ICP Package Units(both Units Combined) Manual L0909100

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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Page Count: 37

Installation Instructions

PGD3 /PGS3 /WPG3 Series

PACKAGED GAS/ELECTRIC UNIT

InternationalComfortProducts,LLC 509 01 3402 01 04-09-09

Lewisburg,TN.37091

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS ............................ 1

INTRODUCTION ....................................... 2

RECEIVING AND INSTALLATION ..................... 2-13

Check Equipment ..................................... 2

Identify Unit ........................................ 2

Inspect Shipment ................................... 2

Provide Unit Support .................................. 2

Roof Curb ......................................... 2

Slab Mount ........................................ 2

Field Fabricate Ductwork .............................. 2

Provide Clearances ................................... 6

Rig and Place Unit .................................... 6

Inspection ......................................... 6

Rigging/Lifting ...................................... 6

Connect Condensate Drain ............................ 9

Install Flue Hood ..................................... 9

Install Gas Piping ..................................... 9

Install Duct Connections .............................. 10

Configuring Units for Downflow (Vertical)

Discharge ........................................ 10

Install Electrical Connections .......................... 10

High-Voltage Connections .......................... 12

Special Procedures for 208-V Operation .............. 12

Control Voltage Connections ........................ 12

Standard Connection ............................... 12

Heat Anticipator Setting ............................. 13

Transformer Protection ............................. 13

PRE-START-UP ...................................... 13

START-UP ....................................... 13-20

Check for Refrigerant Leaks ........................... 13

Start-Up Heating & Make Adjustments .................. 14

Check Heating Control ............................. 14

Check Gas Input ................................... 14

Adjust Gas Input ................................... 15

Check Burner Flame ............................... 15

Normal Operation .................................. 19

Airflow and Temperature Rise ........................ 19

Heating Sequence of Operation ...................... 19

Limit Switches ..................................... 19

Rollout Switch ..................................... 19

Start-Up Cooling & Make Adjustments .................. 19

Checking Cooling Control Operation .................. 19

Checking & Adjusting Refrigerant Charge ............. 19

Indoor Airflow and Airflow Adjustments ................ 20

Continuous Fan Operation .......................... 20

Cooling Sequence of Operation ...................... 20

MAINTENANCE ................................... 28-30

Air Filter .......................................... 28

Indoor Blower and Motor ............................ 28

Induced Draft (Combustion Air) Blower ................ 29

Flue Gas Passageways ............................ 29

Limit Switch ....................................... 29

Burner Ignition ..................................... 29

Main Burners ...................................... 29

Removal of Gas Train .............................. 29

Outdoor Coil, Indoor Coil, & Condensate Drain Pan ..... 29

Outdoor Fan ...................................... 30

Electrical Controls and Wiring ........................ 31

Refrigerant Circuit .................................. 31

Gas Input ......................................... 31

Evaporator Airflow ................................. 31

R-410A Items ..................................... 32

TROUBLESHOOTING ................................. 32

START-UP CHECKLIST ............................... 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 PGD3/PGS3/WPG3 (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.

1 509 01 3402 01

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON

MONOXIDE POISONING HAZARD

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.

CUT HAZARD

Failure to follow this caution may result in personal injury.

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.

INTRODUCTION

The PGD3/PGS3/WPG3 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 NOx requirements apply only to natural gas

installations.

RECEIVING AND INSTALLATION

Step 1 m Check 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 m Provide 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.

For hurricane tie downs, contact distributor for details and PE

(Professional Engineering) Certificate if required.

Roof Curb

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.

Slab Mount

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.

Fig. 2 -Slab Mounting Details

i n

I Illll

I Illll

2" lT dJJJ.[J

(50.8mm) l

±,,L

EVAR COIL COND. COIL

Step 3 _Field Fabricate 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 space must be

insulated and covered with a vapor barrier.

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.

509 01 3402 01 2

Fig. 3 -PGD3/PGS3/WPG324-36 Unit Dimensions

I I_1_1_1_ .............

I_1__1__1©1_

==1 I_,l&l-°l-= !!!!! :: :: ::: -=_

...... _z_ z ..... _

=1 I-_1-_1-_1-_ _- ::::: _ o ......

..... _ _ ...... z

_1 I£1_1_1£

<.= _ .

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o

T

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3 509 01 3402 01

Fig. 4 -PGD3/PGS3/WPG342-60 Unit Dimensions

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,© o

c_J

t °

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Lr)

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509 01 3402 01 4

Fig. 5 - Roof Curb Dimensions

ROOF CURB DETAIL

COMMON CURB

Dashed Lines show cross suppori

location for barge basepan units.

A09096

F

SMALL

BASE

UNiT

LARGE

BASE

UNIT

LARGE CURB /

A09095

UNIT PLACEMENT ON

COMMON CURB

SMALL OR LARGE BASE UNIT

A09094

UNIT SIZE

Small or

Large

Large

CATALOG

NUMBER

CPRFCURB010A00

CPRFCURB011A00

CPRFCURB012A00

CPRFCURB013A00

A

IN. (mm)

11 (279)

14 (356)

11 (279)

14 (356)

B(small base) B (large base) CD E F

IN. (mm)* IN. (mm)* IN. (mm) IN. (mm) IN. (mm) IN. (mm)

10 (254)

N/A

14 (356) 16 (406) 47.8 (1214)

32.4 (822)

43.9 (1116)

2.7 (69)

* Part Numbers CPRFCURB010A00 and CPRFCURB011A00 can be used on both small and large basepan units. The cross supports must be located based on whether the

unit is a small basepan or a large basepan.

NOTES:

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.

5509 01 3402 01

Step 4 mProvide 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 mRig 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 could result in personal

injury/death or property damage.

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.

is placed on the roof curb or mounting pad, remove

After the unit

the top skid.

509 01 3402 01 d

Fig. 6- PGD3/PGS3/WPG3 Unit Suggested Rigging

SMALL CABINET

24 30 36

Unit * Ib kg Ib kg Ib kg

Rigging Weight 311 141 316 143 326 148

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

NOTE: See dimensional drawing for corner weights.

Unit *

Rigging Weight

50CY502286 2,0

Ib

420

LARGE CABINET

42 48

kg Ib

191 428

kg Ib

194 450

60

kg

204

? 509 01 3402 01

UNIT SIZE

NOMINAL CAPACITY (ton)

SHIPPING WEIGHT** lb.

SHIPPING WEIGHT** (kg)

COMPRESSORS

Quantity

REFRIGERANT (R-410A)

Quantity lb.

Quantity (kg)

REFRIGERANT METERING DEVICE

OUTDOOR COIL

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 BLOWER

Nominal Cooling Airflow (Cfm)

Size in.

Size (mm.)

