Nordyne iHybrid PDF2SF Series User manual
ATTENTION INSTALLERS:
It is your responsibility to know this product better than your customer. This includes being able to install the product according
to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product.
Safety should always be the deciding factor when installing this product and using common sense plays an important role as
well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the unit
or failure to follow safety warnings could result in serious injury, death, or property damage. These instructions are primarily
intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require
licensed installation/service personnel for this type of equipment. After completing the installation, return these instructions to
the customer’s package for future reference.
15 SEER / 8.0 HSPF / 80% AFUEDF6SF / PDF2SF - REV. A SERIES
Premium Model Shown
INSTALLATION INSTRUCTIONS
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
WHAT TO DO IF YOU SMELL GAS
WARNING:
FIRE OR EXPLOSION HAZARD
2
IMPORTANT SAFETY INFORMATION .......................3
.......................................4
GENERAL INFORMATION..........................................5
BeforeYou Install this Unit.........................................5
Locating the Equipment.............................................5
Heating Load ............................................................5
...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 .........................................10
Line Voltage.............................................................11
Thermostat / Low Voltage Connections...................11
2-Stage Heat / Cool T-stat Configuration..............11
Heating Configuration..............................................12
Heat Pump Defrost Mode ....................................12
Checking Heat Anticipator Settings......................12
Configuring the Variable Speed Blower ..................12
Selecting Cooling Airflow.....................................12
Selecting Gas Heating Airflow..............................13
Delay Profile.........................................................13
Demand Defrost Control..........................................13
Ambient Sensor Mounting.......................................13
Optional Humidistat.................................................13
Optional Comfort AlertTM Diagnostics Module.........14
24VAC Power Wiring............................................14
Thermostat Demand Wiring.................................14
L Terminal Wiring .................................................14
DC SOL Connection ............................................14
Interpreting the Diagnostic LED’s.........................15
LED Description...................................................15
Installation Verification .........................................15
Troubleshooting the Installation............................15
Resetting Alert Codes..........................................15
Grounding................................................................15
............................................16
Leak Check .............................................................17
High Altitude Conversion.........................................17
LP/Propane Gas Conversion...................................17
...................................18
Pre - Start Checklist................................................18
Start-up Procedure..................................................18
Air Circulation.......................................................18
Short Cycle Protection.........................................18
System Cooling Operation (2-Stage)...................18
System Heating (Heat Pump Mode)....................18
System Heating (Emergency Heat Mode) ...........19
Verifying & Adjusting Temperature Rise..................19
Verifying & Adjusting Firing Rate.............................19
Verifying Over-Temperature Limit
Control Operation....................................................19
Manifold Pressure Adjustment ................................20
Verifying Burner Operation......................................20
Refrigerant Charging...............................................20
Charging R-410A Unit in AC Mode......................20
Charging R-410A Unit in Heating Mode...............20
OPERATING SEQUENCE .........................................21
2-Stage Heating Mode (Heat Pump).......................21
Gas Heating Mode (Emergency Heat)....................21
2-Stage Cooling Mode.............................................22
Fan Mode................................................................22
EQUIPMENT MAINTENANCE...................................22
Cleaning of Heat Exchanger ...................................23
Cleaning of Burners ................................................24
TROUBLESHOOTING ...............................................24
COMPONENT FUNCTIONS......................................25
REPLACEMENT PARTS............................................25
.................................................26
Figure 10. Unit Dimensions..................................26
Table 9.Center of Gravity & Shipping Weights.....26
Airflow Information...................................................27
Table 10.Nominal Airflow Rates & Temp Rises ...27
Table 11.Airflow Settings for Cooling...................27
Table 12.Airflow Settings for Heating...................27
Gas Information.......................................................28
Table 13.Gas Pipe Capacities.............................28
Table 14.Gas Flow Rates....................................28
Figure 11. Gas Valve Label..................................29
Wiring Diagrams......................................................30
Figure 12.T-Stat Connection for Two-Stage
Heating / Two-Stage Cooling ..............30
Figure 13.Two-Stage Heat / Two-Stage Cool
Heat Pump (2 & 5 Ton) .......................31
Figure 14.Two-Stage Heat / Two-Stage Cool w/
Optional Comfort Alert (2 & 5 Ton)......32
Figure 15.Two-Stage Heat / Two-Stage Cool
Heat Pump (3 & 4 Ton) .......................33
Figure 16.Two-Stage Heat / Two-Stage Cool w/
Optional Comfort Alert (3 & 4 Ton)......34
Comfort Alert Troubleshooting Charts.....................35
Table 15.LED Diagnostics...................................35
Table 16. Module Wiring Troubleshooting.............37
Refrigerant Charging Charts...................................37
Figure 17. Charging Chart for 2 Ton Units............38
Figure 18. Charging Chart for 3 Ton Units............38
Figure 19. Charging Chart for 4 Ton Units............39
Figure 20. Charging Chart for 5 Ton Units............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
degreeorlevelofseriousnessand shouldnotbe ignored.
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:
needed.
WARNING:
.
• Beforebeginningtheinstallation,verifythattheunit
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.
• Nevertestforgas leaks withanopen ame. Usea
commercially available soap solution to check all
connections.See page 17.
• 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.
• Usecautionwhenhandlingthisapplianceorremoving
components. Personal injury can occur from sharp
WARNING:
HAZARD
WARNING:
WARNING:
4
metal edges present in all sheet metal constructed
equipment.
• Followall precautions inthe 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.
• Theinstallershouldbecomefamiliarwiththeunitswiring
diagram before making any electrical connections to
the unit. See the unit wiring label or Figures 13 - 16
(pages 31 - 34).
•
CAN/CGA B149.1.
• Allelectricalwiringmustbecompletedinaccordance
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.
• Thisequipmentcontainsliquidandgaseousrefrigerant
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.
• ConsultTable10(page27),andtheratingplateforthe
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
improperlydesignedductsystemcanresultinnuisance
shutdowns, and comfort or noise issues.
• Thisunitisdesignedforoutdoorinstallationsonlyand
should be located in a position as shown on page 5.
• Useonlywiththetypeofgasapprovedforthisunit.
Refer to the unit rating plate.
• Provideadequatecombustionandventilationairtothe
unit. See pages 6 - 8.
• Provideadequateclearancesaroundthecombustion
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.
• Additionalcodeslistedbelowareforreferencepurposes
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.
• 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
• 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
• US:NationalElectricalCode(NEC)ANSI/NFPA70
• CANADA:CanadianElectricalCodeCSAC22.1
• US:NFGCandNationalPlumbingCodes
• CANADA:NSCNGPIC
• US:CurrenteditionoftheNFGCandtheNFPA90B.
