Tappan DF6SF-A, DF6SF, PDF2SF-A Installation guide

Tappan DF6SF-A, DF6SF, PDF2SF-A Installation guide
DF6SF / PDF2SF - REV. A SERIES
15 SEER / 8.0 HSPF / 80% AFUE
INSTALLATION INSTRUCTIONS
Dual Fuel Heating & Cooling Packaged System
Premium Model Shown
ATTENTION INSTALLERS:
It is your responsibility to know this product better than your customer. This includes being able to install the product according
to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product.
Safety should always be the deciding factor when installing this product and using common sense plays an important role as
well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the unit
or failure to follow safety warnings could result in serious injury, death, or property damage. These instructions are primarily
intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require
licensed installation/service personnel for this type of equipment. After completing the installation, return these instructions to
the customer’s package for future reference.
WARNING:
FIRE OR EXPLOSION HAZARD
WHAT TO DO IF YOU SMELL GAS
•Failure to follow safety warnings exactly
could result in serious injury or property
damage.
• Do not try to light any appliance.
•Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
• Leave the building immediately.
• Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
neighbors phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call
the fire department.
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
table of contents
IMPORTANT SAFETY INFORMATION........................3
REQUIREMENTS & CODES........................................4
GENERAL INFORMATION...........................................5
Before You Install this Unit..........................................5
Locating the Equipment.............................................5
Heating Load .............................................................5
Combustion Air & Venting Requirements ....6
General Information ...................................................7
Vent Termination ........................................................7
Circulating Air Supply .......................................8
Air Ducts ....................................................................8
Air Filter Requirements .............................................8
Unconditioned Spaces...............................................9
Acoustical Duct Work.................................................9
UNIT INSTALLATION...................................................9
Packaging Removal....................................................9
Rigging & Hoisting......................................................9
Clearances to Combustible Materials.........................9
Ground Level..............................................................9
Rooftop.......................................................................9
Horizontal to Downflow Conversion..........................10
Condensate Drain ...................................................10
ELECTRICAL WIRING................................................10
Pre - Electrical Checklist..........................................10
Line Voltage..............................................................11
Thermostat / Low Voltage Connections....................11
2-Stage Heat / Cool T-stat Configuration...............11
Heating Configuration...............................................12
Heat Pump Defrost Mode.....................................12
Checking Heat Anticipator Settings.......................12
Configuring the Variable Speed Blower ...................12
Selecting Cooling Airflow......................................12
Selecting Gas Heating Airflow...............................13
Delay Profile..........................................................13
Demand Defrost Control..........................................13
Ambient Sensor Mounting........................................13
Optional Humidistat..................................................13
Optional Comfort AlertTM Diagnostics Module..........14
24VAC Power Wiring.............................................14
Thermostat Demand Wiring..................................14
L Terminal Wiring..................................................14
DC SOL Connection.............................................14
Interpreting the Diagnostic LED’s..........................15
LED Description....................................................15
Installation Verification..........................................15
Troubleshooting the Installation.............................15
Resetting Alert Codes...........................................15
Grounding................................................................15
GAS SUPPLY & PIPING.............................................16
Leak Check..............................................................17
High Altitude Conversion..........................................17
LP/Propane Gas Conversion....................................17
STARTUP & ADJUSTMENTS....................................18
Pre - Start Checklist.................................................18
Start-up Procedure...................................................18
Air Circulation........................................................18
2
Short Cycle Protection..........................................18
System Cooling Operation (2-Stage)....................18
System Heating (Heat Pump Mode).....................18
System Heating (Emergency Heat Mode)............19
Verifying & Adjusting Temperature Rise...................19
Verifying & Adjusting Firing Rate..............................19
Verifying Over-Temperature Limit
Control Operation.....................................................19
Manifold Pressure Adjustment.................................20
Verifying Burner Operation.......................................20
Refrigerant Charging................................................20
Charging R-410A Unit in AC Mode.......................20
Charging R-410A Unit in Heating Mode................20
OPERATING SEQUENCE..........................................21
2-Stage Heating Mode (Heat Pump)........................21
Gas Heating Mode (Emergency Heat).....................21
2-Stage Cooling Mode.............................................22
Fan Mode.................................................................22
EQUIPMENT MAINTENANCE....................................22
Cleaning of Heat Exchanger....................................23
Cleaning of Burners.................................................24
TROUBLESHOOTING................................................24
COMPONENT FUNCTIONS.......................................25
REPLACEMENT PARTS.............................................25
FIGURES & TABLES..................................................26
Figure 11. Unit Dimensions...................................26
Table 9. Center of Gravity & Shipping Weights......26
Airflow Information....................................................27
Table 10. Nominal Airflow Rates & Temp Rises....27
Table 11. Airflow Settings for Cooling....................27
Table 12. Airflow Settings for Heating....................27
Gas Information........................................................28
Table 13. Gas Pipe Capacities..............................28
Table 14. Gas Flow Rates.....................................28
Figure 12. Gas Valve Label...................................29
Wiring Diagrams.......................................................30
Figure 13A. T-Stat Connection for Two-Stage
Heating / Two-Stage Cooling .............30
Figure 13B. Two-Stage, Hot Surface Ignition &
Blower Control Board ........................30
Figure 14. Two-Stage Heat / Two-Stage Cool
Heat Pump (2 & 5 Ton) ........................31
Figure 15. Two-Stage Heat / Two-Stage Cool w/
Optional Comfort Alert (2 & 5 Ton).......32
Figure 16. Two-Stage Heat / Two-Stage Cool
Heat Pump (3 & 4 Ton) ........................33
Figure 17. Two-Stage Heat / Two-Stage Cool w/
Optional Comfort Alert (3 & 4 Ton).......34
Comfort Alert Troubleshooting Charts......................35
Table 15. LED Diagnostics....................................35
Table 16. Module Wiring Troubleshooting..............37
Refrigerant Charging Charts....................................37
Figure 18. Charging Chart for 2 Ton Units.............38
Figure 19. Charging Chart for 3 Ton Units.............38
Figure 20. Charging Chart for 4 Ton Units.............39
Figure 21. Charging Chart for 5 Ton Units.............39
INSTALLATION / PERFORMANCE CHECKLIST......40
IMPORTANT SAFETY INFORMATION
Please read all instructions before servicing this equipment.
Pay attention to all safety warnings and any other special
notes highlighted in the manual. Safety markings are
used frequently throughout this manual to designate a
degree or level of seriousness and should not be ignored.
WARNING indicates a potentially hazardous situation that
if not avoided, could result in personal injury or death.
CAUTION indicates a potentially hazardous situation that
if not avoided, may result in minor or moderate injury or
property damage.
WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could
result in serious injury or property damage.
Improper servicing could result in dangerous
operation, serious injury, death or property
damage.
• Before servicing, disconnect all electrical
power to the indoor blower.
• When servicing controls, label all wires prior
to disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.
WARNING:
These units are fully charged with R-410A
refrigerant and ready for installation. When
a system is installed according to these
instructions, no refrigerant charging is
required. If repairs make it necessary for
evacuation and charging, it should only be
attempted by qualified, trained personnel
thoroughly familiar with this equipment. Some
local codes require licensed installation
service personnel to service this type of
equipment. Under no circumstances should the
homeowner attempt to install and/or service
this equipment. Failure to comply with this
warning could result in equipment damage,
personal injury, or death.
WARNING:
Do not place combustible material on or against
the unit cabinet. Do not place combustible
materials, including gasoline and any other
flammable vapors and liquids, in the vicinity
of the unit.
WARNING:
PROPOSITION 65 WARNING: This product
contains fiberglass wool, a product known
to the state of California to cause cancer.
Disturbing the insulation of this product during
installation, maintenance, or repair will expose
you to fiberglass wool.
• Breathing this material may cause respiratory
irritations or may cause lung cancer.
• Fiberglass wool may also cause eye
irritation, skin sensitization, or other allergic
responses in susceptible individuals.
• Always wear goggles, disposable gloves,
long sleeved shirt, and appropriate breathing
protection when working near this insulation.
If contact with skin occurs, wash immediately
with soap and water. In case of contact with
eyes, flush immediately with water for at
least 15 minutes. Contact a physician if
needed.
WARNING:
The information listed below and on the next
page must be followed during the installation,
service, and operation of this unit. Unqualified
individuals should not attempt to interpret these
instructions or install this equipment. Failure
to follow safety recommendations could result
in possible damage to the equipment, serious
personal injury or death.
• Before beginning the installation, verify that the unit
model is correct for the job. The unit model number
is printed on the data label. Follow all precautions in
the literature, on tags, and on labels provided with
the equipment. Read and thoroughly understand
the instructions provided with the equipment prior to
performing the installation and operational checkout
of the equipment.
• Never test for gas leaks with an open flame. Use a
commercially available soap solution to check all
connections. See page 17.
• Installation of equipment may require brazing
operations. Installer must comply with safety codes
and wear appropriate safety equipment (safety glasses,
work gloves, fire extinguisher, etc.) when performing
brazing operations.
• This equipment is NOT to be used for temporary heating
of buildings or structures under construction.
• Use caution when handling this appliance or removing
components. Personal injury can occur from sharp
3
metal edges present in all sheet metal constructed
equipment.
• Follow all precautions in the literature, on tags, and
on labels provided with the equipment. Read and
thoroughly understand the instructions provided with
the equipment prior to performing the installation and
operational checkout of the equipment.
• The installer should become familiar with the units wiring
diagram before making any electrical connections to
the unit. See the unit wiring label or Figures 13 - 16
(pages 31 - 34).
REQUIREMENTS & CODES
• This equipment must be installed in accordance with
instructions outlined in this manual, all applicable
local building codes, and the current revision of
the National Fuel Gas Code (NFPA54/ANSI Z223.1)
or the Natural Gas and Propane Installation Code,
CAN/CGA B149.1.
• All electrical wiring must be completed in accordance
with local, state and national codes and regulations
and with the National Electric Code (ANSI/NFPA 70)
or in Canada the Canadian Electric Code Part 1 CSA
C.22.1.
• The installer must comply with all local codes and
regulations which govern the installation of this type
of equipment. Local codes and regulations take
precedence over any recommendations contained in
these instructions. Consult local building codes and the
National Electrical Code (ANSI CI) for special installation
requirements.
• This equipment contains liquid and gaseous refrigerant
under high pressure. Installation or servicing should only
be performed by qualified trained personnel thoroughly
familiar with this type equipment.
• Air Ducts must be installed in accordance with the
standards of the National Fire Protection Association
“Standards for Installation of Air Conditioning and
Ventilation Systems” (NFPA 90A), “Standard for
Installation of Residence Type Warm Air Heating and Air
Conditioning Systems” (NFPA 90B), these instructions,
and all applicable local codes.
• Consult Table 10 (page 27), and the rating plate for the
proper circulating air flow and temperature rise. It is
important that the duct system be designed to provide
the correct flow rates and external pressure rise. An
improperly designed duct system can result in nuisance
shutdowns, and comfort or noise issues.
• This unit is designed for outdoor installations only and
should be located in a position as shown on page 5.
• Use only with the type of gas approved for this unit.
Refer to the unit rating plate.
• Provide adequate combustion and ventilation air to the
unit. See pages 6 - 8.
• Provide adequate clearances around the combustion
air intake louvers. See Figure 1 (page 5).
• Combustion products must be discharged outdoors.
Connect this unit to an approved vent system only, as
specified on page 7.
4
• Additional codes listed below are for reference purposes
only and do not necessarily have jurisdiction over
local or state codes. Local codes and regulations take
precedence over any recommendations contained in
these instructions. Always consult with local authorities
before installing any gas appliance.
Combustion & Ventilation Air
• US: National Fuel Gas Code (NFGC), Air for
Combustion and Ventilation
• CANADA: Natural Gas and Propane Installation
Codes (NSCNGPIC), Venting Systems and Air
Supply for Appliances
Duct Systems
• US and CANADA: Air Conditioning Contractors
Association (ACCA) Manual Q, Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers
(ASHRAE) Fundamentals Handbook
Electrical Connections
• US: National Electrical Code (NEC) ANSI/NFPA 70
• CANADA: Canadian Electrical Code CSA C22.1
Gas Piping & Gas Pipe Pressure Testing
• US: NFGC and National Plumbing Codes
• CANADA: NSCNGPIC
General Installation
• US: Current edition of the NFGC and the NFPA 90B.
For copies, contact the National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA
02269; or American Gas Association, 400 N. Capitol,
N.W., Washington DC 20001 or www.NFPA.org.
• CANADA: NSCNGPIC. For a copy, contact Standard
Sales, CSA International, 178 Rexdale Boulevard,
Etobicoke (Toronto), Ontario, M9W 1R3 Canada
Safety
• US: (NFGC) NFPA 54–1999/ANSI Z223.1 and the
Installation Standards, Warm Air Heating and Air
Conditioning Systems ANSI/NFPA 90B.
• CANADA: CAN/CGA-B149.1–and .2–M00 National
Standard of Canada. (NSCNGPIC)
The Dual Fuel iHybrid™ heat pump is designed only for
outdoor rooftop or ground level installations and can be
readily connected to the duct system of a home. This unit
has been tested for capacity and efficiency in accordance
with AHRI Standards and will provide many years of safe
and dependable comfort, providing it is properly installed
and maintained. With regular maintenance, this unit will
operate satisfactorily year after year. Abuse, improper use,
and/or improper maintenance can shorten the life of the
appliance and create unsafe hazards.
To achieve optimum performance and minimize equipment
failure, it is recommended that periodic maintenance be
performed on this unit. The ability to properly perform
maintenance on this equipment requires certain tools
and mechanical skills.
Before you install this unit
√ The cooling load of the area to be conditioned must be
calculated and a system of the proper capacity selected.
It is recommended that the area to be conditioned be
completely insulated and vapor sealed.
√ Check the electrical supply and verify the power supply
is adequate for unit operation. Consideration should be
given to availability of electric power, service access,
noise, and shade. If there is any question concerning
the power supply, contact the local power company.
√ All units are securely packed at the time of shipment and
upon arrival should be carefully inspected for damage
prior to installing the equipment at the job site. Verify
coil fins are straight. If necessary, comb fins to remove
flattened or bent fins. Claims for damage (apparent or
concealed) should be filed immediately with the carrier.
√ Please consult your dealer for maintenance information
and availability of maintenance contracts. Read all
instructions before installing the unit.
Locating the Equipment
• Survey the job site to determine the best location for
the packaged unit. The unit should be located with
consideration of minimizing the length of the supply
and return ducts. If practical, place the equipment and
its ducts in an area where they will be shaded from
the afternoon sun, when the heat load is greatest.
Consideration should also be given to the accessibility
of fuel, electric power, service access, noise, and shade.
• Select a solid, level position, preferably on a concrete
slab, slightly above the grade level, and parallel to the
home. DO NOT PLACE UNIT UNDER THE HOME.
• Overhead obstructions, poorly ventilated areas, and
areas subject to accumulation of debris should be
avoided. Do not place the unit in a confined space or
recessed area where discharge air from the unit could
re-circulate back through the condenser coil.
• Sufficient clearance for unobstructed airflow through the
louvered control access panel and outdoor coil must
be maintained in order to achieve rated performance.
See Figure 1 for minimum clearance requirements.
• A clearance of at least 36 inches from the blower access
panel and from the louvered control access panel is
recommended for servicing and maintenance.
Where accessibility clearances are greater
than clearances to combustibles, accessibility
clearances must take preference.
• The hot condenser air must be discharged up and away
from the home.
Heating Load
This unit should be sized to provide the design heating
load requirement. Heating load estimates can be made
using approved methods available from Air Conditioning
Contractors of America (Manual J); American Society of
Heating, Refrigerating, and Air Conditioning Engineers;
or other approved engineering methods. For installations
above 2,000 ft., the unit should have a sea level input
rating large enough that it will meet the heating load after
deration for altitude.
See Note 1
See Note 2
TOP OF UNIT
TO BE
UNOBSTRUCTED
GENERAL INFORMATION
36"
36"
36"
Minimum Required
Clearances to Combustibles
NOTE 1: 6” When coil is present on duct side.
NOTE 2: 1” When no coil is present on duct side.
Figure 1. Clearance Requirements
5
Combustion Air & Venting Requirements
WARNING:
Carbon monoxide poisoning hazard
Failure to follow the steps outlined below for
each appliance connected to the venting system
being placed into operation could result in carbon
monoxide poisoning or death. The following steps
shall be followed with each individual appliance
connected to the venting system being placed in
operation, while all other appliances connected to
the venting system are not in operation:
1.Seal any unused openings in the venting
system.
2.Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 or the CSA
B149.1, Natural Gas and Propane Installation
Codes and these instructions. Determine that
there is no blockage or restriction, leakage,
corrosion and other deficiencies which could
cause an unsafe condition.
3.As far as practical, close all building doors and
windows and all doors between the space in
which the appliance(s) connected to the venting
system are located and other spaces of the
building.
4.Close fireplace dampers.
5.Turn on clothes dryers and any appliance
not connected to the venting system. Turn on
any exhaust fans, such as range hoods and
bathroom exhausts, so they are operating at
maximum speed. Do not operate a summer
exhaust fan.
6.Follow the lighting instructions. Place the
appliance being inspected into operation.
Adjust the thermostat so appliance is operating
continuously.
7.Test for spillage from draft hood equipped
appliances at the draft hood relief opening
after 5 minutes of main burner operation. Use
the flame of a match or candle.
8.If improper venting is observed during any of
the above tests, the venting system must be
corrected in accordance with the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and/or CSA
B149.1, Natural Gas and Propane Installation
Codes.
9.After it has been determined that each appliance
connected to the venting system properly vents
when tested as outlined above, return doors,
windows, exhaust fans, fireplace dampers and
any other gas-fired burning appliance to their
previous conditions of use.
