ICP Package Units(both Units Combined) Manual L0909099

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
PGD4 / PGS4 Series

PACKAGED GAS/ELECTRIC

International
ComfortProducts,
LLC
Lewisburg,
TN.37091

UNIT

462 01 2002 01

04-09-09

TABLE

OF CONTENTS
PAGE
1
2
2
2
2
2
2
2
2
2
6
6
6
6
9
9
9
10

SAFETY CONSIDERATIONS
............................
INTRODUCTION .......................................
RECEIVING AND INSTALLATION ........................
Check Equipment .....................................
Identify Unit ........................................
Inspect Shipment ...................................
Provide Unit Support ..................................
Roof Curb .........................................
Slab Mount ........................................
Field Fabricate Ductwork ..............................
Provide Clearances ...................................
Rig and Place Unit ....................................
Inspection .........................................
Rigging/Lifting ......................................
Connect Condensate Drain ............................
Install Flue Hood .....................................
Install Gas Piping .....................................
Install Duct Connections ..............................
Configuring Units for Downflow (Vertical)
Discharge ........................................
Install Electrical Connections ..........................
High-Voltage Connections ..........................
Special Procedures for 208-V Operation ..............
Control Voltage Connections ........................
Standard Connection ...............................
Heat Anticipator Setting .............................
Transformer Protection .............................
PRE-START-UP
......................................
START-UP ...........................................
Check for Refrigerant Leaks ...........................
Start-Up Heating & Make Adjustments ..................
Check Heating Control .............................
Check Gas Input ...................................
Adjust Gas Input ...................................
Check Burner Flame ...............................
Normal Operation ..................................
Airflow and Temperature Rise ........................
Heating Sequence of Operation ......................
Limit Switches .....................................
Rollout Switch .....................................
Start-Up Cooling & Make Adjustments ..................
Checking Cooling Control Operation ..................
Checking & Adjusting Refrigerant Charge .............
Indoor Airflow and Airflow Adjustments ................
Continuous Fan Operation ..........................
Cooling Sequence of Operation ......................
MAINTENANCE .......................................
Air Filter ..........................................
Indoor Blower and Motor ............................
Induced Draft (Combustion Air) Blower ................
Flue Gas Passageways
............................
Limit Switch .......................................
Burner Ignition .....................................
Main Burners ......................................
Removal of Gas Train ..............................
Outdoor Coil, Indoor Coil, & Condensate Drain Pan .....
Outdoor Fan ......................................
Electrical Controls and Wiring ........................
Refrigerant Circuit ..................................
Gas Input .........................................
Evaporator Airflow .................................
R-410A Items .....................................
TROUBLESHOOTING
.................................
START-UP CHECKLIST ...............................

10
11
12
12
12
12
12
12
13
13
13
13
14
14
15
15
19
19
19
19
19
19
19
19
20
21
21
28
28
28
29
29
29
29
29
29
29
30
31
31
31
31
32
32
32

NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Installer: Make sure the Owner's Manual and Service
Instructions are left with the unit after installation.
Fig. 1 - Unit PGD4 / PGS4 (Low NOx models available)

SAFETY

CONSIDERATIONS

Improper
installation,
adjustment,
alteration,
service
maintenance, or use can cause explosion, fire, electrical shock,
or other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory-authorized
kits or
accessories when modifying this product. Refer to the individual
instructions
packaged with the kits or accessories
when
installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. consult local
building codes, the current editions of the National Fuel Gas
Code (NFGC) NFPA 54/ANSI Z223.1, and the National Electrical
Code (NEC) NFPA 70.
In Canada refer to the current editions of the National Standards
of Canada CAN/CSA-B149.1
and .2 Natural Gas and Propane
Installation codes, and Canadian Electrical Code CSA O22.1
Recognize safety information. This is the safety-alert symbol/_
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words: DANGER, WARNING,
and CAUTION.
These words are used with the safety-alert symbol. DANGER
identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal 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.

ELECTRICALSHOCKHAZARD
Failure to follow this warning could result in personal injury or
death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be more
than one disconnect switch. Turn off accessory heater power
switch if applicable.
462 01 2002

FIRE, EXPLOSION, ELECTRICAL
MONOXIDE POISONING HAZARD

SHOCK AND CARBON

For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate if required.
Roof Curb

CUT HAZARD

Install accessory roof curb in accordance with instructions
shipped with curb (See Fig. 5). Install insulation, cant strips,
roofing, and flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a water tight seal. Install gasketing material supplied with the
roof curb. Improperly applied gasketing also can result in air
leaks and poor unit performance.
Curb should be level to within 1/4 in. (6 mm). This is necessary
for unit drain to function properly. Refer to accessory roof curb
installation instructions for additional information as required.

Failure to follow this caution may result in personal injury.

Slab Mount

When removing access panels or performing maintenance
functions inside your unit, be aware of sharp sheet metal parts
and screws. Although special care is taken to reduce sharp
edges to a minimum, be extremely careful when handling
parts or reaching into the unit.

Place the unit on a solid, level concrete pad that is a minimum of
4 in. (102 mm) thick with 2 in. (51 mm) above grade. The slab
should extend approximately 2 in. (51 mm) beyond the casing on
all 4 sides of the unit. (See Fig. 2.) Do not secure the unit to the
slab except when required by local codes.

Failure to follow this warning could result in personal injury or
unit damage.
A
qualified
installer
or
agency
must
use
only
factory-authorized
kits or accessories when modifying this
product.

INTRODUCTION

Fig. 2 - Slab Mounting Details

The PGD4 / PGS4 units (see Fig. 1) are a fully self-contained,
combination
Category
I gas heating/electric
cooling unit
designed for outdoor installation (See Fig. 3 and 4 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 or on a cement slab. (See Fig. 5 for
roof curb dimensions).
Models with the number "1" in the 13th position of the model
number are dedicated Low NOx units designed for California
installations. These models meet the California maximum oxides
of nitrogen (NOx) emissions requirements of 40 nanograms/joule
or less 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.
NOTE: Low
installations.

NOx

requirements

RECEIVING
Step

1 -- Check

AND

apply

only to

natural

gas

INSTALLATION

Equipment

Identify Unit
The unit model number and serial number are stamped on the
unit information plate. Check this information against shipping
papers.
Inspect Shipment
Inspect for shipping
damage
before removing
packaging
materials. If unit appears to be damaged or is torn loose from its
anchorage, have it examined by transportation inspectors before
removal.
Forward claim papers directly to transportation
company. Manufacturer is not responsible for any damage
incurred in transit. Check all items against shipping list.
Immediately notify the nearest equipment distribution
office if
any item is missing. To prevent loss or damage, leave all parts in
original packages until installation.
Step 2 -- Provide

oPT,O,ALr,

_ttll

RETURN
AIR

IIIII

[#]iI

NIII

._/-_(

_, _

_%.1,1
_---___

/
/

it
tl

!//

',WJ._ rl_j_-'-_-,/_---Jb_/-----_tt
\\'_ V
"_
///
"I_ /f
)
/4

I IIIII
11 dEIJ

(50.8mm) 1

SUPPLY
AIR

1//IIH _

.....
I liill
I IIIII
2

"
IIII
II II
Nil

///
///

J/7

±L
EVAR COIL

Step 3 --

Field

Fabricate

COND. COIL

Ductwork

Secure all ducts to roof curb and building structure on vertical
discharge units. Do not connect ductwork to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secured to the flanges.
Insulate and weatherproof all external ductwork, joints, and roof
openings with counter flashing and mastic in accordance with
applicable codes.
Ducts passing through an unconditioned
insulated and covered with a vapor barrier.

space

must

If a plenum return is used on a vertical unit, the return should be
ducted through the roof deck to comply with applicable fire
codes.
Read unit rating plate for any required clearances around
ductwork. Cabinet return-air static shall not exceed -.25 IN.
W.C.

Unit Support

IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit
base rails. When installing large base units onto the common
curb, the screws must be installed before allowing the full weight
of the unit to rest on the curb. A minimum of six screws are
required for large base units. Failure to secure unit properly
could result in an unstable unit. See Warning near Rigging/Lifting
information and accessory curb instructions for more details.

462 01 2002 01

Fig. 3 - PGD4 / PGS424-36

UNIT
3O

Electrical
Characteristics

UnitWT.
LB
KG

Unit HT.
A

Unit Dimensions
Corner Weight LB/KG

Center of Gravity
Y

208/230=1-60

330

149.6

1014

22-13/16

579.4

15=5/16

388.9

15=11/16 398.5

UNIT
24

208/230=1-60,208/230=3=60

342

155.0

1014

22-13/16

579.4

15=5/16

388.9

15=13/16 401.6

208/230

51.3

23.3

68.4

31.0

102.5

46.5

119.8

54.3

208/230
460

56.4
56.4

25.6
25.6

75.2
75.2

34.1
34.1

112.7
121.7

51.2
55.3

131.5
136.5

59.7
62.0

208/230=1-60,208/230=3=60
460=3=60

376
390

170.4
176.8

46
46

1167
1167

22-13/16
22-13/16

579.4
579.4

15=5/16
15=5/16

388.9
388.9

16=5/8
16=5/8

422.3
422.3

Voltage
208/230

1
49.5

22.5

66.0

2
29.9

98.9

3
44.9

115.4

4
52.4

1-15-15/16

TOP OF UNIT ...............................................
DUET SIDE OF UNIT .........................................
SIDE OPPOSITE DUCTS.......................................
BOTTOM OF UNIT ...........................................
FLUE PANEL ................................................

u
[152,4]

[]

]

BETWEEN UNITS, POWERENTRY SIDE ..........................
UNIT AND UNGROUNDEDSURFACES, POWERENTRY SIDE ...........
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDEDBURFACEB, POWERENTRY SIDE ......................

INCHES [MN]
14 [355.N]
D [50.8]
14 [3DB.U]
112 [12,7]
36 [914,4]

INCHES [MN]
42 [1066.G]
3B
[914.0]
42 [IOUU.G]

TOP ViEW

EVAP, COIL ACCESS SIDE ...................................
POWERENTRY BIDE .........................................
{EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP .................................................
SIDE OPPOSITE DUCTS......................................
DUCT PANEL...............................................

INCHES [MN]
36
[914.0]
4B [IO66.G]
48 [IDI9.D]
3D [914.0]
12 [3BN,G]_

_MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12 [304,8]
PROMWALL
SYSTEM,THEN SYSTEM PERFORMANCEMAYBE COMPROMISED,
[TRB.5]

[114,3]

ELECTRICAL
CCESS PANEL
4-lIB
I-I/G"

[123.8]
4-71G

7/8'

[DG,6]

DIA.

CONTROL ENTRY
[22.2]
DIA.
HOLE_

1N-15/16
14-5/1U
[363,6]

DRAIN
3/4"
[IH,I]
N,P,T,
N 7/B" [B2,2]
DEEP

'Z"

1
,f

[250,8]

[1224,0]

LEFT SiDE ViEW

FRONTViEW

[4U,O]

RIGHTSiDE VIEW

21-5/8 _
[BNB.3]

9-7/8
[250,G]

REAR VIEW
DIMENSIONS

[]

ARE

48VL500191

_Riv0

Fig. 4 - PGD4 / PGS442-60
UNIT
42
48
60

Electrical
Characteristics

UnitWT.
LB
KG

Unit HT.
A

Center of Gravity
Y

Unit Dimensions
Corner Weight LB/KG

UNIT

208/230-1-60,208/230-3-60

463

210.1

1267

22-13/16

579.4

457.2

17-1/8

435

460-3-60
208/230-1-60, 208/230-3-60

477
481

216.5
218.3

50
50

1267
1267

22-13/16
22-13/16

579.4
579.4

18
18

457.2
457.2

17-1/8
17-3/8

435
441

460-3-60

495

224.6

1267

22-13/16

579.4

457.2

17-3/8

441

208/230-1-60, 208/230-3-60
460-3-60

509
523

231.0
237.3

54
54

1368
1368

22-13/16
22-13/16

579.4
579.4

18
18

457.2
457.2

17-5/8
17-5/8

448
448

42
48
60

Voltage
208/230
460

1
69.5
69.5

31.5
31.5

92.6
92.6

2
42.1
42.1

139.0
148.0

3
63.1
67.2

162.1
167.1

4
73.6
75.9

208/230
460

72.2
72.2

32.8
32.8

96.2
96.2

43.7
43.7

144.4
153.4

65.5
69.6

168.4
173.4

76.5
78.7

208/230

76.4

34.7

101.8

46.2

152.9

69.4

178.2

80.9

460

76.4

34.7

101.8

46.2

161.8

73.4

183.2

83.2

[71,4]
INCHES [MM]
TOP OF UNIT ............................................
14 [355,6]
DUCT $1DE OF UNIT .......................................
D [5U,83
$10E OPPOSITE DUCTS ..................................... 14 [355,6]
BOTTOM OF UNIT ......................................... I12 [IU,7]
FLUE PANEL .............................................
3N [R14.43
tU(:_
INCHES INN]
BETWEEN UNITD, POWER ENTRY SIDE ........................ 42 [IOG6,8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE ......... 3S [914,03
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE ................... 4U [IOGN,D]
llIBi_Ui_IR}
C_

U-13116
[173.03
I

4R-IN/16
[IOUO,U]

RTR _'INOil

Al_IbBIm_VK::ING

EVAP. COIL ACCESS SIDE .................................
POWER ENTRY SIDE .......................................
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP ...............................................
SIDE OPPOSITE DUCTS ....................................
DUCT PANEL .............................................

