Nordyne R6GP-072 Series User manual

R6GP - 072/090/120 Series
Installation Instructions
Single Package Gas Heating/Electric Cooling Rooftop Units
R6GP-090 Shown
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.
WARNING:
!
DO NOT DESTROY. PLEASE READ CAREFULLY AND 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
neighbors phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call
the fire department.
High Efficiency

2
SAFETY INFORMATION .............................................3
REQUIREMENTS AND CODES..................................4
GENERAL INFORMATION..........................................4
Air Ducts ..................................................................4
Air Filter Requirements............................................4
Clearances to Combustible Materials ......................5
Combustion Air Quality............................................5
Condensate Drain....................................................5
Equipment Check ....................................................5
Equipment Application.............................................5
Heating Load ...........................................................5
Thermostat ..............................................................5
VENTING REQUIREMENTS........................................6
COMBUSTION AIR REQUIREMENTS........................6
UNIT INSTALLATION ..................................................7
Packaging Removal .................................................7
Rigging and Hoisting ...............................................7
Minimum Clearance Requirements .........................8
Rooftop Mounting ....................................................8
Ground Level ...........................................................8
CIRCULATING AIR SUPPLY.......................................9
Unconditioned Spaces.............................................9
Acoustical Ductwork ................................................9
Downflow to Horizontal Conversion.........................9
GAS SUPPLY AND PIPING.......................................10
Leak Check............................................................10
High Altitude Deration............................................10
Conversion to LP/Propane.....................................11
ELECTRICAL WIRING...............................................11
Pre-Electrical Checklist..........................................11
Line Voltage ...........................................................12
Grounding..............................................................12
Unbalanced 3-Phase Supply Voltage ....................12
Blower Speed ........................................................13
Thermostat ............................................................13
Heat Anticipator .....................................................13
STARTUP AND ADJUSTMENTS ..............................13
Pre-Start Check List ..............................................13
Startup Procedures................................................14
Air Circulation ........................................................14
System Cooling .....................................................14
System Heating .....................................................14
Verifying and Adjusting Temperature Rise.............14
Verifying Burner Operation ....................................15
Verifying Operation of Over-Temperature
Limit Control ..........................................................15
Verifying and Adjusting Firing Rate .......................15
OPERATING SEQUENCE .........................................16
Cooling Mode ........................................................16
Heating Mode (200 & 235 kBtuh) ......................... 16
Heating Mode (100 & 166 kBtuh) ......................... 16
Blower Mode......................................................... 16
TROUBLESHOOTING .............................................. 17
UNIT MAINTENANCE................................................17
Condensate Drain and Outdoor Coil......................17
Air Filters ...............................................................17
Blower Compartment.............................................18
Heat Exchanger and Burner Maintenance ............18
Cleaning of Burners...............................................18
Cleaning of Heat Exchanger..................................18
Vent Cover Assembly.............................................19
Electrical ................................................................19
Motor Lubrication...................................................19
Refrigerant Charging .............................................19
COMPONENT FUNCTIONS ......................................20
Centrifugal Switch..................................................20
Flame Roll-Out Control..........................................20
Flame Sensor ........................................................20
Gas Valve...............................................................20
High Pressure Switch ............................................20
Indoor Coil Freeze Protection Thermostats ...........20
Low Pressure Switch .............................................20
Over-Temperature Limit Control ............................20
Pressure Switch.....................................................20
FIGURES and TABLES .............................................21
Figure 12 - Component Locations.......................21
Physical Dimensions..............................................22
Figure 12 - 072 Series.........................................22
Figure 13 - 090 Series.........................................24
Figure 14 - 120 Series.........................................26
Table 4 - Unit Shipping Weights ..........................27
Blower Performance Data......................................28
Table 5 - 072C - 100 Series - Downflow..............28
Table 6 - 072C - 100 Series - Horizontal .............29
Table 7 - 072C -166 Series - Downflow...............30
Table 8 - 072C - 166 Series - Horizontal .............31
Table 9 - 090C Series - Downflow.......................32
Table 10 - 090C Series - Horizontal ....................33
Table 11 - 120C Series - Downflow.....................34
Table 12 - 120C Series - Horizontal ....................35
Electrical Information .............................................36
Table 13 - Electrical Data ....................................36
Figure 15 - Ladder Diag. - 072 Series .................37
Figure 16 - Ladder Diag. - 090/120 Series ..........38
Figure 17 - Wiring Diagram - 072 Series.............39
Figure 18 - Wiring Diagram - 090 Series.............40
Figure 19 - Wiring Diagram - 120 Series.............41
Gas Information .....................................................42
Table 14 - Gas Pipe Capacities...........................42
Table 15 - Orifice or Drill Sizes............................42
Table 16- Heating Rise/Range ............................42
Table 17- Gas Flow Rates...................................43
R6 Charging Charts...............................................44
Figure 20 - R6GP-072 Series..............................44
Figure 21 - R6GP-090 Series..............................45
Figure 22 - R6GP-120 Series..............................45
R6 Gas Valve Labels .............................................46
Figure 23 - 6 Ton Units ........................................46
Figure 24 - 7.5 and 10 Ton Units .........................47
INSTALLATION CHECKLIST ....................................48
TABLE OF CONTENTS

3
SAFETY INFORMATION
Safety markings are used frequently throughout this
manual to designate a degree or level of seriousness and
should not be ignored. WARNING indicates a potentially
hazardous situation that if not avoided, could result in
personal injury or death.CAUTION indicates a potentially
hazardous situation that 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,
long sleeved shirt, and appropriate breathing
protection when working near this insulation.
If contact with skin occurs, wash immediately
with soap and water. In case of contact with
eyes, flush immediately with water for at
least 15 minutes. Contact a physician if
needed.
WARNING:
Improper installation, service, adjustment, or
maintenancemaycauseexplosion,fire,electrical
shock or other hazardous conditions which may
result in personal injury or property damage.
Unless otherwise noted in these instructions,
only factory authorized kits or accessories may
be used with this product.
WARNING:
Do not place combustible material on or against
the unit cabinet. Do not place combustible
materials, including gasoline and any other
flammable vapors and liquids, in the vicinity of
the unit.
WARNING:
The safety information listed below must be
followed during the installation, service, and
operation of this unit. Failure to follow safety
recommendations could result in possible
damage to the equipment, serious per sonal
injury or death
.
• Thisequipmentcontains liquid and gaseous refrigerant
underhigh pressure.Installationorservicingshould only
beperformedbyqualified trainedpersonnel thoroughly
familiar with this type equipment.
• 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.
• Use only with the type of gas approved for this unit.
Refer to the unit rating plate.
• Installthisunit only in a locationandpositionasspecified
on page 8.
• Provide adequate combustion and ventilation air to the
unit as specified on page 6.
• Provideadequate clearances around the air ventintake
terminal as specified in on page 6.
• Combustion products must be discharged outdoors.
Connect this unit to an approved vent system only, as
specified on page 6.
• Never test for gas leaks with an open flame. Use a
commercially available soap solution to check all
connections (See page 10).
• Consult Table 16 (page 42), 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.
• Follow all precautions in the literature, on tags and
on labels provided with the unit and/or approved field
installed kits. The type of hazard and severity are
described on each label or tag.
• This unit is designed only for outdoor installations and
should be located with consideration of minimizing the
length of the supply and return ducts. Consideration
should also be given to the accessibility of fuel, electric
power, service access, noise, and shade.