6
AVERTISSEMENT:
RISQUE D’EMPOISONNEMENT AU
MONOXYDE DE CARBONEd
Le non-respect des consignes suivantes portant
sur chacun des appareils raccordés au système
d’évacuation mis en service pourrait entraîner
l’empoisennement au monoxyde de carbone ou
la mort. Les consignes suivantes doivent être
observées pour chaque appareil raccordé au système
d’évacuation mis en service si les autres appareils
raccordés au système ne sont pas en service:
1.Sceller toute ouverture non utilisée de la systéme
d’évacuation;
2.S’assurer que la systéme d’évacuation présente
des dimensions et une pente horizontale
conformes à la norme ANSI Z223.1/NFPA
54, intitulée National Fuel Gas Code ou aux
codes d’installation CSA-B149.1, ainsi qu’aux
présentes instructions. S’assurer que la systéme
d’évacuation n’est pas bloquée, restreinte,
corrodée, qu’elle ne fuit pas et qu’elle ne présente
aucun autre défaut potentiellement dangereux;
3.Dans la mesure du possible, fermer toutes les
portes et fenêtres du bâtiment, et toutes les portes
entre la pièce où se trouve l’appareil raccordé à
la systéme d’évacuation et les autres pièces du
bâtiment.
4.Fermer les registres des foyers;
5.Mettre en service les sécheuses et tout autre
appareil qui n’est pas raccordé à la systéme
d’évacuation. Faire fonctionner à régime maximal
tout ventilateur d’évacuation, tel que les hottes de
cuisinière et les ventilateurs de salles de bains.
Ne pas mettre en service les ventilateurs d’été.
6.Respecter les instructions d’allumage. Mettre en
service l’appareil à l’essai. Régler le thermostat
de manière à ce que l’appareil fonctionne sans
interruption;
7.Vérifier s’il y a débordement à l’orifice
d’évacuation du coupe tirage des appareils dotés
d’un coupe tirage 5 minutes après l’allumage
du brûleur principal. Utiliser la flamme d’une
allumette ou d’une chandelle.
8.Si l’on constate, au cours de l’un des essais
qui précèdent, que l’évacuation est déficiente,
corriger le système d’évacuation conformément
à la norm ANSI Z223.1/NFPA 54, National Fuel
Gas Code, et (ou) aux codes d’installation CSA
B149.1.
9.Après avoir déterminé que tous les appareils
raccordés à la systéme d’évacuation évacuent
correctement tel que prescrit ci-dessus,
rouvrir les portes et les fenêtres et remettre les
ventilateurs d’évacuation, les registres de foyers
et tout autre appareil fonctionnant au gaz à leur
état de fonctionnement initial.
General Information
WARNING:
Installation methods other than those described
in the following sections must comply with the
National Fuel Gas Code and all applicable local
codes for providing sufficient combustion air
to the furnace.
Provisions must be made during the installation of this
unit that provide an adequate supply of air for combustion.
• Instructions for determining the adequacy of an
installation can be found in the current revision of the
NFGC (ANSI Z223.1 / NFPA54). Consult local codes
for special requirements. These requirements are for
US installations as found in the NFGC.
• The requirements in Canada (B149.1) are structured
differently. Consult with B149.1 and local code officials
for Canadian installations.
WARNING:
Combustible air must not be drawn from a
contaminated atmosphere. Excessive exposure
to contaminated combustion air will result in
safety and performance related problems.
To maximize heat exchanger life, the combustion air
must be free of chemicals that can form corrosive acidic
compounds in the combustion gases. The recommended
source of combustion air is to use clean air from outside.
DO NOT place any chemicals with flammable or caustic
vapors or these other corrosive chemicals near the
vent termination:
•
•
•
•
•
•
•
•
•
•
•
•
•
Gasoline/Kerosene
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine based swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents
Cements, glues, paint removers, varnishes, etc.
Hydrochloric acid
Masonry acid washing materials
Plumbing Stack
Air openings in the door of the unit, warm air registers, and
return air grilles must never be restricted. If the unit does
not receive an adequate supply of air for combustion, the
flame roll-out control located above the burners will open,
turning off the gas supply to the burners.This safety device
is a manually reset switch. IMPORTANT NOTE: DO NOT
install jumper wires across this control to defeat its
function or reset the control without identifying and
correcting the fault condition.
If this control must be replaced, use only factory authorized
replacement parts. See the Replacement Parts List on
page 25.
Vent Termination
This unit has been equipped with an integral venting
system and designed to operate only with this venting
system. No additional venting shall be used. This unit
must be vented to the outdoors.
WARNING:
This unit is intended for outdoor installation
only. Do not vent the unit through a conventional
venting system.
A vent cover assembly has been supplied with the unit
and can be found secured to the gas controls within
the control area of this unit. Figure 2 shows the proper
installation of the vent cover assembly over the vent outlet
on the exterior of the corner panel. The fasteners used to
secure the vent cover assembly have been included in
the owner’s package. The vent cover assembly must
be installed to assure proper operation of the unit.
The following list summarizes the requirements for the
location of the vent system termination:
• The location of the vent termination must be consistent
with the National Fuel Gas Code (ANSI Z223.1) or
CAN/CGA-B149 Installation Codes.
• The vent termination must be located at least 4 feet
horizontally from any electric meters, gas meters,
regulators, and relief equipment.
• The vent termination must be located at least 3 feet
above any forced air inlet located within 10 feet.
• The vent termination must be located at least 4 feet
below, 4 feet horizontally from, or 1 foot above any
door, window, or gravity air inlet into any building.
• The vent termination must be located at least 1 foot
above grade.
• The unit should be installed in a way that prevents any
obstruction of the vent termination during accumulating
snow.
Figure 2. Vent Assembly
7
• The unit installation shall avoid areas where condensate
drainage may cause problems by dropping on planters
or patios, etc. Also verify exhaust gases will not
impinge on windows or building surfaces, which may
be compromised or damaged by condensation.
• Do not install the unit such that exhaust from the vent
termination is directed into window wells, stairwells,
under decks, or in alcoves or similarly recessed areas.
The vent termination must not be located above any
public walkways.
Circulating Air Supply
WARNING:
Do not allow combustion products to enter the
return air ductwork or the circulating air supply.
Failure to prevent the circulation of combustion
products into the living space can create
potentially hazardous conditions including
carbon monoxide poisoning that could result
in personal injury or death.
All return ductwork must be secured to the unit
with sheet metal screws. All return ductwork
must be adequately sealed and all joints must
be taped. When return air is provided through
the bottom of the unit, the joint between the
unit and the return air plenum must be air tight.
The roof curb or cement pad on which the unit is
mounted must provide sound physical support
of the unit with no gaps, cracks, or sagging
between the unit and the curb or pad.
Return air and circulating air ductwork must not
be connected to any other heat producing device
such as a fireplace insert, stove, etc. Doing so
may result in fire, explosion, carbon monoxide
poisoning, personal injury, or property damage.
Air Ducts
This unit is designed only for use with a supply and return
duct. Air ducts should be installed in accordance with the
standards of the National Fire Protection Association
“Standard for Installation of Air Conditioning Systems”
(NFPA 90A), “Standard for Installation of Residence Type
Warm Air Heating and Air Conditioning Systems” (NFPA
90B), and all applicable local codes. NFPA publications are
available by writing to: National Fire Protection Association,
Batterymarch Park, Quincy, ME 02269 or visit www.NFPA.
org on the web.
• Design the duct work according to Manual D by the Air
Conditioning Contractors of America (ACCA).
• The ducts must be properly sized not to exceed the
unit maximum ESP rating at 400 scfm per nominal ton
of cooling capacity.
8
• Duct work should be attached directly to the unit flanges
for horizontal applications.
• If roof curb is installed, the ducts must be attached to
the curb hangers, not the unit.
• It is recommended that the outlet duct be provided
with a removable access panel. The opening should
be accessible when the unit is installed in service and
shall be sizes so that smoke or reflected light may be
observed inside the casing to indicate the presence of
leaks in the heat exchanger. The cover for the opening
shall be attached in a way that will prevent leaks.
• If outside air is utilized as return air to the unit for
ventilation or to improve indoor air quality, the system
must be designed so that the return air to the unit is
not less than 50° F (10° C) during heating operation.
• If a combination of indoor and outdoor air is used, the
ducts and damper system must be designed so that the
return air supply to the furnace is equal to the return
air supply under normal, indoor return air applications.
Air Filter Requirements
WARNING:
Never operate the unit without a filter in place.
Dust and lint could accumulate on internal
parts, resulting in loss of efficiency, equipment
damage and possible fire.
• This unit is not supplied with air filter(s) and has no
factory equipped means for accommodating internal
filter(s). A suitable air filter must be installed upstream
of the evaporator coil of the return air system. Refer to
Table 1 for recommended filter sizes.
• All return air must pass through the filters before entering
the evaporator coil. It is important that all filters be
kept clean and replaced frequently to ensure proper
operation of unit. Dirty or clogged filters will reduce the
efficiency of the unit and result in unit shutdowns.
• Air filter pressure drop must not exceed 0.08 inches WC.
• Horizontal and downflow Installations require the air
filter system be installed in the return air ductwork.
NOTE TO INSTALLER: After installing or replacing the
filtration system for this unit, add the following statement
on or adjacent to the filter service panel: “Replace
filter(s) installed in your system only with the same
dimensional size filters that are being replaced.”
Nominal Approximate Approximate
Cooling
Air Flow
Filter Area
(Tons) Range (CFM)
(Sq. In.)*
2.0
3.0
4.0
5.0
700 - 900
1,000 - 1,300
1,400 - 1,800
1,700 - 2,150
450
625
900
1100
Recommended
Filter Size
(In. x In.)
18 x 25
25 x 25
18 x 25 (2 required)
22 x 25 (2 required)
* Based on velocity of 300 ft/min for disposable filters
and 500 ft/min for high velocity (cleanable) Filters.
Table 1. Air Filter Requirements
Unconditioned Spaces
All duct work passing through unconditioned space must
be properly insulated to minimize duct losses and prevent
condensation. Use insulation with an outer vapor barrier.
Refer to local codes for insulation material requirements.
Acoustical Duct Work
Certain installations may require the use of acoustical
lining inside the supply duct work.
• Acoustical insulation must be in accordance with the
current revision of the Sheet Metal and Air Conditioning
Contractors National Association (SMACNA) application
standard for duct liners.
• Duct lining must be UL classified batts or blankets with
a fire hazard classification of FHC-25/50 or less.
• Fiber duct work may be used in place of internal duct
liners if the fiber duct work is in accordance with the
current revision of the SMACNA construction standard
on fibrous glass ducts. Fibrous duct work and internal
acoustical lining must be NFPA Class 1 air ducts when
tested per UL Standard 181 for Class 1 ducts.
UNIT INSTALLATION
Packaging Removal
Remove the shipping carton and User’s Manual from the
equipment.Take care not to damage the tubing connections
when removing the carton. For rooftop installations, remove
and discard the two supports attached beneath the unit.
Rigging & Hoisting
WARNING:
To avoid the risk of property damage, personal
injury, or death, it is the rigger’s responsibility
to ensure that whatever means are used to hoist
the unit are safe and adequate:
• The lifting equipment must be adequate for
the load. Refer to Table 9 (page 26) for unit
weights.
• The unit must be lifted from the holes in the
base rails using cables or chains.
• Spreader bars are required to protect the unit
and ensure even loading.
• Keep the unit in an upright position at all times.
The rigging must be located outside the units
center of gravity. Refer to Figure 10 (page 26)
for locating the center of gravity.
• All panels must be securely in place during
rigging and hoisting.
• If using bottom discharge with return air ducts a roof
curb must be installed prior to unit installation. See
Rigging and Hoisting section for setting of the unit.
• Sufficient clearance for unobstructed airflow through
the outdoor coil must also be maintained in order to
achieve rated performance. See page 5 for information
about locating the equipment.
Ground Level
Ground level installations must be located according to
local building codes or ordinances and these requirements:
• Clearances must be in accordance with those shown
in Figure 1 (page 5).
• A suitable mounting pad (Figure 3) must be provided
and be separate from the building foundation. The pad
must be level to ensure proper condensate disposal
and strong enough to support the unit’s weight. The
slab height must be a minimum of 2” (5cm) above grade
and with adequate drainage.
• Remove and discard the horizontal Supply and Return
duct covers located on the rear of the unit. Form duct
attachment flanges by bending the sheet metal outward
90 degrees along the perforated lines.
• Firmly attach ductwork directly to these flanges with
screws or other approved mechanical connections and
not to the Supply/Return air panels to avoid damage to
internal components of the equipment. Once completed
use approved duct sealing methods to ensure an air
and watertight seal is achieved.
Rooftop
Rooftop installations must be located according to local
building codes or ordinances and these requirements:
• The roof must be capable of handling the weight of the
unit. For unit weights, see Table 9. Reinforce the roof
if necessary.
• The appropriate accessory roof curb (Figure 4, page
10) must be installed prior to unit installation. The
roof curb must be square and level to ensure proper
condensate drainage. Please follow all instructions
provided with the kit.
• Secure roof curb or frame to roof using acceptable
mechanical methods per local codes. NOTE: Make sure
the two supports beneath the unit have been removed.
Clearances to Combustible Materials
These units are certified as combination heating and
cooling equipment for outdoor rooftop or ground level
installations. Units may be installed on combustible
flooring or Class A, B, or C roofing material when used
with bottom supply and return air ducts as long as the
following requirements are met:
2”
Figure 3. Ground Level Installation
9
Horizontal to Downflow Conversion
The unit is shipped ready for horizontal duct connections.
If down flow ducts are required, the unit must be converted
following the steps below for both the supply and return
ducts.
1.Remove both horizontal duct caps.
2.Locate the duct cap inside the duct openings and remove
the screw holding it in place.
3.Lift the cap out of the unit. (Hint: The cap can be pushed
up from the bottom by reaching through the fork slot).
4.Cover the horizontal duct openings with the horizontal
duct caps. The insulation will be on the indoor side.
5.Fasten the cover with screws to seal.
Condensate Drain
Condensate is removed from the unit through the 3/4”
female pipe fitting (Figure 5) located on the front side of
the unit. Install a 2 inch condensate trap in the drain line of
the same size and prime with water. When connecting rigid
drain line, hold the female fitting with a wrench to prevent
twisting. Do not over tighten! Refer to local codes and
restrictions for proper condensate disposal requirements.
ELECTRICAL WIRING
WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could
result in serious injury or property damage.
Improper servicing could result in dangerous
operation, serious injury, death or property
damage.
• Before servicing, disconnect all electrical
power to furnace.
• When servicing controls, label all wires prior
to disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.”
AVERTISSEMENT:
RISQUE DE CHOC ÉLECTRIQUE,D’INCENDIE
OU D’EXPLOSION
Le non-respect des avertissements de sécurité
pourrait entraîner un fonctionnement dangereux
de l’appareil, des blessures graves, la mort ou
des dommages matériels.
Un entretein incorrect pourrait entraîner un
fonctionnement dangereux de l’appareil, des
blessures graves, la mort ou des dommages
matériels
Figure 4. Roof Top Installation
• Couper toute alimentation électrique au
générateur d’air chaud avant de prodéder
aux travaux d’entretein.
• Au moment de l’entretien des commandes,
étiquetez tous les fils avant de les
débrancher. S’assurer de les raccorder
correctement.
• S’assurer que l’appareil fonctionne
adéquatement aprés l’entretien.
• Electrical connections must be in compliance with
all applicable local codes and ordinances, and with
the current revision of the National Electric Code
(ANSI/NFPA 70).
• For Canadian installations the electrical connections
and grounding shall comply with the current Canadian
Electrical Code (CSA C22.1 and/or local codes).
Condensate Drain
Figure 5. Condensate Drain Location
10
Pre-Electrical Checklist
√ Verify the voltage, frequency, and phase of the supply
source match the specifications on the unit rating plate.
√ Verify that the service provided by the utility is sufficient
to handle the additional load imposed by this equipment.
See Table 2 (page 11) or the unit wiring label for proper
high and low voltage wiring.
Voltage Range Compressor
Model
Number
Maximum
Heating
Input
Nominal
Electrical
Supply
X24K080CA
X36K100CA
X48K120CA
X60K120CA
80,000
100,000
120,000
120,000
208-230/60/1
208-230/60/1
208-230/60/1
208-230/60/1
Min
Max
RLA
LRA
Fan
Motor
FLA
187
187
187
187
253
253
253
253
11.7
15.3
21.2
28.8
58.3
83.0
104.0
152.9
0.91
2.6
2.6
1.46
Single Circuit
Indoor
Blower
FLA
MCA
MOP
4.3
6.8
9.1
9.1
20.3
29.0
38.6
47.0
30.0
40.0
50.0
70.0
Note: FLA = Full Load Amps; LRA = Lock Rotor amps; RLA = Rated Load Amps.
Table 2. Electrical Data
√ Verify factory wiring is in accordance with the unit
wiring diagram (Figures 13 - 16, pages 31 - 34). Verify
none of the connections loosened during shipping or
installation.
Line Voltage
• The line voltage to the unit should be supplied from a
dedicated branch circuit containing the correct fuse or
circuit breaker for the unit.
• An electrical disconnect must be located within
sight of and readily accessible to the unit. This
switch shall be capable of electrically de-energizing the
outdoor unit. See unit data label for proper incoming field
wiring. Any other wiring methods must be acceptable
to authority having jurisdiction.
• Use only copper wire for the line voltage power supply
to this unit (Table 3, page 12). Use proper code agency
listed conduit and a conduit connector for connecting
the supply wires to the unit. Use of rain tight conduit is
recommended.
• Provide power supply for the unit in accordance with
the unit wiring diagram and the unit rating plate.
• Overcurrent protection must be provided at the branch
circuit distribution panel and sized as shown on the unit
rating label and according to applicable local codes.
See the unit rating plate for maximum circuit ampacity
and maximum overcurrent protection limits.
• A wiring diagram is located on the inside cover of the
control access panel of the outdoor unit. The installer
should become familiar with the wiring diagram before
making any electrical connections to the outdoor unit.
See Figures 13 - 16.
• If any of the original wires supplied with the unit must
be replaced, they must be replaced with material of
the same gauge and temperature rating.
