Goodman GPG10 Manual

INSTALLATION& OPERATING
INSTRUCTIONSfor
GPG10& GPG12
SINGLEPACKAGEGAS-ELECTRIC
HEATING& COOLINGUNIT
Affix this manual and Users Information Manual adjacent to the unit.
US
ThisForcedAirCentralUnitDesignCompliesWith
RequirementsEmbodiedinTheAmericanNational
Standard/ NationalStandardofCanadaShownBelow.
ANSIZ21.47-CSA-2.3CentralFurnaces
RECOGNIZETHISSYMBOLASA SAFETYPRECAUTION.
ATTENTIONINSTALLINGPERSONNEL
Priortoinstallation,thoroughlyfamiliarizeyourselfwiththisInstallationManual.Observeallsafetywarnings.During
installationorrepair,cautionistobeobserved.
Itisyourresponsibilitytoinstalltheproductsafelyandtoeducatethecustomeronitssafeuse.
Theseinstallationinstructionscovertheoutdoor
installationofsinglepackagegaselectricheatingand
coolingunits.SeetheProductDataBookapplicableto
yourmodel*forinformationregardingaccessories.
'NOTE:Pleasecontactyourdistributororour
websitefortheapplicableproductdata
bookreferredtointhismanual.
10-245
GoodmanManufacturingCompany,L.R
2550NorthLoopWest,Suite400,Houston,TX77092
www.qoodmanmfg.com
©2004GoodmanManufacturingCompany,L.R
6/04

REPLACEMENTPARTS
ORDERINGPARTS
Whenreportingshortagesordamages,ororderingrepairparts,
givethecompleteunitmodelandserialnumbersasstamped
ontheunit'snameplate.
Replacementpartsforthisapplianceareavailablethroughyour
contractororlocaldistributor.Forthelocationofyournearest
distributor,consultthewhitebusinesspages,theyellowpage
sectionofthelocaltelephonebookorcontact:
SERVICEPARTSDEPARTMENT
GOODMANMANUFACTURINGCOMPANY,L.P.
2550NORTHLOOPWEST.SUITE400
HOUSTON.TEXAS77092
[phone]
SAFETYINSTRUCTIONS
TO THE INSTALLER
Beforeinstallingthisunit,pleasereadthismanualtofamiliarize
yourselfonthespecificitemswhichmustbeadheredto,
includingmaximumexternalstaticpressuretounit,air
temperaturerise,minimumormaximumCFMandmotorspeed
connections.
TO THE OWNER
AwarrantycertificateisprovidedwiththeunitReadthewarranty
carefullyandnotewhatiscovered.Keepthewarrantycertificate
ina safeplacesoyoucanfinditwhennecessary.
Keepthisliteratureina safeplaceforfuturereference.
IFTHEINFORMATIONINTHESEINSTRUCTIONSISNOTFOLLOWEDEXACTLY,A
FIREOREXPLOSIONMAYRESULTCAUSINGPROPERTYDAMAGE,PERSONAL
INJURYORLOSSOFLIFE.
-DoNOTSTOREORUSEGASOLINEOROTHERFLAMMABLEVAPORSAND
LIQUIDSINTHEVICINITYOFTHISORANYOTHERAPPLIANCE.
-WHATTODOIFYOUSMELLGAS:
-DONOTTRYTOLIGHTANYAPPLIANCE
-DONOTTOUCHANYELECTRICALSWITCH,DONOTUSEANY
PHONEINYOURBUILDING.
-IMMEDIATELYCALLYOURGASSUPPLIERFROMA NEIGHBOR'S
PHONE.FOLLOWTHEGASSUPPLIER'SINSTRUCTIONS.
-IfYOUCANNOTREACHYOURGASSUPPLIER,CALLTHEFIRE
DEPARTMENT.
-INSTALLATIONANDSERVICEMUSTBEPERFORMEDBYA QUALIFIEDINSTALLER,
SERVICEAGENCYORTHEGASSUPPLIER.
SHOULDOVERHEATINGOCCURORTHEGASSUPPLYFAILTOSHUTOFF,TURN
OFFTHEMANUALGASSHUTOFFVALVEEXTERNALTOTHEFURNACEBEFORE
TURNINGOFFTHEELECTRICALSUPPLY.
THISPRODUCTCONTAINSORPRODUCESA CHEMICALORCHEMICALSWHICH
MAYCAUSESERIOUSILLNESSORDEATHANDWHICHAREKNOWNTOTHE
STATEOFCALIFORNIATOCAUSECANCER,BIRTHDEFECTSOROTHER
REPRODUCTIVEHARM.
HEATINGUNITSHOULDNOTBEUTILIZEDWITHOUTREASONABLE,ROUTINE,
INSPECTION,MAINTENANCEANDSUPERVISION.|FTHEBUILIDNGINWHICHANY
SUCHDEVICEISLOCATEDWILLBEVACANT,CARESHOULDBETAKENTHAT
SUCHDEVICEISROUTINELYINSPECTED,MAINTAINEDANDMONITORED.INTHE
EVENTTHATTHEBUILDINGMAYBEEXPOSEDTOFREEZINGTEMPERATURES
ANDWILLBEVACANT,ALLWATER-BEARINGPIPESSHOULDBEDRAINED,THE
BUILDINGSHOULDBEPROPERLYWINTERIZED,ANDTHEWATERSOURCE
CLOSED.INTHEEVENTTHATTHEBUILDINGMAYBEEXPOSEDTOFREEZING
TEMPERATURESANDWILLBEVACANT,ANYHYDRONICCOILUNITSSHOULD
BEDRAINEDASWELLAND,INSUCHCASE,ALTERNATIVEHEATSOURCES
SHOULDBEUTILIZED.
TOAVOIDPROPERTYDAMAGE,PERSONALINJURYORDEATH,DONOTUSE
THISUNITIFANYPARTHASBEENUNDERWATER.IMMEDIATELYCALLA
QUALIFIEDSERVICETECHNICIANTOINSPECTTHEFURNACEANDTOREPLACE
ANYPARTOFTHECONTROLSYSTEMANDANYGASCONTROLHAVINGBEEN
UNDERWATER.
THISUNITMUSTNOTBEUSEDASA "CONSTRUCTIONHEATER"DURINGTHE
FINISHINGPHASESOFCONSTRUCTIONONA NEWSTRUCTURE.THISTYPEOF
USEMAYRESULTINPREMATUREFAILUREOFTHEUNITDUETOEXTREMELY
LOWRETURNAIRTEMPERATURESANDEXPOSURETOCORROSIVEORVERY
DIRTYATMOSPHERES.
CARBONMONOXIDEPOISONINGHAZARD
SpecialWarningforInstallationofFurnacesorAirHandlingUnitsin
EnclosedAreassuchasGarages,UtilityRoomsorParkingAreas
Carbonmonoxideproducingdevices(suchasanautomobile,space
healer,gaswaterheater,etc.)shouldnotbeoperatedinenclosedareas
suchasunventilatedgarages,utilityroomsorparkingareasbecauseof
thedangerofcarbonmonoxide(CO)poisoningresultingfromtheexhaust
emissions.Ifa furnaceorairhandlerisinstalledinanenclosedareasuch
asagarage,utilityroomorparkingareaandacarbonmonoxideproducing
deviceisoperatedtherein,theremustbeadequate,directoutside
ventilation.
ThisventilationisnecessarytoavoidthedangerofCOpoisoningwhich
canoccurifa carbonmonoxideproducingdevicecontinuestooperatein
theenclosedareaCarbonmonoxideemissionscanbe(re)circiliated
throughoutthestructureifthefurnaceorairhandlerisoperatinginany
mode
COcancauseseriousillnessincludingpermanentbraindamageordeath
B10259-216

