Download Amana PGD**C Operating instructions
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Package Gas-Electric Installation Instructions is a trademark of Maytag Corporation and is used under license to Goodman Company, L.P. All rights reserved. ® DESIGN CE RTIF IE D CE R TI FI E D ® 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 TO THE INSTALLER Before installing this unit please read this manual to familiarize yourself on the specific items which must be adhered to such as maximum external static pressure to unit, air temperature rise, minimum or maximum CFM and motor speed connections. TO THE OWNER It is important to complete the owner registration card and mail it immediately. This will assist us in contacting you if any service or warranty information should change in the future. When completing the registration card, be sure to include the Model, Manufacturing and Serial Numbers, plus the installation date. The warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe place so you can find it if necessary. If additional operating instructions are required, call the dealer where the purchase was made. Keep this literature in a safe place for future reference. Part No. 10692413 Printed in USA These installation instructions cover the outdoor installation of single package gas electric heating and cooling units. See the Product Data Book applicable to your model* for information regarding accessories. *NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual. Goodman Company, L.P. 1810 Wilson Parkway • Fayetteville, Tennessee 37334 www.amana-hac.com 2002-2004 Goodman Company, L.P. Effective: June 2004 Table of Contents RECOGNIZE SAFETY SYMBOLS, WORDS, AND LABELS .............................................................................................. 3 Safety Instructions ............................................................................................................................................................. 3 ALL INSTALLATIONS: ........................................................................................................................................... 4 GROUND LEVEL INSTALLATIONS ONLY ................................................................................................................... 4 ROOFTOP INSTALLATIONS ONLY ............................................................................................................................ 4 General Information ........................................................................................................................................................... 4 SHIPPING AND HANDLING ..................................................................................................................................... 5 RIGGING AND HANDLING ...................................................................................................................................... 5 PROPER PIPING PRACTICE .................................................................................................................................. 5 HIGH ALTITUDE DERATE (U.S. INSTALLATIONS ONLY) ............................................................................................. 5 GAS PIPING CHECKS .......................................................................................................................................... 6 Propane Gas Installations ................................................................................................................................................. 6 TANKS AND PIPING ............................................................................................................................................. 7 PROPANE GAS PIPE SIZING ................................................................................................................................. 7 Electrical Connections ....................................................................................................................................................... 7 THERMOSTAT ..................................................................................................................................................... 7 WIRING ............................................................................................................................................................ 7 UNIT VOLTAGE .................................................................................................................................................. 8 Air Circulation and Filters ................................................................................................................................................. 8 AIRFLOW CONVERSION ....................................................................................................................................... 8 DUCTWORK ....................................................................................................................................................... 