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.Foracopy,contactStandard
Sales, CSA International, 178 Rexdale Boulevard,
Etobicoke (Toronto), Ontario, M9W 1R3 Canada
• US:(NFGC)NFPA54–1999/ANSIZ223.1andthe
Installation Standards, Warm Air Heating and Air
Conditioning Systems ANSI/NFPA 90B.
• CANADA:CAN/CGA-B149.1–and.2–M00National
Standard of Canada. (NSCNGPIC)
5
GENERAL INFORMATION
The Dual Fuel iHybrid™ heat pump is designed only for
outdoor rooftop or ground level installations and can be
readily connected to the duct system of a home.This unit
hasbeentestedforcapacityandefficiencyinaccordance
withA.H.R.I.Standardsandwillprovidemanyyearsofsafe
and dependable comfort, providing it is properly installed
and maintained. With regular maintenance, this unit will
operatesatisfactorilyyearafteryear.Abuse,improperuse,
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.
√Thecooling load of the area to beconditioned must be
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.
• Surveythejobsitetodeterminethebestlocationfor
the packaged unit. The unit should be located with
consideration of minimizing the length of the supply
and return ducts.If practical, place the equipment and
its ducts in an area where they will be shaded from
the afternoon sun, when the heat load is greatest.
Considerationshould also be givento the accessibility
offuel,electricpower,serviceaccess,noise,andshade.
• Selectasolid,levelposition,preferablyonaconcrete
slab, slightly above the grade level, and parallel to the
home. DO NOT PLACE UNIT UNDER THE HOME.
• Overheadobstructions,poorly ventilatedareas,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.
• Sufcientclearanceforunobstructedairowthroughthe
louvered control access panel and outdoor coil must
be maintained in order to achieve rated performance.
See Figure 1 for minimum clearance requirements.
• Aclearanceofatleast36inchesfromthebloweraccess
panel and from the louvered control access panel is
recommended for servicing and maintenance.
• Thehotcondenserairmustbedischargedupandaway
from the home.
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 approvedengineering methods.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 Obstructions
0"
36"
36"
36"
TOP OF UNIT
TO BE
UNOBSTRUCTED
36” For Coil Only
6
WARNING:
CARBON MONOXIDE POISONING HAZARD
AVERTISSEMENT:
RISQUE D’EMPOISONNEMENT AU
MONOXYDE DE CARBONED
B149.1.
7
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:
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 following list summarizes the requirements for the
locationoftheventsystemtermination:
• Thelocationoftheventterminationmustbeconsistent
with the National Fuel Gas Code (ANSI Z223.1) or
CAN/CGA-B149 Installation Codes.
• Theventterminationmustbelocatedatleast4feet
horizontally from any electric meters, gas meters,
regulators, and relief equipment.
• Theventterminationmustbelocatedatleast3feet
above any forced air inlet located within 10 feet.
• Theventterminationmustbelocatedatleast4feet
below, 4 feet horizontally from, or 1 foot above any
door, window, or gravity air inlet into any building.
• Theventterminationmustbelocatedatleast1foot
above grade.
• Theunitshouldbeinstalledinawaythatpreventsany
obstructionoftheventterminationduringaccumulating
snow.
WARNING:
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(ANSIZ223.1/NFPA54).
.Theserequirementsarefor
US installations as found in the NFGC.
• TherequirementsinCanada(B149.1)arestructured
differently.Consultwith B149.1 and local code officials
for Canadian installations.
WARNING:
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.
• Gasoline/Kerosene
• Permanentwavesolutions
• Chlorinatedwaxesandcleaners
• Chlorinebasedswimmingpoolchemicals
• Watersofteningchemicals
• De-icingsaltsorchemicals
• Carbontetrachloride
• Halogentyperefrigerants
• Cleaningsolvents
• Cements,glues,paintremovers,varnishes,etc.
• Hydrochloricacid
• Masonryacidwashingmaterials
• PlumbingStack
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-outcontrollocatedabovetheburnerswillopen,
turningoffthegassupplytotheburners.Thissafetydevice
is a manually reset switch.IMPORTANT NOTE:DO NOT
.
Ifthiscontrolmustbereplaced,useonlyfactoryauthorized
replacement parts. See the Replacement Parts List on
page 25.
8
CIRCULATING AIR SUPPLY
WARNING:
Thisunit is designed only forusewithasupplyand 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”
(NFPA90A),“Standard forInstallation of ResidenceType
Warm Air Heating and Air Conditioning Systems” (NFPA
90B),andallapplicablelocalcodes.NFPApublicationsare
availablebywritingto:NationalFireProtectionAssociation,
BatterymarchPark,Quincy,ME02269orvisitwww.NFPA.
org on the web.
• Designthe duct work accordingto ManualD bythe Air
Conditioning Contractors of America (ACCA).
• The ducts must be properly sized and not exceed 0.2”
W.C. pressure drop at 400 scfm per nominal ton of
cooling capacity.
• Ductworkshouldbeattacheddirectlytotheunitflanges
for horizontal applications.
• Ifroof curb is installed, the ducts must be attached to
the curb hangers, not the unit.
• It is recommended that the outlet duct be provided
with a removable access panel. The opening should
be accessible when the unit is installed in service and
shall be sizes so that smoke or reflected light may be
observed inside the casing to indicate the presence of
leaks in the heat exchanger.The cover for the opening
shall be attached in a way that will prevent leaks.
• If outside air is utilized as return air to the unit for
ventilation or to improve indoor air quality, the system
must be designed so that the return air to the unit is
not less than 50° F (10° C) during heating operation.
• Ifacombinationofindoorandoutdoorairisused,the
ductsanddampersystemmustbedesignedsothatthe
return air supply to the furnace is equal to the return
airsupply under normal, indoor return air applications.
WARNING:
• Thisunitisnotsuppliedwithairlter(s)andhasno
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.
• Allreturnairmustpassthroughtheltersbeforeentering
the evaporator coil. It is important that all filters be
kept clean and replaced frequently to ensure proper
operationof unit.Dirty or clogged filters will reducethe
efficiency of the unit and result in unit shutdowns.
• Airlterpressuredropmustnotexceed0.08inchesWC.
• HorizontalanddownowInstallationsrequiretheair
filter system be installed in the return air ductwork.
NOTETOINSTALLER:Afterinstallingorreplacingthe
filtrationsystemforthisunit,addthefollowingstatement
on or adjacent to the lter service panel:
• Theunitinstallationshallavoidareaswherecondensate
drainagemaycauseproblemsbydroppingonplanters
or patios, etc. Also verify exhaust gases will not
impinge on windows or building surfaces, which may
be compromised or damaged by condensation.
