Service Instructions
*PD14
14 SEER 81% AFUE Dual Fuel Package Units
with R-410A Refrigerant
& Accessories
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
This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.
is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
RS6313001r1
December 2015
Copyright © 2015 Goodman Company, L.P.
TABLE OF CONTENTS
IMPORTANTINFORMATION ................................. |
2 - 3 |
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PRODUCTIONIDENTIFICATION ............................ |
4 - 5 |
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LIGHTINGINSTRUCTIONS ......................................... |
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6 |
ACCESSORIES ................................................... |
7 |
- 12 |
PRODUCTDESIGN ........................................... |
13 |
- 19 |
SYSTEM OPERATION ...................................... |
20 |
- 25 |
SCHEDULEDMAINTENANCE ........................... |
26 |
- 27 |
TROUBLESHOOTINGCHARTS ......................... |
29 - 30 |
SERVICING TABLE OF CONTENTS ........................ |
31 |
SERVICING ...................................................... |
32 - 58 |
BLOWER PERFORMANCE DATA .................... |
59 - 61 |
WIRINGDIAGRAMS .......................................... |
62 - 63 |
ACCESSORIES WIRING DIAGRAM ......................... |
64 |
IMPORTANTINFORMATION
Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL
BEFORE BEGINNING REPAIRS.
IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS
WARNING
This unit should not be connected to, or used in conjunction with, any devices that are not design certified for use with this unit or have not been tested and approved by Goodman. Serious property damage or personal injury, reduced unit performance and/or hazardous conditions may result from the use of devices that have not been approved or certified by Goodman.
ONLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR REPAIR (HEREINAFTER, “SERVICE”) THE EQUIPMENT IN THIS MANUAL SHOULD SERVICE THE EQUIPMENT. IN ADDITION, IN JURISDICTIONS THAT REQUIRE ONE OR MORE LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT. IMPROPER INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR OF THE EQUIPMENT SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST, SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WARNING
Do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this appliance as property damage or personal injury could occur. Have your contractor point out and identify the various cut-off devices, switches, etc., that serves your comfort equipment.
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.
To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:
GOODMAN® BRAND PRODUCTS |
AMANA® BRAND PRODUCTS |
TOLL FREE |
TOLL FREE |
1-877-254-4729 (U.S. only) |
1-877-254-4729 (U.S. only) |
email us at: customerservice@goodmanmfg.com |
email us at: customerservice@goodmanmfg.com |
fax us at: (713) 856-1821 |
fax us at: (713) 856-1821 |
(Not a technical assistance line for dealers.) |
(Not a technical assistance line for dealers.) |
Outside the U.S., call 1-713-861-2500. |
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(Not a technical assistance line for dealers.) |
Your telephone company will bill you for the call. |
2
IMPORTANTINFORMATION
SAFE REFRIGERANT HANDLING
While these items will not cover every conceivable situation, they should serve as a useful guide.
WARNING
Refrigerants are heavier than air. They can "push out" the oxygen in your lungs or in any enclosed space.To
avoid possible difficulty in breathing or death:
•Never purge refrigerant into an enclosed room or space. By law, all refrigerants must be reclaimed.
•If an indoor leak is suspected, thoroughly ventilate the area before beginning work.
•Liquid refrigerant can be very cold. To avoid possible frostbite or blindness, avoid contact with refrigerant and wear gloves and goggles. If liquid refrigerant does contact your skin or eyes, seek medical help immediately.
•Always follow EPA regulations. Never burn refrigerant, as poisonous gas will be produced.
WARNING
To avoid possible explosion:
•Never apply flame or steam to a refrigerant cylinder. If you must heat a cylinder for faster charging, partially immerse it in warm water.
•Never fill a cylinder more than 80% full of liquid refrigerant.
•Never add anything other than R-22 to an R-22 cylinder or R-410A to an R-410A cylinder. The service equipment used must be listed or certified for the type of refrigerant used.
•Store cylinders in a cool, dry place. Never use a cylinder as a platform or a roller.
WARNING
To avoid possible injury, explosion or death, practice safe handling of refrigerants.
WARNING
The compressor POE oil for R-410A units is extremely susceptible to moisture absorption and could cause compressor failure. Do not leave system open to atmosphere any longer than necessary
for installation.
WARNING
To avoid possible explosion, use only returnable (not disposable) service cylinders when removing refrigerant from a system.
•Ensure the cylinder is free of damage which could lead to a leak or explosion.
•Ensure the hydrostatic test date does not exceed 5 years.
•Ensure the pressure rating meets or exceeds 400 lbs.
When in doubt, do not use cylinder.
WARNING
System contaminants, improper service procedure and/or physical abuse affecting hermetic compressor electrical terminals may cause dangerous system venting.
The successful development of hermetically sealed refrigeration compressors has completely sealed the compressor's moving parts and electric motor inside a common housing, minimizing refrigerant leaks and the hazards sometimes associated with moving belts, pulleys or couplings.
Fundamental to the design of hermetic compressors is a method whereby electrical current is transmitted to the compressor motor through terminal conductors which pass through the compressor housing wall. These terminals are sealed in a dielectric material which insulates them from the housing and maintains the pressure tight integrity of the hermetic compressor. The terminals and their dielectric embedment are strongly constructed, but are vulnerable to careless compressor installation or maintenance procedures and equally vulnerable to internal electrical short circuits caused by excessive system contaminants.
In either of these instances, an electrical short between the terminal and the compressor housing may result in the loss of integrity between the terminal and its dielectric embedment. This loss may cause the terminals to be expelled, thereby venting the vaporous and liquid contents of the compressor housing and system.