4
GENERAL INFORMATION
WARNING:
Improper installation, service, adjustment, or
maintenancemaycauseexplosion,fire,electrical
shock or other hazardous conditions which may
result in personal injury or property damage.
Unless otherwise noted in these instructions,
only factory authorized kits or accessories may
be used with this product.
R6GP Series Single Package Gas Heating/Electric
Cooling units are designed for outdoor rooftop or ground
level slab installations. The units are shipped ready for
downflow duct connections and are easily converted for
horizontal duct connections with an optional accessory
kit. See the unit Technical Sales Literature for factory
and field installed accessory information and part
numbers. This information can also be found online at
www.nordyne.com.
Air Ducts
• Air Ducts must be installed in accordance with the
National Fire Protection Association “Standards for
InstallationofAir Conditioning andVentilationSystems”
(NFPA 90A). The ductwork should be appropriately
sized to the capacity of the heating unit to ensure its
proper airflow rating.
• Installation of combination heating/cooling units
must also conform with current C.S.A. Standard B52
“Mechanical Refrigeration Code.”
Air Filter Requirements
WARNING:
Never operate the unit without a filter in place.
Dust and lint could accumulate on internal parts,
resultingin lossof efficiency,equipmentdamage
and possible fire.
All return air must pass through the filters before entering
the unit. It is important that all filters be kept clean and
replaced frequently to ensure proper operation of unit.
Dirty or clogged filters will reduce the efficiency of the
unit and result in unit shutdowns. Air filter pressure drop
must not exceed 0.08 inches WC. When replacing the air
filters, a suitable air filter must be installed ahead of the
evaporator coil of the return air system. Refer to page 17
for recommended filter sizes.
REQUIREMENTS and CODES
This unit must be installed in accordance with
these instructions, 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.
Additional codes listed below are for reference purposes
only and do not necessarily have jurisdiction over local or
statecodes.Localcodesandregulationstakeprecedence
overanyrecommendationscontainedinthese instructions.
Always consult with local authorities before installing any
gas appliance.
Combustion and Ventilation Air
• US:NationalFuelGas Code(NFGC),AirforCombustion
and Ventilation
• CANADA:Natural Gas andPropaneInstallation 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 and Gas Pipe Pressure Testing
• US: NFGC and National Plumbing Codes
• CANADA: NSCNGPIC
General Installation
• US:Current edition ofthe NFGCand the NFPA 90B.For
copies,contact the National Fire Protection Association
Inc.,Batterymarch Park,Quincy,MA02269;orAmerican
Gas Association, 400 N.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
The condensate drain line must be J-trapped using field
supplied parts and may be combined with other drain
lines when routed to the drain.
When connecting rigid drain line, hold any fittings with a
wrench to prevent twisting. Do not overtighten!
Clearances to Combustible Materials
• The R6GP series gas/electric unit is suitable for
installation on combustible flooring or class A, B, or C
roofing materials.
• A clearance of at least 36 inches from the blower
access panel and from the louvered control access
panel is the required clearance to combustibles.Please
refer to Figure 6 (page 8) for all requirements. Where
accessibilityto combustiblesclearancesaregreater
thanminimumclearances,accessibility clearances
must take preference.
• Sufficient clearance for unobstructed airflow through
the louvered control access panel and through the
outdoor coil must be maintained in order to achieve
rated performance.
Combustion Air Quality
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
compounds in the combustion gases.The recommended
source of combustion air is to use clean air from outside.
DONOTplaceanychemicalswith flammableorcaustic
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
Condensate Drain
The method for disposing of condensate varies accord-
ing to local codes. Consult your local code or authority
having jurisdiction.
Condensate is drained from the unit through a
3/4” (19mm) PVC pipe located on the front side of the
unit (Figure 1). For proper drainage, install a 3” (8cm)
Min. trap between the drain line and an open vent of the
same size. Avoid areas where condensate drainage may
cause problems.
3”
Min Roof Curb
Condensate
Drain
Figure 1. Condensate Drain
Equipment Check
All units have been securely packaged at the point of
shipment. After unpacking the unit, carefully inspect for
apparent and concealed damage. Claims for damage
should be filed with the carrier by the consignee.
Equipment Application
Before beginning the installation, verify the unit voltage
requirements and that the model is correct for the job.The
unit model number is printed on the data label. This unit
is NOT to be used for temporary heating of buildings or
structures under construction.
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;
or other approved engineering methods. For installations
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.
Thermostat
A two-stage cooling/ heating 24VAC thermostat should
be used with these units, and installed according to the
instructions supplied by the thermostat manufacturer.The
thermostat should not be installed on an outside wall or
any other location where its operation may be adversely
affected by radiant heat sources such as sunlight, lighting
fixtures, or fireplaces and convective heat from warm/cold
air registers or electrical appliances.

6
VENTING REQUIREMENTS
WARNING:
This unit is intended for outdoor installation
only. Do not vent the unit through a conventional
venting system.
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:
The vent cover assembly must be installed to
assure proper operation of the unit.
A vent cover assembly has been supplied with the unit
and can be found secured to the gas controls within the
burner area of this unit.
Figure 2 displays the proper installation of the vent cover
assembly over the vent outlet of the corner panel. The
fasteners used to secure the vent cover assembly have
been included on the unit end panel.
• Ensure that the exhaust gases will not impinge
on windows or building surfaces, which may be
compromised or damaged by condensation.
• Do not install the unit in a location where exhaust from
the vent termination will be directed into windows,
stairwells, under decks, or other recessed areas.
Figure 2. Vent Cover Assembly
The list below summarizes the location requirements for
the venting 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.
• Must be located at least four (4) feet horizontally from
any electric meters, gas meters, regulators, and relief
equipment.
• Must be located at least 3 feet above any forced air
inlet located within 10 feet of unit.
• Mustbelocatedatleast4feetbelow,4feethorizontally
from, or 1 foot above any door, window, or gravity air
inlet into any building.
• Mustbe locatedatleast1footabovegradeand installed
in such a manner as to prevent snow accumulation
from obstructing the vent termination.
• The vent termination must not be located above any
public walkways.
COMBUSTION AIR REQUIREMENTS
WARNING:
Installation using methods other than those
described in the following sections must comply
withtheNational FuelGas Codeandallapplicable
local codes.
Provisionsmust be madeduring the installation ofthis unit
that provide an adequate supply of air for combustion.
• 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.These requirements are for
US installations as found in the NFGC.
• The requirements in Canada (B149.1) are structured
differently. Consult with B149.1 and local code officials
for Canadian installations.
• Additional reference information for US and Canadian
installations can be found in the Combustion and
Ventilation Air section on page 4.
Air openings in the door of the unit, warm air registers, and
return air grilles must never be restricted. If the unit does
not receive an adequate supply of air for combustion, the
flame roll-out control located above the burners will open,
turning offthe gas supplyto the burners.This safetydevice
is a manually reset switch. IMPORTANT NOTE: DO NOT
install jumper wires across this control to defeat its
function or reset the control without identifying and
correcting the fault condition.
Ifthiscontrolmustbe replaced, use only factory authorized
replacement parts specified in the Replacement Parts
List provided online.
CAUTION:
Appliances that force air from the building to
the outdoors can create negative pressures
inside,resulting in improper operation or unsafe
conditions. It is imperative that sufficient air
exchangewiththeoutdoorsisprovidedtoprevent
depressurization.
Additional information about how to test for
negative pressure problems can be found in the
National Fuel Gas Code.