INCHES INN]
3N [91K,O]
42 [1066,8]
4B [IZlU,D]
36 [91N,O]
IZ [304.83_

_NINIMUM DISTANCES:IF
UNIT IS PLACED
THAN 12 NAYBE
[3UK,B]FRON
WALL
SYUTEN,TUEN
SYDTEM LESS
PERFORNANDE
DOMPRONISED.

47
[119B.8]

(S0.B!

"A"

SUPPLY
DUCT
OPENING
-3-11/IN
[U3.7]

I',:
C
C
Pc
C

3/4"
X 7/8"

[I9,1]N.P.T,
[22,2]

DEEP

[328,U]
44-1/8
[1122,4]

6-5/8
[168,3]

\ o,O,EN
°°

COMPRESSOR j
PANEL

13-5/8
[BAG,I]

PANEL
3-3/8_
[87.3]

4D-S/IN
[1224.03

13-718
[SBZ,4]
EAR.U]

LEFT SiDEViEW

RETURN
DUCT
OPENING

FRONTVIEW

RIGHTSiDEVIEW
DIMENSIONS

IN [] ARE IN MN

13-718
[SBZ,4]

REAR VIEW
48VL500192

2"iVO

Fig. 5 - Roof Curb Dimensions

Dashed Lines show cross suppori
location for barge basepan units.

COMMON

CURB

A09096

ROOF CURB DETAIL

SMALL
BASE
UNIT

/
LARGE
BASE
UNIT

UNIT PLACEMENT
ON
COMMON CURB

A09094

/
LARGE CURB

UNIT

SIZE

Small or
Large

CATALOG
NUMBER

A
IN. (mm)

CPRFCURB010A00

11 (279)

CPRFCURB011A00

14 (356)

CPRFCURB012A00
Large

SMALL OR LARGE BASE UNIT

A09095

B (small base)
IN. (mm)*

C
IN. (mm)

D
IN. (mm)

14 (356)

16 (406)

47.8 (1214)

10 (254)

11 (279)

CPRFCURB013A00

B (large base)
IN. (mm)*

N/A

14 (356)

* Part Numbers CPRFCURB010A00
and CPRFCURB011A00
unit is a small basepan or a large basepan.
NOTES:

E
IN. (mm)

F
IN. (mm)

32.4 (822)
2.7 (69)
43.9 (1116)

can be used on both small and large basepan units. The cross supports must be located based on whether the

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 mm) thick fiberglass

1 Ib. density.

462 01 2002

Step 4 m Provide

Clearances

The required minimum operating and service clearances are
shown in Fig. 3 and 4. Adequate combustion, ventilation and
condenser air must be provided.
IMPORTANT: Do not restrict outdoor airflow. An air restriction at
either the outdoor-air
inlet or the fan discharge may be
detrimental to compressor life.
The condenser fan pulls air through the condenser coil and
discharges it through the top grille. Be sure that the fan
discharge does not recirculate to the condenser coil. Do not
locate the unit in either a corner or under an overhead
obstruction. The minimum clearance under a partial overhang
(such as a normal house overhang) is 48-in. (1219 mm) above
the unit top. The maximum horizontal extension of a partial
overhang must not exceed 48-in. (1219 mm).
Do not place the unit where water, ice, or snow from an
overhang or roof will damage or flood the unit. Do not install the
unit on carpeting or other combustible materials. Slab-mounted
units should be at least 4 in. (102 mm) above the highest
expected water and runoff levels. Do not use unit if it has been
under water.
Step 5 m Rig and Place

Unit

Rigging and handling of this equipment can be hazardous for
many reasons due to the installation location (roofs, elevated
structures, etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached
to the
equipment, and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
Follow atl applicable safety codes. Wear safety shoes and work
gloves.
1. Application of the lifter to the load, and adjustment of the
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 the lifting
kit, such as balance, temperature, etc.

Inspection
Prior to initial use, and at monthly intervals, atl rigging shackles,
clevis pins, and straps should be visually inspected for any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Materials showing any
kind of wear in these areas must not be used and should be
discarded.

UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury or
death.
Never stand beneath rigged units or lift over people.

PROPERTY DAMAGE HAZARD
Failure to follow this warning
injury/death or property damage.

could

result

in personal

When straps are taut, the clevis should be a minimum of 36
in. (914 mm) above the unit top cover.
Rigging/Lifting

of Unit (See Fig. 6)

UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury
or death.
Large base units must be secured to common curb before
allowing full weight of unit to rest on curb. Install screws
through curb into unit base rails while rigging crane is still
supporting unit.
Lifting holes are provided in base rails as shown in Fig. 3 and 4.
1. Leave top shipping skid on the unit for use as a spreader
bar to prevent the rigging straps from damaging the unit. If
the skid is not available, use a spreader bar of sufficient
length to protect the unit from damage.
2. Attach shackles, clevis pins, and straps to the base rails
of the unit. Be sure materials are rated to hold the weight
of the unit. (See Fig. 6).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted
level with the ground.
After the unit is placed on the roof curb or mounting pad, remove
the top skid.

462 01 2002 01

Fig. 6 - PGD4 / PGS4 Unit Suggested

Rigging

.......y

DUCTS_
M{NIMUM HEIGHT: 36" (9!4.4 ram)
HAUTEUR MiNiMUM

SEAL

STRtP

MUST

PLACE
BEFORE
UNIT
ON ROOF

BE IN

PLACING
CURB

BANDE

SCELLANT

DOlT

ETRE

EN PL,_CE
AVANT
DE PLACER
L:UNITE SUR LA BASE
DE TO_T

DETAIL A
VOIR DIETAIL A
50CY502286

SMALL CABINET
24
30

Unit *
Rigging Weight

Unit *

337

153

349

158

383

174

Rigging Weight

2,0

LARGE CABINET
42
48

472

214

490

222

518

235

* For 460 volt units add 14 Ib (6.35 kg) to the rigging weight.
NOTE: See dimensional drawing for corner weights.

462 01 2002

Table 1 - Physical Data - Unit PGD4 / PGS4
UNIT SIZE
NOMINAL CAPACITY (ton)
SHIPPING WEIGHT"* lb.
SHIPPING WEIGHT** (kg)
COMPRESSORS

24040

24060

30040

30060

36060

36090

42060

42090

2
337
153

2-1/2
349
158

3
383
174

3-1/2
472
214

9.5
4.3

8.8
4.0

Scroll

Quantity

REFRIGERANT (R-410A)
Quantity lb.
Quantity (kg)
REFRIGERANT METERING DEVICE
OUTDOOR COIL

6.0
2.7

(Cfm)

Burner Orifice No. (Qty._Drill Size)
Natural Gas
Propane Gas
HIGH-PRESSURE SWITCH
(psi9) Cut-out Reset (Auto)
LOSS-OF-CHARGE / LOW-PRESSURE SWITCH
(Liquid Line) (psi9) cut-out Reset (auto)
RETURN-AIR FILTERSI_:
Throwaway Size in.
(mm)

1...21
11.9

1...21
13.6

2...21
15.4

2...21
13.6

2500
24
609.6
1/10 (810)

2500
24
609.6
1/10(810)

2700
24
609.6
1/10 (810)

2800
24
609.6
1/5 (810)

3000
26
660.4
1/5 (810

3000
26
660.4
1/5 (810)

2...17
3.7

3...17
3.7

3...17
4.7

800
10x10
254x254
1/2 (1050)

1000
10x10
254x254
1/2 (1050)

1200
1lx10
279,4x254
3/4 (1000)

1200
1 lx10
279,4x254
3/4 (1000)

1400
1 lx10
279,4x254
3/4 (1075)

1400
1lx10
279,4x254
3/4 (1075)

2...44

2...38

2...44

2...38

3...38

2...38

3...38

2...55

2...53

2...55

2...53

3...53

2...53

3...53

650 +/420 +/20 +/45 +/-

Table 1--Physical
NOMINAL CAPACITY (ton)
SHIPPING WEIGHT** Ib
SHIPPING WEIGHT** kg
COMPRESSORS
Quantity

15
25
5
10

20x24x1
508x610x25

24x30x1
610x762x25

Data Con't - Unit PGD4

PGS4

48090
4

48115
4

48130
4

60090
5

60115
5

60130
5

490
222

518
235

12.5
5.7

Scroll

REFRIGERANT (R-410A)
Quantity Ib
Quantity (kg.)
REFRIGERANT METERING DEVICE

9.4
4.3

Diameter (mm)
Motor Hp (Rpm)
INDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
INDOOR BLOWER

9.4
4.3

2...21
17.5

2...21
21.4

3200
26
660.4
1/5 (810)

3600
26
660.4
1/5 (810)

3...17
4.7

3...17
5.7

1600
11x10
279.4x254
1.0 (1075)

3...33
3...51

3...31
3...49

1600
11x10
279.4x254
1.0 (1075)

Nominal Cooling Airflow (Cfm)
Size in.
Size (mm)
Motor HP (RPM)
FURNACE SECTION*
Burner Orifice No. (Qty._Drill Size)
Natural Gas

3...38
3...53

Propane Gas
HIGH-PRESSURE SWITCH
(psi9) Cut-out Reset (Auto)
LOSS-OF-CHARGE / LOW-PRESSURE SWITCH
(Liquid Line) (psig) cut-out Reset (auto)
Throwawayt$

9.4
4.3

TXV

OUTDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
OUTDOOR FAN
Nominal Cfm
Diameter in.

FILTERS

5.6
2.5

1..21
11.9

20x20x1
508x508x25

UNIT SIZE

RETURN-AIR
(mm)

5.6
2.5

TXV

Rows...Fins/in.
Face Area (sq ft)
OUTDOOR FAN
Nominal CFM
Diameter in.
Diameter (mm)
Motor Hp (Rpm)
INDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
INDOOR SLOWER
Nominal Cooling Airflow
Size in.
Size (mm.)
Motor HP (RPM)
FURNACE SECTION*

6.0
2.7

1750
11x10
279.4x254
1.0 (1040)

3...38
3...53

1750
11x10
279.4x254
1.0 (1040)

3...33
3...51

1750
1 lx10
279.4x254
1.0 (1040)

3...31
3...49

650 +/- 15
420 +/- 25
20 +/- 5
45 +/- 10

in.

24x36x1
61 Oxg14x25

*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 of 300 ft/minute for throwaway type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.
If using accessory filter rack refer to the filter rack installation instructions
** For 460 volt units, add 14 Ibs (6.35 kg) to the shipping weight.

462 01 2002 01

for correct filter sizes and quantity.

Step 6 1

Connect

Condensate

Drain

Step 8 1

NOTE: When installing condensate drain connection be sure to
comply with local codes and restrictions.
Unit disposes of condensate water through a 3/4 in. NPT fitting
which exits through the base on the evaporator coil access side.
See Fig. 3 & 4 for location.
Condensate water can be drained directly onto the roof in
rooftop installations (where permitted) or onto a gravel apron in
ground level installations. Install a field-supplied 2-in. (51 mm)
condensate trap at the end of condensate connection to ensure
proper drainage. Make sure that the outlet of the trap is at least 1
in. (25 mm) lower than the drain-pan condensate connection to
prevent the pan from overflowing (See Fig. 7). Prime the trap
with water. When using a gravel apron, make sure it slopes away
from the unit.
Connect a drain tube using a minimum of 3/4-in. PVC or 3/4-in.
copper pipe (all field-supplied)
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 (3.1
m) of horizontal run. Be sure to check the drain tube for leaks.
Fig. 7 - Condensate Trap
TRAP

t-in. (25 ram) rain.
OUTLET

ram) rain.

Step 7 1

Install

Flue Hood

The flue assembly is secured and shipped in the return air duct.
Remove duct cover to locate the assembly (See Fig. 9).
NOTE: Dedicated low NOx models MUST be installed in
California Air Quality Management Districts where a Low NOx
rule exists.
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory.
NOTE: Low NOx requirements
apply only to natural gas
installations.

CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
The venting system is designed to ensure proper venting. The
flue hood assembly must be installed as indicted in this
section of the unit installation instructions.
Install the flue hood as follows:
1. This installation must conform with local building codes
and with NFPA 54/ANSI Z223.1 National Fuel Gas Code
(NFGC), (in Canada, CAN/CGA B149.1, and B149.2)
latest revision. Refer to Provincial and local plumbing or
wastewater codes and other applicable local codes.
2,

Install

Gas Piping

The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2-in.
(12.7 mm) FPT gas inlet on the gas valve.
Install a gas supply line that runs to the heating section. Refer to
the NFGC for gas pipe sizing. Do not use cast-iron pipe. It is
recommended that a black iron pipe is used. Check the local
utility for recommendations concerning existing lines. Size gas
supply piping for 0.5 in. wc maximum pressure drop. Never use
pipe smaller than the 1/2-in. (12.7 mm) FPT gas inlet on the unit
gas valve.
For natural gas applications, the gas pressure at unit gas
connection must not be less than 4.0 in. wc or greater than 13 in.
wc while the unit is operating. For propane applications, the gas
pressure must not be less than 11.0 in. wc or greater than 13 in.
wc at the unit connection.
A 1/8-in. (3.2 mm) NPT plugged tapping, accessible for test
gauge connection, must be installed immediately upstream of
the gas supply connection to the gas valve.
When installing the gas supply line, observe local codes
pertaining to gas pipe installations. Refer to the NFPA 54/ANSI
Z223.1 latest edition (in Canada, CAN/CGA B149.1).
NOTE: In the state of Massachusetts:
1. Gas supply connections
MUST be performed by a
licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T-handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
In the absence of local building codes, adhere to the following
pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.
(6.35 mm) for every 15 ft (4.6 m) of length to prevent traps.
Grade all horizontal runs downward to risers. Use risers to
connect to heating section and to meter.
2. Protect all segments of piping system against physical
and thermal damage. Support all piping with appropriate
straps, hangers, etc. Use a minimum of one hanger every
6 ft (1.8 m). For pipe sizes larger than 1/2 in., follow
recommendations of national codes.
3. Apply joint compound (pipe dope)
male threads of joint when making
only pipe dope that is resistant
petroleum gases as specified by
codes. Never use Teflon tape.

sparingly and only to
pipe connections. Use
to action of liquefied
local and/or national

4. Install sediment trap in riser leading to heating section
(See Fig. 8). This drip leg functions as a trap for dirt and
condensate.
5. Install an accessible, external, manual main shutoff valve
in gas supply pipe within 6 ft (1.8 m) of heating section.
6. Install ground-joint
union close to heating section
between unit manual shutoff and external manual main
shut-off valve.
7. Pressure test all gas piping in accordance with local and
national plumbing and gas codes before connecting piping
to unit.

Remove flue hood from shipping location (inside the return
section of the blower compartment-see
Fig. 9 & 10). Remove the return duct cover to locate the flue hood. Place
flue hood assembly over flue panel. Orient screw holes in
flue hood with holes in the flue panel.
Secure flue hood to flue panel by inserting a single screw
on the top flange and the bottom flange of the hood.
462 01 2002

Table 2 - Maximum
NOMINAL
IRONPIPE
SIZE (IN,)

INTERNAL
DIAMETER
(IN,)

10
(3)

20
(6)

30
(9)

40
(12)

1/2
3/4

.622
.824

175
360

120
250

97
200

Gas Flow Capacity*

50
(15)

LENGTHOF PIPE FT (m)t
60
70
80
90
(18)
(21)
(24)
(27)

100
(30)

125
(38)

150
(46)

175
(53)

200
(61)

82
170

73
151

66
138

61
125

57
118

53
110

50
103

44
93

40
84

-77

-72

1.049

680

465

375

320

285

260

240

220

205

195

175

160

145

135

1-1/4

1.380

1400

950

770

600

580

530

490

460

430

400

360

325

300

280

1-1/2

1.610

2100

1460

1180

990

900

810

750

690

650

620

550

500

460

430

*Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of O.5-in. wc (based on a 0.60 specific gravity gas). Refer to Table, National Fire
Protection Association NFPA 54.
1- This length includes an ordinary number of fittings.

Fig. 8 - Sediment Trap
IN

Step 9 -- Install Duct Connections
The unit has duct flanges on the supplyand return-air
openings on the side and bottom of the unit. For downshot
applications, the ductwork connects to the roof curb (See Fig. 3
and 4 for connection sizes and locations).
Configuring Units for Downflow (Vertical) Discharge

3
TEE

NIPPLE

CAP

NOTE: Pressure test the gas supply system after the gas supply
piping is connected to the gas valve. The supply piping must be
disconnected from the gas valve during the testing of the piping
systems when test pressure is in excess of 0.5 psig. Pressure
test the gas supply piping system at pressures equal to or less
than 0.5 psig. The unit heating section must be isolated from the
gas piping system by closing the external main manual shutoff
valve and slightly opening the ground-joint union.

FIRE OR EXPLOSION HAZARD

ELECTRICAL

SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off
main power to system and install lockout tag. There
may be more than one disconnect switch.

1. Open all electrical disconnects before starting any service
work.
2. Remove horizontal (metal) duct covers to access vertical
(downflow) discharge duct knockouts in unit basepan.
3. Starting in a corner as shown in Fig. 10, score the panel in
both directions from the corner. Tap the panel out from the
scored corner using a small hammer. Be careful and not
damage any other part of the unit.
4. If unit ductwork is to be attached to vertical opening
flanges on the unit base (jackstand applications only), do
so at this time.

Failure to follow this warning could result in personal
injury, death and/or property damage.
-Connect gas pipe to unit using a backup wrench to
avoid damaging gas controls.
-Never purge a gas line into a combustion chamber.
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.
-Use proper length of pipe to avoid stress on gas
control manifold.
-If a flexible connector is
authority having jurisdiction,
installed at furnace gas valve
2 in. (51 mm) outside furnace

required or allowed by
black iron pipe shall be
and extend a minimum of
casing.

-If codes allow a flexible connector, always use a new
connector,
do not use a connector which has
previously serviced another gas appliance.
8. Check
for
gas leaks
at the field-installed
and
factory-installed
gas lines after all piping connections
have been completed. Use a commercially available soap
solution (or method specified by local codes and/or
regulations).
462 01 2002 01

PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property
damage.
Collect ALL screws that were removed. Do not leave
screws on rooftop as permanent damage to the roof
may occur.
5. It is recommended that the base insulation around the
perimeter of the vertical return-air opening be secured to
the base with aluminum tape. Applicable local codes may
require aluminum tape to prevent exposed fiberglass.
6. Reinstall both horizontal
air- and watertight.

duct covers. Ensure opening is

7. After completing unit conversion, perform all safety checks
and power up unit.
NOTE: The design and installation of the duct system must be
in accordance with the standards of the NFPA for installation of
nonresidence-type
air conditioning and ventilating systems,
NFPA 90A or residence-type,
NFPA 90B; and/or local codes
and ordinances.

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

Fig. 9 - Supply and Return Duct Opening

5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.
6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest
issue of Sheet Metal and Air Conditioning Contractors
National Association
(SMACNA) and Air Conditioning
Contractors of America (ACCA) minimum installation
standards for heating and air conditioning
systems.
Secure all ducts to building structure.
7. Flash, weatherproof, and vibration isolate all openings in
building structure in accordance with local codes and
good building practices.

Horizontal Duct Covers

Step 10 m Install

Jl
Basepan
Downflow

Connections

ELECTRICALSHOCKHAZARD

(Vertical)
Supply

Electrical

Basepan
Downflow

Failure to follow this warning could result in personal injury or
death.

Return

The unit cabinet must have an uninterrupted,
unbroken
electrical ground. This ground may consist of an electrical
wire connected to the unit ground screw in the control
compartment, or conduit approved for electrical ground when
installed in accordance with NFPA 70 (NEC) (latest edition)
(in Canada, Canadian Electrical Code CSA C22.1) and local
electrical codes.

Knockout

Fig. 10- Vertical (Downflow) Discharge Duct Knockouts

UNIT COMPONENT

INSTRUCTIONS

FOR REMOVING

DOWNSHOT

1 Score groove in corner 1 in both directions as far
2 Starting in corner 1 tap out atl sides with a smatl
not to damage any other part of unit
3. If side from corner 3 to 4 is not accessible due to
pivot panel up and down by hand until remaining

Failure to follow this caution may result in damage to the unit
being installed.
1. Make all electrical connections in accordance withh
NFPA 70 (NEC) (latest edition) 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.

PANELS

as you can reach
hammer, Be careful
heat exchanger.
side breaks off
A09054

Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Units are shipped for horizontal duct installation (by
removing duct covers).
2. Select and size ductwork, supply-air
registers, and
return-air
grilles according
to American
Society of
Heating, Refrigeration and Air Conditioning Engineers
(ASHRAE) recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather-tight and airtight seat.

DAMAGE HAZARD

3. Be sure that high-voltage
power to unit is within
operating voltage range indicated on unit rating plate.
On 3-phase units, ensure phases are balanced within
2 percent. Consult local power company for correction
of improper voltage and/or phase imbalance.
4. Insulate low-voltage
wires for highest
voltage
contained within conduit when low-voltage
control
wires are in same conduit as high-voltage wires.
5. Do not damage internal components when drilling
through any panel to mount electrical hardware,
conduit, etc.

462 01 2002

High-Voltage

Connections

Control Voltage Connections

When routing power leads into unit, use only copper wire
between disconnect and unit. The high voltage leads should be
in a conduit until they enter the duct panel; conduit termination at
the duct panel must be watertight.
The unit must have a separate electrical service with a
field-supplied,
waterproof disconnect switch mounted at, or
within sight from, the unit. Refer to the unit rating plate, NEC and
local codes for maximum fuse/circuit breaker size and minimum
circuit amps (ampacity) for wire sizing.
The field-supplied
disconnect switch box may be mounted on
the unit over the high-voltage
inlet hole when the standard
power and low-voltage entry points are used (See Fig. 3 and 4
for acceptable location).
See unit wiring label (Fig. 15, 16 and 17) and Fig. 11 for
reference when making high voltage connections. Proceed as
follows to complete the high-voltage connections to the unit.
Single phase units:
1. Run the high-voltage (L1, L2) and ground lead into the
control box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line
side of the contactor (if equipped).
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection
the compressor contactor.
Three-phase units:
1. Run the high-voltage
control box.

23 of

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

2. Connect ground lead to chassis ground connection.

Run the low-voltage leads from the thermostat, through the inlet
hole, and into unit low-voltage splice box.
Locate six (seven for 3-phase)
18-gage wires leaving control
box. These low-voltage connection leads can be identified by
the colors red, green, yellow, brown, blue, and white (See Fig.
11). A gray wire is standard on 3-phase units for connection to
an economizer. Ensure the leads are long enough to be routed
into the low-voltage splice box (located below right side of
control box). Route leads through hole in bottom of control box
and make low-voltage connections (See Fig. 11). Secure all cut
wires, so that they do not interfere with operation of unit.
Fig. 11 - High- and Control-Voltage

SHOWN

1-PHASE USES
TWO POWER
LEADS

CONTROL

L_
EQUIP GR

FIELD-SUPPLIED
FUSED DISCONNECT

BOX
r

dHTLVVZ)
"_=@
O=

Special Procedures

13 of

Connections

HIGH VOLTAGE
POWER LEADS
_c=
(SEE UNIT WIRtNG 1
LABEL)
_:_

3. Locate the black and yellow wires connected to the line
side of the contactor (if equipped).
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L3 to yellow wire on connection
the compressor contactor.
6. Connect field wire L2 to blue wire from compressor.

LOW-VO LTAG E __
POWER LEADS
(SEE UNIT
WIRING LABEL)

O_
OO-

for 208-v Operation

GR_ O=Q
_--ED4%
.D=@
B_nN(C)
_
BLU4"D--H)9"
_-Ph_
Dn]y

SPLICE

BOX

Heat Anticipator Setting (Electro-Mechanical
ELECTRICAL

Make sure the power supply to the unit is switched OFF and
install lockout tag. before making any wiring changes. With
disconnect switch open, move black wire from transformer
(3/16 in. [4.8 mm]) terminal marked 230 to terminal marked
208. This retaps transformer to primary voltage of 208 vac.

SHOCK FIRE/EXPLOSION

HAZARD

Failure to follow this warning could result in personal injury or
death and property damage.
Before making any wiring changes, make sure the gas
supply is switched off first. Then switch off the power supply
to the unit and install lockout tag.

462 01 2002 01

Thermostats

on__eLv3

SHOCK HAZARD

Failure to follow this warning could result in personal injury or
death.

ELECTRICAL

Unit control

Use no. 18 American Wire Gage (AWG) color-coded, insulated
(35_'C minimum) wires to make the control voltage connections
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. 16 AWG color-coded, insulated
(35_'C minimum) wires.
Standard Connection

3-PHASE

(L1, L2, L3) and ground lead into the

thermostat.

The room thermostat heat anticipator must be properly adjusted
to ensure proper heating performance. Set the heat anticipator,
using an ammeter between the W and R terminals to determine
the exact required setting.
NOTE: For thermostat selection purposes, use 0.18 amp for the
approximate required setting. Failure to make a proper heat
anticipator
adjustment
will result in improper operation,
discomfort to the occupants of the conditioned space, and
inefficient energy utilization; however, the required setting may
be changed slightly to provide a greater degree of comfort for a
particular installation.
Transformer Protection
The transformer is of the energy-limiting type, however
short will likely blow a secondary fuse. If an overload or
present, correct overload condition and check for blown
Indoor Fan board or Integrated Gas Controller. Replace
required with correct size and rating.

a direct
short is
fuse on
fuse as

PRE-START-UP
FIRE, EXPLOSION HAZARD
ENVIRONMENTAL,
SHOCK HAZARD

FIRE,

EXPLOSION,

ELECTRICAL

Failure to follow this warning could result in personal injury or
death.
1. Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
2. Do not operate compressor or provide any electric
power to unit unless compressor plug is in place and
secured.
3. Do not remove ccompressor plug until all electrical
sources are disconnected and tagged.
4. Relieve and recover all refrigerant from system before
touching or disturbing compressor plug if refrigerant
leak is suspected around compressor terminals.
5. Never attempt to repair soldered connection while
refrigerant 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 goggles and
proceed as follows:
a. Shut off electrical power to unit and install lockout
tag.
b. Relieve and reclaim all refrigerant from system
using both high- and low-pressure ports.
c. Cut component connecting tubing with tubing cutter
and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to torch
flame.
Use the Start-Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial
start-up:
1. Remove access panels.
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION
labels attached to, or
shipped with unit.
3. Make the following inspections:
a. Inspect for shipping and handling damage, such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections and
on unit base. Detecting oil generally indicates a
refrigerant leak.
c. Leak-test all refrigerant tubing connections using
electronic leak detector, or liquid-soap solution. If a
refrigerant leak is detected, see following Check for
Refrigerant Leaks section.
d. Inspect all field- and factory-wiring connections.
sure that connections are completed and tight.

e. Ensure wires do not touch refrigerant tubing or sharp
sheet metal edges.
f. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.

