ICP Package Units(both Units Combined) Manual L0611374

User Manual: ICP ICP Package Units(both units combined) Manual ICP Package Units(both units combined) Owner's Manual, ICP Package Units(both units combined) installation guides

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Installation Instructions
PDX3 Series
PACKAGED

DUAL FUEL UNITS

TABLEOF CONTENTS
UNITDIMENSIONS ......................................

2-3

BALANCEPOINTTEMPERATURES .......................

SAFEINSTALLATIONREQUIREMENTS .........................

DUCTWORK.........................................

LOCATINGTHE UNIT .......................................

FILTERS ............................................

CLEARANCES ............................................

AIRFLOWADJUSTMENT ...............................

INSTALLATION............................................

START-UPPROCEDURES ..............................

GROUNDLEVELINSTALLATION ..............................

GAS PRESSURES ....................................

HOISTING................................................

6
GAS HEATINGSTART-UP PROCEDURES ..................

DOWNFLOWCONVERSION ..................................

HEATINGVENTASSEMBLY ..................................

OPERATION.........................................

CONDENSATEDRAIN.......................................

MAINTENANCE ......................................

PRE-EXISTINGCOMMONVENTCHECK .........................

INSPECTIONAND CLEANING............................

GAS SUPPLYAND PIPING ...................................

COMPONENTLOCATION ...............................

ORIFICES ...............................................

RIGGING ...........................................

ELECTRICALWIRING ......................................

WIRING DIAGRAMS ................................

22- 23

CQUS
................. LISTED

InternationalComfortProducts,LLC
Lewisburg,TN. 37091

518 01 1601 00
Printed in U.S.A.
Code: PDX3

2-22-06

"B" CHASSIS UNIT DIMENSIONS

1. Unit Dimensions
Units

COMBINATION
GAS/
ELECTRIC
UNITS
"B" Chassis
DIM=

A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
Q
R
S

in "B"

PDX324

Chassis

Configuration

- 36

(473/8 x 473/8)
INCHES

"0" _

"B"

MILLOMETERS

47-3/8
47-3/8
3-1/8
32-1/2
11-1/8
12

1203
1203
79
826
283
306

14-1/4

363

14-1/4

383

308

314_I19_28
4

lO8
311

12-1/8
14-1/4

308
363

12-1/4

318

_..J

'w'

_I" J'"_
"1''/

.t 7.
y/_

[ o \

I1_% 1_1
12-1/4

102

4-1/4

.....
_

;'E'_

<. _.

j'G_._

'U'_'" _
_
_

"H"
'

i_--_

'_
-">,/

._--'/_
/

2-1/2"

"d"

1-1/2"

(53975)

.-li8

(282.575)

'_L"_

_._

_'__

(101.6)

//_¢

..X._/_--

ROOF CURB

Unit Base shown separately to

for units in
"B" Chassis

illustrate

(473/8 x 473/8)

Units

in "B"

Chassis

INCHES

42-3/4
39-3/4
18

18
3-3/4
42-3/4

.........

PDX324

1086
1010
457
95
1086

_._.

/
_

_/._..._
/_

_._

"F'_

* Roof curbs are also available in 8" (203) and 24" (610) heights (K Dimensions),

121

•

openings,

_x
_

of duct

/'_

457

bottom

Configuration_

DIM.

A
B
C
D
E
F
G
H
K*

8o:_o:12

"C" CHASSIS UNIT DIMENSIONS
CAL
CONDUIT

_/2"
GAS
1/2"

POWER

('K"
VOLTAGE
(12.7)

DIM.)

CONDUIT

CONNECTION
(12,7)
PIPE

1/2"

COMBINATION
GAS/
ELECTRIC
UNITS
"C" Chassis
(473/8 x 73)
DIM

A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
Q
R
S
T

INCHES

36
47-3/8
73
4-5/8
15
12
18-3/4
18-3/4
12
4
1 &1-1/4
4-1/4
5-1/4
12-1/4
19
15
19
12-1/4
16-7/8

MILLOMETERS

914
1203
1354
117
361
307
476
476
306
102
25&31
108
133
311
483
381
483
318
429

,,p,,

Unit Base shown separately to
illustrate bottom of duct openings,

ROOF

CURB
for
"C" Chassis
(473/8 x 73)

_IM

A
B
C
D
E
F
G
H
I
J
K*

INCHES

67-3/4
64-3/4
23
23
2-1/2
42-3/4
39-3/4
23
12
12
14

Units in "C" Chassis Configuration
PDX342-60

MgLLIM_T_RS

1721
1645
584
584
64
1086
1010
584
305
305
356

* Roof curbs are also available in 8" (203) and 24" (610) heights (K Dimensions),

131

2. SAFE INSTALLATION

REQUIREMENTS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical
components. Only trained and qualified personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance
functions of cleaning coils and filters. All other operations
should be performed by trained service personnel. When
working
on
air-conditioning
equipment,
observe
precautions in the literature, tags, and labels attached to the
unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations.
Have fire extinguisher available for all brazing operations.

FIRE,
EXPLOSION,
ELECTRICAL
SHOCK,
CARBON MONOXIDE POISON HAZARD

AND

Improper installation, adjustment, alteration, service,
maintenance,
or use can cause carbon monoxide
poisoning, fire, or an explosion which could result in
personal injury or unit damage.
Consult a qualified
installer, service agency, or gas supplier for information
or assistance. The qualified installer or agency must use
only factory-authorized
kits or accessories
when
modifying this product.

FIRE,
EXPLOSION,
ELECTRICAL
SHOCK,
CARBON MONOXIDE POISON HAZARD

AND

Failure to follow this warning could result in personal
injury, death and/or property damage.
Before performing service or maintenance operations
on unit, turn off gas supply to unit. Then turn off unit main
power switch and install lockout tag.

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON
MONOXIDE POISON HAZARD
Failure to carefully read and follow all instructions in this
manual could result in furnace malfunction, property
damage, personal injury and/or death.
Installation or repairs made by unqualified persons can
result in hazards to you and others. Installation MUST
conform with local building codes or, in the absence of
local codes, with the National Fuel Gas Code NFPA
54-2005/ANSI Z223.1-2005 and the National Electrical
Code NFPA70-2005 or in Canada the National Standard
CAN/CGA B149-1 and CSA C.22.1 - Canadian Electrical
Code Part 1.
The information contained in this manual is intended for
use by a qualified service technician familiar with safety
procedures and equipped with the proper tools and test
instruments.
SAFETY CONSIDERATIONS
• Use only with type of gas approved for this unit. Refer to
unit rating plate.
• Install this unit only in a location and position as specified
in section 3 of this manual.
• Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the
detection of leaks to check all connections.
• Always install unit to operate within the unit's intended
temperature-rise range with a duct system, which has an
external static pressure within the allowable range, as
specified in section 9. Refer to unit rating plate for the allowable external static pressures.
• All connecting ductwork to the unit (supply and return)
must be sealed to the unit casing.
• Do NOT use this furnace as a construction heater.
• Check to see that filters are installed correctly and are the
proper type an size.
NOTE: It is the personal responsibility and obligation of the
customer to contact a qualified installer to ensure that the
installation is adequate and conforms to governing codes
and ordinances.

Recogniz_ safety information. This is the safety-alert
symbol/.rX. When you see this symbol in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the
safety-alert symbol. DANGER identifies the most serious
hazards which will result in serious injury or death.
WARNING signifies a hazard which could result in serious
injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation,
reliability, or operation.
These instructions cover minimum requirements and
conform to existing national standards and safety codes. In
some instances, these instructions exceed certain local
codes and ordinances, especially those that may not have
kept up with changing residential construction practices.
We require these instructions as a minimum for a safe
installation.

141

INTRODUCTION
The PDX3 unit is a fully self-contained,
combination
Category I gas heating / electric heat pump unit designed for
outdoor installation (See pages 2 and 3 for unit
dimensions).
All unit sizes have return and discharge
openings for both horizontal and downflow configurations,
and are factory-shipped with all downflow duct openings
covered.
Units may be installed either on a rooftop, cement slab, or
directly on the ground if local codes permit.
Models with a"l" in the twelfth position ofthe model number
are dedicated Low NOx units designed for California
installations. The emissions ofthese models do not exceed
40 nanograms of nitrogen oxide emissions per joule of heat
output as shipped from the factory, and must be installed in
California Air Quality Management Districts or any other
regions in North America where a Low NOx rule exists.