7
Figure 5. Rigging and Hoisting
LIFTING
BEAM CABLE OR CHAIN
SPREADER
BAR
SPREADER
BAR
BASE
RAIL
BASE
RAIL
Rigging and Hoisting
WARNING:
To avoid the risk of property damage, personal
injury, or death, it is the rigger’s responsibility
to ensure that whatever means are used to hoist
the unit are safe and adequate:
• The lifting equipment must be adequate for
the load. Refer to Table 4 (page 27) for unit
weights.
• The unit must be lifted from the holes in the
base rails using cables or chains. Refer to
Figure 5 for example setup.
• Spreader bars are required to protect the unit
and ensure even loading (See Figure 5).
• Keeptheunit inan uprightposition atall times.
The rigging must be located outside the units
centerof gravity.RefertoFigures 12-14 (pages
22-27) for locating the center of gravity.
• All panels must be secured in place during
rigging and hoisting.
UNIT INSTALLATION
Packaging Removal
1. Remove top crate brackets and wooden cap assembly
from top of unit (Figure 3).
2. Remove lower crate brackets, 4 side skids, and 2 end
skids from each side of unit. NOTE: DO NOT remove
base rails from unit.
3. Rigunitandraiseup approximately4 feetofftheground.
(Also see Rigging and Hoisting section).
4. Remove crate brackets (Figure 4) securing long and
short bottom boards to underside of unit.NOTE:Some
screws are located in fork slots.
5. Remove long and short bottom boards from beneath
unit.
6. Inspect unit thoroughly for shipping damage.
7. Carefully lower and position unit to it’s permanent
location.
Figure 4. Bottom View
Crate Brackets (x4)
Long Bottom
Boards (x2)
Short Bottom
Boards (x2)
Base
Rails
Figure 3. Side View
Wood Cap
Assembly
Top Crate
Brackets
Lower
Crate
Brackets
End Skid
Side Skids

8
Top of unit
to be
unobstructed
Recommended Clearances
for Servicibility
Minimum Required
Clearances to Combustibles 36"
36"
36"
36"
48"
48"
60"
48"
Figure 6. Unit Clearance Requirements
Minimum Clearance Requirements
R6GP units are certified as combination heating and
cooling equipment for outdoor installation only. Figure 6
displays the minimumclearancesto combustiblematerials
for both Downflow and Horizontal discharge.
R6GPunitsmaybe installed on non-combustiblesurfaces
when used with bottom supply and return air ducts.
Units may be installed on wood flooring or on Class A,
B, or C roof covering material as long as the following
requirements are met:
• If using side supply with return air ducts, the
horizontal discharge kit must be installed prior to unit
installation.
• If using bottom discharge with return air ducts
a roof curb must be installed prior to unit
installation. See Rigging and Hoisting section on
page 8 for setting of the unit.
Rooftop Mounting
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. For unit weights, see Table 4 (page 27).Reinforce
the roof if necessary.
• The appropriate accessory roof curb (Figure 7) 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.
WARNING:
Never drill or punch holes in unit base when installing
downflow units. Leakage may occur if bottom pan is
punctured.
• On bottom discharge applications, the supply and
return air ducts must be attached to the roof curb duct
supports, not the unit.Install all ductwork before setting
unit on curb or frame.
• Frame support must be constructed using
noncombustible materials. Full perimeter support is
required under the unit. Supports must be made of
steel or weather resistant wooden materials. The unit
must be square and level to ensure proper condensate
drainage.
• The frame must be high enough to ensure prevention
of any moisture from entering the unit. Recommended
height to unit base is 8” (20cm) for both Downflow and
Horizontal installations.
• Secure roof curb or frame to roof using acceptable
mechanical methods per local codes.
Figure 8. Concrete Mounting Pad
3” min
Figure 7. Roof Curb
Roof Curb
Ground Level
Groundlevelinstallationsmustbelocatedaccording tolocal
building codes or ordinances and these requirements:
• Clearances must be in accordance with those shown
in Figure 6.
• A concrete mounting pad (Figure 8) must be provided
and separate from the building foundation. The pad
must be level to ensure proper condensate disposal
and strong enough to support the unit’s weight. The
slab height must be a minimum of 3”(8cm) above grade
and with adequate drainage.
• Units require horizontal supply and return kit for
horizontal installations.
• Ductwork should be attached directly to flanges on
panels supplied in horizontal duct conversion kits.

9
CIRCULATING AIR SUPPLY
WARNING:
Do not allow combustion products to enter the
return air ductwork or the circulating air supply.
Failure to prevent the circulation of combustion
products into the occupied space can create
potentially hazardous conditions including
carbon monoxide poisoning that could result in
personal injury or death.
All return ductwork must be secured to the
unit with sheet metal screws. All joints must be
taped and adequately sealed. 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 framing must provide sound
physical support of the unit with no gaps,cracks,
or sagging between the unit and the curb or
frame.
Return air and circulating air ductwork must
not be connected to any other heat producing
device such as a fireplace insert, stove, etc.This
may result in fire, explosion, property damage,
personal injury, or death from carbon monoxide
poisoning.
This unit is designed only for use with a supply and return
duct.Any exterior ducts, joints, or openings in the building
roof or walls must be weatherized with conventional
flashing and sealing compounds. Air ducts should be
installed in accordance with all applicable local codes and
the standards of the National Fire Protection Association
“Standard for Installation of Air Conditioning Systems”
(NFPA 90A).
Design the ductwork according to methods described
by the Air Conditioning Contractors of America (ACCA)
Manual Q .
It is recommended that the outlet duct be equipped
with a removable access panel. This opening should be
accessible when the unit is installed in service and shall
be of a size such that the 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 such a manner as to prevent leaks.
If outside air is used as return air 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 ducts and damper system must
be designed so that the return air supply to the unit is
equal to the return air supply under normal, indoor return
air applications.
Additional reference information for US and Canadian
installations can be found in the Duct Systems section
on page 4.
Unconditioned Spaces
Allductworkpassing through unconditionedspacemustbe
properly insulated to prevent condensation and minimize
ductlosses.Useinsulationwith anoutervaporbarrier.Refer
to local codes for insulation material requirements.
Acoustical Ductwork
Certain installations may require acoustical lining inside
the supply ductwork. Acoustical insulation must be in
accordance with the current revision of the Sheet Metal
and Air Conditioning Contractors National Association
(SMACNA) application standard forductliners.Ductlining
must be UL classified batts or blankets with a fire hazard
classification of FHC-25/50 or less.
Fiber ductwork may be used in place of internal duct
liners if the fiber ductwork is in accordance with the
current revision of the SMACNA construction standard
on fibrous glass ducts.
Fibrous ductwork and internal acoustical lining must be
NFPA Class 1 air ducts when tested per UL Standard
181 for Class 1 ducts.
Downflow to Horizontal Conversion
Theunit is shipped ready fordownflow duct connections.If
horizontal ducts are required, the unit must be converted
according to the directions in the conversion kit for both
the supply and return ducts.

