Maytag iQ Drive R6GI User manual

20 SEER / 81% AFUE
Multi-Stage,Variable Speed, Inverter Driven System with Gas Heating / Electric Cooling
R6GI / PPG2GI
Premium Model Shown
INSTALLATION INSTRUCTIONS
DO NOT DESTROYTHIS MANUAL. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
FIRE OR EXPLOSION HAZARD
• Failuretofollowsafetywarningsexactlycould
result in serious injury or property damage.
• Installationandservicemustbeperformed
by a qualified installer,service agency or the
gas supplier.
•Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
ofthisoranyotherappliance.
WHAT TO DO IF YOU SMELL GAS
• Donottrytolightanyappliance.
• Donottouchanyelectricalswitch;donotuse
any phone in your building.
• Leavethebuildingimmediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• Ifyoucannotreachyourgassupplier,callthe
fire department.
RISQUE D’INCENDIE OU D’EXPLOSION
•Le non-respect des avertissements de
sécurité pourrait entraîner des blessures
graves,la mort ou des dommages matériels.
•L’installation et l’entretien doivent être
effectués par un installateur qualié, un
organismedeservice ou lefournisseurde
gazstaller,serviceagencyorthegassupplier.
•Nepasentreposerniutiliserdel’essenceni
d’autres vapeurs ou liquides inflammables
dans le voisinage de cet appareil, ni de tout
autre appareil.
QUE FAIRE S’ILY A UNE ODEUR DE GAZ
•Nepastenterd’allumeraucunappareil.
•Netoucheràaucuninterrupteurélectrique;
n’utiliser aucun téléphone dans le bâtiment.
•Évacuerl’immeubleimmédiatement.
•Appeler immédiatement le fournisseur de
gaz en employant le téléphone d’un voisin.
Respecter à la lettre les instructions du
fournisseurdegaz.
•Sipersonnenerépond,appelerleservicedes
incendies.
WARNING: AVERTISSEMENT

2
IMPORTANT SAFETY INFORMATION .......................3
REQUIREMENTS & CODES.......................................4
GENERAL INFORMATION..........................................5
BeforeYou Install this Unit.........................................5
Locating the Equipment.............................................5
Heating Load ............................................................5
COMBUSTION AIR &VENTING REQUIREMENTS ...6
General Information ..................................................7
Vent Termination .......................................................7
CIRCULATING AIR SUPPLY ......................................8
Air Ducts ...................................................................8
Air Filter Requirements .............................................8
Unconditioned Spaces ..............................................9
Acoustical Duct Work ................................................9
UNIT INSTALLATION ..................................................9
Packaging Removal...................................................9
Rigging & Hoisting.....................................................9
Clearances to Combustible Materials........................9
Ground Level.............................................................9
Rooftop......................................................................9
Horizontal to Downflow Conversion.........................10
Condensate Drain ..................................................10
ELECTRICALWIRING...............................................10
Pre - Electrical Checklist .........................................11
Grounding................................................................11
Line Voltage.............................................................11
Thermostat / Low Voltage Connections...................11
Heat / Cool Thermostat........................................12
Checking Heat Anticipator Settings......................12
Cooling Configurations............................................12
Heating Configurations............................................12
Configuring the Variable Speed Blower ..................13
Selecting Cooling Airflow.........................................13
Selecting Heating Airflow ........................................13
Optional Blower Control Connections .....................13
Dehumidification Control......................................13
Operation .............................................................13
GAS SUPPLY & PIPING............................................14
Leak Check .............................................................14
High Altitude Conversion.........................................15
LP/Propane Gas Conversion...................................15
STARTUP & ADJUSTMENTS ...................................17
Pre - Start Checklist................................................17
Start-up Procedure..................................................17
Air Circulation.......................................................17
System Cooling....................................................17
System Heating....................................................17
Verifying & Adjusting Temperature Rise..................17
Verifying & Adjusting Firing Rate.............................18
Verifying Over-Temperature Limit
Control Operation....................................................18
Verifying Burner Operation......................................18
Manifold Pressure Adjustment ................................18
OPERATING SEQUENCE .........................................19
Heating Mode..........................................................19
Cooling Mode..........................................................20
Delay Override ........................................................20
Fan Only Mode........................................................20
EQUIPMENT MAINTENANCE...................................20
Cleaning of Heat Exchanger ...................................21
Cleaning of Burners ................................................22