• Donotinstalltheunitsuchthatexhaustfromthevent
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.
Air Flow
2.0 700 - 900 450 18 x 25
3.0 1,000 - 1,300 625 25 x 25
4.0 1,400 - 1,800 900 18 x 25 (2 required)
5.0 1,700 - 2,150 1100 22 x 25 (2 required)
* Based on velocity of 300 ft/min for disposable filters
and 500 ft/min for high velocity (cleanable) Filters.
9
• Ifusingbottomdischargewithreturnairductsaroof
curb must be installed prior to unit installation. See
Rigging and Hoisting section for setting of the unit.
• Sufcientclearanceforunobstructedairowthrough
the outdoor coil must also be maintained in order to
achieveratedperformance.Seepage5forinformation
about locating the equipment.
Ground level installations must be located according to
localbuildingcodesorordinancesandtheserequirements:
• Clearancesmustbeinaccordancewiththoseshown
in Figure 1 (page 5).
• Asuitablemountingpad(Figure3)mustbeprovided
andbe separatefromthe buildingfoundation.The pad
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.
• RemoveanddiscardthehorizontalSupplyandReturn
duct covers located on the rear of the unit. Form duct
attachmentflangesbybendingthesheetmetaloutward
90 degrees along the perforated lines.
• Firmlyattachductworkdirectlytotheseangeswith
screwsorotherapprovedmechanicalconnectionsand
nottotheSupply/Returnairpanelstoavoiddamageto
internalcomponentsoftheequipment.Oncecompleted
use approved duct sealing methods to ensure an air
and watertight seal is achieved.
Rooftop installations must be located according to local
buildingcodesorordinancesandtheserequirements:
• Theroofmustbecapableofhandlingtheweightofthe
unit. For unit weights, see Table 9. Reinforce the roof
if necessary.
• Theappropriateaccessoryroofcurb(Figure4,page
10) must be installed prior to unit installation. The
roof curb must be square and level to ensure proper
condensate drainage.
.
• Secure roof curb or frame to roof using acceptable
mechanicalmethodsperlocalcodes.NOTE:Makesure
thetwosupportsbeneaththeunithavebeenremoved.
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.
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.
• Ductliningmustbe UL classified battsor blanketswith
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
currentrevisionofthe SMACNAconstructionstandard
on fibrous glass ducts.Fibrous duct work and internal
acousticallining mustbeNFPA Class 1 air ducts when
tested per UL Standard 181 for Class 1 ducts.
UNIT INSTALLATION
Remove the shipping carton and User’s Manual from the
equipment.Takecarenottodamagethetubingconnections
whenremovingthecarton.Forrooftopinstallations,remove
and discard the two supports attached beneath the unit.
WARNING:
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
followingrequirementsaremet:
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).
• ForCanadianinstallationstheelectricalconnections
and grounding shall comply with the current Canadian
Electrical Code (CSA C22.1 and/or local codes).
√Verify the voltage, frequency, and phase of the supply
sourcematchthespecificationsontheunitratingplate.
√Verifythattheserviceprovidedbytheutilityissufficient
tohandletheadditionalloadimposedbythisequipment.
SeeTable2(page11)orthe unitwiringlabelforproper
high and low voltage wiring.
Condensate Drain
Theunitis shipped ready forhorizontalduct connections.
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.(Thecapcanbepushed
up from the bottom by reaching through the fork slot).
4.Cover the horizontal duct openings with the horizontal
duct caps.The insulation will be on the indoor side.
5.Fasten the cover with screws to seal.
Condensate 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. Refer to local codes and
restrictionsforpropercondensatedisposalrequirements.
HAZARD
WARNING:
OU D’EXPLOSION
AVERTISSEMENT:
ELECTRICALWIRING
11
√Verify factory wiring is in accordance with the unit
wiring diagram (Figures 13 - 16, pages 31 - 34).Verify
none of the connections loosened during shipping or
installation.
• Thelinevoltagetotheunitshouldbesuppliedfroma
dedicated branch circuit containing the correct fuse or
circuit breaker for the unit.
•
. This
switchshallbecapableofelectricallyde-energizingthe
outdoorunit.Seeunitdatalabelforproperincomingfield
wiring. Any other wiring methods must be acceptable
to authority having jurisdiction.
• Useonlycopperwireforthelinevoltagepowersupply
tothisunit (Table3,page12).Usepropercodeagency
listed conduit and a conduit connector for connecting
the supply wires to the unit.Use of rain tight conduit is
recommended.
• Providepowersupplyfortheunitinaccordancewith
the unit wiring diagram and the unit rating plate.
• Overcurrentprotectionmustbeprovidedatthebranch
circuitdistributionpanelandsizedasshownontheunit
rating label and according to applicable local codes.
See the unit rating plate for maximum circuit ampacity
and maximum overcurrent protection limits.
• Awiringdiagramislocatedontheinsidecoverofthe
control access panel of the outdoor unit.The installer
should become familiar with the wiring diagram before
making any electrical connections to the outdoor unit.
See Figures 13 - 16.
• Ifanyoftheoriginalwiressuppliedwiththeunitmust
be replaced, they must be replaced with material of
the same gauge and temperature rating.
• Unitsareshippedfromthefactorywiredfor240volt
transformeroperation.For208Voperation,removethe
lead from the transformer terminal marked 240V and
connect it to the terminal marked 208V.
• Connecttheline-voltageleadstotheterminalsonthe
contactor inside the control compartment.
• These Gas / Electric units are designed to operate
witha24VACClassIIcontrolcircuit.Thecontrolcircuit
wiring must comply with the current provisions of the
NEC (ANSI/NFPA 70) and with applicable local codes
having jurisdiction.Thermostat connections should be
madeinaccordancewiththeinstructionssuppliedwith
the thermostat and the indoor equipment.
• These units use a special 2 speed compressor to
achieve a high level of efficiency in a compact frame.
This system is capable of providing two stages of
cooling, two stages of heating in heat pump mode and
an additional 2 stages of secondary gas heating.See
Figure 12 (page 30)
• The low voltage wires must be properly connected
to the units low voltage terminal block. Route 24V
control wires through the gas furnace side of the unit.
Recommendedwiregaugeandwirelengthsfortypical
thermostat connectionsare listedinTable 4 (page 12).
