International comfort products PGD/S524?60 User manual

INSTALLATION INSTRUCTIONS
R−410A Single Package Gas/Electric Units
PGD/S524−60
Single Phase
These instructions must be read and understood completely before attempting installation
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and NOTE
The signal words DANGER, WARNING,
CAUTION,and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is only
used on product labels to signify an immediate hazard.
The signal words WARNING, CAUTION, and NOTE will
be used on product labels and throughout this manual
and other manual that may apply to the product.
DANGER −Immediate hazards which will result in
severe personal injury or death.
WARNING −Hazards or unsafe practices which could
result in severe personal injury or death.
CAUTION −Hazards or unsafe practices which may
result in minor personal injury or product or property
damage.
NOTE −Used to highlight suggestions which will result
in enhanced installation, reliability, or operation.
!WARNING
Signal Words in Manuals
The signal word WARNING is used throughout
this manual in the following manner:
The signal word CAUTION is used throughout
this manual in the following manner:
!CAUTION
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures or product labels.
SAFETY CONSIDERATIONS 2..................
RECEIVING AND INSTALLATION 2..............
Step 1 −Check Equipment 2....................
Step 2 −Provide Unit Support 3..................
Step 3 −Field Fabricate Ductwork 3..............
Step 4 −Provide Clearances 7...................
Step 5 −Rig and Place Unit 7...................
Step 6 −Connect Condensate Drain 11............
Step 7 −Install Flue Hood 11.....................
Step 8 −Install Gas Piping 11....................
Step 9 −Install Duct Connections 12..............
Step 10 −Install Electrical Connections 13.........
Wiring Diagrams 15.............................
PRE−START−UP 17.............................
START−UP 17..................................
Step 1 −Check for Refrigerant Leaks 17...........
Step 2 −Start−Up Heating and Adjustments 17.....
Step 3 −Start−Up Cooling and Adjustments 20.....
Maintenance 23.................................
Troubleshooting 26..............................
Start−Up Checklist 34...........................
TABLE OF CONTENTS PAGE
!WARNING
PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Failure to carefully read and follow this warning
could result in equipment malfunction, property
damage, personal injury and/or death.
Installation or repairs made by unqualified
persons could result in equipment malfunction,
property damage, personal injury and/or death.
The information contained in this manual is
intended for use by a qualified service technician
familiar with safety procedures and equipped
with proper tools and test instruments.
Installation must conform with local building
codes and with the national Electrical Code
NFPA70 current edition or Canadian Electrical
Code part 1 CSA C.22.1.
462 01 2103 01 07−09−13

2462 01 2103 01
SAFE INSTALLATION REQUIREMENTS
FIGURE 1 PACKAGED GAS / ELECTRIC UNIT
SAFETY CONSIDERATIONS
Improper installation adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock,
or other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory−authorized kits or
accessories when modifying this product Refer to the individual
instructions packaged with the kits or accessories when
installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. Consult local
building codes, the current editions of the National Fuel Gas
Code (NFGC 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.
In Canada refer to the current editions of the National Standards
of Canada CAN/CSA−B149.1 and .2 Natural Gas and Propane
Installation codes, and Canadian electrical Code CSA C22.1.
Recognize safety information. This is the safety−alert symbol .
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words: DANGER, WARNING, and CAUTION.
These words are used with the safety−alert symbol. DANGER
identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
CAUTION
!
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels or performing maintenance
functions inside your unit, be aware of sharp sheet metal parts
and screws. Although special care is taken to reduce sharp
edges to a minimum, be extremely careful when handling
parts or reaching into the unit.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. TAG DISCONNECT SWITCH WITH LOCKOUT TAG.
!WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or unit damage.
A qualified installer or agency must use only
factory−authorized kits or accessories when modifying this
product.
WARNING
!
INTRODUCTION
The PGD5 / PGS5 units (see Fig. 1) are a fully self−contained,
combination Category I gas heating/electric cooling unit
designed for outdoor installation (See Fig. 3 and 4 for unit
dimensions). All unit sizes have return and discharge openings
for both horizontal and downflow configurations, and are factory
shipped with all downflow duct openings covered. Units may be
installed either on a rooftop or on a cement slab. (See Fig. 5 for
roof curb dimensions).
Models with the number “1” in the 13th position of the model
number are dedicated Low NOx units designed for California
installations. These models meet the California maximum oxides
of nitrogen (NOx) emissions requirements of 40 nanograms/joule
or less as shipped from the factory and must be installed in
California Air Quality Management Districts or any other regions
in North America where a Low NOx rule exists.
NOTE:Low NOx requirements apply only to natural gas
installations.
In gas heating mode, this unit is designed for a minimum
continuous return−air temperature of 55°F (13°C) db and a
maximum continuous return−air temperature of 80°F (27°C) db.
Failure to follow these return−air temperature limits may affect
reliability of heat exchangers, motors, and other components.

3
462 01 2103 01
RECEIVING AND INSTALLATION
STEP 1 — Check Equipment
Identify Unit
The unit model number and serial number are stamped on the unit
information plate. Check this information against shipping papers.
Inspect Shipment
Inspect for shipping damage before removing packaging materials.
If unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify the nearest
equipment distribution office if any item is missing. To prevent loss
or damage, leave all parts in original packages until installation.
STEP 2 — Provide Unit Support
IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit base
rails. When installing large base units onto the common curb, the
screws must be installed before allowing the full weight of the unit
to rest on the curb. A minimum of six screws are required for large
base units. Failure to secure unit properly could result in an
unstable unit. See Warning near Rigging/Lifting information and
accessory curb instructions for more details.
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate if required.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a water tight seal. Install gasketing material supplied with the
roof curb. Improperly applied gasketing also can result in air
leaks and poor unit performance.
Curb should be level to within 1/4 in. (6 mm). This is necessary
for unit drain to function properly. Refer to accessory roof curb
installation instructions for additional information as required.
Roof Curb
Install accessory roof curb in accordance with instructions shipped
with curb. See Fig. 5. Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
Accessory kits are available to aid in installing a new metal base
rail unit on an old roof curb.
Accessory kit number CPADCURB001A00, (small chassis) and
accessory kit number CPADCURB002A00, (large chassis)
includes roof curb adapter and gaskets for the perimeter seal
and duct openings. No additional modifications to curb are
required when using this kit.
Slab Mount
Place the unit on a solid, level concrete pad that is a minimum of 4”
(102mm) thick with 2” (51mm) above grade (see Figure 2). The slab
should extend approximately 2” beyond the casing on all 4 sides of
the unit. Do not secure the unit to the slab except when required by
local codes.
OPTIONAL
RETURN
AIR
OPENING
OPTIONAL
SUPPLY
AIR
OPENING
EVAP. COIL COND. COIL
2"
FIGURE 2 Slab Mounting Details
STEP 3 — Field Fabricate Ductwork
Secure all ducts to roof curb and building structure on vertical
discharge units. Do not connect ductwork to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secured to the flanges. Insulate
and weatherproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applicable
codes.
Ducts passing through an unconditioned space must be insulated
and covered with a vapor barrier.
If a plenum return is used on a vertical unit, the return should be
ducted through the roof deck to comply with applicable fire codes.
A minimum clearance is not required around ductwork. Cabinet
return−air static shall not exceed −.25 inches water column.

