Nortek iHybrid DF6SF 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.
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 qualied installer, service agency or the
gas supplier.
• Do not store or use gasoline or other
ammable 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 re department.
15 SEER
Dual Fuel Heating and Cooling Packaged System
DF6SF SERIES
Premium Model Shown
INSTALLATION INSTRUCTIONS

2
SAFETY IINFORMATION ............................................4
ABOUT THE HEAT PUMP ...........................................4
OPERATING IINSTRUCTIONS....................................4
Cooling Operation .....................................................4
Heating Operation .....................................................4
Emergency Heat........................................................4
Defrost Operation......................................................4
Operating the Heat Pump for Automatic
Cooling and Heating..................................................5
Oper. the Indoor Blower Continuously.......................5
Shutting the Heat Pump Off ......................................5
HEAT PUMP MAINTENANCE .....................................5
Regular Cleaning.......................................................5
Before You Call a Technician .....................................5
TROUBLESHOOTING .................................................5
WARRANTY INFORMATION.......................................5
USER INFORMATION

3
SAFETY IINFORMATION ............................................6
REQUIREMENTS & CODES .......................................7
GENERAL INFORMATION..........................................8
Pre - Installation Check .............................................8
Locating the Heat Pump Unit ....................................8
Field Connections for Electrical Power
Supply .......................................................................8
Heating Load ............................................................8
Combustion Air Requirements .................................8
Venting Requirements ..............................................9
Circulating Air Supply .............................................11
Air Ducts .............................................................11
Air Filter Requirements ........................................11
Unconditioned Spaces .........................................11
Acoustical Duct Work ...........................................12
EQUIPMENT INSTALLATION ...................................12
Packaging Removal.................................................12
Rigging and Hoisting ...............................................12
Clearances to Combustibles....................................12
Ground Level...........................................................12
Rooftop....................................................................12
Condensate Drain ..................................................12
Horizontal to Downflow Conversion.........................12
ELECTRICAL WIRING...............................................13
Pre - Electrical Checklist .........................................13
Line Voltage.............................................................13
Grounding................................................................14
Thermostat / Low Voltage Connections...................14
Heating Configurations............................................15
Two - Stage Heating configuration .......................15
High Fire Configuration ........................................15
Timed Staging Configuration................................15
Two - Stage Cooling Configuration.......................15
Checking Heat Anticipator Settings......................15
Configuring the Variable Speed Blower ..................15
Selecting Basic Cool/Heat Pump Airflow .............15
Selecting Gas Heating Airflow..............................15
Delay Profile.........................................................16
Demand Defrost Control..........................................16
Ambient Sensor Mounting.......................................16
Optional Humidistat.................................................16
Optional Comfort AlertTM Diagnostics Module .........16
24VAC Power Wiring ............................................17
Thermostat Demand Wiring .................................17
L Terminal Wiring .................................................17
DC SOL Connection ............................................18
Interpreting the Diagnostic LED’s.........................18
LED Description ...................................................18
Installation Verification .........................................18
Troubleshooting the Installation............................18
Optional Outdoor Thermostat..................................18
GAS SUPPLY & PIPING............................................19
Leak Check .............................................................19
High Altitude Conversion.........................................19
Lp/Propane Gas Conversion...................................20
STARTUP & ADJUSTMENTS ...................................20
Pre - Start Checklist ................................................20
Start-up Procedure..................................................20
Air Circulation.......................................................21
Short Cycle Protection .........................................21
System Cooling....................................................21
Secondary Heating ..............................................21
Verifying & Adjusting Temperature Rise ..................21
Verifying & Adjusting Firing Rate.............................21
Manifold Pressure Adjustment ................................22
Verifying Burner Operation......................................22
Verifying Over-Temperature Limit
Control Operation....................................................22
Refrigerant Charging...............................................22
Charging an R-410A Unit in AC Mode ....................23
Charging an R-410A Unit in Heating Mode.............23
REPLACEMENT PARTS............................................23
OPERATING SEQUENCE .........................................23
2 - Stage Heating Mode ..........................................23
Gas Heating / Emergency Heat Mode.....................23
2 - Stage Cooling Mode...........................................24
Fan Mode ................................................................24
EQUIPMENT MAINTENANCE...................................24
Cleaning of Heat Exchanger ...................................25
Cleaning of Burners ................................................25
TROUBLESHOOTING ...............................................26
COMPONENT FUNCTIONS ......................................26
FIGURES & TABLES .................................................27
Figure 11. DF6SF Heat Pump Dimensions..........27
Table 9. Center of Gravity & Shipping Weights.....27
Airflow Information...................................................28
Table 10. Nominal Airflow Rates & Temp Rises ...28
Table 11. Airflow Settings for Cooling...................28
Table 12. Airflow Settings for Heating...................28
Gas Information.......................................................29
Table 13. Gas Pipe Capacities .............................29
Table 14. Gas Flow Rates ....................................29
Figure 12. DF6SF Gas Valve Label......................30
Electrical Information...............................................31
Figure 13. Wiring Diagram for 2 & 5 Ton Units .....31
Figure 14. Wiring Diagram for 2 & 5 Ton Units
w/ Optional Comfort Alert ....................32
Figure 15. Wiring Diagram for 3 & 4 Ton Units ..... 33
Figure 16. Wiring Diagram for 3 & 4 Ton Units
w/ Optional Comfort Alert ....................34
Cooling Charging Charts.........................................35
Figure 17. Charging Chart for 2 Ton Units............35
Figure 18. Charging Chart for 3 Ton Units............35
Figure 19. Charging Chart for 4 Ton Units............36
Figure 20. Charging Chart for 5 Ton Units............36
Comfort Alert Troubleshooting Charts .....................37
Table 15. LED Diagnostics ...................................37
Table 16. Module Wiring Troubleshooting.............39
FRENCH TRANSLATIONS ........................................40
INSTALLER INFORMATION