A venting compressor terminal normally presents no danger to anyone, providing the terminal protective cover is properly in place.
If, however, the terminal protective cover is not properly in place, a venting terminal may discharge a combination of
(a)hot lubricating oil and refrigerant
(b)flammable mixture (if system is contaminated with air)
in a stream of spray which may be dangerous to anyone in the vicinity. Death or serious bodily injury could occur.
Under no circumstances is a hermetic compressor to be electrically energized and/or operated without having the terminal protective cover properly in place.
See Service Section S-17 for proper servicing.
3
PRODUCTIDENTIFICATION
The model number is used for positive identification of component parts used in manufacturing. Please use this number when requesting service or parts information.
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24 |
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BRAND: |
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REFRIGERANT: |
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MINOR |
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G: Goodman® |
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4: R-410A |
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REVISION: |
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A: Amana® |
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Brand |
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PRODUCT |
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SERIES: |
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MAJOR |
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SEER |
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REVISION: |
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Rating |
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HEATING INPUT |
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060: 60,000 BTUH |
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PRODUCT |
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070: 69,000 BTUH |
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TYPE: |
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080: 80,000 BTUH |
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VOLTAGE: |
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090: 92,000 BTUH |
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Single Package |
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100: 100,000 BTUH |
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1: |
208-230V/1ph/60Hz |
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Cooling/Heating |
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115: 115,000 BTUH |
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CONFIGURATION: |
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PRODUCT |
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M: Multi Position |
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FAMILY: |
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D: Dual Fuel |
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NOMINAL
CAPACITY:
24: 24,000 BTUH 30: 30,000 BTUH 36: 36,000 BTUH 42: 42,000 BTUH 48: 48,000 BTUH
is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
These units have R410A refrigerant.
4
PRODUCTIDENTIFICATION
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Single Phase Dual Fuel Package Units |
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Model # |
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Description |
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*PD1424060M41A* |
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*PD1430080M41A* |
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Amana® Brand/Goodman® Brand Package Dual Fuel units, 14 SEER |
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*PD1436080M41AA |
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with R410A. Initial release of 81% AFUE models. |
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*PD1442100M41A* |
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*PD1448100M41A* |
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*PD1436080M41AB |
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Amana® Brand/Goodman® Brand Package Dual Fuel units, 14 SEER |
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with R410A. Compressor change. |
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RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE
Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio.
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Las emisiones de monóxido de carbono pueden circular a través |
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del aparato cuando se opera en cualquier modo. |
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CO can cause serious illness including permanent brain |
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El monóxido de carbono puede causar enfermedades severas |
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damage or death. |
B10259-216 |
como daño cerebral permanente ó muerte. |
B10259-216 |
Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouvant survenir si un appareil produisant du monoxyde
de carbone continue de fonctionner au sein de la zone confinée.
Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort.
These units have R410A refrigerant
5
LIGHTINGINSTRUCTIONS |
*PD14**M1AA |
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FOR YOUR SAFETY |
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LIRE AVANT DE METTRE |
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READ BEFORE OPERATING |
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EN MARCHELIRE |
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WARNING: If you do not follow these instructions exactly,a fire or explosion may result causing property damage, personal injury or loss of life.
A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor
settle on the floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch;
do not use any phone in your building.
Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control lever. Never use tools. If the lever will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control
system and any gas control which has been underwater.
AVERTISSEMENT: Quiconque ne respecte pas à la lettre les instructions dans le presént manuel
risque de déclencher un incendie ou une explosion entraînant des dommages matériels, des lesions corporelles ou la perte de vies humaines.
A.Cet appareil ne comporte pas de veilleuse. Il est muni d'un dispositif d'allumage qui allume
automatiquement le brûleur. Ne pas tenter d'allumer le brûleur manuellement.
B. AVANT DE LE FAIRE FONCTIONNER,
une odeur de gaz. Renifler prés du plancher, car certains gaz sont plus lourds que l'air et peuvent s'accumuler au niveau du sol.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
Ne pas tenter d'allumer d'appareils.
Ne toucher à aucun interrupteur; ne pas vous servir des téléphones dans le bâtiment.
Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur de gaz
Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le service des incendies.»
C. Ne pousser ou tourner la manette d'admission du gaz
qu'à la main. Ne jamais emploer d'outil à cette fin. Si la manette reste coincée, ne tenter pas de la réparer; appelez un technicien qualifié. Quiconque tente de forcer la manette ou de la réparer peut provoquer une explosion ou un incendie.»
D. Ne pas se servir de cet appareil s'il a été plongé dans l'eau, même partiellement. Faire inspecter l'appareil
par un technicien qualifié et remplacer toutr partie du systéme de contrôle et toute commande qui ont été
plongées dans l'eau.»
OPERATING INSTRUCTIONS
STOP .
2.Set the thermostat to lowest setting.
3.Turn off all electric power to the appliance.
4.This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
5. |
Push the gas control lever to "OFF" Position. |
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Do not force. |
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6. |
Wait five (5) minutes to clear out any gas. Then |
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smell for gas, including near the floor. If you |
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then smell gas, STOP. Follow"B" |
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in the safety. information above |
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on this label if you don't smell |
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gas, go to next step. |
GAS |
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7. |
Push gas control lever |
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INLET |
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to "ON". |
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8. |
Replace access panel. |
ARRIVEE |
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9. |
Turn on all electric |
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power to the appliance. |
DU GAZ |
10.Set thermostat to desired setting.
11.If the appliance will not operate, follow the instructions "To Turn
Off Gas To Appliance" and call your service technician or gas company.
MISE EN MARCHE
.
