INSTALLATION INSTRUCTIONS FOR
COMMERCIAL HEATING & COOLING
15 & 20 TON PACKAGE GAS SERIES
CPG SERIES
®
US
C
This Forced Air Central Unit Design Complies With
Requirements Embodied in The American National
Standard / National Standard of Canada Shown
Below.
ANSI Z21.47•CSA-2.3 Central Furnaces
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
Prior to installation, thoroughly familiarize yourself with this Installation Manual. Observe all safety warnings.
During installation or repair, caution is to be observed.
It is your responsibility to install the product safely and to educate the customer on its safe use.
All information contained herein is subject to change without notice.
© 2010 Goodman Manufacturing Company, L.P.
IO-366B
7/10
5151 San Felipe, Suite 500 ◊ Houston, TX 77056
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WARNING
WARNING
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS
WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS OR OTHER REPRODUCTIVE HARM.
CARBON MONOXIDE POISONING HAZARD
Failure to keep this compartment closed except
when servicing could result in carbon monoxide
poisoning or death.
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT
USE THIS UNIT IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY
CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND
TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS
CONTROL HAVING BEEN UNDER WATER.
This compartment must be closed except
when servicing.
DANGER
RISQUE D'EMPOISONNEMENT AU
MONOXYDE DE CARBONE
Si ce compartiment n'est pas ferme en tout temps, sauf
en cas de reparation, il y a risque d'empoisonnement
ou monoxyde de carbon ou de mort.
WARNING
Ce compartiment doit être ferme sauf au
moment de l'entretien.
THIS UNIT MUST NOT BE USED AS A “CONSTRUCTION HEATER” DURING
THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE. THIS
TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO
EXTREMELY LOW RETURN AIR TEMPERATURES AND EXPOSURE TO
CORROSIVE OR VERY DIRTY ATMOSPHERES.
PELIGRO
PELIGRO MONOXIDO DE CARBONO
TOXICO
El fracaso de no mantener compartimiento cerrado
menos durante, atender, podria tener como resultado
envenar de monoxido de carbona o muerte.
WARNING
Este compartimiento debe cerrado menos
HIGH VOLTAGE !
al atender.
0140L00106 REV C
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
GENERAL INFORMATION
WARNING
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSIONS, SMOKE, SOOT, CONDENSATION, ELECTRIC SHOCK OR
CARBON MONOXIDE, THIS UNIT MUST BE PROPERLY INSTALLED,
REPAIRED, OPERATED AND MAINTAINED.
TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH, DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR
OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS
APPLIANCE.
This unit is approved for outdoor installation ONLY. To
assure that your unit operates safely and efficiently, it must
be installed, operated, and maintained in accordance with
these installation and operating instructions, all local building
codes and ordinances, or in their absence, with the latest
edition of the National Fuel Gas Code NFPA54/ANSI Z223.1
and National Standard of Canada CAN/CSA B149 Installa-
tion Codes.
WARNING
HIGH VOLTAGE!
INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE
PERFORMED ONLY BY INDIVIDUALS MEETING (AT A
MINIMUM) THE REQUIREMENTS OF AN “ENTRY LEVEL
TECHNICIAN” AS SPECIFIED BY THE AIR CONDITIONING,
HEATING, AND REFRIGERATION INSTITUTE (AHRI).
ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT
SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE,
PERSONAL INJURY OR DEATH.
The heating and cooling capacities of the unit should be
greater than or equal to the design heating and cooling loads
of the area to be conditioned. The loads should be calculated
by an approved method or in accordance withASHRAE Guide
or Manual J - Load Calculations published by the Air Condi-
tioning Contractors of America.
Obtain from:
American National Standards Institute
1430 Broadway
New York, NY 10018
3
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System design and installation should also, where applicable, IMPORTANT NOTE: Remove wood shipping rails prior to
follow information presented in accepted industry guides such installation of the unit. See important note under Roof Curb
as the ASHRAE Handbooks. The manufacturer assumes no Installation Only.
responsibility for equipment installed in violation of any code
or regulation. The mechanical installation of the packaged
roof top units consists of making final connections between
the unit and building services; supply and return duct con-
nections; and drain connections (if required). The internal
systems of the unit are completely factory-installed and tested
prior to shipment.
ALL INSTALLATIONS:
IMPORTANT NOTE: Unit should be energized 24 hours prior
to compressor start up to ensure crankcase heater has
sufficientlywarmedthecompressors.Compressordam-
age may occur if this step is not followed.
Units are generally installed on a steel roof mounting curb
assembly which has been shipped to the job site for installa-
tion on the roof structure prior to the arrival of the unit. The
NOTE: Appliance is shipped from factory for vertical duct
application.
model number shown on the unit’s identification plate identi- Proper installation of the unit ensures trouble-free operation.
fies the various components of the unit such as refrigeration Improper installation can result in problems ranging from
tonnage, heating input and voltage.
noisy operation to property or equipment damages, danger-
ous conditions that could result in injury or personal property
damage and could void the warranty. Give this booklet to the
user and explain it’s provisions. The user should retain these
instructions for future reference.
Carefully inspect the unit for damage including damage to
the cabinetry. Any bolts or screws which may have loosened
in transit must be re-tightened. In the event of damage, the
receiver should:
1. Make notation on delivery receipt of any visible
damage to shipment or container.
• For proper flame pattern within the heat exchanger
and proper condensate drainage, the unit must be
mounted level.
2. Notify carrier promptly and request an inspection.
3. In case of concealed damage, carrier should be
notified as soon as possible-preferably within 5 days.
4. File the claim with the following supporting documents:
a. Original Bill of Lading, certified copy, or indemnity
bond.
b. Original paid freight bill or indemnity in lieu thereof.
c. Original invoice or certified copy thereof, showing
trade and other discounts or reductions.
d. Copy of the inspection report issued by carrier
representative at the time damage is reported to the
carrier. The carrier is responsible for making prompt
inspection of damage and for a thorough
investigation of each claim. The distributor or
manufacturer will not accept claims from dealers for
transportation damage.
• The flue outlet must be at least 12 inches from any
opening through which flue gases could enter a
building, and at least three feet above any forced air
inlet located within ten feet. The economizer/manual
fresh air intake/motorized fresh air intake and
combustion air inlet mounted on the unit are not
affected by this restriction.
• To avoid possible corrosion of the heat exchanger,
do not locate the unit in an area where the outdoor air
(i.e. combustion air for the unit) will be frequently
contaminated by compounds containing chlorine or
fluorine. Common sources of such compounds include
swimming pool chemicals and chlorine bleaches, paint
stripper, adhesives, paints, varnishes, sealers, waxes
(which are not yet dried) and solvents used during
construction and remodeling. Various commercial and
industrial processes may also be sources of chlorine/
fluorine compounds.
NOTE: When inspecting the unit for transportation damage,
remove all packaging materials. Recycle or dispose of the
packaging material according to local codes.
PRE-INSTALLATION CHECKS
Carefully read all instructions for the installation prior to in-
stalling unit. Ensure each step or procedure is understood
and any special considerations are taken into account be-
fore starting installation. Assemble all tools, hardware and
supplies needed to complete the installation. Some items may
need to be purchased locally.
• To avoid possible illness or death of the building
occupants, do NOT locate outside air intake device
(economizer, manual fresh air intake, motorized fresh
air intake) too close to an exhaust outlet, gas vent
termination, or plumbing vent outlet. For specific
distances required, consult local codes.
• Allow minimum clearances from the enclosure for fire
protection, proper operation, and service access (see
unit clearances). These clearances must be
permanently maintained.
UNIT LOCATION
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
OBSERVED WHEN INSTALLING THE UNIT.
4
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• The combustion air inlet and flue outlet on the unit
must never be obstructed. If used, do not allow the
economizer/manual fresh air damper/ motorized fresh
air damper to become blocked by snow or debris. In
some climates or locations, it may be necessary to
elevate the unit to avoid these problems.
• When the unit is heating, the temperature of the return
air entering the unit must be between 50° F and 100°
F.
GROUND LEVEL INSTALLATIONS ONLY:
• When the unit is installed on the ground adjacent to
the building, a level concrete (or equal) base is
recommended. Prepare a base that is 3” larger than
the package unit footprint and a minimum of 3” thick.
ELECTRICAL ENTRANCE LOCATIONS
•
•
•
Do not remove any access panels until unit has been
installed on roof curb or field supplied structure.
Do not roll unit across finished roof without prior
approval of owner or architect.
Do not skid or slide on any surface as this may
damage unit base. The unit must be stored on a
flat, level surface. Protect the condenser coil
because it is easily damaged.
• The base should also be located where no runoff of
water from higher ground can collect in the unit.
ROOF TOP INSTALLATIONS ONLY:
• To avoid possible property damage or personal injury,
the roof must have sufficient structural strength to carry
the weight of the unit(s) and snow or water loads as
required by local codes. Consult a structural engineer
to determine the weight capabilities of the roof.
ROOF CURB INSTALLATIONS ONLY:
• The unit may be installed directly on wood floors or
on ClassA, Class B, or Class C roof covering material.
• To avoid possible personal injury, a safe, flat surface
for service personnel should be provided.
• As indicated on the unit data plate, a minimum
clearance of 36” to any combustible material is
required on the furnace access side of the unit. All
combustible materials must be kept out of this area.
Before installing this unit...
IMPORTANT NOTE: This unit has been equipped with a ship-
ping brace under the compressor section that MUST BE RE-
MOVED before installing the unit on a roof curb.
Please follow the instructions below to remove brace.
• This 36” clearance must also be maintained to insure
proper combustion air and flue gas flow. The
combustion air intake and furnace flue discharge must
not be blocked for any reason, including blockage by
snow.
CAUTION
WHEN UNIT IS SUSPENDED, BOARDS AND SHIPPING BRACE WILL DROP WHEN
SCREWS ARE REMOVED. TO PREVENT PERSONAL INJURY, STAND CLEAR.
REMOVE FORK HOLE BRACKETS, BOARDS AND SHIPPING BRACE FROM BOTTOM
OF UNIT BEFORE PLACING UNIT ONTO CURB.
• Adequate clearances from the furnace flue discharge
to any adjacent public walkways, adjacent buildings,
building openings or openable windows must be
maintained in accordance with the latest edition of
the National Fuel Gas Code (ANSI Z223.1)
1. Remove wooden struts and shipping brace per
installation instructions. The struts are located in the
fork holes and are used to protect the unit from
damage while lifting with forks. The shipping brace
is located under the unit (under compressor). Also
remove the fork hole brackets as shown in the
following figure.
• Minimum horizontal clearance of 48” from the furnace
flue discharge to any electric meters, gas meters,
regulators and relief equipment is required.
2. Locate and remove the end brackets as shown in the
following figure.
UNIT PRECAUTIONS
•
•
Do not stand or walk on the unit.
Except for holes in the wiring entrances (see Figure
below), do not drill holes anywhere in panels or in
the base frame of the unit. Unit access panels
provide structural support.
5
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LIFT OVERAPPROXIMATE
CENTER OF UNIT
WARNING
SPREADER BARS
MUST BE USED WITH
LIFTING STRAPS THAT
ARE LESS THAN 16
FEET LONG
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
OBSERVED WHEN INSTALLING THE UNIT.
• Sufficient structural support must be determined prior
to locating and mounting the curb and package unit.
• Ductwork must be constructed using industry
guidelines. The duct work must be placed into the
roof curb before mounting the package unit. Our full
perimeter curbs include duct connection frames to be
assembled with the curb. Cantilevered type curbs
are not available from the factory.
• Curb insulation, cant strips, flashing and general
roofing material are furnished by the contractor.
The curbs must be supported on parallel sides by roof mem-
bers. The roof members must not penetrate supply and re-
turn duct opening areas as damage to the unit might occur.
NOTE: The unit and curb accessories are designed to allow
vertical duct installation before unit placement. Duct
installation after unit placement is not recommended.
CAUTION
ALL CURBS LOOK SIMILAR. TO AVOID INCORRECT CURB POSITIONING,
CHECK JOB PLANS CAREFULLY AND VERIFY MARKINGS ON CURB
ASSEMBLY. INSTRUCTIONS MAY VARY IN CURB STYLES AND SUPERCEDE
INFORMATION SHOWN.
REMOVE 2 BRACKETS
ON EACH END TO
REMOVE
REMOVE 2 BRACKETS
ON EACH END TO
REMOVE
WOODEN STRUTS
SHIPPING BRACE
See the manual shipped with the roof curb for assembly and
installation instructions.
CLEARANCES
3. Lift unit per the “Rigging Details” section of this manual,
observing all warnings and cautions. When unit is
lifted, boards and shipping brace will drop if screws
have been removed. To avoid injury, STAND CLEAR.