3. LOCATING

THE UNIT
FIGURE i

Minimum Clearances
Panels(B
Chassis and
Shown)
Access

ACCESS PANELS
I

See Figure 1 for a general view of unit and location of
access panels.

Blower Compartment

Panel

B Chassis - 2"
C Chassis - 6"

CLEARANCES
The location MUST allow for minimum clearances

and

should not be adjacent to a patio or other area where the
unit's operating sound level might be objectionable. The
combustion air inlet openings MUST not be obstructed (see
Figure 1). In addition, local codes MUST be observed.
NOTE: Units with available filter racks (3-1/2 to 5ton), need
a 26" minimum clearance at side of unit for removal of
filters. See chart below if unit is going to be placed near
combustible construction or materials.
While minimum clearances are acceptable for safety
reasons, they may not allow adequate air circulation around
the unit for proper operation in the cooling mode. Whenever
possible, it is desirable to allow additional clearance,
especially around the condenser inlet and discharge
openings.
Do NOT install the unit in a location that will permit
discharged air from the condenser to recirculate to the
condenser inlet.

Internat Filter Access
from Burner Compartment
26" (C Chassis Units)

Side

Burner Compartment
Panel

INSTALLATION
NOTICE

Unit will NOT operate properly unless it is installed
level front to rear and side to side. The slope MUST NOT
be greater than 1/8" per foot (10mm per meter). For side
to side leveling, the drain side MUST always be lower.
Ground Level Installation
Ground level platform requirements:
- The unit MUST be situated to provide safe access for
servicing.
- Platform may be made of either concrete or pressure
treated wood and MUST be level and strong enough to
support unit weight.

UNIT DAMAGE HAZARD

- Position platform separate from building foundation.

Failure to follow this caution may result in shorten life
of unit components.

- Install in well-drained area, with top surface of platform
above grade level.
- Platform must be high enough to allow for proper
condensate
trap installation and drainage. See
FIGURE 4 and associated text for more information
about condensate drainage.

Do NOT operate unit in a corrosive atmosphere
containing chlorine, fluorine, or any other corrosive
chemicals.
Minimum

Clearances

to Combustible

Construction

Furnace Plenum .....................................
Duct Side ...........................................
Condenser Inlet ....................................
Blower Service (Side) ...............................
Control Service Side

2"
2"
30"
30"

(Front Combustion Air Inlet) ..............
Clearance between 3 Ft. Overhang
and Top of Unit .........................
Combustible Base
(Wood or Class A, B or C
roof covering material) .....................

30"
30"

151

Rooftop Installation
Rooftop platform requirements:

FIGURE2

Heating Vent Assembly

Screws for
"B" Chassis
(473/8 x 473/8)

- The unit MUST be situated to provide safe access for
servicing.

Screw for
"C" Chassis
(473/8 x 73)

- The existing roof structure MUST be adequate to
support the weight of the unit or the roof MUST be
reinforced.
Check the weight of the unit in relation to the roof
structure and local building codes or ordinances and
reinforce roof structure if necessary. See the last page
of this manual for unit weights.
- Support for the unit MUST be level and strong enough
to carry unit weight. The support may consist of a
platform or a combination of platform and roof beams or
curb.
- See Hoisting section for hoisting instructions,
HOISTING
NOTE: All access panels MUST be secured in place before
hoisting.
The unit should be hoisted with two lifting slings. Attach the
slings to rigging shackles that have been hooked through
holes in the base rail,
Two spreader bars MUST be placed on top of the unit to
protect the unit from damage from the pressure exerted by
the slings. Make sure that all equipment is adequate to
handle the weight ofthe unit and that the slings will not allow
the unit to shift.
Refer to FIGURE 10 on the back cover of this manual for
illustrated rigging instructions and weight chart,
DOWNFLOW CONVERSION
NOTE: In downflow applications with roof curbs or jack
stands, the center rail under the unit must be removed. The
center rail is attached to the base rail with screws.

2. Install the removed plates on the horizontal return and
supply air openings.
3, Install roof curb on the building. Be sure to follow all
directions included with curb and all applicable building
codes in your installation. See page 2 or 3 for
appropriate roof curb to use.
Heating Vent Assembly
The flue cover is packed with installation screws in the
return air compartment, Refer to FIGURE 3 and assemble
as shown,
FIGURE

Heating Vent Assembly

Flue Support
(Shipped mounted to unit
Flue Cover

These units are adaptable to downflow use, To convert to
downflow use, follow these steps:
1. Remove the blockoff plates found in the return air
compartment and the supply air compartment.
NOTE: Blockoff plate in the supply air compartment only
contains one screw. If reinstalling plate, back part of plate
MUST fit into mating dimples on flange. To reinstall, slant
plate into dimples, then put plate into position and fasten
with screw.

UNIT DAMAGE
Failure to follow this caution may result in unit
damage.
Do not operate the unit without the vent assembly
installed.

161

Condensate Drain

5. GAS SUPPLY AND PIPING

The condensate drain outlet is a 3/4" (19.1 mm) female PVC
connection located atthe bottom ofthe unit to the right ofthe
filter access panel (see FIGURE 4).

NOTE: Because there are many types of liquified petroleum
(LP) gases, the term LP as used in this manual refers to
propane gas. If you intend to use any type of LP gas, proper
precautions MUST be used in the handling, piping, and use
of such gas. NOTE: In Canada, installations MUST be
performed by licensed LP installers.

The circulating blower creates a negative pressure on the
condensate drain line that can prevent the condensate from
draining properly. To combat this negative pressure, a field
supplied condensate trap that will allow a standing column
of water of at least 2" (50.8mm) MUST be installed. Top of
outlet from trap MUST be at least 1" (25.4mm) below top of
outlet from unit. Install the trap as near to the unit as
possible for proper drainage.
A 3/4" (19.1 mm) drain line MUST be installed if required by
local codes or if location of unit requires it. Run the drain line
to an open drain or other suitable disposal point.
FIGURE 4

Condensate

Drain Information*

25-1/2 ("B" Chassis)
32-1/4 ("C" Chassis)

The UL rating plate located on the side panel on the unit
contains the model number, type of gas, gas input rating,
and other important information.

FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Make certainthe unit isequipped to operate on the type of
gas available. Models designated as natural gas are to be
used with natural gas only. Models designated for use
with liquefied petroleum (LP) gas are shipped with
orifices sized for commercially pure propane gas. They
MUST not be used with butane or a mixture of butane and
propane unless properly sized orifices are installed by a
licensed LP installer.

3/4" (19,1mm)
Threaded Female

GAS PIPING

PVC Fitting
1 "

(25.4mm)

/
2" (5O.8mm)

The gas supply line MUST be of adequate size to handle the
Btu/hr requirements and length of the run for the unit being
installed. Determine the minimum pipe size for natural gas
from the table in FIGURE 5 or FIGURE 6. Base the length
of the run from the gas meter or source to the unit.
Gas Pipe Size
Btu ratings of all other gas appliances MUST be considered
for sizing of main gas line. Check gas line to installation for
compliance with local codes or, in the absence of local
codes, with the National Fuel Gas Code NFPA
54-2005/ANSI Z223.1-2005 or in Canada the National
Standard CAN/CGA B149-1 or current editions.

80-30-27

* Condensate

4. PRE-EXISTING

trap MUST be installed,

COMMON

VENT CHECK

If the installation of this new combination gas heat/electric
cool unit involves removing an existing gas-fired furnace
from a common vent system with other gas-fired
appliances (gas-fired hot water heater, etc.), the existing
vent system must be checked and inspected by a qualified
technician. The qualified technician can determine if the
existing vent system will properly vent the flue products of
the remaining gas-fired appliances. In many cases, the
existing vent system may be oversized for the remaining
appliances.

