International Comfort Products RGS210, RGS240, RGS300, RGS336 Installation Manual
INSTALLATION INSTRUCTIONS
R-410A Single Package Rooftop with
Gas Heat/Electric Cooling
RGS210-336 Vertical Supply and Return with RTPF
RGS units for installation in the United States contain use of 2-speed indoor fan control system. This
complies with the U.S. Department of Energy (DOE) efficiency standard of 2018.
RGS units for installation outside the United States may or may not contain use of the 2-speed indoor fan
control system as they are not required to comply with the U.S. Department of Energy (DOE) efficiency
standard of 2018.
For specific details on operation of the 2-speed indoor fan system refer to the Variable Frequency Drive
(VFD) Factory-Installed Option 2-Speed Motor Control Installation, Setup, and Troubleshooting manual.
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Job-Site Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 1 — Plan for Unit Location. . . . . . . . . . . . . . . . . . . 10
Step 2 — Plan for Sequence of Unit
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 3 — Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 4 — Provide Unit Support. . . . . . . . . . . . . . . . . . . . 11
Step 5 — Field Fabricate Ductwork . . . . . . . . . . . . . . . . 16
Step 6 — Rig and Place Unit. . . . . . . . . . . . . . . . . . . . . . 16
Step 7 — Install Outside Air Hood . . . . . . . . . . . . . . . . . 17
Step 8 — Install Flue Hood and Combustion
Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 9 — Install Gas Piping . . . . . . . . . . . . . . . . . . . . . . 18
Step 10 — Install External Condensate Trap
and Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 11 — Make Electrical Connections. . . . . . . . . . . . . 20
Step 12 — Adjust Factory-Installed Options . . . . . . . . . 40
Step 13 — Install Accessories. . . . . . . . . . . . . . . . . . . . . 40
Step 14 — Check Belt Tension . . . . . . . . . . . . . . . . . . . . 40
Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, mainte-
nance, or use can cause explosion, fire, electrical shock or other
conditions which may cause personal injury or property damage.
Consult a qualified installer, service agency, or your distributor or
branch for information or assistance. The qualified installer or
agency must use factory-authorized kits or accessories when
modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloths for brazing operations and have a fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult local
building codes and appropriate national electrical codes (in USA,
ANSI/NFPA70, National Electrical Code (NEC); in Canada,
CSA C22.1) for special requirements.
It is important to recognize safety information. This is the
safety-alert symbol . When you see this symbol on the unit
and in instructions or manuals, be alert to the potential for
personal injury.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the safetyalert symbol. DANGER identifies the most serious hazards
which will result in severe personal injury or death. WARNING
signifies hazards which could result in personal injury or death.
CAUTION is used to identify unsafe practices, which may result
in minor personal injury or product and property damage. NOTE
is used to highlight suggestions which will result in enhanced
installation, reliability, or operation.
WARNING
Failure to follow this warning could result in personal
injury or death. Disconnect gas piping from unit when leak
testing at pressure greater than 0.5 psig (3450 Pa). Pressures greater than 0.5 psig (3450 Pa) will cause gas valve
damage resulting in hazardous condition. If gas valve is
subjected to pressure greater than 0.5 psig (3450 Pa), it
must be replaced before use. When pressure testing fieldsupplied gas piping at pressures of 0.5 psig (3450 Pa) or
less, a unit connected to such piping must be isolated by
closing the manual gas valve.
WARNING
Failure to follow this warning could cause personal injury
or death. Before performing service or maintenance operations on unit, always turn off main power switch to unit and
install lock(s) and lockout tag(s). Unit may have more than
one power switch.
!
WARNING
Failure to follow this warning could cause personal injury,
death and/or equipment damage.
®
Puron
(R-410A) refrigerant systems operate at higher
pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment.
509 01 4004 01 04/04/2018
WARNING
MANIFOLD
GAS VALVE
MANIFOLD PRESSURE
TAP SET SCREW
Failure to follow this warning could cause personal
injury or death.
Relieve pressure and recover all refrigerant before system
repair or final unit disposal.
Wear safety glasses and gloves when handling refrigerants.
Keep torches and other ignition sources away from refrigerants and oils.
CAUTION
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing air conditioning
equipment.
WARNING
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Manifold pressure tap set screw must be tightened and
1
/8 in. NPT pipe plug must be installed to prevent gas leaks.
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Inlet pressure tap set screw must be tightened and
1
/8 in. NPT
pipe plug must be installed to prevent gas leaks.
GAS VALVE
INLET PRESSURE
TAP SET SCREW
WARNING
CARBON-MONOXIDE POISONING HAZARD
Failure to follow instructions could result in severe personal injury of death due to carbon-monoxide poisoning, if
combustion products infiltrate into the building.
Check that all openings in the outside wall around the vent
(and air intake) pipe(s) are sealed to prevent infiltration of
combustion products into the building.
Check that furnace vent (and air intake) terminal(s) are not
obstructed in any way during all seasons.
GENERAL
These installation instructions cover the RGS units with gas
heat and electric cooling. Units are pre-wired and pre-charged
with environmentally balanced Puron
®
(R-410A) refrigerant at
the factory. See Fig. 1 for model number nomenclature. See
Fig. 2-4 for unit dimensions. See Fig. 5 for service clearances.
Rated Indoor Airflow (cfm) — Table 1 lists the rated in-
door airflow used for the AHRI efficiency rating for the units
covered in this document.
Table 1 — AHRI Efficiency — Rated Indoor Airflow
MODEL NUMBER FULL LOAD AIRFLOW (CFM)
RGS210 6125
RGS240 8000
RGS300 8750
RGS336 9750
2
MODEL SERIES
R G S 2 1 0 H D A B 0 A A
T
Position Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14
R = Rooftop
G = Gas/Electric Typ e
S = Standard ASHRAE 90.1-2010 Efficiency Efficiency
210 = 210,000 = 17.5 Tons Dedicated Vertical SA/RA (SA = Supply Air, RA = Return Air)
240 = 240,000 = 20 Tons Dedicated Vertical SA/RA
300 = 300,000 = 25 Tons Dedicated Vertical SA/RA
336 = 330,000 = 27.5 Tons Dedicated Vertical SA/RA
Nominal Cooling Capacity
H = 208/230-3-60
L = 460-3-60
S = 575-3-60 Voltage
D = Low Heat
E = Medium Heat
F = High Heat
S = Low Heat, Stainless Steel Heat Exchanger
R = Medium Heat, Stainless Steel Heat Exchanger
T = High Heat, Stainless Steel Heat Exchanger
Heating Capacity
A = Standard Static Option (all sizes, with 1-speed and 2-speed indoor fan motor)
B = High Static Option (all sizes, with 2-speed indoor fan motor)
C = Medium Static Option (17.5 ton, with 1-speed indoor fan motor, all sizes with 2-speed indoor fan motor)
E = High Static High Efficiency Option (all sizes, with 1-speed indoor fan motor)
F = Medium Static High Efficiency Option (20, 25, 27.5 ton, with 1-speed indoor fan motor)
G = High Static Motor with Hot Gas Re-heat (20, 25, 27.5 ton, with 1-speed indoor fan motor) Motor Option
A = None
B = Economizer w/Bara-relief, OA Temp sensor
E = Economizer w/Bara-relief + CO2 sensor, OA Temp sensor
H = Economizer w/Bara-relief, Enthalpy sensor
L = Economizer w/Bara-relief + CO2 sensor, Enthalpy sensor
U = Ultra Low Leak Temp Economizer w/Bara-relief (2-speed indoor fan motor only)
W = Ultra Low Leak Temp Enthalpy Economizer w/Bara-relief (2-speed indoor fan motor only)
P = 2-Position damper Outdoor Air Options / Control
0A = No Options
4B = Non-fused Disconnect
AA = Hinged Access Panels
AT = Non-powered 115v Convenience Outlet.
BR = Supply Air Smoke Detector Other Factory Installed Options
A = Alum / Cu Cond & Alum / Cu Evap
B = Pre coated Alum / Cu Cond & Alum / Cu Evap
C = E-coated Alum / Cu Cond & Alum / Cu Evap
D = E-coated Alum / E-coated Cu Cond & Alum / Cu Evap
E = Cu / Cu Cond & Alum / Cu Evap
F = Cu / Cu Cond & Cu / Cu Evap Coil Factory Installed Options
A = Single Speed Indoor Fan Motor, for W7212 controls
B = Single Speed Indoor Fan Motor, for W7220 controls
T = Two-Speed Indoor Motor Controller (VFD) (Standard on U.S. models)
Motor Type Option
Fig. 1 — Model Number Nomenclature (Example)
3
Fig. 2 — Unit Dimensional Drawing – RGS210
4
RGS210
Fig. 2 — Unit Dimensional Drawing – RGS210 (cont)
5
Fig. 3 — Unit Dimensional Drawing – RGS240 and RGS300
6
RGS240
RGS300
Fig. 3 — Unit Dimensional Drawing – RGS240 and RGS300 (cont)
7
Fig. 4 — Unit Dimensional Drawing – RGS336
8
RGS336
Fig. 4 — Unit Dimensional Drawing – RGS336 (cont)
9
Fig. 5 — Service Clearances
NOTE: Unit not designed to have overhead obstruction. Contact Application Engineering for guidance on any application planning overhead
obstruction or for vertical clearances.
LOCATION
DIMENSION
in. (mm)
CONDITION
A 36 (914) Recommended clearance for air flow and service
B 42 (1067) Recommended clearance for air flow and service
C
18 (457)
No convenience outlet
No economizer
No field-installed disconnect on the economizer hood side (factory-installed disconnect installed)
36 (914)
Convenience outlet installed
Vertical surface behind servicer is electrically non-conductive (e.g. wood, fiberglass).
42 (1067)
Convenience outlet installed
Vertical surface behind servicer is electrically conductive (e.g. metal, masonry)
96 (2438)
Economizer and/or power exhaust installed
Check for sources of flue products with 10 feet (3 meters) of economizer fresh air intake
D 42 (1067) Recommended clearance for service
C
B
D
A
NOTE: Unit is not designed to have overhead obstruction.
Contact Application Engineering for guidance on any application planning overhead obstruction or for vertical
clearances.
INSTALLATION
Job-Site Survey —
installation.
1. Consult local building codes and the NEC (National
Electrical Code) ANSI/NFPA 70 for special installation requirements.
2. Determine unit location (from project plans) or select unit
location.
3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.
Step 1 — Plan for Unit Location — Select a location
for the unit and its support system (curb or other) that provides
for the minimum clearances required for safety. This includes
the clearance to combustible surfaces, unit performance and
service access below, around and above unit as specified in unit
drawings. See Fig. 5.
Complete the following checks before
NOTE: Consider also the effect of adjacent units. Be sure
that unit is installed such that snow will not block the combustion intake or flue outlet.
Unit may be installed directly on wood flooring or on class
A, B, or C roof-covering material when roof curb is used.
Do not install unit in an indoor location. Do not locate air
inlets near exhaust vents or other sources of contaminated air.
For proper unit operation, adequate combustion and ventilation
air must be provided in accordance with Section 5.3 (Air for
Combustion and Ventilation) of the National Fuel Gas Code,
ANSI Z223.1 (American National Standards Institute) and
NFPA (National Fire Protection Association) 54 TIA-54-84-1.
In Canada, installation must be in accordance with the CAN1B149 installation codes for gas burning appliances.
Although unit is weatherproof, avoid locations that permit
water from higher level runoff and overhangs to fall onto the
unit.
Locate mechanical draft system flue assembly at least 4 ft
(1.2 m) from any opening through which combustion products
could enter the building, and at least 4 ft (1.2 m) from any adjacent building (or per local code). Locate the flue assembly at
least 10 ft (3.05 m) from an adjacent unit’s fresh air intake hood
if within 3 ft (0.91 m) of same elevation (or per local code).
10
When unit is located adjacent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade.
Select a unit mounting system that provides adequate height
to allow installation of condensate trap per requirements. Refer
to Step 10 — Install External Condensate Trap and Line – for
required trap dimensions.
ROOF MOUNT — Check building codes for weight distribution requirements. Unit operating weight is shown in
Table 2.
Step 2 — Plan for Sequence of Unit Installation —
The support method used for this unit will dictate different
sequences for the steps of unit installation. For example, on
curb-mounted units, some accessories must be installed on the
unit before the unit is placed on the curb. Review the following
for recommended sequences for installation steps.
CURB-MOUNTED INSTALLATION
• Install curb
• Install field-fabricated ductwork inside curb
• Install accessory thru-base service connection package
(affects curb and unit) (refer to accessory installation
instructions for details)
• Rig and place unit
• Remove top skid
• Install outdoor air hood
• Install smoke detector tube
• Install combustion air hood
• Install flue hood
• Install gas piping
• Install condensate line trap and piping
• Make electrical connections
• Install other accessories
PAD-MOUNTED INSTALLATION
• Prepare pad and unit supports
• Rig and place unit
• Remove duct covers and top skid
• Install smoke detector return air sensor tube
• Install field-fabricated ductwork at unit duct openings
• Install outdoor air hood
• Install combustion air hood
• Install flue hood
• Install gas piping
• Install condensate line trap and piping
• Make electrical connections
• Install other accessories
FRAME-MOUNTED INSTALLATION — Framemounted applications generally follow the sequence for a curb
installation. Adapt as required to suit specific installation plan.
Step 3 — Inspect Unit — Inspect unit for transportation
damage. File any claim with transportation agency. Confirm
before installation of unit that voltage, amperage and circuit
protection requirements listed on unit data plate agree with
power supply provided.
On units with hinged panel option, check to be sure all
latches are tight and in closed position.
Locate the carton containing the outside air hood parts in the
rear blower assembly. Do not remove carton until unit has been
rigged and located in final position.
Step 4 — Provide Unit Support
ROOF CURB MOUNT — Assemble and install accessory
roof curb in accordance with instructions shipped with the
curb.
Curb should be level. This is necessary for unit drain to
function properly. Unit leveling tolerances are show in Fig. 6.
Refer to Accessory Roof Curb Installation Instructions for additional information as required.
Accessory roof curb details and dimensions are shown in
Fig. 8-10.
C
A
B
Fig. 6 — Unit Leveling Tolerances
Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the
unit. Thru-the-base power connection must be installed before
the unit is set on the roof curb. If field-installed thru-the-roof
curb gas connections are desired remove knockout in basepan
located in the gas section, see Fig. 7 for location. Gas connections and power connections to the unit must be field installed
after the unit is installed on the roof curb.
If electric and control wiring is to be routed through the
basepan, remove knockouts in basepan located in control box
area of access panel, see Fig. 7. See Fig. 8-10 for basepan
knockout locations for location. Attach the service connections
to the basepan.
NOTE: The gasketing of the unit to the roof curb is critical
for a watertight seal. Install gasket supplied with the roof
curb as shown in Fig. 8-10. Improperly applied gasket can
also result in air leaks and poor unit performance.
MAXIMUM ALLOWABLE
DIFFERENCE IN. (MM)
A-B
0.25" (6)
B-C
0.5" (12)
A-C
0.5" (12)
Table 2 — Operating Weights
RGS
Base Unit
RTPF Coil 1922 (874) 2072 (942) 2197 (999) 2640 (1200)
Economizer 246 (112) 246 (112) 246 (112) 246 (112)
Powered Outlet 35 (16) 35 (16) 35 (16) 35 (16)
Hot Gas Re-Heat System 110 (50) 120 (54) 120 (54) N/A
Curb
14-in. (356 mm) 240 (109) 255 (116) 255 (116) 255 (116)
24-in. (610 mm) 340 (154) 355 (161) 355 (161) 355 (161)
210 240 300 336
UNITS — lb (kg)
11
Fig. 7 — Typical Access Panel and Compressor
CONTROL BOX
ACCESS PANEL
FILTER AND
INDOOR COIL
ACCESS PANEL
INDOOR BLOWER
ACCESS PANEL
GAS HEAT
ACCESS PANEL
COMPRESSOR
(EACH SIDE)
HOOD CARTON LOCATION
(REAR ACCESS PANEL)
Locations
ALTERNATE UNIT SUPPORT (IN LIEU OF CURB
OR SLAB MOUNT) — A non-combustible sleeper rail can
be used in the unit curb support area. If sleeper rails cannot be
used, support the long sides of the unit with a minimum of 4
equally spaced 4-in. x 4-in. (102 mm x 102 mm) pads on each
side. Locate pads so that they support the rails. Make sure to
avoid the fork openings.
12
210
Fig. 8 — Roof Curb Details — RGS210
13
240-300
Fig. 9 — Roof Curb Details — RGS240-300
14
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