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Installation InstructionsSingle Package Gas Heating/Electric Cooling
Do not store or use gasoline or otherflammable vapors and liquids in thevicinity of this or any other appliance.Do not use this furnace if any part hasbeen under water. A flood-damaged fur-nace is extremely dangerous. Attemptsto use the furnace can result in fire orexplosion. A qualified service agencyshould be contacted to inspect the fur-nace and to replace all gas controls,control system parts, electrical partsthat have been wet or the furnace ifdeemed necessary.
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
Improper installation,adjustment, alteration,service, or maintenancecan cause injury or prop-erty damage. Refer tothis manual. For assis-tance or additional in-formation consult aqualified installer, ser-vice agency, or the gassupplier.
These instructions are primarily intended to assist qualified individuals experienced in the proper installation of thisappliance. Some local codes require licensed installation/service personnel for this type of equipment. Read allinstructions carefully before starting the installation.
FOR YOUR SAFETYWHAT TO DO
IF YOU SMELL GAS
• Do not try to light anyappliance.
• Do not touch any electri-cal switch; do not useany phone in your build-ing.
• Immediately call yourgas supplier from aneighbor's phone. Fol-low the gas supplier'sinstructions.
• If you cannot reach yourgas supplier, call the firedepartment.
• Extinguish any openflame.
High Efficiency
FOR YOUR SAFETYWARNING:!
2
3
GENERAL SPECIFICATIONS ..................................... 4
SAFETY CONSIDERATIONS ...................................... 4• Literature, Labels, and Tags.................................. 4• Pressures Within The System .............................. 4
INSTALLATION REQUIREMENTS .............................. 4• Equipment Application .......................................... 4• Equipment Check ................................................. 4• Requirements and Codes ...................................... 4• Unit Location......................................................... 4• Venting Requirements ........................................... 4• Unit Dimensions ................................................... 5• Clearances to Combustible Materials .................... 6• Thermostat ........................................................... 6• Air Filter Requirements ......................................... 6• Condensate Drain ................................................. 7
UNIT INSTALLATION .................................................. 7• Ground Level ........................................................ 7• Rigging and Hoisting ............................................. 8• Rooftop ................................................................. 8
AIR SUPPLY FOR COMBUSTIONAND VENTILATION ................................................ 8
CIRCULATING AIR SUPPLY ....................................... 9• Unconditioned Spaces .......................................... 9• Acoustical Ductwork ............................................. 9• Airflow Data ........................................................ 10• Horizontal to Down Flow Conversion ................... 11
GAS SUPPLY AND PIPING ...................................... 11• Leak Check ........................................................ 11
GAS AND HIGH ALTITUDE CONVERSIONS ............ 11• High Altitude Application ..................................... 12• Natural Gas High Altitude Conversion ................. 12• LP/Propane Gas Conversion ............................... 12
ELECTRICAL WIRING ............................................... 13• General ............................................................... 13• Line Voltage ........................................................ 13• Electrical Data Table .......................................... 14
LOW VOLTAGE WIRING ........................................... 14• Heating Configurations ........................................ 14
VARIABLE SPEED BLOWER.................................... 17• Configuring the Blower ........................................ 17• Selecting Heat Airflow ......................................... 17• Selecting the Cooling Airflow .............................. 17
WIRING DIAGRAMS ................................. 15-17, 19-20
SYSTEM CHECK ..................................................... 18• Pre-Start Check List .......................................... 18
START-UP PROCEDURE ......................................... 18• Air Circulation .................................................... 18• Short Cycle Protection ....................................... 21• System Cooling ................................................. 21• System Heating ................................................. 21• Verifying and Adjusting Firing Rate .................... 21• Verifying and Adjusting Temperature Rise ......... 21• Lighting/Operating Instructions .......................... 22• Verifying Burner Operation ................................. 23• Verifying Operation of Over-Temperature
Limit Control ................................................... 23
COMPONENT FUNCTIONS ..................................... 23• Flame Sensor .................................................... 23• Flame Roll-Out Control ....................................... 23• Gas Valve .......................................................... 23• Pressure Switch ................................................ 23• Over-Temperature Limit Control ......................... 24
UNIT MAINTENANCE............................................... 24• Refrigerant Charging .......................................... 24• Routine Maintenance ......................................... 25• Air Filter ............................................................. 25• Vent Cover Assembly ........................................ 25• Condensate Drain and Outdoor Coil ................... 25• Electrical ........................................................... 25• Motor Lubrication ............................................... 25• Blower Compartment ......................................... 25• Heat Exchanger and Burner Maintenance .......... 25• Cleaning of Heat Exchanger ............................... 25• Cleaning of Burners ........................................... 26
SEQUENCE OF OPERATION .................................. 26• Heating Mode .................................................... 26• Cooling Mode ..................................................... 27• Fan Mode .......................................................... 27• Unit Fails to Operate .......................................... 27
INSTALLATION CHECKLIST................................... 28
TABLE OF CONTENTS
4
GENERAL SPECIFICATIONS
Single Package Gas Heating/Electric Cooling units aredesigned for outdoor rooftop or ground level slab installations.The units are shipped ready for horizontal duct connectionsand are easily converted for down flow connections.
All models are shipped from the factory with the following:
1. Variable speed direct-drive blower.2. Horizontal or down flow duct connections.3. 24V fuse protection.
The unit dimensions are shown in Figure 1.
SAFETY CONSIDERATIONS
It is the responsibility of the installer to ensure that theinstallation is made in accordance with all applicable localand national codes.
! WARNING:Improper installation, service, adjustment, ormaintenance may cause explosion, fire, electricalshock or other hazardous conditions which mayresult in personal injury or property damage.Unless otherwise noted in these instructions,only factory authorized kits or accessories maybe used with this product.
Literature, Labels, and Tags — When working with thisequipment, follow all precautions in the literature, on tags,and on labels provided with the unit and/or approved fieldinstalled kits. The type of hazard and severity are describedon each label or tag.
Pressures Within The System — This equipment containsliquid and gaseous refrigerant under high pressure.Installation or servicing should only be performed byqualified trained personnel thoroughly familiar with this typeequipment.
INSTALLATION REQUIREMENTS
Equipment Application — Before beginning the installation,verify that the unit model is correct for the job. The unitmodel number is printed on the data label. This furnace isNOT to be used for temporary heating of buildings orstructures under construction.
Equipment Check — All units have been securely packagedat the point of shipment. After unpacking the unit, carefullyinspect it for apparent and concealed damage. Claims for
damage should be filed with the carrier by the consignee.Also check that there are no obvious signs of deteriorationof the unit.
Requirements and Codes — The installer must complywith all local codes and regulations which govern this typeof equipment. Local codes and regulations take precedenceover any recommendations contained in these instructions.In the absence of local codes, the installation mustconform with the National Fuel Gas Code (ANSI 2223.1,NFPA-54), or Canadian installations must conform withCAN/CGA-B149 installation codes. All electrical wiringmust be made in accordance with codes and regulationsand with the National Electric Code (ANSI/NFPA 70) or inCanada the Canadian Electric Code Part 1 CSA C.22.1. AirDucts must be installed in accordance with the standardsof the National Fire Protection Association “Standards forInstallation of Air Conditioning and Ventilation Systems”(NFPA 90A), “Standard for Installation of Residence TypeWarm Air Heating and Air Conditioning Systems” (NFPA90B), these instructions, and all applicable local codes.
The National Fuel Gas Code is available by writing:
American National Standards Institute, Inc.1430 BroadwayNew York, NY 10018
NFPA publications are available by writing:
National Fire Protection AssociationBatterymarch ParkQuincy, ME 02269
Unit Location — The gas/electric unit is designed only foroutdoor installations. Choosing the location of the unitshould be based on minimizing the length of the supply andreturn ducts. Consideration should also be given toavailability of fuel, electric power, service access, noise,and shade.
Venting Requirements — This unit has been equippedwith an integral venting system and designed to operateonly with this venting system. No additional venting shallbe used. This unit must be vented to the outdoors.
! WARNING:Do not vent furnace through a conventionalventing system.
A vent cover assembly has been supplied with the unit. Itcan be found secured to the gas controls within the control
5
Back ViewSide View
24.9
13.5
16.0
23.512.0
13.3
45.7
13.516.0
12.0
CG
B
A
47.5
DownflowReturn DuctOpening
DownflowSupply DuctOpening
InsidePerimeterof Base Rail
2.63"
To ElectricalOpening
DIMENSIONS
Figure 1. Dimensions
Top View
47.5
ElectricSupply Entry
Low Voltage Entry
Gas SupplyEntry
16.6
24.6
31.0
2.9
1.8
4.0
12.4512.45
4.055.8
8.75
HorizontalSupply Duct
Opening
HorizontalReturn Duct
Opening
4.0
1.75
9.75 24.75
16.0
CondensingCoil
13.513.516.016.0
C
29.75
23.75
15.75
4.0
Model Center of Gravity Height (in inches)Number C13 SEER with base rails without base rails
X24K072X 410 420 25.5 27.0 35.0 31.3X30K072X 430 440 26.0 26.5 39.0 35.3X36K100X 480 490 26.0 27.0 39.0 35.3X42K100X 480 490 27.0 26.5 39.0 35.3X48K120X 530 540 27.0 26.5 43.0 39.3X60K120X 530 540 27.0 26.5 43.0 39.3
A BUnit
WeightShippingWeight
6
Nominal Approximate Approximate RecommendedCooling Air Flow Range Filter Area (Sq. In.)* Filter Size (In. x In.)
Tonnage (Ton) (CFM) Disposable High Velocity Disposable High Velocity2.0 700-900 450 275 20 x 25 15 x 202.5 800-1100 550 325 20 x 30 16 x 203.0 1000-1300 625 375 25 x 25 20 x 203.5 1200-1500 725 450 24 x 30 20 x 254.0 1300-1700 825 500 18 x 24 (2 required) 20 x 255.0 1700-2100 1000 600 20 x 25 (2 required) 25 x 25
*Based on velocity of 300 ft/min for disposable filters and 500 ft/min for high velocity (cleanable) filters.
area of this unit. Figure 2 shows the proper installation ofthe vent cover assembly over the vent outlet on the exteriorof the corner panel. The fasteners used to secure the ventcover assembly have been included in the homeowner'spackage.