10
GAS SUPPLY AND PIPING
All gas piping must be installed in compliance with local
codes and utility regulations.In the absence of local codes
the gas line installation must comply with the latest edition
of the National Fuel Gas Code ANSI Z223.1 or CAN/CGA
B149 Installation Codes.
Additional reference information for US and Canadian
installations can be found in the Gas Piping and Gas Pipe
Pressure Testing section on page 4.
IMPORTANT NOTES:
• DONOTrun gas piping inorthroughairducts,chimneys,
gas vents, elevator shafts, etc.
• Compounds used on threaded ends of gas piping
must be resistant to the actions of liquefied petroleum
gases.
• The main gas valve and main power disconnect to the
unit must be properly labeled by the installer in case
emergency shutdown is required.
• A drip leg must be installed in the pipe run to the unit.
(Figure 9).
• An1/8inchNPTplugged tap mustbeinstalled in the gas
lineimmediatelyupstreamof the gas supply connection
to the furnace for use when measuring the gas supply
pressure. The plug should be readily accessible for
service use.
Some local regulations require the installation of a manual
main shut-off valve and ground joint union external to the
unit. The shut-off valve should be readily accessible for
service and/or emergency use. Consult the local utility
or gas supplier for additional requirements regarding
placement of the manual main gas shut-off.
Table 14 (page 42), lists gas pipe capacities for standard
pipe sizes as a function of length in typical applications
based on nominal pressure drop in the line.
Figure 9.Typical Gas Service Connection.
1. All piping must comply with local codes, ordinances, and/or National Fuel Gas Codes.
2. A manual shutoff valve must be installed within 6 feet of this equipment.
3. Always include a drip leg in piping.
NOTES:
Gas Valve
Gas Valve Riser
3 in.
Minimum
Horizontal
Drop
Piped Gas Supply Tubing Gas Supply
3 in.
Minimum
Horizontal Drop
Gas Valve
3 in.
Min.
Riser
Piped Gas Supply
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.
This unit is shipped from the factory for natural gas
operation at sea level elevation and is equipped with a
#36 orifice at each burner.
Leak Check
WARNING:
FIRE OR EXPLOSION HAZARD
Nevertest forgas leakswith anopenflame.Check
all connections using a commercially available
soap solution. A fire or explosion may result
causing property damage, personal injury or
loss of life. Failure to follow the safety warnings
exactly could result in serious injury, death or
property damage.
After the gas piping to the unit is complete, all connections
must be tested for gas leaks.This includes pipe connec-
tions at the main gas valve, emergency shutoff valve and
other gas connectors.The 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
adequatelyandmust be retightened.Repeat thetightening
and soap check process until bubbling ceases.
IMPORTANT NOTES:
• Ifpressuretestingthegassupplylines at pressures
greater than 1/2 psig (14 inchesWC), the unit must
bedisconnectedfromthegassupplypiping system
to prevent damage to the gas valve.
• If the test pressure is less than or equal to 1/2 psig
(14 inches WC), the unit must be isolated from the
gas supply line by closing the manual shut-off
valve.
High Altitude Deration
High altitude application with this unit depends on the
installation altitude and the heating value of the gas. At
high altitudes, the heating value of natural gas is always
lower than the heating value at sea level.
All installations of this equipment must be made in
accordance with the National Fuel Gas Code or with
local jurisdiction codes. For installations at exactly
2,000 feet in altitude or under, the installer does not
need to derate the heat exchanger performance. For
any installation that exceeds 2,000 feet, please see the
following instructions and example:

11
WARNING:
The reduction of input rating necessary for high
altitude installation may only be accomplished
with factory supplied orifices. Do not attempt to
drill out orifices in the field. Improperly drilled
orifices may cause fire, explosion, carbon
monoxide poisoning, personal injury or death.
• If installing this unit above 2,000 feet, the input rate must
be reduced 4% per 1,000 feet of altitude (Example:12%
at 3,000 feet, 16% at 4,000 feet, etc). Always round up
to the next highest value of 1,000. So an installation
at 3,120 feet is derated by 16% due to rounding up to
4,000.NOTE:Thisderationis necessary to compensate
for lowatmospheric pressure at high altitudes.Generally
this will require obtaining the gas heating value from
the local gas utility and replacing the burner orifices.
• Table 15 (page 42) lists the correct orifice size to use
at different altitudes. See Installation Example 1 to
determine the unit rating and orifice size.
• After changing the orifices, it is required that you
measure the gas input rate by clocking the gas meter
and using the local gas heating value. See section on
Verifying and Adjusting the Firing Rate on page 15.
IMPORTANT NOTE: Observe the action of the
burners to make sure there is no yellowing, lifting
or flashback of the flame.
Conversion to LP/Propane
WARNING:
The furnace was shipped from the factory
equipped to operate on natural gas. Conversion
to LP/propane gas must be performed by
qualified service personnel using a factory
supplied conversion kit.Failure to use the proper
conversionkit cancause fire,explosion,property
damage, carbon monoxide poisoning, personal
injury, or death.
If installing the unit above 2,000 ft., refer to Table 15 to
determine the correct orifice size. When conversion is
complete, verify the input rate is correct as listed in the
tables. Approved conversion kit must be used. Please
follow the instructions provided with each kit.
INSTALLATION EXAMPLE:
Elevation:............................................ 3,890 feet
Type of Gas: ............................................Natural
Unit Model: .............................R6GP-090C200C
At 4,000 feet, the unit needs to be derated by 4% for
each 1,000 feet of elevation. This equates to 16% or
less than the sea level rating of 200,000 Btu/h.
1. Determine unit input rating:
[200k x (100-16)%] = 168,000 Btuh. The required
heating rate for 3,890 feet is 168,000 Btu/h.
2. Determine orifice size:
From Table 15 (page 42), find the Unit Model
Number. Follow across the natural gas row and
stop at the 2,000-4,000 elevation column. For this
example, the orifice size displayed is #38. Install
one #38 orifice in every burner and check firing
rate.Thefiring rate in thisexamplemust not exceed
168,000 Btu/h.
ELECTRICAL WIRING
WARNING:
To avoid the risk of electrical shock, personal
injury, or death, disconnect all electrical power
to the unit before performing any maintenance
or service.
• 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).
• Additional reference information for US and Canadian
installations can be found in the Electrical Connections
section on page 4.
Pre-Electrical Checklist:
√Verify that the voltage, frequency, and phase of the
supply source match the specifications on the unit
rating plate.
√Verify that the service provided by the utility is sufficient
tohandlethe additional load imposed bythis equipment.
SeeTable13 (page 36)or the unitwiringlabelforproper
high and low voltage wiring.
√Verify factory wiringis in accordance with theunit wiring
diagram. Inspect for loose connections.
√For 3 phase units always check the phase balance
(page 12).