• Units are shipped from the factory wired for 240 volt
transformer operation. For 208V operation, remove the
lead from the transformer terminal marked 240V and
connect it to the terminal marked 208V.
• Connect the line-voltage leads to the terminals on the
contactor inside the control compartment.
Thermostat / Low Voltage Connections
• These Gas / Electric units are designed to operate
with a 24 VAC Class II control circuit. The control circuit
wiring must comply with the current provisions of the
NEC (ANSI/NFPA 70) and with applicable local codes
having jurisdiction. Thermostat connections should be
made in accordance with the instructions supplied with
the thermostat and the indoor equipment.
• These units use a special 2 speed compressor to
achieve a high level of efficiency in a compact frame.
A 2 stage heat / 2 stage cool thermostat with backup fossil fuel heat capability is required with the
Dual Fuel iHybrid™ heat pump packaged system.
This system is capable of providing two stages of
cooling, two stages of heating in heat pump mode and
an additional 2 stages of secondary gas heating. See
Figure 12 (page 30)
• The low voltage wires must be properly connected
to the units low voltage terminal block. Route 24V
control wires through the gas furnace side of the unit.
Recommended wire gauge and wire lengths for typical
thermostat connections are listed in Table 4 (page 12).
• The thermostat should be mounted about 5 feet
above the floor on an inside wall. DO NOT install the
thermostat on an outside wall or any other location
where its operation may be adversely affected by radiant
heat from fireplaces, sunlight, or lighting fixtures, and
convective heat from warm air registers or electrical
appliances. Refer to the thermostat manufacturer’s
instruction sheet for detailed mounting information.
2 Stage Heat/Cool Thermostat Configuration
For proper operation and highest efficiency, a 2
Stage Heat Pump thermostat with back-up fossil fuel
capabilities is required for this product. A 2 stage heat
pump thermostat is required to control the special 2 speed
compressor in both Heating and Cooling modes of heat
pump operation. The 2 Stage Heat Pump thermostat will
also allow the unit to operate as a two stage gas heat
system while set in the Emergency Heat mode.
Connect the low voltage thermostat wires between
terminals R (24VAC), Y1 (1st Stage Cool), G (Fan), Y2
(2nd Stage Cool), W1 (1st Stage Heat), W2 (2nd Stage
Heat), C (24V Com.), E (Emer. Heat), O or O/B (Reversing
Valve), and L (Defrost board fault monitoring-Optional)
on both the thermostat sub-base and unit low voltage
terminal board. See Figures 13 - 16 and your heat pump
thermostat installation manual for proper connections.
NOTE: Thermostats with a single “O/B” terminal for
selection of reversing valve control must be configured
for the “O” terminal to energize the reversing valve coil in
the cooling mode of operation.
11
COPPER WIRE SIZE — AWG
(1% Voltage Drop)
Supply Wire Length-Feet
200
6
4
4
4
3
3
2
2
2
1
150
8
6
6
4
4
4
3
3
3
2
100
10
8
8
6
6
6
4
4
4
3
50
14
12
10
10
8
8
6
6
6
4
Supply Circuit
Ampacity
15
20
25
30
35
40
45
50
55
60
Wire Size based on N.E.C. for 60° type copper conductors.
Table 3. Copper Wire Size
Heating Configuration
This furnace is factory configured for two stage heat pump
operation and as a 2 stage gas heating system when the
thermostat is set to the Emergency Heat position.
Heat Pump Defrost Mode
The Ignition/Blower Control board has an Automatic
Heat Staging jumper which can be repositioned to bring
on the second stage of gas heat after a pre-determined
delay in minutes that can be used to offset any cool air
while the unit may be in a prolonged defrost cycle. This
feature should only be used in applications where extreme
outdoor coil icing may occur. Reposition the automatic heat
staging jumper from factory setting “NONE” to 5 or 10 for
the desired delay in minutes before the gas furnace will
automatically move to high heat operation. See Figure
12B (page 30).
Checking Heat Anticipator Settings
• Add the current draw of the system components.
OR
• Measure the current flow on the thermostat R-W
circuit after the circulating blower motor has started.
Set the heat anticipator according to the thermostat
manufacturer’s instructions for heat anticipator settings.
Configuring the Variable Speed Blower
The variable speed blower has been designed to give
the installer maximum flexibility for optimizing system
performance, efficiency, and comfort. It is equipped with
a microprocessor-controlled variable speed motor that is
pre-programmed to deliver optimum airflow in a variety of
conditions and system configurations. Because the blower
can be configured in many ways, it is important to read
and follow all instructions carefully.
CAUTION:
To avoid personal injury or property damage,
make certain that the motor leads cannot
come into contact with any uninsulated metal
components of the unit.
12
Thermostat
Wire Gauge
Recommended T-Stat Wire
Length (Unit to T-Stat)
2-Wire
(Heating)
5-Wire
(Heating/Cooling)
24
55
25
22
90
45
20
140
70
18
225
110
Table 4. Thermostat Wire Gauge
Before operation, the variable speed blower must be
configured to match the unit with the system, climatic
conditions, and other system options. With the blower
installed and configured properly, the furnace will gradually
change speed in response to changes in system variables
such as thermostat settings, duct static, filters, etc. The
variable speed blower is configured by setting the heat,
cool, and adjust jumpers located on the ignition control
board as described below. See Figure 12B (page 30).
Selecting Cooling Airflow
The cooling airflow is selected by setting the Cool and
Adjust jumpers on the ignition control board. Table 11
(page 27) lists the recommended airflow values (CFM) and
selector tap settings for each nominal system capacity. All
airflows for other modes of operation (except secondary
gas heat) are determined by this basic setting. For
maximum capacity, generally, a selection at or near the
top of the CFM range for that nominal capacity is best.
NOTES:
• The CFM values listed in Table 11 are not dependent
on duct static pressure. The motor automatically
compensates (within the limits of the motor) for changes
in duct static pressure.
• If coil icing occurs, the basic cooling airflow selected
may be too low. Verify the selected setting is within the
range shown in Table 11 and the system is properly
charged. If icing continues, raise the selected airflow
to the next higher tap.
• For maximum dehumidification and energy efficiency,
select an airflow near the middle or bottom of the CFM
range for that nominal capacity.
• The 2-stage cooling feature of the unit requires
modulating the airflow.The unit will automatically adjust
the airflow to the appropriate rate when the unit capacity
changes.
Selecting Gas Heating Airflow
The heating airflow is selected by setting the heat jumper
to the desired tap (A,B,C, or D) located on the ignition
control board. Refer to Table 12 (page 27) and select a
nominal rise based on the furnace’s nominal efficiency
and firing input. Follow across the table row to find the
tap setting and nominal air-flow. Verify the selected rise is
within the specification shown on the furnace rating label.
Delay Profile
The delay profile controls the start-up and shut-down
characteristics of the packaged heat pump unit. By varying
the start-up and shut-down characteristics of the packaged
heat pump unit, the system can be optimized for energy
efficiency, humidity control, and comfort.
The delay profile has a two-step ON delay. The blower
will begin operation at 31% airflow for 30 seconds. The
second step operation is 75% airflow for 30 seconds.
After the two-step ON delay has been completed, the
blower operation will be 100% until the thermostat has
been satisfied. There is also a 60 second OFF delay at
50% airflow.
Demand Defrost Control
The demand defrost board controls the defrost cycle
in response to ambient temperature, outdoor coil
temperature and accumulated compressor run time. The
heat pump is allowed to operate in the heating mode
until the combination of outdoor ambient and outdoor
coil temperatures indicate that defrosting is necessary,
based on the programmed defrost curve. There are four
preprogrammed defrost curves on the board.
• The defrost board is equipped with a 5 minute Anti-Short
Cycle Delay (ASCD). The outdoor unit remains off for
the 5 minute delay if the thermostat call is interrupted
or there is a loss of power to the unit.
• A jumper pin is used to switch between the different
curves. The default jumper position is curve 1 and is the
recommended setting for most standard applications.
See Table 5 for additional defrost curves settings.
• The factory default setting does not include a 30 second
compressor delay function and has a 40 ° F defrost
terminate temperature. If additional defrost time is
needed, a higher terminate temperature is available
by selecting a different demand curve. NOTE: The
30 second compressor delay function is optional and
based on the demand curve selected.
• The standard defrost cycle will terminate after 13
minutes and 39 seconds or when the coil temperature
reaches its terminate temperature, whichever occurs
first.
• The control contains a forced - defrost feature, which
places the system into defrost mode every 6 hours
and 4 minutes, unless the coil temperature is above
the selected terminate temperature.
• The system can be manually forced into defrost mode at
any time by shorting the TEST terminals on the demand
defrost board together for more than 9 seconds. The
coil temperature sensor does not need to be cold when
the unit is forced into defrost. After the TEST input
Minimum Time
Terminate
Jumper
Between Defrosts Temperature
Position
(min)
(° F)
Compressor
Delay Function
1
20
40
NO
2
3
4
20
20
20
40
75
75
YES
NO
YES
is removed, the defrost mode will terminate in 13.7
minutes, if the coil temperature is above the terminate
set-point, or when the Y input is removed, whichever
occurs first.
NOTE: If a demand curve is selected which has a 30
second compressor time delay in defrost, the delay is
reduced to 10 seconds in TEST mode.
Ambient Sensor Mounting
For optimum performance of the heat pump system, the
ambient sensor must be mounted on the outside of the
unit. See Figure 6 (page 14).
1.Remove the mounting bracket wire tied to the control
bracket and all hardware included in the packet.
2.Remove star bushing from 7/8” hole in corner panel of
the unit. See Figure 7 (page 14).
3.Route the ambient sensor through the 7/8” hole in the
corner panel of the unit, and then through the 7/8” hole
in the mounting bracket.
4.Route the sensor through the star bushing. Use the star
bushing to secure the mounting bracket to the unit.
5.Secure the ambient sensor inside the plastic clip and
secure it to the mounting bracket with the screw and
nut provided.
6.Install one spacer nut between the plastic clip and
mounting bracket.
7.Bend the mounting bracket into position and screw the
mounting bracket to the corner panel.
Optional Humidistat
An optional humidistat may be installed in the return
air duct for humidity control (when needed), maximum
system capacity and energy efficiency. The humidistat
senses when humidity in the return air stream is above
a preset level and sends a signal to the motor to reduce
airflow. This allows more moisture to be removed until
the humidity level drops. NOTE: The indoor blower motor
of this packaged unit is pre-programmed for humidistat
operation. Remove the Red jumper wire between the R
and DEHUM terminals on the ignition control board.
If installing a humidistat, install it in the return air duct
as directed in the installation instructions included with
the kit. Wire the humidistat through the low-voltage wire
entrance in the packaged unit to the screw terminals
marked R & DEHUM. Wire the humidistat to open on
rise in humidity.
When the HI/LO Dehumidify Green LED status light is
ON, it signals Low Humidity and keeps 24V supplied to
the motor for normal airflow requirements. If the humidity
level of the conditioned space increases the humidistat
will open. Loss of the 24V signal to the indoor blower
motor allows the motor to reduce to approximately 75%
of normal airflow selected until the humidity level drops.
The Green LED is OFF during high humidity conditions.
See Figure 12B (page 30).
Table 5. Demand Defrost Curve Profiles
13
Check all factory wiring to the units wiring diagram. Inspect
the factory wiring connections to be sure none loosened
during shipping or installation.
Optional Comfort Alert TM Diagnostics
Module
The Comfort AlertTM Diagnostics Module is a breakthrough
innovation for troubleshooting heat pump and air
conditioning system failures. The module installs easily in
the electrical box of the outdoor unit near the compressor
contactor. By monitoring and analyzing data from the
Copeland scroll compressor and the thermostat demand,
the module can accurately detect the cause of electrical
and system related failures without any sensors. A
flashing LED indicator communicates the ALERT code
and a diagnostic key is also imprinted on the side of the
module to quickly direct the technician to the root cause
of a problem. See Figure 8.
Figure 6. Ambient Sensor Location
NOTE: This module does not provide safety protection!
The Comfort AlertTM Diagnostics Module is a monitoring
device and cannot control or shut down other devices.
24 VAC Power Wiring
The Comfort AlertTM module requires a constant nominal
24 VAC power supply. The module should be powered by
an R & C that doesn’t have the potential for loss of power
due to safety controls, defrost boards, or other control
boards which could lead to nuisance alerts.
Nut
Nut
Bolt
Ambient Sensor
Thermostat Demand Wiring
The Comfort Alert module requires a two stage thermostat
to operate properly. The Y2 thermostat wire entering the
outdoor unit should be connected to the Y2 input on the
unit terminal strip.
While the compressor is running, Comfort Alert will provide
power to the second stage cooling solenoid inside the
compressor after Y2 has been energized for 5 seconds.
When the compressor is not running, Comfort Alert will
not power the solenoid, regardless of the state of Y2. If
Alert codes 1 or 9 appear while the compressor is running,
Comfort Alert will turn off the solenoid to prevent solenoid
damage from overheating conditions.
Plastic Clip
Star Bushing
Figure 7. Ambient Sensor Mounting
POWER LED
(Green)
Diagnostics
Key
ALERT LED
(Yellow)
L Terminal Wiring
White-Rodgers Compatible Thermostats - The L
connection is used to communicate Comfort Alert codes
to compatible White-Rodgers thermostats. The L terminal
of these thermostats should be connected to the Comfort
Alert L terminal. See unit wiring diagram label included
on the unit or in these instructions for correct field wiring
connections.
NOTE: On some White-Rodgers combatible thermostats,
an icon on the thermostat display will flash at the same rate
as the Comfort Alert yellow Alert LED. An advanced option
on these thermostats is to lock out the compressor when
certain Alert codes are detected in indicating impending
compressor damage. Refer to White-Rodgers thermostat
manuals for more information.
14
TRIP LED
(Red)
Figure 8. Comfort AlertTM Diagnostics Module
Standard Non-Compatible Thermostats – The L
connection on non-compatible type thermostats are used
for heat pump defrost control board fault monitoring. The L
terminal of these thermostats should be connected directly
to the defrost control board L terminal. See the wiring
diagram label or the heat pump installation instructions
for correct field wiring connections.
DC SOL Connection
The two pin DC SOL connector provides a connection
to the Copeland UltraTech second stage compressor
solenoid (see Figure 12). This 24VDC solenoid is internal
to the compressor and will not operate properly if 24VAC
is applied to the compressor solenoid terminals.
To reduce the VA load of the solenoid on the system,
Comfort Alert uses a phase control method to reduce the
DC voltage to the solenoid to the minimum level required to
keep the solenoid pulled in. As the 24VAC supply voltage
varies, Comfort Alert intelligently changes the solenoid
DC voltage supply to minimize power consumption.
A voltmeter attached to the DC SOL output will measure
4 - 18VDC, when solenoid should be energized, depending
on the level of the 24 VAC supply.
Interpreting the Diagnostic LED’s
When an abnormal system condition occurs, the Comfort
AlertTM module displays the appropriate ALERT and/or
TRIP LED. The yellow ALERT LED will flash a number of
times consecutively, pause and then repeat. To identify
a Flash Code number, count the number of consecutive
flashes. See Table 15 (pages 35 - 36) for flash code
identification or Table 16 (page 37) for module wiring
troubleshooting.
Each time the module powers up, the last ALERT Flash
Code that occurred prior to shut down is displayed for
one minute. The module will continue to display the LED
until the condition returns to normal or if 24 VAC power
is removed from the module.
LED Description
• POWER LED (Green): indicates voltage is present at
the power connection of the module.
• ALERT LED (Yellow): communicates an abnormal
system condition through a unique flash code.
NOTE: The ALERT LED will flash consecutively, pause
and then repeat the process.The number of consecutive
flashes, referred to as the Flash Code, correlates to
a particular abnormal condition. Detailed descriptions
of these ALERT Flash Codes are listed in Table 15.
• TRIP LED (Red): indicates a demand signal is received
from the thermostat, but current to the compressor is
not detected by the module. The TRIP LED typically
indicates if the compressor protector is open or the
compressor has no power.
The scroll compressor’s R (run), C (common), and S
(start) wires are routed through the holes in the Comfort
AlertTM module marked R, C, & S. NOTE: The common
wire does not need to be routed through the module for
it to operate.
Installation Verification
To verify the Comfort Alert is correctly installed, two
functional tests can be performed.
1.Disconnect power from the compressor and force a
thermostat call for cooling. NOTE: The Trip LED (red)
should turn on indicating a compressor trip as long as
24VAC is measured at the Y terminal. If the Trip LED
does not function as described, refer to the wiring
diagrams (Figures 14 or 16, pages 32 or 34).
2.Disconnect power from the compressor and 24VAC
from Comfort Alert.
3.Remove the wire from Y terminal of Comfort Alert,
reapply 24VAC power to Comfort Alert and reconnect
power to the compressor.
4.Set the thermostat’s system mode to COOL.
NOTE: When the compressor starts to run, the Alert
LED (yellow) will begin flashing a Code 8 indicating a
welded contactor.
5.Disconnect power from the compressor and 24VAC
from Comfort Alert.
6.With Comfort Alert OFF, reattach the wire to the Y
terminal. Reapply power to compressor and 24VAC to
Comfort Alert. NOTE: The Alert LED (yellow) will flash
the previous code 8 for 1 minute and then turn off. If
the yellow LED does not function, refer to the wiring
diagrams (Figures 14 or 16).
Troubleshooting the Installation
Depending on system configuration, some ALERT Flash
codes may not be active. The presence of safety switches
affects how the system alerts are displayed by this module.
Resetting Alert Codes
Alert Codes can be reset manually and automatically.
The manual method to reset an Alert code is to cycle the
power to Comfort Alert off and on. For automatic reset,
Comfort Alert continues to monitor the compressor and
system after an Alert is detected. If conditions return to
normal, the Alert code is turned off automatically.
Optional Outdoor Temperature Sensor
An outdoor temperature sensor can be installed in the
field for use in conjunction with a compatible heat pump
thermostat to convert heat pump mode of operation over
to the gas heat system when outdoor conditions no longer
favor operating the heat pump. Refer to the installation
and operating instructions of the accessory kit for further
information.