Motor HP (RPM)

FURNACE SECTION*

Burner Orifice No. (Qty...Drill Size)

Natural Gas

Propane Gas

HIGH-PRESSURE SWITCH

(psig) Cut-out Reset (Auto)

LOSS-OF-CHARGE /LOW-PRESSURE

SWITCH (Liquid Line) (psig) cut-out Reset

(auto)

RETURN-AIR FILTERSt$

Throwaway Size in.

(mm)

UNIT SIZE

NOMINAL CAPACITY (ton)

SHIPPING WEIGHT** Ib

SHIPPING WEIGHT** kg

COMPRESSORS

Quantity

REFRIGERANT (R-410A)

Quantity Ib

Quantity (kg,)

REFRIGERANT METERING DEVICE

OUTDOOR COIL

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 BLOWER

Nominal Cooling Airflow (Cfm)

Size in.

Size (mm)

Motor HP (RPM)

FURNACE SECTION*

Burner Orifice No. (Qty._Drill Size)

Natural Gas

Propane Gas

HIGH-PRESSURE SWITCH

(psig) Cut-out Reset (Auto)

LOSS-OF-CHARGE /LOW-PRESSURE

SWITCH (Liquid Line) (psig) cut-out Reset

(auto)

RETURN-AIR FILTERS Throwawayt$ in.

(mm)

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

Table 1 - Physical Data -Unit PGD3/PGS3/WPG3

24040 24060 30040 30060 36060

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

311 311 316 316 326

141 141 143 143 148

Scroll

1

36090 42060 42090

3 3-1/2 3-1/2

326 420 420

148 191 191

4.8 4.8 6.2 6.2 6.4 6.4 6.1 6.1

2.2 2.2 2.8 2.8 2.9 2.9 2.7 2.7

TXV

1..21 1...21 1...21 1...21 1...21 1...21 1...21 1...21

10.2 10.2 11.9 11.9 15.4 15.4 13.6 13.6

2800 2800 3000 3000 3200 3200 3600 3600

24 24 24 24 24 24 26 26

609.6 609.6 609.6 609.6 609.6 609.6 660.4 660.4

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

2...17 2...17 3...17 3...17 3...17 3...17 3...17 3...17

3.7 3.7 3.7 3.7 3.7 3.7 4.7 4.7

800 800 1000 1000 1200 1200 1400 1400

10x10 10x10 10x10 10x10 1lx10 1lx10 1lx10 1lx10

254x254 254x254 254x254 254x254 279,4x254 279,4x254 279,4x254 279,4x254

1/2 (1050) 1/2 (1050) 1/2 (1050) 1/2 (1050) 3/4 (1000) 3/4 (1000) 3/4 (1075) 3/4 (1075)

2.. ,44 2.. ,38 2.. ,44 2.. ,38 2.. ,38 3...38 2.. ,38 3...38

2...55 2...53 2...55 2...53 2...53 3...53 2...53 3...53

650 ,._- 15

420 ,. _- 25

20 -.__ 5

45 ,._- 10

20x20x1 20x24x1 24x30x1

508x508x25 508x610x25 610x762x25

Table llphysical Data Con't -Unit PGD3/PGS3/WPG3

48090 48115 48130 60090 60115 60130

44 4555

428 428 428 450 450 450

194 194 194 204 204 204

Scroll

1

6.4 6.4 6.4 10,0 10,0 10,0

2.9 2.9 2.9 4.5 4.5 4.5

TXV

1...21 1...21 1...21 2...21 2...21 2...21

15.5 15.5 15.5 15.5 15.5 15.5

4000 4000 4000 3200 3200 3200

26 26 26 26 26 26

660.4 660.4 660.4 660.4 660.4 660.4

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

3...17 3...17 3...17 3...17 3...17 3...17

4.7 4.7 4.7 5.7 5.7 5.7

1600 1600 1600 1750 1750 1750

11x10 11x10 11x10 11x10 11x10 11x10

279.4x254 279.4x254 279.4x254 279.4x254 279.4x254 279.4x254

1.0 (1075) 1.0 (1075) 1.0 (1075) 1.0 (1040) 1.0 (1040) 1.0 (1040)

3...38 3...33 3...31 3...38 3...33 3...31

3...53 3...51 3...49 3...53 3...51 3...49

650 +/- 15

420 +/- 25

20 +/- 5

45 +/- 10

24x36x1

610x914x25

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/min-

ute 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 correct filter sizes and quantity.

** For 460 volt units, add 14 Ibs (6.35 kg) to the shipping weight.

509 01 3402 01 8

Step 6 mConnect Condensate Drain

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

t-in. (25 ram) rain.

TRAP

OUTLET

ram) rain.

Step 7 m 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. Remove flue hood from shipping location (inside the return

section of the blower compartment-see Fig. 9 & 10). Re-

move 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.

3. Secure flue hood to flue panel by inserting a single screw

on the top flange and the bottom flange of the hood.

Step 8 _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) sparingly and only to

male threads of joint when making pipe connections. Use

only pipe dope that is resistant to action of liquefied

petroleum gases as specified by local and/or national

codes. Never use Teflon tape.

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.

509 01 3402 01

Table 2 - Maximum Gas Flow Capacity*

NOMINAL INTERNAL LENGTHOF PIPE FT (m)f

IRONPIPE DIAMETER 10 20 30 40 50 60 70 80 90 100 125 150 175 200

SIZE (IN,) (IN,) (3) (6) (9) (12) (15) (18) (21) (24) (27) (30) (38) (46) (53) (61)

1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 -- --

3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

1 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 cuft 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.

This length includes an ordinary number of fittings.

Fig. 8 - Sediment Trap

IN

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

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 required or allowed by

authority having jurisdiction, black iron pipe shall be

installed at furnace gas valve and extend a minimum of

2 in. (51 mm) outside furnace 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).

Step 9 mInstall Duct Connections

The unit has duct flanges on the supply- and 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

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.

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 duct covers. Ensure opening is

air- and watertight.

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.

509 01 3402 01 10

Fig. 9 - Supply and Return Duct Opening

Basepan

Downflow

(Vertical)

Supply _

Knockout

Horizontal Duct Covers

Basepan

Downflow

J (Vertical)

Return

Knockout

Fig. 10- Vertical (Downflow) Discharge Duct Knockouts

i .....

p ..................

INSTRUCTIONS FOR REMOVING DOWNSHOT PANELS

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

2 Starting in corner 1 tap out atl sides with a smatl hammer, Be careful

not to damage any other part of unit

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

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

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.

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.

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.

Step 10 m Install Electrical Connections

ELECTRICALSHOCKHAZARD

Failure to follow this warning could result in personal injury or

death.

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.

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit

being installed.

1. Make atl 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.

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.

11 509 01 3402 01

High-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 23 of

the compressor contactor.

Three-phase units:

1. Run the high-voltage (L1, L2, L3) 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 L3 to yellow wire on connection 13 of

the compressor contactor.

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

Special Procedures for 208-v Operation

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or

death.

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.

ELECTRICAL 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.

Control Voltage Connections

Do not use any type of power-stealing thermostat. Unit control

problems may result.

