Installation Instructions - c.searspartsdirect.com · START-UP CHECKLIST ..... 41...

Installation InstructionsPDD3 / PDS3 Series

13 SEER, Single & Three Phase

PACKAGED DUAL FUEL UNITS

TABLEOF CONTENTSPAGE

SAFETY CONSIDERATIONS ......................... 2INTRODUCTION .................................... 2RECEIVING AND INSTALLATION .................... 2

Check Equipment ................................. 2Identify Unit ..................................... 2Inspect Shipment ................................ 2

Provide Unit Support ............................... 3Roof Curb ...................................... 3Slab Mount ..................................... 3

Field Fabricate Ductwork ........................... 3Provide Clearances ................................ 3

Rig and Place Unit ................................. 7Connect Condensate Drain ......................... 8Install Flue Hood .................................. 8

Install Gas Piping .................................. 8Install Duct Connections ........................... 12

Configuring Units for Downfiow (Vertical)Discharge ..................................... 12

Install Electrical Connections ....................... 13

High-Voltage Connections ....................... 13Special Procedures for 208-V Operation ........... 13Control Voltage Connections ..................... 13Balance Point Setting Dual Fuel Thermostat ....... 14Transformer Protection .......................... 14

PRE-START-UP ................................... 14START-UP ........................................ 15

Check for Refrigerant Leaks .................... 15Unit Sequence of Operation .................... 15Start-Up Heating and Make Adjustments ......... 15

Checking Heating Control .................... 16Check Gas Input ............................ 16Adjust Gas Input ............................ 16Check Burner Flame ......................... 17

Start-Up Cooling and Make Adjustments ......... 18Checking Cooling Control Operation ........... 18Checking and Adjusting Refrigerant ............ 18Indoor Airflow and Airflow Adjustments ......... 19

MAINTENANCE ................................ 31Air Filter ...................................... 31Indoor Blower and Motor ....................... 31

Flue Gas Passageways ........................ 32Limit Switch .................................. 32

Burner Ignition ................................ 32Main Burners ................................. 32Outdoor Coil, Indoor Coil, & Condensate Drain Pan 32Outdoor Fan .................................. 33Electrical Controls and Wiring ................... 33Refrigerant Circuit ............................. 33Gas Input .................................... 34Indoor Airflow ................................. 34Check Defrost Thermostat ...................... 34R-410A Items ................................. 38

TROUBLESHOOTING ........................... 39START-UP CHECKLIST ......................... 41

InternationalComfort Products,LLCLewisburg,TN. 37091

518 01 2301 00 05-11-09

FIGURE 1 J PDD3 HEAT PUMP UNIT

SAFETY CONSIDERATIONS

Improper installation adjustment, alteration, service,maintenance, or use can cause explosion, fire, electricalshock, or other conditions which may cause death, personalinjury, or property damage. Consult a qualified installer,service agency, or your distributor or branch for informationor assistance. The qualified installer or agency must usefactory-authorized kits or accessories when modifying thisproduct Refer to the individual instructions packaged withthe kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protectiveclothing, and work gloves. Have a fire extinguisheravailable. Read these instructions thoroughly and follow allwarnings or cautions included in literature and attached tothe unit. Consult local building codes, the current editions ofthe National Fuel Gas Code (NFGC 54/ANSI Z223.1, andthe National Electrical Code (NEC) NFPA 70.

In Canada refer to the current editions of the NationalStandards of Canada CAN/CSA-B149.1 and .2 Natural Gasand Propane Installation codes, and Canadian electricalCode CSA C22.1.

Recognize safety information. This is the safety-alert sym-

bol/K. When you see this symbol on the unit and in instruc-

tions or manuals, be alert to the potential for personal injury.Understand these signal words: DANGER, WARNING, andCAUTION. These words are used with the safety-alert sym-bol. DANGER identifies the most serious hazards which will

result in severe personal injury or death. WARNING signi-fies hazards which could result in personal injury or death.CAUTION is used to identify unsafe practices which may re-sult in minor personal injury or product and property dam-age. NOTE is used to highlight suggestions which will resultin enhanced installation, reliability, or operation.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personalinjury or death.

Before installing or servicing system, always turn offmain power to system. There may be more than onedisconnect switch. Turn off accessory heater powerswitch if applicable. TAG THE DISCONNECTSWITCH WITH A SUITABLE WARNING LABEL.

FIRE, EXPLOSION, ELECTRICAL SHOCK ANDCARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personalinjury, death or property damage.

A qualified installer or agency must use onlyfactory-authorized kits or accessories when modifyingthis product.

CUT HAZARD

Failure to follow this caution may result in personalinjury.

When removing access panels or performingmaintenance functions inside your unit, be aware ofsharp sheet metal parts and screws. Although specialcare is taken to reduce sharp edges to a minimum,be extremely careful when handling parts or reachinginto the unit.

INTRODUCTIONThe PDD/S unit (see Fig. 1) is a fully self-contained,combination Category I gas heating/electric heating andcooling unit designed for outdoor installation (See Fig. 2 and3 for unit dimensions). All unit sizes have return anddischarge openings for both horizontal and downftowconfigurations, and are factory shipped with all downftowduct openings covered. Units may be installed either on arooftop, or on a cement slab (See Fig. 4 for roof curbdimensions).

Models with a "1" in the thirteenth position of the modelnumber are dedicated Low NOx units designed forCalifornia installations. These models meet the California

maximum oxides of nitrogen (NOx) emissions requirementsof 40 nanograms/joule or less as shipped from the factoryand must be installed in California Air Quality ManagementDistricts or any other regions in North America where a LowNOx rule exists.

RECEIVING AND INSTALLATION

Step 1 m Check EquipmentIDENTIFY UNIT

The unit model number and serial number are stamped onthe unit information plate. Check this information againstshipping papers.

INSPECT SHIPMENT

Inspect for shipping damage before removing packagingmaterials. If unit appears to be damaged or is torn loosefrom its anchorage, have it examined by transportationinspectors before removal. Forward claim papers directly totransportation company. Manufacturer is not responsible forany damage incurred in transit. Check all items againstshipping list. Immediately notify the nearest equipmentdistribution office if any item is missing. To prevent loss ordamage, leave all parts in original packages untilinstallation.

Step 2 m Provide Unit SupportFor hurricane tie downs, contact distributor for details andPE (Professional Engineering) Certificate if required.ROOF CURB

IMPORTANT: The unit must be secured to the curb byinstalling screws through the bottom of the curb flangeand into the unit base rails, When installing large baseunits onto the common curb, the screws must beinstalled before allowing the full weight of the unit to reston the curb, A minimum of six screws are required forlarge base units, Failure to secure unit properly couldresult in an unstable unit. See Warning nearRigging/Lifting information and accessory curbinstructions for more details.

Install accessory roof curb in accordance with instructionsshipped with curb (See Fig. 4). Install insulation, cant strips,roofing, and flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb iscritical for a water tight seal. Install gasketing materialsupplied with the roof curb. Improperly applied gasketingalso can result in air leaks and poor unit performance.

Curb should be level to within 1/4 in. (6 mm). This isnecessary for unit drain to function properly. Refer toaccessory roof curb installation instructions for additionalinformation as required.SLAB MOUNT

Place the unit on a solid, level concrete pad that is aminimum of 4 in. (102 mm) thick with 2 in. (51 mm) abovegrade. The slab should be flush on the compressor end ofthe unit (to allow condensate drain installation) and shouldextend 2 in. (51 mm) on the three remaining sides of theunit. Do not secure the unit to the slab except whenrequired by local codes.

Step 3 m Field Fabricate DuctworkSecure all ducts to roof curb and building structure onvertical discharge units. Do not connect ductwork to unit.For horizontal applications, unit is provided with flanges onthe horizontal openings. All ductwork should be secured tothe flanges. Insulate and weatherproof all external ductwork,joints, and roof openings with counter flashing and mastic inaccordance with applicable codes.

Ducts passing through an unconditioned space must beinsulated and covered with a vapor barrier.

If a plenum return is used on a vertical unit, the returnshould be ducted through the roof deck to comply withapplicable fire codes.

See unit rating plate for any required clearances aroundductwork. Cabinet return-air static shall not exceed -.25 IN.W.C.

Step 4 _ Provide ClearancesThe required minimum operating and service clearances areshown in Fig. 2 and 3.IMPORTANT: Do not restrict outdoor airflow. An air

restriction at either the outdoor-air inlet or the fan dischargemay be detrimental to compressor life.

The condenser fan pulls air through the condenser coil anddischarges it through the top grille. Be sure that the fandischarge does not recircuIate to the condenser coil. Do notlocate the unit in either a corner or under an overhead

obstruction. The minimum clearance under a partialoverhang (such as a normal house overhang) is 48-in.(1219 mm) above the unit top. The maximum horizontalextension of a partial overhang must not exceed 48-in.(1219 mm).

Do not place the unit where water, ice, or snow from anoverhang or roof will damage or flood the unit. Do not installthe unit on carpeting or other combustible materials. Theunit may be installed on Class A, B, or C roof coveringmaterials. Stab mounted units should be at least 4-in. (102mm) above the highest expected water and runoff levels.Do not use unit if it has been under water.

[]

4 ×

zozILl

o

i

oQa.

w

ii

ssssss _s_ s ss sss _

_i i i _ii i gi i i £_ s

_- : : : : : U S%S_ .... ] :_ : : : =S

[]

9_

4 _8

FIGURE 4 J Roof Curb Dimensions

HVAC unitbase raits

Anchor screw j

Flashing field

supplied _

HVAC unit

basepan

Sealing

Gasket

_ Roofcurb

Woodnailer*

Roofcurb*Insulation

J(field supplied)Roofing material

CC°- /field supplied "_ /

A09090

ROOF CURB DETAIL

F

÷

SMALL CURB Ao9110

F

"--4..LARGE CURB A09095

A09110

B C D E F

IN, (mm)* IN, (mm) IN, (mm) IN, (mm) IN, (mm)UNIT SIZE

Small

Large

NOTES:

CATALOGNUMBER

CPRFCURB010A00

CPRFCURB011A00

CPRFCURB012A00

CPRFCURB013A00

A

IN. (mm)

11 (279)

14 (356)

11 (279)

14 (356)

1. Roof curb must be set up for unit being installed.

2. Seal strip must be applied, as required, to unit being installed.

3. Roof curb is made of 16-gauge steel.

4. Attach ductwork to curb (flanges of duct rest on curb).

5. Insulated panels: 1-in. (25,4 ram) thick fiberglass 1 lb. density.

IMPORTANT: Do not install large base pan packaged dualfuel units onto the small base pan (common curb). Thecenter of gravity on a large base pan packaged dual fuelunit could overhang the curb causing an unsafe condition.Before installing any large base pan unit onto the common

10 (254)

14 (356)

16 (406) 47.8 (1214)

32.4 (822)

43.9 (1116)

2.7 (69)

curb, check the "Y" distance in the product literaturedimensional drawing to ensure that "Y" is greater than 14 in.(356 mm). Do not install any large base pan unit onto thecommon curb with a "Y" dimension (center of gravity) lessthan 14 in. (356 mm).

FIGURE 5 J PDD/S Suggested Rigging

jJJ MINIMUM HEIGHT: 36" (914.4 mm}J HAUTEUR MINIMUM

UNIT HEIGHT

HAUTEUR D'UNITE

j ....

SEE DETAIL A

VOIR DETA{L A

RIGGING WEIGHTS (SMALL CABINET)

24 30 36

Unit Ib kg Ib kg Ib kg

Riggingweight 359 163 373 169 379 172

*For 460 Volt units add 14 Ib (6.35 kg) to the rigging weight.

NOTE: See dimensional drawing for corner weights.

Step 5 m Rig and Place Unit

Unit

RiggingWeight

PERSONAL INJURY OR PROPERTY DAMAGEHAZARD


When installing the unit on a rooftop, be sure the roofwill support the additional weight.

Rigging and handling of this equipment can be hazardousfor many reasons due to the installation location (roofs,elevated structures, etc.).

Only trained, qualified crane operators and ground supportstaff should handle and install this equipment.

When working with this equipment, observe precautions inthe literature, on tags, stickers, and labels attached to theequipment, and any other safety precautions that mightapply.

Training for operators of the lifting equipment shouldinclude, but not be limited to, the following:

1. Application of the lifter to the load, and adjustment ofthe lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of thelifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes andwork gloves.

DETAIL AVOIR DIeTAIL A

SEAL STRIP MUST BE IN BANDE SC ELLANT DOlT ETRE

PLACE BEFORE PLACING EN PLACE AVANT DE PLACERUNET ON ROOF CURB L UNETE SUR LA BASE DE TOrT

50CY502286 2.0

RIGGING WEIGHTS (LARGE CABINET)

Inspection

Prior to initial use, and at monthly intervals, all riggingshackles, clevis pins, and straps should be visuallyinspected for any damage, evidence of wear, structuraldeformation, or cracks. Particular attention should be paid toexcessive wear at hoist hooking points and load supportareas. Materials showing any kind of wear in these areasmust not be used and should be discarded.

UNIT FALLING HAZARD


Never stand beneath rigged units or lift over people.

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personalinjury/death or property damage.

When straps are taut, the clevis should be a minimumof 36 in. (914 mm) above the unit top cover.

Riqqinq/Liftinq of Unit (See Fiq. 5)

Lifting holes are provided in base rails as shown in Fig. 2and 3.

1. Leave top shipping skid on the unit for use as aspreader bar to prevent the rigging straps fromdamaging the unit. If the skid is not available, use aspreader bar of sufficient length to protect the unitfrom damage.

2.Attachshackles,clevispins,andstrapsto thebaserailsoftheunit.Besurematerialsareratedtoholdtheweightoftheunit(SeeFig.5).

3.Attacha clevisofsufficientstrengthin themiddleofthestraps.Adjusttheclevislocationtoensureunitisliftedlevelwiththeground.

Aftertheunitisplacedontheroofcurbormountingpad,removethetopskid.Step 6 1 Connect Condensate DrainNOTE: When installing condensate drain connection besure to comply with local codes and restrictions.

Model PDD/S disposes of condensate water through a 3/4in. NPT fitting which exits through the compressor accesspanel (See Fig. 2 and 3 for location).

Condensate water can be drained directly onto the roof inrooftop installations (where permitted) or onto a gravel apronin ground level installations. Install a field-supptiedcondensate trap at end of condensate connection to ensureproper drainage. Make sure that the outlet of the trap is atleast 1 in. (25 mm) lower than the drain-pan condensateconnection to prevent the pan from overflowing (See Fig.6). Prime the trap with water. When using a gravel apron,make sure it slopes away from the unit.

If the installation requires draining the condensate wateraway from the unit, install a 2-in. (51 mm) trap at thecondensate connection to ensure proper drainage (SeeFig. 6). Make sure that the outlet of the trap is at least 1 in.(25 mm) lower than the drain-pan condensate connection.This prevents the pan from overflowing.

Prime the trap with water. Connect a drain tube - using aminimum of 3/4-in. PVC or 3/4-in. copper pipe (alIfield-supptied) - at the outlet end of the 2-in. (51 mm) trap.Do not undersize the tube. Pitch the drain tube downward

at a slope of at least 1-in. (25 mm) for every 10 ft (3 m) ofhorizontal run. Be sure to check the drain tube for leaks.

FIGURE6 J Condensate Trap

TRAP

OUTLET

ram) rain.

Step 7 1 Install Flue HoodThe flue assembly is secured and shipped in the return airduct. Remove duct cover to locate the assembly (See Fig. 8and 9).

NOTE: Dedicated Iow NOx models MUST be installed in

California Air Quality Management Districts where a LowNOx rule exists.