ROBINET A GAZ MANUEL, EN POS "ON/MARCHE"
1.ARRÊTEZ Lisez les instructions de sécurité dans la section supérieure de cette étiquette.
2.Régler le thermostat à la température la plus basse.
3.Couper l'alimentation électrique de l'appareil.
4.Cet appareil menager etant dote d'un systeme d'allumage automatique, ne pas essayer à allumer le brûleur manuellement.
5.Pousse le levier du contrÔle du gaz a "OFF/ ARRET" position.
6.Attendre cinq (5) minutes pour laisser echapper tout le
gaz. Renifler tout autour de l'appareil, y compris prés du plancher, pour déceler une odeur de gaz. Si c'est le cas,
ARRÊTEZ. Passer à l'etape B des instructions de securite sur la portion superieure de cette etiquette.
S'il n'y a pas d'odeur de gaz, passer à l'etàpe suivante.
7.Pousse le levier du contrôle du gaz à "ON/MARCHE" position.
8.Remettre en place le panneau d'accés.
9.Mettre l'appareil sous tension.
10.Régler le thermostat à la température désirée.
11.Si l'appareil ne se met pas en marche, suivre les instructions intitulées Comment couper l'admission
de gaz de l'appareil et appeler un technicien qualifié ou le fournisseur de gaz.
TO TURN OFF GAS TO APPLIANCE
1.Set the thermostat to lowest setting.
2.Turn off all electric power to the appliance
if service is to be performed.
3. Push the gas control lever to "OFF" Position. Do not force.
4. Replace control access panel.
POUR COUPER L'ADMISSION
DE GAZ DE L'APPAREIL
1.Régler le thermostat à la température la plus bassé.
2.Couper l'alimentation électrique de l'appareil s'il faut procéder à des operations d'entretien.
3. |
Pousse le levier du contrôle du gaz à |
"OFF/ ARRET" |
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position. |
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Ne pas forcer. |
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4. |
Remettre en place le panneau d'accés. |
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0140F00000P REV D
6
ACCESSORIES
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*PD14***M ACCESSORIES |
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Part Number |
Description |
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OTDFPKG-01 |
Outdoor Thermostat Kit |
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LPM-08 |
Propane Conversion Kit for 2-stage 81% AFUE |
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HA-02 |
High Altitude Kit |
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PGC101/102/103 |
Roof Curb |
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PGEDJ101/102 |
Downflow Economizer *PD-M, Medium Chassis |
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PGEDJ103 |
Downflow Economizer, *PD-M, Large Chassis |
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DHZECNJPCGHMM |
Horizontal Economizer, *PD-M, Medium Chassis |
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DHZECNJPCGHML |
Horizontal Economizer, *PD-M, Large Chassis |
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PGMDD101/102 |
Manual 25% Fresh Air Damper Downflow Application, Medium Chassis |
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PGMDD103 |
Manual 25% Fresh Air Damper Downflow Application, Large Chassis |
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PGMDH102 |
Manual 25% Fresh Air Damper Horizontal Application, Medium Chassis |
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PGMDH103 |
Manual 25% Fresh Air Damper Horizontal Application, Large Chassis |
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PGMDMD101/102 |
Motorized 25% Fresh Air Damper Downflow Application, Medium Chassis |
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PGMDMD103 |
Motorized 25% Fresh Air Downflow Application, Large Chassis |
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PGMDMH102 |
Motorized 25% Fresh Air Damper Horizontal Application, Medium Chassis |
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PGMDMH103 |
Motorized 25% Fresh Air Damper Horizontal Application, Large Chassis |
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SQRPG101/102 |
Square to Round Adapter w/ 16" Round Downflow Application, Medium Chassis |
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SQRPG103 |
Square to Round Adapter w/ 18" Round Downflow Application, Large Chassis |
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SQRPGH101/102 |
Square to Round Adapter w/ 16" Round Horizontal Application, Medium Chassis |
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SQRPGH103 |
Square to Round Adapter w/ 18" Round Horizontal Application, Large Chassis |
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PGFR101/102/103 |
Internal Filter Rack All Chassis |
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GPGHFR101-103 |
External Horizontal Filter Rack for Goodman/Amana Gas/Electric |
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& Multi-position Package Units All Chassis |
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CDK36 |
Flush Mount Concentric Duct Kit |
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CDK36515 |
Flush Mount Concentric Duct Kit w/ Filter |
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CDK36530 |
Step Down Concentric Duct Kit |
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CDK36535 |
Step Down Concentric Duct Kit w/ Filter |
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CDK4872 |
Flush Mount Concentric Duct Kit |
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CDK4872515 |
Flush Mount Concentric Duct Kit w/ Filter |
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CDK4872530 |
Step Down Concentric Duct Kit |
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CDK4872535 |
Step Down Concentric Duct Kit w/ Filter |
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NOTE: Complete lineup of thermostats can be found in the Thermostat Specification Sheets.
7
ACCESSORIES
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ROOF CURBS |
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B |
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S |
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C |
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1 5/8 |
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14 1/2 |
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1 3/8 |
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MODEL |
A |
B |
C |
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RETURN |
SUPPLY |
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PGC101/102/103 |
46 1/4 |
39 3/8 |
14 1/2 |
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12 1/2 x 23 |
15 x 22 1/2 |
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DOWNFLOW FILTER RACK (PGFR101/102/103)
25
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1 1/2 |
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2 |
14 |
3 |
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26 1/2 |
Filter Size: 14" x 25" x 2"
Measurement in inches.
NOTE: PGFR cannot be used with downflow economizers.