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

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.

HIGH VOLTAGE l

POWER LEADS _c= =

(SEE UNIT WIRtNG 1

LABEL) _:_ =

3-PHASE SHOWN

1-PHASE USES L_

TWO POWER

LEADS EQUIP GR

Fig. 11 - High- and Control-Voltage Connections

FIELD-SUPPLiED

FUSED DISCONNECT

CONTROL BOX

o=

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SPLICE BOX

LOW-VO LTAG E

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Heat Anticipator Setting (Electro-Mechanical Thermostats

on__eLv3

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 a direct

short will likely blow a secondary fuse. If an overload or short is

present, correct overload condition and check for blown fuse on

Indoor Fan board or Integrated Gas Controller. Replace fuse as

required with correct size and rating.

509 01 3402 01 12

PRE-START-UP

ENVIRONMENTAL, FIRE, EXPLOSION, ELECTRICAL

SHOCK HAZARD

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. Be

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.

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal injury,

death or property damage.

Do not purge gas supply into the combustion chamber. Do

not use a match or other open flame to check for gas leaks.

Use a commercially available soap solution made specifically

for the detection of 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 mCheck 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 high-

and 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 mStart-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.

13 509 01 3402 01

Fig. 12 - Burner Assembly

Fig. 13 - Monoport Burner

"Manifold

BURNER FLAME

BURNER

MANIFOLD

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 in-

crease the evaporator "OFF" delay in the event of high

duct static and/or partially-clogged filter.

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

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

2500 Btu/ft 3 at 1.5 specific gravity.

IN THE U.S.A.:

The input rating for altitudes above 2,000 ft (610 m) must 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

ALTITUDEFT (M) PERCENTOF DERATE FACTOR1"

0-2000

(0-610) 0 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

9001-10,000 36-40 0.62

(2744-3048)

*In Canada see Canadian Altitude Adjustment.

1-Derate multiplier factors are based on midpoint altitude for altitude

range.

IN CANADA:

The input rating for altitudes from 2,000 (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.

FurnaceInputRateat Sea X DerateMultiplier = FurnaceInputRateatIn-

Level Factor stallationAltitude

90,000 X 0.90 = 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.

509 01 3402 01 14

HEATING INPUT

(BTUH)

40,000

60,000

90,000

115,000

130,000

NUMBEROF ORI-

FICES

2

2

3

3

3

Min

4.0

4.0

4.0

4.0

4.0

Table 4 - Heating Inputs

GASSUPPLYPRESSURE(IN.W.C.)

Naturall-

Max

13.0

13.0

13.0

13.0

13.0

Propane*l-

Min

11.0

11.0

11.0

11.0

11.0

Max

13.0

13.0

13.0

13.0

13.0

MANIFOLDPRESSURE

(IN.W.C.)

Natural1-

3.2-3.8

3.2-3.8

3.2-3.8

3.2-3.8

3.2-3.8

Propane*f

10.0-1 l.O

10,0-11.0

10,0-11.0

10,0-11.0

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

REGULATOR

_COVERSCREW

PLASTIC

ADJUSTMENT

SCREM/

ON/OFF SWITCH

(PROPANE -WHITE)

(NATURAL- SILVER)

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).

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 ft 3 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.

FIRE AND UNIT DAMAGE HAZARD

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).

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.

Measure Manifold Pressure (Propane Units)

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.

15 509 01 3402 01

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509 01 3402 01 16

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509 01 3402 01 ;8

Normal Operation

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).

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 of Operation

(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 On

No Power or Hardware Failure Off

Limit Switch Fault 2 Flashes

Flame Sense Fault 3 Flashes

Four Consecutive Limit Switch Faults 4 Flashes

Ignition Lockout Fault 5 Flashes

Pressure Switch Fault 6 Flashes

Rollout Switch Fault 7 Flashes

Internal Control Fault 8 Flashes

Temporary 1 hr auto reset I9 Flashes

NOTES:

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

hr. Fault can be caused by stray RF signals in the structure or nearby.

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.

Rollout Switch

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.

Step 3 mStart-up 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 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 thermocouple- or 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.

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.

19 509 01 3402 01

Proceed as follows:

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

fittings.

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 grilles are open,

free from obstructions, and adjusted properly.

ELECTRICAL 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).

Gas Heatinq Fan Speed Set-up

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

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).

509 01 3402 01 20

Fig. 18- Interface Fan Board (IFB)

GAS

HEAT HIGH LOW CQM

GCCo

QC6 QC7 QC4 QC3

c

RL3 C8 R1L Q1 D2

.o000

.... nr-]

0 00004

SSTZ-8 u [

Y2/ _1/ cW2 DH G R

q3

F

Table 6 - Color Coding for Indoor Fan Motor Leads

Black = High Speed

Orange = Med-High Speed

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.

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.

21 509 01 3402 01

50901340201 22

FILTER SIZE

in. (ram)

20X20X1

(508X508X25)

20X24X1

(508X610)(25)

24X30X1

(610X762x25)

24X36X1

(610X914X25)

500

0.05 0.07 0.08 O.1 O.12 O.13 O.14 O.15 ........

.... 0.09 O.10 O.11 O.13 O.14 O.15 O.16 .....

-- -- -- 0.04 0.05 0.06 0.07 0.07 0.08 0.09 O.1 ........

....... 0.06 0.07 0.07 0.08 0.09 0.09 O.10 O.11 O.12 O.13 O.14 O.14

Table 8 - Filter Pressure Drop Table (IN. W.C.)

CFM

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

UNIT

Size

24040

24060

RISERANGE

OF(oc)

Table 9 - Dry Coil Air Delivery* -Horizontal and Downflow Discharge -Unit PGD3/PGS3/WPG3

HEATING MOTOR WIRE EXTERNALSTATICPRESSURE(IN, W.C.)

SPEED COLOR 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

CFM 754 650

Heating 40 46 56 NA NA NA NA NA NA

Low Blue Rise(°F)

Heating 22 26 31 NA NA NA NA NA NA

Rise(°C)

CFM 777 675 ! _75:: _

Heating 36 39 45 51 NA NA NA NA NA

Med-Low Pink Rise (°F)

Heating 20 22 25 28 NA NA NA NA NA

Rise(°C)

CFM 774 684

Heating 32 36 39 44 52 NA NA NA NA

30 - 60 Medium2 Red Rise(°F)

(17- 33) Heating 18 20 22 25 29 NA NA NA NA

Rise(°C)

CFM !009: ! 91 _ 840: 759 667

Heating 30 33 36 40 45 52 NA NA NA

Med-High1 Orange Rise (°F)

Heating 17 18 20 22 25 29 NA NA NA

Rise(°C)

CFM

Heating NA NA NA NA 31 34 37 41 47

High Black Rise(°F)

Heating NA NA NA NA 17 19 21 23 26

Rise(°C)

CFM 754 650

Heating NA NA NA NA NA NA NA NA NA

Low Blue Rise(°F)