12
Line Voltage
It is recommended that the line voltage to the unit be
supplied from a dedicated branch circuit containing the
correct fuse or circuit breaker for the unit.
IMPORTANT NOTE: An electrical disconnect must
be installed readily accessible from and located
within sight of the unit. (See unit data label for proper
incomingfieldwiring).Any other wiring methods must
be acceptable to authority having jurisdiction.
The power supply for the unit must be in accordance with
the unit wiring diagram, and the unit rating plate. Connect
the line-voltage leads to the corresponding terminals on
the terminal block inside the control compartment. Use
only copper wire for the line voltage power supply to this
unit.Use proper code agencylisted conduit andconnector
for connecting the supply wires.
CAUTION:
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improperand dangerousoperation.Verify proper
operation after servicing.
Units are shipped from the factory wired for 230 or 460
volt operation. On 208-230V units being placed into 208
volt operation, remove the lead from the transformer
terminal marked 240V and connect it to the terminal
marked 208V.
Overcurrent protection must be provided at the branch
circuit distribution panel and sized as shown on the unit
rating label and according to the National Electric Code
andapplicablelocal codes.NOTE:Seethe unitratingplate
for maximum circuit ampacity and maximum overcurrent
protection limits.
Grounding
WARNING:
The unit cabinet must have an uninterrupted or
unbroken electrical ground to minimize personal
injury if an electrical fault should occur. Do not
use gas piping as an electrical ground!
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.
Example:
AB = 451V
BC = 460V
AC = 453V
2. Determine the average voltage in the power supply.
3. Determine the maximum deviation:
4. Determine percent of
voltage imbalance by
using the results from
steps2 & 3 inthefollowing
equation.
max voltage deviation
from average voltage
=100x average voltage
% Voltage Imbalance
6
454
100 x= 1.32%
Example:
1. Measurethelinevoltages
of your 3-phase power
supplywhereitentersthe
building and at a location
thatwillonlybe dedicated
to the unit installation.(at
theunitscircuit protection
or disconnect).
Unbalanced 3-Phase Supply Voltage
Voltage unbalance occurs when the voltages of all phases
of a 3-phase power supply are no longer equal. This
unbalance reduces motor efficiency and performance.
Someunderlyingcausesof voltageunbalancemayinclude:
Lackofsymmetryintransmissionlines,large single-phase
loads, and unbalanced or overloaded transformers. A
motor should never be operated when a phase imbalance
in supply is greater than 2%.
Perform the following steps to determine the percentage
of voltage imbalance:
In this example, the measured line voltages were
451, 460, and 453.The average would be 454 volts
(451 + 460 + 453 = 1,364 / 3 = 454).
The amount of phase imbalance (1.32%) is satisfactory
since the amount is lower than the maximum allowable
2%. Please contact your local electric utility company if
your voltage imbalance is more than 2%.
Example:
From the values given in step 1, the BC voltage
(460V) is the greatest difference in value from
the average:
460 - 454 = 6
454 - 451 = 3
454 - 453 = 1
Highest Value

13
Blower Speed
The blower speed is preset at the factory but must
be verified at each installation. For optimum system
performance and comfort, it may be necessary to change
the factory set speed. Refer to Blower Performance Data
(Tables 5 - 12, pages 28 - 35) for proper operating range.
Always ensure drive belt is secure and tensioned properly.
Also inspect variable pitch sheaves for proper tightness
of the set screws
CAUTION:
To avoid personal injury or property damage,
make certain that the motor leads do not make
contact with any uninsulated metal components
of the unit.
To change the blower speed:
1. Disconnect all electrical power to the unit and remove
the blower access panel.
2. Loosen the motor tension bars to allow removal of the
blower belt from the motor sheave.
3. Loosen top set screw on motor sheave and turn
clockwise to close (increases blower speed), or
counterclockwise to open (decreases blower speed).
4. Replace belt on pulleys and position motor mounting
plate to correct position for proper belt tension.
5. Tighten tension bar bolts.
Thermostat
A two-stage heating/cooling thermostat is required for
R6GP series units. Select a thermostat which operates
in conjunction with the installed accessories. See Figure
10 for proper wire gauge and their recommended lengths
for typical thermostat connections.
The thermostat should be mounted about five feet above
the floor on an inside wall.
IMPORTANT NOTE: DO NOT install the thermostat
on an outside wall or any other location where its
operation may be adversely affected by radiant heat
from fireplaces, sunlight, or lighting fixtures, and
convective heat from warm air registers or electrical
appliances. Refer to the thermostat manufacturer’s
instructionsheet fordetailedmountingandinstallation
information.
Heat Anticipator
Verify if the thermostat being used for the installation has a
heatanticipatorsetting.This function allowsthethermostat
to anticipate the space heating rate and time the burner
to shutoff accordingly. Always refer to the thermostat
manufacturers instructions for the correct settings.
Figure 10.Typical Connections - 2 Stage
Heat/Cool T-Stat
Y1
Y2
W2
W1
G
RH
RC
Y1
Y2
W2
W1
G
R
Indoor
Thermostat
Sub-Base
Unit Low Voltage
Terminal
T-Stat Wire
Gauge
Recommended T-Stat Wire
Length - Ft. (Unit to T-Stat)
18 Ga. 0 - 60
16 Ga. 61 - 130
Field Supplied Wiring - - - - - Use Solid Class II Copper Wire
STARTUP AND ADJUSTMENTS
Pre-Start Check List
√Verify unit is properly supported.
√Verify unit is level for proper condensate drainage.
√Verify all clearance requirements are met. Airflow to
and from the outdoor coil must be unrestricted.
√Verify the ductwork is adequately sealed to prevent air
leakage. Insulate if necessary.
√Verify the line voltage power leads are securely
connected and the unit is properly grounded.
√Verify low voltage wires are securely connected to
the correct leads in the low voltage area of the control
box.
√Verify gas line pressure. For natural gas, the line
pressure must not exceed 10.0 inchesWC (0.36 psig),
or be less than 5.5 inches WC (0.20 psig). For LP gas,
the line pressure must not exceed 14 inches WC (0.51
psig) and must not be less than 11.0 inches WC (0.40
psig).
√Verify the flame roll-out control is closed.
IMPORTANTNOTE:Thissafety deviceisamanually
reset switch. If necessary, press the red button to
reset the control. DO NOT install a jumper wire
across the control to defeat its function. If the
control reopens upon start-up, DO NOT reset the
control without identifying and correcting the fault
condition which caused the control to trip.
√Verify the gas linehas been purgedand allconnections
are adequately sealed.To check for gas leakage, see
Leak Check section on page 10.
√Verify the indoor blower is properly set for the
installation.
√Verify the outdoor fan turns freely.