TROUBLESHOOTING-COOLING MODE .................24
Diagnostic Display...................................................24
Instrumentation .......................................................24
TROUBLESHOOTING-HEATING MODE ..................24
REPLACEMENT PARTS............................................25
HEATING COMPONENT FUNCTIONS.....................25
OPTIONAL FURNACE CONTROL
BOARD CONNECTIONS...........................................25
UNIT DIMENSIONS &WEIGHTS ..............................26
Figure 10. Unit Dimensions..................................26
Table 11. Center of Gravity & Shipping Weights...26
AIRFLOW DATA.........................................................27
Table 12. Nominal Airflow Rates & Temp Rises ...27
Table 13. Airflow Settings for Cooling...................27
Table 14. Airflow Settings for Heating...................27
GAS INFORMATION..................................................28
Table 15. Gas Pipe Capacities.............................28
Table 16. Gas Flow Rates....................................28
Figure 11. Gas Valve Label..................................29
ELECTRICAL INFORMATION...................................30
Figure 12.VSHE Blower Control Board ..............30
Figure 13.Two-Stage, Hot Surface Ignition &
Blower Control Board .........................30
Figure 14. Interface Board ...................................31
Table 17. Interface Board Operating Codes ........31
Figure 15. R6GI Inverter ......................................32
Figure 16. R6GI Typ. Heat Exchanger Assy ........33
Figure 17.Wiring Diagram (2,3, & 4 Ton) ............34
Figure 18.Wiring Diagram (5 Ton) .......................35
REFRIGERANT CHARGING.....................................36
Alternate Procedure for Charging Air Conditioner
in Cooling Mode ......................................................36
Application Notes on the use of Charging Charts...36
Figure 19. Charging Chart for 2Ton Units............37
Figure 20. Charging Chart for 3Ton Units............37
Figure 21. Charging Chart for 4Ton Units............38
Figure 22. Charging Chart for 5Ton Units............38
Figure 23.Temperature Resistance Charts..........39
INSTALLATION / PERFORMANCE CHECKLIST.....40
TABLE OF CONTENTS

3
IMPORTANT SAFETY INFORMATION
Pleasereadallinstructionsbeforeservicingthisequipment.
Pay attention to all safety warnings and any other special
notes highlighted in the manual. Safety markings are
used frequently throughout this manual to designate a
degreeorlevelofseriousness and shouldnotbeignored.
WARNINGindicatesapotentiallyhazardoussituationthat
if not avoided, could result in personal injury or death.
CAUTIONindicatesapotentiallyhazardoussituationthat
if not avoided, may result in minor or moderate injury or
property damage.
WARNING:
PROPOSITION 65 WARNING: This product
contains fiberglass wool, a product known
to the state of California to cause cancer.
Disturbingtheinsulationofthisproductduring
installation,maintenance,orrepairwillexpose
you to fiberglass wool.
• Breathingthismaterialmaycauserespiratory
irritations or may cause lung cancer.
• Fiberglass wool may also cause eye
irritation, skin sensitization, or other allergic
responses in susceptible individuals.
• Always wear goggles, disposable gloves,
longsleevedshirt,andappropriatebreathing
protectionwhenworkingnearthisinsulation.
Ifcontactwithskinoccurs,washimmediately
withsoapandwater.Incaseofcontactwith
eyes, ush immediately with water for at
least 15 minutes. Contact a physician if
needed.
WARNING:
Theinformationlistedbelowandonthenext
pagemustbefollowedduringtheinstallation,
service,andoperationofthisunit.Unqualied
individualsshouldnotattempttointerpretthese
instructions or install this equipment. Failure
tofollowsafetyrecommendationscouldresult
in possible damage to the equipment, serious
per sonal injury or death .
• Beforebeginningthe installation,verify thattheunit
model is correct for the job. The unit model number
is printed on the data label. Follow all precautions in
the literature, on tags, and on labels provided with
the equipment. Read and thoroughly understand
the instructions provided with the equipment prior to
performing the installation and operational checkout
of the equipment.
• Nevertest forgasleakswithan open ame. Use a
commercially available soap solution to check all
connections.See page 14.
• Installation of equipment may require brazing
operations. Installer must comply with safety codes
andwearappropriatesafetyequipment(safetyglasses,
work gloves, fire extinguisher, etc.) when performing
brazing operations.
• ThisequipmentisNOTtobeusedfortemporaryheating
of buildings or structures under construction.
WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failuretofollowsafetywarningsexactlycould
result in serious injury or property damage.
Improper servicing could result in dangerous
operation, serious injury, death or property
damage.
• Before servicing, disconnect all electrical
power to the unit.
• Whenservicingcontrols,labelallwiresprior
to disconnecting. Reconnect wires correctly.
• Verifyproperoperationafterservicing.
WARNING:
These units are fully charged with R-410A
refrigerant and ready for installation.When
a system is installed according to these
instructions, no refrigerant charging is
required. If repairs make it necessary for
evacuation and charging, it should only be
attempted by qualified, trained personnel
thoroughlyfamiliarwiththisequipment.Some
local codes require licensed installation
service personnel to service this type of
equipment.Undernocircumstancesshouldthe
homeowner attempt to install and/or service
this equipment. Failure to comply with this
warning could result in equipment damage,
personal injury, or death.
