copper wire for the line voltage power supply to this unit See Table 3 page 12 Use proper code agency listed conduit and a conduit connector for connecting the supply wires to the unit Use of outdoor shielded conduit metal lined Sealtite is recommended Provide power supply for the unit in accordance with the unit wiring diagram and the unit rating plate Remove the control panel cover Route the power and ground wires 3 wires including earth ground from the disconnect box to the unit Connect the line voltage leads to L1 amp L2 box lugs of the high voltage terminal block and the ground wire to the grounding lug located above the terminal block Replace the
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73. ndie ou une explosion pouvant causer des dammages votre propri t votre personne ou la mort A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or move by hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water A Cet appareil m nager n a pas de veilleuse est dot d un syst me d allumage automatique Ne pas essayer d allumer le br leur manuellement B AVANT L USAGE Attention une possible odeur de gaz surtout au niveau du pl
74. nds To remove this type of burner box lift the burner box upwards and then remove the box from the unit 9 Inspect the burners for accumulated dust or debris If necessary carefully clean them with a soft wire brush andavacuumcleaner DO NOT DAMAGETHE IGNITER WHILE CLEANING THE BURNER 10 Reinstall the burner box assembly using the 4 screws removed in Step 13 11 Reconnectthe wirestothe flame roll out switch flame sensor and ignitor removed earlier in step 13 12 Reinstall the gas manifold assembly to the burner assembly with the 4 screws that were removed earlier in step 8 NOTE It is important that the center of the orifices are aligned with the center of the burners 13 Reconnect the gas piping to the gas valve inlet 14 Reconnect the wires to the gas valve terminals 15 After re installing the gas valve manifold assembly inspect the alignment of the burners with the heat exchanger tubes The center of the burners should be aligned with the center of the tubes 16 Follow the operating instructions found on the right side of the door and in the User s Manual to return the unit to operation Heat Exchanger Panel Flame Sensor Flame Ignitor Roll Out Switch Burner S Gas Valve Gas Valve i NOx Baffie Terminals ON OFF Switch A Retainer Clip amp Screw Per Tube If equipped NOx Baffle Per Tube If Equipped Gas Valve Inlet Orifices Gas Manifold dl X4 Figure 8 Burner amp Manifo
75. nnections and grounding shall comply with the current Canadian Electrical Code CSA C22 1 and or local codes IMPORTANT NOTE If replacing any ofthe original wires supplied with the furnace the replacement wire must be copper wiring having the same guage voltage and temperature rating NOMINAL COOLING CAPACITY TONS MODEL NUMBER R6GI PPG2GI E24K080X MAXIMUM HEATING INPUT NOMINAL ELECTRICAL SUPPLY E48K120X E60K120X 120 000 RA 7 5 FAN INDOOR MOTOR BLOWER FLA FLA N SINGLE CIRCUIT MCA 253 20 9 26 7 32 8 40 8 s 400 NEIN NOTE FLA Full Load Amps LRA Lock Rotor amps RLA Rated Load Amps Table 2 Electrical Data Pre Electrical Checklist Verify the voltage frequency and phase of the supply source match the specifications on the unit rating plate Verify that the service provided by the utility is sufficient to handle the additional load imposed by this equipment See Table 2 or the unit wiring label for proper high and low voltage wiring y Verify factory wiring is in accordance with the unit wiring diagram See Figure 17 page 34 amp Figure 18 page 35 Verify the connections didn t loosen during shipping or installation Grounding WARNING The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur Do not use gas piping as an electrical ground This unit
76. o to 1 999 2 000 to 4 999 5 000 to 5 999 6 000 to 7 999 8 000 to 10 000 1 000 TO 1 100 BTU CU FT 35 3 0 28 25 Table 5 Manifold Pressure Setting in WC for Natural Gas ALTITUDE ABOVE SEA LEVEL LP HEATING VALUE OF 2 500 BTU FT 3 ZERO TO 2 000 TO 3 000 TO 5 000 TO 6 000 TO 8 000 TO 1 999 2 999 4 999 5 999 7 999 10 000 MANIFOLD PRESSURE ORIFICE SIZE NOTE Manifold pressure based on sea level LP heating value of 2 500 Btu cu ft Table 6 Manifold Pressure Setting in WC amp Orifice Size for LP Gas 16 START UP amp ADJUSTMENTS Pre Start Check List Y Verify the unit is level and allows proper condensate drainage y Verify all clearance requirements are met and there is free airflow to and from the outdoor coil Verify thatthe ductworkis sealedto preventair leakage Verify that the line voltage power leads are securely connected and the unit is properly grounded Y Verify that the low voltage wires are securely connected to the correct leads on the low voltage terminal strip Verify that the gas line service pressure does not exceed 10 0 inches WC 0 36 psig and is not less than 4 5 inches WC 0 16 psig for natural gas For LP gas the line service pressure must not exceed 14 inches WC 0 51 psig and must not be less than 11 0 inches WC 0 40 psig Y Verify that the flame roll out control is closed If necessary press the red button to reset the control DO NOT inst