8 FILTERS ............................................................................................................................................................ 9 FILTER INSTALLATION .......................................................................................................................................... 9 Venting ................................................................................................................................................................................ 9 FLUE HOOD AND AIR INLET HOOD INSTALLATION .................................................................................................... 9 HIGH STATIC OR DOWN-DISCHARGE INSTALLATION .................................................................................................. 9 CONDENSATE DRAIN CONNECTION ........................................................................................................................ 9 Normal Sequences of Operation ..................................................................................................................................... 10 HEATING ......................................................................................................................................................... 10 COOLING ........................................................................................................................................................ 10 FAN ONLY ...................................................................................................................................................... 10 Startup, Adjustments, and Checks ................................................................................................................................. 10 HEATING STARTUP ........................................................................................................................................... 10 COOLING STARTUP ........................................................................................................................................... 14 Troubleshooting ............................................................................................................................................................... 14 ABNORMAL OPERATION - HEATING ...................................................................................................................... 14 IGNITION CONTROL DIAGNOSTIC INDICATOR CHART ................................................................................................ 15 Maintenance ..................................................................................................................................................................... 15 REPLACING OR CLEANING FILTER ...................................................................................................................... 15 MAINTAINING CABINET FINISH ............................................................................................................................ 16 CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY) .............................................................................................. 16 CONDENSER, EVAPORATOR, AND INDUCED DRAFT MOTORS .................................................................................... 16 FLAME SENSOR (QUALIFIED SERVICER ONLY) ...................................................................................................... 16 FLUE PASSAGES (QUALIFIED SERVICER ONLY) ..................................................................................................... 16 MAIN BURNER FLAME (QUALIFIED SERVICER ONLY) .............................................................................................. 16 Accessories and Functional Parts .................................................................................................................................. 17 SHEET METAL ACCESSORIES ............................................................................................................................. 17 FUNCTIONAL PARTS ......................................................................................................................................... 17 2 SAFETY INSTRUCTIONS RECOGNIZE SAFETY SYMBOLS, WORDS, AND LABELS The following symbols and labels are used throughout this manual to indicate immediate or potential safety 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 personal injury, property damage, and/or product damage. WARNING WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION CAUTION - Hazards or unsafe practices which COULD result in minor or moderate personal injury, product damage, property damage. WARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. – DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. – WHAT TO DO IF YOU SMELL GAS: • DO NOT TRY TO LIGHT ANY APPLIANCE. • DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY CARBON MONOXIDE POISONING HAZARD Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas PHONE IN YOUR BUILDING. • IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS. Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation. • IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT. – INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. WARNING This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode. THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER CO can cause serious illness including permanent brain damage or death. REPRODUCTIVE HARM. B10259-216 WARNING WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, TURNING OFF THE ELECTRICAL SUPPLY. INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILIDNG IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT WARNING SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT USE THIS UNIT IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND TO REPLACE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL HAVING BEEN TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD UNDER WATER. BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED. WARNING THIS UNIT MUST NOT BE USED AS A "CONSTRUCTION HEATER" DURING THE THIS TYPE OF FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE. USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TERMPERATURES AND EXPOSURE TO CORROSIVE OR VERY DIRTY ATMOSPHERES. 3 UNIT LOCATION • The combustion air inlet and flue outlet hoods on the side of 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. • Provisions must be made for adequate combustion and ventilation air in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, NFPA 54/ ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CAN/ CSA B149 Installation Codes, or applicable provisions of the local building codes. WARNING TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING 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 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. • GROUND LEVEL INSTALLATIONS ONLY 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. • 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 clearances from the enclosure as shown for fire protection, proper operation, and service access. These clearances must be permanently maintained. • The base should also be located where no runoff of water from higher ground can collect in the unit. • To avoid possible personal injury or property damage, 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. • 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. NOTE: Refer to the Product Data Book applicable to your model* or the unit Rating Plate for approved duct orientation, before using down discharge openings. This unit is approved only for an outdoor installation. GENERAL INFORMATION 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 NFPA54/ANSI Z223.1 and National Standard of Canada CAN/CSA-2.3. 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 A.S.H.R.A.E. 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 TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, CLEARANCES TO COMBUSTIBLE SURFACES LISTED IN THE FIGURE BELOW MUST BE OBSERVED. 24" Clearance (Condenser End) When the unit is installed on the ground adjacent to the building, a level concrete (or equal) base is recommended. Prepare a base 47 inches by 49 inches or slightly larger and 3 inches thick. ROOFTOP INSTALLATIONS ONLY CAUTION 36" Side Clearance for Servicing Recommended • 36" Maximum Overhang 48" Minimum Overhang Vinyl Coated Canvas Connections Insulated Return Duct Minimum 9" Clearance to Combustibles 36" Clearance for Service Required 0" Minimum Clearance to Combustibles Insulated Supply Duct Minimum Clearances for Unit *NOTE: Please contact your distributor or our website for the applicable product data book referred to in this manual. 4 PROPER PIPING PRACTICE 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. IMPORTANT NOTE: This unit is factory set to operate on natural gas at the altitudes shown on the rating plate. The 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. 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. SHIPPING AND HANDLING Units are securely packed in shipping containers approved by the International Safe Transit Association. Check the carton upon arrival for external damage. If damage is found, file a request in writing for inspection by the carrier agent immediately. 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. If no damage is found, carefully remove all shipping material and properly dispose of it. Keep the unit as upright as possible. Laying the unit on its side or top could cause equipment damage. DO NOT VARY FROM THE MINIMUM SUPPLY PRESSURE GIVEN IN THE INLET GAS PRESSURE TABLE. Doing so could create ignition problems. Inlet Gas Pressure Natural Propane Min. 5.0" W.C., Max. 10.0" W.C. Min. 11.0" W.C., Max. 13.0" W.C. Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in Table Above. DO NOT EXCEED THE RATED INPUT SHOWN ON THE RATING PLATE. Overfiring of the unit could result in premature heat exchanger failure. RIGGING AND HANDLING WARNING DO NOT UNDERSIZE THE NATURAL/PROPANE GAS PIPING FROM THE METER/TANK TO THE UNIT. Doing so could cause unsatisfactory operation or equipment damage due to under firing of equipment. When sizing a trunk line, include all appliances on that line that could be operated simultaneously. TO PREVENT 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. NOTE: Refer to Product Data Book applicable to your model* or the unit Rating Plate for approved duct orientation, before using down discharge openings. Natural Gas Capacity of Pipe in Cubic Feet of Gas Per Hour (CFH) Nominal Black Pipe Size (inches) Length of Pipe in Feet 1 1/2 3/4 1 1/4 1 1/2 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) 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. If using a fork lift, see the following figure for location of fork prongs. Make certain prongs support unit weight. CFH = Fork Lift From Back Of Unit BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot) 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 HIGH ALTITUDE UNSATISFACTORY OPERATION AND/OR EQUIPMENT DAMAGE. KITS ARE FOR IN U.S. INSTALLATIONS ONLY AND ARE NOT APPROVED FOR USE CANADA. 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. Fork Lift Unit Positioning 5 GAS PIPING CHECKS At all altitudes, the manifold pressure must be within 0.3 inches w.c. of that listed in the “Product Data Book applicable to your model*” for the fuel used. At all altitudes and with either fuel, the air temperature rise must be within the range listed on the unit nameplate. Refer to the following table for kit conversions from natural gas to propane gas and for altitude adjustments. CAUTION TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS AND PRESSURE TESTING: • HIGH ALTITUDE GAS ORIFICE CHART Altitude (Ft) 0 - 6000 6001 - 11000 Gas Kit Orifice Natural Propane Natural Propane None LPTK09 HANG07 HALP09 #43 #55 #45 #56 Manifold Pressure 3.5" W.C 10.0" W.C. 3.5" W.C 10.0" W.C. THE UNIT AND ITS GAS CONNECTIONS MUST BE LEAK TESTED BEFORE PLACING IN OPERATION. BECAUSE OF THE DANGER OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. NEVER EXCEED SPECIFIED PRESSURES FOR TESTING. HIGHER PRESSURE MAY DAMAGE GAS VALVE 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 • NOTE: In Canada, gas furanceare are certified to 4500 feet only. 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 Manual Shut-Off Valve EQUAL TO OR LESS THAN 1/2 PSIG (3.48 KPA). WARNING Gas Valve TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, BE SURE THERE IS NO OPEN FLAME IN THE VICINITY DURING AIR BLEEDING. 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. Follow the steps below to bleed air from the gas line. 1. Ensure there is no open flame in the vicinity. 2. Disconnect power to the unit. 3. Loosen the ground joint union until pure gas expels. 4. Tighten joint union and wait five minutes until gas is dispersed. 5. Close the main electrical disconnect switch for the unit. Drip Leg Ground Joint Union (Installed Ahead Of Gas Valve) Reduce coupling 1/2" x 1/8", with 1/8" pipe plug to measure line gas pressure. General Layout at the Unit Natural Gas Connection Refer to the above figure for the general layout at the unit. The following rules apply: 1. Use black iron or steel pipe and fittings for the supply piping. 2. Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used. 3. Use ground joint unions. 4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long. 5. Use two pipe wrenches when making connection to the gas valve to keep it from turning. 6. Install a manual shut-off valve 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). PROPANE GAS INSTALLATIONS WARNING TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETECTING WARNING DEVICE. SINCE RUST CAN REDUCE THE LEVEL OF ODORANT IN PROPANE GAS, A GAS DETECTING WARNING DEVICE IS THE ONLY RELIABLE WAY TO DETECT A PROPANE GAS LEAK. CONTACT A LOCAL PROPANE GAS SUPPLIER ABOUT INSTALLING A GAS DETECTING WARNING DEVICE. IMPORTANT NOTE: Propane gas conversion kits must be installed to convert units to propane gas. See High Altitude Gas Orifice chart for kit part number for this model. 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 10 inch w.c. at the unit manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors: 1. Vaporization rate, which depends on (a) temperature of the liquid, and (b) wetted surface area of the container or containers. 2. Proper pressure regulation. 3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size required 6 will depend on length of pipe run and total load of all appliances. standard commercial compounds, special pipe dope must be used. Shellac based compounds resistant to the actions of liquefied petroleum gases such as Gasolac®, Stalactic®, Clyde’s® or John Crane® are satisfactory. The figure below shows a typical propane gas installation. TANKS AND PIPING WARNING 5 to 15 PSIG (20 PSIG Max.) First Stage Regulator TO PREVENT PROPERTY DAMAGE OR SERIOUS PERSONAL INJURY DUE TO Continuous 11" W.C. FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETECTING WARNING DEVICE. IF THE PROPANE GAS UNIT IS INSTALLED IN AN EXCAVATED AREA OR A 200 PSIG Maximum CONFINED SPACE, A WARNING DEVICE IS REQUIRED DUE TO: • PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN • PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE Second Stage Regulator