Goodman JVM1600 User Manual

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NSTALLATION INSTRUCTIONS

OMMERCIAL

EATING

& C

OOLING

3 T

- 6 T

CPG S

ACKAGE

ERIES

NIT

This Forced Air Central Unit Design Complies With Requirements Embodied in The American National Standard / National Standard of Canada Shown Below.

ANSI Z21.47•CSA-2.3 Central Furnaces

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

Prior to installation, thoroughly familiarize yourself with this Installation Manual. Observe all safety warnings.

During installation or repair, caution is to be observed.

It is your responsibility to install the product safely and to educate the customer on its safe use.

All information contained herein is subject to change without notice.

Goodman Manufacturing Company, L.P . IO-353C 5151 Felipe, Suite 500, Houston, TX 77056 11/10 www.goodmanmfg.com www.amana-hac.com

Index

REPLACEMENT PARTS

Replacement Parts ........................................................2

Safety Instructions ........................................................2

General Information ......................................................3

Unit Location ................................................................. 4

Clearances .....................................................................5

Roof Curb Post-Installation Checks ............................ 6

Roof Top Duct Connections .........................................6

Rigging Details ..............................................................7

Electrical Wiring ............................................................9

Gas Supply Piping.......................................................10

Propane Gas Installations ..........................................12

Circulating Air and Filters...........................................13

Venting ......................................................................... 13

Condensate Drain Connection ...................................13

Startup, Adjustment s, and Checks ............................14

Normal Sequence Of Operation ................................. 19

Troubleshooting ..........................................................20

Input Rating .................................................................21

Air flow Adjustments................................................... 22

ORDERING PARTS

When reporting shortages or damages, or ordering repair parts, give the complete unit model and serial numbers as stamped on the unit’s nameplate.

Replacement parts for this appliance are available through your contractor or local distributor. For the location of your nearest distributor, consult the white business pages, the yellow page section of the local telephone book or contact:

CONSUMER AFFAIRS

GOODMAN MANUFACTURING COMPANY, L.P.

7401 SECURITY WAY

HOUSTON, TEXAS 77040

(877) 254-4729

SAFETY INSTRUCTIONS

TO THE INSTALLER

Before installing this unit, please read this manual to familiarize yourself on the specific items which must be adhered to, including maximum external static pressure to unit, air temperature rise, minimum or maximum CFM and motor speed connections.

Keep this literature in a safe place for future reference.

WARN ING

Motor Sheave Adjustments ........................................ 22

Maintenance ................................................................22

Appendix A Blower Performance Tables................... 25

Direct Drive .............................................................. 25

CPG036 Down Shot and Horizontal...................25

CPG048 Down Shot and Horizontal...................26

CPG060 Down Shot............................................. 27

CPG060 Horizontal ..............................................28

Belt Drive ................................................................. 29

Standard Down Shot...........................................29

Standard Horizontal ............................................30

High Static Down Shot........................................31

Belt Drive - High Static Horizontal ..................... 32

Appendix B Electrical Data......................................... 33

Appendix C Unit Dimensions ..................................... 34

Appendix D Wiring Diagrams .....................................35

THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE

- D

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS

AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

- WHAT T O D O IF YO U SMELL GA S:

- I

* D

O NOT TRY TO LIGHT ANY APPLIANCE O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE

* D

ANY PHONE IN YOUR BUILDING

* I

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBORS PHONE INSTRUCTIONS

* I

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

FIRE DEPARTMENT

. F

OLLOW THE GAS SUPPLIERS

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN

OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

CAUTION

HEET METAL PARTS, SCREWS, CLIPS AND SIMILAR ITEMS INHERENTLY HAVE SHARP EDGES, AND IT IS NECESSARY THAT THE INSTALLER AND SERVICE PERSONNEL EXERCISE CAUTION

WARN ING

NOT CONNECT TO OR USE ANY DEVICE THAT IS NOT DESIGN CERTIFIED BY GOODMAN FOR USE WITH THIS UNIT PROPERTY DAMAGE, PERSONAL INJURY, REDUCED UNIT PERFORMANCE AND FROM THE USE OF SUCH NON-APPROVED DEVICES

/OR

HAZARDOUS CONDITIONS MAY RESULT

. S

ERIOUS

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE

TATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER

REPRODUCTIVE HARM.

WARNING

CARBON MONOXIDE POISONING HAZARD

FAILUR E TO KEEP THIS CO MPARTMENT CLOS ED EXCEPT WHEN SERVICING COULD RESULT IN CARBON MONOXIDE POISONING OR DEATH.

THIS COMPARMENT MUST BE CLOSED EXCEPT WHEN SERVICING

A VERTISSEMENT

RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE

SI CE COMPARTMENT N'EST PAS FERME EN TOUT TEMPS, SAU F EN CAS D E REPARATION, IL Y A RISQUE D'EM POISONNEME NT OU MONOXYDE DE CARBON E OU DE MORT.

CE COMPARTIMENT DO IT ETRE FE RME SAUF AU MOMENT DE L'ENTRETIEN.

O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT USE

THIS UNIT IF ANY PART HAS BEEN UNDER WATER. QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL HAVING BEEN UNDER WATER.

HIS UNIT MUST NOT BE USED AS A "CONSTRUCTION HEATER DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TEMPERATURE AND EXPOSURE TO CORROSIVE OR VERY DIRTY

. T

HIS TYPE OF USE MAY RESULT IN PREMATURE

ATMOSPHERES

MMEDIATELY CALL A

WARN ING

HIGH VOLTAGE!

ISCONNECT ALL POWER BEFORE SERVICI NG OR

INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWER SOURCES MAY

WARNING

TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,

DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUI DS OR VAPORS I N THE V ICINIT Y OF THI S APPL IANCE.

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. ESTE COMPARTIMIENTO DEBE CERRADO MENOS AL A TEN DER

GENERAL INFORMA TION

WARNING

O 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.

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 NFP A54/ANSI Z223.1 and National Standard of Canada CAN/CSA B149 Installation Codes.

0140L00106

WARN ING

HIGH VOLTAGE!

INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED REQUIREMENTS OF AN SPECIFIED BY THE AIR CONDITIONING AND

EFRIGERATION INSTITUTE INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH

ONLY BY

INDIVIDUALS MEETING THE

“E

NTRY LEVEL TECHNICIAN” AS

(ARI). A

TTEMPTING TO

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 with ASHRAE Guide or Manual J - Load Calculations published by the Air Conditioning Contractors of America.

Obtain from:

American National Standards Institute

1430 Broadway

New York, NY 10018 System design and installation should also, where applicable, follow information presented in accepted industry guides such as the ASHRAE Handbooks. The manufacturer assumes no

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 connections; and drain connections (if required). The internal systems of the unit are completely factory-installed and tested prior to shipment.

Units are generally installed on a steel roof mounting curb assembly which has been shipped to the job site for installation on the roof structure prior to the arrival of the unit. The model number shown on the unit’s identification plate identifies the various components of the unit such as refrigeration tonnage, heating input and voltage.

Carefully inspect the unit for damage including damage to the cabinetry . Any bolts or screws which may have loosened in transit must be re-tightened. In the event of damage, the receiver should:

1. Make notation on delivery receipt of any visible damage to shipment or container.

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.

NOTE: When inspecting the unit for transportation damage, remove all packaging materials. Recycle or dispose of the packaging material according to local codes.

PRE-INSTALLATION CHECKS

Carefully read all instructions for the installation prior to installing unit. Ensure each step or procedure is understood and any special considerations are taken into account before starting installation. Assemble all tools, hardware and supplies needed to complete the installation. Some items may need to be purchased locally.

UNIT LOCA TION

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

IMPORTANT NOTE: Remove wood shipping rails prior to

installation of the unit.

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, dangerous 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.

• For proper flame pattern within the heat exchanger

and proper condensate drainage, the unit must be mounted level.

• The flue outlet must be at least 12 inches from any

opening through which flue gases could enter a building, and at least three feet above any forced air inlet located within ten feet. The economizer/manual fresh air intake/motorized fresh air intake and combustion air inlet mounted on the unit are not affected by this restriction.

• To avoid possible corrosion of the heat exchanger,

do not locate the unit in an area where the outdoor air (i.e. combustion air for the unit) will be frequently contaminated by compounds containing chlorine or fluorine. Common sources of such compounds include swimming pool chemicals and chlorine bleaches, paint stripper, adhesives, p aints, varnishes, sealers, waxes (which are not yet dried) and solvents used during construction and remodeling. V arious commercial and industrial processes may also be sources of chlorine/ fluorine compounds.

• To avoid possible illness or death of the building

occupants, do NOT locate outside air intake device (economizer, manual fresh air intake, motorized fresh air intake) too close to an exhaust outlet, gas vent termination, or plumbing vent outlet. For specific distances required, consult local codes.

• Allow minimum clearances from the enclosure for fire

protection, proper operation, and service access (see unit clearances). These clearances must be permanently maintained.

• The combustion air inlet and flue outlet on the unit

must never be obstructed. If used, do not allow the economizer/manual fresh air damper/ motorized fresh air damper to become blocked by snow or debris. In some climates or locations, it may be necessary to elevate the unit to avoid these problems.

• When the unit is heating, the temperature of the return

air entering the unit must be between 50° F and 100° F.

GROUND LEVEL INSTALLATIONS ONLY:

• When the unit is installed on the ground adjacent to

the building, a level concrete (or equal) base is recommended. Prepare a base that is 3” larger than the package unit footprint and a minimum of 3” thick.

• The base should also be located where no runoff of

water from higher ground can collect in the unit.

ROOF TOP INSTALLATIONS ONLY:

• T o 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.

• The unit may be installed directly on wood floors or

on Class A, Class B, or Class C roof covering material.

• To avoid possible personal injury, a safe, flat surface

for service personnel should be provided.

• As indicated on the unit data plate, a minimum

clearance of 36” to any combustible material is required on the furnance 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 furance flue discharge must not be blocked for any reason, including blockage by snow.

• 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)

• Minimum horizontal clearance of 48” from the furnace

flue discharge to any electric meters, gas meters, regulators and relief equipment is required.

UNIT PRECAUTIONS

• Do not stand or walk on the unit.

• Do not drill holes anywhere in panels or in the base frame of the unit. Unit access panels provide structural support.

• 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 achitect.

• 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.

Full perimeter roof curbs are available from the factory and are shipped unassembled. Field assembly, squaring, leveling 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.

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEAT H, THE FOL LOWING BU LLET POINTS MUST BE OB SERVED WHEN INSTALLING THE UNIT.

• Sufficient structural support must be determined prior

to locating and mounting the curb and package unit.

• Ductwork must be constructed using industry

guidelines. The duct work must be placed into the roof curb before mounting the package unit. Our full perimeter curbs include duct connection frames to be assembled with the curb. Cantilevered type curbs are not available from the factory.

• Curb insulation, cant strips, flashing and general

roofing material are furnished by the contractor. The curbs must be supported on parallel sides by roof members. The roof members must not penetrate supply and return 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 installaton after unit placement is not recommended.

CAUTION

ALL

CURBS LOOK SIMILAR POSITIONING, CHECK JOB PLANS CAREFULLY AND VERIFY MARKINGS ON CURB ASSEMBLY SUPERSEDES INFORMATION SHOWN

See the manual shipped with the roof curb for assembly and installation instructions.

. TO

AVOID INCORRECT CURB

. I

NSTRUCTIONS MAY VARY IN CURB STYLES AND

CLEARANCES

ROOF CURB INSTALLATIONS ONLY:

Curb installatons 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.

48”

75”

Unit Clearances

Adequate clearance around the unit should be kept for safety , service, maintenance, and proper unit operation. A total clearance of 75” on the main control panel side of the unit is recommended to facilitate possible fan shaft, coil, electric heat and gas furnace removal. A clearance of 48” is recommended on all other sides of the unit to facilitate possible compressor removal, to allow service access and to insure proper ventilation and condenser airflow. The unit must not be installed beneath any obstruction. The unit should be installed remote from all building exhausts to inhibit ingestion of exhaust air into the unit fresh air intake.

CAUTION

PROTRUSIONS EXIST, DO NO ATTEMPT TO SET UNIT ON CURB

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.

Ensure that the top of the duct connection frame is flush with the top of the roof curb.

Flexible duct connectors between the unit and ducts are recommended. Insulate and weatherproof all external ductwork and joints as required and in accordance with local codes.

11” 4 7/8””

INSULATED PANELS

Roof Curb Installation

ROOF CURB POST-INST ALLA TION CHECKS

After installation, check the top of the curb, duct connection frame and duct flanges to make sure gasket has been applied properly. Gasket should be firmly applied to the top of the curb perimeter, duct flanges and any exposed duct connection frame. If gasket is loose, re-apply using strong weather resistant adhesive.

PROTRUSION

Inspect curb to ensure that none of the utility services (electric) routed through the curb protrude above the curb.

REMOVE COVERS

17” 7 3/8”

12”

SUPPL Y

6 3/16”

Horizontal Discharge Duct Connections

25”

RIGGING DET AILS

WARNING

O PREVENT PROPERTY DAMAGE, THE UNIT SHOULD REMAIN IN AN UPRIGHT

POSITION DURING ALL RIGGING AND MOVING OPERATIONS. LIFTING AND MOVING WHEN A CRANE IS USED, PLACE THE UNIT IN AN ADEQUATE CABLE SLING.

O FACILITATE

CAUTION

UNITS ARE LIFTED TWO AT A TIME, THE FORK HOLES ON THE CONDENSER END OF THE UNIT MUST NOT BE USED LENGTH IS IS RECOMMENDED

42” TO

PREVENT DAMAGE TO THE UNIT; HOWEVER

. M

INIMUM FORK

, 48”

Provisions for forks have been included in the unit base frame. No other fork locations are approved.

WARNING

O 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. S preader bars must be of sufficient length so that cables do not come in contact with the unit during transport. Remove wood struts mounted beneath unit base frame before setting unit on roof curb. These struts are intended to protect unit base frame from fork lift damage. Removal is accomplished by extracting the sheet metal retainers and pulling the struts through the base of the unit. Refer to rigging label on the unit.

Important: If using bottom discharge with roof curb, ductwork should be attached to the curb prior to installing the unit. Ductwork dimensions are shown in Roof Curb Installation Instructions.

Refer to the Roof Curb Installation Instructions for proper curb installation. Curbing must be installed in compliance with the National Roofing Contractors Association Manual.

Lower unit carefully onto roof mounting curb. While rigging unit, center of gravity will cause condenser end to be lower than supply air end.

