Nortek R6GF Series 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 qualied 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
Single Package Gas Heating / Electric Cooling
R6GF SERIES
Premium Model Shown
USER’S MANUAL & INSTALLATION INSTRUCTIONS
2
USER INFORMATION
Important Safety Information ....................................4
Operating Instructions...............................................4
Cooling Operation .....................................................4
Heating Operation .....................................................4
Turning the Air Conditioner Off..................................4
Operating the Indoor Blower Continuously................4
Air Conditioner Maintenance.....................................4
Troubleshooting..........................................................4
WARRANTY INFORMATION
A warranty certificate with full details is included with the
AirConditioner.Carefullyreviewthese responsibilitieswith
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 Air Conditioner.
•Resetting circuit breakers or other switches.
•Adjusting or calibrating of thermostat.
3
IMPORTANT SAFETY INFORMATION .......................5
REQUIREMENTS & CODES .......................................6
GENERAL INFORMATION..........................................7
Before You Install this Unit.........................................7
Locating the Equipment.............................................7
Heating Load ............................................................7
Combustion Air Requirements .................................7
Venting Requirements ..............................................8
Circulating Air Supply .............................................10
Air Ducts .............................................................10
Air Filter Requirements ........................................10
Unconditioned Spaces .........................................10
Acoustical Duct Work ...........................................11
UNIT INSTALLATION ................................................11
Packaging Removal.................................................11
Rigging & Hoisting...................................................11
Clearances to Combustibles....................................11
Ground Level...........................................................11
Rooftop....................................................................11
Condensate Drain ..................................................11
Horizontal to Downflow Conversion.........................11
ELECTRICAL WIRING...............................................12
Pre - Electrical Checklist .........................................12
Line Voltage.............................................................12
Grounding................................................................13
Thermostat / Low Voltage Connections...................13
Cooling Thermostat..............................................13
Heat/Cool Thermostat ..........................................13
Checking Heat Anticipator Settings......................14
Heating Configurations............................................14
Two - Stage Heating configuration .......................14
High Fire Configuration ........................................14
Two - Stage Cooling Configuration.......................14
Configuring the Variable Speed Blower ..................14
Selecting Cooling Airflow .....................................14
Selecting Gas Heating Airflow..............................15
Optional Humidistat.................................................15
Optional Comfort AlertTM Diagnostics Module .........15
24VAC Power Wiring ............................................15
Thermostat Demand Wiring .................................15
L Terminal Wiring .................................................15
DC SOL Connection ............................................16
Interpreting the Diagnostic LED’s.........................16
LED Description ...................................................16
Installation Verification .........................................16
Troubleshooting the Installation............................16
Resetting Alert Codes..........................................16
GAS SUPPLY & PIPING ............................................ 17
Leak Check ............................................................. 17
High Altitude Conversion......................................... 17
Lp/Propane Gas Conversion................................... 18
STARTUP & ADJUSTMENTS ...................................18
Pre - Start Checklist ................................................18
Start-up Procedure..................................................18
Air Circulation.......................................................18
System Cooling....................................................19
System Heating....................................................19
Verifying & Adjusting Temperature Rise ..................19
Verifying & Adjusting Firing Rate.............................19
Verifying Over-Temperature Limit
Control Operation....................................................19
Verifying Burner Operation......................................20
Refrigerant Charging...............................................20
Manifold Pressure Adjustment ................................20
OPERATING SEQUENCE .........................................21
Heating Mode..........................................................21
Cooling Mode ..........................................................21
Fan Mode ................................................................21
EQUIPMENT MAINTENANCE...................................22
Cleaning of Heat Exchanger ...................................22
Cleaning of Burners ................................................23
COMPONENT FUNCTIONS ......................................23
TROUBLESHOOTING ...............................................24
REPLACEMENT PARTS............................................24
FIGURES & TABLES .................................................25
Figure 9. R6GF Dimensions.................................25
Table 8. Center of Gravity & Shipping Weights.....25
Airflow Information...................................................26
Table 9. Nominal Airflow Rates & Temp Rises .....26
Table 10. Airflow Settings for Cooling...................26
Table 11. Airflow Settings for Heating...................26
Gas Information....................................................... 27
Table 12. Gas Pipe Capacities .............................27
Table 13. Gas Flow Rates ....................................27
Figure 10. R6GF Gas Valve Label........................28
Electrical Information...............................................29
Figure 11. T-Stat Connection for High Fire ...........29
Figure 12. T-Stat Connection for Two-Stage
Heating / Two-Stage Cooling ..............29
Figure 13. Wiring Diagram for Two-Stage
Heating / Two-Stage Cooling ..............30
Figure 14. Wiring Diagram for Two-Stage Units
w/ Optional Comfort Alert ....................31
Comfort Alert Troubleshooting Charts .....................32
Table 14. LED Diagnostics ...................................32
Table 15. Module Wiring Troubleshooting.............34
R6GF Charging Charts ...........................................35
Figure 15. Charging Chart for 2 Ton Units............35
Figure 16. Charging Chart for 3 Ton Units............35
Figure 17. Charging Chart for 4 Ton Units............36
Figure 18. Charging Chart for 5 Ton Units............36
FRENCH TRANSLATIONS ........................................37
INSTALLATION / PERFORMANCE CHECKLIST .....40
INSTALLER INFORMATION
4
USER INFORMATION
Figure 1. Digital Thermostat
Fan
Mode
Temperature
Selector
System
Mode
OPERATING INSTRUCTIONS
NOTE: Thermostat styles vary. Some models may not
include the AUTO mode and others will have the AUTO
in place of the HEAT and COOL. Others may include all
three.Please refer to the thermostat manufacturer’s User
manual for detailed programming instructions.