SETTLE IN ANY LOW AREAS OR CONFINED SPACES. EXCEPT WITH A WARNING DEVICE. If the presence of gas is suspected, follow the warnings on Page 2 of this manual. Typical Propane Gas Installation ELECTRICAL CONNECTIONS PROPANE GAS PIPE SIZING THERMOSTAT Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 1 PSIG Pressure Drop at 10 PSIG Setting. Capacities in 1,000 BTU/HR PIPE OR TUBING LENGTH, FEET Movement of air must not be obstructed by furniture, door, draperies, etc. The thermostat must be located a minimum of five feet above the floor on a vibration-free inside wall with good air circulation. The thermostat must not be mounted where it will be affected by drafts, hot or cold water pipes or air ducts in walls, radiant heat from fireplace, lamps, the sun, television, etc. Consult the Instruction Sheet packaged with thermostat for mounting instructions. Adjust the heat anticipator in the room thermostat to obtain the proper number of heating cycles per hour and to prevent the room temperature from overshooting the room thermostat setting. Heat anticipator must be set at 0.4 amps. All units have one stage of heating and one stage of mechanical cooling. NOTE: Units with economizers can use thermostats with one or two stages of cooling. NOMINAL PIPE SIZE, SCHEDULE 40 TUBING SIZE, O.D., TYPE L 30 3/8" 309 1/2" 700 5/8" 1,303 3/4" 2,205 7/8" 3,394 1/2" 1,843 3/4" 3,854 40 265 599 1,115 1,887 2,904 1,577 3,298 50 235 531 988 1,672 2,574 1,398 2,923 60 213 481 896 1,515 2,332 1,267 2,649 70 196 446 824 1,394 2,146 1,165 2,437 80 182 412 767 1,297 1,996 1,084 2,267 90 171 386 719 1,217 1,873 1,017 2,127 100 161 365 679 1,149 1,769 961 2,009 150 130 293 546 923 1,421 772 1,613 200 111 251 467 790 1,216 660 1,381 250 90 222 414 700 1,078 585 1,224 300 89 201 378 634 976 530 1,109 350 82 185 345 584 898 488 1,020 400 76 172 321 543 836 454 949 WARNING To convert to Capacities at 15 PSIG Settings -- Multiply by 1.130 To convert to Capacities at 5 PSIG Settings -- Multiply by 0.879 Sizing Between Single or Second Stage Regulator and Appliance* Maximum Propane Capacities Listed are Based on 1/2" W.C. Pressure Drop at 11" W.C. Setting. Capacities in 1,000 BTU/HR PIPE OR TUBING LENGTH, FEET TO AVOID INJURY, ELECTRICAL SHOCK OR DEATH, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. NOMINAL PIPE SIZE, SCHEDULE 40 TUBING SIZE, O.D., TYPE L 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 1" 1-1/4" 10 49 110 206 348 539 291 608 1,146 2,353 3,525 20 34 76 141 239 368 200 418 788 1,617 2,423 30 27 61 114 192 296 161 336 632 1,299 1,946 40 23 52 97 164 253 137 284 541 1,111 1,665 50 20 46 86 146 224 122 255 480 985 1,476 60 19 42 78 132 203 110 231 436 892 1,337 80 16 36 67 113 174 94 198 372 764 1,144 100 14 32 59 100 154 84 175 330 677 1,014 125 12 28 52 89 137 74 155 292 600 899 150 11 26 48 80 124 67 141 265 544 815 200 10 22 41 69 106 58 120 227 465 697 250 9 19 36 61 94 51 107 201 412 618 WIRING 1-1/2" All internal wiring in the unit is complete. This unit is designed for 60 hertz current operation at the voltages shown on the rating plate. Bring in the contactor power supply per the supplied unit wiring diagram. Connect the unit control panel to the room thermostat using 24 volt wiring. 1 4 7 10 2 5 8 11 3 6 9 12 D1 L1 L1 L2 300 8 18 33 55 85 46 97 182 374 560 350 7 16 30 51 78 43 89 167 344 515 400 7 15 28 47 73 40 83 156 320 479 L2 L2 L2 UNUSED HEAT COOL *DATA IN ACCORDANCE WITH NFPA PAMPHLET NO. 54 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 Low Voltage Terminal Board Optional Low Voltage Terminal Board Location 7 and review the blower performance charts in the Product Data Book applicable to your model*. In some installations it will be necessary to change the blower speed to provide proper air flow. If converting to down discharge airflow, be sure to refer to the unit rating plate for approved duct orientation and proceed as follows: G Y R W R W Y G From Unit • Cut insulation around bottom openings and remove panels from the bottom of the unit, saving the screws holding the panels in place. • Install horizontal duct cover kit. DUCTWORK Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the unit. Ductwork should be designed in accordance with the recommended methods of Air Conditioning Contractors of Proper Thermostat Wiring Refer to the unit wiring diagram for electrical connections. When installed, the unit must be electrically grounded in accordance with local codes or in the absence of local codes, with the National Electrical Code, ANSI/NFPA No. 70, and/or the CSA C22.1 Electrical Code, if an external source is utilized. WARNING TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED. CAUTION TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE ONLY COPPER CONDUCTORS. CAUTION TO PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING ERRORS, LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. VERIFY PROPER OPERATION AFTER SERVICING. The best protection for the wiring is the lowest rated fuse or circuit breaker which will supply power to the unit during normal operation without nuisance trips. Such a device will provide maximum circuit protection. 