WARNING:
Donotplacecombustiblematerialonoragainst
the unit cabinet. Do not place combustible
materials, including gasoline and any other
flammable vapors and liquids, in the vicinity
oftheunit.

4
• Usecautionwhenhandlingthisapplianceorremoving
components. Personal injury can occur from sharp
metal edges present in all sheet metal constructed
equipment.
• Theinstallershouldbecomefamiliarwiththeunitswiring
diagram before making any electrical connections to
the unit. See the unit wiring label or Figures 17 & 18
(pages 34 & 35).
REQUIREMENTS & CODES
• Thisequipmentmustbeinstalledinaccordancewith
instructions outlined in this manual,all applicable
localbuildingcodes,andthecurrentrevisionof
the National Fuel Gas Code (NFPA54/ANSI Z223.1)
or the Natural Gas and Propane Installation Code,
CAN/CGA B149.1.
• Allelectricalwiringmustbecompletedinaccordance
with local, state and national codes and regulations
and with the National Electric Code (ANSI/NFPA 70)
or in Canada the Canadian Electric Code Part 1 CSA
C.22.1.
• The installer must comply with all local codes and
regulations which govern the installation of this type
of equipment. Local codes and regulations take
precedence over any recommendations contained in
theseinstructions.Consultlocalbuildingcodesandthe
NationalElectricalCode(ANSICI)forspecialinstallation
requirements.
• Thisequipmentcontainsliquidandgaseousrefrigerant
underhighpressure.Installationorservicingshouldonly
beperformedbyqualifiedtrainedpersonnelthoroughly
familiar with this type equipment.
• Air Ducts must be installed in accordance with the
standards of the National Fire Protection Association
“Standards for Installation of Air Conditioning and
Ventilation Systems” (NFPA 90A), “Standard for
InstallationofResidenceTypeWarmAirHeatingandAir
ConditioningSystems”(NFPA90B),theseinstructions,
and all applicable local codes.
• ConsultTables12-14(page27),andtheratingplate
for the proper circulating air flow and temperature rise.
It is important that the duct system be designed to
provide the correct flow rates and external pressure
rise. An improperly designed duct system can result
in nuisance shutdowns, and comfort or noise issues.
• Thisunitisdesignedforoutdoorinstallationsonlyand
should be located in a position as shown on page 5.
• Useonlywiththetypeofgasapprovedforthisunit.
Refer to the unit rating plate.
• Provideadequatecombustionandventilationairtothe
unit. See pages 6 & 7.
• Provideadequateclearancesaroundthecombustion
air intake louvers. See Figure 1 (page 5).
• Combustion products must be discharged outdoors.
Connect this unit to an approved vent system only, as
specified on page 7.
• Additionalcodeslistedbelowareforreferencepurposes
only and do not necessarily have jurisdiction over
local or state codes.Local codes and regulations take
precedence over any recommendations contained in
theseinstructions.Alwaysconsultwithlocalauthorities
before installing any gas appliance.
Combustion &Ventilation Air
• US: National Fuel Gas Code (NFGC), Air for
Combustion and Ventilation
• CANADA: Natural Gas and Propane Installation
Codes (NSCNGPIC), Venting Systems and Air
Supply for Appliances
Duct Systems
• US and CANADA: Air Conditioning Contractors
Association (ACCA) Manual Q, Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers
(ASHRAE) Fundamentals Handbook
Electrical Connections
• US:NationalElectricalCode(NEC)ANSI/NFPA70
• CANADA:CanadianElectricalCodeCSAC22.1
Gas Piping & Gas Pipe PressureTesting
• US:NFGCandNationalPlumbingCodes
• CANADA:NSCNGPIC
General Installation
• US:CurrenteditionoftheNFGCandtheNFPA90B.
For copies, contact the National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA
02269;orAmericanGasAssociation,400N.Capitol,
N.W., Washington DC 20001 or www.NFPA.org.
• CANADA:NSCNGPIC.Foracopy,contactStandard
Sales, CSA International, 178 Rexdale Boulevard,
Etobicoke (Toronto), Ontario, M9W 1R3 Canada
Safety
• US:(NFGC)NFPA54–1999/ANSIZ223.1andthe
Installation Standards, Warm Air Heating and Air
Conditioning Systems ANSI/NFPA 90B.
