Nortek R104hd series User manual

13.4 SEER2 / 95% AFUE

SINGLE PACKAGE GAS HEATING / ELECTRIC COOLING

SINGLE PHASE

R104HD SERIES

INSTALLATION INSTRUCTIONS

HORIZONTAL MOUNT SHOWN

WARNING AVERTISSEMENT

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could

result in serious injury or property damage.

RISQUE D’INCENDIE OU D’EXPLOSION

Si les consignes de sécurité ne sont pas suivies à la

lettre,celapeutentraînerlamort,degravesblessures

ou des dommages matériels.

– Donotstore orusegasoline orotherﬂammable

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.

– Installation and service must be performed by

a qualiﬁed installer, service agency or the gas

supplier.

– Nepasentreposerniutiliserdel’essence ni d’autres

vapeursou liquidesinﬂammablesdans levoisinage

de cet appareil, ni de tout autre appareil.

QUE FAIRE SI UNE ODEUR DE GAZ EST

DÉTECTÉE

• Ne mettre en marche aucun appareil.

• Ne toucher aucun interrupteur électrique; ne pas

utiliser de téléphone dans le bâtiment.

• Quitter le bâtiment immédiatement.

• Appeler immédiatement le fournisseur de gaz

en utilisant le téléphone d’un voisin. Suivre les

instructions du fournisseur de gaz.

• Silefournisseurde gazn’estpasaccessible,appeler

le service d’incendie.

– L’installation et l’entretien doivent être effectués

par un installateur ou une entreprise d’entretien

qualiﬁé, ou le fournisseur de gaz.

DO NOT DESTROY THIS MANUAL. READ ALL INSTRUCTIONS IN THIS MANUAL AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

NE PAS DÉTRUIRE. LIRE TOUTES LES INSTRUCTIONS DONNÉE DANS LE MANUEL ET CONSERVER EN UN LIEU SÛR POUR RÉFÉRENCE ULTÉRIEURE.

TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION.............................. 3

REQUIREMENTS & CODES .............................................. 4

GENERAL INFORMATION................................................. 5

Before you install this unit............................................................ 5

Locating the Equipment ............................................................... 5

Heating Load................................................................................ 5

COMBUSTION AIR & VENTING REQUIREMENTS .......... 6

Vent Termination.......................................................................... 7

CIRCULATING AIR SUPPLY ............................................. 8

Air Ducts ...................................................................................... 8

Unconditioned Spaces................................................................. 8

Acoustical Duct Work................................................................... 8

UNIT INSTALLATION......................................................... 9

Packaging Removal..................................................................... 9

Rigging & Hoisting ....................................................................... 9

Clearances to Combustible Materials .......................................... 9

Ground Level ............................................................................... 9

Rooftop ........................................................................................ 9

Horizontal to Downﬂow Conversion ............................................. 10

Condensate Drain (Air Conditioning) ........................................... 10

Air Filter Requirements ................................................................ 11

Installing Filters in the Internal Filter Rack ................................... 11

1” to 2” Filter Conversion......................................................... 11

Removing Filters from Internal Filter Rack................................... 11

ELECTRICAL WIRING ....................................................... 12

Pre-Electrical Checklist................................................................ 12

Grounding .................................................................................... 12

Line Voltage................................................................................. 12

Thermostat / Low Voltage Connections....................................... 13

2-Stage Heat / 1-Stage Cool Thermostat ................................ 13

Single Stage Heat / Single Stage Cool Thermostat ................ 13

Heat Anticipator ........................................................................... 13

Cooling Conﬁgurations................................................................. 13

Heating Conﬁgurations ................................................................ 13

Blower Speed............................................................................... 13

Conﬁguring the Fixed Speed Blower....................................... 14

Selecting Cooling Airﬂow......................................................... 14

Selecting Heating Airﬂow ........................................................ 14

Dehumidiﬁcation Options............................................................. 14

Optional Furnace Control Board Connections ............................. 14

Electronic Air Cleaner.............................................................. 14

Humidiﬁer ................................................................................ 14

GAS SUPPLY & PIPING..................................................... 15

Leak Check.................................................................................. 15

High Altitude Conversion - Natural Gas ....................................... 16

LP / Propane Gas Conversion ..................................................... 16

START UP & ADJUSTMENTS........................................... 17

Pre-Start Check List..................................................................... 17

Start-Up Procedure...................................................................... 17

Air Circulation .......................................................................... 17

Lighting the Appliance ............................................................. 17

Verifying System Heating ........................................................ 18

Verifying & Adjusting Temperature Rise ................................. 18

Gas Supply Pressure Veriﬁcation & Adjustment ..................... 18

Verifying the Firing Rate of the Appliance ............................... 18

Measuring the Manifold Pressure............................................ 19

Adjusting the Manifold Pressure.............................................. 19

Removing the Manometer/Pressure Gauge............................ 19

Verifying Over-Temperature Limit Control Operation.............. 19

Verifying Burner Operation...................................................... 19

Verifying System Cooling ........................................................ 21

OPERATING SEQUENCE.................................................. 22

Heating Mode............................................................................... 22

Thaw Cycle Start Up / Shutdown................................................. 23

Blocked Vent / Condensate Disposal Shut Down........................ 23

Cooling Mode - Single Stage Operation ...................................... 23

De-Humidiﬁcation Control............................................................ 23

Fan Mode..................................................................................... 23

COMPONENT FUNCTIONS ............................................... 23

EQUIPMENT MAINTENANCE............................................ 24

Heat Exchanger & Burner Maintenance ...................................... 24

Cleaning of Burners ..................................................................... 25

REPLACEMENT PARTS.................................................... 25

TROUBLESHOOTING........................................................ 25

Cooling Mode............................................................................... 25

Heating Mode............................................................................... 25

FIGURES & TABLES.......................................................... 26

Figure 8. Unit Dimensions ....................................................... 26

Table 7. Center of Gravity & Shipping Weights....................... 27

Airﬂow Information.................................................................... 28

Table 8. Cooling Airﬂow Settings ............................................ 28

Table 9. Heating Airﬂow Settings ............................................ 28

Table 10. Blower Performance - 2 & 2.5 Ton .......................... 29

Table 11. Blower Performance - 3 Ton ................................... 30

Table 12. Blower Performance - 3.5 Ton ................................ 31

Table 13. Blower Performance - 4 & 5 Ton ............................. 32

Gas Information ......................................................................... 33

Table 14. Gas Pipe Capacities................................................ 33

Table 15. Gas Flow Rates....................................................... 33

Figure 9. Gas Valve Label....................................................... 34

Electrical Data ............................................................................ 35

Table 16. Electrical Data. ........................................................ 35

Table 17. Copper Wire Size .................................................... 35

Table 18. Thermostat Wire Gauge .......................................... 35

Electrical Diagrams.................................................................... 36

Figure 10. Two Stage Heating / Single Stage Cooling

Conﬁguration.......................................................... 36

Figure 11. Fixed Speed Motor Control Board.......................... 36

Figure 12. Ignition Control Board - 624817 ............................. 36

Wiring Diagrams ........................................................................ 37

Figure 13. Single Phase, 2-5 Ton, 208/230V ......................... 37

Charging Charts......................................................................... 38

Figure 14. Charging Chart for 2 Ton Units .............................. 38

Figure 15. Charging Chart for 2.5 Ton Units ........................... 38

Figure 16. Charging Chart for 3 Ton Units .............................. 39

Figure 17. Charging Chart for 3.5 Ton Units ........................... 39

Figure 18. Charging Chart for 4 Ton Units .............................. 40

Figure 19. Charging Chart for 5 Ton Units .............................. 40

Internal Filter Conversion ......................................................... 41

Figure 20. Filter Comversion ................................................... 41

APPENDIX A - HEAT EXCHANGER CONDENSATE

DRAIN & VENT KIT (HORIZONTAL MOUNT

APPLICATIONS)................................................................. 42

About the Kit ................................................................................ 42

Vent Pipe & Drain Hose Assembly .............................................. 42

Vertical Drain Pit Method ............................................................. 42

Preparing the pit ...................................................................... 43

Percolation Test (Optional)...................................................... 43

Vertical Drain Pipe Installation ................................................ 43

Horizontal Drain Trench Method.................................................. 43

Preparing the Trench............................................................... 44

Horizontal Drain Pipe Installation ............................................ 44

Completing the Vent Installation .................................................. 44

APPENDIX B - HEAT EXCHANGER CONDENSATE

DRAIN & VENT KIT (ROOF CURB MOUNT

APPLICATIONS)................................................................. 46

About the Kit ................................................................................ 46

Before Setting unit on the Curb.................................................... 46

Setting the Unit ............................................................................ 47

Completing the Heat Exchanger Condensate Drain Installation.. 47

Condensate Disposal................................................................... 47

Completing the Vent Pipe Installation and Assembly .................. 47

INSTALLATION CHECKLIST............................................. 52

IMPORTANT SAFETY INFORMATION

Please read all instructions before servicing this equipment.