Heating NA NA NA NA NA NA NA NA NA

Rise(°C)

CFM 851 : : 777 675

Heating 52 NA NA NA NA NA NA NA NA

Ned-Low Pink Rise(°F)

Heating 29 NA NA NA NA NA NA NA NA

Rise(°C)

CFM 9_! _::: 851 : 774 684

Heating 47 52 NA NA NA NA NA NA NA

25 - 55 Medium2 Red Rise(°F)

(14- 31) Heating 26 29 NA NA NA NA NA NA NA

Rise(°C)

CFM !00_: ,_i7 759 667

Heating 44 48 53 NA NA NA NA NA NA

Ned-High Orange Rise (°F)

Heating 24 27 29 NA NA NA NA NA NA

Rise(°C)

Heating 36 38 40 43 46 50 54 NA NA

High1 Black Rise(°F)

Heating 20 21 22 24 25 28 30 NA NA

Rise(°C)

23 509 01 3402 01

Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PGD3/PGS3/WPG3

UNIT

HEATING

RISERANGE

OF(oc)

30 - 60

30040 (17 -33)

25 - 55

30060 (14- 31)

25 - 55

36060 (14- 31)

MOTOR WIRE

SPEED COLOR

CFM

Heating

Low Blue Rise(°F)

Heating

Rise(°C)

CFM

Heating

Ned-Low1 Pink Rise (°F)

Heating

Rise(°C)

CFM

Heating

Medium Red Rise(°F)

Heating

Rise(°C)

CFM

Heating

Ned-High2 Orange Rise(°F)

Heating

Rise(°C)

CFM

Heating

High Black Rise (°F)

Heating

Rise(°C)

CFM

Heating

Low Blue Rise(°F)

Heating

Rise(°C)

CFM

Heating

Ned-Low Pink Rise(°F)

Heating

Rise(°C)

CFM

Heating

Medium Red Rise(°F)

Heating

Rise(°C)

CFM

Heating

Ned-High2 Orange Rise(°F)

Heating

Rise(°C)

CFM

Heating

High1 Black Rise (°F)

Heating

Rise(°C)

CFM

Heating

Low1 Blue Rise(°F)

Heating

Rise(°C)

CFM

Heating

Ned-Low Pink Rise(°F)

Heating

Rise(°C)

CFM

Heating

Medium2 Red Rise(°F)

Heating

Rise(°C)

CFM

Heating

Rise(OF)

Heating

Rise(°C)

Ned-High Orange

EXTERNALSTATICPRESSURE(IN,W.C.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

41 47 55 NA NA NA NA NA NA

23 26

973 887

31 34

17 19

_888 , _023

NA 30

NA 16

11'46' , _06_

NA NA

NA NA

31 NA NA NA NA NA NA

823 _73_;_._`_6_:_538_:_1_._1_`

37 41 45 56 NA NA NA

20 23 25 31 NA NA NA

954 881 800 !!!!i!i!!!!i',!'i!723!i11!,!i!!!!!!!,!!!i!i!!!!i',!'i!!658;!;;!;!!;i;i!i,!!!ii!!!!!!!!!i',!'!!S631ii!!i!!i!!!!i!!i!i:!,iiiiiiiiii',i'ili_6i_iiil,ii_ii!;i!;iil

32 34 38 42 46 54 NA

18 19 21 23 26 30 NA

996 915 840 !!!!i!_!!!!i``!`_!758!;_!;!!:_:_!__!!!_i!_!!!!i!!!!i``!`_!!68!!!!`i`!!i!!i!!!!i!!!!!!!!!!!i',!'!!'564!!!!!i,!!!i!i,!!!!!,iiiiiiiiii',i'ili_iSO_i:iiil,iiiiii

30 33 36 40 44 54 NA

17 18 20 22 24 30 NA

NA NA NA 30 31 34 37 41 48

NA NA NA 17 17 19 21 23 27

NA NA NA NA NA NA NA NA NA

NA NA

973 887

46 50

25 28

_888 , _023

41 43

23 24

39 42

22 23

NA NA NA NA NA NA NA

823 _73_._`_6_:_5__:_`_1_1_ '

54 NA NA NA NA NA NA

30 NA NA NA NA NA NA

954 881 800 !!!!i!i!!!!i',!'i!723!i11!,!i!!!!!!!,!!!i!i!!!!i',!'i!!_58;!;;!;!!;i;i!i,!!!ii!!!!!!!!!i``!`!!_5_3_i_!!i!!i!!!!i!!i!i:!`iiii_iiiii``i`i_i_i_ii_ii_ii!;i!_ii_

47 50 NA NA NA NA NA

26 28 NA NA NA NA NA

996 915 840 iiii_iiiii``i`i_i_!ii!iiiiii`!`i!;_i`_iiiiiiiii``i`i_i48Q_i_iii_!`i`!`!!!`i`!`!!!'

45 49 53 NA NA NA NA

25 27 29 NA NA NA NA

37 39 41

21 22 23

_234 1168 1093

36 38 41

20 21 23

_29_ , _'2_8 1154

34 36 39

19 20 21

35_ _2_, _,2_'6

33 34 36

18 19 20

44 46 50 55 NA NA

24 26 28 30 NA NA

1021 961

44 46 50 54 NA NA

24 26 28 30 NA NA

1090 1027 977 89_ _28:62

41 43 45 50 54 NA

23 24 25 28 30 NA

1158 1102 1046 981

38 40 42 45 48 53

21 22 24 25 27

High Black

CFM

Heating

Rise(OF)

Heating

Rise(°C)

509 O1 3402 O1 24

Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PGD3/PGS3/WPG

HEATING EXTERNALSTATICPRESSURE(IN,W.C.)

RISE MOTOR WIRE

UNIT

36090

42060

42090

RANGE

OF(OC)

35 - 65

(19 - 36)

SPEED COLOR

CFM

Heating

Low Blue Rise (°F)

Heating

Rise(°C)

CFM

Heating

Med-Low Pink Rise (°F)

Heating

Rise(°C)

CFM

Heating

Medium2 Red Rise (°F)

Heating

Rise(°C)

CFM

Heating

Med-High Orange Rise (°F)

Heating

Rise(°C)

CFM

Heating

High1 Black Rise (°F)

Heating

Rise(°C)

CFM

Heating

Low1 Blue Rise (°F)

Heating

Rise(°C)

CFM

Heating

Med-Low Pink Rise (°F)

Heating

Rise(°C)

CFM

Heating

Medium Red Rise (°F)

Heating

Rise(°C)

CFM

Heating

Med-High2 Orange Rise (°F)

Heating

Rise(°C)

CFM

Heating

High Black Rise (°F)

Heating

Rise(°C)

CFM

Heating

Low Blue Rise (°F)

Heating

Rise(°C)

CFM

Heating

Med-Low Pink Rise (°F)

Heating

Rise(°C)

