ICP PGAA Series User manual

Installation Instructions
IPGAA /PGAC /PGAD -11/2 to 5 TON
PGMD/PGME
COMBINATIONUNITS
GASHEAT/ELECTRICCOOL
TABLEOFCONTENTS
1. SAFETY LABELING AND SIGNAL WORDS .................... 2
DANGER,WARNINGAND CAUTION ............................... 2
SIGNALWORDS ............................................... 2
SignalWordsin Manuals ........................................ 2
PRODUCTLABELING ........................................... 2
DangerLabel ................................................ 2
WarningLabel ............................................... 2
CautionLabel................................................ 2
2. UNIT DIMENSIONS ..................................... 3-4
3. SAFE INSTALLATION REQUIREMENTS ...................... 5
4. LOCATING THE UNIT .................................... 5
ACCESSPANELS .............................................. 5
CLEARANCES................................................. 5
MinimumClearancesto CombustibleConstruction...................... 5
GROUNDLEVEL INSTALLATION................................... 5
ROOFTOPINSTALLATION...................................... 5-6
HOISTING .................................................... 6
DownflowConversion........................................... 6
HeatingVentAssembly ......................................... 6
CondensateDrain ............................................. 6
5. PRE- EXISTING COMMON VENT CHECK ...................... 7
6. GAS SUPPLY AND PIPING ................................ 7
GASPIPING .................................................. 7
GasPipeSize ............................................... 7
PIPINGATUNIT................................................ 7
Connections................................................. 7
ORIFICES .................................................... 7
OrificeSizes ................................................. 7
ChangingOrifices ............................................. 8
7. ELECTRICAL WIRING .................................... 8
UneVoltageWiring ............................................ 8
GroundConnections ........................................... 8
UneConnections .............................................8
THERMOSTAT/HEAT ANTICIPATOR ...............................8
FinalElectricalCheck .......................................... 8
8. DUCTWORK ........................................... 8
DuctworkInsulation ........................................ 9
DuctworkConnections.......................................... 9
FILTERS ..................................................... 9
9. START- UP PROCEDURES ................................ 9
CHECKBEFORESTARTING ...................................... 9
ReverseRotation(ScrollCompressorsOnly) .......................... 9
ManifoldGasPressureAdjustment................................. 9
GASPRESSURES.............................................. 9
CIRCULATINGAIRBLOWER ..................................... 10
HEATINGSTAR-UP PROCEDURES................................ 10
TemperatureRiseCheck ....................................... 10
FANCONTROLCHECK ......................................... 10
SPEEDTAPS................................................. 11
CONTINUOUSFANOPERATION .................................. 11
COOLING ................................................... 11
10. OPERATION ......................................... 12
COMBUSTIONIINDOORFANCONTROL............................. 12
SCROLLANTI-CYCLETIMER .................................... 12
11. MAINTENANCE ....................................... 12
MONTHLYMAINTENANCEANDINSPECTIONCHECKS ................. 12
Air Filters .................................................. 12
HEATINGSEASONCHECKS (MONTHLY) ........................... 12
Pilot Flame ................................................. 12
MainBurnerFlame ........................................... 12
ANNUALMAINTENANCEANDINSPECTION ......................... "12
CondenserFan Motor ......................................... 12
VENTASSEMBLY ............................................. 13
BLOWERMOTORACCESS ...................................... 13
Method1 .................................................. 13
Motorremovalandreplacement.................................. 13
Method2 .................................................. 13
Burners/HeatExchangers/FlueGasPassages ...................... t3
INSPECTIONANDCLEANINGOF BURNERASSEMBLY
/HEATEXCHANGERS/FLUEGASPASSAGES..................... 13-14
ForOaaiifiedServiceTechnicianOnly ........................... t3-t4
12. RIGGING INSTRUCTIONS .............................. 15
13. NOTES ............................................. 16
462 01 1004 00 10-23-01
Printed in U.S.A.

1. Safety Labeling and Signal Words
Danger, Warning and Caution
ThesignalwordsDANGER,WARNINGandCAUTIONareusedtoidentifylevelsofhaz-
ard seriousness.The signalword DANGERis onlyusedon productlabelsto signifyan
immediatehazard.The signalwordsWARNINGandCAUTIONwillbeused onproduct
labelsandthroughoutthis manualand othermanualsthatmayapplyto theproduct.
Danger Label
WhiteletteringonablackbackgroundexceptthewordDANGERwhichiswhitewithared
background.
Signal Words
DANGER- ImmediatehazardswhichWILLresultin severepersonalinjuryordeath.
WARNING- HazardsorunsafepracticeswhichCOULDresultinseverepersonalinjuryor
death.