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.

WARNINGindicates 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:

ELECTRICAL SHOCK, FIRE OR

EXPLOSION HAZARD

Failure to follow safety warnings exactly could

result in serious injury or property damage.

Improper servicing could result in dangerous

operation, serious injury, death or property

damage.

• Beforeservicing,disconnectallelectricalpower

to the unit.

• When servicing controls, label all wires prior

to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

WARNING:

These units are fully charged with R-410A

refrigerant and ready for installation. When

a system is installed according to these

instructions, no refrigerant charging is required.

If repairs make it necessary for evacuation and

charging,itshouldonlybeattemptedby qualiﬁed,

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:

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:

PROPOSITION 65 WARNING: This product

contains ﬁberglass insulation. Disturbing the

insulation of this product during installation,

maintenance, or repair may expose you to

ﬁberglass insulation.

• Breathing this material may cause respiratory

irritations.

• Fiberglass insulation 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:

The information listed below and on the next

page must be followed during the installation,

service, and operation of this unit. Unqualiﬁed

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

personal injury or death.

• Before beginning the installation, verify that the unit

model is correct for the job. The unit model number

is printed on the data label. Follow all precautions in

the literature, on tags, and on labels provided with

the equipment. Read and thoroughly understand

the instructions provided with the equipment prior to

performing the installation and operational checkout

of the equipment.

• Never test for gas leaks with an open ﬂame. Use

a commercially available soap solution to check all

connections. See page 15.

• 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 NOTto be used for temporary heating

of buildings or structures under construction.

• Use caution when handling this appliance or removing

components. Personal injury can occur from sharp metal

edges present in all sheet metal constructed equipment.

• 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.

• The installer should become familiar with the units wiring

diagram before making any electrical connections to the

unit. See the unit wiring label or Figure 13 (page 37).

REQUIREMENTS & CODES

• Thisequipment mustbeinstalled inaccordancewith

instructions outlined in this manual, all applicable

local building codes, and the current revision of

the National Fuel Gas Code (NFPA54/ANSI Z223.1)

or the Natural Gas and Propane Installation Code,

CAN/CGA B149.1.

• All electrical wiring must be completed in accordance

with local, state and national codes and regulations

and with the National Electric Code (ANSI/NFPA 70)

or in Canada the Canadian Electric Code Part 1 CSA

C.22.1.

• The installer must comply with all local codes and

regulations which govern the installation of this type

of equipment. Local codes and regulations take

precedence over any recommendations contained in

these instructions. Consult local building codes and the

National Electrical Code (ANSI CI) for special installation

requirements.

• This equipment contains liquid and gaseous refrigerant

under high pressure. Installation or servicing should only

be performed by qualiﬁed trained personnel thoroughly

familiar with this type equipment.

• Install this unit only in a location and position as speciﬁed

on page 5. 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, shade,

and drainage for the units heat exchanger condensate

drainage pit.

• 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 Residence Type Warm Air Heating

and Air Conditioning Systems” (NFPA 90B), these

instructions, and all applicable local codes. See page

8for additional information.

• Consult Table 8 (page 28), Table 9 (page 28),

Table 10 (page 29), Table 11 (page 30), Table 12

(page 31)& Table 13 (page 32), 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.

• 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 page 6, page 7, & page 8.

• Provide adequate clearances around the combustion

air intake louvers. See Figure 1 (page 5).

• Combustion products must be discharged outdoors.

Connect this unit to an approved vent system only, as

speciﬁed on page 6 and in the Appendix (pages 36-38).

• The information listed below is for reference purposes

only and does not necessarily have jurisdiction over

local or state codes. 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 D, 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., Batterymarch Park, Quincy, MA 02269; or American

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)

GENERAL INFORMATION

This Single Package Gas Heating / Electric Cooling

Unit is designed for outdoor rooftop or ground level

slab installations and can be readily connected to the

duct system of a home or building. This unit has been

tested for capacity and efﬁciency in accordance with

AHRI standards and will provide many years of safe and

dependable comfort, providing it is properly installed

and maintained. With regular maintenance, this unit will

operate satisfactorily year after year. Abuse, improper

use, and/or improper maintenance can shorten the life

of the appliance and create unsafe hazards.

To achieve optimum performance 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 tools

and mechanical skills.

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. Consideration should be

given to availability of electric power, service access,

noise, and shade. If there is any question concerning

the power supply, contact the local power company.

√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.

√Survey the job site to determine the best location for

setting the unit. Choose an appropriate location that

minimizes the length of the supply and return air ducts.

√Please consult your dealer for maintenance information

and availability of maintenance contracts. Please read

all instructions before installing the unit.

Locating the Equipment

• Select a solid, level position, preferably on a concrete

slab, slightly above the grade level, and parallel to the

home. DO NOT PLACE UNIT UNDER THE HOME.

• Overhead obstructions, poorly ventilated areas, and

areas subject to accumulation of debris should be

avoided. Do not place the unit in a conﬁned space or

recessed area where discharge air from the unit to re-

circulate into the condenser air inlet, through the coil.

• Sufﬁcient clearance for unobstructed airﬂow through the

louvered control access panel and outdoor coil must

be maintained in order to achieve rated performance.

See Figure 1 for minimum clearances to obstructions.

• A clearance of at least 36 inches from the blower

access panel and from the louvered control access

panel is recommended for servicing and maintenance.

Where accessibility clearances are greater than

minimumclearancestocombustibles,accessibility

clearances must take preference.

• The hot condenser air must be discharged up and away

from the home, and if possible, in a direction with the

prevailing wind.

• If practical, place the air conditioner and its ducts in an

area where they will be shaded from the afternoon sun,

when the heat load is greatest.

Heating Load

This unit should be sized to provide the design heating

load requirement. Heating load estimates can be made

using approved methods available from Air Conditioning

Contractors of America (Manual J); American Society of

Heating, Refrigerating, and Air Conditioning Engineers;

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.

Minimum Required

Clearances to Combustibles

36"

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 1. Clearance Requirements

COMBUSTION AIR & VENTING REQUIREMENTS

WARNING: AVERTISSEMENT:

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below

for each appliance connected to the venting

system being placed into operation could

resultincarbon monoxide poisoningordeath.

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.Inspectthe venting systemforproper size and

horizontalpitch,asrequiredintheNational 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 deﬁciencies which could

cause an unsafe condition.

3.As far as practical, close all building doors

and windows and all doors between the space

in which the appliance(s) connected to the

venting system are located and other spaces

of the building.

4.Close ﬁreplace dampers.

5.Turn on clothes dryers and any appliance

not connected to the venting system. Turn on

any exhaust fans, such as range hoods and

bathroom exhausts, so they are operating at

maximum speed. Do not operate a summer

exhaust fan.

6.Follow the lighting instructions. Place the

appliance being inspected into operation.

Adjustthethermostatsoapplianceisoperating

continuously.