36”; minimum
roof overhang
4. Dispose of the boards and brace appropriately.
Curb installations must comply with local codes and should
be done in accordance with the established guidelines of the
National Roofing Contractors Association.
48”
72”
Proper unit installation requires that the roof curb be firmly
and permanently attached to the roof structure. Check for
adequate fastening method prior to setting the unit on the
curb.
48”
6”
Full perimeter roof curbs are available from the factory and
are shipped unassembled. Field assembly, squaring, level-
ing and mounting on the roof structure are the responsibility
of the installing contractor. All required hardware necessary
for the assembly of the sheet metal curb is included in the
curb accessory.
UNIT CLEARANCES
Adequate clearance around the unit should be kept for safety,
service, maintenance, and proper unit operation. Atotal clear-
ance of 75” on the main control panel side of the unit is rec-
ommended to facilitate possible fan shaft, coil, electric heat
and gas furnace removal. Aclearance of 48” is recommended
on all other sides of the unit to facilitate possible compressor
6
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removal, to allow service access and to insure proper venti-
lation and condenser airflow. The unit must not be installed
beneath any obstruction. The unit should be installed re-
mote from all building exhausts to inhibit ingestion of exhaust
air into the unit fresh air intake.
RIGGING DETAILS
WARNING
TO PREVENT PROPERTY DAMAGE, THE UNIT SHOULD REMAIN IN AN
UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS.
TO FACILITATE LIFTING AND MOVING WHEN A CRANE IS USED, PLACE
THE UNIT IN AN ADEQUATE CABLE SLING.
CAUTION
DO NOT LIFT UNITS TWO AT A TIME. PROVISIONS FOR FORKS HAVE BEEN
INCLUDED IN THE UNIT BASE FRAME. MINIMUM FORK LENGTH IS 72” TO
PREVENT DAMAGE TO THE UNIT.
Provisions for forks have been included in the unit base frame.
No other fork locations are approved.
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
OBSERVED WHEN INSTALLING THE UNIT.
•
•
•
•
Unit must be lifted by the four lifting holes located at
the base frame corners.
Lifting cables should be attached to the unit with
shackles.
The distance between the crane hook and the top of
the unit must not be less than 60”.
Two spreader bars must span over the unit to prevent
damage to the cabinet by the lift cables. Spreader
bars must be of sufficient length so that cables do not
come in contact with the unit during transport.
Remove wood struts mounted beneath unit base
frame before setting unit on roof curb. These struts
are intended to protect unit base frame from fork lift
damage. Removal is accomplished by extracting the
sheet metal retainers and pulling the struts through
the base of the unit. Refer to rigging label on the unit.
INSULATED
PANELS
ROOF CURB INSTALLATION
ROOF CURB POST-INSTALLATION
CHECKS
After installation, check the top of the curb, duct connection
frame and duct flanges to make sure gasket has been ap-
plied properly. Gasket should be firmly applied to the top of
the curb perimeter, duct flanges and any exposed duct con-
nection frame. If gasket is loose, re-apply using strong
weather resistant adhesive.
Important: If using bottom discharge with roof curb, duct-
work should be attached to the curb prior to installing the
unit. Ductwork dimensions are shown in Roof Curb Installa-
tion Instructions.
Refer to the Roof Curb Installation Instructions for proper curb
installation. Curbing must be installed in compliance with the
National Roofing Contractors Association Manual.
PROTRUSION
Lower unit carefully onto roof mounting curb. While rigging
unit, center of gravity will cause condenser end to be lower
than supply air end.
Inspect curb to ensure that none of the utility services (elec-
tric) routed through the curb protrude above the curb.
CAUTION
IF PROTRUSIONS EXIST, DO NOT ATTEMPT TO SET UNIT ON CURB.
INFORMATION SHOWN.
ROOF TOP DUCT CONNECTIONS
Install all duct connections on the unit before placing the unit
on rooftop.
7
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CAUTION
TO PREVENT SEVERE DAMAGE TO THE BOTTOM OF THE UNIT, DO NOT
FORK LIFT UNIT AFTER WOOD STRUTS HAVE BEEN REMOVED.
Bring condenser end of unit into alignment with the curb. With
condenser end of the unit resting on curb member and using
curb as a fulcrum, lower opposite end of the unit until entire
unit is seated on the curb. When a rectangular cantilever
curb is used, care should be taken to center the unit. Check
for proper alignment and orientation of supply and return
openings with duct.
RIGGING REMOVAL
CAUTION
TO PREVENT DAMAGE TO THE UNIT, DO NOT ALLOW CRANE HOOKS AND
SPREADER BARS TO REST ON THE ROOF OF THE UNIT.
Remove spreader bars, lifting cables and other rigging equip-
ment.
CAUTION
ELECTRICAL WIRING
WHEN UNIT IS SUSPENDED, BOARDS AND SHIPPING BRACE WILL DROP WHEN
SCREWS ARE REMOVED. TO PREVENT PERSONAL INJURY, STAND CLEAR.
REMOVE FORK HOLE BRACKETS, BOARDS AND SHIPPING BRACE FROM BOTTOM
OF UNIT BEFORE PLACING UNIT ONTO CURB.
WARNING
HIGH VOLTAGE !
To assist in determining rigging requirements, unit weights
are shown as follows:
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
A
C
COMPRESSOR 1
Y
WARNING
HIGH VOLTAGE !
CG
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL
SHOCK, DO NOT TAMPER WITH FACTORY WIRING. THE
INTERNAL POWER AND CONTROL WIRING OF THESE UNITS
ARE FACTORY‐INSTALLED AND HAVE BEEN THOROUGHLY
TESTED PRIOR TO SHIPMENT. CONTACT YOUR LOCAL
REPRESENTATIVE IF ASSISTANCE IS REQUIRED.
COMPRESSOR 2
B
D
CAUTION
X
CORNER & CENTER OF GRAVITY LOCATIONS
TO PREVENT DAMAGE TO THE WIRING, PROTECT WIRING FROM SHARP
EDGES. FOLLOW NATIONAL ELECTRICAL CODE AND ALL LOCAL CODES
AND ORDINANCES. DO NOT ROUTE WIRES THROUGH REMOVABLE
ACCESS PANELS.
CPG Weights
(lbs)
CPG Weights
(lbs)
20 Tons
655
DATA
15 Tons
Corner Weight - A
Corner Weight - B
Corner Weight - C
Corner Weight - D
Unit Shipping Weight
Unit Operating Weight
X (Inches)
570
535
545
510
2270
CAUTION
535
CONDUIT AND FITTINGS MUST BE WEATHER‐TIGHT TO PREVENT WATER
ENTRY INTO THE BUILDING.
600
485
For unit protection, use a fuse or HACR circuit breaker that is
in excess of the circuit ampacity, but less than or equal to the
maximum overcurrent protection device. DO NOT EXCEED
THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN
ON UNIT DATA PLATE.
2390
2275
63"
2155
65"
43"
40"
Y (Inches)
NOTE: These weights are without accessories installed.
8
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All line voltage connections must be made through weather-
proof fittings. All exterior power supply and ground wiring
must be in approved weatherproof conduit.
Line voltage connects
to middle contactor
on 460v and 575v
Gas Packs
The main power supply wiring to the unit and low voltage
wiring to accessory controls must be done in accordance with
these instructions, the latest edition of the National Electrical
Code (ANSI/NFPA 70), and all local codes and ordinances.
All field wiring shall conform with the temperature limitations
for Type T wire (63°F/35°C rise).
Ground
Lug
Power Block
(Coolers &
230V Gas Packs
Only)
The main power supply shall be three-phase, three wire. The
unit is factory wired for the voltage shown on the unit’s data
plate.
Line voltage connects
to power block on
Coolers and the 230v
Gas Packs
NOTE: If supply voltage is 208V, all leads on primary of trans-
former TRANS1 must be moved from the 230V to the 208V
tap.
Low Voltage
Terminal Strip
Main power wiring should be sized for the minimum wire
ampacity shown on the unit’s database. Size wires in accor-
dance with the ampacity tables in Article 310 of the National
Electrical Code. If long wires are required, it may be neces-
sary to increase the wire size to prevent excessive voltage
drop. Wires should be sized for a maximum of 3% voltage
drop.
Field wiring enters
from this direction
Thermostat wiring
for all units
connect to low
voltage strip
POWER AND LOW VOLTAGE BLOCK LOCATIONS
WARNING
CAUTION
FAILURE OF UNIT DUE TO OPERATION ON IMPROPER LINE VOLTAGE OR
WITH EXCESSIVE PHASE UNBALANCE CONSTITUTES PRODUCT ABUSE AND
WILL VOID YOUR WARRANTY AND MAY CAUSE SEVERE DAMAGE TO THE
UNIT ELECTRICAL COMPONENTS.
TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE
ONLY COPPER CONDUCTORS.
CAUTION
AREAS WITHOUT CONVENIENCE OUTLET
TO PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING
ERRORS, LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. VERIFY PROPER OPERATION AFTER SERVICING.
It is recommended that an independent 115V power source
be brought to the vicinity of the roof top unit for portable lights
and tools used by the service mechanic.
NOTE: A weather-tight disconnect switch, properly sized for
the unit total load, must be field installed. An external field
supplied disconnect may be mounted on the exterior panel.
UNITS INSTALLED ON ROOF TOPS
Main power and low voltage wiring may enter the unit through
the side or through the roof curb. Install conduit connectors
at the desired entrance locations. External connectors must
be weatherproof. All holes in the unit base must be sealed
(including those around conduit nuts) to prevent water leak-
age into building. All required conduit and fittings are to be
field supplied.
Ensure the data plate is not covered by the field-supplied
disconnect switch.
•
Some disconnect switches are not fused. Protect the
power leads at the point of distribution in accordance
with the unit data plate.
•
The unit must be electrically grounded in accordance
with local codes or, in the absence of local codes,
with the latest edition of the National Electrical Code
(ANSI-NFPA 70). A ground lug is provided for this
purpose. Size grounding conductor in accordance
with Table 250-95 of the National Electrical Code. Do
not use the ground lug for connecting a neutral
conductor.
Supply voltage to roof top unit must not vary by more than
10% of the value indicated on the unit data plate. Phase
voltage unbalance must not exceed 2%. Contact your local
power company for correction of improper voltage or phase
unbalance.
•
Connect power wiring to the middle contactor within
the main control box.
9
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GAS SUPPLY PIPING
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR
INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR
THE GAS SUPPLIER.
IMPORTANT NOTE: This unit is factory set to operate on
natural gas at the altitudes shown on the rating plate.
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH WHEN
EITHER USING PROPANE GAS ALONE OR AT HIGHER ALTITUDES, OBTAIN
AND INSTALL THE PROPER CONVERSION KIT(S). FAILURE TO DO SO CAN
RESULT IN UNSATISFACTORY OPERATION AND/OR EQUIPMENT DAMAGE.
HIGH ALTITUDE KITS ARE FOR U.S. INSTALLATIONS ONLY AND ARE NOT
APPROVED FOR USE IN CANADA.
ELECTRICAL ENTRANCE LOCATIONS
Unit is equipped with a Low Voltage Terminal Block and has
Single Point wiring to the contactor.
LOW VOLTAGE CONTROL WIRING
1. A24V thermostat must be installed for unit operation.
It may be purchased with the unit or field -supplied.
Thermostats may be programmable or
electromechanical as required.
The rating plate is stamped with the model number, type of
gas and gas input rating. Make sure the unit is equipped to
operate on the type of gas available. Conversion to propane
(LP) gas is permitted with the use of the factory authorized
conversion kit (see the unit Technical Manual for the appro-
priate kit). For HighAltitude derates, refer to the latest edition
of the National Fuel Gas Code NFPA 54/ANSI Z223.1.
2. Locate thermostat or remote sensor in the conditioned
space where it will sense average temperature. Do
not locate the device where it may be directly exposed
to supply air, sunlight or other sources of heat. Follow
installation instructions packaged with the thermostat.
3. Use #18 AWG wire for 24V control wiring runs not
exceeding 75 feet. Use #16AWG wire for 24V control
wiring runs not exceeding 125 feet. Use #14 AWG
wire for 24V control wiring runs not exceeding 200
feet. Low voltage wiring may be National Electrical
Code (NEC) Class 2 where permitted by local codes.
4. Route thermostat wires from sub-base terminals to
the unit. Control wiring should enter through the duct
panel (dimple marks entrance location). Connect
thermostat and any accessory wiring to low voltage
terminal block TB1 in the main control box.
INLET GAS PRESSURE
Min. 5.0" W.C., Max. 10.0" W.C.
Min. 11.0" W.C., Max. 14.0" W.C.
NATURAL
PROPANE
Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in Table
Above.