• The thermostat should be mounted about 5 feet
above the floor on an inside wall. DO NOT install the
thermostat on an outside wall or any other location
whereitsoperationmaybeadverselyaffectedbyradiant
heat from fireplaces, sunlight, or lighting fixtures, and
convective heat from warm air registers or electrical
appliances. Refer to the thermostat manufacturer’s
instruction sheet for detailed mounting information.
2 Stage Heat/Cool Thermostat Configuration
A2stageheat
pumpthermostatisrequiredtocontrolthespecial2speed
compressor in both Heating and Cooling modes of heat
pump operation.The 2 Stage Heat Pump thermostat will
also allow the unit to operate as a two stage gas heat
system while set in the Emergency Heat mode.
Connect the low voltage thermostat wires between
terminals R (24VAC), Y1 (1st Stage Cool), G (Fan), Y2
(2nd Stage Cool), W1 (1st Stage Heat), W2 (2nd Stage
Heat),C(24VCom.),E(Emer.Heat),OorO/B(Reversing
Valve), and L (Defrost board fault monitoring-Optional)
on both the thermostat sub-base and unit low voltage
terminal board. See Figures 13 - 16 and your heat pump
thermostat installation manual for proper connections.
NOTE: Thermostats with a single “O/B” terminal for
selection of reversing valve control must be configured
for the “O”terminal to energize the reversing valve coil in
the cooling mode of operation.
Model
FLA
Indoor
Blower
FLA
Min RLA LRA MCA MOP
X24K080CA 80,000 208-230/30/1 187 253 11.4 52.0 0.91 4.3 20.8 30.0
X36K100CA 100,000 208-230/30/1 187 253 19.0 82.0 1.46 4.3 30.9 45.0
X48K120CA 120,000 208-230/30/1 187 253 24.0 96.0 1.46 9.1 41.9 60.0
X60K120CA 120,000 208-230/30/1 187 253 26.0 118.0 1.46 9.1 44.4 60.0
FLA = Full Load Amps; LRA = Lock Rotor amps;RLA = Rated Load Amps.
12
Thisfurnaceisfactoryconfiguredfortwostageheatpump
operation and as a 2 stage gas heating system when the
thermostat is set to the Emergency Heat position.
Heat Pump Defrost Mode
The Ignition/Blower Control board has an Automatic
Heat Staging jumper which can be repositioned to bring
on the second stage of gas heat after a pre-determined
delay in minutes that can be used to offset any cool air
while the unit may be in a prolonged defrost cycle.This
featureshouldonlybeusedinapplicationswhereextreme
outdoorcoilicingmayoccur.Repositiontheautomaticheat
staging jumper from factory setting“NONE”to 5 or 10 for
the desired delay in minutes before the gas furnace will
automatically move to high heat operation.
Checking Heat Anticipator Settings
• Addthecurrentdrawofthesystemcomponents.
OR
• Measure the current ow on the thermostat R-W
circuit after the circulating blower motor has started.
Set the heat anticipator according to the thermostat
manufacturer’sinstructionsforheatanticipatorsettings.
The variable speed blower has been designed to give
the installer maximum flexibility for optimizing system
performance, efficiency, and comfort. It is equipped with
a microprocessor-controlled variable speed motor that is
pre-programmedto deliveroptimumairflow in a varietyof
conditionsandsystemconfigurations.Becausetheblower
can be configured in many ways, it is important to read
and follow all instructions carefully.
CAUTION:
Before operation, the variable speed blower must be
configured to match the unit with the system, climatic
conditions, and other system options. With the blower
installedandconfiguredproperly,thefurnacewillgradually
changespeedinresponsetochangesinsystemvariables
such as thermostat settings, duct static, filters, etc.The
variable speed blower is configured by setting the heat,
cool, and adjust jumpers located on the ignition control
boardasdescribedbelow:
Selecting Cooling Airflow
The cooling airflow is selected by setting the Cool and
Adjust jumpers on the ignition control board. Table 11
(page27)liststherecommendedairflowvalues(CFM)and
selectortapsettingsforeachnominalsystemcapacity.All
airflows for other modes of operation (except secondary
gas heat) are determined by this basic setting. For
maximum capacity, generally, a selection at or near the
top of the CFM range for that nominal capacity is best.
NOTES:
• TheCFMvalueslistedinTable11arenotdependent
on duct static pressure. The motor automatically
compensates(withinthelimitsofthemotor)forchanges
in duct static pressure.
• Ifcoilicingoccurs,thebasiccoolingairowselected
may be too low.Verify the selected setting is within the
range shown in Table 11 and the system is properly
charged. If icing continues, raise the selected airflow
to the next higher tap.
• Formaximumdehumidicationandenergyefciency,
selectan airflownear the middle or bottomof theCFM
range for that nominal capacity.
• The 2-stage cooling feature of the unit requires
modulatingtheairflow.Theunitwillautomaticallyadjust
theairflowtotheappropriateratewhentheunitcapacity
changes.
Selecting Gas Heating Airflow
Theheating airflowis selectedbysettingthe heat jumper
to the desired tap (A,B,C, or D) located on the ignition
control board. Refer to Table 12 (page 27) and select a
nominal rise based on the furnace’s nominal efficiency
and firing input. Follow across the table row to find the
tapsetting and nominalair-flow.Verify theselectedriseis
withinthe specificationshownon thefurnaceratinglabel.
2-Wire
(Heating) 5-Wire
(Heating/Cooling)
24 55 25
22 90 45
20 140 70
18 225 110
COPPERWIRE SIZE — AWG
200 150 100 50
6 8 10 14 15
4 6 8 12 20
4 6 8 10 25
4 4 6 10 30
3 4 6 8 35
3 4 6 8 40
2 3 4 6 45
2 3 4 6 50
2 3 4 6 55
1 2 3 4 60
Wire Size based on N.E.C. for 60° type copper conductors.
13
Delay Profile
The delay profile controls the start-up and shut-down
characteristicsofthepackagedheatpumpunit.Byvarying
thestart-upandshut-downcharacteristicsofthepackaged
heat pump unit, the system can be optimized for energy
efficiency, humidity control, and comfort.
The delay profile has a two-step ON delay. The blower
will begin operation at 31% airflow for 30 seconds. The
second step operation is 75% airflow for 30 seconds.
After the two-step ON delay has been completed, the
blower operation will be 100% until the thermostat has
been satisfied. There is also a 60 second OFF delay at
50% airflow.
The demand defrost board controls the defrost cycle
in response to ambient temperature, outdoor coil
temperature and accumulated compressor run time.The
heat pump is allowed to operate in the heating mode
until the combination of outdoor ambient and outdoor
coil temperatures indicate that defrosting is necessary,
based on the programmed defrost curve.There are four
preprogrammed defrost curves on the board.