These models meet the California maximum oxides ofnitrogen (NOx) emissions requirements of 40nanograms/joule or Iess as shipped from the factory.

NOTE: Low NOx requirements apply only to natural gasinstallations.

CARBON MONOXIDE POISONING HAZARD


The venting system is designed to ensure properventing. The flue hood assembly must be installed asindicted in this section of the unit installationinstructions.

Install

1.

2.

3.

the flue hood as follows:

This installation must conform with local buildingcodes and with the National Fuel Gas Code (NFGC)NFPA 54 / ANSI Z223.1, (in Canada, CAN/CGAB149.1, and B149.2) latest revision. Refer toProvincial and local plumbing or wastewater codesand other applicable local codes.

Remove flue hood from shipping location (inside thereturn section of the blower compartment-see Fig. 8 &9). Remove the return duct cover to locate the fluehood. Place flue hood assembly over flue panel.Orient screw holes in flue hood with holes in the fluepanel.

Secure flue hood to flue panel by inserting a singlescrew on the top flange and the bottom flange of thehood.

Step 8 1 Install Gas PipingThe gas supply pipe enters the unit through the access holeprovided. The gas connection to the unit is made to the1/2-in. (12.7 mm) FPT gas inlet on the gas valve.

Install a gas supply line that runs to the heating section.Refer to Table 2 and the NFGC for gas pipe sizing. Do notuse cast-iron pipe. It is recommended that a black iron pipeis used. Check the local utility for recommendationsconcerning existing lines. Size gas supply piping for 0.5 IN.W.C. maximum pressure drop. Never use pipe smaller thanthe 1/2-in. (12.7 mm) FPT gas inlet on the unit gas valve.

For natural gas applications, the gas pressure at unit gasconnection must not be less than 4.0 IN. W.C. or greaterthan 13 IN. W.C. while the unit is operating. For propaneapplications, the gas pressure must not be less than 11.0IN. W.C. or greater than 13 IN. W.C. at the unit connection.

A 1/8-in. (3.2 mm) NPT plugged tapping, accessible for testgauge connection, must be installed immediately upstreamof the gas supply connection to the gas valve.

When installing the gas supply line, observe local codespertaining to gas pipe installations. Refer to the NFGCNFPA 54/ANSI Z223.1 latest edition (in Canada, CAN/CGAB149.1).NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by alicensed plumber or gas fitter.

2. When flexible connectors are used, the maximumlength shall not exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoffvalves are used, they shall be T-handle valves.

4. The use of copper tubing for gas piping is NOTapproved by the state of Massachusetts.

In the absence of local building codes, adhere to thefollowing pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe1/4 in. (6.35 mm) for every 15 ft (4.6 m) of length toprevent traps. Grade all horizontal runs downward to

risers.Useriserstoconnecttoheatingsectionandtometer.

2.Protectall segmentsof pipingsystemagainstphysicalandthermaldamage.Supportallpipingwithappropriatestraps,hangers,etc.Usea minimumofonehangerevery6ft (1.8m).Forpipesizeslargerthan1/2in.,(12.7mm)followrecommendationsofnationalcodes.

3.Applyjointcompound(pipedope)sparinglyandonlyto male threadsof joint when makingpipeconnections.Useonlypipedopethatis resistanttoactionof liquefiedpetroleumgasesasspecifiedbylocaland/ornationalcodes.NeveruseTeflontape.

4. Installsedimenttrapinriserleadingtoheatingsection(SeeFig.7).Thisdriplegfunctionsasatrapfordirtandcondensate.

5. Installanaccessible,external,manualmainshutoffvalveingassupplypipewithin6ft (1.8m)ofheatingsection.

6. Installground-jointunioncloseto heatingsectionbetweenunitmanualshutoffandexternalmanualmainshut-offvalve.

7.Pressuretestallgaspipinginaccordancewithlocaland nationalplumbingand gas codesbeforeconnectingpipingtounit.

NOTE:Pressuretestthegassupplysystemafterthegassupplypipingisconnectedto thegasvalve.Thesupplypipingmustbedisconnectedfromthegasvalveduringthetestingof the pipingsystemswhentestpressureis inexcessof 0.5psig.Pressuretestthegassupplypipingsystematpressuresequaltoorlessthan0.5psig.Theunitheatingsectionmustbeisolatedfromthegaspipingsystemby closingtheexternalmainmanualshutoffvalveandslightlyopeningtheground-jointunion.

8.Checkfor gas leaksat the field-installedandfactory-installedgaslinesafterallpipingconnectionshavebeencompleted.Usea commerciallyavailablesoapsolutionmadespecificallyforthedetectionofleaks(ormethodspecifiedby localcodesand/orregulations).

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personalinjury, death and/or property damage.

-Connect gas pipe to unit using a backup wrench toavoid damaging gas controls.

-Never purge a gas line into a combustion chamber.Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections.

-Use proper length of pipe to avoid stress on gascontrol manifold.

-If a flexible connector is required or allowed byauthority having jurisdiction, black iron pipe shall beinstalled at furnace gas valve and extend a minimum of2 in. (51 mm) outside furnace casing.

-If codes allow a flexible connector, always use a newconnector. Do not use a connector which haspreviously serviced another gas appliance.

/FIGURE 7 J. Sediment Trap

IN

OUT,_--

TEE

NIPPLE

CAP

Table 1 - Physical Data - Unit PDD/S

24040 24060 30040 30060 36060 36090 42060 42090

2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2

359 359 378 378 379 379 461 461

163 163 169 169 172 172 209 209

Scroll

1

9.6 9.6 10.2 10.2 7.9 7.9 10.0 10.0

4.35 4.35 4.6 4.6 8.6 8.6 4.5 4.5

Indoor-TXV, Outdoor-Accurater

0.038 (Left)

0.032 (2) 0.035 (2) 0.037 (2) O.040(Right)

.81 .89 .94 .97/1.02

UNIT SIZE PDD/SNOMINAL CAPACITY -ton

SHIPPING WEIGHT -Ib,

(kg)COMPRESSORS

Quantity

REFRIGERANT (R-410A)Quantity -Ib

(kg)REFRIGERANT METERING

DEVICE

OUTDOOR ORIFICE

in, (qty)(mm)

OUTDOOR COILRows.,,Fins/in,

Face Area-sq ftOUTDOOR FAN

Nominal CfmDiameter-in,

(mm)Motor Hp (Rpm)INDOOR COILRows.,,Fins/in,

Face Area-sq ft

INDOOR BLOWERNominal CoolingAirflow- (CFM)

Size-in,

(mm)Motor -hp

FURNACE SECTION*Burner Orifice

Natural Gas Qty...Drill SizePropane GasQty...Drill Size

HIGH-PRESSURE SWITCH(psig) Cut-out

Reset (Auto)

LOSS-OF-CHARGE /LOW-PRESSURE SWITCH

(Liquid Line) (psig)Cut-out

Reset (auto)

RETURN-AIR FILTERS t :_

2...21 2...21

11.9 11.9

2000 2000

24 24

610 610

1/2 (800) 1/5 (810)

3...17 3...17

3.7 3.7

80O

10x10

254x254

1/2

2...44

2...55

80O

10x10

254x254

1/2

2...38

2...53

2...21 2...21

11.9 11.9

2700 2700

24 24

610 610

1/5 (810) 1/5 (810)

3...17 3...17

3.7 3.7

1000 1000

10x10 10x10

254x254 254x254

1/2 1/2

2...44 2...44

2...55 2...58

2...21 2...21

11.9 11.9

2700 2700

24 24

610 610

1/5 (810) 1/5 (810)

3...17 3...17

3.7 3.7

1200 1200

11x10 11x10

279x254 279x254

3/4 3/4

2...38 3...38

2...53 3...53

650 +/- 15

420 +/-25

20 +/-5

45 +/-10

2...21 2...21

13.6 13.6

31 O0 31 O0

26 26

660 660

1/5 (810) 1/5 (810)

3...17 3...17

4.7 4.7

1400 1400

11x10 11x10

279x254 279x254

3/4 3/4

2...38 3...38

2...53 3...53

Throwaway (in,) 20x20x1 20x24x1 24xSOx1

(mm) 508x508x25 508x610x25 610x762x25

*Based on altitude of 0 to 2000 ft (0-610 m).

1-Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of300 ft/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.:l: If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity.

10

Table 1 - Physical Data - Unit PDD/S (Cont'd)

UNIT SIZE PDD/SNOMINAL CAPACITY -tonOPERATING WEIGHT-Ib

(kg)COMPRESSORS

QuantityREFRIGERANT (R-410A)

Quantity -Ib(kg)

REFRIGERANT METERING DEVICE

OUTDOOR ORIFICE-in, (qty)(mm)

OUTDOOR COILRows.,,Fins-in,Face Area-sq ftOUTDOOR FAN

Nominal CfmDiameter-in,

(mm)Motor Hp-RpmINDOOR COIL

Rows.,,Fins-in,Face Area-sq ft

INDOOR BLOWER

Nominal Cooling Airflow-(CFM)Size-in,

(mm)Motor -hp

FURNACE SECTION*Burner Orifice

Natural Gas Qty,..Drill SizePropane GasQty...Drill Size

HIGH-PRESSURE SWITCH (psig)Cut-out

Reset (Auto)

LOSS-OF-CHARGE /LOW-PRESSURE SWITCH

(Liquid Line) (psig)Cut-out

Reset (auto)RETURN-AIR FILTERS 1

Throwaway (in,)(mm)

*Based on altitude of 0 to 2000 ff (0-610 m).

48090

4

482

219

2...21

13.6

3100

26

660

1/5 (81 O)

3...17

4.7

1600

11x10

279x254

1.0

3...38

3...53

48115

4

482

219

9.6

4.4

0.046 (2)1.2

2...21

13.6

3100

26

660

1/5 (81 O)

3...17

4.7

1600

11x10

279x254

1.0

3...33

3...51

48130 80090

4 5

482 507

219 230

Scroll

1

TXV

2...21 2...21

13.6 17.5

3100 3500

26 26

660 660

1/5 (810) 1/5 (810)

3...17 3...17

4.7 5.7

1600 1850

11x10 11x10

279x254 279x254

1.0 1.0

3...31 3...38

3...49 3...53

650 +/-1542O +/-25

80115

5

5O7

23O

12.3

5.6

0.052 (2)1.3

2...21

17.5

3500

26

660

1/5 (810)

3...17

5.7

1850

11x10

279x254

1.0

3...33

3...51

20 +/-5

45 +/-10

24x36x1

(610x914x25)

80130

5

507

230

2...21

17.5

3500

26

660

1/5 (81 O)

3...17

5.7

1850

11x10

279x254

1.0

3...31

3...49

1-Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of300 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.:l: If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity.

Table 2 - Maximum Gas Flow Capacity*

NOMINAL INTERNAL LENGTH OF PIPE, FTI (m)IRON

DIAMETER 10 20 30 40 50 60 70 80 90 100 125 150 175

PIPE, (IN.) (3.1) (6.1) (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (46.0) (53.3)SIZE (IN.)1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 --3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 771 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145

1 - 1/4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 3001- 1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460

Capacity of pipe in cuff of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5-IN. W.C. (based on a 0.60 specific gravity gas). Refer to Table,National Fire Protection Association NFPA 54/ANSI Z223.1.1-This length includes an ordinary number of fittings.

2OO

(61.0)

7213528O43O

HEATING INPUT (BTU/h)

Natural

40,000

60,000

90,000

115,000

130,000

Propane

38,000

53,000

79,000

103,000

116,000

NUMBER OF

ORIFICES

2

2

3

3

3

Table 3 - Heating InputsGAS SUPPLYPRESSURE

(inches water column)

Min

4.0

4.0

4.0

4.0

4.0

Naturall-

Max

13.0

13.0

13.0

13.0

13.0

Propane *l-

Min Max

11.0 13.0

11.0 13.0

11.0 13.0

11.0 13.0

11.0 13.0

MANIFOLD PRESSURE

(inches water column)

Natural1- Propane "1-

3.2 - 3.8 10.0 - 11.0

3.2 - 3.8 10.0 - 11.0

3.2 - 3.8 10.0 - 11.0

3.2 - 3.8 10.0 - 11.0

3.2 - 3.8 10.0 - 11.0

*When a unit is converted to propane, different size orifices must be used. See separate, natural-to-propane conversion kit instructions.

1-Based on altitudes from sea level to 2000 ff (610 m) above sea level. For altitudes above 2000 ft (610 m), reduce input rating 4 percent for each additional 1000ff (305 m) above sea level. In Canada, from 2000 ff (610 m) above sea level to 4500 ft (1372 m) above sea level, derate the unit 10 percent.

11

Step 9 m Install Duct ConnectionsThe unit has duct flanges on the supply- and return-airopenings on the side and bottom of the unit. For downshotapplications, the ductwork connects to the roof curb (SeeFig. 2 and 3 for connection sizes and locations).

Confiqurinq Units for Downflow (Vertical)

Discharqe



Before installing or servicing system, always turn offmain power to system. There may be more than onedisconnect switch. Tag the disconnect switch with asuitable warning label.

1. Open all electrical disconnects before starting anyservice work.

2. Remove horizontal (metal) duct covers to accessvertical (downflow) discharge duct knockouts in unitbasepan. (See Fig. 8.)

3. Starting in a corner as shown in Fig. 9, score thepanel in both directions from the corner. Tap thepanel out from the scored corner using a smallhammer. Be careful and not damage any other part ofthe unit.

4. If unit ductwork is to be attached to vertical openingflanges on the unit base (jackstand applications only),do so at this time.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in propertydamage.

Collect ALL screws that were removed. Do not leavescrews on rooftop as permanent damage to the roofmay occur.

5. It is recommended that the base insulation around theperimeter of the vertical return-air opening be securedto the base with aluminum tape. Applicable localcodes may require aluminum tape to prevent exposedfiberglass.

6. Reinstall both horizontal duct covers. Ensure openingis air- and watertight.

7. After completing unit conversion, perform all safetychecks and power up unit.

NOTE: The design and installation of the duct system mustbe in accordance with the standards of the NFPA for

installation of nonresidence-type air conditioning andventilating systems, NFPA 90A or residence-type, NFPA90B; and/or local codes and ordinances.

Adhere to the following criteria when selecting, sizing, andinstalling the duct system:

1. Units are shipped for horizontal duct installation (byremoving duct covers).

2. Select and size ductwork, supply-air registers, andreturn-air grilles according to American Society ofHeating, Refrigeration and Air Conditioning Engineers(ASHRAE) recommendations.

3. Use flexible transition between rigid ductwork and unitto prevent transmission of vibration. The transitionmay be screwed or bolted to duct flanges. Use

suitable gaskets to ensure weather tight and airtightseal.

FIGURE 8

HorizontalDuct Covers

J Supply and Return Duct Opening

BasepanDownflow

ReturnKnockout

FIGURE 91 Vertical (Downflow) Discharge Duct Knockouts

INSTRUCTIONS FOR REMOVING DOWNSHOT PANELS

1. Score groove in corner 1 in both directions as far as you can reach.

2. Starting in corner 1, tap-out all sides with a small hammer. Be carefulnot to damage any other part of unit.

3. If side from corner 3 to 4 is not accessible due to heat exchanger,

pivot panel up and down by hand until remaining side breaks off.

4. All units must have field-supplied filters or accessoryfilter rack installed in the return-air side of the unit.Recommended sizes for filters are shown in Table 1.

5. Size all ductwork for maximum required airflow (eitherheating or cooling) for unit being installed. Avoidabrupt duct size increases or decreases orperformance may be affected.