4
ABOUT THE HEAT PUMP
Your heat pump is a unique, all weather comfort-control
appliancethatwill heatandcool yourhome yearround and
provide energy saving comfort. It’s an unknown fact that
heatisalwaysin theair, evenwhentheoutsidetemperature
is below freezing. The heat pump uses this basic law of
physics to provide energy saving heat during the winter
months. For example, If the outdoor temperature is 47° F
(8° C), your heat pump can deliver approximately 3.5 units
of heat energy per each unit of electrical energy used,
as compared to a maximum of only 1 unit of heat energy
produced with conventional heating systems.
In colder temperatures, the heat pump performs like an air
conditioner run in reverse. Available heat energy outside
the home is absorbed by the refrigerant and exhausted
inside the home. This efficient process means you only
pay for “moving” the heat from the outdoors to the indoor
area.You do not pay to generate the heat, as is the case
with more traditional furnace designs.
During summer, the heat pump reverses the flow of the
heat-absorbing refrigerant to become an energy-efficient,
centralair conditioner.Excessheatenergyinsidethehome
is absorbed by the refrigerant and exhausted outside the
home.
IMPORTANT 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
hazardoussituationthatif not avoided,mayresultin minor
or moderate injury or property damage.
USER INFORMATION
Figure 1. Digital Thermostat
Fan
Mode
Temperature
Selector
System
Mode
OPERATING INSTRUCTIONS
A thermostat with fossil fuel back-up heat capability is
required to operate the Dual Fuel iHybrid™ heat pump
system. Please refer to the thermostat manufacturer’s
User Manual for detailed programming instructions.
Cooling Operation
1. Set the thermostat’s system mode to COOL or AUTO
and change the fan mode to AUTO. See Figure 1
2. Setthetemperatureselectortothedesired temperature
level. The outdoor fan, compressor, and blower
motor will all cycle on and off to maintain the indoor
temperature at the desired cooling level.
NOTE: If the temperature level is re-adjusted, or the
system mode is reset, the fan and compressor in the
outdoor unit may not start immediately. A protective
timercircuitholds the compressorandthe outdoor fan
off for approximately 5 minutes following a previous
operation or the interruption of the main electrical
power.
Heating Operation
1. Set the thermostat’s system mode to HEAT or AUTO
and change the fan mode to AUTO. See Figure 1.
2. Setthetemperatureselectortothedesired temperature
level.The compressor, outdoor fan, and blower motor
will cycle on and off to maintain the indoor temperature
at the desired heating level.
NOTE: If the temperature level is re-adjusted, or the
system mode is reset, the fan and compressor in the
outdoor unit may not start immediately. A protective
timer circuit holds the compressor and the outdoor
fan off for approximately five minutes following a
previous operation or the interruption of the main
electrical power.
Emergency Heat
Some thermostats may include a system mode called EM
HT or AUX HT, etc. This is a back-up heating mode that
should only be used if a problem is suspected. With the
mode set to EM HT, etc., the compressor and outdoor
fan will be locked off and supplemental heat (gas heating)
will be used as a source of heat. Sustained use of gas
heat in place of the heat pump will result in an increase
in electric utility costs.
Defrost Operation
During cold weather heating operation, the outdoor unit
will develop a coating of snow and ice on the heat transfer
coil.This is normal and the unit will defrost itself.This unit
features Demand Defrost that monitors ambient and coil
temperatures to regulate the defrost function accordingly.

5
At the beginning of the defrost cycle, both the outdoor
condenser fan and compressor will turn off. After
approximately 30 seconds, the compressor will turn on
and begin to heat the outdoor coil causing the ice and
snow to melt.
NOTE: While the ice and snow is melting, some steam
may rise from the outdoor unit as the warm coil causes the
melting frost to evaporate.When defrost is completed, the
outdoor fan motor will start, and the compressor will turn
off again. In approximately 30 seconds the compressor
will start up again and continue normal operation.
Operating the Heat Pump for Automatic Cooling
and Heating
1. Set the thermostat system switch to AUTO and the
thermostat fan switch to AUTO. See Figure 1.
NOTE: Thermostat styles vary. Some models will not
includetheAUTOmode andotherswill havethe AUTO
in place of the HEAT and COOL. Others may include
all three. Refer to the instructions supplied with your
thermostat for specific instructions.
2. Set the thermostat temperature to the desired heating
and cooling temperature level(s).The outdoor unit and
the indoor blower will then cycle on and off in either
the heating or cooling mode of operation as required
toautomaticallymaintain theindoortemperature within
the desired limits.
Operating the Indoor Blower Continuously
Thecontinuousindoorbloweroperationistypically usedto
circulatetheindoorairtoequalizeatemperatureunbalance
due to a sun load, cooking, or fireplace operation.
Set the thermostat fan mode to ON (Figure 1).The indoor
blower starts immediately, and will run continually until the
fan mode is reset to AUTO.
The continuous indoor blower operation can be obtained
with the thermostat system mode set in any position,
including OFF.
Shutting the Heat Pump Off
Change the thermostat’s system mode to OFF and the fan
mode to AUTO. See Figure 1. NOTE: The system will not
operate, regardless of the temperature selector setting.
HEAT PUMP MAINTENANCE
CAUTION:
Shut off all electrical power to the unit before
performing any maintenance on the system.
Failure to comply may result in personal injury
or death.
Proper maintenance is most important to achieve the best
performance from the appliance and should be performed
by a qualified service technician at least once a year.
Follow the maintenance schedule and the instructions
below for years of safe, trouble free operation.
Regular Cleaning
WARNING:
Do not place combustible material on or against
the unit cabinet. Do not place combustible
materials, including gasoline and any other
ammable vapors and liquids, in the vicinity of
the unit.
•Clean or replace the indoor air filter at the start of each
heating and cooling season, and when an accumulation
of dust and dirt is visible on the air filter.
• Removeanyleavesandgrassclippingsfromthecoil
in the outdoor unit, being careful not to damage the
aluminum fins.
• Checkforobstructions,suchastwigs,sticks,etc.
TROUBLESHOOTING
If the unit fails to operate, check the following:
•The thermostat is properly set. See Cooling Operation
for air conditioning or Heating Operation for furnace or
air handler.
•The unit disconnect fuses are in good condition and the
electrical power to the unit is turned on.
WARRANTY INFORMATION
A warranty certificate with full details is included with the
heat pump. Carefully review these responsibilities with
your dealer or service company.The manufacturer will not
be responsible for any costs found necessary to correct
problems due to improper setup, improper installation,
adjustments, improper operating procedure on the part
of the user, etc. Some specific examples of service calls
which are not included in the limited warranty are:
•Correcting wiring problems in the electrical circuit
supplying the heat pump.
•Resetting circuit breakers or other switches.
•Adjusting or calibrating of thermostat.
USER INFORMATION