• CANADA:CAN/CGA-B149.1–and.2–M00National
Standard of Canada. (NSCNGPIC)

5
GENERAL INFORMATION
ThisSingle PackageGas Heating / ElectricCooling Units
are designed only for outdoor rooftop or ground level
installations and can be readily connected to the duct
system of a home.This unit has been tested for capacity
and efficiency in accordance with AHRI Standards and
will provide many years of safe and dependable comfort,
providing it is properly installed and maintained. With
regular maintenance, this unit will operate satisfactorily
year after year. Abuse, improper use, and/or improper
maintenance can shorten the life of the appliance and
create unsafe hazards.
Toachieveoptimumperformanceandminimizeequipment
failure, it is recommended that periodic maintenance be
performed on this unit. The ability to properly perform
maintenance on this equipment requires certain tools
and mechanical skills.
Beforeyouinstallthisunit
√Thecooling load of theareato be conditioned mustbe
calculatedandasystemofthepropercapacityselected.
It is recommended that the area to be conditioned be
completely insulated and vapor sealed.
√Checktheelectricalsupplyandverifythepowersupply
isadequateforunitoperation.Considerationshouldbe
given to availability of electric power, service access,
noise, and shade. If there is any question concerning
the power supply, contact the local power company.
√Allunitsaresecurelypackedatthetimeofshipmentand
upon arrival should be carefully inspected for damage
prior to installing the equipment at the job site.Verify
coil fins are straight.If necessary, comb fins to remove
flattened or bent fins.Claims for damage (apparent or
concealed)shouldbefiledimmediatelywiththecarrier.
√Pleaseconsultyourdealerformaintenanceinformation
and availability of maintenance contracts. Read all
instructions before installing the unit.
Locating the Equipment
• Surveythejobsitetodeterminethebestlocationfor
the packaged unit. The unit should be located with
consideration of minimizing the length of the supply
andreturnducts.Considerationshouldalsobegivento
theaccessibilityoffuel,electricpower,serviceaccess,
noise, and shade.
• Selectasolid,levelposition,preferablyonaconcrete
slab, slightly above the grade level, and parallel to the
home. DO NOT PLACE UNIT UNDERTHE HOME.
• Overheadobstructions,poorly ventilatedareas,and
areas subject to accumulation of debris should be
avoided. Do not place the unit in a confined space or
recessed area where discharge air from the unit could
re-circulate back through the condenser coil.
• Sufcientclearanceforunobstructedairowthroughthe
louvered control access panel and outdoor coil must
be maintained in order to achieve rated performance.
See Figure 1 for minimum clearance requirements.
• Aclearanceofatleast36inchesfromthebloweraccess
panel and from the louvered control access panel is
recommended for servicing and maintenance.
Where accessibility clearances are greater
than clearances to combustibles, accessibility
clearancesmusttakepreference.
• Thehotcondenserairmustbedischargedupandaway
from the home.
• Ifpractical,placetheairconditioneranditsductsin
an area where they will be shaded from the afternoon
sun, when the heat load is greatest.
Heating Load
This unit should be sized to provide the design heating
load requirement. Heating load estimates can be made
using approved methods available from Air Conditioning
Contractors of America (Manual J); American Society of
Heating, Refrigerating, and Air Conditioning Engineers;
orother approvedengineeringmethods.Forinstallations
above 2,000 ft., the unit should have a sea level input
rating large enough that it will meet the heating load after
deration for altitude.
Minimum Required
Clearances to Combustibles
36"
36"
36"
TOP OF UNIT
TO BE
UNOBSTRUCTED
6"
Figure 1. Clearance Requirements

6
WARNING:
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for
each appliance connected to the venting system
beingplacedinto operationcould resultin carbon
monoxidepoisoningordeath.Thefollowingsteps
shallbefollowedwitheachindividualappliance
connected to the venting system being placed in
operation,whileallotherappliances connected to
the venting system are not in operation:
1.Seal any unused openings in the venting
system.
2.Inspecttheventingsystemforpropersizeand
horizontalpitch,asrequiredintheNationalFuel
Gas Code, ANSI Z223.1/NFPA 54 or the CSA
B149.1, Natural Gas and Propane Installation
Codes and these instructions. Determine that
there is no blockage or restriction, leakage,
corrosion and other deficiencies which could
causeanunsafecondition.
3.Asfaraspractical,closeallbuildingdoorsand
windows and all doors between the space in
whichtheappliance(s)connectedtotheventing
system are located and other spaces of the
building.
4.Close fireplace dampers.
5.Turn on clothes dryers and any appliance
not connected to the venting system.Turn on
anyexhaustfans,suchas range hoodsand
bathroomexhausts,sotheyareoperatingat
maximum speed. Do not operate a summer
exhaustfan.
6.Follow the lighting instructions. Place the
appliance being inspected into operation.
Adjustthethermostatsoapplianceisoperating
continuously.
7.Test for spillage from draft hood equipped
appliances at the draft hood relief opening
after5minutesofmainburneroperation.Use
theameofamatchorcandle.