8
ACCESSORIES
PGEDJ103
(DOWNFLOW ECONOMIZER)
PDED101/102
A |
B |
16 -1/4 |
16 |
PDED103
A |
B |
16 |
18 |
A
14 X 25 FILTER ATTACHMENT
25
B
16 X 20 x 2” FILTER
+
16 X 20
MIST ELIMINATOR
ECONOMIZER
(HORIZONTAL APPLICATIONS)
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B |
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16 1/8 |
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18 |
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D |
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A |
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E |
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C |
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MODEL |
A |
B |
C |
D |
E |
FILTER |
DHZECNJPCGHMM |
25 1/4 |
18 1/8 |
18 |
13 3/4 |
16 1/8 16 x 25 x 1 |
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DHZECNJPCGHML |
35 1/4 |
18 1/8 |
18 |
18 1/4 |
16 1/8 |
16 x 25 x 1 |
Measurement in inches.
9
ACCESSORIES
MOTORIZED/MANUAL FRESH AIR DAMPERS -
(HORIZONTAL APPLICATIONS)
B 7 5/8
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5 3/4 |
A |
11 7/8 |
B
A
MANUAL
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MODEL |
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B |
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PGMDH102 |
31 1/2 |
29 3/4 |
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PGMDH103 |
30 |
29 3/4 |
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MOTORIZED |
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MODEL |
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PGMDMH102 |
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31 1/2 |
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29 3/4 |
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PGMDMH103 |
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30 |
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29 3/4 |
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MOTORIZED/MANUAL FRESH AIR DAMPERS
(DOWNFLOW APPLICATIONS)
12 1/8 |
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BOTTOM VIEW |
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6 |
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5 3/4 |
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A |
11 7/8 |
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PGMDD103 |
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B |
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BOTTOM VIEW |
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12 1/8 |
6 |
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5 3/4 |
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10 |
A |
11 7/8 |
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PGMDD101/102 |
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MANUAL |
MODEL A B
PGMDD101/102 16 16
PGMDD103 18 16
B
A
MOTORIZED
MODEL A B
PGMDMD101/102 16 16
PGMDMD103 18 16
10
ACCESSORIES
SQUARE TO ROUND CONVERTER
(DOWNFLOW APPLICATIONS)
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12 1/4 |
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14 3/4 |
C |
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S |
D |
22 3/4 |
16 ø |
22 1/4 |
16 ø |
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A R
12 1/4 |
14 3/4 |
B
22 3/4 |
18 ø |
22 1/4 |
18 ø |
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MODEL |
A |
B |
C |
D |
RETURN |
SUPPLY |
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SQRPG101/102 |
22 3/4 |
12 1/4 |
22 1/4 |
14 3/4 |
16 |
16 |
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SQRPG103 |
22 3/4 |
12 1/4 |
22 1/4 |
14 3/4 |
18 |
18 |
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SQUARE TO ROUND CONVERTER (HORIZONTAL APPLICATIONS)
B
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MODEL |
A |
B |
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C |
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C |
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SQRPG101/102 |
16 |
16 1/2 |
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16 1/2 |
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SQRPG103 |
18 |
18 1/2 |
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18 1/2 |
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A |
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Measurements are in inches. |
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11
ACCESSORIES
GPGHFR101-103
(EXTERNAL HORIZONTAL FILTER RACK)
16” x 25" x 2" FILTER
12
PRODUCTDESIGN
Locations and Clearances
NOTE: To ensure proper condensate drainage, unit must be installed in a level position.
In installations where the unit is installed above ground level and not serviceable from the ground (Example: Roof Top installations) the installer must provide a service platform for theservicepersonwithrailsorguardsinaccordancewithlocal codes or ordinances or in their absence with the latest edition of the National Fuel Gas Code ANSI Z223.1.
NOTE: Roof overhang should be no more than 36".
Minimum clearances are required to avoid air recirculation and keep the unit operating at peak efficiency. A minimum 12 inch clearance is required to the condenser coil.
NOTE: The flue outlet hood is packaged separately inside the unit and must be installed prior to operation.
IMPORTANT NOTE: If using bottom discharge with roof curb, ductwork should be attached to the curb prior to installing the unit.
Refer to 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.
NOTE: A roof curb can be used to utilize bottom discharge. *PD14 Package Units are designed for outdoor installations only in either residential or light commercial applications.
NOTE: To ensure proper condensate drainage, unit must be installed in a level position.
The connecting ductwork (Supply and Return) can be connected for either horizontal or down discharge airflow. In the down discharge applications a matching Roof Curb is recommended .
A return air filter must be installed behind the return air grille(s) or provision must be made for a filter in an accessible location within the return air duct. The minimum filter area should not be less than those sizes listed in the Specification Section. Under no circumstances should the unit be operated without return air filters.
13
PRODUCTDESIGN
A 3/4" - 14 NPT drain connector is provided for removal of condensate water from the indoor coil. In order to provide proper condensate flow, do not reduce the drain line size. NOTE: Tighten drain to a maximum torque of 10 in-lbs.
Refrigerant flow control is achieved by use of a flowrator.
The single phase models use permanent split capacitors (PSC) design compressors. Starting components are therefore not required. A low MFD run capacitor assists the compressor to start and remains in the circuit during operation.
A/GPD Package Units are designed for outdoor installations only in either residential or light commercial applications and are available in 2, 2.5, 3, 3.5 & 4 ton sizes. They are designed for 208/230 volt single phase applications.
The connecting ductwork (Supply and Return) can be connected for either horizontal or vertical airflow. In the vertical application, a matching Roof Curb is recommended.
A return air filter must be installed behind the return air grille(s) or provision must be made for a filter in an accessible location within the return air duct (3 phase models have an internal downflow filter rack). The minimum filter area should not be less than those sizes listed in the Specification Section. Under no circumstances should the unit be operated without return air filters.