6
INSTALLER INFORMATION
IMPORTANT SAFETY INFORMATION
Pleaseread allinstructionsbeforeservicingthisequipment.
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
degree or level of seriousness and should not be ignored.
WARNING indicates a potentiallyhazardoussituation 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:
These units are fully charged with R-410A
refrigerant and ready for installation. When
a system is installed according to these
instructions, no refrigerant charging is required.
If repairs make it necessary for evacuation
and charging, it should only be attempted by
qualied, trained personnel thoroughly familiar
with this equipment. Some local codes require
licensed installation service personnel to
service this type of equipment. Under no
circumstances should the homeowner attempt
to install and/or service this equipment. Failure
to comply with this warning could result in
equipment damage, personal injury, or death.
WARNING:
PROPOSITION 65 WARNING: This product
contains berglass 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
berglass 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, ush immediately with water for at
least 15 minutes. Contact a physician if needed.
WARNING:
The information listed below and on the next
page must be followed during the installation,
service, and operation of this unit. Unqualied
individuals should not attempt to interpret these
instructions or install this equipment. Failure
to follow safety recommendations could result
in possible damage to the equipment, serious
per sonal injury or death .
• The installationmustconformwiththe NationalFuelGas
Code(ANSI2223.1,NFPA-54),orCanadianinstallations
must conform with CAN/CGA-B149 installation codes.
• 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
these instructions.Consult local building codes and the
NationalElectricalCode (ANSICI)forspecial installation
requirements.
WARNING:
Improper installation, service, adjustment, or
maintenance may cause explosion, re, 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.
CAUTION:
This unit uses refrigerant R-410A. DO NOT use
any other refrigerant in this unit. Use of another
refrigerant will damage the unit.
WARNING:
Shut off all electrical power to the unit before
performing any maintenance or service on the
system. Failure to comply may result in personal
injury or death.
WARNING:
Do not place combustible material on or against
the unit cabinet. Do not place combustible
materials, including gasoline and any other
ammable vapors and liquids, in the vicinity of
the unit.

7
• Thisequipmentcontainsliquidandgaseousrefrigerant
underhighpressure.Installation orservicing shouldonly
be performed by qualified trained personnel 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.
• 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
Installation of ResidenceTypeWarm Air Heating and Air
Conditioning Systems” (NFPA 90B), these instructions,
and all applicable local codes.
• Installthisunitonlyinalocationandpositionasspecied
on page 8. 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
offuel,electricpower,service access,noise,andshade.
• Before beginning the installation, verify that the unit
model is correct for the job. The unit model number
is printed on the data label. Follow all precautions in
the literature, on tags, and on labels provided with
the equipment. Read and thoroughly understand
the instructions provided with the equipment prior to
performing the installation and operational checkout of
the equipment.
• Useonlywiththetypeofgasapprovedforthisunit.
Refer to the unit rating plate.
• Provideadequatecombustionandventilationairtothe
unit. See pages 8 - 10.
• Provideadequateclearancesaroundtheairventintake
terminal. See Figure 2 (page 8).
• Combustion products must be discharged outdoors.
Connect this unit to an approved vent system only, as
specified on page 9.
• Never test for gas leaks with an open ame. Use a
commercially available soap solution to check all
connections (See page 19).
• ConsultTable10(page28),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 designedductsystem canresultin nuisance
shutdowns, and comfort or noise issues.
• Installationofequipmentmayrequirebrazingoperations.
Installer must comply with safety codes and wear
appropriate safety equipment (safety glasses, work
gloves, fire extinguisher, etc.) when performing brazing
operations.
• This equipment is NOT to be used for temporary heating
of buildings or structures under construction.
REQUIREMENTS AND CODES
This unit must be installed in accordance with
instructions outlined in this manual, all applicable
local building codes, and the current revision of the
National Fuel Gas Code (NFPA54/ANSI Z223.1) or
the Natural Gas and Propane Installation Code, CAN/
CGA B149.1.
Additional codes listed below are for reference purposes
only and do not necessarily have jurisdiction over local or
statecodes.Local codesandregulations takeprecedence
overanyrecommendationscontainedintheseinstructions.
Always consult with local authorities before installing any
gas appliance.
Combustion & Ventilation Air
• US:NationalFuelGasCode(NFGC),AirforCombustion
and Ventilation
• CANADA:NaturalGasandPropaneInstallationCodes
(NSCNGPIC), Venting Systems and Air Supply for
Appliances
Duct Systems
• US and CANADA: Air Conditioning Contractors
Association (ACCA) Manual Q, Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers
(ASHRAE) Fundamentals Handbook
Electrical Connections
• US:NationalElectricalCode(NEC)ANSI/NFPA70
• CANADA:CanadianElectricalCodeCSAC22.1
Gas Piping & Gas Pipe Pressure Testing
• US:NFGCandNationalPlumbingCodes
• CANADA:NSCNGPIC
General Installation
• US:CurrenteditionoftheNFGCandtheNFPA90B.For
copies, contact the National Fire Protection Association
Inc.,BatterymarchPark,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)

8
GENERAL INFORMATION
The Dual Fuel iHybrid™ heat pump has been designed
and tested for capacity and efficiency in accordance with
A.R.I.Standards.This unit will provide many years of safe
and dependable comfort, providing it is properly installed
and maintained. This heat pump is designed only for
outdoor installations. With regular maintenance, this unit
will operate satisfactorily year after year.Abuse, improper
use, and/or improper maintenance can shorten the life of
the appliance and create unsafe hazards.
To achieveoptimumperformance andminimizeequipment
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.
Pre-Installation Check
√Before you install this unit, the cooling load of the area
to be conditioned must be calculated and a system of
the proper capacity selected. It is recommended that
the area to be conditioned be completely insulated and
vapor sealed.
√Check the electrical supply and verify the power supply
is adequate for unit operation. If there is any question
concerning the power supply, contact the local power
company.
√All units are securely packed at the time of shipment and
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) should be filed immediately with the carrier.
√Please consult your dealer for maintenance information
and availability of maintenance contracts. Please read
all instructions before installing the unit.
Locating the Heat Pump
• Surveythejobsitetodeterminethebestlocationfor
mounting the outdoor unit.
• Choose an appropriate location that minimizes the
length of the supply and return air ducts.
• Overhead obstructions, poorly ventilated areas, and
areas subject to accumulation of debris should be
avoided.
• Sufcient clearance for unobstructed airow through
the outdoor coil must be maintained in order to achieve
ratedperformance.See Figure2forminimumclearance
requirements.
• Consideration should also be given to availability of
electric power, service access, noise, and shade.
• Aclearanceofatleast36inchesfromthebloweraccess
panel and from the louvered control access panel is
recommended for servicing and maintenance. Where
accessibility to combustibles clearances are greater
than minimum clearances, accessibility clearances
must take preference.
Field Connections for Electrical Power Supply
• Allwiringmustcomplywithcurrentprovisionsofthe
National Electrical Code (ANSI/NFPA 70) and with
applicable local codes having jurisdiction.
• Theminimumsizeofelectricalconductorsandcircuit
protection must be in compliance with information listed
on the outdoor unit data label.
• Electricalpowersuppliedtotheunitmustbeadequate
for proper operation of the equipment. The system
must be wired and provided with circuit protection in
accordance with local building codes.
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.
Combustion Air Requirements
WARNING:
Using installation methods other than those
described in the following sections must comply
with the National Fuel Gas Code and all applicable
local codes for providing sufcient combustion
air to the furnace.
Provisions must be made during the installation of this
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.
Minimum Required
Clearances to Combustibles
36"
36"
36"
TOP OF UNIT
TO BE
UNOBSTRUCTED
See Note 1 See Note 2
NOTE 1: 6” When coil is present on duct side.
NOTE 2: 1” When no coil is present on duct side.
Figure 2. Clearance Requirements