FIGURE 5

Pipe Length
(includes
Fittings)

Gas Pipe Size, Length and Btu/hr Capacity
for Schedule 40 Iron Pipe/English/
NATURAL GAS
Btu/hr

(in thousands)

3/4"

11/4"

20'

190

350

730

11/2"
1,100

2,100

40'

130

245

500

760

1,450

60'

105

195

400

610

1,150

LP GAS
Pipe Length
(includes
Fittings)

Btu/hr (in thousands)
3/4"

11/4"

11/2"

20'

189

1/2"

393

732

1,496

2,299

40'

129

267

504

1,039

1,559

60'

103

217

409

834

1,275

171

FIGURE 6

Gas Pipe Size, Length and Btu/hr Capacity
for Schedule 40 Iron Pipe (Metric)

UNIT OPERATION AND COMPONENT

NATURAL GAS
Pipe Length
(includes
Fittings)

Failure to follow this caution may result in misaligned
burners, flame rollout and or unit damage.
Overtightening assembly may cause damage to the gas
valve and/or wirin_land may misali_lnthe burners.

kW**
3/4"

6.1m

103

12.2m

18.3m

11/4 "

11/2"

214

322

615

147

223

425

117

179

337

6. Use a wrench on gas valve when making connections
to prevent gas valve from turning. Do NOT use a pipe
wrench on the gas valve body.

LP GAS
Pipe Length
(includes
Fittings)

7. Provide a t/8 inch (3mm) National Pipe Thread (NPT)
plug for test gauge connection immediately upstream of
the gas supply connection to the furnace if none is
supplied with the gas valve of unit.

kW**
1/2"

3/4"

11/4 "

11/2 "

6.1m

115

1"
215

438

674

12.2m

148

305

457

18.3m

120

244

374

**kW (Ki!owatts) is the metric equivalent

DAMAGE HAZARD

8. Install a manual shutoff valve and tighten all joints
securely.

of Btu/hr.

LEAK CHECK/PRESSURE
PIPING

PIPING AT UNIT

TESTING OF GAS SUPPLY

Connections
NOTE: The rules listed apply to natural and LP gas pipe
installations.
1. If installation is for LP gas, have LP gas installer use
TWO-STAGE
REGULATION
and
make
all
connections from storage tank to unit.
2. Use black iron or steel pipe and fittings or other pipe
approved by local code.
3. If copper tubing is used, it MUST comply with limitation
set in Fuel Gas Code.
NOTE: If a flexible gas connector is used, it MUST be
acceptable to local authority. Connector MUST NOT be
used inside the furnace or be secured or supported by the
furnace or ductwork. Do not use a connector which has
previously serviced another gas appliance. Always use a
new listed connector.

FIRE OR EXPLOSION

HAZARD

Failure to follow the safety warnings could result in personal injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for
the detection of leaks to check all connections.

The unit and its equipment shutoff valve must be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess
of .5 psi (3.5kPa).
The unit must be isolated from the gas supply piping system
by closing the equipment shut off valve during any pressure
testing of the gas supply piping system at test pressures
equal to or less than .5 psi (3.5 kPa).
ORIFICES

Failure to do so could result in personal injury, death
and/or property damage.
Gas connector MUST be properly installed and can NOT
be used inside the furnace.
4. Use pipe joint compound on external (male) threads
ONLY. Joint compound MUST be resistant to any
chemical action of LP gases.
Do NOT put pipe
compound on last 2 threads of pipe.
5. Use ground joint unions and install a drip leg no less
than 3 inches (76 mm) long to trap dirt and moisture
before it can enter gas valve.

TABLE 1 & 2: Equivalent

FIRE OR EXPLOSION

Orifice Sizes
Orifice sizes MUST be matched to the heating value of the
gas (see TABLE 1 & 2). Check with your gas supplier and
the National Fuel Gas Code ANSI Z223.1.
NOTE: An LP Conversion Kit MUST be used for conversion
to LP gas.
NOTE: For elevations above 2000 feet (610 meters), the
Btu input rating MUST be reduced by 4% for each 1000 feet
(305 meters) above sea level, unless the gas supplier's
Btu!ft 3 content has already been adjusted for altitude.
Check Table 1 & 2 for the proper orifice sizes.

Orifice Sizes at High Altitudes

Table1

NATURALGASORIFICESIZING
MEANELEVATIONFEETABOVESEALEVEL
0 to 2000

NominalHeatingSize
All Sizes

181

Orifice
Drill #
44

Kit
Number
1173863

2001to
4000

4001to
5000

5001 to
6000

6001to
7000

7001to
8000

8001to
9000

9001 to
10000

Orifice
Drill #
45

Orifice
Drill #
46

Orifice
Drill #
47

Orifice
Drill #
48

Orifice
Drill #
49

NOTE:

The orifice

sizes

above

sea level.

If converting

330732-401,
Btu/ft3., and

in the chart

above derate

from

the input rate at 4% per 1000 feet above

LP gas to Natural

Gas

at altitudes

exceeding

sea level for altitudes

2000

feet

above

exceeding

sea level,

use

2000 feet

part number

plus the required orifice size # shown in Table 1. Natural Gas data is based on 0.60 specific gravity, a heating value of 1030
3.5" W.C. manifold
pressure.
For fuels with different
specific
gravity, consult
the National
Fuel Gas Code NFPA

54-2005/ANSI

Z223.1-2005

or National

Standard

of Canada,

Table 2

Natural

Gas and Propane

Installation

Code

CSA B149.1-05.

LP GAS ORIFICE SIZING
MEAN ELEVATION FEET ABOVE SEA LEVEL
0 to 2000

Nominal Heating
Size

Orifice
Drill #

All Sizes

NOTE:
above

The orifice
sea level.

sizes

2001 to 4000

Kit
Number

Orifice
Drill #

1173857
in the chart

Kit
Number

Orifice
Drill #

1173857

above derate

Kit
Number

gravity,

a heating

consult the National Fuel Gas Code
Installation
Code CSA B149.1-05.

Changing Orifices

ELECTRICAL
HAZARD

FIRE AND/OR

Orifice
Drill #

1173859

9001 to 10,000

Kit
Number

Orifice
Drill #

1173859

sea level for altitudes

NFPA

Z223.1-2005

Removing

1173861

exceeding

and 10.0" W.C. manifold

54-2005/ANSI

Kit
Number

value of 2500 Btu/ft3.,

FIGURE 7

SHOCK,

7001 to 9000

the input rate at 4% per 1000 feet above

LP Gas data is based on 1.52 specific

fuels with different specific gravity,
Canada,
Natural Gas and Propane

4001 to 7000

2000 feet

pressure.

or National

Standard

For
of

NOx Baffles

EXPLOSION

Failure to follow this warning could result in personal
injury, death and/or property damage.
Shut off electric power at unit disconnect or service
panel and shut off gas at manual shut off valve before
beginning the following procedure.
Changing
technician.

orifices

requires

qualified

service
25-22-46a

1. Shut OFF gas at manual shut off valve.
2. Shut OFF electric power at unit disconnect or service
panel. If unit is still running, allow 3 minutes after gas
shut off before turning off power.
3. Disconnect the wires from the gas valve, sparker, and
flame sensor.

7. Remove the orifices from the manifold with
end or socket wrench.

6. If unit has v-shaped NOx baffles installed in the firing
tubes, they must be removed when converting to LR
Some baffles may be attached by screws. Replace
screws after removing NOx baffles (figure 7).

CARBON MONOXIDE HAZARD.
Failure to follow this warning could result in personal injury death and/or property damage.
NOx baffles for use with Natural Gas units ONLY. If
LP Gas is required, NOx inserts must be removed.

box

8. Check to be sure that the size of each orifice is correct
for the Btu input desired.
FIGURE 8

4. Remove the four screws holding the manifold to the
manifold brackets.
5. Carefully remove the manifold with the gas valve
attached.

a 7/t6"

Manifold/Orifice

Measurement

Measure 13/16 " from face of orifice

_ifold

pipe.

9. Install the correct orifices. Gauge the size of the orifices
with a new twist drill bit of the correct size.
Make sure that the orifices go in straight so that they
form a right angle (90 °) to the manifold pipe.
Tighten the orifices so that there is a ] 3/t6" distance
between the faces of the orifices to the back of the
manifold pipe.
Measure the distance with a set of calipers. If you do not
have a calipers, you can use an adjustable wrench and
measure between the face of the jaws.
10. Reassemble
in reverse order.