14
√Verify the power supply branch circuit overcurrent
protection is properly sized.
√Verify all exterior panels have been reinstalled and
securely fastened.
√Verify the thermostat is wired correctly and preset for
initial operation. Set the thermostat system switch to
OFF and the fan switch to AUTO.
Startup Procedures
WARNING:
This unit is equipped with crankcase heaters.
Allow 24 hrs for heating of the refrigerant
compressor crankcase prior to start up and
anytime the power has been removed for more
than12hrs.Failuretocomplymayresultindamage
or cause premature failure of the system.
• Check all electrical wiring for loose connections and
tighten as required.
• Check unit for return air filters and condensate trap.
• Close all electrical disconnects to energize the
system.
Air Circulation
1. Setthermostatsystemswitchto OFF and the fanswitch
to ON.
2. Verify the blower motor runs continuously. Check for
air delivery at the register(s). Ensure that there are no
obstructions at the registers or in the ductwork.
3. Setthermostatfan switchto AUTO and verify the blower
shuts down immediately.
NOTE: If bloweris turning oppositeof arrow direction, shut
off main power to the unit and switch any two field wires
at the disconnect. DO NOT alter unit wiring.
System Cooling
1. Set the thermostat system switch to COOL and the fan
switch to AUTO.
2. Lower the thermostat temperature switch below
room temperature and observe that the blower, both
compressors and fans) energize.
3. Verify blower is turning in direction indicated by arrow
and air discharged at the register is cooler than room
temperature.
4. Verify HI and LO refrigerant pressures.
NOTE: If refrigerant pressures are abnormal and blower
is rotating in the opposite direction of the arrow, shut off
main power to the unit and switch any two field wires at
the disconnect. Ensure proper rotation of the blower. DO
NOTalter unit wiring.Listen foranyunusualnoises.Locate
the source and correct as needed.
5. Allow the unit to run for several minutes. Set the
temperature selector above room temperature and
verify that the fan, blower, and compressors cycle off
with the thermostat.
System Heating
1. Set the thermostat to the lowest setting.
2. Follow the startup procedures on this page or the
operating instruction label inside the louvered control
access panel.
3. Set the thermostat above room temperature and verify
the Operating Sequence (page 16).
4. Verify that the compressor and outdoor fan motor are
not energized.
5. Run the unit and after approximately five minutes, set
the thermostat below room temperature. Verify the
shutdown sequence (see Operating Sequence).
Verifying and Adjusting Temperature Rise
Verify the temperature rise through the unit is within the
range specified on the unit data label.Temperature rises
outside the specified range could result in premature heat
exchanger failure.
1. Placethermometersin the return and supplyair stream
asclose to the unit aspossible.The thermometer on the
supplyairside mustbe shielded against direct radiation
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: For typical duct systems, the temperature rise will
fall within the range specified on the data label (with the
blower speed at the factory recommended setting) shown
inTable16, page42.Ifthemeasured temperaturerise falls
outsidethespecifiedrange,itmaybe necessary to change
the blower speed. Lowering the blower speed increases
the temperature rise and a higher speed decreases the
temperature rise.
The unit is equipped with a belt driven blower and variable
pitch motor sheave. The selection of a sheave setting
should be based on the desired CFM and the duct system
parameters.Refer to the ACCA’s Manual Q for a complete
description of how to determine these parameters and
Manual N for determination of the commercial load
requirements.The blower performance data can be found
in Tables 5 - 12 (pages 28 - 35).
For 71/2and10tonunits,the integratedcontrol is designed
to start the circulating air blower 45 seconds after the gas
valve opens and designed to turn the blower motor off 150
seconds after the gas valve is closed.
For 6 ton units, the integrated control is designed to start
the circulating air blower 40 seconds after the gas valve
opens and turn the blower motor off 150 seconds after
the gas valve is closed

15
Verifying Burner Operation
WARNING:
Uninsulated live components are exposed when
the louvered control access panel is removed.
1. Remove the louvered control access panel to ensure
there is power to the unit.
2. Set the thermostat above room temperature and
observe the ignition sequence.The burnerflame should
carry over immediately between all burners and should
extend from each burner without lifting off, curling, or
floating. The flames should be blue, without yellow
tips.
3. After verifying flame characteristics, set the thermostat
below room temperature and verify that the burner
flame extinguishes completely.
Verifying Operation of Over-Temperature Limit
Control
To verify operation of the over-temperature limit control,
make sure the louvered control access panel is in place
and that there is power to the unit.
1. Block the return airflow to the unit by installing a close-
off plate in place of or upstream of the filter.
2. Set the thermostat above room temperature and verify
theunitoperateswith the correct sequence of operation
(see Operating Sequence).
NOTE:The over-temperature limit control should function
to turn off the gas valve within approximately four minutes
(exact time depends on the efficiency of the close-off when
blockingthe return air).The circulating air andcombustion
blowersshouldcontinueto runwhentheover-temperature
limit control switch opens.
3. 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 the unit, and replace the over-temperature limit
control.
Verifying and Adjusting Firing Rate
The firing rate must be verified for each installation to
prevent over-firing of the unit.
CAUTION:
Do not re-drill the burner orifices. If the orifice
size must be changed, use only new orifices.
IMPORTANT NOTE: The firing rate must not exceed
the rate shown on the unit data label. At altitudes
above 2,000 ft., it must not exceed that on the data
label less 4% for each 1,000 ft.
Follow the steps below to determine the unit firing rate:
• For installations at 2,000 feet and less, the firing rate
is the same as shown on the unit rating label.
• Forinstallationsabove2,000feet,computethecorrect
firing rate as shown in the installation example on
page 11.
1. Obtain the gas heating value from the gas supplier
(HHV).
2. Shut off all other gas fired appliances.
3. Start the unit in heating mode and allow it to run for at
least three 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 17 (page 43).
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:
Example:
• Time for 1 revolution of a gas meter with a 1
cubic foot dial = 40 seconds.
• From Table 17 read 90 cubic feet gas per hour.
• Local heating value of the gas (obtained from
gas supplier) = 1,040 Btu per cubic foot.
• Input rate = 1,040 x 90 = 93,600 Btuh.
7. Adjustments to the firing rate can be made by adjusting
the gas manifold pressure. See the High Altitude
Deration section (page 10) for additional information
of firing rate at elevations above 2000 ft.
The manifold pressure must be set to the appropriate
value for your installation. Refer to Table 15 (page 42)
for the correct orifice size and manifold pressure setting
required for your particular installation. To adjust the
manifold pressure, remove the regulator cap and turn
the adjusting screw clockwise to increase pressure
or counterclockwise to reduce pressure. Replace the
regulator cap after adjustments are complete.