9
of the corner panel.The fasteners used to secure the vent
cover assembly have been included in the homeowner’s
package.
WARNING:
The vent cover assembly must be installed to
assure proper operation of the unit.
The following list is a summary of the requirements for the
location of the termination of the venting system:
• Thelocationoftheventterminationmustbeconsistent
withtheNationalFuelGasCode(ANSIZ223.1)orCAN/
CGA-B149 Installation Codes.
• Theventterminationmustbelocatedatleast4feet
horizontally from any electric meters, gas meters,
regulators, and relief equipment.
• Theventterminationmustbelocatedatleast3feet
above any forced air inlet located within 10 feet.
• Theventterminationmustbelocatedatleast4feet
below, 4 feet horizontally from, or 1 foot above any door,
window, or gravity air inlet into any building.
• Theventterminationmustbelocatedatleast1foot
above grade.
• Theunitshouldbeinstalledinawaythatpreventsany
obstruction of the vent termination during accumulating
snow.
• Theunitinstallationshallavoidareaswherecondensate
drainage may cause problems by dropping on planters
or patios, etc. Also verify exhaust gases will not
impinge on windows or building surfaces, which may
be compromised or damaged by condensation.
• Donotinstalltheunitsuchthatexhaustfromthevent
termination is directed into window wells, stairwells,
under decks, or in alcoves or similarly recessed areas.
The vent termination must not be located above any
public walkways.
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 off thegassupply to theburners.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.
Ifthiscontrol mustbe replaced,useonly factoryauthorized
replacement parts. See the Replacement Parts List on
page 23.
WARNING:
Combustible 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.
DO NOT place any chemicals with ammable or caustic
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
Venting Requirements
This unit has been equipped with an integral venting
system and designed to operate only with this venting
system. No additional venting shall be used. This unit
must be vented to the outdoors.
WARNING:
This unit is intended for outdoor installation
only. Do not vent the unit through a conventional
venting system.
A vent cover assembly has been supplied with the unit. It
can be found secured to the gas controls within the control
area of this unit. Figure 3 shows the proper installation of
theventcoverassemblyoverthe vent outletonthe exterior
Figure 3. Vent Assembly

10
WARNING:
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below
for each appliance connected to the venting
system being placed into operation could result
in carbon monoxide poisoning or death. The
following steps shall be followed with each
individual appliance connected to the venting
system being placed in operation, while all
other appliances connected to the venting
system are not in operation:
1. Seal any unused openings in the venting
system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 or the CSA
B149.1, Natural Gas and Propane Installation
Codes and these instructions. Determine that
there is no blockage or restriction, leakage,
corrosion and other deciencies which could
cause an unsafe condition.
3. As far as practical, close all building doors
and windows and all doors between the space
in which the appliance(s) connected to the
venting system are located and other spaces
of the building.
4. Close replace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on
any exhaust fans, such as range hoods and
bathroom exhausts, so they are operating at
maximum speed. Do not operate a summer
exhaust fan.
6. Follow the lighting instructions. Place the
appliance being inspected into operation.
Adjust the thermostat so appliance is operating
continuously.
7. Test for spillage from draft hood equipped
appliances at the draft hood relief opening
after 5 minutes of main burner operation. Use
the ame of a match or candle.
8. If improper venting is observed during any of
the above tests, the venting system must be
corrected in accordance with the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and/or CSA
B149.1, Natural Gas and Propane Installation
Codes.
9. After it has been determined that each appliance
connected to the venting system properly vents
when tested as outlined above, return doors,
windows, exhaust fans, replace dampers and
any other gas-red burning appliance to their
previous conditions of use.
AVERTISSEMENT:
RISQUE D’EMPOISONNEMENT AU
MONOXYDE DE CARBONED
Le non-respect des consignes suivantes portant
sur chacun des appareils raccordés au système
d’évacuation mis en service pourrait entraîner
l’empoisennement au monoxyde de carbone ou
la mort. Les consignes suivantes doivent être
observées pour chaque appareil raccordé au
système d’évacuation mis en service si les autres
appareils raccordés au système ne sont pas en
service:
1. Sceller toute ouverture non utilisée de la systéme
d’évacuation;
2. S’assurer que la systéme d’évacuation présente
des dimensions et une pente horizontale
conformes à la norme ANSI Z223.1/NFPA
54, intitulée National Fuel Gas Code ou aux
codes d’installation CSA-B149.1, ainsi qu’aux
présentes instructions. S’assurer que la systéme
d’évacuation n’est pas bloquée, restreinte,
corrodée, qu’elle ne fuit pas et qu’elle ne présente
aucun autre défaut potentiellement dangereux;
3. Dans la mesure du possible, fermer toutes les
portes et fenêtres du bâtiment, et toutes les
portes entre la pièce où se trouve l’appareil
raccordé à la systéme d’évacuation et les autres
pièces du bâtiment.
4. Fermer les registres des foyers;
5. Mettre en service les sécheuses et tout autre
appareil qui n’est pas raccordé à la systéme
d’évacuation. Faire fonctionner à régime
maximal tout ventilateur d’évacuation, tel que
les hottes de cuisinière et les ventilateurs de
salles de bains. Ne pas mettre en service les
ventilateurs d’été.
6. Respecter les instructions d’allumage. Mettre en
service l’appareil à l’essai. Régler le thermostat
de manière à ce que l’appareil fonctionne sans
interruption;
7. Vérifier s’il y a débordement à l’orifice
d’évacuation du coupe tirage des appareils dotés
d’un coupe tirage 5 minutes après l’allumage
du brûleur principal. Utiliser la amme d’une
allumette ou d’une chandelle.
8. Si l’on constate, au cours de l’un des essais
qui précèdent, que l’évacuation est déciente,
corriger le système d’évacuation conformément
à la norm ANSI Z223.1/NFPA 54, National Fuel
Gas Code, et (ou) aux codes d’installation CSA
B149.1.
9. Après avoir déterminé que tous les appareils
raccordés à la systéme d’évacuation évacuent
correctement tel que prescrit ci-dessus,
rouvrir les portes et les fenêtres et remettre les
ventilateurs d’évacuation, les registres de foyers
et tout autre appareil fonctionnant au gaz à leur
état de fonctionnement initial.

