INSTALLATION INSTRUCTIONS FOR
COMMERCIAL HEATING & COOLING
7.5 TON - 12.5 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.
*NOTE: Please contact your distributor or our website
for the applicable Specification Sheet referred to in this manual.
All information contained herein is subject to change without notice.
© 2008 - 2010 Goodman Manufacturing Company, L.P.
IO-337J
6/10
5151 San Felipe, Suite 500 ◊ Houston, TX 77056
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
THIS COMPARMENT MUST BE CLOSED EXCEPT
WHEN SERVICING
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.
AVERTISSEMENT
RISQUE D'EMPOISONNEMENT AU
MONOXYDE DE CARBONE
SI CE COMPARTMENT N'EST PAS FERME EN
TOUT TEMPS, SAUF EN CAS DE REPARATION, IL Y
A RISQUE D'EMPOISONNEMENT OU MONOXYDE
DE CARBONE OU DE MORT.
WARNING
CE COMPARTIMENT DOIT ETRE 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.
ADVERTENCIA
PELIGRO MONOXIDO DE CARBONO
TOXICO
EL FRACASO DE NO MANTENER
COMPARTIMIENTO CERRADO MENOS DURANTE,
ATENDER, PODRIA TENER COMO RESULTADO
ENVENENAR DE MONOXIDO DE CARBONO O
MUERTE.
WARNING
HIGH VOLTAGE !
ESTE COMPARTIMIENTO DEBE CERRADO MENOS
-
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.
0140L00106
AL ATENDER
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
ONLY INDIVIDUALS MEETING (AT A MINIMUM) THE REQUIREMENTS
OF AN “ENTRY LEVEL TECHNICIAN” AS SPECIFIED BY THE AIR
CONDITIONING, HEATING, AND REFRIGERATION INSTITUTE (AHRI)
MAY USE THIS INFORMATION. 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
Download from Www.Somanuals.com. All Manuals Search And Download.
System design and installation should also, where applicable, IMPORTANT NOTE: Remove wood shipping rails and metal
follow information presented in accepted industry guides such shipping brace (if applicable) prior to installation of the unit
as the ASHRAE Handbooks. The manufacturer assumes no on a roof curb.
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:
NOTE: Appliance is shipped from factory for vertical duct
application.
Proper installation of the unit ensures trouble-free operation.
Improper installation can result in problems ranging from
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.
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
model number shown on the unit’s identification plate identi-
fies the various components of the unit such as refrigeration
tonnage, heating input and voltage.
• For proper flame pattern within the heat exchanger
and proper condensate drainage, the unit must be
mounted level.
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:
• 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.
1. Make notation on delivery receipt of any visible
damage to shipment or container.
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.
• 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.
• 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.
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.
• Allow minimum clearances from the enclosure for fire
protection, proper operation, and service access (see
unit clearances). These clearances must be
permanently maintained.
• 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.
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.
• When the unit is heating, the temperature of the return
air entering the unit must be between 50° F and 100°
F.
4
Download from Www.Somanuals.com. All Manuals Search And Download.
GROUND LEVEL INSTALLATIONS ONLY:
3 3/4”
DIMPLES MARK DRILL LOCATIONS
• 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.
HIGH VOLTAGE ENTRANCE
• The base should also be located where no runoff of
10 3/16”
water from higher ground can collect in the unit.
LOW VOLTAGE ENTRANCE
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.
26 ½”
• 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.
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.
• 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.
• 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.
ROOF CURB INSTALLATIONS ONLY:
• 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)
Curb installations must comply with local codes and should
be done in accordance with the established guidelines of the
National Roofing Contractors Association.
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.
• Minimum horizontal clearance of 48” from the furnace
flue discharge to any electric meters, gas meters,
regulators and relief equipment is required.
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 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.
WARNING
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.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
• 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.
INSULATED
PANELS
See the manual shipped with the roof curb for assembly and
installation instructions.
CLEARANCES
ROOF CURB INSTALLATION
48”
ROOF CURB POST-INSTALLATION
CHECKS
48”
36” MIN.
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.
75”
6”
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
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.
PROTRUSION
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.
HORIZONTAL DISCHARGE
For horizontal discharge, remove the supply and return duct
covers and place them over the vertical discharge return and
supply openings. Install with insulation facing up, using the
longer screws provided in the literature package.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
Ensure that the top of the duct connection frame is flush with
the top of the roof curb.
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.
Your unit may be equipped with a steel shipping brace
located underneath the unit (under compressors). If
installing on a roof curb, the brace MUST be removed.
Follow the following instructions for removal.
Flexible duct connectors between the unit and ducts are rec-
ommended. Insulate and weatherproof all external ductwork
and joints as required and in accordance with local codes.
•
5 7/8”
12 5/8”
REMOVE
COVERS
CAUTION
28 3/8”
7 3/8”
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.
RETURN
36 3/8”
13 7/8”
SUPPLY
Before installing this unit on a roof curb:
1. Remove wooden struts per installation instructions.
These are the struts that are located in the fork holes
and are used to protect the unit from damage while
lifting with forks.
2. Locate and remove the twelve (12) screws that attach
the shipping brace to the side rails. There will be six
(6) screws on each side of the unit and they are in a
diagonal pattern. See following figure.
6 1/4”
HORIZONTAL DISCHARGE DUCT CONNECTIONS
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 48” 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.
3. Lift unit per the “Rigging Details” section of the
installation instructions, observing all warnings and
cautions. Lift the unit high enough off the ground to
reach under and grasp the shipping brace.
4. Rotate the brace by tapping the ends until the brace
falls free from the unit.
5. Dispose of the brace appropriately.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
CPG Weights (lbs)
DATA
Corner Weight - A
090/102
120
230
330
280
405
1275
1235
55
150
335
390
295
345
1390
1365
47
195
270
240
330
1055
1030
55
Corner Weight - B
Corner Weight - C
Corner Weight - D
Unit Shipping Weight
Unit Operating Weight
X (Inches)
Refer to the Roof Curb Installation Instructions for proper curb
installation. Curbing must be installed in compliance with the
National Roofing Contractors Association Manual.