CFM

Heating

Medium1 Red Rise (°F)

Heating

Rise(°C)

CFM

Heating

Med-High2 Orange Rise (°F)

Heating

Rise(°C)

25 - 55

(14 - 31)

35 - 65

(19 - 36)

High

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

_234 1168 1093 1021 961

55 58 62 NA NA

31 32 35 NA NA NA

_90, _223 1154 1090 1027 977

53 56 59 62 NA NA

29 31 33 35 NA NA

1158 1102 1046

50 53 55 59 62 65

89_; ,_25 : ,759 ;,68 :

NA NA NA NA

NA NA NA

89_

28 29 31 33 34 36 NA NA

iiiiiiiii',i'_i_i31ii6i_i_i_i_fii_;iiill

42 44 46 48 50 52 54 56

NA NA NA

NA NA NA

981 9!8 _3 _

NA NA NA

NA

24 24 25 26 28 29 30 31

1140

60

33

42 43 45 46 48 51 53 56 60

23 24 25 26 27 28 30 31 33

1295 1234 1182 1126 !!!i!i!!!!i_!!_i!O_iSi!!!!i,!!!ii!iiiiiiiiii_i_ii_iiOi_iii6iiiiiiiiiii!;iiilliiiiiiiii_,i_,i!i_955!i!ili!iii_iii!i!iiiiiiiii_,i_,li,898ii!iii!:_ii!i!:iiii!iiiiiiiiiiii_,i_,li,_Ti_!i!,ii_iiiiill

34 36 38 39 41 44 47 49 52

19 20 21 22 23 24 26 27 29

1345 1282 1235 1194 1140 !!!i!i!!!!i_!!_i!09_;!iii!!,!!!ii!i; iiiiiiiiiiii_,i_,i_i_:;_!iii_ii!ii_iill

33 35 36 37 39 41 43 46 48

18 19 20 21 22 23 24 25 27

1358 1323 1282 1234 1169 1130

30 31 31 33 34 35 36 38 39

16 17 17 18 19 19 20 21 22

1362 1313 1278 1231 1188

29 30 31 31 33 34 35 36 37

16 17 17 17 18 19 19 20 21

_7o5', _. _. _s_s, _s_ _4_3 _,_,_s _4o_ _6o

26 27 28 28 29 30 31 32 33

14 15 15 16 16 17 17 18 18

1295 1234 1182 1126 !!!!f!!!!!i_:!_i_i!;_75!i!!!!_!_!!i!!_!!iiiiiiiiii_i_ii_il;_i_ii_i_i_i_i_ili!!_!_!_ _85!_i!i!li!!lii!ii

53 55 58 60 63 NA NA NA NA

29 31 32 34 35 NA NA NA NA

1345 1282 1235 1194 1140 !!!!!!!!!!ii:!ii_i!;_9_!!!!i!i!!i!!i!!;

51 53 55 57 60 62 NA NA NA

28 29 31 32 33 35 NA NA NA

1358 1323 1282 1234 1169 1130

45 47 48 50 51 53 55 58 60

25 26 27 28 29 29 31 32 33

1362 1313 1278 1231 1188

44 46 47 48 50 52 53 55 57

24 25 26 27 28 29 30 31 32

CFM

Heating

Black Rise (°F)

Heating

Rise (°C)

40 41 42 43 45 46 47 48 50

22 23 24 24 25 25 26 27 28

25 509 01 3402 01

Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PGD3/PGS3/WPG3

UNIT

48090

48115

MOTOR WIRE EXTERNALSTATICPRESSURE(IN,W.C.)

SPEED COLOR 0.1 0.2 0.3 0.4 0.5 0.6 0.7

HEATING

RISE

RANGE

OF(oc)

35 -65

(19- 36)

Low1 Blue

CFM 1402 1351

Heating 49 50

Rise (OF)

Heating 27 28

Rise(°C)

CFM 1457 1404

Med-Low

Medium2

48130

Med-High

0.8 0.9

High

Low

Med-Low

30 - 60 Medium 2

(17 - 33)

Med-

High 1

High

Low

Med-Low

35 - 65 Medium 2

(19 - 36)

Med-

High 1

High

Heating

Pink Rise (°F)

Heating

Rise (°C)

CFM

Heating

Red Rise (°F)

Heating

Rise (°C)

CFM

Heating

Orange Rise (°F)

Heating

Rise (°C)

CFM

Heating

Black Rise (°F)

Heating

Rise (°C)

CFM

Heating

Blue Rise (OF)

Heating

Rise (°C)

CFM

Heating

Pink Rise (OF)

Heating

Rise (°C)

CFM

Heating

Red Rise (OF)

Heating

Rise (°C)

CFM

Heating

Orange Rise (OF)

Heating

Rise (°C)

CFM

Heating

Black Rise (OF)

Heating

Rise (°C)

CFM

Heating

Blue Rise (OF)

Heating

Rise (°C)

CFM

Heating

Pink Rise (OF)

Heating

Rise (°C)

CFM

Heating

Red Rise (OF)

Heating

Rise (°C)

CFM

Heating

1311 _6_. _22_ 1172 )))))','I;)36))));)X:!)))','1080))),)

52 54 56 58 60 63 65

29 30 31 32 33 35 36

1367 1318 1284 _23_ I_:_ I_'4_ 1104

47 48 50 52 53 55 57 59 62

26 27 28 29 29 31 32 33 34

1553 1512 1465 1427 1381

39 40 41 42 44 45 46 48 49

22 22 23 24 24 25 26 26 27

_2)4).2),2082 ,_2026.!)80 !))_ ))),,I)0):18_ 1793_

NA NA NA NA NA 35 36 36 38

NA NA NA NA NA 19 20 20 21

_234_, _230_, 225_, 220_, 2_I _D 199_ 1902 1803

NA NA NA NA NA NA NA 36 38

NA NA NA NA NA NA NA 20 21

1402 1351 1311

NA NA NA NA NA NA NA NA NA

NA NA NA

1457 1404 1367

60 NA NA

NA NA NA NA NA NA

1318 1284 _!'97 _!4_

NA NA NA NA NA NA

33 NA NA NA NA NA NA NA NA

_36, _69_:, 64_, _60_ 1553 1512 1465 1427 1381

50 51 53 54 56 57 59 NA NA

28 28 29 30 31 32 33 NA NA

_79_

40 41 42 43 44 45 46 47 48

22 23 23 24 24 25 25 26 27

!!!!i!i!!!2344_!i!ii!!i!!i!'!!!i!i!!i!2306!!i!!i!!!i!i'!!!!!i!!i!2259!i!i!i!i!!i!i!i!!i!'!!!!i!!_i!22_3!i!!i!!!i!'!!!!!i!!!!i_i!_!i_!!!!i!!!!i_i!_i'!,!!!i!i!!!!i_i!20_O_X_X_!!i!ii!ill))i)iiiii,ii_)))8D_ii)i)iiiii