• Thedefrostboardisequippedwitha5minuteAnti-Short
Cycle Delay (ASCD).The outdoor unit remains off for
the 5 minute delay if the thermostat call is interrupted
or there is a loss of power to the unit.
• Ajumperpinisusedtoswitchbetweenthedifferent
curves.Thedefaultjumperpositioniscurve1andisthe
recommended setting for most standard applications.
See Table 5 for additional defrost curves settings.
• Thefactorydefaultsettingdoesnotincludea30second
compressor delay function and has a 40 ° F defrost
terminate temperature. If additional defrost time is
needed, a higher terminate temperature is available
by selecting a different demand curve. NOTE: The
30 second compressor delay function is optional and
based on the demand curve selected.
• The standard defrost cycle will terminate after 13
minutes and 39 seconds or when the coil temperature
reaches its terminate temperature, whichever occurs
first.
• Thecontrolcontainsaforced-defrostfeature,which
places the system into defrost mode every 6 hours
and 4 minutes, unless the coil temperature is above
the selected terminate temperature.
• Thesystemcanbemanuallyforcedintodefrostmodeat
anytimebyshortingtheTESTterminalsonthedemand
defrost board together for more than 9 seconds.The
coiltemperaturesensordoesnotneedtobecoldwhen
the unit is forced into defrost. After the TEST input
MinimumTime
1 20 40 NO
2 20 40 YES
3 20 75 NO
4 20 75 YES
is removed, the defrost mode will terminate in 13.7
minutes, if the coil temperature is above the terminate
set-point, or when the Yinput is removed, whichever
occurs first.
NOTE: If a demand curve is selected which has a 30
second compressor time delay in defrost, the delay is
reduced to 10 seconds in TEST mode.
For optimum performance of the heat pump system, the
ambient sensor must be mounted on the outside of the
unit. See Figure 6 (page 14).
1.Remove the mounting bracket wire tied to the control
bracket and all hardware included in the packet.
2.Remove star bushing from 7/8”hole in corner panel of
the unit. See Figure 7 (page 14).
3.Route the ambient sensor through the 7/8” hole in the
corner panel of the unit, and then through the 7/8” hole
in the mounting bracket.
4.Routethesensorthroughthestarbushing.Usethestar
bushing to secure the mounting bracket to the unit.
5.Secure the ambient sensor inside the plastic clip and
secure it to the mounting bracket with the screw and
nut provided.
6.Install one spacer nut between the plastic clip and
mounting bracket.
7.Bend the mounting bracket into position and screw the
mounting bracket to the corner panel.
An optional humidistat may be installed in the return
air duct for humidity control (when needed), maximum
system capacity and energy efficiency. The humidistat
senses when humidity in the return air stream is above
a preset level and sends a signal to the motor to reduce
airflow. This allows more moisture to be removed until
the humidity level drops.NOTE:The indoor blower motor
of this packaged unit is pre-programmed for humidistat
operation. Remove the Red jumper wire between the R
and DEHUM terminals on the ignition control board.
If installing a humidistat, install it in the return air duct
as directed in the installation instructions included with
the kit.Wire the humidistat through the low-voltage wire
entrance in the packaged unit to the screw terminals
marked R& DEHUM.
When the HI/LO Dehumidify Green LED status light is
ON, it signals Low Humidity and keeps 24V supplied to
the motor for normal airflow requirements.If the humidity
level of the conditioned space increases the humidistat
will open. Loss of the 24V signal to the indoor blower
motor allows the motor to reduce to approximately 75%
of normal airflow selected until the humidity level drops.
The Green LED is OFF during high humidity conditions.
Checkallfactorywiringtotheunitswiringdiagram.Inspect
the factory wiring connections to be sure none loosened
during shipping or installation.
14
TM
POWER LED
(Green)
TRIP LED
(Red)
ALERT LED
(Yellow)
Diagnostics
Key
TM
Module
TheComfortAlertTM DiagnosticsModuleisabreakthrough
innovation for troubleshooting heat pump and air
conditioningsystemfailures.Themodule installs easilyin
the electrical box of the outdoor unit near the compressor
contactor. By monitoring and analyzing data from the
Copelandscrollcompressorandthethermostatdemand,
the module can accurately detect the cause of electrical
and system related failures without any sensors. A
flashing LED indicator communicates the ALERT code
and a diagnostic key is also imprinted on the side of the
module to quickly direct the technician to the root cause
of a problem.See Figure 8.
NOTE: This module does not provide safety protection!
The Comfort AlertTM Diagnostics Module is a monitoring
device and cannot control or shut down other devices.
24 VAC Power Wiring
The Comfort AlertTM module requires a constant nominal
24VAC power supply.The module should be powered by
an R& Cthat doesn’t have the potential for loss of power
due to safety controls, defrost boards, or other control
boards which could lead to nuisance alerts.
Thermostat Demand Wiring
TheComfortAlertmodulerequiresatwostagethermostat
to operate properly.The Y2 thermostat wire entering the
outdoor unit should be connected to the Y2 input on the
unit terminal strip.
Whilethecompressorisrunning,ComfortAlertwillprovide
power to the second stage cooling solenoid inside the
compressor after Y2 has been energized for 5 seconds.
When the compressor is not running, Comfort Alert will
not power the solenoid, regardless of the state of Y2. If
Alertcodes1or9appearwhilethecompressorisrunning,
Comfort Alert will turnoff the solenoid to preventsolenoid
damage from overheating conditions.
L Terminal Wiring
White-Rodgers Compatible Thermostats - The L
connection is used to communicate Comfort Alert codes
tocompatibleWhite-Rodgersthermostats.TheLterminal
of these thermostats should be connected to the Comfort
Alert Lterminal. See unit wiring diagram label included
on the unit or in these instructions for correct field wiring
connections.
NOTE:OnsomeWhite-Rodgerscombatiblethermostats,
anicononthethermostatdisplaywillflashatthesamerate
astheComfortAlertyellowAlertLED.Anadvancedoption
on these thermostats is to lock out the compressor when
certain Alert codes are detected in indicating impending
compressordamage.Refer toWhite-Rodgers thermostat
manuals for more information.
Standard Non-Compatible Thermostats – The L
connectionon non-compatibletypethermostatsareused
Star Bushing
Bolt Nut
Ambient Sensor
Plastic Clip
Nut
forheatpumpdefrostcontrolboardfaultmonitoring.TheL
terminalofthesethermostatsshouldbeconnecteddirectly
to the defrost control board Lterminal. See the wiring
diagram label or the heat pump installation instructions
for correct field wiring connections.