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
approximatelythree minutesfollowingapreviousoperation
or the interruption of the main electrical power.
Cooling Operation
1. Set the thermostat’s system mode to COOL or AUTO
and change the fan mode to AUTO. See Figure 1.
2. Setthe temperatureselector tothedesiredtemperature
level. The outdoor fan, compressor, and blower
motor will all cycle on and off to maintain the indoor
temperature at the desired cooling level.
Heating Operation
1. Set the thermostat’s system mode to HEAT or AUTO
and change the fan mode to AUTO. See Figure 1.
2. Setthe temperatureselector tothedesiredtemperature
level.
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
hazardous situation that if not avoided, may result in minor
or moderate injury or property damage.
Turning the Unit 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.
Operating the Indoor Blower Continuously
Thecontinuousindoor bloweroperationis typicallyused to
circulatetheindoor airtoequalizeatemperatureunbalance
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.
UNIT MAINTENANCE
Proper maintenance is most important to achieve the best
performancefrom the applianceand should beperformed
frequentlyat thebeginningof eachair conditioningseason.
WARNING:
Your equipment contains liquid and gaseous
refrigerant under pressure. Installation and
servicing should only be attempted by qualied,
trained personnel thoroughly familiar with the
equipment and safe responsible refrigerant
handling procedures. Failure to comply with
this warning could result in equipment damage,
personal injury, or death.
• Keeptheunitclean.Hoseoffperiodicallyandkeepunit
fins clear of leaves and grass clippings.
• Keeptheunitclearofobstructions.DONOTobstruct
airflow with tall plants or shrubs.DO NOT store gasoline
or other flammable materials on or near the outdoor unit.
• Neveroperatetheappliancewithoutalterinstalledin
the return air duct. Inspect filters frequently and replace
when necessary with filter of same dimensional size.
TROUBLESHOOTING
If the unit fails to operate, check the following:
• Checkthethermostatsetting.Makesurethesystem
mode and temperature settings are correct.
• Checktheelectricalpanelfortrippedcircuitbreakers.
• Checktheltersfordustaccumulation.
• Checktheoutdoorunitandmakesureitiscleanand
not covered with grass or leaves.
• Iftheitemsabovedon’tresolveyourproblems,then
call your nearest service technician.
5
INSTALLER INFORMATION
IMPORTANT SAFETY INFORMATION
Pleasereadall instructionsbeforeservicingthisequipment.
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 apotentiallyhazardous situationthat
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
qualied, 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. Unqualied
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 installationmust conform withthe NationalFuel Gas
Code (ANSI 2223.1, NFPA-54). Canadian installations
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(ANSI CI)forspecialinstallation
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.
6
• Thisequipmentcontainsliquidandgaseousrefrigerant
underhigh pressure.Installation orservicing shouldonly
be performed by qualified trained personnel thoroughly
familiar with this type equipment.
• Allelectricalwiringmustbecompletedinaccordance
with local, state and national codes and regulations and
with the National Electric Code (ANSI/NFPA 70) or in
Canada the Canadian Electric Code Part 1 CSA C.22.1.
• 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.
• Installthisunitonlyinalocationandpositionasspecied
on page 7. 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, electric power, serviceaccess,noise,and shade.
• 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.
• Useonlywiththetypeofgasapprovedfor this unit.