UNITLOCATION
TOPREVENTPOSSIBLEEQUIPMENTDAMAGE,PROPERTYDAMAGE,PERSONAL
INJURYORDEATH,THEFOLLOWINGBULLETPOINTSMUSTBEOBSERVED
WHENINSTALLINGTHEUNIT.
IMPORTANTNOTE:Removewoodshippingrailspriortoinstalla-
tionoftheunit.
ALLINSTALLATIONS:
•Forproperflamepatternwithintheheatexchangerand
propercondensatedrainage,theunitmustbemounted
level.
•Theflueoutlethoodmustbeatleast12inchesfromany
openingthroughwhichfluegasescouldentera building,
andatleastthreefeetaboveanyforcedairinletlocated
withintenfeetTheeconomizer/manualfreshairintake/
motorizedfreshairintakeandcombustionairinletmounted
ontheunitarenotaffectedbythisrestriction.
•Toavoidpossiblecorrosionoftheheatexchanger,donot
locatetheunitinanareawheretheoutdoorair(i.e.
combustionairfortheunit)willbefrequentlycontaminated
bycompoundscontainingchlorineorfluorine.Common
sourcesofsuchcompoundsincludeswimmingpool
chemicalsandchlorinebleaches,paintstripper,adhesives,
paints,varnishes,sealers,waxes(whicharenotyetdried)
andsolventsusedduringconstructionandremodeling.
Variouscommercialandindustrialprocessesmayalso
besourcesofchlorine/fluorinecompounds.
•Toavoidpossibleillnessordeathofthebuildingoccupants,
doNOTlocateoutsideairintakedevice(economizer,
manualfreshairintake,motorizedfreshairintake)too
closetoanexhaustoutlet,gasventtermination,or
plumbingventoutlet.Forspecificdistancesrequired,
consultlocalcodes.
•Allowminimumclearancesfromtheenclosureforfire
protection,properoperation,andserviceaccess(see
appendix).Theseclearancesmustbepermanently
maintained.
•Thecombustionairinletandflueoutlethoodsontheunit
mustneverbeobstructed.Ifused,donotallowthe
economizer/manualfreshairdamper/motorizedfreshair
dampertobecomeblockedbysnowordebris.Insome
climatesorlocations,itmaybenecessarytoelevatethe
unittoavoidtheseproblems.
•Whentheunitisheating,thetemperatureofthereturnair
enteringtheunitmustbebetween50°F and100°F.
GROUNDLEVELINSTALLATIONSONLY:
•Whentheunitisinstalledontheground adjacenttothe
building,a levelconcrete(orequal)baseisrecommended.
Preparea basethatis3"largerthanthepackageunit
footprintanda minimumof3"thick.
•Thebaseshouldalsobelocatedwherenorunoffofwater
fromhighergroundcancollectintheunit.
OutsideSlabInstallation
ROOFTOPINSTALLATIONSONLY:
•Toavoidpossiblepropertydamageorpersonalinjury,the
roofmusthavesufficientstructuralstrengthtocarrythe
weightoftheunit(s)andsnoworwaterloadsasrequiredby
localcodes.Consulta structuralengineertodeterminethe
weightcapabilitiesoftheroof.
RooftopInstallation
•TheunitmaybeinstalleddirectlyonwoodfloorsoronClass
A,ClassB,orClassC roofcoveringmaterial.
•Toavoidpossiblepersonalinjury,a safe,flatsurfacefor
servicepersonnelshouldbeprovided.
ROOFCURBINSTALLATIONSONLY:
•Sufficientstructuralsupportmustbedeterminedpriorto
locatingandmountingthecurbandpackageunit.
•Ductworkmustbeconstructedusingindustryguidelines.The
ductworkmustbeplacedintotheroofcurbbeforemounting
thepackageunit.
•Curbinsulation,cantstrips,flashingandgeneralroofing
materialarefurnishedbythecontractor.

RoofCurbInstallation
GENERALINFORMATION
TOPREVENTPROPERTYDAMAGE,PERSONALINJURYORDEATH,DUETOFIRE,
EXPLOSIONS,SMOKE,SOOT,CONDENSATION,ELECTRICSHOCKORCARBON
MONOXIDE,THISUNITMUSTBEPROPERLYINSTALLED,REPAIRED,OPERATED,
ANDMAINTAINED.
This unit isapproved for outdoorinstallation ONLY. Toassure
thatyourunitoperatessafelyandefficiently,itmustbeInstalled,
operated,andmaintainedinaccordancewiththeseinstallationand
operatinginstructions,alllocalbuildingcodesandordinances, orin
theirabsence,withthelatesteditionoftheNationalFuelGasCode
NFPA54/ANSIZ223.1andNationalStandardofCanadaCAN/CSA
B149InstallationCodes.
Theheatingandcoolingcapacitiesoftheunitshouldbegreater
thanorequaltothedesignheatingandcoolingloadsoftheareato
beconditioned.Theloadsshouldbecalculatedbyanapproved
methodorinaccordancewithA.S.H.R.A.E.GuideorManualJ -
LoadCalculationspublishedbytheAirConditioningContractorsof
America.
Obtainfrom:
AmericanNationalStandardsinstitute
1430Broadway
NewYork,NY10018
TRANSPORTATIONDAMAGE
Checkthecartonuponarrivalforexternaldamage.Ifdamageis
found,a requestforinspectionbycarrieragentshouldbemadein
writingimmediately.
Carefullyinspecttheunitfordamageincludingdamagetothe
cabinetry.Anyboltsorscrewswhichmayhaveloosenedintransit
mustbere-tightened.Intheeventofdamage,thereceivershould:
1.Makenotationondeliveryreceiptofanyvisibledamageto
shipmentorcontainer.
2.Notifycarrierpromptlyandrequestaninspection.
3.Incaseofconcealeddamage,carriershouldbenotifiedas
soonaspossible-preferabiywithin5 days.
4.Filetheclaimwiththefollowingsupportingdocuments:
a.OriginalBillofLading, certifiedcopy,orindemnitybond.
b.Originalpaidfreightbillorindemnityinlieuthereof.
c.Originalinvoiceorcertifiedcopythereof,showingtradeand
otherdiscountsorreductions.
d.Copyoftheinspectionreportissuedbycarrier
representativeatthetimedamageisreportedtothecarrier.
Thecarrierisresponsibleformakingpromptinspectionof
damageandfora thoroughinvestigationofeachclaim.
Thedistributorormanufacturerwillnotacceptclaimsfrom
dealersfortransportationdamage.
NOTE:Wheninspectingtheunitfortransportationdamage,remove
allpackagingmaterials.Recycleordisposeofthepackagingmate-
rialaccordingtolocalcodes.
RIGGINGDETAILS
TOPREVENTPROPERTYDAMAGE,THEUNITSHOULDREMAININANUPRIGHT
POSITIONDURINGALLRIGGINGANDMOVINGOPERATIONS.ToFACILITATE
LIFTINGANDMOVINGWHENA CRANEISUSED,PLACETHEUNITINAN
ADEQUATECABLESLING.
Important:Ifusingbottomdischargewithroofcurb,ductworkshould
beattachedtothecurbpriortoinstallingtheunit.Ductworkdimen-
sionsareshowninroofcurbinstallationinstructions.
RefertotheRoofCurbInstallationInstructionsforpropercurbin-
stallation.CurbingmustbeinstalledincompliancewiththeNational
RoofingContractorsAssociationManual.
Lowerunitcarefullyontoroofmountingcurb.Whileriggingunit,cen-
terofgravitywillcausecondenserendtobelowerthansupplyair
end.