The minimum supply pressure should not vary from that
shown in the table above because this could prevent the unit
from having dependable ignition. In addition, gas input to the
burners must not exceed the rated input shown on the rating
plate. Overfiring of the unit could result in premature heat
exchanger failure.
NOTE: Field-supplied conduit may need to be installed
depending on unit/curb configuration. Use #18 AWG solid
conductor wire whenever connecting thermostat wires to
terminals on sub-base. DO NOT use larger than #18 AWG
wire. A transition to #18 AWG wire may be required before
entering thermostat sub-base.
PIPING
IMPORTANT NOTE: To avoid possible unsatisfactory opera-
tion or equipment damage due to under firing of equipment,
do not undersize the natural/propane gas piping from the
meter/tank to the unit. When sizing a trunk line, include all
appliances on that line that could be operated simultaneously.
LEAD
Red
THERMOSTAT
R (24V)
The rating plate is stamped with the model number, type of
gas and gas input rating. Make sure the unit is equipped to
operate on the type of gas available. The gas line installation
must comply with local codes, or in the absence of local codes,
with the latest edition of the National Fuel Gas Code NFPA
54/ANSI Z223.1.
Green
Yellow
Purple
Blue
White
Brown
G (Fan)
Y1 (High Cool)
Y2 (Low Cool)
Common (if req'd)
W1 (Heat)
W2 (High Heat)
CPG240 (GAS HEAT)
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Natural Gas Connection
GAS INLET LOCATION (3/4” NPT)
Natural Gas Capacity of Pipe
in Cubic Feet of Gas Per Hour (CFH)
Nominal Black Pipe Size (inches)
Length of
Pipe in Feet
1
1/2
132
92
73
63
56
50
46
43
40
38
3/4
278
190
152
130
115
105
96
1
1/4
1050
730
590
500
440
400
370
350
320
305
1
1/2
1600
1100
980
760
670
610
560
530
490
460
10
20
30
40
50
60
70
80
90
100
520
350
285
245
215
195
180
170
160
150
90
84
79
46-1/10”
74-11/12”
Pressure = .50 PSIG or less and Pressure Drop of 0.3" W.C. (Based
on 0.60 Specific Gravity Gas)
HOOD LOCATED
INSIDE HEAT SECTION
DURING SHIPPING
BTUH Furnace Input
CFH =
Heating Value of Gas (BTU/Cubic Foot)
Refer to the Proper Piping Practice drawing for the general
layout at the unit. The following rules apply:
DOOR
1. Use black iron pipe and fittings for the supply piping.
The use of a flex connector and/or copper piping is
permitted as long as it is in agreement with local
codes.
2. Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.
PROVIDE
CLEARANCE
FOR REMOVAL OF
ACCESS PANELS
3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum
of three inches long.
DRIP LEG
MANUAL
SHUT OFF
VALVE
GROUND
JOINT
UNION
5. Use two pipe wrenches when making connection to
the gas valve to keep it from turning.
6. Install a manual shut-off valve in a convenient location
(within six feet of unit) between the meter and the
unit.
7. Tighten all joints securely.
PROPER PIPING PRACTICE
8. The unit must be connected to the building piping by
one of the following methods:
NOTE: The unit gas supply entrance is factory sealed with
plugs. Keep plugs in place until gas supply is ready to be
installed. Once ready, replace the plugs with the supplied
grommets and install gas supply line.
•
•
Rigid metallic pipe and fittings
Semirigid metallic tubing and metallic fittings
(Aluminum alloy tubing must not be used in exterior
locations)
•
•
Listed gas appliance connectors used in accordance
with the terms of their listing that are completely in
the same room as the equipment
In the prior two methods above the connector or
tubing must be protected from physical and thermal
damage.Aluminum alloy tubing and connectors must
be coated to protect against external corrosion when
in contact with masonry, plaster or insulation or are
subject to repeated wettings by liquids (water - not
rain water, detergents or sewage).
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1. Vaporization rate, which depends on (a) temperature
of the liquid, and (b) wetted surface area of the
container or containers.
GAS PIPING CHECKS
CAUTION
2. Proper pressure regulation.
TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE,
THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS
CONNECTIONS AND PRESSURE TESTING:
• THE UNIT AND ITS GAS CONNECTIONS MUST BE LEAK TESTED
BEFORE PLACING IN OPERATION. BECAUSE OF THE DANGER OF
EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST
FOR LEAKS. NEVER EXCEED SPECIFIED PRESSURES FOR TESTING.
HIGHER PRESSURE MAY DAMAGE GAS VALVE AND CAUSE
OVERFIRING WHICH MAY RESULT IN PREMATURE HEAT EXCHANGE
FAILURE.
3. Pressure drop in lines between regulators, and
between second stage regulator and the appliance.
Pipe size required will depend on length of pipe run
and total load of all appliances.
TANKS AND PIPING
Complete information regarding tank sizing for
vaporization, recommended regulator settings and pipe
sizing is available from most regulator manufacturers and
propane gas suppliers.
Since propane gas will quickly dissolve white lead or most
standard commercial compounds, special pipe dope
must be used. Shellac base compounds resistant to the
actions of liquefied petroleum gases such as Gasolac®,
Stalactic®, Clyde’s® or John Crane® are satisfactory.
See following figure for typical propane gas piping.
• THIS UNIT AND ITS SHUT‐OFF VALVE MUST BE DISCONNECTED FROM
THE GAS SUPPLY DURING ANY PRESSURE TESTING OF THAT SYSTEM
AT TEST PRESSURES IN EXCESS OF 1/2 PSIG (3.48
KPA).
• THIS UNIT MUST BE ISOLATED FROM THE GAS SUPPLY SYSTEM BY
CLOSING ITS MANUAL SHUT‐OFF VALVE DURING ANY PRESSURE
TESTING OF THE GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES
EQUAL TO OR LESS THAN 1/2 PSIG (3.48
KPA).
5 to 15 PSIG
(20 PSIG Max.)
First Stage
Regulator
WARNING
Continuous
11" W.C.
TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, BE SURE THERE IS
NO OPEN FLAME IN THE VICINITY DURING AIR BLEEDING.
200 PSIG
Maximum
Second Stage
Regulator
There will be air in the gas supply line after testing for leaks
on a new installation. Therefore, the air must be bled from
the line by loosening the ground joint union until pure gas is
expelled. Tighten union and wait for five minutes until all gas
has been dissipated in the air. Be certain there is no open
flame in the vicinity during air bleeding procedure. The unit is
placed in operation by closing the main electrical disconnect
switch for the unit.
TYPICAL PROPANE GAS PIPING
ROOF TOP LOCATION AND INSTALLATION
The gas supply piping location and installation for roof top
units must be in accordance with local codes or, in the ab-
sence of locals codes, with ordinances of the latest edition of
the National Fuel Gas Code (ANSI Z223.1).
PROPANE GAS INSTALLATIONS
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS
DETECTING WARNING DEVICE. SINCE RUST CAN REDUCE THE LEVEL OF
ODORANT IN PROPANE GAS, A GAS DETECTING WARNING DEVICE IS THE
ONLY RELIABLE WAY TO DETECT A PROPANE GAS LEAK. CONTACT A
LOCAL PROPANE GAS SUPPLIER ABOUT INSTALLING A GAS DETECTING
WARNING DEVICE.
A manual gas shutoff valve must be field installed external to
the roof top unit. In addition, a drip leg must be installed near
the inlet connection. A ground joint union connection is re-
quired between the external shutoff valve and the unit con-
nection to the gas valve to permit removal of the burner as-
sembly for servicing.
1. Route gas piping to unit so that it does not interfere
with the removal of access panels. Support and align
piping to prevent strains or misalignment of the
manifold assembly.
IMPORTANT NOTE: Propane gas conversion kits must be
installed to convert units to propane gas.
2. All units are furnished with standard female NPT pipe
connections. Connection pipe size is 3/4" NPT. The
size of the gas supply piping to the unit must be based
on length of run, number of units on the system, gas
characteristics, BTU requirement and available supply
pressure. All piping must be done in accordance with
local codes or, in the absence of local codes, with the
latest edition of the National Fuel Gas Code (ANSI
Z223.1).
All propane gas equipment must conform to the safety
standards of the National Board of Fire Underwriters (See
NBFU Manual 58). Line pressure 11.3 - 14” w.c.
For satisfactory operation, propane gas manifold pressure
must be within 9.7 - 10.3 inches w.c. for high fire and within
6.7 - 7.3 inches w.c. low fire at the manifold with all gas appli-
ances in operation. Maintaining proper gas pressure depends
on three main factors:
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NOTE: The gas connection size at the unit does NOT
establish the size of the supply line.
CIRCULATING AIR AND FILTERS
DUCTWORK
3. These units are designed for either natural or propane
(LP) gas and are specifically constructed at the factory
for only one of these fuels. The fuels are NOT
interchangeable. However, the furnace can be
converted in the field from natural gas to LP gas with
the appropriate factory kit (see unit Technical Manual
for the appropriate kit). Only a qualified contractor,
experienced with natural and propane gas systems,
should attempt conversion. Kit instructions must be
followed closely to assure safe and reliable unit
operation.
The supply duct should be provided with an access panel
large enough to inspect the air chamber downstream of the
heat exchanger. A cover should be tightly attached to pre-
vent air leaks.
Ductwork dimensions are shown in the roof curb installation
manual.
If desired, supply and return duct connections to the unit may
be made with flexible connections to reduce possible unit
operating sound transmission.
VENTING
4. With all units on a common line operating under full
fire, natural gas main supply pressure should be
adjusted to approximately 7.0" w.c., measured at the
unit gas valve. If the gas pressure at the unit is greater
than 10.5" w.c., the contractor must furnish and install
an external type positive shutoff service pressure
regulator. The unit will not function satisfactorily if
supply gas pressure is less than 5.5" w.c. or greater
than 10.5" w.c..
NOTE: Venting is self-contained.
CONDENSATE DRAIN CONNECTION
CONDENSATE DRAIN CONNECTION
A 3/4” NPT drain connection is supplied for condensate pip-
ing. An external trap must be installed for proper condensate
drainage.
NOTE: A minimum horizontal distance of 48"
between the regulator and the furnace flue discharge
is required.
UNIT
2" MINIMUM
5. With all units on a common line operating under full
LP gas main supply pressure should be at least 11.0"
w.c. and must be no greater than 14.0" w.c., measured
at the unit gas valve. Unit will not function satisfactorily
if supply gas pressure is less than 11.0" w.c. or greater
than 14.0" w.c..
6. All pipe connections should be sealed with a pipe
thread compound, which is resistant to the fuel used
with the furnace. A soapy water solution should be
used to check all joints for leaks. A 1/8" NPT plugged
tap is located on the entering side of the gas valve for
test gauge connection to measure supply (main) gas
pressure. Another 1/8" tap is provided on the side of
the manifold for checking manifold pressure.
FLEXIBLE
TUBING-HOSE
OR PIPE
3" MINIMUM
A POSITIVE LIQUID
SEAL IS REQUIRED
DRAIN CONNECTION
Install condensate drain trap as shown. Use 3/4" drain line
and fittings or larger. Do not operate without trap.
HORIZONTAL DRAIN
Drainage of condensate directly onto the roof may be ac-
ceptable; refer to local code. It is recommended that a small
drip pad of either stone, mortar, wood or metal be provided to
prevent any possible damage to the roof.
WARNING
THIS UNIT AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE
DISCONNECTED FROM THE GAS SUPPLY SYSTEM DURING ANY
PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN EXCESS OF
CLEANING
1/2 PSIG (13.8”
W.C.).
Due to the fact that drain pans in any air conditioning unit
will have some moisture in them, algae and fungus will
grow due to airborne bacteria and spores. Periodic clean-
ing is necessary to prevent this build-up from plugging the
drain.
CAUTION
THIS UNIT MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM
BY CLOSING ITS INDIVIDUAL MANUAL SHUTOFF VALVE DURING ANY
PRESSURE TESTING EQUAL TO OR LESS THAN 1/2 PSIG.
7. There must be no obstruction to prevent the flow of
combustion and ventilating air. A vent stack is not
required and must never be used. The power ventor
will supply an adequate amount of combustion air as
long as the air passageways are kept free of any
obstructions and the recommended external unit
clearances are maintained.
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STARTUP, ADJUSTMENTS, AND CHECKS
TOOLS REQUIRED
Refrigeration gauge and manifold
Voltmeter
WARNING
Clamp-on ammeter
Ohmmeter
Test lead
(Minimum #16 AWG with insulated alligator clips)
Manometer for verifying gas pressure 0 to 20" w.c.
Air temperature measuring device
General refrigeration mechanics’ tools
HIGH VOLTAGE!