DC SOL Connection
The two pin DC SOL connector provides a connection
to the Copeland UltraTech second stage compressor
solenoid(see Figure 12).This 24VDCsolenoidisinternal
to the compressor and will not operate properly if 24VAC
is applied to the compressor solenoid terminals.
15
from Comfort Alert.
3.Remove the wire from Yterminal of Comfort Alert,
reapply 24VAC power to Comfort Alert and reconnect
power to the compressor.
4.Set the thermostat’s system mode to COOL.
NOTE: When the compressor starts to run, the Alert
LED (yellow) will begin flashing a Code 8 indicating a
welded contactor.
5.Disconnect power from the compressor and 24VAC
from Comfort Alert.
6.With Comfort Alert OFF, reattach the wire to the Y
terminal. Reapply power to compressor and 24VAC to
Comfort Alert.NOTE: The Alert LED (yellow) will flash
the previous code 8 for 1 minute and then turn off. If
the yellow LED does not function, refer to the wiring
diagrams (Figures 14 or 16).
Troubleshooting the Installation
Depending on system configuration, some ALERT Flash
codesmaynotbeactive.Thepresenceofsafetyswitches
affectshowthesystemalertsaredisplayedbythismodule.
Resetting Alert Codes
Alert Codes can be reset manually and automatically.
The manual method to reset an Alert code is to cycle the
power to Comfort Alert off and on. For automatic reset,
Comfort Alert continues to monitor the compressor and
system after an Alert is detected. If conditions return to
normal, the Alert code is turned off automatically.
An outdoor temperature sensor can be installed in the
field for use in conjunction with a compatible heat pump
thermostat to convert heat pump mode of operation over
tothegasheatsystemwhenoutdoorconditionsnolonger
favor operating the heat pump. Refer to the installation
and operating instructions of the accessory kit for further
information.
WARNING:
This unit must be electrically grounded in accordance
with local codes or, in the absence of local codes, with
the National Electrical Code (ANSI/NFPA 70) or the CSA
C22.1 Electrical Code.Use the grounding lug provided in
the control box for grounding the unit.
To reduce the VA load of the solenoid on the system,
Comfort Alert uses a phase control method to reduce the
DCvoltagetothesolenoidtotheminimumlevelrequiredto
keep the solenoid pulled in.As the 24VAC supply voltage
varies, Comfort Alert intelligently changes the solenoid
DC voltage supply to minimize power consumption.
A voltmeter attached to the DC SOL output will measure
4-18VDC,whensolenoidshouldbeenergized,depending
on the level of the 24VAC supply.
Interpreting the Diagnostic LED’s
Whenanabnormalsystemconditionoccurs,theComfort
AlertTM module displays the appropriate ALERT and/or
TRIP LED.The yellow ALERT LED will flash a number of
times consecutively, pause and then repeat. To identify
a Flash Code number, count the number of consecutive
flashes. See Table 15 (pages 35 - 36) for flash code
identification or Table 16 (page 37) for module wiring
troubleshooting.
Each time the module powers up, the last ALERT Flash
Code that occurred prior to shut down is displayed for
one minute.The module will continue to display the LED
until the condition returns to normal or if 24 VAC power
is removed from the module.
LED Description
• POWERLED(Green):indicatesvoltageispresentat
the power connection of the module.
• ALERT LED (Yellow): communicates an abnormal
system condition through a unique flash code.
NOTE:TheALERTLEDwillflashconsecutively,pause
andthenrepeattheprocess.Thenumberofconsecutive
flashes, referred to as the Flash Code, correlates to
a particular abnormal condition.Detailed descriptions
of these ALERT Flash Codes are listed in Table 15.
• TRIPLED(Red):indicatesademandsignalisreceived
from the thermostat, but current to the compressor is
not detected by the module. The TRIP LED typically
indicates if the compressor protector is open or the
compressor has no power.
The scroll compressor’s R (run), C(common), and S
(start) wires are routed through the holes in the Comfort
AlertTM module marked R, & S.NOTE: The common
wire does not need to be routed through the module for
it to operate.
Installation Verification
To verify the Comfort Alert is correctly installed, two
functional tests can be performed.
1.Disconnect power from the compressor and force a
thermostat call for cooling. NOTE: The Trip LED (red)
should turn on indicating a compressor trip as long as
24VAC is measured at the Yterminal. If the Trip LED
does not function as described, refer to the wiring
diagrams (Figures 14 or 16, pages 32 or 34).
2.Disconnect power from the compressor and 24VAC
16
•
This unit only has right side gas entry.When connecting
the gas, provide clearance between the gas supply line
and the entry hole in the unit’s casing to avoid unwanted
noise and/or damage to the unit. A typical gas service
hookup is shown in Figure 9.
Table 13 (page 28) lists gas pipe capacities for standard
pipe sizes as a function of length in typical applications
based on nominal pressure drop in the line.
Ground
Joint
Union
Dripleg
Shut-Off Valve
with 1/8 NPT
plugged tap
Burner
Assembly
Manifold
Some utilities
require Shut-Off
Valve to be
4 to 5 feet
above floor
Automatic Gas Valve
(with manual shut-off)
WARNING:
FIRE OR EXPLOSION HAZARD
WHAT TO DO IF YOU SMELL GAS
AVERTISSEMENT:
RISQUE D’INCENDIE OU D’EXPLOSION
QUE FAIRE S’ILY A UNE ODEUR DE GAZ
17
Afterthegaspipingtotheunitiscomplete,allconnections
mustbetestedforgasleaks.Thisincludespipeconnections
at the main gas valve, emergency shutoff valve and
other gas connectors.A soap and water solution can be
applied on each joint or union using a small paintbrush.
If any bubbling is observed, the connection is not sealed
adequatelyandmustberetightened.Repeatthetightening
and soap check process until bubbling ceases.
•
•
Conversion of this unit must be performed by qualified
service personnel, using only approved parts. All
installationsmustbemadeinaccordancewiththeNational
Fuel Gas Code and/or local jurisdiction codes.
High altitude conversion can be field performed by a
simple adjustment of manifold pressure or a change of
the orifices (if necessary) as described on page 20.The
changes required depend on the installation altitude and
the heating value of the gas (based on sea level) which
can be obtained from your local gas utility. The heating
value of gas at high altitude is always lower than the sea
level heating value.The heating values listed inTables 6
& 7 (page 20) are based on sea level values.
WARNING:
If installing this unit above 2,000 feet, the input rate must
bereduced4%per1,000feetofaltitude(Example:12%
at 3,000 feet, 16% at 4,000 feet, etc).NOTE: Deration is
necessary to compensate for low atmospheric pressure
at high altitudes.