GASPIPINGNaturalGasConnection
IMPORTANTNOTE:Thisunitisfactorysettooperateonnatural
gasatthealtitudesshownontheratingplate.
TOAVOIDPROPERTYDAMAGE,PERSONALINJURYORDEATHWHENEITHER
USINGPROPANEGASALONEORATHIGHERALTITUDES,OBTAINANDINSTALL
THEPROPERCONVERSIONKIT(S).FAILURETODOSOCANRESULTIN
UNSATISFACTORYOPERATIONAND/OREQUIPMENTDAMAGE.HLGHALTITUDE
KITSAREFORU.S.INSTALLATIONSONLYANDARENOTAPPROVEDFORUSE
INCANADA.
Theratingplateisstampedwiththemodelnumber,typeofgasand
gasinputrating.Makesuretheunitisequippedtooperateonthe
typeofgasavailable.ConversiontoLPgasispermittedwiththe
useofthefactoryauthorizedconversionkitLPT-OOA.
InletGasPressureMustNotExceedtheMaximumValueShowninTable
Above.
Theminimumsupplypressureshouldnotvaryfromthatshownin
thetableabovebecausethiscouldpreventtheunitfromhaving
dependableignition.Inaddition,gasinputtotheburnersmustnot
exceedtheratedinputshownontheratingplate.Overfiringofthe
unitcouldresultinprematureheatexchangerfailure.
HIGHALTITUDEDERATE(U.S.INSTALLATIONSONLY)
IMPORTANTNOTE:Thegas/electricunitsnaturallyderatewithal-
titude.Donotattempttoincreasethefiringratebychangingorifices
orincreasingthemanifoldpressure.Thiscancausepoorcombus-
tionandequipmentfailure.Atallaltitudes,themanifoldpressure
mustbewithin0-3inchesW.C.ofthatlistedonthenameplatefor
thefuelused.Atallaltitudesandwitheitherfuel,theairtempera-
turerisemustbewithintherangelistedontheunitnameplate.
RefertotheInstallationManualprovidedwiththeLPkitfor
conversionfromnaturalgastopropanegasandforaltitude
adjustments.
PIPING
IMPORTANTNOTE:Toavoidpossibleunsatisfactoryoperationor
equipmentdamageduetounderfiringofequipment,donotunder-
sizethenatural/propanegaspipingfromthemeter/tanktotheunit.
Whensizinga trunklineasshowninTable2,includeallappliances
onthatlinethatcouldbeoperatedsimultaneously.
Theratingplateisstampedwiththemodelnumber,typeofgasand
gasinputrating.Makesuretheunitisequippedtooperateonthe
typeofgasavailable.Thegaslineinstallationmustcomplywith
localcodes,orintheabsenceoflocalcodes,withthelatestedition
oftheNationalFuelGasCodeNFPA54/ANSIZ223.1.
HeatingValueofGas(BTU/Cubic_Foot)
RefertotheProperPipingPracticedrawingforthegenerallayoutat
theunit.Thefollowingrulesapply:
1.Useblackironpipeandfittingsforthesupplypiping.The
useofa flexconnectorand/orcopperpipingispermittedas
longasitisinagreementwithlocalcodes.
2.Usepipejointcompoundonmalethreadsonly.Pipejoint
compoundmustberesistanttotheactionofthefuelused.
3.Useground jointunions.
4.Installa driplegtotrapdirtandmoisturebeforeitcanenter
thegasvalve.Thedriplegmustbea minimumofthreeinches
long.
5.Usetwopipewrencheswhenmakingconnectiontothegas
valvetokeepitfromturning.
6.Installa manualshut-offvalveina convenientlocation(within
sixfeetofunit)betweenthemeterandtheunit.
7.Tightenalljointssecurely.
8.Theunitmustbeconnectedtothebuildingpipingbyoneof
thefollowingmethods:
Rigidmetallicpipeandfittings
•Semirigidmetallictubingandmetallicfittings(Aluminumalloy
tubingmustnotbeusedinexteriorlocations)
Listedgasapplianceconnectorsusedinaccordancewith
thetermsoftheirlistingthatarecompletelyinthesame
roomastheequipment
•Inthepriortwomethodsabovetheconnectorortubing
mustbeprotectedfromphysicalandthermaldamage.
Aluminumalloytubingandconnectorsmustbecoatedto
protectagainstexternalcorrosionwhenincontactwith
masonry,plasterorinsulationoraresubjecttorepeated
wettingsbyliquids(water- notrainwater,detergentsor
sewage)
6

ProperPipingPractice
NOTE:Theunitgassupplyentranceisfactorysealedwithplugs.
Keepplugsinplaceuntilgassupplyisreadytobeinstalled.Once
ready,replacetheplugswiththesuppliedgrommetsandinstallgas
supplyline.
GASPIPINGCHECKS
TOPREVENTPROPERTYDAMAGEORPERSONALINJURYDUETOFIRE,THE
FOLLOWINGINSTRUCTIONSMUSTBEPERFORMEDREGARDINGGAS
CONNECTIONSANDPRESSURETESTING:
•THEUNITANDITSGASCONNECTIONSMUSTBELEAKTESTEDBEFORE
PLACINGINOPERATION.BECAUSEOFTHEDANGEROFEXPLOSIONOR
FIRE,NEVERUSEA MATCHOROPENFLAMETOTESTFORLEAKS.NEVER
EXCEEDSPECIFIEDPRESSURESFORTESTING.HIGHERPRESSUREMAY
DAMAGEGASVALVEANDCAUSEOVERFIRINGWHICHMAYRESULTIN
PREMATUREHEATEXCHANGEFAILURE.
•THISUNITANDITSSHUT-OFFVALVEMUSTBEDISCONNECTEDFROM
THEGASSUPPLYDURINGANYPRESSURETESTINGOFTHATSYSTEMAT
TESTPRESSURESINEXCESSOF1/2PSIG(3.48KPA).
•THISUNITMUSTBEISOLATEDFROMTHEGASSUPPLYSYSTEMBY
CLOSINGITSMANUALSHUT-OFFVALVEDURINGANYPRESSURE
TESTINGOFTHEGASSUPPLYPIPINGSYSTEMATTESTPRESSURES
EQUALTOORLESSTHAN1/2PSIG(3.48KPA).
TOAVOIDPROPERTYDAMAGEORPERSONALINJURY,BESURETHEREIS
NOOPENFLAMEINTHEVICINITYDURINGAIRBLEEDING.
Therewillbeairinthegassupplylineaftertestingforleakson
anewinstallation.Therefore,theairmustbebledfromtheline
bylooseningthegroundjointunionuntilpuregasisexpelled.
Tightenunionandwaitforfiveminutesuntilallgashasbeen
dissipatedintheair.Becertainthereisnoopenflameinthe
vicinityduringairbleedingprocedure.Theunitisplacedin
operationbyclosingthemainelectricaldisconnectswitchfor
theunit.
PROPANEGASINSTALLATIONS
TOAVOIDPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETOFIRE
OREXPLOSIONCAUSEDBYA PROPANEGASLEAK,INSTALLA GAS
DETECTINGWARNINGDEVICE.SINCERUSTCANREDUCETHELEVEL
OFODORANTINPROPANEGAS,A GASDETECTINGWARNINGDEVICE
ISTHEONLY RELIABLEWAYTODETECTA PROPANEGASLEAK.
CONTACTA LOCALPROPANEGASSUPPLIERABOUTINSTALLINGA
GASDETECTINGWARNINGDEVICE.
IMPORTANTNOTE:Propanegasconversionkitsmustbe
installedtoconvertunitstopropanegas.SeetheProductData
Bookapplicabletoyourmodel*forkitpartnumberforthismodel.
Allpropanegasequipmentmustconformtothesafetystandards
oftheNationalBoardofFireUnderwriters(SeeNBFUManual
58).
Forsatisfactoryoperation,propanegassupplypressuremust
bewithin9.7- 10.3inchesW.C.atthemanifoldwithallgas
appliancesinoperation.Maintainingpropergaspressure
dependsonthreemainfactors:
1.Vaporizationrate,whichdependson(a)temperatureofthe
liquid,and(b)wettedsurfaceareaofthecontaineror
containers.
2.Properpressureregulation.
3.Pressuredropinlinesbetweenregulators,andbetween
secondstageregulatorandtheappliance.Pipesizerequired
willdependonlengthofpiperunandtotalloadofall
appliances.
TANKSANDPIPING
Completeinformationregardingtanksizingforvaporization,
recommendedregulatorsettingsandpipesizingisavailable
frommostregulatormanufacturersandpropanegassuppliers.
Sincepropanegaswillquicklydissolvewhiteleadormost
standardcommercialcompounds,specialpipedopemustbe
used.Shellacbasecompoundsresistanttotheactionsof
liquefiedpetroleumgasessuchasGasolac,Stalactic,Clyde's
orJohnCranearesatisfactory.
Seebelowfortypicalpropanegaspiping.
*NOTE;Pleasecontactyourdistributororourwebsitefortheapplicableproductdatabookreferredtointhismanual.
7