8.Ifimproperventingisobservedduringanyof
the above tests, the venting system must be
correctedinaccordancewiththe NationalFuel
Gas Code, ANSI Z223.1/NFPA 54 and/or CSA
B149.1, Natural Gas and Propane Installation
Codes.
9.Afterithasbeendeterminedthateachappliance
connectedtotheventingsystemproperlyvents
when tested as outlined above, return doors,
windows,exhaustfans,replacedampersand
any other gas-fired burning appliance to their
previousconditionsofuse.
AVERTISSEMENT:
RISQUE D’EMPOISONNEMENT AU
MONOXYDE DE CARBONED
Le non-respect des consignes suivantes portant
sur chacun des appareils raccordés au système
d’évacuation mis en service pourrait entraîner
l’empoisennement au monoxyde de carbone ou
la mort. Les consignes suivantes doivent être
observéespourchaqueappareilraccordéausystème
d’évacuation mis en service si les autres appareils
raccordés au système ne sont pas en service:
1.Scellertouteouverturenonutiliséedelasystéme
d’évacuation;
2.S’assurer que la systéme d’évacuation présente
des dimensions et une pente horizontale
conformes à la norme ANSI Z223.1/NFPA
54, intitulée National Fuel Gas Code ou aux
codes d’installation CSA-B149.1, ainsi qu’aux
présentesinstructions.S’assurerquelasystéme
d’évacuation n’est pas bloquée, restreinte,
corrodée,qu’ellenefuitpasetqu’elleneprésente
aucunautredéfautpotentiellementdangereux;
3.Danslamesuredupossible,fermertoutesles
portesetfenêtresdubâtiment,ettouteslesportes
entrelapièceoùsetrouvel’appareilraccordéà
la systéme d’évacuation et les autres pièces du
bâtiment.
4.Fermerlesregistresdesfoyers;
5.Mettre en service les sécheuses et tout autre
appareil qui n’est pas raccordé à la systéme
d’évacuation.Fairefonctionneràrégimemaximal
toutventilateurd’évacuation,telqueleshottesde
cuisinière et les ventilateurs de salles de bains.
Ne pas mettre en service les ventilateurs d’été.
6.Respecterles instructionsd’allumage.Mettreen
servicel’appareilàl’essai.Réglerlethermostat
demanièreàcequel’appareilfonctionnesans
interruption;
7.Vérifier s’il y a débordement à l’orifice
d’évacuationducoupetiragedesappareilsdotés
d’un coupe tirage 5 minutes après l’allumage
du brûleur principal. Utiliser la flamme d’une
allumette ou d’une chandelle.
8.Si l’on constate, au cours de l’un des essais
qui précèdent, que l’évacuation est déficiente,
corrigerlesystèmed’évacuationconformément
àlanormANSIZ223.1/NFPA54,NationalFuel
GasCode,et(ou)auxcodesd’installationCSA
B149.1.
9.Après avoir déterminé que tous les appareils
raccordésàlasystémed’évacuationévacuent
correctement tel que prescrit ci-dessus,
rouvrirlesportesetlesfenêtresetremettreles
ventilateursd’évacuation,lesregistresdefoyers
ettoutautreappareilfonctionnantaugazàleur
étatdefonctionnementinitial.
COMBUSTION AIR &VENTING REQUIREMENTS

7
VentTermination
This unit has been equipped with an integral venting
system and designed to operate only with this venting
system. No additional venting shall be used. This unit
must be vented to the outdoors.
WARNING:
Thisunitisintended foroutdoorinstallation
only.Donotventtheunitthroughaconventional
venting system.
A vent cover assembly has been supplied with the unit
and can be found secured to the gas controls within
the control area of this unit. Figure 2 shows the proper
installationoftheventcoverassemblyovertheventoutlet
on the exterior of the corner panel.The fasteners used to
secure the vent cover assembly have been included in
the owner’s package. The vent cover assembly must
beinstalledtoassureproperoperationoftheunit.
The following list summarizes the requirements for the
locationoftheventsystemtermination:
• Thelocationoftheventterminationmustbeconsistent
with the National Fuel Gas Code (ANSI Z223.1) or
CAN/CGA-B149 Installation Codes.
• Theventterminationmustbelocatedatleast4feet
horizontally from any electric meters, gas meters,
regulators, and relief equipment.
• Theventterminationmustbelocatedatleast3feet
above any forced air inlet located within 10 feet.
• Theventterminationmustbelocatedatleast4feet
below, 4 feet horizontally from, or 1 foot above any
door, window, or gravity air inlet into any building.
• Theventterminationmustbelocatedatleast1foot
above grade.
• Theunitshouldbeinstalledinawaythatpreventsany
obstructionoftheventterminationduringaccumulating
snow.