77. ondensate uit anis dits pl eier 1 ELECTRICAL WIBING 5 10 Pre Elecirical Checklist uuu tri trece trn 11 tiis 11 Siku 11 Thermostat Low Voltage Connections 11 Heat Cool Thermostat sure 12 Checking Heat Anticipator Settings 12 Cooling Conngalelibrfa acis aa t o ates 12 Heating Conflpgiratiofis eebe 12 Configuring the Variable Speed Blower 13 Selecting Cooling 13 Selecting Heating Airflow 13 NER SO 13 GAS SUPPLY amp 14 RE 14 High Altitude Conversion 15 LP Propane Gas Conversion 15 START UP amp ADJUSTMENTS 17 Presan Check E 17 Silat 17 ee 17 17 BEEN 17 Verifying amp Adjusting Temperature Rise I7 Verifying amp Adjusting Firing Rate 18 Verifying Over Temperature Limit Control Ea ELL E eH 18 Verifying Burner 18 Manifold Pressure Adjustment 18 OPERATING SEQUENCE 19 PASS ers 19 oa areitan
78. ons S assurer que la syst me d vacuation n est pas bloqu e restreinte corrod e qu elle ne fuit pas et qu elle ne pr sente aucun autre d faut potentiellement dangereux 3 Dans la mesure du possible fermer toutes les portes etfen tres du batiment et toutes les portes entre la pi ce se trouve l appareil raccord la syst me d vacuation et les autres pieces du batiment 4 Fermer les registres des foyers 5 Mettre en service les s cheuses et tout autre appareil qui n est pas raccord a la syst me d vacuation Faire fonctionner r gime maximal tout ventilateur d vacuation tel que les hottes de cuisini re et les ventilateurs de salles de bains Ne pas mettre en service les ventilateurs d t 6 Respecter les instructions d allumage Mettre en service l appareil l essai R gler le thermostat de que l appareil fonctionne sans interruption 7 V rifiers il yad bordement l orifice d vacuation du coupe tirage des appareils dot s d un coupe tirage 5 minutes apr s l allumage du br leur principal Utiliser la flamme d une allumette ou d une chandelle 8 Si l on constate au cours de l un des essais qui pr cedent que l vacuation est d ficiente corriger le syst me d vacuation conform ment la norm ANSI Z223 1 NFPA 54 National Fuel Gas Code et ou aux codes d installation CSA B149 1 9 Apr s avoir d termin que tous les appareils raccord s la syst me
79. ontrol board Table 14 page 27 lists the recommended airflow values CFM and switch settings for each heat exchanger capacity All airflows are determined by these basic settings For most applications the factory heat setting will operate at a nominal rise based on the furnace s nominal efficiency and firing input Follow across the table row to find the switch setting and nominal air flow Verify the selected rise is within the specification shown on the furnace rating label or Table 12 page 27 Operation When 24VAC is present at the DEHUM terminal of the blower control board the airflow requirements will be reduced to 7596 of the nominal airflow requirements If the humidity level of the conditioned space decreases during the cycle and the humidistat opens the airflow will be restored to 10096 of the selected value 13 GAS SUPPLY amp PIPING WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Installation and service must be performed by a qualified installer service agency or the gas supplier Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a n
80. r determining the system is operating properly after 1 2 minutes raise the thermostat temperature set point an additional 3 4 degrees until the heating System moves into 2nd stage or high heat operating mode The gas valve will energize to high heat mode while the induced draft motor and indoor blower motor both increase in speed 6 After the unit has run for approximately five minutes set the thermostat below room temperature Verify the shutdown sequence steps 10 12 in the Operating Sequence section page 19 Verifying amp Adjusting Temperature Rise Verify the temperature rise through the unit is within the range specified on the unit data label for both high and low firing rates