191

6. ELECTRICAL

ELECTRICAL

WIRING

SHOCK

HAZARD.

Failure to follow this warning could result in personal
injury, death, and/or property damage.
The unit cabinet must have an uninterrupted,
unbroken electrical ground to minimize the possibility
of serious injury if an electrical fault should occur.
This ground may consist of an electrical
wire
connected to the unit ground lug in the control
compartment,
or conduit approved for electrical
ground when installed in accordance with National
Electric Code (NEC) NFPA 70, National Fuel Gas Code
NFPA 54-2005/ANSI Z223.1-2005 and local electrical
codes. In Canada, follow Canadian Electrical Code
CSA (Canadian Standards Association) C22.1 and
local electrical codes.

REDUCED EQUIPMENT

LIFE HAZARD

Failure to follow these cautions could result in damage
to the unit being installed.
1) Make all electrical connections in accordance with
National Electric code (NEC) NFPA 70, National Fuel Gas
Code NFPA 54-2005/ANSI
Z223.1-2005
and local
electrical codes governing such wiring. In Canada, all
electrical connections must be in accordance with CSA
standard C22.1, Canadian Electrical Code Part 1, and
applicable local codes. Refer to unit wiring diagram.
2) Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3) Be sure that high-voltage
power to unit is within
operating voltage range indicated on unit rating plate.
4) Do not damage internal components when drilling
through any panel to mount electrical hardware,
conduit, etc.
Consult local power company for
correction of improper voltage and/or phase imbalance.

For access, remove the burner access panel. See Figure 1
for access panel location. Wiring MUST be protected from
possible mechanical damage.
Disconnect

Switch

The unit must have separate electrical service with a
field-supplied, waterproof, disconnect switch mounted at,
orwithin sight from, the unit. Refer tothe unit rating plate for
maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.
Ground Connections
Do NOT complete line voltage connections until unit is
permanently grounded. All line voltage connections and the
ground connection MUST be made with copper wire.
A ground lug is installed in the control box area for the
ground connection. Use a copper conductor of the
appropriate size from the unit to a grounded connection in
the electrical service panel or a properly driven and
electrically grounded ground rod. See warning above.

11ol

Line Voltage Wiring
Connections for line voltage are made in the unit control box
area. Refer to wiring diagram located on the Burner Access
panel. For access, remove the burner access panel.
1. Run the high voltage (L1, L2) and ground leads into the
control box.
2. Connect ground lead to chassis ground connection.
3. Connect L1 to pressure lug connection 11 of the
compressor contactor.
4. Connect L2 to pressure lug connection 23 of the
compressor contactor.
Thermostat

/ Low Voltage Wiring

Location of the thermostat has an important effect on home
comfort. FOLLOW THE THERMOSTAT INSTRUCTION
MANUAL FOR CORRECT LOCATION, MOUNTING, AND
WIRING.
Atwo-stage dual fuel-compatible thermostat is required for
proper operation. Thermostat should have the following
terminals: "R', "W2", "YI", "Y2", "G'. and "O". Some
electronic thermostats use low voltage from the unit for
power for temperature display and programming. These
electronic thermostats will have a"C" terminal. The outdoor
unit has color-coded wires for easy connection. Using wire
nuts, follow figure 9 for proper connections:
FIGURE 9

Thermostat

Connections

=1_ Red
White

White
Yellow
Red
Pink

Y_ _

@..1_

Green

..1_- Green

Orange

..1_- Brown

..IP,- Orange

..1_-

..IP-

Typical
Mechanical
Thermostat
Subbase

THERMOSTAT

Yellow
Pink

Typical
Electronic
Thermostat
Subbase

HEAT ANTICIPATOR

Some thermostats have an adjustable heat anticipator. The
heat anticipator prevents temperature overshoot in heating
mode. If the heat doesn't turn off until the set point
temperature on the thermostat is exceeded, then the
anticipator setting is too low. If the heat turns off before the
thermostat reaches the set point temperature on the
thermostat, then the anticipator setting is too high. Follow
the thermostat instruction manual for proper adjustment of
the heat anticipator.
BALANCE POINT TEMPERATURES
The dual fuel models require a dual fuel thermostat for
proper operation. A dual fuel thermostat allows a balance
point temperature to be programmed into the thermostat
and has an outdoor temperature sensor that must be
installed outside.
Follow the thermostat installation
instructions for proper location of outdoor sensor. The dual
fuel unit operates either in heat pump mode or gas heat
mode, but NEVER both modes at the same time.

There are 2 differentbalancepoint temperaturesto heat may be met using the heat pump mode. If the outdoor
considerwhenprogramming
the thermostat:Economic temperature is below the load balance point temperature,
andLoad.
the gas heat mode is required to meet the building load.
Economic Balance Point Temperature
The economic balance point temperature is the outdoor
temperature where the utility cost of running in heat pump
mode is the same as running in gas heat mode.
If the
outdoor temperature is above the economic balance point
temperature, then the heat pump mode will be less costly. If
the outdoor temperature is below the economic balance
point temperature, then the gas heat mode will be less
costly. The economic balance point temperature is affected
by electrical utility cost, gas utility cost, and model size.
Knowing the utility cost of electricity and gas, the economic
balance point temperature can be determined using Figure
10.

To find the load balance point temperature, a load
calculation must be performed on the building. The load
calculation must be performed at 3 different outdoor
temperatures and graphed on Figure 11. Plot the three
load calculations at their appropriate outdoor temperatures
and draw a smooth line through the 3 points. NOTE: The
line connecting the 3 points may not be a straight line.
Locate where the building load line intersects the
appropriate model capacity line. This is the load balance
)oint temperature.
Figure

Load

Balance
-_--

Point

Temperature

PDX324040
PDX330060

Figure10 - EconomicBalancePointTemperatureChart
EconomicBalancePointTemperature(°F)
Cost
PDX324 PDX330 PDX336 PDX342 PDX348 PDX360
Ratio*
040
060
080
080
120
120
0.075
0
0
0
0
0
2
0.100

0.125
0.1375

38
45

29
35

32
39

37
45

29
36

33
38

0.150

* CostRatioisthe electricalcost, in$ perkilowatt-hour,dividedbythe gas
cost, in$ per therm.

Example: A PDX342080 is installed in a residence where
the electrical utility cost is 9 cents per kilowatt-hour and the
gas cost is 90 cents per therm. Proceed as follows:

PDX336080
-x-

PDX348120
-o-

70000

...............................................................................................................................................

60000

PDX348120

50000

PDX342080

PDX336080

_. 40000
Ix:

PDX330060

30000
_

20000 :

Some natural gas suppliers sell gas by every 1O0 cubic feet
(CCF) of gas. For an approximate gas cost per therm,
multiply CCF by 97. Example: A price of $.01 per CCF is
approximately equivalent to $.97 per therm.
Note: The 97 multiplier is based on a typical heating
value of 1030 Btu per cubic foot of natural gas. For a
more accurate cost, contact your gas supplier to obtain
the Btu content of natural gas in your area. Divide
100,000 by the actual Btu content per cubic foot to obtain
the correct multiplier.
If the economic balance point is chosen, keep in mind that
utility rates fluctuate substantially over time.
Review
monthly utility bills and re-calculate economic balance
points as necessary.
Load Balance

Point Temperature

The load balance point temperature is the outdoor
temperature at which the load may be met using either heat
pump mode or gas heat mode. Ifthe outdoor temperature is
above the load balance point temperature, the demand for

PDN324040

10000

0
10

Some utilities have a sliding cost based on consumption. In
this case, take the total bill and divide by the total
consumption to determine the average utility cost.

PDX360120

1. $.09/$.90 = .1
2. Using Figure 10, a PDX342080 with a .1 cost ratio =>
Economic Balance Point Temperature = 18°F

PDX342080

20
Outdoor

Air Temperature

(°F)

No matter what the balance point temperature is set at, the
unit will automatically switch to gas heat if the heat pump is
not able to meet the demand of the house. Calculating the
load balance point temperature and programming it into the
thermostat will minimize temperature fluctuations in the
house.
Final Electrical

Check

1. Make a final wiring check to be sure system is correctly
wired. Inspect field installed wiring and the routing to
ensure that rubbing or chafing due to vibration will not
occur.
NOTE: Wiring MUST be installed so it is protected from
possible mechanical damage.