7.Test for spillage from draft hood equipped

appliances at the draft hood relief opening

after 5 minutes of main burner operation. Use

the ﬂame 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, ﬁreplace

dampers and any other gas-ﬁred burning

appliance to their previous conditions of use.

RISQUE D’INTOXICATION AU MONOXYDE

DE CARBONE

Si les étapes décrites ci-dessous ne sont pas

suivies pour chacun des appareils raccordés au

système de ventilation au moment de sa mise

en marche, cela peut entraîner une intoxication

au monoxyde de carbone ou la mort. Les étapes

suivantes doivent être suivies pour chacun des

appareils raccordés au système de ventilation

au moment de sa mise en marche, alors que tous

les autres appareils raccordés au système de

ventilation ne sont pas en marche :

1.Scellertoutes lesouverturesinutilisées dusystème

de ventilation.

2.Inspecter le système de ventilation aﬁn de vériﬁer

si la taille et l’inclinaison par rapport à l’horizontale

sont conformes aux exigences du National Fuel Gas

Code,ANSIZ223.1/NFPA 54ou duCoded’installation

du gaz naturel et du propane, CSA B149.1 et à ces

instructions. Vériﬁer qu’il n’y a pas d’obstruction

ou de restriction, de fuite, de corrosion et d’autres

problèmes qui pourraient entraîner une situation

dangereuse.

3.Si possible, fermer toutes les portes et fenêtres

du bâtiment ainsi que toutes les portes séparant

l’endroit où se trouvent les appareils raccordés

au système de ventilation et les autres zones du

bâtiment.

4.Fermer le registre des foyers.

5.Mettre les sécheuses en marche ainsi que tous

les autres appareils qui ne sont pas raccordés au

système de ventilation. Mettre en marche tous les

ventilateurs de tirage, comme celui des hottes de

cuisine et des salles de bains, et les régler à la

puissance maximale. Ne pas mettre en marche les

ventilateurs d’été.

6.Suivre les instructions d’allumage. Mettre en

marche l’appareil soumis à l’inspection. Régler le

thermostatde manière àce que l’appareil fonctionne

en continu.

7.Vériﬁerla présence defuite auniveau del’ouverture

ducoupe-tiragedes appareilsquien sontdotésaprès

5 minutes de fonctionnement du brûleur principal.

Utiliser la ﬂamme d’une allumette ou d’une bougie.

8.Si un problème de ventilation est observé pendant

l’un des essais décrits ci-dessus, des correctifs

doivent être apportés au système de ventilation

conformément au National Fuel Gas Code, ANSI

Z223.1/NFPA 54 et (ou) au Code d’installation du

gaz naturel et du propane, CSA B149.1.

9.Une fois qu’il a été déterminé que chaque appareil

raccordé au système de ventilation fonctionne

correctementaumoyen desessaisdécritsci-dessus,

lesportes, lesfenêtres,les ventilateurs, lesregistres

de foyer et tous les autres appareils de combustion

alimentés au gaz doivent être remis dans leur état

initial.

WARNING:

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 sufﬁcient combustion air

to the unit.

• 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.

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 which form corrosive acidic

compounds in the combustion gases.

IMPORTANT NOTE:

Do not store any chemicals with ﬂammable or caustic

vapors near the vent termination. Some examples of

these chemicals are:

• Carbon tetraChloride • Gasoline/Kerosene

• Cements,Glues,paint removers,

varnishes, etC.• haloGen type refriGerants

• CleaninG solvents • hydroChloriC aCid

• Chlorine based swimminG pool

ChemiCals • masonry aCid washinG materials

• Chlorinated waxes & Cleaners • permanent wave solutions

• de-iCinG salts or ChemiCals • water softeninG ChemiCals

Vent Termination

This unit has been developed for use with a combination

heat exchanger condensate drain and venting system

designed to operate only with this type of system.

Condensate Drain and Vent Kits are available for purchase

as accessory items.

Horizontal ground mount applications can use P/N-922323

to attach the 13.25” x 2” PVC pipe within the control area of

this unit. Rooftop mount applications can use the downﬂow

condensate drain / vent kit (P/N-922485). If any of these

kits are not being used, see Appendix on page 42 or

page 44 for your speciﬁc application.

HORIZONTAL GROUND MOUNT

Combined condensate

Drain / Vent System

ROOF MOUNTED UNIT

(ROOF CURB AND ROOF NOT SHOWN)

2” PVC x 22.5 Degree Elbow

& 1/4” Mesh Screen

Figure 2. Heat Exchanger Condensate Drain

& Vent Assembly

WARNING:

This unit is intended for outdoor installation

only. This unit must be vented to the outdoors.

No additional venting shall be used. Do not vent

the unit through a conventional venting system.

The vent and drain assembly must be installed to

assure proper operation of the unit. Figure 2 shows the

proper installation of the vent and drain assembly for both

horizontal and downﬂow applications. The fasteners used

to secure the vent and drain assembly have been included

in the kit. The following list summarizes the requirements

for the location of the vent system termination:

• The location of the vent termination must be consistent

with the National Fuel Gas Code (ANSI Z223.1) or CAN/

CGA-B149 Installation Codes.

• The vent termination must be located at least 4 feet

horizontally from any electric meters, gas meters,

regulators, and relief equipment.

• Design the duct work according to Manual D by the Air

Conditioning Contractors of America (ACCA).

• The ducts must be properly sized not to exceed the

units maximum ESP rating at 400 SCFM per nominal

ton of cooling capacity.

• Duct work should be attached directly to the unit ﬂanges

for horizontal applications.

• If a 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.

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.

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

Contractors National Association (SMACNA) application

standard for duct liners.

• Duct lining must be UL classiﬁed 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.

• 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 unit should be installed in a way that prevents any

obstruction of the vent termination during accumulating

snow.

• 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.

CIRCULATING AIR SUPPLY

WARNING:

Products of combustion must not be allowed to

enterthe return airductworkor thecirculatingair

supply.Failuretopreventproductsofcombustion

from being circulated into the living space can

createpotentiallyhazardousconditions 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 that the unit is

mountedmustprovidesoundphysicalsupportof

theunit withno gaps,cracks,or saggingbewteen

the unit and pad.

Return air and circulating air ductwork must not

beconnected toany other heatproducing device

such as a ﬁreplace insert, stove, etc. Doing so

may result in ﬁre, 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 available by writing to: National Fire Protection

Association, Batterymarch Park, Quincy, ME 02269 or

visit www.NFPA.org on the web.

UNIT INSTALLATION

Packaging Removal

Remove the shipping carton and User’s Manual from the

equipment. Set aside the 13” x 2” PVC pipe for later use

when installing the heat exchanger condensate drain and

vent kit. Take care not to damage the coil or cabinet when

removing the carton. For rooftop installations, remove

and discard the two supports attached beneath the unit

Rigging & Hoisting

WARNING:

To avoid the risk of property damage, personal

injury, or death, it is the rigger’s responsibility

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 7 (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 7 (page 19)

for locating the center of gravity.

• All panels must be securely in place during

rigging and hoisting, except control access

panel. See page 47 for additional lifting and

setting of unit requirements.

Clearances to Combustible Materials

These units are certiﬁed as combination heating and

cooling equipment for outdoor rooftop or ground level

installations. Units may be installed on combustible

ﬂooring or class A, B, or C rooﬁng material when used

with bottom supply and return air ducts as long as the

following requirements are met:

• 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.

• Sufﬁcient clearance for unobstructed airﬂow through the

outdoor coil must also be maintained in order to achieve

rated performance. For information about locating the

equipment, see page 5.

Ground Level

Ground level installations must be located according to

local building codes or ordinances and these requirements:

• Clearances must be in accordance with those shown

in Figure 1 (page 5).

• A suitable mounting pad 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. See Figure 3.

• Remove and discard the horizontal Supply and Return

duct covers located on the rear of the unit. Form duct

Figure 3. Ground & Rooftop Installation

2”

ROOFTOP INSTALLATION

GROUND LEVEL INSTALLATION

ACCESSORY

ROOF CURB

attachment ﬂanges by bending the sheet metal outward

90 degrees along the perforated lines.