Failure to follow this warning could result in personal injury,
death or property damage.
Do not purge gas
not use a match or
Use a commercially
for the detection of

supply into the combustion chamber. Do
other open flame to check for gas leaks.
available soap solution made specifically
leaks to check all connections.

4. Verify the following conditions:
a. Make sure gas line is free of air. Before lighting the unit
for the first time, perform the following with the gas
valve in the OFF position:
NOTE: If the gas supply pipe was not purged before connecting
the unit, it will be full of air. It is recommended that the ground
joint union be loosened, and the supply line be allowed to purge
until the odor of gas is detected. Never purge gas lines into a
combustion chamber. Immediately upon detection of gas odor,
retighten the union. Allow 5 minutes to elapse, then light unit.
b. Ensure fan hub is positioned correctly with respect to
motor housing.
c. Make sure that air filter(s) is in place.
d. Make sure that condensate drain trap is filled with
water to ensure proper drainage.
e. Make sure that all tools and miscellaneous loose parts
have been removed.

START-UP
Step 1 m Check for Refrigerant

Leaks

Proceed as follows to locate and repair a refrigerant leak and to
charge the unit:
1. Locate leak and make sure that refrigerant system
pressure has been relieved and reclaimed from both highand low-pressure ports.
2. Repair leak following accepted practices.
NOTE:
Install a filter drier whenever the system has been
opened for repair.
3. Add a small charge of R-410A refrigerant vapor to system
and leak-test unit.
4. Recover refrigerant from refrigerant system and evacuate
to 500 microns if no additional leaks are found.
5. Charge unit with R-410A refrigerant, using an accurate
scale. Refer to unit rating plate for required charge.
Step 2 m Start-up

Heating

and Make Adjustments

Complete the required procedures given in the Pre-Start-Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Make sure that burner orifices are
properly aligned. Unstable operation my occur when the burner
orifices in the manifold are misaligned.
Follow the lighting instructions on the heating section operation
label (located on the inside of the control access panel) to start
the heating section.
NOTE: Make sure that gas supply has been purged, and that all
gas piping has been checked for leaks.

462 01 2002

0.60 specific gravity, or propane gas with a heating value of

Fig. 12 - Burner Assembly

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 be
reduced by 4% for each 1,000 ft (305 m) above see level.
For installations below 2,000 ft (610 m), refer to the unit rating
plate.
For installations above 2,000 ft (610 m). multiply the input by on
the rating plate by the derate multiplier in Table 3 for correct input
rate.
Table 3 - Altitude Derate Multiplier for U.S.A.*
DERATEMULTIPLIER

"Manifold
Fig. 13 - Monoport Burner
BURNER

FLAME

BURNER

MANIFOLD

ALTITUDEFT (M)

PERCENTOF DERATE

FACTOR1"

0-2000
(0-610)

1.00

2001-3000*
(610-914)

8-12

0.90

3001-4000
(915-1219)

12-16

0.86

4001-5000
(1220-1524)

16-20

0.82

5001-6000
(1524-1829)

20-24

0.78

6001-7000
(1829-2134)

24-28

0.74

7001-8000
(2134-2438)

28-32

0.70

8001-9000
(2439-2743)

32-36

0.66

36-40

0.62

9001-10,000
(2744-3048)
*In Canada
1-Derate
range.

Check Heatinq Control
Start and check the unit for proper heating control operation as
follows (see furnace lighting instructions located on the inside of
the control access panel):
1. Place room thermostat SYSTEM switch in the HEAT
position and the fan switch is placed in AUTO position.
2. Set the heating temperature control of the thermostat
above room temperature.
3. The induced-draft motor will start.
4. On a call for heating, the main burner should light within 5
sec. of the spark being energized. If the burners do not
light, there is a 22-sec. delay before another 5-sec. try. If
the burners still do not light, this sequence is repeated. If
the burners do not light within 15 minutes from the initial
call for heat, there is a lockout. To reset the control, break
the 24-v power to W.
5. The evaporator fan will turn on 45 sec. after the flame has
been established. The evaporator fan wilt turn off 45 sec.
after the thermostat has been satisfied. Please note that
the integrated gas unit controller (IGC) has the capability
to automatically reduce the evaporator "ON" delay and increase the evaporator "OFF" delay in the event of high
duct static and/or partially-clogged filter.

see Canadian

multiplier

factors

Altitude
are based

Adjustment.
on midpoint

altitude

for altitude

IN CANADA:
The input rating for altitudes from 2,000 (610 m) to 4,500 ft (1372
m) above sea level must be derated 10% by an authorized Gas
Conversion Station or Dealer.
EXAMPLE:
90,000 Btu/hr Input Furnace Installed at 4300 ft.
Furnace
InputRateatSea X DerateMultiplier
Level
Factor
90,000

0.90

= FurnaceInputRateat Installation
Altitude
=

81,000

When the gas supply being used has a different heating value or
specific gravity, refer to national and local codes, or contact your
distributor to determine the required orifice size.

Check Gas Input
Check gas input and manifold pressure after unit start-up (See
Table 4). If adjustment is required proceed as follows:
• The rated gas inputs shown in Table 4 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
462 01 2002 01

Table
HEATING INPUT

4 - Heating

Inputs

GAS SUPPLYPRESSURE(IN. W.C.)
NaturallPropane*lMax
Min

MANIFOLDPRESSURE

NUMBEROF
ORIFICES

Min

4.0

13.0

11.0

13.0

Natural13.2-3.8

60,000

4.0

13.0

11.0

13.0

3.2-3.8

10,0-11.0

90,000

4.0

13.0

11.0

13.0

3.2-3.8

10,0-11.0

115,000
130,000

3
3

4.0
4.0

13.0
13.0

11.0
11.0

13.0
13.0

3.2-3.8
3.2-3.8

10,0-11.0

(BTUH)
40,000

(IN. W.C.)
Max

Propane*f
10.0-1 l.O

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

UNIT DAMAGE HAZARD
Failure to follow this caution may result in reduced unit and/or
component life.
Do Not
redrill
an orifice.
Improper
drilling
(burrs,
out-of-round
holes, etc.) can cause excessive burner noise
and misdirection of burner flame. If orifice hole appears
damaged or it is suspected to have been redrilted, check
orifice hole with a numbered drill bit of correct size.
Adjust Gas Input
The gas input to the unit is determined by measuring the gas
flow at the meter or by measuring the manifold pressure.
Measuring the gas flow at the meter is recommended for natural
gas units. The manifold pressure must be measured to
determine the input of propane gas units.
Measure Gas Flow (Natural Gas Units)
Minor adjustment to the gas flow can be made by changing the
manifold pressure. The manifold pressure must be maintained
between 3.2 and 3.8 IN. W.C.
Fig. 14 - Single-Stage

Gas Valve

5. Multiply result of Step 4 by the number of cubic feet (cu ft)
shown for one revolution of test dial to obtain cubic feet
(cu ft) of gas flow per hour.
6. Multiply result of Step 5 by Btu heating value of gas to
obtain total measured input in Btuh. Compare this value
with heating input shown in Table 4 (Consult the local gas
supplier if the heating value of gas is not known).
EXAMPLE: Assume that the size of test dial is 1 cu ft, one
revolution takes 32 sec, and the heating value of the gas is 1050
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 minor change in
the manifold pressure is required.
Observe manifold pressure and proceed as follows to adjust gas
input:
1. Remove regulator cover screw over plastic adjustment
screw on gas valve (See Fig. 14).
2. Turn plastic adjustment screw clockwise to increase gas
input, or turn plastic adjustment screw counterclockwise to
decrease input (See Fig. 14). Manifold pressure must be
between 3.2 and 3.8 IN. WC.

PLASTIC

FIRE AND UNIT DAMAGE HAZARD
(NATURAL-

SILVER)

Failure to follow this warning could result in personal injury or
death and/or property damage.
Unsafe operation of the unit may result if manifold pressure is
outside this range.
3. Replace regulator cover screw on gas valve (See Fig. 14).

MAN_FOLD
PRESSURE

4. Turn off gas supply to unit. Remove manometer from
pressure tap and replace pipe plug on gas valve. (See
Fig. 12.) Turn on gas to unit and check for leaks.
TAP

Measure Manifold Pressure (Propane Units)
If larger adjustments are required, change main burner orifices
following the recommendations of national and local codes.
NOTE: All other appliances that use the same meter must be
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. 12) and connect
manometer. Turn on gas supply to unit.
3. Record number of seconds for gas meter test dial to make
one revolution.
4. Divide number of seconds in Step 3 into 3600 (number of
seconds in one hr).

Refer to propane kit installation instructions for properly checking
gas input.
NOTE: For installations below 2,000 ft (610 m), refer to the unit
rating plate for proper propane conversion kit. For installations
above 2,000 ft (610 m), contact your distributor for proper
propane conversion kit.
Check Burner Flame
With control access panel removed, observe the unit heating
operation. Watch the burner flames to see if they are light blue
and soft in appearance, and that the flames are approximately
the same for each burner. Propane will have blue flame (See
Fig. 13). Refer to the Maintenance section for information on
burner removal.

462 01 2002

Fig. 15 - 208/230-1-60

Wiring Diagram

I................

462 01 2002 01

,, Z_IZIIII _

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g_s_7

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

Fig. 16-

208/230-3-60

Wiring Diagram

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dC_

C%
L_J
C_'h

<:C
cf>

z
4
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L_J
O

CC3
CZ:::
_J
O
C_

Z
Z
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C.J
O0
, 4

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Z
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462 01 2002

Fig. 17-

460-3-60

Wiring Diagram

L..J

z_
i

462 01 2002 01

Normal Operation

Rollout Switch

An LED (light-emitting
diode) indicator is provided on the
integrated gas unit controller (IGC) to monitor operation. The IGC
is located by removing the control access panel. During normal
operation, the LED is continuously on (See Table 5 for error
codes).

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

Airflow

and Temperature

Rise

The heating section for each size unit is designed and approved
for heating operation within the temperature-rise
range stamped
on the unit rating plate.
Table 9 shows the approved temperature rise range for each
heating input, and the air delivery cfm at various temperature
rises for a given external static pressure. The heating operation
airflow must produce a temperature rise that falls within the
approved range.
Refer to Indoor Airflow and Airflow Adjustments section to adjust
heating airflow when required.
Heating Sequence

(See Fig. 15-17 and unit wiring label.)
On a call for heating, terminal W of the thermostat is energized,
starting the induced-draft
motor. When the pressure switch
senses that the induced-draft
motor is moving sufficient
combustion air, the burner sequence begins. This function is
performed by the integrated gas unit controller (IGC). The indoor
(evaporator)-fan
motor is energized 45 sec after flame is
established.
When the thermostat
is satisfied and W is
de-energized, the burners stop firing and the indoor (evaporator)
fan motor shuts off after a 45-sec time-off delay. Please note
that the IGC has the capability to automatically reduce the
indoor fan motor on delay and increase the indoor fan motor off
delay in the event of high duct static and/or partially-clogged
filter.
Limit Switches
Normally closed limit switch (LS) completes the control circuit.
Should the leaving-air temperature rise above the maximum
allowable temperature, the limit switch opens and the control
circuit "breaks." Any interruption in the control circuit instantly
closes the gas valve and stops gas flow to the burners and pilot.
The blower motor continues to run until LS resets.
When the air temperature at the limit switch drops to the
low-temperature setting of the limit switch, the switch closes and
completes the control circuit. The direct-spark
ignition system
cycles and the unit returns to normal heating operation.
Table 5 - LED Indications
STATUS CODE

LED INDICATION

Normal Operation 2
No Power or Hardware Failure
Fault

2 Flashes

Flame Sense Fault
Four Consecutive

Limit Switch

3 Flashes
Faults

Ignition Lockout Fault
Pressure Switch Fault
Rollout
Internal
Temporary

On
Off

4 Flashes
5 Flashes
6 Flashes

Switch Fault

7 Flashes

Control

8 Flashes

Fault

1 hr auto reset I

9 Flashes

Cooling

and Make Adjustments

Complete the required procedures given in the Pre-Start-Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Do not operate the compressor when
the outdoor temperature
is below 40°F
(4.4°0) (unless
accessory low-ambient kit is installed). Do not rapid-cycle the
compressor. Allow 5 minutes between on cycles to prevent
compressor damage.
Checking

of Operation

Limit Switch

Step 3 m Start-up

Cooling

Control

Operation

Start and check the unit for proper cooling control operation as
follows:
1. Place room thermostat SYSTEM switch in OFF position.
Observe that blower motor starts when FAN switch is
placed in ON position and shuts down when FAN switch is
placed in AUTO position.
2. Place SYSTEM switch in COOL position and FAN switch
in AUTO position. Set cooling control below room
temperature. Observe that compressor, condenser fan,
and evaporator blower motors start. Observe that cooling
cycle shuts down when control setting is satisfied. The
evaporator fan will continue to run for 90 sec.
IMPORTANT:
Three-phase,
scroll compressors are direction
oriented. Unit must be checked to ensure proper compressor
3-phase
power lead orientation. If not corrected within 5
minutes, the internal protector will shut off the compressor. The
3-phase power leads to the unit must be reversed to correct
rotation. When turning backwards, the difference between
compressor suction and discharge pressures will be minimal.
Checkinq

and Adjustinq

Refriqerant

Charge

The refrigerant system is fully charged with R-410A refrigerant
and is tested and factory sealed. Allow system to operate a
minimum of 15 minutes before checking or adjusting charge.
NOTE: Adjustment of the refrigerant charge is not required
unless the unit is suspected of not having the proper R-410A
charge.
The charging label and the tables shown refer to system
temperatures and pressures in cooling mode only. A refrigerant
charging label is attached to the inside of the compressor access
panel. The chart includes the required liquid line temperature at
given
discharge
line
pressures
and
outdoor
ambient
temperatures.
An accurate
thermocoupleor thermistor-type
thermometer,
and a gauge manifold are required when using the subcooling
charging method for evaluating the unit charge. Do not use
mercury or small dial-type thermometers because they are not
adequate for this type of measurement.