CAUTION- HazardsorunsafepracticeswhichCOULDresultinminorpersonalinjuryor
productor propertydamage.
Warning Label
WhiteletteringonablackbackgroundexceptthewordWARNINGwhichisblackwithan
orangebackground.
Signal Words in Manuals
Thesignal wordWARNINGisusedthroughoutthismanualinthefollowingmanner:
Thesignal wordCAUTIONisusedthroughoutthismanualin the followingmanner:
CAUTION
Product Labeling
Signalwords areusedin combinationwithcolorsand/orpicturesonproductlabels.Fol-
lowingareexamplesof productlabelswith explanationsofthe colorsused.
Caution Label
Whiteletteringon a blackbackgroundexceptthewordCAUTIONwhichis blackwitha
yellowbackground.

2. Unit Dimensions "B" CHASSIS UNIT DIMENSIONS
COMBINATION GAS/
A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
Q
R
S
D01_<
A
B
C
D
E
F
G
H
K*
Units in "B" Chassis Configuration
PGAA18-42
ELECTRIC UNITS
"B" Chassis PGAC36-42 _ A
(473/8x473/8) PGAD24-36_ _ _ _"B"
INCHES MILLI_IETER "C" /__
32-1/2I 828
47-3/8 I1203 / / (- _((_,(_..(_)_J))))))))]/ _. _.
47-378 I 1203 / / _ _._.___/JJJ _ "%1
3-1/8 I 79 / / ___/ _ /"
11-1/8 I 283 _ _ _/
12 I306 _ //
14-1/4 I 363 _ //
14-1/4 I 363 _ //
12 I306 __ _ _ "A"
4 102 'T'/"
4-1/4 to8 _ _ "E'_
12-1/4 311 // \_Xj _ _/'_ / _ -
12-118 308 / / 'D" // 'H" -"_/, /
14-1/4 363 / / y _ _O_
I
12-1/4 318
t&5)_> _._ _ ,,,
I-1/2'_
(539.75) _ } "",_ '_L"<,..,._ / _ _.. /_ \
11-1/8" _ 4"_
UNBT NAgN NHOWN 8NPARATNLY _
ROOFCURB TO ILLUSTRATE BOTTOM
for units in #UOT OPSN_I8
"B" Chassis
(473/8 x 473/8) Units in "B" Chassis Configuration_
"NCHES M,LI=IM_T_.8 PGAA18-42 _ _.
42-3/4 1086 PGAC36-42 _
3-3/4
42-3/4 1086 _ _ _ _
14 356
80-10-12
7_ROOF CU_E_S ARE ALSO AVA_LAE_LE I_ 8"(203} AND 24"(610) HEIGHTS (K D_MENSION).

"C" CHASSIS UNIT DIMENSIONS
1-1/2"
COMBINATION GAS/
ELECTRIC UNITS
"C" Chassis
(473/8 X 73)
DgM. INCHES MILLIMETER8
A 36 914
B 47-3/8 t 203
C 73 1354
D 4-5/8 117
E 15 361
F 12 307
G 18-3/4 476
H 18-3/4 476
I 12 306
J 4 t02
K 1 & 1-1/4 25 & 31
L 4-1/4 108
M 5-1/4 133
N 12-1/4 311
P 19 483
Q 15 381
R 19 483
S 12-1/4 318
T 16-7/8 429
ROOF CURB
for
"C" Chassis
(473/8 X 73)
#_M. "NCHE8 M_LL_METER8
A 67-3/4 1721
B 64-3/4 1645
C 23 584
D 23 584
E 2-1/2 64
F 42-3/4 1086
G 39-3/4 1010
H 23 584
I 12 305
J 12 305
K* 14 356
(10t.8)
ELECTRICAL POWER
CONDUIT ('K' DIM.)
VOLTAGE
1/2" (12.7) CONDUIT
GAS CONNECTION
_/2" (12,7) P_PE
Units in "C" Chassis Configuration
PGAA48-60
PGAC48-60
PGAD42-60
UNIT BASE SHOWN SEPARAT
TO ILLUSTRATE BOTTOM
DUCT OPENINGS
"F\
-/_-ROOF CURBS ARE ALSO AVAILABLE IN 8"(208) AND 24"(810) HEIGHTS (K DIMENSION),
80-18-11

3. SAFE INSTALLATION REQUIREMENTS
Installation or repairs made by unqualified persons can result
in hazards to you and others. Installation MUST conform with
local building codes or, in the absence of local codes, with the
ANSI Z223.1 and the National Electrical Code NFPA70-f 990 or
in Canada the National Standard CANiCGA B149-1 and CSA
C.22.1 -Canadian Electrical Code Part 1.