For altitudes between 5,000 and 10,000 feet above sea
level, the unit can be converted by adjusting the furnace
manifold pressure. See Tables 6 or 7 for the correct
manifold pressure settings.
WARNING:
Conversion of this equipment to LP/Propane gas must
be made by qualified service personnel, using approved
factory parts.Conversion to LP can be accomplished by
replacingthenaturalgasorificeswiththeappropriateLP/
Propaneorificesandthenadjustingthemanifoldpressure
(page 20).Conversion to LP/Propane (sea level and high
altitude)isdetailedintheinstallationinstructionsprovided
with the conversion kit.
Approvedconversionkitsare:
• TheUnitedStatesLP/PropaneGasSeaLevelandHigh
AltitudeConversionKitisforLP/propaneconversionin
theUnitedStatesataltitudesbetweenzeroand10,000
ft. above sea level.
• TheCanadianLP/PropaneGasSeaLevelandHigh
AltitudeConversionKitisforLP/Propaneconversions
inCanadaataltitudesbetweenzeroand4,500ft.above
sea level.
For installations between zero and 4,999 ft. above sea
level, a #55 drill size orifice should be used.Installations
5,000 ft. above sea level require a # 56 drill size orifice.
RISQUE D’INDENDIE OU D’EXPLOSION
.
AVERTISSEMENT:
FIRE OR EXPLOSION HAZARD
WARNING:
18
Table 7 (page 20) lists the correct orifice size to use at
different altitudes.
Afterchangingtheorifices,itisrequiredthatyoumeasure
the gas input rate by clocking the gas meter and using
the local gas heating value. See Verifying and Adjusting
the Firing Rate section on page 19.
√Verify the unit is level and allows proper condensate
drainage.
√Verify all clearance requirements are met and there is
free airflow to and from the outdoor coil.
√Verifythattheductworkissealedtopreventairleakage.
√Verify that the line voltage power leads are securely
connected and the unit is properly grounded.
√Verifythatthelowvoltagewiresaresecurelyconnected
to the correct leads on the low voltage terminal strip.
√Verifythatthegaslineservicepressuredoesnotexceed
10.0 inches WC (0.36 psig), and is not less than 4.5
inches WC (0.16 psig) for natural gas. For LP gas the
line service pressure must not exceed 14 inches WC
(0.51 psig) and must not be less than 11.0 inchesWC
(0.40 psig).
√Verify that the flame roll-out control is closed. If
necessary,presstheredbuttontoresetthecontrol.DO
NOT install a jumper wire across the control to defeat
its function. If the control reopens upon start-up, DO
NOTresetthecontrolwithoutidentifyingandcorrecting
the fault condition which caused the control to trip.
√Verify that the gas line has been purged and all
connections are leak tight.
√Verifythatallexteriorpanelsarereplacedandsecurely
fastened.
√Verify that the outdoor fan turns freely.
√Verify that the power supply branch circuit overcurrent
protection is sized properly.
√Verify that the thermostat is wired correctly. The
thermostat function switch should be set to OFF and
the thermostat fan switch should be set to AUTO.
WARNING:
• Checkallelectricalwiringforlooseconnectionsand
tighten as required.
• Checkunitforreturnairltersandcondensatetrap.
• Closeallelectricaldisconnectstoenergizethesystem.
Air Circulation
Leave the thermostat system mode on OFF and set the
fan mode to ON. Blower will run continuously. Check the
air delivery at the supply registers and adjust register
openingsfor balanced air distribution.Examineductwork
for leaks or obstruction if insufficient air is detected. Set
the thermostat fan mode to AUTO.The blower will stop
running.
Short Cycle Protection
1. With the system operating in cooling mode, note the
temperaturesettingofthethermostatandgraduallyraise
the set-point temperature until the unit de-energizes.
2. Immediately lower the set point temperature of the
thermostat to its original setting and verify that the
indoor blower is energized.
3. After approximately 5 minutes, verify the compressor
and fan energize and the temperature of the discharge
air is cooler than the room temperature.NOTE: This is
available only for the single phase models.
System Cooling Operation (2-Stage)
1.Set the thermostat’s system mode to COOL and the
fan mode to AUTO.Lower the thermostat temperature
setpointonedegreebelowroomtemperatureandverify
theoutdoorunitandblowerenergizeon 1st stage cool.
2.Feel the air being circulated by the indoor blower and
verifythatitiscoolerthanambienttemperature.Listenfor
anyunusualnoises.Ifunusualsoundsoccur,determine
the source of the noise and correct as necessary.
3.Afterdeterminingthesystemisoperatingproperly,wait
1-2minutesandthenlowerthethermostattemperature
set point an additional 3-4 degrees until the cooling
system moves into 2nd stage or high cool operating
mode.The compressor and indoorblowerwill increase
in speed.
4. Allowthecoolingsystemtooperateforseveralminutes
and then set the temperature selector above room
temperature. Verify the fan and compressor cycle off
withthethermostat.NOTE:Theblowershouldalsostop
in approximately 60 seconds, unless the fan switch is
set to the ON position.
System Heating (Heat Pump Mode)
1.Set the thermostat system mode to HEAT and the fan
mode to AUTO. Raise the thermostat temperature set
point one degree above room temperature and verify
theoutdoorunitandblowerenergizeon1ststageheat.
2.Feel the air being circulated by the indoor blower and
verify that it is warmer than ambient temperature.
Listen for any unusual noises. If unusual sounds
occur, determine the source of the noise and correct
as necessary.
3.After determining the system is operating properly,
raisethethermostattemperaturesetpointanadditional
1-2 degrees until the system moves to 2nd stage heat
pump mode of operation. The compressor and blower
will increase in speed during 2nd stage cooling.
19
NOTE: If thermostat differential is set too high the gas
heat system may energize (depending on thermostat
model)andde-energizetheheatpumpoutdoorsystem.
Gas heat will remain in operation until the thermostat
call for heat is satisfied.
4.Allowtheheatingsystemtooperateforseveralminutes
and then set the temperature selector below room
temperature. Verify the system shutdown sequence.
Note:Theblowerwillremainoperatingfor60or150
seconds after the call for heat is removed depending
on if the system was in heat pump or gas heat mode,
respectively, unless the thermostat switch is set to the
ON position.
Gas Heating (Emergency Heat Mode)
NOTE: When thermostat is set to the emergency heat
position, heat pump operation will be locked out.
1.Set the thermostat to the lowest setting.