*PD model units use EEM type indoor blower motors. EEM motors are constant torque motors with very low power consumption and are energized by a 24V signal from the ignition control board. The EEM motors feature an integrated control module.
Air for condensing (cooling cycle) is drawn through the outdoor coil by a propeller fan, and is discharged vertically out the top of the unit. The outdoor coil is designed for .0 static. No additional restriction (ductwork) shall be applied.
Conditioned air is drawn through the filter(s), field installed, across the coil and back into the conditioned space by the indoor blower.
*PD series package units use the Compliant Scroll compressor; there are a number of design characteristics which are different from the traditional reciprocating compressor.
-Due to their design Scroll compressors are inherently more tolerant of liquid refrigerant. NOTE: Even though the compressor section of a Scroll compressor is more tolerant of liquid refrigerant, continued flood back or flooded start conditions may wash oil from the bearing surfaces causing premature bearing failure.
-These Scroll compressors use "POE" or polyolester oil which is NOT compatible with mineral oil based lubricants like 3GS. "POE" oil must be used if additional oil is required.
-Compliant scroll compressors perform “quiet” shutdowns that allow the compressor to restart immediately without the need for a time delay. This compressor will restart even if the system has not equalized.
-Operating pressures and amp draws may differ from standard reciprocating compressors. This information may be found in the “Cooling Performance Data” section.
A scroll is an involute spiral which, when matched with a mating scroll form as shown, generates a series of crescent shaped gas pockets between the two members.
During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form.
As this motion occurs, the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of the scroll form, the gas, which is now at a high pressure, is discharged out of a port located at the center.
During compression, several pockets are being compressed simultaneously, resulting in a very smooth process. Both the suction process (outer portion of the scroll members) and the discharge process (inner portion) are continuous.
ELECTRICAL WIRING
The units are designed for operation on 60 hertz current and at voltages as shown on the rating plate. All internal wiring is complete. Ensure the power supply to the compressor contactor is brought to the unit as shown on the supplied unit wiring diagram. The 24V wiring must be connected between the unit control panel and the room thermostat.
LINE VOLTAGE WIRING
Power supply to the unit must be N.E.C. Class 1, and must comply with all applicable codes. The unit must be electrically grounded in accordance with the local codes or, in their absence, with the latest edition of the National Electrical Code, ANSI/NFPA No. 70, or in Canada, Canadian Electrical Code, C22.1, Part 1. A fused disconnected must be provided and sized in accordance with the unit minimum circuit ampacity.
The best protection for the wiring is the smallest fuse or breaker which will hold the equipment on line during normal operation without nuisance trips. Such a device will provide maximum circuit protection.
14
PRODUCTDESIGN
All line voltage connections must be made through weather proof fittings. All exterior power supply and ground wiring must be in approved weather proof conduit. Low voltage wiring from the unit control panel to the thermostat requires coded cable. See the following figures for ground level and rooftop wiring.
JUNCTION BOX
The unit transformer is connected for 230V operation. If the unit is to operate on 208V, reconnect the transformer primary lead and the induced draft blower leads as shown on the unit wiring diagram.
If it is necessary for the installer to supply additional line voltage wiring to the inside of the package unit, the wiring must comply with all local codes. This wiring must have a minimum temperature rating of 105°C. and must be routed away from the burner compartment. All line voltage splices must be made inside the unit control box.
GAS SUPPLY AND PIPING
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.
|
Inlet Gas Pressure |
Natural |
Min. 5.0" W.C., Max. 10.0" W.C. |
Propane |
Min. 11.0" W.C., Max. 13.0" W.C. |
Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in the table above.
The minimum supply pressure must not be varied downward because this could lead to unreliable 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.
15
PRODUCTDESIGN
GAS PIPING
The gas pipe supplying the unit must be properly sized based on the cubic feet per hour of gas flow required, specific gravity of the gas and length of the run. 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 ANSI Z223.1.
NATURAL GAS CAPACITY OF PIPE IN CUBIC FEET OF
GAS PER HOUR (CFH)
LENGTH OF |
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NOMINAL BLACK PIPE SIZE |
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PIPE IN FEET |
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1/2" |
3/4" |
1" |
1 1/4" |
1 1/2" |
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10 |
132 |
278 |
520 |
1050 |
1600 |
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20 |
92 |
190 |
350 |
730 |
1100 |
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30 |
73 |
152 |
285 |
590 |
980 |
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40 |
63 |
130 |
245 |
500 |
760 |
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50 |
56 |
115 |
215 |
440 |
670 |
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60 |
50 |
105 |
195 |
400 |
610 |
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70 |
46 |
96 |
180 |
370 |
560 |
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80 |
43 |
90 |
170 |
350 |
530 |
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90 |
40 |
84 |
160 |
320 |
490 |
|
100 |
38 |
79 |
150 |
305 |
460 |
BTUH FURNACE INPUT CFH = CALORIFIC VALUE OF GAS
CONNECTING THE GAS PIPING - NATURAL GAS
c. Listed gas appliance connectors used in accordance with the terms of their listing that are completely in the same room as the equipment.
NOTE: In "b" and "c", the connector or tubing must be installed so as to be protected against physical and thermal damage. Aluminum-alloy tubing and connectors must be coated to protect against external corrosion where they are in contact with masonry, plaster, or insulation or are subject to repeated wettings by such liquids as water (except rain water), detergents, or sewage.
MANUAL
SHUT-OFF
VALVE
DRIP LEG
GROUND JOINT UNION (INSTALLED AHEAD OF GAS VALVE)
GROMMET
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.