! WARNING:The vent cover assembly must be installed toassure proper operation of the unit.
The following list is a summary of the requirements for thelocation of the termination of the venting system:
1. The location of the vent termination must be consistentwith the National Fuel Gas Code (ANSI Z223.1) orCAN/CGA-B149 Installation Codes.
2. The vent termination must be located at least four (4)feet horizontally from any electric meters, gas meters,regulators, and relief equipment.
3. The vent termination must be located at least three (3)feet above any forced air inlet located within ten (10)feet.
4. The vent termination must be located at least four (4)feet below, four (4) feet horizontally from, or one (1) footabove any door, window, or gravity air inlet into anybuilding.
5. The vent termination must be located at least one (1)foot above grade.
6. The unit should be installed in such a manner as toprevent snow accumulation from obstructing the venttermination.
7. The unit installation shall avoid areas where condensatedrainage may cause problems by dropping on planters
Table 1. Air Filter Requirements
IMPORTANT NOTICE TO INSTALLER: After installingor replacing the filtration system for this unit, add thefollowing marking on the filter service panel or reasonablyadjacent thereto: “Replace filter(s) installed in yoursystem only with the same dimensional size filtersthat are being replaced.”
or patios, etc. Furthermore, ensure that the exhaustgases will not impinge on windows or building surfaces,which may be compromised or damaged bycondensation. Do not install the unit such that exhaustfrom the vent termination is directed into window wells,stairwells, under decks, or in alcoves or similarlyrecessed areas. The vent termination must not belocated above any public walkways.
Clearances to Combustible Materials — See Figure 3for required clearances to combustible materials. Refer tothe unit data label for the model number. The gas/electricunit is suitable for installation on combustible flooring orclass A, B, or C roofing materials. A clearance of at least36 inches from the blower access panel and from thelouvered control access panel is recommended to allow forservicing and maintenance. Where accessibility tocombustibles clearances are greater than minimumclearances, accessibility clearances must takepreference. Sufficient clearance for unobstructed airflowthrough the louvered control access panel and through theoutdoor coil must be maintained in order to achieve ratedperformance. See Figure 3 for minimum clearances toobstructions.
Thermostat — A single stage cooling/two stage heating24VAC thermostat should be used with the 2-4 ton units. Asingle stage cooling/single-stage heating thermostat canbe used for single stage, outdoor ambient or timed twostage operation. See Figure 8a-e for typical thermostatwiring.
The 5-Ton Gas/Electric unit uses a special two speedcompressor to achieve a high level of efficiency in acompact frame. For the highest efficiency the use of a two-stage cooling thermostat is recommended. Refer to Figure9b for unit wiring diagram.
Figure 2. Vent Assembly
Corner Panelof Unit
Vent CoverAssembly
Fastener
Exhaust DuctOpening
7
36"
36"
1"*
36"
36"
Figure 3. Minimum Clearances to combustible materials.
Air Filter Requirements — A suitable air filter systemmust be installed in the unit or in the return air systemupstream of the evaporator coil. Refer to Table 1 forrecommended filter sizes. Air filter pressure drop must notexceed 0.08 inches WC. This unit is not supplied with air
! WARNING:Never operate unit without a filter. A failure tofollow this warning could result in a fire, personalinjury, or death.
filter(s) and has no factory equipped means foraccommodating internal air filter(s). For downflowinstallations only, an internal filter accessory kit can beordered. For horizontal installations, the air filter systemmust be installed in the return air ductwork. All return airto this unit must pass through the filter(s) before enteringthe evaporator coil.
Condensate Drain — Condensate is removed from theunit through the 3/4" female pipe fitting located on the frontside of the unit. (See Figure 4.) Install a 2 inch deepcondensate trap in the drain line of the same size and primewith water.
When connecting rigid drain line, hold the female fitting witha wrench to prevent twisting. Do not over tighten! Referto local codes and restrictions for proper condensatedisposal requirements.
UNIT INSTALLATION
Ground Level — When installing the unit at ground level(See Figure 5), provide a concrete mounting pad separatefrom the building foundation. The pad must be level toinsure proper condensate disposal and strong enough tosupport the unit’s weight (Refer to Figure 1). Make sure theslab is a minimum of 2" above the grade and in an area thatdrains well.
Figure 4. Condensate Drain.
Condensate Drain
* If accessories are installed, see Accessory Installation Instructions for proper clearances.
8
2"
Figure 5. Ground Level Installation.
Rigging and Hoisting — The unit should be lifted usingslings and spreader bars. The spreader bars are necessaryto prevent damaging the top of the unit’s cabinet. Makesure that the lifting equipment is adequate for the load.Refer to Figure 1 for unit weights. Keep the unit in anupright position at all times. The rigging must be locatedoutside the unit’s center of gravity. Refer to Figure 1 forcenter of gravity location. For rooftop installations,remove and discard the two supports attached beneaththe unit.
! WARNING:To avoid the risk of property damage or personalinjury, it is the rigger’s responsibility to ensurethat whatever means are used to hoist the unitare safe and adequate.
! CAUTION:All panels must be securely in place when riggingand hoisting.
Rooftop — For rooftop installations (See Figure 6) use theappropriate accessory roof curb and follow all instructionsincluded with it. Make sure the supports beneath the unithave been removed. Locate the unit according to localbuilding codes and ordinances. The curb must be level toinsure proper condensate drainage.
The roof must be capable of handling the weight of the unit.See Figure 1 for unit weights. Reinforce the roof ifrequired.
! WARNING:Do not place combustible material on or againstthe unit cabinet. Do not place combustiblematerials, including gasoline and any otherflammable vapors and liquids, in the vicinity ofthe unit.
AIR SUPPLY FOR COMBUSTION ANDVENTILATION
Provisions must be made in the installation of this unit toprovide an adequate supply of air for combustion. Detailedinstructions for determining the adequacy of an installationcan be found in the current revision of the National FuelGas Code (ANSI Z223.1) and NFPA 54, or in Canadian
installation codes (CAN/CGA-B149), or in applicable localbuilding codes. Consult local codes for special requirements.
! WARNING:Installation using methods other than thosedescribed in the following sections must complywith the National Fuel Gas Code and all applicablelocal codes to provide sufficient combustion airfor the furnace.
If the unit is operated with inadequate combustion airsupply the flame roll-out control located above the burnerswill open, turning off the gas supply to the burners. Theflame roll-out control is a manually re-setable device. DONOT install a jumper wire across this control to defeat itsfunction. DO NOT reset the control without identifying and
Figure 6. Roof Curb Installation.
9
correcting the fault condition which caused the control totrip. If this control must be replaced, use only the replacementpart specified in the Replacement Parts List.
Air Openings in the door of the unit, warm air registers, andreturn air grilles must not be restricted.
To maximize heat exchanger life, the combustion airmust be free of chemical contaminants which formcorrosive acidic compounds when combusted. Someexamples of these chemical contaminants are chlorine,fluorine, and sulphur. Some common sources of thesechemical contaminants are detergents, bleaches,aerosol sprays, cleaning solvents, and a wide varietyof commercial and household products.
! WARNING:Combustible air must not be drawn from acontaminated atmosphere. Excessive exposureto contaminated combustion air will result insafety and performance related problems.
CIRCULATING AIR SUPPLY
! WARNING:Products of combustion must not be allowed toenter the return air ductwork or the circulatingair supply. Failure to prevent products ofcombustion from being circulated into the livingspace can create potentially hazardousconditions including carbon monoxide poisoningthat could result in personal injury or death.
All return ductwork must be adequately sealed,all joints must be taped, and the ductwork mustbe secured to the unit with sheet metal screws.When return air is provided through the bottomof the unit, the joint between the unit and thereturn air plenum must be air tight.
The roof curb or cement pad on which the unit ismounted must provide sound physical supportof the unit with no gaps, cracks, or saggingbetween the unit and the curb or pad.
Return air and circulating air ductwork must notbe connected to any other heat producing devicesuch as a fireplace insert, stove, etc. Doing somay result in fire, explosion, carbon monoxidepoisoning, personal injury, or property damage.
This unit is designed only for use with a supply and returnduct. Air ducts should be installed in accordance with allapplicable local codes and the standards of the NationalFire Protection Association “Standard for Installation of AirConditioning Systems” (NFPA 90A), and “Standard forInstallation of Residence Type Warm Air Heating and AirConditioning Systems” (NFPA 90B).
Design the ductwork according to methods described bythe Air Conditioning Contractors of America (ACCA) ManualD. The ducts must be properly sized not to exceed 0.2inches WC pressure drop at 400 scfm per nominal ton ofcooling capacity.
Ductwork should be attached directly to the unit flanges forhorizontal applications. On roof curb installations the ductsmust be attached to the curb duct supports, not the unit.
It is recommended that the outlet duct be provided with aremovable access panel. This opening should be accessiblewhen the unit is installed in service and shall be of a sizesuch that the smoke or reflected light may be observedinside the casing to indicate the presence of leaks in theheat exchanger. The cover for the opening shall be attachedin such a manner as to prevent leaks.
If outside air is utilized as return air to the unit for ventilationor to improve indoor air quality, the system must bedesigned so that the return air to the unit is not less than50°F (10°C) during heating operation. If a combination ofindoor and outdoor air is used, the ducts and dampersystem must be designed so that the return air supply to thefurnace is equal to the return air supply under normal, indoorreturn air applications.
Unconditioned Spaces — All ductwork passing throughunconditioned space must be properly insulated to minimizeduct losses and prevent condensation. Use insulation withan outer vapor barrier. Refer to local codes for insulationmaterial requirements.
Acoustical Ductwork — Certain installations may requirethe use of acoustical lining inside the supply ductwork.Acoustical insulation must be in accordance with thecurrent revision of the Sheet Metal and Air ConditioningContractors National Association (SMACNA) applicationstandard for duct liners. Duct lining must be UL classifiedbatts or blankets with a fire hazard classification of FHC-25/50 or less. Fiber ductwork may be used in place of internalduct liners if the fiber ductwork is in accordance with thecurrent revision of the SMACNA construction standard onfibrous glass ducts. Fibrous ductwork and internal acousticallining must be NFPA Class 1 air ducts when tested per ULStandard 181 for Class 1 ducts.