The information contained in this manual is intended for use
by a qualified service technician familiar with safety proce-
dures and equipped with the proper tools and test instru-
ments.
Failure to carefully read and follow all instructions in this
manual can result in furnace malfunction, property damage,
personal injury and/or death.
• DoNOTusethisfurnaceas aconstructionheater.
• UseonlytheTypeofgas approvedfor thisfurnace(SeeRatingPlate).
• DoNOTuseopen flametotestfor gas leak.
• Sealsupplyand returnair ducts.
• Checktoseethatfiltersareinstalledcorrectlyandarethepropertypeand size.
NOTE:Itisthepersonalresponsibilityandobligationofthecustomertocontacta qualified
installerto ensurethat theinstallationisadequateandconformsto governingcodesand
ordinances.
CAUTION
It is recommended that aqualified service technician check the heat
exchanger integrity every two (2) years, after the first four (4) years of
operation.
4. LOCATING THE UNIT
ACCESS PANELS
See FIGURE1forageneralviewofunitandlocationofaccesspanels.
Carbon monoxide poisoning hazard.
Do NOTinstalltheunit in alocationthatwill permitdischargedairfromthecondenserto
recirculatetothe condenserinlet.
CAUTION
Do NOT operate unit in a corrosive atmosphere containing chlorine,
fluorine, or any other corrosive chemicals.
Minimum Clearances to Combustible Construction
Furnace Plenum ........................................... 2"
Duct Side ........................ 2" (6" on large chassis models)
Condenser Inlet Side ...................................... 30"
Blower Service (Rear) ..................................... 30"
Control Service Side
(Front Combustion Air Inlet) ................... 30"
Clearance between 3 Ft. Overhang
and Top of Unit .............................. 30"
Combustible Base
(Wood or Class A, B or C
roof covering material) ......................... 0"
FIGURE 1
\I Minimum Clearances and Access Panels
(B Chassis Shown)
Blower Compartment Panel
I nternal Filter Access
from Burner Compartment Side
26" (C Chassis Units)
30"
80-00-01
Burner Compartment
Panel
Keep blower door closed.
Failure to keep blower door closed can result in bodily injury
and/or death.
CLEARANCES
ThelocationMUSTallowfor minimumclearancesandshouldnotbeadjacenttoapatioor
otherareawheretheunit'soperatingsoundlevelmightbeobjectionable.Thecombustion
airinletopeningsMUSTnotbeobstructed(seeFIGURE1).Inaddition,localcodesMUST
beobserved.
NOTE:Unitswithbuiltinfilterracks( "C" Chassis48x 73 models),need a26" minimum
clearanceatfrontof unitforremovalof filters.Seechartbelowif unitisgoingtobe placed
nearcombustibleconstructionormaterials.
While minimumclearancesare acceptablefor safetyreasons,they may not allowade-
quateair circulationaroundthe unitfor properoperationinthecoolingmode.Whenever
possible,itisdesirabletoallowadditionalclearance,especiallyaroundthecondenserinlet
anddischargeopenings.
INSTALLATION
NOTICE
Unit will NOT operate properly unless it is installed level front to rear
and side to side.
The slope MUST NOT be greater than 1/8" per foot (10mm per meter).
For side to side leveling, the drain side MUST always be lower.
Ground Level Installation
Groundlevel platformrequirements:
- The unitMUSTbesituatedtoprovidesafo accessforservicing.
Platformmay bemadeof eitherconcreteor pressuretreatedwoodand MUSTbe
level andstrongenoughto supportunitweight.
Positionplatformseparatefrom buildingfoundation.
Installin well-drainedarea,withtopsurfaceofplatformabovegradelevel.
Platformmust behighenoughto allowfor propercondensatetrapinstallationand
drainage.SeeFIGURE4and associatedtextfor moreinformationabout conden-
satedrainage.
Rooftop Installation
Rooftopplatformrequirements:
-The unitMUSTbesituatedtoprovidesafo accessforservicing.

- TheexistingroofstructureMUSTbeadequatetosupporttheweightoftheunitorthe
roofMUSTbereinforced.
Checkthe weightofthe unitin relationtothe roofstructureand localbuildingcodes
orordinancesand reinforceroofstructureifnecessary.See FIGURE21ontheback
coverofthismanualforunit weights.
- Supportfor theunit MUSTbelevelandstrongenoughtocarryunitweight.Thesup-
portmayconsistofaplatformoracombinationof platformandroofbeamsorcurb.
- See Hoistingsectionbelowfor hoistinginstructions.
HOISTING
NOTE:All accesspanelsMUSTbesecuredin place beforehoisting.
Theunitshouldbehoistedwithtwoliftingslings.Attachthe slingsto riggingshacklesthat
havebeen hookedthrough holesin the baserail.
