Goodmans CPG User Manual

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-353D 5151 Felipe, Suite 500, Houston, TX 77056 6/11 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 I N 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 that are not covered by 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.

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