37 38 38 39 41 42 44 46 48

21 21 21 22 23 23 24 25 27

1402 1351 1311 !!!!i!i!!_!!!26_i!i!!i!!!i!,!!!!!i!!!!i_i!_i_!!!224ii_!ii!!!!!i,!!!i!i!!!!i_i!_i_!!!_!!!_!ii)X!!i!i,!_)))!)!!!!)_)!_)_)))_)))_!!!!!!i!!!!!,)Di)iiii)_)i_)_)))QB_iil)i)ii)i)i);i))i)iiiii,ii_)))Q_)))i)i)iii)i))))

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

1457 1404 1367 1318 1284 )))))!))!!!)0!!)))23_!)!))!!!)!))i)))i)iii,iil)))_)))Q_iiiiii)i;i)ii

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

1553 1512 1465 1427 1381

55 57 59 60 62 64 NA NA NA

Orange Rise (OF)

Heating

Rise (°C)

CFM

Heating

Black Rise (°F)

Heating

Rise (°C)

31 32 33 33 34 35 NA NA NA

45 46 47 48 49 50 51 52 54

25 25 26 26 27 28 28 29 30

!!!!i!i!!!2344_!i!ii!!i!!i!'!!!i!i!!i!2306!!i!!i!!!i!i'!!!!!i!!i!2258!i!i!i!i!!i!i!i!!i!'!!!!i!!_i!22_3!i!!i!!!i!'!!!!!i!!!!i_i!_!i_!!!!i!!!!i_i!_i'!,!!!i!i!!!!i_i!201_O_X_X_!!i!ii!ill))i)iiiii,ii_)))8_ii)i)iiiii

41 42 43 44 45 47 48 51 53

23 23 24 24 25 26 27 28 30

509 01 3402 01 2d

Table 9 - Dry Coil Air Delivery* - Horizontal and Downflow Discharge - Unit PGD3/PGS3/WPG3

UNIT

60090

60115

HEATING

RISE

RANGE

OF (oc)

35 - 65

(19 - 36)

30 - 60

(17 - 33)

35 -65

(19 - 36)

60130

MOTOR WIRE

SPEED COLOR

CFM

Heating

Low 1 Blue Rise (°F)

Heating

Rise (°C)

CFM

Heating

Med-Low Pink Rise (°F)

Heating

Rise (°C)

CFM

Heating

Medium 2 Red Rise (°F)

Heating

Rise (°C)

CFM

Heating

Med-High Orange Rise (°F)

Heating

Rise (°C)

CFM

Heating

High Black Rise (°F)

Heating

Rise (°C)

CFM

Heating

Low Blue Rise (°F)

Heating

Rise (°C)

CFM

Heating

Med-Low Pink Rise (°F)

Heating

Rise (°C)

CFM

Heating

Medium 2 Red Rise (°F)

Heating

Rise (°C)

CFM

Med- Heating

High1 Orange Rise (°F)

Heating

Rise (°C)

CFM

Heating

High Black Rise (°F)

Heating

Rise (°C)

CFM

Heating

Low Blue Rise (°F)

Heating

Rise (°C)

CFM

Heating

Ned-Low Pink Rise (°F)

Heating

Rise (°C)

CFM

Heating

Medium 2 Red Rise (°F)

Heating

Rise (°C)

CFM

Heating

Ned-High 1 Orange Rise (°F)

Heating

Rise (°C)

CFM

Heating

High Black Rise (°F)

Heating

Rise (°C)

EXTERNAL STATIC PRESSURE (IN. W.C.)

0.1 0.2 0.3 0.4 0.5 0.6

47 49 51 53 55 57 60

26 27 28

1678 1635 1602

41 42 42

63 NA

NA

*Air delivery values are without air filter and are for dry coil (See Table 10 - PGD3/PGS3/WPG3 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.

27

19 20 20 20 21 22 22 23 23

23 23 24 24 25 26 26 27 28

iiiii_iii_ii_6_ii;_;_i_i_i_.!!!_!!!!_!!_i_iii!ii_.!!!i!_!!!_88_i!i!i!i!iii_i;i.!!!!_!!!!_84_i_i_i_i_i_ii!ii!ii{.iiii_iiiiiiii`i_ii_9_`!`i_ii_;iii_ii_;_;iii}iiiiiiiii'i_ii_!i!!i!!i!ili_;i1711 1675 1628

35 36 36 37 38 39 40 41 42

33 NA NA NA NA NA NA NA NA

1678 1635 1602 !!!i!i!!!_!!_i!ii;ii!iiiiiii,!!!i!!!!i_i!_i_!!51i_iii!ii!iiiii_ili[iiiiiiii_ii_i_i_i;i;iiiiiilJ;il;iiiiiiiii,ii_i438i!!i!i!iiii:iSiii,ii_i4041_i__34_iiii

52 53 54 56 57 59 60 NA NA

29 30 30 31 32 33 34 NA NA

_6_ , _15 , _880 , _84_ , _ 9_ 1711 1675 1628

44 45 46 47 48 50 51 52 53

25 25 26 26 27 28 28 29 30

!!!!!_!_i_!_!_!_!_!_iii!iiii_!_'!!!!_!_iH_o_8_i_i_i_i_!i_iii!i!ii_'!!!!_!_iH_o_6_!!!H!_!_iH'!!!!_!_iH_!_!_!_!Hi_!_i_'!!!!_!_i_!!_!_98_!_!!;!;!;!_!_iiiiiiliiiiii_94i_iiiiiiiiiiiiiiiii_i_i_{;ii_i_i8_i_i_i_i_ii!_i_ii;i_!iii_i_i_{_ixi_i86:8_iiii_i_:;_:;iiiiiiiii{iiiii_ii78_i;i;ii;iiii:ii:il;ii

41 42 42 43 44 45 46 47 49

NA NA NA NA NA 35 36 37 38

NA NA NA NA NA 19 20 20 21

NA NA NA NA NA NA NA 35 36

NA NA NA NA NA NA NA 19 20

!!!i!_!!!_!_ii_ii_iii_!!!i!_!!!_!!_89_i_i_;iiii_i1i_ii_ii3¢_iiiiiiii_i_ii_i_iiiii_iii_ii_i_iiiiiiii_i_ii_i_!!!i!_!!!!_!_!_236iii_;_i_i_iii:iiiiiiiiii_i'_iiii!,89!;i;i_!i;!iiiiiiiiiiiii,_,i',_iiii_ii_iiiiiiiii:_iiiiiiiii,_,i',_iii_;!;ii:iiii!;ii:i!iiiiiliiii,_,i',_iiiO_;_iiiii!,ii;ili;iii