TwospreaderbarsMUSTbeplacedontopoftheunitto protecttheunitfromdamagefrom
thepressureexertedbythe slings.Makesurethatallequipmentisadequatetohandlethe
weightoftheunit andthatthe slingswillnotallowtheunitto shift.
RefertoFIGURE21onthebackcoverofthismanualforillustratedrigginginstructionsand
weightchart.
DOWNFLOW CONVERSION
These unitsare adaptableto downflowuse. Toconvertto downflow use,follow these
steps:
1. Removethe blockoffplatesfoundin the returnair cempartmentand thesupplyair
compartment.See FIGURE2.
NOTE:Blockoffplateinthesupplyaircempartmentonlycontainsonescrew.Ifreinstalling
plate,backpartofplateMUSTfit intomatingdimplesonflange.Toreinstall,slantplateinto
dimples,thenputplate intopositionandfastenwithscrew.
2. Instantheremovedplatesonthehorizontalreturnandsupplyair openings.
3. Installroofcurb onthe building.Besure tofollowall directionsincludedwithcurb
andallapplicablebuildingcodesinyour installation.(SeePages2or3forappropri-
atecurbto use withyourmodel.)
FIGURE 2 Blockoff Plate (Return Air Compartment)
I
FIGURE 3 l Heating Vent Assembly
Flue Support
(Shipped mounted to unit
Flue Cover
\
CAUTION
DO NOT OPERATE THE UNIT WITHOUT THE VENT ASSEMBLY
INSTALLED
Condensate Drain
Thecondensatedrainoutletisa 3/4"(19.1mm)threadedfemalePVCconnectionlocated
atthebottomoftheunittotherightofthefilteraccesspanel(seeFIGURE4).Condensate
drain outletMUSTbe heldwith wrenchwheninstallingtrapand drainline.
Thecirculatingblowercreatesa negativepressureonthecondensatedrainlinethatcan
preventthecondensatefromdrainingproperly.Tocombatthisnegativepressure,afield
suppliedcondensatetrapthatwillallowastandingcolumnofwaterofatleast2" (50.8mm)
MUSTbeinstalled. Topofoutletfromtrap MUSTbeat least1" (25.4mm)belowtop of
outletfromunit.Install the trapas nearto the unitas possiblefor properdrainage.
A3/4"(19.1mm)drainlineMUSTbeinstalledif requiredbylocalcodesoriflocationofunit
requiresit.Runthedrainlinetoan opendrainorothersuitabledisposalpoint.
I Condensate Drain Information*
FIGURE 4
A
25-1/2 ("B" Chassis)
32-1/4 ("C" Chassis)
3/4" (19.1mm)
Threaded Female
PVC Fitting
I r,
(25.4mm)
2" (50.8mm)
Heating Vent Assembly
Thefluecoverispackedwithscrewsinthereturnaircompartment.RefertoFIGURE3and
assembleas shown. *Condensate trap MUST be installed.
5. PRE-EXISTING COMMON VENT CHECK
Iftheinstallationofthecombinationunitinvolvesremovinganexistingfurnacefromacom-
monventwithotherappliances,theexistingventingsystemwillprobablybetoolargefor
the remainingappliancesand they willnotvent properly.The existingventingsystem
MUSTbe checkedby a qualifiedtechnicianto ensureit isproperlysizedand
ventsproperly.

6. GAS SUPPLY AND PIPING
NOTE:Becausetherearemanytypesof liquifiedpetroleum(LP)gases,thetermLPas
usedinthis manualreferstopropanegas. Ifyouintendto useanytypeofLPgas,proper
precautionsMUSTbeusedinthehandling,piping,anduseofsuchgas.NOTE:InCana-
da,installationsMUSTbeperformedby licensedLP installers.
TheUL/CSARatingPlatelocatedonthesidepanelonthe unitcontainsthemodelnumber,
typeof gasandgas inputrating,andotherimportantinformation.
Fire and/or explosion hazard.
Make certain the unit is equipped to operate onthe type of gas
available. Models designated as natural gas are to be used with
natural gas only. Models designated for use with liquefied pe-
troleum (LP) gas are shipped with orifices sized for commer-
cially pure propane gas. They MUST not be used with butane or
a mixture of butane and propane unless properly sized orifices
are installed by a licensed LP installer.
Failure to follow this warning can result in property damage,
personal injury, and/or death.
GAS PIPING
The gassupplyline MUST beof adequatesize to handlethe Btu/hr requirementsand
lengthoftherunforthe unitbeinginstalled.Determinetheminimumpipesizefor natural
gasfromthetable inFIGURE5 orFIGURE6. Basethelengthof therunfrom thegas
meterorsourcetothe unit.