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. Low voltage wiring from the unit control panel to the thermostat requires coded cable. For ground level and rooftop wiring see figures below. Electrical Power Directly To Junction Box UNIT VOLTAGE The unit transformer is factory connected for 230V operation. If the unit is to operate on 208V, reconnect the transformer primary lead and induced draft blower motor leads as shown on the unit wiring diagram. AIR CIRCULATION AND FILTERS AIRFLOW CONVERSION This package gas unit is shipped from the factory with the appropriate blower setting for a normal horizontal discharge installation. Units can easily be converted from horizontal to vertical airflow delivery. In down-discharge or high static installations, the installer should measure the total external static Electrical Power Routed Through Bottom of Unit 8 If using the Over/Under Transition Kit, the filter(s) may be located in the return air duct(s) or return air filter grille(s). Filters installed external to the unit should be sized in accordance with their manufacturer recommendations. A throwaway filter must be sized for a maximum face velocity of 300 feet per minute. America Manual D (Residential) or Manual Q (Commercial). All ductwork exposed to the outdoors must include a weatherproof barrier and adequate insulation. A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B. The warm air supply duct from the unit through a wall fabricated of combustible material may be installed without clearance. However, minimum clearances for the unit must be observed as shown in the Minimum Clearances for Unit figure on page 4. The outlet duct should be provided with an access panel. This access should be large enough to inspect the air chamber downstream from the heat exchanger for any smoke or combustion gas leaks. A cover should be tightly attached to prevent air leaks. For horizontal airflow, duct flange dimensions on the unit are shown in the Product Data Book applicable to your model*. For vertical airflow, the ductwork should be attached to the roof curb prior to installing the unit. 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. FILTER INSTALLATION Important: When installing a filter, the air flow arrows on the filter must point toward the circulator blower. VENTING NOTE: Venting is self-contained. Do not modify or block. FLUE HOOD AND AIR INLET HOOD INSTALLATION Install the flue hood and air inlet hood prior to operation of the unit. To install the flue hood cover: 1. Remove the flue hood and bug screen from inside the compressor compartment. 2. Attach the flue hood (enclosed side down) and screen with the sheet metal screw provided. To install the air inlet hood: 1. Remove hood from the compressor compartment. 2. Attach hood by using the supplied sheet metal screws. FILTERS CAUTION Flue Hood TO PREVENT PROPERTY DAMAGE DUE TO FIRE AND LOSS OF Screen EQUIPMENT EFFICIENCY OR EQUIPMENT DAMAGE DUE TO DUST AND LINT BUILD UP ON INTERNAL PARTS, NEVER OPERATE UNIT WITHOUT AN AIR FILTER INSTALLED IN THE RETURN AIR SYSTEM. Even though a return air filter is not supplied with this unit, there must be a means of filtering all return air. Refer to the following table for filter size information. Model PGA24C***2(E/F) PGA30C***2(E/F) PGA36C***2(E/F) PGA42C***2(E/F) Disposable Permanent Rated Cooling Filter Filter Airflow 2* 2** CFM ft ft 3.8 1.9 800 3.8 1.9 1000 4.0 2.0 1200 4.5 2.3 1350 PGA48C***2(E/F) PGA60C***2(E/F) 5.3 5.8 2.7 2.9 1600 1750 PGB24C***2(E/F) PGB30C***2(E/F) PGB36C***2(E/F) PGC42C***2(E/F) 3.0 3.5 4.0 4.5 1.5 1.8 2.0 2.3 800 1000 1150 1350 PGB42C***2(E/F) PGB48C***2(E/F) PGB60C***2(E/F) 5.0 5.5 7.0 2.5 2.8 3.5 1400 1600 2000 PGD24C***2(E/F) PGD30C***2(E/F) PGD36C***2(E/F) PGD42C***2(E/F) 3.0 3.5 4.0 4.5 1.5 1.8 2.0 2.3 800 1000 1150 1350 PGD48C***2(E/F) PGD60C***2(E/F) 5.0 6.0 2.5 3.0 1500 1750 *Based on a face velocity of 300ft/min. **Based on a face velocity of 600 ft/min. Air Intake Hood Hood Installation CONDENSATE DRAIN HIGH STATIC OR DOWN-DISCHARGE INSTALLATION IMPORTANT: Elevated internal static pressure can cause condensate to be drawn out of the drain pan and into the return air plenum. For gas package units and down discharge installations experiencing total external pressure of 0.30” w.c. or greater, add a splash baffle. It will prevent condensate from seeping over into the return air plenum in high static applications. The baffles are factory installed in all large chassis gas/electric package units. Contact your distributor for the correct splash baffle for your model. CONDENSATE DRAIN CONNECTION These units are equipped with a built-in trap and do not require an external trap. To avoid double trapping and an overflowing drain pan, soft plastic drain lines are not recommended. 9 NORMAL SEQUENCES OF OPERATION HEATING This unit is equipped with an ignition control that automatically lights the main burner. DO NOT attempt to light the main burners by any other method. 1. Thermostat calls for heat. The induced draft blower energizes for a 15-second pre-purge. 