60 NA NA NA NA NA NA NA NA

23 23 23 24 24 25 26 26 27

!!!i!_!!!246!_!!!!_!_!!!_!_!!!i!_!!!2489!_!_!_!_!!i!i!i!!_!!_!!!_!!_i!2389!_!_!_!_!!i!i!i!!_!!_!!!_!!_i!2286_i_i_!!!!!_!!_!!!!_!!!!_!_!_!_i_i_!!_!_!_iii}iiiiii_ii_ii_0_i_i_i_i_iiiil;il;:iiiiiiiiii,i2062iiii!ii!!iiiiiiiiiiiiii,ii_iii968iii!;ii!iiiliiiiiiiiiiiii,ii_iii8g4iiii!iliiiii

35 36 37 38 40 41 42 44 46

20 20 21 21 22 23 23 25 26

iiiii_iiiii_;i44_!!!!_!_!!_!!!!!!!!!i!_Xa_!!!_!!!_!_!_!!!_!!!!i!_!_!_!!!!!_!_!!!i!_!!!!i_!!!_!_!!!!_!_!!!!!!!!!!i`_!`:_23!6_!_!!!_!`_!ii;iiiiiii',i'_i_iii;ii!i!i,!!! iiiiiiiiiii;,,i,,i_!!:o2_iii_;li_i_,l_i;i

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

1678 1635 1602 !!!!!!!!!!i_i!_58!!!!'!!_i_!_i!!!!!!!!!!!i_;!_:_i!_!_!i!i!i!i!!!!!_!! iiiiiiiiii_i_ii_ii47i_ii_iii:liiii

57 59 60 62 64 65 NA NA NA

32 33 33 34 35 36 NA NA NA

1711 1675 1628

49 50 51 52 54 55 56 57 59

27 28 28 29 30 31 31 32 33

ii;iiiiiii',i'_i_;_iii_iiiiiilil

45 46 47 48 49 50 51 52 54

25 26 26 27 27 28 28 29 30

!!!i!_!!_6_!_!!!!i!!!!_!_!!!!!!!!_!!!_!!!_!_!_!!!!!_233_!!!_!!!_!_!_!!!!!_22_6!!!_!_!!_!_!_!!!i!_!!!!i_i!_!92!!!!_!!!!_!!_iiiiiiiiii_i_i_i_i!_i8_liiii,!!!!iiiiiii:_,i_206_iiiiiiii,i_,li,i:iiiiiiiii:_,i_,i_!_6_i,i,i_,li,i,i_,_i_iiiiiiiiiiii:_,i_,i_!_!i_ii!:li!iii

39 40 41 42 44 45 47 49 51

22 22 23 23 24 25 26 27 29

509 01 3402 01

29 31 32 33 35

!!!i!i!!!_!!_i!ii;ii!iiiiil;,!!!i!!!!i'i!'i_!!_i_iii!ii!;ii;i_Hiiiiiiiiii'ii'i_i_i;i;iiiiiilJ;i;;iiiiiiiii,ii_i4_Si!!i;i!iiii:iSiii,ii_i40_;_i_"_34_;;il

44 45 46 47 48 50

Table 10 - PGD3/PGS3/WPG3 Wet Coil Pressure Drop (IN. W.C.)

UNIT STANDARDCFM (S.C.EM)

SIZE 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

24 0.030 0.037 0.044 0.053 0.063 - -

30 0,037 0,044 0,053 0,063 0,072 0,081 0,105 - -

36 - 0,055 0,060 0,090 0,100 0,110 0,140 - -

42 - - 0,045 0,050 0,060 0,065 0,075 0,080 0,090 0,094 0,110

48 - - 0,041 0,063 0,085 0,100 0,104 0,110 0,120 0,130

60 - - 0,060 0,065 0,072 0,077 0,085 0,100

Table 11 - Wet Coil Air Delivery -- Downflow Discharge -- High Speed

EXTERNALSTATICPRESSURE (in. W.C.)

UNIT SIZE 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

36 1333 1289 1256 1214 1152 1118 1076 1035 997 950

42 1612 1569 1527 1481 1451 1393 1351 1317 1278 1242

48 2166 2085 2002 1919 1798 1709 1582 1467 1270 988

60 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.

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 could result in personal

injury or death:

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 when removing panels and

parts.

3. Never place anything combustible either on or in

contact with the unit.

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper

operation.

Errors made when reconnecting wires may cause

improper and dangerous operation. Label all wires prior to

disconnecting when servicing.

The minimum maintenance requirements for this equipment are

as follows:

1. Inspect air filter(s) each month. Clean or replace when

necessary.

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 hood and remove any obstructions, if

necessary.

Air Filter

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. Do not attempt to lubricate

these motors.

For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease from the blower wheel and

motor annually.

509 01 3402 01 28

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury

or death.

Disconnect and tag electrical power to the unit before

cleaning the blower motor and wheel.

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 capa-

citor.

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 as-

sembly 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.

29

Flue Gas Passageways

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 control access 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 parti-

tion 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. 509 01 3402 01

Fig. 19 - Blower Housing and Flue Collector Box

FanPartitionMountingBracket

integrated

Gas Unit

dGC)

Auto Transformer

fuses used on 460

ty.

(Hidden)

Board (IFB)

Induced Draft

Motor

Flue

Collector

Box Blower

Housing

Burner

Rack Mounting

Screw

Rollout

Switch

Fig. 20 -Unit Access Panels

Fig. 21 -Removal of Motor and Blower Wheel

BLOWER

HOUSING

2 SETSCREWS

(HIDDEN)

Fig. 22 -Burner Rack Removed t

Outdoor Fan

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.

7. Replace grille.

509 01 3402 01 30

T

A

Fig. 23 - Fan Blade Position

MOTOR

X

FAN GRILLE

/

MOTOR SHAFT

SIZE

24

30

36

42

48

60

MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE

"A"

IN.

7.3

7.3

7.3

7.6

7.6

7.6

MM

185

185

185

193

193

193

Electrical Controls and Wiring

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.

Gas Input

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

31 509 01 3402 01

all system charge so that pressure gauges read 0 psig. Never

open system without breaking vacuum with dry nitrogen.

High-Pressure 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.

Refrigerant System

This information covers the refrigerant system of the

PGD3/PGS3/WPG3, 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

necessary precautions to avoid exposure of the oil to the

atmosphere.

Servicing Systems on Roofs with Synthetic Materials

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 material per

local codes.

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 Guides (See Tables 12-14) if problems

occur with these units.

START-UP CHECKLIST

Use Start-Up checklist to ensure proper start-up procedures are

followed.

509 01 3402 01 32

R-410A QUICK REFERENCE GUIDE

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

replacement components are designed to operate with R-410A

• R-410A refrigerant cylinders are rose colored.

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

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

hose when charging into suction line with compressor operating

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

• Use hoses with minimum 700 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

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

• Vacuum pumps will not remove moisture from oil.

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

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

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

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

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

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

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

• Do NOT use an R-22 TXV.

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

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

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

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

• Observe all warnings, cautions, and bold text.

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

33 509 01 3402 01

SYMPTOM

Compressor and condenser fan will not start.

Compressor will not start but condenser fan

runs

Three-phase scroll compressor

makes excessive noise, and there may be alow

pressure differential.