16
OPERATING SEQUENCE
The operating sequences for the heating, cooling, and
fan modes are described below. Refer to the wiring
diagrams (Figures 15 - 19, pages 37 - 41).
Cooling Mode:
1. On a call for cooling the thermostat closes, applying
24 VAC to “Y1”, “G”, and “Y2” if Stage 2 cooling is
calling.
2. “G” applies 24VAC to the main circulating blower
circuit.
3. “Y1” and “Y2” apply 24VAC through all safety switches
before energizing their respective contactors.
4. When the thermostat is satisfied the contactors are
de-energized.
5. The circulating blower motor de-energizes
immediately.
Heating Mode for 200 & 235 kBtuh Heat
Exchangers:
1. On a call for heat, the thermostat closes, applying 24
VAC to the “W1”terminal (and “W2” terminal if Stage 2
heat is required). NOTE: There is a three minute time
delay before Stage 2 heat is energized.
2. The integrated control monitors the safety circuit at all
times.If either theroll-outswitch ortheover-temperature
limit controls open, the gas valve will not energize.
The main blower continues to operate until the over-
temperature limits close, the flame roll-out switch is
manually reset, or the thermostat is satisfied.
3. The integrated control checks all safety switches at
the beginning of each heating cycle. If closed, the
combustion blower performs a 15 second pre-purge.
4. The integrated control will then supply power to the
direct spark ignitor and immediately energizes the gas
valve.
5. The flame must be proven through the flame sensor in
7 seconds to hold the gas valve open. The integrated
control will monitor the gas flame with the flame sensor
for the entire time thegas valve is open.Ifforany reason
the gas flame drops out, the gas valve will immediately
close.After 30 second purge, the integrated control will
try to ignite two more times.
6. The main air blower will start and continue to run 45
seconds after the gas valve opens.
7. When the thermostat is satisfied, the integrated control
is de-energized.The gas valve and combustion blower
de-energize immediately while the main air blower
continues to run through the blower off delay of 150
seconds.
8. Iftheunitfailstoproveflameafterthree ignitionattempts,
it will go into a soft lockout.The unit will re-attempt the
start-up procedure every hour until the thermostat is
satisfied or 24 VAC power is removed from the unit for
a minimum period of 5 seconds.
Heating Mode for 100 & 166 kBtuh Heat
Exchangers:
1. On a call for heat, the thermostat closes, applying 24
VAC to the W1 terminal (and W2 terminal if Stage 2
heat is required).
2. The integrated control monitors the safety circuit at all
times.If either the roll-out switchortheover-temperature
limit controls open, the gas valve will not energize.
The main blower continues to operate until the over-
temperature limits close, the flame roll-out switch is
manually reset, or the thermostat is satisfied.
3. The integrated control checks all safety switches at
the beginning of each heating cycle. If closed, the
combustion blower performs a 10 second pre-purge.
4. The integrated control will then supply power to the
direct spark ignitor and immediately energizes the gas
valve.NOTE:Burner operationbegins in high firemode
with both Stage 1 and Stage 2 gas valve energized,
independent of the thermostat call for Stage 2 heat.
If after 30 seconds of operation with no call for Stage
2 heat, the integrated control will resume heating
operation in low fire mode of operation and Stage 2
gas valve is de-energized.
5. The flame must be proven through the flame sensor in
10 seconds to hold the gas valve open.The integrated
control will monitor the gas flame with the flame sensor
for the entire timethe gas valveis open.If foranyreason
the gas flame drops out, the gas valve will immediately
close.After 30 second purge, the integrated control will
try to ignite fourteen more times.
6. The main air blower will start and continue to run 40
seconds after the gas valve opens.
7. When the thermostat is satisfied, the integrated
control is de-energized.The gas valve and combustion
blower de-energize immediately while the main air
blower continues to run through the blower off delay
of approximately 150 seconds.
8. If the unit fails to prove flame after fifteen ignition
attempts, it will go into a soft lockout. The unit will
re-attempt the start-up procedure every hour until the
thermostat is satisfied or 24 VAC power is removed
from the unit for a minimum period of 5 seconds.
NOTE: See Table 2 (page 17) or Figure 15 (page 37)
for a complete list of heating operation fault codes.
Blower Mode:
1. On a call for fan operation, the thermostat applies 24
VAC directly to the blower contactor.
2. The circulating blower is energized immediately.

17
TROUBLESHOOTING
If the unit does not operate properly in the cooling
mode, check the following:
• The thermostat is operating properly.
• Electrical power to the unit is turned on.
• All safety switches are closed.
• The service doors are in place.
• Transformer circuit breaker is reset.
If the unit does not operate properly in the heating
mode, check the following:
• The thermostat is operating properly.
• Electrical power to the unit is turned on.
• All safety switches are closed.
• The gas is on and shut-off valve is open.
• The service doors are in place.
• The flame roll-out control is closed.
• Refer to the diagnostic codes in Tables 1 or 2, or the
wiring diagrams (Figures 15 - 19, pages 37 - 41).
• Transformer circuit breaker is reset.
Table 1. Diagnostic Codes For 7 1/2 & 10 Ton Units
STATUS LIGHT
(RED)
FAULT
CONDITION
Continuous ON Internal Control Failure
2 Flashes Flame Sense Problem
3 Flashes Ignition Lockout
STATUS LIGHT
(Red LED)
FAULT
CONDITION
Continuous ON Operation Normal
2 Flashes Pressure/centrifugal switch open
with inducer on
3 Flashes Pressure/centrifugal switch closed
with inducer off
4 Flashes Lockout from too many
failed ignition tries
5 Flashes Lockout from too many
flame losses
6 Flashes High temperature switch open
7 Flashes Rollout switch open
8 Flashes Flame present with gas off
9 Flashes Exceeded max limit trips (5)
in one call for heat
10 Flashes Gas valve fault
Table 2. Diagnostic Codes For 6 Ton Units
UNIT MAINTENANCE
NOTE: These maintenance instructions are primarily
intended to assist qualified technicians experienced in the
proper maintenance and operation of this appliance.
To achieve optimum performance from the air conditioner
and minimize equipment failure, it is recommended
that periodic maintenance be performed on this unit.
The ability to properly perform maintenance on this
equipment requires certain mechanical skills and tools.
Please consult your dealer for maintenance information
and availability of maintenance contracts.
CAUTION:
Use care when removing parts from this unit.
Personal injury can result from sharp metal
edges present in all equipment of sheet metal
construction.
At a minimum, routine maintenance should include the
following items:
Condensate Drain and Outdoor Coil
Inspect the condensate drain and outdoor coil at the
beginning of each cooling season. Remove any debris.
Clean the outdoor coil and hail guard louvers (optional)
as necessary using a mild detergent and water. Rinse
thoroughly with water.
Air Filters
WARNING:
Neveroperatethe unitwithout filtersinplace.Dust
and lint in the return air can build up on internal
components, resulting in loss of efficiency,
equipment damage, and possible fire.
It is recommended that the air filters be inspected and
cleaned or replaced every three to four weeks using filters
of like size and kind. Table 3 lists the correct filter sizes
and quantities for each unit.
IMPORTANT NOTE: R6GP units are equipped with 2”
pleated disposable filters.Filter rack is adjustable for
1” permanent type filters. DO NOT use 1” disposable
filters.
UNIT
FACTORY
FILTER
SIZE
QTY
R6GP-072*-(100/166)C 16x20x2 4
R6GP-090*-200C 16x20x2 4
R6GP-120*-235C 16x25x2 4
Table 3. Filter Sizes and Quantities