Refer to the unit rating plate.
• Provideadequatecombustionandventilationairtothe
unit. See pages 7 - 9.
• Provideadequateclearancesaroundtheairventintake
terminal. See Figure 2 (page 7).
• Combustion products must be discharged outdoors.
Connect this unit to an approved vent system only, as
specified on page 8.
• Never test for gas leaks with an open ame. Use a
commercially available soap solution to check all
connections (See page 17).
• ConsultTable9(page26),andtheratingplateforthe
proper circulating air flow and temperature rise. It is
important that the duct system be designed to provide
the correct flow rates and external pressure rise. An
improperly designed duct system can result in nuisance
shutdowns, and comfort or noise issues.
• Installationofequipmentmayrequirebrazingoperations.
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 & 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.Localcodes andregulations takeprecedence
overanyrecommendationscontainedin theseinstructions.
Always consult with local authorities before installing any
gas appliance.
Combustion and Ventilation Air
• US:NationalFuelGasCode(NFGC),AirforCombustion
and Ventilation
• CANADA:NaturalGasandPropaneInstallationCodes
(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:NationalElectricalCode(NEC)ANSI/NFPA70
• CANADA:CanadianElectricalCodeCSAC22.1
Gas Piping and Gas Pipe Pressure Testing
• US:NFGCandNationalPlumbingCodes
• CANADA:NSCNGPIC
General Installation
• US:CurrenteditionoftheNFGCandtheNFPA90B.For
copies, contact the National Fire Protection Association
Inc.,BatterymarchPark,Quincy, MA02269;or American
Gas Association, 400 N.Capitol, N.W., Washington DC
20001 or www.NFPA.org.
• CANADA:NSCNGPIC.Foracopy,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)
7
GENERAL INFORMATION
The R6GF Single Package Gas Heating / Electric Cooling
Unit is designed only for outdoor rooftop or ground level
installations and can be readily connected to the duct
system of a home.This unit has been tested for capacity
and efficiency in accordance with A.R.I. 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 achieveoptimumperformanceand minimizeequipment
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
calculatedand a systemof theproper 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
the packaged 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. Read all
instructions before installing the unit.
Locating the Equipment
• Selectasolid,levelposition,preferablyonaconcrete
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.
• Sufcientclearanceforunobstructedairowthroughthe
louvered control access panel and outdoor coil must be
maintained in order to achieve rated performance. See
Figure 2 for minimum clearance requirements.
• Aclearanceofatleast36inchesfromthebloweraccess
panel and from the louvered control access panel is
recommended for servicing and maintenance.
Where accessibility to clearances are greater
than clearances to combustibles, accessibility
clearances must take preference.
• Thehotcondenserairmustbedischargedupandaway
from the home.
• Ifpractical,placetheairconditioneranditsductsinan
area where they will be shaded from the afternoon sun,
when the heat load is greatest.
Combustion Air Requirements
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 sufcient 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(ANSIZ223.1/NFPA54).Consult local codes
for special requirements.These requirements are for
US installations as found in the NFGC.
• TherequirementsinCanada(B149.1)arestructured
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
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.
8
The following list summarizes the requirements for the
location of the vent system termination:
• Thelocationoftheventterminationmustbeconsistent
withtheNationalFuelGasCode(ANSIZ223.1)orCAN/
CGA-B149 Installation Codes.
• Theventterminationmustbe locatedatleast4 feet
horizontally from any electric meters, gas meters,
regulators, and relief equipment.
• Theventterminationmustbe locatedatleast3 feet
above any forced air inlet located within 10 feet.
• Theventterminationmustbe locatedatleast4 feet
below, 4 feet horizontally from, or 1 foot above any door,
window, or gravity air inlet into any building.
• Theventterminationmustbe locatedatleast1 foot
above grade.
• Theunitshouldbeinstalledinawaythatpreventsany
obstruction of the vent termination during accumulating
snow.
• Theunitinstallationshallavoidareaswherecondensate
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.
• Donotinstalltheunitsuchthatexhaustfromthevent
termination is directed into window wells, stairwells,
under decks, or in alcoves or similarly recessed areas.
The vent termination must not be located above any
public walkways.
Figure 3 shows the proper installation of the vent cover
assembly over the vent outlet on the exterior of the
corner panel.The fasteners used to secure the vent cover
assembly have been included in the owner’s package.
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 thegas supply tothe burners.This safetydevice
is a manually reset switch. IMPORTANT NOTE: DO NOT
install jumper wires across this control to defeat its
function or reset the control without identifying and
correcting the fault condition.