Grounding
WARNING:
The unit cabinet must have an uninterrupted or
unbroken electrical ground to minimize personal
injury if an electrical fault should occur. Do not
use gas piping as an electrical ground!
This unit must be electrically grounded in accordance
with local codes or, in the absence of local codes, with
the National Electrical Code (ANSI/NFPA 70) or the CSA
C22.1 Electrical Code. Use the grounding lug provided in
the control box for grounding the unit.
15
GAS SUPPLY & PIPING
WARNING:
FIRE OR EXPLOSION HAZARD
• Failure to follow safety warnings exactly
could result in serious injury or property
damage.
• Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
• Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call
the fire department.
AVERTISSEMENT:
RISQUE D’INCENDIE OU D’ EXPLOSION
• Le non-respect des avertissements de sécurité
pourrait entraîner des blessures graves, la mort
ou des dommages matériels.
• L’installation et l’entretien doivent être effectués
par un installateur qualifié, un organisme de
service ou le fournisseur de gazstaller, service
agency or the gas supplier.
• Ne pas entreposer ni utiliser de l’essence ni
d’autres vapeurs ou liquides inflammables dans le
voisinage de cet appareil, ni de tout autre appareil.
•
•
•
•
•
16
QUE FAIRE S’IL Y A UNE ODEUR DE GAZ
Ne pas tenter d’allumer aucun appareil.
Ne toucher à aucun interrupteur électrique;
n’utiliser aucun téléphone dans le bâtiment.
Évacuer l’immeuble immédiatement.
Appeler immédiatement le fournisseur de gaz en
employant le téléphone d’un voisin. Respecter à
la lettre les instructions du fournisseur de gaz.
Si personne ne répond, appeler le service des
incendies.
• All gas piping must be installed in compliance with
local codes and utility regulations. In the absence
of local codes the gas line installation must comply
with the latest edition of the National Fuel Gas Code
ANSI Z223.1 or CAN/CGA B149 Installation Codes.
• Some local codes require the installation of a
manual main shut-off valve and ground joint union
external to the furnace (Figure 9). The shut-off
valve should be readily accessible for service and/
or emergency use. Consult the local utility or gas
supplier for additional requirements regarding
placement of the manual main gas shut-off.
• The manifold pressure must be set to the
appropriate value for your installation. Refer to the
Manifold Pressure Adjustment section (page 19)
for adjustment instructions.
• Gas piping must never run in or through air ducts,
chimneys, gas vents, or elevator shafts.
• Compounds used to seal joints on gas piping must
be resistant to the actions of LP propane gas.
• The main gas valve and main power disconnect to
the furnace must be properly labeled by the installer
in case emergency shutdown is required.
• An 1/8 inch NPT plugged tap must be installed in
the gas line immediately upstream of the gas supply
connection to the furnace for use when measuring
the gas supply pressure.The plug should be readily
accessible for service use.
• A drip leg should be installed in the vertical pipe
run to the unit (Figure 9).
This unit only has right side gas entry. When connecting
the gas, provide clearance between the gas supply line
and the entry hole in the unit’s casing to avoid unwanted
noise and/or damage to the unit. A typical gas service
hookup is shown in Figure 9.
Table 13 (page 28) lists gas pipe capacities for standard
pipe sizes as a function of length in typical applications
based on nominal pressure drop in the line.
Automatic Gas Valve
(with manual shut-off)
Shut-Off Valve
with 1/8 NPT
plugged tap
Some utilities
require Shut-Off
Valve to be
4 to 5 feet
above floor
Burner
Assembly
Ground
Joint
Union
Dripleg
Manifold
Figure 9. Typical Gas Hookup - Right Side Entry
Leak Check
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury or property damage.
Never test for gas leaks with an open flame.
Use a commercially available soap solution
made specifically for the detection of leaks to
check all connections. A fire or explosion may
result causing property damage, personal
injury or loss of life.
the heating value of the gas (based on sea level) which
can be obtained from your local gas utility. The heating
value of gas at high altitude is always lower than the sea
level heating value. The heating values listed in Tables 6
& 7 (page 20) are based on sea level values.
WARNING:
The reduction of input rating necessary for high
altitude installation may only be accomplished
with factory supplied orifices. Do not attempt to
drill out orifices in the field. Improperly drilled
orifices may cause fire, explosion, carbon
monoxide poisoning, personal injury or death.
RISQUE D’INDENDIE OU D’EXPLOSION
If installing this unit above 2,000 feet, the input rate must
be reduced 4% per 1,000 feet of altitude (Example: 12%
at 3,000 feet, 16% at 4,000 feet, etc). NOTE: Deration is
necessary to compensate for low atmospheric pressure
at high altitudes.
Le non-respect des avertissements de sécurité
pourrait d’entraîner des blessures graves, la mort
ou des dommages matériels.
For altitudes between 5,000 and 10,000 feet above sea
level, the unit can be converted by adjusting the furnace
manifold pressure. See Tables 6 or 7 for the correct
manifold pressure settings.
AVERTISSEMENT:
Ne jamais utiliser une flamme nue por
vérifier la présence des fuites de gaz. Pour la
vérification de tous les joints, utiliser plutôt une
solution savonneuse commerciale fabriquée
spécifiquement pur la détection des fuites de gaz.
Un incendie ou une explosion peut entraîner des
dommages matériels, des blessures ou la mort.
After the gas piping to the unit is complete, all connections
must be tested for gas leaks.This includes pipe connections
at the main gas valve, emergency shutoff valve and
other gas connectors. A soap and water solution can be
applied on each joint or union using a small paintbrush.
If any bubbling is observed, the connection is not sealed
adequately and must be retightened. Repeat the tightening
and soap check process until bubbling ceases.
• If pressure testing the gas supply lines at pressures
greater than 1/2 psig (14 inches WC), the unit must
be disconnected from the gas supply piping system
to prevent damage to the gas valve.
• If the test pressure is less than or equal to 1/2 psig
(14 inches WC), the unit must be isolated from the
gas supply line by closing the manual shut-off valve.
High Altitude Conversion
Conversion of this unit must be performed by qualified
service personnel, using only approved parts. All
installations must be made in accordance with the National
Fuel Gas Code and/or local jurisdiction codes.
High altitude conversion can be field performed by a
simple adjustment of manifold pressure or a change of
the orifices (if necessary) as described on page 20. The
changes required depend on the installation altitude and
LP/Propane Gas Conversion
WARNING:
This unit was equipped at the factory for use
with natural gas only. A special kit, supplied
by the manufacturer, is required to convert the
unit to operate on LP/Propane gas. Failure to
use the proper conversion kit can cause fire,
explosion, property damage, carbon monoxide
poisoning, personal injury, or death.
Conversion of this equipment to LP/Propane gas must
be made by qualified service personnel, using approved
factory parts. Conversion to LP can be accomplished by
replacing the natural gas orifices with the appropriate LP/
Propane orifices and then adjusting the manifold pressure
(page 20). Conversion to LP/Propane (sea level and high
altitude) is detailed in the installation instructions provided
with the conversion kit. Please follow the instructions
provided in each kit. Approved conversion kits are:
• The United States LP/Propane Gas Sea Level and High
Altitude Conversion Kit is for LP/propane conversion in
the United States at altitudes between zero and 10,000
ft. above sea level.
• The Canadian LP/Propane Gas Sea Level and High
Altitude Conversion Kit is for LP/Propane conversions
in Canada at altitudes between zero and 4,500 ft. above
sea level.
For installations between zero and 4,999 ft. above sea
level, a #55 drill size orifice should be used. Installations
5,000 ft. above sea level require a # 56 drill size orifice.
17
Table 7 (page 20) lists the correct orifice size to use at
different altitudes.
After changing the orifices, it is required that you measure
the gas input rate by clocking the gas meter and using
the local gas heating value. See Verifying and Adjusting
the Firing Rate section on page 19.
START UP & adjustments
Pre-Start Check List
√ Verify the unit is level and allows proper condensate
drainage.
√ Verify all clearance requirements are met and there is
free airflow to and from the outdoor coil.
√ Verify that the duct work is sealed to prevent air leakage.
√ Verify that the line voltage power leads are securely
connected and the unit is properly grounded.
√ Verify that the low voltage wires are securely connected
to the correct leads on the low voltage terminal strip.
√ Verify that the gas line service pressure does not exceed
10.0 inches WC (0.36 psig), and is not less than 4.5
inches WC (0.16 psig) for natural gas. For LP gas the
line service pressure must not exceed 14 inches WC
(0.51 psig) and must not be less than 11.0 inches WC
(0.40 psig).
√Verify that the flame roll-out control is closed. If
necessary, press the red button to reset the control. DO
NOT install a jumper wire across the control to defeat
its function. If the control reopens upon start-up, DO
NOT reset the control without identifying and correcting
the fault condition which caused the control to trip.
√Verify that the gas line has been purged and all
connections are leak tight.
√ Verify that all exterior panels are replaced and securely
fastened.
√ Verify that the outdoor fan turns freely.
√ Verify that the power supply branch circuit overcurrent
protection is sized properly.
√Verify that the thermostat is wired correctly. The
thermostat function switch should be set to OFF and
the thermostat fan switch should be set to AUTO.
Start-Up Procedure
WARNING:
If this unit is equipped with crankcase heaters,
allow 24 hrs for heating of the refrigerant
compressor crankcase prior to start up and
anytime the power has been removed for more
than 12 hrs. Failure to comply may result in
damage or cause premature failure of the
system.
• Check all electrical wiring for loose connections and
tighten as required.
• Check unit for return air filters and condensate trap.
• Close all electrical disconnects to energize the system.
18
Air Circulation
Leave the thermostat system mode on OFF and set the
fan mode to ON. Blower will run continuously. Check the
air delivery at the supply registers and adjust register
openings for balanced air distribution. Examine ductwork
for leaks or obstruction if insufficient air is detected. Set
the thermostat fan mode to AUTO. The blower will stop
running.
Short Cycle Protection
1.With the system operating in cooling mode, note the
temperature setting of the thermostat and gradually raise
the set-point temperature until the unit de-energizes.
2.Immediately lower the set point temperature of the
thermostat to its original setting and verify that the
indoor blower is energized.
3.After approximately 5 minutes, verify the compressor
and fan energize and the temperature of the discharge
air is cooler than the room temperature. NOTE: This is
available only for the single phase models.
System Cooling Operation (2-Stage)
1.Set the thermostat’s system mode to COOL and the
fan mode to AUTO. Lower the thermostat temperature
setpoint one degree below room temperature and verify
the outdoor unit and blower energize on 1st stage cool.
2.Feel the air being circulated by the indoor blower and
verify that it is cooler than ambient temperature. Listen for
any unusual noises. If unusual sounds occur, determine
the source of the noise and correct as necessary.
3.After determining the system is operating properly, wait
1-2 minutes and then lower the thermostat temperature
set point an additional 3-4 degrees until the cooling
system moves into 2nd stage or high cool operating
mode. The compressor and indoor blower will increase
in speed.
4.Allow the cooling system to operate for several minutes
and then set the temperature selector above room
temperature. Verify the fan and compressor cycle off
with the thermostat. NOTE: The blower should also stop
in approximately 60 seconds, unless the fan switch is
set to the ON position.
System Heating (Heat Pump Mode)
1.Set the thermostat system mode to HEAT and the fan
mode to AUTO. Raise the thermostat temperature set
point one degree above room temperature and verify
the outdoor unit and blower energize on 1st stage heat.
2.Feel the air being circulated by the indoor blower and
verify that it is warmer than ambient temperature.
Listen for any unusual noises. If unusual sounds
occur, determine the source of the noise and correct
as necessary.
3.After determining the system is operating properly,
raise the thermostat temperature set point an additional
1-2 degrees until the system moves to 2nd stage heat
pump mode of operation. The compressor and blower
will increase in speed during 2nd stage cooling.
NOTE: If thermostat differential is set too high the gas
heat system may energize (depending on thermostat
model) and de-energize the heat pump outdoor system.
Gas heat will remain in operation until the thermostat
call for heat is satisfied.
4.Allow the heating system to operate for several minutes
and then set the temperature selector below room
temperature. Verify the system shutdown sequence.
Note: The blower will remain operating for 60 or 150
seconds after the call for heat is removed depending
on if the system was in heat pump or gas heat mode,
respectively, unless the thermostat switch is set to the
ON position.
Gas Heating (Emergency Heat Mode)
NOTE: When thermostat is set to the emergency heat
position, heat pump operation will be locked out.
1.Set the thermostat to the lowest setting.
2.Follow the procedures given on the gas operating
instruction label, in this installation instructions or
attached inside the louvered control access panel.
3.Set the thermostat one degree above room temperature
and verify the sequence of operation. See Operating
Sequence section (page 21.)
4.Verify that the compressor and outdoor fan motor are
not energized.
5.After determining the system is operating properly, wait
1-2 minutes and then raise the thermostat temperature
set point an additional 1-2 degrees until the heating
system moves into 2nd stage or high heat operating
mode. The gas valve will energize to high heat mode
while the induced draft motor and indoor blower motor
both increase in speed.
6.After the unit has run for approximately five minutes,
set the thermostat below room temperature. Verify the
shutdown sequence; steps 10 -12 in the Operating
Sequence section (page 22).
Verifying & Adjusting Temperature Rise
Verify the temperature rise through the unit is within the
range specified on the unit data label for both high and
low firing rates. Temperature rises outside the specified
range could result in premature heat exchanger failure.
1.Place thermometers in the return and supply air stream
as close to the unit as possible. The thermometer on the
supply air side must be shielded against direct radiation
from the heat exchanger to avoid false readings.
2.Adjust all registers and duct dampers to the desired
position. Run the unit for 10 to 15 minutes before
taking any temperature readings. The temperature
rise is the difference between the supply and return air
temperatures.
NOTE: For typical duct systems, the temperature rise will
fall within the range specified on the data label (with the
blower speed at the factory recommended setting) shown
in Table 9 (page 27). If the measured temperature rise falls
outside the specified range, it may be necessary to change
the blower speed. Lowering the blower speed increases
the temperature rise and a higher speed decreases the
temperature rise.
The unit is equipped with a variable speed motor. Heating
and cooling speed selection is made by changing the tap
settings on the ignition control board located in the unit
control box. Refer to Configuring the Variable Speed Blower
Section (page 12) for additional information.
The Variable Speed Blower (VSB) is designed with built
in delay profiles for start up and shut down of the system.
Refer to the Operating Sequence section (page 21) for
more details.
Verifying & Adjusting Firing Rate
CAUTION:
Do not re-drill the burner orifices. If the orifice
size must be changed, use only new orifices.
The firing rate must be verified for each installation to
prevent over-firing of the furnace. The firing rate must
not exceed the rate shown on the unit data label. To
determine the firing rate, follow these steps:
1.Obtain the gas heating value (HHV) from the gas supplier.
2.Shut off all other gas fired appliances.
3.Start the unit in heating mode and allow it to run for at
least 3 minutes.
4.Measure the time (in seconds) required for the gas
meter to complete one revolution.
5.Convert the time per revolution to cubic feet of gas per
hour using Table 14 (page 28).
6.Multiply the gas flow rate in cubic feet per hour by the
heating value of the gas in Btu per cubic foot to obtain
the firing rate in Btu per hour. See Example.
7.Adjust the manifold pressure if necessary. See Manifold
Pressure Adjustment instructions on page 20. For
additional information about elevations above 2,000
feet, see page 17.
Example:
• Time for 1 revolution of a gas meter with a 1 cubic
foot dial = 40 seconds.
• From Table 14, read 90 cubic feet gas per hour.
• Local heating value of the gas (obtained from gas
supplier) = 1,040 Btu per cubic foot.
• Input rate = 1,040 x 90 = 93,600 Btuh.
Verifying Over-Temperature Limit Control
Operation
1.Verify the louvered control access panel is in place and
that there is power to the unit.
2.Block the return airflow to the unit by installing a closeoff plate in place of or upstream of the filter.
3.Set the thermostat above room temperature and verify
the units operating sequence (page 21).
19
Manifold Pressure (in W.C.) for
Natural Gas Installations
Manifold Pressure (in W.C.) and Orifice Sizes
for LP/Propane Gas Installations
Heating Value Btu/cu. ft.
Altitude above
sea level
800 to 899
zero to 1,999 FT
2,000 to 4,999 FT
3.5
3.5
3.5
3.5
3.5
3.5
2,000 to 4,999 FT
8.5
55
5,000 to 5,999 FT
3.5
3.5
3.0
5,000 to 5,999 FT
10.0
56
6,000 to 7,999 FT
8,000 to 10,000 FT
3.5
3.0
3.2
2.8
2.8
2.5
900 to 999 1,000 to 1,100
Table 6. Manifold Pressure (in W.C.) for Natural Gas
NOTE: The over-temperature limit control should turn
off the gas valve within approximately four minutes
(exact time depends on the efficiency of the close-off
when blocking the return air). The circulating air and
combustion blowers should continue to run when the
over-temperature limit control switch opens.
4.Remove the close-off plate immediately after the overtemperature limit control opens. If the unit operates
for more than four minutes with no return air, set the
thermostat below room temperature, shut off power to
the unit, and replace the over-temperature limit control.
Manifold Pressure Adjustment
The manifold pressure must be set to the appropriate
value for your installation. To adjust the manifold pressure:
1.Obtain the required manifold pressure setting. Use
Table 6 for natural gas or Table 7 for LP/propane gas.
NOTE: The values listed in the tables are based on sea
level values. At higher altitudes, the heating value of
gas is lower than the sea level heating value.
2.Remove the regulator cap. Turn the high fire
adjusting screw clockwise to increase the pressure or
counterclockwise to reduce the pressure. See Figure
10 (page 25) for adjusting screw locations.
3.Replace the regulator cap after adjustments are
complete.
Verifying Burner Operation
WARNING:
Uninsulated live components are exposed when
louvered control access panel is removed.
1. Remove the louvered control access panel and verify
there is power to the unit.