To assist in determining rigging requirements, unit weights are shown as follows:

CONDENSER

COIL

COMPRESSOR

RETURN

EVAPOR ATOR COIL

SUPPL Y

Corner & Center of Gravity Locations

Operating

Weight

(lbs)

Corner Weights ( lbs )

ABCD

Model

(in)

Shipping

Weight

(lbs)

CPG036045* 37 30 550 525 100 165 100 165 CPG036090* 37 30 560 535 100 170 100 170 CPG048090* 37 30 600 575 110 180 110 180 CPG048115* 37 30 605 580 110 180 110 180 CPG060090* 37 30 645 620 115 190 120 195 CPG060140* 37 30 655 630 120 195 120 195 CPG072140* 37 30 715 690 130 215 130 215

* Weights shown are belt drive with no accessories.

CAUTION

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

PREVENT DAMAGE TO THE UNIT, DO NOT ALLOW CRANE HOOKS

AND SPREADER BARS TO REST ON THE ROOF OF THE UNIT

Remove spreader bars, lifting cables and other rigging equipment.

ELECTRICAL WIRING

WARN ING

HIGH VOLTAGE!

ISCONNECT ALL POWER BEFORE SERVICI NG OR

INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWER SOURCES MAY

Electrical Code. If long wires are required, it may be necessary to increase the wire size to prevent excessive voltage drop. Wires should be sized for a maximum of 3% voltage drop.

O AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE

ONLY COPPER CONDUCTORS.

CAUTION

WARN ING

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DO NOT TAMPER WITH FACTORY WIRING

. THE

OF THESE UNITS ARE FACTORY-INSTALLED AND HAVE BEEN THOROUGHLY TESTED PRIOR TO SHIPMENT

ONTACT YOUR LOCAL REPRESENTATIVE IF

ASSISTANCE IS REQUIRED

INTERNAL POWER AND CONTROL WIRING

CAUTION

PREVENT DAMAGE TO THE WIRING, PROTECT WIRING FROM SHARP EDGES LOCAL CODES AND ORDINANCES REMOVABLE ACCESS PANELS

. F

OLLOW NATIONAL ELECTRICAL CODE AND ALL

. DO

NOT ROUTE WIRES THROUGH

CAUTION

ONDUIT 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.

All line voltage connections must be made through weatherproof fittings. All exterior power supply and ground wiring must be in approved weatherproof conduit.

CAUTION

O PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING ERRORS,

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

ERIFY PROPER OPERATION AFTER SERVICING.

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.

• Some disconnect switches are not fused. Protect the power leads at the point of distribution in accordance with the unit data plate.

• The unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the latest edition of the National Electrical Code (ANSI-NFPA 70). A ground lug is provided for this purpose. Size grounding conductor in accordance with T able 250-95 of the National Electrical Code. Do not use the ground lug for connecting a neutral conductor.

• Connect power wiring to the compressor contactor closest to the entrance located within the main control box.

MAIN POWER

LOW VOLTAGE BLOCK

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 Electriacl 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).

The main power supply for the CPG036XXX3,4,7 through CPG072 shall be three-phase, three wire. The power supply for the CPG036XXX1 through CPG060 shall be singlephase, two wire. The unit is factory wired for the voltage shown on the unit’s data plate.

NOTE: If supply voltage is 208V, lead on primary of transformer 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 accordance with the ampacity tables in Article 310 of the National

LOW VOLTAGE ENTRANCE

POWER THRU THE CURB

Power and Low Voltage Block Connections

WARN ING

AILURE 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

Areas Without Convenience Outlet

(Hig

)

It is recommended that an independant 115V power source be brought to the vicinity of the roof top unit for portable lights and tools used by the service mechanic.

UNITS INSTALLED ON ROOF TOPS

Main power and low voltage wiring may enter the unit through the condenser end of unit 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 leakage into building. All required conduit and fittings are to be field supplied.

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.

HIGH VOLTAGE ENTRANCE

(REMOVE PLUG)

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 #16 A WG 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 condenser end of unit or through curb. Connect thermostat and any accessory wiring to low voltage terminal block TB1 in the main control box.

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.

12 3/8”

30 1/4”*

47 1/2”

1:4

LOW VOLTAGE ENTRANCE

3.5 DIA.

4 1/2”

7 1/2”

* (6 Ton - 34 1/4”)

Electrical Entrance and Thru Curb

POWER THRU THE CURB

Unit is equipped with a Low Voltage Terminal Block and has Single Point wiring to the contactor.

LOW VOLTAGE CONTROL WIRING

1. A 24V 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.

LEAD THERMOSTAT

Re d R (24V)

Green G (Fan) Yellow Y1 (High Cool) Purple Y2 (Low Cool)

Blue C om m on ( if req'd)

White W1 (Heat)

Brown W2

CPG 036 Thru 072 (Gas Heat)

h Heat

GAS SUPPL Y PIPING

WARN ING

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER

. FOR

ADDITIONAL

IMPORTANT NOTE: This unit is factory set to operate on

natural gas at the altitudes shown on the rating plate.

WARN ING

AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH WHEN EITHER USING PROPANE GAS ALONE OR AT HIGHER ALTITUDES OBTAIN AND INSTALL THE PROPER CONVERSION KIT(S DO SO CAN RESULT IN UNSATISFACTORY OPERATION AND/OR EQUIPMENT DAMAGE

NSTALLATIONS ONLY AND ARE NOT APPROVED FOR USE IN CANADA

. H

IGH ALTITUDE KITS ARE FOR

). F

U.S.

AILURE TO

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 appropriate kit). For High Altitude derates, refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1.

INLET GAS PRESSUR E

NATURAL

PROPANE

IInlet Gas Pressure Must Not Exceed the Maximum Value Shown in Table Above.

Min. 5.0" W .C. , Max . 10 .0" W.C. Min. 11.0" W .C. , M ax . 14 .0" W .C.

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

IMPORT ANT NOTE: T o 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 .

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.

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.

7. Tighten all joints securely.

8. The unit must be connected to the building piping by one of the following methods:

• Rigid metallic pipe and fittings

• Semirigid metallic tubing and metallic fittings (Aluminum alloy tubing must not be used in exterior locations)

• Listed gas appliance connectors used in accordance with the terms of their listing that are completely in the same room as the equipment

• In the prior two methods above the connector or tubing must be protected from physical and thermal damage. Aluminum alloy tubing and connectors must be coated to protect against external corrosion when in contact with masonry, plaster or insulation or are subject to repeated wettings by liquids (water - not rain water, detergents or sewage).

BURNER DOOR

Natural Gas Connection

Natural Gas Capaci ty of Pipe

in Cubic Feet of Gas Per H our (C FH)

Length of

Pipe in Feet

10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 980 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610 70 46 96 180 370 560 80 43 90 170 350 530 90 40 84 160 320 490

100 38 79 150 305 460

Pressure = .50 PSIG or less and Pressure Drop of 0.3" W.C. (Based

CFH =

Heatin

Nominal Black Pipe Si ze (i nches)

1/2 3/4

on 0.60 S

BTUH Furnace Input

Va lu e o f Ga s (BTU/Cubic Foot

ecific Gravity Gas

1 1/4 1 1/2

Refer to the Proper Piping Practice drawing for the general layout at the unit. The following rules apply:

1. Use black iron pipe and fittings for the supply piping. The use of a flex connector and/or copper piping is permitted as long as it is in agreement with local codes.

2. Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used.

3. Use ground joint unions.

TBD

MANUAL SHUT-OFF

GROUND JOINT UNION

DRIP LEG

Proper Piping Practice

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.

GAS PIPING CHECKS

CAUTION

O PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS AND PRESSURE TESTING:

HE UNIT AND ITS GAS CONNECTIONS MUST BE LEAK TESTED BEFORE

•

PLACING IN OPERATION. FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. EXCEED SPECI FIED PRES SURES FOR TESTI NG. DAMAGE GAS VALV E AND CAUSE OVERFIRING WHICH MAY RESULT IN PREMATURE HEAT EXCHANGE FAILURE.

HIS UNIT AND ITS SHUT-OFF VALVE MUST BE DISCONNECTED FROM

•

THE GAS S UPPLY DURING ANY PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSUR E S IN EX CES S OF 1/2

HIS UNI T MUST BE I SOLAT ED FROM THE GAS SUPPL Y SYS TEM BY

•

CLOSING ITS MANUAL SHUT-OFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PI PING SYSTEM AT TEST PRESSURE S EQUAL TO OR LESS THAN 1/2

ECAUSE OF THE DANGER OF EXPLOSION OR

IGHER PRESSURE MAY

(3.48 KPA).

PSIG

(3.48 KPA).

PSIG

WARNING

EVER

1. Vaporization rate, which depends on (a) temperature of the liquid, and (b) wetted surface area of the container or containers.

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.

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.

O AVOID PROPERTY DAMAGE OR PERSONAL INJURY

NO OPEN FLAME IN THE VICINITY DURING AIR BLEEDING.

, BE SURE THERE IS

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.

PROP ANE GAS INST ALLA TIONS

WARNING

O AVOID PROPERTY DAMAGE, PERSONAL INJURY O R DEATH DUE TO FIR E

OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A G AS DETECTING WARNING DE VICE. OF ODORANT IN PROPANE GAS, A GAS DETECTING W ARNING DEVICE IS THE ONLY RELIABLE WAY TO DETECT A PROPANE GAS LEAK.

ONTACT A LOCAL PROPANE GAS SUPPLIER ABOUT INSTALLING A

GAS DETECTING WARNING DEVICE.

INCE RUST CAN REDUCE THE LEVEL

First Stage Regulator

200 PSIG Maximum

5 to 15 PSIG (20 PSIG Max.)

Continuous

Second Stage Regulator

11" W.C.

Typical Propane Gas Piping

ROOF TOP LOCATION AND INSTALLATION

The gas supply piping location and installation for roof top units must be in accordance with local codes or, in the absence of locals codes, with ordinances of the latest edition of the National Fuel Gas Code (ANSI Z223.1).

A manual gas shutoff valve must be field inst alled external to the roof top unit. In addition, a drip leg must be installed near the inlet connection. A ground joint union connection is required between the external shutoff valve and the unit connection to the gas valve to permit removal of the burner assembly for servicing.

IMPORTANT NOTE: Propane gas conversion kits must be installed to convert units to propane gas. NOx screens must be removed before converting to LP. Remove burner assembly and pull NOx screens from each burner tube. When all the screens are out, reassemble the burner assembly without the screens.

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters (See NBFU Manual 58).

For satisfactory operation, propane gas supply pressure must be within 9.7 - 10.3 inches W.C. at the manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

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.

2. All units are furnished with standard female NPT pipe connections. Connection pipe sizes for CPG036 through 072 units is 1/2" NPT on 045 to 140 mBH units. 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).

NOTE: The gas connection size at the unit does NOT establish the size of the supply line.

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 inst all an external type positive shutoff service pressure regulator. The unit will not function satisfactorily if supply gas pressure is less than 5.5" w.c. or greater than 10.5" w.c..

NOTE: A minimum horizontal distance of 48" between the regulator and the furnace flue discharge is required.

5. With all units on a common line operating under full LP gas main supply pressure should be at least 1 1.0" w.c. and must be no greater than 13.0" w .c., measured at the unit gas valve. Unit will not function satisfactorily if supply gas pressure is less than 1 1.0" w.c. or greater than 13.0" w.c..

6. All pipe connections should be sealed with a pipe thread compound, which is resistant to the fuel used with the furnace. A soapy water solution should be used to check all joints for leaks. A tap is located on the entering side of the gas valve for test gauge connection to measure supply (main) gas pressure. Another tap is provided on the manifold side of the gas valve for checking manifold pressure.

WARN ING

HIS UNIT AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE

DISCONNECTED

PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN EXCESS OF

1/2 PSIG (13.8” W.C.).

FROM THE GAS SUPPLY SYSTEM DURING ANY

CIRCULA TING AIR AND FILTERS

DUCTWORK

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 prevent air leaks.

Ductwork dimensions are shown in the roof curb installation manual.

If desired, supply and return duct connections to the unit may be made with flexible connections to reduce possible unit operating sound transmission.

VENTING

NOTE: Venting is self-contained.

CONDENSA TE DRAIN CONNECTION

CONDENSATE DRAIN CONNECTION

A 3/4” NPT drain connection is supplied for condensate piping. An external trap must be inst alled for proper condensate drainage.

DRAIN CONNECTION

UNIT 2" MINIMUM

FLEXIBLE TUBING-HOSE OR PIPE

A POSITIVE LIQUID SEAL IS REQUIRED

Drain Connection

3" MIN IMUM

Install condensate drain trap as shown. Use 3/4" drain line and fittings or larger. Do not operate without trap.

HORIZONTAL DRAIN

Drainage of condensate directly onto the roof may be acceptable; 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.

CAUTION

HIS UNIT MUST BE SYSTEM BY CLOSING ITS INDIVIDUAL MANUAL SHUTOFF VALVE DURING ANY PRESSURE TESTING EQUAL TO OR LESS THAN

PSIG.

ISOLAT ED

FROM THE GAS SUPPLY PIPING

1/2

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 cleaning is necessary to prevent this build-up from plugging the drain.

ST ARTUP , ADJUSTMENTS, AND CHECKS

WARN ING

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, B THE BUILDING ELECTRICAL GROUND BY USE OF THE GROUNDING TERMINAL PROVIDED OR OTHER ACCEPTABLE MEANS SERVICING OR INSTALLING THIS UNIT

OND THE FRAME OF THIS UNIT TO

. D

ISCONNECT ALL POWER BEFORE

TOOLS REQUIRED

Refrigeration gauge and manifold Voltmeter Clamp-on ammeter Ohmmeter Test lead (Minimum #16 AWG with insulated alligator clips) Manometer for verifying gas pressure 0 to 20" w.c. Air temperature measuring device General refrigeration mechanics’ tools

PRE-STARTUP INSTRUCTIONS

CAUTION

PREVENT PROPERTY DAMAGE OR PERSONAL INJURY START THE UNIT UNTIL ALL NECESSARY PRE-CHECKS AND TESTS HAVE BEEN PERFORMED

, DO

NOT

Prior to the beginning of Startup, Adjustments, and Checks procedures, the following steps should be completed in the building.

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.

WARN ING

MOVING MACHINERY HAZARD!

O PREVENT POSSIBLE PERSONAL INJURY OR DEATH, DISCONNECT

POWER TO THE UNIT AND PADLOCK IN THE SERVICNG FANS

“OFF”

POSITION BEFORE

HEATING STARTUP

This unit is equipped with an electronic ignition device to automatically 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 replaced, the operation of the unit must be checked.