10
Table 3. 13 SEER Airflow Data.
NOTE: 0 = OFF 1 = ON
Table 4a. Cooling Airflow Settings
NOTE: 0 = OFF 1 = ON
# Switch is not used — Can be 0 or 11. Recommended temperature rises are highlighted in bold.
2. Temperature rises in the table are approximate. Actual temperature rises may vary.
Table 4b. Heating Airflow Settings
High Fire Input High Fire Input High Fire Input5 6 70 0 # N/A N/A N/A N/A 900 51 1500 51 900 61 1500 611 0 # N/A N/A N/A N/A 1100 42 1585 48 1100 50 1585 580 1 # 750 49 1000 55 1100 42 1805 42 1100 50 1805 511 1 # 990 37 1200 46 1200 38 2005 38 1200 46 2005 46
48,000 72,000Low Fire Input
Switches
Nominal Airflow Rates (CFM) and Temperature Rises (ºF)
120,000
R4GD-*072X R4GD-*100X R4GD-*120XLow Fire Input
60,000 100,000Low Fire Input
72,000
Model Heating Heating Heat Heating CoolingNumber Input Output Switch Rise Output Blower MotorR4GD (Btuh) (Btuh) Setting CFM Range (°F) (Btuh) Size HP
1,1 12000,1 10001,1 9900,1 7501,1 12000,1 10001,1 9900,1 7501,0 15850,0 15001,0 11000,0 9001,0 15850,0 15001,0 11000,0 9001,1 20050,1 18051,1 12000,1 11001,1 20050,1 18051,1 12000,1 1100
40-70 56,000 11 X 10 1 X60K120X120,000
72,000
94,000
56,000
40-70 45,000 11 X 10 1 X48K120X120,000
72,000
94,000
56,000
40-70 40,000 11 X 10 1
78,000
47,000
X42K100X100,000
60,000
78,000
47,000
29,000 10 X 10 1/2
X36K100X 40-70 35,000 11 X 10 1 100,000
60,000
X24K072X 35-65
X24K072X 35-6572,000
48,000
56,000
37,500
72,000
48,000
56,000
37,50010 X 10 1/224,000
1 2 3 4 5 6 70 0 0 1 675 9001 0 0 1 720 10000 0 0 0 750 11001 0 0 0 800 12150 0 1 0 825 13501 0 1 0 880 14850 1 0 1 945 15301 1 0 1 990 17000 1 0 0 1050 18701 1 0 0 1100 18900 1 1 0 1155 21001 1 1 0 1210 2310
SWITCH NUMBER Recommended A/C Airflow Rate (CFM)2 - 2.5 TON 3 - 5 TON
5 T
on
4 T
on
3.5
To
n 3 T
on
2.5
To
n
2 T
on
11
Figure 7. Typical Right Side EntryGas Service Connection.
Ground JointUnion
Dripleg
Shut-Off Valvewith 1/8 NPTplugged tap
BurnerAssembly
Manifold
Some utilitiesrequire Shut-Off
Valve to be4 to 5 feet
above floor
Automatic GasValve (with manual
shut-off)
Horizontal to Down flow Conversion — The unit isshipped ready for horizontal duct connections. If downflow ducts are required, the unit must be convertedfollowing the steps below for both the supply and returnducts.
1. Remove the duct covers from the horizontal flow ductopenings.
2. Locate the duct cap inside the duct openings andremove the screw holding it in place.
3. Lift the cap out of the unit. The cap can be pushed upfrom the bottom by reaching through the fork slot.
4. Reinstall the covers over the horizontal duct opening.
5. Fasten the cover with screws and seal to prevent airleakage.
GAS SUPPLY AND PIPING
This unit has right side gas entry. A typical gas servicehookup is shown in Figure 7. When making the gasconnection, provide clearance between the gas supply lineand the entry hole in the unit’s casing to avoid unwantednoise and/or damage to the unit.
All gas piping must be installed in compliance with localcodes and utility regulations. Some local regulationsrequire the installation of a manual main shut-off valve andground joint union external to the unit. The shut-off valveshould be readily accessible for service and/or emergencyuse. Consult the local utility or gas supplier for additionalrequirements regarding placement of the manual main gasshut-off. In the absence of local codes the gas lineinstallation must comply with the latest edition of theNational Fuel Gas Code ANSI Z223.1 or CAN/CGA B149Installation Codes.
! CAUTION:Do not use matches, lighters, candles or othersources of open flame to check for gas leaks.
A 1/8 inch NPT plugged tap must be installed in the gas lineimmediately upstream of the gas supply connection to thefurnace for use when measuring the gas supply pressure.The plug should be readily accessible for service use. Adrip leg should be installed in the pipe run to the unit. Table5 lists gas flow capacities for standard pipe sizes as afunction of length in typical applications based on nominalpressure drop in the line.
IMPORTANT NOTES:
1. Gas piping must not be run in or through air ducts,chimneys, gas vents, elevator shafts, etc.
2. Compounds used on threaded joints of gas piping mustbe resistant to the actions of liquefied petroleumgases.
3. The main manual gas valve and main power disconnectto the furnace must be properly labeled by the installerin case emergency shutdown is required.
Leak Check — After the gas piping to the unit is complete,all connections must be tested for gas leaks. To check forleaks in gas piping systems, use only a soap and watersolution or other approved method.
IMPORTANT NOTE: When pressure testing the gassupply lines at pressures greater than 1/2 psig (14inches WC), the unit must be disconnected from thegas supply piping system to prevent damage to the gascontrol valve.
If the test pressure is less than or equal to 1/2 psig (14inches WC), the unit must be isolated from the gassupply line by closing the manual shut-off valve.
! WARNING:This unit was equipped at the factory for use withnatural gas only. A special kit, supplied by themanufacturer, is required to convert the unit tooperate on LP/propane gas. Failure to use theproper conversion kit can cause fire, explosion,property damage, carbon monoxide poisoning,personal injury, or death.
GAS AND HIGH ALTITUDE CONVERSIONS
Conversion: conversion of this unit must be performed byqualified service personnel, using only approved parts.
12
High Altitude ApplicationHigh altitude application with this furnace can be fieldperformed by a simple adjustment of manifold pressureand if necessary, a change of the orifices. The changesrequired depend on the installation altitude and the heatingvalue of the gas. The gas heating value based on sea levelcan be obtained from your local gas utility. The heatingvalue of gas at high altitude is always lower than the sealevel heating value. The heating values used in the Tables6 & 7 are based on sea level values.
Natural Gas High Altitude ConversionAll factory shipped furnaces are ready to operate betweenzero and 4999 ft. above sea level. For higher altitudes(between 5000 and 10,000 ft. above sea level), conversioncan be achieved simply by adjusting the furnace manifoldpressure as shown in Table 6.
LP/Propane Gas ConversionIMPORTANT NOTE: When converting a low NOxFurnace from Natural gas to LP/Propane gas, it isnecessary to remove the NOx Baffles.Conversion of this furnace to utilize LP/Propane gas mustbe made by qualified service personnel, using approvedparts. Conversion for the LP/Propane gas can beaccomplished by adjusting the manifold pressure, afterreplacing the natural gas orifices with the appropriate LP/Propane orifices shown in Table 7. Note: that forinstallations between zero and 5000 ft. above sea level, a#54 drill size orifice should be used. However forinstallations above 5000 ft. over sea level, a # 55 drill sizeorifice should be used. Then use Table 7 to determine theappropriate manifold pressure for your altitude installation.Conversion to LP/Propane (sea level and high altitude ) isdetailed in the installation instructions provided with theconversion kit. Approved conversion kits are:
United States LP/Propane Gas Sea Level and High AltitudeConversion Kit - P/N 903616This kit is for LP/propane conversion in the United Statesat altitudes between zero and 10,000 ft. above sea level.Follow the installation instructions supplied with the kit forproper installation.Canadian LP/Propane Gas Sea Level and High AltitudeConversion Kit - P/N 903617This kit is for LP/propane conversions in Canada ataltitudes between zero and 4500 ft. above sea level. Followthe installation instructions supplied with the kit for properinstallation.
! WARNING:To avoid the risk of electrical shock, personalinjury, or death, disconnect all electrical powerto the unit before performing any maintenanceor service. The unit may have more than oneelectrical power supply. When servicing controls,label all wires prior to disconnecting andreconnect wires correctly. Verify properoperations after any servicing.
! WARNING:The unit cabinet must have an uninterrupted orunbroken electrical ground to minimize personalinjury if an electrical fault should occur. Thisground may consist of electrical wire or approvedconduit when installed in accordance withexisting national or local codes.
Table 5. Capacity of Black Iron Gas Pipe (cubic feetper hour) for Natural Gas (specific gravity = .60).
NOMINAL LENGTH OF PIPE RUN
BLACK IRON (feet)
PIPE DIAMETER
(in.) 10 20 30 40 50 60 70 80
1/2 130 90 75 65 55 50 45 40
3/4 280 190 150 130 115 105 95 90
1 520 350 285 245 215 195 180 170
1 1/4 1050 730 590 500 440 400 370 350
1 1/2 1600 1100 890 760 670 610 560 530
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 flow required by the unit, divide
the input rate of the unit by the heating value of the gas:
Cubic Feet Per Hour Required = Input To Unit (Btu/hr)
Heating Value of Gas (Btu/Cu. Ft.)
CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR)FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)
13
Table 7. Manifold Pressure (in WC) for LP/Propane Gas at Various Altitudes
Elevation, (feet above sea level)0 to 2,000 to 5,000 to 6,000 to 8,000 to
1,999 4,999 5,999 7,999 10,000
10.0 8.5 10.0 9.0 8.5
Orifice Size 54 54 55 55 55
Manifold Pressure in (WC)Based on Sea Level LPHeating Value of 2,500 Btu/ft.