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, BOND THE FRAME OF THIS UNIT TO
THE BUILDING ELECTRICAL GROUND BY USE OF THE
GROUNDING TERMINAL PROVIDED OR OTHER
ACCEPTABLE MEANS. DISCONNECT ALL POWER BEFORE
SERVICING OR INSTALLING THIS UNIT.
TEMPORARY HEATING OR COOLING
PRE-STARTUP INSTRUCTIONS
If the unit is to be used for temporary heating or cooling, a
“Startup, Adjustments, and Checks” must first be performed
in accordance with this manual. Failure to comply with this
requirement will void the warranty. After the machines are
used for temporary heating or cooling, inspect the coils, fans,
and motors for unacceptable levels of construction dust and
dirt and install new filters.
CAUTION
TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY, DO NOT START
THE UNIT UNTIL ALL NECESSARY PRE‐CHECKS AND TEST HAVE BEEN
PERFORMED.
Prior to the beginning of Startup, Adjustments, and Checks
procedures, the following steps should be completed in the
building.
CONTRACTOR RESPONSIBILITY
THERMOSTAT. Set the thermostat in the conditioned
space at a point at least 10°F below zone temperature.
Set the thermostat system switch on COOL and the
fan switch on AUTO.
The installing contractor must be certain that:
•
•
•
All supply and return air ductwork is in place and
corresponds with installation instructions.
All thermostats are mounted and wired in accordance
with installation instructions.
All electric power, all gas, hot water or steam line
connections, and the condensate drain installation
have been made to each unit on the job. These main
supply lines must be functional and capable of
operating all units simultaneously.
WARNING
MOVING MACHINERY HAZARD!
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH, DISCONNECT
POWER TO THE UNIT AND PADLOCK IN THE “OFF” POSITION BEFORE
SERVICING FANS.
HEATING STARTUP
ROOF CURB INSTALLATION CHECK
This unit is equipped with an electronic ignition device to au-
tomatically light the main burners. It also has a power vent
blower to exhaust combustion products.
Inspect the roof curb for correct installation. The unit and curb
assembly should be level. Inspect the flashing of the roof
mounting curb to the roof, especially at the corners, for good
workmanship. Also check for leaks around gaskets. Note any
deficiencies in a separate report and forward to the contrac-
tor.
On new installations, or if a major component has been re-
placed, the operation of the unit must be checked.
Check unit operation as outlined in the following instructions.
If any sparking, odors, or unusual sounds are encountered,
shut off electrical power and recheck for wiring errors, or ob-
structions in or near the blower motors. Duct covers must
be removed before operating unit.
OBSTRUCTIONS, FAN CLEARANCE AND WIRING
Remove any extraneous construction and shipping materi-
als that may be found during this procedure. Rotate all fans
manually to check for proper clearances and that they rotate
freely. Check for bolts and screws that may have jarred loose
during shipment to the jobsite. Retighten if necessary. Re-
tighten all electrical connections.
The Startup, Adjustments, and Checks procedure provides a
step-by-step sequence which, if followed, will assure the
proper startup of the equipment in the minimum amount of
time. Air balancing of duct system is not considered part of
this procedure. However, it is an important phase of any air
conditioning system startup and should be performed upon
completion of the Startup, Adjustments, and Checks proce-
dure. The Startup, Adjustments, and Checks procedure at
outside ambients below 55°F should be limited to a readi-
ness check of the refrigeration system with the required final
check and calibration left to be completed when the outside
ambient rises above 55°F.
PRE-STARTUP PRECAUTIONS
It is important to your safety that the unit has been properly
grounded during installation. Check ground lug connection
in main control box for tightness prior to closing circuit breaker
or disconnect switch. Verify that supply voltage on line side
of disconnect agrees with voltage on unit identification plate
and is within the utilization voltage range as indicated in Ap-
pendix C Electrical Data.
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System Voltage - That nominal voltage value assigned to a
circuit or system for the purpose of designating its voltage
class.
SET EVAPORATOR FAN RPM
Actual RPM’s must be set and verified with a tachometer or
strobe light. Refer to Appendices A and B for basic unit fan
RPM. Refer also to “Airflow” section of this manual. With
disconnect switch open, disconnect thermostat wires from
terminals Y and W. This will prevent heating and mechanical
cooling from coming on. Place a jumper wire across termi-
nals R and G at TB1 terminal block. Close disconnect switch;
evaporator fan motor will operate so RPM can be checked.
Nameplate Voltage - That voltage assigned to a piece of
equipment for the purpose of designating its voltage class
and for the purpose of defining the minimum and maximum
voltage at which the equipment will operate.
Utilization Voltage - The voltage of the line terminals of the
equipment at which the equipment must give fully satisfac-
tory performance. Once it is established that supply voltage
will be maintained within the utilization range under all sys-
tem conditions, check and calculate if an unbalanced condi-
tion exists between phases. Calculate percent voltage un-
balance as follows:
For gas heat units, the airflow must be adjusted so that the
air temperature rise falls within the ranges given stated on
Data Plate (see Appendix A - Blower Performance).
TENSION AND ALIGNMENT ADJUSTMENT
Correct belt tension is very important to the life of your belt.
Too loose a belt will shorten its life; too tight, premature mo-
tor and bearing failure will occur. Check you belt drive for
adequate “run-in” belt tension by measuring the force required
to deflect the belt at the midpoint of the span length. Belt
tension force can be measured using a belt tension gauge,
available through most belt drive manufacturers.
Three Phase Models
2) MAXIMUM VOLTAGE DEVIATIONS
FROM AVERAGE VOLTAGE
3) PERCENT VOLTAGE
UNBALANCE
= 100 X
1) AVERAGE VOLTAGE
HOW TO USE THE FORMULA:
EXAMPLE: With voltage of 220, 216, and 213
1) Average Voltage = 220+216+213=649 / 3 = 216
2) Maximum Voltage Deviations from Average Voltage = 220 - 216 = 4
4
216
400
216
3) Percent Voltage Unbalance = 100 x
=
= 1.8%
Percent voltage unbalance MUST NOT exceed 2%
.
FIELD DUCT CONNECTIONS
Verify that all duct connections are tight and that there is no
air bypass between supply and return.
CONTROL VOLTAGE CHECK
With disconnect switch in the open “OFF” position, discon-
nect blue wire from low voltage transformer TRANS1. Close
the disconnect switch to energize TRANS1 control trans-
former. Check primary and secondary (24V) of control trans-
former TRANS1.
t = Span length, inches
C = Center distance, inches
D = Larger sheave diameter, inches
d = Smaller sheave diameter, inches
h = Deflection height, inches
THERMOSTAT PRELIMINARY CHECK
DRIVE BELT TENSION ADJUSTMENT
With disconnect switch open and blue wire disconnected from
TRANS1 transformer, attach one lead of ohmmeter to termi-
nal R on TB1 terminal block. Touch, in order, the other ohm-
meter lead to terminals Y1, Y2 and G at TB1 terminal block.
There must be continuity from terminal R to terminals Y and
G. R to Y indicates cool. R to G indicates fan (auto). Replace
blue wire on TRANS1 transformer.
SHEAVE
DIAMETER
DEFLECTION
FORCE (lbs)
DEFLECTION
(in)
TYPE
MODEL
(in)
BELT DRIVE
Used
New
15 Ton B, BA Standard 4.3 to 5.5 5.5 + .5 8.2 + .5
High
1/4 ± 1/16
1/4 ± 1/16
15 Ton B, BA
4.3 to 5.5 5.5 + .5 8.2 + .5
FILTER SECTION CHECK
Static
Remove filter section access panels and check that filters
are properly installed. Note airflow arrows on filter frames.
20 Ton B, BA Standard 4.3 to 5.5 5.5 + .5 8.2 + .5
1/4 ± 1/16
1/4 ± 1/16
High
20 Ton B, BA
4.3 to 5.5 5.5 + .5 8.2 + .5
Static
BEARING CHECK
RECOMMENDED POUNDS OF FORCE PER BELT
Prior to energizing any fans, check and make sure that all
setscrews are tight so that bearings are properly secured to
shafts.
The correct deflection force is 5 Ibs. for a new belt and 3.5
Ibs. for a belt that has been run in. New belt tension includes
initial belt stretch. When new V-belts are installed on a drive
the initial tension will drop rapidly during the first few hours.
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Check tension frequently during the first 24 hours of opera-
tion. Subsequent retensioning should fall between the mini-
mum and maximum force. To determine the deflection dis-
tance from the normal position, use a straightedge or stretch
a cord from sheave to sheave to use as a reference line. On
multiple belt drives, an adjacent undeflected belt can be used
as a reference.
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE OR EXPLOSION, A QUALIFIED SERVICER MUST INVESTIGATE THE
REASON FOR THE ROLLOUT PROTECTION DEVICE TO OPEN BEFORE
MANUALLY RESETTING THE ROLLOUT PROTECTION DEVICE.
Secondary Limit Control
EVAPORATOR FAN ROTATION CHECK (THREE PHASE MODELS
ONLY)
The secondary limit control is located on the side of the blower
scroll assembly. This control opens when elevated tempera-
tures are sensed. Elevated temperatures at the control are
normally caused by blower failure. The reason for the open-
ing should be determined and repaired prior to resetting.
Check that fan rotates clockwise when viewed from the drive
side of unit and in accordance with rotation arrow shown on
blower housing. If it does not, reverse any two incoming power
cables at Single Point Power Block. In this case, repeat bear-
ing check.
If the power to the unit is interrupted during the heating cycle,
it may cause the secondary limit to trip. Once the blower com-
partment temperature drops below the limit reset tempera-
ture, the limit will automatically reset.
Do not attempt to change load side wiring. Internal wiring
assures all motors and compressors will rotate in correct di-
rection once evaporator fan motor rotation check has been
made.
Pre-Operation Checks
1. Close the manual gas valve external to the unit.
2. Turn off the electrical power supply to the unit.
3. Set the room thermostat to its lowest possible setting.
4. Remove the heat exchanger door on the side of the
unit by removing screws.
5. This unit is equipped with an ignition device which
automatically lights the main burner. DO NOT try to
light burner by any other method.
ELECTRICAL INPUT CHECK
Make preliminary check of evaporator fan ampere draw and
verify that motor nameplate amps are not exceeded. A final
check of amp draw should be made upon completion of air
balancing of the duct system (see Appendix C).
RESTORING CONNECTIONS
6. Move the gas control valve switch to the OFF position.
Do not force.
With disconnect switch open, remove jumper wire from ter-
minals R and G at TB1 terminal block, and reconnect ther-
mostat wires to terminals Y and W.
7. Wait five minutes to clear out any gas.
8. Smell for gas, including near the ground. This is
important because some types of gas are heavier than
air. If you have waited five minutes and you do smell
gas, immediately follow the warnings on page 3 of
this manual. If having waited for five minutes and no
gas smell is noted, move the gas control valve switch
to the ON position.
9. Replace the heat exchanger door on the side of the
unit.
10. Open the manual gas valve external to the unit.
11. Turn on the electrical power supply to the unit.
12. Set the thermostat to desired setting.
REFRIGERATION SYSTEM CHECKS
Ensure the hold-down bolts on the compressor are secure
and have not vibrated loose during shipment. Check that vi-
bration grommets have been installed. Visually check all pip-
ing and clamps. The entire refrigeration system has been
factory charged and tested, making it unnecessary to field
charge. Factory charges are shown in Appendix C and on
the unit nameplate.
Install service manifold hoses. Gauges should read satura-
tion pressure corresponding to ambient temperature. Charge
should be checked to obtain 12° to 15° of sub-cooling per
system (i.e. compressor circuits).
Gas Supply And Manifold Check
Gas supply pressure and manifold pressure with the burners
operating must be as specified on the rating plate.
Rollout Protection Control
The rollout protection device opens, cutting power to the
gas valve, if the flames from the burners are not properly
drawn into the heat exchanger. The rollout protection
device is located above the burner bracket (See page
19). The reason for elevated temperatures at the control
should be determined and repaired prior to resetting this
manual reset control.
Gas Inlet Pressure Check
Gas inlet pressure must be checked and adjusted in accor-
dance to the type of fuel being consumed.
With Power And Gas Off:
1. Connect a water manometer or adequate gauge to
the inlet pressure tap of the gas valve.
Inlet gas pressure can also be measured by removing
the cap from the dripleg and installing a predrilled cap
with a hose fitting.
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With Power And Gas On:
Input = 1000 x 3600 / 34 = 106,000 BTU per Hour.
NOTE: BTU content of the gas should be obtained
from the gas supplier. This measured input must not
be greater than shown on the unit rating plate.
4. Relight all other appliances turned off in step 1. Be
sure all pilot burners are operating.
2. Put unit into heating cycle and turn on all other gas
consuming appliances.
INLET GAS PRESSURE
Min. 5.0" W.C., Max. 10.0" W.C.