Temperature rises outside the specified range could result in premature heat exchanger failure 1 Place thermometers in the return and supply air stream as close to the unit as possible The thermometer on the supply air side mustbe shielded against direct radiation from the heat exchanger to avoid false readings 2 Adjust all registers and duct dampers to the desired position Run the unit for 10 to 15 minutes before taking any temperature readings The temperature rise is the difference between the supply and return air temperatures NOTE Fortypical duct systems the temperature rise will fall within the range specified on the data label with the blower speed atthe factory recommended setting shown in Table 12 page 27 If the measured temperat
81. re le panneau volet d acc s de commande en place panneau sup rieur s il s agit d un mod le deux panneaux Rebrancher l appareil sur le r seau lectrique Ajuster le thermostat la position d sir e Si l appareil ne fonctionne pas suivre les Directives d arr t cidessous et appeler le technicien de service TO TURN OFF l DIRECTIVES D ARR T GAS TO APPLIANCE 1 Set the thermostat to the lowest setting 2 Turn off all electrical power to the appliance if service is to be performed 3 Remove the control access door panel upper door if two door model 4 Move the gas control switch to the OFF position Do not use force See Figure 1 5 the control access door panel upper door if 1 Mettre le thermostat la position minimale 2 D brancher l appareil en pr vision de la r paration 3 Retirer le panneau volet d acc s de commande panneau sup rieur s il s agit d un mod le deux panneaux 4 R glez l interrupteur de commande du gaz la position OFF Ne forcez pas voir Figure 1 5 Remettre le panneau volet d acc s de commande en place panneau sup rieur s il s agit d un mod le deux panneaux 7111710 04 11 Figure 11 Gas Valve Label 29 Electrical Information Ignition Control Fault Red amp Green LED s Yellow Flame Sense Heating Mode See OPERATING SEQUENCE amp Table 9 See OPERATING SEQUENCE amp Table 9 Blower O
82. ro and 10 000 ft above sea level The Canadian LP Propane Gas Sea Level and High Altitude Conversion Kit is for LP propane conversions in Canada ataltitudes between zero and 4 500 ft above sea level For installations between zero and 4 999 ft above sea level a 55 drill size orifice should be used Installations 5 000 ft above sea level require a 56 drill size orifice Table 6 page 16 lists the correct orifice size to use at different altitudes After changing the orifices itis required that you measure the gas input rate by clocking the gas meter and using the local gas heating value See Verifying amp Adjusting the Firing Rate section on page 18 15 Shut Off Valve Automatic Gas Valve 1 21 with manual shut off plugged tap Some utilities require Shut Off Valve to be E 4105 feet above floor Burner Assembly X l lt Dripleg LN gu Manifold Figure 7 Typical Gas Hookup Right Side Entry ALTITUDE ABOVE SEA LEVEL NATURAL GAS HEATING VALUE OF ZERO TO 1 999 2 000 TO 4 999 5 000 TO 5 999 6 000 TO 7 999 8 000 TO 10 000 800 TO 899 BTU CU FT 3 5 3 5 3 5 3 0 ALTITUDE ABOVE SEA LEVEL NATURAL GAS HEATING VALUE OF ZERO TO 1 999 2 000 TO 4 999 5 000 TO 5 999 6 000 TO 7 999 8 000 TO 10 000 900 TO 999 BTU CU FT 3 5 3 5 3 2 2 8 ALTITUDE ABOVE SEA LEVEL NATURAL GAS HEATING VALUE OF zer
83. tion Association Standard for Installation of Air Conditioning Systems 904 Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems NFPA 90B and all applicable local codes NFPA publications are available by writing to National Fire Protection Association Batterymarch Park Quincy ME 02269 or visit www NFPA org on the web Design the duct work according to Manual D by the Air Conditioning Contractors of America ACCA The ducts must be properly sized not to exceed the unit maximum ESP rating at 400 scfm per nominal ton of cooling capacity Duct work should be attached directly to the unit flanges for horizontal applications If roof curb is installed the ducts must be attached to the curb hangers not the unit It is recommended that the outlet duct be provided with a removable access panel The opening should be accessible when the unit is installed in service and shall be sized so that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger The cover for the opening shall be attached in a way that will prevent leaks If outside air is utilized as return air to the unit for ventilation or to improve indoor air quality the system must be designed so that the return air to the unit is not less than 50 F 10 C during heating operation If a combination of indoor and outdoor air is used the ducts and damper