3
Table 6. Manifold Pressure (in WC) for Natural Gas at Various Altitudes and Heating Values
For a Natural Gas Sea Level Heating Value of 800 to 899 Btu/cu.ft.Elevation (feet above sea level)
zero to 1999
2000 to 4999
5000 to 5999
6000 to 7999
8000 to 10000
Manifold Pressure Setting (in WC) 3.5 3.5 3.5 3.5 3.0
For a Natural Gas Sea Level Heating Value of 900 to 999 Btu/cu.ft.Elevation (feet above sea level)
zero to 1999
2000 to 4999
5000 to 5999
6000 to 7999
8000 to 10000
Manifold Pressure Setting (in WC) 3.5 3.5 3.5 3.2 2.8
For a Natural Gas Sea Level Heating Value of 1,000 to 1,100 Btu/cu.ft.Elevation (feet above sea level)
zero to 1999
2000 to 4999
5000 to 5999
6000 to 7999
8000 to 10000
Manifold Pressure Setting (in WC) 3.5 3.5 3.0 2.8 2.5
ELECTRICAL WIRING
General — Electrical power wiring must be made inaccordance with all applicable local codes and ordinances,and with the current revision of the National Electric CodeNFPA 70 or in Canada CSA C.22.1 Canadian ElectricalCode Part 1. If any of the original wire as supplied with theunit must be replaced, it must be replaced with material ofthe same gauge and temperature rating.
Line Voltage — Before proceeding with the electricalconnections, make certain that the voltage, frequency andphase of the supply source are the same as those specifiedon the unit rating plate. Also verify that the service providedby the utility is sufficient to handle the additional loadimposed by this equipment.
This unit must be electrically grounded in accordance withlocal codes or, in the absence of local codes, with theNational Electrical Code (ANSI/NFPA 70) or the CSAC22.1 Electrical Code.
See Figure 9a-b or the unit wiring label for proper high andlow voltage wiring. Make all electrical connections inaccordance with all applicable codes and ordinances.
Use a separate branch electrical circuit for this unit. Ameans of electrical disconnect must be located within sightof and readily accessibility to the unit.
The unit is shipped from the factory wired for 240 volttransformer operation. For 208 volt operation, remove thelead from the transformer terminal marked 240V andconnect it to the terminal marked 208V. For maximumcircuit ampacity and maximum over current protection, seethe unit rating plate or Table 8.
Overcurrent protection must be provided at the branchcircuit distribution panel and sized as shown in Table 8 oron the unit rating label and according to the NationalElectric Code and applicable local codes.
Provide power supply (or supplies) for the unit in accordancewith the unit wiring diagram, and the unit rating plate.Connect the line-voltage leads to the corresponding
14
Table 8. Electrical Data.
Notes: FLA = Full Load Amps; LRA = Lock Rotor amps; RLA = Rated Load Amps.
terminals on the contactor inside the control compartment.Use only copper wire for the line voltage power supply tothis unit. Use proper code agency listed conduit and aconduit connector for connecting the supply wires to theunit and for obtaining proper grounding. Grounding mayalso be accomplished by using the grounding lug providedin the control box. Do not use gas piping as an electricalground.
LOW VOLTAGE WIRING
Heating ConfigurationsThese furnaces are factory configured to operate on highfire only, but can be field converted to operate as two-stagefurnaces.
NOTE: TO achieve full rated capacity and efficiency, thefurnace should be operated in the factory configuration(high fire only as described in part 2.)
1. Two stage thermostat configuration – For this installa-tion a two stage heating thermostat is used. CAUTION:Disconnect yellow/black wire from primary gas valve.Remove female connector from yellow/black wireand strip insulation from end. Connect strippedyellow/black wire to (W2) from the thermostat. (SeeFigure 8a). The first stage bulb (W1) is connected toW on the furnace control board. On a call for first stageheat, the furnace will operate at low fire and the blowerwill run at a lower speed. On a call for second stageheat, the furnace will operate at high fire and the blowerwill run at a higher speed. The furnace will stagebetween low fire, high fire, and off depending on thethermostat signal.
2. High fire only configuration – As shipped from thefactory, the primary and secondary gas valves areconnected in parallel (See Figure 8b). This defeats thestaging feature and the furnace operates on high fireonly. All of the burners will operate on a call for heat andthe variable speed blower will operate at a higherspeed.
3. Low fire only configuration – For this installation, thesecondary gas valve is disconnected (See Figure 8c).This defeats the staging feature and the furnace
operates on low fire only. The low fire burners willoperate on a call for heat and the variable speed blowerwill operate at a lower speed.
4. Outdoor ambient dependent configuration – For thisinstallation, the primary and secondary gas valves areconnected in parallel with an outdoor thermostat (openon rise style) in series with the secondary gas valve(See Figure 8d). CAUTION: DO NOT CONNECT W2from thermostat to the furnace wiring when using theoutdoor ambient dependent configuration. When theoutdoor temperature is above the set point, the outdoorthermostat opens keeping the secondary gas valveclosed. The furnace operates in the low fire mode at alower blower speed. When the outdoor thermostatcloses, the secondary gas valve opens with theprimary gas valve and the furnace operates in the highfire mode at higher blower speed.
5. Timed staging configuration – For this installation, theprimary and secondary gas valves are connected inparallel with a delay on make timer (two wire style) inseries with the secondary gas valve (See Figure 8e).CAUTION: DO NOT CONNECT W2 from thermostat tothe furnace wiring when using timed staged configura-tion. When the primary gas valve is energized, thefurnace operates in the low fire mode at a lower blowerspeed and the timer begins its delay function. If theroom thermostat is not satisfied before the timeractivates, the furnace will stage to high fire and theblower will operate at a higher speed until the roomthermostat is satisfied.
Install the thermostat per the manufacturer's instructions.The low voltage (24 volt) connections from the thermostatare made at the terminal strip on the control board in thefurnace. See Figures 8a-8e for the proper connections forheating only (four wire) and heating/cooling (five wire)applications. The recommended minimum wire gauge forthermostat wiring is shown in Table 10.
The thermostat must not be installed on an outside wall orany other location where its operation may be adverselyaffected. Adverse affects include radiant loading from fire-places, sunlight, or lighting fixtures, and convective loadingfrom warm air registers or electrical appliances.
Min Max RLA LRA MCA MOP
R4GD-X24K072X 72,000 208-230/30/1 187 253 12.1 54 1.2 4.3 20.6 30
R4GD-X30K072X 72,000 208-230/30/1 187 253 13.6 67 1.2 4.3 22.5 35
R4GD-X36K100X 100,000 208-230/30/1 187 253 16.4 83 1.2 9.1 30.8 45
R4GD-X42K100X 100,000 208-230/30/1 187 253 17.9 88 1.2 9.1 32.7 50
R4GD-X48K120X 120,000 208-230/30/1 187 253 20.4 109 1.2 9.1 35.8 50R4GD-X60K120X 120,000 208-230/30/1 187 253 28.0 169 1.5 9.1 45.6 70
ELECTRICAL DATACompressor Fan Motor
FLAIndoor Blower
FLA
Single CircuitModel Number
Max. Heating Input
Nominal Electrical Supply
Voltage Range
15
Figure 8a. Two Stage Configuration
Figure 8b. High Fire Only Configuration
Legend
Field WiringFactory Wiring:
Low VoltageHigh Voltage PRIMARY
GASVALVE
ROOM THERMOSTAT
R
Y
G
W
SECONDARYSOLENOIDGAS VALVE
YELLOW/BLACK
TOVARIABLE
SPEEDBLOWER
CLOSED ENDCONNECTOR
DO NOT REMOVE!
BROWN
RED
GREY
YELLOW
GREEN
YELLOW
BR
OW
N
BROWNYELLOW
FLAME SENSORR
BROWN
BROWN
YE
LL
OW
BROWN
FLAME SENSORR
Legend
Field WiringFactory Wiring:
Low VoltageHigh Voltage
PRIMARYGAS
VALVE
TWO STAGEROOM THERMOSTAT
R
Y
G
W
SECONDARYSOLENOIDGAS VALVE
TOVARIABLE
SPEEDBLOWER
W2
YELLOW/BLACK
CLOSED ENDCONNECTOR
DO NOT REMOVE!
BROWN
RED
GREY
YELLOW
GREEN
YELLOWBROWN
YELLOWB
RO
WN BROWN Y
EL
LO
W
YE
LL
OW
BROWN BROWN
16
Figure 8c. Low Fire Only Configuration
Legend
Field WiringFactory Wiring:
Low VoltageHigh Voltage
PRIMARYGAS
VALVE
ROOM THERMOSTAT
R
Y
G
W
SECONDARYSOLENOIDGAS VALVE
TOVARIABLE
SPEEDBLOWER
YELLOW/BLACK
CLOSED ENDCONNECTOR
DO NOT REMOVE!
BROWN
RED
GREY
YELLOW
GREEN
YELLOW BROWN
YELLOWBROWN
BR
OW
N
FLAME SENSORR
BROWNYELLOW
BROWN
YE
LL
OW
YE
LL
OW
Figure 8d. Outdoor Ambient Dependent
PRIMARYGAS
VALVE
ROOM THERMOSTAT
R
Y
G
W
TOVARIABLE
SPEEDBLOWER
SECONDARYSOLENOID
GAS VALVE
CLOSED ENDCONNECTOR
DO NOT REMOVE!
ODT
Legend
Field WiringFactory Wiring:
Low VoltageHigh VoltageODT: Open on rise outdoor thermostat
YELLOW/BLACK
VSBW
BROWN
RED
GREY
YELLOW
GREEN
YELLOW
BROWN
YELLOW YELLOWBROWNBROWN
BR
OW
N
FLAME SENSORR
BROWN YE
LL
OW
YE
LL
OW
BROWN
17
Figure 8e. Timed Two Stage Configuration
PRIMARYGAS
VALVE
ROOM THERMOSTAT
R
Y
G
W
SECONDARYSOLENOID
GAS VALVE
SDT
Legend
Field WiringFactory Wiring:
Low VoltageHigh Voltage
CLOSED ENDCONNECTOR
DO NOT REMOVE!