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.

CONTRACTOR RESPONSIBILITY

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.

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 contractor.

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 obstructions 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 procedure. The Startup, Adjustments, and Checks procedure at outside ambients below 55°F should be limited to a readiness 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 materials 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. Retighten 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 Appendix C Electrical Data.

System Voltage - That nominal voltage value assigned to a circuit or system for the purpose of designating its voltage class.

Nameplate Voltage - That voltage assigned to a piece of equipment for the purpose of designating its voltage class and for the purpose of defining the minimum and maximum voltage at which the equipment will operate.

Utilization Voltage - The voltage of the line terminals of the equipment at which the equipment must give fully satisfactory performance. Once it is established that supply voltage will be maintained within the utilization range under all system conditions, check and calculate if an unbalanced condition exists between phases. Calculate percent voltage unbalance as follows.

Three Phase Models Only

2) MAXIMUM VOLTAGE DEVIATIONS

3) PERCENT VOLTAGE UNBALANCE

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 Deviation s fro m Average Voltage = 220 - 216 = 4

3) Percent Voltage Unbalance = 100 x = = 1.8%

Percent voltage unbalance MUST NOT exceed 2%

= 100 X

FROM AVERAGE VOLT AG E

1) AVERAGE VOLTAGE

216

400 216

SET EVAPORATOR FAN RPM

Actual RPM’s must be set and verified with a tachometer or strobe light. Refer to Appendices A and B for basic unit fan RPM. Refer also to “Airflow” section of this manual. With disconnect switch open, disconnect thermostat wires from terminals Y and W . This will prevent heating and mechanical cooling from coming on. Place a jumper wire across terminals R and G at TB1 terminal block. Close disconnect switch; evaporator fan motor will operate so RPM can be checked.

For gas heat units, the airflow must be adjusted so that the air temperature rise falls within the ranges given stated on Data Plate (see Appendix A - Blower Performance).

TENSION AND ALIGNMENT ADJUSTMENT

Correct belt tension is very important to the life of your belt. Too loose a belt will shorten its life; too tight, premature motor 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.

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, disconnect blue wire from low voltage transformer TRANS1. Close the disconnect switch to energize TRANS1 control transformer. Check primary and secondary (24V) of control transformer TRANS1.

THERMOSTAT PRELIMINARY CHECK

With disconnect switch open and blue wire disconnected from TRANS1 transformer, att ach one lead of ohmmeter to terminal R on TB1 terminal block. Touch, in order, the other ohmmeter 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.

FILTER SECTION CHECK

Remove filter section access panels and check that filters are properly installed. Note airflow arrows on filter frames.

BELT DRIVE MODELS ONLY

BEARING CHECK

Prior to energizing any fans, check and make sure that all setscrews are tight so that bearings are properly secured to shafts.

Belt Tension Adjustment

t = Span length, inches C = Center distance, inches D = Larger sheave diameter, inches

d = Smaller sheave diameter, inches h = Deflection height, inches

SMALL

TYPE DEFLECTION

BELT DRIVE USED NEW

AX Standard 3.0 to 4.0 4.2 ± 0.5 5.5 ± 0.5 0.313

Recommended Pounds of Force Per Belt

SHEAVE

DIAMETER

(in)

DEFLECTION

FORCE (lbs)

(in)

New V-belts will drop rapidly during the first few hours of use. Check tension frequently during the first 24 hours of operation. T ension should fall between the minimum and maximum force. To determine the deflection distance from a normal position, measure the distance from sheave to sheave using a straightedge or a cord. This is your reference line. On multiple belt drives, an adjacent undeflected belt can be used as a reference.

EVAPORATOR FAN ROTATION CHECK (THREE PHASE MODELS ONLY)

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 bearing check.

Do not attempt to change load side wiring. Internal wiring assures all motors and compressors will rotate in correct direction once evaporator fan motor rotation check has been made.

ELECTRICAL INPUT CHECK

Make preliminary check of evaporator fan ampere draw and verify that motor nameplate amps are not exceeded. A final check of amp draw should be made upon completion of air balancing of the duct system (see Appendix C).

RESTORING CONNECTIONS

With disconnect switch open, remove jumper wire from terminals R and G at TB1 terminal block, and reconnect thermostat wires to terminals Y and W.

REFRIGERATION SYSTEM CHECKS

Ensure the hold-down bolts on the compressor are secure and have not vibrated loose during shipment. Check that vibration grommets have been installed. Visually check all piping and clamps. The entire refrigeration system has been factory charged and tested, making it unnecessary to field charge. Factory charges are shown in Appendix C and on the unit nameplate.

Install service manifold hoses. Gauges should read saturation pressure corresponding to ambient temperature. Charge should be checked to obtain 12° to 15° of sub-cooling per system (i.e. compressor circuits).

If the power to the unit is interrupted during the heating cycle, it may cause the secondary limit to trip. Once the blower compartment temperature drops below the limit reset temperature, the limit will automatically reset. The unit will restart after one (1) hour.

Pre-Operation Checks

1. Close the manual gas valve external to the unit.

2. Turn off the electrical power supply to the unit.

3. Set the room thermostat to its lowest possible setting.

4. Remove the heat exchanger door on the side of the unit by removing screws.

5. This unit is equipped with an ignition device which automatically lights the main burner. DO NOT try to light burner by any other method.

6. Move the gas control valve switch to the OFF position. Do not force.

7. Wait five minutes to clear out any gas.

8. Smell for gas, including near the ground. This is important because some types of gas are heavier than air. If you have waited five minutes and you do smell gas, immediately follow the warnings on page 3 of this manual. If having waited for five minutes and no gas smell is noted, move the gas control valve switch to the ON position.

9. Replace the heat exchanger door on the side of the unit.

10.Open the manual gas valve external to the unit.

11. Turn on the electrical power supply to the unit.

12.Set the thermostat to desired setting.

Gas Supply And Manifold Check

Gas supply pressure and manifold pressure with the burners operating must be as specified on the rating plate.

Gas Inlet Pressure Check

Gas inlet pressure must be checked and adjusted in accordance to the type of fuel being consumed.

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.

WARNING

O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE

OR EXPLOSION, A QUALIFIED SERVICER MUST INVESTIGATE THE REASON FOR THE ROLLOUT PROTECTION DEVICE TO OPEN BEFORE MANUALLY RESETTING THE ROLLOUT PROTECTION DEVICE.

Secondary Limit Control

The secondary limit control is located on the top of the blower scroll assembly . This control opens when elevated temperatures are sensed. Elevated temperatures at the control are normally caused by blower failure. The reason for the opening should be determined and repaired prior to resetting.

With Power And Gas Off:

1. Connect a water manometer or adequate gauge to the inlet pressure tap of the gas valve. Inlet gas pressure can also be measured by removing the cap from the dripleg and installing a predrilled cap with a hose fitting.

With Power And Gas On:

2. Put unit into heating cycle and turn on all other gas consuming appliances.

INLET GAS PRESSUR E

NATURAL

PROPANE

Min. 5.0" W .C. , Max . 10 .0" W.C. Min. 11.0" W .C. , Max . 14.0" W .C.

NOTE: Inlet Gas Pressure Must Not Exceed the Maximum 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

The gas valve has a tapped opening to facilitate measurement of the manifold pressure. A “U” Tube manometer having a scale range from 0 to 12 inches of water should be used for this measurement. The manifold pressure must be measured with the burners operating.

1. With disconnect switch open, remove field connected thermostat wire from terminal R, W1 and W2 on TB1. Place jumper wire between R, W1 and W2 to engage high stage heat. (note on 045 kbtu/hr units W2 is not used, only jumper R to W1).

2. See Figure in input rating section for gas valve adjustment.

T o adjust the pressure regulator , remove the adjustment screw or cover on the gas valve. Turn out (counterclockwise) to decrease pressure, turn in (clockwise) to increase pressure. Only small variations in gas flow should be made by means of the pressure regulator adjustment. In no case should the final manifold pressure vary more than plus or minus 0.3 inches water column from the specified nominal pressure. Any major changes in flow should be made by changing the size of the burner orifices. The measured input rate to the furnace must not exceed the rating specified on the unit rating plate.

For natural gas, the high stage manifold pressure must be between 3.2 and 3.8 inches water column (3.5 nominal). Low stage manifold pressure must be between 1.7 to 2.3 inches water column (2.0 nominal).

3. To set low fire rate on 090, 1 15 and 140 kbtu/hr: Open disconnect switch, and remove jumper from R to W2. T o set low fire manifold pressure, repeat steps above. Refer to Figure in input rating section for location of high and low stage adjustment.

For propane gas, the manifold pressure must be between

9.7 and 10.3 inches water column (10.0 nominal). Low stage manifold must be between 5.7 and 6.3 inches water column (6.0 nominal).

4. Relight all other appliances turned off in step 1. Be sure all pilot burners are operating.

Main Burner Flame Check

Flames should be stable, soft and blue (dust may cause orange tips but they must not be yellow) and extending directly outward from the burner without curling, floating or lifting off.

NOx Screen Check

Verify that the alignment of the NOx screens is at 6 o' clock. In jurisdictions that do not require low NOx emissions, NOx screens may be removed.

Temperature Rise Check

Check the temperature rise through the unit by placing thermometers 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.

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 before taking readings.

2. The temperature rise must be within the range specified on the rating plate.

NOTE: Air temperature rise is the temperature difference between supply and return air.

With a properly designed system, the proper amount of temperature rise will normally be obtained when the unit is operated at rated input with the recommended blower speed.

If the correct amount of temperature rise is not obtained, it may be necessary to change the blower speed. A higher blower speed will lower the temperature rise. A slower blower speed will increase the temperature rise.

NOTE: Blower speed MUST be set to give the correct air temperature rise through the unit as marked on the rating plate.

Gas Input (Natural Gas Only) Check

To measure the gas input use a gas meter and proceed as follows:

1. Turn off gas supply to all other appliances except the unit.

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:

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.

REFRIGERATION SEQUENCE CHECK

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 following operational sequence should be observed.

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 Y of terminal block TB1. The cooling is energized when the room temperature is above the thermostat setpoint for cooling. The thermostat makes R to Y.

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.

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.

PSC Motor

Adjust the CFM for the unit by changing the speed tap of the indoor blower motor at the EBTDR “com” connection with one of the speed taps on “M1” or “M2”. (Black-High Speed, Blue-Medium Speed, Red-Low Speed.)

EEM Motor

Adjust the CFM for the unit by changing the position of the low voltage leads on the motor terminal block. White is for fan only and gas heat, Y ellow is for cooling. Refer to Appendix A for blower performance at each speed tap. NOTE: If more than one lead is energized simultaneously , the motor will run at the higher speed.

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. In addition, cont actor C1 closes its contact L3 to T3 , energizing the condenser fan motor.

WARN ING

7. Disconnecting the jumper wire between R and Y and between R and G on TB1 terminal block will simulate a satisfied thermostat. The compressor will cycle off and IIC (pin 12) will initiate its time delay cycle. The compressor and the supply fan will cycle off.

8. 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.

9. Open disconnect switch. Reconnect the field thermostat wire at terminal R on terminal block TB1.

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 corresponding to the compressor saturated discharge pressure. Check that compressor RLA corresponds to values shown in Appendix C. RLA draw can be much lower than values listed at low load conditions and low ambient condensing temperatures. Values in Appendix C can slightly exceed at high load conditions and high ambient condensing temperatures.

GAS SUPPLY PRESSURES & REGULATOR ADJUSTMENTS

WARN ING

HOULD 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 T OUCH! DISCHARGE LINE MAY BE HOT!

BURN HA Z ARD!

7. Check that the 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 the compressor is started.

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.

• 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.

• 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.

6. With all safety devices closed, the system will continue cooling operation until the thermostat is satisfied.

WARN ING

AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO

NOT FIRE GAS UNIT WITH FLUE BOX COVER REMOVED

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 p anel is provided to monitor the flame.

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 extremely 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.

The supply gas pressure should be adjusted to 7.0" w.c. on natural gas and 1 1.0" on LP gas with the gas burners operating. 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 gas valve. The normal manifold pressure for full input is 3.5" w .c. on natural gas and 9.5" w.c. for propane gas. Low fire natural gas 2.0” w.c., 6.0” low fire propane gas. Minimum gas supply pressure is 5.5" w.c. for natural gas and 11.0" for propane gas. In order to obtain rating, gas supply pressure must be 11.0" w.c. for propane gas.

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.

The pressure regulator on LP gas models is adjusted for 9.5" w.c. manifold pressure and is intended to prevent over-firing only . Do not attempt adjustment of the built-in pressure regulator unless the supply pressure is at least 7.0" w.c. on natural gas or 13.0" w.c. on propane gas. Check the location of the ignition electrode and the flame sensor for correct gap setting.

Flame Sensor and Ignition Electrode Location

MAXIMUM

INPUT

(BTUH)

45,000 2 23,000 #43 #55

115,000 5 23,000 #43 #55 140,000 6 23,000 #43 #55

90,000 4 23,000 #43 #55

NUMBER

BURNERS

Heat Exchanger and Burner Orifice Specifications

MAXIMUM

BTUH/BURNER

GAS ORIFICES

NATURAL

(Dia)

PROPANE (LP)

(Dia)

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.

Unit Shutdown

1. Set the thermostat to lowest setting.

2. Turn off the electrical power supply to the unit.

NORMAL SEQUENCE OF OPERA TION

HEATING

This unit has one (RS) Manual Reset Limit Control Switch. Check the limit to make sure it has not tripped. The limit may arrive at the job site tripped as a result of shipping shock.

If the ventermotor comes on, but the unit does not attempt ignition, check if the ALS (Auxiliary High Limit Control Switch) requires resetting.

1. With electricity and gas turned on, the system switch in the “HEAT” or “AUTO” position and the fan switch in the “AUTO” position, the thermostat will close the circuit between unit terminals R and W (R-W) when the temperature falls below the thermostat setting.

2. D1 on IIC energizes relay IDMR.

3. Relay IDMR energizes the ventermotor IDM.

4. Operation of the ventermotor closes the pressure switch PS located in the burner compartment. Unless excessive temperatures or shipping shock have opened high limit control ALS, power is fed to the integrated ignition control, which then initiates a 15second pre-purge time delay. During this period, the ventermotor 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 one (1) micro-amp DC current will flow through the flame between the sensor electrode and the grounded burner.