Min. 11.0" W.C., Max. 14.0" W.C.
NATURAL
PROPANE
Main Burner Flame Check
Flames should be stable, soft and blue (dust may cause or-
ange tips but they must not be yellow) and extending directly
outward from the burner without curling, floating or lifting off.
NOTE: Inlet Gas Pressure Must Not Exceed the Maximum
Value Shown.
Temperature Rise Check
If operating pressures differ from above, make necessary
pressure regulator adjustments, check piping size, etc., and/
or consult with local utility.
Check the temperature rise through the unit by placing ther-
mometers in supply and return air registers as close to the
unit as possible. Thermometers must not be able to sample
temperature directly from the unit heat exchangers, or false
readings could be obtained.
Manifold Pressure Check
The gas valve has a tapped opening to facilitate measure-
ment of the manifold pressure. A “U” Tube manometer hav-
ing a scale range from 0 to 12 inches of water should be
used for this measurement. The manifold pressure must be
measured with the burners operating.
1. All registers must be open; all duct dampers must be
in their final (fully or partially open) position and the
unit operated for 15 minutes on HIGH FIRE before
taking readings.
To adjust the pressure regulator, remove the adjustment screw
or cover on the gas valve. Turn out (counterclockwise) to
decrease pressure, turn in (clockwise) to increase pressure.
Only small variations in gas flow should be made by means
of the pressure regulator adjustment. In no case should the
final manifold pressure vary more than plus or minus 0.3
inches water column from the specified nominal pressure.
Any major changes in flow should be made by changing the
size of the burner orifices. The measured input rate to the
furnace must not exceed the rating specified on the unit rat-
ing plate.
2. The temperature rise must be within the range
specified on the rating plate.
NOTE: Air temperature rise is the temperature difference
between supply and return air.
With a properly designed system, the proper amount of tem-
perature rise will normally be obtained when the unit is oper-
ated at rated input with the recommended blower speed.
If the correct amount of temperature rise is not obtained, it
may be necessary to change the blower speed. A higher
blower speed will lower the temperature rise.Aslower blower
speed will increase the temperature rise.
For natural gas, the manifold pressure must be between 3.2
and 3.8 inches w.c. (3.5 nominal) for high fire and between
1.7 and 2.3 inches w.c. (2.0 nominal) for low fire.
NOTE: Blower speed MUST be set to give the correct air
For propane gas, the manifold pressure must be between temperature rise through the unit as marked on the rating
9.7 and 10.3 inches w.c. (10.0 nominal) for high fire and be- plate.
tween 6.7 and 7.3 inches w.c. (7.0 nominal) for low fire.
REFRIGERATION SEQUENCE CHECK
Gas Input (Natural Gas Only) Check
With the disconnect switch open, remove the field connected
To measure the gas input use a gas meter and proceed
as follows:
1. Turn off gas supply to all other appliances except the
unit.
thermostat wire from terminal R on TB1 terminal block. Place
a jumper across terminals R and G, and across R and Y on
TB1 terminal block. Close the disconnect switch. The follow-
ing operational sequence should be observed.
2. With the unit operating, time the smallest dial on the
meter for one complete revolution. If this is a 2 cubic
foot dial, divide the seconds by 2; if it is a 1 cubic foot
dial, use the seconds as is. This gives the seconds
per cubic foot of gas being delivered to the unit.
3. INPUT=GAS HTG VALUE x 3600 / SEC. PER CUBIC
FOOT
Example: Natural gas with a heating value of 1000 BTU per
cubic foot and 34 seconds per cubic foot as determined by
Step 2, then:
1. Current through primary winding of transformer
TRANS1 energizes the 24-volt control circuit.
2. To simulate a mechanical call for cooling from the wall
thermostat, place a jumper across terminals R and
Y1 of terminal block TB1.
3. UNIT WITH ECONOMIZER OPTION: The
compressor circuit is interlocked through terminals 3
and 4 of the economizer module. If the outdoor air
enthalpy (temperature and humidity) is not suitable
for cooling, the economizer terminals will be closed
permitting compressor to be energized.
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4. The belt drive blower contactor closes its contacts L1,
L2 and L3 to T1, T2 and T3 to provide power to the
supply fan motor.
11. Open disconnect switch. Reconnect the field
thermostat wire at terminal R on terminal block TB1.
REFRIGERATION PERFORMANCE CHECK
5. Check supply fan rotation. If the supply fan is rotating
in the wrong direction, disconnect and lock off Single
Point Power Block. Do not attempt to change load
side wiring. Internal wiring is set at the factory to assure
that the supply fan and compressors all rotate in the
proper direction. Verification of correct supply fan
rotation at initial startup will also indicate correct
compressor rotation. Reconnect power and check for
proper operation.
6. Compressor contactor closes its contacts L1, L2 and
L3 to T1, T2 and T3 to provide power to the
compressor motor COMP 1; COMP 2, if conditions
are correct. In addition, contactor C1 closes its contact
L3 to T3 , energizing the condenser fan motor.
Under normal summertime (full load) operating conditions,
superheat should be between 8°F and 12°F and sub-cooling
measured at the condenser outlet should be 15°F (nominal).
A 25°F to 35°F temperature difference should exist between
the entering condenser air and the temperature correspond-
ing to the compressor saturated discharge pressure. Check
that compressor RLA corresponds to values shown in Ap-
pendix C. RLA draw can be much lower than values listed at
low load conditions and low ambient condensing tempera-
tures. Values in Appendix C can slightly exceed at high load
conditions and high ambient condensing temperatures.
GAS SUPPLY PRESSURES & REGULATOR ADJUSTMENTS
WARNING
WARNING
BURN HAZARD!
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF,
TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE UNIT
BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
DO NOT TOUCH! DISCHARGE LINE MAY BE HOT!
7. Check that each compressor is operating correctly.
The scroll compressors in these units MUST operate
in the proper rotation. To ensure the compressors are
operating in the correct direction, check the
compressor discharge line pressure or temperature
after each compressor is started.
WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT
FIRE GAS UNIT WITH FLUE BOX COVER REMOVED.
The discharge pressure and discharge line
temperature should increase. If this does not occur
and the compressor is producing an exceptional
amount of noise, perform the following checks.
NOTE: Except during brief periods when gas pressures are
being measured by qualified service personnel, the furnace
access panel must always be secured in place when the
furnace is in operation.An inspection port in the access panel
is provided to monitor the flame.
•
Ensure all compressors and the supply fan motor
are operating in the proper direction. If a single
motor is operating backwards, check the power
wiring for that motor and correct any leads that
have been interchanged at the contactor or at the
motor.
The first step in checking out the gas-fired furnace is to test
the gas supply piping to the unit for tightness and purge the
system of air using methods outlined in the latest edition of
the National Fuel Gas Code ANSI Z223.1. Verify that the
disconnect switch is in the “OFF” position. A soapy water
solution should be used to check for gas leaks. Since the unit
is subject to considerable jarring during shipment, it is ex-
tremely important that all gas connections and joints be tested
for tightness. Gas piping downstream from the unit inlet should
be checked for leaks during the subsequent sequence check.
•
If all of the motors are operating backward,
disconnect the unit power supply and lock it in the
“OFF” position. Switch two leads of the power
supply at the unit Single Point Power Block.
Reconnect power and check for compressor and
supply fan motor operation.
8. With all safety devices closed, the system will continue
cooling operation until the thermostat is satisfied.
9. Disconnecting the jumper wire between R and Y1 and
Y2 and between R and G on TB1 terminal block will
simulate a satisfied thermostat. The compressors will
cycle off and IIC (pin 12) will initiate its time delay
cycle. The compressor and the supply fan will cycle
off.
10. After a time delay of approximately 3 minutes, the
compressor control circuits will be ready to respond
to a subsequent call for cooling from the wall
thermostat.
The supply gas pressure should be adjusted to 7.0" w.c. on
natural gas and 11.0" on LP gas with the gas burners operat-
ing. If there is more than one unit on a common gas line, the
pressures should be checked with all units under full fire. A
supply pressure tap is provided on the upstream side of the
gas valve. A manifold pressure tap is provided on the mani-
fold. The normal manifold pressure for full input is 3.5" w.c.
on natural gas and 10.0" w.c. for propane gas. Minimum gas
supply pressure is 5.5" w.c. for natural gas and 11.0" for pro-
pane gas. In order to obtain rating, gas supply pressure must
be 11.0" w.c. for propane gas.
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The pressure regulator on LP gas models is adjusted for 10.0"
w.c. manifold pressure and is intended to prevent over-firing
only. Do not attempt adjustment of the built-in pressure regu-
lator unless the supply pressure is at least 7.0" w.c. on natu-
ral gas or 14.0" w.c. on propane gas. Check the location of
the ignition electrode and the flame sensor for correct gap
setting.
NORMAL SEQUENCE OF OPERATION
HEATING
This unit has one (RS) Manual Reset Limit Control Switch.
Check the limit to make sure it has not tripped. The limit may
arrive at the job site tripped as a result of shipping shock.
If the ventor motor comes on, but the unit does not attempt
ignition, check if the ALS (Automatic Reset High Limit Con-
trol Switch) requires resetting.
1. With electricity and gas turned on, the system switch
in the “HEAT” or “AUTO” position and the fan switch
in the “AUTO” position, the thermostat will close the
circuit between unit terminals R and W (R-W) when
the temperature falls below the thermostat setting.
2. D1 on IIC energizes relay IDMR.
3. Relay IDMR energizes the ventor motor IDM.
4. Operation of the vent motor closes the pressure switch
PS located in the burner compartment. the control
then initiates a 15-second pre-purge time delay.
During this period, the ventor motor will clear the
combustion chamber of any residual gas.
5. After the pre-purge period, the ignition control
energizes the Wl-C gas valve and simultaneously
initiates a “three (3)-try” spark ignition sequence.
6. When the burners are ignited, a minimum four (4)
micro-amp DC current will flow through the flame
between the sensor electrode and the grounded
burner.
Flame
Sensor
Ignitor
GAS ORIFICES
NATURAL PROPANE (LP)
#30 #48
MAXIMUM NUMBER
INPUT
(BTUH) BURNERS
MAXIMUM
BTUH/BURNER
of
7. When the controller proves that the flame has been
established, it will keep the gas valve energized and
discontinue the ignition spark. First stage manifold
pressure will be approximately 2.0" w.c. for natural
gas and 7.0" w.c. for propane (LP).
400,000
8
50,000
HEAT EXCHANGER AND BURNER ORIFICE SPECIFICATIONS
8. If the control is unable to ignite the burners after its
initial attempt, it will initiate another purge and spark
sequence. A third purge and spark sequence will be
initiated if the second attempt is unsuccessful. If the
third attempt is unsuccessful, the controller will close
the gas valve and lock itself out. It may be reset by
momentarily interrupting power. This may be
accomplished by briefly lowering the room thermostat
set-point below room temperature, or by shutting off
the main power to the unit. (See TP-105 for more
details.)
NOTE: Gas appliances located more than 2000 feet above
sea level must be derated 4% per 1000 feet of total elevation
and that variance in gas heating value and specific gravity
require change in manifold pressure to obtain rating, it is
mandatory that the input be adjusted at the installation site.
All installations should be made as outlined in the latest edition
of the National Fuel Gas Code ANSI Z223.1, section
“Procedures To Be Followed To Place An Appliance in
Operation”. Refer also to the “User’s Information Manual”
supplied with the unit for additional information on the gas
furnace.
9. Integrated ignition control will close its normally open
contacts after a delay of approximately 30 seconds.
This action energizes contactor BC and starts the
supply fan motor. Operation of the supply fan
circulates air across the heat exchanger and delivers
heated air to the conditioned space.
Unit Shutdown
1. Set the thermostat to lowest setting.
2. Turn off the electrical power supply to the unit.
3. Remove the heat exchanger door on the side of the
unit by removing screws.
10. When the space temperature rises, the thermostat
will open R-W. Opening R-W will cause the gas valve
to close, and the furnace to shut down.
11. The furnace has three high temperature limit controls,
which can shut down the burner. They do not shut
down the ventor motor.
4. Move the gas control valve switch to the OFF position.
Do not force.
5. Close manual gas shutoff valve external to the unit.
6. Replace the heat exchanger door on the unit.
7. If cooling and/or air circulation will be desired, turn
ON the electrical power.
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The diagnostic fault code is 1 flash for a lockout due to failed
ignition attempts or flame dropouts. The integrated control
will automatically reset after one hour, or it can be reset by
removing the thermostat signal or disconnecting the electri-
cal power supply for over five seconds. If the diagnostic LED
indicates an external lockout, perform the following checks:
AUTOMATIC RESET HIGH LIMIT CONTROL (LS)
Located in the burner compartment on the heat exchanger,
its sensing element projects through the blower section bulk-
head and senses the temperature at the rear of the furnace.