Gas Pipe Size
Btu ratingsofall othergas appliancesMUSTbe consideredfor sizingof maingas line.
Checkgasline to installationfor compliancewith localcodes or,in theabsenceoflocal
codes,withtheNationalFuelGasCode ANSIZ223.1orin CanadatheNationalStandard
CAN/CGAB149-1 orcurrenteditions.
FIGURE 5 Gas Pipe Size, Length and Btuihr Capacity
for Schedule 40 Iron Pipe (English)
NATURAL GAS
Pipe Length Btu/hr (in thousands)
(includes
Fittings) 3/4" 1" 11/4" 11/2" 2"
20' t90 350 730 1,t00 2,100
40' t 30 245 500 760 1,450
60' t05 195 400 610 1,150
LP GAS
Pipe Length Btu/hr (in thousands)
(Includes
Fittings) 1/2" 3/4" 1" 11/4 " 11/2"
20' t89 393 732 1,496 2,299
40' t29 267 504 1,039 1,559
60' t 03 217 409 834 1,275
Gas Pipe Size, Length and Btu/hr Capacity
FIGURE 6 for Schedule 40 Iron Pipe (English)
Pipe Length
(Includes
Fittings) 3/4" 2"
6.1m 56 615
12.2m 38 425
18.3m 31 337
Pipe Length
(Includes
Fittings) 1/2" 11/2"
6.1 m 55 674
t2.2m 38 457
t8.3m 30 374
NATURAL GAS
kW**
1" 11/4" 11/2"
103 214 322
72 147 223
57 117 179
LP GAS
kW**
3/4" 1" 11/4"
1t5 215 438
78 t 48 305
64 t 20 244
**kW (Kilowatts) is the metric equivalent of Btu/hr.
PIPING AT UNIT
Connections
NOTE: The ruleslistedapplyto naturalandLP gaspipe installations.
1. Ifinstallationisfor LPgas,haveLP gasinstalleruseTW0- STAGEREGULATION
andmakeallconnectionsfromstoragetankto unit.
2. Use blackironor steel pipeandfittingsor otherpipeapprovedby local code.
3. Ifceppertubing isused,it MUSTcemplywith limitationsetin Fuel GasCode.
NOTE: Ifa gas connectoris used,it MUSTbe acceptableto local authority.Connector
UUST NOTbeusedinsidethefurnaceorbesecuredorsupportedbythefurnaceorduct-
work.
Fire and/or explosion hazard.
Gas connector MUST be properly installed and can NOT be
used inside the furnace.
Failure to do so can result in property damage, bodily inju-
ry or death,
4. Use pipejointcompoundonexternal(male)threadsONLY.JointcempoundMUST
beresistanttoany chemicalactionofLP gases(NOTAG). DoNOTputpipecom-
poundon last2 threadsofpipe.
5. Usegroundjoint unionsandinstalla driplegnolessthan3 inches(76ram)Iongto
trapdirtand moisturebefore it canenter gas valve.
CAUTION
Overtightening assembly may cause damage to the gas valve and/or
wiring and may misalign the burners.
6. Use a wrenchongas valve whenmakingconnectionsto preventgas valvefrom
turning.Do NOTusea pipewrench onthegasvalve body.
7. Providea_t8inch(3ram)NationalPipeThread(NPT)plugfortestgaugecennection
immediatelyupstreamofthegas supplyconnectiontothefurnace ifnone is sup-
pliedwiththe gasvalveofunit.
8. Installa manualshutoffvalve andtightenanjoints securely.
9. Makesurepilottube and burnerorificesarecheckedfor leakage.
ORIFICES
Orifice Sizes
Orificesizes BUST bematchedto the heatingvalueof the gas (seeFIGURE7 and
TABLE1).CheckwithyourgassupplierandtheNationalFuelGasCodeANSIZ223.1.

FIGURE8 I Manifold/OrificeMeasurement
NOTE:An LP ConversionKit MUSTbeusedfor conversionto LPgas.
NOTE:For elevationsabove2000 feet(610meters),the Btu inputrating MUSTbe re-
ducodby 4%for each 1000feet (305meters)abovesea level,unlessthegassupplier's
Btuflt3contenthasalready beenadjustedfor altitude.CheckTable 1.
FIGURE 7 Orifice Sizes
Pilot
Gas Specific Btuift 3 Orifice
Type Gravity (kJ/L) Sizes
Natural 0.6 1000 .018#
2500 .012#
Propane 1.53
#Adjust pilot flame as needed
TABLE 1: Equivalent Orifice Sizes at High Altitudes
(Includes 4% input reduction for each 1,000 ft.