1.Use black iron or steel pipe and fittings for the building piping.
2.Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used.
3.Use ground joint unions.
4.Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.
5.Use two pipe wrenches when making connection to the gas valve to keep it from turning.
6.Install a manual shut off valve. This shut off valve should be conveniently located within six (6) feet of the unit, and between the meter and unit.
7.Tighten all joints securely.
8.Connect the unit to the building piping by one of the following methods.
a.Rigid metallic pipe and fittings.
CHECKING THE GAS PIPING
CAUTION
TO AVOID THE POSSIBILITY OF PROPERTY DAMAGE, PERSONAL INJURY OR FIRE, THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS AND PRESSURE TESTING.
The unit and its gas connections must be leak tested before placing in operation. Because of the danger of explosion or fire, never use a match or open flame to test for leaks. Never exceed specified pressure for testing. Higher pressure may damage the gas valve and cause overfiring which may result in heat exchanger failure.
This unit must be isolated from the gas supply system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures
b.Semi-rigid metallic tubing and metallic fittings. equal to or less than 1/2 psig (3.48 kPa). Aluminum alloy tubing shall not be used in exterior
locations.
16
PRODUCTDESIGN
TANKS AND PIPING - PROPANE UNITS |
TYPICAL PROPANE PIPING |
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First Stage |
5 to 15 PSIG |
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(20 PSIG Max.) |
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Regulator |
Continuous |
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11" W.C. |
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200 PSIG |
Second Stage |
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Maximum |
Regulator |
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All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters (See NBFU Manual 58) or Natural Standards of Canada B149.2, Installation Code for Propane Gas Burning Appliances and Equipment.
For satisfactory operation, propane gas pressure must be 10 inch W.C. at the unit manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors.
1.Vaporization rate, which depends on (a) temperature of the liquid, and (b) "wetted surface" area of the container or containers.
2.Proper pressure regulation. (Two-stage regulation is recommended from the standpoint of both cost and efficiency.)
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.
Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.
Propane is an excellent solvent, and special pipe dope must be used when assembling piping for this gas as it will quickly dissolve white lead or most standard commercial compounds. Shellac base compounds resistant to the actions of liquefied petroleum gases such as Gasolac®, Stalactic®, Clyde's or John Crane are satisfactory.
WARNING
PROPANE TANK SIZING (MINIMUM)
|
TANK SIZE REQUIRED IF LOWEST OUTDOOR |
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MAXIMUM GAS |
TEMPERATURE (AVG. FOR 24 HOURS) REACHES |
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NEEDED TO |
32°F |
20°F |
10°F |
0°F |
-10°F |
-20°F |
|
-30°F |
VAPORIZE* |
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125K BTU/HR |
115 |
115 |
115 |
250 |
250 |
400 |
|
600 |
(50 CFH) |
GAL |
GAL |
GAL |
GAL |
GAL |
GAL |
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GAL |
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250K BTU/HR |
250 |
250 |
250 |
400 |
500 |
1000 |
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1500 |
(100 CFH) |
GAL |
GAL |
GAL |
GAL |
GAL |
GAL |
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GAL |
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375K BTU/HR |
300 |
400 |
500 |
500 |
1000 |
1500 |
|
2500 |
(150 CFH) |
GAL |
GAL |
GAL |
GAL |
GAL |
GAL |
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GAL |
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500K BTU/HR |
400 |
500 |
750 |
1000 |
1500 |
2000 |
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3500 |
(200 CFH) |
GAL |
GAL |
GAL |
GAL |
GAL |
GAL |
|
GAL |
750K BTU/HR |
750 |
1000 |
1500 |
2000 |
2500 |
4000 |
|
5000 |
(300 CFH) |
GAL |
GAL |
GAL |
GAL |
GAL |
GAL |
|
GAL |
* AVERAGE RATE/HOUR WITHDRAWL IN 8 HOUR PERIOD
17
PRODUCTDESIGN
PROPANE GAS PIPING CHARTS
Sizing Between First and Second Stage Regulator
Maximum Propane Capacities listed are based on 1 PSIG Pressure Drop at 10 PSIG Setting. Capacities in 1,000 BTU/HR
PIPE OR |
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TUBING SIZE, O.D., TYPE L |
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NOMINAL PIPE SIZE, |
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TUBING |
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SCHEDULE 40 |
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LENGTH, |
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FEET |
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3/8" |
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1/2" |
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5/8" |
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3/4" |
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7/8" |
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1/2" |
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3/4" |
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30 |
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309 |
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700 |
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1,303 |
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2,205 |
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3,394 |
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1,843 |
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3,854 |
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40 |
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265 |
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599 |
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1,115 |
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1,887 |
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2,904 |
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1,577 |
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3,298 |
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50 |
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235 |
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531 |
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988 |
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1,672 |
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2,574 |
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1,398 |
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2,923 |
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60 |
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213 |
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481 |
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896 |
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1,515 |
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2,332 |
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1,267 |
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2,649 |
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70 |
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196 |
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446 |
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824 |
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1,394 |
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2,146 |
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1,165 |
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2,437 |
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80 |
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182 |
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412 |
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767 |
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1,297 |
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1,996 |
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1,084 |
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2,267 |
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90 |
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171 |
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386 |
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719 |
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1,217 |
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1,873 |
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1,017 |
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2,127 |
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100 |
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161 |
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365 |
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679 |
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1,149 |
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1,769 |
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961 |
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2,009 |
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150 |
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130 |
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293 |
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546 |
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923 |
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1,421 |
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772 |
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1,613 |
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200 |
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111 |
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251 |
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467 |
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790 |
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1,216 |
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660 |
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1,381 |
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250 |
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90 |
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222 |
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414 |