It will cycle the furnace off if the temperature exceeds 100°F
plus maximum rise.
• Check the supply and manifold pressures
• Check the gas orifices for debris
AUTOMATIC RESET HIGH LIMIT CONTROL (ALS)
• Check gas valve for proper operation
• Check secondary limit
Located in the blower compartment on the blower housing, it
senses air temperature within the blower compartment and
protects the filters from excessive temperature. It will shut
down the furnace if it senses excessive temperatures.
A dirty filter, excessive duct static, insufficient air
flow, a faulty limit, or a failed circulator blower can
cause this limit to open. Check filters, total external
duct static, circulator blower motor, blower motor
speed tap (see wiring diagram), and limit. An
interruption in electrical power during a heating
cycle may also cause the auxiliary limit to open.
The automatic reset secondary limit is located on
top of the circulator blower assembly.
MANUAL RESET FLAME ROLLOUT CONTROL (RS)
Located in the burner compartment at the top of the burner
assembly, it senses high temperature that could occur if the
heat exchanger tubes were plugged and the flame was roll-
ing out instead of entering the tubes. It has a manual push-
button reset that cannot be actuated until the limit control has
cooled.
• Check rollout limit
If the burner flames are not properly drawn into
the heat exchanger, the flame rollout protection
device will open. Possible causes are restricted
or blocked flue passages, blocked or cracked heat
exchanger, a failed induced draft blower, or
insufficient combustion air. The rollout protection
device is a manual reset limit located on the burner
bracket. The cause of the flame rollout must be
determined and corrected before resetting the limit.
• Check flame sensor
TROUBLESHOOTING
IGNITION CONTROL ERROR CODES
The following presents probable causes of questionable unit
operation. Refer to Diagnostic Indicator Chart for an inter-
pretation of the signal and to this section for an explanation.
Remove the control box access panel and note the number
of diagnostic LED flashes. Refer to Diagnostic Indicator Chart
for an interpretation of the signal and to this section for an
explanation.
A drop in flame signal can be caused by nearly
invisible coating on the sensor. Remove the sensor
and carefully clean with steel wool.
ABNORMAL OPERATION - HEATING
• Check wiring
Check wiring for opens/shorts and miswiring.
Internal Control Failure
If the integrated ignition control in this unit encounters an in-
ternal fault, it will go into a “hard” lockout and turn off the
diagnostic LED. If diagnostic LED indicates an internal fault,
check power supply to unit for proper voltage, check all fuses,
circuit breakers and wiring. Disconnect electric power for
five seconds. If LED remains off after restoring power, re-
place control.
IMPORTANT: If you have to frequently reset your gas/electric
package unit, it means that a problem exists that should be
corrected. Contact a qualified servicer for further information.
Pressure Switch Stuck Open
A pressure switch stuck open can be caused by a faulty pres-
sure switch, faulty wiring, a disconnected or damaged hose,
a blocked or restricted flue, or a faulty induced draft blower.
External Lockout
If the control senses an open pressure switch during the pre-
purge cycle, the induced draft blower only will be energized.
If the pressure switch opens after ignition has begun the gas
valve is deenergized, the circulator blower heat off cycle be-
gins, and the induced draft blower remains on. The diagnos-
tic fault code is two flashes.
An external lockout occurs if the integrated ignition control
determines that a measurable combustion cannot be estab-
lished within three (3) consecutive ignition attempts. If flame
is not established within the seven (7) second trial for igni-
tion, the gas valve is deenergized, 15 second inter-purge cycle
is completed, and ignition is reattempted. The control will
repeat this routine three times if a measurable combustion is
not established. The control will then shut off the induced
draft blower and go into a lockout state.
Pressure Switch Stuck Closed
A stuck closed pressure switch can be caused by a faulty
pressure switch or faulty wiring. If the control encounters a
pressure switch stuck closed, the induced draft blower re-
mains off. The diagnostic LED code for this fault is three (3)
flashes.
If flame is established but lost, the control will energize the
circulator blower at the heat speed and then begin a new
ignition sequence. If flame is established then lost on subse-
quent attempts, the control will recycle for four (4) consecu-
tive ignition attempts (five attempts total) before locking out.
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Open Thermal Protection Device
the range specified on the unit data plate. NOTE: Thermal
efficiency of the furnace is a product efficiency rating deter-
mined under continuous operating conditions independent
of any installed system.
If the primary limit switch opens, the gas valve is immediately
deenergized, the induced draft and air circulating blowers
are energized. The induced draft and air circulator blowers
remain energized until the limit switch recloses. The diag-
nostic fault code for an open limit is four (4) flashes.
Regulator Cover Screws
(Reg. Adj. Beneath these screws)
High Fire
Adjust
A primary limit will open due to excessive supply air tempera-
tures. This can be caused by a dirty filter, excessive duct
static, insufficient air flow, or a faulty limit. Check filters, total
external duct static, blower motor, blower motor speed tap
(see wiring diagram), and limit. This limit will automatically
reset once the temperature falls below a preset level.
Low Fire
Adjust
INLET
OUTLET
Gas Valve
On/Off Switch
Flame Detected with Gas Valve Closed
WHITE-RODGERS 36H54 PRESSURE ADJUSTMENTS
If flame is detected with the gas valve deenergized, the com-
bustion and air circulator blowers are energized. The diag-
nostic fault code is five (5) flashes for this condition. The
control can be reset by removing the power supply to the unit
or it will automatically reset after one hour. Miswiring is the
probable cause for this fault.
ABNORMAL OPERATION - COOLING
Short Cycle Compressor Delay
The automatic ignition control has a built-in feature that pre-
vents damage to the compressor in short cycling situations.
In the event of intermittent power losses or intermittent ther-
mostat operation, the ignition control will delay output to the
compressor contactor for three minutes from the time power
is restored. (Compressor is off a total of three minutes). The
diagnostic LED will flash six (6) times to indicate the com-
pressor contactor output is being delayed.
HONEYWELL 0151M00015 PRESSURE ADJUSTMENTS
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING
PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING
THE GAS VALVE PRESSURE REGULATOR.
NOTE: Some electronic thermostats also have a built-in
compressor short cycle timer that may be longer than the
three minute delay given above. If you are using an electronic
thermostat and the compressor has not started after three
minutes, wait an additional five minutes to allow the thermostat
to complete its short cycle delay time.
AIR FLOW ADJUSTMENTS
The drive on the supply fan is typically set in the middle of the
RPM range. The drive motor sheave pitch diameter is field
adjustable for the required airflow. Refer to “Drive
Adjustments” section below.
INPUT RATING
It is the responsibility of the contractor to adjust the gas input
to the unit. The input rate can be calculated by using the
formula:
When the final adjustments are complete, the current draw
of the motor should be checked and compared to the full
load current rating of the motor. The amperage must not ex-
ceed the service factor stamped on the motor nameplate.
The total airflow must not be less than that required for op-
eration of the electric heaters or the furnace.
3600 x HV
INPUT Btu/Hr =
T
WHERE:
HV = Heating value of fuel = Btu/ft3 of gas
T = Time in seconds per ft3 of gas flow as read from gas meter
If an economizer is installed, check the unit operating bal-
ance with the economizer at full outside air and at minimum
outside air. Upon completion of the air flow balancing, we
recommend replacing the variable pitched motor sheave with
a properly-sized fixed sheave. A matching fixed sheave will
provide longer belt and bearing life and vibration free opera-
tion. Initially, it is best to have a variable pitched motor sheave
Adjust input rate by varying the adjustment of the gas pres-
sure regulator on the gas valve.All adjustments must be made
with furnace operating at high fire and at normal operating
temperature. Clockwise (P) rotation of the pressure regula-
tor screw increases pressure and gas flow rate. Turn screw
counterclockwise (Q) to decrease pressure and gas flow rate.
After adjustment the furnace temperature rise must be within
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for the purpose of airflow balancing, but once the balance
has been achieved, fixed sheaves maintain alignment and
minimize vibration more effectively. For direct drive units, move
green wire for fan.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR
INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR
THE GAS SUPPLIER.
MOTOR SHEAVE ADJUSTMENTS
VL, VM & 2VP VARIABLE PITCH KEY TYPE MOTOR SHEAVES
CAUTION
The driving and driven motor sheaves should be in align-
ment with each other and the shafts parallel.
SHEET METAL PARTS, SCREWS, CLIPS AND SIMILAR ITEMS INHERENTLY
HAVE SHARP EDGES, AND IT IS NECESSARY THAT THE INSTALLER AND
SERVICE PERSONNEL EXERCISE CAUTION.
VL & VM SHEAVES ADJUSTMENT
1. Loosen set screw “B” using a 5/32" Allen key.
2. Making half or full turns from closed position, adjust
sheave pitch diameter for desired speed. DO NOT
OPEN MORE THAN SIX FULL TURNS.
3. Tighten set screw “B” securely over flat.
4. Carefully put on belts and adjust belt tension. DO NOT
FORCE BELTS OVER GROOVES.
5. Ensure all keys are in place and the set screws tight
before starting drive. Recheck set screws and belt
tension after 24 hours service.
Preventive maintenance is the best way to avoid unneces-
sary expense and inconvenience. Have this system inspected
at regular intervals by qualified service personnel, at least
twice a year. Routine maintenance should cover the follow-
ing items:
1. Tighten all belts, set screws, and wire connections.
2. Clean evaporator and condenser coils mechanically
or with cold water, if necessary. Usually any fouling is
only matted on the entering air face of the coil and
can be removed by brushing.
3. Lubricate motor bearings.
4. Align or replace belts as needed.
5. Replace filters as needed (see below).
6. Check for blockage of condensate drain.
7. Check power and control voltages.
NOTE: Future adjustments should be made by loosening the
belt tension and increasing or decreasing the pitch diameter
of the sheave by half or full turns as required. Readjust belt
tension before starting drive.
8. Check running amperage.
9. Check operating temperatures and pressures.
10. Check and adjust temperature and pressure controls.
11. Check and adjust damper linkages.
C
12. Check operation of all safety controls.
13. Examine gas furnaces (see below and the User’s
Information Manual).
B
14. Check condenser fans and tighten set screws.
VL & VM
FILTERS
NOTE: For horizontal discharge, remove the supply and return
duct covers and place them over the vertical discharge return
and supply openings (bottom of unit).
CAUTION
TO PREVENT PROPERTY DAMAGE DUE TO FIRE AND LOSS OF EQUIPMENT
EFFICIENCY OR EQUIPMENT DAMAGE DUE TO DUST AND LINT BUILD UP
ON INTERNAL PARTS, NEVER OPERATE UNIT WITHOUT AN AIR FILTER
INSTALLED IN THE RETURN AIR SYSTEM.
NOTE: Do not operate sheave with flange projecting beyond
the hub end.
MAINTENANCE
Every application may require a different frequency of replace-
ment of dirty filters. Filters must be replaced at least every
three (3) months during operating seasons.
WARNING
HIGH VOLTAGE !
Dirty filters are the most common cause of inadequate heat-
ing or cooling performance. Filter inspection should be made
at least every two months; more often if necessary because
of local conditions and usage.
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
Dirty throwaway filters should be discarded and replaced with
a new, clean filter.
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Disposable return air filters are supplied with this unit. See
the unit Specification Sheet or Technical Manual for the cor-
rect size and part number. To remove the filters, remove the
filter access panel on return side of the unit.
d. The entire burner assembly can now be removed
from the unit.
NOTE: Use all screws that were removed; they are
necessary for safe and proper operation of the unit.
3. Inspect and periodically clean the vent outlet (bird
screen) on the access panel.
CABINET FINISH MAINTENANCE
Use a fine grade automotive wax on the cabinet finish to
maintain the finish’s original high luster. This is especially
important in installations with extended periods of direct sun-
light.
NOTE: Periodic observation of the flame and a log of C02
measurements are recommended. This will aid in determining
whether the furnace is operating efficiently or if the furnace
requires cleaning.
CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)
Flames should be stable, soft and blue (dust may cause or-
ange tips but must not be yellow). The flames must extend
directly outward from the burner without curling, floating or
lifting off.
The coil with the outside air flowing over it should be inspected
annually and cleaned as frequently as necessary to keep the
finned areas free of lint, hair and debris.
CONDENSER, EVAPORATOR, AND INDUCED DRAFT MOTORS
Bearings on the air circulating blower motor, condenser mo-
tor and the combustion fan motor are permanently lubricated.
No additional oiling is required.
FLAME SENSOR (QUALIFIED SERVICER ONLY)
A drop in the flame current can be caused by a nearly invis-
ible coating on the flame sensor. This coating, created by the
fuel or combustion air supply, can be removed by carefully
cleaning the flame sensor with steel wool.