Ifthis controlmustbe replaced,use onlyfactory authorized
replacement parts. See the Replacement Parts List on
page 24.
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
• Permanentwavesolutions
• Chlorinatedwaxesandcleaners
• Chlorinebasedswimmingpoolchemicals
• Watersofteningchemicals
• De-icingsaltsorchemicals
• Carbontetrachloride
• Halogentyperefrigerants
• Cleaningsolvents
• Cements,glues,paintremovers,varnishes,etc.
• Hydrochloricacid
• Masonryacidwashingmaterials
• PlumbingStack
Figure 3. Vent Assembly
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
and can be found secured to the gas controls within the
control area of this unit. The vent cover assembly must
be installed to assure proper operation of the unit.
9
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 deciencies 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 déciente,
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.
10
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 allapplicablelocalcodes.NFPApublicationsare
availablebywritingto:NationalFire ProtectionAssociation,
BatterymarchPark,Quincy, ME 02269or visitwww.NFPA.
org on the web.
• DesigntheductworkaccordingtoManualDbytheAir
Conditioning Contractors of America (ACCA).
• Theductsmustbeproperlysizedandnotexceed0.2”
W.C. pressure drop at 400 scfm per nominal ton of
cooling capacity.
• Ductworkshouldbeattacheddirectlytotheunitanges
for horizontal applications.
• Ifroofcurbisinstalled,theductsmustbeattachedto
the curb hangers, not the unit.
• It is recommended that the outlet duct be provided
with a removable access panel. The opening should
be accessible when the unit is installed in service and
shall be sizes so that smoke or reflected light may be
observed inside the casing to indicate the presence of
leaks in the heat exchanger.The cover for the opening
shall be attached in a way that will prevent leaks.
• If outside air is utilized as return air to the unit for
ventilation or to improve indoor air quality, the system
must be designed so that the return air to the unit is not
less than 50° F (10° C) during heating operation.
• Ifacombinationofindoorandoutdoorairisused,the
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 efciency, equipment damage
and possible re.
• This unit is not supplied with air filter(s) and has no
factory equipped means for accommodating internal
filter(s). A suitable air filter must be installed upstream
of the evaporator coil of the return air system. Refer to
Table 1 for recommended filter sizes.
• Allreturnair mustpassthroughthefilters beforeentering
the evaporator coil. It is important that all filters be kept
cleanandreplaced frequentlyto ensureproperoperation
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.
• Horizontal and downow Installations require the air
filter system be installed in the return air ductwork.
NOTETO INSTALLER: After installing or replacing the
filtrationsystemforthis unit,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 20 x 25
3.0 1,000 - 1,300 625 25 x 25
4.0 1,500 - 1,900 915 18 x 25 (2 required)
5.0 1,600 - 2,000 975 20 x 25 (2 required)
* Based on velocity of 300 ft/min for disposable 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.
11
• Sufcient clearance for unobstructed airow through
the outdoor coil must also be maintained in order to
achieve rated performance. See page 7 for information
about locating the equipment.
Ground Level
Ground level installations must be located according to
localbuildingcodesor ordinancesandthese requirements:
• Clearancesmustbeinaccordancewiththoseshown
in Figure 2 (page 7).
• Asuitablemountingpad(Figure4,page12)mustbe
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.
• Unitsrequirehorizontalroofcurbandreturnairkitfor
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 8. Reinforce the roof if
necessary.
• Theappropriateaccessoryroof curb(Figure 5,page 12)
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
mechanicalmethods per localcodes.NOTE:Make sure
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 12) 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.
• Acousticalinsulationmustbeinaccordancewiththe
current revision of the Sheet Metal and Air Conditioning
ContractorsNationalAssociation (SMACNA)application
standard for duct liners.
• DuctliningmustbeULclassiedbattsorblanketswith
a fire hazard classification of FHC-25/50 or less.
• Fiberductworkmaybeusedinplaceofinternalduct
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.Takecarenottodamage thetubingconnections
whenremovingthecarton.Forrooftopinstallations,remove
and discard the two supports attached beneath the unit.
Rigging & Hoisting
WARNING:
To avoid the risk of property damage, personal
injury, or death, it is the rigger’s responsibility
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 8 (page 25) 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 9 (page 25)
for locating the center of gravity.
• All panels must be securely in place during
rigging and hoisting.
Clearances to Combustible Materials
R6GF 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 horizontal supply and return air ducts, the
horizontalroof curb kitand return air kitmustbeinstalled
prior to unit installation. Horizontal roof curb is required.