6. Adequately insulate and weatherproof all ductworklocated outdoors. Insulate ducts passing throughunconditioned space, and use vapor barrier inaccordance with latest issue of Sheet Metal and Air

Conditioning Contractors National Association

12

(SMACNA) and Air Conditioning Contractors ofAmerica (ACCA) minimum installation standards forheating and air conditioning systems. Secure all ductsto building structure.

7. Flash, weatherproof, and vibration-isolate allopenings in building structure in accordance withlocal codes and good building practices.

Step 10 m Install Electrical Connections



The unit cabinet must have an uninterrupted,unbroken electrical ground. This ground may consistof an electrical wire connected to the unit groundscrew in the control compartment, or conduitapproved for electrical ground when installed inaccordance with NEC, NFPA 70 National FireProtection Association (latest edition) (in Canada,Canadian Electrical Code CSA C22.1) and localelectrical codes.

UNITCOMPONENTDAMAGEHAZARD

Failure to follow this caution may result in damage tothe unit being installed.1. Make all electrical connections in accordance with

NEC NFPA 70 (latest edition) and local electricalcodes governing such wiring. In Canada, allelectrical connections must be in accordance withCSA standard C22.1 Canadian Electrical Code

Part 1 and applicable local codes. Refer to unitwiring diagram.

2. Use only copper conductor for connectionsbetween field-supplied electrical disconnect switchand unit. DO NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is withinoperating voltage range indicated on unit ratingplate. On 3-phase units, ensure phases arebalanced within 2 percent. Consult local powercompany for correction of improper voltage and/orphase imbalance.

4. Insulate low-voltage wires for highest voltagecontained within conduit when low-voltage controlwires are in same conduit as high-voltage wires.

5. Do not damage internal components when drillingthrough any panel to mount electrical hardware,conduit, etc.

Hiqh-Voltaqe Connections

When routing power leads into unit, use only copper wirebetween disconnect and unit. The high voltage leads shouldbe in a conduit until they enter the duct panel; conduittermination at the duct panel must be watertight.

The unit must have a separate electrical service with afield-supplied, waterproof disconnect switch mounted at, orwithin sight from, the unit. Refer to the unit rating plate, NECand local codes for maximum fuse/circuit breaker size and

minimum circuit amps (ampacity) for wire sizing.

The field-supplied disconnect switch box may be mountedon the unit over the high-voltage inlet hole when thestandard power and low-voltage entry points are used (SeeFig. 2 and 3 for acceptable location).

See unit wiring label (Fig. 15 and 16) and Fig. 10 forreference when making high voltage connections. Proceedas follows to complete the high-voltage connections to theunit.

Single phase units:

1. Run the high-voltage (L1, L2) and ground lead intothe control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to theline side of the contactor.

4. Connect field L1 to black wire on connection 11 of the

compressor contactor.

5. Connect field wire L2 to yellow wire on connection 23of the compressor contactor.

Three-phase units:

1. Run the high-voltage (L1, L2, L3) and ground leadinto the control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to theline side of the contactor.

4. Connect field L1 to black wire on connection 11 of the

compressor contactor.

5. Connect field wire L3 to yellow wire on connection 13of the compressor contactor.

6. Connect field wire L2 to blue wire from compressor.

Special Procedures for 208-V Operation



Make sure the power supply to the unit is switchedOFF before making any wiring changes. Tag thedisconnect switch with a suitable warning label. Withdisconnect switch open, move black wire fromtransformer (3/16 in.) terminal marked 230 to terminalmarked 200. This retaps transformer to primaryvoltage of 208 vac.

ELECTRICALSHOCK AND EXPLOSION HAZARD


Before making any wiring changes, make sure thegas supply is switched off first. Then switch off thepower supply to the unit and install lockout tag.

Control Voltaqe Connections

Do not use any type of power-stealing thermostat. Unitcontrol problems may result.

Use no. 18 American Wire Gage (AWG) color-coded,insulated (35°C minimum) wires to make the control voltageconnections between the thermostat and the unit. If the

thermostat is located more than 100 ft (30.5 m)from the unit(as measured along the control voltage wires), use no. 16AWG color-coded, insulated (35°C minimum) wires.

Locate the seven (eight on 3-phase) low voltage thermostatleads in 24 volt splice box. See Fig. 10 for connectiondiagram. Run the low-voltage leads from the thermostat,

13

through the control wiring inlet hole grommet (Fig. 2 and 3),and into the low-voltage splice box. Provide a drip loopbefore running wires through panel. Secure and strain reliefall wires so that they do not interfere with operation of unit. Agray wire is standard on 3-phase unit for connection to aneconomizer.

E_

HIGH VOLTAGE !POWER LEADS <:o,=(SEE UNITWIRING|LABEL) _:_

EQUIP GR

FIGURE 10J High and Control-Voltage Connections

FIELD SUPPLIEDFUSED DISCONNECT

SPLICE BOX

t o-

O-

O,,,-

O-

O,,,-

C-

O.=

O_

CONTROL BOX

LOWWOLTAGEPOWER LEADS(SEE UNITWIRING LABEL)

w HT.LVV_I){:_

Y EL_)=, ,_

GROG_)

=RED_R_, {).

amN4C±{>.

-O-RN-(O-){>.

\@®@®©®@_Phase

3nly

THERMOSTAT(TYPICAL)

Balance Point Settinq-Dual Fuel ThermostatBALANCE POINT TEMPERATURE-The "balance point"temperature is a setting which affects the operation of theheating mode. This is a field-selected input temperature(range 5 to 55°F) (-15 to 12°C) where the Thermidistat ordual fuel thermostat will monitor outdoor air temperature anddecide whether to enable or disable the heat pump. If theoutdoor temperature is above the "balance point", the heatpump will energize first to try to satisfy the indoortemperature demand. If the heat pump does not make asufficient improvement within a reasonable time period (i.e.15 minutes), then the gas furnace will come on to satisfy theindoor temperature demand. If the outdoor temperature isbelow the "balance point", the heat pump will not be allowedto operate (i.e. locked out), and the gas furnace will be usedto satisfy the indoor temperature. There are three separateconcepts which are related to selecting the final "balancepoint" temperature. Read each of the following carefully todetermine the best "balance point" in a dual fuel installation:

1. Capacity Balance Temperature: This is a point wherethe heat pump cannot provide sufficient capacity tokeep up with the indoor temperature demandbecause of declining outdoor temperature. At orbelow this point, the furnace is needed to maintainproper indoor temperature.

2. Economic Balance Temperature: Above this point,the heat pump is the most cost efficient to operate,and below this point the furnace is the most costefficient to operate. This can be somewhatcomplicated to determine and it involves knowing thecost of gas and electricity, as well as the efficiency ofthe furnace and heat pump. For the most economicaloperation, the heat pump should operate above thistemperature (assuming it has sufficient capacity) andthe furnace should operate below this temperature.

3. Comfort Balance Temperature: When the heat pumpis operating below this point, the indoor supply airfeels uncomfortable (i.e. too cool). This is purelysubjective and will depend on the homeowner's idea

of comfort. Below this temperature the gas furnaceshould operate in order to satisfy the desire for indoorcomfort.

Transformer Protection

The transformer is of the energy-limiting type. It is set towithstand a 30-sec. overload or shorted secondarycondition. If an overload or short is present, correct overloadcondition and check for blown fuse on gas control board orInterface Fan Board. Replace fuse as required with correctsize and rating.

PRE-START-UP

FIRE, EXPLOSION, ELECTRICAL SHOCKHAZARD


1. Follow recognized safety practices and wearprotective goggles when checking or servicingrefrigerant system.

2. Do not operate compressor or provide any electricpower to unit unless compressor terminal cover isin place and secured.

3. Do not remove compressor terminal cover until allelectrical sources are disconnected and tagged.

4. Relieve and recover all refrigerant from systembefore touching or disturbing anything insideterminal box if refrigerant leak is suspected aroundcompressor terminals.

5. Never attempt to repair soldered connection whilerefrigerant system is under pressure.

6. Do not use torch to remove any component.System contains oil and refrigerant under pressure.To remove a component, wear protective gogglesand proceed as follows:

a. Shut off electrical power to unit and installlockout tag.

b. Relieve and reclaim all refrigerant from systemusing both high- and low-pressure ports.

c. Cut component connecting tubing with tubingcutter and remove component from unit.

d. Carefully unsweat remaining tubing stubswhen necessary. Oil can ignite when exposedto torch flame.

Proceed as follows to inspect and prepare the unit for initialstart-up:

1. Remove access panels.2. Read and follow instructions on all WARNING,

CAUTION, and INFORMATION labels attached to, orshipped with, unit.

3. Make the following inspections:

a. Inspect for shipping and handling damages suchas broken lines, loose parts, disconnected wires,etc.

b. Inspect for oil at all refrigerant tubing connectionsand on unit base. Detecting oil generally indicatesa refrigerant leak.

c. Leak test all refrigerant tubing connections usingelectronic leak detector, halide torch, orliquid-soap solution. If a refrigerant leak isdetected, see the Check for Refrigerant Leakssection.

d. Inspect all field- and factory-wiring connections.Be sure that connections are completed and tight.

14

e. Ensure wires do not touch refrigerant tubing orsharp sheet metal edges.

f. Inspect coil fins. If damaged during shipping andhandling, carefully straighten fins with a fin comb.

FIRE, EXPLOSION HAZARD


Do not purge gas supply into the combustionchamber. Do not use a match or other open flame tocheck for gas leaks. Use a commercially availablesoap solution made specifically for the detection ofleaks to check all connections.

4. Verify the following conditions:

a. Make sure gas line is free of air. Before lightingthe unit for the first time, perform the following withthe gas valve in the "OFF" position:

NOTE: If the gas supply pipe was not purged beforeconnecting the unit, it will be full of air. It is recommended

that the ground joint union be loosened, and the supply linebe allowed to purge until the odor of gas is detected. Neverpurge gas lines into a combustion chamber. Immediatelyupon detection of gas odor, retighten the union. Allow 5minutes to elapse, then light unit.

b.

C.

d.

e.

Make sure that condenser-fan blade is correctlypositioned in fan orifice. Leading edge ofcondenser-fan blade should be 1/2 in. (12 mm)maximum from fan orifice.

Make sure that air filter(s) is in place.

Make sure that condensate drain trap is filled withwater to ensure proper drainage.

Make sure that alI tools and miscellaneous loose

parts have been removed.

START-UP

Step 1 -- Check for Refrigerant LeaksProceed as follows to locate and repair a refrigerant leakand to charge the unit:

1. Locate leak and make sure that refrigerant systempressure has been relieved and reclaimed from bothhigh- and low-pressure ports.

2. Repair leak following Refrigerant Service procedures.

NOTE: Install a bi-flow filter drier whenever the system hasbeen opened for repair.

3. Add a small charge of R-410A refrigerant vapor tosystem and leak-test unit.

4. Recover refrigerant from refrigerant system and evac-uate to 500 microns if no additional leaks are notfound.

5. Charge unit with R-410A refrigerant, using an elec-tronic scale. Refer to unit rating plate for requiredcharge.

Step 2 -- Unit Sequence of Operation

PDD/S Sequence of Operation

a. CONTINUOUS FAN

(1.) Thermostat closes circuit R to G energizingthe blower motor for continuous fan.

b. COOLING MODE

(1.) If indoor temperature is above temperatureset point thermostat closes circuits R to G, Rto Y and R to O-The unit delivers coolingairflow.

c. HEAT PUMP HEATING MODE

Outdoor temperature above balance point setpointof thermostat.

(1 .) On a call for heating, terminals "Y" and "G" ofa dual fuel thermostat are energized. The "Y"signal is sent to the Defrost Board (DB)terminal "Y". The DB has a built in five minute

anti-short cycle timer which will not allow thecompressor to restart before the time delayhas expired.

(2.) "T2" energizes the compressor contactor viathe High Pressure Switch (HPS) and LowPressure Switch (LPS). The compressor andoutdoor fan start. Thermostat "G" energizesthe Interface Fan Board terminal "G". Theblower motor is energized through contacts ofthe IFB.

(3.) When the thermostat removes the "Y" and "G"calls, the compressor contactor and outdoorfan are de-energized. The evaporator motoris de-energized after a 90 sec. delay.

d. GAS HEATING MODE

Outdoor temperature below balance point setpointof thermostat.

Heatinq Sequence of Operation

(See Fig. 15 and 16 and unit wiring label.)

On a call for heating, terminal W of the thermostat isenergized, starting the induced-draft motor. When thepressure switch senses that the induced-draft motor ismoving sufficient combustion air, the burner sequencebegins. This function is performed by the integrated gas unitcontroller (IGC). The indoor (evaporator)-fan motor isenergized 45 sec after flame is established. When thethermostat is satisfied and W is de-energized, the burnersstop firing and the indoor (evaporator) fan motor shuts offafter a 45-sec time-off delay. Please note that the IGC hasthe capability to automatically reduce the indoor fan motoron delay and increase the indoor fan motor off delay in theevent of high duct static and/or partially-clogged filter.

NOTE: An LED (light-emitting diode) indicator is providedon the control board to monitor operation. The control boardis located by removing the burner access panel. Duringnormal operation, the LED is continuously on.

Step 3 _ Start-up Heating and Make Adjust-ments

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage tothe unit being installed.

Complete the required procedures given in thePre-Start-Up section before starting the unit. Do notjumper any safety devices when operating the unit.

Complete the required procedures given in the Pre-Start-Upsection before starting the unit. Do not jumper any safetydevices when operating the unit. Make sure that burnerorifices are properly aligned. Unstable operation my occurwhen the burner orifices in the manifold are misaIigned.

Follow the lighting instructions on the heating sectionoperation label (located inside the burner or blower accessdoor) to start the heating section.

NOTE: Make sure that gas supply has been purged, andthat alI gas piping has been checked for leaks.

15

FIGURE 11 ] Burner Assembly

FIGURE 12 ] Monoport Burner

Manifold

BURNER FLAME

BURNER

MANIFOLD

Check Heatinq Control

Start and check the unit for proper heating control operationas follows (see furnace lighting instructions located insideburner or blower access panel):

1. Place room thermostat SYSTEM switch in the HEATposition and the fan switch is placed in AUTOposition.

2. Set the heating temperature control of the thermostatabove room temperature.

3. The induced-draft motor will start.

4. On a call for heating, the main burner should lightwithin 5 sec. of the spark being energized. If theburners do not light, there is a 22-sec. delay beforeanother 5-sec. try. If the burners still do not light, thissequence is repeated. If the burners do not lightwithin 15 minutes from the initial call for heat, there isa lockout. To reset the control, break the 24-v powerto W.

5. The evaporator fan will turn on 45 sec. after the flamehas been established. The evaporator fan will turn off45 sec. after the thermostat has been satisfied.Please note that the integrated gas unit controller(IGC) has the capability to automatically reduce theevaporator "ON" delay and increase the evaporator"OFF" delay in the event of high duct static and/orpartially-clogged filter.

Check Gas Input

Check gas input and manifold pressure after unit start-up(See Table 3). If adjustment is required proceed as follows:• The rated gas inputs shown in Table 3 are for altitudes

from sea level to 2000 ft (610 m) above sea level. These

inputs are based on natural gas with a heating value of

1025 Btu/ft 3 at 0.60 specific gravity, or propane gas with a

heating value of 2500 Btu/ft 3 at 1.5 specific gravity.

IN THE U.S.A.:

The input rating for altitudes above 2,000 ft (610 m) must bereduced by 4% for each 1,000 ft (305 m) above see level.

For installations below 2,000 ft (610 m), refer to the unitrating plate.