• Firmly attach ductwork directly to these ﬂanges with

screws or other approved mechanical connections and

not to the Supply/Return air panels to avoid damage to

internal components of the equipment. Use approved

duct sealing methods to ensure an air and watertight

seal is achieved.

Rooftop

Rooftop installations must be located according to local

building codes or ordinances and these requirements:

• The roof must be capable of handling the weight of the

unit. Reinforce the roof if necessary For unit weights,

see Table 7 (page 27).

• The appropriate accessory roof curb must be installed

prior to unit installation. The roof curb must be square

and level to ensure proper condensate drainage. See

Figure 2 (page 7). Please follow all instructions

provided with the kit.

• Secure roof curb or frame to roof using acceptable

mechanical methods per local codes. NOTE:Make sure

the two supports beneath the unit have been removed.

IMPORTANT NOTES TO INSTALLER

• When setting the roof curb for installation, routing and

securement of the gas heat exchanger condensate

drain line must be determined and installed prior to

setting the unit on the curb. It is recommended to drill

a 1.00”-1.25” diameter hole through the roof below

the rectangular opening located in outer close off curb

panel (G), approximately 15” in from the short side of

curb and 1”-2” in from the long side of curb. If drilling a

hole is not an option, routing the condensate drain hose

over to the duct passage opening with enough slope is

acceptable as long as drain line is secured to curb and

duct, ensuring no kinks or traps can form between the

collector box drain or interior of the building. Leave a

minimum of 24” drain line extending out the top of roof

curb front close off panel (G) for passage through unit

bottom and connection to unit drain when unit is being

set. See unit or condensate/vent drain kit (P/N-922485)

instructions for completion of the drain connection.

• It is recommended no non-serviceable connections are

introduced in the drain line between unit drain connection

and an accessible area within the building interior.

• Securement of the drain line to the inside surface of

the roof curb is acceptable and should be made in the

wood nailer area (top 3.5”) to avoid possible leaks or

penetrations to rooﬁng materials.

• Cut and remove the insulation covering the 2” x 3”

condensate drain passage in outer panel (G) only. Before

installing inner panel (G) ensure there is enough slope

and there are no kinks or high spots that could trap

water in the line prior to entering the warmer interior of

the building where a drain trap is acceptable.

• All panels must be securely in place during rigging and

hoisting, except control access panel. See page 47

for additional lifting and setting of unit requirements.

Horizontal to Downﬂow 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 both horizontal duct caps.

2. Locate the duct cap inside the duct openings and remove

the screw holding it in place.

3. Lift the cap out of the unit. (Hint: The cap can be pushed

up from the bottom by reaching through the fork slot).

4. Cover the horizontal duct openings with the horizontal

duct caps removed earlier in step 1. The insulation will

be on the indoor side.

5. Fasten the cover with screws to seal.

6. Remove and discard the two wood supports beneath

the unit.

Condensate Drain (Air Conditioning)

Air conditioning condensate is removed from the unit

through the 3/4” female pipe and supplied ﬁtting located

on the front side of the unit. Figure 4 (page 11).

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.

Table 1. External & Internal Filter Sizes

EXTERNAL FILTER SIZES

NOMINAL

COOLING

(TONNAGE)

FILTER SIZE

(IN. X IN.)

APPROXIMATE

AIR FLOW

RANGE (CFM)

APPROXIMATE

FILTER AREA

(SQ. IN.)*

2.0 20 x 25 600-900 450

2.5 20 x 30 750-1200 550

3.0 25 x 25 1100-1300 625

3.5 24 x 30 1200-1600 750

4.0 18 x 24 (2 required) 1400-1800 850

5.0 20 x 25 (2 required) 1700-2200 1000

INTERNAL FILTER SIZES

CABINET

HEIGHT

OUTDOOR

FAN

DIAMETER

FILTER SIZE

(IN. X IN.)

APPROXIMATE

AIR FLOW

RANGE (CFM)

APPROXIMATE

FILTER AREA

(SQ. IN.)*

30” 20 (2) 14”x25” 700 - 1300 700

24” (1) 12”x20” and (1) 16”x25” 640

34” 20 (2) 16”x25” 900 - 1400 800

24” (1) 12”x20” and (2) 10”x25” 740

38” 20” (2) 18”x25” 1100 - 1600 900

24” (1) 12”x20” and (2) 12”x25” 840

42” 20” (2) 20”x25” 1300 - 1800 1000

24” (1) 12”x20” and (2) 14”x25” 940

* Based on velocity of 300 ft/min for disposable ﬁlters.

Figure 4. Refrigerant Service Ports & Air

Conditioning Condensate Drain Locations

HIGH SIDE

LOW SIDE

CONDENSATE

DRAIN

Securing

Screws

Figure 5. Internal Filter Rack Location

Air Filter Requirements

WARNING:

Never operate the unit without a ﬁlter in place.

Dust and lint could accumulate on internal parts,

resultinginloss ofefﬁciency, equipmentdamage

and possible ﬁre.

NOTE TO INSTALLER: After installing or replacing the

ﬁltration system for this unit, add the following statement

on or adjacent to the ﬁlter service panel: “Replace

ﬁlter(s) installed in your system only with the same

dimensional size ﬁlters that are being replaced.”

• An air ﬁlter is not supplied with this package unit as

shipped from the factory. The installer must provide

a high velocity ﬁlter that is appropriately sized to the

return air duct opening or internal ﬁlter rack. The ﬁlters

must comply with ANSI/UL 900 or CAN/ULC-S111.

• For recommended external filter sizes, refer to

Table 1 (page 10).

• All return air must pass through the ﬁlters before entering

the evaporator coil. 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 is recommended not to exceed

0.08 inches WC.

• Single phase downﬂow applications require either a

Nortek internal ﬁlter kit be used or an air ﬁlter system

be installed in the return air ductwork. See Table 1 for

speciﬁc unit model and ﬁlter sizes. Nortek internal ﬁlter

rack adjusts for 1” or 2” ﬁlters. To convert the unit from

1 inch to 2 inch ﬁlters, see 1” to 2” Filter Conversion

section below.

• Horizontal installations require the air ﬁlter system be

installed in the return air ductwork.

Installing Filters in the Internal Filter Rack

(If Equipped)

1. Remove access panel screws from return air panel.

(Hint: Loosen the unit’s top panel screws near the

top edge of the access panel. The access panel was

designed to be captured underneath the top panel.)

2. Slide the ﬁrst ﬁlter between both guide channels of ﬁlter

rack and allow the ﬁlter to drop easily into place.

3. Verify the bottom of the ﬁlter is within the channels of

the rack.

4. Slide the 2nd ﬁlter (and 3rd ﬁlter on taller models)

between both guide channels of ﬁlter rack.

5. Verify the top of the ﬁlter is within the channels of the

rack.

6. Replace access cover by sliding the top edge of panel

under the lip of the unit’s top panel. Secure access

panel by replacing the screws.

1” to 2” Filter Conversion

Factory installed internal ﬁlter rack (3 phase models only)

is set up to accept 1” ﬁlters. If conversion to 2” ﬁlters is

desired, remove the two (or three) 1” ﬁlter adaptors secured

in the assembly with clips by pulling straight off the frame.

The ﬁlter bracket must be reoriented to accept 2” ﬁlters by

removing two screws securing it to the hinge and rotating

180 degrees. See Figure 22 (page 45).

Removing Filters from Internal Filter Rack

(If Equipped)

1. Remove access panel screws from return air panel.

(Hint: Loosen the unit’s top panel screws near the

top edge of the access panel. The access panel was

designed to be captured underneath the top panel.)

2. Remove upper ﬁlter by gently pulling ﬁlter through the

access panel opening.

3. Remove lower ﬁlter by lifting media to top of ﬁlter rack.

Remove in the same manner as described in step 2.