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700 |
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1,078 |
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585 |
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1,224 |
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300 |
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89 |
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201 |
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378 |
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634 |
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976 |
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530 |
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1,109 |
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350 |
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82 |
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185 |
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345 |
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584 |
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898 |
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488 |
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1,020 |
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400 |
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76 |
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172 |
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321 |
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543 |
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836 |
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454 |
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949 |
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To convert to Capacities at 15 PSIG Settings -- Multiply by 1.130 |
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To convert to Capacities at 5 PSIG Settings -- Multiply by 0.879 |
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Sizing Between Single or Second Stage Regulator and Appliance* |
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Maximum Propane Capacities Listed are Based on 1/2" W.C. Pressure Drop at |
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11" W.C. Setting. Capacities in 1,000 BTU/HR |
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PIPE OR |
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TUBING SIZE, O.D., TYPE L |
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NOMINAL PIPE SIZE, |
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TUBING |
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SCHEDULE 40 |
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LENGTH, |
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FEET |
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3/8" |
1/2" |
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5/8" |
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3/4" |
7/8" |
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1/2" |
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3/4" |
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1" |
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1-1/4" |
1-1/2" |
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10 |
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49 |
110 |
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206 |
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348 |
539 |
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291 |
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608 |
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1,146 |
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2,353 |
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3,525 |
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20 |
|
34 |
76 |
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141 |
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239 |
368 |
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200 |
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418 |
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788 |
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1,617 |
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2,423 |
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30 |
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27 |
61 |
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114 |
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192 |
296 |
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161 |
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336 |
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632 |
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1,299 |
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1,946 |
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40 |
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23 |
52 |
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97 |
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164 |
253 |
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137 |
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284 |
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541 |
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1,111 |
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1,665 |
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50 |
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20 |
46 |
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86 |
|
146 |
224 |
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122 |
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255 |
|
480 |
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985 |
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1,476 |
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60 |
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19 |
42 |
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78 |
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132 |
203 |
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110 |
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231 |
|
436 |
|
892 |
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1,337 |
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80 |
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16 |
36 |
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67 |
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113 |
174 |
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94 |
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198 |
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372 |
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764 |
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1,144 |
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100 |
|
14 |
32 |
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59 |
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100 |
154 |
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84 |
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175 |
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330 |
|
677 |
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1,014 |
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125 |
|
12 |
28 |
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52 |
|
89 |
|
137 |
|
74 |
|
155 |
|
292 |
|
600 |
|
899 |
|||
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150 |
|
11 |
26 |
|
48 |
|
80 |
|
124 |
|
67 |
|
141 |
|
265 |
|
544 |
|
815 |
|||
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|||
200 |
|
10 |
22 |
|
41 |
|
69 |
|
106 |
|
58 |
|
120 |
|
227 |
|
465 |
|
697 |
|||
250 |
|
9 |
|
19 |
|
36 |
|
61 |
|
94 |
|
51 |
|
107 |
|
201 |
|
412 |
|
618 |
||
300 |
|
8 |
|
18 |
|
33 |
|
55 |
|
85 |
|
46 |
|
97 |
|
182 |
|
374 |
|
560 |
||
350 |
|
7 |
|
16 |
|
30 |
|
51 |
|
78 |
|
43 |
|
89 |
|
167 |
|
344 |
|
515 |
||
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||
400 |
|
7 |
|
15 |
|
28 |
|
47 |
|
73 |
|
40 |
|
83 |
|
156 |
|
320 |
|
479 |
||
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*DATA IN ACCORDANCE WITH NFPA PAMPHLET NO. 54
COOLING
The refrigerant used in the system is R-410A. It is a clear, colorless, non-toxic and non-irritating liquid. R-410A is a 50:50 blend of R-32 and R-125. The boiling point at atmospheric pressure is -62.9°F.
A few of the important principles that make the refrigeration cycle possible are: heat always flows from a warmer to a cooler body. Under lower pressure, a refrigerant will absorb heat and vaporize at a low temperature. The vapors may be drawn off and condensed at a higher pressure and temperature to be used again.
The indoor evaporator coil functions to cool and dehumidify the air conditioned spaces through the evaporative process taking place within the coil tubes.
NOTE: Actual temperatures and pressures are to be obtained from the expanded ratings in the Technical Information Manual.
High temperature, high pressure vapor leaves the compressor through the discharge line and enters the condenser coil. Air drawn through the condenser coil by the condenser fan causes the refrigerant to condense into a liquid by removing heat from the refrigerant. As the refrigerant is cooled below its condensing temperature it becomes subcooled.
The subcooled high pressure liquid refrigerant now leaves the condenser coil via the liquid line until it reaches the indoor expansion device.
As the refrigerant passes through the expansion device and into the evaporator coil a pressure drop is experienced causing the refrigerant to become a low pressure liquid. Low pressure saturated refrigerant enters the evaporator coil where heat is absorbed from the warm air drawn across the coil by the evaporator blower. As the refrigerant passes through the last tubes of the evaporator coil it becomes superheated, that is, it absorbs more heat than is necessary for the refrigerant to vaporize. Maintaining proper superheat assures that liquid refrigerant is not returning to the compressor which can lead to early compressor failure.
Low pressure superheated vapor leaves the evaporator coil and returns through the suction line to the compressor where the cycle begins again.
Heat Pump Models
Any time the room thermostat is switched to cool, the O terminal is energized. This energizes the 24 volt coil on the reversing valve and switches it to the cooling position.
When the contacts of the room thermostat close, this closes the circuit from R to Y and R to G in the unit.