18
8. Remove four screws securing the burner assembly to
the unit.
9. Carefully remove the burner assembly from the unit.
DONOTDAMAGETHE IGNITORWHILEREMOVING
THE BURNER ASSEMBLY.
10. Inspect the burners for accumulated dust or debris.
If necessary, carefully clean them with a soft wire
brush and/or the nozzle of a vacuum cleaner. DO
NOT DAMAGETHE IGNITOR OR FLAME SENSOR
WHILE CLEANING THE BURNER.
11. Replace all the parts in reverse order from which they
were removed.
12. Follow the lighting instructions found on the right
side door to return the unit to operation.Verify proper
operation after servicing.
Cleaning of Heat Exchanger
If the heat exchanger must be cleaned due to soot or
scale build up, follow the steps below.
1. Shut off the gas supply to the unit either at the meter
or at the manual valve in the gas supply piping.
2. Turn off all power to the unit and set the thermostat to
the lowest temperature setting.
CAUTION:
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
3. Disconnect the wires from the gas valve, ignitor, and
flame sensor.
4. Using two wrenches, separate the ground-joint union
in the gas supply piping at the unit.
5. Remove the piping between the gas valve and the
ground-joint union, if necessary.
6. Remove the four screws securing the burner assembly
to the unit.
7. Carefullyremovetheburner assemblyfrom the unit.DO
NOT DAMAGE THE IGNITOR OR FLAME SENSOR
WHILE REMOVING THE BURNER ASSEMBLY.
8. Remove three nuts securing the combustion blower to
the collector pan.
9. Remove the complete combustion blower from the
unit.
10. Remove the screws securing the collector box cover
to the unit and remove cover plate.
11. Remove the screws securing the balance plate to the
collector box and the balance plate.
12. Remove the turbulator from each heat exchanger
tube.
13. Attach a round wire brush to a length of high grade
stainless steel cable, such as drain cleanout cable.
Attach the other end of the spring cable to a variable
speedreversibledrill.Slowlyinsertandrotatethecable
into the top portion of the heat exchanger. Operate
Blower Compartment
Build up of dirt and lint on the blower and motor can create
excessive loads on the motor resulting in higher than
normal operating temperatures and possible shortened
servicelife.Itisrecommendedthat the blowercompartment
be cleaned monthly during heating and cooling seasons
to remove any dirt and lint that may have accumulated in
the compartment or on the blower and motor. Inspect the
blower drive belt for cracks, excessive wear and proper
tension after cleaning the compartment.
Heat Exchanger and Burner Maintenance
The unit should operate for many years without excessive
scale buildup in the heat exchanger, however, the heat
exchanger, the vent system, and the burners should be
inspectedand cleaned (ifrequired)byaqualifiedtechnician
annually to ensure continued safe operation. Particular
attention must be given to identify deterioration from
corrosion or other sources.
WARNING:
Holes in the heat exchanger can cause products
of combustion to enter the structure. Replace
the heat exchanger if leaks are found. Failure
to prevent products of combustion from being
circulated into the occupied space can create
potentially hazardous conditions including
carbon monoxide poisoning that could result in
personal injury or death.
Cleaning of Burners
It is recommended that the burners be inspected and
cleaned periodically (if required) by a qualified technician
annually to ensure continued safe operation. Particular
attention must be given to identify deterioration from
corrosionor other sources.If the burnersmustbe cleaned,
follow the steps below.
1. Shut off the gas supply to the unit either at the meter
or at a manual valve in the supply piping.
2. Turn off all power to the unit and set the thermostat to
the lowest temperature setting.
3. Remove the louvered access panel from the unit.
4. Turn the gas control knob to the “OFF” position.
CAUTION:
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
5. Disconnect the wires from the gas valve, ignitor, and
flame sensor.
6. Using two wrenches, separate the ground-joint union
in the gas supply piping at the unit.
7. Remove the piping between the gas valve and the
ground-joint union (if necessary).

19
the drill alternating between forward and reverse,
working the cable in and out several times to obtain
sufficient cleaning. Repeat this sequence for each
heat exchanger tube.
14. Remove all loosened debris from the heat exchanger
tubes using a vacuum cleaner.
15. Using a light, check the condition of the upper and
lower sections of the heat exchanger tube.
16. Inspect the burners and if necessary, clean them
carefully with a soft wire brush and/or the nozzle of
a vacuum cleaner.DO NOT DAMAGETHE IGNITOR
OR FLAME SENSOR WHILE CLEANING THE
BURNER.
17. Replace all the parts in reverse order from which they
were removed. NOTE: If screws or other hardware
are corroded, replace only with corrosion resistant
stainless steel hardware of similar design.
18. Follow the operating instructions found on the right
side door and the User’s Information Manual to return
the unit to operation.
Vent Cover Assembly
Inspect and clean the screen of the vent cover assembly
at the beginning of each heating and cooling seasons.
Electrical
WARNING:
This unit may have more than one electrical
supply.To avoid risk of electrical shock,personal
injury, or death, disconnect all electrical power
to the unit before performing any maintenance
or service.
Inspect the electrical connections for tightness at the
beginning of each heating and cooling season. Service
as necessary.
CAUTION:
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
Motor Lubrication
The motors for the circulating air blower, outdoor fan, and
combustion blower are pre-lubricated at the factory. No
further oiling is required for the life of this product.
WARNING:
Lubrication of the motors in this unit is not
required. Do not lubricate any motor in this
product.
Refrigerant Charging
TheR6 Seriespackagedgas/electricunitsare fullycharged
at the factory and when installed accordingly, no charging
is required. The refrigerant charge can be checked and
adjusted through the service ports provided on the units.
Use only gauge lines which have a“Schrader”depression
device present to actuate the valve. Refer to Figures 20
- 22 (pages 44 - 45)
Refrigerant charging must be done by qualified personnel
familiar with safe and environmentally responsible
refrigerant handling procedures. See Unit Rating Plate
for the proper type and amount of refrigerant.
WARNING:
If repairs make it necessary for evacuation and
charging, it should only be done by qualified,
trained personnel thoroughly familiar with this
equipment. Some local codes require licensed
installation/servicepersonnelto servicethistype
of equipment. Under no circumstances should
the owner attempt to install and/or service this
equipment.
Failure to comply with this warning could result
in property damage, personal injury, or death.

20
COMPONENT FUNCTIONS
Thedescriptions belowarevariousfunctional components
that affect the operation and shutting down of this unit.
Some of these components and their locations are shown
in Figure 11 (page 21).
If any component on this unit must be replaced, use only
factory authorized replacement parts specified in the
Replacement Parts List provided online.
Centrifugal Switch
The centrifugal switch acts to verify that the inducer motor
is running.Combustion gases are drawn through the heat
exchanger tubes and vented through the vent system.
Flame Roll-Out Control
The flame roll-out control acts to verify that the burner
flame is being drawn into the heat exchanger tubes. If the
burner flame is not being drawn into the heat exchanger
tubes, the roll-out control will open within several seconds.
Thecombustionblower will continue to operate if the flame
roll-out control opens until it is manually reset.
Flame Sensor
The flame sensor acts to prove that flame has carried
over from the ignitor to the right-most burner. If no flame
is sensed, the unit will be shut down automatically and
attempt two additional ignition trials before going into
lockout. Recovery from lockout requires a manual reset
by either resetting the thermostat or removing 24 volts
for a period of 5 seconds. If the thermostat is still calling
for heat after one hour the control will automatically reset
and attempt to ignite the burner again.
Gas Valve
The gas valve controls the flow of gas to the burners in
both low and high fire. When the valve is energized, it
automatically opens and regulates the gas pressure to
the manifold.
High Pressure Switch
This factory installed switch is designed to de-energize
the unit when excessive pressure occurs due to abnormal
conditions.Under normal conditions, the switch is closed.
If the discharge pressure rises above 650 psig, then the
switch will open and de-energize the outdoor unit. The
switch is a manually reset type and will remain open until
the button on top of the switch is depressed.
Indoor Coil, Freeze Protection Thermostats
Thefreezeprotection switchesare designedto protectthe
indoor coils from ice and frost accumulations in the event
of a loss of airflow by preventing the liquid refrigerant from
reaching the compressors. During normal operation, the
switches are closed and will open if the coil temperature
reaches 28° F (-2° C). The switches will close if the coil
temperature reaches 57° F (12° C).
Low Pressure Switch
This factory installed switch is designed to protect the
compressorfrom alossofcharge.Undernormal conditions,
the switch is closed. If the suction pressure falls below 5
psig,thentheswitchwill open and de-energizetheoutdoor
unit.The switch will close again once the suction pressure
increases above 20 psig.
Over-Temperature Limit Control
The over-temperature limit control acts to prevent the
air temperature leaving the unit from exceeding the
maximum outlet air temperature. If the limit opens, the
blower limit relay will energize.The circulating air blower
and combustion blower will continue to operate if the
over-temperature limit control opens.