SizingBetweenFirstandSecondStageRegulator
MaximumPropaneCapacitieslistedarebasedon1 PSIGPressureDropat10
PSIGSetting,Capacitiesin1.000BTU/HR
Table3 - PropaneGasPipeSizing
TOPREVENTPROPERTYDAMAGEORSERIOUSPERSONALINJURYDUETO
FIREOREXPLOSIONCAUSEDBYA PROPANEGASLEAK,INSTALLA GAS
DETECTINGWARNINGDEVICE.
IFTHEPROPANEGASUNITISINSTALLEDINANEXCAVATEDAREAORA
CONFINEDSPACE,A WARNINGDEVICEISREQUIREDDUETO:
•PROPANEGASISHEAVIERTHANAIRANDANYLEAKINGGASCAN
SETTLEINANYLOWAREASORCONFINEDSPACES.
•PROPANEGASODORANTMAYFADE,MAKINGTHEGASUNDETECTABLE
EXCEPTWITHA WARNINGDEVICE.
ELECTRICALWIRING
THERMOSTATLOCATION
Mountthethermostatapproximatelyfivefeetabovethefloor,
inanareathathasaninside,vibration-freewallandhasgood
aircirculation.
Movementofairmustnotbeobstructedbyfurniture,door,
draperies,etc.Thethermostatmustnotbemountedwhereit
willbeaffectedbydrafts,hotorcoldwaterpipesorairductsin
walls,radiantheatfromfireplace,lamps,thesun,television,
etc. ConsulttheInstructionSheetpackagedwiththermostatfor
mountinginstructions.
Allunitshaveonestageofheatingandonestageofmechanical
cooling.Unitswhichwillhaveeconomizersmayusethermostats
withoneortwostagesofcooling.
ToAVOIDINJURY,ELECTRICALSHOCKORDEATH,DISCONNECTELECTRICAL
POWERBEFORESERVICINGORCHANGINGANYELECTRICALWIRING.
Theunitsaredesignedforoperationon60hertzcurrentandat
voltagesasshownontheratingplate.Allinternalwiringinthe
unitiscomplete.Itisnecessarytobringinthepowersupplyto
thecontactorasshownontheunitwiringdiagramwhichis
suppliedwitheachunit-24voltwiringmustbeconnected
betweentheunitcontrolpanelandtheroomthermostat.
LowVoltageWiring
Refertotheunitwiringdiagramforelectricalconnections.When
installed,theunitmustbeelectricallygroundedinaccordance
withlocalcodesorintheabsenceoflocalcodes,withthe
NationalElectricalCode,ANSI/NFPANo.70,and/ortheCSA
C22.1ElectricalCode.Ensurelowvoltageconnectionsare
waterproof.
TOAVOIDTHERISKOFELECTRICALSHOCK,WIRINGTOTHEUNITMUSTBE
POLARIZEDANDGROUNDED.
TOAVOIDPROPERTYDAMAGEORPERSONALINJURYDUETOFIRE,USE
ONLYCOPPERCONDUCTORS.
TOPREVENTIMPROPERANDDANGEROUSOPERATIONDUETOWIRINGERRORS,
LABELALLWIRESPRIORTODISCONNECTIONWHENSERVICINGCONTROLS.
VERIFYPROPEROPERATIONAFTERSERVICING.
Forunitprotection,usea fuseorHACRcircuitbreakerthatisin
excessofthecircuitampacity,butlessthanorequaltothe
maximumovercurrentprotectiondevice.DONOTEXCEEDTHE
MAXIMUMOVERCURRENTDEVICESIZESHOWNONUNIT
DATAPLATE.

Alllinevoltageconnectionsmustbemadethroughweatherproof
fittings.Allexteriorpowersupplyandground wiringmustbein
approvedweatherproofconduitLowvoltagewiringfromthe
unitcontrolpaneltothethermostatrequirescodedcable.See
belowforgroundlevelandrooftopwiring.
Note:Junctionboxlocation
shownisoptionalandis
forillustrationpurposesonly.
ElectricalPowerDirectlyToJunctionBox
From
Unit
TypicalThermostatand
Unit24V WiringHookup
CIRCULATINGAIRANDFILTERS
AIRFLOWCONVERSION
Unitscaneasilybeconvertedfromhorizontaltodown-discharge
airflowdelivery.Indown-dischargeorhighstaticinstallations,
theinstallershouldmeasurethetotalexternalstaticandreview
theblowerperformancechartsbeforeperformingtheinstallation.
Insomeinstallationsitwillbenecessarytochangetheblower
speedtoprovideproperairflow.
HorizontalAirFlow
Removesupplyandreturnductcoverswhichareattachedto
theunitasshownbelow.
ElectricalPowerRoutedThroughBottomofUnit
TypicalElectricalWiringUnitVoltage
UNITVOLTAGE
Theunittransformerisfactoryconnectedfor230Voperation.
Iftheunitistooperateon208V,reconnectthetransformer
primaryleadandinduceddraftblowermotorleadsasshown
ontheunitwiringdiagram.
HEATANTICIPATORSETTING
Theheatanticipatoristobesetbymeasuringtheload
(amperage)atthe"R"circuit.Followtheinstructionsprovided
bythethermostatformoredetails.
Removethesecovers
forhorizontalduct
applications
Removethesepanels
fordownflowduct
applications
DuctCoverInstallation