7. DUCTWORK
Ductwork

permitted. If flexible connectors are used, they should be
protected from potential mechanical damage such as
punctures and tears.

Sizing

The maximum recommended velocity in trunk ducts is 1000
feet per minute. The maximum recommended velocity in
branch ducts is 800 feet per minute.
Ductwork sizing affects the discharge temperature, airflow
velocity, and efficiency of the system. Be sure to properly
size ductwork to the capacity of the unit and to the airflow
requirements of the conditioned space. Failure to properly
size ductwork can result in inadequate airflow and poor
efficiency. Undersized ductwork may result in tripped limit
controls and premature failure of compressors, motors and
other components.
Ductwork

Insulation

Ductwork installed outdoors must have a minimum 2" thick
fiberglass "wrap" insulation and a weatherproof vapor
barrier installed around it. The insulation and vapor barrier
must be protected against potential damage. Caulking,
flashing, and other means of providing a permanent
weather seal must be used.
Ductwork

NOTE: When connecting the supply and return plenums to
the unit, make sure that the plenums are sealed against the
side casing of the unit and do not interfere with removal of
the top of the unit.
FILTERS
All return air MUST pass through a filter before entering the
unit. An electronic air cleaner, optional filter racks, or other
accessible filter arrangement must be installed in the return
air ductwork. Minimum recommended filter sizes are listed
in FIGURE 11 and are based on maximum face velocities of
300 ft/min for disposable filters and 600 ft/min for washable
(high velocity) filters. See figure 10 for filter sizes.

REDUCED

EQUIPMENT

LIFE

HAZARD

Failure to follow this caution may result in improper
unit operation,

Connections

The use of flexible, non-combustible connectors between
main trunk ducts and supply and return air plenums is
Figure 11

Filter Sizes

Disposable Filters

PDX324040K....
PDX330060K....
PDX336080K....
PDX342080K....
PDX348120K....
PDX360120K....

Do not operate the unit without

Washable Filters'

Nominal Size

MinimumArea

Nominal Size

MinimumArea

(qty x w x d)
1 x 20" x 20"
1 x 20" x 24"
2 x 15"x 20"
2 x 18"x 20"
2 x 20" x 24"
2 x 20" x 24"

(sq. inches)
384
480
576
672
854
960

(qty x w x d)
1 x 10" x 20"
1 x 12" x 20"
1 x 15" x 20"
1 x 18" x 20"
1 x 20" x 24"
1 x 20" x 24"

(sq. inches)
192
240
288
336
427
480

Washablefilter size based on an allowableface velocity of 600 ft/min. Refer to
filter manufacturer'sspecificationsfor allowableface velocity and required filter area.

a filter,

8. AIRFLOW

ADJUSTMENT
PDX3 SERIES HEATING

CHART
External

Cooling
M0del

Tons

PDX32404OK....

(BNih0

PDX33O06OK....

PDF342080K....

35 65

120000

NA No, Allowed_rheating

35 65

80000

PDX360120K....

35 65

80000

PDX348120K....

35 65

60000

Speed

Range(_F)

40000

PDX336080K....

Heatinglnpu_ Heating Rise

35 65

120000

35 65

.2"

Heating

Tap

OFM

125/

951

Rise(°F/

Heating

Static Pressure

Heating

(in H2O )
.5"

Heating

OFM

Rise(°F)

OFM

Rise(°F/

OFM

Rise(°F)

/218

/I94

1170

914

883

858

869

842

809

768

2
I

7II
661

42
45

655
4(8

45
62

623
334

48
NA

5
4

1255
1106

35
40

/227
I080

36
41

/291
I048

958

923

2
I

789
(b4

56
bg

747
/08

5g
63

4
3

1630
1276

36
46

/588
/242

37
48

2
1

1026
8(6

58
NA

994
84I

1569

/537

1481

1302

2
1

Heating
OFM

.T'

Heating

.8"

Heat}ng

Heating

Rise(°F)

CFM

Rise(°F)

CFM

Rise(_F)

CFM

Rise(°F)

lt3g

tt0O

/063

988

8II

775

733

697

736

684

650

599

564
262

53
NA

529
219

56
NA

48/
/96

62
NA

43/
NA

NA
NA

392
NA

NA
NA

37
42

1164
1017

38
44

1138
992

39
45

1II2
g54

40
47

/077
924

4I
48

/027
88/

43
50

894

857

828

786

750

712

7/4
6(I

62
NA

668
618

NA
NA

630
b84

NA
NA

582
524

NA
NA

542
494

NA
NA

495
443

NA
NA

/526
/209

39
49

1477
1179

40
50

1415
1150

42
52

/354
1II7

44
53

/287
/086

46
55

/216
1045

49
57

6g
NA

949
(94

62
NA

9/3
(b6

65
NA

87I
694

NA
NA

841
65/

NA
NA

793
598

NA
NA

735
543

NA
NA

150g

1463

1423

I389

/353

1317

/448

/412

1374

1336

/298

/263

/226

/260

/21g

1179

1138

1103

/06g

/015

1170
1028

51
b6

II29
969

52
61

I088
924

54
64

1050
88I

56
NA

1007
838

59
NA

g63
/89

62
NA

912
/3I

65
NA

866
660

NA
NA

2103

2051

2001

1942

1878

I809

/723

1632

183I

1797

1763

1732

1696

/661

1621

/559

1680

/650

/614

1578

1544

1507

/470

/427

2
1

1304
11/3

NA
NA

I256
112/

NA
NA

I216
1065

NA
NA

1167
I02/

NA
NA

1126
983

NA
NA

/077
92(

NA
NA

I026
88I

NA
NA

979
82/

NA
NA

5
4

2188
209I

41
43

2140
2056

42
43

2096
2023

42
44

2039
1987

44
45

1974
1935

45
46

/905
/878

47
47

/827
1811

49
49

/745
/729

51
5/

1839

/807

/772

1735

1702

1667

/629

/590

2
1

1393
1300

64
NA

I356
1263

NA
NA

1313
1214

NA
NA

1280
II69

NA
NA

1226
111/

NA
NA

/I84
/g/3

NA
NA

II30
1026

NA
NA

I086
9/b

NA
NA

speed

CIRCULATING AIR BLOWER SPEEDS
Fi,qure 12

Factory-Shipped

Blower Tap Connections

Factory-Shipped

_4odel
_DX324040K
_DX33006gK
_DX336080K
_DX34208gK
_DX348120K
_DX360120K

....
....
....
....
....
....

Cooling
Tons
2
2.5
3
3.5
4
5

Heating Input
(Btu/hr)
40000
60000
80000
80000
120000
120000

Blower

Heating
Range
35 35 35 35 35 35 -

Rise
(°F)
65
65
65
65
65
65

Tap

Connections

Heating
Speed Tap
(Red)
2
5
4
5
4
3

High Stage
Cooling Speed
Tap (Black)
3
4
3
4
3
4

Low Stage
Cooling Speed
Tap (Violet)
I
I
I
2
1
2

If the same speed is required for gas heating and high stage
cooling the following procedure must be used:
ELECTRICAL

SHOCK HAZARD.

Failure to follow this warning could result in personal
injury, death and/or property damage.
Turn off electric power supply at disconnect switch or
service panel before removing access or service panels
from unit.

Verify that the proper blower speeds for heating and cooling
are selected on the blower motor by removing the blower
access panel and inspecting the blower motor. The motor
has up to 5 speeds numbered "1 ", "2", "3", "4", and "5". The
wires for the speed selection are as follows:
Red

Black _

Gas Heating
High Stage Cooling / High Stage Heat
Pump Heating

Violet miD" Low Stage Cooling / Low Stage Heat
Pump Heating
Using the same speed for Gas Heating and Cooling.