4. Install new ﬁlter in the ﬁlter rack as described in the

previous section.

Pre-Electrical Checklist

(Single Phase Models)

√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

to handle the additional load imposed by this equipment.

See Table 16 (page 35) (or the unit rating label) for

proper high voltage wiring requirements.

√Verify factory wiring is in accordance with the unit

wiring diagram. Figure 13 (page 37). Make sure the

connections didn’t loosen during shipping or installation.

Grounding

WARNING:

The unit cabinet must have an uninterrupted or

unbrokenelectrical groundto minimizepersonal

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. Grounding of the unit is accomplished

by using the grounding lug provided in the control box.

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.

• Anelectricaldisconnectmust belocatedwithin sight

of and readily accessible to the unit. This switch shall

be capable of electrically de-energizing the 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. See Table 17 (page 35). 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

rating label and according to applicable local codes.

See Table 16 (page 35) or the unit rating plate for

minimum 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 Figure 13 (page 37).

• All 208-240 volt 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.

• Connect the line-voltage leads to the terminals on the

contactor inside the control compartment.

ELECTRICAL WIRING

WARNING:

ELECTRICAL SHOCK, FIRE OR

EXPLOSION HAZARD

Failure to follow safety warnings exactly could

result in serious injury or property damage.

Improper servicing could result in dangerous

operation, serious injury, death or property

damage.

• Before servicing, disconnect all electrical

power to furnace.

• When servicing controls, label all wires prior

to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

AVERTISSEMENT:

RISQUE DE CHOC ÉLECTRIQUE,

D’INCENDIE OU D’EXPLOSION

Le non-respect des avertissements de sécurité

pourrait entraîner un fonctionnement dangereux

de l’appareil, des blessures graves, la mort ou des

dommages matériels.

Un entretein incorrect pourrait entraîner un

fonctionnement dangereux de l’appareil, des

blessures graves, la mort ou des dommages

matériels

•Couper toute alimentation électrique au générateur

d’airchaud avantde prodéder auxtravaux d’entretein.

•Au moment de l’entretien des commandes, étiquetez

tous les ﬁls avant de les débrancher. S’assurer de les

raccorder correctement.

•S’assurer que l’appareil fonctionne adéquatement

aprés l’entretien.

• Electrical connections must be in compliance with all

applicable local codes with the current revision of the

National Electric Code (ANSI/NFPA 70).

• For Canadian installations the electrical connections

and grounding shall comply with the current Canadian

Electrical Code (CSA C22.1 and/or local codes).

IMPORTANT NOTE:

If replacing any of the original wires supplied with the

furnace, the replacement wire must be copper wiring

having the same guage, voltage, and temperature

rating.

Thermostat / Low Voltage Connections

• This unit is designed to operate from a 24 VAC Class II

control circuit. A single stage cooling / two stage heating

thermostat should be used with this unit. See Figure 10

(page 36)for typical thermostat connection.

• 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 should be made 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 18 (page 35).

• Several thermostat options are available depending

on the accessories installed with the unit. Select a

thermostat that operates in conjunction with the installed

accessories.

• 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 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 instruction sheet

for detailed mounting information.

2-Stage Heat / 1-Stage Cool Thermostat

(Recommended): For highest efﬁciency a 2 Stage Heating/

Single Cooling thermostat is recommended for this unit. A

Single Stage Cool thermostat is only required for cooling

operation control of this unit. A 2 Stage Heat thermostat

will allow the gas heat to operate at a more efﬁcient low

heat condition until there is a demand for higher heat

output to the conditioned space.

Single Stage Heat / Single Stage Cool Thermostat

(Optional): A Single Stage Cool thermostat is only required

for cooling operation of this unit. A Single Stage Heat

thermostat can be used in conjunction with the automatic

heat staging jumper on the ignition control board. The heat

staging function will automatically move the unit into high

heat operation after 10 minutes when the jumper is moved

from OFF to the ON position. See Figure 12 (page 36).

Connect the Red, Yellow, Green, White, and Brown low

voltage thermostat wires to terminals R, Y1 (1st Stage

Cool), G, W1 (1st Stage Heat), & W2 2nd Stage Heat-

optional) on both the thermostat sub-base and unit low

voltage terminal board. The Cterminal (Black wire), is the

24V common wire required on some thermostat models.

See Figure 10 (page 36).

Heat Anticipator

Verify if the thermostat being used for the installation

has a heat anticipator setting. This function allows the

thermostat to anticipate the space heating rate and time

the burner to shutoff accordingly. Always refer to the

thermostat manufacturer’s instructions for correct settings.

• Add the current draw of the system heating components.

• Measure the current ﬂow on the thermostat R-Wcircuit

after the circulating blower motor has started. Set the heat

anticipator according to the thermostat manufacturer’s

instructions for heat anticipator settings.

Cooling Conﬁgurations

This unit is designed to connect with any single stage

cooling thermostat. The connection between Y1 on the

thermostat and Y1 on the unit terminal strip energizes

cooling operation. See Figure 10 (page 36).

Heating Conﬁgurations

This gas pack is factory conﬁgured for two stage gas

heating operation with a two stage heating thermostat.

Connect the low voltage thermostat White & Brown wires

to W1 & W2, between the unit low voltage terminal board

and thermostat sub-base. See Figure 10.

To operate with a single stage heat thermostat, only

connect the low voltage thermostat White wire between

W1 on the unit low voltage terminal board and thermostat

sub-base. Reposition the automatic heat staging jumper

located on the ignition control module from OFF to ON

to set a 10 minute time delay before the gas furnace will

automatically move to high heat operation. 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. The inducer motor and blower will ramp to a

higher speed until the thermostat is satisﬁed.

Blower Speed

The blower speed is preset at the factory for proper

fan only, heating, and cooling operation. These factory

settings are listed in Table 8 (page 28), Table 9 (page

28), Table 10 (page 29), Table 11 (page 30), Table

12 (page 31)& Table 13 (page 32). For optimum

system performance and comfort, it may be necessary to

change the factory set speed. To avoid personal injury

or property damage, make sure the motor leads do

not come into contact with any un-insulated metal

components of the unit.

NOTES:

• The CFM values listed in Table 8, Table 9, Table 10,

Table 11, Table 12 & Table 13 are DEPENDANT on

duct static pressure for individual switch settings.

• If coil icing occurs, the basic cooling airﬂow selected

may be too low. Verify the selected setting is within

the range shown in Table 8 and the system is properly

charged. If icing continues, raise the selected airﬂow

to the next higher tap.

• For maximum dehumidiﬁcation and energy efﬁciency,

select an airﬂow near the middle or bottom of the CFM

range for that nominal capacity.

• The 2-stage heating feature of the unit requires

modulating the airﬂow. The unit will automatically adjust

the airﬂow to the appropriate rate when the unit heating

capacity changes.

Conﬁguring the Fixed Speed Blower

The ﬁxed speed blower assembly has been designed to

give the installer maximum ﬂexibility for optimizing system

performance, efﬁciency, and comfort. It is equipped with

a microprocessor-controlled motor when coupled with a

ﬁxed speed motor control board delivers constant torque

to optimize airﬂow in a variety of conditions and system

conﬁgurations. Because the blower can be conﬁgured in

many ways, it is important to read and follow all instructions

carefully.

Upon initial start up, the ﬁxed speed blower must be

checked so that the factory settings match the unit with

the system, climatic conditions, and other system options.

With the blower installed and conﬁgured properly, the

furnace will change speed in response to changes in

system variables such as Heat/Cool setting, Fan Auto/

On, or 2 Stage furnace High/Low Heat. The ﬁxed speed

blower is conﬁgured by setting the 8 switches for heating

and cooling operation located on the blower control board.

Use pins 1 to 4 to set the blower speed for heating and

pins 5 to 8 to set the speed for cooling. To determine the

appropriate switch settings for your installation, see Table

9, Table 10, Table 11, Table 12 & Table 13 for heating or

Table 8 for cooling. See Figure 10 (page 36)for switch

locations. NOTE: For change in blower speed selection to

take effect, system power must be cycled off then restored

after 10 seconds.