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.
This is a UL requirement.
2. LED indicates acceptable operation. Do not change ignition control
board.
3. When W is energized the burners will remain on for a minimum of 60
sec.
4. If more than one error code exists they will be displayed on the LED in
sequence.

UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage.
When evaluating the refrigerant
charge, an indicated
adjustment to the specified factory charge must always be
very minimal. If a substantial adjustment is indicated, an
abnormal condition exists somewhere in the cooling system,
such as insufficient airflow across either coil or both coils.
462 01 2002

Proceed as follows:
1. Remove
fittings.

caps

Gas Heating Fan Speed Set-up
from

low-

and

high-pressure

service

2. Using hoses with valve core depressors, attach tow- and
high-pressure
gauge hoses to low- and high-pressure
service fittings, respectively.
3. Start unit in Cooling Mode and let unit run until system
pressures 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 reference only).

5. Using "Cooling Charging Charts," compare outdoor-air
temperature(°F [°C] db) with the discharge line pressure
(psig) to determine desired system operating liquid line
temperature (See Table 7).
6. Compare actual liquid line temperature with desired liquid
line temperature. Using a tolerance of _+2°F (_+1.1°C), add
refrigerant if actual temperature is more than 2°F (1.1°C)
higher than proper liquid line temperature,
or remove
refrigerant if actual temperature is more than 2°F (1.1°C)
lower than required liquid line temperature.
NOTE: If the problem causing the inaccurate readings is a
refrigerant leak, refer to the Check for Refrigerant Leaks section.
Indoor Airflow

and Airflow

Adjustments

UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airflow is 350 to
450 cfm for each 12,000 Btuh of rated cooling capacity. For
heating operation, the airflow must produce a temperature
rise that falls within the range stamped on the unit rating
plate.
NOTE: Be sure that all supply-and return-air
free from obstructions, and adjusted properly.

ELECTRICAL

grilles are open,

SHOCK HAZARD

Failure to follow this warning could result in personal injury or
death.
Disconnect electrical power to the unit and install lockout tag
before changing blower speed.
This unit has independent fan speeds for gas heating and
cooling. In addition, this unit has the field-selectable capability to
run two different cooling fan speeds: A normal cooling fan speed
(350-400 CFM/Ton) and an enhanced dehumidification
fan
speed (As low as 320 CFM/Ton) for use with either a
dehumidistat or a thermostat that supports dehumidification.
This unit is factory-set up for use with a single cooling fan speed.
The cooling speed is marked "LOW" on the interface fan board
(IFB)(Fig. 18) . The factory-shipped settings are noted in Table
9. There are 3 additional speed tap wires available for use in
either gas heating or cooling (For color coding on the indoor fan
motor leads, see Table 6). The additional 3 speed tap wires are
shipped loose with vinyl caps and are located in the control box,
near the interface fan board (IFB) (Fig. 18).

462 01 2002 01

To change the gas heating speed:
1. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 6 for color coding). Table 9 shows the
temperature rise associated with each fan speed for a
given static pressure. Make sure that the speed chosen
delivers a temperature rise within the rise range listed on
the unit rating plate.
2. Remove the current speed tap wire from the "GAS HEAT"
terminal on the interface fan board (IFB) (Fig.18) and
place vinyl cap over the connector on the wire.
3. Connect the desired speed tap wire to the "GAS HEAT"
terminal on the interface fan board (IFB).
Single Cooling Fan Speed Set-up (Dehumidification
feature
not used)
To change cooling speed:
1. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 6 for color coding). Add the wet coil
pressure drop in Table 10 to the system static to
determine the correct cooling airflow speed in Table 9 that
will deliver the nominal cooling airflow as listed in Table 1
for each size.
2. Remove the current speed tap wire from the "LOW"
terminal on the interface fan board (IFB) (Fig. 18) and
place 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 Cooling Fan Speeds Set-up (Dehumidification feature)
IMPORTANT: Dehumidification control must open control circuit
on humidity rise above set point.
Use of the dehumidification cooling fan speed requires use of
either a 24 VAC dehumidistat or a thermostat which includes
control of a 24 VAC dehumidistat connection. In either case, the
dehumidification control must open the control circuit on humidity
rise above the dehumidification
set point. Dehumidification
controls are available with the reverse logic; these must not be
used.
1. Remove fan speed tap wire from the "LOW" terminal on
the interface fan board (IFB) (Fig. 18).
2. Determine correct normal cooling fan speed for unit and
application. Add the wet coil pressure drop in Table 10 to
the system static to determine the correct cooling airflow
speed in Table 9 that will deliver the nominal cooling
airflow as listed in Table 1 for each size.
3. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 6 for color coding) for the normal cooling
fan speed and place desired speed tap wire on "HIGH" on
the interface board.
4. Refer to airflow tables (Table 9) to determine allowable
speeds for the dehumidification
cooling fan speed.
In
Table 9, speeds that are not allowed for dehumidification
cooling are shaded.
5. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 6 for color coding) for the dehumidification
cooling fan speed and place desired speed tap wire on the
"LOW" connection on the interface board (IFB). Verify that
static pressure is in the acceptable range for the speed
tap to be used for dehumidification cooling.
6. Use any spare vinyl plugs to cap any unused speed tap
wires.
NOTE: For cooling operation, the recommended airflow is 350 to
450 CFM for each 12,000 Btuh of rated cooling capacity.

Continuous

Fan Operation

Table

6 - Color

Fig. 18-

Interface Fan Board (IFB)

Coding

for Indoor

Fan Motor

Leads

Black = High Speed
Orange = Med-High Speed

When the DEHUM feature is not used, the continuous fan speed
will be the same as cooling fan speed. When the DEHUM
feature is used, the continuous fan will operate on IFB "LOW"
speed when the DH control lead is not energized, or IFB "HIGH"
speed when the DH lead is energized. (See Figure 18).

Red = Med Speed
Pink = Med-Low

Speed

Blue = Low Speed

Cooling

Sequence

of Operation

With the room thermostat SYSTEM switch in the COOL position
and the FAN switch in the AUTO position, the cooling sequence
of operation is as follows:
1. When the room temperature rises to a point that is slightly
above the cooling control setting of the thermostat, the
thermostat
completes the circuit between thermostat
terminal R to terminals Y and G.

JW4

2. The normally open contacts of energized contactor (C)
close and complete the circuit through compressor motor
(COMP) to condenser (outdoor) fan motor (OFM). Both
motors start instantly.
3. The set of normally open contacts on the interface fan
board (IFB) are closed which energizes a circuit to the
indoor fan motor (IFM).
NOTE: Once the compressor has started and then stopped, it
should not be started again until 5 minutes have elapsed. The
cooling cycle remains on until the room temperature drops to a
point that is slightly below the cooling control setting of the room
thermostat. At this point, the thermostat breaks the circuit
between thermostat terminal R to terminals Y and G. These
open circuits deenergize contactor coil C. The condenser and
compressor motors stop. After a 90-sec. delay, the blower motor
stops. The unit is in a standby condition, waiting for the next call
for cooling from the room thermostat.

462 01 2002

Table 7 - Cooling Charging Chart

"Ol

n, I

== =

_=_

o_
E

>
LU
r_

462 01 2002 01

Table 8 - Filter Pressure

Drop Table (IN. W.C.)
CFM

FILTER SIZE
in. (ram)
20X20X1
(508X508X25)
20X24X1
(508X610)(25)
24X30X1
(610X762x25)
24X36X1
(610X914X25)

500

600

700

800

900

1000

1100

1200

0.05

0.07

0.08

0.1

0.12

0.13

0.14

0.15

0.09

0.10

0.11

0.13

0.14

0.05

0.06

0.07

0.06

....
--

0.04

Table 9 - Dry Coil Air Delivery*
UNIT
Size

HEATING

RISERANGE
OF(oc)

MOTOR
SPEED

Low

Med-Low

24040

30 - 60
(17 - 33)

Medium2

Med-High1

High

Low

Med-Low

24060

25 - 55

Medium2

(14 - 31)

Med-High

High1

- Horizontal

WIRE
COLOR

Blue

Pink

Red

Orange

Black

Blue

Pink

Red

Orange

Black

1300

1400

1500

1600

0.15

0.16

.....

0.08

0.09

0.1

.....

0.07

0.08

0.09

1700

1800

1900

2000

2100

2200

2300

0.09

0.10

0.11

0.12

0.13

0.14

...........

and Downflow

Discharge

- Unit PGD4 / PGS4

EXTERNALSTATICPRESSURE(IN. W.C.)
0.1

0.2

CFM

754

650

Heating
Rise (°F)
Heating
Rise (°C)
CFM

40
22

Heating
Rise (°F)
Heating
Rise (°C)
CFM

36
20
,!

0.4

0.5

0.6

0.7

0.8

0.9

777

675

_!:

....

! _75::,

774

684

Heating
Rise (°F)
Heating
Rise (°C)
CFM

759

667

Heating
Rise (°F)
Heating
Rise (°C)
CFM

0.3

!!!H!i!!!!!!ili_i_!!!!!!!i!!i!!!i

!!!!H
!i!!!!;;
!i!!;!i_i
_:_i_!!
!_i!!!!i!i!!!
i!i!
!!!H!I!!!!;
;!i!!;!
i_!_i
_i:_
_!!_;!!;!;
!!i!i!;!!i!i!;
iiiiiii
iii;
;ii
ii;;i
;i_i
_ii_ii
iiii
iiiiiiii
iiiiil

!!!i!!!!;
;!i!_!!i_!!;i!!i!
!i!i!i!!
ii!
i;i!!i!!!!;
;!i7a
!i _!
iii;i_ii
;!;i!iiii
;!!!i!!i!
!!!;
;!!
!_i!!!!!;!
i!!;
;!!!i!;

754

650

Heating
Rise (°F)
Heating
Rise (°C)
CFM

777

675

Heating
Rise (°F)
Heating
Rise (°C)
CFM

!!!!H}i!!!!!!ii!!i!ii_!i!!!!!!}!!!!!:!!:!!:!!!!!:,
!!!i}i}!!!!!ii!!i!ii!!851:!!!!!i!!:!!:!!!!!!!!!!!i
.... 774
684

!!H}i!!!!!!ii!_;!!;!i!!:i!i,!i!:,
iiiiiiiiiiiiiil_iiiiiiiiiiili
iiH_iiiiiii_iiii_ii!iii_iiiiiiiiiiiiiii_Hiiii_}iiiiiii_ii_i_iiiii_ii
,iiiHliiiiiiilliiii_ii!iiiiiiiiiiiiiiiiiii

Heating
Rise (°F)
Heating
Rise (°C)
CFM

759

667

Heating
Rise (°F)
Heating
Rise (°C)
CFM

Heating
Rise (OF)
Heating
Rise (°C)

462 O1 2002

Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PGD4 / PGS4
HEATING
RISERANGE
UNIT

OF(oc)

MOTOR
SPEED

WIRE
COLOR

Low

Blue

Ned-Low1

30040

30 - 60
(17 - 33)

Medium

Ned-High2

High

Low

Ned-Low

30060

25- 55
(14 - 31)

Medium

Ned-High2

High1

Low1

Ned-Low

36060

25- 55
(14 - 31)