11
Circulating Air Supply
WARNING:
Products of combustion must not be allowed to
enter the return air ductwork or the circulating air
supply. Failure to prevent products of combustion
from being circulated into the living space can
create potentially hazardous conditions including
carbon monoxide poisoning that could result in
personal injury or death.
All return ductwork must be adequately sealed,
all joints must be taped, and the ductwork must
be secured to the unit with sheet metal screws.
When return air is provided through the bottom
of the unit, the joint between the unit and the
return air plenum must be air tight.
The roof curb or cement pad on which the unit is
mounted must provide sound physical support of
the unit with no gaps, cracks, or sagging between
the unit and the curb or pad.
Return air and circulating air ductwork must not
be connected to any other heat producing device
such as a replace insert, stove, etc. Doing so
may result in re, explosion, carbon monoxide
poisoning, personal injury, or property damage.
Air Ducts
This unit is designed only for use with a supply and return
duct. Air ducts should be installed in accordance with the
standards of the National Fire Protection Association
“Standard for Installation of Air Conditioning Systems”
(NFPA 90A), “Standard for Installation of Residence Type
Warm Air Heating and Air Conditioning Systems” (NFPA
90B), and all applicable local codes. NFPA publications
are avaialable by writing to: National Fire Protection
Association, Batterymarch Park, Quincy, ME 02269 or
visit www.NFPA.org on the web.
• DesigntheductworkaccordingtoManualDbytheAir
Conditioning Contractors of America (ACCA).
• Theductsmustbeproperlysizedandnotexceed.2”
W.C. pressure drop at 400 scfm per nominal ton of
cooling capacity.
• Ductworkshouldbeattacheddirectlytotheunitanges
for horizontal applications.
• Ifroofcurbisinstalled,theductsmustbeattachedto
the curb hangers, not the unit.
• It is recommended that the outlet duct be provided
with a removable access panel. The opening should
be accessible when the unit is installed in service and
shall be 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.
• 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 furnace is equal to the return air
supply under normal, indoor return air applications.
Air Filter Requirements
WARNING:
Never operate the unit without a lter in place.
Dust and lint could accumulate on internal parts,
resulting in loss of efciency, equipment damage
and possible re.
• This unit is not supplied with air filter(s) and has no
factory equipped means for accomodating 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.
• Allreturnairmustpassthrough thefiltersbeforeentering
the evaporator coil. It is important that all filters be kept
cleanandreplacedfrequentlytoensureproperoperation
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.
• DownowInstallationsrequireaninternallteraccessory
kit to be installed.
• HorizontalInstallationsrequiretheairltersystembe
installed in the return air ductwork.
NOTETO INSTALLER: After installing or replacing the
filtrationsystem for thisunit,add thefollowingstatement
on or adjacent to the filter service panel: “Replace
lter(s) installed in your system only with the same
dimensional size lters that are being replaced.”
Table 1. Air Filter Requirements
Nominal
Cooling
(Tons)
Approximate
Air Flow
Range (CFM)
Approximate
Filter Area
(Sq. In.)*
Recommended
Filter Size
(In. x In.)
2.0 700 - 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.
Unconditioned Spaces
All duct work passing through unconditioned space must
be properly insulated to minimize duct losses and prevent
condensation. Use insulation with an outer vapor barrier.
Refer to local codes for insulation material requirements.

12
• Ifusingbottomdischargewithreturnairductsaroof
curb must be installed prior to unit installation. See
Rigging and Hoisting section for setting of the unit.
Ground Level
Ground level installations must be located according to
localbuildingcodes orordinancesandtheserequirements:
• Clearancesmustbeinaccordancewiththoseshown
in Figure 2 (page 8).
• Asuitablemountingpad(Figure4,page13)mustbe
provided and be 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 2” (5cm) above
grade and with adequate drainage.
• Unitsrequirehorizontalroofcurbandreturnairkitfor
horizontal installations.
• Ductwork should be attached directly to anges on
panels supplied in horizontal duct conversion kits.
Rooftop
Rooftop installations must be located according to local
building codes or ordinances and these requirements:
• The roof must be capable of handling the weight of the
unit. For unit weights, see Table 9. Reinforce the roof if
necessary.
• Theappropriateaccessoryroofcurb (Figure5,page 13)
must be installed prior to unit installation.The roof curb
must be square and level to ensure proper condensate
drainage.Please follow all instructions provided with
the kit.
• Secure roof curb or frame to roof using acceptable
mechanicalmethodsper local codes.NOTE:Makesure
the two supports beneath the unit have been removed.
Condensate Drain
Condensate is removed from the unit through the 3/4”
female pipe fitting (Figure 6, page 13) located on the front
side of the unit. Install a 2 inch condensate trap in the
drain line of the same size and prime with water. When
connecting rigid drain line, hold the female fitting with a
wrench to prevent twisting. Do not over tighten! Refer
to local codes and restrictions for proper condensate
disposal requirements.
Acoustical Duct Work
Certain installations may require the use of acoustical
lining inside the supply duct work.
• Acousticalinsulationmustbeinaccordancewiththe
current revision of the Sheet Metal and Air Conditioning
ContractorsNational Association(SMACNA)application
standard for duct liners.
• DuctliningmustbeULclassiedbattsorblanketswith
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
current revision of the SMACNA construction standard
on fibrous glass ducts. Fibrous duct work and internal
acoustical lining must be NFPA Class 1 air ducts when
tested per UL Standard 181 for Class 1 ducts.
UNIT INSTALLATION
Packaging Removal
Remove the shipping carton and User’s Manual from the
equipment.Takecarenottodamagethetubingconnections
whenremovingthecarton.Forrooftopinstallations,remove
and discard the two supports attached beneath the unit.
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 9 (page 27) for unit weights.
• The unit must be lifted from the holes in the
base rails using cables or chains.
• Spreader bars are required to protect the unit
and ensure even loading.
• Keep the unit in an upright position at all times.
The rigging must be located outside the units
center of gravity. Refer to Figure 11 (page 27)
for locating the center of gravity.
• All panels must be securely in place during
rigging and hoisting.
Clearances to Combustible Materials
DF6SF units are certified as combination heating and
cooling equipment for outdoor rooftop or ground level
installations. Figure 2 (page 8) displays the minimum
clearance requirements for both downflow and horizontal
discharge.
Units may be installed on wood flooring or on Class A, B,
or C roof covering material when used with bottom supply
and return air ducts as long as the following requirements
are met:
• If using horizontal supply and return air ducts, the
horizontalroofcurb kit andreturn airkitmustbeinstalled
prior to unit installation. Horizontal roof curb is required.
Horizontal to Downow Conversion
The unit is shipped ready for horizontal duct connections.
If down flow ducts are required, the unit must be converted
following the steps below for both the supply and return
ducts.
1. Remove the horizontal duct cap.
2. Locate the duct cap inside the duct openings and
remove the screw holding it in place.
3. Liftthecap out oftheunit.(Hint: The capcanbe pushed
up from the bottom by reaching through the fork slot).
4. Cover the horizontal duct opening with the horizontal
duct cap. The insulation will be on the indoor side.
5. Fasten the cover with screws to seal.