• Ifusingbottomdischargewithreturnairductsaroofcurb
must be installed prior to unit installation. See Rigging
and Hoisting section for setting of the unit.
Horizontal to Downow 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. Liftthe capoutof theunit.(Hint: Thecapcan bepushed
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.
12
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
tohandle the additionalload imposedbythis equipment.
See Table 2 (page 13) 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 - 14, pages 30 - 31).Verify none of
theconnections loosenedduringshippingorinstallation.
Line Voltage
• Thelinevoltagetotheunitshouldbesuppliedfroma
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
becapableof electrically de-energizing theoutdoor unit.
See unit data label for proper incoming field wiring. Any
other wiring methods must be acceptable to authority
having jurisdiction.
• Useonlycopperwireforthelinevoltagepowersupply
to this unit (Table 3, page 13). 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.
• Providepowersupplyfortheunitinaccordancewith
the unit wiring diagram and the unit rating plate.
• Overcurrentprotectionmustbeprovidedatthebranch
circuit distribution panel and sized as shown on the unit
ratinglabel andaccording toapplicablelocal codes.See
the unit rating plate for maximum circuit ampacity and
maximum overcurrent protection limits.
• Awiringdiagramislocatedontheinsidecoverofthe
control access panel of the outdoor unit. The installer
should become familiar with the wiring diagram before
making any electrical connections to the outdoor unit.
See Figures 13 - 14.
Condensate Drain
Figure 6. Condensate Drain Location
Figure 5. Roof Top Installation
Figure 4. Ground Level Installation
13
• Ifanyoftheoriginalwiressuppliedwiththeunitmust
be replaced, they must be replaced with material of the
same gauge and temperature rating.
• Unitsareshippedfromthefactorywiredfor240volt
transformer operation. For 208V operation, remove the
lead from the transformer terminal marked 240V and
connect it to the terminal marked 208V.
• Internallymountedcircuitbreakersareavailableaseld
installed options. These circuit breakers can be used
as an electrical disconnect.
• Connecttheline-voltageleadstotheterminalsonthe
contactor(or thecircuit breakerifthe fieldinstalled circuit
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.
Thermostat / Low Voltage Connections
• TheR6GFGas/Electricunitisdesignedtooperate
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 should be
made in accordance with the instructions supplied with
the thermostat and the indoor equipment.
• TheR6GFunitusesaspecial2speedcompressorto
achieve a high level of efficiency in a compact frame. A
2 stage cooling/2 stage heating 24V thermostat can be
used with this unit. See Figure 13 & 14 (pages 30 - 31).
• The low voltage wires must be properly connected
to the units low voltage terminal block. Route 24V
control wires through the gas furnace side of the unit.
Recommended wire gauge and wire lengths for typical
thermostat connections are listed in Table 4.
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
• Thethermostatshouldbemountedabout5feetabovethe
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.
Cooling Thermostat
Connect the red and yellow wires from the unit to the R
and Yterminals respectively on the thermostat subbase.
Connect the green wire to the yellow wire at the unit.
See Figures 11 or 12 (page 29).
Heat/Cool Thermostat
For the highest efficiency, the use of a 2-stage Heating/
Cooling thermostat is recommended. The heat/cool
thermostat preventssimultaneousoperationof theheating
and cooling units and is equipped with an ON-AUTO fan
mode that allows the home owner to operate the indoor
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
R6GF-X24K072C 72,000 208-230/30/1 187 253 11.4 52.0 0.91 4.3 20.8 30.0
R6GF-X36K100C 100,000 208-230/30/1 187 253 19.0 82.0 1.46 4.3 30.9 45.0
R6GF-X48K120C 120,000 208-230/30/1 187 253 24.0 96.0 1.46 9.1 41.9 60.0
R6GF-X60K120C 120,000 208-230/30/1 187 253 26.0 118.0 1.46 9.1 44.4 60.0
Note: FLA = Full Load Amps; LRA = Lock Rotor amps; RLA = Rated Load Amps.
14
blower when only air circulation is desired. Connect the
red,yellow,greenandbrownlow voltage wiresto the Ror
RC, Y, G, and Wterminals respectively on the thermostat
base. The black wire is the 24 volt common required on
some thermostats. See Figures 11 or 12.
Checking Heat Anticipator Settings
• Addthecurrentdrawofthesystemcomponents.
OR
• MeasurethecurrentowonthethermostatR-Wcircuit
afterthecirculating blowermotorhasstarted.Setthe heat
anticipator according to the thermostat manufacturer’s
instructions for heat anticipator settings.