For installations above 2,000 ft (610 m) multiply the input byon the rating plate by the derate multiplier in Table 4 forcorrect input rate.

Table 4 - Altitude Derate Multiplier for U.S.A.*DERATE MULTIPLIER

ALTITUDE FT (M) PERCENT OF DERATEFACTORt

0-20000 1,00

(0-610)

2001-3000*8-12 0,90

(610-914)

3001-400012-16 0,86

(315-1219)

4001-500016-20 0,82

(1220 - 1524)

5001-600020-24 0,78

(1524-1829)

6001-700024-28 0,74

(1829 - 2134)

7001-800028-32 0,70

(2134-2438)

8001-900032-36 0,66

(2439-2743)

9001-10,000 36-40 0.62(2744-3048)

*In Canada see Canadian Altitude Adjustment.1-Derate multiplier factors are based on midpoint altitude for altitude range.

IN CANADA:

The input rating for altitudes from 2,000 to 4,500 ft (610 m to1372 m) above sea level must be derated 10% by anauthorized Gas Conversion Station or Dealer.

EXAMPLE:

90,000 Btu/hr Input Furnace Installed at 4300 ft (1311 m).

Furnace Input Rate at X Derate Multiplier = Furnace Input Rate atSea Level Factor Installation Altitude

90,000 X 0.90 = 81,000

When the gas supply being used has a different heatingvalue or specific gravity, refer to national and local codes, orcontact your distributor to determine the required orificesize.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in reducedunit and/or component life.

Do Not redrilI an orifice. Improper drilling (burrs,out-of-round holes, etc.) can cause excessive burnernoise and misdirection of burner flame. If orifice hole

appears damaged or it is suspected to have beenredriIIed, check orifice hole with a numbered drill bit ofcorrect size.

Adjust Gas Input

The gas input to the unit is determined by measuring thegas flow at the meter or by measuring the manifoldpressure. Measuring the gas flow at the meter isrecommended for natural gas units. The manifold pressuremust be measured to determine the input of propane gasunits.

16

Measure Gas Flow (Natural Gas Units)

Minor adjustment to the gas flow can be made by changingthe manifold pressure. The manifold pressure must bemaintained between 3.2 and 3.8 IN. W.C.

If larger adjustments are required, change main burnerorifices following the recommendations of national and localcodes.

NOTE: All other appliances that use the same meter mustbe turned off when gas flow is measured at the meter.

Proceed as follows:

1. Turn off gas supply to unit.

2. Remove pipe plug on manifold (See Fig. 11) andconnect manometer. Turn on gas supply to unit.

3. Record number of seconds for gas meter test dial tomake one revolution.

4. Divide number of seconds in Step 3 into 3600(number of seconds in one hr).

5. Multiply result of Step 4 by the number of cubic feet(cu ft) shown for one revolution of test dial to obtaincubic feet (cu ft) of gas flow per hour.

6. Multiply result of Step 5 by Btu heating value of gas toobtain total measured input in Btuh. Compare thisvalue with heating input shown in Table 3 (Consultthe local gas supplier if the heating value of gas is notknown).

EXAMPLE: Assume that the size of test dial is 1 cu ft, onerevolution takes 32 sec, and the heating value of the gas is1050 Btu/ft 3. Proceed as follows:

1. 32 sec. to complete one revolution.

2. 3600 + 32 = 112.5.

3. 112.5 x 1 =112.5 ft3 of gas flow/hr.

4. 112.5 x 1050 = 118,125 Btuh input.

If the desired gas input is 115,000 Btuh, only a minorchange in the manifold pressure is required.

Observe manifold pressure and proceed as follows to adjustgas input:

1. Remove regulator cover screw over plasticadjustment screw on gas valve (See Fig. 13).

2. Turn plastic adjustment screw clockwise to increasegas input, or turn plastic adjustment screwcounterclockwise to decrease input (See Fig. 13).Manifold pressure must be between 3.2 and 3.8 IN.W.C.

FIGURE 13J Single Stage Gas ValveREGU_TOR

_COVERSCREW

PLASTIC

_ADJUSTMENT

INLET

MANIFOLDPRESSURE TAP

FIRE AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personalinjury or death and/or property damage.

Unsafe operation of the unit may result if manifoldpressure is outside this range.

3. Replace regulator cover screw on gas valve (See Fig.13).

4. Turn off gas supply to unit. Remove manometer frompressure tap and replace pipe plug on gas valve.(See Fig. 11 .) Turn on gas to unit and check for leaks.

Measure Manifold Pressure (Propane Units)

Refer to propane kit installation instructions for properlychecking gas input.

NOTE: For installations below 2,000 ft (610 m), refer to theunit rating plate for proper propane conversion kit. Forinstallations above 2,000 ft (610 m), contact your distributorfor proper propane conversion kit.Check Burner Flame

With burner access panel removed, observe the unit heatingoperation. Watch the burner flames to see if they are lightblue and soft in appearance, and that the flames areapproximately the same for each burner. Propane will haveblue flame (See Fig. 12). Refer to the Maintenance sectionfor information on burner removal.

Normal Operation

An LED (light-emitting diode)indicator is provided on theintegrated gas unit controller (IGC) to monitor operation. TheIGC is located by removing the burner access panel. Duringnormal operation, the LED is continuously on (See Table 5for error codes).

Airflow and Temperature Rise

The heating section for each size unit is designed andapproved for heating operation within the temperature-riserange stamped on the unit rating plate.

Table 10 shows the approved temperature rise range foreach heating input, and the air delivery cfm at varioustemperature rises for a given external static pressure. Theheating operation airflow must produce a temperature risethat falls within the approved range.

Refer to Indoor Airflow and Airflow Adjustments section toadjust heating airflow when required.Limit Switches

Normally closed limit switch (LS) completes the controlcircuit. Should the leaving-air temperature rise above themaximum allowable temperature, the limit switch opens andthe control circuit "breaks." Any interruption in the controlcircuit instantly closes the gas valve and stops gas flow tothe burners. The blower motor continues to run until LSresets.

When the air temperature at the limit switch drops to thelow-temperature setting of the limit switch, the switch closesand completes the control circuit. The direct-spark ignitionsystem cycles and the unit returns to normal heatingoperation.

17

Table 5 - LED IndicationsSTATUS CODE LED INDICATION

Normal Operation 2 On

No Power or Hardware Failure Off

Limit Switch Fault 2 Flashes

Flame Sense Fault 3 Flashes

Four Consecutive Limit Switch Faults 4 Flashes

Ignition Lockout Fault 5 Flashes

Pressure Switch Fault 6 Flashes

Rollout Switch Fault 7 Flashes

Internal Control Fault 8 Flashes

Temporary 1 hr auto reset I 9 Flashes

NOTES:

1.This code indicates an internal processor fault that will reset itself in one

hr. Fault can be caused by stray RF signals in the structure or nearby. Thisis a UL requirement.2, LED indicates acceptable operation. Do not change ignition controlboard,

3. When W is energized the burners will remain on for a minimum of 60 sec.4. If more than one error mode exists they will be displayed on the LED in

sequence.

Rollout Switch

The function of the rolIout switch is to close the main gasvalve in the event of flame rolIout. The switch is locatedabove the main burners. When the temperature at therolIout switch reaches the maximum allowable temperature,the control circuit trips, closing the gas valve and stoppinggas flow to the burners. The indoor (evaporator) fan motor(IFM) and induced draft motor continue to run until switch isreset. The IGC LED will display FAULT CODE 7.

Step 4 m Start-up Cooling and Make Adjust-ments

Complete the required procedures given in the Pre-Start-Upsection before starting the unit. Do not jumper any safetydevices when operating the unit. Do not operate thecompressor when the outdoor temperature is below 40°F(4.4°C) (unless accessory low-ambient kit is installed). Donot rapid-cycle the compressor. Allow 5 minutes between oncycles to prevent compressor damage.

Checkinq Coolinq Control Operation

Start and check the unit for proper cooling control operationas follows:

1. Place room thermostat SYSTEM switch in OFF

position. Observe that blower motor starts when FANswitch is placed in ON position and shuts down whenFAN switch is placed in AUTO position.

2. Place SYSTEM switch in COOL position and FANswitch in AUTO position. Set cooling control belowroom temperature. Observe that compressor,condenser fan, and evaporator blower motors start.Observe that cooling cycle shuts down when controlsetting is satisfied. The evaporator fan will continue torun for 90 sec.

IMPORTANT: Three-phase, scroll compressors units aredirection oriented. Unit must be checked to ensure propercompressor 3-phase power lead orientation. If not correctedwithin 5 minutes, the internal protector will shut off thecompressor. The 3-phase power leads to the unit must bereversed to correct rotation. When turning backwards, thedifference between compressor suction and dischargepressures will be near zero.

Checkinq and Adiustinq Refriqerant Charqe

The refrigerant system is fully charged with R-410A®(R-410A) refrigerant and is tested and factory sealed. Allow

system to operate a minimum of 15 minutes beforechecking or adjusting charge.

NOTE: Adjustment of the refrigerant charge is not requiredunless the unit is suspected of not having the properR-410A® (R-410A) charge.

The charging label and the tables shown refer to systemtemperatures and pressures in cooling mode only. Arefrigerant charging label is attached to the outside of theservice access door. The chart includes the required liquidline temperature at given discharge line pressures andoutdoor ambient temperatures.

An accurate thermocoupte- or thermistor-type thermometer,and a gauge manifold are required when using thesubcooling charging method for evaluating the unit charge.Do not use mercury or small dial-type thermometersbecause they are not adequate for this type ofmeasurement.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unitdamage.

When evaluating the refrigerant charge, an indicatedadjustment to the specified factory charge mustalways be very minimal. If a substantial adjustment isindicated, an abnormal condition exists somewhere inthe cooling system, such as insufficient airflow acrosseither coil or both coils.

Proceed as follows:

1. Remove caps from low- and high-pressure servicefittings.

2. Using hoses with valve core depressors, attach low-and high-pressure gauge hoses to low- andhigh-pressure service fittings, respectively.

3. Start unit in Cooling Mode and let unit run until systempressures stabilize.

4. Measure and record the following:

a. Outdoor ambient-air temperature (°F [°C] db).

b. Liquid line temperature (°F [°C]).

c. Discharge (high-side) pressure (psig).

d. Suction (low-side) pressure (psig) (for referenceonly).

5. Using "Cooling Charging Charts," compareoutdoor-air temperature(°F [°C] db) with the dischargeline pressure (psig) to determine desired systemoperating liquid line temperature (See Fig. 17).

6. Compare actual liquid line temperature with desiredliquid line temperature. Using a tolerance of _+2°F(_+1.1°C), add refrigerant if actual temperature is morethan 2°F (1.1°C) higher than proper liquid linetemperature, or remove refrigerant if actualtemperature is more than 2°F (1.1°C) lower thanrequired liquid line temperature.

NOTE: If the problem causing the inaccurate readings is arefrigerant leak, refer to the Check for Refrigerant Leakssection.

18

Indoor Airflow and Airflow Adiustments

UNIT OPERATION HAZARD

Failure to follow this caution may result in unitdamage.

For cooling operation, the recommended airflow is350 to 450 cfm for each 12,000 Btuh of rated coolingcapacity. For heating operation, the airflow mustproduce a temperature rise that falls within the rangestamped on the unit rating plate.

NOTE: Be sure that all supply-and return-air grilles areopen, free from obstructions, and adjusted properly. Airflowcan be changed using the User Interface.

ELECTRICAL SHOCK AND EXPLOSION HAZARD


Before making any indoor wiring adjustments, shut offgas supply. Then disconnect electrical power to theunit and install lockout tag before changing blowerspeed.

This unit has independent fan speeds for gas heating andcooling. In addition, this unit has the fieId-seIectabtecapability to run two different cooling fan speeds: A normalcooling fan speed (350~400 CFM/Ton) and an enhanceddehumidification fan speed (As low as 320 CFM/Ton) foruse with either a dehumidistat or a thermostat that supportsdehumidification.

This unit is factory-set up for use with a single cooling fanspeed. The cooling speed is marked "LOW" on theinterface fan board (IFB) (Fig. 14) . The factory-shippedsettings are noted in Table 10. There are 3 additionalspeed tap wires available for use in either gas heating orcooling (For color coding on the indoor fan motor leads, seeTable 6). The additional 3 speed tap wires are shippedloose with vinyl caps and are located in the control box,near the interface fan board (IFB) (Fig. 14).

Gas Heatinq Fan Speed Set-up

To change the gas heating speed:

1. Remove the vinyl cap off of the desired speed tapwire (Refer to Table 6 for color coding). Table 10shows the temperature rise associated with each fanspeed for a given static pressure. Make sure that thespeed chosen delivers a temperature rise within therise range listed on the unit rating plate.

2. Remove the current speed tap wire from the "GASHEAT" terminal on the interface fan board (IFB)(Fig.14) and place vinyl cap over the connector on thewire.

3. Connect the desired speed tap wire to the "GASHEAT" terminal on the interface fan board (IFB).

Sinqle Coolinq Fan Speed Set-up (Dehumidifica-

tion feature not used)

To change cooling speed:

1. Remove the vinyl cap off of the desired speed tapwire (Refer to Table 6 for color coding). Add the wetcoil pressure drop in Table 8 to the system static todetermine the correct cooling airflow speed in Table10 that will deliver the nominal cooling airflow as listedin Table 1 for each size.

2. Remove the current speed tap wire from the "LOW"terminal on the interface fan board (IFB) (Fig. 14) andplace vinyl cap over the connector on the wire.

3. Connect the desired speed tap wire to the "LOW"terminal on the interface fan board (IFB).

Two Coolinq Fan Speeds Set-up (Dehumidifica-

tion feature used)

IMPORTANT: Dehumidification control must open controlcircuit on humidity rise above set point.

Use of the dehumidification cooling fan speed requires useof either a 24 VAC dehumidistat or a thermostat whichincludes control of a 24 VAC dehumidistat connection. Ineither case, the dehumidification control must open thecontrol circuit on humidity rise above the dehumidificationset point. Dehumidification controls are available with thereverse logic; these must not be used.

1. Remove fan speed tap wire from the "LOW" terminalon the interface fan board (IFB) (Fig. 14).

2. Determine correct normal cooling fan speed for unitand application. Add the wet coil pressure drop inTable 8 to the system static to determine the correctcooling airflow speed in Table 10 that will deliver thenominal cooling airflow as listed in Table 1 for eachsize.

3. Remove the vinyl cap off of the desired speed tapwire (Refer to Table 6 for color coding) for the normalcooling fan speed and place desired speed tap wireon "HIGH" on the interface board.

4. Refer to airflow tables (Table 10) to determineallowable speeds for the dehumidification cooling fanspeed. In Table 10, speeds that are not allowed fordehumidification cooling are shaded.

5. Remove the vinyl cap off of the desired speed tapwire (Refer to Table 6 for color coding) for thedehumidification cooling fan speed and place desiredspeed tap wire on the "LOW" connection on theinterface board (IFB). Verify that static pressure is inthe acceptable range for the speed tap to be used fordehumidification cooling.

6. Use any spare vinyl plugs to cap any unused speedtap wires.

Continuous Fan Operation

When the DEHUM feature is not used, the continuous fanspeed will be the same as cooling fan speed. When theDEHUM feature is used, the continuous fan speed willoperate on Low when the D2 control lead is energized, orHigh when the D2 lead is not energized.

NOTE: For heat pump operation, the recommended airflowis 350 to 450 CFM for each 12,000 Btuh of rated coolingcapacity.