Compressor cycles (other than normally satisfy-

ing thermostat)

Compressor operates continuously

Excessive head pressure

Head pressure too low

Excessive suction pressure

Suction pressure too low

Table 12- Troubleshooting Chart

CAUSE

Power failure

Fuse blown or circuit breaker tripped

Defective contactor, transformer, or high-pressure, loss-

of-charge or low-pressure switch

Insufficient line voltage

Incorrect or faulty wiring

Thermostat setting too high

Faulty wiring or loose connections in compressor circuit

Compressor motor burned out, seized, or

internal overload open

Defective run/start capacitor, overload, start relay

One leg of 3-phase power dead

Low input voltage

Scroll compressor is rotating in the wrong direction

Refrigerant overcharge or undercharge

Defective compressor

Insufficient line voltage

Blocked outdoor coil

Defective run/start capacitor

Faulty outdoor fan motor or capacitor

Restriction in refrigerant system

Dirty air filter

Unit undersized for load

Thermostat temperature set too low

Low refrigerant charge

Air in system

Outdoor coil dirty or restricted

Dirty air filter

Dirty condenser coil

Refrigerant overcharged

Air in system

Condenser air restricted or air short-cycling

Low refrigerant charge

Restriction in liquid tube

Refrigerant overcharged

Dirty air filter

Low refrigerant charge

Metering device or low side restricted

Insufficient evaporator airflow

Temperature too low in conditioned area

Outdoor ambient below 55°F (13°C)

Filter drier restricted

Table 13- Troubleshooting Guide-Heating

SYMPTOM CAUSE

Water in gas line

No power to furnace

No 24-v power supply to control circuit

Burners will not ignite Mis-wired or loose connections

Misaligned spark electrodes

No gas at main burners

Dirty air filter

Gas input to furnace too low

Unit undersized for application

Inadequate heating Restricted airflow

Limit switch cycles main burners

Poor flame characteristics Incomplete combustion results in: Aldehyde odors, carbon

monoxide, sooting flame, floating flame

REMEDY

Call power company

Replace fuse or reset circuit breaker

Replace component

Determine cause and correct

Check wiring diagram and rewire correctly

Lower thermostat temperature setting below room

temperature

Check wiring and repair or replace

Determine cause

Replace compressor

Determine cause and replace

Replace fuse or reset circuit breaker

Determine cause

Determine cause and correct

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

Replace and determine cause

Determine cause and correct

Determine cause and correct

Determine cause and replace

Replace

Locate restriction and remove

Replace filter

Decrease load or increase unit size

Reset thermostat

Locate leak, repair, and recharge

Recover refrigerant, evacuate system, and recharge

Clean coil or remove restriction

Replace filter

Clean coil

Recover excess refrigerant

Recover refrigerant, evacuate system, and recharge

Determine cause and correct

Check for leaks, repair, and recharge.

Remove restriction

Recover excess refrigerant

Replace filter

Check for leaks, repair and recharge

Remove source of restriction

Increase air quantity

Check filter-replace if necessary

Reset thermostat

Install low-ambient kit

Replace filter

REMEDY

Drain. Install drip leg.

Check power supply fuses, wiring or circuit breaker.

Check transformer.

NOTE: Some transformers have internal over-current protection that

requires a cool-down period to reset.

Check all wiring and wire nut connections

Check flame ignition and sense electrode positioning.

Adjust as necessary.

1. Check gas line for air. Purge as necessary. NOTE: After purging

gas line of air, wait at least 5 minutes for any gas to dissipate before

attempting to light unit.

2. Check gas valve.

Clean or replace filter as necessary

Check gas pressure at manifold match with that on unit nameplate

Replace with proper unit or add additional unit

Clean or replace filter. Remove any restriction.

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

sary.

1. Tighten all screws around burner compartment

2. Cracked heat exchanger. Replace.

3. Unit over-fired. Reduce input (change orifices or adjust gas line or

manifold pressure).

4. Check burner alignment.

5. Inspect heat exchanger for blockage. Clean as necessary.

509 01 3402 01 34

Table 14- Troubleshooting Guide-LED Status Codes

SYMPTOM CAUSE REMEDY

Check 5-amp fuse son IGC*, power to unit, 24-v circuit breaker, and

No Power or Hardware failure transformer. Units without a 24-v circuit breaker have an internal

(LED OFF) Loss of power to control module (IGC)*. overload in the 24-v transformer. If the overload trips, allow 10 min-

utes for automatic reset.

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

(LED 2 flashes) High temperature limit switch is open. the supply-air temperature rise is in accordance with the range on the

unit nameplate. Clean or replace filters.

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

(LED 3 flashes)

4 consecutive limit switch faults Check the operation of the indoor (evaporator) fan motor and that

(LED 4 flashes) Inadequate airflow to unit. supply-air temperature rise agrees with range on unit nameplate

information.

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

(LED 5 flashes) Unit unsuccessfully attempted ignition for 15 minutes, 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 fault pressure switch hose is tightly connected to both inducer housing and

(LED 6 flashes) Open pressure switch, pressure switch. Verify inducer wheel is properly attached to inducer

motor shaft. Verify inducer motor shaft is turning.

Rollout switch will automatically reset, but IGC* will continue to lockout

Rollout switch fault unit. Check gas valve operation. Ensure that induced-draft blower

(LED 7 flashes) Rollout switch has opened, wheel is properly secured to motor shaft. Inspect heat exchanger.

Reset unit at unit disconnect.

Internal control fault Microprocessor has sensed an error in the software or

(LED 8 flashes) hardware. If error code is not cleared by resetting unit power, replace the IGC*.

Temporary 1 hr auto reset fault I Reset 24-v. to control board or turn thermostat off, then on again.

(LED 9 flashes) Electrical interference impeding IGC software Fault will automatically reset itself in one (1) hour.

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

sensitive to static electricity and my be damaged if the necessary precautions are not taken.

IMPORTANT: Refer to Table 12-Troubleshooting Guide-Heating for additional troubleshooting analysis.

LEGEND

IGC--Integrated Gas Unit Controller

LED--Light-Emitting Diode

35 509 01 3402 01

I. PRELIMINARY INFORMATION

MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

START-UP CHECKLIST

(Remove and Store in Job Files)

II. PRESTART-UP (Insert check mark in box as each item is completed)

() VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS

( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS

( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)

( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE

() VERIFY THAT UNIT INSTALLATION IS LEVEL

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

COMPRESSOR AMPS

III. START-UP

ELECTRICAL

SUPPLY VOLTAGE

OUTDOOR (CONDENSER) AIR TEMPERATURE_DB

RETURN-AIR TEMPERATURE DB

COOLING SUPPLY AIR DB

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 inletto compressor

1- Measuredat liquid line leaving condenser.

INDOOR (EVAPORATOR) FAN AMPS

TEMPERATURES

WB

WB

509 01 3402 01 3d