Heating Congurations
This furnace is factory 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 heating thermostat is used:
1. Remove the jumper wire between W1 and W2 on the
terminal block.
2. Move the brown wire on the low side of the gas valve
to W2 on the terminal block.
3. Connect 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
secondstage heat isinitialized,the furnacewill 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 with a brown
wire. 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.
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.
IMPORTANT NOTE: Do not connect the thermostat’s
W2 to the furnace wiring when using timed stage
conguration
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.
Conguring 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
conditionsand systemconfigurations.Becausetheblower
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
installedandconfigured properly, thefurnacewillgradually
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 Cooling Airflow
The cooling airflow is selected by setting switches 1 - 4
on the motor control board. Table 10 (page 26) lists the
recommended airflow values (CFM) and selector switch
settings for each nominal system capacity. All airflows for
othermodes of operation(except secondary gas heat)are
determined by this basic setting. For maximum capacity,
generally, a selection at or near the top of the CFM range
for that nominal capacity is best.
NOTES:
• TheCFMvalueslistedinTable10arenotdependent
on duct static pressure. The motor automatically
compensates(withinthe limits ofthe motor) forchanges
in duct static pressure.
• Ifcoilicingoccurs,thebasiccoolingairowselected
may be too low. Verify the selected setting is within the
range shown in Table 10 and the system is properly
charged. If icing continues, raise the selected airflow
one or two steps.
• Formaximumdehumidicationandenergyefciency,
select an airflow near the middle or bottom of the CFM
range for that nominal capacity.
• The 2-stage cooling feature of the unit requires
modulating the airflow.The unit will automatically adjust
the airflow to the appropriate rate when the unit capacity
changes.
15
Figure 7. Comfort AlertTM Diagnostics Module
POWER LED
(Green)
TRIP LED
(Red)
ALERT LED
(Yellow)
Diagnostics
Key
Ifthe constant24VAC(Rwire)is notpresentinthe 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 Alertmodule requiresa twostagethermostat
to operate properly. The Y2 thermostat wire entering the
outdoor unit should be connected to the Y2 input on the
unit terminal strip.
Whilethe compressoris running, 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
compatibleWhite-Rodgers thermostats.The Lterminal of
thethermostatshould beconnected directlyto theComfort
Alert Lterminal as shown in Figure 14.
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 to White-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.
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.
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.
Checkallfactory wiring tothe unitswiring diagram.Inspect
the factory wiring connections to be sure none loosened
during shipping or installation.
Selecting Gas Heating Airflow
The heating airflow is selected by setting switches 5 &
6. Refer to Table 11 (page 26) 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.
Optional Comfort AlertTM Diagnostics Module
TheComfort AlertTM DiagnosticsModuleisabreakthrough
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
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 7.
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
withoutexperiencingnuisance alerts.NOTE:The wiring to
the module’s R& Cterminals must be routed directly from
the indoor unit or thermostat. See Figure 14 (page 31).
16
DC SOL Connection
The two pin DC SOL connector provides a connection
to the Copeland UltraTech second stage compressor
solenoid (see Figure 14).This 24VDC solenoid is internal
to the compressor 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
DCvoltageto thesolenoid tothe 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,when solenoidshouldbe energized,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. See Table 14 (pages 32 - 33) for flash code
identification or Table 15 (page 34) for module wiring
troubleshooting.
Each time the module powers up, the last ALERT Flash
Code that occurred prior to shut down is displayed for
one minute.The module will continue to display the LED
until the condition returns to normal or if 24 VAC power
is removed from the module.
LED Description
• POWERLED(Green):indicatesvoltageispresentat
the power connection of the module.
• ALERT LED (Yellow): communicates an abnormal
system condition through a unique flash code.
NOTE: The ALERT LED will flash consecutively, pause
andthen repeatthe process.The numberof 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 14.
• TRIPLED(Red):indicatesademandsignalisreceived
from the thermostat, but current to the compressor is
not detected by the module. The TRIP LED typically
indicates if the compressor protector is open or the
compressor has no power.
The scroll compressor’s R (run), C(common), and S
(start) wires are routed through the holes in the Comfort
AlertTM module marked R, 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
diagrams (Figures 13 or 14, pages 30 - 31).
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
diagrams (Figure 13 or 14).
Troubleshooting the Installation
Depending on system configuration, some ALERT Flash
codes may not be active.The presence of safety switches
affectshow thesystem alertsare displayedbythis module.