DownDischargeApplications
Cutinsulationaroundbottomopeningsandremovepanelsfrom
thebottomoftheunit,savingthescrewsholdingthepanelsin
place.
DUCTWORK
Ductsystemsandregistersizes mustbeproperlydesignedfor
theC.F.M.andexternalstaticpressureratingoftheunit.
Ductworkshouldbedesignedinaccordancewiththe
recommendedmethodsofAirConditioningContractorsof
AmericaManualD (Residential)orManualQ (Commercial).
Allductworkexposedtotheoutdoorsmustincludea
weatherproofbarrierandadequateinsulation.
AductsystemshouldbeinstalledinaccordancewithStandards
oftheNationalBoardofFireUnderwritersfortheInstallationof
AirConditioning,WarmAirHeatingandVentilatingSystems.
PamphletsNo.90Aand90B.
Thesupplyductfromtheunitthrougha wallmaybeinstalled
withoutclearance.However,minimumunitclearancesasshown
intheappendixmustbemaintained.Thesupplyductshould
beprovidedwithanaccesspanellargeenoughtoinspectthe
airchamberdownstreamoftheheatexchanger.A covershould
betightlyattachedtopreventairleaks,
ForductflangedimensionsontheunitrefertotheUnit
Dimensionillustrationintheappendix.
Fordown-dischargeapplications,theductworkshouldbe
attachedtotheroofcurbpriortoinstallingtheunit.Ductwork
dimensionsareshownintheroofcurbinstallationmanual.
Ifdesired,supplyandreturnductconnectionstotheunitmay
bemadewithflexibleconnectionstoreducepossibleunit
operatingsoundtransmission.
FILTERS
ToPREVENTPROPERTYDAMAGEDUETOFIREANDLOSSOF
EQUIPMENTEFFICIENCYOREQUIPMENTDAMAGEDUETODUSTANDLINT
BUILDUPONINTERNALPARTS,NEVEROPERATEUNITWITHOUTANAIR
FILTERINSTALLEDINTHERETURNAIRSYSTEM.
Eventhougha returnairfilterisnotsuppliedwiththisunit,
theremustbea meansoffilteringallreturnair.The*PG1248
and*PG1260modelsareprovidedwithinternalfilterracksfor
down-dischargeapplications.Allunitsmaybeexternallyfiltered.
Refertotheunitfiltersizechartintheappendixforfiltersize
information.
Filtersinstalledexternaltotheunitshouldbesizedin
accordancewiththeirmanufacturerrecommendations.A
throwawayfiltermustbesizedfora maximumfacevelocityof
300feetperminute.
FilterInstallation
Important:Wheninstallinga filter,theairflowarrowsonthe
filtermustpointtowardthecirculatorblower.
VENTING
NOTE:Ventingisself-contained.Donotmodifyorblock.
FLUEHOODINSTALLATION
Installthefluehoodandbugscreenpriortooperationofthe
unit.
Toinstallthefluehoodcoverandbugscreen:
1.Removethefluehoodandbugscreenfrominsidetheheat
exchangercompartment.
2.Slidethebugscreenovertheflangesofthefluehoodand
attachthefluehoodandscreentotheunitwiththesheet
metalscrewsprovided.
FlueHoodandBugScreenInstallation
CONDENSATEDRAIN
CONDENSATEDRAINCONNECTION
A3/4"NPTdrainconnectionissuppliedforcondensatepiping.An
externaltrapmustbeinstalledforpropercondensatedrainage.
DRAIN
CONNECTION
APOSITIVELIQUID
SEALISREQUIRED
DrainConnection
NORMALSEQUENCESOFOPERATION
HEATING
Thisunitisequippedwithanignitioncontrolthatautomatically
lightsthemainburner.DONOTattempttolightthemain
burnersbyanyothermethod.
1.Thermostatcallsforheat.Theinduceddraftblower
energizesfora 15-secondpre-purge.
2.Thesparkigniterandgasvalveenergizesfor7 seconds.
NOTE:Theigniterproducesa veryintenseelectricalspark
thatignitesthegas.
3.The30-secondHEATFANONdelaytimebegins.
4.Theunitdeliversheattotheconditionedspaceuntilthe
thermostatissatisfied.
10

5.Thegasvalvedeenergizes.Theinduceddraftblower
continuesoperationfora 29-secondpost-purge.
6.ignitioncontrolbeginstiming theHEATFANOFFdelay.
ThereisanadjustableHEATFANOFFdelayof
approximately120/135/150seconds(factorysetat150).
AftertheHEATFANOFFdelaytimehaselapsed,theblower
willdeenergize.Thisallowsanyadditionalheatintheheat
exchangertobetransferredtotheconditionedspace.
COOLING
1.Thermostatcallsforcooling.Thecompressorandoutdoor
fanareenergized.
2.Approximatelysevensecondslater,theindoorfanstarts.
3.Theunitwilldelivercoolingtotheconditionedspaceuntil
thethermostatissatisfied.
4.Thecompressorandoutdoorfanwillbedeenergizedwhen
thethermostatopens.
5.Theindoorfancontinuestorunforapproximately60
secondsafterthethermostatissatisfied.Thisallows
additionalcoolingfromtheindoorcoiltobetransferredto
theconditionedspace.Then,theindoorfanstops.
NOTE:A180-secondanti-shortcycleisintegraltothecontroland
preventsrecyclingofthecompressor.
FANONLY
1.ThermostatcallsforFANONLYbyenergizing"G".
2.Approximatelysevensecondslater,theindoorfanstarts.
3.Theindoorfancontinuestorunforapproximately60
secondsafter"G"isdeenergized.
STARTUP,ADJUSTMENTS,ANDCHECKS
HEATINGSTARTUP
Thisunitisequippedwithanelectronicignitiondeviceto
automaticallylightthemainburners.Italsohasa powervent
blowertoexhaustcombustionproducts.
Onnewinstallations,orifa majorcomponenthasbeen
replaced,theoperationoftheunitmustbechecked.
Checkunitoperationasoutlinedinthefollowinginstructions.If
anysparking,odors,orunusualsoundsareencountered,shut
offelectricalpowerandrecheckforwiringerrors,orobstructions
inorneartheblowermotors.Ductcoversmustberemoved
beforeoperatingunit.
HeatAnticipatorSetting
Settheheatanticipatorontheroomthermostatto0.4ampsto
obtainthepropernumberofheatingcyclesperhourandto
preventtheroomtemperaturefromovershootingtheroom
thermostatsetting.
RolloutProtectionControl
Therolloutprotectiondeviceopens,cuttingpowertothegas
valve,iftheflamesfromtheburnersarenotproperlydrawn
intotheheatexchanger.Therolloutprotectiondeviceislocated
ontheburnerbracket.Thereasonforelevatedtemperatures
atthecontrolshouldbedeterminedandrepairedpriorto
resettingthismanualresetcontrol.
TOAVOIDPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETOFIRE
OREXPLOSION,A QUALIFIEDSERVICERMUSTINVESTIGATETHEREASONFOR
THEROLLOUTPROTECTIONDEVICETOOPENBEFOREMANUALLYRESETTING
THEROLLOUTPROTECTIONDEVICE.
RolloutProtectiononBurnerBracket
SecondaryLimitControl
Thesecondarylimitcontrolislocatedonthetopoftheblower
scrollassembly.Thiscontrolopenswhenelevatedtemperatures
aresensed.Elevatedtemperaturesatthecontrolarenormally
causedbyblowerfailure.Thereasonfortheopeningshouldbe
determinedandrepairedpriortoresetting.
Ifthepowertotheunitisinterruptedduringtheheatingcycle,it
may causethesecondarylimittotrip.Oncetheblower
compartmenttemperaturedropsbelowthelimitreset
temperature,thelimitwillautomaticallyreset.
SecondaryLimitControl
Pre-OperationChecks
1.Closethemanualgasvalveexternaltotheunit.
2.Turnofftheelectricalpowersupplytotheunit.
3.Settheroomthermostattoitslowestpossiblesetting.
4.Removetheheatexchangerdooronthesideoftheunitby
removingscrews.
5.Thisunitisequippedwithanignitiondevicewhich
automaticallylightsthemainburner.DONOTtrytolight
burnerbyanyothermethod.
6.MovethegascontrolvalveswitchtotheOFFposition.Do
notforce.
11