SDT: Two wire delay on make timer
TOVARIABLE
SPEEDBLOWER
YELLOW/BLACK
VSBW
BROWN
RED
YELLOW
GREEN
YELLOW
GREY
BROWN
BROWN
BR
OW
NYELLOW YELLOW
BROWN
FLAME SENSORR
BROWN YE
LL
OW
YE
LL
OW
To check the heat anticipator setting either:
1. Add the current draw of the system components; or2. Measure the current flow on the thermostat R-W circuit
after the circulating blower motor has started. Set theheat anticipator according to the thermostatmanufacturer's instructions for heat anticipator set-tings.
! CAUTION:To avoid personal injury or property damage,make certain that the motor leads cannotcome into contact with any uninsulated metalcomponents of the unit.
VARIABLE SPEED BLOWER
Configuring the Blower—The variable speed blower isequipped with a microprocessor-controlled variable speedmotor that is pre-programmed to deliver optimum airflow ina variety of conditions and system configurations. Beforeoperation, the variable speed blower must be configured tomatch the unit with the system, system options, andclimatic conditions. With the variable speed blower in-stalled and configured properly, the furnace will respond
directly to gradually change speed in response to changesin system variables such as the thermostat settings, ductstatic, filter, etc. The variable speed blower is configured bysetting the 6 switches located on the motor control boardas described below.
! IMPORTANT:The variable speed blower has been designedto give the installer maximum flexibility tooptimize system performance, efficiency, andcomfort. Because there are so many ways toconfigure, it is important to read and followthese instructions carefully.
Selecting Heat Airflow—The heating airflow is selectedby setting switches 5 and 6, refer to Table 4b and select anominal rise based on the furnace nominal efficiency andinput. Follow the table column up to find the switch settingand nominal air-flow. Be sure that the selected rise is withinthe specification of the furnace as shown on the furnacerating label.
Selecting The Cooling Airflow—The cooling airflow isselected by setting switches 1 through 4 on the motorcontrol board located in the controls area. All airflows forother modes of operation (except gas heat) are determined
18
by this setting. Table 4a shows the airflow values versusthe airflow selector switch settings, and the range of airflowsettings recommended for each nominal system capacity.
NOTE: The CFM values listed on Table 4a and 4b are notdependent on duct static pressure. The motor auto-matically compensates for changes in duct static pres-sure (within the limits of the motor).
For maximum capacity, generally, a selection at or near thetop of the CFM range for that nominal capacity is best. Formaximum dehumidification and energy efficiency, selectan airflow near the middle or bottom of the CFM range forthat nominal capacity.
The two stage cooling feature of the 5-ton unit requiresmodulating the airflow. The unit will automatically adjustthe airflow to the appropriate rate when the unit capacitychanges.
NOTE: If coil icing is observed, the cooling airflowselected may be too low. Double-check to be sure thesetting selected is within the range shown in Table 4a.Also check to be sure the system is properly charged.If icing continues to occur, raise the selected airflowone or two steps.
Room Thermostat — Several options are available for aroom thermostat depending on the accessories installedwith the unit. Select a thermostat which operates inconjunction with the installed accessories. The thermostatshould be mounted about five feet above the floor on aninside wall. The thermostat should be kept away fromdrafts, slamming doors, lamps, direct sunlight and thesupply air flow.
To install the thermostat:
1. Position the subbase on an inside wall and mark themounting holes and thermostat cable openings.
2. Cut out the cable opening and route the thermostatcable from the unit’s low voltage compartment to thethermostat location. The thermostat cable is suppliedby the installer.
3. Connect the cable leads to the subbase or thermostatterminals and to the unit’s low voltage connector on thefurnace board as shown in Figure 8a-e. A systemwiring diagram is also provided on the inside of thelouvered control access panel and in Figure 9a-b ofthese installation instructions.
4. Secure the subbase or thermostat to the wall usingscrews provided with the thermostat.
5. If subbase is used, install the correct thermostathousing to subbase.
6. Refer to thermostat instruction sheet for completedetailed mounting information.
To determine the heat anticipator setting, either:
1. Add the current draw of the system components or,
2. Measure the current flow on the thermostat R-W circuitafter the circulating blower motor has started.
SYSTEM CHECKPre-Start Check List
• Verify that the unit is level to allow proper condensatedrainage.
• Verify that there is free airflow to and from the outdoorcoil and that all clearance requirements are met.
• Verify that the ductwork is sealed to prevent airleakage.
• Verify that the line voltage power leads are securelyconnected and the unit is properly grounded.
• Verify that the low voltage wires are securely connectedto the correct leads in the low voltage area of thecontrol box.
• Verify that the gas line service pressure does notexceed 10.0 inches WC (0.36 psig), and is not lessthan 4.5 inches WC (0.16 psig) for natural gas. For LPgas the line service pressure must not exceed 14inches WC (0.51 psig) and must not be less than 11.0inches WC (0.40 psig).
• Verify that the flame roll-out control is closed. Ifnecessary, press the red button to reset the control.DO NOT install a jumper wire across the control todefeat its function. If the control reopens upon start-up, DO NOT reset the control without identifying andcorrecting the fault condition which caused the controlto trip.
• Verify that the gas line has been purged and allconnections are leak tight.
• Verify that all exterior panels are replaced and securelyfastened.
• Verify that the outdoor fan turns freely.
• Verify that the power supply branch circuit overcurrentprotection is sized properly.
• Verify that the thermostat is wired correctly. Thethermostat function switch should be set to “Off” andthe thermostat fan switch should be set to “Auto.”
START-UP PROCEDURE
Close all electrical disconnects to energize the system.
Air Circulation — Leave the thermostat system switch setto “Off” and set the thermostat fan switch to “On.” Theblower motor should run continuously. Check for air deliveryat the register(s). Ensure that there are no obstructions atthe registers or in the ductwork. Set thermostat fan switchto “Auto,” the blower will shut down in 60 seconds.
19
Figure 9a. 2-4 Ton; Single Stage Cool, Two Stage Heat.
CO
NT
RO
L W
IRIN
G L
EA
DS
Ref
er t
o In
stal
lati
on
Inst
ruct
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s fo
r C
on
nec
tio
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do
or
Th
erm
ost
at
XF
MR
L1
EA
C
M3
CO
OL
HE
AT
HU
M2
M1 HUM
EAC
NEUTRALS
Pin
Nu
mb
ers
P2
3 2
16
5 4
Pin
Nu
mb
ers
P1
9 8
7
3 2
16
5 4
24VCOM
3AFUSE
FL
AM
E(Y
EL
LO
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ST
AT
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(RE
D)
T3
T1
T2*A
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T1
T2
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CO
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AC
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BL
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K
BL
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R
BROWN
BROWN
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BLUE
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BROWN
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76
54
32
1
117
513
R
1 2 43 7 865 13 14 161511 12109987654321 161514121110 13
W2
WH
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WH
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DU
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OR
F
OR
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BL
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BL
AC
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OT
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54
23
1 15
43
2
BL
AC
K
WH
ITE
YE
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OW BL
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BR
OW
NO
RA
NG
E
RE
D
VA
RIA
BL
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PE
ED
CO
NT
RO
L
BR
OW
N
WH
ITE
YE
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RED
GR
EE
N
RE
D
RO
OM
TH
ER
MO
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AT
CO
MP
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SS
OR
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TD
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R
FA
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YELLOW
BL
AC
KL
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PR
ES
SU
RE
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CH
RED
PO
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UP
PL
Y
R S
C
GR
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GR
AY
WG
YC
R
R
S
C
R
No
te:
See
Inst
alla
tio
nin
stru
ctio
ns
for
spec
ific
blo
wer
sp
eed
set
tin
g.
GR
EE
N
W W
SE
NS
OR
*AS
CT
-AN
TI S
HO
RT
CY
CL
E T
IME
R
SE
E
NO
TE
7
YELLOW/BLACK
N
NO
TE
S:
1.D
isco
nn
ect a
ll p
ow
er b
efo
rese
rvic
ing
.2.
For s
uppl
y co
nnec
tions
use
cop
per
cond
ucto
rs o
nly.
3.N
ot s
uita
ble
on
sys
tem
s th
atex
ceed
150
V to
gro
un
d.
4.If
an
y o
f th
e o
rig
inal
wir
e as
sup
plie
d w
ith th
e fu
rnac
e m
ust
be
rep
lace
d, i
t mu
st b
e re
pla
ced
wit
hw
irin
g m
ater
ial h
avin
g a
tem
per
atu
re r
atin
g o
f at l
east
105°
C.
5.F
or s
up
ply
wir
e am
pac
itie
s an
do
verc
urr
ent p
rote
ctio
n, s
ee u
nit
rati
ng
pla
te.
6.E
nsu
re th
at w
ires
fro
m th
e b
low
erre
mai
n c
on
nec
ted
to th
e b
oar
dth
erm
ost
at te
rmin
als
afte
r mak
ing
the
field
ther
mo
stat
co
nn
ectio
ns.
7.W
irin
g s
ho
wn
for 2
-sta
ge
op
erat
ion
wh
en u
sin
g a
mu
ltist
age
ther
mo
-st
at. W
arn
ing
-Rem
ove
Yello
w/B
lack
wir
e fr
om
pri
mar
y g
as v
alve
an
du
tiliz
e fo
r w
irin
g fu
rnac
e fo
r 2
stag
e o
per
atio
n. S
ee In
stal
lati
on
Inst
ruct
ion
for a
lter
nat
e m
ean
s o
fus
ing
seco
nd s
tage
.
1.C
ou
per
le c
ou
ran
t ava
nt d
e fa
ire
letr
etie
n.
2.E
mpl
oyez
uni
quem
ent d
esco
nd
uct
eurs
en
cu
ivre
.3.
Ne
con
vien
t pas
au
x in
stal
latio
ns
de
plu
s d
e 15
0 V
a la
ter
re.