2. Set thermostat above room temperature and observe
the ignition sequence. NOTE: The burner flame should
carry over immediately between all burners without
lifting off, curling, or floating. The flames should be blue,
without yellow tips. Make sure the flame is drawn into
the center of the heat exchanger tube. In a properly
adjusted burner assembly, the flame bends down and
to the right at the end of the heat exchanger tube. The
end of the flame will be out of sight around the bend.
3. After validating flame characteristics, set the thermostat
below room temperature and verify the burner flame
extinguishes completely.
20
Altitude above
sea level
zero to 1,999 FT
Manifold
Pressure
Orifice
Size
10.0
55
6,000 to 7,999 FT
9.0
56
8,000 to 10,000 FT
8.5
56
NOTE: Manifold pressure based on sea level LP heating value
of 2,500 Btu/cu. ft.3
Table 7. Manifold Pressure (in W.C.) for LP Gas
Refrigerant Charging
WARNING:
These units are shipped fully charged with
R-410A refrigerant and ready for installation.
When a system is installed according to these
instructions, no refrigerant charging is required.
If repairs make it necessary for evacuation and
charging, it should only be done by qualified,
trained personnel thoroughly familiar with this
equipment. Some local codes require licensed
installation/service personnel to service this
type of equipment. Under no circumstances
should the owner attempt to install and/or
service this equipment. Failure to comply with
this warning could result in property damage,
personal injury, or death.
CAUTION:
This unit uses R-410A refrigerant. DO NOT use
any other refrigerant in this unit. Use of another
refrigerant will damage the unit.
The system refrigerant charge can be checked and
adjusted through the service ports provided at the front
panel. Use only gauge lines which have a Schrader
depression device present to actuate the valve. Refrigerant
charging must be done by qualified personnel familiar with
safe and environmentally responsible refrigerant handling
procedures. Refer to the application notes and charging
charts on pages 37 - 39
Charging an R-410A unit in AC mode at
outdoor temperatures above 65F.
1.With the system operating at steady-state, measure the
liquid refrigerant pressure in psig at the service valve.
2.Measure the liquid refrigerant temperature in Fahrenheit
at the outlet of the condensor coil.
3.For the temperature measured, determine the required
liquid refrigerant pressure from the appropriate charging
charts in Figures 18 - 21 (pages 38 & 39).
4.If the pressure measured in step 1 is greater than the
required liquid refrigerant pressure determined in step
3, then there is too much charge in the system. Remove
refrigerant and repeat steps 1 through 3 until the system
is correctly charged.
5.If the pressure measured in step 1 is less than the
required liquid refrigerant pressure determined in step
3, then there is too little charge in the system. Add
refrigerant and repeat steps 1 through 3 until the system
is correctly charged.
Charging an R-410A Unit in Heating Mode
1.Evacuate the refrigerant system.
2.Weigh in the proper charge based on the charge level
noted on the rating plate. Unit charge MUST be verified
in cooling season.
3.Verify the unit is operating properly as outlined in System
Heating.
OPERATINg sequence
The operating sequences for the heating, cooling, and
fan modes are described below. Refer to the field and
furnace wiring diagrams (Figures 14 - 17, pages 31 - 34).
2-Stage Heating Mode (Heat Pump)
1.On an initial call for heat, the thermostat closes and
applies 24 VAC to terminals G & Y1. NOTE: This closes
the compressor contactor and the compressor operates
on first stage. The reversing valve is not energized in
heating mode.
2.The control energizes the circulating blower at first stage
for the selected air flow.
3.If the thermostat is not satisfied in the required time
(based on the operation of the two-stage cooling
thermostat), Y2 will energize and the compressor will
run in 2nd stage. Refer to the thermostat installation
instructions for the heating profile.
4.When the thermostat is satisfied, terminals G & Y on the
control board are de-energized, opening the compressor
contactor.
5.If the thermostat does not satisfy on 2nd stage heat pump
mode, the thermostat or outdoor sensor will call for the
back-up gas heat. NOTE: If the unit is switching from
heat pump to furnace, the outdoor fan and compressor
will continue to run until flame ignition is detected in the
furnace. The indoor blower will continue to run.
Gas Heating Mode - Emergency Heat &
Defrost Mode
1.On a call for 1st stage heat, the thermostat closes and
applies 24 VAC to terminal W on the control board.
2.Safety Circuit Proving - The control board verifies
continuity through the 24VAC limit control circuit. If the
high temperature limit switch and flame roll-out switch
are closed and both the high and low vent pressure
switches are open, the control board will then begin
pressure switch proving. If an open limit is detected, the
control board will energize the indoor blower motor and
operate it continuously while the limit switch circuit is
open. All other system functions will be inoperable until
the limit circuit closes. While the limit circuit is open, the
control will flash 1 on the red LED.
3.The furnace control checks for continuity (24 VAC)
across the pressure switch. If the pressure switch is
closed, the heat mode sequence will not continue. If it
remains closed for 10 seconds, the red LED will flash
3 times repetitively until the fault condition clears.
4.Pressure Switch Proving - The control energizes the
induced draft motor on High speed and waits for the
low pressure vent switch to close. If the low pressure
switch does not close within 60 seconds, the control
will flash 2 on the red LED. If the low pressure switch
does not close before 60 seconds expires, the control
will de-energize the inducer for 60 minutes and continue
to flash 2 during the 60 minute inducer off period. After
the inducer has been off for 60 minutes, the control
energizes the inducer motor and restarts the 60 second
pressure switch proving period.
5.Pre-Purge - If the low pressure switch closes the control
runs the inducer on high speed for a 30 second pre-purge
time while monitoring the thermostat call for heat, limit
switch circuit, low pressure switch, and flame sense.
High pressure switch is ignored.
6.Igniter Warm Up - When the 30 second pre-purge time
has elapsed, the control begins the Hot Surface Ignition
(HSI) warm-up as follows:
Initial Power up: After 30 seconds of igniter warm-up,
the gas valves (24 VAC) will open. The igniter circuit will
stay energized for 3 seconds after the gas valve opens.
After Initial Power up: The control has a programmed
adaptive ignition feature which varies the warm-up
period as follows: If ignition is successful the warm-up
is reduced by 3 seconds on each subsequent call for
heat until ignition failure occurs. Upon ignition failure,
the warm-up is increased by 3 seconds on the next try.
If successful, the timing remains fixed at this level. In
general, whenever ignition failure occurs the warm-up
interval is increased by 3 seconds on the next try. And
if successful, it remains there. Minimum and maximum
warm-up time limits are set at 9 and 54 seconds.
7.Flame Proving / Ignition / Low Heat Operation - The
furnace control must prove flame via the flame sensor
5 seconds after the low main gas valve is energized. If
flame is sensed, burners are on and the igniter cools off.
If no flame is sensed, the gas valve closes immediately
and the inducer continues to run. A second trial for
ignition (step 6) begins. If no flame is sensed on the
fifth try for ignition, the furnace control is locked and the
red LED will flash 4 times repetitively. The thermostat
must be opened for at least ten seconds to reset the
furnace control after a lock out. Otherwise, the furnace
will attempt another ignition sequence in 1 hour.
Low Fire Heat (Stage 1): If flame is present at the end
of the trial for ignition time, the control leaves Low main
gas valve energized, inducer motor on High speed for the
first 15 seconds, and begins the heat blower on delay.
Control inputs are continuously monitored while the call
for heat remains. The control will always energize the
gas valve on Low fire with the inducer on high speed for
21
the first 15 seconds of any heating cycle and ignores
any second stage heat demand. After this 15 second
period, the control switches inducer to Low speed if no
second stage demand is present, or attempts to stage
to high heat if thermostat W2 terminal is energized.
8.Blower Start-Up - After flame is proven, the furnace
control energizes the circulating air blower at a very
low speed. After 30 seconds, the blower will ramp to
the airflow selected for heating.
9.High Heat Staging (with 2 Stage Heat Thermostat) - Unit
will always start in low heat operation. See step 7 for
start up sequence. After the initial 15 second start up
sequence is satisfied, the control will wait for a W2 call
from a 2-stage thermostat. After a second stage heat
demand is present (W2 energized), the gas valve will
open to High heat mode increasing the flow of gas to
the burners while the inducer and blower motor ramp
to high speed.
10. When the thermostat has been satisfied, gas valve is
de-energized.
11. The inducer motor is de-energized after a 30 second
post purge.
12.The circulating air blower will remain energized for
approximately 120-150 seconds after the demand for
heat is no longer present.
13.Abnormal Conditions - If a limit switch opens during
heating operation the gas valve is de-energized
immediately. The control de-energizes the induced
draft motor and runs the indoor blower motor
continuously while the limit switch is open.
2-Stage Cooling Mode
1.On a call for cooling the thermostat closes, applying
24 VAC to the G, O and Y1 terminals on the control.
This closes the compressor contactor, energizes the
reversing valve, and the compressor operates on 1st
stage.
2.The control energizes the circulating blower to 1/3 of
the selected airflow for approximately 30 seconds.
3.The circulating blower will then ramp to approximately
3/4 of the selected airflow for another 30 seconds before
adjusting to full airflow until the thermostat is satisfied.
4.If the thermostat is not satisfied in the required time,
based on the operation of the two-stage cooling
thermostat, Y2 will energize and the compressor will
run at second stage. Refer to the thermostat installation
instructions for the cooling profile.
5.When the thermostat is satisfied, the G, O and Y
terminals on the control board are de-energized
opening the compressor contactor, and de-energizing
the reversing valve.
6.The circulating air blower will operate at 1/2 of the
selected speed for 60 seconds, and de-energize.
Fan Mode
1.On a call for fan operation, the thermostat applies 24
VAC to the G terminal on the furnace control board.
2.The circulating air blower ramps to 1/2 of the selected
airflow.
22
equipment MAINTENANCE
WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could
result in serious injury or property damage.
Improper servicing could result in dangerous
operation, serious injury, death or property
damage.
• Before servicing, disconnect all electrical
power to furnace.
• When servicing controls, label all wires prior
to disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.”
AVERTISSEMENT:
RISQUE DE CHOC ÉLECTRIQUE,D’INCENDIE
OU D’EXPLOSION
Le non-respect des avertissements de sécurité
pourrait entraîner un fonctionnement dangereux
de l’appareil, des blessures graves, la mort ou
des dommages matériels.
Un entretein incorrect pourrait entraîner un
fonctionnement dangereux de l’appareil, des
blessures graves, la mort ou des dommages
matériels
• Couper toute alimentation électrique au
générateur d’air chaud avant de prodéder
aux travaux d’entretein.
• Au moment de l’entretien des commandes,
étiquetez tous les fils avant de les
débrancher. S’assurer de les raccorder
correctement.
• S’assurer que l’appareil fonctionne
adéquatement aprés l’entretien.
CAUTION:
Use care when removing parts from this unit.
Personal injury can result from sharp metal
edges present in all equipment of sheet metal
construction.
Proper maintenance is important to achieve optimum
performance from the system. The ability to properly
perform maintenance on this equipment requires certain
mechanical skills and tools. If you do not possess these
skills, contact your dealer for maintenance. Consult your
local dealer about the availability of maintenance contracts.
Routine maintenance should include the following:
CAUTION:
The unit should never be operated without a
filter in the return air system. Replace disposable
filters with the same type and size.
• Inspect, clean or replace air filters at the beginning of
each heating and cooling season, or more frequently
if required.
• Inspect the condensate drain and outdoor coil at the
beginning of each cooling season. Remove any debris.
Clean the outdoor coil and louvers as necessary using
a mild detergent and water. Rinse thoroughly with water.
• Inspect the electrical connections for tightness at the
beginning of each heating and cooling season.
• The blower compartment should be cleaned monthly
during the heating and cooling seasons to remove
any dirt and lint that may have accumulated in the
compartment or on the blower and motor. Buildup
of dirt and lint on the blower and motor can create
excessive loads on the motor resulting in higher than
normal operating temperatures and possible shortened
service life.
• Maintain heat exchanger and burners. The unit should
operate for many years without excessive scale buildup
in the heat exchanger, however, the heat exchanger,
the vent system, and the burners should be inspected
and cleaned (if required) by a qualified serviceman
annually to ensure continued safe operation. Particular
attention must be given to identify deterioration from
corrosion or other sources.
• The motors for the circulating air blower, outdoor fan,
and combustion blower are pre-lubricated at the factory.
No further oiling is required for the life of this product.
• Inspect and clean the screen of the vent cover assembly
at the beginning of each heating and cooling season.
Cleaning of Heat Exchanger
WARNING:
Holes in the heat exchanger can cause products
of combustion to enter the home. Replace the
heat exchanger if leaks are found. Failure to
prevent products of combustion from being
circulated into the living space can create
potentially hazardous conditions including
carbon monoxide poisoning that could result
in personal injury or death.
3.Remove the louvered access panel from the unit.
4.Turn the gas control knob (gas valve) to the OFF
position. See Figure 12 (page 29) for gas valve shut
off instructions.
5.Disconnect the wires from the gas valve, ignitor, flame
sensor, combustion air motor, flame roll-out control,
over-temperature limit switch, and pressure switch.
6.Remove the silicone rubber tube from the collector pan
to the pressure switch.
7.Remove 4 nuts securing the combustion blower to the
collector pan. Remove the combustion blower.
8.Remove all screws securing the collector pan to the
unit. Remove the collector pan from the unit.
CAUTION:
To prevent damage to the unit or internal
components, it is recommended that two
wrenches be used when loosening or tightening
nuts. Do not over tighten!
9.Using 2 wrenches, separate the ground-joint union in
the gas supply piping at the unit.
10.Remove the piping between the gas valve and the
ground-joint union, if necessary.
11. Remove the screws that secure the burner assembly
in place and the burner assembly. BE EXTREMELY
CAREFUL NOT TO DAMAGE THE IGNITOR WHILE
REMOVING THE BURNER ASSEMBLY.
12.Attach a round wire brush to a length of high grade
stainless steel cable, such as drain clean-out cable.
Attach the other end of the spring cable to a variable
speed reversible drill. Slowly insert and rotate the cable
into the top portion of the heat exchanger. Operate the
drill alternating between forward and reverse, working
the cable in and out several times to obtain sufficient
cleaning. Repeat this process at each exchanger tube.
13. Remove all loosened debris from the heat exchanger
tubes using high pressure air and vacuum cleaner.
14.Using a light, check the condition of the upper and
lower sections of the heat exchanger tube.
15.Inspect the burners and if necessary, clean them
carefully with a soft wire brush and/or the nozzle of a
vacuum cleaner. DO NOT DAMAGETHE IGNITOR OR
FLAME SENSOR WHILE CLEANINGTHE BURNER.
16. Replace all the parts in reverse order from which they
were removed.
17.Follow the operating instructions found on the right
side door and the User’s Information Manual to return
the unit to operation.
If the heat exchanger must be cleaned due to soot or
scale build up, follow the steps below.
1.Shut off the gas supply to the unit at the meter or at the
manual valve in the gas supply piping.
2.Turn off all power to the unit and set the thermostat to
the lowest temperature setting.
23
Cleaning of Burners
If the burners require cleaning, follow the steps below.
1.Shut off the gas supply to the unit either at the meter
or at a manual valve in the supply piping.
2.Turn off all power to the unit and set the thermostat to
the lowest temperature setting.
3.Remove the louvered control access panel from the
unit.
4.Turn the gas control knob to the OFF position. See
Figure 12 (page 29) for gas valve shut off instructions.
5.Disconnect the wires from the gas valve, ignitor, and
flame sensor.
CAUTION:
To prevent damage to the unit or internal
components, it is recommended that two
wrenches be used when loosening or tightening
nuts. Do not over tighten!
6.Using two wrenches, separate the ground-joint union
in the gas supply piping at the unit.
7.Remove the piping between the gas valve and the
ground-joint union (if applicable).
8.Remove all screws securing the burner assembly to
the furnace.
9.Carefully remove the burner assembly from the furnace.
DO NOT DAMAGE THE IGNITER WHILE REMOVING
THE BURNER ASSEMBLY.
10.Inspect the burners for accumulated dust or debris.
If necessary carefully clean them with a soft wire
brush and a vacuum cleaner. DO NOT DAMAGE THE
IGNITER WHILE CLEANING THE BURNER.
11. Replace all the parts in reverse order from which they
were removed.
12. Follow the lighting instructions found on the lower unit
door to return the unit to operation.
13.Verify proper operation after servicing.
Troubleshooting
If the unit does not operate in the cooling mode, check
the following:
•
•
•
•
•
The thermostat is operating properly
Electrical power to the unit is turned on
The filters are not dirty
The service doors are in place
The 5 amp fuse is operational
If the unit does not operate in the heating mode, check
the following:
•
•
•
•
•
•
•
•
The thermostat is operating properly
Electrical power to the unit is turned on
The filters are not dirty
The gas is turned on and the manual shut-off valve
is open
The service doors are in place
The flame roll-out control is closed
The diagnostic codes listed in Table 7 or on the
wiring diagrams (Figures 14 - 17, pages 31 - 34).
The 5 amp fuse is operational
SYSTEM STATUS - IGNITION
Power On (Normal Operation)
High Limit Circuit Open
LED STATUS
(RED)
ON
1 Flash
Pressure Switch Open with Inducer On
2 Flashes
Pressure Switch Closed with Inducer Off
3 Flashes
Failed Ignition (5 attempts) - Control in 1 Hour Lockout
4 Flashes
208-230 Volt Polarity Issue
5 Flashes
Excess High limit trips (5) within one call for heat
6 Flashes
Excess pressure switch cycles (5) within one call for heat
7 Flashes
Excess flame dropouts (5) within one call for heat
8 Flashes
Not Used
9 Flashes
Flame present with gas valve Off
10 Flashes
SYSTEM STATUS - 2nd STAGE HEAT DEMAND
No demand for 2nd stage heat
2nd stage heat demand (Normal operation)
LED STATUS
(GREEN)
OFF
ON
2nd stage heat demand, high pressure switch not closed
Flashing
SYSTEM STATUS - HI/LO DEHUMIDIFY
(Cooling Mode only)
LED STATUS
(GREEN)
Factory jumper wire “R” to “DEHUM” in place or “Close
on Fall” humidistat (Low humidity) - Closed
ON
Humidistat open (High Humidity) Low Speed Blower call
OFF
SYSTEM STATUS - CFM
LED STATUS
(YELLOW)
NOT USED
OFF
Table 8. Ignition / Blower Control Diagnostic Codes
24
COMPONENT FUNCTIONS
Comfort Alert™ Diagnostics -The Comfort Alert
diagnostics module troubleshoots heat pump and air
conditioning system failures and accurately detects the
cause of electrical and system related failures without
any sensors. A flashing LED indicator communicates the
ALERT code to quickly direct the technician to the root
cause of a problem.