Medium2

Ned-High

High

462 O1 2002 O1

Pink

Red

Orange

Black

Blue

Pink

Red

Orange

Black

Blue

Pink

Red

Orange

Black

EXTERNALSTATICPRESSURE(IN, W.C.)
0.1
0.2
CFM
Heating
41
47
Rise (°F)
Heating
23
26
Rise (°C)
CFM
973
887
Heating
31
34
Rise (°F)
Heating
17
19
Rise (°C)
CFM
_888 , _023
Heating
NA
30
Rise (°F)
Heating
NA
16
Rise (°C)
CFM
Heating
NA
NA
Rise (°F)
Heating
NA
NA
Rise (°C)
CFM
Heating
NA
NA
Rise (°F)
Heating
NA
NA
Rise (°C)
CFM
Heating
NA
NA
Rise (°F)
Heating
NA
NA
Rise (°C)
CFM
973
887
Heating
46
50
Rise (°F)
Heating
25
28
Rise (°C)
CFM
_88:, _023
Heating
41
43
Rise (°F)
Heating
23
24
Rise (°C)
CFM
Heating
39
42
Rise (°F)
Heating
22
23
Rise (°C)
CFM
Heating
37
39
Rise (°F)
Heating
21
22
Rise (°C)
CFM
_234
1168
Heating
36
38
Rise (°F)
Heating
20
21
Rise (°C)
CFM
_290, _'2_8
Heating
34
36
Rise (°F)
Heating
19
20
Rise (°C)
CFM
Heating
33
34
Rise (°F)
Heating
18
19
Rise (°C)
CFM
Heating
28
29
Rise (OF)
Heating
15
16
Rise (°C)
CFM
Heating
27
28
Rise (OF)
Heating
15
16
Rise (°C)

0.3

0.4

0.5

0.6

0.7

0.8

0.9

31
823

!!!!i!i!}!!iii!iZ3_;!il;!!ii!i!!!!i!,!!!'!!!!!!iii!ii!!66_!!i!!!:i!!i!!!!i!i:
!!!!!!!!!ii!!i!!_538!_!!!!i!!!!i!!i!i_!.iiiHiiiiiiiiii_i_ii!_iiiii}i_i!_i_
iiiiiiiiiiiii_iiiiiiii_i_iiiiiiiii_iiii_iiiiiiiiii!i_i_iiiiiiiiii_iiiii_i_iiiiiiii

954

881

800

996

915

840

823

!!!i}i!!!!i',!'i!723!i11!_!i!!!!!}!!
iiiHiiiii',i'iii658;i;;i;ii:i:iil,iiiiiii;
iiiii;i:',i',151631i}ii!:_ii!i!:iiiiiiiiiiii:',i'}i_6i_iii!,ii_ii!i!iiii

!!!i!i!!!!i',!'i!758!;i!;!!:i:i!i,!!!ii!i
iiiiiiiii',i'iii68!ili,i,i!ii!iiii!ii!i
iiiiiii}:',i'}5164iii!ii,_{{!il,}iii!iiiiii;},i'}i_80%iiiii

!!!!i!i!}!!iii!iZ3_;!il;!!ii!i!!!!i!,!!!'!!!!!!iii!ii!!_6_!!i!!!:i!!i!!!!i!i:
!!!!!!!!!ii!!i!!_538!_!!!!i!!!!i!!i!i_!_iiiHiiiiiiiiii_i_ii!;iiiii}i_i!_i_
iiiiiiiiiiiii_iiiiiiii_i_iiiiiiiii_iiii_iiiiiiiiii!i_i_iiiiiiiiii_iiiii_i_iiiiiiii

954

881

800

!!!i}i!!!!i',!'i!723!i11!_!i!!!!!}!!
iiiHiiiii',i'iii_58;i;;i;ii:i:iil,iiiiiii;
iiiii;i:',i',151631i}ii!:_ii!i!:iiiiiiiiiiii:',i'}i_6i_iii!,ii_ii!i!iiii
NA

996

915

840

1093

1021

961

89_:

!!!!}!!!!!i',!'=!_58!!!!i!!i!i,!!!!i{
!!!i!!!!i',i'ili,i68_iiiiiiiiliiiiii;
iii_i}iii``i`i_i_!ii!iiiiii`!`i!;_i`_iiiiiiiii``i`i_i48_i_iii_i`i`i`i_i
i

_25_

1154

1090

1027

977

1158

1102

!!!i!i!!!!i_!_i_!89_!_!!!!!!!i!;!!:!!;!
_28_ :'_ii_i_62,i,i,iii,liiiii'liiii{i

1046

981

!!i}i!}!!i',!'i!_'8!,!!!!i!!!!:i!i{
!!i!!!!i',!'i!!,_i;i;i{;!i!!!!i!i!!!!
48

Table 9 - Dry Coil Air Delivery*

UNIT

HEATING
RISE
RANGE

- Horizontal
MOTOR
SPEED

and Downflow

WIRE
COLOR

OF(oc)

Low

Med-Low

36090

35 - 65

Medium 2

(19 - 36)

Med-High

High1

Low 1

Med-Low

42060

25 - 55

Medium

(14 - 31)

Med-High2

High

Low

Med-Low

42090

35 - 65
(19 - 36)

Medium1

Med-High2

High

Blue

Pink

Red

Orange

Black

Blue

Pink

Red

Orange

Black

Blue

Pink

Red

Orange

Black

Discharge

- Unit PGD4 / PGS4
EXTERNALSTATICPRESSURE(IN, W.C.)

0.1
CFM
_234
Heating
55
Rise (°F)
Heating
31
Rise (°C)
CFM
_90
Heating
53
Rise (°F)
Heating
29
Rise (°C)
CFM
Heating
50
Rise (°F)
Heating
28
Rise (°C)
CFM
Heating
42
Rise (°F)
Heating
24
Rise (°C)
CFM
Heating
42
Rise (°F)
Heating
23
Rise (°C)
CFM
1295
Heating
34
Rise (°F)
Heating
19
Rise (°C)
CFM
1345
Heating
33
Rise (°F)
Heating
18
Rise (°C)
CFM
Heating
30
Rise (°F)
Heating
16
Rise (°C)
CFM
Heating
29
Rise (°F)
Heating
16
Rise (°C)
CFM
Heating
26
Rise (°F)
Heating
14
Rise (°C)
CFM
1295
Heating
53
Rise (°F)
Heating
29
Rise (°C)
CFM
1345
Heating
51
Rise (°F)
Heating
28
Rise (°C)
CFM
Heating
45
Rise (°F)
Heating
25
Rise (°C)
CFM
Heating
44
Rise (°F)
Heating
24
Rise (°C)
CFM
Heating
40
Rise (OF)
Heating
22
Rise (°C)

0.2

0.3

0.4

0.5

1168

1093

1021

961

0.6

0.7

0.8

_25

759

1090

1027

977

1158

1102

1046

981

89_

;68

1154

, _223

0.9

NA
_6_

1140

1234

1182

1126

!!!!i!_!!!!i`_!!_i!o_5_!!!!_!!!_i!_!!!!i!x!!i`_!`_!_i!oi_!!_6iiiiiiii!
!!!!!!!!!i`_!`_!_i_55_!!i!_!_!!!!!!!!!!_i1i_iiiii
i;iiii:;,;,_i,;,ii_iiiil;
41

1282

1235

1194

1140

1358

1323

1282

1234

1169

1130

_69_

1362

1313

1278

1231

1188

1234

1182

1126

1282

1235

1194

1140

1358

1323

1282

1234

1169

1130

1362

1313

1278

1231

1188

!!!!!f!!!!!iii!ii_i!;_75!i!!!!i!i!!i!!i!,
iiiiiiiiiiiiiiiii_il;0!_!!_!iiiii!ii!iiiii_i

!!!!!!!!!!!iii!ii_i!;09_!!!!i!i!!i!!i!!

462 O1 2002

Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PGD4 / PGS4
UNIT

HEATING
RISE
RANGE

MOTOR
SPEED

EXTERNALSTATICPRESSURE(IN, W.C.)

WIRE
COLOR

OF(oc)
CFM
Heating
Low 1

Blue

Rise (°F)
Heating
Rise (°C)
CFM
Heating

Med-Low

48090

35 - 65

Medium2

(19 - 36)

Med-High

High

Low

Med-Low

48115

30 - 60
(17 - 33)

Medium 2

MedHigh 1

High

Low

Med-Low

48130

35 - 65
(19 - 36)

Medium 2

MedHigh 1

High

462 01 2002 01

Pink

Red

Orange

Black

Blue

Pink

Red

Orange

Black

Blue

Pink

Red

Orange

Black

Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)
CFM
Heating
Rise (OF)
Heating
Rise (°C)

0.1

0.2

0.3

1402

1351

1311

0.4

0.5

0.6

0.7

0.8

0.9

!!!i!i!!!!i_i!2o_!_i:!;!!!!_!,!!!!i!!!!i'_!'_!_i!_!_!!i!!i!i!!!i
iiiiiiiiii',i'_;i_i_ii'ii_ii;iiiill
54

1457

1404

1367

1318

1284

!!!i!i!!!!i_!!_i!23_;!i:!!!;!!i!
iiiiiiiii_,i_,_;i_i:iS_iiiiiiiiili,!iiiiiiiiiii_,i_,_;i_i_,li,_,i_,liiiii
iiiiiiiiiiii_,i_,_;i_i04!i!iliiiiiiil

1553
1512
1465
1427
1381
!!!i!_!!!!i_!_61!!!!!!!1!_!!_!!!!!!!_g_:i:i:!!_!!!_:_:_!1!_!!!!!_42,_!!!_!:!;!_!!!i!_!!!!i_0!_!!!_!!!!!!_
39

_234_,

_230_,

:2258,

1402

1351

1311

:220_ :, _I

1457

1404

1367

1318

1284

_ 36:,

_69_:,

64_,

_803

!!!i!_!!!!_!_!_23_i_i!ii!_ii_i_iiiii_iiii'_'i_iiii_97ii_i_i_iii_iii_iiii'_'i_iiii_ill_iii_iliiJiiiii
NA

_60_

1553

1512

1465

1427

1381

_79_

!!!i!_!!!2344_!_!:_!!_!!i!!i.!!i!_!!i!2306!i!!i!!!_!i!.!!!!_!!i!2259!_!_!_!_!!i!i!i!!_!!.!!!_!!_i!22_3!_!!_!!!_!.!!!!_!!!!_!_!_!!!!_!!!!_!_.!_
iiiiiiiiii_ii20_0_i_i_i_i_iiiiiiiii:i
iii_iiiii_ii_iii_i!i!i!iiiiii_i_.?i_iiiii_ii_iii9_ii!iiii!!iiiii)iiiii_iiiii_ii_iii8_ii!iiii
37

1402

1351

1311

1457

1404

1367

1318

1284

!!!i!i!!_!!!26_i!i!!i!!!i!,!!!!i!!!!i_i!_i_!!!224ii_!ii!!!!!i!
iiiiiiiiii_ii_i_iii_iii_iiii_i_iiiiii,li

iiiiiiiiiiii,ii_iiiS#_iiiiiiiiiiiiiiii:

1553

1512

1465

1427

1381
NA

_79_
45

Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PGD4 / PGS4
UNIT

HEATING
RISE
RANGE
OF (oc)

MOTOR
SPEED

0.1

Low 1

Med-Low

60090

35 - 65
(19 - 36)

Medium 2

Med-High

High

Low

Med-Low

60115

30 - 60
(17 - 33)

Medium 2

Blue

Pink

Red

Orange

Black

Blue

Pink

Red

MedHigh1

Orange

High

Black

Low

Ned-Low

60130

Blue

Pink

35 - 65
(19 - 36)

EXTERNAL STATIC PRESSURE

WIRE
COLOR

Medium 2

Ned-High 1

Red

Orange

CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM
Heating
Rise (°F)
Heating
Rise (°C)
CFM

0.2
49

0.3

0.4

1678

1635

1602

0.5

0.6

29
_

31
,

_51!3

_4_

0.7
60

0.8
63

0.9
NA

_438

_40_

:2_

_6_

28_,

_236

NA
_89
NA

,i_34_,
NA

:2_

_98_ ::, _

NA
_34_

:2_

_4_,

(IN. W.C.)