Lower unit carefully onto roof mounting curb. While rigging
unit, center of gravity will cause condenser end to be lower
than supply air end.
33.5
Y (Inches)
36
36
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.
To assist in determining rigging requirements, unit weights
are shown as follows:
Remove spreader bars, lifting cables and other rigging equip-
ment.
C
A
ELECTRICAL WIRING
Y
RETURN
WARNING
EVAPORATOR COIL
HIGH VOLTAGE !
COMPRESSOR 1
COMPRESSOR 2
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.
CG
SUPPLY
WARNING
B
D
X
CORNER & CENTER OF GRAVITY LOCATIONS
HIGH VOLTAGE !
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
TEST PRIOR TO SHIPMENT. CONTACT YOUR LOCAL
REPRESENTATIVE IF ASSISTANCE IS REQUIRED.
CAUTION
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.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
(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.
CAUTION
CONDUIT AND FITTINGS MUST BE WEATHER‐TIGHT TO PREVENT WATER
ENTRY INTO THE BUILDING.
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.
•
Connect power wiring to the middle contactor within
the main control box.
RCCF
RCCF
All line voltage connections must be made through weather-
proof fittings. All exterior power supply and ground wiring
must be in approved weatherproof conduit.
4
1
6
3
2
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).
POWER
WIRING
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.
THERMOSTAT
WIRING
NOTE: If supply voltage is 208V, all leads on primary of trans-
former TRANS1 must be moved from the 230V to the 208V
tap.
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.
POWER AND LOW VOLTAGE BLOCK LOCATIONS
WARNING
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.
CAUTION
AREAS WITHOUT CONVENIENCE OUTLET
TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE
ONLY COPPER CONDUCTORS.
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.
CAUTION
UNITS INSTALLED ON ROOF TOPS
TO PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING
ERRORS, LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. VERIFY PROPER OPERATION AFTER SERVICING.
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.
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.
Ensure the data plate is not covered by the field-supplied
disconnect switch.
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.
•
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
9
Download from Www.Somanuals.com. All Manuals Search And Download.
LEAD
Red
THERMOSTAT
R (24V)
3 3/4”
DIMPLES MARK DRILL LOCATIONS
Green
Yellow
Purple
Blue
White
Brown
G (Fan)
Y1 (High Cool)
Y2 (Low Cool)
Common (if req'd)
W1 (Heat)
HIGH VOLTAGE ENTRANCE
10 3/16”
W2 (High Heat)
LOW VOLTAGE ENTRANCE
CPG 090 THROUGH 300 (GAS HEAT)
GAS SUPPLY PIPING
WARNING
26 ½”
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.
ELECTRICAL ENTRANCE LOCATIONS
Unit is equipped with a Low Voltage Terminal Block and has
Single Point wiring to the contactor.
IMPORTANT NOTE: This unit is factory set to operate on
natural gas at the altitudes shown on the rating plate.
LOW VOLTAGE CONTROL WIRING
WARNING
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.
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.
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.
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.
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.
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.
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.
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.
10
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
DOOR
Natural Gas Connection
PROVIDE CLEARANCE
FOR REMOVAL OF
ACCESS PANELS
Natural Gas Capacity of Pipe
in Cubic Feet of Gas Per Hour (CFH)
Nominal Black Pipe Size (inches)
Length of
MANUAL
SHUTOFF VALVE
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
DRIP LEG
GROUND JOINT
UNION
PROPER PIPING PRACTICE
90
84
79
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.
Pressure = .50 PSIG or less and Pressure Drop of 0.3" W.C. (Based
on 0.60 Specific Gravity Gas)
BTUH Furnace Input
CFH =
Heating Value of Gas (BTU/Cubic Foot)
GAS PIPING CHECKS
Refer to the Proper Piping Practice drawing for the general
layout at the unit. The following rules apply:
CAUTION
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.
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.
2. Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.
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.
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.
• 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
7. Tighten all joints securely.
8. The unit must be connected to the building piping by
one of the following methods:
EQUAL TO OR LESS THAN 1/2 PSIG (3.48
KPA).
WARNING
•
•
Rigid metallic pipe and fittings
TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, BE SURE THERE IS
NO OPEN FLAME IN THE VICINITY DURING AIR BLEEDING.
Semirigid metallic tubing and metallic fittings
(Aluminum alloy tubing must not be used in exterior
locations)
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.
•
•
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).
11
Download from Www.Somanuals.com. All Manuals Search And Download.
PROPANE GAS INSTALLATIONS
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).
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.
IMPORTANT NOTE: Propane gas conversion kits must be
installed to convert units to propane gas.
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.
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.
2. All units are furnished with standard female NPT pipe
connections. Connection pipe sizes for CPG090
through 300 units 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).
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:
1. Vaporization rate, which depends on (a) temperature
of the liquid, and (b) wetted surface area of the
container or containers.
NOTE: The gas connection size at the unit does NOT
establish the size of the supply line.
2. Proper pressure regulation.
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.
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.
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..
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 below for typical propane gas piping.
5 to 15 PSIG
(20 PSIG Max.)
First Stage
Regulator
Continuous
11" W.C.
NOTE: A minimum horizontal distance of 48"
between the regulator and the furnace flue discharge
is required.
200 PSIG
Maximum
Second Stage
Regulator
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..
TYPICAL PROPANE GAS PIPING
12
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
UNIT
2" MINIMUM
FLEXIBLE
TUBING-HOSE
OR PIPE
3" MINIMUM
A POSITIVE LIQUID
SEAL IS REQUIRED
WARNING
DRAIN CONNECTION
THIS UNIT AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE
DISCONNECTED FROM THE GAS SUPPLY SYSTEM DURING ANY
Install condensate drain trap as shown. Use 3/4" drain line
and fittings or larger. Do not operate without trap.
PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN EXCESS OF
1/2 PSIG (13.8”
W.C.).
HORIZONTAL DRAIN
CAUTION
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.
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 venter
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.
CLEANING
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.
STARTUP, ADJUSTMENTS, AND CHECKS
CIRCULATING AIR AND FILTERS
DUCTWORK
WARNING
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.
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.
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.
PRE-STARTUP INSTRUCTIONS
VENTING
CAUTION
NOTE: Venting is self-contained.
TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY, DO NOT START
THE UNIT UNTIL ALL NECESSARY PRE‐CHECKS AND TEST HAVE BEEN
PERFORMED.
CONDENSATE DRAIN CONNECTION
CONDENSATE DRAIN CONNECTION
Prior to the beginning of Startup, Adjustments, and Checks
procedures, the following steps should be completed in the
building.
A 3/4” NPT drain connection is supplied for condensate pip-
ing. An external trap must be installed for proper condensate
drainage.
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.
13
Download from Www.Somanuals.com. All Manuals Search And Download.
CONTRACTOR RESPONSIBILITY
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.
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.
HEATING STARTUP
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.
On new installations, or if a major component has been re-
placed, the operation of the unit must be checked.
ROOF CURB INSTALLATION CHECK
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.
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.
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.
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.
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.
TOOLS REQUIRED
Refrigeration gauge and manifold
Voltmeter
Clamp-on ammeter
Ohmmeter
Test lead
System Voltage - That nominal voltage value assigned to a
circuit or system for the purpose of designating its voltage
class.
(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
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.
TEMPORARY HEATING OR COOLING
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.
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:
14
Download from Www.Somanuals.com. All Manuals Search And Download.
Three Phase Models
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.
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
THERMOSTAT PRELIMINARY CHECK
D = Larger sheave diameter, inches
d = Smaller sheave diameter, inches
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.
h = Deflection height, inches
DRIVE BELT TENSION ADJUSTMENT
DEFLECTION
FORCE (lbs)
SHEAVE
DIAMETER
(in)
TYPE
DEFLECTION
(in)
MODEL
BELT DRIVE
Used New
FILTER SECTION CHECK
Remove filter section access panels and check that filters
are properly installed. Note airflow arrows on filter frames.
7.5 Ton
8.5
2.6 to 3.6 4.5 ± .5 5.5 ± .5 1/4 ± 1/16
2.6 to 3.6 4.5 ± .5 5.5 ± .5 1/4 ± 1/16
3.0 to 4.0 4.5 ± .5 5.5 ± .5 1/4 ± 1/16
BEARING CHECK
A, AX Standard
10 Ton
Prior to energizing any fans, check and make sure that all
setscrews are tight so that bearings are properly secured to
shafts.
1/4 ± 1/16
12.5 Ton
2.6 to 3.6 4.5 ± .5 5.5 ± .5
1/4 ± 1/16
1/4 ± 1/16
7.5 Ton
8.5
SET EVAPORATOR FAN RPM
3.0 to 4.0 4.5 ± .5 5.5 ± .5 1/4 ± 1/16
1/4 ± 1/16
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-
High
A, AX
10 Ton
Static
1/4 ± 1/16
12.5 Ton
3.6 to 4.6 4.9 ± .5 6.0 ± .5
1/4 ± 1/16
RECOMMENDED POUNDS OF FORCE PER BELT
nals R and G at TB1 terminal block. Close disconnect switch; The correct deflection force is 5 Ibs. for a new belt and 3.5
evaporator fan motor will operate so RPM can be checked.
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.
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.
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).
15
Download from Www.Somanuals.com. All Manuals Search And Download.
Secondary Limit Control
EVAPORATOR FAN ROTATION CHECK (THREE PHASE MODELS
ONLY)
The secondary limit control is located on the top 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.
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).
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.
6. Move the gas control valve switch to the OFF position.
Do not force.
RESTORING CONNECTIONS
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.
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.
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.
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 on the burner bracket. 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.
WARNING
Inlet gas pressure can also be measured by removing
the cap from the dripleg and installing a predrilled cap
with a hose fitting.
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.
With Power And Gas On:
2. Put unit into heating cycle and turn on all other gas
consuming appliances.
16
Download from Www.Somanuals.com. All Manuals Search And Download.
Main Burner Flame Check
INLET GAS PRESSURE
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.
Min. 5.0" W.C., Max. 10.0" W.C.
Min. 11.0" W.C., Max. 14.0" W.C.
NATURAL
PROPANE
Temperature Rise Check
NOTE: Inlet Gas Pressure Must Not Exceed the Maximum
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.
Value Shown.
If operating pressures differ from above, make necessary
pressure regulator adjustments, check piping size, etc., and/
or consult with local utility.
Manifold Pressure Check
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.
2. The temperature rise must be within the range
specified on the rating plate.
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.
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
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.
inches water column from the specified nominal pressure. If the correct amount of temperature rise is not obtained, it
Any major changes in flow should be made by changing the may be necessary to change the blower speed. A higher
size of the burner orifices. The measured input rate to the blower speed will lower the temperature rise.Aslower blower
furnace must not exceed the rating specified on the unit rat- speed will increase the temperature rise.
ing plate.
NOTE: Blower speed MUST be set to give the correct air
For natural gas, the manifold pressure must be between 3.2
temperature rise through the unit as marked on the rating
and 3.8 inches w.c. (3.5 nominal) for high fire and between
plate.
1.7 and 2.3 inches w.c. (2.0 nominal) for low fire.
REFRIGERATION SEQUENCE CHECK
For propane gas, the manifold pressure must be between
9.7 and 10.3 inches w.c. (10.0 nominal) for high fire and be-
tween 6.7 and 7.3 inches w.c. (7.0 nominal) for low fire.
With the disconnect switch open, remove the field connected
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.
Gas Input (Natural Gas Only) Check
To measure the gas input use a gas meter and proceed
as follows:
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.
1. Turn off gas supply to all other appliances except the
unit.
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:
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.
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.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
REFRIGERATION PERFORMANCE CHECK
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.
11. Open disconnect switch. Reconnect the field
thermostat wire at terminal R on terminal block TB1.
18
Download from Www.Somanuals.com. All Manuals Search And Download.
The pressure regulator on LP gas models is adjusted for 10.0" If the ventor motor comes on, but the unit does not attempt
w.c. manifold pressure and is intended to prevent over-firing ignition, check if the ALS (Automatic Reset High Limit Con-
only. Do not attempt adjustment of the built-in pressure regu- trol Switch) requires resetting.
lator unless the supply pressure is at least 7.0" w.c. on natu-
1. With electricity and gas turned on, the system switch
ral gas or 14.0" w.c. on propane gas. Check the location of
in the “HEAT” or “AUTO” position and the fan switch
the ignition electrode and the flame sensor for correct gap
in the “AUTO” position, the thermostat will close the
setting.
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.
GAS ORIFICES
MAXIMUM NUMBER
INPUT of
(BTUH) BURNERS
MAXIMUM
BTUH/BURNER
NATURAL PROPANE (LP)
(Dia)
(Dia)
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).
210,000
6
35,000
#34
#52
HEAT EXCHANGER AND BURNER ORIFICE SPECIFICATIONS
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.
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.)
Unit Shutdown
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.
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.
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.
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.
11. The furnace has three high temperature limit controls,
which can shut down the burner. They do not shut
down the ventor motor.
NORMAL SEQUENCE OF OPERATION
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.
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.
19
Download from Www.Somanuals.com. All Manuals Search And Download.
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 (ALS)
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.
MANUAL RESET FLAME ROLLOUT CONTROL (RS)
• Check the supply and manifold pressures
• Check the gas orifices for debris
• Check gas valve for proper operation
• Check secondary limit
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.
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.
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.
• 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
A drop in flame signal can be caused by nearly
invisible coating on the sensor. Remove the sensor
and carefully clean with steel wool.
• Check wiring
Check wiring for opens/shorts and miswiring.
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.
ABNORMAL OPERATION - HEATING
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.
External Lockout
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.
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 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.
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.
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.
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.
20
Download from Www.Somanuals.com. All Manuals Search And Download.
Open Thermal Protection Device
After adjustment the furnace temperature rise must be within
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)
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.
High Fire
Adjust
Low Fire
Adjust
INLET
OUTLET
Flame Detected with Gas Valve Closed
Gas Valve
On/Off Switch
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.
WHITE-RODGERS 36H54 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.
ABNORMAL OPERATION - COOLING
Short Cycle Compressor Delay
AIR FLOW ADJUSTMENTS
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.
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.
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.
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.
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
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.
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:
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
MOTOR SHEAVE ADJUSTMENTS
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.
VL, VM & 2VP VARIABLE PITCH KEY TYPE MOTOR SHEAVES
The driving and driven motor sheaves should be in align-
ment with each other and the shafts parallel.
21
Download from Www.Somanuals.com. All Manuals Search And Download.
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:
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 FIVE FULL TURNS.
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. 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.
3. Lubricate motor bearings.
4. Align or replace belts as needed.
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.
5. Replace filters as needed (see below).
6. Check for blockage of condensate drain.
7. Check power and control voltages.
8. Check running amperage.
9. Check operating temperatures and pressures.
10. Check and adjust temperature and pressure controls.
11. Check and adjust damper linkages.
12. Check operation of all safety controls.
13. Examine gas furnaces (see below and the User’s
Information Manual).
C
14. Check condenser fans and tighten set screws.
B
FILTERS
VL & VM
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: For horizontal discharge, remove the supply and return
duct covers and place them over the vertical discharge return
and supply openings (bottom of unit).
NOTE: Do not operate sheave with flange projecting beyond
the hub end.
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.
MAINTENANCE
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.
WARNING
HIGH VOLTAGE !
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.
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.
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.
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.
CAUTION
SHEET METAL PARTS, SCREWS, CLIPS AND SIMILAR ITEMS INHERENTLY
HAVE SHARP EDGES, AND IT IS NECESSARY THAT THE INSTALLER AND
SERVICE PERSONNEL EXERCISE CAUTION.
22
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)
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
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.
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.
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.
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.
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.
23
Download from Www.Somanuals.com. All Manuals Search And Download.
APPENDIX A BLOWER PERFORMANCE DATA
BELT DRIVE - STANDARD HORIZONTAL
CPG090 STANDARD BELT DRIVE HORIZONTAL
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.1
0.3
3381 703 0.99 3078 659 0.78
3560 796 1.26 3271 747 1.02 2946 703 0.82 2604 659 0.63
3492 841 1.36 3159 799 1.09 2819 752 0.86
0.5
0.7
0.9
1.1
3453 891
1.5 3094 846 1.18
2964 896 1.29 2524 852 0.96
2537 902 1.08
CPG102 STANDARD BELT DRIVE HORIZONTAL
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.1
0.3
3231 700 0.96 2928 656 0.75
3410 793 1.23 3121 744 0.99 2796 700 0.79
3342 838 1.33 3009 796 1.06 2669 749 0.83
3303 888 1.47 2944 843 1.15
0.5
0.7
0.9
2814 893 1.26
CPG120 STANDARD BELT DRIVE HORIZONTAL
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.2
0.4
4391 737 1.48 4054 693 1.22 3760 645 0.97
4314 781 1.61 3969 737 1.29 3534 693
4255 826 1.69 3894 781 1.38 3447 743 1.09
4234 876 1.85 3792 832 1.47
3724 877 1.59
1
0.6
0.8
1
1.2
CPG150 STANDARD BELT DRIVE HORIZONTAL
0 TURNS
1 TURN
2 TURNS
3 TURNS
4 TURNS
5 TURNS
ESP (IN
W.C.)
CFM
BHP
3.08
2.91
2.65
2.43
2.20
2.01
CFM
BHP
2.63
2.44
2.25
1.99
1.76
CFM
BHP
2.21
2.03
1.81
1.58
CFM
BHP
1.84
1.64
1.45
CFM
4513
4100
BHP
1.48
1.29
CFM
4197
BHP
0.2
0.4
0.6
0.8
1.0
1.2
5762
5550
5202
4898
4549
4258
5485
5207
4922
4515
4135
5140
4857
4487
4074
4855
4489
4113
1.20
NOTE: High Static airflow requires installation of High Static Kit (HSKT*), or factory-built High Static model. Unit factory shipped at 2.5 turns open.
Tables represent dry coil without filter. To compensate for filter, add 0.08" to measured E.S.P. SCFM correction for wet coil = 4%.
24
Download from Www.Somanuals.com. All Manuals Search And Download.
APPENDIX A BLOWER PERFORMANCE DATA
BELT DRIVE - STANDARD DOWN SHOT
CPG090 STANDARD BELT DRIVE DOWN SHOT
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.1
0.3
3522 750 1.14 3228 706 0.94 2964 661 0.73
3337 800 1.19 3102 756
3387 844 1.32 2834 806 0.99 2603 757
1.5 2903 850 1.12
1
2800 706 0.76 2504 661 0.59
0.5
0.7
0.9
0.8
3453 893
2957 899 1.29
CPG102 STANDARD BELT DRIVE DOWN SHOT
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.1
0.3
3372 747 1.11 3078 703 0.91 2814 658 0.70
3187 797 1.16 2952 753 0.97 2650 703 0.73
3237 841 1.29 2684 803 0.96 2453 754 0.77
3303 890 1.47 2753 847 1.09
0.5
0.7
0.9
2807 896 1.26
CPG120 STANDARD BELT DRIVE DOWN SHOT
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.2
4316 780 1.57 4118 738 1.36 3771 687 1.08 3376 644 0.85
0.4
0.6
0.8
1
4282 830 1.76 3928 786
4232 874 1.87 3872 830 1.52 3444 786
3839 880 1.64 3367 836 1.27
1.4 3595 740 1.13
1.2
3326 885
1.4
1.2
CPG150 STANDARD BELT DRIVE DOWN SHOT
0 TURNS
1 TURN
2 TURNS
3 TURNS
4 TURNS
5 TURNS
ESP (IN
W.C.)
CFM
BHP
2.92
2.74
2.67
2.37
2.01
CFM
BHP
3.22
2.40
2.20
2.02
CFM
5064
4696
4352
BHP
2.16
1.94
1.74
CFM
BHP
1.81
1.63
1.43
CFM
BHP
1.49
1.31
CFM
4271
BHP
0.2
0.4
0.6
0.8
1.0
5514
5279
5185
4766
4223
5604
5110
4813
4526
4775
4447
4039
4514
4123
1.23
NOTE: High Static airflow requires installation of High Static Kit (HSKT*), or factory-built High Static model. Unit factory shipped at 2.5 turns open.
Tables represent dry coil without filter. To compensate for filter, add 0.08" to measured E.S.P. SCFM correction for wet coil = 4%.
25
Download from Www.Somanuals.com. All Manuals Search And Download.
APPENDIX A BLOWER PERFORMANCE DATA
BELT DRIVE - HIGH STATIC (“AA” MODELS ONLY)
CPG090 HIGH STATIC BELT DRIVE DOWN SHOT
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.7
0.9
1.1
1.3
1.5
1.7
1.9
2.1
3575 904
3258 925 1.56 3113 909
1.66
1.41
1.25
3580 1013 1.97 3001 948 1.42 2722 915
DO NOT
OPERATE
3616 1063 2.17 3247 1019 1.79 2646 959
3275 1069 2.05 2803 1025 1.68
3346 1118 2.24 2885 1074 1.97
3009 1125 2.05
1.3
CPG120 HIGH STATIC BELT DRIVE DOWN SHOT
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.8
1
4188 943 2.11 3793 889
1.67
1.45
4305 1002 2.39 3836 946 1.89 3416 893
1.2
1.4
1.6
1.8
2
4324 1053 2.63 3879 1003 2.11 3425 951 1.63
4428 1109 2.92 3973 1056 2.35 3434 1009 1.8
4465 1160 3.2 4088 1113 2.67 3506 1068 2.1
4129 1168 2.9 3625 1122
3694 1175 2.65
2.3
CPG090 HIGH STATIC BELT DRIVE HORIZONTAL
TURNS OPEN
ESP, In
0
1
2
3
4
5
H2O
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.7
0.9
1.1
1.3
1.5
1.7
1.9
2.1
3567 903
3596 953 1.79 3145 906
1.58
1.39
1.18
3630 1007 1.97 3168 963 1.56 2675 909
DO NOT
OPERATE
3649 1063 2.19 3255 1021
3316 1068 2823 1058 1.61
3287 1112 2.16 2869 1074 1.78
2970 1122
2644 1133 1.92
1.8
2724 965 1.35
2
2
CPG120 HIGH STATIC BELT DRIVE HORIZONTAL
TURNS OPEN
ESP, In
H2O
0
1
2
3
4
5
CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP CFM RPM BHP
0.8
1
4408 885
2.02
1.76
1.46
4464 940 2.29 3929 891
1.2
1.4
1.6
1.8
2
4585 996
2.58 4026 946
2
3436 897
DO NOT
OPERATE
4697 1049 2.92 4141 1001 2.26 3509 951
4264 1056 2.58 3663 1007 1.96
1.7
4359 1105 2.85 3785 1061 2.22
3907 1114 2.49
CPG150 HIGH STATIC BELT DRIVE HORIZONTAL
0 TURNS
1 TURN
2 TURNS
3 TURNS
4 TURNS
5 TURNS
ESP (IN
W.C.)
CFM
BHP
CFM
BHP
CFM
BHP
CFM
BHP
3.92
3.61
3.39
3.06
2.71
CFM
5451
5223
4999
4803
4440
BHP
3.16
2.97
2.80
2.65
2.38
CFM
5275
4959
4635
4160
BHP
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
5967
5628
5385
5003
4576
2.77
2.54
2.31
1.99
5840
5643
5229
4917
4397
4.10
3.90
3.51
3.23
2.79
6007
5752
5380
5065
4.93
4.64
4.24
3.91
5740
5401
5033
4573
4.32
3.97
3.61
3.18
CPG150 HIGH STATIC BELT DRIVE DOWN SHOT
0 TURNS
1 TURN
2 TURNS
3 TURNS
4 TURNS
5 TURNS
ESP (IN
W.C.)
CFM
BHP
CFM
BHP
CFM
BHP
CFM
BHP
CFM
5515
5344
4887
4404
4197
BHP
3.21
3.07
2.71
2.35
2.21
CFM
5124
4721
4365
3986
BHP
2.68
2.37
2.13
1.88
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
5840
5643
5229
4917
4397
4.06
3.86
3.47
3.19
2.75
5781
5369
4853
4584
4204
3.73
3.36
2.92
2.71
2.41
5908
5542
5180
4960
4553
4315
4.49
4.11
3.75
3.53
3.16
2.95
5869
5464
5229
4961
4790
4.74
4.30
4.05
3.78
3.61
NOTE: High Static airflow requires installation of High Static Kit (HSKT*), or factory-built High Static model. Unit factory shipped at 2.5 turns open.
Tables represent dry coil without filter. To compensate for filter, add 0.08" to measured E.S.P. SCFM correction for wet coil = 4%.
26
Download from Www.Somanuals.com. All Manuals Search And Download.
APPENDIX B ELECTRICAL DATA
ELECTRICAL DATA
VOLTAGE
LIMITATION
COMPRESSOR
(ea)
OD FAN MOTORS
(ea)
ID FAN
MOTOR (ea)
VOLTAGE
(NAMEPLATE)
MODELS
ID MOTOR APPL
MIN MAX Qty RLA LRA Qty
13.1 83.1
HP RLA
HP
1.5
1.5
1.5
FLA
5.0
208/230-60-3 187 253
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1/4
1/4
1.40 BD STD STATIC
0.80 BD STD STATIC
7.5 TON
460-60-3
575-60-3
414 506
518 633
6.1
4.4
41.0
33
2.5
1/4 0.60 BD STD STATIC
2.3
208/230-60-3 187 253
14.5 98.0
1/4
1/4
1.40 BD STD STATIC
0.80 BD STD STATIC
2.0
2.0
2.0
2.0
2.0
2.0
3.0
3.0
3.0
7.8
3.9
2.5
7.8
3.9
2.5
9.4
4.7
4.2
8.5 TON
10 TON
460-60-3
575-60-3
414 506
518 633
6.3
6.0
55.0
41.0
1/4 0.60 BD STD STATIC
208/230-60-3 187 253
16.0 110.0
1/3
1/3
2.40 BD STD STATIC
1.20 BD STD STATIC
460-60-3
575-60-3
414 506
518 633
7.8
6.4
52.0
38.9
1/3 0.90 BD STD STATIC
208/230-60-3 187 253
22.4 149.0
10.6 75.0
7.70 54.0
1/3
1/3
1/3
2.40 BD STD STATIC
1.20 BD STD STATIC
0.90 BD STD STATIC
12.5 TON
460-60-3
575-60-3
414 506
518 633
27
Download from Www.Somanuals.com. All Manuals Search And Download.
APPENDIX C UNIT DIMENSIONS
7.5
8.5
10
12.5
Y
52 7/8" 52 7/8" 52 7/8" 58 7/8"
99 1/8”
Y
61 3/4”
12 5/8”
5 7/8”
28 3/8”
7 3/8”
RETURN
36 3/8”
SUPPLY
13 7/8”
6 1/2”
RETURN
6 1/4”
HORIZONTAL DISCHARGE
5 3/8”
SUPPL
Y
NOTE
For horizontal discharge, remove the supply
and return duct covers and place them over
the vertical discharge return and supply
openings. Install with insulation facing up,
using the longer screws provided in the
literature package.
7 1/2”
VERTICAL DISCHARGE (BOTTOM OF UNIT)
28
Download from Www.Somanuals.com. All Manuals Search And Download.
CPG(090/102/120/150)2104B*/7B* THREE PHASE 460-575/60 HZ BELT DRIVE WIRING DIAGRAM
HIGH VOLTAGE!
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.
PU
YL
BL
YL/PK
PU
BL
BR
BK
RD
BK
BR
T1
L1
T2
T3
L3
CM2
OR
BK
CC2
L2
FC2
OR
POWER SUPPLY
460-575/3/60
RD
YL
RD
BK
SEE NOTE 4
YL
RD
BK
RD
RD
RD
GND
OR
T3 T2 T1
T3 T2
T1
T1
T2
L2
T3
L3
CC1
BK
COMP2
COMP1
L1
BK
YL/PK
BL
RD
YL
RD
PU
BR
BK
BR
FC1
WH
BK
RD
BK
BK
4
2
3
LPS2
HPS2
1
2
3
OR
CM1
BL
460
C
1
OR APPROPRIATE
INPUT VOLTAGE
460
VMR
OR APPROPRIATE
INPUT VOLTAGE
240
24V
LS
WH
RD
RD
TR
BL
GR
BL
EM
RD
TR
GR
PK
BC
BK
BK
SMOKE/FIRE
DETECTOR
REPLACES JUMPER
RD
RD
S1
S2
RD
WIRE
TB1
BR
OR
OR
BL
BL
OR
AL
S
BL/PK
ECON
GR
IIC
RD
PU
GR
RD
RD
BL
PU
YL
YL
PS
YL
YL
PU
WH
YL
YL
RD
PU
BL
WH
RD
9
8
6
5
4
3
2
1
RS
WH
BR
YL
RD
PU
YL
7
RD
WH
SEE
NOTE 3
BL
BL
NOTE 2
PLF
PU
RD
GR
GR
GV
WH
BL
BR
BL
BL
C
GR
YL/PK
Y1
Y2
R W1 G
W2
TB1
BK
WH
LPS1
BL
NOTE 5
VM
RD
OR
FS
IGN
RD
HPS1
BL/PK
BK
WH
RD
0140L00550 REV A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
29
Download from Www.Somanuals.com. All Manuals Search And Download.
CPG(090/102/120/150)2104B*/7B* THREE PHASE 460-575/60 HZ BELT DRIVE WIRING DIAGRAM
HIGH VOLTAGE!
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.
SUPPLY VOLTAGE
460-575/3/60
L1
L2
L3
CC1
T2
T2
T1 COMP1
CC1
CC1
T3
COMPONENT LEGEND
C
F
ALS
BC
AUXILIARY LIMIT SWITCH
BLOWER CONTACTOR
RCCF1
COMP COMPRESSOR
FACTORY WIRING
CM
CC
EM
F
FC
FS
CONDENSER MOTOR
CM1
LINE VOLTAGE
LOW VOLTAGE
OPTIONAL
COMPRESSOR CONTACTOR
EVAPORATOR MOTOR
FUSE
FAN CAPACITOR
FLAME SENSOR
C
F
RCCF2
HIGH VOLTAGE
GND
GV
HPS
IBR
IIC
IGN
LPS
LS
PLF
PS
RS
TB1
TR
EQUIPMENT GROUND
GAS VALVE
HIGH PRESSURE SWITCH
INDOOR BLOWER RELAY
INTEGRATED IGNITION CONTROL
IGNITOR
CM2
CC2
FIELD WIRING
HIGH VOLTAGE
LOW VOLTAGE
T2
CC2
T1
T2
T1 COMP2
T3
CC2
T3
LOW PRESSURE SWITCH
LIMIT SWITCH
WIRE CODE
BLACK
BLUE
BROWN
GREEN
ORANGE
PINK
PURPLE
RED
WHITE
YELLOW
BC
BC
BK
BL
FEMALE PLUG/CONNECTOR
PRESSURE SWITCH
ROLLOUT SWITCH
TERMINAL BLOCK (24V SIGNAL)
TRANSFORMER
BC
EM
BR
GR
OR
PK
PU
RD
WH
YL
2
4
WH VM
R
VM
VMR
VENT MOTOR
VENT MOTOR RELAY
460V OR APPROPRIATE INPUT VOLTAGE
1
3
TR
460V OR APPROPRIATE INPUT VOLTAGE
YL/PK YELLOW WITH
1
3
PINK STRIP
TB1
BL/PK BLUE WITH
PINK STRIP
TR
NOTE 3
NOTE 3
L1
L2
24V
IGN
FS
IIC
NOTES
BC
1
FS
D1
F
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.
3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.
4. USE COPPER CONDUCTORS ONLY.
USE NEC CLASS 2 WIRE.
5. FOR TWO STAGE OPERATION REMOVE
W1 TO W2 WIRE JUMPER.
H
C
4
5
VMR
LS
ALS
RS
3
6
8
GV
IIC
C2
PS
LPS2
HPS2
ECON
9
2
7
10
12
11
THERMOSTAT
FIELD WIRING
C1
2 STAGE COOLING
HPS1
NOTE 5
Y1
LPS1
WH
GR
RD
YL
W
G
W
G
R
R
9
6
3
2
1
PLF
NOTE
2
Y1
Y1
Y2
Y
Y2
8
7
5
4
PK
BL
Y/Y2
C
R
G
C
W1 W2
C
OR
O
TO THERMOSTAT
TB1
O
STAT
TB1
NO ECONOMIZER
INSTALLER/SERVICEMAN
THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUIDE TO
TROUBLESHOOTING THIS APPLIANCE. STATUS LIGHT CODES ARE AS FOLLOWS:
W
G
R
WH
GR
RD
W
G
R
Y1
Y/Y2
C
STATUS LIGHT
ON
EQUIPMENT STATUS
NORMAL OPERATION
CHECK
YL
BL
Y2
C
------
CHECK INPUT POWER
CHECK FUSE ON CONTROL
REPLACE CONTROL
NO POWER OR
INTERNAL CONTROL
OR
O
O
OFF
STAT
TB1
GAS FLOW
GAS PRESSURE
GAS VALVE
FLAME SENSOR
FLAME ROLLOUT
BAD SWITCH
AUX. LIMIT OPEN
CHECK
PRESSURE SWITCH
IGNITION FAILURE
OPEN ROLLOUT
SWITCH
WITH ECONOMIZER OPTION
1 BLINK
W
G
WH
GR
RD
YL
W
G
R
Y
OPENAUX. LIMIT
SWITCH
R
PRESSURE SWITCH
OPEN
PRESSURE SWITCH CLOSED
WITHOUT INDUCER ON
Y1
2 BLINKS
3 BLINKS
Y/Y2
C
CHECK
BL
C
PRESSURE SWITCH
MAIN LIMIT OPEN
BAD SWITCH
O
OR
O
STAT
4 BLINKS
5 BLINKS
OPEN LIMIT SWITCH
TB1
FALSE FLAME SENSED
STICKING GAS VALVE
COMPRESSOR
OUTPUT DELAY
3 MIN. COMP.
ANTI-CYCLE TIMER
6 BLINKS
460-575/3/60 0140L00551 REV B
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
30
Download from Www.Somanuals.com. All Manuals Search And Download.
CPG(090/102/120/150)2103B* THREE PHASE 208-240/60 HZ BELT DRIVE WIRING DIAGRAM
HIGH VOLTAGE!
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.
BK
PU
PU
YL
BL
BL
BK
BR BK
CM2
BR
YL
T3
RD
T2
BK
RD
T1
FC2
OR
BK
CC2
BK
L1
L2
L3
POWER SUPPLY
208-240/3/60
SEE NOTE 4
RD
RD
YL
YL
RD
BK
RD
BK
RD
GND
OR
T1
L1
T2
T3
L3
CC1
BK
COMP1
PU
COMP2
L2
RD
YL
BL
YL
BK
BR
BK
WH
RD
CM1
BK
3
LPS2
HPS2
3
240
2
208
TR
24V
1
C
BL
RD
FC1
OR
1
VMR
WH
BK
BK
RD
LS
EM
GR
BL
BL
GR
RD
BC
PK
BK
RD
S1
S2
TB1
SMOKE/FIRE
DETECTOR
REPLACES JUMPER
RD
RD
BL
WIRE
BR
OR
OR
BL
BL
OR
ALS
GR
IIC
GR
RD
PU
RD
RD
BL
PU
YL
PS
RS
YL
YL
YL
PU
WH
YL
YL
RD
PU
BL
WH
9
8
6
5
4
3
2
1
RD
YL
WH
PU
YL
7
BR
WH
NOTE 2
PLF
SEE
BL
BL
NOTE 3
PU
GR
GR
GV
WH BL
RD
GR BL
BR
BL
C
SEE
NOTE
5
W2
Y2 Y1
R W1 G
TB1
YL
BL
WH
LPS1
WH
BK
VM
FS
IGN
RD
OR
RD
HPS1
RD
BK
WH
BL
RD
BK
0140L00552 REV B
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
31
Download from Www.Somanuals.com. All Manuals Search And Download.
CPG(090/102/120/150)2103B* THREE PHASE 208-240/60 HZ BELT DRIVE WIRING DIAGRAM
HIGH VOLTAGE!
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.
SUPPLY VOLTAGE
208-240/3/60
L1
L3
L2
COMPONENT LEGEND
FACTORY WIRING
CC1
T2
AUXILIARY LIMIT SWITCH
BLOWER CONTACTOR
COMPRESSOR CONTACTOR
CONDENSER MOTOR
COMPRESSOR
EVAPORATOR MOTOR
FUSE
FAN CAPACITOR
ALS
BC
CC
CM
COMP
EM
F
T2
LINE VOLTAGE
LOW VOLTAGE
CC1
COMP1
T1
T3
CC1
OPTIONAL HIGH
VOLTAGE
T3
C
F
FIELD WIRING
RCCF1
FC
FS
HIGH VOLTAGE
LOW VOLTAGE
FLAME SENSOR
EQUIPMENT GROUND
GAS VALVE
CM1
GND
GV
HPS
IBR
IIC
IGN
LPS
LS
PLF
PS
RS
TB1
TR
VM
VMR
WIRE CODE
C
F
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)
TRANSFORMER
RCCF2
BK BLACK
BL BLUE
BR BROWN
GR GREEN
OR ORANGE
PK PINK
PU PURPLE
RD RED
WH WHITE
YL YELLOW
CM2
CC2
T2
T3
CC2
T1
T2
BC
COMP2
T1
T3
CC2
BC
VENT MOTOR
VENT MOTOR RELAY
EM
YL /PK YELLOW WITH
PINK STRIP
BL /PK BLUE WITH
PINK STRIP
BC
VM
2
VMR
208-240V
1
3
TB1
S2
S1
TR
NOTE 3
NOTE 3
24V
NOTES
IGN
FS
IIC
BC
1. REPLACEMENT WIRE MUST BE THE SAME
SIZE AND TYPE OF INSULATION AS ORIGINAL.
(USE COPPER CONDUCTOR ONLY).
1
F
FS
D1
H
C
. ACCESSORY ECONOMIZER PLUG ADJACENT
TO BLOWER HOUSING IN RETURN AIR
COMPARTMENT. REMOVE MALE PLUG AND
ATTACH FEMALE PLUG TO THE ECONOMIZER
ACCESSORY.
3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.
4. USE COPPER CONDUCTORS ONLY.
USE NEC CLASS 2 WIRE.
2
4
5
VMR
LS
ALS
RS
GV
3
6
8
IIC
C2
5. FOR TWO STAGE OPERATION REMOVE
W1 TO W2 JUMPER WIRE
6. FOR 208V 0PERATION MOVE BLACK WIRE
PS
HPS2
LPS2
FROM TERMINAL
TRANSFORMER.
3
TO TERMINAL
2
ON
9
2
7
10
12
11
C1
LPS1
HPS1
NOTE 2
9
NOTE 5
6
5
4
3
2
1
PLF
8
7
THERMOSTAT
FIELD WIRING
Y
Y2
Y1
R
G
W1
W2
C
2 STAGE COOLING
TB1
W1
G
R
WH
GR
RD
YL
W1
G
R
Y1
Y2
C
INSTALLER/SERVICEMAN
Y1
PK
BL
BR
Y/Y2
C
W2
TB1
W2
STAT
CHECK
------
STATUS LIGHT
ON
EQUIPMENT STATUS
NORMAL OPERATION
NO POWER OR
INTERNAL CONTROL
OFF
GAS FLOW
IGNITION FAILURE
GAS PRESSURE
OPEN ROLLOUT
SWITCH
GAS VALVE
FLAME SENSOR
FLAME ROLLOUT
BAD SWITCH
1 BLINK
OPEN AUX. LIMIT
SWITCH
AUX. LIMIT OPEN
CHECK
PRESSURE SWITCH
PRESSURE SWITCH
OPEN
2 BLINKS
3 BLINKS
CHECK
WITHOUT INDUCER ON
OPEN LIMIT SWITCH
FALSE FLAME SENSED
PRESSURE SWITCH
MAIN LIMIT OPEN
BAD SWITCH
4 BLINKS
5 BLINKS
COMPRESSOR
OUTPUT DELAY
3 MIN. COMP.
ANTI-CYCLE TIMER
6 BLINKS
SEE UNIT RATING PLATE FOR TYPE AND SIZE
OF OVER CURRENT PROTECTION
208-240/3/60 0140L00553 REV B
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
32
Download from Www.Somanuals.com. All Manuals Search And Download.
|