2
tABlE oF contEntS
iMPoRtAnt SAFEtY inFoRMAtion 3
4
gEnERAl inFoRMAtion 5
Before you install this unit ........................................................... 5
Locating the Equipment .............................................................. 5
Heating Load ............................................................................... 5
5
Vent Termination.......................................................................... 6
ciRcUlAting AiR SUPPlY 7
Air Ducts...................................................................................... 7
Unconditioned Spaces................................................................ 7
Acoustical Duct Work.................................................................. 7
Unit inStAllAtion 7
Packaging Removal..................................................................... 7
Rigging & Hoisting....................................................................... 7
Clearances to Combustible Materials......................................... 8
Ground Level ............................................................................... 8
Rooftop ........................................................................................ 8
Horizontal to Downflow Conversion............................................ 9
Condensate Drain (Air Conditioning).......................................... 9
Air Filter Requirements................................................................ 9
Removal of Internal Filter Rack................................................... 9
Installing Filters in the Internal Filter Rack.................................. 9
1” to 2” Filter Conversion ......................................................... 9
Removing Filters from Internal Filter Rack.................................. 10
ElEctRicAl WiRing 11
Pre-Electrical Checklist............................................................... 11
Grounding.................................................................................... 11
Line Voltage................................................................................. 11
Unbalanced 3-Phase Supply Voltage......................................... 12
Thermostat / Low Voltage Connections...................................... 12
2-Stage Heat / 1-Stage Cool Thermostat ................................ 12
Single Stage Heat / Single Stage Cool Thermostat................. 12
Heat Anticipator........................................................................... 13
Cooling Configurations................................................................ 13
Heating Configurations................................................................ 13
Blower Speed .............................................................................. 13
Configuring the Fixed Speed Blower ....................................... 13
Selecting Cooling Airflow......................................................... 13
Selecting Heating Airflow......................................................... 13
Dehumidification Options............................................................ 14
Optional Furnace Control Board Connections............................ 14
Electronic Air Cleaner.............................................................. 14
Humidifier ................................................................................ 14
15
Leak Check.................................................................................. 15
High Altitude Conversion - Natural Gas...................................... 16
LP / Propane Gas Conversion..................................................... 16
18
Pre-Start Check List.................................................................... 18
Start-Up Procedure ..................................................................... 18
Air Circulation .......................................................................... 18
Lighting the Appliance............................................................. 18
Verifying System Heating ........................................................ 19
Verifying & Adjusting Temperature Rise .................................. 19
Gas Supply Pressure Verification & Adjustment...................... 19
Verifying the Firing Rate of the Appliance ............................... 19
Measuring the Manifold Pressure............................................ 20
Adjusting the Manifold Pressure.............................................. 20
Removing the Manometer/Pressure Gauge............................ 20
Verifying Over-Temperature Limit Control Operation............... 20
Verifying Burner Operation...................................................... 21
Verifying System Cooling......................................................... 21
oPERAting SEQUEncE 21
Heating Mode .............................................................................. 21
Thaw Cycle Start Up / Shutdown ................................................ 22
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
26
Figure 8. Unit Dimensions ....................................................... 26
Table 7. Center of Gravity & Shipping Weights........................ 27
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
33
Table 14. Gas Pipe Capacities................................................. 33
Table 15. Gas Flow Rates........................................................ 33
Figure 9. Gas Valve Label........................................................ 34
35
Table 16. Electrical Data.......................................................... 35
Table 17. Copper Wire Size ..................................................... 35
Table 18. Thermostat Wire Gauge........................................... 35
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
37
Figure 13. Single Phase, 2-5 Ton, 208/230V .......................... 37
Figure 14. Three Phase, 3-5 Ton, 208/230V............................ 38
Figure 15. Three Phase, 3-5 Ton, 460V................................... 39
40
Figure 16. Charging Chart for 2 Ton Units ............................... 40
Figure 17. Charging Chart for 2.5 Ton Units ............................ 40
Figure 18. Charging Chart for 3 Ton Units ............................... 41
Figure 19. Charging Chart for 3.5 Ton Units ............................ 41
Figure 20. Charging Chart for 4 Ton Units ............................... 42
Figure 21. Charging Chart for 5 Ton Units ............................... 42
43
Figure 22. Filter Comversion ................................................... 43
44
About the Kit................................................................................ 44
Vent Pipe & Drain Hose Assembly.............................................. 44
Vertical Drain Pit Method ............................................................ 44
Preparing the pit...................................................................... 45
Percolation Test (Optional) ...................................................... 45
Vertical Drain Pipe Installation................................................. 45
Horizontal Drain Trench Method ................................................. 45
Preparing the Trench ............................................................... 46
Horizontal Drain Pipe Installation ............................................ 46
Completing the Vent Installation ................................................. 46
48
About the Kit................................................................................ 48
Before Setting unit on the Curb................................................... 48
Setting the Unit............................................................................ 49
Completing the Heat Exchanger Condensate Drain Installation 49
Completing the Vent Pipe Installation and Assembly................. 49
inStAllAtion / PERFoRMAncE cHEck liSt 52