7. When the controller proves that the flame has been established, it will keep the gas valve energized and discontinue the ignition spark. High stage manifold pressure will be approximately 3.5" w.c. for natural gas and 10.0" w.c. for propane (LP). Low fire natural gas is 2.0” w.c.; low fire propane 6.0” w.c.

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.)

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 1. The furnace has three high temperature limit controls,

which can shut down the burner. They do not shut down the ventermotor.

AUTOMATIC RESET HIGH LIMIT CONTROL (LS)

Located in the burner compartment on the heat exchanger, its sensing element projects through the blower section bulkhead 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.

AUXILIARY 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)

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 rolling out instead of entering the tubes. It has a manual pushbutton 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 interpretation of the signal and to this section for an explanation.

Remove the control box access panel and note the number of diagnostic LED flashes. Refer to Diagnostic Indicator Chart for an interpretation of the signal and to this section for an explanation.

ABNORMAL OPERATION - HEATING

Internal Control Failure

If the integrated ignition control in this unit encounters an internal 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, replace control.

External Lockout

An external lockout occurs if the integrated ignition control determines that a measurable combustion cannot be established within three (3) consecutive ignition attempts. If flame is not established within the seven (7) second trial for ignition, 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.

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 subsequent attempts, the control will recycle for four (4) consecutive ignition attempts (five attempts total) before locking out.

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 electrical power supply for over five seconds. If the diagnostic LED indicates an external lockout, perform the following checks:

• 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.

• 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.

IMPORTANT: If you have to frequently reset your gas/electric package unit, it means that a problem exists that should be corrected. Contact a qualified servicer for further information.

Pressure Switch Stuck Open

A pressure switch stuck open can be caused by a faulty pressure 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 prepurge 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 begins, and the induced draft blower remains on. The diagnostic fault code is two flashes.

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 remains off. The diagnostic LED code for this fault is three (3) flashes.

Open Thermal Protection Device

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 diagnostic fault code for an open limit is four (4) flashes.

A primary limit will open due to excessive supply air temperatures. This can be caused by a dirty filter, excessive duct static, insufficient air flow , or a faulty limit. Check filters, tot al 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.

INPUT RA TING

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:

NPUT Btu/Hr =

WHERE: HV = Heating value of fuel = B tu/ft of gas T = Time in seconds per ft of gas flow as read from gas meter

Adjust input rate by varying the adjustment of the gas pressure 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 regulator screw increases pressure and gas flow rate. Turn screw counterclockwise (Q) to decrease pressure and gas flow rate. After adjustment the furnace temperature rise must be within the range specified on the unit data plate. NOTE: Thermal efficiency of the furnace is a product efficiency rating determined under continuous operating conditions independent of any installed system.

Outlet Pre ssure

INLET

3600 x HV

Tap

Pressure Regulator

Adjustment

(Under Cap Screw)

OUTLET

Flame Detected with Gas Valve Closed

If flame is detected with the gas valve deenergized, the combustion and air circulator blowers are energized. The diagnostic fault code is five (5) flashes for this condition. The control can be reset by removing the power supply to the unit or it will automatically reset after one hour. Miswiring is the probable cause for this fault.

ABNORMAL OPERATION - COOLING

Short Cycle Compressor Delay

The automatic ignition control has a built-in feature that prevents damage to the compressor in short cycling situations. In the event of intermittent power losses or intermittent thermostat 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 compressor contactor output is being delayed.

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.

Inlet Pressure

Tap

Gas Valve

On/Off

Selector

Switch

White-Rodgers 36G22 - Single Stage

Open t

Atmosphere

Inlet

Pressure Boss

White-Rodgers 36G54 (2-Stage) Connected to Manometer

Outlet

Pressure Boss

Pressure Adjustments

High Fire Re gulator

Adjust

Regulator

Vent

Low Fire

Regulator Adjust

To connect manometer to gas valve:

1. Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more than one turn).

2. Attach a hose and manometer to the outlet pressure boss of the valve.

To remove manometer from gas valve:

1. Remove manometer hose from outlet pressure boss.

2. Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb. minimum).

3. Turn on electrical power and gas supply to the system.

4. Turn on system power and energize valve.

5. Using a leak detection solution or soap suds, check for leaks at pressure boss screw. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY.

CAUTION

PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ADJUSTING THE GAS VALVE PRESSURE REGULATOR

. O

NLY MINOR ADJUSTMENTS SHOULD BE MADE BY

AIR FLOW ADJUSTMENTS

The drive on the supply fan is typically set in the middle of the RPM range. The drive motor sheave pitch diameter is field adjustable for the required airflow. Refer to “Drive Adjustments” section below.

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 exceed the service factor stamped on the motor nameplate. The total airflow must not be less than that required for operation of the electric heaters or the furnace.

EEM Motor

Adjust the CFM for the unit by changing the position of the low voltage leads on the motor terminal block. Green is for Fan Only . Yellow is for Cooling and Heat Pump Heating. Refer to Appendix A for blower performance at each speed tap. NOTE: If more than one lead is energized simultaneously, the motor will run at the higher speed.

MOTOR SHEA VE ADJUSTMENTS

VL, VM, & 2VP VARIABLE PITCH KEY TYPE MOTOR SHEAVES

The driving and driven motor sheaves should be in alignment with each other and the shafts parallel.

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.

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.

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.

If an economizer is installed, check the unit operating balance 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 operation. 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 fan speed wire.

NOTE: Never run CFM below 350 CFM per ton, evaporator freezing or poor unit performance is possible.

PSC MOTOR

Adjust the CFM for the unit by changing the speed tap of the indoor blower motor at the heat or cool tap on the control board connection with the one of the speed taps on “M1” or “M2” (Black-High Speed, Blue-Medium Speed, Red-Low Speed).

VL & V M

Sheave

NOTE: Do NOT operate sheave with flange projecting

beyond the hub end.

MAINTENANCE

WARN ING

HIGH VOLTAGE!

ISCONNECT ALL POWER BEFORE SERVICI NG OR

INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWER SOURCES MAY

WARN ING

. FOR

ADDITIONAL

CAUTION

HEET METAL PARTS, SCREWS, CLIPS AND SIMILAR ITEMS INHERENTLY HAVE SHARP EDGES, AND IT IS NECESSARY THAT THE INSTALLER AND SERVICE PERSONNEL EXERCISE CAUTION

Preventive maintenance is the best way to avoid unnecessary expense and inconvenience. Have this system inspected at regular intervals by qualified service personnel, at least twice a year. Routine maintenance should cover the following items:

1. Tighten all belts, set screws, and wire connections.

2. Clean evaporator and condenser coils mechanically or with cold water, if necessary. Usually any fouling is only matted on the entering air face of the coil and can be removed by brushing.

3. Lubricate motor bearings.

4. Align or replace belts as needed.

5. Replace filters as needed (see below).

6. Check for blockage of condensate drain.

7. Check power and control voltages.

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).

14.Check condenser fans and tighten set screws.

FILTERS

CAUTION

O PREVENT PRO PERTY DAMAG E DUE TO FIRE AND LOSS O F 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.

Every application may require a different frequency of replacement of dirty filters. Filters must be replaced at least every three (3) months during operating seasons.

Dirty filters are the most common cause of inadequate heating or cooling performance. Filter inspection should be made at least every two months; more often if necessary because of local conditions and usage.

Disposable return air filters are supplied with this unit. See the unit Specification Sheet or Technical Manual for the correct size and part number. To remove the filters, remove the filter access panel on return side of the unit.

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 sunlight.

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 motor 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 invisible 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.

NOTE: After cleaning, the microamp signal should be stable and in the range of 4 - 6 microamps DC.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

At the start of each heating season, inspect and, if necessary, clean the unit flue passage.

LUBRICATION

The fan shaft bearings, the 1 to 2 HP supply fan motors the condenser fan motors and compressors are permanently lubricated.

INSPECTION & CLEANING

All flue product carrying areas of the furnace, its vent system, 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. Particular attention should be given to deterioration from corrosion or other sources. This examination is accomplished in the following manner.

1. Disconnect power to the unit and remove furnace section access panel.

2. Remove burner assembly:

a. Disconnect the wires from the gas valve after noting

which wires are connected to each terminal.

Dirty throwaway filters should be discarded and replaced with a new, clean filter.

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 C0 measurements are recommended. This will aid in determining whether the furnace is operating efficiently or if the furnace requires cleaning.

Flames should be stable, soft and blue (dust may cause orange tips but must not be yellow). The flames must extend directly outward from the burner without curling, floating or lifting off.

WARNING

O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,

DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. FLAME SHOULD DEVELOP.

ONTACT A QUALIFIED SERVICER AT ONCE IF AN ABNORMAL

At least once a year, prior to or during the heating season, make a visual check of the burner flames.

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.

If a strong wind is blowing, it may alter the airflow pattern within the unit enough that an inspection of the burner flames is not possible.

FUNCTIONAL PARTS

Refer to the unit Parts Catalog for a list of functional parts. Parts are available from your distributor.

Check the burner flames for:

1. Good adjustment

2. Stable, soft and blue

3. Not curling, floating, or lifting off.

Burner Flame

APPENDIX A BLOWER PERFORMANCE TABLES

3 T

ith

LOW

DIRECT DRIVE

CPG036 DOWN SHOT AND HORIZONTAL

CPG036 DIRECT DRIVE DOWN SHOT

SPEED TAP

LOW

MED

HIGH

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

0.10 1313 1.68 356 748

0.20 1247 1.63 344 786

0.30 1178 1.59 334 832

0.40 1094 1.55 324 869

0.50 1002 1.50 312 913

0.60 919 1.45 296 940

0.10 1471 2.11 454 830

0.20 1400 2.06 440 863

0.30 1354 2.02 432 896

0.40 1271 1.95 416 929

0.50 1188 1.90 398 957

0.60 1083 1.82 378 984

0.70 955 1.74 356 1012

0.30 1470 2.37 510 935

0.40 1390 2.31 492 957

0.50 1310 2.25 476 978

0.60 1206 2.17 454 1000

0.70 1098 2.09 436 1023

0.80 966 1.99 412 1045

STANDARD

CFM

AMPS WATTS RPM

CPG036 DIRECT DRIVE HORIZONTAL

EXTERNAL STATIC

SPEED TAP

LOW

MED

HIGH

NOTES: Tables represent dry coil wit hout filter, to compensate for filter add 0.08" to measured E.S.P. SCFM correction for wet coil = 4 %.

on models are shipped from the factory w

PRESSURE (ESP)

in w.c.

0.10 1293 1.72 364 715

0.20 1235 1.67 354 759

0.30 1173 1.62 342 803

0.40 1124 1.58 330 841

0.50 1056 1.54 316 880

0.60 978 1.47 298 913

0.10 1500 2.13 462 808

0.20 1434 2.10 448 838

0.30 1381 2.04 436 869

0.40 1318 2.00 424 902

0.50 1238 1.94 406 929

0.60 1163 1.88 392 951

0.70 1055 1.80 370 990

0.80 936 1.72 350 1017

0.40 1441 2.35 504 940

0.50 1355 2.28 484 962

0.60 1264 2.21 468 989

0.70 1157 2.13 446 1012

0.80 1027 2.03 418 1034

0.90 840 1.90 388 1067

STANDARD

CFM

speed tap set on

AMPS WATTS RPM

APPENDIX A BLOWER PERFORMANCE TABLES

DIRECT DRIVE

CPG048 DOWN SHOT AND HORIZONTAL

CPG048 DIRECT DRIVE DOWN SHOT

SPEED TAP

LOW

MED

HIGH

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

0.10 1592 2.54 543 815

0.20 1528 2.43 521 858

0.30 1464 2.32 499 901

0.40 1380 2.21 475 930

0.50 1296 2.10 451 959

0.10 1828 3.08 665 892

0.20 1700 2.75 601 924

0.30 1606 2.61 563 966

0.40 1531 2.48 537 990

0.50 1401 2.32 503 1023

0.60 1287 2.22 477 1045

0.70 1123 2.05 441 1073

0.10 1926 3.34 740 937

0.20 1825 3.18 700 965

0.30 1712 3.03 660 989

0.40 1598 2.87 626 1015

0.50 1482 2.76 596 1032

0.60 1357 2.62 564 1049

STANDARD

CFM

AMPS WATTS RPM

CPG048 DIRECT DRIVE HORIZONTAL

EXTERNAL STATIC

SPEED TAP

LOW

MED

HIGH

NOTES: Tables represent dry coil without filter, to comp ensate f or filt er add 0.08" to measured E.S.P. SCFM correction fo r wet coi l = 4 % . 4 Ton models are shipped from the factory with speed tap set on MED.

PRESSURE (ESP)

in w.c.

0.10 1612 2.60 554 789

0.20 1548 2.49 532 832

0.30 1484 2.38 510 875

0.40 1400 2.27 486 904

0.50 1316 2.16 462 933

0.10 1846 3.14 676 866

0.20 1718 2.81 612 898

0.30 1624 2.67 574 940

0.40 1549 2.54 548 964

0.50 1419 2.38 514 997

0.60 1305 2.28 488 1019

0.70 1141 2.11 452 1047

0.10 1954 3.43 758 924

0.20 1853 3.27 718 952

0.30 1740 3.12 678 976

0.40 1626 2.96 644 1002

0.50 1510 2.85 614 1019

0.60 1385 2.71 582 1036

STANDARD

CFM

AMPS WATTS RPM

APPENDIX A BLOWER PERFORMANCE TABLES

DIRECT DRIVE

CPG060 DOWN SHOT

CPG060 DIRECT DRIVE DOWN S HOT

SPEED

TAP

NOTES: Tables represent dry coil wit hout filter, to compensate for filter add 0.08" to measure d E.S.P. SCFM correction fo r wet coi l = 4 %. 5 Ton models are sh ipped from the factory wi th speed tap set on T 4.