Table 6 - Color Coding for Indoor Fan Motor LeadsBlack = High Speed

Orange = Med-High Speed

Red = Med Speed

Pink = Med-Low Speed

Blue = Low Speed

19

FIGURE 14 ] Interface Fan Board

FILTER SIZE

in, (ram)

20X20X1

(5o8x5o8x25)20X24X1

(508X610x25 )

24X30X1

(61 OX762x25)

24X36X1

(610X914X25)

Table 7 - Filter Pressure Drop Table (IN. W.C.)CFM

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

0.05 0.07 0.08 0.1 0.12 0.13 0.14 0.15 ...........

-- 0.06 0.07 0.07 0.08 0.09 0.09 0.10 0.11 0.12 0.13 0.14 0.14

.... 0.09 0.10 0.11 0.13 0.14 0.15 0.16 .....

-- -- -- 0.04 0.05 0.06 0.07 0.07 0.08 0.09 0.1 .....

Table 8 - PDD/S Wet Coil Pressure Drop

Unit Size Standard CFM (S.C.F.M)500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700

24 0.06 0.07 0.08 0.09 0.130 0.12 0.15 0.19 0.23 0.2736 0.07 0.11 0.18 0.26 0.3542 0.04 0.07 0.1 0.15 0.2148 0.11 0.14 0.17 0.22 0.2860 0.1 0.17 0.23

1800 1900 2000

0.31

UNIT SIZE0.1 0.9 1.0

36 1527 1098 106542 1630 1322 128848 2265 1331 108960 2286 1635 1531

Table 9 - Wet Coil Air Delivery -- Downflow Discharge -- High SpeedEXTERNAL STATIC PRESSURE (in.W.C.)

0.2 0.3 0.4 0.5 0.6 0.7 0.81466 1401 1339 1274 1228 1187 11421593 1556 1526 1487 1442 1405 13652185 2088 2000 1891 1791 1650 15082222 2144 2068 1986 1905 1820 1737

0.36

20

Table 10 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PDD/S24-60HEATING MOTOR WIRE

UNITRISE RANGE SPEED COLOR 0.1 0.2

CFM 754 650

Heating 40 46Low Blue Rise (OF)

HeatingRise (°C)

CFM

HeatingMad-Low Pink Rise (OF)

HeatingRise (°C)

CFM

30 - 60°F Heating24040 Medium 2 Red Rise (OF)

(17 - 33°C) Heating

Rise (°C)CFM

Med- Heating

High1 Orange Rise (OF)Heating

Rise (°C)CFM

Heating

High Black Rise (OF)

Heating NARise (°C)

CFM 754

Heating NALow Blue Rise (OF)

HeatingRise (°C)

CFM


HeatingRise (°C)

CFM



Rise (°C)CFM

HeatingMed-High Orange Rise (OF)

HeatingRise (°C)

CFM

HeatingHigh 1 Black Rise (OF)

Heating 20 21 22 24 25 28Rise (°C)

* Air delivery values are without air filter and are for dry coil (See Table 8 - PDD/S Wet Coil Pressure Drop table).1 Factory-shipped gas heating speed

2 Factory-shipped heat pump heating / cooling speed

NA - Not allowed for heating speed

Note: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting.

Shaded areas indicate speed/static combinations that are not permitted for dehumidification speed.

EXTERNAL STATIC PRESSURE (in. W.C.)0.3 0.4 0.5 0.6 0.7 0.8 0.9

538, _29; , i i

56 NA NA NA NA NA NA

22 26 31 NA NA NA NA NA NA

85_ 777 675

36 39 45 51 NA NA NA NA NA

20 22 25 28 NA NA NA NA NA

85_ 774 684 _6

32 36 39 44 52 NA NA NA NA

18 20 22 25 29 NA NA NA NA

840 759 667 _77 _ _ _ _

30 33 36 40 45 52 NA NA NA

17 18 20 22 25 29 NA NA NA

i_ 869' 88_ 731 640

NA NA NA NA 31 34 37 41 47

NA NA NA 17 19 21 23 26

650 538 _ _29

NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

iiiiii!i!_ii!85!_iiiiiiiiiiiiiiill777 675

52 NA NA NA NA NA NA NA NA


iiiiii!i!_ii!!9_iiiii;i!i!_ii!i!!iiiii!i!_ii!85_iiiiiiiiiiiiiiili774 684 iiiiii!i!_ii!!_6_i_ii_iii_ijiiiiii!i!_ii_i_i_ii_i!ii_i!_iiiii!i!_ii!i!_i_i_ii_i_i_i!_ii!i!_i_i_ii_i_i!_ii!i!_i_i_ii_

47 52 NA NA NA NA NA NA NA

26 29 NA NA NA NA NA NA NA

iiiiii!i!Di_i!i!i!_iiiiiii!_ii!!_iii_iii!_iii!i!i!i_i_i!_ii!84_ii_ii_i759 667 iiiiii!i!_ii!!_77iiiii!_iii!i!_ii1i!i!_ii_iii!_iii!i!i_iiii!i!_ii!i!_i_i_ii_i_i!_ii!i!_i_i_ii_



36 38 40 43 46 50 54 NA NA

30 NA NA

21

Table 10 (cont) - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PDD/S24-60HEATING MOTOR WIRE

UNITRISE RANGE SPEED COLOR

CFM

HeatingLow Blue Rise (OF)

Heating 23 26Rise (°C)

CFM 973 887

Med- Heating 31 34Pink Rise (OF)

Low 1Heating 17 19 20 23

Rise (°C)CFM _,088 _,023i 954 881

30 - 60°F Heating NA 30 32 3430040 Medium Red Rise (OF)

(17 - 33°C) Heating NA 16 18 19Rise (°C)

CFM _40 996 915

Med- Heating NA NA 30 33


Rise (°C)CFM

Heating

High Black Rise (OF)Heating

Rise (°C)CFM


Heating NA NARise (°C)

CFM 973 887

Heating 46 50Mad-Low Pink Rise (OF)

Heating 25 28 30 NARise (°C)

CFM _,088' _,023! 954 881

25 - 55°F Heating 41 43 47 5030060 Medium Red Rise (OF)

(14 - 31°C) Heating 23 24 26 28Rise (°C)

CFM 996 915

Med- Heating 39 42 45 49


Rise (°C)CFM

HeatingHigh 1 Black Rise (OF)

HeatingRise (°C)

CFM

HeatingLow 1 Blue Rise (OF)

Heating

Rise (°C)CFM

Heating

Mad-Low Pink Rise (OF)

Heating 19 20 21 23 24 25 28Rise (°C)

CFM 1158 1102 1046 981

25 - 55°F Heating 33 34 36 38 40 42 4536060 Medium 2 Red Rise (OF)


Rise (°C)CFM

Heating

Med-High Orange Rise (OF)Heating

Rise (°C)CFM

Heating


Heating 15 16 16 17 18 18Rise (°C)






EXTERNAL STATIC PRESSURE (in. W.C.)0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

74_;, 638, i i ,; i i



823 733 _ 665 j B38 _ 45_ _ i

37 41 45 56 NA NA NA

25 31 NA NA NA

80038 42 46 54 NA

21 23 26 30 NA

840

36 40 44 54 NA

NA NA 17 18 20 22 24 30 NA

_40 861 88_ 732 63_, , , , , ,

NA NA NA 30 31 34 37 41 48

NA NA NA 17 17 19 21 23 27

74_ _ 638


NA NA NA NA NA NA NA

823 _73_i_i_665ii_l_i_y_538iii_i_i_%_45_H;_i_i_'__


NA NA NA NA NA

800

NA NA NA NA NA

NA NA NA NA NA

840

53 NA NA NA NA

22 23 25 27 29 NA NA NA NA

37 39 41 44 46 50 55 NA NA

21 22 23 24 26 28 30 NA NA

_128 1168 1093 1021 961

36 38 41 44 46 50 54 NA NA

20 21 23 24 26 28 30 NA NA

_1_ , _'223 1154 1090 1027 977

34 36 39 41 43 45 50 54 NA

3O NA

48 53

15 16 17 17 18 19 20 20 22

!!!!!i!i!!_!!!681@ii!!!!!i!!_i!,!!!!i!!!_!!_81_i!i!!i!!i!i!!i!!i,!!i!i!!!_!!_i_I_!!i!_!ii!!i!!i!i'!i,!i!i!!!_!!_68!!!ii!!!,!!!!!!i!!!_!!_07!ii!!!!!!,!!!!!!i!!!_!!___!i!;ii!!i!!i!i!!i!,!!!!!i!!!__;__!:i!i'!!i!i'!!!i!!!__!_!i_ii!!!!i!!_i!i,!!i!!!_!!_!!_;i;_!i!i!i!!i!i!

27 28 29 30 32 33 35 37 39

19 20 22

22



CFM _23_ 1168

Heating 55 58Low Blue Rise (OF)

HeatingRise (°C)

CFM


HeatingRise (°C)

CFM



Rise (°C)CFM


HeatingRise (°C)

CFM

Heating

High 1 Black Rise (OF)Heating

Rise (°C)CFM


HeatingRise (°C)

CFM


HeatingRise (°C)

CFM

25 - 55°F Heating42060 Medium Red Rise (OF)


Rise (°C)CFM

Med- Heating


Rise (°C)CFM

HeatingHigh Black Rise (OF)

HeatingRise (°C)

CFM


Heating

Rise (°C)CFM

Heating

Mad-Low Pink Rise (OF)Heating

Rise (°C)CFM



Rise (°C)CFM

Med- Heating


Rise (°C)CFM

Heating


Heating 22 23 24 24 25 25Rise (°C)







1093 1021 961 894 687



_290 _223 1154 1090 1027 977 894 762

53 56 59 62 NA NA NA NA NA

29 31 33 35 NA NA NA NA NA

_3_ _290 _2_6i 1158 1102 1046 981 _ 848

50 53 55 59 62 65 NA NA NA

28 29 31 33 34 36 NA NA NA

_,6Q_' _:, _489' _430 _, _ _, _1,6' _253' _3 1140

42 44 46 48 50 52 54 56 60

24 24 25 26 28 29 30 31 33

_,03_, 580 5_, _463 , _40_, _, _, _,o, 342 43 45 46 48 51 53 56 60

23 24 25 26 27 28 30 31 33

1295 1234 1182 1126 !!!!!!)!)!!_5_i_i!_!_!!_)!i!!_!!!!!)!!!!_)_6!!_i!!!!_!_'!!!_!)!)!!!))_55ii;!i)!!_!!_!!!!_!!_!)'!!!i!)!!!)8_8_`_`_`!!!)_!!!)!!!'!!i!)!!!)85!_ii!!!!!)!!!)i!

34 36 38 39 41 44 47 49 52

19 20 21 22 23 24 26 27 29

1345 1282 1235 1194 1140 _,g95 , _,02 , _ , 92_

33 35 36 37 39 41 43 46 48

18 19 20 21 22 23 24 25 27

_ , _452;:, _4_3 1358 1323 1282 1234 1169 1130

30 31 31 33 34 35 36 38 39

16 17 17 18 19 19 20 21 22

1362 1313 1278 1231 1188

29 30 31 31 33 34 35 36 37

16 17 17 17 18 19 19 20 21

26 27 28 28 29 30 31 32 33

14 15 15 16 16 17 17 18 18

1295 1234 1182 1126 '1075 _!Q_ , _55' , 83_ , __

53 55 58 60 63 NA NA NA NA

29 31 32 34 35 NA NA NA NA

1345 1282 1235 1194 1140 _1Q8_ , _!_ , _74 , _

51 53 55 57 60 62 NA NA NA

28 29 31 32 33 35 NA NA NA

_1#_5 , _ ,!_ _ 1358 1323 1282 1234 1169 1130

45 47 48 50 51 53 55 58 60

25 26 27 28 29 29 31 32 33

!!!!!i!)!!_!!!54_!i!!!)i!!!!,!!!!!)!!!_!!49_i)i)i)i!!!!!!i,!!!)!!!_!!449!i!;ii!!i!!;!;!!;!!),!!!)!!!_!!_!!!_!!!!)!!!!)_)!1362 1313 1278 1231 1188

44 46 47 48 50 52 53 55 57

24 25 26 27 28 29 30 31 32

40 41 42 43 45 46 47 48 50

26 27 28

23



CFM 1402 1351

Heating 49 50Low 1 Blue Rise (OF)

HeatingRise (°C)

CFM


HeatingRise (°C)

CFM



Rise (°C)CFM


HeatingRise (°C)

CFM

Heating


Rise (°C)CFM


HeatingRise (°C)

CFM


HeatingRise (°C)

CFM



Rise (°C)CFM

Med- Heating


Rise (°C)CFM


HeatingRise (°C)

CFM


Heating

Rise (°C)CFM

Heating


Rise (°C)CFM



Rise (°C)CFM

Med- Heating


Rise (°C)CFM

Heating


Heating 23 23 24 24 25 26Rise (°C)







131152 54 56 58 60 63 65

27 28 29 30 31 32 33 35 36

1457 1404 1367 1318 1284

47 48 50 52 53 55 57 59 62

26 27 28 29 29 31 32 33 34

_736' _,69_' _,64_;:, _,6Q_ 1553 1512 1465 1427 1381

39 40 41 42 44 45 46 48 49

22 22 23 24 24 25 26 26 27

2148 21_ !980 !945 !_64 !_93

NA NA NA NA NA 35 36 36 38

NA NA NA NA NA 19 20 20 21

2344 230_ i225_ 2_ 2_4_ 2070 i 1i80_

NA NA NA NA NA NA NA 36 38


1402 1351 1311 iii!i!Di_iii2_i!ii_i!iiiii_ii!i!_i_iii2_@!!i_iii_!iiiiiii!i!_i1iii_ii72iii_ii_ii!ii_i!i!Di1iii_ii36_i_ii_ii_i_i!i!Di_8_i_;iiii_ii`_iiii!_i_iiiii_i_iiii



1457 1404 1367 1318 1284 !23_ !_4_



_736!:, _,69_' _,64_;:, _,6Q_ 1553 1512 1465 1427 1381

50 51 53 54 56 57 59 NA NA

28 28 29 30 31 32 33 NA NA

2_4, 2, 20_::, 20_6, _980 :, 45,, _[_64 99

40 41 42 43 44 45 46 47 48

22 23 23 24 24 25 25 26 27

44, _ ,!225 22_ 2_ _ !_03

37 38 38 39 41 42 44 46 48

21 21 21 22 23 23 24 25 27

1402 1351 1311 !!iti!!_!!!_681_!!!ii!!!,!!!!!!i!!!_'22_i!i!!!ii!!,!!!!iti!!!_!!_!!!_;i;i;i;!!!!!!,!!!ti!!!_!!_!!_!!ii!!!!i!i,!,!!iti!!!_!!O8_iiii!!!i!!:i#i,!!i!!!_!!0__!!!!i!!!!i'i!'