GeneralInformation
WARNING:
Installationmethodsotherthanthosedescribed
inthefollowingsectionsmustcomplywiththe
NationalFuelGasCodeandallapplicablelocal
codesforprovidingsufcientcombustionair
tothefurnace.
Provisions must be made during the installation of this
unitthatprovideanadequatesupplyofairforcombustion.
• Instructions for determining the adequacy of an
installation can be found in the current revision of the
NFGC(ANSIZ223.1/NFPA54).Consult local codes
forspecialrequirements.Theserequirementsarefor
US installations as found in the NFGC.
• TherequirementsinCanada(B149.1)arestructured
differently.Consult with B149.1and localcode officials
for Canadian installations.
WARNING:
Combustion air must not be drawn from a
contaminatedatmosphere.Excessiveexposure
to contaminated combustion air will result in
safetyandperformancerelatedproblems.
To maximize heat exchanger life, the combustion air
must be free of chemicals that can form corrosive acidic
compoundsin the combustiongases.The recommended
source of combustion air is to use clean air from outside.
DONOTplaceanychemicalswithflammableorcaustic
vapors or these other corrosive chemicals near the
vent termination:
• Gasoline/Kerosene
• Permanentwavesolutions
• Chlorinatedwaxesandcleaners
• Chlorinebasedswimmingpoolchemicals
• Watersofteningchemicals
• De-icingsaltsorchemicals
• Carbontetrachloride
• Halogentyperefrigerants
• Cleaningsolvents
• Cements,glues,paintremovers,varnishes,etc.
• Hydrochloricacid
• Masonryacidwashingmaterials
• PlumbingStack
Airopeningsinthedooroftheunit,warmairregisters,and
return air grilles must never be restricted.If the unit does
not receive an adequate supply of air for combustion, the
flameroll-outcontrollocatedabovethe burners willopen,
turningoffthegassupplytotheburners.Thissafetydevice
is a manually reset switch.
IMPORTANTNOTE:DONOTinstalljumperwiresacross
thiscontroltodefeatitsfunctionorresetthecontrol
withoutidentifyingandcorrectingthefaultcondition.
Ifthiscontrolmustbereplaced,useonlyfactoryauthorized
replacement parts. See the Replacement Parts List on
page 25.
Figure 2.Vent Assembly

8
CIRCULATING AIR SUPPLY
WARNING:
Do not allow combustion products to enter the
returnairductworkorthecirculatingairsupply.
Failuretopreventthecirculationofcombustion
products into the living space can create
potentially hazardous conditions including
carbonmonoxidepoisoningthatcouldresult
in personal injury or death.
Allreturnductworkmustbe securedto theunit
with sheet metal screws. All return ductwork
must be adequately sealed and all joints must
be taped.When return air is provided through
thebottomoftheunit,thejointbetweenthe
unit and the return air plenum must be air tight.
Theroofcurborcementpadonwhichtheunitis
mountedmustprovidesoundphysicalsupport
of the unit with no gaps, cracks, or sagging
between the unit and the curb or pad.
Returnairandcirculatingairductworkmustnot
beconnectedtoanyotherheatproducingdevice
such as a fireplace insert, stove, etc. Doing so
mayresultinre,explosion,carbonmonoxide
poisoning,personalinjury,orpropertydamage.
Air Ducts
Thisunitisdesignedonlyforusewithasupplyand return
duct.Air ducts should be installed in accordance with the
standards of the National Fire Protection Association
“Standard for Installation of Air Conditioning Systems”
(NFPA 90A),“StandardforInstallation of ResidenceType
Warm Air Heating and Air Conditioning Systems” (NFPA
90B),andallapplicablelocalcodes.NFPApublicationsare
availablebywritingto:NationalFireProtectionAssociation,
BatterymarchPark,Quincy,ME02269orvisitwww.NFPA.
org on the web.
• DesigntheductworkaccordingtoManualDbytheAir
Conditioning Contractors of America (ACCA).
• Theductsmustbeproperlysizednottoexceedthe
unit maximum ESP rating at 400 scfm per nominal ton
of cooling capacity.
• Ductworkshouldbeattacheddirectlytotheunitanges
for horizontal applications.
• Ifroofcurbisinstalled,theductsmustbeattachedto
the curb hangers, not the unit.
• It is recommended that the outlet duct be provided
with a removable access panel. The opening should
be accessible when the unit is installed in service and
shall be sized so that smoke or reflected light may be
observed inside the casing to indicate the presence of
leaks in the heat exchanger.The cover for the opening
shall be attached in a way that will prevent leaks.
• If outside air is utilized as return air to the unit for
ventilation or to improve indoor air quality, the system
must be designed so that the return air to the unit is
not less than 50° F (10° C) during heating operation.