7.Waitfiveminutestoclearoutanygas.
8.Smellforgas,includingneartheground.Thisisimportant
becausesometypesofgasareheavierthanair.Ifyouhave
waitedfiveminutesandyoudosmellgas,immediatelyfollow
thewarningsonpage3 ofthismanual.Ifhavingwaitedfor
fiveminutesandnogassmellisnoted,moveorrotatethe
gascontrolvalveswitchtotheONposition.
9.Replacetheheatexchangerdooronthesideoftheunit.
10.Openthemanualgasvalveexternaltotheunit.
11.Turnontheelectricalpowersupplytotheunit.
12.Setthethermostattodesiredsetting.
GasValve
On/Off
Selector
Switch
White-Rodgers36G22
GasSUPPIYAndManifoldCheck
Gassupplypressureandmanifoldpressurewiththeburners
operatingmustbeasspecifiedontheratingplate.
GasInletPressureCheck
Gasinletpressuremustbecheckedandadjustedinaccordance
tothetypeoffuelbeingconsumed.
WithPowerAndGasOff:
1.Connecta watermanometeroradequategaugetotheinlet
pressuretapofthegasvalve.
Inletgaspressurecanalsobemeasuredbyremovingthe
capfromthedriplegandinstallinga predrilledcapwitha
hosefitting.
WithPowerAndGasOn:
2.Putunitintoheatingcycleandturnonallothergas
consumingappliances.
NOTE:InletGasPressureMustNotExceedtheMaximumValue
Shown.
Ifoperatingpressuresdifferfromabove,makenecessary
pressureregulatoradjustments,checkpipingsize,etc.,and/or
consultwithlocalutility.
Manometer
MeasuringInletGasPressure
Alternate Method
ManifoldPressureCheck
Thegasvalvehasa tappedopeningtofacilitatemeasurementof
themanifoldpressure.A "U"Tubemanometerhavinga scale
rangefrom0 to12inchesofwatershouldbeusedforthis
measurement.Themanifoldpressuremustbemeasuredwith
theburnersoperating.
Toadjustthepressureregulator,removetheadjustmentscrew
orcoveronthegasvalve.Turnout(counterclockwise)todecrease
pressure,turnin(clockwise)toincreasepressure.Onlysmall
variationsingasflowshouldbemadebymeansofthepressure
regulatoradjustment.Innocaseshouldthefinalmanifoldpressure
varymorethanplusorminus0.3incheswatercolumnfromthe
specifiednominalpressure.Anymajorchangesinflowshouldbe
madebychangingthesizeoftheburnerorifices.Themeasured
inputratetothefurnacemustnotexceedtheratingspecifiedon
theunitratingplate.
Fornaturalgas,themanifoldpressuremustbebetween3.2and
3.8incheswatercolumn(3.5nominal).
Forpropanegas,themanifoldpressuremustbebetween9.7
and10.3incheswatercolumn(10.0nominal).
GasInput(NaturalGasOnly)Check
Tomeasurethegasinputusea gasmeterandproceedasfollows:
1. Turnoffgassupplyto allotherappliancesexcepttheunit.
2.Withtheunitoperating,timethesmallestdialonthemeterfor
onecompleterevolution.Ifthisisa 2 cubicfootdial,divide
thesecondsby2;ifitisa 1 cubicfootdial,usethesecondsas
is.Thisgivesthesecondspercubicfootofgasbeingdelivered
totheunit.
3.INPUT=GASHTGVALUEx 3600/ SEC.PERCUBICFOOT
Example:Naturalgaswitha heatingvalueof1000BTUpercubicfoot
and34secondspercubicfootasdeterminedbyStep2,then:
Input= 1000x 3600/ 34= 106,000BTUperHour.NOTE:
BTUcontentofthegasshouldbeobtainedfromthegas
supplier.Thismeasuredinputmustnotbegreaterthanshown
ontheunitratingplate.
4.Relightallotherappliancesturnedoffinstep1.Besureall
pilotburnersareoperating.
12

MainBurnerFlameCheck
Flamesshouldbestable,softandblue(dustmaycauseorange
tipsbuttheymustnotbeyellow)andextendingdirectlyoutward
fromtheburnerwithoutcurling,floatingorliftingoff.
TemperatureRiseCheck
Checkthetemperaturerisethroughtheunitbyplacing
thermometersinsupplyandreturnairregistersasclosetothe
unitaspossible.Thermometersmustnotbeabletosample
temperaturedirectlyfromtheunitheatexchangers,orfalse
readingscouldbeobtained.
1.Allregistersmustbeopen;ailductdampersmustbeintheir
final(fullyorpartiallyopen)positionandtheunitoperated
for15minutesbeforetakingreadings.
2.Thetemperaturerisemustbewithintherangespecifiedon
theratingplate.
NOTE:Airtemperatureriseisthetemperaturedifferencebetween
supplyandreturnair.
Witha properlydesignedsystem,theproperamountof
temperaturerisewillnormallybeobtainedwhentheunitis
operatedatratedinputwiththerecommendedblowerspeed,
ifthecorrectamountoftemperatureriseisnotobtained,it
maybenecessarytochangetheblowerspeed.A higherblower
speedwilllowerthetemperaturerise.Aslowerblowerspeed
willincreasethetemperaturerise.
NOTE:BlowerspeedMUSTbesettogivethecorrectairtempera-
turerisethroughtheunitasmarkedontheratingplate.
ExternalStaticPressureCheck
Thetotalexternalstaticpressuremustbecheckedonthisunit
todetermineiftheairflowisproper.
BlowerSpeedAdjustments
TOAVOIDPERSONALINJURYORDEATHDUETOELECTRICSHOCK,REMOVE
ELECTRICALPOWERFROMTHEUNITBEFORECHANGINGSPEEDTAPSONTHE
BLOWERMOTOR.
Refertothewiringdiagramintheappendixtoverifyspeedtap
settings.
Blowerspeedsaretobechangedattheignitioncontrolboard.
Bothheatspeedandcoolspeedterminalsaresuppliedonthe
boardalongwithtwounusedmotorleadterminals.
LimitCheck
Checklimitcontroloperationafter15minutesofoperationby
blockingthereturnairgrille(s).
1.AfterseveralminutesthemainburnersmustgoOFF.Blower
willcontinuetorun.
2.Removeairrestrictionsandmainburnerswillrelightaftera
cooldownperiodofa fewminutes.
Adjustthethermostatsettingbelowroomtemperature.
1.MainburnersmustgoOFF.
2.CirculatingAirBlowerwillcontinuetorunfor120,135or
150seconds,dependingonthesetting.
ControlBoard(Top)
NOTE:Ifnecessary,adjustfanOFFdelaysettingstoobtainsatis-
factorycomfortlevel.
THISUNITMUSTNOTBEUSEDASA -CONSTRUCTIONHEATER-DURINGTHE
FINISHINGPHASESOFCONSTRUCTIONONA NEWSTRUCTURE.THISTYPEOF
USEMAYRESULTINPREMATUREFAILUREOFTHEUNITDUETOEXTREMELY
LOWRETURNAIRTEMPERATURESANDEXPOSURETOCORROSIVEORVERY
DIRTYATMOSPHERES.
UnitShutdown
1.Setthethermostattolowestsetting.
2.Turnofftheelectricalpowersupplytotheunit.
3.Removetheheatexchangerdooronthesideoftheunitby
removingscrews.
4.Move(Figures12& 13)orrotate(Figure14)thegascontrol
valveswitchtotheOFFposition.Donotforce.
5.Closemanualgasshutoffvalveexternaltotheunit.
6.Replacetheheatexchangerdoorontheunit.
7.Ifcoolingand/oraircirculationwillbedesired,turnONthe
electricalpower.
COOLINGSTARTUP
NOTE:Checkallmanualresetlimitcontrolsinheatingcircuitifcool-
ingmodedoesnotoperate.
CompressorProtectionDevices
Thecompressorincludescomponentswhicharedesignedto
protectthecompressoragainstabnormaloperatingconditions.
TOPREVENTPERSONALINJURYORDEATH,ALWAYSDISCONNECTELECTRICAL,
POWERBEFOREINSPECTINGORSERVICINGTHEUNIT.ALLCOMPRESSOR
PROTECTIONDEVICESRESETAUTOMATICALLY,ENERGIZINGTHECONTACTOR
ANDOUTDOORFAN.
CoolingRefrigerantCharging
Checkunitchargebeforeputtingthecoolingsectionintofull
operation.TheunitisfactorychargedwithR-22fornominalair
flowandstaticpressureconditions.Theunithasa piston
flowratorexpansiondevice.Toensuretheunitisproperly
chargedfortheintendedapplication,checktheunitrefrigerant
superheatatthecompressor.Therefrigerantsuperheatisa
13

functionofoutdoorambienttemperatureandreturnair
temperatureoftheconditionedspace.Itistheinstalling
contractorsresponsibilitytoensuretheproperrefrigerant
superheatatthecompressorisadjustedforeachapplication.
Forexample,10degreerefrigerantsuperheatlevelisadequate
fora 95degreeoutdoorambienttemperatureanda 78- 80
degreeforindoorreturnairtemperature.Astheoutdoor
ambienttemperaturerisesthesuperheatdecreasesandas
theoutdoorambienttemperaturelowersthesuperheat
increases.Propersuperheatadjustmentoptimizescooling
performance.
CoolingOperation
NOTE:Mechanicalcoolingcannotbereliablyprovidedatambient
temperaturesbelow50°F.
1.Turnontheelectricalpowersupplytotheunit.
2.PlacetheroomthermostatselectorswitchintheCOOL
position(orAUTOifavailable,andifautomaticchangeover
fromcoolingtoheatingisdesired).
3.Settheroomthermostattothedesiredtemperature.
TROUBLESHOOTING
IGNITIONCONTROLERRORCODES
Thefollowingpresentsprobablecausesofquestionableunit
operation.RefertoDiagnostic indicator Chart foran
interpretationofthesignalandtothissectionforanexplanation.
Removethecontrolboxaccesspanelandnotethenumberof
diagnosticLEDflashes.RefertoDiagnostic Indicator Chart
foraninterpretationofthesignalandtothissectionforan
explanation.
ABNORMAL OPERATION - HEATING
InternalControlFailure
Iftheintegratedignitioncontrolinthisunitencountersan
internalfault,itwillgointoa "hard"lockoutandturnoffthe
diagnosticLED.IfdiagnosticLEDindicatesaninternalfault,
checkpowersupplytounitforpropervoltage,checkall
fuses,circuitbreakersandwiring.Disconnectelectricpower
forfiveseconds.IfLEDremainsoffafterrestoringpower,
replacecontrol.
ExternalLockout
Anexternallockoutoccursiftheintegratedignitioncontrol
determinesthata measurablecombustioncannotbe
establishedwithinthree(3)consecutiveignitionattempts.
Ifflameisnotestablishedwithintheseven(7)secondtrial
forignition,thegasvalveisdeenergized,15secondinter-
purgecycleiscompleted,andignitionisreattempted.The
controlwillrepeatthisroutinethreetimesifa measurable
combustionisnotestablished.Thecontrolwillthenshut
offtheinduceddraftblowerandgointoa lockoutstate.
Ifflameisestablishedbutlost,thecontrolwillenergizethe
circulatorblowerattheheatspeedandthenbegina new
ignitionsequence.Ifflameisestablishedthenloston
subsequentattempts,thecontrolwillrecycleforfour(4)
consecutiveignitionattempts(fiveattemptstotal)before
lockingout.
Thediagnosticfaultcodeis1 flashfora lockoutdueto
failedignitionattemptsorflamedropouts.Theintegrated
controlwillautomaticallyresetafteronehour,oritcanbe
resetbyremovingthethermostatsignalordisconnecting
theelectricalpowersupplyforoverfiveseconds.Ifthe
diagnosticLEDindicatesanexternallockout,performthe
followingchecks;
•Check the supply and manifold pressures
•Check the gas orifices for debris
•Check gas valve forproper operation
•Check secondary limit
Adirtyfilter,excessiveductstatic,insufficientairflow,a
faultylimit,ora failedcirculatorblowercancausethis
limittoopen.Checkfilters,totalexternalductstatic,
circulatorblowermotor,blowermotorspeedtap(see
wiringdiagram),andlimit.Aninterruptioninelectrical
powerduringa heatingcyclemayalsocausetheauxiliary
limittoopen.Thesecondarylimitislocatedontopofthe
circulatorblowerassembly.Theautomaticresetauxiliary
limitislocatedonthecirculatorblowerscroll.
•Check rollout limit
Iftheburnerflamesarenotproperlydrawnintotheheat
exchanger,theflamerolloutprotectiondevicewillopen.
Possiblecausesarerestrictedorblockedfluepassages,
blockedorcrackedheatexchanger,afailedinduceddraft
blower,orinsufficientcombustionair.Therollout
protectiondeviceisa manualresetlimitlocatedonthe
burnerbracket.Thecauseoftheflamerolloutmustbe
determinedandcorrectedbeforeresettingthelimit.
•Check flame sensor
Adropinflamesignalcanbecausedbynearlyinvisible
coatingonthesensor.Removethesensorandcarefully
cleanwithsteelwool.
•Check wiring
Checkwiringforopens/shortsandmiswiring.
Important:Ifyouhavetofrequentlyresetyourgas/electric
packageunit,itmeansthata problemexiststhatshouldbe
corrected.Contacta qualifiedservicerforfurtherinformation.
PressureSwitchStuckOpen
Apressureswitchstuckopencanbecausedbya faulty
pressureswitch,faultywiring,a disconnectedordamaged
hose,a blockedorrestrictedflue,ora faultyinduceddraft
blower.
Ifthecontrolsensesanopenpressureswitchduringthe
pre-purgecycle,theinduceddraftbloweronlywillbe
energized.Ifthepressureswitchopensafterignitionhas
begunthegasvalveisdeenergized,thecirculatorblower
heatoffcyclebegins,andtheinduceddraftblowerremains
on.Thediagnosticfaultcodeistwoflashes.
PressureSwitchStuckClosed
Astuckclosedpressureswitchcanbecausedbya faulty
pressureswitchorfaultywiring.Ifthecontrolencountersa
pressureswitchstuckclosed,theinduceddraftblower
remainsoff.ThediagnosticLEDcodeforthisfaultisthree
(3)flashes.
OpenThermalProtectionDevice
Iftheprimarylimitswitchopens,thegasvalveisimmediately
deenergized,theinduceddraftandaircirculatingblowers
areenergized.Theinduceddraftandaircirculatorblowers
remainenergizeduntilthelimitswitchrecloses.The
diagnosticfaultcodeforanopenlimitisfour(4)flashes.
Aprimarylimitwillopenduetoexcessivesupplyair
temperatures.Thiscanbecausedbya dirtyfilter,excessive
ductstatic,insufficientairflow,ora faultylimit.Checkfilters,
totalexternalductstatic,blowermotor,blowermotorspeed
tap(seewiringdiagram),andlimitThislimitwillautomatically
resetoncethetemperaturefallsbelowa presetlevel.
14