1457 1404 1367 1318 1284



!!!!!i!i!!_!!!_8_!!ii!!!!i!i'!!!i!i!!!_!!!618_iiiilili!!!ii!!i'!!!!i!!!_!!!6_iiiiiii!!!!!!i!,!!!i!!!_!!!6_ii_!i!i!i!!i!i!1553 1512 1465 1427 1381

55 57 59 60 62 64 NA NA NA

31 32 33 33 34 35 NA NA NA

45 46 47 48 49 50 51 52 54

25 25 26 26 27 28 28 29 30

41 42 43 44 45 47 48 51 53

27 28 30

24


UNITRISE RANGE SPEED COLOR

CFM


HeatingRise (°C)

CFM


HeatingRise (°C)

CFM



Rise (°C)CFM


HeatingRise (°C)

CFM

Heating


Rise (°C)CFM


HeatingRise (°C)

CFM


HeatingRise (°C)

CFM



Rise (°C)CFM

Med- Heating


Rise (°C)CFM


HeatingRise (°C)

CFM


Heating

Rise (°C)CFM

Heating


Rise (°C)CFM



Rise (°C)CFM

Med- Heating


Rise (°C)CFM

Heating


Heating 22 22 23 23 24 25Rise (°C)






EXTERNAL STATIC PRESSURE (in. W.C.)0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

_445' _389' _' _28_' !23_' !'02_

47 49 51 53 55 57 60 63 NA

26 27 28 29 31 32 33 35 NA

1678 1635 1602 558 , 5_3 _4_ , !438 , !404 , !_

41 42 42 44 45 46 47 48 50

23 23 24 24 25 26 26 27 28

1927 _89_ , _85_ , _824 , _9_ , _ 1720 1689 1640

35 36 37 37 38 39 40 40 41

20 20 20 21 21 21 22 22 23

2_ 2088 1888 1860 1785

NA NA NA NA NA 35 36 37 38

NA NA NA NA NA 19 20 20 21

2z_6_ 2z_09 23_8 2286 2_9_ 2140 _68 1874



!!!!!!i!i!!!_ 45!_i_!!i!!!i!!,![!!!i!1!!1!!389i!!!!!;!!;!;!!;,!!!i!1!!1!!___!!!![!!i!!!!i_i!,[!!i!i!!!!!!28 _!!!![i!i!!!i,!!![!!i!1!!1!!!23 B!!!!!!!!i;!i,!!![i!i!i!!_!!!_!!i89i!!!!!;!!;!;!!,!!!!i!i!!_!!!_!!_!_!iili!!!i!!;!;!!;!,!!!i!i!!!___ii!:i!!!!!!!!,!!!i!i!!!,02_!i!!!!i!!!



1678 1635 1602 558 , 5_3 _4_ , !438 , !40_ , !_

52 53 54 56 57 59 60 NA NA

29 30 30 31 32 33 34 NA NA

1893 1858 1824 1791 1759 1720 1689 1640

45 46 47 48 49 49 51 51 53

25 26 26 26 27 27 28 29 29

1888 1860 1785

41 42 42 43 44 45 46 47 49

23 23 23 24 24 25 26 26 27

_, 2_, 23_, 2286, _!_2 _!_Q, _6_ :,!_68 1874

35 36 37 38 40 41 42 44 46

20 20 21 21 22 23 23 25 26



1678 1635 1602 !!i!_!!_!!!558i!_;!!_i!!!'!!!!!!_!!!_!!8_1!_i_i_i_i!_i!_!i!!_!!!!!!_!!!_!!_74_!_!!!_!!'!!!!i!_!!_!!438i!_;!!_i!!!!_'!!!!_!!!_!!_!_!!!_!!_!'!!i!_!!_!!349!i!;i_!!i!!;!;!!

57 59 60 62 64 65 NA NA NA

32 33 33 34 35 36 NA NA NA

_1_ 1893 1858 1824 1791 1759 1720 1689 1640

50 51 52 53 54 55 56 57 59

28 28 29 29 30 30 31 32 33

!!!!!i!_!!_!1!_!_!_!_!!_!_!!.!!!!!_!!!_88i!_;!!_i!!!!_.!!!!_!!!_6_i_i_!i!i!!!!_!_.!!!_!!!_!_i_i_i_i!_i!!!.!!!!!!_!!!_!!!_8_;_;_;_;_;!!_i!_!!_!!!!!!_!!!_!!!94_!!!!!_!!!!_i_!__ 1888 1860 1785

45 46 47 48 49 50 51 52 54

25 26 26 27 27 28 28 29 30

_, 2_, 23_, 2286, _!_2 _!_Q, _6_ :,!_68 1874

39 40 41 42 44 45 47 49 51

26 27 29

25

FIGURE 15 1 208/230-1-60 Connection Wiring Diagram

DANGERNOTES :

CONNECTION WIRIN6 DIAGRAM

ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE

I. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT.

2. SEE PRICE PAGES FOR THERMOSTATS.

3. USE ?B DEG. COPPER CONDUCTORS FOR FIELD INSTALLATION.

4. SEE INSTALLATION INSTRUCTIONS FOR PROPER HEATING ANDCOOLING CONNECTIONS FOR YOUR UNIT, INDOOR FAN MOTORPLUGS - "DO NOT DISCONNECT UNDER LOAD"

5. ON SMALL BASE MODELS LSI AND LS2 ARE WIREDIN SERIES, LARGE BASE MODELS HAVE LSI ONLY.

F_BK.

SUPPLY_y

EQUIP_GND6. INDUCER CAPACITOR AND WIRING ON CERTAIN MODELS ONLY, --_

IF CAP2 IS PRESENT, YELLOW WIRES FROM IGC AND IDM CONNECTON SAME SIDE OF CAP2,

7. THIS FUSE IS MANUFACTURED BY LITTELFUSE, P/N 257003,

8. THIS FUSE IS MANUFACTURED BY LITTELFUSE, P/N 2BTOO5,LEGEND

/-x FIELD SPLICE<_ TERMINAL (MARKED) DR DEFROST BOARD RELAYo TERMINAL (UNMARKED) EOUIP EQUIPMENT• SPLICE FS FLAME SENSOR0 SPLICE (MARKED) GND GROUND-- FACTORY WIRING HPB HIGH PRESSURE SWITCH- - FIELD CONTROL WIRING I IGNITOR--- FIELD POWER WIRING IGC INTERGRATEU GAS UNIT CONTROLLER--- ACCSSE ORY OR OPTIONAL IFB INDOOR FAN BOARD

WIRING IDM INDUCED DRAFT MOTOR

-- rUL..I_LUL.:_RT_N_T_N_MMON IFM INDOOR FAN MOTORNOT TO REPRESENT WIRING LGPS LOW GAS PRESSURE SWITCH (WHEN USED)

LPS LOW PRESSURE GWITCHC CONTACTOR LSI PRIMARY LIMIT SWITCHCAP 1 CAPACITOR, COMP LS2 SECONDARY LIMIT SWITCHCAP 2 CAPACITOR, INDUCER MGV MAIN GAS VALVECCH CRANK CAGE HEATER OFM OUTDOOR FAN MOTORCOMP COMPRESSOR MOTOR PRS PRESSURE SWITCHCR COMBUSTION RELAY RG ROLLOUT SWITCHDB DEFROST BOARD RVS REVERSING VALVEDFT DEFROST TEMPERATURE TRAN TRANSFORMER

SWITCH T-STAT THERMOSTAT

COLOR CODE

BK BLACK

BL BLUEBR BROWNGY GRAY

G GREEN0 ORANGEP PINKR REDV VIOLET

W WHITEY YELLOW

CCH

BK

R

GY

SERVICINGSCHEMATIC208/230-1 -60

5AMP

FUSE

LGPS (WH

NOTE 8

USED)

-IF USED I

DEFROST BOARDcTD(DB)_

P1 P3_

--:_ HPS LPS LBRI

-BN_BK--,--BL_ I

-BL J I-BR

DIP SWITCH SETTINGSDEFAULT

SOMINUTES 60 MINUTES90 MINUTES 120 MINUTES

m _

S_p_OlIIIII JUNPERED TEST PINS (USE METAL OBJECT)FIELD SPEED-UP CYCLE

I) MOMENTARILY SHORT PINS AND RELEASE TO BYPASSCOMPRESSOR OFF DELAY.

2) SHORT FOR 5+ SEC, AND RELEASE FOR FORCED DEFROST,3) PERMANENT SHORT WILL BE IGNORED.

,0 I+

FIELD SELECTABLE OPTIONS FOB TIME PERIODBETWEEN DEFROST CYCLES (MINUTES)THE COMPREGGOR WILL GHUT OFF FOR 30 GEC. ON DEFROSTINITIATION AND TERMINATION IN THE "QUIET SHIFT" ON DEFROST WILL TERMINATE IN 30 SEC, IF OFT OPEN.POSITION DEFROST WILL TERMINATE NORMALLY IF DFT IS CLOSED.

148EZ500123 I .o I

26

Figure 15 1 208/230-1-60 Ladder Wiring Diagram

LADDER WIRING DIAGRAM

DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING

OUTDOOR FAN

SECTION

:OMPRE_ON;ECTION

COMP

C sR

INDOOR FAN

NECTION L$I (LARGE)

CAP I

SEE NOTE 7_

IL1 I USE COPPER CONDUCTORS ONLY G/Y

BK FIELD SUPPLY J_I_ UNITCOMPONENTARRANGEMENT 208/230 VAC, 60 HZ, IPH

11

C 2111 _ F-- --BK •

(GMALLCABINET)

T "STAT

0 --_- 0 --

TT_G-- G

W --_- W--

DH- z_ BL-

y__Z_ Y--

c__z_

BR

-- CONTROL BOX AREA

GAS []

SECTION ®

SEE NOTE

24VAC R (._

FUSE I)

p2- 2"C"([}--BR

P2-5"X"O--GyP2- 3"w"O- W

P2- 4" R"O- R

---OP1-111Rll

_P1 - 6"W"

--_[_ P1-5"Y2/DH"

---0 P1-311yI/YI'

YO--YLOW0

HIGH 0

GAS HEAT0

11

11

BN

CCH I(IF USED) T 23

I,_BKJ

1

R:L L)

,W--

BK-- YG/Y

/Y CAP2

"_/_L_ Y _SEE NOTE 6

230 TRAN COM

BK PRIMARY208/230V Y

R_BRDFTDB

P3-1 O"P3-20-

TI 0

OPI-T,R

YO-

0 _PI-8,0

y- OPI-5,Y

W- 4[])P1-6,W2

T2P2-4 0-

0P2-1 O-

LPS HPS

-BL--_-BL+BK--_K f--BK_BR

RVS

SEE NOTE

-- BK_

27

I

L2

IFB

)co,)IFB

IDB-C

)DB-C

) IGCC

IFB

) CO_

IFBPI-;

)

48EZ5001 23 6.C

FIGURE 16 1 208/230-3-60 Connection Wiring Diagram

CONNECTION WIRING DIAGRAM

DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE

IF

BK

F_BK

GUPPL!_ Y

---_BL

EQUIP_GNU

COLOR CODE

NOTES:I. IF ANY OF THE ORIGINAL WIRES FHRNISHED ARE REPLACED,

THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT.R. SEE PRICE PACES FOR THERMOSTATS.s. USE ?5 DEG. COPPER CONDUCTORS FOR FIELD INSTALLATIOH.4. GEE INSTALLATIONINSTRUCTIONSFOR PROPER HEATING AND COOLING

CONNECTIONS FOR YOUR UNIT. INDOORFAN MOTOR PLNCD- 'NO NOT DIGCONGECT UNDER LOAD"

B. THIS FUSE IS MANUFACTUREDBY LITTELFNGE,P/N 2BTOOC.6. THIS FUSE IS MANUFACTUREDBY LITTELFNGE,PNN 2BTOO5.7. INDUCERCAPACITOR AND WIRING ON CERTAIN MODELS ONLY.

IF CAP2 IS PRESENT, YELLOWWIRES FROM IGC AND IDM CONNECTON SAME SIDE OF CAP2.

8. REMOVEYELLOW SPLICE WIRE WHEN ECONOMIZERAND ECONOMIZERRELAYGARE USED AND CONNECT TO RELAY R) AS DNGWN.

H. WHEN ECONOMIZER AND ECONOMIZER RELAYSARE USED,CONNECT THE YELLOWAND BLACK WIREG TO RELAY RAG SHOWN. RELAYKIT REQUIRED WITH ECONOMIZER AND HEAT PNMP/DNNL FUEL NNITD.

IN. WHEN ECONOMIZER AND ECONOMIZER RELAYSARE NGED,INSTALLWIRES AS SNGWN ONTO THE COILS OF RELAY R AND RELAY R1.

11. DEHUMIDIFICATIONFEATURE CANNOT DE USED WHEN ECONOMIZER ISINSTALLED.

LEGEND

FIELD SPLICE ECON ECONOMIZERTERMINAL (MARMED) EQUIP EQUIPMENTo TERMINAL {UNMARKED) FG FLAME DENSOR

SPLICE QMO GROUNDSPLICE (MARMED) HPG NIGH PRECSURE SWITCH

CCH

DB

.... V/

SERVICINGSCHEMATIC208/230-3-60

-- FACTORY WIRING I IGNITOR- -- FIELD CONTROL WIRING IGC INTENGRATED GAS UNIT CONTROLLER--- FIELD POWER WIRING IFB INDOOR FAN BOARD--- AUCEGOORY OR OPTIONAL IDM INDUCED DRAFT MOTOR

WIRING IFM INDOOR FAN MOTOR-- TO INDICATE COMMON LGPC LOW GAG PRESSURE GWITCH (WHEN USED)

POTENTIAL ONLY: LPS LOW PRESSURE _WITDNNOT TO REPRESENT WIRING L$I PRIMARY LIMIT GWITCH

C CONTNOTOR LS2 SECONDARY LIMIT SWITCHCAP I CAPACITOR, COMP MGV MAIN GAS VALVECAP 2 CAPACITOR, INDUCER OFM OUTDOOR FAN MOTORCCH CRANK CASE HEATER PRG PREGSURE SWITCHCOMP COMPREDOOR MOTOR NG ROLLOUT DWITCHCR COMBUSTION RELAY RW REVERSING VALVEDB DEFROGT BOARD DAT DUPPLY AIR TEMPERATUREDFT DEFROST TEMPERATURE TNAN TRANSFORMER

SWITCH T-STAT THERMODTATDN DEHUMIDIFICATION MODE R ECON RELAYDR DEFROST BOARD RELAY R) ECON RELAY

:_----BR-- --

--BK--

_RY_ _ _

<_[P--

,_Z)---

<]_[}-- V

_N

o--

GROUNDEDTNRU STANDOFF

BE BLACKBL BLUEBR BROWNGY GRAY

g GREENORANGEP PINKR REDV VIOLETW WHITEY YELLOW

--G_

jv

QT /

rSEE NOTE @ Ii

R I

tBLL LGPS (WHEN USED)

o PRS

-BR

FS--y.._ o

0 -oI c-BR_

W--

GEE NOTE lO__

DTP SWTTCH SETTTNGS

K SEE NOTE _yy Y--

THE COMPREGSOR WILL SHUT OFF FORSO DEC. ON DEFROST INITIATION ANDTERMINATION IN THE "QUIET SHIFT'ON POSITION.

m _

s_F_um JUMPERED TEST PINS (USE METAL OBJECT)FIELD SPEED-UP CYCLE

I) MOMENTARILY SHORT PINS AND RELEASE TO BYPASSCOMPRESSOR OFF DELAY.

Z) SHORT FOR G÷ DEC, AND RELEASE FOR FORCED DEFROST3) PERMANENT SHORT WILL BE IGNORED.

DEFROST WILL TERMINATE IN 50 GEC. IF DFT OPEN.DEFROST WTLL TERMINATE NOBMALLY IF DFT IS CLOSED

148EZ5001241 8.0

28

Figure 16 208/230-3-60 Ladder Wiring Diagram

LADDER WIRING DIAGRAM

DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFOREUNIT COMPONENT ARRANGEMENT

OUTER FANSECTION

COMPRE_RSECTION

[][]cowP

T2

BASSECTION

E ®..... [5_DCABINET)

SEE NOTE

TFI_ /

2,,vAcN0 tFUSE..)--3A

P2-I"R"_- R

P2-2II C ll([_-- B R

T/_TAT P2-5"X"(}--Gy" _'"" P2-3"VV"O-W

P2-4"R"O- RR--J L R OPI-I"R"

0 __z]__ 0

G --'T_---G -- _--OPI-4"G"

W__Z]_ W_ '_OP1 6"W"

DH--j _ BL-- "_OPI-5"Y21DH"

i_2--_R _I1E - '__ 1 '31_

HIGH 0GY GAS HEAT0

/

L1

11

IG/YJ_

CCH I

21 (IF USED) _ 23

( )" BK "_//_,r,,_'_ GiY Y X

IGC _ "-_

LI CR CM IGC

( )-BH--4[)--I_-O---V _ ._ Y _I L2

L IDM _/Z_BR___L Y_ _ y

""-_/_ Y CAR2 _--

230" TR_N _ " _"'_SEE NOTE 7

BH PRIMARY 208123RV Y

R _BR

DB DFT

P3-1 O" --_'--_IGC _SEE NOTE 6 l5AMP P3-Z_ --

--BK BK_BL

z<"BL

11

I

I USE COPPER CONDUCTORS ONLYBK FIELD SUPPLY

L 208/230 VAC, 60 HZ, 3PHC

8

--o_4yo _

oY_

-0IFO

-OW

--OR

Y _

SEE NOTE 4

ECONHARNESS

2----Y

3----R--

4

6-- -P_BL:

7-- -P_B

8---GYq

T1 0

OPI-?,R

YO-

-- 0 - -0P1-8,0

-- y- 40P1-5,Y

-- -- IV--OP1-6,W2

T2PZ-4 (}

P2-I _

_€/_SEE NOTE 8SEE NOTE 4)

q_y_,

SERVICING

IL3BL IL2

Y

C 13I ¢)

)23

c

-BL_BR

--BK_BR

RVS R

SEE NOTE lO

)23

, r_Rl-Sq

_3T--_BK-_ _SEE NOTE U

IFB

ico _FB

--UN--

DB-C

DB-C

IGC

n_6/Y_ ) IGCC

" ZBpL__-- 7_ IFB

--BR--___-_ HIFB)P1-2

COM C

148EZ5OO1241 8.o

29

FIGURE 17

_=

"68

.==

=EI-

..J

*o

5ou.o

"68==u_

J Cooling Charging Table-Subcooling

{,O O3 M3 €OI'-. OO O'_ O _

E

E_ IN CN _11'_1

t_ o'} co o3

N N o"_ o")

O4 o') ,_- I,,_

u'l €OI,.- t_.

O _ (N o3t,13 IX1 IX1 Ln

o3 ',_- _,o ¢o

O"_ _0 I',.- €0O_ ¢o o'3 C_

0303o303

I',-- O_ _ o3u'l L(1 €0 _0

O4 '_- ¢D €,0€O €O €0 ¢D

¢O ¢D I',,- I'_

I',... I,,... o0 o0

(N '_- ¢0 o0_o =o =o _0

u'l 04 O o0,_1. ke) ¢D €004 N N t'N

_O ¢O ¢OI',.-

_ {N "_1" €0o0 o0 e0 €0

o0 o0 o0 O"=

O O,I _1" ¢0

N O4 {._1 ¢.e_

o3 tO I_,. O_

€,o O €_1 '_-

03 t.O i'._ 03_0 _0 _0 _0

O_ O"_ O"_ 0'_

O _ O,I o3_ o.) {.e) o.)

€0 €0 €0 o0

•.,o o0 €_ O.I

000_

0000O0 03 '_- N

.e- .e- _.a. N

o0 0_ ._- 0,1O4O4O3O3

o • ._ ._"0 ,,C

= _ ,= ==o o _== E

"'_ Z.= == _, .o _ E= "-

_''_=1_ ==-- E

t'N N t'_l CN

O,I O_ O'_ O3

03 03 eea o3

O _ (N o3I,_'1 I,..'1 u'3 t._

O,N

:>LUn,'

N

3O

MAINTENANCETo ensure continuing high performance and to minimize thepossibility of premature equipment failure, periodicmaintenance must be performed on this equipment. Thiscombination heating/cooling unit should be inspected atleast once each year by a qualified service person. Totroubleshoot cooling or heating of units, refer to Tables 10,11 and 12.

NOTE: Consult your local dealer about the availability of amaintenance contract.

PERSONALINJURY AND UNIT DAMAGEHAZARD

Failure to follow this warning could result in personalinjury or death and unit component damage.

The ability to properly perform maintenance on thisequipment requires certain expertise, mechanicalskills, tools and equipment. If you do not possessthese, do not attempt to perform any maintenance onthis equipment, other than those proceduresrecommended in the Owner's Manual.

ELECTRICALSHOCK AND EXPLOSION HAZARD

Failure to follow these warnings could result inpersonal injury or death:

1. Turn off electrical power to the unit and install alockout tag before performing any maintenance orservice on this unit.

2. Use extreme caution when removing panels andparts.

3. Never place anything combustible either on or incontact with the unit.

4. Should overheating occur or the gas supply fail toshut off, turn off external main manual gas valve tothe unit. Then shut off electrical supply.

CUT HAZARD

Failure to follow this caution may result in personalinjury.

When removing access panels or performingmaintenance functions inside your unit, be aware ofsharp sheet metal parts and screws. Although specialcare is taken to reduce sharp edges to a minimum,be extremely careful when handling parts or reachinginto the unit.


Failure to follow this caution may result in improperoperation.

Errors made when reconnecting wires may causeimproper and dangerous operation. Label all wiresprior to disconnecting when servicing.

The minimum maintenance requirements for this equipmentare as follows:

1. Inspect air filter(s) each month. Clean or replacewhen necessary. Certain geographical locations mayrequire more frequent inspections.

2. Inspect indoor coil, outdoor coil, drain pan, andcondensate drain each cooling season forcleanliness. Clean when necessary.

3. Inspect blower motor and wheel for cleanliness at thebeginning of each heating and cooling season. Cleanwhen necessary. For first heating and coolingseason, inspect blower wheel bi-monthIy to determineproper cleaning frequency.

4. Check electrical connections for tightness andcontrols for proper operation each heating andcooling season. Service when necessary. Ensureelectrical wiring is not in contact with refrigerant tubingor sharp metal edges.

5. Check and inspect heating section before eachheating season. Clean and adjust when necessary.

6. Check flue hood and remove any obstructions, ifnecessary.

Air Filter

IMPORTANT: Never operate the unit without a suitable airfilter in the return-air duct system. Always replace the filterwith the same dimensional size and type as originallyinstalled. (See Table 1 for recommended filter sizes.)

Inspect air filter(s) at least once each month and replace(throwaway-type) or clean (cleanabte-type) at least twiceduring each heating and cooling season or whenever thefilter(s) becomes clogged with dust and/or lint.

Indoor Blower and Motor

NOTE: All motors are prelubricated. Do not attempt tolubricate these motors.

For longer life, operating economy, and continuingefficiency, clean accumulated dirt and grease from theblower wheel and motor annually.



Disconnect and tag electrical power to the unit beforecleaning and lubricating the blower motor and wheel.

Cleaning the Blower Motor and Wheel

1. Remove and disassemble blower assembly asfollows:

a. Remove blower access panel.b. Disconnect 5 pin plug and 4 pin plug from indoor

blower motor. Remove capacitor if required.c. On all units, remove blower assembly from unit.

Remove screws securing blower to blowerpartition and slide assembly out. Be careful not totear insulation in blower compartment.

d. Ensure proper reassembty by marking blowerwheel and motor in relation to blower housingbefore disassembly.

e. Loosen setscrew(s) that secures wheel to motorshaft. Remove screws that secure motor mount

brackets to housing, and slide motor and motormount out of housing.

2. Remove and clean blower wheel as follows:

a. Ensure proper reassembty by marking wheelorientation.

b. Lift wheel from housing. When handling and/orcleaning blower wheel, be sure not to disturbbalance weights (clips) on blower wheel vanes.

c. Remove caked-on dirt from wheel and housingwith a brush. Remove lint and/or dirt

31

accumulations from wheel and housing withvacuum cleaner, using soft brush attachment.Remove grease and oil with mild solvent.

d. Reassemble wheel into housing.

e. Reassemble motor into housing. Be suresetscrews are tightened on motor shaft flats andnot on round part of shaft. Reinstall blower intounit. Reinstall capacitor.

f. Connect 5 pin plug and 4 pin plug to indoor blowermotor.

g. Reinstall blower access panel.

3. Restore electrical power to unit. Start unit and checkfor proper blower rotation and motor speeds duringheating and cooling cycles.

FIGURE 18 J Blower Housing and Flue Collector Box

integratedGas Unit

(tGC)

Auto Transformerfuses used on 460

(Hidden)

Board (tFB)

induced Draft

Motor

FlueCollectorBox Blower

Housing

BurnerRack

MountingScrew

RolloutSwitch

FIGURE 19 J Unit Access Panels

Flue Gas Passaqeways

To inspect the flue collector box and upper areas of the heatexchanger:

1. Remove the induced draft blower assembly accordingto directions in the Induced Draft Blower Assemblysection.

2. Remove the 11 screws holding the flue collector boxcover (See Fig. 18) to the heat exchanger assembly.Inspect the heat exchangers.

3. Clean all surfaces, as required, using a wire brush.

Limit Switch

Remove unit access panel. Limit switch is located on theblower partition.

Burner Iqnition

Unit is equipped with a direct spark ignition 100 percentlockout system. Ignition module (IGC) is located in thecontrol box (See Fig. 18). Module contains a self-diagnosticLED. During servicing, refer to label diagram or Table 5 inthese instructions for LED interpretation.

If lockout occurs, unit may be reset by either momentarilyinterrupting power supply to unit or by turning selectorswitch to OFF position at the thermostat.

Main Burners

At the beginning of each heating season, inspect fordeterioration or blockage due to corrosion or other causes.Observe the main burner flames and adjust, if necessary.Removal of Gas Train

To remove the gas train for servicing:

1. Shut off main gas valve.

2. Shut off power to unit and install lockout tag.

3. Remove unit access panels (See Fig. 19).

4. Disconnect gas piping at unit gas valve.

5. Remove fan partition mounting bracket (2 screws loc-ated on the left side of the control compartment on thefan partition panel). Slide bracket forward, bottom first,to remove (See Fig. 18).

6. Remove wires connected to gas valve. Remove wiresconnected to the rottout switch. Mark each wire.

7. Remove ground wire from fan partition panel.

8. Remove the mounting screw that attaches the burnerrack to the unit base (see Figure 18).

9. Slide the burner rack out of the unit (see Figure 21).Remove ignitor wire from ignitor and remove flamesensor wire from flane sensor.

10. To reinstall, reverse the procedure outlined above.

Outdoor Coil, Indoor Coil, and Condensate DrainPan

Inspect the outdoor coil, indoor coil, and condensate drainpan at least once each year. The coils are easily cleanedwhen dry; therefore, inspect and clean the coils eitherbefore or after each cooling season. Remove allobstructions, including weeds and shrubs, that interfere withthe airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint,clean the coils with a vacuum cleaner, using the soft brushattachment. Be careful not to bend the fins. If coated with oilor grease, clean the coils with a mild detergent-and-watersolution. Rinse coils with clear water, using a garden hose.Be careful not to splash water on motors, insulation, wiring,or air filter(s). For best results, spray outdoor coil fins frominside to outside the unit. On units with an outer and innercondenser coil, be sure to clean between the coils. Be sureto flush all dirt and debris from the unit base.

32

Inspect the drain pan and condensate drain line wheninspecting the coils. Clean the drain pan and condensatedrain by removing all foreign matter from the pan. Flush thepan and drain tube with clear water. Do not splash water onthe insulation, motor, wiring, or air filter(s). If the drain tube isrestricted, clear it with a "plumbers snake" or similar probedevice. Ensure that the auxiliary drain port above the draintube is also clear.

FIGURE 20 ] Removal of Motor and Blower Wheel

BLOWERHOUSING

2 SETSCREWS(HIDDEN)

FIGURE 21 ] Burner Rack Removal

b

//

FIGURE 22 ]DefrostThermostat Location

FEEDERTUBE

STUB TUBE

DEFROSTTHERMOSTAT

FIGURE 23 J Burner Rack Removed

Outdoor Fan


Failure to follow this caution may result in damage tounit components.

Keep the outdoor fan free from all obstructions toensure proper cooling operation. Never place articleson top of the unit.

1. Remove 6 screws holding outdoor grille and motor totop cover.

2. Turn motor/grille assembly upside down on top coverto expose the fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen the setscrew andslide the fan off the motor shaft.

5. When replacing fan blade, position blade back to thesame position as before.

6. Ensure that setscrew engages the flat area on themotor shaft when tightening.

7. Replace grille.

Electrical Controls and Wirinq

Inspect and check the electrical controls and wiringannually. Be sure to turn off the gas supply, and then theelectrical power to the unit.

Remove access panel to locate all the electrical controlsand wiring. Check all electrical connections for tightness.Tighten all screw connections. If any discolored or burnedconnections are noticed, disassemble the connection, cleanall the parts, re-strip the wire end and reassemble theconnection properly and securely.

After inspecting the electrical controls and wiring, replacethe access panel. Start the unit, and observe at least onecomplete heating cycle and one complete cooling cycle toensure proper operation. If discrepancies are observed inany operating cycle, or if a suspected malfunction hasoccurred, check each electrical component with the properelectrical instrumentation. Refer to the unit wiring label whenmaking these checkouts.

NOTE: Refer to the heating and/or cooling sequence ofoperation in this publication as an aid in determining proper

control operation.

Refriqerant Circuit

Annually inspect all refrigerant tubing connections and theunit base for oil accumulations. Detecting oil generallyindicates a refrigerant leak.

33

FIGURE 24 I Defrost Control

©

0

0

7"1--4

m

0"13r_

----CD---

Speedup QuietPins Shift

Defrost intervalDIP switches

EXPLOSION, PERSONALENVIRONMENTAL HAZARD

INJURY AND


System under pressure. Relieve pressure andrecover all refrigerant before system repair or final unitdisposal. Use all service ports and open allflow-control devices, including solenoid valves.

If oil is detected or if low cooling performance is suspected,leak-test all refrigerant tubing using an electronicleak-detector, halide torch, or liquid-soap solution. If arefrigerant leak is detected, refer to the Check forRefrigerant Leaks section.

If no refrigerant leaks are found and low coolingperformance is suspected, refer to the Checking andAdjusting Refrigerant Charge section.

Gas Input

The gas input does not require checking unless improperheating performance is suspected. If a problem exists, referto the Start-Up section.

Indoor Airflow

The heating and/or cooling airflow does not requirechecking unless improper performance is suspected. If aproblem exists, be sure that all supply- and return-air grillesare open and free from obstructions, and that the air filter isclean. When necessary, refer to the Indoor Airflow andAirflow Adjustments section to check the system airflow.

Check Defrost Thermostat

The defrost thermostat is usually located on the lowest liquidleaving circuit of the left condenser coil (see Fig. 22). Thethermostat closes at 32°F (0°C) and opens at 65°F (18°C).

R-410A Items

Meterinq Device (Thermostatic Expansion Valve &

Piston)

This unit uses both a hard shutoff, balance port TXV in theindoor coil and a piston in each side of the outdoor coil. TheTXV maintains a constant superheat at the evaporator coilexit (cooling mode) resulting in higher overall systemefficiency.

Pressure Switches

Pressure switches are protective devices wired into controlcircuit (low voltage). They shut off compressor if abnormallyhigh or low pressures are present in the refrigeration circuit.These pressure switches are specifically designed tooperate with R-410A systems. R-22 pressure switchesmust not be used as replacements for the R-410A system.

Loss of Charqe Switch

This switch is located on the liquid line and protects againstlow suction pressures caused by such events as loss ofcharge, low airflow across indoor coil, dirty filters, etc. Itopens on a pressure drop at about 20 psig. If systempressure is above this, switch should be closed. To checkswitch:

1. Turn off all power to unit.

34

FIGURE 25 J Refrigeration Circuit

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You shouldhave continuity on a good switch.

NOTE: Because these switches are attached to

refrigeration system under pressure, it is not advisable toremove this device for troubleshooting unless you are

reasonably certain that a problem exists. If switch must beremoved, remove and recover all system charge so thatpressure gauges read 0 psi. Never open system withoutbreaking vacuum with dry nitrogen.

High-Pressure Switch

The high-pressure switch is located in the discharge lineand protects against excessive condenser coil pressure. Itopens at 650 psig.

High pressure may be caused by a dirty outdoor coil, failedfan motor, or outdoor air recirculation. To check switch:

1. Turn off all power to unit.2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You shouldhave continuity on a good switch.

Copeland Scroll Compressor (R-410A Refrigerant)

The compressor used in this product is specifically designedto operate with R-410A refrigerant and cannot beinterchanged.

The compressor is an electrical (as well as mechanical'device. Exercise extreme caution when working nearcompressors. Power should be shut off, if possible, for mosttroubleshooting techniques. Refrigerants present additionalsafety hazards.

EXPLOSION HAZARD

Failure to follow this warning could result in personalinjury or death and/or property damage.

Wear safety glasses and gloves when handlingrefrigerants. Keep torches and other ignition sourcesaway from refrigerants and oils.

The scroll compressor pumps refrigerant throughout thesystem by the interaction of a stationary and an orbitingscroll. The scroll compressor has no dynamic suction ordischarge valves, and it is more tolerant of stresses causedby debris, liquid slugging, and flooded starts. Thecompressor is equipped with an internal pressure relief port.The pressure relief port is a safety device, designed toprotect against extreme high pressure. The relief port hasan operating range between 550 and 625 psi differentialpressure.

35

FIGURE 26 J Typical Heat Pump Operation, Cooling Mode

HPS

LEGEND

HPS - High Pressure Switch

LCS - Loss of Charge Switch

_ ',_t Accurater_Metering Device

[}7 Arrow indicates direction of flow

OUTDOORCOIL

]--.

TXV in MeteringPosition

:CZ3't

INDOORCOIL

BypassPosition

LCS

FIGURE 27 J Typical Heat Pump Operation, Heating Mode

f

LEGEND

OUTDOOR COIL

-4-q

I

TXV in BypassPosition

:EC]

LCS

INDOOR COIL

Mete@gPosition

HPS - High Pressure Switch

LCS - Loss of Charge Switch

_0 ii iii_ Accurater_:Mete[ing Device

_] Arrow indicates direction of flow

3d

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could result in personalinjury or equipment damage.

This system uses R-410A refrigerant which hashigher operating pressures than R-22 and otherrefrigerants. No other refrigerant may be used in thissystem. Gauge set, hoses, and recovery systemmust be designed to handle R-410A. If you areunsure, consult the equipment manufacturer.

Refrigerant System

This information covers the refrigerant system of the PDD/S,including the compressor oil needed, servicing systems onroofs containing synthetic materials, the filter drier andrefrigerant charging.

Compressor Oil

If additional oil is needed use Uniqema RL32-3MAF. If thisoil is not available, use Copeland Ultra 32CC or Mobil ArticEAL22CC. This oil is extremely hygroscopic, meaning itabsorbs water readily. POE oils can absorb 15 times asmuch water as other oils designed for HCFC and CFCrefrigerants. Take all necessary precautions to avoidexposure of the oil to the atmosphere.

Servicing Systems on Roofs and with Syntheticmaterials

POE (polyolester) compressor lubricants are known tocause long term damage to some synthetic roofingmaterials.

Exposure, even if immediately cleaned up, may causeembritttement (leading to cracking) to occur in one year ormore. When performing any service that may risk exposureof compressor oil to the roof, take appropriate precautions toprotect roofing. Procedures which risk oil leakage include,but are not limited to, compressor replacement, repairingrefrigerant leaks, replacing refrigerant components such asfilter drier, pressure switch, metering device, coil,accumulator, or reversing valve.

Synthetic Roof Precautionary Procedure

1. Cover extended roof working area with an

impermeable polyethylene (plastic) drip cloth or tarp.Cover an approximate 10x10 ft (3x3 m) area.

2. Cover area in front of the unit service panel with aterry cloth shop towel to absorb lubricant spills andprevent run-offs, and protect drop cloth from tearscaused by tools or components.

3. Place terry cloth shop towel inside unit immediatelyunder component(s) to be serviced and preventlubricant run-offs through the Iouvered openings inthe unit base.

4. Perform required service.

5. Remove and dispose of any oil contaminated materialper local codes.

Liquid Line Filter Drier

This filter drier is specifically designed to operate withR-410A. Use only factory-authorized components. Filterdrier must be replaced whenever the refrigerant system isopened. When removing a filter drier, use a tubing cutter tocut the drier from the system. Do not unsweat a filter drierfrom the system. Heat from unsweating will release moistureand contaminants from drier into system.

R-410A Refrigerant Charging

Refer to unit information plate and charging chart. SomeR-410A refrigerant cylinders contain a dip tube to allowliquid refrigerant to flow from cylinder in upright position. Forcylinders equipped with a dip tube, charge R-410A unitswith cylinder in upright position and a commercial meteringdevice in manifold hose. Charge refrigerant into suction-line.

TROUBLESHOOTING

Use the Troubleshooting Guides (See Tables 10-12) ifproblems occur with these units.

START-UP CHECKLIST

Use Start-Up checklist to ensure proper start-up proceduresare followed.

37

R-410A QUICK REFERENCE GUIDE

• R-410A refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and

replacement components are designed to operate with R-410A

• R-410A refrigerant cylinders are rose colored.

• Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.

• R-410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold

hose when charging into suction line with compressor operating

• Manifold sets should be minimum 700 psig high side and 180 psig low side with 550 psig low-side retard.

• Use hoses with minimum 700 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• R-410A, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Do not use liquid-line filter driers with rated working pressures less than 600 psig.

• Do not leave R-410A suction line filter driers in line longer than 72 hrs.

• Do not install a suction-line filter drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter driers and service valves with wet cloth when brazing.

• A factory approved liquid-line filter drier is required on every unit.

• Do NOT use an R-22 TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and

replace filter driers. Evacuate to 500 microns prior to recharging.

• Do not vent R-410A into the atmosphere.

• Observe all warnings, cautions, and bold text.

• All indoor coils must be installed with a hard shutoff R-410A TXV metering device.

38

Table 11 -Troubleshooting Guide -Cooling or Heat Pump Heating Mode

SYMPTOM

Compressor and Outdoor fan will notstart.

Compressor will not start but Outdoorfan runs.

CAUSE

Power Failure

Fuse blown or circuit breaker tripped

Defective thermostat, contactor, transformer, or control

relay

Insufficient line voltage

Incorrect or faulty wiring

Thermostat setting too high

Faulty wiring or loose connections in compressor circuit

Compressor motor burned out, seized, or internal over-load open

Defective run/start capacitor, overload, start relay

REMEDY

Call power company.

Replace fuse or reset circuit breaker.

Replace component.

Determine cause and correct.

Check wiring diagram and rewire correctly.

Lower thermostat setting below room temperature.

Check wiring and repair or replace.

Determine cause Replace compressor.

Determine cause and replace.

Replace fuse or reset circuit breaker. Determine

cause.One leg of 3-phase power dead

Three-phase scroll compressor makes Correct the direction of rotation by reversing theexcessive noise, and there may Scroll compressor is rotating in the wrong directionbe a low pressure differential. 3-phase power leads to the unit.

Refrigerant overcharge or undercharge

Compressor cycles (other than normally

satisfying thermostat).

Defective compressor

Insufficient line voltageBlocked Outdoor

Defective run/start capacitor, overload or start relay

Defective thermostat

Faulty Outdoor-fan motor or capacitor

Damaged reversing valve

Restriction in refrigerant system

Dirty air filter

Unit undersized for load

Thermostat set too low

Low refrigerant charge

Mechanical damage in compressor.

Air in system

Frosted coil with incorrect defrost operation

Outdoor coil dirty or restricted

Dirty air filter

Dirty Indoor or Outdoor coil

Refrigerant overcharged

Air in system

Indoor or Outdoor air restricted or air short-cycling


Compressor IPR leaking

Restriction in liquid tube

High heat load

Compressor IPR leaking

Refrigerant overcharged

Reversing valve hung up or leaking internally

Dirty air filter


Metering device or low side restricted

Insufficient Indoor airflow

Temperature too low in conditioned area

Outdoor ambient below 55°F (12.8°C)

Field-installed filter-drier restricted

Compressor operates continuously.

Excessive head pressure.

Head pressure too low.

Excessive suction pressure.

Suction pressure too low.

(Heat) Outdoor coil frosted

Compressor runs but outdoor fan doesnot NC (normally closed) contacts on defrost board open

Recover refrigerant, evacuate system, and rechargeto capacities shown on nameplate.

Replace and determine cause.



Determine cause and replace.

Replace thermostat.

Replace.

Determine cause and correct

Locate restriction and remove.

Replace filter.

Decrease load or increase unit size.

Reset thermostat.

Locate leak, repair, and recharge.

Replace compressor.

Recover refrigerant, evacuate system, and recharge.

Check defrost time settings, Reset as necessaryCheck defrost temperature switch, Replace as nec-essary

Clean coil or remove restriction.

Replace filter.

Clean coil.

Recover excess refrigerant.

Recover refrigerant, evacuate system, and recharge.


Check for leaks, repair, and recharge.

Replace compressor.Remove restriction.

Check for source and eliminate.

Replace compressor.

Recover excess refrigerant.

Replace valve

Replace Filter.

Check for leaks, repair, and recharge.

Remove source of restriction.

Increase air quantity. Check filter -- replace if neces-

sary.Reset thermostat.

Install low-ambient kit.

Replace.Move timer on control board to 30 minutes between

defrost cycles

Check condition of relay on board Replace if neces-sary

39

Table 12- Troubleshooting Guide-HeatingSYMPTOM CAUSE

Water in gas line

No power to furnace

No 24-v power supply to control circuit

Burners will not ignite Mis-wired or loose connections

Misaligned spark electrodes

No gas at main burners

Dirty air filter

Gas input to furnace too low

Inadequate heating Unit undersized for applicationRestricted airflow

Limit switch cycles main burners

Incomplete combustion results in: Aldehyde odors,carbon monoxide, sooting flame, floating flame

Poor flame characteristics

REMEDY

Drain. Install drip leg.

Check power supply fuses, wiring or circuit breaker.Check transformer.

NOTE: Some transformers have internal over-current protectionthat requires a cool-down period to reset.

Check all wiring and wire nut connections

Check flame ignition and sense electrode positioning.Adjust as necessary.

1. Check gas line for air. Purge as necessary. NOTE: After purginggas line of air, wait at least 5 minutes for any gas to dissipate be-fore attempting to light unit.2. Check gas valve.

Clean or replace filter as necessary

Check gas pressure at manifold match with that on unit nameplate

Replace with proper unit or add additional unit

Clean or replace filter. Remove any restriction.

Check rotation of blower, temperature rise of unit. Adjust as neces-

sary.

1. Tighten all screws around burner compartment

2. Cracked heat exchanger. Replace.3. Unit over-fired. Reduce input (change orifices or adjust gas lineor manifold pressure).4. Check burner alignment.5. Inspect heat exchanger for blockage. Clean as necessary.

Table 13- Troubleshooting Guide-LED Error CodesSYMPTOM CAUSE REMEDY

Check 5-amp fuse son IGC*, power to unit, 24-v circuit breaker,No Power or Hardware fail- and transformer. Units without a 24-v circuit breaker have an

ure Loss of power to control module (IGC)*. internal overload in the 24-v transformer. If the overload trips,(LED OFF) allow 10 minutes for automatic reset.

Limit switch faults Check the operation of the indoor (evaporator) fan motor, Ensure

(LED 2 flashes) High temperature limit switch is open. that the supply-air temperature rise is in accordance with therange on the unit nameplate. Clean or replace filters.

Flame sense faultThe IGC* sensed flame that should not be present. Reset unit. If problem persists, replace control board.

(LED 3 flashes)

4 consecutive limit switch Check the operation of the indoor (evaporator) fan motor and thatfaults Inadequate airflow to unit. supply-air temperature rise agrees with range on unit nameplate(LED 4 flashes) information.

Ignition lockout Check ignitor and flame sensor electrode spacing, gaps, etc.

(LED 5 flashes) Unit unsuccessfully attempted ignition for 15 minutes. Ensure that fame sense and ignition wires are properly terminated.Verify that unit is obtaining proper amount of gas.

Verify wiring connections to pressure switch and inducer motor.

Pressure Switch Fault Verify pressure switch hose is tightly connected to both inducer

(LED 6 flashes) Open pressure switch, housing and pressure switch, Verify inducer wheel is properlyattached to inducer motor shaft. Verify inducer motor shaft is turn-

ing.

Rollout switch will automatically reset, but IGC will continue to

Rollout switch fault lockout unit. Check gas valve operation. Ensure that induced-draft(LED 7 flashes) Rollout switch has opened, blower wheel is properly secured to motor shaft. Inspect heat

exchanger. Reset unit at unit disconnect.

Internal control fault Microprocessor has sensed an error in the software If error code is not cleared by resetting unit power, replace the(LED 8 flashes) or hardware. IGC*.

Temporary I hr auto reset Reset 24-v. to control board or turn thermostat off, then on again.(LED 9 flashes) Electrical interference impeding IGC software Fault will automatically reset itself in one (1) hour.

*WARNING .!_ : If the IGC must be replaced, be sure to ground yourself to dissipate any electrical charge that my be present before handling new control

board. The IGC is sensitive to static electricity and my be damaged if the necessary precautions are not taken.IMPORTANT: Refer to Table 11 -Troubleshooting Guide-Heating for additional troubleshooting analysis.LEGEND

IGC--Integrated Gas Unit ControllerLED--Light-Emitting Diode

40

I. PRELIMINARY INFORMATION

MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

START-UP CHECKLIST

(Remove and Store in Job Files)

II. PRESTART-UP (Insert check mark in box as each item is completed)THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS

CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS

CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)

CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE_VERIFY THAT UNIT INSTALLATION IS LEVEL

CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

III. START-UP

ELECTRICAL

SUPPLY VOLTAGE

COMPRESSOR AMPS

INDOOR (EVAPORATOR) FAN AMPS

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE__ DBRETURN-AIR TEMPERATURE DB

COOLING SUPPLY AIR DB

HEAT PUMP SUPPLY AIR

GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE

GAS MANIFOLD PRESSURE

REFRIGERANT SUCTION

REFRIGERANT DISCHARGE

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS

GAS HEAT TEMPERATURE RISE

TEMPERATURE RISE (See Literature) RANGE

MEASURED TEMPERATURE RISE* Measured at suction inlet to compressor

1- Measured at liquid line leaving condenser.

IN. W.C.

IN. W.C.

PSIG, SUCTION LINE TEMP*

PSIG, LIQUID TEMPI

WB

WB

41

Installation Instructions - c.searspartsdirect.com · START-UP CHECKLIST ..... 41...

Documents

Transcript of Installation Instructions - c.searspartsdirect.com · START-UP CHECKLIST ..... 41...