Selecting Cooling Airﬂow

(Switches # 5, 6, 7, & 8)

The COOLING airﬂow is selected by setting switches # 5,

6, 7, & 8 on the motor control board (Figure 10). Table 8

(page 28) lists the recommended airﬂow values (CFM)

and switch settings for each nominal cooling system

capacity. All airﬂows for other modes of operation are

determined by these basic settings. For maximum capacity,

generally, a selection near the middle or top of the CFM

range for that nominal capacity is used. Factory settings

are displayed in BOLD ITALICS

Selecting Heating Airﬂow

(Switches # 1, 2, 3, & 4)

The HEATING airﬂow is selected by setting switches #

1, 2, 3, & 4 on the motor control board (Figure 10, Page

31). Table 9, Table 10, Table 11, Table 12 & Table 13

list the recommended airﬂow values (CFM) and switch

settings for each heat exchanger capacity. All airﬂows are

determined by these basic settings. For most applications

the factory heat setting will operate at 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 or in the tables.

Dehumidiﬁcation Options

The ﬁxed speed motor control board has a DEHUM

connection that allows the system to increase the amount

of humidity that is removed from the circulating air. This

is accomplished by reducing the CFM and allowing the

cooling coil to become colder. This function is only available

when there is a call for cooling. There are many ways this

function can be electrically wired.

When 24VAC is present at the DEHUM terminal of the

blower control board the airﬂow requirements will be

reduced to approximately 75% of the nominal airﬂow

requirements. If the humidity level of the conditioned space

decreases during the cycle and the humidistat opens, the

airﬂow will be restored to 100% of the selected value.

• If the room thermostat incorporates a humidity sensor

and DEHUM output, connect the DEHUM on the

thermostat to the DEHUM terminal on the motor control

board. See Figure 10 (page 36).

• If using a separate humidistat, connect the DEHUM & R

terminals on the humidistat to the DEHUM& Rterminals

on the motor control board. In this option, the DEHUM

output of the humidistat must be set to be normally open

and closed when there is a call for dehumidiﬁcation.

If a humidistat is not available, it is an acceptable option

to directly jumper the R& DEHUM on the blower control

board. NOTE: This option will always operate the blower

at 75% the rated airﬂow for the ﬁrst 10 minutes of every

cooling cycle no matter what the humidity level of the

home is. See Figure 10.

CAUTION:

To avoid personal injury or property damage,

make sure the motor leads do not come into

contact with any uninsulated metal components

of the unit.

Optional Furnace Control Board Connections

Electronic Air Cleaner

The furnace control board provides output terminals

for an optional electronic air cleaner (EAC) that can be

installed in the return air duct of your system. The EAC

output is energized any time the HEAT or COOL blower

speed is energized. Control ratings are 1.0 Amp. @ 240

VAC. Output connections are made via board terminals

labeled EAC and NEUTRAL.

Humidiﬁer

The furnace control board provides output terminals for

an optional humidiﬁer (HUM) that can be installed on

your system. The HUM output is energized any time the

furnace inducer motor is energized. Control ratings are

1.0 Amp. @ 240 VAC. Output connections are made via

board terminals labeled HUM and NEUTRAL.

Check all factory wiring to the proper unit wiring diagram:

Figure 13 (page 37). Inspect the factory wiring

connections and make sure they didn’t loosen during

shipping or installation.

GAS SUPPLY & PIPING

WARNING:

FIRE OR EXPLOSION HAZARD

• Failureto followsafetywarningsexactlycould

result in serious injury or property damage.

• Installation and service must be performed

by a qualiﬁed installer, service agency or the

gas supplier.

• Do not store or use gasoline or other

ﬂammable vapors and liquids in the vicinity

of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the

ﬁre department.

AVERTISSEMENT:

RISQUE D’INCENDIE OU D’ EXPLOSION

•Le non-respect des avertissements de sécurité

pourrait entraîner des blessures graves, la mort ou

des dommages matériels.

•L’installation et l’entretien doivent être effectués par

un installateur qualiﬁé, un organisme de service ou le

fournisseur de gazstaller, service agency or the gas

supplier.

•Ne pas entreposer ni utiliser de l’essence ni d’autres

vapeurs ou liquides inﬂammables dans le voisinage

de cet appareil, ni de tout autre appareil.

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

•Ne pas tenter d’allumer aucun appareil.

•Ne toucher à aucun interrupteur électrique; n’utiliser

aucun téléphone dans le bâtiment.

•Évacuer l’immeuble immédiatement.

•Appeler immédiatement le fournisseur de gaz en

employant le téléphone d’un voisin. Respecter à la

lettre les instructions du fournisseur de gaz.

•Si personne ne répond, appeler le service des

incendies.

• 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 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. See Figure 6 (page

16).

• Themanifold pressuremustbe settotheappropriate

value for your installation. To measure and adjust

the manifold pressure see page 19.

• 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 shutoff valve and main power

disconnect to the unit must be properly labeled

by the installer in case emergency shutdown is

required.

• An 1/8 inch NPT plugged tap can be installed in the

gas line immediately upstream of the gas supply

connection to the unit for use when measuring

the gas supply pressure when not using the inlet

pressure tap supplied on the factory installed gas

valve. The plug should be readily accessible for

service use.

• A drip leg should be installed in the vertical pipe

run to the unit. See Figure 6.

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 6.

Table 14 (page 33) 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

Failure to follow safety warnings exactly could

result in serious injury or property damage.

Never test for gas leaks with an open ﬂame. Use

a commercially available soap solution made

speciﬁcally for the detection of leaks to check

all connections. A ﬁre or explosion may result

causing property damage, personal injury or

loss of life.

AVERTISSEMENT:

RISQUE D’INDENDIE OU D’EXPLOSION

Si les consignes de sécurité ne sont pas suivies à la

lettre, cela peut entraîner la mort, de graves blessures

ou des dommages matériels.

Ne jamais vériﬁer la présence de fuites de gaz au

moyen d’une ﬂamme nue. Vériﬁer tous les raccords en

utilisantune solutionsavonneusecommerciale conçue

spécialement pour la détection de fuites. Un incendie

ou une explosion risque de se produire, ce qui peut

entraîner la mort, des blessures ou des dommages

matériels.

After the gas piping to the unit is complete, all connections

must be tested for gas leaks. This includes pipe connections

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

adequately and must be retightened. Repeat the tightening

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

bedisconnected from the gassupply 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

gassupply line by closing the manual shut-off valve.

High Altitude Conversion - Natural Gas

Conversion of this unit must be performed by qualiﬁed

service personnel, using only approved parts. All

installations must be made in accordance with the National

Fuel Gas Code and/or local jurisdiction codes.

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.

High altitude conversion can be ﬁeld performed by a simple

adjustment of manifold pressure or a change of the oriﬁces

(if necessary) as described in the Measuring & Adusting

the Manifold section (page 19). The changes required

depend on the installation altitude and the heating value

of the gas (based on sea level) which can be obtained

from your local gas utility. The heating value of gas at high

altitude is always lower than the sea level heating value.

Natural Gas heating values listed in Table 3 (page 20)

are based on sea level values.

All factory shipped furnaces are ready to operate using

Natural Gas between zero and 2,000 ft. above sea level.

For altitudes between 2,000 and 10,000 feet above sea

level, the unit can be converted by adjusting the unit’s

manifold pressure and/or changing the oriﬁces. See Table

3for the correct manifold pressure settings.

NOTE: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). Deration is

necessary to compensate for low atmospheric pressure

at high altitudes.