2.Follow the procedures given on the gas operating
instruction label, in this installation instructions or
attached inside the louvered control access panel.
3.Setthethermostatonedegreeaboveroomtemperature
and verify the sequence of operation. See Operating
Sequence section (page 21.)
4.Verify that the compressor and outdoor fan motor are
not energized.
5.Afterdeterminingthesystemisoperatingproperly,wait
1-2minutesandthenraisethethermostat temperature
set point an additional 1-2 degrees until the heating
system moves into 2nd stage or high heat operating
mode. The gas valve will energize to high heat mode
while the induced draft motor and indoor blower motor
both increase in speed.
6.After the unit has run for approximately five minutes,
set the thermostat below room temperature.Verify the
shutdown sequence; steps 10 -12 in the Operating
Sequence section (page 22).
Verify the temperature rise through the unit is within the
range specified on the unit data label for both high and
low firing rates.Temperature rises outside the specified
range could result in premature heat exchanger failure.
1. Placethermometersinthereturnandsupplyairstream
asclosetotheunitaspossible.Thethermometeronthe
supplyairsidemustbeshieldedagainstdirectradiation
from the heat exchanger to avoid false readings.
2.Adjust all registers and duct dampers to the desired
position. Run the unit for 10 to 15 minutes before
taking any temperature readings. The temperature
rise is the difference between the supply and return air
temperatures.
NOTE: Fortypical duct systems,the temperature rise will
fall within the range specified on the data label (with the
blowerspeedatthefactoryrecommendedsetting)shown
inTable9(page27).Ifthemeasuredtemperaturerisefalls
outsidethespecifiedrange,itmaybenecessarytochange
the blower speed. Lowering the blower speed increases
the temperature rise and a higher speed decreases the
temperature rise.
Theunitisequippedwithavariablespeedmotor.Heating
and cooling speed selection is made by changing the tap
settings on the ignition control board located in the unit
controlbox.RefertoConfiguringtheVariableSpeedBlower
Section (page 12) for additional information.
The Variable Speed Blower (VSB) is designed with built
in delay profiles for start up and shut down of the system.
Refer to the Operating Sequence section (page 21) for
more details.
CAUTION:
The firing rate must be verified for each installation to
prevent over-firing of the furnace.
To
determinetheringrate,followthesesteps:
1.Obtainthegasheatingvalue(HHV)fromthegassupplier.
2.Shut off all other gas fired appliances.
3.Start the unit in heating mode and allow it to run for at
least 3 minutes.
4.Measure the time (in seconds) required for the gas
meter to complete one revolution.
5.Convert the time per revolution to cubic feet of gas per
hour using Table 14 (page 28).
6.Multiply the gas flow rate in cubic feet per hour by the
heating value of the gas in Btu per cubic foot to obtain
the firing rate in Btu per hour.See Example.
7.Adjustthemanifoldpressureifnecessary.SeeManifold
Pressure Adjustment instructions on page 20. For
additional information about elevations above 2,000
feet, see page 17.
:
• Timefor1revolutionofagasmeterwitha1cubic
foot dial = 40 seconds.
• FromTable14,read90cubicfeetgasperhour.
• Localheatingvalueofthegas(obtainedfromgas
supplier) = 1,040 Btu per cubic foot.
• Inputrate=1,040x90=93,600Btuh.
1.Verifythe louveredcontrolaccesspanelisin place and
that there is power to the unit.
2.Block the return airflow to the unit by installing a close-
off plate in place of or upstream of the filter.
3.Set the thermostat above room temperature and verify
the units operating sequence (page 21).
20
NOTE: The over-temperature limit control should turn
off the gas valve within approximately four minutes
(exact time depends on the efficiency of the close-off
when blocking the return air). The circulating air and
combustion blowers should continue to run when the
over-temperature limit control switch opens.
4.Remove the close-off plate immediately after the over-
temperature limit control opens. If the unit operates
for more than four minutes with no return air, set the
thermostat below room temperature, shut off power to
theunit, and replace the over-temperaturelimit control.
The manifold pressure must be set to the appropriate
valueforyourinstallation.Toadjustthemanifoldpressure:
1. Obtain the required manifold pressure setting. Use
Table 6 for natural gas orTable 7 for LP/propane gas.
NOTE:Thevalueslistedinthetablesarebasedonsea
level values. At higher altitudes, the heating value of
gas is lower than the sea level heating value.
2. Remove the regulator cap. Turn the high fire
adjusting screw clockwise to increase the pressure or
counterclockwise to reduce the pressure.
3. Replace the regulator cap after adjustments are
complete.
WARNING:
1. Remove the louvered control access panel and verify
there is power to the unit.
2. Set thermostat above room temperature and observe
theignitionsequence.NOTE:Theburnerflameshould
carry over immediately between all burners without
liftingoff,curling,orfloating.Theflamesshouldbeblue,
without yellow tips.Make sure the flame is drawn into
the center of the heat exchanger tube. In a properly
adjusted burner assembly, the flame bends down and
to the right at the end of the heat exchanger tube.The
end of the flame will be out of sight around the bend.
3. Aftervalidatingflamecharacteristics,setthethermostat
below room temperature and verify the burner flame
extinguishes completely.
zero to 1,999 FT 3.5 3.5 3.5
2,000 to 4,999 FT 3.5 3.5 3.5
5,000 to 5,999 FT 3.5 3.5 3.0
6,000 to 7,999 FT 3.5 3.2 2.8
8,000 to 10,000 FT 3.0 2.8 2.5
zero to 1,999 FT 10.0 55
2,000 to 4,999 FT 8.5 55
5,000 to 5,999 FT 10.0 56
6,000 to 7,999 FT 9.0 56
8,000 to 10,000 FT 8.5 56
NOTE: Manifold pressure based on sea level LP heating value
of 2,500 Btu/cu. ft.3
WARNING:
CAUTION:
The system refrigerant charge can be checked and
adjusted through the service ports provided at the front
panel. Use only gauge lines which have a Schrader
depressiondevicepresenttoactuatethevalve.Refrigerant
chargingmustbedonebyqualifiedpersonnelfamiliarwith
safeandenvironmentallyresponsiblerefrigeranthandling
procedures. Refer to the charging application notes and
charts on pages 37 - 39
Charging an R-410A unit in AC mode at
outdoor temperatures above 65F.
1.Withthesystemoperatingatsteady-state,measurethe
liquid refrigerant pressure in psig at the service valve.
2.MeasuretheliquidrefrigeranttemperatureinFahrenheit
at the outlet of the condensor coil.
3.Forthetemperaturemeasured, determinetherequired
This manual suits for next models
5
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