2. The spark igniter and gas valve energizes for seven seconds. NOTE: The igniter produces a very intense electrical spark that ignites the gas. 3. The 30-second HEAT FAN ON delay time begins. 4. The unit delivers heat to the conditioned space until the thermostat is satisfied. 5. The gas valve deenergizes. The induced draft blower continues operation for a 29-second post-purge. 6. Ignition control begins timing the HEAT FAN OFF delay. This allows any additional heat in the heat exchanger to be transferred to the conditioned space. After the HEAT FAN OFF delay time has elapsed, the blower will deenergize. Models with a PSC (Permanent Split Capacitor) circulator blower motor have an adjustable HEAT FAN OFF delay of 90/120/ 150/ seconds OR 60/90/120/180 seconds. Models with variable speed motor (ECM) have a fixed HEAT FAN OFF delay of 120 seconds. HEATING STARTUP Heat Anticipator Setting Set the heat anticipator on the room thermostat to 0.4 amps to obtain the proper number of heating cycles per hour and to prevent the room temperature from overshooting the room thermostat setting. 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 (see figure below). The reason for elevated temperatures at the control should be determined and repaired prior to resetting this manual reset control. Rollout Protection Rollout Protection Device COOLING 1. Thermostat calls for cooling. The compressor and outdoor fan are energized. 2. Approximately seven seconds later, the indoor fan starts. NOTE: Models with a variable speed motor (ECM) do not have a seven-second COOL FAN ON delay. The motor “ramps” up to full speed over a 30-second period. 3. The unit will deliver cooling to the conditioned space until the thermostat is satisfied. 4. The compressor and outdoor fan will be deenergized when the thermostat opens. 5. The indoor fan continues to run for approximately 30 seconds after the thermostat is satisfied. This allows additional cooling from the indoor coil to be transferred to the conditioned space. Then, the indoor fan stops. WARNING TO 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 A second limit control is placed on the blower scroll. This control will open due to elevated temperature caused by the blower failing. The reason for elevated temperatures at the control should be determined and repaired prior to resetting. The secondary limit control is located on the top of the blower scroll assembly (see figure below). 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. FAN ONLY 1. Thermostat calls for FAN ONLY by energizing “G”. 2. Approximately seven seconds later, the indoor fan starts. NOTE: Not all models will have a “7-Second ON” indoor fan start delay or an “OFF” delay in continuous fan mode. 3. The indoor fan continues to run for approximately 30 seconds after “G” is deenergized. Secondary Limit Control Condenser Coil STARTUP, ADJUSTMENTS, AND CHECKS Duct Opening 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. 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. Blower Assembly Blower Compartment Access Door Top View Secondary LImit Control 10 Heating Timing Chart On Circulator Blower Off On Gas Valve Off Igniter On Off Induced Draft Blower On Off On Thermostat Off Seconds 0 15 22 52 0 29 90, 120, or 60, 90, 150 120,180 Cooling Timing Chart Circulator Blower ON OFF Outdoor Fan and Compressor Thermostat ON OFF ON OFF Seconds 0 7 0 11 30 Pre-Operation Checks Gas Valve On/Off Selector Switch INLET Gas Valve 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. OUTLET Inlet Pressure Tap (Side of Valve) Pressure Regulator Adjustment (Under Cap Screw) White-Rodgers Model 36F22 Proper Gas Valve Mounting Location Close the manual gas valve external to the unit. Turn off the electrical power supply to the unit. Set the room thermostat to its lowest possible setting. Remove the heat exchanger door on the side of the unit by removing screws. This unit is equipped with an ignition device which automatically lights the main burner. DO NOT try to light burner by any other method. Move or rotate (depending on your gas valve) the gas control valve switch to the OFF position. Do not force. Wait five minutes to clear out any gas. 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 2 of this manual. If having waited for five minutes and no gas smell is noted, move or rotate the gas control valve switch to the ON position. Replace the heat exchanger door on the side of the unit. Open the manual gas valve external to the unit. Turn on the electrical power supply to the unit. Set the thermostat to desired setting. Gas Inlet Pressure Check INLET OUTLET Inlet Pressure Tap Gas Valve On/Off Selector Switch White-Rodgers 36G22 Pressure Regulator Adjustment (Under Cap Screw) O F F INLET M 1 P 3 C 2 ON Outlet (Manifold) Pressure Tap Honeywell INLET OUTLET ON OFF Inlet Pressure Tap Gas Valve On/Off Control Knob Honeywell Model VR8205 With Power And Gas Off: 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. Gas inlet pressure must be checked and adjusted in accordance to the type of fuel being consumed. Gas Valve On/Off Selector Switch Pressure Regulator Adjustment (Under Cap Screw) Outlet Pressure Tap Gas Supply And Manifold Check Gas supply pressure and manifold pressure with the burners operating must be as specified on the rating plate. Outlet (Manifold) Pressure Tap Gas Line Gas Shutoff Valve OUTLET Gas Line To Furnace Inlet Pressure Tap (Side of Valve) Pressure Regulator Adjustment (Under Cap Screw) Outlet (Manifold) Pressure Tap (Side of Valve) Open To Atmosphere White-Rodgers Model 36E22 Drip Leg Cap With Fitting Manometer Hose Manometer Gauge Attachment to Inlet Pressure Tap 12 4. Relight all other appliances turned off in step 1. Be sure all pilot burners are operating. With Power And Gas On: Put unit into heating cycle and turn on all other gas consuming appliances. 