7083
33A
FA
UL
T C
ON
DIT
ION
ST
AT
US
LIG
HT
(R
ED
)
Pow
er O
nO
n
Lim
it C
ircui
t Ope
n1
Fla
sh
Pre
ssur
e S
witc
h S
tuck
Ope
n w
ith In
duce
r O
n2
Fla
sh
Pre
ssur
e S
witc
h S
tuck
Clo
sed
with
Indu
cer
Off
3 F
lash
Igni
tion
Fai
lure
(C
heck
Gro
und)
4 F
lash
230
VA
C &
Neu
tral
Rev
erse
d or
No
Gro
und
5 F
lash
Fal
se F
lam
e or
Gas
Rel
ay S
hort
edC
ontin
uous
Fla
sh
Pow
er O
ffO
ff
FA
UL
T C
ON
DIT
ION
ST
AT
US
LIG
HT
(Y
EL
LO
W)
Low
Fla
me
Sen
sor
Sig
nal
Con
tinuo
us F
lash
Fla
me
Pre
sent
On
Fie
ld W
irin
g
Fac
tory
Wir
ing
Lo
w V
olt
age
Hig
h V
olt
age
20
Figure 9b. 5 Ton; Two Stage Cool, Two Stage Heat
N
NO
TE
S:
1.D
isco
nn
ect a
ll p
ow
er b
efo
rese
rvic
ing
.2.
For s
uppl
y co
nnec
tions
use
cop
per
cond
ucto
rs o
nly.
3.N
ot s
uita
ble
on
sys
tem
s th
atex
ceed
150
V to
gro
un
d.
4.If
an
y o
f th
e o
rig
inal
wir
e as
sup
plie
d w
ith th
e fu
rnac
e m
ust
be
rep
lace
d, i
t mu
st b
e re
pla
ced
wit
hw
irin
g m
ater
ial h
avin
g a
tem
per
atu
re r
atin
g o
f at l
east
105°
C.
5.F
or s
up
ply
wir
e am
pac
itie
s an
do
verc
urr
ent p
rote
ctio
n, s
ee u
nit
rati
ng
pla
te.
6.E
nsu
re th
at w
ires
fro
m th
e b
low
erre
mai
n c
on
nec
ted
to th
e b
oar
dth
erm
ost
at te
rmin
als
afte
r mak
ing
the
field
ther
mo
stat
co
nn
ectio
ns.
7.W
irin
g s
ho
wn
for 2
-sta
ge
op
erat
ion
wh
en u
sin
g a
mu
ltist
age
ther
mo
-st
at. W
arn
ing
-Rem
ove
Yello
w/B
lack
wir
e fr
om
pri
mar
y g
as v
alve
an
du
tiliz
e fo
r w
irin
g fu
rnac
e fo
r 2
stag
e o
per
atio
n. S
ee In
stal
lati
on
Inst
ruct
ion
for a
lter
nat
e m
ean
s o
fus
ing
seco
nd s
tage
.
1.C
ou
per
le c
ou
ran
t ava
nt d
e fa
ire
letr
etie
n.
2.E
mpl
oyez
uni
quem
ent d
esco
nd
uct
eurs
en
cu
ivre
.3.
Ne
con
vien
t pas
au
x in
stal
latio
ns
de
plu
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21
Short Cycle Protection — For single phase units only,with the system operating in cooling mode, note thetemperature setting of the thermostat and gradually raisethe set-point temperature until the unit de-energizes.Immediately lower the set point temperature of thethermostat to its original setting and verify that the indoorblower is energized. Verify that after approximately 5minutes the compressor and fan energize and that thetemperature of the discharged air is cooler than the roomtemperature.
System Cooling
1. Set the thermostat system switch to “Cool” and thethermostat fan switch to “Auto.” Gradually lower thethermostat temperature switch below room temperatureand observe that the blower, compressor and fanenergize. Check that air cooler than room temperatureis being discharged at the register. Listen for anyunusual noises. Locate the source and correct asneeded.
2. After allowing the unit to run for several minutes, setthe temperature selector above room temperature,verify that:a. The fan and compressor cycle off with the
thermostat.b. The blower also stops after the 60 second
ramp down.
System Heating
1. Set the thermostat to the lowest setting.2. Follow the procedures given on the operating instruction
label, in this installation instructions or attached insidethe louvered control access panel.
3. Set the thermostat above room temperature and verifythe sequence of operation. (See Operating Sequenceon page 26.)
4. Verify that the compressor and outdoor fan motor arenot energized.
5. After the unit has run for approximately five minutes,set the thermostat below room temperature and verifythe shutdown sequence. (See Operating Sequence onpage 26.)
Verifying and Adjusting Firing Rate — The firing ratemust be verified for each installation to prevent over-firingof the furnace.
! CAUTION:Do not re-drill the burner orifices. If the orificesize must be changed, use only new orifices.
IMPORTANT NOTE: The firing rate must not exceed therate shown on the unit data label. At altitudes above2,000 ft. it must not exceed that on the data label less4% for each 1,000 ft.
Follow the procedure below to determine the firing rate:1. Shut off all other gas fired appliances.2 Start the unit in heating mode and allow it to run for at
least three minutes.3. Measure the time (in seconds) required for the gas
meter to complete one revolution.4. Convert the time per revolution to cubic feet of gas per
hour using Table 8.5. Multiply the gas flow rate in cubic feet per hour by the
heating value of the gas in Btu per cubic foot to obtainthe firing rate in Btu per hour. Example:a. Time for one revolution of a gas meter with a one
cubic foot dial = 40 seconds.b. From Table 8 read 90 cubic feet per hour of gas.c. Heating value of the gas (obtained from gas
supplier) = 1040 Btu per cubic foot.d. Firing rate = 1040 x 90 = 93,600 Btuh.
6. Adjustments to the firing rate can be made by adjustingthe gas manifold pressure. See the High AltitudeApplication section for additional information of firingrate at elevations above 2000 ft.
The manifold pressure must be set to the appropriate valuefor your installation. Refer to either Table 5 for natural gasor Table 6 for LP/propane gas to verify the manifoldpressure setting required for your particular installation. Toadjust the manifold pressure, remove the regulator cap andturn the adjusting screw clockwise to increase pressure orcounterclockwise to reduce pressure. Replace the regula-tor cap after adjustments are complete.
Verifying and Adjusting Temperature Rise — Verify thatthe temperature rise through the unit is within the rangespecified on the unit data label. Temperature rises outsidethe specified range could result in premature heat exchangerfailure.
Place thermometers in the return and supply air stream asclose to the duct connections as possible. The thermometeron the supply air side must be shielded from direct radiationfrom the heat exchanger to avoid false readings. Adjustall registers and duct dampers to the desired position andrun the unit for ten to fifteen minutes before taking anytemperature readings. The temperature rise is the differencebetween the supply and return air temperatures.
For typical duct systems, the temperature rise will fallwithin the range specified on the data label with the blowerspeed at the factory recommended setting (see Table 3).If the temperature rise measured is outside the range
22
(See Figure 11) 9. Replace the control access door/panel
(upper door if two-door model).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 “To Turn Off Gas To Appliance” and call your service technician or gas supplier.
1. STOP! Read the safety information above on this label.2. Set the thermostat to the lowest setting.3. Turn off all electrical power to the appliance.4. The appliance’s ignition device automatically lights the burner. Do
not try to light burner by hand.5. Remove the control access door/panel (upper door if two-door
model).6. Move the gas control knob clockwise to “OFF”.
(See Figure 11)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” inabove information. If you don’t smell gas, go to the next step.
8. Move the gas control knob counterclockwise to “ON”.
WARNING: If you do not follow theseinstructions exactly, a fire or explosion mayresult causing property damage, personalinjury, or loss of life.
MODE D'EMPLOI
DIRECTIVES D’ARRÊT
A. This appliance does not have a pilot. It is equipped with anignition device which automatically lights the burner. Do not tryto light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area forgas. Be sure to smell next to the floor because some gas isheavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electrical switch; do not use any phone in
your building.• Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.• If you cannot reach your gas supplier, call the fire department.C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or move by hand, do not try to repair it, call a qualified service technician. Force
or attempted repair may result in a fire or explosion.D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect theappliance and to replace any part of the control system andany gas control which has been under water.
OPERATING INSTRUCTIONS
A. Cet appareil ménager n'a pas de veilleuse. II est doté d’unsystème d’allumage automatique. Ne pas essayer d'allumer lebrûleur manuellement.
B. AVANT L’USAGE. Attention à une possible odeur de gazsurtout au niveau du plancher où les gaz les plus lourds ont latendance de se concentrer.
EN CAS D’ODEUR DE GAZ.• Ne mettre en marche aucun appareil électrique.• Ne toucher à aucun commutateur électrique, ne pas employer le
téléphone.• Quitter le bâtiment immédiatement et avertir la compagnie du
gaz en utili sant le téléphone d'un voisin.• A défaut de la compagnie du gaz, avertir le service des
pompiers.C. Enfoncer ou faire tourner le robinet à gaz à la main seulement. Nejamais utiliser d'outils. S’il n’est pas possible de faire tourner ou
d’enfoncer le robinet à la main, ne pas essayer de le réparer. Faireappel à un spécialiste. Forcer ou tenter de réparer le robinetpourrait être à l’origine d’une explosion ou d’un incendie.D. II est déconseillé d’utiliser cet appareil en contact prolongé avec
l’eau. Faire inspecter ou remplacer toute commande par untechnicien qualifié si un des systèmes de contrôle du gaz s'esttrouvé sous l'eau.
ATTENTION! L’inobservation de cesinstructions peut entraîner un incendie ou uneexplosion pouvant causer des dammages àvotre propriété à votre personne, ou la mort.
POUR VOTRE SÉCURITÉ.À LIRE AVANT L’EMPLOI
FOR YOUR SAFETYREAD BEFORE OPERATING
TO TURN OFFGAS TO APPLIANCE
Figure 11
KNOB(ROBINET)
1. ATTENTION! Lire d'abord la liste des mesures de sécurité ci-dessus.
2. Mettre le thermostat à la position minimale. 3. Couper le courant électrique qui mène à l’appareil. 4. Cet appareil ménager étant doté d’un système d’allumage
automatique, ne pas essayer d'allumer le brûleur manuellement. 5. Retirer le panneau/volet d’accès de commande (panneau
supérieur s’il s’agit d’un modèle à deux panneaux). 6. Faire tourner le robinet à gaz dans le sens des aiguilles d’une
montre pour l’amener sur la position OFF (Arrêt) (VoirFigure 11).