NaturalGasManifoldOrificeSize Requiredby Elevation
BTU 0'- 2000' 4500'
INPUT 2000' 4000' 5000' 6000' 7000' 8000' 9000' 10000'
40.000to 44 45 46 47 47 48 48 49
60,00
90,000to 43 44 45 45 46 47 47 48
150,000
LPGas ManifoldOrifice Size Requiredby Elevation
BTU 0'- 2000' 4500'
INPUT 2000' 4000' 5000' 6000' 7000' 8000' 9000' 10000'
40.000to 55 56 56 56 56 56 56 57
60,000
90,000to 54 55 55 55 55 56 56 56
150,000
*2-1/2 & 3 Ton with 3 burners.
** 3-1/2 & 4 ton with 4 burners.
Changing Orifices
Electrical shock, fire and/or explosion hazard.
Sh ut off electric power at unit discon nect or service panel and
shut off gas at manual shut off valve before beginning the fol-
lowing procedure.
Changing orifices requires a qualified service technician.
Failure to follow this warning can result in property damage,
personal injury, and/or death.
1. Shut OFFgasat manualshutoffvalve.
2. Shut OFFelectricpoweratunit disconnector servicepanel.Ifunit isstillrunning,
allow2.5minutesaftergasshut offbeforeturningoffpower.
3. Disconnectthe wiresfromthe gasvalve.
4. Removethefour screwsholdingthemanifoldtothemanifoldbrackets.
5. Carefullyremovethe manifoldwiththegas valveattached.
6. Removethe orificesfromthemanifoldwith a7/16"box end orsocketwrench.
7. Checkto besurethatthesizeof eachorificeis correctfortheBtuinputdesired.
Measure 11/16" (27mm) from
face of orifice to back edge of
_manifold pipe.
8. Installthecorrectorifices.Gaugethesizeoftheorificeswithanewtwistdrillbit ofthe
correctsize.
Makesurethat theorificesgoinstraightsothattheyforma rightangle(90°) tothe
manifoldpipe.
Tightentheorificessothat thereisa11/16" (27mm)distancebetweenthefacesof
theorificesto thebackofthemanifoldpipe.
Measurethe distancewitha setof calipers.Ifyoudo nothaveacalipers,you can
use anadjustablewrenchandmeasurebetweentheface ofthejaws.
9. Reassembleinreverseorder.
7. ELECTRICAL WIRING
Electrical shock hazard.
Disconnect power at fuse box or service panel before making
any electrical connections.
Unit MUST be grounded to electrical service panel.
Failure to follow this warning can result in property damage,
personal injury, and/or death.
NOTE:All electricalworkMUST conformwiththerequirementsof localcodesandordi-
nances andthe NationalElectrical Code ANSI/NFPA-No.70-1990 or currentedition.
Providelinevoltagepowersupplyfrom aseparatefusedcircuitwithadisconnectswitch
locatedwithinsightoftheunit.
Foraccess,removetheheateraccesspaneland thecontrolboxcover.See FIGURE1for
accesspanellocation. WiringMUSTbeprotectedfrompossiblemechanicaldamage.
Line Voltage Wiring
Connectionsforlinevoltagearemadeintheunitcontrolbox.Foraccess,removetheburn-
er accesspanelandthecontrolboxcover.
Ground Connections
DoNOTcompletelinevoltageconnectionsuntilunitispermanentlygrounded.Alllinevolt-
ageconnectionsand thegroundconnectionMUSTbe madewith copperwire.
Agroundlug isinstalledinthecontrolboxforthegroundconnection.Useacopperconduc-
torof theappropriatesizefromthe unittoagroundedconnectionintheelectricalservice
panelor a properlydrivenand electricallygroundedground rod.Seewarning above.
Line Connections
Completethelineserviceconnectionstothecontactor'L'terminalsinsidethecontrolbox.
Refertoapplicablewiringdiagram.Checkallscrewterminalstoensurethey aretight.
THERMOSTAT/HEAT ANTICIPATOR
Thelocationofthethermostathasanimportanteffectontheoperationoftheunit. FOL-
LOW THE INSTRUCTIONSINCLUDEDWITHTHETHERMOSTATFOR CORRECT
MOUNTINGANDWIRING.
Set the thermostatheatanticipatorto.58 in accordancewiththermostatinstructions.

FinalElectricalCheck
1. MakeafinaIwiringchecktobesuresystemiscerrectlywired.Inspectfieldinstalled
wiringandtheroutingtoensurethatrubbingorchafingduetovibrationwillnotoccur.
NOTE:WiringMUSTbe installedso it isprotectedfrompossiblemechanicaldamage.
8. DUCTWORK
Maximum recommendedvelocity in trunk ducts is 1000 feet per minute.Velocity in
branchesshould notexceed 800feetperminute.