4462 01 2103 01
Unit
Electrical
Characteristics
Unit WT. Unit HT. Center of Gravity
LB KG A X Y Z
24040 208/230-1-60 419 189.9 44-3/4 1136.7 22-13/16 579.4 15-5/16 388.9 17-5/8 447.7
24060 208/230-1-60 426 193.1 44-3/4 1136.7 22-13/16 579.4 15-5/16 388.9 17-5/8 447.7
UNIT Voltage
Corner Weight LB/KG
1 2 3 4
24040 208/230 62.8 28.5 83.8 38.0 125.6 57.0 146.6 66.5
24060 208/230 63.6 28.9 84.8 38.5 127.1 57.7 148.3 67.3
FIGURE 3 Model Size 24 Dimensions

5
462 01 2103 01
Unit
Electrical
Characteristics
Unit WT. Unit HT. Center of Gravity
LB KG A X Y Z
36060 208/230-1-60 513 232.8 48-5/8 1235.1 22-13/16 579.4 18 457.2 16-5/8 422.3
36090 208/230-1-60 521 236.4 48-5/8 1235.1 22-13/16 579.4 18 457.2 16-5/8 422.3
48090 / 115 / 130 208/230-1-60 549 249.1 50-5/8 1285.9 22-13/16 579.4 18 457.2 17-5/8 447.7
60090 / 115 / 130 208/230-1-60 600 272.3 54-5/8 1387.5 22-13/16 579.4 18 457.2 18 457.2
Unit Voltage
Corner Weight LB/KG
1 2 3 4
36060 208/230 77.0 35.0 102.6 46.6 154.0 69.9 179.6 81.6
36090 208/230 78.2 35.5 104.2 47.3 156.4 71.0 182.4 82.8
48090 / 115 / 130 208/230 82.4 37.4 109.8 49.9 164.8 74.8 192.2 87.3
60090 / 115 / 130 208/230 90.0 40.9 120.0 54.5 180.1 81.8 210.1 95.4
FIGURE 4 Model Size 36−60 Dimensions
2

6462 01 2103 01
FIGURE 5 Roof Curb Dimensions
RETURN
AIR
SMALL
BASE
UNIT
SUPPLY
AIR
LARGE
BASE
UNIT
UNIT PLACEMENT ON
COMMON CURB
LARGE CURB SMALL OR LARGE BASE UNIT
SMALL/COMMON CURB
ROOF CURB DETAIL
Wood nailer*
(field supplied)
*Provided with roofcurb
Cant strip
field supplied
Roofing material
field supplied
Flashing field
supplied
HVAC unit
base rails
Roofcurb
Sealing
Gasket
HVAC unit
basepan
Anchor screw
C
B
AF
DE
Dashed lines show cross support
location for large basepan units.
G
H
C
B
A
F
D
E
G
H
field supplied
*
UNIT
SIZE
CATALOG
NUMBER
A
IN. (mm)
B
(small/common
base)
IN. (mm)*
B
(large base)
IN. (mm)*
C
IN. (mm)
D
IN. (mm)
E
IN. (mm)
F
IN. (mm)
G
IN. (mm)
H
IN. (mm)
Small
or
Large
CPRFCURB010A00 11 (279) 10 (254)
14 (356) 16 (406) 47.8
(1214)
32.4 (822)
2.7 (69)
30.6 (778)
46.1 (1170)
CPRFCURB011A00 14 (356)
Large CPRFCURB012A00 11 (279) 14 (356) 43.9
(1116)
42.2
(1072)
CPRFCURB013A00 14 (356)
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Roof curb is made of 16−gauge steel.
4. Attach ductwork to curb (flanges of duct rest on curb).
5. Insulated panels: 1−in. (25 mm) thick fiberglass 1 lb. density.

7
462 01 2103 01
STEP 4 — Provide Clearances
The required minimum operating and service clearances are
shown in Fig. 3 and 4. Adequate combustion, ventilation and
condenser air must be provided.
IMPORTANT: Do not restrict outdoor airflow. An air restriction at
either the outdoor−air inlet or the fan discharge may be
detrimental to compressor life.
The condenser fan pulls air through the condenser coil and
discharges it through the top grille. Be sure that the fan
discharge does not recirculate to the condenser coil. Do not
locate the unit in either a corner or under an overhead
obstruction. The minimum clearance under a partial overhang
(such as a normal house overhang) is 48−in. (1219 mm) above
the unit top. The maximum horizontal extension of a partial
overhang must not exceed 48−in. (1219 mm).
Do not place the unit where water, ice, or snow from an
overhang or roof will damage or flood the unit. Do not install the
unit on carpeting or other combustible materials. Slab−mounted
units should be at least 4 in. (102 mm) above the highest
expected water and runoff levels. Do not use unit if it has been
under water.
STEP 5 — Rig and Place Unit
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated structures,
etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the lifts to
adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting kit,
such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and
work gloves.
INSPECTION
Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Materials showing any kind
of wear in these areas must not be used and should be discarded.
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Never stand beneath rigged units or lift over people.
!WARNING
Rigging/Lifting of Unit
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
When straps are taut, the clevis should be a minimum of
36 in. (914 mm) above the unit top cover.
!WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Large base units must be secured to common curb
before allowing full weight of unit to rest on curb. Install
screws through curb into unit base rails while rigging
crane is still supporting unit.
!WARNING
Lifting holes are provided in base rails as shown in Fig. 3 and 4.
1. Leave top shipping skid on the unit for use as a spreader bar to
prevent the rigging straps from damaging the unit. If the skid is
not available, use a spreader bar of sufficient length to protect
the unit from damage.
2. Attach shackles, clevis pins, and straps to the base rails of the
unit. Be sure materials are rated to hold the weight of the unit
(See Fig. 6).
3. Attach a clevis of sufficient strength in the middle of the straps.
Adjust the clevis location to ensure unit is lifted level with the
ground.
After the unit is placed on the roof curb or mounting pad, remove
the top crating.

8462 01 2103 01
Cabinet MODEL NUMBER
Rigging Weight
lb kg
Small PG(D,S)524 431 196
Large
PG(D,S)536 530 240
PG(D,S)548 558 253
PG(D,S)560 609 276
FIGURE 6 Unit Corner Weight (lbs) and Rigging
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.
50CY502286 2.0
CAUTION - NOTICE TO RIGGERS
PRUDENCE - AVIS AUX MANIPULATEUR
Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition
SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB
DUCTS
DETAIL A
VOIR DÉTAIL A
MINIMUM HEIGHT: 36" (914.4 mm)
HAUTEUR MINIMUM
UNIT HEIGHT
HAUTEUR D'UNITÉ
SEE DETAIL A
VOIR DÉTAIL A
BANDE SCELLANT DOIT ÊTRE
EN PLACE AVANT DE PLACER
L'UNITÉ SUR LA BASE DE TOIT