BURNER FLAME
NOTE: After cleaning, the microamp signal should be stable
and in the range of 4 - 6 microamps DC.
WARNING
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DO
NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY
ADJUSTMENT. CONTACT A QUALIFIED SERVICER AT ONCE IF AN
ABNORMAL FLAME SHOULD DEVELOP.
FLUE PASSAGES (QUALIFIED SERVICER ONLY)
At the start of each heating season, inspect and, if neces-
sary, clean the unit flue passage.
At least once a year, prior to or during the heating season,
make a visual check of the burner flames.
LUBRICATION
The fan shaft bearings, the 1 to 2 HP supply fan motors the
condenser fan motors and compressors are permanently lu-
bricated.
NOTE: This will involve removing and reinstalling the heat
exchanger door on the unit, which is held by two screws. If
you are uncertain about your ability to do this, contact a
qualified servicer.
INSPECTION & CLEANING
All flue product carrying areas of the furnace, its vent sys-
tem, and main burners should be examined by a qualified
service agency before the start of each heating season. This
examination is necessary for continued safe operation. Par-
ticular attention should be given to deterioration from corro-
sion or other sources. This examination is accomplished in
the following manner.
If a strong wind is blowing, it may alter the airflow pattern
within the unit enough that an inspection of the burner flames
is not possible.
FUNCTIONAL PARTS
Refer to the unit Parts Catalog for a list of functional parts.
Parts are available from your distributor.
1. Disconnect power to the unit and remove furnace
section access panel.
2. Remove burner assembly:
a. Disconnect the three wires from the gas valve after
noting which wires are connected to each terminal.
b. Disconnect wires from the flame rod and ignition
electrode.
c. Disconnect the gas piping at the union.
23
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APPENDIX A BLOWER PERFORMANCE DATA
BELT DRIVE - STANDARD HORIZONTAL
CPG180 STANDARD BELT DRIVE
TURNS OPEN
3
ESP, In H2O
0
1
2
4
5
6
CFM
---
BHP
---
CFM
---
BHP
---
CFM
---
BHP
---
CFM
---
BHP
0.00
2.76
CFM
6827
6161
BHP
2.67
2.34
CFM
6394
5706
BHP
2.28
1.98
CFM
5982
5271
BHP
1.94
1.66
0.2
0.4
---
---
---
---
7079
3.20
6623
0.6
0.8
1.0
1.2
---
---
6903
6198
3.32
2.92
6405
5668
2.83
2.45
5923
5152
2.41
2.05
5434
---
2.02
---
4949
---
1.68
---
---
---
---
---
6717
3.42
5975
5147
2.99
2.55
5418
---
2.51
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
CPG240 STANDARD BELT DRIVE
TURNS OPEN
3
ESP, In H2O
0
1
2
4
5
6
CFM
---
BHP
---
CFM
---
BHP
---
CFM
9359
8632
BHP
4.92
4.39
CFM
8991
8251
BHP
3.79
3.39
CFM
8621
7867
BHP
3.54
3.15
CFM
8188
7363
BHP
3.27
2.85
CFM
7826
6992
BHP
3.04
2.63
0.2
0.4
---
---
9018
3.18
0.6
0.8
1.0
1.2
---
---
8279
7513
2.96
2.73
7879
7097
3.86
3.35
7484
---
2.99
---
7085
---
2.75
---
---
---
---
---
---
---
---
---
7957
4.82
7179
6368
4.23
3.66
6716
---
2.49
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
NOTES:
High static airflow requires installation of high static kit (HSKT240), or factory-built High Static model.
Unit factory shipped with sheave set at 2.5 turns open.
Air flow tables represent dry coil with filters installed; SCFM correction factor for wet coil is 4%.
24
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APPENDIX A BLOWER PERFORMANCE DATA
BELT DRIVE - HIGH STATIC
CPG180 HIGH STATIC BELT DRIVE
TURNS OPEN
3
ESP, In H2O
0
1
2
4
5
6
CFM
---
BHP
---
CFM
---
BHP
---
CFM
---
BHP
---
CFM
---
BHP
---
CFM
6690
5922
5056
BHP
3.69
3.22
2.74
CFM
6008
5182
---
BHP
3.02
2.58
---
CFM
5321
---
BHP
2.43
---
1.0
1.2
1.4
1.6
1.8
2.0
---
---
---
---
---
---
6653
5857
3.95
3.44
---
---
---
---
6634
2.80
---
---
---
---
6638
5784
4788
4.55
3.95
3.32
5808
4855
---
2.43
2.05
---
4948
---
2.91
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
6683
5803
4.93
4.27
---
---
CPG240 HIGH STATIC BELT DRIVE
TURNS OPEN
3
ESP, In H2O
0
1
2
4
5
6
CFM
---
BHP
---
CFM
---
BHP
---
CFM
BHP
CFM
9001
BHP
6.83
CFM
8394
BHP
6.01
CFM
BHP
4.78
CFM
7227
BHP
4.28
1.0
1.2
1.4
1.6
1.8
2.0
7797
---
---
8891
8148
6.83
6.15
8262
7495
6.15
5.48
7632
6841
5.35
4.71
7012
---
4.20
---
---
---
---
---
---
---
---
---
8811
6.86
---
---
8065
7290
---
6.19
5.52
---
7377
5.48
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
7998
6.89
---
---
---
---
7221
6.10
NOTES:
High static airflow requires installation of high static kit (HSKT240), or factory-built High Static model.
Unit factory shipped with sheave set at 2.5 turns open.
Air flow tables represent dry coil with filters installed; SCFM correction factor for wet coil is 4%.
25
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APPENDIX B ELECTRICAL DATA
ELECTRICAL DATA
VOLTAGE
LIMITATIONS
LARGER
COMPRESSOR
SMALLER
COMPRESSOR
OD FAN MOTORS (ea)
ID FAN MOTOR
VOLTAGE
(NAMEPLATE)
ID MOTOR
APPL
MODELS
15 TON
MIN
187
414
518
MAX
253
506
633
Qty
RLA LRA
Qty
RLA LRA
25.0 164.0
12.2 100.0
Qty
3
HP
1/3
1/3
1/3
RLA
2.40
1.20
0.90
HP
5.0
5.0
5.0
FLA
12.7
6.4
208/230-60-3
460-60-3
1
1
1
29.5 195.0
1
1
1
BD STD STATIC
BD STD STATIC
BD STD STATIC
14.7
12.2
95.0
80.0
3
575-60-3
9.0
78.0
3
5.1
ELECTRICAL DATA
VOLTAGE
LIMITATIONS
COMPRESSOR
(ea)
OD FAN MOTORS
(ea)
ID FAN
MOTOR
VOLTAGE
(NAMEPLATE)
ID MOTOR
APPL
MODELS
MIN
187
414
518
MAX
253
506
633
Qty RLA LRA Qty
HP
1/3
1/3
1/3
RLA
HP
5.0
5.0
5.0
FLA
208/230-60-3
460-60-3
2
2
2
33.3 239.0
17.9 125.0
12.8 80.0
3
3
3
2.40 BD STD STATIC
1.20 BD STD STATIC
0.90 BD STD STATIC
12.7
6.4
20 TON
575-60-3
5.1
NOTES: See unit nameplate for proper overcurrent protection.
26
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APPENDIX C UNIT DIMENSIONS
Model
A
B
C
D
15 Ton
20 Ton
133-1/2"
88-7/32" 50-9/32" 5-5/32"
B
A
C
D
21”
60”
7”
48”
22”
VERTICAL DISCHARGE (TOP VIEW)
27
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CPG1803503B* & CPG2404003B* THREE PHASE 208-230/60 HZ BELT DRIVE WIRING DIAGRAM
BK
OR
OR
BK
PB
RD
RD
BK
RD
BK
RD
RD
BK
OR
RD
OR
OR
WH
OR
OR
BK
L1
T1
L2
T2
L3
T3
L1
T1
L2
T2
L3
T3
POWER SUPPLY
208V / 240V - 3 ph - 60 Hz
SEE NOTE 4
L1
T1
L2
T2
L3
T3
OR
BK
CC
2
CC
1
BC
BL
BL
GR
GRND
RD
RD
BL
OR
BK
RD
BL
C
PU
BK
FC1
BL
BK
OR
YL
RD
YL
BK
RD
RD
F
YL
BK
BR
BL
YL
EM
BL
BL
C
FC2
F
PU
BR
BK
RD
CCH2
T1
BK
RD
YL
COMP
2
T2
T3
RD
BL
PU
C
FC3
F
BK
OR
WH
BK
CCH1
T1
BK
RD
YL
BR
COMP
1
T2
T3
RD
BK
PU BR
PU
RD
BR
YL
BK
4
GR
BL
BL
2
4
6
BL
BK
3
2
1
BK
2
1
4
6
230
208
C
YL
BK
TB2
3
1
BK
PU
OR
1
BL
BL
OR
YL
VMR
CCHR2
BK
BK
24V
CCHR1
VM
6
BK
PU BR
BL
GR
PU
WH
YL
CM3
PK
GR
OR
WH
GR
WH
RD
YL
BL
YL
PU
BK
S1
S2
LPS2
HPS2
3
2
1
9
8
6
5
4
BL
BR
PU
WH
CM2
CM1
PS
WH
TB1
BR
YL
PU
BL
7
BL
YL
GR
BK
LPS1
WH
HPS1
YL
YL
YL
BL
YL
BR
PU
BL
BR
ALS
PU
PU
PU
PU
GR
YL
WH
YL
YL
RD
RD
YL
BL
PU
PU
BL
WH
LS
PU
YL
RS
BL
BL
GR
GR
BR
BL
BL
BR
BL
BL
YL
GR
RD
BR
YL
1
BL
IIC
L2
3
2
5
8
YL
RD
ECON
PU
4
6
9
GR
L1
UNUSED
BL
BR
YL
DI
7
RD
SEE NOTE 5
PU
GV
12
YL
11 10
BL
BR
BL
HEAT
YL
BL
COOL
WH
YL
PU
YL
RD
GR
WH
FS
WH
Y1
R
G
W1
C
Y2
W2
TB1
GR
WH
GR
RD
RD
FS
OR
IGN
TO THERMOSTAT
++
0140L00954 REV A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
28
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CPG1803503B* & CPG2404003B* THREE PHASE 208-230/60 HZ BELT DRIVE WIRING DIAGRAM
SUPPLY VOLTAGE
208-240/3/60
COMPONENT LEGEND
L
1
L3
L2
ALS
BC
COMP
CM
AUXILIARY LIMIT SWITCH
BLOWER CONTACTOR
COMPRESSOR
CONDENSER MOTOR
COMPRESSOR CONTACTOR
CRANK CASE HEATER
CRANK CASE HEATER RELAY
EVAPORATOR MOTOR
FUSE
T
2
C
C1
T2
CC
1
T1
T1
COMP1
T
3
CC
1
T
3
CC
C
F
CCH
CCHR
EM
RCCF
1
C
M1
F
FC
FS
FAN CAPACITOR
FLAME SENSOR
C
F
R
CCF3
C
F
GND
GV
HPS
IBR
IIC
IGN
LPS
LS
EQUIPMENT GROUND
GAS VALVE
HIGH PRESSURE SWITCH
INDOOR BLOWER RELAY
INTEGRATED IGNITION CONTROL
IGNITOR
LOW PRESSURE SWITCH
LIMIT SWITCH
POWER DISTRUBTION BLOCK
C
M3
R
C
CF2
CM2
CC2
T
2
2
CC2
T1
T
2
COMP
T1
CC2
T3
T3
B
C
T
2
PB
PLF
PS
RS
TB1
TB2
TR
VM
VMR
FEMALE PLUG/CONNECTOR
PRESSURE SWITCH
ROLLOUT SWITCH
TERMINAL BLOCK (24V SIGNAL)
TERMINAL BLOCK (L1)
TRANSFORMER
T
1
BC
EM
T3
BC
1
3
VM
CCH1
CCH2
2
2
1
VENT MOTOR
VENT MOTOR RELAY
1
208-240v
3
1
2
NOTES
TB1
S1
S2
TR
1. REPLACEMENT WIRE MUST BE THE SAME
SIZE AND TYPE OF INSULATIONAS ORIGINAL.
(USE COPPER CONDUCTOR ONLY).
2. ACCESSORY ECONOMIZER PLUG ADJACENT
TO BLOWER HOUSING IN RETURN AIR
COMPARTMENT. REMOVE MALE PLUG AND
ATTACH FEMALE PLUG TO THE ECONOMIZER
ACCESSORY.
NOTE 3
IIC
NOTE 3
1
24V
L1
L2
IGN
FS
FS
D1
F
BC
H
C
6
4
4
5
3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.