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 ﬁre, 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. Conversion to LP can be accomplished by

replacing the natural gas oriﬁces with the appropriate LP/

Propane oriﬁces and then adjusting the manifold pressure

(page 19). Conversion to LP/Propane (sea level and

high altitude) is detailed in the installation instructions

provided with the conversion kit. Please follow the

instructions provided in each kit. Approved conversion

kits are listed below:

• The United States LP/Propane Gas Sea Level and High

Altitude Conversion Kit (P/N 922311) is for LP/propane

conversion in the United States at altitudes between

zero and 10,000 ft. above sea level.

• The Canadian LP/Propane Gas Sea Level and High

Altitude Conversion Kit (P/N 922312) is for LP/propane

conversions in Canada at altitudes between zero and

4,500 ft. above sea level.

For installations between zero and 4,999 ft. above sea

level, a #55 drill size oriﬁce should be used. Installations

5,000 ft. above sea level require a # 56 drill size oriﬁce.

Table 4 (page 20) lists the correct oriﬁce sizes and

manifold pressures for operation 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 the Firing Rate

of the Appliance section on page 18.

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 6. Typical Gas Hookup - Right Side Entry

START UP & ADJUSTMENTS

Pre-Start Check List

√Verify the unit is level and allows evaporator condensate

to drain.

√Verify heat exchanger condensate drain and vent kit

have been installed according to the instructions included

with horizontal kit 922323 or downﬂow kit 922485 or as

described in the Appendix section (page 42).

√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

and air ﬁlter is installed.

√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 terminals in the low voltage area of the

control box.

√Verify that the gas line service pressure does not exceed

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).

√Verify that the ﬂame roll-out control is closed. 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

compressorcrankcasepriortostartuporanytime

the power has been removed for more than 12

hrs. Failure to comply may result in damage or

cause premature failure of 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.

NOTE: When FAN ON is selected, the blower will operate

at 50% of selected airﬂow when no call for heating or

cooling is present.

Lighting the Appliance

WARNING:

FIRE OR EXPLOSION HAZARD

• Failureto followsafetywarningsexactlycould

result in serious injury or property damage.

• Installation and service must be performed

by a qualiﬁed installer, service agency or the

gas supplier.

• Do not store or use gasoline or other

ﬂammable vapors and liquids in the vicinity

of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the

ﬁre department.

AVERTISSEMENT:

RISQUE D’INCENDIE OU D’ EXPLOSION

•Le non-respect des avertissements de sécurité

pourrait entraîner des blessures graves, la mort ou

des dommages matériels.

•L’installation et l’entretien doivent être effectués par

un installateur qualiﬁé, un organisme de service ou le

fournisseur de gazstaller, service agency or the gas

supplier.

•Ne pas entreposer ni utiliser de l’essence ni d’autres

vapeurs ou liquides inﬂammables dans le voisinage

de cet appareil, ni de tout autre appareil.

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

•Ne pas tenter d’allumer aucun appareil.

•Ne toucher à aucun interrupteur électrique; n’utiliser

aucun téléphone dans le bâtiment.

•Évacuer l’immeuble immédiatement.

•Appeler immédiatement le fournisseur de gaz en

employant le téléphone d’un voisin. Respecter à la

lettre les instructions du fournisseur de gaz.

•Si personne ne répond, appeler le service des

incendies.

1. Turn ON the manual gas valve, located on the outside

of the unit to the ON position.

2. Check all gas connections for leaks with a soap and

water solution. If the solution bubbles there is a gas

leak which must be corrected.

3. Turn on the electrical power to the appliance.

4. Place the gas valve ON/OFF switch to the ON position.

See Figure 7 (page 19).

5. Set the thermostat above room temperature to begin

the heating cycle of the furnace.

6. Check that the furnace ignites and operates properly.

7. After ignition, visually inspect the burner assembly to

ensure that the ﬂame is drawn directly into the center of

the heat exchanger tube. In a properly adjusted burner

assembly, the ﬂame color should be blue with some light

yellow streaks near the outer portions of the ﬂame.

NOTE: The ignitor may not ignite the gas until all air is

bled from the gas line. If the ignition control locks out,

turn the thermostat to its lowest setting and wait one

minute then turn the thermostat above room temperature

and the ignitor will try again to ignite the main burners.

This process may have to be repeated several times

before the burners will ignite. After the burners are lit,

check all gas connections for leaks again with the soap

and water solution.

Verifying System Heating

(2-Stage Heating)

1. Set the thermostat to the lowest setting.

2. Follow the procedures given on the operating instruction

label, in this manual or attached inside the louvered

control access panel.

3. Set the thermostat one degree above room temperature

and verify the Operating Sequence (page 22).

4. Verify that the compressor and outdoor fan motor are

not energized.

5. After determining the system is running (1-2 minutes),

raise the thermostat’s setpoint an additional 3-4 degrees

until the heating system moves into 2nd stage or high

heat operating mode. The gas valve will energize to high

heat mode while the induced draft motor and indoor

blower motor both increase in speed.

6. After the unit has run for approximately ﬁve minutes,

set the thermostat below room temperature and verify

the shutdown sequence; steps 10 -12 in the Operating

Sequence section (page 22).

Verifying & Adjusting Temperature Rise

Verify the temperature rise through the unit is within the

range speciﬁed on the unit data label and in Table 2 (page

20). Temperature rises outside the speciﬁed range could

result in premature heat exchanger failure.

1. Place thermometers in the return and supply air stream

as close to the unit as possible. The thermometer on the

supply air side must be 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) see

in Table 8 (page 28), Table 9 (page 28), Table 10

(page 29), Table 11 (page 30), Table 12 (page 31)

& Table 13 (page 32). If the measured temperature rise

falls outside the speciﬁed range, it may be 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 an ECM type motors. Speed

selection is made by setting the switches on the motor

control board. See Figure 11 (page 36). NOTE: For

change in blower speed selection to take effect, system

power must be cycled off then restored after 10 seconds.

Refer to the Blower Speed section (page 13) for

additional information.

The integrated control starts the circulating air blower 22

seconds after the gas valve is opened. The control board

is factory set to turn the blower motor off 120 seconds

after the gas valve is closed.

Gas Supply Pressure Veriﬁcation & Adjustment

1. Turn OFF the gas supply at the manual valve located

on the outside of the unit.

2. Using a 3/16” Allen wrench, remove the plug from the

inlet pressure tap (INLET side of gas valve). See Figure

7 (page 19).

3. Install an 1/8” NPT pipe thread ﬁtting, that is compatible

with a Manometer or similar pressure gauge.

4. Connect the Manometer or pressure gauge to the Inlet

Pressure Tap.

5. Turn ON the main gas supply at the manual valve.

6. Check and adjust the incoming gas line pressure to 4.5-

10.0 inches Water Column for Natural gas or 11.0-14.0

inches Water Column if converting unit to LP/Propane

gas.

7. Turn OFF the gas supply at the manual valve.

8. Disconnect the Manometer or pressure gauge.

9. Remove the NPT ﬁtting and reinstall the INLET pressure

tap plug. Hand tighten the plug ﬁrst to prevent cross

threading. Tighten with 3/16 Allen wrench.

Verifying the Firing Rate of the Appliance

WARNING:

Donotattempt to drillthegas oriﬁces.Ifthe oriﬁce

size must be changed, use only factory supplied

oriﬁces. Improperly drilled oriﬁces may cause

ﬁre, explosion, carbon monoxide poisoning,

personal injury or death.

The ﬁring rate must be veriﬁed for both LOW and HIGH

ﬁre for each installation to prevent over-ﬁring of the unit.

The ﬁring rate must not exceed the rate shown on the

unit data label. To determine the ﬁring rate, follow the

steps below:

1. Obtain the gas heating value (HHV) from the gas supplier.

2. Shut off all other gas ﬁred appliances.

3. Start the unit in LOW heating mode and allow it to run

for at least 3 minutes.

4. Measure the time (in seconds) required for the gas

meter to complete one revolution.

5. Convert the time per revolution to cubic feet of gas per

hour using Table 15 (page 33).

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

(INPUT --> HIGH = 100,000 / LOW = 65,000)

• Time for 1 revolution of a gas meter with a 1 cubic foot dial

= 58 seconds.