9
462 01 2103 01
Table 1 −PHYSICAL DATA PG(D,S)524−36
UNIT SIZE 24040 24060 36060 36090
NOMINAL COOLING CAPACITY (ton) 2 2 3 3
NOMINAL HEATING CAPACITY (Btu) 40,000 60,000 60,000 90,000
SHIPPING WEIGHT (lb)
(kg)
426
193
431
196
522
237
530
240
COMPRESSORS
Quantity
2−Stage Scroll
1
REFRIGERANT: R−410A
Quantity (lb)
(kg)
10.1
4.6
10.1
4.6
9.5
4.3
9.5
4.3
REFRIGERANT METERING DEVICE TXV
Size 2 Ton 2 Ton 3 Ton 3 Ton
OUTDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
2...21
13.6
2...21
13.6
2...21
17.5
2...21
17.5
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
(mm)
Motor Hp (Rpm)
2700
22
559
1/8 (825)
2700
22
559
1/8 (825)
2800
22
559
1/8 (825)
2800
22
559
1/8 (825)
INDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
3...17
3.7
3...17
3.7
3...17
4.7
3...17
4.7
INDOOR FAN
Nominal Low Stage Cooling Airflow (Cfm)
Nominal High Stage Cooling Airflow (Cfm)
600
800
600
800
850
1200
850
1200
Size (in.)
(mm)
10x10
254x254
10x10
254x254
11x10
279x254
11x10
279x254
Motor HP (RPM) 1/2 1/2 3/4 3/4
FURNACE SECTION*
Burner Orifice No. (Qty...Drill Size)
Natural Gas 2...44 2...38 2...38 3...38
HIGH−PRESSURE SWITCH (psig) Cut−out
Reset (Auto) 670 ±10
470 ±25
HIGH−PRESSURE SWITCH 2 (psig)
(Compressor Solenoid)
Cut−out
Reset (Auto)
565 ±15
455 ±15
LOSS−OF−CHARGE /
LOW−PRESSURE SWITCH
(Liquid Line) (psig)
Cut−out
Reset (auto)
23 ±5
55 ±5
RETURN−AIR FILTERS Throwaway†
(in.)
(mm)
20x20x1
508x508x25
20x24x1
508x610x25
24x30x1
610x762x25
Continued next page.

10 462 01 2103 01
Table 2—Physical Data PG(D,S)548−60
UNIT SIZE 48090 48115 48130 60090 60115 60130
4 4 4 5 5 5
NOMINAL HEATING CAPACITY (Btu) 90,000 115,000 130,000 90,000 115,000 130,000
SHIPPING WEIGHT (lb)
(kg)
558
253
558
253
558
253
609
276
609
276
609
276
COMPRESSORS
Quantity
2−Stage Scroll
1
REFRIGERANT: R−410A
Quantity (lb)
(kg)
15.3
6.9
15.3
6.9
15.3
6.9
15.8
7.2
15.8
7.2
15.8
7.2
REFRIGERANT METERING DEVICE TXV
Size 4 Ton 4 Ton 4 Ton 5 Ton 5 Ton 5 Ton
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
(mm)
Motor Hp (Rpm)
3300
22
559
1/4 (1100)
3300
22
559
1/4 (1100)
3300
22
559
1/4 (1100)
3300
22
559
1/3 (1110)
3300
22
559
1/3 (1110)
3300
22
559
1/3 (1110)
OUTDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
2...21
19.4
2...21
19.4
2...21
19.4
2...21
23.3
2...21
23.3
2...21
23.3
INDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
3...17
5.7
3...17
5.7
3...17
5.7
4...17
5.7
4...17
5.7
4...17
5.7
INDOOR FAN
Nominal Low Stage Cooling Airflow (Cfm)
Nominal High Stage Cooling Airflow (Cfm)
1100
1600
1100
1600
1100
1600
1200
1750
1200
1750
1200
1750
Size (in.)
(mm)
11x10
279x254
11x10
279x254
11x10
279x254
11x10
279x254
11x10
279x254
11x10
279x254
Motor HP (RPM) 1 1 1 1 1 1
FURNACE SECTION*
Burner Orifice No. (Qty...Drill Size)
Natural Gas 3...38 3...33 3...31 3...38 3...33 3...31
HIGH−PRESSURE SWITCH (psig)
Cut−out
Reset (Auto)
670 ±10
470 ±25
HIGH−PRESSURE SWITCH 2 (psig)
(Compressor Solenoid)
Cut−out
Reset (Auto)
565 ±15
455 ±15
LOSS−OF−CHARGE /
LOW−PRESSURE SWITCH
(Liquid Line) (psig)
Cut−out
Reset (auto)
23 ±5
55 ±5
RETURN−AIR FILTERS Throwaway†(in.)
(mm)
24x36x1
610x914x25
*Based on altitude of 0 to 2000 ft (0 to 610 m).
Recommended filter sizes for field-installed air filter grilles mounted on the wall or ceiling of the conditioned structure. Required filter sizes shown are based on the larger
of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute for throwaway type or 450 ft/minute for
high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.

11
462 01 2103 01
STEP 6 — Connect Condensate Drain
NOTE: When installing condensate drain connection be sure to
comply with local codes and restrictions.
Unit disposes of condensate water through a 3/4 in. NPT fitting
which exits through the base on the evaporator coil access side.
See Fig. 3 & 4 for location.
Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations. Install a field−supplied 2−in. (51 mm)
condensate trap at the end of condensate connection to ensure
proper drainage. Make sure that the outlet of the trap is at least 1
in. (25 mm) lower than the drain−pan condensate connection to
prevent the pan from overflowing (See Fig. 7). Prime the trap
with water. When using a gravel apron, make sure it slopes away
from the unit.
Connect a drain tube using a minimum of 3/4−in. PVC or 3/4−in.
copper pipe (all field−supplied) at the outlet end of the 2−in. (51
mm) trap. Do not undersize the tube. Pitch the drain tube
downward at a slope of at least 1−in. (25 mm) for every 10 ft (3.1
m) of horizontal run. Be sure to check the drain tube for leaks.
TRAP
OUTLET
1-in. (25 mm) min.
2-in. (51 mm) min.
FIGURE 7 Condensate Trap
STEP 7 — Install Flue Hood
The flue assembly is secured and shipped in the return air duct.
Remove duct cover to locate the assembly (See Fig. 9).
NOTE:Dedicated low NOx models MUST be installed in
California Air Quality Management Districts where a Low NOx
rule exists.
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory.
NOTE:Low NOx requirements apply only to natural gas
installations.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
The venting system is designed to ensure proper venting. The
flue hood assembly must be installed as indicted in this section
of the unit installation instructions.
!WARNING
Install the flue hood as follows:
1. This installation must conform with local building codes
and with NFPA 54/ANSI Z223.1 National Fuel Gas Code
(NFGC), (in Canada, CAN/CGA B149.1, and B149.2)
latest revision. Refer to Provincial and local plumbing or
wastewater codes and other applicable local codes.
2. Remove flue hood from shipping location (inside the return
section of the blower compartment−see Fig. 9). Remove
the return duct cover to locate the flue hood. Place flue
hood assembly over flue panel. Orient screw holes in flue
hood with holes in the flue panel.
3. Secure flue hood to flue panel by inserting a single screw
on the top flange and the bottom flange of the hood.
Step 8 — Install Gas Piping
The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2−in.
(12.7 mm) FPT gas inlet on the gas valve.
Install a gas supply line that runs to the heating section. Refer to
the NFGC for gas pipe sizing. Do not use cast−iron pipe. It is
recommended that a black iron pipe is used. Check the local
utility for recommendations concerning existing lines. Size gas
supply piping for 0.5 in. wc maximum pressure drop. Never use
pipe smaller than the 1/2−in. (12.7 mm) FPT gas inlet on the unit
gas valve.
For natural gas applications, the gas pressure at unit gas
connection must not be less than 4.0 in. wc or greater than 13 in.
wc while the unit is operating. For propane applications, the gas
pressure must not be less than 11.0 in. wc or greater than 13 in.
wc at the unit connection.
A 1/8−in. (3.2 mm) NPT plugged tapping, accessible for test
gauge connection, must be installed immediately upstream of the
gas supply connection to the gas valve.
When installing the gas supply line, observe local codes
pertaining to gas pipe installations. Refer to the NFPA 54/ANSI
Z223.1 latest edition (in Canada, CAN/CGA B149.1).
NOTE:In the state of Massachusetts:
1. Gas supply connections MUST be performed by a
licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T−handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
In the absence of local building codes, adhere to the following
pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.
(6.35 mm) for every 15 ft (4.6 m) of length to prevent
traps. Grade all horizontal runs downward to risers. Use
risers to connect to heating section and to meter.
2. Protect all segments of piping system against physical and
thermal damage. Support all piping with appropriate
straps, hangers, etc. Use a minimum of one hanger every
6 ft (1.8 m). For pipe sizes larger than 1/2 in., follow
recommendations of national codes.
3. Apply joint compound (pipe dope) sparingly and only to
male threads of joint when making pipe connections. Use
only pipe dope that is resistant to action of liquefied
petroleum gases as specified by local and/or national
codes. Never use Teflon tape.
4. Install sediment trap in riser leading to heating section
(See Fig. 8). This drip leg functions as a trap for dirt and
condensate.
5. Install an accessible, external, manual main shutoff valve
in gas supply pipe within 6 ft (1.8 m) of heating section.
6. Install ground−joint union close to heating section between
unit manual shutoff and external manual main shut−off
valve.
7. Pressure test all gas piping in accordance with local and
national plumbing and gas codes before connecting piping
to unit.
8. Check for gas leaks at the field−installed and
factory−installed gas lines after all piping connections
have been completed. Use a commercially available soap
solution (or method specified by local codes and/or
regulations).

12 462 01 2103 01
Table 3—Maximum Gas Flow Capacity*
NOMINAL
IRON PIPE
SIZE (IN.)
INTERNAL
DIAMETER
(IN.)
LENGTH OF PIPE FT (m)†
10
(3)
20
(6)
30
(9)
40
(12)
50
(15)
60
(18)
70
(21)
80
(24)
90
(27)
100
(30)
125
(38)
150
(46)
175
(53)
200
(61)
1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 — —
3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72
11.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135
1−1/4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280
1−1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430
*Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5−in. wc (based on a 0.60 specific gravity gas). Refer to Table, National Fire
Protection Association NFPA 54.
This length includes an ordinary number of fittings.
OUT
TEE
NIPPLE
CAP
IN
FIGURE 8 Sediment Trap
NOTE: Pressure test the gas supply system after the gas supply
piping is connected to the gas valve. The supply piping must be
disconnected from the gas valve during the testing of the piping
systems when test pressure is in excess of 0.5 psig. Pressure
test the gas supply piping system at pressures equal to or less
than 0.5 psig. The unit heating section must be isolated from the
gas piping system by closing the external main manual shutoff
valve and slightly opening the ground−joint union.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
−Connect gas pipe to unit using a backup wrench to
avoid damaging gas controls.
−Never purge a gas line into a combustion chamber.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically
for the detection of leaks to check all connections.
−Use proper length of pipe to avoid stress on gas
control manifold.
−If a flexible connector is required or allowed by
authority having jurisdiction, black iron pipe shall be
installed at furnace gas valve and extend a minimum of
2 in. (51 mm) outside furnace casing.
−If codes allow a flexible connector, always use a new
connector. do not use a connector which has previously
serviced another gas appliance.
!WARNING
Step 9 — Install Duct Connections
The unit has duct flanges on the supply−and return−air openings
on the side and bottom of the unit. For downshot applications,
the ductwork connects to the roof curb (See Fig. 3 and 4 for
connection sizes and locations).
Configuring Units for Downflow (Vertical) Discharge
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off
main power to system and install lockout tag. There
may be more than one disconnect switch.
!WARNING
1. Open all electrical disconnects before starting any service
work.
2. Remove horizontal (metal) duct covers to access vertical
(downflow) discharge duct knockouts in unit basepan.
3. To remove downflow return and supply knockout covers,
break front and right side connecting tabs with a
screwdriver and hammer. Push cover down to break rear
and left side tabs.
FIGURE 9 Supply and Return Opening
Horizontal Duct Covers
Basepan
Downflow
(Vertical)
Supply
Knockout
Basepan
Downflow
(Vertical)
Return
Knockout

13
462 01 2103 01
NOTE:These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (Fig. 9)
shipped on unit from factory. Insure openings are air and
watertight.
NOTE:The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence−type air conditioning and ventilating systems,
NFPA 90A or residence−type, NFPA 90B; and/or local codes and
ordinances.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Units are shipped for horizontal duct installation (by
removing duct covers).
2. Select and size ductwork, supply−air registers, and
return−air grilles according to American Society of
Heating, Refrigeration and Air Conditioning Engineers
(ASHRAE) recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather−tight and airtight seal.
4. All units must have field−supplied filters or accessory filter
rack installed in the return−air side of the unit.
Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.
6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest
issue of Sheet Metal and Air Conditioning Contractors
National Association (SMACNA) and Air Conditioning
Contractors of America (ACCA) minimum installation
standards for heating and air conditioning systems.
Secure all ducts to building structure.
7. Flash, weatherproof, and vibration isolate all openings in
building structure in accordance with local codes and good
building practices.
STEP 10 — Install Electrical Connections
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
The unit cabinet must have an uninterrupted, unbroken
electrical ground. This ground may consist of an electrical wire
connected to the unit ground screw in the control compartment,
or conduit approved for electrical ground when installed in
accordance with NEC, ANSI/NFPA American National
Standards Institute/National Fire Protection Association (latest
edition) (in Canada, Canadian Electrical Code CSA C22.1) and
local electrical codes.
!WARNING
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the unit
being installed.
1. Make all electrical connections in accordance with NEC
ANSI/NFPA (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical connections
must be in accordance with CSA standard C22.1 Canadian
Electrical Code Part 1 and applicable local codes. Refer to
unit wiring diagram.
2. Use only copper conductor for connections between
field−supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high−voltage power to unit is within operating
voltage range indicated on unit rating plate. On 3−phase
units, ensure phases are balanced within 2 percent. Consult
local power company for correction of improper voltage
and/or phase imbalance.
4. Insulate low−voltage wires for highest voltage contained
within conduit when low−voltage control wires are in same
conduit as high−voltage wires.
5. Do not damage internal components when drilling through
any panel to mount electrical hardware, conduit, etc.
!CAUTION
High Voltage Connections
When routing power leads into unit, use only copper wire between
disconnect and unit. The high voltage leads should be in a conduit
until they enter the duct panel; conduit termination at the duct panel
must be watertight.
The unit must have a separate electrical service with a
field−supplied, waterproof disconnect switch mounted at, or within
sight from, the unit. Refer to the unit rating plate, NEC and local
codes for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.
The field−supplied disconnect switch box may be mounted on the
unit over the high−voltage inlet hole when the standard power and
low−voltage entry points are used (see Figures 3 and 4 for
acceptable location).
NOTE: Field supplied disconnect switch box should be
positioned so that it does not cover up any of the unit gas
combustion supply air louvers.
See unit wiring label (Figure 11) and Figure 10 for reference when
making high voltage connections. Proceed as follows to complete
the high−voltage connections to the unit.
Single−phase units:
1. Run the high−voltage (L1, L2) and ground lead into the control
box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line side of
the contactor.
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection 23 of the
compressor contactor.

14 462 01 2103 01
Special Procedures For 208 Volt Operation
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
Before installing or servicing system, always turn off main
power to system. with disconnect switch open, move black wire
from transformer (3/16” [4.8mm]) terminal marked 230 to
terminal marked 208. This re−taps transformer to primary
voltage of 208 VAC.
!WARNING
ELECTRICAL SHOCK FIRE/EXPLOSION HAZARD
Failure to follow this warning could result in personal injury or
death.
Before making any wiring changes, make sure the gas supply
is switched off first. Then switch off the power supply to the unit
and install lockout tag.
!WARNING
Control Voltage Connections
Do not use any type of power−stealing thermostat. Unit control
problems may result.
Use no. 18 American Wire Gage (AWG) color−coded, insulated
(35C minimum) wires to make the control voltage connections
between the thermostat and the unit. If the thermostat is located
more than 100 feet from the unit (as measured along the control
voltage wires), use no. 16 AWG color−coded, insulated (35C
minimum) wires.
Standard Connection
FIGURE 10 High and Control Voltage Connections
FIELD −SUPPLIED
FUSED DISCONNECT
POWER
SUPPLY
EQUIP GR
HIGH VOLTAGE
POWER LEADS
(SEE UNIT WIRING
LABEL)
CONTROL BOX
W2
Y1
Y2
G
R
C
Y1
Y2
G
R
C
()
()
()
()
()
()
WHT
YEL
PNK
GRN
RED
BRN
SPLICE BOX
LOW −VOLTAGE
POWER LEADS
(SEE UNIT
WIRING LABEL)
Thermostat
W1
Run the low−voltage leads from the thermostat, through the inlet
hole, and into unit low−voltage splice box.
Locate six 18−gage wires leaving control box. These low−voltage
connection leads can be identified by the colors red, green, yellow,
brown, pink, and white (see Figure 10). Ensure the leads are long
enough to be routed into the low−voltage splice box (located below
right side of control box). Route leads through hole in bottom of
control box and make low−voltage connections (see Figure 10).
Secure all cut wires so that they do not interfere with operation of
unit.
Heat Anticipator Setting
The room thermostat heat anticipator must be properly adjusted to
ensure proper heating performance. Set the heat anticipator, using
an ammeter between the W and R terminals to determine the exact
required setting.
NOTE: For thermostat selection purposes, use 0.18 amp for the
approximate anticipator setting. Failure to make a proper heat
anticipator adjustment will result in improper operation, discomfort
to the occupants of the conditioned space, and inefficient energy
utilization; however, the required setting may be changed slightly
to provide a greater degree of comfort for a particular installation.
Transformer Protection
The transformer is of the energy−limiting type, however a direct
short will likely blow a secondary fuse. If an overload or short is
present, correct overload condition and check for blown fuse on
Indoor Fan board or Integrated Gas Controller. Replace fuse as
required with correct size and rating.

15
462 01 2103 01
FIGURE 11 208/230−1−60 ALL UNITS
FIELD
SUPPLY
BK
CF
SCHEMATIC
208/230−1−60
SEE NOTE 5
0
G
ENERGIZED
T
G
DE−ENERGIZED
0
W
45
BR
T
W
T+45
BR
ENERGIZED DE−ENERGIZED
T+60
HEATING FAN LOGIC
COOLING FAN LOGIC
LEGEND
FIELD SPLICE
TERMINAL (MARKED)
TERMINAL (UNMARKED)
SPLICE
SPLICE (MARKED)
FACTORY WIRING
FIELD CONTROL WIRING
FIELD POWER WIRING
ACCESSORY OR OPTIONAL
WIRING
TO INDICATE COMMON
POTENTIAL ONLY:
NOT TO REPRESENT WIRING
BLR BLOWER RELAY
C CONTACTOR
COMP COMPRESSOR MOTOR
CR COMBUSTION RELAY
EQUIP EQUIPMENT
FS FLAME SENSOR
FU FUSE
GND GROUND
GVR GAS VALVE RELAY
HV TRAN HIGH VOLTAGE TRANSFORMER
I IGNITOR
IGC INTERGRATED GAS UNIT
CONTROLLER
IDM INDUCED DRAFT MOTOR
IFM INDOOR FAN MOTOR
LS1 PRIMARY LIMIT SWITCH
MGV MAIN GAS VALVE
OFM OUTDOOR FAN MOTOR
QT QUADRUPLE TERMINAL
RS ROLLOUT SWITCH
TRAN TRANSFORMER
EQUIP_GND
C
C1 C2
IDM
V
Y
BR
G/Y
CAP 2
QT
COMP
C
R
S
L2
L2
L2
L1
C
J2
W
IFO
G
R
RS
RS
LS
LS
CS
CS
GV
GV
C
IGC
GROUNDED
THRU STANDOFF
CM
BM
FS
RT
Y
BR
FS
LS1
RS
LS2
R
TRAN
24V
C
230
COM
MGV
MC
OFM
CAP1
Y
BR
C
11 21
23 23
BK
Y
BL
COMPRESSOR PLUG
Y
Y
BK
V
BK
Y
BL
BL
V
V
Y
GY
BR
G/Y
BR
Y/P BR
BK
BK
CCH
GRN
IF USED
NOTES:
1. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE
REPLACED, THEY MUST BE REPLACED WITH TYPE
90 DEG. C WIRE OR ITS EQUIVALENT.
2. SEE PRICE PAGES FOR THERMOSTAT AND SUBBASES.
3. USE 75 DEG. COPPER CONDUCTORS FOR FIELD
INSTALLATION.
4. SEE INSTALLATION INSTRUCTIONS
FOR PROPER HEATING AND COOLING CONNECTIONS
FOR YOUR UNIT. INDOOR FAN MOTOR PLUGS
−DO NOT DISCONNECT UNDER LOAD
5. ON SOME MODELS LS1 AND LS2 ARE WIRED IN SERIES.
ON OTHER MODELS ONLY LS1 USED.
6. INDUCER CAPACITOR AND WIRING ON CERTAIN MODELS ONLY.
IF CAP2 IS PRESENT, YELLOW WIRES FROM IGC AND IDM CONNECT
ON SAME SIDE OF CAP2.
7. THIS FUSE IS MANUFACTURED BY LITTLEFUSE, P/N 257003.
8. THIS FUSE IS MANUFACTURED BY LITTLEFUSE, P/N 257005.
H
L2
L1
SEE
NOTE 4
BL
P
R
O
BK
BK
BK
BK
Y
O
DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
CONNECTION WIRING DIAGRAM
Y
R
G
P
Y1
R
G
Y2
COLOR CODE
BK BLACK
BL BLUE
BR BROWN
GY GRAY
G GREEN
O ORANGE
P PINK
R RED
V VIOLET
W WHITE
Y YELLOW
I
BR C
Y
CAP 1 CAPACITOR, COMP
CAP 2 CAPACITOR, INDUCER PRS PRESSURE SWITCH
3
C
X5
W
4
R
24V
P2
1 2
HEAT
LOW
COOL
G4
Y1
R C
3 2 1
P1
COM
C
C
FUSE
COM
R
3A
24VAC
IFB
R
W
R
BR
IFM
GND
L2
L1
COM
124 35
BR
Y
BK
GY
LPS
HPS1
Y/P
BL/P
PRS
SEE
NOTE 6
GND
1
1
1
1
1
SEE NOTE 4
OO
IFB INDOOR FAN BOARD
LGPS LOW GAS PRESSURE SWITCH (WHEN USED)
LGPS (WHEN USED)
LS2 SECONDARY LIMIT SWITCH
T’STAT THERMOSTAT
BR
R
5A FUSE
SEE
NOTE 7
SEE NOTE 8
BL/P
Y2 5
WW
T’STAT
1
Y
COMP SOLENOID
HPS2
BK
R
R
BK
BK
R
R
2
1SOL
P3
208
HIGH
COOL

16 462 01 2103 01
Fig. 11 (Cont.) 208/230-1-60 All Units
SEE NOTE 4
Y
BL
BK
DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
LADDER WIRING DIAGRAM
48EZ500078
IFM
Y
VRV
Y
C
21
L1
208/230 VAC, 60 HZ, 1PH
CCH
IF USED
C
11
23
COMP
CR
S
OFM
CAP
H
F
C
23
R
C
S
FIELD SUPPLY
BK
Y
Y
Y
BK
BK BK
L2
BK
G/Y
BR
USE COPPER CONDUCTORS ONLY
GRN
11
G/Y
TRAN
208
230
24V
COM
C
BR
IDM
CAP2
CR CM
Y
G/Y
5A FUSER
FS
RS
RS
LS
LS
GV
R
G
W
BL BL
RS
LS1 LS2
MC
MGV
GY
BR
G/Y
L2
IGC
IGC
C
GV
C
CONT
C1 C2
BR
1
1
1
1
R
G
W
Y1
C
T’STAT
BK Y
V
BK
Y
BR
CS
CS
IFO
24VAC R
FUSE
3A
P2−1R
P1−1R
P1−4G
P2−5X
P1−6W
P2−3W
P2−4R
P1−3Y1
HPS1
BL/P
LPS
BL/P Y/P
Y
12 4
35
IFM
PRS
BL
O
BR
COM C
P2−2C
C
COM
P1−2C
L1
SEE NOTE 6
IFB
IFB
F
11
11
23
23
Y
IGC
IGC
Y
BR
GY
W
R
BK
R
OO
Y/P
BR
PR
BK
LGPS (WHEN USED)
FS
(SEE NOTE 5)
IFB
OFM
CONTROL BOX AREA
COMP
C
S
R
CAP 1
HCF
IFM
1 UNIT COMPONENT ARRANGEMENT
OUTDOOR FAN
SECTION
COMPRESSOR
SECTION
INDOOR FAN
SECTION
TRAN
C
21 23
2311
LS1
LS1
IGC
CAP 2
IDM
PRS
I
MGV
MC
FS
RS
GAS
SECTION
(SMALL
CABINET)
(LARGE)
LS2 (SMALL)
LPS
HPS
SEE NOTE 7
SEE NOTE 8
R
1
Y2
P1−5Y2
SOL
HPS2
BK RRBK
RR
BK
COMP
SOLENOID
1
2
P3
HEAT LOW
COOL
HIGH
COOL
R
G
W
Y
P

17
462 01 2103 01
PRE−STARTUP
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
1. Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
2. Do not operate compressor or provide any electric power to
unit unless compressor terminal cover is in place and
secured.
3. Do not remove compressor terminal cover until all electrical
sources are disconnected and tagged.
4. Relieve and recover all refrigerant from system before
touching or disturbing anything inside terminal box if
refrigerant leak is suspected around compressor terminals.
5. Never attempt to repair soldered connection while
refrigerant system is under pressure.
6. Do not use torch to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective goggles and
proceed as follows:
a. Shut off electrical power to unit and install lockout tag.
b. Relieve and reclaim all refrigerant from system using
both high−and low−pressure ports.
c. Cut component connecting tubing with tubing cutter
and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to torch
flame.
!WARNING
Use the Start−Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial
start−up:
1. Remove access panels. See Fig. 16)
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION labels attached to, or shipped
with unit.
3. Make the following inspections:
a. Inspect for shipping and handling damage, such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections and on
unit base. Detecting oil generally indicates a refrigerant
leak.
c. Leak−test all refrigerant tubing connections using
electronic leak detector, or liquid−soap solution. If a
refrigerant leak is detected, see following Check for
Refrigerant Leaks section.
d. Inspect all field−and factory−wiring connections. Be sure
that connections are completed and tight.
e. Ensure wires do not touch refrigerant tubing or sharp
sheet metal edges.
f. Inspect coil fins. If damaged during shipping and handling,
carefully straighten fins with a fin comb.
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
Do not purge gas supply into the combustion chamber. Do
not use a match or other open flame to check for gas leaks.
Use a commercially available soap solution made specifically
for the detection of leaks to check all connections.
!WARNING
4. Verify the following conditions:
a. Make sure gas line is free of air. Before lighting the
unit for the first time, perform the following with the
gas valve in the OFF position:
NOTE: If the gas supply pipe was not purged before connecting the
unit, it will be full of air. It is recommended that the ground joint union
be loosened, and the supply line be allowed to purge until the odor
of gas is detected. Never purge gas lines into a combustion
chamber. Immediately upon detection of gas odor, retighten the
union. Allow 5 minutes to elapse, then light unit.
b. Ensure fan hub is positioned correctly with respect
to motor housing.
c. Make sure that air filter(s) is in place.
d. Make sure that condensate drain trap is filled with
water to ensure proper drainage.
e. Make sure that all tools and miscellaneous loose
parts have been removed.
STARTUP
STEP 1 — Check for refrigerant leaks
Proceed as follows to locate and repair a refrigerant leak and to
charge the unit:
1. Locate leak and make sure that refrigerant system pressure
has been relieved and reclaimed from both high−and
low−pressure ports.
2. Repair leak following accepted practices.
NOTE: Install a filter drier whenever the system has been opened
for repair.
3. Add a small charge of R−410A refrigerant vapor to system and
leak−test unit.
4. Recover refrigerant from refrigerant system and evacuate to
500 microns if no additional leaks are found.
5. Charge unit with R−410A refrigerant, using an accurate scale.
Refer to unit rating plate for required charge.
STEP 2 — Start−up heating and make adjustments
Complete the required procedures given in the Pre−Start−Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Make sure that burner orifices are properly
aligned. Unstable operation my occur when the burner orifices in
the manifold are misaligned.
Follow the lighting instructions on the heating section operation
label (located inside of the control access panel) to start the heating
section.
NOTE: Make sure that gas supply has been purged and that all gas
piping has been checked for leaks.
Check Heating Control
Start and check the unit for proper heating control operation as
follows (see furnace lighting instructions located on the inside of the
control access panel):

18 462 01 2103 01
1. Place room thermostat SYSTEM switch in the HEAT position
and the fan switch in the AUTO position.
2. Set the heating temperature control of the thermostat above
room temperature.
3. The induced−draft motor will start.
4. On a call for heating, the main burner should light within 5
seconds of the sparker being energized. If the burners do not
light, there is a 22 second delay before another 5 second try. If
the burners still do not light, this sequence is repeated. If the
burners do not light within 15 minutes from the initial call for
heat, there is a lockout. To reset the control, break the 24−v
power to W.
5. The indoor (evaporator) fan motor will turn on 45 seconds after
the flame has been established. The indoor (evaporator) fan
motor will turn off 45 seconds after the thermostat has been
satisfied.
NOTE: The integrated gas unit controller (IGC) has the
capability to automatically reduce the indoor (evaporator) fan
motor “ON” delay and increase the indoor (evaporator) “OFF”
delay in the event of high duct static and/or partially−clogged
filter.
Check Gas Input
Check gas input and manifold pressure after unit start−up (see
Table 6). If adjustment is required, proceed as follows:
NOTE: The rated gas inputs shown in Table 6 are for altitudes
from sea level to 2000 feet above sea level. These inputs are
based on natural gas with a heating value of 1025 Btu/ft3at 0.6
specific gravity, or Propane with a heating value of 2500 Btu/ft3
at 1.5 specific gravity. When the gas supply being used has a
different heating value or specific gravity, refer to national and
local codes, or contact your distributor to determine the required
orifice size.
In the USA:
The input rating for altitudes above 2,000 feet must be reduced
by 4% for each 1,000 feet above see level.
(For installations below 2,000 feet, refer to the unit rating plate.)
For installations above 2,000 feet. multiply the input on the rating
plate by the de−rate multiplier in Table 4 for correct input rate.
If the natural gas is not derated by the gas utility company, refer
to Table 5 for correct orifice sizes and manifold pressures.
Table 4 −Altitude Derate Multiplier for U.S.A.
ALTITUDE FT (M)
PERCENT OF
DERATE
DERATE MULTIPLIER
FACTOR{
0−2000
(0−610) 0 1.00
2001−3000*
(610−914) 8−12 0.90
3001−4000
(915−1219) 12−16 0.86
4001−5000
(1220−1524) 16−20 0.82
5001−6000
(1524 −1829) 20−24 0.78
6001−7000
(1829−2134) 24−28 0.74
7001−8000
(2134−2438) 28−32 0.70
8001−9000
(2439−2743) 32−36 0.66
9001−10,000
(2744−3048) 36−40 0.62
* De−rate multiplier factors are based on midpoint altitude
for altitude range.
In Canada:
The input rating for altitudes from 2,000 to 4,500 feet above sea
level must be derated 10% by an authorized Gas Conversion
Station or Dealer.
Example:
90,000 BTU/hr Input Furnace Installed at 4300 feet:
Furnace Input
Rate at Sea Level XDe-rate
Multiplier =Furnace Input Rate at
Installation Altitude
90,000 X 0.90 = 81,000
UNIT DAMAGE HAZARD
Failure to follow this caution may result in reduced unit
and/or component life.
Do Not redrill an orifice. Improper drilling (burrs,
out−of−round holes, etc.) can cause excessive burner
noise and misdirection of burner flame. If orifice hole
appears damaged or it is suspected to have been
redrilled, check orifice hole with a numbered drill bit of
correct size.
!CAUTION
Table 5 −Natural Gas Orifice Sizes and Manifold Pressures
Nameplate Input
(Btu/hr)
ALTITUDE OF INSTALLATION (FT. ABOVE SEA LEVEL) U.S.A.*
0 to 2000
(0−610 m)
2001 to 3000*
(611 to 914 m)
3001 to 4000
(915 to 1219 m)
4001 to 5000
(1220 to 1524 m)
5001 to 6000
(1524 to 1829 m)
40000 Orifice No. (Qty) 44 (2) 45 (2)† 48 (2)† 48 (2)† 48 (2)†
Manifold Press. 3.2 3.2 3.8 3.5 3.2
60000 Orifice No. (Qty) 38 (2) 41 (2)† 41 (2)† 42 (2)† 42 (2)†
Manifold Press. 3.6 3.8 3.4 3.4 3.2
90000 Orifice No. (Qty) 38 (3) 41 (3)† 41 (3)† 42 (3)† 42 (3)†
Manifold Press. 3.6 3.8 3.4 3.4 3.2
115000 Orifice No. (Qty) 33 (3) 36 (3)† 36 (3)† 36 (3)† 38 (3)†
Manifold Press. 3.8 3.8 3.6 3.3 3.6
130000 Orifice No. (Qty) 31 (3) 31 (3) 33 (3)† 33 (3)† 34 (3)†
Manifold Press. 3.8 3.2 3.7 3.4 3.3
*In the U.S.A., the input rating for altitudes above 2000 ft (610m) must be reduced by 4% for each 1000 ft (305 m) above Sea level.
In Canada, the input rating for altitudes from 2001 to 4500 ft (611 to 1372 m) above sea level must be derated by 10% by an authorized gas conversion station or dealer.
For Canadian Installations from 2000 to 4500 ft, use U.S.A. column 2001 to 3000 ft.
Note: Orifice sizes and manifold pressure settings are based on natural gas with a heating value of 1025 Btu/ft3 amd a specific gravity of .6.
† Orifices available through your distributor.

19
462 01 2103 01
Adjust Gas Input
The gas input to the unit is determined by measuring the gas
flow at the meter or by measuring the manifold pressure.
Measuring the gas flow at the meter is recommended for natural
gas units. The manifold pressure must be measured to
determine the input of propane gas units.
Measure Gas Flow (Natural Gas Units)
Minor adjustment to the gas flow can be made by changing the
manifold pressure. The manifold pressure must be maintained
between 3.2 and 3.8 in. wc.
Burner Assembly
Pipe Plug Manifold
FIGURE 12
Gas Valve Components
REGULATOR
COVER SCREW
ADJUSTMENT
SCREW
REGULATOR SPRING
(PROPANE - WHITE)
NATURAL - SILVER)
GAS PRESSURE
REGULATOR
ADJUSTMENT
MANIFOLD
PRESSURE TAP
INLET
PRESSURE TAP
ON/OFF SWITCH
PLASTIC
(
FIGURE 13
Monoport Burner
MANIFOLD
BURNER
BURNER FLAME
FIGURE 14
If larger adjustments are required, change main burner orifices
following the recommendations of national and local codes.
NOTE: All other appliances that use the same meter must be turned
off when gas flow is measured at the meter.
Proceed as follows:
1. Turn off gas supply to unit.
2. Remove pipe plug on manifold (see Figure 12) and connect
manometer. Turn on gas supply to unit.
3. Record number of seconds for gas meter test dial to make one
revolution.
4. Divide number of seconds in Step 3 into 3600 (number of
seconds in one hour).
5. Multiply result of Step 4 by the number of ft3(cubic feet) shown
for one revolution of test dial to obtain ft3of gas flow per hour.
6. Multiply result of Step 5 by BTU heating value of gas to obtain
total measured input in BTU/h. Compare this value with
heating input shown in Table 6 (Consult the local gas supplier if
the heating value of gas is not known).
Example: Assume that the size of test dial is 1 ft3, one revolution
takes 32 seconds, and the heating value of the gas is 1050 BTU/ft3
. Proceed as follows:
1. 32 seconds to complete one revolution.
2. 3600 / 32 = 112.5.
3. 112.5 x 1 = 112.5 ft3of gas flow/hr.
4. 112.5 x 1050 = 118,125 BTU/h input.
If the desired gas input is 115,000 BTU/h, only a minor change in
the manifold pressure is required.
Observe manifold pressure and proceed as follows to adjust gas
input:
1. Remove cover screw over regulator adjustment screw on gas
valve (see Figure 13).
2. Turn regulator adjustment screw clockwise to increase gas
input, or turn regulator adjustment screw counterclockwise to
decrease input. Manifold pressure must be between 3.2 and
3.8 inches water column.
FIRE AND UNIT DAMAGE HAZARD
Failure to follow this warning could result in personal injury or
death and/or property damage.
Unsafe operation of the unit may result if manifold pressure is
outside this range.
!WARNING
3. Replace cover screw cap on gas valve.
4. Turn off gas supply to unit. Remove manometer from pressure
tap and replace pipe plug on gas valve. Turn on gas to unit and
check for leaks.
Measure Gas Flow (Propane Units)
Refer to Propane kit installation instructions for gas input
measurement procedure.
NOTE:For installations below 2,000 feet, refer to the unit rating
plate for proper Propane conversion kit part number. For
installations above 2,000 feet, contact your distributor for proper
Propane conversion kit.
Check Burner Flame
With control access panel removed (See Fig. 16), observe the unit
heating operation. Watch the burner flames to see if they are light
blue and soft in appearance, and that the flames are approximately
the same for each burner. Propane will have blue flame. Refer to
the Maintenance section for information on burner removal.

20 462 01 2103 01
Airflow and Temperature Rise
The heating section for each size unit is designed and approved for
heating operation within the temperature−rise range marked on the
unit rating plate.
Table 5 shows the approved temperature rise range for each
heating input, and the air delivery CFM at various temperature rises
for a given external static pressure. The heating operation airflow
must produce a temperature rise that falls within the approved
range.
Refer to Indoor Airflow and Airflow Adjustments section to adjust
heating airflow when required.
Heating Sequence of Operation
(see Figure 11, unit wiring label.)
On a call for heating, thermostat closes R to W, starting the
induced−draft motor. When the pressure switch senses that the
induced−draft motor is moving sufficient combustion air, the burner
sequence begins. This function is performed by the Integrated Gas
Control (IGC) board. The indoor (evaporator) fan motor is
energized 45 seconds after flame is established. When the
thermostat is satisfied and W is de−energized, the burners stop
firing and the indoor (evaporator) fan motor shuts off after a 45
second time−off delay.
NOTE: The integrated gas unit controller (IGC) has the capability
to automatically reduce the indoor (evaporator) fan motor “ON”
delay and increase the indoor (evaporator) “OFF” delay in the event
of high duct static and/or partially−clogged filter.
Table 6 −Heating Inputs
HEATING INPUT (BTU/h)
O
GAS SUPPLY PRESSURE
(inches water column) MANIFOLD PRESSURE
Natural Propane
NUMBER OF NaturalPropane *(inches water column)
NUMBER OF
ORIFICES Min Max Min Max NaturalPropane *†
40,000 38,000 2 4.0 13.0 11.0 13.0 3.2 −3.8 10.0 −11.0
60,000 53,000 2 4.0 13.0 11.0 13.0 3.2 −3.8 10.0 −11.0
90,000 79,000 3 4.0 13.0 11.0 13.0 3.2 −3.8 10.0 −11.0
115,000 103,000 3 4.0 13.0 11.0 13.0 3.2 −3.8 10.0 −11.0
130,000 116,000 3 4.0 13.0 11.0 13.0 3.2 −3.8 10.0 −11.0
* When unit is converted to Propane, different size orifices must be used. See separate, natural−to−Propane conversion kit instructions.
 Based on altitudes from sea level to 2000 feet above sea level. For altitudes above 2000 feet, reduce input rating 4 percent for each
additional 1000 feet above sea level. In Canada, from 2000 feet above sea level to 4500 feet above sea level, de−rate the unit 10
percent.
LED Monitor
An LED (light−emitting diode) indicator is provided on the
Integrated Gas Control board (IGC) to monitor operation. The IGC
is located by removing the control access panel. During normal
operation, the LED is continuously on (See Table 6 for error codes).
Limit Switches
Normally closed limit switch (LS) completes the control circuit. If the
supply air temperature rises above the maximum allowable
temperature, the limit switch opens and the control circuit “breaks.”
Any interruption in the control circuit instantly closes the gas valve
and stops gas flow to the burners. The blower motor continues to
run until LS resets.
When the air temperature at the limit switch drops to the
low−temperature setting of the limit switch, the switch closes and
completes the control circuit. The direct−spark ignition system
cycles and the unit returns to normal heating operation.
Rollout Switch
The function of the rollout switch is to close the main gas valve in
the event of flame rollout. The switch is located above the main
burners. When the temperature at the rollout switch reaches the
maximum allowable temperature, the control circuit trips, closing
the gas valve and stopping gas flow to the burners. The indoor
(evaporator) fan motor (IFM) and induced draft motor continue to
run until switch is reset. The IGC board is in a hard lockout and unit
will require power reset to remove the hard lockout function. The
IGC Board LED will display FAULT CODE 7.
When the air temperature at the limit switch drops to the
low−temperature setting of the limit switch, the switch closes and
completes the control circuit. The direct−spark ignition system
cycles and the unit returns to normal heating operation.
Table 7 −LED INDICATIONS
STATUS CODE LED INDICATION
Normal Operation2On
No Power or Hardware Failure Off
Limit Switch Fault 2 Flashes
Flame Sense Fault 3 Flashes
Four Consecutive Limit Switch Faults 4 Flashes
Ignition Lockout Fault 5 Flashes
Pressure Switch Fault 6 Flashes
Rollout Switch Fault 7 Flashes
Internal Control Fault 8 Flashes
Temporary 1 hr auto reset19 Flashes
NOTES:
1.This code indicates an internal processor fault that will reset
itself in one hr. Fault can be caused by stray RF signals in the
structure or nearby. This is a UL requirement.
2. LED indicates acceptable operation. Do not change ignition
control board.
3. When W is energized the burners will remain on for a
minimum of 60 sec.
4. If more than one error code exists they will be displayed on
the LED in sequence.
STEP 3 — Start−up cooling and make adjustments
Complete the required procedures given in the Pre−Start−Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Do not operate the compressor when the
outdoor temperature is below 40° F (4.4°C) (unless accessory
low−ambient kit is installed). Do not rapid−cycle the compressor.
Allow 5 minutes between on cycles to prevent compressor
damage.
Check Cooling Control Operation
Start and check the unit for proper cooling control operation as
follows:
1. Place room thermostat SYSTEM switch in OFF position.
Observe that blower motor starts when FAN switch is placed in
ON position and shuts down when FAN switch is placed in
AUTO position.
2. Place SYSTEM switch in COOL position and FAN switch in
AUTO position. Set desired temperature at least 10 degrees