84. ure rise falls outside the specified range it may be necessary 17 to change the blower speed Lowering the blower speed increases the temperature rise and a higher speed decreases the temperature rise The unit is equipped with a variable speed motor Heating and cooling speed selection is made by changing the dip switch settings on the blower control board located in the unit control box Refer to Configuring the Variable Speed Blower Section page 13 for additional information NOTE For change in blower speed selection to take effect system power must be cycled off then restored after 10 seconds The Variable Speed Blower VSB Control Board Figure 13 page 30 is designed with built in delay profiles for start up and shut down of the system Refer to the Operating Sequence section page 19 for more details Verifying amp Adjusting Firing Rate A CAUTION Do not re drill the burner orifices If the orifice size must be changed use only new orifices The firing rate must be verified for each installation to prevent over firing of the furnace The firing rate must not exceed the rate shown on the unit data label To determine the firing rate follow the steps below 1 Obtain the gas heating value HHV from the gas supplier 2 Shut off all other gas fired appliances 3 Start the unit in heating mode and allow it to run for at least 3 minutes 4 Measure the time in seconds required for the gas meter to comp
85. ured to the gas controls within the control area of this unit Figure 2 shows the proper installation of the vent cover assembly over the vent outlet on the exterior of the corner panel The fasteners used to secure the vent cover assembly have been included in the owner s package The vent cover assembly must be installed to assure proper operation of the unit The following list summarizes the requirements for the location of the vent system termination The location of the vent termination must be consistent with the National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 Installation Codes The vent termination must be located at least 4 feet horizontally from any electric meters gas meters regulators and relief equipment The vent termination must be located at least 3 feet above any forced air inlet located within 10 feet The vent termination must be located at least 4 feet below 4 feet horizontally from or 1 foot above any door window or gravity air inlet into any building The vent termination must be located at least 1 foot above grade The unit should be installed in a way that prevents any obstruction of the vent termination during accumulating snow Figure 2 Vent Assembly Theunitinstallation shall avoid areas where condensate drainage may cause problems by dropping on planters or patios etc Also verify exhaust gases will not impinge on windows or building surfaces which may be compromised or damaged by
86. urnace control board 2 The circulating air blower ramps to 1 2 of the selected airflow EQUIPMENT MAINTENANCE A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A AVERTISSEMENT RISQUE DE CHOC ELECTRIQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourrait entrainer un fonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Un entretein incorrect pourrait entrainer un fonctionnement dangereux de l appareil des blessures graves la mort ou des dommages mat riels Couper toute alimentation lectrique au g n rateur d air chaud avant de prod der aux travaux d entretein Au moment de l entretien des commandes tiquetez tous les fils avant de les d brancher S assurer de les raccorder correctement S assurerquel appareilfonctionnead quatement apr s l entretien A CAUTION Use care when removing parts from this unit Personal injury can result from sharp metal edges present in all equipment of sheet metal construction Proper ma