• From Table 15, read 62 cubic feet gas per hour.

• Local heating value of the gas (obtained from gas supplier)

= 1,040 Btu per cubic foot.

• Low Input rate = 1,040 x 62 = 64,480 Btuh = PASS

7. Record your ﬁndings and move unit operation to HIGH

heating mode and Repeat Steps 3-6.

8. Adjust the manifold pressure if necessary by following

the steps in the Measuring & Adusting the Manifold

sections. For additional information about elevations

above 2,000 feet, see High Altitude Conversion section

(page 16).

Measuring the Manifold Pressure

The manifold pressure must be measured for both LOW

and HIGH ﬁre by installing a pressure gauge (Manometer,

Magnehelic Meter, etc.) to the outlet end of the gas valve

as follows:

1. Turn off all electrical power to the appliance.

2. Shut OFF the gas supply at the manual shutoff valve

located outside of the appliance.

3. Using a 3/16” Allen wrench, remove the manifold

pressure tap plug located on the outlet side of the gas

valve (Figure 7).

4. Install an 1/8” NPT pipe thread ﬁtting, that is compatible

with a Manometer or similar pressure gauge.

5. Connect the Manometer or pressure gauge to the

manifold pressure tap.

6. Set the room thermostat 1 degree above room

temperature To start the furnace on LOW ﬁre.

7. Allow the furnace to operate for 3 minutes and then

check the manifold pressure. Compare the measured

value with the value shown in Table 3 (page 20) for

Natural Gas and Table 4 (page 20) for LP/Propane

gas. If the manifold pressure is not set to the appropriate

pressure, then it must be adjusted.

8. Record your ﬁndings and move unit operation to HIGH

heating mode and Repeat Steps 3-6.

Inlet

Pressure

Tap

Manifold

pressure

Tap

2-STAGE GAS VALVE

Model VR9205Q1127

ON / OFF

Switch

High Input

Adjusting

Screw

Lo Input

Adjusting

Screw

Cap

Screws

Figure 7. Regulator Capscrew & Tap Locations

Adjusting the Manifold Pressure

NOTE: If adjustment must be made to either LOW or

HIGH ﬁre settings perform the following steps:

1. Remove the cap screw from the top of the gas valve

regulator (Figure 7).

2. Using a screwdriver or Allen wrench (where appropriate),

slowly turn the adjustment screw till the appropriate

manifold pressure listed in Table 3 or Table 4, or the

LOW and/or HIGH ﬁring rate for your speciﬁc gas HHV

is achieved.

NOTE: Turning the screw clockwise increases

the pressure, turning the screw counter-clockwise

decreases the pressure. To prevent the screw from

backing all the way out from the valve, turn the screw

slowly.

3. Replace and tighten the cap screw or the plastic cap

over the adjustment screw.

Removing the Manometer/Pressure Gauge

After the LOW and HIGH manifold pressures are properly

adjusted, the Manometer or pressure gauge must be

removed from the gas valve.

1. Turn the thermostat to its lowest setting.

2. Turn OFF the main gas supply to the unit at the manual

shut-off valve, which is located outside of the unit.

3. Turn OFF all of the electrical power supplies to the unit.

4. Remove the pressure gauge adapter from the gas valve

and replace it with the 1/8” NPT manifold pressure plug

that had been removed earlier. NOTE: Make sure the

plug is tight and not cross-threaded.

5. Turn ON the electrical power to the unit.

6. Turn ON the main gas supply to the unit at the manual

shut-off valve.

Verifying Over-Temperature Limit Control Operation

1. Verify the louvered control access panel is in place and

that there is power to the unit.

2. Block the return airﬂow to the unit by installing a close-

off plate in place of or upstream of the ﬁlter.

3. Set the thermostat above room temperature and verify

the units operating sequence (page 22).

NOTE: The over-temperature limit control should turn

off the gas valve within approximately four minutes

(exact time depends on the efﬁciency of the close-off

when blocking the return air). The circulating air and

combustion blowers should continue to run when the

over-temperature limit control switch opens.

4. Remove the close-off plate immediately after the over-

temperature limit control opens. If the unit operates

for more than four minutes with no return air, set the

thermostat below room temperature, shut off power to

the unit, and replace the over-temperature limit control.

Verifying Burner Operation

WARNING:

Uninsulated live components are exposed when

louvered control access panel is removed.

1. Remove the louvered control access panel and verify

there is power to the unit.

Table 2. R104HD Nominal Rates and Temperature Rises

MODEL

NUMBER

R104HD

MAXIMUM GAS

SUPPLY PRESSURE (IN.WC)

MINIMUM GAS SUPPLY

PRESSURE (IN.WC)

MANIFOLD

PRESSURE (IN.WC)

HIGH INPUT

(BTU/HR)

HIGH OUTPUT

(BTU/HR)

LOW INPUT

(BTU/HR)

LOW OUTPUT

(BTU/HR)

GAS ORIFICE SIZE

RISE RANGE (OF)

MAX. OUTLET

AIR TEMP.

MAXIMUM EXTERNAL

STATIC PRESSURE

E.S.P. (IN WC)

NET COOLING

CAPACITY (BTUH)

BLOWER SIZE

MOTOR (HP)

-X24K060C 10.0 4.5 3.5 60,000 57,000 39,000 37,050 45 30-60 160 0.80 24,000 11” x 8” 3/4

-X30K060C 10.0 4.5 3.5 60,000 57,000 39,000 37,050 45 30-60 160 0.80 28,600 11” x 8” 3/4

-X36K080C 10.0 4.5 3.5 80,000 76,000 52,000 49,400 45 35-65 165 0.80 34,600 11” x 8” 1

-X42K080C 10.0 4.5 3.5 80,000 76,000 52,000 49,400 45 35-65 165 0.80 41,000 11” x 10” 1

-X48K096C 10.0 4.5 3.5 96,000 91,200 62,400 59,300 45 40-70 170 0.80 47,000 11” x 10” 1

-X60K096C 10.0 4.5 3.5 96,000 91,200 62,400 59,300 45 40-70 170 0.80 57,000 11” x 10” 1

Table 3. Manifold Pressure Setting (in WC) &

Oriﬁce Sizes for Natural Gas

MANIFOLD PRESSURE (IN W.C.) FOR

NATURAL GAS INSTALLATIONS

ALTITUDE

ABOVE SEA

LEVEL

HEATING VALUE BTU/CU. FT ORIFICE

SIZE

800 TO

899 FT 900 TO

999 FT 1,000 TO

1,100 FT

Zero to

1,999 Ft. 3.5 3.5 3.5 45

2,000 to

2,999 Ft. 3.2 3.2 3.2 45

3,000 to

3,999 Ft. 2.9 2.9 2.9 45

4,000 to

4,999 Ft. 2.7 2.7 2.7 45

5,000 to

5,999 Ft. 3.4 3.4 3.4 48

6,000 to

6,999 Ft. 3.1 3.1 3.1 48

7,000 to

7,999 Ft. 2.9 2.9 2.9 48

8,000 to

8,999 Ft. 2.7 2.7 2.7 48

9,000 to

10,000 Ft. 2.6 2.6 2.6 48

Table 4. Manifold Pressure Setting (in WC) &

Oriﬁce Sizes for LP Gas

MANIFOLD PRESSURE (IN W.C.) AND ORIFICES FOR

LP/PROPANE GAS INSTALLATIONS

ALTITUDE

ABOVE SEA

LEVEL

MANIFOLD

PRESSURE ORIFICE

SIZE

Zero to

1,999 Ft. 10 54

2,000 to

2,999 Ft. 9.2 54

3,000 to

3,999 Ft. 8.5 54

4,000 to

4,999 Ft. 8 54

5,000 to

5,999 Ft. 9.2 55

6,000 to

6,999 Ft. 8.4 55

7,000 to

7,999 Ft. 8 55

8,000 to

8,999 Ft. 10 56

9,000 to

10,000 Ft. 9 56

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