Flame Roll-Out Control - The flame roll-out control acts to
verify that the burner flame is being drawn into the heat
exchanger tubes. If the burner flame is not being drawn
into the heat exchanger tubes, the roll-out control will
open within several seconds and the integrated control
diagnostic light will flash one time. If the limit opens, the
integrated control diagnostic will flash one time. The
circulating air blower will continue to operate while the
flame roll-out control is open.
Flame Sensor - The flame sensor acts to prove that flame
has carried over from the ignitor to the right-most burner. If
no flame is sensed, the unit will be shut down automatically.
Dual Pressure Switch - The dual pressure switch verifies
that the inducer motor is drawing the combustion gases
through the heat exchanger tubes and venting the
gases through the vent system for both high and low fire
conditions.
Gas Valve - The gas valve controls the flow of gas to the
burners in both low and high fire. When the gas valve is
energized it automatically opens and regulates the gas
pressure in the manifold. See Figure 10 below.
2-STAGE GAS VALVES
Over-Temperature Limit Control - The over-temperature
limit control prevents the air temperature leaving the unit
from exceeding the maximum outlet air temperature. If the
limit opens, the integrated control diagnostic will flash one
time. The circulating air blower will continue to operate
while the over-temperature limit control is open.
REPLACEMENT PARTS
Replacement parts are available through all Nordyne
distributors. Please have the complete model and serial
number of the unit when ordering replacement parts.
Electrical:
•
•
•
•
•
•
•
Capacitors
Compressors
Contactors
Defrost Control Board
Gas Valves
Ignition Controls
Ignitors/Flame Sensors
•
•
•
•
•
•
•
Pressure Switches
Relays
Reversing Valve Solenoid
Temperature Limit Switches
Thermostats
Time Delay Relays
Transformers
Motors:
• Blower Motor
• Fan Motor
• Inducer Blower Motor
Components:
•
•
•
•
•
Blower Assembly
Burner Manifold
Burners/Orifices
Cabinet Panels
Expansion Valves
•
•
•
•
•
Fan Grille
Filter/Driers
Gaskets
Heat Exchanger
Reversing Valve
Lo Input
Adjusting Screw
HI Input
Adjusting Screw
Manifold
pressure
Tap
IN
ON
Inlet
Pressure
Tap
OFF
ON / OFF
Knob
Model VR8205Q2381
ON / OFF
Switch
HI Input
Adjusting
Screw
Manifold
pressure
Tap
Model VR9205Q1028
Lo Input
Adjusting
Screw
Inlet
Pressure
Tap
Figure 10. HI & LO Input Adjusting Screws
25
figures & tables
3/4" NPT Female
Drain Connector
24 9/10
DOWNFLOW
SUPPLY DUCT
OPENING
47 1/2
CG
13 1/2
16
16
13 1/2
B
13 3/10
12
1.8
12
DOWNFLOW
RETURN DUCT
OPENING
23 1/2
A
Electric
Supply Entry
Top View
Low Voltage Entry
Gas Supply
Entry
29.75
23.75
15.75
4.0
2.9
47.5
Side View
1.75
Back View
Horizontal
Supply Duct
Opening
4.0
Horizontal
Return Duct
Opening
Condensing
Coil
C
16.0
16.0
8.75
13.5
13.5
12.45
12.45
4.0
9.75
24.75
D
Figure 11. Unit Dimensions
Center of Gravity
Model Number
Unit Weight
A
B
Height (in inches)
C
with base rails
X24K080CA
480
26.0
27.0
39.0
35.3
55.8
X36K100CA
599
27.0
26.5
39.0
35.3
55.8
X48K120CA
618
27.0
26.5
47.0
43.3
55.8
X60K120CA
655
30.0
26.5
47.0
43.3
63.6*
*Extended base pan models use same roof curb as 2 - 4 ton units.
Table 9. Center of Gravity & Unit Shipping Weights
26
D
without base rails
airflow information
Model Number
Heating Input
(Btuh)
Heating Output
(Btuh)
CFM Range
80,000
64,000
1100 - 1350
52,000
41,600
750 - 1050
100,000
80,000
1200 - 1600
65,000
52,000
900 - 1200
120,000
96,000
1350 - 2000
78,000
62,400
950 - 1300
120,000
96,000
1350 - 2000
78,000
62,400
950 - 1300
Heating Rise
Range (°F)
Cooling Output
(Btuh)
Blower
Size
Motor
(HP)
35-65
24,000
10 X 10
1/2
40-70
35,000
10 X 10
1/2
40-70
46,000
11 X 10
1
40-70
55,500
11 X 10
1
X24K080CA
X36K100CA
X48K120CA
X60K120CA
NOTE: CFM and Rise are independent of ESP in a variable speed blower.
Table 10. Nominal Airflow Rates & Temperature Rises (° F)
2 TON UNITS
BLOWER
SELECTOR
SETTING
COOL
ADJUST
3 TON UNITS
Normal
+10%
-10%
TAP “B”
TAP “C”
TAP “D”
685
2
T
O
N
TAP “A”
760
COOL
-10%
840
Normal
930
+10%
1025
835
840
-10%
TAP “B”
BLOWER
SELECTOR
SETTING
RECOMMENDED
A/C AIRFLOW
RATE (CFM)
ADJUST
COOL
-10%
TAP “A”
BLOWER
SELECTOR
SETTING
RECOMMENDED
A/C AIRFLOW
RATE (CFM)
4 - 5 TON UNITS
ADJUST
-10%
1485
TAP “A” Normal
+10%
975
3
T
O
N
-10%
TAP “B”
Normal
4
T
O
N
1815
1620
930
+10%
1025
+10%
-10%
975
-10%
Normal
1080
Normal
1230
+10%
1190
+10%
1350
+10%
2035
-10%
1110
-10%
1290
-10%
1800
Normal
+10%
1230
1350
Normal
+10%
1430
1575
Normal
+10%
2000
2200
TAP “D”
1080
1650
Normal
TAP “C”
Normal
RECOMMENDED
A/C AIRFLOW
RATE (CFM)
1190
+10%
1110
-10%
TAP “C”
TAP “D”
Normal
1800
5
T
O
N
1980
1665
1850
Table 11. Airflow Settings for Cooling
2 TON
Blower HEAT
Selector Setting
Low Input
52,000
3 TON
High Input
80,000
Low Input
65,000
High Input
100,000
4 & 5 TON
Low Input
High Input
78,000
120,000
CFM
Rise
CFM
Rise
CFM
Rise
CFM
Rise
CFM
Rise
CFM
TAP “A”
750
51
1100
55
900
53
1200
63
950
61
1350
Rise
67
TAP “B”
850
45
1150
53
1000
48
1300
58
1050
55
1500
61
TAP “C”
TAP “D”
950
1050
41
37
1250
1350
49
45
1100
1200
44
40
1400
1600
54
47
1150
1300
50
44
1700
2000
54
46
NOTES:
1. Recommended temperature rises are highlighted in bold. Use of any other setting may result in nuisance trips.
2. Temperature rises in the table are approximate. Actual temperature rises may vary.
3. Blower “ADJUST” tap non-functional in Heating mode.
Table 12. Airflow Settings (CFM) & Rise (° F) for Heating Operation Mode
27
gas information
GAS PIPE CAPACITIES
Length of Pipe Run (Feet)
Nominal Pipe
Diameter (IN.)
10
1/2
130
90
75
65
3/4
280
190
150
130
1
520
350
285
245
1 1/4
1,050
730
590
1 1/2
1,600
1,100
890
20
30
Cubic Feet Per Hour Required =
40
50
60
70
80
55
50
45
40
115
105
95
90
215
195
180
170
500
440
400
370
350
760
670
610
Input To Furnace (Btu/hr)
Heating Value of Gas (Btu/Cu. Ft.)
NOTE: The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by
the furnace. To determine the cubic feet per hour of gas flow required by the furnace, divide the input rate of the furnace by
the heating value (from gas supplier) of the gas.
Table 13. Capacity of Black Iron Gas Pipe (cu. ft. per hour)
for Natural Gas w/ Specific Gravity = 0.60
GAS FLOW RATES
TIME FOR
ONE REVOLUTION
(SECONDS)
10
12
GAS FLOW RATES
CUBIC FEET PER
REVOLUTION OF GAS METER
1
5
10
TIME FOR
ONE REVOLUTION
(SECONDS)
360
300
1,800
1,500
3,600
3,000
66
68
1
5
10
55
53
273
265
545
529
14
257
1,286
2,571
70
51
257
514
16
225
1,125
2,250
72
50
250
500
18
200
1,000
2,000
74
49
243
486
20
180
900
1,800
76
47
237
474
22
164
818
1,636
78
46
231
462
24
150
750
1,500
80
45
225
450
26
138
692
1,385
82
44
220
439
28
129
643
1,286
84
43
214
429
30
120
600
1,200
86
42
209
419
32
113
563
1,125
88
41
205
409
34
106
529
1,059
90
40
200
400
36
100
500
1,000
92
39
196
391
38
95
474
947
94
38
191
383
40
90
450
900
96
38
188
375
42
86
429
857
98
37
184
367
44
82
409
818
100
36
180
360
46
78
391
783
102
35
176
353
48
75
375
750
104
35
173
346
50
72
360
720
106
34
170
340
52
69
346
692
108
33
167
333
54
67
333
667
110
33
164
327
56
64
321
643
112
32
161
321
58
62
310
621
114
32
158
316
60
60
300
600
116
31
155
310
62
64
58
56
290
281
581
563
118
120
31
30
153
150
305
300
Table 14. Gas Flow Rates
28
CUBIC FEET PER
REVOLUTION OF GAS METER
FOR YOUR SAFETY READ
BEFORE OPERATING
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury, or loss of life.
POUR VOTRE SÉCURITÉ.
À LIRE AVANT L’EMPLOI
ATTENTION! L’inobservation de ces instructions
peut entraîner un incendie ou une explosion pouvant
causer des dammages à votre propriété à votre
personne, ou la mort.
A. This appliance does not have a pilot. It is equipped with
an ignition device which automatically lights the burner.
Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone
in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or move
by hand, do not try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
A. Cet appareil ménager n’a pas de veilleuse. II est doté
d’un système d’allumage automatique. Ne pas essayer
d’allumer le brûleur manuellement.
B. AVANT L’USAGE. Attention à une possible odeur de
gaz surtout au niveau du plancher où les gaz les plus
lourds ont la tendance de se concentrer.
EN CAS D’ODEUR DE GAZ.
• Ne mettre en marche aucun appareil électrique.
• Ne toucher à aucun commutateur électrique, ne pas
employer le téléphone.
• Quitter le bâtiment immédiatement et avertir la
compagnie du gaz en utili sant le téléphone d’un voisin.
• A défaut de la compagnie du gaz, avertir le service des
pompiers.
C. Enfoncer ou faire tourner le robinet à gaz à la main
seulement. Ne jamais utiliser d’outils. S’il n’est pas
possible de faire tourner ou d’enfoncer le robinet à la
main, ne pas essayer de le réparer. Faire appel à un
spécialiste. Forcer ou tenter de réparer le robinet pourrait
être à l’origine d’une explosion ou d’un incendie.
D. II est déconseillé d’utiliser cet appareil en contact
prolongé avec l’eau. Faire inspecter ou remplacer
toute commande par un technicien qualifié si un des
systèmes de contrôle du gaz s’est trouvé sous l’eau.
OPERATING INSTRUCTIONS
MODE D’EMPLOI
1. STOP! Read the safety information above on this label. 1. ATTENTION! Lire d’abord la liste des mesures de
sécurité ci-dessus.
2. Set the thermostat to the lowest setting.
2. Mettre le thermostat à la position minimale.
3. Turn off all electrical power to the appliance.
3. Couper le courant électrique qui mène à l’appareil.
4. The appliance’s ignition device automatically lights the
4. Cet appareil ménager étant doté d’un système
burner. Do not try to light burner by hand.
d’allumage automatique, ne pas essayer d’allumer le
5. Remove the control access door/panel (upper door if
brûleur manuellement.
two-door model).
6. Move the gas control switch to the “OFF” position. (See 5. Retirer le panneau/volet d’accès de commande
(panneau supérieur s’il s’agit d’un modèle à deux
Figure 1)
panneaux).
7. Wait five (5) minutes to clear out any gas. Then
6. Réglez l’interrupteur de commande du gaz à la position
smell for gas, including near the floor. If you
“OFF”. (voir Figure 1).
smell gas, STOP! Follow “B” in
SWITCH
7. Attendre cinq (5) minutes pour s’assurer de la
above information. If you
(INTERRUPTEUR)
dissipation du gaz.
don’t smell gas, go to
En cas d’odeur, ARRÊTER LE PROCÉDÉ. Suivre les
the next step.
instructions ci-dessus (Section B). En l’absence de
8. Move the gas control
toute odeur de gaz, avancer à l’étape suivante.
switch to the “ON”
8. Réglez l’interrupteur de commande du gaz à la position
position. (See Figure 1)
“ON”. (voir Figure 1).
9. Replace the control
9. Remettre le panneau/volet d’accès de commande en
access door/panel
place (panneau supérieur s’il s’agit d’un modèle à deux
(upper door if two-door
Figure 1
panneaux).
model).
10. Rebrancher l’appareil sur le réseau électrique.
10. Turn on all electrical power to the appliance.
11. Ajuster le thermostat à la position désirée.
11. Turn the thermostat to a desired setting.
12. If the appliance will not operate, follow the instructions 12. Si l’appareil ne fonctionne pas, suivre les “Directives
d’arrêt” cidessous et appeler le technicien de service.
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
TO TURN OFF
GAS TO APPLIANCE
DIRECTIVES D’ARRÊT
1. Set the thermostat to the lowest setting.
1. Mettre le thermostat à la position minimale.
2. Turn off all electrical power to the appliance if service is 2. Débrancher l’appareil en prévision de la réparation.
to be performed.
3. Retirer le panneau/volet d’accès de commande
3. Remove the control access door/panel (upper door if
(panneau supérieur s’il s’agit d’un modèle à deux
two-door model).
panneaux).
4. Move the gas control switch to the “OFF” position. Do
4. Réglez l’interrupteur de commande du gaz à la position
not use force. (See Figure 1)
“OFF”. Ne forcez pas. (voir Figure 1).
5. Replace the control access door/panel (upper door if
5. Remettre le panneau/volet d’accès de commande en
two-door model).
place (panneau supérieur s’il s’agit d’un modèle à deux
panneaux).
7111710 (04/11)
Figure 12. Gas Valve Label
29
Wiring Diagrams
TYPICAL HEAT PUMP
THERMOSTAT
TERMINAL
STRIP
E
E
Emergency Heat
Y2
BLUE
Y2
R
RED
R
Legend
Y1
YELLOW
Y1
Field Wiring
G
GREEN
G
Factory Wiring:
W1
WHITE
W1
C
BLACK
C
W2
BROWN
W2
IGNITION / BLOWER
CONTROL BOARD
O
BLUE
L
Y2
R
DEFROST
BOARD
O
Reversing Valve
(See Note 1)
L
Fault Monitoring
(See Note 2)
S2 Heat Pump (Heat / Cool)
24VAC
Y S1 Heat Pump (Heat / Cool)
G Fan
W1 S1 Gas Heat
C
24VAC Com
W2 S2 Gas Heat
BROWN
NOTES:
1. Reversing valve energized in cooling mode of operation. Refer to the thermostat manual for detailed installation and programming instructions.
2. For use with standard heat pump thermostats with defrost control board fault monitoring only.
Figure 13A. Thermostat Connection for Two Stage Heating / Two Stage Cooling Configuration
Low Voltage
Control Circuit
5 Amp Fuse
Heating Speed
Selector (Table 11)
Cooling Speed
Selector (Table 10)
HEAT
ABCD
COOL
ABCD
PARK2
ADJUST
PARK1
COOL
EAC
CONT
NORM
(+)
(-)
TEST
LO-HEAT
HI-HEAT
Y2
LINE
P2
1
DEHUM
0
XMFR
HUM
CFM Adjustment Selector
Cooling Speed Only(Table 10)
HOT SURFACE IGNITION
VARIABLE SPEED BLOWER
CONTROL BOARD
Y
G
LED (Yellow) - Not Used
LED (Green) - Dehumidification
(Cooling Mode Only) See Page 13
& Troubleshooting Page 23
R
C
5 NEUTRALS
AUTO
HEAT STAGE
W2
W1
10 5 NONE
Automatic Heat Staging
(Used with Single Stage
Heating Thermostat)
LED (Red) - Ignition
(See Operating Sequence
& Troubleshooting)
LED (Green) - High Heat Demand
(See Troubleshooting)
Figure 13B. Two-Stage, Hot Surface Ignition & Blower Control Board
30
BLACK
COMPRESSOR
S
H
T2
L2
T1
C
L1
F
5 4 3 2 1
5 4 3 2 1
5
6
7
8
9
10
11
12
13
14
15
16
5
6
7
8
9
10
11
12
13
14
15
16
BROWN
BROWN
COM
1
2
3
WHITE
240V
208V
TRANSFORMER
IGNITOR
R
BLACK
WHITE
WHITE
RED
BROWN
BROWN
BLACK
BLACK
P2
HUM
ADJUST
HEAT
ABCD
COOL
ABCD
5A FUSE
1 2 3
LEGEND:
(STATUS)
RED
GREEN
HI/LO
DEHUMIDIFY
(CFM)
YEL
P6
16PIN
SYSTEM STATUS - HI/LO DEHUMIDIFY (Cooling Mode only) LED STATUS (GREEN)
Factory jumper wire “R” to “DEHUM” in place or
“Close on Fall” humidistat (Low humidity) - Closed
ON
Humidistat open (High Humidity) Low Speed Blower call
OFF
Y2
W1
W2
C
R
G
Y
AMBIENT
COND
FAN
M
PRESS
ORANGE
BLUE
11/11
7111840
(Replaces 711137A)
LED STATUS (YELLOW)
OFF
YELLOW
YELLOW
HIGH
PRESSURE
SWITCH
YELLOW
YELLOW
SYSTEM STATUS - CFM
NOT USED
BROWN
GREEN
BLACK
WHITE
RED
YELLOW
LOW
PRESSURE
SWITCH
LED STATUS (RED)
ON
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
10 Flashes
WHITE
BROWN
BLACK
RED
GREEN
YELLOW
BLUE
W1
L
C
G
W2
TERM.