1. Set Red wire on proper speed selection on blower
motor.
2. Remove Black wire from "HI" on Blower Interface
Board. Tape end of Black lead using electrical tape.
3. Jumper the Red wire to both the "Heat" terminal and
"HI" terminal on the Blower Interface Board.
If the same speed is required for gas heating and low stage
cooling, the following procedure must be used:
1. Set Red wire on proper speed selection on blower
motor.
2. Remove Violet wire from "LO" on Blower Interface
Board. Tape end of Violet lead using electrical tape.
3. Jumper the Red wire to both the "Heat" terminal and the
"LO" terminal on the Blower Interface Board.

CONTINUOUS
FANOPERATION
Figure i3
I
Honeywell Gas Valve
Continuous
fan speedoperatesat the lowstagecooling
RegulatorAdjustment
speedforallmodels.
UnderCa
Outlet
HONEYWELL
Pressure
COOLING
Tap
1.TurnelectricpowerOFF
1/8NPT
©
2. SetthermostatHeat-Coolselectto COOL.
3.Adjustthermostat
settingto belowroomtemperature.
OUTLET
4. TurnpowerON,for approximately
oneminute,then
Inlet
OFF.Duringpowerapplication
checkthefollowing:
Pressure
a. Contactor
- ContactsClosing
Tap 1/8NPT
b.Compressor
- ON
c. Condenser
fan motor- ON
25-24-98a
d. Circulating
Air Blower- ON0 seconddelay
5.TurnpowerOFEcheckthefollowing:
GAS PRESSURES
a. Contactor
contactsopening.
1. Do NOT allow gas supply pressure to fall below the
b. Compressor
- OFF
listed minimums. Doing so will decrease input to
c. Condenser
fanmotor- OFF
furnace. Refer to Figure 14 for gas supply pressures.
d. Circulating
blower- OFFafter90seconddelayon
2.
Gas input MUST NOT exceed rated input shown on
allmodels.
/

rating plate.

9. START-UP

3. Do NOT allow pressures to exceed the maximum limits
as listed in Figure 14.

PROCEDURES

Figure
FIRE OR EXPLOSION

Gas Pressures

HAZARD
Natural Gas

Failure to follow this warning could result in personal
injury, death and/or property damage.
Do NOT attempt to light the burner with a match or
flame of any kind.

CHECK BEFORE STARTING
1. Check that the blower motor speed terminal block is
running the correct heating and cooling speeds.
2. Check to see that clean, properly sized air filters are
installed.
3. Replace all service access panels.

FIRE OR EXPLOSION

Minimum
Inlet

4.5"W.C. (1120 Pa)

11" W.C. (2740 Pa)

Recommended
Inlet

7" W.C. (1740 Pa)

11" W.C. (2740 Pa)

Maximum
Inlet

13" W.C. (3230 Pa)

Manifold
Pressure

3.5" W.C. (870 Pa)

10" W.C. (2490 Pa)

Manifold Pressure Adjustment
Manifold pressures are listed in Figure 15. Check manifold
pressure using the following procedure.
1. With gas OFE Connect U-Tube manometer to tapped
opening on gas valve. Use manometer with a 0 to 12
inches water column range.

HAZARD.

Failure to follow this warning
personal injury and/or death.

LP Gas

could

Turn OFF gas at shut off before connecting
manometer.

result

Figure 15
Gas Type

U-tube

Manifold Pressure

Settings

Manifold Pressure

Natural

3.5 Inches Water Column (870 Pa)

Propane

10 Inches Water Column (2490 Pa)

2. Turn gas ON and remove adjustment screw cover on
gas valve. Turn counterclockwise to decrease pressure
and clockwise to increase.
NOTE: Adjustment screw cover MUST be placed on gas
valve before reading manifold pressure and operating
furnace.

1141

FIRE

AND/OR

EXPLOSION

HAZARD

FIRE AND/OR EXPLOSION

Failure to follow this warning could result in personal injury, death and/or property damage.
Do NOT adjust manifold pressure more than + 0.3
inches water column to obtain rated input.

3. Set pressure to value shown in Figure 14, _+0.3 inches
water column (_+0.07kPa). Pressure is also listed on
furnace rating plate. In NO case should final manifold
pressure vary more than _+0.3 inches water column
(_+0.07kPa).
Check the unit's operation as outlined in the following
instructions. If any unusual sparking, odors or unusual
noises
are encountered,
shut off electric
power
immediately. Recheck for wiring errors, or obstructions in or
near blower motors.
1. Set thermostat Heat-Cool selector to OFE
2. Set thermostat fan switch to AUTO.

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

Do NOT attempt to light the burner with a match or
flame of any kind.
GAS HEATING INPUT RATE CHECK
The gas input to the unit is determined by measuring
the gas flow at the meter. Measuring gas flow at the
meter is recommended for natural gas units.
To
measure the heating input, perform the following
steps:
1.

Turn off all other gas appliances that use the same
meter.

Turn off gas supply to unit and attach manifold
pressure gauge as instructed in the "Manifold
Pressure Adjustment" section.

With gas ON to the unit and the unit operating, record
the number of seconds for the gas meter dial to make
one revolution.

Divide number of seconds in Step 3 into 3600
(number of seconds in 1 hour).

Multiply result of Step 4 by the number of cubic feet
shown for one revolution of the meter dial to obtain the
cubic feet of gas flow per hour.

3. Turn electric power ON. Nothing should start running.
4. Turn manual gas valve ON.
5. Turn gas control valve ON.
6. Set thermostat fan switch to ON.
7. Reset thermostat fan switch to AUTO.
GAS HEATING START-UP

PROCEDURE

1. Adjust thermostat setting above room temperature and
set thermostat
selector
to EMERGENCY
OR
AUXILIARY HEAT. The combustion air blower should
come ON.
2. The combustion air blower will run for 15 seconds to
purge the combustion chamber.
3. After the 15 second purge, the combustion air blower
will remain on. The sparker will turn on to ignite the gas.
Make sure the gas valve is in the "ON" position. (Refer
to Figure 14 and the instructions label located on
Burner Access Panel of unit.
NOTE: On a call for heat the sparker will remain energized
for 7 seconds or until a flame is detected by the flame
sensor. It may take several ignition attempts to purge the air
out of the gas lines at initial start-up of the unit.
4.30 seconds after the burners
blower will begin to run.

light, the circulating

HAZARD

Multiply result of Step 5 by Btu heating value of gas to
obtain total measured input in Btu/hr. Compare this
with the heating value shown in figure 14. Consult
with local gas supplier ifthe heating value of gas is not
known.

Example: Assume that the size of the meter dial is 1 ft 3,one
revolution takes 44 seconds, and the heating value of the
gas is 1020 Btu/ft 3, Proceed as follows:
1.38 sec. To complete 1 revolution
2.3600/38 = 94.7
3.94.7 x 1 = 94.7
4.94.7 x 1020 = 96,632 Btu!hr
For this example, the nameplate input is 100,000 Btu/hr, so
only a minor change in manifold pressure is required. In no
case should the final manifold pressure vary more than
_+0.3" water column from the values in figure 15.
TEMPERATURE

RISE CHECK

NOTE: Air temperature rise is the temperature difference
between supply and return air. With a properly designed
distribution system, the proper amount of temperature rise

willnormallybeobtained
whentheunitisoperating
atrated 10. OPERATION
inputwiththerecommended
blowerspeed.
1. Thetemperature
risemustbewithinthespecifications
marked
ontheunitrating
plate.
To check the temperature rise through the unit, place thermometers in the supply and return air ducts as close to the
unit as possible.
Open ALL registers and duct dampers. Operate unit AT
LEAST 15 minutes before taking readings.

If the correct amount of temperature rise is not obtained
when operating on the recommended blower speed, it may
be necessary to change the blower speed. A faster blower
speed will decrease the temperature rise. A slower blower
speed will increase the temperature rise.
NOTE: The blower speed MUST be set to give the correct
air temperature rise through the furnace as marked on the
rating plate. See Figure 12 for more information.
2. After 15 minutes of operation check the limit control
function by blocking the
return air grille(s).
After several minutes the main burners and pilot should
go OFE The circulating air blower should continue to
run.
Remove air restrictions. Pilot and main burners should
relight after a cool down period of a few minutes.
3, Adjust the thermostat setting below room temperature.
Main burners and combustion air blower should go
OFF,
The circulating air blower should continue to run for 60,
100, 140 or 180 seconds. This time is adjustable. See
Figure 16 for more information.
4. Set thermostat Heat-Cool selector to OFF,
FAN CONTROL CHECK
Figure 16
IGNITION

Fan Delay DIP Switch

CONTROL BOARD EAT

COOL
SEC,HEAT
ON DELAY;
DELAY:

0 SEC.
30

OFF DELAY SELECTION

100180_ 14060_;
IlEAl
0FF-DEL)*'f

q00180
J_

Settings
Jl

_G0140_; '00180_1 60140_

HEAT
OFF rJELA_

flEAT
OFF DELAY

100188_

140_6(}

HEAT
OFF DELAY

The Fan Control has adjustable settings for the circulating
air blower to delay it "ON" and "OFF".
1. The Fan Control has a fixed "ON" delay of 30 seconds,
and a field adjustable "OFF" delay of 60, 100, 140 and
180 seconds. The "OFF" delay is factory set at 140
seconds.
Refer to NO TAG for proper DIP switch settings.
2. Operate the furnace and ensure that the blower turns
ON and OFF at the appropriate time to provide the
desired comfort level.

ELECTRICAL

SHOCK HAZARD.

Cooling Operation
These units utilize a 2 stage indoor thermostat. With a first
stage call for cooling (Y1), the indoor fan (low stage)
energizes immediately where as the contactor energizes
after a 5 minute time delay (incase of an initial start up)
starting the compressor (low stage) and the outdoor fan
motor. If the low stage operation cannot satisfy the cooling
demand, the second stage cooling (Y2) energizes
switching the compressor into high stage cooling through
energizing an internal solenoid valve inside the scroll
compressor and switching the indoor fan into high stage.
When second stage cooling is satisfied, Y2 de-energizes
switching the compressor and the indoor fan into low stage
cooling. When the low stage cooling demand is met, Y1
de-energizes shutting the compressor, indoor fan and the
outdoor fan.
Heating Operation
With a first stage call for heating (Y1), the indoor fan (low
stage) energizes immediately whereas the contactor
energizes after a 5 minute time delay (incase of an initial
start up) starting the compressor (low stage) and the
outdoor fan motor. If the low stage operation cannot satisfy
the heating demand, the second stage heating (Y2)
energizes switching the compressor into high stage heating
through energizing an internal solenoid valve inside the
scroll compressor and switching the indoor fan into high
stage. The auxiliary gas heat is controlled by a third stage
(W2). If the auxiliary gas heat is energized, the dual fuel
thermostat will deactivate both the low stage heat pump
(Y1) and high stage heat pump (Y2) operation.
Scroll Recycle Delay timer
The defrost board is equipped with a recycle delay timer
which will delay the start of the compressor for 5 minutes in
the event of a power interruption. This sequences power
throughout the system and prevents possible reverse
rotation of the scroll compressor. The output of the timer
controls the compressor contactor via a normally open
contact of K3 (T2). The timer starts the delay cycle when the
compressor is turned off by removal of "Y." If application of
"Y" occurs before the timer has expired, the compressor
contactor will not be energized until the timer has expired.

CONTINUOUS
FANOPERATION
Withthe continuousIndoorfan optionselectedon the
thermostat,
G iscontinuously
energized.
Thesystemruns
lowstage(Y1)airflowforcontinuous
fanoperation.
DefrostMode
Ona callfor defrost:
Whenthedefrostsensorclosesintheheatingmode,there
isa 30,60,90or 120minutedelaybeforethedefrostmode
begins. This delayis selectedby the positionof the
dipswitches
onthe defrostboard. Defrostintervaltiming
can be configuredby selectionswitch1 and 2 on the
dipswitchperthefollowingtable:SeeFigure17.
Switch

Switch

Figure i7

Defrost Board & Dip Switches

Time

OFF

30 Minutes

OFF

60 Minutes

OFF

90 Minutes

120 Minutes

Defrost

Board

NOTES:
1.The backup defrost terminate
minutes.

time is fixed at 10
Dip Switch

2. The compressor recycle delay timer is 5 minutes.
3. The power interrupt response is minimum 17 msec. to
maximum 35 msec.
4. Quite shift compressor recycle delay is 30 seconds.
In normal defrost mode, the following sequence will occur
after the set delay:
1. Condenser fan off.
2. Reversing valve energized to cooling and auxiliary gas
heat (W2) is energized.
3. After defrost sensor opens or a maximum of 10
minutes; the condenser fan is energized (after 20
seconds) and the reversing valve is de-energized to
the heat mode. The call for heating is completed bythe
auxiliary gas heat. ON the next call for heat, the heat
pump will be used for heat, provided the outdoor
temperature is above the balance point.
4. Should the system indoor thermostat be satisfied
during the defrost cycle, the control will de-energize the
reversing valve and auxiliary heat outputs and "hold"
the defrost timer until the next call for heat, at which time
the defrost cycle will be completed.
Service testing: the pins marked "speed up" when
momentarilyshorted together (for 5 seconds) and released,
will defeat the 5 minutes recycle delay timer and allow the
compressor contactor to be immediately energized, thus
forcing a defrost cycle. Termination of this forced mode will
be by the defrost thermostat or the 10 minute backup timer,
provided the defrost thermostat was closed when the
defrost was "forces." If the defrost thermostat was not
closed, at the time of the "forced defrost," the defrost mode
will remain for 30 seconds and then terminate.

COMBUSTION/INDOOR

FAN CONTROL

All functions of the combustion and indoor blower are
controlled by the ignition control board and interface board.
On a call for auxiliary gas heat:
The ignition control energizes the combustion blower.
Once the combustion air proving switch closes, the ignition
sequence begins. The ignition control will sense when the
main operator of gas valve has been energized thereby
firing the burners and starting the "delay on" timing
sequence of the indoor blower.
NOTE: Ifthe control senses that one of the safety limits has
opened, the combustion and indoor fans will operate until
the limit resets.
On a call for heat pump heating and cooling:
The fan control board starts the indoor blower immediately.
Once the thermostat is satisfied, the fan control will operate
the blower for 90 additional seconds.

11. MAINTENANCE
MONTHLY MAINTENANCE
CHECKS

AND INSPECTION

Air Filters

REDUCED EQUIPMENT

LIFE HAZARD

Failure to follow this cautions may result in damage to
the unit being installed.
Do not operate the unit without a filter.

Inspect filters at least monthly and replace or clean as
required. Washable filters may be cleaned by soaking in
mild detergent and rinsing with cold water. Replace filters
with the arrows on the side pointing in the direction of air
flow. Dirty filters are the most common cause of inadequate
heating or cooling performance,
and of compressor
failures.
HEATING SEASON CHECKS

(MONTHLY)

Main Burner Flame
Flames should be stable and solid blue, (dust may cause
orange tips or they may have wisps of yellow, but they
MUST not have solid yellow tips). They should extend
directly into the heat exchanger tubes and the turbulators
should glow orange (after about five minutes of operation).
Main burner flame should be inspected monthly.
Figure18 L

NormalFlame

ELECTRICAL

SHOCK HAZARD.

Failure to follow this warning could result in personal
injury, and/or death.
Turn off electric power supply at disconnect switch or
service panel before removing any access or service
panel from unit.

The annual inspection should include cleaning as required
to ensure efficient operation of the unit. To simplify access,
remove all access panels and the top from the unit if
possible.
Condenser Fan Motor
Note: The condenser fan motor is permanently lubricated.
No further lubrication is required.
Do not attempt to
lubricate the condenser fan motor.
VENT ASSEMBLY

Turbulator will glow
orange when hot.

Flame should be
stable and solid
blue.

BURN HAZARD.
Failure to follow this caution may result in personal
injury or property damage.

Flue cover may be hot! Allow adequate time for flue
cover to cool.
Clean the surrounding area and the condenser and
evaporator coils. Use caution to avoid damage to coil fins.
BLOWER MOTOR ACCESS
Refer to Figure 19 for a view of blower
compartment.
1. Remove the blower access panel

Using a light and mirror (as required) inspect the inside of
the vent hood and the inlet air opening in the burner
compartment. Look for soot and severe rust or corrosion
and any obstructions due to leaves, spiderwebs, etc. Clean
as required.
COOLING SEASON CHECKS (MONTHLY)
Condenser Coil
Keep the condenser inlet and outlet area clean and free of
leaves, grass clippings or other debris. Grass should be
kept short in front of the condenser inlet. Shrubbery MUST
be trimmed back so it is no closer than 30 inches to unit.
Condensate Drain
Check for condensate drainage.
ANNUAL MAINTENANCE

Clean as required.