13
ELECTRICAL WIRING
WARNING:
To avoid risk of electrical shock, personal injury,
or death, disconnect all electrical power to the unit
before performing any maintenance or service.
The unit may have more than one electrical supply.
Label all wires prior to disconnection when
servicing the unit. Wiring errors can cause
improper and dangerous operation
• 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).
Pre-Electrical Checklist:
√Verify 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 loadimposedbythisequipment.
See Table 2 (page 14) or the unit wiring label for proper
high and low voltage wiring.
√Verify factory wiring is in accordance with the unit wiring
diagram (Figures 13 - 16, pages 31 - 34).Verify none of
theconnectionsloosenedduringshippingorinstallation.
Line Voltage
• Thelinevoltagetotheunitshouldbesuppliedfroma
dedicated branch circuit containing the correct fuse or
circuit breaker for the unit.
• An electrical disconnect must be located within sight
of and readily accessible to the unit.This switch shall
becapableofelectricallyde-energizingthe outdoor unit.
See unit data label for proper incoming field wiring. Any
other wiring methods must be acceptable to authority
having jurisdiction.
• Useonlycopperwireforthelinevoltagepowersupply
to this unit (Table 3, page 14). Use proper code agency
listed conduit and a conduit connector for connecting
the supply wires to the unit. Use of rain tight conduit is
recommended.
• Providepowersupplyfortheunitinaccordancewith
the unit wiring diagram and the unit rating plate.
• Overcurrentprotectionmustbeprovidedatthebranch
circuit distribution panel and sized as shown on the unit
ratinglabel and accordingtoapplicablelocalcodes.See
the unit rating plate for maximum circuit ampacity and
maximum overcurrent protection limits.
• Awiringdiagramislocatedontheinsidecoverofthe
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.
Condensate
Drain
Figure 6. Condensate Drain Location
Roof
Curb
Figure 5. Roof Top Installation
2”
Figure 4. Ground Level Installation

14
• Unitsareshippedfromthefactorywiredfor240volt
transformer operation. For 208V operation, remove the
lead from the transformer terminal marked 240V and
connect it to the terminal marked 208V.
• Internallymountedcircuitbreakersareavailableaseld
installed options. These circuit breakers can be used
as an electrical disconnect.
• Connecttheline-voltageleadstotheterminalsonthe
contactor(orthe circuitbreakerifthe fieldinstalledcircuit
breaker kits are used) inside the control compartment.
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.
Table 4. Thermostat Wire Gauge
Thermostat
Wire Gauge
Recommended T-Stat Wire
Length (Unit to T-Stat)
2-Wire
(Heating)
5-Wire
(Heating/Cooling)
24 55 25
22 90 45
20 140 70
18 225 110
Thermostat / Low Voltage Connections
• Theunitisdesignedtooperatefroma24VACClass
II control circuit. The control circuit wiring must comply
with the current provisions of the NEC (ANSI/NFPA
70) and with applicable local codes having jurisdiction.
Thermostat connections shouldbemade in accordance
with the instructions supplied with the thermostat and
the indoor equipment.
• The low voltage wires must be properly connected.
Route 24V control wires through the sealing grommet
near the power entrance. Recommended wire gauge
and wire lengths for typical thermostat connections are
listed in Table 4.
• Several thermostat options are available depending
on the accessories installed with the unit. Select a
thermostat that operatesin conjunctionwiththe installed
accessories.
• Back-upfossilfuelheatcapabilityisrequiredwiththe
Dual Fuel iHybrid™ heat pump packaged system.This
systemiscapableofprovidingtwostages ofcooling,two
stages of heating in heat pump mode, and an additional
two stages of secondary gas heating.
• 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 where its operation
maybeadverselyaffectedbyradiantheatfromfireplaces,
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.
COPPER WIRE SIZE — AWG
(1% Voltage Drop)
Supply Wire Length-Feet Supply Circuit
Ampacity
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.
Table 3. Copper Wire Size
Table 2. Electrical Data
Model
Number
Maximum
Heating
Input
Nominal
Electrical
Supply
Voltage Range Compressor Fan
Motor
FLA
Indoor
Blower
FLA
Single Circuit
Min Max RLA LRA MCA MOP
DF6SF-X24K072C 72,000 208-230/60/1 187 253 11.4 52.0 0.91 4.3 20.8 30.0
DF6SF-X36K100C 100,000 208-230/60/1 187 253 19.0 82.0 2.8 6.8 34.7 50.0
DF6SF-X48K120C 120,000 208-230/60/1 187 253 24.0 96.0 2.8 9.1 43.3 60.0
DF6SF-X60K096C 96,000 208-230/60/1 187 253 26.0 118.0 1.5 9.1 44.5 60.0
DF6SF-X60K120C 120,000 208-230/60/1 187 253 26.0 118.0 1.5 9.1 44.5 60.0
Note: FLA = Full Load Amps; LRA = Lock Rotor amps; RLA = Rated Load Amps.

15
Heating Congurations
Theback-upfurnace inthis heatpumpisfactory configured
to operate on high fire only, but can be field converted to
operate as a two-stage furnace.
Two Stage Heating Configuration
To configure this unit for two stage gas heating, a two
stage heat pump thermostat is used:
1. Remove the jumper wire between W1 and W2 on the
terminal block.
2. Remove the brown jumper wire from the low side of
the gas valve and place it on W2 of the terminal block.
3. Connect W1 and W2 to the thermostat. When the call
for first stage heat is received, the furnace will operate
at low fire and the blower will run at a lower speed.
When second stage heat is initialized, the furnace will
operate at high fire and the blower will run at a higher
speed.NOTE: The furnace will stage between low fire,
high fire and off depending on the thermostat signal.
High Fire Configuration
When shipped from the factory, the W1 and W2 terminals
on the terminal block are jumpered together. NOTE: This
overrides the staging feature and the furnace operates
on high fire only. All of the burners will operate on a call
for heat and the variable speed blower will operate at a
higher speed.
Timed Staging Configuration
1. Remove the jumper between W1 & W2 on the terminal
block and replace with a delay on make timer (2 wire
style).
2. Move the brown wire from the low side of the gas valve
to the W2 of the terminal block.
IMPORTANT NOTE: Do not connect the thermostat’s
W2 to the furnace wiring when using timed stage
conguration
NOTE: When low fire on the gas valve is energized,
the furnace operates in low fire mode at a lower blower
speed and the timer begins its delay function. If the room
thermostat is not satisfied before the timer activates, the
furnace will stage to high fire and the blower will operate
at a higher speed until the thermostat is satisfied.
Two Stage Cooling Configuration
The low voltage (24V) connections from the thermostat
are made at the terminal block in the gas furnace side
of the unit. Connect Y2 from the thermostat to Y2 on the
terminal block.
Checking Heat Anticipator Settings
• Addthecurrentdrawofthesystemcomponents.
OR
• MeasurethecurrentowonthethermostatR-Wcircuit
afterthe circulatingblowermotorhasstarted.Settheheat
anticipator according to the thermostat manufacturer’s
instructions for heat anticipator settings.
Conguring the Variable Speed Blower
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-programmed to deliver optimum airflow in a variety of
conditionsandsystem configurations.Because theblower
can be configured in many ways, it is important to read
and follow all instructions carefully.
CAUTION:
To avoid personal injury or property damage,
make certain that the motor leads cannot
come into contact with any uninsulated metal
components of the unit.
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
installedand configuredproperly,the furnacewill gradually
change speed in response to changes in system variables
such as thermostat settings, duct static, filters, etc. The
variable speed blower is configured by setting the 6
switches located on the motor control board as described
below:
Selecting the Basic Cooling/Heat Pump Airflow
Thebasiccooling/heat-pumpairflow isselectedbysetting
switches 1 - 4 on the variable speed input board.Table 11
(page 28) lists the recommended airflow values (CFM)
and selector switch settings for each nominal system
capacity. All airflows for other modes of operation (except
secondary gas heat) are determined by this basic setting.
NOTE: The CFM values listed in Table 11 are not
dependentonductstaticpressure.Themotorautomatically
compensates (within the limits of the motor) for changes
in duct static pressure.
NOTE: If coil icing occurs, the basic cooling/heat-pump
airflow selected 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 one or two steps.
Selecting Gas Heating Airflow
The gas heating airflow is selected by setting switches
5 & 6 . Refer to Table 12 (page 28) and select a nominal
rise based on the furnace’s nominal efficiency and firing
input.Follow across the table row to find the switch setting
and nominal air-flow.Verify the selected rise is within the
specification shown on the furnace rating label.
NOTE: The Dual Fuel iHybrid™ heat pump is equipped
with a two stage furnace. The units are shipped from the
factory configured for high fire only. If configuring for two-
stage operation, the furnace will run at low fire during a
call for emergency heat.