FIGURE 9 Capacities Air Delivery
Nominal Tons
Air Conditioning
Up Thru 2
21/2
3
31/2
4
41/2
5
61/3
Nominal Air
Flow Cubic Feet
per Minute
800-900
900-1100
1100-t300
Recommended Filter Sizes
Sq. In. Surface Area/Nominal Size
Disposable Filters Cleanable Filters
400 or 20 x 25 246 or 15 x 20
487 or 20 x 30 301 or 14 x 25
576 or 14 x 25 (2Req.) 356 or 16 x 25
Unit Size
Heating Input
1000 x Btu h
40 and 50
40, 50, 75 and 100
40, 50, 75 and 100
1300-1500 665 or 16 x 25 (2Req.) 411 or 20 x25 (2Req.) 75, 100 and 125
1500-1700 753 or 20 x 25 (2 Req.) 466 or 20 x 25 100 and 125
1700-1900 841 or 20 x 25 (2 Reg.) 521 or 24 x 25 125
1900-2100 960 or 20 x 30 (2 Req.) 575 or 24 x 25 125
2300-2500 1108 or 20 x 30 (2 Req.) 685 or 24 x 30 150
NOTE: Minimum recommended filter areas are based on a velocity of 325 ft./rain, for disposable filters and 525 ft./min, for high velocity filters (washable).
NOTE:Ductworksizingaffectstemperatureriseand coolingtemperaturedifferential.Be
suretoproperlysizeductworktothecapacityand airflowcharacteristicsofyourunit.Fail-
ureto doso canaffectlimitcontrols,compressors,motors,andothercomponentsandwill
leadto prematurefailure ofcomponents. Thiswillalsoadverselyaffectday to dayunit
performance.Refertorating plateand TemperatureRiseCheck,Page21.
Ductwork Insulation
Ductworkinstalled outdoorsshouldhave a minimum of2" fiberglassinsulationand a
weatherproofvapor barrier,tt shouldbe protectedagainstdamage.Caulkingandflash-
ings,orother meansadequatetoprovidea permanentweatherseal,should beused.
Ductworkinstalledin atticsor other areas exposedto outsidetemperaturesshould be
installedwitha minimumof 2" fiberglassinsulationandhavean indoortypevapor barrier.
Ductwork Connections
Theuseofflexible,non-combustibleconnectorsbetweenmaintrunk ductsandsupply
andreturnairplenumsis recommendedtominimizevibrationtransmission.
NOTE: Connectsupplyandreturnairplenumsto unitinamannerthatwillallowthetopof
theunittoberemovedwithoutremovingplenums.PlenumsMUSTbeindividuallysealed
tounit casingwithductsterminatinginsidestructure.
FILTERS
AllreturnairMUSTpassthroughafilterbeforeenteringtheunit.Anelectronicaircleaner,
optionalfilter racks,or otheraccessiblefilterarrangementMUSTbeinstalledinthereturn
airductwork.MinimumrecemmendedfilterareasarelistedinFIGURE9and arebasedon
avelocityof325 _min for disposablefiltersand525ft!minfor highvelocityfilters(wash-
able).
CAUTION
9. START-UP PROCEDURES
Fire and/or explosion hazard.
Do NOT attempt to light the pilot or burner with a match or
flame of any kind.
Failure to follow this warning can result in property damage,
personal injury, and/or death.
CHECK BEFORE STARTING
1. Checkthat the blowermotorspeed terminalblock or thesettingof the variable
speedpulleyisrunningthe correct heatingandcoolingspeeds.
2. Checkto seethatclean,properlysizedairfiltersareinstalled.
3. Replaceall serviceaccesspanels.
Reverse Rotation (Scroll Compressors Only)
ThreephasescrollcompressorequippedunitsCANrunin reverseif improperlywired.If
the compressormakesanunusuallyloudnoise,orif highandIowsidepressuresarenear-
lyidentical,thisindicatesreverserotation.Tocorrect,reverseanytwowiresatlinevoltage
connectionsONLY. DoNOTre-wireanycircuitsinsidethe unitto attemptcorrectionof
reverserotation.
Manifold Gas Pressure Adjustment
NOTE:Makeadjustmenttomanifoldpressurewithburnersoperating.
DO NOT OPERATE THE UNIT WITHOUT A FILTER.

Fireorexplosionhazard.
NOTE: Adjustmentscrew coverMUSTbeplacedon gasvalvebeforereadingmanifold
pressureandoperatingfurnace.
Turn OFF gas at shut off before connecting U-tube ma-
nometer.
Failure to properly seal duct can result in personal injury
and/or death.