87. utomatically Dual Pressure Switch The dual pressure switch verifies that the inducer motor is drawing the combustion gases through the heat exchanger tubes and venting the gases through the vent system for both high and low fire conditions Gas Valve The gas valve controls the flow of gas to the burners in both low and high fire When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold Over Temperature Limit Control The over temperature limit control prevents the air temperature leaving the unit from exceeding the maximum outlet air temperature If the limit opens the integrated control diagnostic will flash one time The circulating air blower will continue to operate while the over temperature limit control is open OPTIONAL FURNACE CONTROL BOARD CONNECTIONS Electronic Air Cleaner The furnace control board provides output terminals for an optional electronic air cleaner EAC that can be installed in the return air duct of your system THE EAC output is energized any time the HEAT or COOL blower speed is energized Control ratings are 1 0 Amp 240 VAC Output connections are made via board terminals labeled EAC and NEUTRAL Humidifier The furnace control board provides output terminals for an optional humidifier HUM that can be installed on your system The HUM output is energized any time the furnace inducer motor is energized Control ratings are 1 0 Amp 240 VAC O
88. utput connections are made via board terminals labeled HUM and NEUTRAL 25 FIGURES amp TABLES Dimensions shown in inches mm Top View 3 4 NPT INSIDE PERIMETER FEMALE DRAIN OF BASE RAIL 31 5 CONNECTOR IF USED DOWNFLOW SUPPLY DUCT OPENING 47 50 45 75 Sak B 16 n Tz z lt 23 50 DOWNFLOW 40a A RETURN DUCT HORIZONTAL RETURN OU OPENING 175 gt SUPPLY DUCT OPENING OPENING X o z 9 16 0 B 8 13 5 5 o 9175 gt 24 75 1 8 Le D gt Back View ELECTRIC 4 SUPPLY ENTRY BLOWER ACCESS NUT LOW VOLTAGE ENTRY Side View GAS SUPPLY ENTRY Figure 10 Unit Dimensions MODEL HEIGHT IN INCHES WITHOUT BASE RAILS E24K080X E36K100X 37 57 NOTE Unit weights shown are with the unit unpacked Extended base pan models use same roof curb as 2 4 ton units Table 11 Center of Gravity amp Shipping Weights 26 Airflow Data HEATING INPUT HEATING OUTPUT HEATING HEATING RISE BLOWER MOTOR 80 000 64 800 1025 1375 100 000 81 000 1150 1500 40 7 11X 1 2 120 000 97 200 1550 2000 40 7 11X1 1 120 000 97 200 1550 2000 40 7 11X1 1 NOTE CFM and Rise are independent of ESP in a variable speed blower Table 12 Nominal Heating Airflow Rates amp Temperature Rises F 2 TON CFM
89. ver the heat exchanger the vent system and the burners should be inspected and cleaned if required by aqualified serviceman annually to ensure continued safe operation Particular attention must be given to identify deterioration from corrosion or other sources The motors for the circulating air blower outdoor fan and combustion blower are pre lubricated atthe factory No further oiling is required for the life of this product Inspectand clean the screen ofthe vent cover assembly at the beginning of each heating and cooling season Cleaning of Heat Exchanger WARNING Holes in the heat exchanger can cause products of combustion to enter the home Replace the heat exchanger if leaks are found Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death If the heat exchanger must be cleaned due to soot or scale build up follow the steps below 1 Shut off the gas supply to the unit at the meter or at the manual valve in the gas supply piping 2 Turn off all power to the unit and set the thermostat to the lowest temperature setting 3 Remove the louvered access panel from the unit 4 Turn the gas control knob gas valve to the OFF position See Figure 11 page 29 for gas valve shut off instructions 5 Disconnect the wires from the gas valve ignitor flame sensor
90. vice use A AVERTISSEMENT A drip leg should be installed in the vertical pipe run to the unit Figure 7 RISQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit This unit only has right side gas entry When connecting the gas provide clearance between the gas supply line pourrait entrainer des blessures graves la mort ou des dommages mat riels L installationet l entretien doivent tre effectu s par un installateur qualifi un organisme de service ou le fournisseur de gazstaller service agency or the gas supplier Ne pas entreposer ni utiliser de l essence ni d autres vapeurs ouliquides inflammables dans le voisinage de cet appareil ni de tout autre appareil QUE FAIRE S IL Y A UNE ODEUR DE GAZ Ne pas tenter d allumer aucun appareil Ne toucher aucun interrupteur lectrique n utiliser aucun t l phone dans le b timent vacuer l immeuble imm diatement Appeler imm diatement le fournisseur de gazen employantle t l phone d un voisin Respecter la lettre les instructions du fournisseur de gaz Si personne ne r pond appeler le service des incendies 14 and the entry hole in the unit s casing to avoid unwanted noise and or damage to the unit A typical gas service hookup is shown in Figure 7 Table 15 page 28 lists gas pipe capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line Leak Check

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