16
Delay Profile
The delay profile controls the start-up and shut-down
characteristicsofthepackagedheatpump unit.By varying
thestart-up andshut-downcharacteristicsof thepackaged
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
beginoperationat 31% airflowfor30 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.
Demand Defrost Control
The demand defrost board controls the defrost cycle in
responseto ambienttemperature,outdoorcoiltemperature
and accumulated compressor run time.The heat pump is
allowedtooperatein theheatingmodeuntilthecombination
ofoutdoorambientand outdoorcoiltemperatures indicate
that defrosting is necessary, based on the programmed
defrost curve. There are four preprogrammed defrost
curves on the board.
• Ajumperpinis used to switchbetweenthedifferent
curves. The default setting is program two and is the
recommended setting for most standard applications.
See Table 5 (page 17) for additional defrost curves
settings.
• The factory default setting includes a 30 second
compressordelayfunctionwitha40 °Fdefrost terminate
temperature.Ifadditionaldefrost timeisneeded,ahigher
terminate temperatureis availablebyselectingadifferent
demandcurve.NOTE:The30second compressordelay
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.
• Thedefrostboardisequippedwitha5minuteAnti-Short
Cycle Delay (ASCD). The compressor will not turn on
until it reaches the minimum 5 minute off time.
• Thecontrolcontainsaforced-defrostfeature,which
places the system into defrost mode every 6 hours and
4 minutes, unless the coil temperature is above the
selected terminate temperature.
• Thesystemcanbemanuallyforcedintodefrostmodeat
any time by shorting the TEST terminals on the demand
defrost board together for more than 9 seconds. The
coil temperature sensor does not need to be cold when
the unit is forced into defrost. After the TEST input is
removed,the defrostmodewillterminatein13.7 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.
Ambient Sensor Mounting
For optimum performance of the heat pump system, the
ambient sensor must be mounted on the outside of the
unit. See Figure 7 (page 17).
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 8 (page 17).
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. Route the sensor through the star bushing. Use the
star 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.
Optional Comfort AlertTM Diagnostics Module
TheComfortAlertTM DiagnosticsModuleis abreakthrough
innovation for troubleshooting heat pump and air
conditioning system failures.The module installs easily in
the electrical box of the outdoor unit near the compressor
contactor. By monitoring and analyzing data from the
Optional Humidistat
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 packaged heat pump unit is pre-programmed
for humidistat operation. Remove the jumper connector
between the two terminals marked HUM on the variable
speed board.
Install the humidistat 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 heat pump unit to the quick-connect terminals
marked HUM. Wire the humidistat to open on rise in
humidity.
CAUTION:
To avoid personal injury or property damage,
make certain that the motor leads cannot
come into contact with any uninsulated metal
components of the unit.
Checkall factorywiringto theunitswiringdiagram.Inspect
the factory wiring connections to be sure none loosened
during shipping or installation.

17
Star Bushing
Bolt Nut
Ambient Sensor
Plastic Clip
Nut
Figure 8. Ambient Sensor Mounting
Figure 7. Ambient Sensor Location
Figure 9. Comfort AlertTM Diagnostics Module
POWER LED
(Green)
TRIP LED
(Red)
ALERT LED
(Yellow)
Diagnostics
Key
Table 5. Demand Defrost Curve Proles
Jumper
Position
Minimum Time
Between Defrosts
(min)
Terminate
Temperature
(° F)
Compressor
Delay Function
1 20 40 NO
2 20 40 YES
3 20 75 NO
4 20 75 YES
Copeland scroll compressor and the thermostat demand,
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 9.
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
24 VAC power supply.The module cannot be powered by
the Cterminal on a defrost board or other control board
without experiencing nuisance alerts. NOTE: The wiring
to the module’s R& Cterminals must be routed directly
from the indoor unit or thermostat.
Iftheconstant 24VAC(Rwire)is not presentin the outdoor
unit, use one of the spare wires in the thermostat cable to
bring power to the module. Connect the other end of the
spare wire to Rat the indoor unit or thermostat.
Thermostat Demand Wiring
TheComfort Alert modulerequires atwostagethermostat
to operate properly. The Y2 thermostat wire entering the
outdoor unit should be connected to the Y2 input on the
unit terminal strip.
Whilethecompressor isrunning,ComfortAlert willprovide
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
Alert codes 1 or 9 appear while the compressor is running,
Comfort Alert will turn off the solenoid to prevent solenoid
damage from overheating conditions.
L Terminal Wiring
The Lconnection is used to communicate Alert codes to
compatible White-Rodgers thermostats. The Lterminal
of the thermostat should be connected directly to the
Comfort Alert Lterminal.
On some White-Rodgers thermostats, an icon on the
thermostat display will flash at the same rate as the
Comfort Alert yellow Alert LED. An advanced option on
these thermostats is to lock out the compressor when
certain Alert codes are detected in indicating impending
compressor damage.Refer toWhite-Rodgers thermostat
manuals for more information.
If using a White-Rodgers compatible thermostat, DO
NOT connect the Lterminal from the thermostat to Lon
the terminal block in the unit, if it is already connected
to the Comfort Alert Module. Standard thermostats with
an Lterminal which are not compatible with the Comfort
Alert Module, can only be connected to Lon the terminal
block in the unit.