I
FIGURE 10 [Honeywell Gas Valve
Inlet Pressure
Tap (Hidden)
Wiring
Terminals
INLET
Outlet
Pressure
Tap
Pilot Adjustment
25-50-06
GAS PRESSURES
1. Do NOTallowgas supplypressureto fallbelowthe listedminimums.Doingso wUl
decreaseinputtofurnace.Referto FIGURE11 for gassupplypressures.
2. GasinputMUSTNOTexceedratedinputshownonratingplate.
3. Do NOTallowpressurestoexceedthemaximumlimitsas listedin FIGURE11.
FIGURE 11 Gas Pressures
Natural Gas LP Gas
Minimum 4.5"W.C. (1120 Pa) 1t" W.C. (2740 Pa)
Inlet
Recommended 7" W.C. (t740 Pa) 1t" W.C. (2740 Pa)
Inlet
Maximum 13" W.C. (3230 Pa) 13" W.C. (3230 Pa)
Inlet
Manifold 3.5" W.C. (870 Pa) 10" W.C. (2490 Pa)
Pressure
Manifold Pressures
Manifoldpressuresare coveredin the startupproceduresection.Referto Chapter 9
Start-Up Procedureson Page20.
1. Withgas OFF,ConnectU-Tubemanometertotappedopeningongas valve.Use
manometerwitha 0to 12incheswatercolumn range.
FIGURE 12 Manifold Pressure Settings
Gas Type Manifold Pressure
Natural 3.5 Inches Water Column (870 Pa)
Propane 10 Inches Water Column (2490 Pa)
2. TurngasONandremoveadjustmentscrewceverongasvalve.Turnccunterclock-
wisetodecreasepressureandclockwiseto increase.
Fire and/or explosion hazard.
Do NOT adjust manifold pressure more than ±0.3 inches
water column to obtain rated input.
Failure to properly set input pressure can result in proper-
ty damage, personal injury and/or death.
3. Set pressuretovalueshowninFIGURE12,-+0.07kPa(0.3inches)waterceNmn.
Pressureisalsolistedonfurnaceratingplate.InNOcaseshouldfinalmanifoldpres-
surevarymorethan -+0.07kPa(0.3inches)watercolumn.
CIRCULATING AIR BLOWER
Checktheunit'soperationasoutlinedinthefollowinginstructions.Ifanyunusualsparking,
odorsorunusualnoisesareencountered,shutoffelectricpowerimmediately.Recheckfor
wiringerrors,or obstructionsin ornear blowermotors.
1. Set thermostatHeat-Cool selectortoOFF
2. Set thermostatfan switchto AUTO.
3. TurnelectricpowerON. Nothingshouldstart running.
4. Turn manualgasvalve ON.
5. Turngas controlvalve ON.
6. Set thermostatfan switchto ON.
7. Resetthermostatfan switchto AUTO.
HEATING START-UP PROCEDURE
1. Adjustthermostatsettingaboveroomtemperatureand set thermostatselectorto
HEAT.The combustionair blowershouldcome ON.
2. Theignitorshouldbegintoglowand pilotflameshouldlight.Referto Lighting/Oper-
atingInstructionslabellocatedon BurnerAccessPanelofunit.
NOTE:On acall forheat theignitorandpilotvalvewill remainenergizeduntila flameis
detectedby the flamesensor. Itmaytakeseveralminutestopurgetheair outofthe gas
linesat initialstart-up ofthe unit.
3. Oncetheflamesensordetectsthat a flameis present,the hotsurfaceignitorwill
de-energizeandthemain burnerswilllightfromthe pilot.
4. 30secondsafterthe burnerslight,the circulatingblowershouldbeginto run.
Fire and/or explosion hazard.
Do NOT attempt to light the pilot or burner with a match or
flame of any kind.
Failure to follow this warning can result in property damage,
personal injury, and/or death.
Temperature Rise Check
NOTE:Airtemperatureriseisthe temperaturedifferencebetweensupplyandreturnair.
Witha properlydesigneddistributionsystem,theproperamountoftemperaturerisewill
normallybeobtainedwhentheunitisoperatingatratedinputwiththe recommendedblow-
er speed.
The temperature rise must be within the specifications marked on the unit
rating plate.
To check the temperature rise through the unit, place thermometers in the
supply and return air ducts as close to the unit as possible,
Open ALL registers and duct dampers, Operate unit AT LEAST 15 minutes
before taking readings.
If thecorrectamountof temperatureriseis notobtainedwhenoperatingontherecom-
mendedblowerspeed,itmay benecessarytochangetheblowerspeed.Afasterblower
speedwilldecreasethetemperaturerise.Aslowerblowerspeedwillincreasethetemper-
aturerise.
10