_,888

_,86_ _85

::, _!,89

1678

1635

1602

_6_

, _1'5

, _,880

!!!!i!_!!!_!!_i!ii_ii!ii_ii'!!!!_!!!!_i_!_!!51i_iii!ii!_ii_i_iii!_!![i!_!!!!_i_!_!_i_i_!i!!!!_i!_i!
iiiiiiiiiiiii_i_i438!i!i!i!!!!iiiiiiii_!,![!!i!!!!!i!!_!_!40_i!!i!i_!!!i;!_!i_
ii}iiiiiiiii_i_ii34_iiiiili

1711

1675

1628

, _,84_
47

_ 9_
48

_ _
50

iiiiii_iiiii_i44_!!!!_!_!!i!!_!!!!!!!!!!i!_X_!!!_!!!_!_!!!!_!!!!i!_!_!_i!!!!!_!_!!!!i!_!!!!i_!!!_!i!!!!_!!!!!!!!!!!i`:!`:_23!6!_!!!_i_!`_!_
iiiiiiiii',i'i_i_ii39!;!i;ii,
l,iiiiiiiii',i'ii_il;_i_iiiiiiii,i'ili,
_ iliiiiiii',i',i_ii02i_iii!ili,!,i!,liii_
NA

1678

1635

1602

Heating
Rise (°F)
Heating
Rise (°C)
CFM

1711

1675

1628

Heating
Rise (°F)
Heating
Rise (°C)
CFM

Heating
Rise (°F)

Heating
Rise (°C)

Heating
Rise (°F)
Heating
Rise (°C)
CFM

High

Black

*Air delivery values are without air filter and are for dry coil (See Table 10 - PGD4 / PGS4 Wet Coil Pressure Drop table).
1 Factory-shipped heating speed
2 Factory-shipped 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.
28

462 01 2002

Table
UNIT
SIZE
24
30
36
42
48
60

600
0.030
-

700
0.037
0.037
-

800
0.044
0.044

Table
UNITSIZE

900
0.053
0.053
0.055

10 - PGD4 / PGS4
1000
0.063
0.063
0.060
0.045

1100
0.072
0.090
0.050

11 - Wet Coil Air Delivery

Wet Coil Pressure

STANDARDCFM (S.C.F.M)
1200
1300
1400
0.081
0.105
0.100
0.110
0.140
0.060
0.065
0.075
0.041
0.063
0.085
-

-- Downflow

-- High

Speed

Drop (IN. W.C.)
1500
0.080
0.100
0.060
with 1-in.

1600

1700

1800

1900

2000

0.090
0.104
0.065

0.094
0.110
0.072

0.110
0.120
0.077

0.130
0.085

0.100

Filter and Economizer

EXTERNALSTATICPRESSURE(in.W.C.)
0.5
0.6
0.7

0.1

0.2

0.3

0.4

0.8

0.9

1.0

1333

1289

1256

1214

1152

1118

1076

1035

997

950

42
48

1612
2166

1569
2085

1527
2002

1481
1919

1451
1798

1393
1709

1351
1582

1317
1467

1278
1270

1242
988

2298

2239

2180

2110

2044

1951

1862

1777

1697

1591

MAINTENANCE
To ensure continuing high performance and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment. This unit should be
inspected at least once each year by a qualified service person.
To troubleshoot unit, refer to Table 12-14, Troubleshooting
Chart.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.

ENVIRONMENTAL

HAZARD

Failure to follow this caution may result in environmental
pollution.
Remove and re-cycle all components or materials (i.e. oil,
refrigerant, etc) before unit final disposal.

The minimum maintenance
as follows:
PERSONAL INJURY AND UNIT DAMAGE HAZARD
Failure to follow this warning could result in personal injury
or death and unit component damage.
The ability to properly perform maintenance
on this
equipment requires certain expertise, mechanical skills,
tools and equipment. If you do not possess these, do not
attempt to perform any maintenance on this equipment,
other than those procedures recommended in the Owner's
Manual.

ELECTRICAL

SHOCK HAZARD

Failure to follow these warnings
injury or death:

could result in personal

1. Turn off electrical power to the unit and install lock
out tag before performing any maintenance
or
service on this unit.
2. Use extreme caution
parts.
3. Never place anything
contact with the unit.

when removing
combustible

panels and

either on or in

UNIT OPERATION HAZARD
Failure to follow
operation.

this caution

may result

in improper

Errors made when reconnecting
wires may cause
improper and dangerous operation. Label all wires prior to
disconnecting when servicing.

462 01 2002 01

1. Inspect air filter(s)
necessary.

requirements

for this equipment are

each month. Clean or replace when

2. Inspect indoor coil, drain pan, and condensate drain each
cooling season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for cleanliness at the
beginning of each heating and cooling season. Clean
when necessary. For first heating and cooling season,
inspect blower wheel bi-monthly
to determine proper
cleaning frequency.
4. Check electrical connections for tightness and controls for
proper operation each heating and cooling season.
Service when necessary.
5. Ensure electric wires are not in contact with refrigerant
tubing or sharp metal edges.
6. Check and inspect heating section before each heating
season. Clean and adjust when necessary.
7. Check flue
necessary.
Air Filter

hood

and

remove

any

obstructions,

IMPORTANT: Never operate the unit without a suitable air filter
in the return-air duct system. Always replace the filter with the
same dimensional size and type as originally installed. See
Table 1 for recommended filter sizes.
Inspect air filter(s) at least once each month and replace
(throwaway-type) or clean (cleanable-type) at least twice during
each cooling season and twice during the heating season, or
whenever the filter becomes clogged with dust and lint.
Indoor Blower and Motor
NOTE: All motors are pre-lubricated.
these motors.

Do not attempt to lubricate

For longer life, operating economy, and continuing efficiency,
clean accumulated dirt and grease from the blower wheel and
motor annually.

Flue Gas Passageways
ELECTRICAL

SHOCK HAZARD

Failure to follow this warning could result in personal injury
or death.
Disconnect and tag electrical power
cleaning the blower motor and wheel.

to the unit before

To clean the blower motor and wheel:
1. Remove and disassemble blower assembly as follows:
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 blower partition
and slide assembly out. Be careful not to tear
insulation in blower compartment.
d. Ensure proper reassembly by marking blower wheel
and motor in relation to blower housing before
disassembly.
e. Loosen setscrew(s) that secures wheel to motor shaft,
remove screws that secure motor mount brackets to
housing, and slide motor and motor mount out of
housing.
2. Remove and clean blower wheel as follows:
a. Ensure proper reassembly by marking wheel
orientation.
b. Lift wheel from housing. When handling and/or
cleaning blower wheel, be sure not to disturb balance
weights (clips) on blower wheel vanes.
c. Remove caked-on dirt from wheel and housing with a
brush. Remove lint and/or dirt accumulations from
wheel and housing with vacuum cleaner, using soft
brush attachment. Remove grease and oil with mild
solvent.
d. Reassemble wheel into housing.
e. Reassemble motor into housing. Be sure setscrews
are tightened on motor shaft flats and not on round
part of shaft. Reinstall blower into unit. Reinstall capacitor.
f. Connect 5 pin plug and 4 pin plug to indoor blower
motor.
g. Reinstall blower access panel.
3. Restore electrical power to unit. Start unit and check for
proper blower rotation and motor speeds during heating
and cooling cycles.
Induced Draft (combustion
air) Blower Assembly
The induced-draft
blower assembly consists of the inducer
motor, the blower housing, and the induced-draft blower wheel.
Clean periodically to assure proper airflow and heating efficiency.
Inspect blower wheel every fall and periodically during the
heating season. For the first heating season, inspect blower
wheel bimonthly to determine proper cleaning frequency.
To inspect blower wheel, remove draft hood assembly. Shine a
flashlight into opening to inspect wheel. If cleaning is required,
remove induced-draft blower assembly as follows:
1. Remove control access panel.
2. Remove the 5 screws that attach induced-draft blower assembly to the flue collector box cover.
3. Slide the assembly out of the unit. Clean the blower
wheel. If additional cleaning is required, continue with
Steps 4 and 5.
4. To remove blower wheel, remove 2 setscrews.
5. To remove inducer motor, remove screws that hold the
inducer motor to the blower housing.
6. To reinstall, reverse the procedure outlined above.

To inspect the flue collector box and upper areas of the heat
exchanger:
1. Remove the induced draft blower assembly according to
directions in the Induced Draft Blower Assembly section.
2. Remove the 11 screws holding the flue collector box cover
(See 19) to the heat exchanger assembly. Inspect the heat
exchangers.
3. Clean all surfaces, as required, using a wire brush.
Limit Switch
Remove blower access panel. Limit switch is located on the fan
partition.
Burner Ignition
Unit is equipped with a direct spark ignition 100 percent lockout
system. Ignition module (IGC) is located in the control box (See
19). Module contains a self-diagnostic
LED. During servicing,
refer to label diagram or Table 5 in these instructions for LED
interpretation.
If lockout occurs, unit may be reset by either momentarily
interrupting power supply to unit or by turning selector switch to
OFF position at the thermostat.
Main Burners
At the beginning
of each heating season,
inspect for
deterioration 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 controlaccess panel (See Fig. 20).
4. Disconnect gas piping at unit gas valve.
5. Remove fan partition mounting bracket (2 screws located
on the left side of the control compartment on the fan partition panel). Slide bracket forward, bottom first, to remove
(See Fig. 19 & 20).
6. Remove wires connected to gas valve. Mark each wire.
7. Remove ignitor and sensor wires at the ignitor module.
8. Remove the mounting screw that attaches the burner rack
to the unit base (See Fig. 19).
9. Slide the burner rack out of the unit (See Fig. 19 and 22).
10. To reinstall, reverse the procedure outlined above.
Outdoor Coil, Indoor Coil, and Condensate Drain Pan
Inspect the condenser coil, evaporator coil, and condensate
drain pan at least once each year.
The coils are easily cleaned when dry; therefore, inspect and
clean the coils either before or after each cooling season.
Remove all obstructions,
including weeds and shrubs, that
interfere with the 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 brush
attachment. Be careful not to bend the fins. If coated with oil or
grease, clean the coils with a mild detergent and water solution.
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 condenser coil fins from inside to outside the
unit. On units with an outer and inner condenser coil, be sure to
clean between the coils. Be sure to flush all dirt and debris from
the unit base.
Inspect the drain pan and condensate drain line when inspecting
the coils. Clean the drain pan and condensate drain by removing
all foreign matter from the pan. Flush the pan and drain trough
with clear water. Do not splash water on the insulation, motor,
wiring, or air filter(s). If the drain trough is restricted, clear it with a
"plumbers snake" or similar probe device.

462 01 2002

Outdoor Fan

Fig. 20 - Unit Access Panels

UNIT OPERATION HAZARD
Failure to follow this caution may result in damage to
unit components.
Keep the condenser fan free from all obstructions to
ensure proper cooling operation. Never place articles
on top of the unit.

1. Remove 6 screws holding outdoor grille and motor to top
cover.
2. Turn motor/grille assembly upside down on top cover to
expose fan blade.
3. Inspect the fan blades for cracks or bends.
4. If fan needs to be removed, loosen setscrew and slide fan
off motor shaft.
5. When replacing fan blade, position blade as shown in Fig.
23.
6. Ensure that setscrew engages the flat area on the motor
shaft when tightening.
Fig. 21 - Removal of Motor and Blower Wheel

7. Replace grille.
Fig. 19 - Blower Housing and Flue Collector Box
FanPartitionMountingBracket

BLOWER
HOUSING

Integrated
Gas Unit
(IGO)
Auto Transformer
fuses used on 460
only.
(Hidden)
Fan
Board (IFB)

Induced
Motor

2 SETSCREWS
(HIDDEN)

Draft

Roflout
Collector
Box

Inducel
Blower
Housing

Burner
Rack

Mounting
Screw

Switch

Fig. 22 - Burner Rack Removed

462 01 2002 01

Fig. 23 - Fan Blade Position

FAN GRILLE

MOTOR

SHAFT

MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE
"A"
SIZE
IN.
MM
24
6.3
160
30
6.3
160
36
7.3
185
42
7.6
193
48
7.6
193
60
7.6
193
Electrical Controls

and Wiring

Gas Input

Inspect and check the electrical controls and wiring annually. Be
sure to turn off the electrical power to the unit.
Remove access panels to locate all the electrical controls and
wiring. Check all electrical connections for tightness. Tighten all
screw connections. If any smoky or burned connections are
noticed, disassemble the connection, clean all the parts, re-strip
the wire end and reassemble the connection properly and
securely.
After inspecting the electrical controls and wiring, replace all the
panels. Start the unit, and observe at least one complete cooling
cycle to ensure proper operation. If discrepancies are observed
in operating cycle, or if a suspected malfunction has occurred,
check each electrical component with the proper electrical
instrumentation. Refer to the unit wiring label when making these
checks.
Refriqerant Circuit
Annually inspect all refrigerant tubing connections and the unit
base for oil accumulations. Detecting oil generally indicates a
refrigerant leak.

EXPLOSION,

SAFETY AND ENVIRONMENTAL

HAZARD

Failure to follow this warning could result in personal injury,
death 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.
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. If a refrigerant leak is
detected, refer to the Check for Refrigerant Leaks section.
If no refrigerant leaks are found and low cooling performance is
suspected, refer to the Checking and Adjusting Refrigerant
Charge section.

The gas input does not require checking unless improper
heating performance is suspected. If a problem exists, refer to
the Start-Up section.
Evaporator

Airflow

The heating and/or cooling airflow does not require checking
unless improper performance is suspected. If a problem exists,
be sure that all supply- and return-air grilles are open and free
from obstructions,
and that the air filter is clean. When
necessary, refer to the Indoor Airflow and Airflow Adjustments
section to check the system airflow.
R-410A Items
Metering Device (Thermostatic

Expansion Valve )

This metering device is a hard shutoff, balance port TXV. The
TXV maintains a constant superheat at the evaporator exit
resulting in higher overall system efficiency.
Pressure Switches
Pressure switches are protective devices wired into control
circuit (low voltage). They shut off compressor if abnormally high
or low pressures are present in the refrigeration circuit. These
pressure switches are specifically designed to operate with
R-410A systems. R-22 pressure switches must not be used as
replacements for the R-410A system.
Loss of Charqe Switch
This switch is located on the liquid line and protects against low
suction pressures caused by such events as loss of charge, low
airflow across indoor coil, dirty filters, etc. It opens on a pressure
drop at about 20 psig. If system pressure is above this, switch
should be closed. To check switch:
1. Turn off all power to unit.
2. Disconnect leads on switch.
3. Apply ohm meter leads across switch. You should have
continuity on a good switch.
NOTE: Because these switches are attached to refrigeration
system under pressure, it is not advisable to remove this device
for troubleshooting
unless you are reasonably certain that a
problem exists. If switch must be removed, remove and recover
462 01 2002

all system charge so that pressure gauges read 0 psig. Never
open system without breaking vacuum with dry nitrogen.

necessary precautions
atmosphere.