18
DC SOL Connection
The two pin DC SOL connector provides a connection
to the Copeland UltraTech second stage compressor
solenoid.This 24VDCsolenoidisinternaltothecompressor
and will not operate properly if 24VAC is applied to the
compressor solenoid terminals.
To reduce the VA load of the solenoid on the system,
Comfort Alert uses a phase control method to reduce the
DCvoltagetothe solenoidtothe minimumlevelrequiredto
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,whensolenoidshould beenergized,depending
on the level of the 24 VAC supply.
Interpreting the Diagnostic LED’s
When an abnormal system condition occurs, the Comfort
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.
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. See Table 15 (pages 37 -
38) for flash code identification or Table 16 (page 39) for
module wiring troubleshooting.
LED Description
• POWERLED(Green):indicatesvoltageispresentat
the power connection of the module.
• ALERT LED (Yellow): communicates an abnormal
system condition through a unique flash code.
NOTE: The ALERT LED will flash consecutively, pause
andthenrepeat theprocess.Thenumberof consecutive
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.
• TRIPLED(Red):indicatesademandsignalisreceived
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, C, & 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
diagram (Figure 14, page 32).
2. Disconnect power from the compressor and 24VAC
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
diagram (Figure 14).
Troubleshooting the Installation
Depending on system configuration, some ALERT Flash
codes may not be active.The presence of safety switches
affectshowthe systemalerts are displayedbythismodule.
Optional Outdoor Thermostat
An outdoor thermostat can be installed in the field with
2-stage electric heat. To install the outdoor thermostat,
removetheorangewirefrom the Eterminal on theterminal
block, and connect to the outdoor thermostat. Connect
the other side of the outdoor thermostat to W2 from the
thermostat.

19
GAS SUPPLY & 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.
• Some local codes require the installation of a manual
main shut-off valve and ground joint union external
to the furnace as shown in Figure 10. 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.
• The manifold pressure must be set to the appropriate
value for your installation. Refer to the Manifold
Pressure Adjustment section (page 22) for
adjustment instructions.
• Gas piping must never run in or through air ducts,
chimneys, gas vents, or elevator shafts.
• Compounds used to seal joints on gas piping must
be resistant to the actions of LP propane gas.
• The main gas valve and main power disconnect to
the furnace must be properly labeled by the installer
in case emergency shutdown is required.
• An 1/8 inch NPT plugged tap must be installed in
the gas line immediately upstream of the gas supply
connection to the furnace for use when measuring
the gas supply pressure. The plug should be readily
accessible for service use.
• A drip leg should be installed in the vertical pipe
run to the unit (Figure 10).
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 10.
Table 13 (page 29) lists gas pipe capacities for standard
pipe sizes as a function of length in typical applications
based on nominal pressure drop in the line.
Leak Check
WARNING:
FIRE OR EXPLOSION HAZARD
Never test for gas leaks with an open ame. Check
all connections using a commercially available
soap solution. A re 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
mustbetestedforgasleaks.This includespipeconnections
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.Repeat thetightening
and soap check process until bubbling ceases.
• If pressure testing the gas supply lines at pressures
greater than 1/2 psig (14 inches WC), the unit must
be disconnected from the gas supply piping 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 Conversion
Conversion of this unit must be performed by qualified
service personnel, using only approved parts. All
installationsmustbemadeinaccordancewiththeNational
Fuel Gas Code or with local jurisdiction codes.
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). NOTE: Deration is
necessary to compensate for low atmospheric pressure
at high altitudes.
WARNING:
The reduction of input rating necessary for high
altitude installation may only be accomplished
with factory supplied orices. Do not attempt to
drill out orices in the eld. Improperly drilled
orifices may cause fire, explosion, carbon
monoxide poisoning, personal injury or death.
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 22. 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.
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)
Figure 10. Typical Gas Hookup - Right Side Entry

20
START UP & ADJUSTMENTS
Pre-Start Check List
√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.
√Verify that the duct work is sealed to prevent air leakage.
√Verify that the line voltage power leads are securely
connected and the unit is properly grounded.
√Verify that the low voltage wires are securely connected
to the correct leads on the low voltage terminal strip.
√Verify thatthegas line service pressure doesnotexceed
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 inches WC
(0.40 psig).
√Verifythattheflameroll-outcontrolisclosed.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 that the gas line has been purged and all
connections are leak tight.
√Verify that all exterior panels are replaced and securely
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.
Start-Up Procedure
WARNING:
If 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
than 12 hrs. Failure to comply may result in
damage or cause premature failure of the system.
• Checkallelectrical wiring forloose connections and
tighten as required.
• Checkunitforreturnairltersandcondensatetrap.
• Closeallelectricaldisconnectstoenergizethesystem.
Air Circulation
Leave the thermostat system mode on OFF, and set the
fan mode to ON. Blower should run continuously. Check
the air delivery at the supply registers and adjust register
openings for balanced air distribution. Examine ductwork
for leaks or obstruction if insufficient air is detected. Set
the thermostat fan mode to AUTO. The blower should
stop running.
LP/Propane Gas Conversion
WARNING:
This unit was equipped at the factory for use
with natural gas only. A special kit, supplied by
the manufacturer, is required to convert the unit
to operate on LP/propane gas. Failure to use the
proper conversion kit can cause re, explosion,
property damage, carbon monoxide poisoning,
personal injury, or death.
Conversion of this equipment to LP/Propane gas must
be made by qualified service personnel, using approved
factory parts. LP/Propane gas conversion can be
accomplished by replacing the natural gas orifices with
theappropriateLP/Propaneorificesand thenadjustingthe
manifold pressure as outlined on page 22. Conversion to
LP/Propane (sea level and high altitude) is detailed in the
installation instructions provided with the conversion kit:
• The United States LP/Propane Gas Sea Level and High
AltitudeConversionKit(P/N904404)isforLP/propane
conversion in the United States at altitudes between
zero and 10,000 ft. above sea level. Please follow the
instructions provided with the kit.
• The Canadian LP/Propane Gas Sea Level and High
Altitude Conversion Kit (P/N 904405) kit is for LP/
propane conversions in Canada at altitudes between
zero and 4,500 ft. above sea level. Please follow the
instructions provided with the kit.
For installations between zero and 4,999 ft. above sea
level, a #54 drill size orifice should be used. Installations
5,000 ft. above sea level require a # 55 drill size orifice.
Table 7 (page 22) lists the correct orifice size to use at
different altitudes.
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 Verifying and Adjusting
the Firing Rate section on page 21.