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

0.10 1237 1.64 180 638

0.20 1191 1.75 194 682

0.30 1127 1.80 200 715

0.40 1065 1.89 214 753

0.50 994 1.97 220 797

0.10 1437 2.13 248 687

0.20 1384 2.24 254 726

0.30 1312 2.29 262 759

0.40 1245 2.42 280 803

0.50 1185 2.54 294 847

0.10 1988 4.49 558 885

0.20 1942 4.58 574 907

0.30 1882 4.69 582 935

0.40 1847 4.80 600 962

0.50 1784 4.87 612 990

0.60 1762 4.97 626 1008

0.70 1688 5.05 642 1039

0.10 2106 5.14 650 924

0.20 2050 5.26 670 951

0.30 1993 5.32 678 969

0.40 1960 5.47 696 1001

0.50 1920 5.54 706 1021

0.60 1880 5.61 726 1041

0.70 1810 5.73 736 1072

0.80 1760 5.81 750 1093

0.90 1694 5.84 752 1122

0.10 2199 5.87 762 968

0.20 2146 5.96 772 989

0.30 2121 6.06 788 1012

0.40 2066 6.15 804 1039

0.50 2010 6.21 814 1056

0.60 1978 6.32 834 1084

0.70 1919 6.28 830 1102

0.80 1837 6.22 814 1122

0.90 1738 6.04 786 1127

STANDARD

CFM

AMPS WATTS RPM

APPENDIX A BLOWER PERFORMANCE TABLES

DIRECT DRIVE

CPG060 HORIZONTAL

CPG060 DIRECT DRIVE HORIZONTAL

SPEED

TAP

NOTES: Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P. SCFM correction fo r wet coi l = 4 %. 5 Ton m o dels are ship ped f ro m th e facto ry with speed tap set o n T4.

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

0.10 1416 1.63 176 588

0.20 1295 1.61 174 621

0.30 1200 1.68 186 660

0.40 1133 1.79 196 704

0.50 1045 1.90 208 753

0.10 1543 2.00 220 627

0.20 1485 2.12 236 671

0.30 1425 2.20 250 698

0.40 1352 2.26 258 748

0.50 1304 2.39 274 786

0.10 2107 4.02 502 797

0.20 2031 4.13 518 819

0.30 1980 4.27 536 858

0.40 1954 4.37 554 880

0.50 1887 4.48 572 913

0.60 1839 4.58 582 940

0.70 1782 4.72 602 968

0.10 2224 4.73 592 832

0.20 2165 4.79 612 860

0.30 2123 4.91 630 891

0.40 2079 5.01 642 913

0.50 2029 5.14 666 946

0.60 1978 5.26 676 969

0.70 1926 5.38 698 1001

0.80 1872 5.48 712 1028

0.90 1817 5.58 722 1056

0.10 2318 5.42 700 874

0.20 2296 5.55 720 903

0.30 2228 5.66 734 929

0.40 2193 5.76 748 950

0.50 2145 5.90 766 979

0.60 2097 5.99 784 1012

0.70 2054 6.10 798 1034

0.80 1991 6.15 810 1050

0.90 1952 6.26 826 1079

STANDARD

CFM

AMPS WATTS RPM

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE

STANDARD DOWN SHOT

CPG036 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

1541 0.43 1284 0.32 1024 0.23 714 0.14 1444 0.45 1193 0.33 936 0.24 1111 0.34 806 0.23

744 0.22

CPG048 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

1910 0.67 1612 0.50 133 0 0.37 1030 0.23 1813 0.69 1571 0.54 1222 0.36 989 0.25 1478 0.56 1142 0.32 1107 0.41

TU RNS O PEN

1524 0.32 1340 0.25

16280.4113960.3211710.24900 0.16

TU RNS O PEN

1800 0.47 1556 0.35

20020.6517080.4914380.3611670.22

CPG060 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

24081.0022060.8419820.6818080.5515720.41 2402 1.08 2173 0.89 1943 0.72 1701 0.55 1511 0.43 2153 0.95 1917 0.77 1667 0.59 1888 0.82 1634 0.63 1601 0.67

TU RNS O PEN

24600.9622510.8020730.6518620.51

CPG072 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

NOTE Tables represent dry coil without filter, to comp ensate f or filter add 0.08" to measured E.S.P.

SCF M correctio n for w et coi l = 4 %.

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

2765 1.52 2596 1.28 2476 1.09 2327 0.94 2159 0.75 1938 0.59 2650 1.43 2452 1.18 2325 1.00 2070 0.80 1898 0.64 2443 1.29 2251 1.06 2068 0.86 1868 0.71 2258 1.17 2040 0.94 1806 0.73 2021 1.02

TU RNS O PEN

26251.1824861.0223220.8321520.68

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE

STANDARD HORIZONTAL

CPG036 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

1541 0.43 1284 0.32 1024 0.23 714 0.14 1444 0.45 1193 0.33 936 0.24 1111 0.34 806 0.23

744 0.22

CPG048 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

1910 0.67 1612 0.50 1330 0.37 1 030 0.2 3 1813 0.69 1571 0.54 1222 0.36 989 0.25 1478 0.56 1142 0.32 1107 0.41

TU RNS O PEN

1524 0.32 1340 0.25

16280.4113960.3211710.24900 0.16

TU RNS O PEN

1800 0.47 1556 0.35

20020.6517080.4914380.3611670.22

CPG060 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

24081.0022060.8419820.6818080.5515720.41 2402 1.08 2173 0.89 1943 0.72 1701 0.55 1511 0.43 2153 0.95 1917 0.77 1667 0.59 1888 0.82 1634 0.63 1601 0.67

TU RNS O PEN

24600.9622510.8020730.6518620.51

CPG072 STANDARD BELT DRIVE HORIZONTAL

ESP, In

0.2

0.4

0.6

0.8

1.0

1.2

NOTE Tables represent dry coil without filter, to comp ensate f or filter add 0.08" to measured E.S.P.

SCF M correctio n for w et coi l = 4 %.

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

26551.3124981.1023060.9220940.7218900.57 2703 1.47 2486 1.20 2263 0.97 2076 0.81 2515 1.34 2272 1.07 2002 0.83 2253 1.16 2028 0.93

TU RNS O PEN

2749 1.18 2573 0.96 2402 0.79

26801.2225441.0623460.8421640.68

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE

HIGH STATIC DOWN SHOT

CPG036 HIGH STATIC BELT DRIVE DOWN SHOT

ESP, In

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

0.8

1.0

1.2

1638 0.692 1307 0.519 984 0.362 1307 0.579 1002 0.416

1.4

1002 0.476 717 0.319

1.6

1.8

717 0.379

1638 0.632 1326 0.471 1002 0.317 713 0.192

CPG048 HIGH STATIC BELT DRIVE DOWN SHOT

ESP, In

0.6

0.8

1.0

1.2

1.4

1.6

1.8

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

1952 0.876 1622 0.665 1335 0.494 1056 0.345 1897 0.93 1611 0.726 1315 0.543 1008 0.357 1616 0.80 1298 0.588 1007 0.419 1316 0.659 1007 0.46

TU RNS O PEN

450123

1655 0.526 1389 0.395 1103 0.275

1640 0.571 1342 0.426 1035 0.289 775 0.19

TU RNS O PEN

1989 0.769 1712 0.594 1433 0.441

1929 0.788 1662 0.631 1384 0.469 1106 0.329

CPG060 HIGH STATIC BELT DRIVE DOWN SHOT

ESP, In

0.6

0.8

1.0

1.2

1.4

1.6

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

2277 1.271 2070 1.048 1852 0.837 1646 0.656 2304 1.387 2089 1.153 1872 0.931 1647 0.722 2104 1.255 1893 1.029 1668 0.811 1912 1.129 1690 0.90 1720 1.00

TU RNS O PEN

2262 1.161 2051 0.948 1851 0.763 1657 0.60

CPG072 HIGH STATIC BELT DRIVE DOWN SHOT

ESP, In

0.6

0.8

1.0

1.2

1.4

1.6

1.8

NOTE Tables represent dry coil without filter, to comp ensate for filter add 0.08" to measured E.S.P.

SCF M correctio n for w et coi l = 4 %.

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

2775 1.762 2638 1.526 2407 1.253 2226 1.045 2011 0.835 2821 1.894 2660 1.668 2407 1.358 2194 1.116 2012 0.923 2696 1.787 2497 1.54 2228 1.235 1977 0.985 2455 1.591 2236 1.346 2013 1.10 2262 1.44 2032 1.20 2069 1.30

TU RNS O PEN

2793 1.645 2575 1.367 2407 1.155 2250 0.963

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE - HIGH STATIC HORIZONTAL

CPG036 HIGH STATIC BELT DRIVE HORIZONTAL

ESP, In

0.6

0.8

1.0

1.2

1.4

1.6

1.8

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

1458 0.57 1146 0.41 802 0.25 1458 0.63 1139 0.46 782 0.30 1139 0.52 844 0.36

844.3 0.42

CPG048 HIGH STATIC BELT DRIVE HORIZONTAL

ESP, In

0.6

0.8 1

1.2

1.4

1.6

1.8

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

1786 0.80 1445 0.59 1115 0.40 1764 0.86 1426 0.64 1107 0.46 1446 0.72 1098 0.50 1099 0.56

TU RNS O PEN

1568 0.45 1266 0.32

1492 0.47 1194 0.34 922 0.23

1476 0.52 1163 0.37 856 0.24

TU RNS O PEN

1894 0.66 1585 0.49

1839 0.71 1532 0.53 1223 0.37

17820.7314770.5511700.39

CPG060 HIGH STATIC BELT DRIVE HORIZONTAL

ESP, In

0.6

0.8

1.0

1.2

1.4

1.6

1.8

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

2260 1.26 1983 1.00 1683 0.74 2288 1.38 2009 1.10 1711 0.84 2032 1.21 1741 0.93 1776 1.04

TU RNS O PEN

2215 1.04 1956 0.82 1697 0.62

22401.1519570.9016810.67

CPG072 HIGH STATIC BELT DRIVE HORIZONTAL

ESP, In

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

012345

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

2748 1.74 2518 1.44 2255 1.13 1 970 0.8 7 2797 1.87 2562 1.59 2273 1.27 2025 0.99 2556 1.67 2314 1.40 2035 1.11 2342 1.50 2037 1.21 2137 1.35

TU RNS O PEN

2690 1.42 2529 1.20 2263 0.94

27401.6024711.2722461.0219720.79

2219 0.95 1970 0.75

2677 1.29 2486 1.07

NOTE Tables represent dry coil without filter, to comp ensate f or filter add 0.08" to measured E.S.P.

SCF M correctio n for w et coi l = 4 %.

MODELS

3 TON

4 TON

APPENDIX B ELECTRICAL DATA

ELECTRICAL DATA

VOLTAGE

(NAMEPLATE)

20 8/230- 60-1 187 2 53 1 1 6.67 7 9 1 1 /4 1.40 DD STD ST ATIC 1/3 2.5

208/230-60-3

46 0-60 - 3 41 4 5 06 1 5.77 38.0 1 1/4 0.80 BD STD STAT IC 1.0 1. 9

57 5-60 - 3 51 8 633 1 3.8 37.0 1 1/4 0.60 BD STD STAT IC 1.5 2.3

20 8/230- 60-1 187 253 1 19.87 109 1 1 /4 1.40 DD STD STATIC 1/2 2.9

208/230-60-3 187 253 1 13.14 83.1

VOLTAGE

LIMITATION

MIN. MAX. QTY RLA LRA QTY HP RLA HP FLA

COMPRESSOR

110.4573.0 1187 253

OUTDOOR

FAN M OTOR

1/4 1.40

11/41.40

INDOOR

MOTOR

APPLICATION

DD STD STATI C 1/ 3 2.5

BD STD STAT IC 1.0 3.8

DD STD STATI C 1/ 2 2.9

BD STD STATIC 1.0 3.8

INDOOR

FAN MOTOR

5 TON

6 TON

46 0-60 - 3 41 4 5 06 1 6.09 41.0 1 1/4 0.80 BD STD STAT IC 1.0 1. 9

57 5-60 - 3 51 8 633 1 4.4 33.0 1 1/4 0.60 BD STD STAT IC 1.5 2.3

20 8/230- 60-1 187 253 1 26.41 134 1 1 /4 1.40 DD STD STATIC 1.0 7.6

DD STD STATI C 1. 0 7.6

208/230-60-3

46 0-60 - 3 41 4 5 06 1 7.76 52.0 1 1/4 0.80 BD STD STAT IC 1.0 1. 9

57 5-60 - 3 51 8 6 33 1 5.71 38.9 1 1/4 0.60 BD STD STAT IC 1.5 2. 3

20 8/2 30-60 - 3 187 253 1 19 123 1 1/ 3 1. 92 BD STD STATI C 1.5 5.0

46 0-60 - 3 41 4 5 06 1 9.70 62.0 1 1/3 1.20 BD STD STAT IC 1.5 2. 5

57 5-60 - 3 51 8 633 1 7.4 50.0 1 1/3 0.90 BD STD STAT IC 1.5 2.3

187 253 1/4 1.401 15.96 110.0 1

BD STD STATIC 1.0 3.8

APPENDIX C UNIT DIMENSIONS

47 1/2”

73 1/4”

38 13/16”*

74 1/16”

*6 Ton - 42 13/16

48 3/16”

11”

4 7/8”

17” 7 3/8”

RETURN

12”

SUPPLY

6 1/4”

Horizontal Discharge

NOTE

25”

19 7/16”

RETURN

5 7/8”

SUPPLY

8 3/16”

DRAIN THRU CURB LOCATION

27 3/8”

47 1/2”

BOTTOM VIEW OF UNIT

Vertical Discharge

EMBOSS FOR THRU THE BASE UTILITIES

4 1/2”

7 1/2”

APPENDIX D WIRING DIAGRAMS

COMP

CPG036(48)0451D SINGLE PHASE 240V/60HZ DIRECT DRIVE

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.

GND

208-240/1/60 SEE NOTE 5

3 SPEE D

ALTERNATE MOTOR 6-WIRES SEE NOTE 6 & 7

321

208

24V

240

FOR SMOKE/FIRE DETECTOR REPLACE JUMPER

3 SPEED

SEE NOTE 7

TB1

ALS

IIC

GAS VALVE

W. R.

NOTE 4 PLF

3 6 2

1 4

(ALT.) HONEYWELL

GAS VALVE

IGN

YL/PK

TB1

Y1W1

SEE NOTE 8 GREEN JUMPER

RD OR

RCCF

BL/PK

208-240/1/60 0140L00510 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

YL RD

LPS

HPS

CPG036(48)0451D SINGLE PHASE 240V/60HZ DIRECT DRIVE

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.