Resetting Alert Codes
Alert Codes can be reset manually and automatically.
The manual method to reset an Alert code is to cycle the
power to Comfort Alert off and on. For automatic reset,
Comfort Alert continues to monitor the compressor and
system after an Alert is detected. If conditions return to
normal, the Alert code is turned off automatically.
17
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 (Figure 8, page 18). 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 20) 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 8).
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 8.
Table 12 (page 27) 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.Thisincludespipeconnections
at the main gas valve, emergency shutoff valve and
other gas connectors. A soap and water solution can be
applied on each joint or union using a small paintbrush.
If any bubbling is observed, the connection is not sealed
adequatelyand mustberetightened.Repeatthe 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
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
installationsmustbemadein accordancewith theNational
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 orices. Do not attempt to
drill out orices 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 20. The
changes required depend on the installation altitude and
the heating value of the gas (based on sea level) which
can be obtained from your local gas utility. The heating
value of gas at high altitude is always lower than the sea
level heating value.The heating values listed in Tables 5
& 6 (page 20) are based on sea level values.
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.
For altitudes between 5,000 and 10,000 feet above sea
level, the unit can be converted by adjusting the furnace
manifoldpressure.SeeTables5or 6forthecorrectmanifold
pressure settings.
18
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 thatthe gasline servicepressure does notexceed
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-out controlisclosed.Ifnecessary,
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.
• Checkall electricalwiring forlooseconnectionsand
tighten as required.
• Checkunitforreturnairltersandcondensatetrap.
• Closeallelectricaldisconnectstoenergizethesystem.
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. 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 20). 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:
• TheUnitedStatesLP/PropaneGasSeaLevelandHigh
AltitudeConversionKitisforLP/propaneconversionin
the United States at altitudes between zero and 10,000
ft. above sea level.
• TheCanadianLP/PropaneGasSeaLeveland High
AltitudeConversionKitisforLP/propaneconversions
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 #54 drill size orifice should be used. Installations
5,000 ft. above sea level require a # 55 drill size orifice.
Table 6 (page 20) 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 19.
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 8. Typical Gas Hookup - Right Side Entry
19
System Cooling
1.Set the thermostat’s system mode to COOL and the
fan mode to AUTO. Gradually lower the thermostat
temperaturesetpointbelowroom temperatureandverify
the outdoor unit and blower energize.
2.Feel the air being circulated by the indoor blower and
verifythatit iscooler thanambienttemperature.Listenfor
any unusual noises.If unusual sounds occur, determine
the source of the noise and correct as necessary.
3.Allow the cooling system to operate for several minutes
and then set the temperature selector above room
temperature. Verify the fan and compressor cycle off
with the thermostat. NOTE: The blower should also
stop unless fan switch is set to the ON position.
System Heating
1.Set the thermostat to the lowest setting.
2.Followtheprocedures givenonthe operatinginstruction
label, in this installation instructions or attached inside
the louvered control access panel.
3.Set the thermostat above room temperature and verify
the sequence of operation. See Operating Sequence
section (page 21.)
4.Verify that the compressor and outdoor fan motor are
not energized.
5.After the unit has run for approximately five minutes,
set the thermostat below room temperature. Verify the
shutdown sequence; steps 10 -12 in the Operating
Sequence section (page 21).
Verifying & Adjusting Temperature Rise
Verify the temperature rise through the unit is within the
range specified on the unit data label.Temperature rises
outside the specified range could result in premature heat
exchanger failure.
1. Place thermometersin thereturn andsupply air stream
asclose tothe unit aspossible.Thethermometer onthe
supplyair sidemust beshielded againstdirect radiation
from the heat exchanger to avoid false readings.
2. Adjust all registers and duct dampers to the desired
position. Run the unit for 10 to 15 minutes before
taking any temperature readings. The temperature
rise is the difference between the supply and return
air temperatures.
NOTE: For typical duct systems, the temperature rise will
fall within the range specified on the data label (with the
blower speed at the factory recommended setting) shown
inTable 9 (page 26).If the measured temperature rise falls
outsidethe specifiedrange,itmaybenecessary tochange
the blower speed. Lowering the blower speed increases
the temperature rise and a higher speed decreases the
temperature rise.
The unit is equipped with a variable speed motor.Heating
and cooling speed selection is made by changing the
switch settings on the integrated control located in the
unit control box. Refer to Configuring the Variable Speed
Blower Section (page 14) for additional information.
The VSB is designed with built in delay profiles for start
up and shut down of the system. Refer to the Operating
Sequence section (page 21) for more details.