• Ifacombinationofindoorandoutdoorairisused,the
ductsanddampersystemmustbedesignedsothatthe
return air supply to the furnace is equal to the return
airsupply under normal, indoor return airapplications.
Air Filter Requirements
WARNING:
Never operate the unit without a filter in place.
Dust and lint could accumulate on internal
parts,resultinginlossofefciency,equipment
damage and possible fire.
• Thisunitisnotsuppliedwithairlter(s)andhasno
factory equipped means for accommodating internal
filter(s).A suitable air filter must be installed upstream
of the evaporator coil of the return air system.Refer to
Table 1 for recommended filter sizes.
• Allreturnairmustpassthroughtheltersbeforeentering
the evaporator coil. It is important that all filters be
kept clean and replaced frequently to ensure proper
operationof unit.Dirty or clogged filterswill reducethe
efficiency of the unit and result in unit shutdowns.
• Airlterpressuredropmustnotexceed0.08inchesWC.
• HorizontalanddownowInstallationsrequiretheair
filter system be installed in the return air ductwork.
NOTE TOINSTALLER:Afterinstallingorreplacingthe
filtrationsystemforthisunit,addthefollowingstatement
on or adjacent to the lter service panel: “Replace
filter(s)installedinyoursystemonlywiththesame
dimensional size filters that are being replaced.”
Table 1. Air Filter Requirements
Nominal
Cooling
(Tons)
Approximate
Air Flow
Range (CFM)
Approximate
Filter Area
(Sq. In.)*
Recommended
Filter Size
(In.xIn.)
2 700 - 900 450 20 x 25
3 1,000 - 1,300 625 25 x 25
4 1,500 - 1,900 915 18 x 25 (2 required)
5 1,600 - 2,000 975 20 x 25 (2 required)
* Based on velocity of 300 ft/min for disposable filters.
• Theunitinstallationshallavoidareaswherecondensate
drainagemaycauseproblemsbydroppingonplanters
or patios, etc. Also verify exhaust gases will not
impinge on windows or building surfaces, which may
be compromised or damaged by condensation.
• Donotinstalltheunitsuchthatexhaustfromthevent
termination is directed into window wells, stairwells,
under decks, or in alcoves or similarly recessed areas.
The vent termination must not be located above any
public walkways.

9
• Ifusingbottomdischargewithreturnairductsaroof
curb must be installed prior to unit installation. See
Rigging and Hoisting section for setting of the unit.
• Sufcientclearanceforunobstructedairowthrough
the outdoor coil must also be maintained in order to
achieveratedperformance.Seepage5forinformation
about locating the equipment.
Ground Level
Ground level installations must be located according to
localbuildingcodesorordinancesandtheserequirements:
• Clearancesmustbeinaccordancewiththoseshown
in Figure 1 (page 5).
• Asuitablemountingpad(Figure3)mustbeprovided
andbe separate from the buildingfoundation.Thepad
must be level to ensure proper condensate disposal
and strong enough to support the unit’s weight. The
slabheightmustbeaminimumof2”(5cm)abovegrade
and with adequate drainage.
• RemoveanddiscardthehorizontalSupplyandReturn
duct covers located on the rear of the unit.Form duct
attachmentflangesbybendingthesheetmetaloutward
90 degrees along the perforated lines.
• Firmlyattachductworkdirectlytotheseangeswith
screwsorotherapprovedmechanicalconnectionsand
nottotheSupply/Returnairpanelstoavoiddamageto
internalcomponentsoftheequipment.Oncecompleted
use approved duct sealing methods to ensure an air
and watertight seal is achieved.
Rooftop
Rooftop installations must be located according to local
buildingcodesorordinancesandtheserequirements:
• Theroofmustbecapableofhandlingtheweightofthe
unit.Forunitweights,seeTable11(page26).Reinforce
the roof if necessary.
• Theappropriateaccessoryroofcurb(Figure4,page
10) must be installed prior to unit installation. The
roof curb must be square and level to ensure proper
condensate drainage.Pleasefollowallinstructions
provided with the kit.
• Secure roof curb or frame to roof using acceptable
mechanicalmethodsperlocalcodes.NOTE:Makesure
thetwosupportsbeneaththeunithavebeenremoved.
Unconditioned Spaces
All duct work passing through unconditioned space must
beproperlyinsulatedtominimizeductlossesandprevent
condensation.Use insulation with an outer vapor barrier.
Refer to local codes for insulation material requirements.
Acoustical DuctWork
Certain installations may require the use of acoustical
lining inside the supply duct work.
• Acoustical insulation must be in accordance with the
currentrevisionoftheSheetMetalandAirConditioning
ContractorsNationalAssociation(SMACNA)application
standard for duct liners.