HEAT

PCB

COOL

4 5

IIC

TO THERMOSTAT TERMINAL BLOCK

STAT US LIGHT

OFF

1 BLINK

2 BLINKS

3 BLINKS

4 BLINKS 5 BLINKS

6 BLINKS

SUPP LY VOLTAGE

208-240/1/60

TB1

3 6 8

12 11

W Y2

IGN

ALS

LPS

HPS

INSTALLER/SERVICEMAN

EQUIP. STATUS

NORMAL O PERATIO N

NO POWER OR

INTERN AL CONTROL

FAULT

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

COM

PONENT LEGEND

AUXILIARY LIMIT SWITCH

ALS

COMP

COMPRESSOR

PCB

VMLI

IIC

NOTE 4

TB1

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SEN SO R

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

3 MIN . COMP.

PLF

CHECK

321

CM CONDENSER MOTOR

CONTACTOR

EVAPORATOR MOTOR

FUSE FLAME SENSOR

EQUIPMENT GROUND

GND GV

GAS VALVE

HPS HIGH PRESS URE S WITCH

INTEGRATED IGNITION CO NTRO L

IIC

IGNITOR

IGN LS LIMIT SWITCH

LPS LOW PRESSURE SWITCH

FEMALE PLUG/CONNECTOR

PLF

PRESSURE SWITCH

RUN CAPACITOR FOR CONDENSER FAN

RCCF

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TB1 TR

TRANSFORMER VENT MOTOR

VENT MOTOR RELAY

VMR BC

BLOWE R CAPACITOR

TES

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL. (USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. FOR DIFF ERENT THAN FACTORY SPEED TAP. CHANGE COOLING SPEED AT COOL TERMI NAL. CHA NGE HE ATI N G SPE E D AT HEAT TERMINAL ON CONTROL BOARD

SPEED MOTOR

3 RD - LOW SPEED BL - MED. SPEED BK - HIGH SPEED

4. ACCESSOR Y ECONO MIZER PLUG ADJACENT TO BL OWER H OUSING IN RETURN A IR COMPARTMENT. REMOVE MALE PLUG AND ATTACH FEMALE PLUG TO ECONOMIZER ACCESSORY.

5. USE COP PER CONDUCTORS ONLY.

6. PURPLE WIRE CONNECTS TO TRANSFORMER (PIN 1).

7. SPEED TAP TERMINATIONS S HOWN ON DIAGRAM ARE REPRESENTATIVE, BU T ACTUAL FA CTORY SETTING MAY BE DIFFEREN T BASED ON HEATING VALUE AND CAPACITY OF UNIT.

8. TO RUN DIFFERENT SP EED FOR HEATING AND COOLING, DISCONNECT GEEEN JUMPER FROM "COOL" TERMINAL AND REPLACE WITH APPROPRIATE SPEED TAP. THEN PLACE DISCONNECTED END OF JUMPER ON "UNUSED" TERMINAL LEFT OP EN BY MOVING THE SPEED TAP.

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVERCURRENT PROTECTION.

USE NEC CLASS 2 WIRE.

208-240/1/60 0140L00510 REV A

BK BLA CK BL BLUE BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHITE YL YELLOW BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

FAC TORY WIRING

LINE VOLTAGE LOW VOLT AGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

E CODE

WIR

THERMOSTAT FIELD WIRING

O ECONOMIZER

G R

Y/Y2

TB1

TH ECONOMIZER OPTION

W G

Y/Y2

TB1

G R

Y/Y2

TB1

WH GR RD

YL BL

WH GR RD

STAGE COOLING

WH GR RD YL

PK BL

G R

Y C

STAT

W G R Y

STAT

G R

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

(

COMP

CPG036(048)0901D SINGLE PHASE 240V/60HZ DIRECT DRIVE

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.

GND

208-240/1/60 SEE NOTE 5

RD PU

3 SPEED

ALTERNATE MOTOR 6-WIRES SEE NOTE 6 & 7

321

208

240

24V

BL GR

FOR SMOKE/FIRE DETECTOR REPLACE JUMPER

3 SPEED

SEE NOTE 7

TB1

ALS

IIC

GAS VALVE

W. R.

NOTE 4 PLF

SEE NOTE 9

3 6 2

1 4

ALT.) HONEYWELL

GAS VAL VE

IGN

YL/PK

TB1

RGY1W1

SEE NOTE 8 GREEN J UMPER

BL/PK

RCCF

208-240/1/60 0140L00506 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

YL RD

LPS

HPS

CPG036(048)0901D SINGLE PHASE 240V/60HZ DIRECT DRIVE

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.

HEAT

PCB

COOL

4 5

IIC

TO THERMOSTAT TERMINAL BLOCK

STATUS LIGHT

OFF

1 BLINK

2 BLINKS 3 BLINKS 4 BLINKS

5 BLINKS 6 BLINKS

SUPPLY VOLTAGE

208-240/1/60

TB1

3 6 8

W Y2

IGN

ALS

LPS

HPS

INSTALLER/SER VICEMAN

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CO NT ROL

FAULT

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OPEN AU X. LIMI T

SWITCH

PRESSURE SWITCH

OPEN

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

FALSE FLAME SENSED

COMPRE SSOR

OUTPUT DE L AY

PCB

VMLI

NOTE 4

PLF

TB1

CHECK

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

3 MIN. COMP.

IIC

321

OMPONENT LEGEND

AUXILIARY LIMIT SWITCH

ALS COMP

COMPRESSOR

CM CO NDENSER MOTOR

CONTACTOR

C EM

EVAPORATOR MOTOR

FUSE FLAME S ENSOR

EQUIPMENT G RO UND

GND

GAS VALVE

GV HPS HIGH PRESSURE SWITCH IIC

INTEGRATED IGNITION CONTROL

IGN

IGNITOR

LS LIMIT SWITCH LPS LOW PRESSURE SWITCH

PLF

FEMALE PLUG/CONNECTOR RUN CAPACITOR FOR CONDENSER FANRCCF

PRESSURE SWITCH

ROLLOUT SWITCH

TER MINAL B L OCK (24 V SIGNAL)

TB1 TR TRANSFORMER

VENT MOTOR

VM VMR

VENT MOTOR RELAY BLOWER CAPACITOR

BC OTES

1. REPLACEMENT WIRE MUST BE THE SA ME SIZE AND TYPE OF INSULA TION A S ORIGINAL. (USE COPPER CONDUCTOR ONLY).

2. FOR 20 8 V OLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMIN AL 2 ON TRANSFO RM E R.

3. FOR DIFFERENT THAN FACTORY SPEED TAP. CHANGE COOLING SPEED AT COOL TERMINAL. C H ANGE HEATING SPEED AT HEAT TERM IN AL ON CONTROL BOARD

SPEED MOTOR

3 RD - LOW SPEED BL - MED. SPEED BK - HIGH SPEED

4. ACCESSO RY ECO NOM IZER PLUG A DJACENT TO BLOWER HOUSING IN RETURN AIR COMPARTMENT. REMOVE MALE PLUG AND ATTACH FEM ALE PLUG TO ECONOMI ZER ACCESSORY.

5. USE COPPER C ONDUCTORS ONLY.

6. PURPLE WIRE CONNECTS TO TRANSFORMER (PIN 1).

7. SPEE D TAP TERMINATIONS SHOW N ON DIAGRAM ARE REPRESENT ATIVE, BUT ACTU AL FACTORY SETTING MAY BE DIFFERENT BASED ON HEATING VALUE AND CAPACITY OF UNIT.

8. TO RUN DIFFERENT SPEED FOR HEATING AND COOLING, DISCONNECT GEEEN JUMPER FROM "COOL" T ERMINAL AND REPLACE WITH APPROPRI ATE SPEED TAP. THEN PLACE DISCONNECTED END OF JUMPER ON "UNUSED" TERMINAL LEFT OPEN BY MOVING THE SPEED TAP.

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVERCURRENT PROTECTION.

USE NEC CLASS 2 WIRE.

9. FOR LOW STAGE OPERATION ONLY, REMOVE WHITE JUMP ER . FO R 2 STAGE OPER ATION, REMOVE JUMPER AND CONNECT W2 TO W1 ON THERMOSTAT.

208-240/1/60 0140L00506 REV A

FACTORY WIRING

LINE VOLTAGE LOW VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

W BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHITE YL YELLOW BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

IRE CODE

THERMOSTAT FIELD WIRING

ECONOMIZER

G R

Y/Y2

TB1

ECONOMIZER OPTION

WITH

W G

Y/Y2

TB1

STAGE COOLING

G R

Y/Y2

TB1

WH GR RD

YL BL

GR RD

WH GR RD YL

PK BL

W G R

Y C

STAT

W G R Y

STAT

W G R Y1

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG0060*1D SINGLE PHASE 240V/60HZ DIRECT DRIVE

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.

COMP

GND

POWER SUPPLY 240/1/60

SEE NOTE 6

BR WH

NOTE 3 & 7

GAS VALVE

TB1

WH YL

ALS

W. R.

NOTE 4

GEMLC

YL YL

(ALT.) HONEYWELL

GAS VALVE

3 6 2

1 4

PLF

IGN

YL/PK

YL WH

YL/PK

LPS

HPS

1 23

20 8

24V

VMR

SEE NOTE 6

TB1

SMOKE/FIRE DETECTOR REPLACES JUMPER WIRE

TB1

SEE NOTE 8

RCCF

240/1/ 60 0140L00429 REV B

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG0060*1D SINGLE PHASE 240V/60HZ DIRECT DRIVE

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.

NOTE 6

4 5

IIC

TO THERMOSTAT TERMINAL BLOCK

STATUS LIGHT

OFF

1 BLINK

2 BLINKS 3 BLINKS 4 BLINKS

5 BLINKS 6 BLINKS

321

OMPONENT LEGEND

ALS COMP CM CONDENSER MOTOR C

EM FS

GND GV HPS IIC IGN

LS LIMIT SWITCH PLF PS RCCF RS

TB1

IIC

TR TRANSFORMER VM VMR

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL. (USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. FOR DIFFERENT THAN FACTORY SPEED TAP. CHANGE COOLING SPEED AT MOTOR T4 AND T5 TERMINALS. CHANGE HEATING SPEED AT MOTO R T1. T2, AN D T3 TE RMINALS

4. ACCESSORY ECONOMIZER PLUG ADJACENT TO BLOWER HOUSING IN RETURN AIR COMPARTMENT. REMOVE MALE PL UG AND ATTACH FEMALE PLUG TO ECONOMIZER ACCESSORY.

5. USE COPPER CONDUCTORS ONLY.

6. L1 AND L2 ON ICC CONTROL IS 24V INPUT.

7. SPEED TAP TERMINATIONS SHOWN ON DIAGRAM ARE REPRESENTATIVE, BUT ACTUAL FACTORY SETT INGS M A Y BE

DIFFERENT BASED ON THE HEATING VALUE OF THE UNIT.

8. FOR LOW ST AGE OPERATION ONLY, REMOVE WHITE JUMPER. FOR 2 STAGE OPERATI ON, REMOVE JUMPER AND CONNECT W2 TO W2 ON THERMOSTAT.

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER

240/1/60 0140L00429 REV B

AUXILIARY LIMIT SWITCH COMPRESSOR

CONTACTOR EVAPORATOR MOTOR FUSEF FLAME SENSOR EQUIPMEN T GROUND GAS VALVE HIGH PRESSURE SWITCH INTEGRATED IGNITION CONTROL IGNITOR

LOW PRESS URE SWIT CHLPS

FEMALE PLUG/CONNECTOR PRESSURE SWITCH RUN CAPACITOR FO R CO MPRESSOR/FAN ROLLOUT SWITCH TERMINAL BLOC K (24V S IGNAL)

VENT MOTOR VENT MOTOR RELAY

OOLING SPEED (YELLOW WIRE) T3 - LOW SPEED T4 - HIGH SPEED

HEATING SPEED (WHITE WIRE) T1 - LOW SPEED (070) T2 - MED. SPEED T5 - HIGH SPEED (140)

USE NEC CLASS 2 WIRE.

CURRENT PROTECTION .

BK BLACK BL B LUE BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHITE YL YELLOW BL/PK BLUE WITH PINK STRIP YL/PK YELLOW WITH PINK STRIP

SUPPLY VOLTAGE

240/1/60

VMR

IGN

NOTE 6

TB1

CEM

TB1

C H

3 6

ALS

VMR

TB1

LPS

HPS

TB1

NOTE

PLF

INSTALLER/SERVIC EMAN

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

WITHOUT INDUC ER ON

OPEN LIMIT SWITCH

FALSE FLA ME S ENSED

COMPRESSOR

OUTPUT DELAY

CHECK

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSU RE SWI TCH

CHECK

PRESSU RE SWI TCH

MAIN LIMIT OPEN

BAD SWITCH

3 MIN. COMP.

FACTORY WIRING

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

ODE

WIRE C

THERMOSTAT FIELD WIRING

NO ECO

NOMIZER

W G R

Y/Y2

TB1

TH ECONOMIZER OPTION

W G R

Y/Y2

TB1

G R

Y/Y2

TB1

WH GR RD

2 STAGE COOLIN

GR RD

PK BL

W G R

Y C

STAT

W G R Y

STAT

G R

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG060*3D THREE PHASE 208-230V/60HZ DIRECT

(

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.

T2 T3

COMP

POWER SUPPLY 240/3/60 SEE NOTE 5

GND

BR WH

GEMLC

WH YL

ALS

NOTE 4 PLF

W. R.

GAS VALVE

ALT.) HONEYWELL

GAS VAL VE

YLBR YL

NOTE 3 & 7

3 6

1 4

TB1

IGN

321

208

24V

240

VMR

YL RD

SEE

NOTE 6

RGY1 W

TB1

SEE

NOTE 8

TB1

IIC

FOR SMOKE/FIRE DETECTOR REPLACE JUMPER

YL/PK

LPS

BL/PK

HPS

YL WH

230/3/ 60 0140L 00 9 80 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG060*3D THREE PHASE 208-230V/60HZ DIRECT DRIVE

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.