7. Attendre cinq (5) minutes pour s’assurer de la dissipation du gazEn cas d’odeur, ARRÊTER LE PROCÉDÉ. Suivre les instruc-tions ci-dessus (Section B). En l’absence de toute odeur degaz, avancer à l’étape suivante.
8. Faire tourner le robinet à gaz dans le sens inverse des aiguillesd’une montre pour l’amener sur la position ON (Marche)(Voir Figure 11).
9. Remettre le panneau/volet d’accès de commande en place(panneau supérieur s’il s’agit d’un modèle à deux panneaux).
10. Rebrancher l’appareil sur le réseau électrique.11. Ajuster le thermostat à la position désirée.12. Si l’appareil ne fonctionne pas, suivre les “Directives d’arrêt”
cidessous et appeler le technicien de service.
1. Set the thermostat to the lowest setting.2. Turn off all electrical power to the appliance if service is to
be performed.3. Remove the control access door/panel (upper door if two-
door model).4. Move the gas control knob clockwise to “OFF”. Do
not use force. (See Figure 11)5. Replace the control access door/panel (upper door if two-
door model).
1. Mettre le thermostat à la position minimale.2. Débrancher l’appareil en prévision de la réparation.3. Retirer le panneau/volet d’accès de commande (panneausupérieur s’il s’agit d’un modèle à deux panneaux).4. Faire tourner le robinet à gaz dans le sens des aiguilles d’une
montre pour l’amener sur la position OFF (Arrêt) Nepas forcer (Voir Figure 11).
5. Remettre le panneau/volet d’accès de commande en place(panneau supérieur s’il s’agit d’un modèle à deux panneaux).
23
specified, it may be necessary to change the blower speed.Lower blower speeds will increase the temperature rise andhigher blower speeds will decrease the temperature rise.
The unit is equipped with a variable speed motor. Heatingand cooling speed selection is made by changing theswitch settings on the integrated control located in the unitcontrol box. Refer to the Variable Speed Blower Section ofthis installation instruction for more details.
The VSB is designed with built in delay profiles for start upand shut down of the system. See the Sequence ofOperation section on page 26 for more details.
Verifying Burner Operation — To verify operation of theburners remove the louvered control access panel toensure there is power to the unit. Set the thermostat to atemperature above room temperature and observe theignition sequence. The burner flame should carry overimmediately between all burners. The flames should beblue, without yellow tips. Flames should extend from eachburner without lifting off, curling, or floating. Make sure theflame is drawn into the center of the heat exchanger tube(See Figure 10). In a properly adjusted burner assembly,the flame bends down and to the right at the end of the heatexchanger tube. The end of the flame will be out of sightaround the bend. After verifying satisfactory flamecharacteristics, set the thermostat to a temperature belowroom temperature and verify that the burner flameextinguishes completely.
! WARNING:Uninsulated live components are exposed whenlouvered control access panel is removed.
Verify Operation of Over-Temperature Limit Control –To verify operation of the over-temperature limit control,make sure that the louvered control access panel is inplace and that there is power to the unit. Block the returnairflow to the unit by installing a close-off plate in place ofor upstream of the filter. Set the thermostat to a temperatureabove room temperature and verify the unit operates withthe correct sequence of operation (see page 26). The over-temperature limit control should function to turn off the gasvalve within approximately four minutes (the exact timedepending on the efficiency of the close-off in blocking thereturn air to the unit). The circulating air and combustionblowers should continue to run when the over-temperaturelimit control switch opens. Remove the close-off immediatelyafter the over-temperature limit control opens. If the unitoperates for more than four minutes with no return air, setthe thermostat to a temperature below room temperature,
shut off the power to the unit, and replace the over-temperature limit control.
COMPONENT FUNCTIONS
Flame Sensor — The flame sensor acts to prove thatflame has carried over from the ignitor to the right-mostburner. If no flame is sensed, the unit will be shut downautomatically.
Flame Roll-Out Control — The flame roll-out control actsto verify that the burner flame is being drawn into the heatexchanger tubes. If the burner flame is not being drawn intothe heat exchanger tubes, the roll-out control will openwithin several seconds and the integrated control diagnosticlight will flash one time. The circulating air blower andcombustion blower will continue to operate if the flame roll-out control opens.
Gas Valve — The gas valve acts to control the flow of gasto the burners. When the gas valve is energized itautomatically opens and regulates the gas pressure in themanifold.
Pressure Switch — The pressure switch acts to verify thatthe inducer motor is drawing the combustion gases throughthe heat exchanger tubes and venting the gases throughthe vent system.
Over-Temperature Limit Control — The over-temperaturelimit control acts to prevent the air temperature leaving theunit from exceeding the maximum outlet air temperature. Ifthe limit opens, the integrated control diagnostic will flashone time. The circulating air blower and combustion blowerwill continue to operate if the over-temperature limit controlopens.
Figure 10. Burner Inspection
Burner Flame
Manifold
24
Secondary Gas Valve — The gas valve controls the flowof gas to the high fire burners only.
UNIT MAINTENANCE
! WARNING:To avoid risk of electrical shock, personal injury,or death, disconnect all electrical power to theunit before performing any maintenance orservice. The unit may have more than oneelectrical supply.
! CAUTION:Use care when removing parts from this unit.Personal injury can result from sharp metal edgespresent in all equipment of sheet metalconstruction.
Refrigerant Charging — The packaged gas/electric unitsare fully charged at the factory. The system refrigerantcharge can be checked and adjusted through the serviceports provided behind the service panel. Use only gaugelines which have a “Schrader” depression device present toactuate the valve. Refrigerant charging must be done byqualified personnel familiar with safe and environmentallyresponsible refrigerant handling procedures.
TIME FOR TIME FORONE REVOLUTION ONE REVOLUTION
(SECONDS) 1 5 10 (SECONDS) 1 5 1010 360 1800 3600 66 55 273 545
12 300 1500 3000 68 53 265 529
14 257 1286 2571 70 51 257 514
16 225 1125 2250 72 50 250 500
18 200 1000 2000 74 49 243 486
20 180 900 1800 76 47 237 474
22 164 818 1636 78 46 231 462
24 150 750 1500 80 45 225 450
26 138 692 1385 82 44 220 439
28 129 643 1286 84 43 214 429
30 120 600 1200 86 42 209 419
32 113 563 1125 88 41 205 409
34 106 529 1059 90 40 200 400
36 100 500 1000 92 39 196 391
38 95 474 947 94 38 191 383
40 90 450 900 96 38 188 375
42 86 429 857 98 37 184 367
44 82 409 818 100 36 180 360
46 78 391 783 102 35 176 353
48 75 375 750 104 35 173 346
50 72 360 720 106 34 170 340
52 69 346 692 108 33 167 333
54 67 333 667 110 33 164 327
56 64 321 643 112 32 161 321
58 62 310 621 114 32 158 316
60 60 300 600 116 31 155 310
62 58 290 581 118 31 153 305
64 56 281 563 120 30 150 300
GAS FLOW RATE (CUBIC FEET PER HOUR)
CUBIC FEET PER REVOLUTION OF METER CUBIC FEET PER REVOLUTION OF METER
Table 9. Gas Flow Rate (Cubic Feet Per Hour).
25
! WARNING:The gas/electric units are shipped fully chargedand ready for installation. When a system isinstalled according to these instructions, norefrigerant charging is required. If repairs makeit necessary for evacuation and charging, itshould only be done by qualified, trainedpersonnel thoroughly familiar with thisequipment. Some local codes require licensedinstallation/service personnel to service this typeof equipment. Under no circumstances shouldthe owner attempt to install and/or service thisequipment. Failure to comply with this warningcould result in property damage, personal injury,or death.
Routine Maintenance — Proper maintenance is importantto achieve optimum performance from the air conditioner.The ability to properly perform maintenance on this equip-ment requires certain mechanical skills and tools.If you do not possess these skills, contact your dealer formaintenance. Consult your local dealer about the availabil-ity of maintenance contracts. It is recommended that theunit be inspected once a year by a qualified service person.At a minimum, routine maintenance should include thefollowing:
Air Filter — Inspect and clean or replace the air filterevery three to four weeks.
! WARNING:Never operate the unit without a filter in place.Dust and lint in the return air can build up oninternal components, resulting in loss ofefficiency, equipment damage, and possible firerisk.
Vent Cover Assembly — Inspect and clean the screen ofthe vent cover assembly at the beginning of each heatingand cooling seasons.
Condensate Drain and Outdoor Coil — Inspect thecondensate drain and outdoor coil at the beginning of eachcooling season. Remove any debris. Clean the outdoor coiland hail guard louvers (optional) as necessary using a milddetergent and water. Rinse thoroughly with water.
Electrical — Inspect the electrical connections for tightnessat the beginning of each heating and cooling season.Service as necessary.
! CAUTION:Label all wires prior to disconnection whenservicing controls. Wiring errors can causeimproper and dangerous operation.
Motor Lubrication — The motors for the circulating airblower, outdoor fan, and combustion blower are pre-lubricated at the factory. No further oiling is required for thelife of this product.
! WARNING:Lubrication of the motors in this unit is notrequired. Do not lubricate any motor in thisproduct.
Blower Compartment — The blower compartment shouldbe cleaned monthly during the heating and cooling seasonsto remove any dirt and lint that may have accumulated inthe compartment or on the blower and motor. Buildup of dirtand lint on the blower and motor can create excessive loadson the motor resulting in higher than normal operatingtemperatures and possible shortened service life.
Heat Exchanger and Burner Maintenance — The unitshould operate for many years without excessive scalebuildup in the heat exchanger, however, the heat exchanger,the vent system, and the burners should be inspected andcleaned (if required) by a qualified serviceman annually toensure continued safe operation. Particular attention mustbe given to identify deterioration from corrosion or othersources.
! WARNING:Holes in the heat exchanger can cause productsof combustion to enter the home. Replace theheat exchanger if leaks are found. Failure toprevent products of combustion from beingcirculated into the living space can createpotentially hazardous conditions includingcarbon monoxide poisoning that could result inpersonal injury or death.
Cleaning of Heat Exchanger — If the heat exchangermust be cleaned due to soot or scale build up, follow thesteps below.
1. Shut off the gas supply to the unit either at the meteror at the manual valve in the gas supply piping.
2. Turn off all power to the unit and set the thermostat tothe lowest temperature setting.
26
3. Remove the louvered control access panel from theunit.
4. Turn the gas control knob on the gas valve to the “OFF”position.
5. Disconnect the wires from the gas valve, ignitor, flamesensor, combustion air motor, flame roll-out control,over-temperature limit switch, and pressure switch.
6. Remove the silicone rubber tube from the collector panto the pressure switch.
7. Remove the four nuts that hold the combustion blowerto the collector pan and remove the completecombustion blower.
8. Remove the screws that hold the collector pan in place,and remove the collector pan from the unit.
9. Using wrenches, separate the ground-joint union in thegas supply piping at the unit.
10. Remove the piping between the gas valve and theground-joint union, if necessary.
11. Remove the screws that hold the burner assembly inplace and remove the burner assembly. BEEXTREMELY CAREFUL NOT TO DAMAGE THEIGNITOR WHILE REMOVING THE BURNERASSEMBLY.
12. The unit heat exchanger tubes can now be cleaned bythe use of a round wire brush attached to a length ofhigh grade stainless steel cable, such as drain cleanoutcable. Attach variable speed reversible drill to the otherend of the spring cable. Slowly rotate the cable with thedrill and insert it into the top portion of the heatexchanger. While reversing the drill, work the cable inand out several times to obtain sufficient cleaning.Repeat this sequence for each heat exchanger tube.
13. When all heat exchanger tubes have been cleaned,any debris inside the tubes can be removed with thenozzle of a vacuum cleaner.
14. With a light, check the condition of the upper and lowersections of the heat exchanger tube.
15. Inspect the burners and clean them (if necessary) witha soft wire brush and/or the nozzle of a vacuumcleaner. BE EXTREMELY CAREFUL NOT TODAMAGE THE IGNITOR WHILE CLEANING THEBURNER.
16. Replace all the parts in reverse order from which theywere removed.
17. Follow the operating instructions found on the right sidedoor and the User’s Information Manual to return theunit 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 meteror at a manual valve in the supply piping.
2. Turn off all power to the unit and set the thermostat tothe lowest temperature setting.
3. Remove the louvered control access panel from theunit.
4. Turn the gas control knob to the “OFF” position.5. Disconnect the wires from the gas valve, ignitor, and
flame sensor.6. Using 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 necessary.8. Remove the screws that hold the burner assembly in
place and remove the burner assembly. BEEXTREMELY CAREFUL NOT TO DAMAGE THEIGNITOR WHILE REMOVING THE BURNERASSEMBLY.
9. Inspect the burners and clean them (if necessary) witha soft wire brush and/or the nozzle of a vacuumcleaner. BE EXTREMELY CAREFUL NOT TODAMAGE THE IGNITOR WHILE CLEANING THEBURNER.
10. Replace all the parts in reverse order from which theywere removed.
11. Follow the lighting instructions found on the lower unitdoor to return the unit to operation.
! CAUTION:Verify proper operation after servicing.
SEQUENCE OF OPERATIONThe operating sequences for the heating, cooling, and fanmodes are described below. Refer to the field and furnacewiring diagrams; Figures 7, 8a-e, 9a-b, and 10.
Heating Mode:1. On a call for heat the thermostat closes, applying 24
VAC to the W terminal on the control board.2. The control board checks for continuity on the 24 VAC
limit control circuit (over-temperature limit switch,flame rollout switches and blocked vent switch inseries). If an open limit is detected the control board willenergize the inducer blower. All other system func-tions will be inoperable until the limit circuit closes.While the limit is open, the red LED will pulse at a rateof 1 blink per unit time.
3. The furnace control checks for continuity across thepressure switch (24 VAC). If the pressure switch isclosed the heat mode sequence will not continue. If itremains closed for 10 seconds the red LED will blink 3times repetitively until the fault condition clears.
4. The inducer is energized.5. The pressure switch will close. If the pressure switch
does not close after 10 seconds the fault LED will blink2 times repetitively and the inducer will continue to rununtil the switch is closed.
6. The inducer will pre-purge for 30 seconds and then theigniter will start its warm-up as follows:Initial Power up: After 30 seconds of igniter warm-up
27
the gas valves (24 VAC) will then open. The ignitercircuit will stay energized for 3 seconds after the gasvalve opens.
After Initial Power up: The control has a programmedadaptive ignition feature which varies the warm-upperiod as follows: If ignition is successful the warm-upis reduced by 3-seconds on each subsequent call forheat 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. Ingeneral, whenever ignition failure occurs the warm-upinterval is increased by 3-seconds on the next try. Andif successful, it remains there. Minimum and maxi-mum warm-up time limits are set at 6 and 54 seconds,respectively.
7. The furnace control must prove flame via the flamesensor 5 seconds after the gas valves open. If flameis sensed, burners are on and the igniter cools off. If noflame is sensed, the gas valve closes immediately andthe inducer continues to run. A second trial for ignition(step 6) begins. If no flame is sensed on the fifth try forignition, the furnace control is locked and the red LEDwill blink 4 times repetitively. The thermostat must beopened for at least ten seconds to reset the furnacecontrol after a lock out. Otherwise, the furnace willattempt another ignition sequence in 1 hour.
8. The furnace control energizes the circulating air blowerat a very low speed. After 30 seconds, the blower willramp to the airflow selected for heating.
9. If the unit is wired for two stage operation, only the low-fire burners will be fired. If the need for stage 2 occurs,the secondary gas valve will open firing the remainingburners. At this time the circulating air blower will rampup to the high-fire airflow.
10. When the thermostat has been satisfied, gas valve isde-energized.
11. The inducer is de-energized after a 30 secondpostpurge.
12. The circulating air blower remains on for 120 seconds.13. Abnormal conditions: If a limit opens during operation,
the inducer blower continues to operate. The gas valveis de-energized immediately. The inducer blower con-tinues to operate until the limit closes, then is de-energized.
Cooling Mode:1. On a call for cooling the thermostat closes, applying 24
VAC to the G and Y terminals on the furnace control.This closes the compressor contactor.
2. The furnace control energizes the circulating blower to1/3 of the selected airflow for approximately 30 sec-onds.
3. The circulating blower will then ramp to approximately3/4 of the selected airflow for another 30 secondsbefore adjusting to full airflow until the thermostat issatisfied.
4. When the thermostat is satisfied, the G and Y termi-nals on the control board are de-energized opening thecompressor contactor.
5. The circulating air blower will operate at 1/2 of theselected speed for 60 seconds, and de-energize.
Fan Mode:1. On a call for fan operation, the thermostat applies 24 VAC
to the G terminal on the furnace control board.2. The circulating air blower ramps to 1/2 of the selected
airflow.
Unit Fails to Operate
If the unit does not operate in the cooling mode, be certainto check the following:
1. The thermostat is operating properly.2. Electrical power to the unit is turned on.3. The filters are not dirty.4. The service doors are in place.5. The 3 amp fuse is operational.6. The anti-short cycle timer’s 5-minute cycle has finished
for single phase units.
If the unit does not operate in the heating mode, be certainto check the following:
1. The thermostat is operating properly.2. Electrical power to the unit is turned on.3. The filters are not dirty.4. The gas is turned on.5. The manual shut-off valve is open.6. The service doors are in place.7. The flame roll-out control is closed.8. Refer to the diagnostic code table on the wiring
diagram or see Table 9.9. The 5 amp fuse is operational.
Power On OnLimit Circuit Open 1 FlashPressure Switch Stuck Open 2 FlashPressure Switch Stuck Closed 3 FlashIgnition Failure (Check Ground) 4 Flash230 VAC & Neutral Reversed or No Ground 5 FlashFalse Flame or Gas Relay Shorted Continuous FlashPower Off Off
Low Flame Sensor Signal Continuous FlashFlame Present On
FAULTCONDITION
STATUSLIGHT (RED)
Table 9. Diagnostic Codes.
FAULTCONDITION
STATUS LIGHT(YELLOW)
¢708334'¤708334C
708334C (Replaces 708334B)
Specifications and illustrations subject to changewithout notice and without incurring obligations.
Printed in U.S.A. (04/05)O’Fallon, MO
INSTALLATION/PERFORMANCE CHECK LIST
LOCATION ____________________________ CITY _____________________________ STATE _______
INSTALLER ____________________________ CITY _____________________________ STATE _______
UNIT MODEL NUMBER __________________ UNIT SERIAL NUMBER ______________
Is the vent hood installed? _______________________
Is there Proper Draft? __________________________
Is vent hood free from restrictions? ________________
Is the Filter(s) clean? ___________________________
Has the Thermostat been calibrated? ______________
Is the Thermostat level? ________________________
Is the Heat Anticipator Setting correct? _____________
Has the Owner's Information been reviewed with the
homeowner? _________________________________
Has the Literature Package been left with the
homeowner? _________________________________
Minimum Clearances per Table 1? _________________
Electrical Connections tight? _____________________
Supply Voltage: ________________ Volts
Blower Motor H.P.: _____________
FUEL TYPE:
Natural Gas ____________ LP/Propane _______
Gas Piping Connections leak-tested? ___________
Gas Line Pressure: _____________
(in. water column, with furnace operating)
Manifold Pressure: _____________
(in. water column, with furnace operating)
Is there adequate fresh air supply for combustion and
ventilation? _______________
Furnace Input: ____________________ Btu/hr)
Supply Air Temperature: ____________ (°F)
Return Air Temperature:_____________ (°F)
Temperature Rise: _________________ (°F)
INSTALLER: PLEASE LEAVETHESE INSTALLATION
INSTRUCTIONS WITH THEHOMEOWNER.