AND INSPECTION

motor and

2. Remove the three screws securing the blower motor
housing. If unit has a support bracket, remove the two
screws securing the bracket.
3. Remove the two red wires attached to the limit switch.
Motor removal and replacement
This method is required to replace or repair blower wheel,
blower housing, or any unreachable components behind
blower assembly.
1. Remove all screws around rim of unit top, (except
screws which are inaccessible because of proximity to
structure).
2. Raise unit top at corner of unit closest to blower at least
2" and place a sturdy brace at least 2" thick between top
and unit corner. A 2X4 piece of wood is ideal for this.
3. Disconnect all wires from housing and slide housing out
of unit. Reverse this process to reinstall.
Circulating Air Blower
Visually inspect the blower wheel for accumulations of dirt
or lint. Clean the compartment and the blower wheel. If
accumulation is excessive on blower wheel, or does not
easily remove, it will be necessary to remove the blower
assembly.

Note:The blowermotoris permanently
lubricated.No
furtherlubricationis required.Donotattemptto lubricate
theblowermotor.
Burners/ Heat Exchangers / Flue Gas Passages

10. Clean flue gas passages by using small brushes and a
vacuum cleaner. It may be necessary to fabricate
handle extensions for the brushes to reach the areas
that require cleaning. Reinspect after cleaning and
replace the heat exchanger if defective.

To inspect the burners, heat exchanger and interior flue gas
passages, use a light and small mirror on an extension
handle.

11. Reinstall parts and gaskets in reverse order. On direct
spark models check the spark gap. 1/8 inch is required
between the sparker electrodes.

Check the exterior of the heat exchanger and the interior
flue gas passages for any evidence of deterioration due to
corrosion, cracking or other causes. If signs of scaling or
sooting exist, remove the burners and clean the heat
exchanger, as required.

12. Turn gas on and check for leaks.

INSPECTION AND CLEANING OF BURNER
ASSEMBLY/HEAT EXCHANGERS/FLUE GAS
PASSAGES
For Qualified Service Technician

Only

13. Install all access panels, turn power on and check for
normal operation.
REFRIGERANT CIRCUIT
For Qualified Service Technician Only
Annually inspect all refrigerant tubing connections and the
unit base for oil accumulations.
Detecting oil generally
indicates a refrigerant leak.

See Figure 19 for identification of parts.
1. Disconnect electrical power to unit.

ENVIRONMENTAL

HAZARD.

2. Turn OFF gas at manual shut off valve.
3. Remove burner access panel.
4. Remove the vent assembly flue pipe.
5. Disconnect gas pipe at union.
6. Disconnect wires from gas valve, note connections.
7. Remove screws that secure the flame shield and
remove gas control valve, manifold and burners as an
assembly.
8. Remove collector box, injector plate, and restrictor
plate, including gaskets.
9. Hold the burner assembly vertically and lightly tap it
against a wood block. Clean also with a stiff brush.
Severe cases of lint clogging may require washing the
burners in hot water.

Failure to follow this warning could result in personal
injury, death and/or property damage.
System under pressure. Relieve pressure and recover
all refrigerant before system repair or final unit
disposal. Use all service ports and open all flow
control devices, including solenoid valves.
Federal regulations require that you do not vent
refrigerant to atmosphere. Recover during system
repair or final unit disposal

If oil is detected or if low cooling performance is suspected,
leak-test all refrigerant tubing using an electronic leak
detector, halide torch, or liquid-soap solution,

1191

R MOTE SPARK R UNIT

\
\

0
\
\
\

GAS VA}VE_

_SPARKER
SENSOR
"'

ROLLOUT SWITCH

1004
IFH AND SPEED SELECTOR LEADS_

"00
_PRIMAR

LIMIT SWITCH

RIGGING INSTRUCTIONS

10962_,,_-A

FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN PROPERTY DAMAGE,
BODILY INJURY OR DEATH.

/K WARNING
- ALL PANELS

MUST BE IN PLACE WHEN

RIGGING

AND LIFTING.

- HOOK RIGGING SHACKLES THROUGH
HOLES IN BASE RAIL, AS SHOWN IN DETAIL-A.
- USE SPREADER BARS, WHEN RIGGING,
TO PREVENT UNIT DAMAGE.
- BE SURE RIGGING AND SHACKLES ARE SUFFICIENT TO HANDLE WEIGHT LISTED BELOW.

DETAIL-A

fo
m,

BARS

o
:3

____

H'_EIGHT

-OR-

r.. ilillimiili .
LENGTH _,_

WIDTH
MAX, HEIGHT

MAX. WEIGHT

IN
,,, ,,,,,,

MAX. WIDTH'

MAX. LENGTH

CABINET

.,_,,,

SMALL

52.00

1219

48.00

1219

38.00

965

50O

LARGE

73.00.

1854

48.00

1219

38.00

965

900

409

CONNECTION

WIRING DIAGRAM - ALL MODELS

r ILD
r
SPPLY
208/230
VAC
601Z,
]PH

LOW
VOLTAGE
TERM]RAtION

TRARS

BR
Y
G

w]?
P

W--

GNIT[ON

CON

BOARD
Pl
COMPSOL

PRESSURE
SWIICN
MAIN
J
i

SPANKER
0
W
IF

ANY 01: IHE

÷ SEE !NSIALIAIION
I

ORIGINAL

WIRE

]NSFRUCFIONS

LIN_E VO[TAG( FACTORY
.

AS SUPPLIED

I COLOR CODE

I[OW
VOLTAGE FACTORY
---IIN_
VOLTAGE FIELD
-INTERNAL
CIRCUII
-I
LOW VOLTAGE
FIELD
[
--BOARD
WIRING

WIHI

FHE APPLIANCE

MUST BE REPLACED,

FOR PROPER HEATING AN!) COOLING CONNECIIONS
:

CLACK

GREEN

GROWN NR

RED

GRAY
GLUE
PINK

V!O!ET
ORANGE

GY
B_
P

FOR YOUR UNIT

WHILE

YELLOW

MUST BE REPLACED

WITR

[YPE

INDOOR FAN MOTOR PLUGS-

AWMwlO5_C

OR irs

'IDo No@ Dis(onn¢c_

EOUIVALENT
Under

load _'

LADDER WIRING DIAGRAM - ALL MODELS
USE COPP{R CONDUCTORSON!Y
FIELD SUPPLY
208/230 VAC, 60 HZ, 1PIt
CONT

Ii 2

I
G/Y

-L

CRANKCASEHEAIEI:/

CON[
25

DR @ DB
OUlDOOR
FAN MTR
CAP

INOOOR
FAN MTR

IGNITION
CONTROl
BOARD

P2 2

P2 1
P2

REMOTE
SPARKER
FR

230V

RANS

/--_

XFMR
24

VACR

R
IERMINAIION

OFT BOARD

VOLTAGE

-R-pO

LOW
RO--

,,__/

PR20

P!-6

124 MAC

O-

P13

-0

O-

..-0

P23

-0
¥0 i

COM C

ii,,

-0

24V

, __@

COM

OFT
_ip
DFT

HPS

OTlO
.>

T20
0

oO ii

OP_

O-

--BL--

4
R/-3

O-

MAIN
LIMIT

,P2

P14

0O- P221 _,.2J
P1

INTERFACE
BOARD

O-- JR
P18
OP/-IR

PRSO'- 6//
A{ 0
IlI

OR/!1
O-Ox
"

-0_
Jy

PRESS RE SWlC i

SENSOR

INDOOR FAN
CONTROL PLUG

-BR

R/4

LO0

¢0--

IGNITIONCONTROL
_ARD
H_S2

COMPRESSOR
SOI_:N[OD PLUG
c
P31

yROi

-0
P1

c OJJ

50CY501462

3.0

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Producer                        : Goby Monitor Application version 3, 2, 1, 4
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ICP Package Units(both Units Combined) Manual L0611374

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