NOTE 6

4 5

IIC

TO THERMOSTAT TERMINAL BLOCK

STATUS LIGHT

OFF

1 BLINK

2 BLINKS 3 BLINKS 4 BLINKS 5 BLINKS

6 BLINKS

SUPPLY VOLTAGE

240/3/60

TB1

3 6 8

W Y2

INSTALLER/SERVICEMAN

IGN

VMR

ALS

LPS

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

IGNITION FAILURE

OPEN ROLLOUT

OPEN AUX. LIMIT

PRESSURE SWITCH

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

FALSE FLAME SENSED

COMPRESSOR

OUTPUT D EL AY

FAULT

SWITCH

OPEN

HPS

L2 L3

VMR

NOTE 6

1 2

3 4 5

TB1

NOTE 3

NOTE 4

PLF

TB1

CHECK

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIM IT O PEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

3 MIN. COMP.

VM1

IIC

321

NENT LEGEND

COMPO

AUXILIARY LIMIT SWITCH

ALS COMP

COMPRE SSOR CM CONDENSER MOTOR C

CONTACTOR

EVAPORATOR MOTOR

EM F

FUSE FC

FAN CAPACITOR FS

FLAME SENSOR GND

EQUIPMENT GROUND

GAS VALVE HPS HIGH PRESSURE SWITCH

IIC

INTEGRATED IGNITION CONTROL IGN

IGNITOR LS LIMIT SWITCH LPS LOW PRESSURE SWITCH

FEMALE PLUG/CONNECTOR

PLF

PRESSURE S WIT CH

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TB1 TR TRANSFORMER

VENT MOTOR

VM VMR

VENT MOTOR RELAY

NOTE

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE O F INS ULATION AS O RIGINAL. (USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRES FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. FOR DIFFERENT THAN FACTORY SPEED TAP. CHANGE COOLING SPEED AT M OTOR T3 A ND T4 TERMINALS. CHANGE HEATING SPEED AT MOTOR T1. T2, AND T5 TERMINALS

COOLING SPEED (YELLOW WIRE) T3 - LOW SPEED T4 - HIGH SPEED

EATING SPEED (WHITE WIRE)

H T1 - LOW SPEED (070)

T2 - MED. SPEED T5 - HIGH SPEED (140)

4. ACCESSORY ECONOMIZER PLUG ADJACENT TO BLOWER HOUSING IN RETURN AIR COMPARTMENT. REMOVE MALE PLUG AND ATTACH FEMALE PLUG TO ECONOMIZER ACCESSORY.

5. USE COPPER CONDUCTORS ONLY.

6. L1 AND L2 ON ICC CONTROL IS 24V INPUT.

7. SPEED TAP TERMINATIONS SHOWN ON DIAGRAM ARE REPRESENTATIVE, BUT ACTUAL FACTORY SETTINGS MAY BE DIFFERENT BASED ON THE HEATING VALUE OF THE UNIT.

8. FOR LOW STAGE OPERATION ONLY, REMOVE WHITE JUMPER. FOR 2 STAGE OPERATION, REMOVE JUMPER AND CONNECT W2 TO W2 ON THERMOSTAT.

USE NEC CLASS 2 WIRE.

SEE UNIT RATING P L AT E FOR TYPE AND SIZ E OF OV E R

CURREN T PR OTECTION

230/3/60 0140L00980 REV A

FACTORY WIRING

LINE VOLTAGE LOW VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

WIRE COD BK BLACK BL BLUE

BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHITE YL YELLOW

BL/PK BLUE WITH PINK STRIP YL/PK YELLOW WITH PINK STRIP

THERMOSTAT FIELD WIRING

ECONOMIZER

2 STAGE

WH GR RD

COOLING

GR RD

PK BL

G R

Y/Y2

TB1

ITH ECONOMIZER OPTION W

G R

Y/Y2

TB1

W G R Y1

Y/Y2

TB1

W G R

Y C

STAT

W G R Y

STAT

G R

Y1 Y2

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

COMP

CPG036(048)*3D THREE PHASE 208-230V/60HZ DIRECT DRIVE

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.

GND

RD PU

GAS VALVE

3 SPEED

ALS

W. R.

BR RD

ALTERNATE MOTOR 6-WIRES SEE NOTE 6 & 7

3 SPEED

SEE NOTE 7

YL YL

NOTE 4 PLF

3 6 2 1 4

(ALT.) HONEYWELL

GAS VALVE

PU BL

BR PU

POWERSUPPLY

208-240/3/60 SEE NOTE 5

208

24V

240

321

FOR SMOKE/FIRE

DETECTOR REPLACE JUMPER

YL RD

TB1

IIC

IGN

TB1

RGY1W1

SEE NOTE 8 GREEN JUMPER

YL/PK

BL/PK

LPS

HPS

208-240/3/60 0140L00512 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

HEAT

PCB

COOL

4 5

IIC

TO THERMOSTAT TERMINAL BLOCK

STA TU S LIGHT

OFF

1 BLINK

2 BLINKS 3 BLINKS 4 BLINKS 5 BLINKS

6 BLINKS

CPG036(048)*3D THREE PHASE 208-230V/60HZ DIRECT DRIVE

SUPPLY VOLTAGE

208-240/3/60

T2 T3

TB1

3 6 8

W Y2

INSTALLER/SERVICEMAN

12 11

NORMAL OP ERA TION

INTERNAL CONTROL

IGNITION FAILURE

OPEN AUX. LIMIT

PRESSURE SWITCH

WITHOUT INDUCER ON

OPEN LIM IT SWITCH

FA LSE FL AM E SEN SED

OUTPUT DELAY

IGN

ALS

LPS

HPS

EQUIP . STA TU S

NO POWER OR

FAULT

OPEN R OLLOUT

SWITCH

OPEN

COMPRESSO R

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.

OMPONENT LEGEND

L2 L3

PCB

IIC

NOTE 4

TB1

GAS FLOW

GAS PRES SURE

GAS VALVE

FLAM E SENSOR

FLAME ROLLOUT

BAD SWITC H

AUX. LIMIT OPEN PRESSURE SWI TCH PRESSURE SWI TCH

MAIN LIMIT OPEN

BAD SWITC H

3 MIN. COMP.

PLF

CHECK

CHECK CHECK

321

ALS

AUXILIARY LIMIT SWITCH

COMP

COMPRESSOR CM CONDENSER MOTOR C

CONTACTOR

EVAPOR ATOR MOTOR

EM F

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL. (USE COPPER CONDUC TOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. FOR DIFFERENT THAN FACTORY SPEED TAP. CHANGE COOLING SPEED AT COOL TERMINAL. CHANGE HEATING SPEED AT HEAT TERMINAL ON CONTROL BOARD

4. ACCESSORY ECONOMIZER PLUG ADJACENT TO BLOWER HOUSING IN RETURN AIR COMPARTMEN T. REMOVE MALE PLUG AND ATTACH FEMA LE PLUG TO ECONOMIZER ACCESSORY.

5. USE COPPER CONDUCTORS ONLY.

6. PURPLE WIRE CONNECTS TO TRANSFORMER (PIN 1).

7. SPEED TAP TERM INATIONS SHOWN ON DIAGRAM ARE RE PRESENTATIVE, BUT ACTUAL FACTORY SETTING MAY BE DIFFERENT BASED ON HEATING VALUE AND CAPACITY OF UNIT.

8. TO RUN DIFFER ENT SPEED FOR HEATING AND COOLING, DISCONNECT GEEEN JUMPER FROM "COOL" TERMINAL AND REPLACE WITH APPROPRIATE SPEED TAP. THEN PLACE DISCONNECTED END OF JUMPER ON "UNUSED" TERMINAL LEFT OPEN BY MOVING THE S PEED TAP.

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVERCURRENT PROTECTION.

FUS E FC

FAN CAPACITOR FS

FLAME SENSOR

EQUIPMENT GROUND

GND GV

GAS VALVE HPS HIGH PR E S S U RE SWITCH IIC

INTEGRATED IGNITION CONTROL

IGNITOR

IGN LS LIMIT SWITCH LPS LOW PRES S URE SWITCH PLF

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

PS RS TB1

TR VM VMR

OTES

SPEED MOTOR

3 RD - LOW SPEED

BL - MED. SPEED BK - HIGH SPEED

ROLLOUT SWITCH TERMINAL BLOCK (24V SIGNAL) TRANSFORMER VENT MOTOR VENT MOTOR RELAY BLOWER CAPACI TO R

USE NEC CLASS 2 WIRE.

208-240/3/60 0140L00512 REV A

FACTORY WIRING

LINE VOLTAGE LOW VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

W BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHIT E YL YELLOW

BL/PK BLUE WITH PINK STRIP YL/PK YELLOW WITH PINK STRIP

IRE CODE

THERMOSTAT FIELD WIRING

ECONOMIZER

G R

Y/Y2

TB1

WITH

ECONOMIZER OPTION

W G

Y/Y2

TB1

STAGE COOLING

G R

Y/Y2

TB1

WH GR RD

YL BL

WH GR RD

WH GR RD YL

PK BL

W G R

Y C

STAT

W G R Y

STAT

W G R Y1

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

COMP

CPG036(048)*3D THREE PHASE 230V/60HZ DIRECT DRIVE

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.

GND

RD PU

GAS VALVE

3 SPEED

ALS

W. R.

BR RD

ALTERNATE MOTOR 6-WIRES SEE NOTE 6 & 7

3 SPEED

NOTE 4 PLF

(ALT.) HONEYWELL

SEE NOTE 9

BR PU

SEE NOTE 7

YL YL

3 6 2

1 4

GAS VALVE

IGN

TB1

RGY1W1

208

24V

SEE NOTE 8 GREEN JUMPER

321

240

POWERSUPPLY

208-240/3/60 SEE NOTE 5

FOR SMOKE/FIRE DETECTOR REPLACE JUMPER

YL RD

TB1

IIC

LPS

YL/PK

BL/PK

HPS

208-240/3/60 0140L00507 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

HEAT

PCB

COOL

4 5

IIC

TO THERMOSTAT TERMINAL BLOCK

STA TU S LIGHT

OFF

1 BLINK

2 BLINKS 3 BLINKS 4 BLINKS 5 BLINKS

6 BLINKS

CPG036(048)*3D THREE PHASE 230V/60HZ DIRECT DRIVE

SUPPLY VOLTAGE

208-240/3/60

T2 T3

TB1

3 6 8

W Y2

INSTALLER/SERVICEMAN

12 11

NORMAL OP ERA TION

INTERNAL CONTROL

IGNITION FAILURE

OPEN AUX. LIMIT

PRESSURE SWITCH

WITHOUT INDUCER ON

OPEN LIM IT SWITCH

FA LSE FL AM E SEN SED

OUTPUT DELAY

IGN

ALS

LPS

HPS

EQUIP . STA TU S

NO POWER OR

FAULT

OPEN R OLLOUT

SWITCH

OPEN

COMPRESSO R

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.

OMPONENT LEGEND

L2 L3

PCB

IIC

NOTE 4

TB1

GAS FLOW

GAS PRES SURE

GAS VALVE

FLAM E SENSOR

FLAME ROLLOUT

BAD SWITC H

AUX. LIMIT OPEN PRESSURE SWI TCH PRESSURE SWI TCH

MAIN LIMIT OPEN

BAD SWITC H

3 MIN. COMP.

PLF

CHECK

CHECK CHECK

321

ALS

AUXILIARY LIMIT SWITCH

COMP

COMPRESSOR CM CONDENSER MOTOR C

CONTACTOR

EVAPOR ATOR MOTOR

EM F

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL. (USE COPPER CONDUC TOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

3. FOR DIFFERENT THAN FACTORY SPEED TAP. CHANGE COOLING SPEED AT COOL TERMINAL. CHANGE HEATING SPEED AT HEAT TERMINAL ON CONTROL BOARD

4. ACCESSORY ECONOMIZER PLUG ADJACENT TO BLOWER HOUSING IN RETURN AIR COMPARTMEN T. REMOVE MALE PLUG AND ATTACH FEMA LE PLUG TO ECONOMIZER ACCESSORY.

5. USE COPPER CONDUCTORS ONLY.

6. PURPLE WIRE CONNECTS TO TRANSFORMER (PIN 1).

7. SPEED TAP TERM INATIONS SHOWN ON DIAGRAM ARE RE PRESENTATIVE, BUT ACTUAL FACTORY SETTING MAY BE DIFFERENT BASED ON HEATING VALUE AND CAPACITY OF UNIT.

8. TO RUN DIFFER ENT SPEED FOR HEATING AND COOLING, DISCONNECT GEEEN JUMPER FROM "COOL" TERMINAL AND REPLACE WITH APPROPRIATE SPEED TAP. THEN PLACE DISCONNECTED END OF JUMPER ON "UNUSED" TERMINAL LEFT OPEN BY MOVING THE S PEED TAP.

9. FOR LOW STAGE OPERATION ONLY, REMOVE WHITE JUMPER. FOR 2 STAGE OPERATION, REMOVE JUMPER AN D CONNECT W2 TO W1 ON THERMOSTAT.

SEE UNIT RATING PLA TE FOR TYPE AND SI ZE OF OVERCURRENT PROTECTION.

FUS E FC

FAN CAPACITOR FS

FLAME SENSOR

EQUIPMENT GROUND

GND GV

GAS VALVE HPS HIGH PR E S S U RE SWITCH IIC

INTEGRATED IGNITION CONTROL

IGNITOR

IGN LS LIMIT SWITCH LPS LOW PRES S URE SWITCH PLF

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

PS RS TB1

TR VM VMR

OTES

SPEED MOTOR

3 RD - LOW SPEED

BL - MED. SPEED BK - HIGH SPEED

ROLLOUT SWITCH TERMINAL BLOCK (24V SIGNAL) TRANSFORMER VENT MOTOR VENT MOTOR RELAY BLOWER CAPACI TO R

USE NEC CLASS 2 WIRE.

208-240/3/60 0140L00507 REV A

FACTORY WIRING

LINE VOLTAGE LOW VOLTAGE

OPTIONAL HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

W BK BLACK BL BLUE BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHIT E YL YELLOW

BL/PK BLUE WITH PINK STRIP YL/PK YELLOW WITH PINK STRIP

IRE CODE

THERMOSTAT FIELD WIRING

ECONOMIZER

G R

Y/Y2

TB1

WITH

ECONOMIZER OPTION

W G

Y/Y2

TB1

STAGE COOLING

G R

Y/Y2

TB1

WH GR RD

YL BL

WH GR RD

WH GR RD YL

PK BL

W G R

Y C

STAT

W G R Y

STAT

W G R Y1

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(48)0904B(7B)/CPG060*4B(7B)/CPG072*4B(7B) THREE PHASE 460V/575V/60HZ BELT DRIVE

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.

COMP

460

575

24V

T1 T2

L1 L2

460/575

240

POWER SUPPLY

460/3/60 575/3/60 SEE NOTE 4

VMR

GND

ALS

YL YL

NOTE 2

PLF

63 5412

W. R .

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

IGN

TB1

SMOKE/FIRE DETECTOR REPLACES JUMPER WIRE

RD BL PU

3265

RD BL BL

GYY1CRW

UNUSED

HE TCOOL

SEE

SEE NOTE 3

NOTE 3

IIC

YL/PK

LPS

SEE

NOTE 5

HPS

BL/PK

460-575/3/60 0140L00870 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(48)0904B(7B)/CPG060*4B(7B)/CPG072*4B(7B) THREE PHASE 460V/575V/60HZ BELT DRIVE

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.