STRIP
Y1
O
E
Y2
R
YELLOW
ORANGE
BLACK
BLACK
YELLOW
YELLOW
REV. VALVE
SOLENOID
DEMAND
DEFROST CONTROL SW
COILG
BOARD
REV
COIL
W2 W2
IN
OUT
L
R
C
Y
O
TEST
VALVE
AMBG
1. Couper le courant avant de faire letretien.
2. Employez uniquement des conducteurs en cuivre.
3. Ne convient pas aux installations de plus de 150 V a la terre.
Single Phase / 60 Hz.
SYSTEM STATUS - IGNITION
Power On (Normal Operation)
High Limit Circuit Open
Pressure Switch Open with Inducer On
Pressure Switch Closed with Inducer Off
Failed Ignition (5 attemps) - Control in 1 Hour Lockout
208-230 Volt Polarity Issue
Excess High limit trips (5) within one call for heat
Excess pressure switch cycles (5) within one call for heat
Excess flame dropouts (5) within one call for heat
Not Used
Flame present with gas valve Off
GREEN
COIL
SENSOR
AMBIENT
SENSOR
DEHUM
LED STATUS (GREEN)
OFF
ON
Flashing
FIELD WIRING
LOW VOLTAGE
HIGH VOLTAGE
10 5 NONE
(HIGH HEAT
AUTO
DEMAND)
HEAT STAGE GREEN
IGNITION / BLOWER
CONTROL BOARD
5 NEUTRALS
1
LINE
XMFR
PARK1
COOL
EAC
CONT
PARK2
LO-HEAT
HI-HEAT
ORANGE
BLUE
BLACK
GAS VALVE GAS VALVE
624787 LO HI C
YELLOW
BROWN
BROWN
LPS
RED
GAS VALVE GAS VALVE
624652 LO HI C
HPS
FLAME SENSOR
BLACK
SYSTEM STATUS - 2nd STAGE HEAT DEMAND
No demand for 2nd stage heat
2nd stage heat demand (Normal operation)
2nd stage heat demand, high pressure switch not closed
24V
S
C
BLACK
RED
WHITE
OUTDOOR
FAN MOTOR
RED
1
INDUCER 2
MOTOR
3
BLUE
ORANGE
-- Heat Pump operates in heating mode until the combination of outdoor ambient
and outdoor coil temperatures initiate a defrost cycle. The outdoor coil
temperature must be at or below 32˚F before the defrost cycle begins.
-- There must be a minimum of 20 minutes between defrost cycles. After this
time, temperature conditions must call for defrost continuously for 4 1/2
minutes before a defrost cycle is initiated.
-- The defrost cycle ends when either the outdoor coil temperature sensor reaches
the defrost terminate set point, or 13 minutes, 39 seconds of compressor run time
has elasped with the control in the defrost mode. (See installation instructions for
available terminate temperatures and their specific jumper location)
1
2
3
4
1
2
3
4
DUAL CAPACITOR
VARIABLE
SPEED
BLOWER
MOTOR
BLUE
BLUE
RED
YELLOW/BLACK
DEFROST BOARD OPERATION:
C
R
BLACK/WHITE
CCH
IF
EQUIPPED
CONTACTOR
BLUE
FLAME ROLL-OUT
SWITCH
1
2
3
HIGH TEMP LIMIT
SWITCH
4
5
6
RED
YELLOW
7
8
9
YELLOW
BLACK
BROWN
BLACK
12 11 10
TO 208/230 VAC
POWER SUPPLY
VIOLET
5. For supply wire ampacities and overcurrent protection, see unit rating plate.
6. Ensure that wires from the blower remain connected to the board thermostat terminals after
making the field thermostat connections.
7. A heat pump thermostat with fossil fuel back-up heat capability is REQUIRED for this system.
RED
1. Disconnect power before servicing.
2. For supply connections use copper conductors only.
3. Not suitable on systems that exceed 150V to ground.
4. If any of the original wire as supplied with the furnace must be replaced, it must
be replaced with wiring material having a temperature rating of at least 105°C.
YELLOW
208/230 Volt
WHITE
NOTES:
BROWN
RED
BLACK
BLACK
YELLOW
ORANGE
Dual Fuel Heating and Cooling Packaged System
WHITE
WIRING DIAGRAM
GREEN
NORM
(+)
(-)
TEST
0
Figure 14. Two-Stage Cool, Two Stage Heat (Heat Pump)
Two-Stage Gas Heating (2 & 5 Ton Only)
31
S
5 4 3 2 1
5 4 3 2 1
VARIABLE
SPEED
BLOWER
MOTOR
COMPRESSOR
C
R
T1
L1
C
F
BROWN
BROWN
COM
240V
208V
TRANSFORMER
IGNITOR
1
INDUCER 2
MOTOR
3
3
1
2
S
C
BLACK
WHITE
WHITE
RED
RED
RED
BLACK
P2
HUM
RED
COOL
ABCD
ADJUST
HEAT
ABCD
1 2 3
LEGEND:
(STATUS)
RED
GREEN
HI/LO
DEHUMIDIFY
(CFM)
YEL
P6
16PIN
SYSTEM STATUS - HI/LO DEHUMIDIFY (Cooling Mode only) LED STATUS (GREEN)
Factory jumper wire “R” to “DEHUM” in place or
“Close on Fall” humidistat (Low humidity) - Closed
ON
Humidistat open (High Humidity) Low Speed Blower call
OFF
Y2
W1
W2
C
R
G
Y
GREEN
AMBIENT
COND
FAN
PRESS
M
LED STATUS (YELLOW)
OFF
SYSTEM STATUS - CFM
NOT USED
11/11
7111850
(Replaces 711138A)
LED STATUS (RED)
ON
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
10 Flashes
BROWN
GREEN
BLACK
WHITE
RED
BLUE
YELLOW
ORANGE
YELLOW
HIGH
PRESSURE
SWITCH
YELLOW
YELLOW
YELLOW
LOW
PRESSURE
SWITCH
YELLOW
SYSTEM STATUS - IGNITION
Power On (Normal Operation)
High Limit Circuit Open
Pressure Switch Open with Inducer On
Pressure Switch Closed with Inducer Off
Failed Ignition (5 attemps) - Control in 1 Hour Lockout
208-230 Volt Polarity Issue
Excess High limit trips (5) within one call for heat
Excess pressure switch cycles (5) within one call for heat
Excess flame dropouts (5) within one call for heat
Not Used
Flame present with gas valve Off
WHITE
BROWN
BLACK
RED
GREEN
YELLOW
BLUE
C
G
W2
W1
L
Y2
R
O
E
TERM.
STRIP
Y1
REV. VALVE
SOLENOID
BLACK
BLACK
YELLOW
YELLOW
1. Couper le courant avant de faire letretien.
2. Employez uniquement des conducteurs en cuivre.
3. Ne convient pas aux installations de plus de 150 V a la terre.
Single Phase / 60 Hz.
DEMAND
DEFROST CONTROL SW
COILG
BOARD
REV
COIL
W2 W2
IN
OUT
L
R
C
Y
O
TEST
VALVE
AMBG
ORANGE
BLACK
COIL
SENSOR
AMBIENT
SENSOR
DEHUM
LED STATUS (GREEN)
OFF
ON
Flashing
FIELD WIRING
LOW VOLTAGE
HIGH VOLTAGE
10 5 NONE
(HIGH HEAT
AUTO
DEMAND)
HEAT STAGE GREEN
IGNITION / BLOWER
CONTROL BOARD
5 NEUTRALS
1
LINE
XMFR
PARK1
COOL
EAC
CONT
PARK2
LO-HEAT
HI-HEAT
ORANGE
BLACK
GAS VALVE GAS VALVE
624787 LO HI C
YELLOW
BROWN
BROWN
LPS
5A FUSE
GAS VALVE GAS VALVE
624652 LO HI C
HPS
BLACK
BLUE
FLAME ROLL-OUT
SWITCH
SYSTEM STATUS - 2nd STAGE HEAT DEMAND
No demand for 2nd stage heat
2nd stage heat demand (Normal operation)
2nd stage heat demand, high pressure switch not closed
24V
BLACK
FLAME SENSOR
BROWN
BROWN
BLACK
RED
WHITE
YELLOW
WHITE
RED
BLUE
BLUE
ORANGE
R
OUTDOOR
FAN MOTOR
-- Heat Pump operates in heating mode until the combination of outdoor ambient
and outdoor coil temperatures initiate a defrost cycle. The outdoor coil
temperature must be at or below 32˚F before the defrost cycle begins.
-- There must be a minimum of 20 minutes between defrost cycles. After this
time, temperature conditions must call for defrost continuously for 4 1/2
minutes before a defrost cycle is initiated.
-- The defrost cycle ends when either the outdoor coil temperature sensor reaches
the defrost terminate set point, or 13 minutes, 39 seconds of compressor run time
has elasped with the control in the defrost mode. (See installation instructions for
available terminate temperatures and their specific jumper location)
15 15
16 16
13 13
14 14
11 11
12 12
9 9
10 10
7 7
8 8
5 5
6 6
3 3
4 4
1 1
2 2
DUAL CAPACITOR
H
T2
L2
BLACK
DEFROST BOARD OPERATION:
BLACK
COMFORT
ALERT
SOL
DC
C
R
L
Y2
Y
S
C
R
BLACK/WHITE
YELLOW/BLACK
RED
CCH
IF
EQUIPPED
CONTACTOR
BLUE
HIGH TEMP LIMIT
SWITCH
1
2
TO 208/230 VAC
POWER SUPPLY
BLACK
YELLOW
BLACK
4
5
6
3
VIOLET
5. For supply wire ampacities and overcurrent protection, see unit rating plate.
6. Ensure that wires from the blower remain connected to the board thermostat terminals after
making the field thermostat connections.
7. A heat pump thermostat with fossil fuel back-up heat capability is REQUIRED for this system.
7
8
9
YELLOW
BROWN
12 11 10
1. Disconnect power before servicing.
2. For supply connections use copper conductors only.
3. Not suitable on systems that exceed 150V to ground.
4. If any of the original wire as supplied with the furnace must be replaced, it must
be replaced with wiring material having a temperature rating of at least 105°C.
NORM
(+)
(-)
TEST
YELLOW
208/230 Volt
RED
NOTES:
WHITE
Dual Fuel Heating and Cooling Packaged System
BROWN
RED
BLACK
BLACK
YELLOW
ORANGE
WIRING DIAGRAM
GREEN
WHITE
32
0
Figure 15. Two Stage Cool, Two Stage Heat (Heat Pump)
Two-Stage Gas Heating - With Optional Comfort Alert (2 & 5 Ton Only)
BLACK
COMPRESSOR
S
H
T2
L2
T1
C
L1
F
5 4 3 2 1
5 4 3 2 1
3
4
5
6
9
10
11
12
N 2
G 3
L 1
COM
BROWN
BROWN
240V
208V
TRANSFORMER
IGNITOR
1
INDUCER 2
MOTOR
3
3
1
2
WHITE
RED
BLACK
OUTDOOR
MOTOR
YE/GN
BLACK
-- Heat Pump operates in heating mode until the combination of outdoor ambient
and outdoor coil temperatures initiate a defrost cycle. The outdoor coil
temperature must be at or below 32˚F before the defrost cycle begins.
-- There must be a minimum of 20 minutes between defrost cycles. After this
time, temperature conditions must call for defrost continuously for 4 1/2
minutes before a defrost cycle is initiated.
-- The defrost cycle ends when either the outdoor coil temperature sensor reaches
the defrost terminate set point, or 13 minutes, 39 seconds of compressor run time
has elasped with the control in the defrost mode. (See installation instructions for
available terminate temperatures and their specific jumper location)
16 16
13 13
14 14
15 15
9
10
11
12
7 7
8 8
3
4
5
6
1 1
2 2
DUAL CAPACITOR
VARIABLE
SPEED
BLOWER
MOTOR
BLUE
BLUE
RED
YELLOW
DEFROST BOARD OPERATION:
C
R
BLACK
BROWN
CCH
IF
EQUIPPED
CONTACTOR
RED
BLACK
WHITE
WHITE
P2
HUM
COOL
ABCD
ADJUST
HEAT
ABCD
RED
5A FUSE
WHITE
BROWN
BROWN
1 2 3
LEGEND:
(STATUS)
RED
GREEN
HI/LO
DEHUMIDIFY
(CFM)
YEL
P6
16PIN
GREEN
COIL
SENSOR
SYSTEM STATUS - HI/LO DEHUMIDIFY (Cooling Mode only) LED STATUS (GREEN)
Factory jumper wire “R” to “DEHUM” in place or
“Close on Fall” humidistat (Low humidity) - Closed
ON
Humidistat open (High Humidity) Low Speed Blower call
OFF
W1
W2
C
R
G
Y
Y2
AMBIENT
COND
FAN
M
PRESS
BLUE
2/13
7113340
(Replaces 7111860)
LED STATUS (YELLOW)
OFF
SYSTEM STATUS - CFM
NOT USED
BROWN
GREEN
BLACK
WHITE
RED
YELLOW
HIGH
PRESSURE
SWITCH
YELLOW
YELLOW
YELLOW
YELLOW
LOW
PRESSURE
SWITCH
LED STATUS (RED)
ON
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
10 Flashes
WHITE
BROWN
BLACK
RED
GREEN
YELLOW
BLUE
ORANGE
C
G
W2
W1
L
R
TERM.
STRIP
Y1
O
E
Y2
YELLOW
ORANGE
BLACK
BLACK
YELLOW
YELLOW
REV. VALVE
SOLENOID
DEMAND
DEFROST CONTROL SW
COILG
BOARD
REV
COIL
W2 W2
IN
OUT
L
R
C
Y
O
TEST
VALVE
AMBG
Single Phase / 60 Hz.
1. Couper le courant avant de faire letretien.
2. Employez uniquement des conducteurs en cuivre.
3. Ne convient pas aux installations de plus de 150 V a la terre.
SYSTEM STATUS - IGNITION
Power On (Normal Operation)
High Limit Circuit Open
Pressure Switch Open with Inducer On
Pressure Switch Closed with Inducer Off
Failed Ignition (5 attemps) - Control in 1 Hour Lockout
208-230 Volt Polarity Issue
Excess High limit trips (5) within one call for heat
Excess pressure switch cycles (5) within one call for heat
Excess flame dropouts (5) within one call for heat
Not Used
Flame present with gas valve Off
BLUE
AMBIENT
SENSOR
DEHUM
LED STATUS (GREEN)
OFF
ON
Flashing
FIELD WIRING
LOW VOLTAGE
HIGH VOLTAGE
10 5 NONE
(HIGH HEAT
AUTO
DEMAND)
HEAT STAGE GREEN
IGNITION / BLOWER
CONTROL BOARD
5 NEUTRALS
1
LINE
XMFR
PARK1
COOL
EAC
CONT
PARK2
LO-HEAT
HI-HEAT
YELLOW
WHITE
ORANGE
GAS VALVE GAS VALVE
624787 LO HI C
YELLOW
LPS
BLUE
FLAME ROLL-OUT
SWITCH
SYSTEM STATUS - 2nd STAGE HEAT DEMAND
No demand for 2nd stage heat
2nd stage heat demand (Normal operation)
2nd stage heat demand, high pressure switch not closed
24V
RED
BROWN
BROWN
BLACK
BLACK
BLUE
GAS VALVE GAS VALVE
624652 LO HI C
HPS
FLAME SENSOR
BLACK
BLACK
RED
WHITE
BLUE
HIGH TEMP LIMIT
SWITCH
BLACK
YELLOW
12 11 10
TO 208/230 VAC
POWER SUPPLY
1
2
3
YELLOW
208/230 Volt
4
5
6
YELLOW
BROWN
7
8
9
VIOLET
5. For supply wire ampacities and overcurrent protection, see unit rating plate.
6. Ensure that wires from the blower remain connected to the board thermostat terminals after
making the field thermostat connections.
7. A heat pump thermostat with fossil fuel back-up heat capability is REQUIRED for this system.
RED
1. Disconnect power before servicing.
2. For supply connections use copper conductors only.
3. Not suitable on systems that exceed 150V to ground.
4. If any of the original wire as supplied with the furnace must be replaced, it must
be replaced with wiring material having a temperature rating of at least 105°C.
WHITE
NOTES:
BROWN
RED
BLACK
BLACK
YELLOW
ORANGE
Dual Fuel Heating and Cooling Packaged System
WHITE
WIRING DIAGRAM
GREEN
NORM
(+)
(-)
TEST
0
Figure 16. Two Stage Cool, Two Stage Heat (Heat Pump)
Two-Stage Gas Heating (3 & 4 Ton)
33
S
R
C
F
15 15
16 16
14 14
11 11
12 12
13 13
9 9
10 10
7 7
8 8
5 5
6 6
3 3
4 4
1 1
2 2
COM
BROWN
BROWN
240V
208V
TRANSFORMER
IGNITOR
1
2
3
WHITE
RED
BLUE
1
INDUCER 2
MOTOR
3
YELLOW
OUTDOOR
MOTOR
YE/GN
L 1
N 2
G 3
-- Heat Pump operates in heating mode until the combination of outdoor ambient
and outdoor coil temperatures initiate a defrost cycle. The outdoor coil
temperature must be at or below 32˚F before the defrost cycle begins.