4. USE COPPER CONDUCTORS ONLY.
USE NEC CLASS 2 WIRE.
VMR
LS
5. FOR TWO STAGE OPERATION REMOVE
W1 TO W2 WIRE JUMPER.
ALS
RS
3
6
8
GV
6. FOR 208V OPERATION MOVE BLACK WIRE
FROM TERMINAL 3 TO TERMINAL 2 ON THE
TRANSFORMER.
IIC
CC2
PS
LPS2
HPS2
ECON
9
2
7
10
12
11
LPS1
4
HPS1
CC1
4
6
6
THERMOSTAT
FIELD WIRING
CCHR1
CCHR2
2 STAGE COOLING
NOTE 5
Y1
9
8
7
6
5
4
3
2
1
PLF
2
FACTORY WIRING
WH
GR
RD
YL
W
G
W
G
Y
Y2
R
G
C
W1 W2
LINE VOLTAGE
LOW VOLTAGE
OPTIONAL
R
R
Y1
Y1
Y2
TB1
TO THERMOSTAT
PK
Y/Y2
C
HIGH VOLTAGE
BL
C
OR
O
O
INSTALLER/SERVICEMAN
FIELD WIRING
STAT
TB1
HIGH VOLTAGE
LOW VOLTAGE
THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUIDE TO
TROUBLESHOOTING THIS APPLIANCE. STATUS LIGHT CODES ARE AS FOLLOWS:
NO ECONOMIZER
W
G
R
WH
GR
RD
W
G
R
STATUS LIGHT
ON
EQUIPMENT STATUS
NORMAL OPERATION
CHECK
------
WIRE CODE
BLACK
BLUE
Y1
CHECK INPUT POWER
CHECK FUSE ON CONTROL
REPLACE CONTROL
NO POWER OR
INTERNAL CONTROL
BK
BL
YL
BL
OFF
Y/Y2
C
Y2
C
BR
GR
OR
PK
PU
RD
BROWN
GREEN
ORANGE
PINK
PURPLE
RED
GAS FLOW
GAS PRESSURE
GAS VALVE
FLAME SENSOR
FLAME ROLLOUT
BAD SWITCH
AUX. LIMIT OPEN
CHECK
PRESSURE SWITCH
IGNITION FAILURE
OR
O
O
STAT
TB1
OPEN ROLLOUT
SWITCH
1 BLINK
OPEN AUX. LIMIT
SWITCH
WITH ECONOMIZER OPTION
W
G
WH
GR
RD
YL
W
G
R
Y
WH
YL
WHITE
YELLOW
PRESSURE SWITCH
OPEN
PRESSURE SWITCH CLOSED
WITHOUT INDUCER ON
2 BLINKS
3 BLINKS
R
CHECK
YL/PK YELLOW WITH
PINK STRIPE
BL/PK BLUE WITH
PINK STRIPE
Y1
PRESSURE SWITCH
MAIN LIMIT OPEN
BAD SWITCH
Y/Y2
C
4 BLINKS
5 BLINKS
OPEN LIMIT SWITCH
BL
C
FALSE FLAME SENSED
STICKING GAS VALVE
O
OR
O
STAT
COMPRESSOR
OUTPUT DELAY
3 MIN. COMP.
ANTI-CYCLE TIMER
TB1
6 BLINKS
SEE UNI
OF OVER CU
T
RATI
R
N
G PL
T
A
TE
R TYPE AND SIZE
O
F
0140L00955 REV A
REN PROTECTION
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
29
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CPG1803504B*/7B & CPG2404004B*/7B* THREE PHASE 460-575/60 HZ BELT DRIVE WIRING DIAGRAM
P
OWER SUPPL
Y
460V
/ 575 - 3 ph - 6
0
Hz
BL
SEE NO
TE 4
O
R
BL
RD
OR
O
R
R
D
K
RD
BK
RD
WH
B
BK
BK
B
L
BL
BL
BK
L1
L2
L
3
L
1
L2
T2
LL3
L
1
L
2
L3
GRN
D
C
2
C
C
1
C
B
L
BC
T1
T2
T3
T3
T1
T2
T3
B
L
GR
RD
RD
OR
BK
RD
C
PU
B
L
BK
FC1
BK
YL
RD
YL
RD
BK
RD
YL
BK
BR
F
YL
EM
PU
BR
C
FC2
F
RD BK
BL
CCH2
T
1
BK
C
OMP
2
T2
T3
R
D
R
D
YL
PU
C
BK
W
H
BK
F
C3
CCH1
T
1
B
K
BR
F
C
OMP
1
T2
RD
BK
T3
Y
L
BK
R
D
B
K
R
D
P
U BR
PU
BR
YL
O
R
4
6
2
1
GR
BL
BL
1
2
3
BK
YL
46
0
C
T
B2
3
BK
BK
BK
4
VMR
46
R APP
IN T VOLTAG
0
OR APPROPR
I
I
ATE
B
R
L
NPUT VOLTAGE
O
ROPRIAT
E
C
CHR2
BK
B
L
BK
PU
E
BK
BK
BK
2
4V
2
40
6
PU BR
1
PU
BL
G
VM
WH
Y
L
CM3
CM2
PK
G
R
R
D
RD
WH
WH
RD
YL
SEE
TE 2
G
R
N
O
YL
BL
P
U
S1
LPS
2
HPS2
3
2
1
9
6
5
4
BL
B
R
S
2
WH
YL
PU
PS
WH
TB
1
8
7
BL
YL
PU
BL
BR
B
L
YL
GR
B
K
LPS1
WH
H
PS1
Y
L
YL
BL
Y
L
B
L
BR
PU
CM
1
BL
B
R
BK
2
ALS
P
U
PU
PU
PU
G
R
4
WH YL
YL
R
D
YL
W
BL
PU
PU
6
O
R
1
RD
BL
H
L
S
PU
YL
RS
CCHR1
BL
BL
GR
GR
BL
BL
BL
YL
BR
BR
BL
YL
G
R
RD
BR
YL
BL
1
IIC
L
2
3
6
9
2
5
8
RD
YL
PU
ECO
N
4
7
G
R
L
1
UNUSED
BL
BR
DI
YL
R
D
SEE NOT
E
5
Y
L
GV
12 11
10
BL
C
BR
BL
HEAT
YL
B
L
COO
L
Y
L
W
H
PU
Y
L
R
D
GR
WH
PU
FS
WH
Y1
R
G
W1
Y
2
W2
TB1
G
R
W
H
R
O
D
R
GR
RD
FS
I
GN
TO
THERMOSTAT
++
01
4
0
L00956 REV
A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
30
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CPG1803504B*/7B & CPG2404004B*/7B* THREE PHASE 460-575/60 HZ BELT DRIVE WIRING DIAGRAM
SUPPLY VOLTAGE
460-575/3/60
L
1
L2
L3
COMPONENT LEGEND
T
2
C
C1
ALS
BC
AUXILIARY LIMIT SWITCH
T2
CC1
T1
BLOWER CONTACTOR
CRANK CASE HEATER
CRANK CASE HEATER RELAY
COMPRESSOR
CONDENSER MOTOR
COMPRESSOR CONTACTOR
EVAPORATOR MOTOR
FUSE
FAN CAPACITOR
FLAME SENSOR
EQUIPMENT GROUND
GAS VALVE
T1
COMP1
T
3
CC
1
CCH
CCHR
COMP
CM
CC
EM
F
FC
FS
T3
C
F
RCCF
1
C
M
1
C
F
R
CCF3
C
F
CM3
GND
GV
RCCF
2
C
M2
HPS
IBR
IIC
IGN
LPS
LS
PLF
PS
RS
HIGH PRESSURE SWITCH
INDOOR BLOWER RELAY
INTEGRATED IGNITION CONTROL
IGNITOR
LOW PRESSURE SWITCH
LIMIT SWITCH
FEMALE PLUG/CONNECTOR
PRESSURE SWITCH
ROLLOUT SWITCH
TERMINAL BLOCK (24V SIGNAL)
TERMINAL BLOCK (L1)
CC2
T2
CC2
T
1
T
2
T1 COMP2
C
C2
T
3
T3
BC
T
2
T1
BC
EM
T
3
B
C
1
3
VM
TB1
TB2
460V OR 575V
TR
VM
VMR
TRANSFORMER
VENT MOTOR
VENT MOTOR RELAY
1
3
CCH1
CCH2
460V OR 575V
TR
2
2
1
1
1
3
NOTES
TBB1
S1
S2
TR
1. REPLACEMENT WIRE MUST BE THE SAME
SIZE AND TYPE OF INSULATION AS ORIGINAL.
(USE COPPER CONDUCTOR ONLY).
2. ACCESSORY ECONOMIZER PLUG ADJACENT
TO BLOWER HOUSING IN RETURN AIR
COMPARTMENT. REMOVE MALE PLUG AND
ATTACH FEMALE PLUG TO THE ECONOMIZER
ACCESSORY.
NOTE 3
IIC
NOTE 3
1
L1
L2
24V
IGN
FS
FS
D1
F
BC
H
C
6
4
4
5
3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.
4. USE COPPER CONDUCTORS ONLY.
USE NEC CLASS 2 WIRE.
VMR
LS
5. FOR TWO STAGE OPERATION REMOVE
W1 TO W2 WIRE JUMPER.
ALS
RS
3
6
8
GV
IIC
CC2
PS
LPS2
HPS2
ECON
9
2
7
10
12
11
LPS1
HPS1
6
CC1
4
4
6
THERMOSTAT
FIELD WIRING
CCHR1
CCHR2
NOTE 5
Y1
2 STAGE COOLING
9
8
7
6
5
4
3
2
1
PLF
NOTE
2
FACTORY WIRING
W
G
R
WH
GR
RD
YL
W
G
Y
Y2
R
G
C
W1 W2
LINE VOLTAGE
LOW VOLTAGE
OPTIONAL
R
TB1
TO THERMOSTAT
Y1
Y/Y2
C
Y1
Y2
PK
BL
HIGH VOLTAGE
C
OR
O
O
FIELD WIRING
STAT
INSTALLER/SERVICEMAN
TB1
HIGH VOLTAGE
LOW VOLTAGE
THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUIDE TO
TROUBLESHOOTING THIS APPLIANCE. STATUS LIGHT CODES ARE AS FOLLOWS:
NO ECONOMIZER
W
G
R
WH
GR
RD
W
G
R
CHECK
----
NPUT PO
N CO
E C
FLOW
K
STATUS LIGHT
ON
EQUIPMENT STATUS
NORMAL OPERATION
-
---
O
N
WIRE CODE
BLACK
BLUE
BROWN
GREEN
ORANGE
PINK
Y1
C
H
C
K
U
P
I
U
OWWEERR
ONTRROOL
NO POWER OR
INTERNAL CONTROL
BK
BL
YL
BL
Y/Y2
C
Y2
CHE
S
E
O
N
OFFF
ACE
OONTROL
C
O
BR
GR
OR
PK
PU
RD
F
R
O
OR
IGNI
OP
TTIO
S
S
REE
STAT
TB1
O
E
N
R
L
A
M
M
E
S
SSO
OOU
S
TTC
1
RO
L
PURPLE
RED
WITH ECONOMIZER OPTION
OOP
BAD SWITCH
S
W
H
AUX. LIMIT OPEN
W
G
WH
GR
RD
YL
W
G
R
Y
WH
YL
WHITE
YELLOW
CHECK
CH CK
P
R
E
SS
U
OOP
S
TT
ITCH
R
SS RE SW TCH
PEN
E S ITC
IN UC
2
3
4
B
L
LI
NNKKSS
P
R
S
U
R
RE WITC
CHECK
SS RE WI
N LIMIT OPEN
D SWITCH
VALVE
3 MIN. COMP..
YC E TIMER
S
S
W
CHH
R
YL/PK YELLOW WITH
PINK STRIPE
BL/PK BLUE WITH
PINK STRIPE
PR
E
S
T
R
UU
W
W
C
H
H
C
C
L
L
OSED
B
LLI
NNKKSS
Y1
WIT
O
N
D
D
C
E
E
R O
ONN
PR
U
I
S
G
R
SS
W
TTCHH
Y/Y2
C
MA
I
B
LLI
N
NKSS
K
OPEN LIMIT SWITCH
FALSE FLAME SENSED
BL
A
II
D
N
IT
C
O
OR
5 B
6 B
L
LI
N
NK
S
S
ST
I
G
A
S
V
O
STAT
C
P
TB1
LL
IN
NK
KS
OUTPUT DELAY
AN
I
-
-
C
Y
LLE
SEE UNIT RATING PLATE FOR TYPE AND SIZE
OF OVER CURRENT PROTECTION
0140L00957 REV A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
31
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© 2010 Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500 ◊ Houston, TX 77056
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