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Installation Instructions

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1. ceeeek EEE 9 Ground Level 9 Condensate Drain 9 Horizontal to Downflow Conversion 9 ELECTRICAL 10 Pre Electrical 11 tite eee nice tea 11 Line Voltage iere n Pe eee ds 11 Thermostat Low Voltage Connections 11 Checking Heat Anticipator Settings 11 Blower Speed 12 5 Speed ECM 12 PSG gere 12 Optional Furnace Control Board Connections 12 Electronic Air Cleaner 12 etie ens 12 GAS SUPPLY amp PIPING 13 ie runs a Tene denen 13 High Altitude Conversion Natural Gas 14 Lp Propane Gas Conversion 14 STARTUP amp ADJUSTMENTS 16 Pre Start Checklist sssssssss 16 Start up Procedure 16 Air Circulation 16 System Cooling 16 System Heating 16 Verifying amp Adjusting Temperature Rise 16 Verifying amp Adjusting Firing Rate 17 Manifold Pressure Adjustment 17 Verif
2. 1eddoo asn suornoeuuoo Ajddns 104 2 JULINOD 5 ay parddns se asim ay jo Aue p je 12euuooSiq SALON 2809 HOA 022 802 Jeuonipuo 21129 3 1e8H 5 peDexoedg ONIHIM 27 _____ _____ 1 4 0641 LZ Seoe eu 9M1d OZLELLZ Y3ZINONO93 JHIM 8 ASSY SS3NHVH YAdWNP H3ZINONO93 Site YAZIINONOOA Use j snonuguo sec 10 eure 4 espe J USERS ON HOIH Jo EN N OVA 022 45914 12845 ameg ONIYIM 91313 95914 HO Jeonpuy MONIA 0aN3931 pesojo xonis YMS 9018 USE UO Jeonpuj wer veao moro TUN ___ E HOSN3S HIV 438 1H917 SALVLS NOILIQNOO 17073 39NVHO OL HOLIMS HOSN3S ama MOTISA 3unssaud MOTI3A MoTI3A MOT ON 4 Q3ulniO3H 310N HOLIMS ea unn Qaadainoa HOLI9vdv9 dl HOLIMS 3unsS3ud MO HOLIMS MOTISA 1NO TIOH annoys NA worsA SOLOW Nv Nagus Y Hoodino HOSS3Hdloo MOTI3A MOTI3A 3NIVA SVO MOTISA HOLIMS 3unsS3ud HOIH MOTISA 3LIHM ISNA dv 440 Er Movig HOLOVINOO 9 31ON 33S
3. 29 Table 12 Charging Table for 2 Ton Units 29 Table 13 Charging Table for 2 5 Ton Units 29 Table 14 Charging Table for Ton Units 30 Table 15 Charging Table for 3 5 Ton Units 30 Table 16 Charging Table for 4 Ton Units 31 Figure 13 Charging Chart for 5 Ton Units 31 INSTALLATION PERFORMANCE CHECKLIST 32 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 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 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 disconnectall electrical power to the unit When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing WARNING These units are
4. seuoui oneis jeujejx3 ezIS X 40 9 urejuoo Jequunu ed 4 peeds pue jas sejouaq zyx peeds 195 sajoueq peeds jas 10192 Sajouag asiy 00096 008 9 000 96 00892 008 97 009 8 008 97 00978 00978 000 9 009 8 000 9 dino 000021 00096 000 021 000 96 000 96 000 27 000 96 000 22 00024 000 9 000 27 ndul 4021090 4 9607090 Doe 4 960 8 0 1J 9eoxevo Hzzoyzro Ho60 9 0 zL0H9 0 zL0H0 0 5t0H0 0 20 0 4 srourzo JequinN lepon Table 8 Nominal Airflow Rates amp Temperature Rises F 23 GAS INFORMATION GAS PIPE CAPACITIES Nominal Pipe Length of Pipe Run Feet Diameter IN 10 2 50 60 70 80 55 50 45 40 0 30 40 90 75 65 190 150 130 115 105 95 90 350 285 245 215 195 180 170 730 590 500 440 400 370 350 1 100 890 Cubic Feet Per Hour Required 760 670 610 Input To Furnace Btu hr 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 unit To determine the cubic feet per hour of gas fl
5. a G3ddin03 21 H31VIH SDIVIS INVIA ASVOMNVHO 1HVHO 145 13 33S AlddNS H3MOd OVA 02 802 OL Figure 12 Wiring Diagram for 208 230V 60 Hz Unit with PSC Motor 2 SOL 15281 1e jo eunjejeduie e uoneiodo paveda eq 15 ji 1snui 10 y0q si peeds euo ay parddns se asim au Aue p 2119 e snid ep suonejeijsui xne sed U9IAUO9 N 1002 pue 1Y2H SS019e si Jeduun 401284 9 punouB AOGL jeu suiejs Ss JON 2 ue sep jueuienbiun ze ojdui3 z ayejd Gunes 295 s101onpuoo 1eddoo esn suoioeuuoo Ajddns 104 z jueJnoo 5 u01 99 01d ju911n91910 pue senioeduie Ajddns 104 Buas 18mod je 312euuoosIq S310N ZHO9 HOA 0 2 808 Jeuonipuo 21129 3 1e8H ejDuis INVYSVIG ONIYIM 28 REFRIGERANT CHARGING TABLES COOLING MODE LIL Shaded boxes indicate flooded conditions Rated design values The suction pressure will be lower than design value if indoor air flow entering dry bulb or entering wet bulb temperature are lower than design 1 All pressures are lis
6. A US a 4 Lis Teo m mum BRL cn DING Residential Fumaces Through Technician DOE 10 CFR Part 430 Intertek Certification by NATE US ASSEMBLED CERTIFIED www ahridirectory org GAS SYSTEM Gas Propane Gas pipe connections leak tested NO Gas Line Pressure in W C Is there adequate fresh air supply YES N for combustion and ventilation Supply Air Temperature F F Deration Percentage During Unit Operation REFRIGERATION SYSTEM Was unit given 24 hr warm up period for crankcase heaters if equipped YES NO Stage 1 Liquid Pressure high side Stage 1 Suction Pressure low side ATTENTION INSTALLERS It is 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 using 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 unit or failure to follow safety warnings could result in serious injury death or property damage These instructions are primarily intendedto assist qualified individuals experienced in the proper installation of this appli
7. Back View 024K045T Side View SUPPLY ENTRY 4 4 4 4 amp i NU LOW VOLTAGE ENTRY GAS SUPPLY ENTRY BLOWER ACCESS Figure 9 Unit Dimensions Shipping Weight Center of Gravity Height in inches C A B with base rails without base rails 024K072 030K045T 030K072T 036 0721 036K096T 042 0721 042K096T 048K096T 048K120T X60KO96T X60K120T T Denotes C or X Table 7 Center of Gravity amp Unit Shipping Weights AIRFLOW INFORMATION 80 499 28 0 u mg LV 90 L LV INJO u nig esu 9202 SE 081 Ord Lt 9961 s 66 1 N L 6v 0191 vx CL del 02 0 1 44 6 9161 LE 0461 26 vost Sv ev 79 1 Ly Sv 0991 1281 6 00 1 0 1 6 902 17 SSEL 926 0 1 9191 se 00 144 LE 0821 E 19 926 ev 6 S94 098 996 9901 088 911 re 0 8 69 926 0501 0911 Orel CM 5161 9821 8 987 979 569 SiZ 5 S08 TE SG sia 4 wo esia 4 uo 3 uo esia 3 GLEL ie 9211 6 088 4 Jesi 3 esi 3 uuinjoo
8. To Turn Off Gas To Appliance and call your service technician or gas supplier D SWITCH INTERRUPTEUR 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 2 En cas d odeur ARRETER LE PROCEDE 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 Remettre le panneau volet d acc s de commande en place panneau sup rieur s il s agit d un mod le deux panneaux 10 Rebrancher l appareil sur le r seau lectrique 11 Ajuster le thermostat la position d sir e 12 Si l appareil ne fonctionne pas suivre les Directives d arr t cidessous et appeler le technicien de service TO TURN OFF DIRECTIVES D ARR T E GAS TO APPLIANCE 1 Set the thermostat to the lowest setting 2 Turn off all electrical power to the applianc
9. m Condensate Drain MM Mot i Bum n ACCESSORY ROOF CURB Figure 5 Refrigerant Service Ports amp Condensate Drain Locations ELECTRICAL WIRING WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failureto 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 Whenservicing controls labelall wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A AVERTISSEMENT RISQUEDECHOC LECTRIQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit pourraitentrainer 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 tiqueteztous lesfils avant deles 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 with th