High-Pressure

Servicing Systems on Roofs with Synthetic Materials

Switch

The high-pressure
switch is located in the discharge line and
protects against excessive condenser coil pressure. It opens at
650 psig.
High pressure may be caused by a dirty outdoor coil, failed fan
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 should have
continuity on a good switch.
Copeland

Scroll

Compressor

(R-410A

Refrigerant)

The compressor used in this product is specifically designed to
operate with R-410A refrigerant and cannot be interchanged.
The compressor is an electrical (as well as mechanical) device.
Exercise extreme caution when working near compressors.
Power should be shut off, if possible, for most troubleshooting
techniques. Refrigerants present additional safety hazards.

FIRE/EXPLOSION

HAZARD

Failure to follow this warning could result in personal injury
or death and/or property damage.
Wear safety glasses and gloves when handling refrigerants.
Keep torches and other ignition sources away from
refrigerants and oils.

The scroll compressor pumps refrigerant throughout the system
by the interaction of a stationary and an orbiting scroll. The scroll
compressor has no dynamic suction or discharge valves, and it
is more tolerant of stresses caused by debris, liquid slugging,
and flooded starts. The compressor is equipped with a noise
reducing shutdown device and an internal pressure relief port.
The pressure relief port is a safety device, designed to protect
against extreme high pressure. The relief port has an operating
range between 550 (26.34 kPa) and 625 psi (29.93 kPa)
differential pressure.

EXPLOSION,

ENVIRONMENTAL

SAFETY HAZARD

Failure to follow this warning could result in personal injury,
death or equipment damage.
This system uses R-410A refrigerant which has higher
operating pressures than R-22 and other refrigerants. No
other refrigerant may be used in this system. Gauge set,
hoses, and recovery system must be designed to handle
R-410A.
If you are unsure, consult the equipment
manufacturer.

to avoid

exposure

of the oil to the

POE (polyolester) compressor lubricants are known to cause
long term damage to some synthetic roofing materials.
Exposure,
even if immediately
cleaned up, may cause
embrittlement (leading to cracking) to occur in one year or more.
When performing any service that may risk exposure of
compressor oil to the roof, take appropriate precautions to
protect roofing. Procedures which risk oil leakage include, but
are not limited to, compressor replacement, repairing refrigerant
leaks, replacing refrigerant components such as filter 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 10 X 10 ft. (3.1 m X 3.1 m) area.
2. Cover area in front of the unit service panel with a terry
cloth shop towel to absorb lubricant spills and prevent
run-offs, and protect drop cloth from tears caused by tools
or components.
3. Place terry cloth shop towel inside unit immediately under
component(s)
to be serviced and prevent lubricant
run-offs through the Iouvered openings in the unit base.
4. Perform required service.
5. Remove and dispose of any oil contaminated
local codes.

material per

Liquid Line Filter Drier
This filter drier is specifically designed to operate with R-410A.
Use only factory-authorized
components. Filter drier must be
replaced whenever the refrigerant system is opened. When
removing a filter drier, use a tubing cutter to cut the drier from the
system. Do not unsweat a filter drier from the system. Heat from
unsweating will release moisture and contaminants from drier
into system.
R-410A Refriqerant Charqinq
Refer to unit information plate and charging chart. Some R-410A
refrigerant cylinders contain a dip tube to allow liquid refrigerant
to flow from cylinder in upright position. For cylinders equipped
with a dip tube, charge R-410A units with cylinder in upright
position and a commercial metering device in manifold hose.
Charge refrigerant into suction-line.

TROUBLESHOOTING
Use the Troubleshooting
occur with these units.

Guides (See Tables 12-14) if problems

START-UP
Use Start-Up
followed.

CHECKLIST

checklist to ensure proper start-up

procedures are

Refrigerant System
This information covers the refrigerant system of the PGD4 /
PGS4, including the compressor oil needed, servicing systems
on roofs containing synthetic materials, the filter drier and
refrigerant charging.
Compressor Oil
The Copeland scroll compressor
uses 3MAF POE oil. If
additional oil is needed, use Uniqema RL32-3MAF. If this oil is
not available, use Copeland Ultra 32 CC or Mobil Arctic EAL22
CC. This oil is extremely hygroscopic, meaning it absorbs water
readily. POE oils can absorb 15 times as much water as other
oils designed for HCFC and CFC refrigerants.
Take all
462 01 2002 01

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

•

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.

retard.

• Vacuum pumps will not remove moisture from oil.
•

Do not use liquid-line

•

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

filter driers with rated working pressures less than 600 psig.

•

Do not install a suction-line

•

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

•

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

filter drier in liquid line.

• Wrap all filter driers and service valves with wet cloth when brazing.
• A factory approved liquid-line
• Do NOT use an R-22 TXV.
•

filter drier is required on every unit.

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.

462 01 2002

Table 12- Troubleshooting
SYMPTOM

Chart

CAUSE

REMEDY

Power failure

Call power company
Replace fuse or reset circuit breaker

Fuse blown or circuit breaker tripped
Compressor

and condenser

fan will not start.

Defective contactor, transformer, or high-pressure,
of-charge or low-pressure switch
Insufficient

loss-

Incorrect or faulty wiring
Thermostat

Check wiring diagram and rewire correctly
Lower thermostat temperature setting below room
temperature

setting too high

Faulty wiring or loose connections in compressor
Compressor motor burned out, seized, or
Compressor
runs

will not start but condenser

fan

internal overload open
Defective run/start capacitor, overload,
One leg of 3-phase

circuit

start relay

Scroll compressor

Refrigerant

is rotating in the wrong direction

overcharge

Replace and determine cause
Determine cause and correct
Determine cause and correct

Defective run/start capacitor
Faulty outdoor fan motor or capacitor
in refrigerant

Dirty air filter
Unit undersized
Compressor

Determine cause and replace
Replace
Locate restriction and remove

system

Replace filter
Decrease load or increase unit size

for load

Thermostat temperature
Low refrigerant charge

operates continuously

Reset thermostat

set too low

Locate leak, repair, and recharge

Air in system

Recover refrigerant, evacuate system, and recharge
Clean coil or remove restriction

Outdoor coil dirty or restricted
Dirty air filter

Replace filter
Clean coil

Dirty condenser coil
Refrigerant overcharged

Excessive head pressure

Recover excess refrigerant

Air in system

Head pressure

Recover refrigerant, evacuate system, and recharge
Determine cause and correct

Condenser air restricted or air short-cycling
Low refrigerant charge

too low

Check for leaks, repair, and recharge.
Remove restriction

Restriction in liquid tube
Refrigerant overcharged

Excessive suction pressure

Recover excess refrigerant

Dirty air filter

Replace filter

Low refrigerant charge
Metering device or low side restricted

Check for leaks, repair and recharge
Remove source of restriction

Insufficient

Suction pressure too low

evaporator

Temperature

Increase air quantity
Check filter-replace if necessary
Reset thermostat

airflow

too low in conditioned

area

Install low-ambient

Outdoor ambient below 55°F (13°C)
Filter drier restricted

Table 13- Troubleshooting
SYMPTOM

Burners will not ignite

heating

462 01 2002 01

Guide-Heating
REMEDY

Water in gas line

Drain. Install drip leg.

No power to furnace

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

No 24-v

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

power supply to control circuit

Mis-wired

or loose connections
spark electrodes

Check all wiring and wire nut connections
Check flame ignition and sense electrode
Adjust as necessary.

protection that

positioning.

No gas at main burners

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

Dirty air filter

Clean or replace filter as necessary

Gas input to furnace too low
Unit undersized for application
Restricted airflow

Check gas pressure at manifold match with that on unit nameplate
Replace with proper unit or add additional unit

Limit switch cycles main burners

Poor flame characteristics

kit

Replace filter

CAUSE

Misaligned

Inadequate

Correct the direction of rotation by reversing the
3-phase power leads to the unit. Shut down unit to
allow pressures to equalize.
Recover refrigerant, evacuate system, and recharge
to capacities shown on rating plate

or undercharge

Insufficient line voltage
Blocked outdoor coil

Restriction

Replace compressor
Determine cause and replace

Determine cause and correct

Defective compressor
Compressor cycles (other than normally satisfying thermostat)

Check wiring and repair or replace
Determine cause

Replace fuse or reset circuit breaker
Determine cause

power dead

Low input voltage
Three-phase
scroll compressor
makes excessive noise, and there may be a low
pressure differential.

Replace component
Determine cause and correct

line voltage

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

Clean or replace filter. Remove any restriction.
Check rotation of blower, temperature rise of unit. Adjust as necessary.
1. Tighten all screws around burner compartment
2. Cracked heat exchanger. Replace.
3. Unit over-fired. Reduce input (change orifices or adjust gas line or
manifold pressure).
4. Check burner alignment.
5. Inspect heat exchanger for blockage. Clean as necessary.

Table 14-

Troubleshooting

SYMPTOM
No Power or Hardware
(LED OFF)

Limit switch

Guide-LED

CAUSE
failure
Loss of power to control module (IGC)*.

faults

Status Codes
REMEDY
Check 5-amp fuse son IGC*, power to unit, 24-v circuit breaker, and
transformer. Units without a 24-v circuit breaker have an internal
overload in the 24-v transformer. If the overload trips, allow 10 minutes for automatic reset.
Check the operation of the indoor (evaporator)

High temperature

Flame sense fault
(LED 3 flashes)

The IGC* sensed flame that should not be present.

Reset unit. If problem persists, replace control board.

Inadequate airflow to unit.

Check the operation of the indoor (evaporator) fan motor and that
supply-air temperature rise agrees with range on unit nameplate
information.

4 consecutive
limit switch
(LED 4 flashes)
Ignition lockout
(LED 5 flashes)

fault

Pressure switch
(LED 6 flashes)

fault

limit switch is open.

fan motor. Ensure that

(LED 2 flashes)

faults

Unit unsuccessfully

attempted

ignition for 15 minutes,

Rollout switch fault
(LED 7 flashes)

Rollout switch has opened,

Internal control
(LED 8 flashes)

Microprocessor
hardware.

Temporary 1 hr auto reset fault I
(LED 9 flashes)

Check ignitor and flame sensor electrode spacing, gaps, etc. 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. Verify
pressure switch hose is tightly connected to both inducer housing and
pressure switch. Verify inducer wheel is properly attached to inducer
motor shaft. Verify inducer motor shaft is turning.

Open pressure switch,

fault

the supply-air temperature rise is in accordance with the range on the
unit nameplate. Clean or replace filters.

Rollout switch will automatically reset, but IGC* will continue to lockout
unit. Check gas valve operation. Ensure that induced-draft blower
wheel is properly secured to motor shaft. Inspect heat exchanger.
Reset unit at unit disconnect.

has sensed an error in the software or

Electrical interference

If error code is not cleared by resetting unit power, replace the IGC*.
impeding IGC software

Reset 24-v. to control board or turn thermostat off, then on again.
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 12-Troubleshooting
Guide-Heating
for additional troubleshooting analysis.
LEGEND
IGC--Integrated
Gas Unit Controller
LED--Light-Emitting
Diode

462 01 2002

START-UP

CHECKLIST

(Remove and Store in Job Files)
I. PRELIMINARY

INFORMATION

MODEL NO.:
SERIAL NO.:
DATE:
TECHNICIAN:
II. PRESTART-UP

(Insert check mark in box as each item is completed)

() VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION
( ) CHECK ALL ELECTRICAL

CONNECTIONS

AND TERMINALS

INSTRUCTIONS

FOR TIGHTNESS

( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)
( ) CHECK THAT INDOOR (EVAPORATOR)
() VERIFY THAT UNIT INSTALLATION

AIR FILTER IS CLEAN AND IN PLACE

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_DB
RETURN-AIR TEMPERATURE
DB

COOLING SUPPLY AIR

GAS HEAT SUPPLY AIR
PRESSURES
GAS INLET PRESSURE

IN. W.C.

GAS MANIFOLD PRESSURE

IN. W.C.

REFRIGERANT

SUCTIONPSIG,

SUCTION LINE TEMP*

REFRIGERANT

DISCHARGE_PSIG,

LIQUID TEMPt

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS
GAS HEAT TEMPERATURE RISE
TEMPERATURE RISE (See Literature) RANGE
MEASURED TEMPERATURE RISE
* Measuredat suction inlet to compressor
1- Measuredat liquid line leaving condenser.

462 01 2002 01

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ICP Package Units(both Units Combined) Manual L0909099

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