-- There must be a minimum of 20 minutes between defrost cycles. After this
time, temperature conditions must call for defrost continuously for 4 1/2
minutes before a defrost cycle is initiated.
-- The defrost cycle ends when either the outdoor coil temperature sensor reaches
the defrost terminate set point, or 13 minutes, 39 seconds of compressor run time
has elasped with the control in the defrost mode. (See installation instructions for
available terminate temperatures and their specific jumper location)
DEFROST BOARD OPERATION:
5 4 3 2 1
5 4 3 2 1
VARIABLE
SPEED
BLOWER
MOTOR
T1
L1
DUAL CAPACITOR
H
T2
L2
BLACK
COMPRESSOR
C
YELLOW
RED
BLACK
CCH
IF
EQUIPPED
BLACK
COMFORT
ALERT
SOL
DC
C
R
L
Y2
Y
S
C
R
BROWN
CONTACTOR
BLACK
BLACK
WHITE
WHITE
P2
HUM
COOL
ABCD
ADJUST
HEAT
ABCD
RED
5A FUSE
WHITE
1 2 3
LEGEND:
(STATUS)
RED
GREEN
HI/LO
DEHUMIDIFY
(CFM)
YEL
P6
16PIN
GREEN
COIL
SENSOR
SYSTEM STATUS - HI/LO DEHUMIDIFY (Cooling Mode only) LED STATUS (GREEN)
Factory jumper wire “R” to “DEHUM” in place or
“Close on Fall” humidistat (Low humidity) - Closed
ON
Humidistat open (High Humidity) Low Speed Blower call
OFF
W1
W2
C
R
G
Y
Y2
COND
FAN
M
PRESS
BLUE
2/13
7113350
(Replaces 7111870)
LED STATUS (YELLOW)
OFF
YELLOW
HIGH
PRESSURE
SWITCH
SYSTEM STATUS - CFM
NOT USED
BROWN
GREEN
BLACK
WHITE
RED
YELLOW
YELLOW
YELLOW
LOW
PRESSURE
SWITCH
YELLOW
LED STATUS (RED)
ON
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
10 Flashes
WHITE
BROWN
BLACK
RED
GREEN
YELLOW
BLUE
ORANGE
C
G
W2
W1
L
Y2
R
O
E
TERM.
STRIP
Y1
YELLOW
ORANGE
BLACK
BLACK
YELLOW
YELLOW
REV. VALVE
SOLENOID
DEMAND
DEFROST CONTROL SW
COILG
BOARD
REV
COIL
W2 W2
L R C Y O IN OUT
TEST
VALVE
AMBG
AMBIENT
BLUE
1. Couper le courant avant de faire letretien.
2. Employez uniquement des conducteurs en cuivre.
3. Ne convient pas aux installations de plus de 150 V a la terre.
Single Phase / 60 Hz.
SYSTEM STATUS - IGNITION
Power On (Normal Operation)
High Limit Circuit Open
Pressure Switch Open with Inducer On
Pressure Switch Closed with Inducer Off
Failed Ignition (5 attemps) - Control in 1 Hour Lockout
208-230 Volt Polarity Issue
Excess High limit trips (5) within one call for heat
Excess pressure switch cycles (5) within one call for heat
Excess flame dropouts (5) within one call for heat
Not Used
Flame present with gas valve Off
AMBIENT
SENSOR
DEHUM
LED STATUS (GREEN)
OFF
ON
Flashing
FIELD WIRING
LOW VOLTAGE
HIGH VOLTAGE
10 5 NONE
(HIGH HEAT
AUTO
DEMAND)
HEAT STAGE GREEN
IGNITION / BLOWER
CONTROL BOARD
5 NEUTRALS
1
LINE
XMFR
PARK1
COOL
EAC
CONT
PARK2
LO-HEAT
HI-HEAT
ORANGE
GAS VALVE GAS VALVE
624787 LO HI C
YELLOW
BROWN
BROWN
LPS
BLUE
FLAME ROLL-OUT
SWITCH
SYSTEM STATUS - 2nd STAGE HEAT DEMAND
No demand for 2nd stage heat
2nd stage heat demand (Normal operation)
2nd stage heat demand, high pressure switch not closed
24V
RED
BROWN
BROWN
BLACK
RED
WHITE
RED
WHITE
RED
YELLOW
BLACK
GAS VALVE GAS VALVE
624652 LO HI C
HPS
BLACK
BLUE
HIGH TEMP LIMIT
SWITCH
VIOLET
FLAME SENSOR
BLACK
YELLOW
BLUE
1
2
3
TO 208/230 VAC
POWER SUPPLY
5. For supply wire ampacities and overcurrent protection, see unit rating plate.
6. Ensure that wires from the blower remain connected to the board thermostat terminals after
making the field thermostat connections.
7. A heat pump thermostat with fossil fuel back-up heat capability is REQUIRED for this system.
4
5
6
YELLOW
7
8
9
BROWN
BLACK
12 11 10
1. Disconnect power before servicing.
2. For supply connections use copper conductors only.
3. Not suitable on systems that exceed 150V to ground.
4. If any of the original wire as supplied with the furnace must be replaced, it must
be replaced with wiring material having a temperature rating of at least 105°C.
NORM
(+)
(-)
TEST
YELLOW
208/230 Volt
RED
NOTES:
WHITE
Dual Fuel Heating and Cooling Packaged System
BROWN
RED
BLACK
BLACK
YELLOW
ORANGE
WIRING DIAGRAM
GREEN
WHITE
34
0
Figure 17. Two Stage Cool, Two Stage Heat (Heat Pump)
Two-Stage Gas Heating “With Optional Comfort Alert” (3 & 4 Ton)
Comfort Alert Troubleshooting Charts
Status LED
POWER
(Green LED)
TRIP
(Red LED)
Status LED Description
Status LED Troubleshooting Information
Module has power
Supply voltage is present at module terminals
Thermostat demand signal Y
is present, but compressor is
not running
• Compressor protector is open
• Check for high head pressure
• Check compressor supply voltage
• Outdoor unit power disconnect is open
• Compressor circuit breaker or fuse(s) is open
• Broken wire or connector is not making contact
• Low pressure switch open if present in system
• Compressor contactor has failed open
ALERT
Long Run Time Compressor
Flash Code 1 is running extremely long run
(Yellow LED) cycles
System Pressure Trip
Discharge or suction
ALERT
Flash Code 2
(Yellow LED) Pressure out of limits
• Low refrigerant charge
• Evaporator blower is not running
— Check blower relay coil and contacts
— Check blower motor capacitor
— Check blower motor for failure or blockage
— Check evaporator blower wiring and connectors
— Check indoor blower control board
— Check thermostat wiring for open circuit
• Evaporator coil is frozen
— Check for low suction pressure
— Check for excessively low thermostat setting
— Check evaporator airflow (coil blockages or return air filter)
— Check ductwork or registers for blockage
• Faulty metering device
— Check TXV bulb installation (size, location and contact)
— Check if TXV/fixed orifice is stuck closed or defective
• Condenser coil is dirty
• Liquid line restriction (filter drier blocked if present in system)
• Thermostat is malfunctioning
— Solenoid plug not connected
— Y2 not wired at Comfort Alert
— Check thermostat sub-base or wiring for short circuit
— Check thermostat installation (location, level)
• Comfort Alert failure
• High head pressure
— Check high pressure switch if present in system
— Check if system is overcharged with refrigerant
— Check for non-condensable in system
• Condenser coil poor air circulation (dirty, blocked, damaged)
• Condenser fan is not running
— Check fan capacitor
— Check fan wiring and connectors
— Check fan motor for failure or blockage
• Return air duct has substantial leakage
Compressor overloaded
• If low pressure switch present in system, check Flash Code 1
information
Table 15. LED Diagnostics
35
Status LED
Status LED Description
Status LED Troubleshooting Information
ALERT
Short Cycling / Compressor
Flash Code 3
is running only briefly
(Yellow LED)
•Thermostat demand signal is intermittent
•Low line voltage (contact utility if voltage at disconnect is low)
•Excessive liquid refrigerant in compressor
•Compressor bearings are seized
ALERT
Flash Code 4 Locked Rotor
(Yellow LED)
•Run capacitor has failed
•Low line voltage (contact utility if voltage at disconnect is low)
•Check wiring connections
•Excessive liquid refrigerant in compressor
•Compressor bearings are seized
•Measure compressor oil level
ALERT
Flash Code 5 Open Circuit
(Yellow LED)
•Outdoor unit power disconnect is open
•Compressor circuit breaker or fuse(s) is open
•Compressor contactor has failed open
—Check compressor contactor wiring and connectors
— Check for compressor contactor failure (burned, pitted or open)
— Check wiring and connectors between supply and compressor
—Check for low pilot voltage at compressor contactor coil
— High pressure switch is open and requires manual reset
•Open circuit in compressor supply wiring or connections
•Unusually long compressor protector reset time due to extreme
ambient temperature
•Compressor windings are damaged
— Check compressor motor winding resistance
ALERT
Open Start Circuit
Flash Code 6
Current only in run circuit
(Yellow LED)
•Run capacitor has failed
•Open circuit in compressor start wiring or connections
— Check wiring and connectors between supply and the
compressor S terminal
•Compressor start winding is damaged
— Check compressor motor winding resistance
ALERT
Open run circuit
Flash Code 7
Current only in start circuit
(Yellow LED)
•Open circuit in compressor run wiring or connections
— Check wiring and connectors between supply and the
compressor R terminal
•Compressor run winding is damaged
— Check compressor motor winding resistance
ALERT
Welded Contactor
Flash Code 8
Compressor always runs
(Yellow LED)
•Compressor contactor has failed closed
•Thermostat demand signal not connected to module
ALERT
Low Voltage
Flash Code 9
Control circuit < 17VAC
(Yellow LED)
•Control circuit transformer is overloaded
•Low line voltage (contact utility if voltage at disconnect is low)
•Check wiring connections
* Flash code number corresponds to a number of LED flashes, followed by a pause and then repeated. Trip and
alert LED’s flashing at same time means control circuit voltage is too low for operation.
Table 15. LED Diagnostics - Continued
36
Miswired Module Indication
Recommended Troubleshooting Action
Green LED is not on, module does not
power up
• Determine if both R & C module terminals are connected.
• Verify voltage is present at module’s R & C terminals.
Green LED intermittent, module powers up
only when compressor runs
• Determine if R & Y terminals are wired in reverse.
• Verify modules R and C terminals have a constant source.
Trip LED is on, but system and
compressor check OK
• Verify Y terminal is connected to 24VAC at contactor coil.
• Verify voltage at contactor coil falls below 0.5VAC when off.
• Verify 24VAC is present across Y & C when thermostat demand
signal is present. If not, R & C are reversed wired.
TRIP LED & ALERT LED flashing together
• Verify R and C terminals are supplied with 19 - 28VAC.
ALERT Flash CODE 3 displayed
incorrectly (Compressor short cycling)
• Verify Y terminal is connected to 24VAC at contactor coil.
• Verify voltage at contactor coil falls below 0.5VAC when off.
ALERT Flash Code 5, 6, or 7 displayed
incorrectly (Open Circuit, Open Start
Circuit or Open Run Circuit)
• Verify the compressor run and start wires are routed through
the module’s current sensing holes.
• Verify the Y terminal is connected to 24VAC at contactor coil.
• Verify voltage at contactor coil falls below 0.5VAC when off.
ALERT Flash Code 6 (Open Start Circuit)
displayed for Code 7 (Open Run Circuit)
or vice-versa
• Verify the compressor run and start wires are routed through
the correct module sensing holes.
ALERT Flash Code 8 displayed incorrectly
(Welded Contactor)
• Determine if module’s Y terminal is connected.
• Verify Y terminal is connected to 24VAC at contactor coil.
• Verify 24VAC is present across Y & C when thermostat demand
signal is present. If not, R and C are reversed wired.
• Verify voltage at contactor coil falls below 0.5VAC when off.
• Review Thermostat Demand Wiring (page 10) for Y & C wiring.
Table 16. Module Wiring Troubleshooting
refrigerant Charging Charts
Application Notes on the Use of Charging Charts
This equipments cooling system contains refrigerant under
high pressure, always use safe practices when servicing
the unit. Always review the factory literature and safety
warnings prior to servicing.
These units are shipped from the factory with the proper
amount and type of refrigerant. Always inspect the unit
rating label to determine the units information prior to
working on the system. Do not mix different refrigerants
or charge the unit with a refrigerant not listed on the unit
rating label.
The charging charts (Figures 17 - 20 pages 38 - 39) are
valid for a variety of indoor, return air conditions and are
most highly influenced by the outdoor ambient temperature,
outdoor fan operation and the unit operating voltage. Before
referencing the charts below, always make sure that the
compressor circuit is energized on high speed and has
stable operation. As can be seen in the charging charts,
the ideal system sub-cooling can vary over the range of
operation. Always reference the charts to determine the
ideal amount of sub-cooling for a given liquid pressure.
Units charged to other values will not perform at the rated
unit efficiency (EER).
To inspect a systems operation, using quality instruments,
match the measured liquid temperature to the units chart.
The measured liquid pressure reading should be within
3% of the value shown for most installations. For two stage
systems, the charts are valid for compressor operating
on high speed.
DO NOT use the charts for a two stage system operating
under a single stage call for cooling.
For systems that are operating with more then a 5%
deviation, inspect the unit for leaks. Always use safe and
environmentally sound methods for refrigerant handling.
When repairing system leakages, always utilize a nitrogen
(inert) gas to protect the refrigerant system and pressure
check the repair before re-charging. Always replace the
filter-dryers when performing any repair to the refrigeration
system. After completing the repairs, evacuate the system
to 350-500 microns and weigh in the refrigerant to the
amount specified on the unit rating label.
37
Charging Charts - Continued
Liquid Pressure (psig)
X24K080C Charging Chart - Cooling
600
580
560
540
520
500
480
460
440
420
400
380
360
340
320
300
280
260
240
220
200
Remove refrigerant when above curve
Add refrigerant when below curve
75
80
85
90
95
100
105
110
115
120
125
130
135
Liquid Temperature (° F)
Figure 18. Charging Chart for 2 Ton Units
Liquid Pressure (psig)
X36K080CA Charging Chart - Cooling
600
580
560
540
520
500
480
460
440
420
400
380
360
340
320
300
280
260
240
220
200
Remove refrigerant when above curve
Add refrigerant when below curve
75
80
85
90
95
100
105
110
115
Liquid Temperature (° F)
Figure 19. Charging Chart for 3 Ton Units
38
120
125
130
135
Charging Charts - Continued
Liquid Pressure (psig)
X48K080CA Charging Chart - Cooling
600
580
560
540
520
500
480
460
440
420
400
380
360
340
320
300
280
260
240
220
200
Remove refrigerant when above curve
Add refrigerant when below curve
75
80
85
90
95
100
105
110
115
120
125
130
135
Liquid Temperature (° F)
Figure 20. Charging Chart for 4 Ton Units
Liquid Pressure (psig)
X60K120CA Charging Chart - Cooling
600
580
560
540
520
500
480
460
440
420
400
380
360
340
320
300
280
260
240
220
200
Remove refrigerant when above curve
Add refrigerant when below curve
75
80
85
90
95
100
105
110
115
120
125
130
135
Liquid Temperature (° F)
Figure 21. Charging Chart for 5 Ton Units
39
INSTALLATION / PERFORMANCE CHECK LIST
GAS SYSTEM
INSTALLATION ADDRESS:
Gas Type: (circle one)
CITY_________________________
STATE_________________
Gas pipe connections leak-tested?
Natural
Gas
Propane
YES
NO
UNIT MODEL #_________________________________________
Gas Line Pressure:_____________________________ (in - W.C.)
UNIT SERIAL #________________________________________
Is there adequate fresh air supply
for combustion and ventilation?
Unit Installed Minimum clearances per
Figure 1 (page 5)?
YES
NO
Installation Altitude:_______________________________ (FT.)
INSTALLER NAME:
CITY________________________
YES
NO
Deration Percentage:_______________________________ (%)
STATE_________________
Furnace Input:__________________________________(Btuh)
Has the owner’s information been
reviewed with the customer?
YES
NO
Supply Air Temperature: ___________________________ (° F)
Has the Literature Package been left
with the unit?
YES
NO
Return Air Temperature: ___________________________ (° F)
Temperature Rise: ________________________________ (° F)
ELECTRICAL SYSTEM
Electrical connections tight?
YES
NO
Line voltage polarity correct?
YES
NO
During Furnace Operation:
Low fire manifold pressure:_______________________ (in - W.C.)
Rated Voltage:____________________________________ VOLTS
High fire manifold pressure:_______________________ (in - W.C.)
L1-L2 Volts:______________________________________ VOLTS
REFRIGERATION SYSTEM
Has the thermostat been calibrated?
YES
NO
Is the thermostat level?
YES
NO
Is the heat anticipator setting correct?
YES
NO
Was unit given 24 hr warm up period
for crankcase heaters?
YES
NO
Stage-1 Liquid Pressure (high side)_________________________
VENTING SYSTEM
Stage-1 Suction Pressure (low side)_________________________
Is the vent hood installed?
YES
NO
Is vent hood free from restrictions
YES
NO
Filter(s) secured in place?
YES
NO
Filter(s) clean?
YES
NO
Stage-2 Liquid Pressure (high side)_________________________
Stage-2 Suction Pressure (low side)_________________________
IMPORTANT - This product has been designed and manufactured
to meet ENERGY STAR criteria for energy efficiency. However,
proper refrigerant charge and proper air flow are critical to
achieve rated capacity and efficiency. Installation of this product
should follow the manufacturer’s refrigerant charging and air flow
instructions. Failure to confirm proper charge and airflow may
reduce energy efficiency and shorten equipment life.
Specifications & illustrations subject to change without notice or incurring obligations.
O’ Fallon, MO | Printed in U.S.A. (03/13)
7094860 (Replaces 7093430)
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