Verifying & Adjusting Firing Rate
CAUTION:
Do not re-drill the burner orices. If the orice
size must be changed, use only new orices.
The firing rate must be verified for each installation to
prevent over-firing of the furnace. The ring rate must
not exceed the rate shown on the unit data label. To
determine the firing rate, follow the steps below:
1. Obtainthegasheatingvalue(HHV)fromthegassupplier.
2.Shut off all other gas fired appliances.
3.Start the unit in heating mode and allow it to run for at
least 3 minutes.
4.Measure the time (in seconds) required for the gas
meter to complete one revolution.
5.Convert the time per revolution to cubic feet of gas per
hour using Table 13 (page 27).
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:
• Timefor1revolutionofagasmeterwitha1cubic
foot dial = 40 seconds.
• FromTable13,read90cubicfeetgasperhour.
• Localheatingvalueofthegas(obtainedfromgas
supplier) = 1,040 Btu per cubic foot.
• Inputrate=1,040x90=93,600Btuh.
7.Adjust the manifold pressure if necessary.See Manifold
Pressure Adjustment instructions on page 20. For
additional information about elevations above 2,000
feet, see page 17.
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 21).
NOTE: The over-temperature limit control should turn off
thegas valvewithinapproximatelyfourminutes(exacttime
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.
3.Remove the close-off plate immediately after the over-
temperature limit control opens. If the unit operates
for more than four minutes with no return air, set the
thermostat below room temperature, shut off power to
the unit, and replace the over-temperature limit control.
20
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.
2.Set thermostat above room temperature and observe
the ignition sequence. NOTE: The burner flame should
carry over immediately between all burners without
lifting off, curling, or floating.The flames should be blue,
without yellow tips. Make sure the flame is drawn into
the center of the heat exchanger tube. In a properly
adjusted burner assembly, the flame bends down and
to the right at the end of the heat exchanger tube. The
end of the flame will be out of sight around the bend.
3.Aftervalidatingflame characteristics,set thethermostat
below room temperature and verify the burner flame
extinguishes completely.
Refrigerant Charging
WARNING:
R6GF units are shipped 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 done by qualied,
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 owner attempt to install and/or service this
equipment. Failure to comply with this warning
could result in property damage, personal injury,
or death.
CAUTION:
This unit uses refrigerant R-410A. DO NOT use
any other refrigerant in this unit. Use of another
refrigerant will damage the unit.
The system refrigerant charge can be checked and
adjusted through the service ports provided at the front
panel. Use only gauge lines which have a “Schrader”
depression device present to actuate the valve. Draw a
vacuum on gauge lines to remove air before attaching
them to the service ports on the unit.Refrigerant charging
must be done by qualified personnel familiar with safe
and environmentally responsible refrigerant handling
procedures.
Manifold Pressure Adjustment
The manifold pressure must be set to the appropriate
value for your installation.To adjust the manifold pressure:
1. Obtain the required manifold pressure setting. Use
Table 5 for natural gas or Table 6 for LP/propane gas.
NOTE: The values listed in the tables are based on sea
level values.At higher altitudes, the heating value of gas
is lower than the sea level heating value.
2. Remove the regulator cap. Turn the high fire
adjusting screw clockwise to increase the pressure or
counterclockwise to reduce the pressure.
3. Replace the regulator cap after adjustments are
complete.
Table 5. Manifold Pressure (in W.C.) for Natural Gas
Manifold Pressure (in W.C.) for
Natural Gas Installations
Altitude above
sea level
Heating Value Btu/cu. ft.
800 to 899 900 to 999 1,000 to 1,100
zero to 1,999 FT 3.5 3.5 3.5
2,000 to 4,999 FT 3.5 3.5 3.5
5,000 to 5,999 FT 3.5 3.5 3.0
6,000 to 7,999 FT 3.5 3.2 2.8
8,000 to 10,000 FT 3.0 2.8 2.5
Table 6. Manifold Pressure (in W.C.) for LP Gas
Manifold Pressure (in W.C.) and Orice Sizes
for LP/Propane Gas Installations
Altitude above
sea level
Manifold
Pressure
Orice
Size
zero to 1,999 FT 10.0 54
2,000 to 4,999 FT 8.5 54
5,000 to 5,999 FT 10.0 55
6,000 to 7,999 FT 9.0 55
8,000 to 10,000 FT 8.5 55
NOTE: Manifold pressure based on sea level LP heating value
of 2,500 Btu/cu. ft.3
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