FlameDetectedwithGasValveClosed
Ifflameisdetectedwiththegasvalvedeenergized,the
combustionandaircirculatorblowersareenergized.The
diagnosticfaultcodeisfive(5)flashesforthiscondition.
Thecontrolcanberesetbyremovingthepowersupplyto
theunitoritwillautomaticallyresetafteronehour.Miswiring
istheprobablecauseforthisfault.
ABNORMAL OPERATION - COOLING
ShortCycleCompressorDelay
Theautomaticignitioncontrolhasa built-infeaturethatprevents
damagetothecompressorinshortcyclingsituations.Inthe
eventofintermittentpowerlossesorintermittentthermostat
operation,theignitioncontrolwilldelayoutputtothecompressor
contactorforthreeminutesfromthetimepowerisrestored,
(Compressorisoffa totalofthreeminutes).Thediagnostic
LEDwillflashsix(6)timestoindicatethecompressorcontactor
outputisbeingdelayed.
NOTE:Someelectronicthermostatsalsohavea built-incompressor
shortcycletimerthatmaybelongerthanthethreeminutedelay
givenabove.Ifyouareusinganelectronicthermostatandthe
compressorhasnotstartedafterthreeminutes,waitanadditional
fiveminutestoallowthethermostattocompleteitsshortcycledelay
time.
MAINTENANCE
TOAVOIDPERSONALINJURYORDEATHDUETOELECTRICSHOCK,
DISCONNECTELECTRICALPOWERBEFOREPERFORMINGANYMAINTENANCE.
Havethegasheatingsectionoftheunitcheckedatleastonce
ayearbeforetheheatingseasonbegins,tobesurethatthe
combustionairinletandflueoutlethoodsarenotblockedby
debris,whichwouldpreventadequatecombustionairanda
properlyoperatingventsystem.
FILTERREPLACEMENTORCLEANING
Areturnairfilterisnotsuppliedwiththisunit;however,there
mustbea meansoffilteringallofthereturnair.Thefilter(s)
maybelocatedinthereturnairduc(s),orreturnairfiltergrille(s).
Consultwithyourinstallingdealerfortheactuallocationofthe
returnairfilter(s)foryourunit.
Dirtyfiltersarethemostcommoncauseofinadequateheating
orcoolingperformance.Filterinspectionshouldbemadeat
leasteverytwomonths;moreoftenifnecessarybecauseof
localconditionsandusage.
Dirtythrowawayfiltersshouldbediscardedandreplacedwith
anew,cleanfilterDirtypermanentfiltersshouldbewashed
withwater,thoroughlydriedandsprayedwitha filteradhesive
beforebeingreinstalled.(Filteradhesivesmaybefoundatmany
hardwarestores.)Permanentfiltersshouldlastseveralyears.
However,shouldonebecometornoruncleanable,itshould
bereplaced.
CABINETFINISHMAINTENANCE
Usea finegradeautomotivewaxonthecabinetfinishto
maintainthefinish'soriginalhighluster.Thisisespecially
importantininstallationswithextendedperiodsofdirectsunlight.
CLEANOUTSIDECOIL(QUALIFIEDSERVICERONLY)
Thecoilwiththeoutsideairflowingoveritshouldbeinspected
annuallyandcleanedasfrequentlyasnecessarytokeepthe
finnedareasfreeoflint,hairanddebris.
CONDENSER,EVAPORATOR,ANDINDUCED DRAFTMOTORS
Bearingsontheaircirculatingblowermotor,condensermotor
andthecombustionfanmotorarepermanentlylubricated.No
additionaloilingisrequired.
FLAMESENSOR(QUALIFIEDSERVICERONLY)
Adropintheflamecurrentcanbecausedbya nearlyinvisible
coatingontheflamesensor.Thiscoating,createdbythefuelor
combustionairsupply,canberemovedbycarefullycleaning
theflamesensorwithsteelwool(Figure18).
NOTE:Aftercleaning,themicroampsignalshouldbestableandin
therangeof4 - 6 microampsDC.
FlameSensor
FLUEPASSAGES(QUALIFIEDSERVICERONLY)
Atthestartofeachheatingseason,inspectand,ifnecessary,
cleantheunitfluepassage.
CLEANINGFLUEPASSAGES(QUALIFIEDSERVICERONLY)
1.Shutoffelectricpowerandgassupplytotheunit.
2.Removeburnerassemblybydisconnectingthegaslineand
removingthemanifoldbracketfromthepartitionpanel.
3.Removethefluefromtheinduceddraftblowerandthe
collectorboxcoverfromthepartitionpanel.
4.Theprimaryheatexchangertubescanbecleanedusinga
roundwirebrushattachedtoa lengthofhighgradestainless
steelcable,suchasdraincleanoutcable.Attacha variable
speedreversibledrilltotheotherendofthespringcable.
Slowly rotatethecablewiththedrillandinsertitintooneof
theprimaryheatexchangertubes.Whilereversingthedrill,
workthecableinandoutseveraltimestoobtainsufficient
cleaning.Usea largecableforthelargetube,andthenrepeat
theoperationwitha smallcableforthesmallertube.Repeat
foreachtube.
5.Whenallheatexchangertubeshavebeencleaned,replace
thepartsinthereverseorderinwhichtheywereremoved.
6.Toreducethechancesofrepeatedfoulingoftheheat
exchanger,performthestepslistedin"Startup,Adjustments,
andChecks".
MAINBURNERFLAME(QUALIFIEDSERVICERONLY)
Flamesshouldbestable,softandblue(dustmaycauseorange
tipsbutmustnotbeyellow).Theflamesmustextenddirectly
outwardfromtheburnerwithoutcurling,floatingorliftingoff.
15

TOAVOIDPERSONALINJURYORDEATHDUETOELECTRICSHOCK,
DONOTREMOVEANYINTERNALCOMPARTMENTCOVERSORATTEMPTANY
ADJUSTMENT.CONTACTA QUALIFIEDSERVICERATONCEIFANABNORMAL
FLAMESHOULDDEVELOP.
Atleastoncea year,priortoorduringtheheatingseason,
makea visualcheckoftheburnerflames.
NOTE:Thiswillinvolveremovingandreinstallingtheheatexchanger
doorontheunit,whichisheldbytwoscrews,ifyouareuncertain
aboutyourabilitytodothis,contacta qualifiedservicer.
Ifa strongwindisblowing,itmayaltertheairflowpatternwithinthe
unitenoughthataninspectionoftheburnerflamesisnotpossible.
CLEANINGBURNERS
1.Shutoffelectricpowerandgassupplytotheunit.
2.Removethescrewssecuringthemanifoldtotheburner
retentionbracket.Removethemanifoldandrotateeach
burnercounterclockwisetoremove.
ManifoldAssembly
3.Removetheburners.
4.Usea bottlebrushtocleanburnerinsertandinsideofthe
burners.
5.Replaceburnersandmanifold,inspecttheburnerassembly
forproperseatingofburnersinretentionslots.
6.Reconnectelectricalpowerandgassupply.
LABELALLWIRESPRIORTODISCONNECTIONWHENSERVICINGCONTROLS.
WIRINGERRORSCANCAUSEIMPROPERANDDANGEROUSOPERATION.
ALWAYSVERIFYPROPEROPERATIONAFTERSERVICING.
Forfurtherinformationontheyearlyinspection,consulttheUser
Manual.Itisrecommendedthata qualifiedservicerinspectand
servicetheunitatleastonceeachyear.
Turntheunitonatthethermostat.Waita fewminutes,since
anydislodgeddustwillalterthenormalflameappearance.
Flamesshouldbepredominantlyblueanddirectedintothetubes.
Theyshouldnotbeyellow.Theyshouldextenddirectlyoutward
fromtheburnerportswithoutcurlingdownward,floatingorlifting
offtheports.
ACCESSORIESANDFUNCTIONALPARTS
SHEETMETALACCESSORIES
Additionalaccessoriescanbepurchasedtofitspecificapplication
needs.Partsandinstructionsareavailablefromyourdistributor.
FUNCTIONALPARTS
FunctionalPartsList
GENERALINFORMATION
1.RefertothedescriptioninFunctionalPartsListwhenordering
anyofthelistedfunctionalparts.Besuretoprovidetheunit
modelandserialnumberswiththeorder.
2.Althoughonlyfunctionalpartsareshown,allsheetmetal
parts,doors,etc.maybeorderedbydescription.
3.Partsareavailablefromyourdistributor.
16