NOTE 3

4 5

IIC

STATUS LIGHT

OFF

1 BLINK

2 BLINKS

3 BLINKS

4 BLINKS 5 BLINKS

6 BLINKS

H C

SUPPLY VOLTAGE

460-575/3/60

VMR

L2 L3

NOTE 3

IIC

IGN

VMR

COMPONENT LEGEND

AUXILIARY LIMIT SWITCH

ALS

BLOWER CONTACTOR

COMPRESSOR

COMP

CONDENSER MOTORCM

CONTACTOR

EVAPORATOR MOTOR

FUSE

FA N CA PACITOR

FLAME SENSOR

GND

EQUIPMENT GROUND

GAS VALVE HIGH PRESSURE SWITCH

HPS

IBR INDOOR BLOWER RELAY

IIC

INTEGRATED IGNITION CONTROL

IGN

IGNITOR

LPS LOW PRESSURE SWITCH

LIMIT SWITCHLS

PLF

FEMALE PLUG/CONNECTOR PRESSURE SWITCH

ROLLOUT SWITCH

TB1

TERMINAL BLOCK (24V SIGNAL) TRANSFORM ERTR

VENT MOTOR

VMR

VENT MOTOR RELAY

FACTORY WIRING

LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAG E

FIELD WIRING

HIGH VOLT AGE LOW VOLTAGE

WIRE CODE BK BLACK BL BLUE

BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHITE YL YELLOW BL/PK BLUE WITH PINK STR IP YL/PK YELLOW WITH PINK STRIP

THERMOSTAT FIELD WIRING

ALS

3 6 8

12 11

LPS

HPS

NOTE 2

PLF

6 3

INST ALLER /SERVICEMAN

EQUI P. STATU S

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

IGNITION FAILURE

OPE N RO L L OUT

SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

WITHOUT INDUCER ON

OPEN LIMIT SWITC H

FALSE FLAM E SEN SED

COMPRESSOR

OUTPUT DELAY

CHECK

GAS FLOW

GAS PRESSU RE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

MAIN L IM IT OPEN

BAD SWITCH

3 MIN. COMP.

NOTES

1. REPLACEMEN T WIRE M UST 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.

5. FOR LO W STAGE OPERATION ONLY, REMOVE

WHITE JUMPER. FOR 2 STAGE OPERATION, REMOVE JUMPER A ND CONNECT W2 TO W2 ON THERMOSTAT.

USE NEC CLASS 2 WIRE.

SEE UNIT RA TING PLATE FOR TYPE AND

SIZE OF OVE R CURRENT PROTE CT I ON .

460-575/3/60 0140L00870 REV A

NO ECONOMIZER

W G R

WH GR RD

Y/Y2

TB1

YL BL

STAT

WITH ECONOMIZER OPTION

W G R

WH GR RD

Y/Y2

TB1

STAT

2 STAGE COOLING

W G R Y1

Y/Y2

TB1

WH GR RD YL

PK BL

STAT

W G R

Y C

W G R Y

W G R Y1

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0903B/CPG060*3B/CPG072*3B THREE PHASE 208-230V/60HZ BEL T DRIVE

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.

COMP

RD BK

T1 T2

L1 L2

GND

208

240

TB1

24V

SMOKE/FIRE DETECTOR REPLACES JUMPER WIRE

T2T3

ALS

GW2

RD BL

SEE NOTE 6

W. R.

GAS VALVE

NOTE 2

PLF

(ALT . ) H O NE Y W E L L

GAS VALVE

63 5412

YL BL

TO THERMOSTAT

IGN

BL PU

RCY Y1

SEE NOTE 3

VMR

POWER SUPPLY 208-240/3/60 SEE NOTE 4

IIC

YL/PK

LPS

BL/PK

HPS

208-240/3/60 0140L00981 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0903B/CPG060*3B/CPG072*3B THREE PHASE 208-230V/60HZ BEL T DRIVE

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.

OMPONENT LEGEND

NOTE 3

4 5

IIC

TO THERMOSTAT

STATUS LIGHT

OFF

1 BLINK

2 BLINKS 3 BLINKS 4 BLINKS 5 BLINKS

6 BLINKS

H C

3 6 8

12 11

INSTALLER/SERVICEMAN

WITHOUT INDUCER ON

FALSE FLAME SENSED

SUPPLY VO LTAGE

208-240/3/60

T2 T3

ALS

LPS

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

OPEN LIMIT SWITCH

COMPRESSOR

OUTPUT DELAY

31 VM

IGN

VMR

HPS

L2 L3

VMR

NOTE 3

NOTE 2

PLF

CHECK

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

MAIN LIM IT OPEN

BAD SWITCH

3 MIN. COMP.

IIC

AUXILIARY LIMIT SWITCH

ALS

BLOWER CONTACTOR

BC COMP

COMPRESSOR CONDENSER MOTORCM CONTACTOR

EVAPOR AT OR MOTOR

EM F

FUSE

FAN CAPACITOR FLAME SENSOR

EQUIPMEN T GROUND

GND

GAS VALVE

GV HPS HIGH PRESSURE SWITCH

IBR INDOOR BLOWER RELAY

INTEGRATED IG NI TION C ON TROL

IIC

IGNITOR

IGN

LPS L OW PRESSU RE SWITCH

LIMIT SWIT CHLS

FEMALE PLUG/CONNECTOR

PLF

PRESSURE SWITCH

ROLLOUT SWITCH

RS TB1

TERMINAL BLOCK (24V SIGNAL) TRANSFORMERTR VENT MOTOR

VM VMR

VENT MOTOR RELAY

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. ACCESSO RY ECONOMIZER PLU G ADJ ACENT TO BLOWER HOUSING IN RETURN AIR COMPARTMENT. REMOVE MALE PLUG AND ATTACH FEMALE PLUG TO THE E CONOMIZER ACCESSORY.

3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.

4. USE COPPER CONDUCTORS ONLY.

5. FOR 20 8 VOLT TR A NS F O RMER OPERATION,

MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER.

6. FOR LOW STAG E O PERATION ONL Y , REMO VE WHITE JUMPER. FOR 2 STAG E OPERATION, REMOVE JUMPER AND CONNECT W2 TO W2 ON THERMOSTAT.

USE NEC CLASS 2 WIRE.

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER

CURRENT PROTECTION

208-240/3/60 0140L00981 REV A

FACTORY WIRING

LINE VOLTAGE LOW VOLT AGE

OPTIONAL HIGH VOLTAGE

LD WIRING

FIE

HIGH VOLTAGE LOW VOLTAGE

WIRE BK BLACK BL BLUE

BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHITE YL YELLOW BL/PK BLUE WITH PINK STRIP YL/PK YELLOW WITH PINK STRIP

CODE

THERMOSTAT FIELD WIRING

NO ECONO

MIZER

W G R

Y/Y2

TB1

TH ECONOMIZER OPTION

G R

Y/Y2

TB1

W G RRD

Y/Y2

TB1

WH GR RD

YL BL

2 STAGE COOLING

WH GR

W G R

Y C

STAT

W G R Y

STAT

W G R Y1

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0454B THREE PHASE 575V/60HZ BEL T DRIVE

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.

COMP

RD BK PU

460 C

575

24V

T1 T2

L1 L2

460/575

240

POWER SUPPLY

460/3/60 575/3/60

SEE NOTE 4

VMR

GND

ALS

W. R.

GAS VALVE

NOTE 2

PLF

(ALT.) HONEY WELL

GAS VALVE

63 5412

RD RD BL

RD BL BL

RW1

TB1

3265

11 12

UNUSED

HE TCOOL

SMOKE/FIRE DETECTOR REPLACES JUMPER WIRE

SEE

SEE NOTE 3

NOTE 3

IIC

YL/PK

LPS

IGN

BL/PK

HPS

460-575/3/60 0140L00871 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0454B THREE PHASE 575V/60HZ BELT DRIVE

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.

NOTE 3

4 5

IIC

STATUS LIGHT

OFF

1 BLINK

2 BLINKS

3 BLINKS

4 BLINKS 5 BLINKS

6 BLINKS

H C

SUPPLY VOLTAGE

460-575/3/60

VMR

L2 L3

NOTE 3

IIC

IGN

VMR

COMPONENT LEGEND

AUXILIARY LIMIT SWITCH

ALS

BLOWER CONTACTOR

COMPRESSOR

COMP

CONDENSER MOTORCM

CONTACTOR

EVAPORATOR MOTOR

FUSE

FA N CA PACITOR

FLAME SENSOR

GND

EQUIPMENT GROUND

GAS VALVE HIGH PRESSURE SWITCH

HPS

IBR INDOOR BLOWER RELAY

IIC

INTEGRATED IGNITION CONTROL

IGN

IGNITOR

LPS LOW PRESSURE SWITCH

LIMIT SWITCHLS

PLF

FEMALE PLUG/CONNECTOR PRESSURE SWITCH

PS RS

ROLLOUT SWITCH

TB1

TERMINAL BLOCK (24V SIGNAL) TRANSFORM ERTR

VENT MOTOR

VMR

VENT MOTOR RELAY

FACTORY WIRING

LINE VOLTAGE LOW VOLTAGE OPTIONAL HIGH VOLTAG E

FIELD WIRING

HIGH VOLTAGE LOW VOLTAGE

WIRE CODE BK BLACK BL BLUE

BR BROWN GR GREEN OR ORANGE PK PINK PU PURPLE RD RED WH WHITE YL YELLOW BL/PK BLUE WITH PINK STR IP YL/PK YELLOW WITH PINK STRIP

THERMOSTAT FIELD WIRING

ALS

3 6 8

12 11

LPS

HPS

NOTE 2

PLF

6 3

INST ALLER /SERVICEMAN

EQUI P. STATU S

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

IGNITION FAILURE

OPE N RO L L OUT

SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

WITHOUT INDUCER ON

OPEN LIMIT SWITC H

FALSE FLAM E SEN SED

COMPRESSOR

OUTPUT DELAY

CHECK

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

MAIN L IM IT OPEN

BAD SWITCH

3 MIN. COMP.

NOTES

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.

SEE UNIT RA TING PLATE FOR TYPE AND

SIZE OF OVER CURRENT PROTECTION.

460-575/3/60 0140L00871 REV A

NO ECONOMIZER

W G R

WH GR RD

Y/Y2

TB1

YL BL

STAT

WITH ECONOMIZER OPTION

W G R

WH GR RD

Y/Y2

TB1

STAT

2 STAGE COOLING

W G R Y1

Y/Y2

TB1

WH GR RD YL

PK BL

STAT

W G R

Y C

W G R Y

W G R Y1

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0453B THREE PHASE 240V/60HZ BEL T DRIVE

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.

COMP

T1 T2

L1 L2

208

240

24V

VMR

GND

POWER SUPPLY 208-240/3/60 SEE NOTE 4

ALS

W. R.

GAS VALVE

NOTE 2

PLF

(ALT.) HON EY WELL

GAS VALVE

T2T3 T1

TB1

SMOKE/FIRE DETECTOR REPLACES JUMPER WIRE

IIC

RD BL PU

RD BL

63 5412

YL BL

RCY2

SEE NOTE 3

YL/PK

LPS

IGN

BL/PK

HPS

208-240/3/60 0140L00979 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

NOTE 3

4 5

STATUS LIGHT

1 BLINK

2 BLIN KS 3 BLIN KS 4 BLINKS 5 BLINKS

6 BLINKS

IIC

OFF

CPG036(048)0453B THREE PHASE 240V/60HZ BELT DRIVE

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.

OMPONENT LEGEND

SUPPLY VOL TAG E

L2 L3

208-240/3/60

VMR

NOTE 3

IGN

IIC

H C

FS D1

ALS

3 6

VMR

LPS

W Y1

HPS

NOTE 2

PLF

INSTALLER/SERVICEMAN

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTER NAL CON TR OL

IGNITI ON FAILURE

OPEN ROLLOUT

SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

CHECK

GAS FLOW

GAS PRESSURE

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWI TCH

AUX. LIMIT OPEN

CHECK

PRESS URE SWI TC H

CHECK

PRESS URE SWI TC H

MAIN LIMIT OPEN

BAD SWI TCH

3 MIN. COMP.

AUXILIARY LIMIT SWITCH

ALS

BLOWER CONTACTOR

COMPRESSOR

COMP

CONDENSER MOTORCM

CONTACTOR

EVAP O R AT O R M OT O R

EM FFUSE FC

FAN CAPACITOR

FLAME SENSOR

GND

EQUIPMENT GROUND

GAS VALVE

HPS HIGH PRESSURE SWITCH

IBR INDOOR BLOWER RELAY

INTEGRATED IGNITION CONTROL

IIC IGN

IGNITOR

LPS LOW PRE S SURE SWITCH

LIMIT SWITCHLS

FEMALE PLUG/CONNECTOR

PLF PS

PRESSURE SWITCH

ROLLO U T SWITCH

TERMINAL BLOCK (24V SIGNAL)

TB1

TRANSFORMERTR

VENT MOTOR

VMR

VENT M OT O R REL A Y

NOTES

1. REPLAC EM ENT WIRE MUS T BE THE S A ME 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 INPU T.

4. USE COPPER CONDUCTORS ONLY.

5. FOR 208 VOLT TRANSFORMER O PERAT ION,

MOVE BLACK WIRE FROM TERMINAL 3 TO

USE NEC CLASS 2 WIRE.

TERMINAL 2 ON TRANSFORMER.

SEE UNIT RATING PLATE FOR TYPE AN D S I ZE OF OVER

CURRENT PROTECTION

208-240/3/60 0140L00979 REV A

FACTORY WIRING

LINE VOLTAGE LOW VOLTAGE

OPTIONAL HIGH VOLTAGE

WIRING

FIELD

HIGH VOLTAGE LOW VOLTAGE

IRECODE BK BLACK BL BLUE

BR BROWN

GR GREEN

OR ORANGE PK PINK PU PURPLE RD RED

WH WHITE YL YELLOW BL/PK BLUE WITH PINK STRIP YL/PK YELLOW WITH PINK STRIP

THERMOSTAT FIELD WIRING

NO ECONO

MIZER

W G R

Y/Y2

TB1

WITH ECO NOMIZE

W G R

Y/Y2

TB1

W G RRD Y1

Y/Y2

TB1

AGE COOLING

2 ST

WH GR RD

YL BL

R OPT ION

GR RD

WH GR

PK BL

W G R

Y C

STAT

W G R Y

STAT

G R

STAT

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

Goodman Manufacturing Company, L.P .

5151 Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com www.amana-hac.com

Goodman JVM1600 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual