McQuay RG024AAARY Installation Manual

Installation and Maintenance Manual IM-805

Group: Light Commercial
Part Number: IM-805
Date: August 2005
Supersedes: March 2005

RG Single Package Gas-Electric
Heating and Cooling Unit

2 to 5 ton

© 2004 McQuay International

IM-805 Page 1

Table of Contents

MODEL NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . 3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Codes and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Important Message to the Installer . . . . . . . . . . . . . . . . . . . .4

Important Message to the Owner . . . . . . . . . . . . . . . . . . . . .4

Recognize Safety Symbols, Words, and Labels . . . . . . . . . .4

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

UNIT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

All Installations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Ground Level Installations Only: . . . . . . . . . . . . . . . . . . . . . .6

Rooftop Installations Only:. . . . . . . . . . . . . . . . . . . . . . . . . . 6

Roof Curb Installations Only:. . . . . . . . . . . . . . . . . . . . . . . . .6

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . 7

RIGGING DETAILS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PROPANE GAS INSTALLATION. . . . . . . . . . . . . . . . . . . . 9

Tanks and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Thermostat Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Unit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Heat Anticipator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .11

CIRCULATING AIR AND FILTERS . . . . . . . . . . . . . . . . . . 11

Airflow Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Horizontal Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Down Discharge Applications . . . . . . . . . . . . . . . . . . . . . . . 11

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Flue Hood Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Condensate Drain Connection . . . . . . . . . . . . . . . . . . . . . .12

NORMAL SEQUENCES OF OPERATION . . . . . . . . . . . . 12

Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Fan Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

STARTUP, ADJUSTMENTS, AND CHECKS . . . . . . . . . . .13

Heating Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Cooling Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Ignition Control Error Codes . . . . . . . . . . . . . . . . . . . . . . . .16

Abnormal Operation - Heating . . . . . . . . . . . . . . . . . . . . . . .16

Abnormal Operation - Cooling . . . . . . . . . . . . . . . . . . . . . . 17

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Filter Replacement or Cleaning . . . . . . . . . . . . . . . . . . . . . 17

Cabinet Finish Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 17

Clean Outside Coil (Qualified Servicer Only) . . . . . . . . . . .17

Condenser, Evaporator, and Induced Draft Motors. . . . . . 17

Flame Sensor (Qualified Servicer Only). . . . . . . . . . . . . . . 17

Flue Passages (Qualified Servicer Only) . . . . . . . . . . . . . .18

Cleaning Flue Passages (Qualified Servicer Only) . . . . . . .18

Main Burner Flame (Qualified Servicer Only) . . . . . . . . . . .18

Cleaning Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

ACCESSORIES AND FUNCTIONAL PARTS. . . . . . . . . . 19

Sheet Metal Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Functional Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

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

"McQuay" is a registered trademark of McQuay International.

© 2004 McQuay International

"Illustrations and information cover the McQuay International products at the time of publication and we reserve the right to make changes in

design and construction at any time without notice."

Manufactured by Goodman Manufacturing Co., L. P., Houston, TX 77008

Page 2 IM-805

MODEL NOMENCLATURE

M

R

N

2
3
3
4
4
6

*

RG

odel

G = Rooftop Gas

ominal Capacity (tons)

4 = 2
0 = 3
6 = 3
2 = 3-1/2
8 = 4
0 = 5

Vintage
SEER

A = 10
B = 12

* 10 SEER Size 036, 042, 048 and 060 only.

Table 1: Unit Nameplate Model Number Ide nt if i er

024

A

ARY

A

Future Use

Voltage/Phase

P = 208-230/3/60
R = 208-230/1/60

Heating Input

(BTUH)
A = 45,000
B = 70,000
C = 90,000
D = 115,000
E = 140,000

Unit Nameplate McQuay Model Number

GPG10240451A RG024AAARY
GPG10240701A RG024AABRY
GPG10300701A RG030AABRY
GPG10360701A RG036AABRY
GPG10360901A RG036AACRY
GPG10420701A RG042AABRY
GPG10420901A RG042AACRY
GPG10480901A RG048AACRY
GPG10481151A RG048AADRY
GPG10600901A RG060AACRY
GPG10601401A RG060AAERY
GPG10360903A RG036AACPY
GPG10480903A RG042AACPY
GPG10600903A RG048AACPY
GPG10601403A RG060AAEPY
GPG12240451A RG024ABARY
GPG12240701A RG024ABBRY
GPG12300701A RG030ABBRY
GPG12360701A RG036ABBRY
GPG12360901A RG036ABCRY
GPG12420701A RG042ABBRY
GPG12420901A RG042ABCRY
GPG12480901A RG048ABCRY
GPG12481151A RG048ABDRY
GPG12600901A RG060ABCRY
GPG12601151A RG060ABDRY

IM-805 Page 3

INTRODUCTION

General Description

These installation instructions cover the outdoor installation of
single package gas-electric heating and cooling units. See the
product catalog applicable to your model for information
regarding specifications applicable to your model and accesso­ries.

Receiving Inspection

McQuay products are carefully inspected prior to shipment
and the carrier has assumed responsibility for loss or damage
upon acceptance of the shipment.

Upon receiving your shipment, check all items carefully
against the Bill of Lading. Inspect the unit and/or accessories
for shipping damage as soon as they are received. Immedi­ately file claims for loss or damage, either shipping or con­cealed, with the shipping company.

Check the unit nameplate to verify the model number an d elec­trical characteristics are correct. In the event an incorrect unit
is shipped, it must be returned to the supplier and must NOT
be installed. The manufacturer disclaims all responsibility for
the installation of incorrectly shipped units.

Codes and Regulations

This product is designed and manufactured to permit installa­tion in accordance with National Codes. System design
should, where applicable, follow information presented in
accepted industry guides such as the ASHRAE Handbooks. It
is the installer' s responsibility to inst all the pro duct in ac cor­dance with National Codes and/or prevailing local codes and
regulations. The manufacturer disclaims all responsibility for
equipment installed in violation of any code or regulations.

Important Message to the Installer

This equipment is to be installed by an experienced installation
company and fully trained personnel. Carefully read all
instructions and take into account any special considerations
prior to installing the unit. Give this manual to the owner and
explain its provisions.

Important Message to the Owner

Read these instructions carefully and keep them near the prod­uct for future reference. Although these instructions are
addressed primarily to the installer, useful maintenance infor­mation is included. Have the installer acquaint you with the
operation of the product and periodic maintenance require­ments.

Recognize Safety Symbols, Words, and Labels

The following symbols and labels are used throughout this
manual to indicate immediate or potential hazards. It is the
owner's and installer's responsibility to read and comply with
all safety information and instructions accompanying these
symbols. Failure to heed safety information increases the risk
of property damage and/or product damage, serious personal
injury or death. Improper installation, operation and mainte­nance can void the warranty.

DANGER

Immediate hazards which WILL result in property
damage, product damage, severe personal injury and/
or death.

WARNING

Hazards or unsafe practice CAN result in property
damage, product damage, sever personal injury and/or
death.

CAUTION

Hazards or unsafe practices which CAN result in
property damage, product damage, and/or personal
injury.

Replacement Parts

Replacement parts can be obtained by contacting McQuay at
1

-800-37-PARTS. When contacting McQuay for service or
replacement parts, refer to the model number and serial num­ber of the unit as stamped on the nameplate attached to the
unit.

Page 4 IM-805

GENERAL WARNINGS

DANGER

CARBON MONOXIDE (CO) POISONING HAZARD

CO can cause brain damage and death. It is odorless
and colorless. Do not install this unit in any enclosure
or location where fumes many enter an enclosure.

DANGER

To avoid property damage, personal injury or death, do
not store or use gasoline or other flammable vapors or
liquids in the vicinity of this unit or in any area sharing
ventilation.

WARNING

IF YOU SMELL GAS

• Immediately evacuate the area.

• Do not try to light any appliances.

• Do not touch any electrical switches.

• Do not use any phones in your building.

• Immediately call your gas supplier from a phone
located in a neighboring building.

• Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire
department.

Failure to follow these instructions can result in fire,
explosion, severe personal injury or death.

WARNING

If overheating occurs or the gas supply fails to shut off,
turn off the manual gas shutoff valve outside the
furnace before turning off the electricity supply to avoid
property damage, severe personal injury or death.

WARNING

To avoid property damage, personal injury or death, do
not use this unit if any part has been under water.
Immediately call a qualified service technician to
inspect the furnace an replace any affected part.

WARNING

This product contains or produces substances which
may cause serious illness or death, and which are
known to the State of California to cause cancer, birth
defects or other reproductive harm.

WARNING

To avoid property damage, personal injury or death,
follow the planned maintenance instructions provided in
the "Maintenance" section of this document..

CAUTION

Freezing can burst pipes. Routinely inspect and
monitor unit and premise. If vacant, drain all water
pipes and close water source. Drain hydronic coils and
use alternative heat source.

CAUTION

Do not use this unit as a "construction heater" during
finishing phases of construction on a new structure.
Extremely low return air temperatures and corrosive or
dirty atmosphere can damage unit.

CAUTION

Sheet metal parts, screws, clips and similar items have
sharp edges. Use caution and wear protective clothing
when installing or servicing this equipment.

CAUTION

Keep these instructions in a safe and accessible space
for future reference or in case of an emergency.

UNIT LOCATION

WARNING

To prevent possible equipment damage, property
damage, personal injury or death, all illustrations
included in this manual must be observed when
installing the unit.

IMPORTANT NOTE: Remove wood shipping rails prior to
installation of the unit.

All Installations:

• For proper flame pattern within the heat exchanger and
proper condensate drainage, the unit must be mounted
level.

• The flue outlet hood must be at least 12 inches from any
opening through which flue gases could enter a buil ding,
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 restricti on.

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

IM-805 Page 5

• To avoid possible illness or death, 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 Appendix
Figure 25). These clearances must be permanently main­tained.

• The combustion air inlet and flue outlet hoods 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 , use a level concrete (or equal) base. Prepare a
base that is 3” larger than the package unit footprint and a
minimum of 3” thick.

• Locate the base where no runoff of water from higher
ground can collect in the unit.

Figure 1. Outside Slab Installation

Figure 2. Rooftop Installation

Roof Curb Installations Only:

• 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.

• Curb insulation, cant strips, flashing and general roofing
material are furnished by the contractor.

Figure 3. Roof Curb Installation

Rooftop Installations Only:

• To avoid possible property damage or personal injury, the
roof must have sufficient structural strength to carry the
weight of the unit(s) and snow or water loads as required
by local codes. Consult a structural engineer to determine
the weight capabilities of the roof.

• 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, provide a flat surface for
service personnel.

Page 6 IM-805

GENERAL INFORMATION

WARNING

To prevent property damage, personal injury or death,
due to fire, explosions, smoke, soot, condensation,
electric shock or carbon monoxide, this unit must be
properly installed, repaired, operated, and maintained.

This unit is approved for outdoor installation ONLY. For
proper operation the unit must be installed, operated, and
maintained in accordance with these installation and operating
instructions, all local building codes and ordinances, or in their
absence, with the latest edition of the National Fuel Gas Code
NFPA54/ANSI Z223.1 and National Standard of Canada
CAN/CSA B149 Installation Codes.

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

RIGGING DETAILS

WARNING

To avoid equipment and property damage, the unit
should remain in an upright position during all rigging
and moving operations.

To facilitate lifting and moving when a crane is used, place the
unit in an adequate cable sling..

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

Figure 4. Rigging

GAS PIPING
IMPORTANT NOTE: This unit is factory set to operate on

natural gas at the altitudes shown on the nameplate.

WARNING

To 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).
Failure to do so can result in unsatisfactory operation
and/or equipment damage. High altitude kits are for
U.S. installations only and are not approved for use in
Canada.

The nameplate is stamped with the model number, type of gas
and gas input rating. Verify that the unit is eq uipped t o oper at e
on the type of gas available. Conversion to LP gas is permitted
with the use of factory-authorized conversion kit LPT-00A.

Table 2: 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 table above.

For dependable ignition, the minimum supply pressure should
not vary from the value shown in Table 2. In addition, gas
input to the burners must not exceed the rated input shown on
the nameplate. Overfiring of the unit could result in premature
heat exchanger failure.

High Altitude Derate (U.S. Installations Only)

IMPORTANT NOTE: The gas/electric units naturally derate

with altitude. Do not attempt to increase the firing rate by
changing orifices or increasing the manifold pressure. This can
cause poor combustion and equipment failure. At all altitudes,
the manifold pressure must be within 0.3 inches W.C. of the
value listed on the nameplate for the fuel used. At all altitudes
and with either fuel, the air temperature rise must be within the
range listed on the nameplate.

Refer to the Installation Manual provided with the LP kit for
conversion from natural gas to propane gas, and for altitude
adjustments.

Piping

IMPORTANT NOTE: To avoid unsatisfactory operation 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, as shown in Table 3,
include all appliances on that line that co uld be oper ated simu l­taneously.

The nameplate is stamped with the model number, type of gas
and gas input rating. Verify that 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.

IM-805 Page 7

Natural Gas Connection

Table 3: Natural Gas Capacity of Pipe in Cubic Feet of Gas
Per Hour (CFH

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 on 0.60
Specific Gravity Gas)

)

Nominal Black Pipe Size (inches)

1/23/4 11 1/41 1/2

BTUH Furnace Input

CFH =

Heating Value of Gas (BTU/Cubic Foot)

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

Figure 5. Proper Piping Practice

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.

Gas Piping Checks

DRIP LEG

MANUAL
SHUT-OFF
VALV E

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.

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
between the meter and the unit (within six feet of 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 contacting
masonry, plaster or insulation, or when they are subject to
repeated wettings by liquids.

CAUTION

To avoid property damage or personal injury due to fire,
the following instructions must be followed regarding
gas connections and pressure testing:

• The unit and its gas connections must be leak tested
before operation. Because of the danger of explosion
or fire, never use a match or open flame to test for
leaks. Never exceed specified pressures for testing.
Higher pressure may damage the gas v al ve and cause
overfiring, which may result in premature heat
exchange failure.

• This unit and its shut-off valve must be disconnected
from the gas supply during any pressure testing of that
system at test pressures in excess of 1/2 PSIG (3.48
kPa).

• This unit must be isolated from the gas supply system
by closing its manual shut-off valve during any
pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 PSIG (3.48
kPa).

WARNING

To a v oid property damage or personal injury during air
bleeding, be sure there is no open flame, sparks, arcing
switches on equipment, cigarette or other sources of
ignition in the vicinity or in areas sharing ventilation.

There will be air in the gas supply line after testing for leaks on
a new installation. Before bleeding the line, verify that there is
no flame, arcing switch on equipment, cigarette, or other
source of ignition in the area or areas sharing ventilation.
Bleed air from the line by loosening the ground joint union
until pure gas is expelled. Tighten the union and wait for at
least five minutes until all gas has been evacuated from the
area. The unit is placed in operation by closing the main elec­trical disconnect switch for the unit.

Page 8 IM-805