This energizes the compressor contactor and will energize the EEM indoor blower motor after a 6-second delay.
When the thermostat is satisfied, it opens its contacts breaking the low voltage circuit causing the compressor contactor to open and indoor fan to stop after the programmed 60 second off delay on the EEM motor.
If the room thermostat fan selector switch should be set to the "on" position then the indoor blower would run continuous rather than cycling with the compressor.
18
PRODUCTDESIGN
HEATING/ GAS & L.P.
The heating cycle is accomplished by using a unique tubular design heat exchanger which provides efficient gas heating on either natural gas or propane gas fuels. The heat exchangers compact tubular construction provides excellent heat transfer for maximum operating efficiency.
Inshot type gas burners with integral cross lighters are used eliminating the need for adjustable air shutters. The same burner is designed for use on either natural or propane gas fuels.
The induced draft blower draws fuel and combustion air into the burners and heat exchanger for proper combustion. A pressure switch is used in conjunction with the I. D. blower to detect a blocked flue condition.
Blower operation is controlled by the ignition control module. The module allows for field adjustment of the blower delay at the end of the heating cycle. The range of adjustment is for 90, 120, 150 or 180 seconds. The factory delay setting is 30 seconds delay on 150 seconds delay off.
Direct Spark Ignition (DSI) Systems
APD/GPD units are equipped with a direct spark ignition system. Ignition is provided by 22,000 volt electronic spark. A flame sensor then monitors for the presence of flame and closes the gas valve if flame is lost.
HEATING CYCLE
On a call for first stage heat, the contacts of the room thermostat close. This energizes terminals R to Y and R to G, the low voltage circuit to the contactor is completed starting the compressor and outdoor fan motor. This also energizes the EEM motor after approximately 6-seconds.
When the thermostat is satisfied, breaking the circuit between R to Y and R to G, the compressor and outdoor fan motor will stop. The indoor blower will stop after a programmed 60 second off delay.
NOTE: Should the second stage heating contacts in the room thermostat close, a W1 signal will be sent to the ignition control and the Y signal would be removed. A normal gas heating sequence would then follow.
19
SYSTEMOPERATION
IGNITION CONTROL SEQUENCE OF OPERATION
A. Heating Operation: Low stage heat
1.Thermostat type is set to two-stage.
2.Thermostat “W1” input initiates low stage heating.
3.Induced draft blower is energized at high speed for the pre-purge period. Pre-purge timer begins after control recognizes pressure switch has closed.
4.Trial-for-ignition period begins after pre-purge period expires. Low and high stage gas valves are energized along with the igniter for trial-for-ignition period. Igniter is de-energized when flame is detected.
5.Flame is achieved and detected during trial-for-ignition period. Flame stabilization period begins when flame is detected.
6.De-energize high stage gas valve and switch induced draft blower to low speed within five seconds of flame detection.
7.Air circulating blower is energized at low heat speed after heat ON delay time expires. Heat ON delay timer begins when flame is detected.
8.Control monitors thermostat, flame, limit, and pressure switch inputs during low stage heating.
9.Thermostat “W1” input is removed.
10.Low stage gas valve is de-energized.
11.Induced draft blower remains energized at low speed for post purge period.
12.Air circulating blower remains energized at low heat speed for heat OFF delay. Heat OFF delay begins when “W1” input is removed.
13.Control returns to Standby and awaits next thermostat request.
B.Heating Operation: High stage heat
1.Thermostat type is set to two-stage.
2.Thermostat “W1” and “W2” inputs initiate high stage heating.
3.Induced draft blower is energized at high speed for the pre-purge period. Pre-purge timer begins after control recognizes pressure switch has closed.
4.Trial-for-ignition period begins after pre-purge period expires. Low and high stage gas valves are energized along with the igniter for trial-for-ignition period. Igniter is de-energized when flame is detected.
5.Flame is achieved and detected during trial-for-ignition period. Flame stabilization period begins when flame is detected.
A/GPD14
6.Gas valve and induced draft blower remain at high stage and high speed.
7.Air circulating blower is energized at high heat speed after heat ON delay time expires. Heat ON delay timer begins when flame is detected.
8.Control monitors thermostat, flame, limit, and pressure switch inputs during high stage heating.
9.Thermostat “W1” and “W2” inputs are removed.
10.High and low stage gas valves are de-energized.
11.Induced draft blower switches from high speed to low speed and remains energized for post purge period.
12.Air circulating blower remains energized at high heat speed for High Stage Heat OFF Delay period then switches to low heat speed for the remainder of the selected heat OFF delay. Heat OFF delay begins when “W1” and “W2” inputs are removed.
13.Control returns to Standby and awaits next thermostat request.
A. Cooling Operation: Low stage cool
1.Thermostat type is set to two-stage.
2.Thermostat “Y1” or thermostat “Y1” and “G” input initiates low stage cooling.
3.IDT/ODT/Pressure/Loss of Charge Switch circuits are checked for closed condition. Cooling operation can proceed only if these circuits are closed.
4.Low stage compressor output is energized.
5.Condenser fan motor is energized at low speed.
6.Air circulating blower is energized at low cool speed after cool ON delay expires. Cool ON delay timer begins when thermostat inputs are detected.
7.Control monitors thermostat, gas valve, flame, and IDT/ ODT/Pressure/Loss of Charge Switches during low stage cooling.
8.Thermostat “Y1” or “Y1” and “G” inputs are removed.
9.Low stage compressor output is de-energized. Low speed condenser fan motor is de-energized.
10.Air circulating blower remains energized at low cool speed for the cool OFF delay. Cool OFF delay timer begins when thermostat input is removed.
11.Control returns to Standby and awaits next thermostat request.
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