10. 500 Btu ft 3 Manifold Pressure zero to 1 999 2 000 to 4 999 5 000 to 5 999 6 000 to 7 999 8 000 to 10 000 3 5 3 5 3 5 3 5 ALTITUDE ABOVE SEA LEVEL 3 zero to 1 999 2 000 to 4 999 5 000 to 5 999 6 000 to 7 999 8 000 to 10 000 3 5 3 5 3 5 3 2 ALTITUDE ABOVE SEA LEVEL 2 8 zero to 1 999 2 000 to 4 999 5 000 to 5 999 6 000 to 7 999 8 000 to 10 000 3 5 3 5 3 2 8 Table 4 Manifold Pressure Setting in WC for Natural Gas ALTITUDE ABOVE SEA LEVEL 2 5 zero to 1 999 2 000 to 2 999 3 000 to 4 999 5 000 to 5 999 6 000 to 7 999 8 000 to 10 000 Orifice Size NOTE Manifold pressure based on sea level LP heating value of 2 500 Btu cu ft Table 5 Manifold Pressure Setting in WC amp Orifice Size for LP Gas 15 START UP amp ADJUSTMENTS Pre Start Check List Verify the unit is level and allows condensate to drain Verify all clearance requirements are met and there is free airflow to and from the outdoor coil Y Verify that the duct work is sealed to prevent air leakage and air filter is installed Y Verify that the line voltage power leads are securely connected and the unit is properly grounded Verifythatthe low voltage wires are securely connected to the correct terminals in the low voltage area of the control box y Verify that the gas line service pressure
11. R8GD PPG3GD SERIES 13 SEER 80 AFUE INSTALLATION INSTRUCTIONS Single Package Gas Heating Electric Cooling Premium Model Shown WARNING FIRE OR EXPLOSION HAZARD e 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 nottouch 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 If you cannot reach your gas supplier call the fire department 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 ODEUR DE GAZ Ne pas tenter d allumer aucun appareil Ne toucher a
12. The unused leads can be placed on M1 M2 or M3 on the furnace control board These are dead terminals NOTE 1 RED Low Speed BLUE Medium Speed BLACK High Speed NOTE 2 Factory settings require the 024K045 and 030K072 models to have the same cooling and heating speed These units will have a jumper from heat to cool with the factory setting motor speed tap placed on the jumper NOTE 3 When a call for the fan G is made the furnace board initiates the heat terminal If heat and cool are jumpered the fan heat and cool will have the same blower speed 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 Output connections are made via board terminals labeled HUM and NEUTRAL Check all factory wiring to the units wiring diagram Inspect the factory wiring connections to be sure none loosened during shipping or inst
13. coil must be maintained in order to achieve rated performance See Figure 1 for minimum clearances to obstructions Aclearance of at least 36 inches from the blower access panel and from the louvered control access panel is recommended for servicing and maintenance Where accessibility to combustibles clearances are greater than minimum clearances accessibility clearances must take preference The hot condenser air must be discharged up and away from the home and if possible in a direction with the prevailing wind 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 COMBUSTION AIR amp VENTING REQUIREMENTS A 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
14. conditions Rated design values The suction pressure will be lower than design value if indoor air flow entering dry bulb or entering wet bulb temperature are lower than design 1 All pressures are listed psig and all temperatures in 2 Discharge temperatures greater than charted values indicate an undercharged system 3 TON MODELS OUTDOOR TEMPERATURE F Table 14 Charging Table for 3 Ton Models 036 Series 3 5 TON MODELS OUTDOOR TEMPERATURE F 30 Table 15 Charging Table for 3 5 Ton Models 042 Series REFRIGERANT CHARGING TABLES COOLING MODE LIL Shaded boxes indicate flooded conditions Rated design values The suction pressure will be lower than design value if indoor air flow entering dry bulb or entering wet bulb temperature are lower than design 1 All pressures are listed psig and all temperatures in 2 Discharge temperatures greater than charted values indicate an undercharged system 4 TON MODELS OUTDOOR TEMPERATURE F M Dis 142 147 152 152 154 Dis PRESS 144 149 154 155 158 Dis Press e Co oj 8 Lio Press ae N OT als N ri OR w Eg a Temp 95 Dis Temp Lia Press Lia
15. immediately with soap and water In case of contact with eyes flushimmediately 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 notattemptto interpretthese 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 instructions 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 13 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 Thisequipmentis NOTto be usedfortemporary heating of buildings or structures under construction Use caution when handling this appliance or removing components Personalinjury can occur from sharp met
16. 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 10 page 25 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 beused when loosening ortightening 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 Remove all screws securing the burner assembly to the unit 9 Carefully remove the burner assembly from the unit DO NOT DAMAGETHE IGNITERWHILE REMOVING THE BURNER ASSEMBLY 10 Inspect the burners for accumulated dust or debris If necessary carefully clean them with a soft wire brush and a vacuum cleaner DO NOT DAMAGETHE IGNITER WHILE CLEANING THE BURNER 11 Replace all the parts in reverse order from which they were removed 12 Follow the lighting instructions found on the lower unit door to return the unit to operation 13 Verify proper operation after servicing 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 ex
17. per hour using Table 10 page 24 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 10 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 Adjustthe manifold pressure if necessary See Manifold Pressure Adjustment above For additional information about elevations above 2 000 feet see page 14 Manifold Pressure Adjustment The manifold pressure must be set to the appropriate value for your installation To adjust the manifold pressure 1 Obtainthe required manifold pressure setting Use Table 4 page 15 for natural gas or Table 5 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 value 2 Remove the regulator capscrew Figure 8 from the INLET side of the regulator 3 Slowly turn the adjustment screw inside the regulator to obtain the appropriate manifold pressure NOTE Turning the screw clockwise increases the pressure and turning the screw counter clockwise decreases the pressure To prevent backing the screw all the way out from the valve turn the screw slowly 4 Replace and tigh
18. speed if 3 SPD is selected on the control 2b PSC Motors The circulating blower is energized immediately on the heat speed NOTE If a call for heat occurs the circulating blower de energizes prior to normal heating cycle 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 Capacitors Pressure Switches Compressors Relays Contactors Temperature Limit Switches Gas Valves Thermostats Ignition Controls Time Delay Relays Ignitors Flame Sensors Transformers Motors Blower Motor Fan Motor Inducer Blower Motor Components Blower Assembly Fan Grille Burner Manifold Filter Driers Burners Orifices Gaskets Cabinet Panels Expansion Valves Heat Exchanger EQUIPMENT MAINTENANCE WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failureto 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 Whenservicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A AVERTISSEMENT RISQUE DECHOC LECTRIQUE D INCENDIE OU D EXPLOSION Le non respect des avertissements de s curit
19. system only as specified on page 7 The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes Always consult with local authorities before installing any gas appliance Combustion amp Ventilation Air US National Fuel Gas Code NFGC Airfor Combustion and Ventilation CANADA Natural Gas and Propane Installation Codes NSCNGPIC Venting Systems and Air Supply for Appliances Duct Systems US and CANADA Air Conditioning Contractors Association ACCA Manual D 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 ofthe NFGC andthe 908 For copies contactthe National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or American Gas Association 400 N Capitol N W Washington DC 20001 or www NFPA org CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario M9W 1R3 Canada Safety e US NFGC 54 1999 ANSI 2223 1 and the Installation Standards Warm
20. to the unit for use when measuring the gas supply pressure The plug should be readily accessible for service use A drip leg should be installed in the vertical pipe run to the unit See Figure 7 This unit only has right side gas entry When connecting the gas provide clearance between the gas supply line 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 9 page 24 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 WARNING FIRE OR EXPLOSION HAZARD Never test for gas leaks with an open flame Check all connections using a commercially available soap solution A fire or explosion may result causing property damage personal injury or loss of life Failure to follow the safety warnings exactly could result in serious injury death or property damage Afterthe gas piping to the unitis complete all connections must be tested for gas 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 13 adequately and must be retightened Repeatthe tightening and soap check process until bubbling ceases If pressure testing the gas suppl
21. which have a Schrader depression device present to actuate the valve Draw a vacuum on gauge lines to remove air before attaching them to the service ports on the unit Refrigerant charging must be done by qualified personnel familiar with safe and environmentally responsible refrigerant handling procedures 18 OPERATING SEQUENCE The operating sequences for the heating cooling and fan modes are described below Refer to the field and unit wiring diagrams Figures 11 amp 12 pages 27 amp 28 Heating Mode 1 On a call for heat the thermostat closes and applies 24 VAC to the W terminal of the control board 2 The control board checks for continuity on the 24 VAC limit control circuit through the over temperature limit switch and flame rollout switch in series If an open limit is detected the control board will energize the inducer blower All other system functions will be inoperable until the limit circuit closes While the limit is open the red LED will pulse at a rate of 1 blink per unit time 3 The furnace control checks for continuity 24 VAC across the pressure switch If the pressure switch is closed the heat mode sequence will not continue If it remains closed for 10 seconds the red LED will flash 3 times repetitively until the fault condition clears 4 The inducer energizes if pressure switch is open 5 The pressure switch will close If the pressure switch does not close after 10 seconds the fault LED will f
22. Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 and 2 MOO National Standard of Canada NSCNGPIC GENERAL INFORMATION This Single Package Gas Heating Electric Cooling Unit is designed only for outdoor rooftop or ground level slab installations and can be readily connected to the high static 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 Toachieve 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 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 sup
23. IZINONO23 H3ZIINONOO3 YAZINONOOS yooyD ampeg uonub USE HO ui xonis YAMS eunsseJg used 2 UO Je9npu uedO onis YAMS einsseid quur MOTI3A 3 45 5 TO ES 1H911 SNLYLS NOILIGNOD 1ueseJg OZZLLLZ HOIH 05815 SNONURUOD 120615 105095 Sue MO MO MOTIAN LHOIT Sn1V1S NOLLIQNO2 11073 SENS HOSN3S 3AV14 ania HOSN3S HIV OL HOLIMS HOLIMS 3unsSdud IMS MOTI3A amp MOTISA MOTONI v Men LON MOTI3A Jl HOLIMS HOLI9vdv9 N3399 3unssdud HOLIMS 31IHM 100 1109 HOSS3HdWOO AAWA SVD HOLINOI HOLIMS 3unssdud H9V14 HOLOVLNOO a3dainoa 21 H31V3H SNIVLS NV ASVOYHNVHO MOTI3A H3MO 18 AlddNS H3MOd OWA 02 802 OL Figure 11 Wiring Diagram for 208 230V 60 Hz Unit with ECM Motor ejejd ees ju911n91910 pue sanioeduie asim Ajddns 104 snid ap suonejjeisur xne sed juarauoo ON 2 2 SOL 15281 je jo AOGL ey suiejs s uo ojqeiins JON 2 sunajonpuoo Sap jueurenbiun ze ojdu3 2 e peoejdai eq 15 1i paveda
24. 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 Anelectrical disconnect mustbe 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 Table 2 Use proper code agency listed conduit and a conduit connector for connecting the supply wires to the unit Use of rain tight conduit is recommended Provide power supply for the unit in accordance with the unit wiring diagram and the unit rating plate 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 Table 11 or the unit rating plate for minimum 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 before making any electrical connections to the outdoor unit See Figures 11 amp 12 Units are shipped from the factory wired for 240 volt transformer operation For 208V operation remove the lead from the transformer terminal marked 240V
25. National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Codes 9 Afterithas been determined that each appliance connectedtothe 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 A 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 Scellertoute 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 instructions 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 b timent et toutes les portes entre la pi ce o se trouve l appareil racco
26. Press Dis Temp Lia Press Wolo QG ND 160 397 159 164 168 172 177 5 5 m m no DIAA amp on co m m m m m 4 RI Table 16 Charging Table for 4 Ton Models 048 Series 5 Ton Charging Chart Remove refrigerant when above curve psig AR 5 a 5 5 S a Add refrigerant when below curve 80 85 90 95 100 105 110 Liquid Temperature F 115 120 125 130 135 Figure 13 Charging Chart for 5 Ton Models X60K Series 31 INSTALLATION PERFORMANCE CHECK LIST INSTALLATION ADDRESS CITY STATE UNIT MODEL UNIT SERIAL UnitInstalled Minimum clearances per Figure 1 page 5 INSTALLER NAME CITY STATE Has the owner s information been YES reviewed with the customer Has the Literature Package been left NO with the unit NO ELECTRICAL SYSTEM NO NO Rated Voltage VOLTS L1 L2 Volts VOLTS Has the thermostat been calibrated Is the thermostat level Is the heat anticipator setting correct NO NO NO Filter s secured in place Filter s clean NO NO NO NO We Encourage Professionalism
27. User s Manual from the equipment For rooftop installations remove and discard the two supports attached beneath the unit Rigging amp Hoisting WARNING To avoid the risk of property damage personal injury or death 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 7 page 22 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 e Keep the unit in an upright position at all times The rigging must be located outside the units center of gravity Refer to Figure 9 page 22 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 If 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 o
28. al edges presentin all sheet metal constructed equipment Follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment Theinstaller should become familiar with the units wiring diagram before making any electrical connections to the unit See the unit wiring label or Figures 11 amp 12 pages 27 amp 28 REQUIREMENTS amp CODES This equipment mustbe 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 Z223 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 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 CI for special installation requirements This equipment contains liquid and gaseous refrigerant under high pressure Installation or se
29. allation 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 aqualified installer service agency orthe 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 mortou 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 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 Evacuer l immeu
30. ance Some local codes require licensed installation service personnel for this type of equipment O ARD CERTIFIED www ahridirectory org Unitary Small AC YOUR ENVIRONMENT amp OUR EXPERTISE v MEMBER COMPANY HRAI NORDYNE COMPLETE COMFORT GENUINE VALUE Ke Specifications amp illustrations subject to change without notice or incurring obligations O Fallon MO Printed in U S A 01 13 709332B Replaces 7093324
31. and connect it to the terminal marked 208V Connect the line voltage leads to the terminals on the contactor inside the control compartment Thermostat Low Voltage Connections This unit is designed to operate from a 24 VAC Class Il control circuit A single stage cooling single stage heating thermostat should be used with this unit A 2 stage cooling 2 stage heating thermostat is recommended for economizer operation See Figure 6 page 12 for typical thermostat connection 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 and the indoor equipment The low voltage wires must be properly connected Route 24V control wires through the sealing grommet near the power entrance Recommended wire gauge and wire lengths for typical thermostat connections are listed in Table 3 page 12 Several thermostat options are available depending on the accessories installed with the unit Select a thermostatthat operates in conjunction with the installed accessories The thermostat should be mounted about 5 feet above the floor onan inside wall DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces sunlight or lighting fixtures a
32. as finished If the unit does not operate in the heating mode check the following The thermostat is operating properly Electrical power to the unit is turned on The filters are not dirty The gas is turned on and the manual shut off valve is open The service doors are in place The flame roll out control is closed The diagnostic codes listed in Table6 or on the wiring diagrams Figures 11 amp 12 pages 27 amp 28 The 3 amp fuse is operational FAULT CONDITION STATUS LIGHT Red LED On Limit Circuit Open 1 Flash 2 Flashes 3 Flashes 4 Flashes Pressure Switch Stuck Open with Inducer ON Pressure Switch Stuck Closed with Inducer OFF Ignition Failure Check Ground 230 VAC amp Neutral Reversed or Continuous Flash False Flame or Gas Relay Shorted Off Power Off STATUS LIGHT Yellow LED Continuous Flash Low Flame Sensor Signal On Flame Present Table 6 Diagnostic Codes FAULT CONDITION 21 22 FIGURES amp TABLES 9 75 m t 24 75 n 4 0 HORIZONTAL HORIZONTAL RETURN DUCT SUPPLY DUCT OPENING OPENING 16 0 13 5 Top View 3 4 INSIDE PERIMETER FEMALE DRAIN OF BASE RAIL 25 CONNECTOR IF USED DOWNFLOW SUPPLY DUCT OPENING CONDENSING COIL i ODEN PN ER DOWNFLOW RETURN DUCT OPENING 47 50 ELECTRIC 55 8
33. ble 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 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 unit 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 ofthe manual main gas shut off See Figure 7 page 15 Themanifold pressure must be settothe appropriate value for your installation Refer to the Manifold Pressure Adjustment section page 17 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 shutoff valve and main power disconnect to the unit 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
34. 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 Refrigerant Charging WARNING These units are shipped fully charged with R 410A refrigerant and ready for installation When a system is installed according to these instructions norefrigerant chargingis required If repairs make it necessary for evacuation and charging it should only be done 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 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 refrigerantin this unit Use of another refrigerant will damage the unit The system refrigerant charge can be checked and adjusted through the service ports provided at the front panel Use only gauge lines
35. changer tubes the roll out control will open within several seconds and the integrated control diagnostic light will flash one time The circulating air blower and combustion blower will continue to operate if the flame roll out control opens Flame Sensor The flame sensor acts to prove that flame has carried over from the ignitor to the right most burner If no flame is sensed the unit will be shut down automatically Gas Valve The gas valve controls the flow of gas to the burners When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold Pressure Switch The 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 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 and combustion blower will continue to operate if the over temperature limit control opens TROUBLESHOOTING If the unit does not operate in the cooling mode check the following The thermostat is operating properly Electrical power to the unit is turned on The filters are not dirty The service doors are in place The 3 amp fuse is operational Theanti short cycle timer s 5 minute cycle h
36. 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 install 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 y 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 WARNING If this unit is equipped with crankcase heaters allow 24 hrs for heating of the refrigerant compressor crankcase prior to start up or anytime the power has been removed for more than 12 hrs Failure to comply may result in damage or cause premature failure of the system Air Circulation Leave the thermostat system mode on OFF and set the fan mode to ON Blower should run continuously Check the air deliver
37. e current revision of the National Electric Code ANSI NFPA 70 For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code CSA C22 1 and or local codes IMPORTANT NOTE If replacing any of the original wires supplied with the furnace the replacement wire must be copper wiring having the same guage voltage and temperature rating 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 and Table 11 page 26 or the unit rating label for proper high voltage wiring requirements y Verify factory wiring is in accordance with the unit wiring diagram Figures 11 amp 12 pages 27 amp 28 Make sure 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 must 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 Grounding of the unit is accomplished by using the grounding lug provided in the control box
38. e 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 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 Figure 10 Gas Valve Label 25 Model Number Heating Input BTUh 45 000 ELECTRICAL DATA amp DIAGRAMS Nominal Electrical Supply 208 230 60 1 Voltage Range Compressor Min Max RLA LRA Minimum Maximum Circuit Over current Ampacity Protection 72 000 208 230 60 1 45 000 208 230 60 1 72 000 208 230 60 1 72 000 208 230 60 1 96 000 208 230 60 1 72 000 208 230 60 1 96 000 208 230 60 1 96 000 208 230 60 1 120 000 208 230 60 1 96 000 208 230 60 1 120 000 208 230 60 1 NOTE FLA Full Load Amps LRA Lock Rotor amps RLA Rated Load Amps 26 Table 11 Electrical Data 9NHMGi 4o z penous ON3931 fejog seo 10 4 espe ON Ond SYIM 8 ASSY SS3NHVH JO 9 OWA OES ONL Y
39. emovers varnishes etc Hydrochloric acid Masonry acid washing materials Plumbing Stack A vent cover assembly has been supplied with the unit and can be found secured to the gas controls within the control area of this unit The vent cover assembly must be installed to assure proper operation of the 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 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 Theunitinstallation shall avoid areas where condensate drainage may cause problems by dropping
40. escribed in the following sections must comply with the National Fuel Gas Code and all applicable local codes for providing sufficient combustion air to the unit 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 Z223 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 Combustible 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 inthe combustion gases The recommended source of combustion air is to use clean air from outside DO NOT place any chemicals with flammable or caustic vapors 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 r
41. etween the gas valve and the ground joint union if necessary 11 Remove the screws that secure the burner assembly in place and the burner assembly BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITOR WHILE REMOVING THE BURNER ASSEMBLY 12 Attach a round wire brush to a length of high grade stainless steel cable such as drain clean out cable Attach the other end of the spring cable to a variable speed reversible drill Slowly insertand 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 13 Remove all loosened debris from the heat exchanger tubes using high pressure air and vacuum cleaner 14 Using a light check the condition of the upper and lower sections of the heat exchanger tube 15 Inspect the burners and if necessary clean them carefully with a soft wire brush and or the nozzle of a vacuum cleaner DO NOT DAMAGETHE IGNITOR OR FLAME SENSORWHILE CLEANINGTHE BURNER 16 Replace all the parts in reverse order from which they were removed 17 Follow the operating instructions found on the right side door and the User s Information Manual to return the unit to operation Cleaning of Burners If the burners must be cleaned 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
42. ft above sea level For altitudes between 5 000 and 10 000 feet above sea level the unit can be converted by adjusting the unit s manifold pressure See Table 4 for the correct manifold pressure settings NOTE 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 etc Deration is necessary to compensate for low atmospheric pressure at high altitudes 14 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 IMPORTANT NOTE When converting a 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 17 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 li
43. 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 A 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 the 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 Breathingthis material may causerespiratory irritations or may cause lung cancer Fiberglass wool may also causeeyeirritation skin sensitization or other allergic responses in susceptible individuals Always wear goggles disposable gloves long sleeved shirt and appropriate breathing protection when working nearthis insulation If contact with skin occurs wash
44. ing diagram or Figures 11 amp 12 pages 27 amp 28 Refer to the Blower Speed section page12 for additional information The integrated control starts the circulating air blower 30 seconds after the gas valve is opened The control is factory wired to turn the blower motor off 90 135 seconds after the gas valve is closed ECM Motors The heating blower off delay is factory set at 90 seconds An additional 45 second off delay is programmed into the ECM blower motor for a total of 135 seconds PSC Motors A moveable jumper is provided to select between four heat blower off delay times 60 90 120 and 180 seconds The control is shipped with the jumpers in the 120 second position The control defaults to 90 seconds if the jumper is not attached 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 unit 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 requiredforthe gas meter to complete one revolution 5 Convert the time per revolution to cubic feet of gas
45. lash 2 times and the inducer will continue to run until the switch is closed 6 The inducer will pre purge for 30 seconds and then the igniter will start its warm up as follows Initial Power up After 30 seconds of igniter warm up the gas valves 24 VAC 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 each 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 6 and 54 seconds 7 The furnace control must prove flame via the flame sensor 5 seconds after the gas valves open If flame is sensed burners are on and the igniter cools off If no flame is sensed the gas valve closes immediately and the inducer continues to run A second trial for ignition step 6 begins If no flame is sensed on the fifth try for ignition the furnace control is locked and the red LED will blink 4 times repetitively The thermostat must be opened for at least ten seconds to reset the furnace control after a l
46. mais 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 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 OPERATING INSTRUCTIONS MODE D EMPLOI Fal STOP Read the safety information above on 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 gas 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 10 Turn on all electrical power to the appliance 11 Turn the thermostat to a desired setting 12 If the appliance will not operate follow the instructions
47. nches WC Nominal Approximate Approximate Recommended Cooling Air Flow Filter Area Filter Size Tonnage Range CFM Sq In In x In 600 900 20 x 25 750 1200 20 x 30 1100 1300 25x25 1200 1600 24 x 30 1400 1800 18 x 24 2 required 1700 2200 20 x 25 2 required Based on velocity of 300 ft min for disposable filters Table 1 Recommended External Air Filter Sizes Unconditioned Spaces All duct work passing through unconditioned space must be properly insulated to minimize ductlosses 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 ofthe 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
48. nd convective heat from warm air registers or electrical appliances Refer to the thermostat manufacturer s instruction sheet for detailed mounting information Checking Heat Anticipator Settings Add the current draw of the system heating 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 COPPER WIRE SIZE AWG 196 Voltage Drop Supply Wire Length Feet Supply Circuit 200 150 100 Ampacity 5 5 02 62 5 5 2 o 0 015 Wire Size based on N E C for 60 type copper conductors Table 2 Copper Wire Size 11 39078 1VNINHAL INDOOR THERMOSTAT SUB BASE TYPICAL FURNACE BOARD Figure 6 Typical Thermostat Connection Field Supplied for 1 Stage Cool 1 Stage Heat Recommended T Stat Wire Thermostat Length Unit to T Stat Wire Gauge 2 Wire Heating 5 Wire Heating Cooling Table 3 Thermostat Wire Gauge Blower Speed The blower speed is preset at the factory for proper fan only heating and cooling operation These factory settings are listed in Table 8 page 23 For optimum system performance and comfort it may be necessary to change the facto
49. ock out Otherwise the furnace will attempt another ignition sequence in 1 hour 8 After the gas valve opens 30 seconds the blower will ramp to the selected airflow and continues to run 9 Whenthe thermostat has been satisfied the W terminal on the integrated control is de energized 10 The gas valve circuit is de energized and the gas valve closes 11 The inducer motor will continue to run for the post purge period of 25 seconds 12 The main blower will continue to run for the BLOWER OFF delay of 90 135 seconds 13 After the BLOWER OFF timer has been satisfied the integrated control de energizes the main circulating blower circuit Cooling Mode 1 On a call for cooling the thermostat closes applying 24 VAC to the G amp Y terminals on the low voltage terminal strip 2 The G terminal applies 24VAC to the G terminal of the integrated control energizing the main circulating blower circuit at the cooling speed 3 The Y terminal applies 24VAC to the contactor 4 When the thermostat is satisfied the contactor and integrated control de energize Compressor and outdoor fan will stop running 5 The circulating blower motor de energizes after a 40 second delay Fan Mode 1 On a call for fan only operation the thermostat applies 24 VAC to the G terminal connected to the G terminal of the integrated control 2a ECM Motors The circulating blower is energized immediately at the heating speed if 2 SPD is selected or fan only
50. ome 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 10 page 25 for gas valve shut off instructions 20 5 Disconnect the wires from the gas valve ignitor flame sensor 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 ortightening nuts Do not over tighten 9 Using 2 wrenches separate the ground joint union in the gas supply piping at the unit 10 Remove the piping b
51. on planters or patios etc Also verify exhaust gases will not impinge on windows or building surfaces which may be compromised or damaged by 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 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 A WARNING This unit is intended for outdoor installation only Do notventthe unitthrough a conventional venting system Figure 2 Vent Assembly CIRCULATING AIR SUPPLY WARNING Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply 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 All return ductwork must be adequately sealed all joints must be taped and the ductwork must be secured to the unit with sheet metal screws 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 unitis mounted m
52. ork 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 Horizontal to Downflow Conversion The unit is 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 the horizontal duct cap 2 Locate the duct cap inside the duct openings and remove the screw holding it in place 3 Lift the cap out of the unit Hint The cap can be pushed up from the bottom by reaching through the fork slot 4 Cover the horizontal duct opening with the horizontal duct cap 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 located on the front side of the unit See Figure 5 on page 10 Install a 2 inch condensate trap in the drain line of the same 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 10 NM VINO JN W Du
53. ow required by the unit divide the input rate of the unit by the heating value from gas supplier of the gas Table 9 Capacity of Black Iron Gas Pipe cu ft per hour for Natural Gas w Specific Gravity 0 60 GAS FLOW RATES CUBIC FEET PER ONE REVOLUTION REVOLUTION OF GAS METER CE 20 180 18e 12e TIME FOR GAS FLOW RATES CUBIC FEET PER REVOLUTION OF GAS METER TIME FOR ONE REVOLUTION SECONDS 250 237 220 209 m o lols n s 0 AJN Table 10 Gas Flow Rates Cubic Feet per Hour 24 FOR YOUR SAFETY READ I POUR VOTRE S CURIT BEFORE OPERATING 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 incendie 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 e Do not try to ligh
54. ply 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 Y Survey the job site to determine the best location for setting the unit Choose an appropriate location that minimizes the length of the supply and return air ducts y Please consult your dealer for maintenance information and availability of maintenance contracts Please read all instructions before installing the unit See Note 1 See Note 2 TOP OF UNIT TO BE UNOBSTRUCTED NOTE 1 6 When coil is present on duct side NOTE 2 1 When no coil is present on duct side Figure 1 Clearance Requirements Locating the Equipment 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 in a confined space or recessed area where discharge air from the unit to re circulate into the condenser air inlet through the coil Sufficient clearance for unobstructed airflow through the louvered control access panel and outdoor
55. pourraitentrainer unfonctionnement 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 tiqueteztous 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 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 maintenance 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 19 A CAUTION The unit should never be operated without a filter inthe returnair 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 ou
56. rd la syst me d vacuation et les autres pi ces du b timent 4 Fermer les registres des foyers 5 Mettre en service les s cheuses et tout autre appareil qui n est pas raccord 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 mani re ce que l appareil fonctionne sans interruption 7 N rifiers il y a d bordement 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 systeme 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 Apres avoir d termin que tous les appareils raccord s la syst me d vacuation vacuent correctementtel que prescrit ci dessus rouvrir les 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 d
57. rder to achieve rated performance See page 5 for information about locating the equipment 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 For unit weights see Table 7 Reinforce the roof if necessary The appropriate accessory roof curb Figure 3 page 10 must be installed prior to unit installation The roof curb must be square and level to ensure proper condensate drainage Please follow allinstructions provided with the kit Secure roof curb or frame to roof using acceptable mechanical methods per local codes NOTE Make sure the two supports beneath the unit have been removed e Ground Level Ground level installations must be located according to local building codes or ordinances and these requirements Clearances must be in accordance with those shown in Figure 1 page 5 A suitable mounting pad must be provided and be separate from the building foundation The pad must be level to ensure proper condensate disposal and strong enough to support the unit s weight The slab height must be a minimum of 2 5cm above grade and with adequate drainage See Figure 4 page 10 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 ductw
58. rvicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment Installthis unitonly in a location and position as specified on page 5 This unit is designed only for outdoor installations and should be located with consideration of minimizing the length of the supply and return ducts Consideration should also be given tothe accessibility of fuel electric power service access noise and shade 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 10 page 23 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 Use only with the type of gas approved for this unit Refer to the unit rating plate Provide adequate combustion 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
59. ry set speed A CAUTION To avoid personal injury or property damage make sure the motor leads do not come into contact with any uninsulated metal components of the unit 5 Speed ECM Motor 1 Shut off all electrical power to the unit and remove the blower panel Locate the orange red and blue wires terminated to the blower motor NOTE The orange wire controls cooling operation while the red wire controls heating operation The blue wire controls fan only operation 2 Verify the required speed from the airflow data found in Table 8 Place appropriate wire on the correct motor speed tap for the required airflow point 3 The integrated furnace control can be set to a 2 or 3 speed mode NOTE 1 When a G only call is received from the thermostat indicating a continuous fan mode the blower will run the HEAT speed when the 2 SPD mode 12 is selected using the jumper on the control board factory setting NOTE 2 When3 SPD modeis selected the FAN speed is energized and may be different than the heating or cooling speed jumper is present the control defaults to the 2 SPD HEAT speed mode of operation A call for heating or cooling takes priority over fan only mode PSC Motor 1 Disconnect all electrical power to the unit and remove the control panel cover 2 Placethe desiredblower lead for cooling onthe furnace board terminal marked COOL 3 Placethe desired blower lead for heating on the furnace board marked HEAT
60. s 18 19 Verifying amp Adjusting Temperature Rise Verify the temperature rise through the unit is within the range specified on the unit data label 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 must be 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 For typical duct systems the temperature rise will fall within the range specified on the data label with the blower speed at the factory recommended setting shown in Table 8 page 23 If the measured temperature rise falls outside the specified range it may be necessary 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 multi soeed motor On units with ECMtype motors speed selection is made by moving the leads on the blower motor terminal block If the unit is equipped with a PSC type motor speed selection is made by moving the leads on the furnace control board The speed taps for adjusting the motor speed are shown in the unit wir
61. sible when the unit is installed in service and shall be sizes 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 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 NOTE TO INSTALLER 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 suitable air filter must be installed upstream of the evaporator coil of the return air system Refer to Table 1 for recommended external filter sizes All return air must pass through the filters before entering the evaporator coil It is important that all filters be kept clean andreplaced frequently to ensure proper operation of unit Dirty or clogged filters will reduce the efficiency of the unit and result in unit shutdowns Air filter pressure drop must not exceed 0 08 i
62. sted below The United States LP Propane Gas Sea Level and High Altitude Conversion Kit P N 9044044 is for LP propane conversion in the United States at altitudes between zero and 10 000 ft above sea level The Canadian LP Propane Gas Sea Level and High Altitude Conversion Kit P N 904405 for LP propane conversions in Canada at altitudes between zero and 4 500 ft above sea level For installations between zero and 4 999 ft above sea level a 54 drill size orifice should be used Installations 5 000 ft above sea level require a 55 drill size orifice Table 5 page 15 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 17 Shut Off Valve with 1 8 NPT plugged tap Automatic Gas Valve with manual shut off Some utilities require Shut Off Valve to be 4 to 5 feet above floor Burner Assembly X Dripleg P gu Manifold Figure 7 Typical Gas Hookup Right Side Entry Natural Gas ALTITUDE ABOVE SEA LEVEL Heating Value of 800 to 899 Btu cu ft Natural Gas Heating Value of 900 to 999 cu ft Natural Gas Heating Value of 1 000 to 1 100 Btu cu ft LP Heating Value of 2
63. t any appliance Do not touch any electrical switch do not use any phone in your building mmediately 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 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 Il 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 plancher 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 ja
64. tdoor 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 heatexchanger however the heat exchanger the vent system and the burners should be inspected and cleaned if required by a qualified 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 Inspect and clean the screen of the vent cover assembly at the beginning of each heating and cooling season Cleaning of Heat WARNING Holes inthe heat exchanger can cause products of combustion to enter the h
65. ted psig and all temperatures in 2 Discharge temperatures greater than charted values indicate an undercharged system 2 TON MODELS OUTDOOR TEMPERATURE F 75 8 85 100 105 r p Dis Lio Dis Lio Dis Lio Dis Lio Dis Lio Dis Lio Dis Lio Dis Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp Press Temp 130 T 135 182 140 137 141 142 143 144 147 0 e AJAJ 148 154 153 157 161 165 388 168 L T ___ ____ EE Table 12 Charging Table for 2 Ton Models 024K Series 2 5 TON MODELS 14 EPI ered PR RI UN BR R R R O Oo o 5 5 alala E AJAJAJ O A 1 o 118 1 1 C Er o E O1 D wo R wo gt gt E o le R A Er E o OUTDOOR TEMPERATURE F Table 13 Charging Table for 2 5 Ton Models 030K Series 29 REFRIGERANT CHARGING TABLES COOLING MODE LIL Shaded boxes indicate flooded
66. ten the regulator capscrew over the adjustment screw Capscrew Inlet Pressure Manifold Pressure Figure 8 Regulator Capscrew amp Tap Locations Verifying Over Temperature Limit Control Operation 1 Verify the louvered control access panel is 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 pages 18 19 NOTE The over temperature limit control should turn off the gas valve within approximately four minutes exacttime 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 limit 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 17 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
67. ucun 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 Sipersonne 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 INFORMATION 5 Before You Install this 5 Locating the Equipment 5 Combustion Air Requirements 5 Heating Load seereis eeraa tooi i 5 COMBUSTION AIR amp VENTING REQUIREMENTS 6 General Information 7 Vent Termination 7 CIRCULATING AIR SUPPLY 8 AW DUGIS pio eo 8 Air Filter Requirements 8 Unconditioned 8 Acoustical Duct Work 8 UNIT INSTALLATION sise 9 Packaging 9 Rigging amp HOISTING 9 Clearances to Combustible Materials 9
68. ust 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 Protection Association Standard for Installation of Air Conditioning Systems 90 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 0 30 inches WC pressure drop per 100 feet of equivalent duct 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 duct supports not the unit It is recommended that the outlet duct be provided with a removable access panel The opening should be acces
69. 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 inthe 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 and all doors between the space in whichthe appliance s connectedto 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 Adjustthethermostat so appliance is 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
70. y 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 should stop running 16 System Coolin 1 Set the thermostat s system mode to COOL and the fan mode to AUTO Gradually lower the thermostat temperature setpoint below room temperature and verify the compressor fan and indoor blower energize 2 Feel the air being circulated by the indoor blower and verify that it is cooler than ambient temperature Listen for any unusual noises If unusual sounds occur determine the source of the noise and correct as necessary 3 Allow the cooling system to operate for several minutes and then set the temperature selector above room temperature Verify the fan and compressor cycle off with the thermostat NOTE The blower will also stop after a 40 second delay System Heating 1 Set the thermostat to the lowest setting 2 Follow the procedures given on the operating instruction label this manual or attached inside the louvered control access panel 3 Set the thermostat above room temperature and verify the Operating Sequence See page 18 4 Verify that the compressor and outdoor fan motor are not energized 5 After the unit has run for approximately five minutes set the thermostat below room temperature and verify the shutdown sequence steps 10 12 in the Operating Sequence section page
71. y lines at pressures greater than 1 2 psig 14 inches WC the unit must 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 Natural Gas Conversion of this unit must be performed by qualified service personnel using only approved parts installations mustbe made in accordance with the National Fuel Gas Code and or local jurisdiction codes WARNING Thereduction 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 High altitude conversion can be field performed by a simple adjustment of manifold pressure or a change of the orifices if necessary as described on page 17 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 Natural Gas heating values listed in Table 4 page 15 are based on sea level values All factory shipped furnaces are ready to operate using Natural Gas between zero and 4999
72. ying Operation of Over Temperature Eimit Controls iiie etes 17 Verifying Burner 18 Refrigerant Charging 18 OPERATING SEQUENCE 18 Heating Mode 2 2 og 18 Cooling Mode 19 Fan Mode Adio ei ha tite ere este 19 REPLACEMENT 19 EQUIPMENT 19 Cleaning of Heat Exchanger 20 Cleaning of 5 sess 20 COMPONENT FUNCTIONS 21 TROUBLESHOOTING eee 21 FIGURES amp TABLES es 22 Figure 9 Unit Dimensions 22 Table 7 Center of Gravity amp Shipping Weights 22 Airflow Information 23 Table 8 Nominal Airflow Rates amp Temp Rises 23 Gas Information 24 Table 9 Gas Pipe Capacities 24 Table 10 Gas Flow Rates 24 Figure 10 Unit Gas Valve Label 25 Electrical Data amp Diagrams 26 Table 11 Electrical Data 26 Figure 11 Wiring Diagram ECM Motor 27 Figure 12 Wiring Diagram PSC Motor 28 Charging Tables amp

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