• Ductlining mustbe UL classified batts orblanketswith
a fire hazard classification of FHC-25/50 or less.
• Fiber duct work may be used in place of internal duct
liners if the fiber duct work is in accordance with the
currentrevisionof theSMACNAconstructionstandard
on fibrous glass ducts.Fibrous duct work and internal
acousticallining must be NFPA Class 1air ducts when
tested per UL Standard 181 for Class 1 ducts.
UNIT INSTALLATION
Packaging Removal
Remove the shipping carton and User’s Manual from the
equipment. Take care not to damage the coil or cabinet
whenremovingthecarton.Forrooftopinstallations,remove
and discard the two supports attached beneath the unit.
Rigging & Hoisting
WARNING:
Toavoidtheriskofpropertydamage,personal
injury, or death, it is the rigger’s responsibility
toensurethatwhatevermeansareusedtohoist
theunitaresafeandadequate:
• Theliftingequipmentmustbe adequate for
theload.RefertoTable11(page26)forunit
weights.
• Theunitmustbeliftedfromtheholesinthe
base rails using cables or chains.
• Spreaderbarsarerequiredtoprotecttheunit
and ensure even loading.
• Keeptheunitinanuprightpositionatalltimes.
The rigging must be located outside the units
centerofgravity.RefertoFigures10&11(page
26)forlocatingthecenterofgravity.
• Allpanelsmustbesecurelyinplaceduring
rigging and hoisting.
Clearances to Combustible Materials
These units are certified as combination heating and
cooling equipment for outdoor rooftop or ground level
installations. Units may be installed on combustible
flooring or Class A, B, or C roofing material when used
with bottom supply and return air ducts as long as the
followingrequirementsaremet:
2”
Figure 3. Ground Level Installation

10
• Electrical connections must be in compliance with
all applicable local codes and ordinances, and with
the current revision of the National Electric Code
(ANSI/NFPA 70).
• ForCanadianinstallationstheelectricalconnections
and grounding shall comply with the current Canadian
Electrical Code (CSA C22.1 and/or local codes).
IMPORTANT NOTE: If replacing anyoftheoriginal
wires supplied with the furnace, the replacement
wire must be copper wiring having the same guage,
voltage, and temperature rating.
Horizontal to Downflow Conversion
Theunitisshipped ready forhorizontalductconnections.
Ifdownflowductsarerequired,theunitmustbeconverted
following the steps below for both the supply and return
ducts.
1.Remove both horizontal duct caps.
2.Locatetheductcapinsidetheductopeningsandremove
the screw holding it in place.
3.Liftthecapoutoftheunit.(Hint:Thecapcanbepushed
up from the bottom by reaching through the fork slot).
4.Cover the horizontal duct openings with the horizontal
duct caps removed earlier in step 1.The insulation will
be on the indoor side.
5.Fasten the cover with screws to seal.
6.Remove and discard the two wood supports beneath
the unit.
Condensate Drain
Condensate is removed from the unit through the 3/4”
female pipe fitting (Figure 5) located on the front side of
theunit.Installa2inchcondensatetrapinthedrainlineof
thesamesizeandprimewithwater.Whenconnectingrigid
drain line, hold the female fitting with a wrench to prevent
twisting. Do not over tighten! Refer to local codes and
restrictionsforpropercondensatedisposalrequirements.
ELECTRICAL SHOCK,FIRE OR EXPLOSION
HAZARD
Failuretofollowsafetywarningsexactlycould
result in serious injury or property damage.
Improper servicing could result in dangerous
operation, serious injury, death or property
damage.
• Before servicing, disconnect all electrical
powertofurnace.
• Whenservicingcontrols,labelallwiresprior
todisconnecting.Reconnectwirescorrectly.
• Verifyproperoperationafterservicing.
WARNING:
RISQUEDECHOCÉLECTRIQUE,D’INCENDIE
OU D’EXPLOSION
Le non-respect des avertissements de sécurité
pourraitentraîner
unfonctionnementdangereux
de l’appareil,
des blessures graves, la mort ou
des dommages matériels.
Un entretein incorrect pourrait entraîner un
fonctionnementdangereuxdel’appareil,des
blessures graves, la mort ou des dommages
matériels
• Couper toute alimentation électrique au
générateur d’air chaud avant de prodéder
auxtravauxd’entretein.
• Aumomentdel’entretiendescommandes,
étiquetez tous les fils avant de les
débrancher. S’assurer de les raccorder
correctement.
• S’assurer que l’appareil fonctionne
adéquatement aprés l’entretien.
AVERTISSEMENT:
ELECTRICALWIRING
Figure4.RoofTopInstallation
ACCESSORY
ROOF CURB
Figure 5. Condensate Drain & Service Ports
Condensate
Drain
High Pressure
Low Pressure