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. Inlet Gas Pressure Natural Propane Min. 5.0" W.C., Max. 10.0" W.C. Min. 11.0" W.C., Max. 13.0" W.C. NOTE: Inlet Gas Pressure Must Not Exceed the Maximum Value Shown. 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. If operating pressures differ from above, make necessary pressure regulator adjustments, check piping size, etc., and/or consult with local utility. Manifold Pressure Check 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. Honeywell Model VR8205, White-Rodgers Models 36E22/ 36F22: A tapped opening is provided in the gas valve to facilitate measurement of the manifold pressure. White Rodgers Model 36G22: Using a 3/32 inch hex wrench, loosen the outlet pressure tap screw 1 turn only (DO NOT REMOVE). Attach a length of 5/16 inch hose to the outlet pressure tap boss. Connect the 5/16 inch hose to a water manometer or other adequate gauge. To 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 manifold pressure must be between 3.2 and 3.8 inches water column (3.5 nominal). For propane gas, the manifold pressure must be between 9.7 and 10.3 inches water column (10.0 nominal). External Static Pressure Check The total external static pressure must be checked on this unit to determine if the airflow is proper. Limit Check Check limit control operation after 15 minutes of operation by blocking the return air grille(s). 1. After several minutes the main burners must go OFF. Blower will continue to run. 2. Remove air restrictions and main burners will relight after a cool down period of a few minutes. Adjust the thermostat setting below room temperature. 1. Main burners must go OFF. 2. Circulating Air Blower will continue to run for selected HEAT FAN OFF delay. Gas Input (Natural Gas Only) Check NOTE: On outdoor equipment, the gas input will vary with the temperature of the gas. Rated input will be obtained at approximately 10° F. With warmer ambient and gas temperatures, the input will decrease. Example: At 70° F the input will decrease 12%. To measure the gas input using the gas meter 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. Blower Speed Adjustment WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, REMOVE ELECTRICAL POWER FROM THE UNIT BEFORE CHANGING SPEED TAPS ON THE BLOWER MOTOR. Refer to the wiring diagram on the unit to verify speed tap settings. Blower speeds can be adjusted on the ignition control board. Both heat speed and cool speed terminals are supplied on the board along with two unused motor lead terminals. 13 1 10 LED. If diagnostic LED indicates a hard lockout, check power supply to unit for proper voltage, check all fuses, circuit breakers and wiring. Disconnect electric power for five seconds. If LED remains off after restoring power, replace control. 11 8 5 2 11 R31 2 9 6 12 3 12 3 9 6 K1 C27 D7 FS External Lockout D5 R25 An external lockout occurs if the integrated ignition control determines that a measurable combustion cannot be established within three (3) consecutive ignition attempts. If flame is not established within the seven (7) second trial for ignition, the gas valve is deenergized, 15 second inter-purge cycle is completed, and ignition is re-attempted. The control will repeat this routine three times if a measurable combustion is not established. The control will then shut off the induced draft blower and go into a lockout state. If flame is established but lost, the control will energize the circulator blower at the heat speed and then begin a new ignition sequence. If flame is established then lost on subsequent attempts, the control will recycle for four (4) consecutive ignition attempts (five attempts total) before locking out. The diagnostic fault code is 1 flash for a lockout due to failed ignition attempts or flame dropouts. The integrated control will automatically reset after one hour, or it can be reset by removing the thermostat signal or disconnecting the electrical power supply for five seconds. Important: If you have to frequently reset your gas/electric package unit, it means that a problem exists that should be corrected. Contact a qualified servicer for further information. R10 R38 D3 C13 R8 K2 R22 D1 D9 R29 Z1 D10 L1 R34 R3 R35 L1 L2 UNUSED C20 L2 K3 D14 HEAT R4 L2 K4 R11 R42 D12 COOL L2 D11 R36 LED 1068-83-400A Control Board NOTE: If necessary, adjust HEAT FAN OFF delay settings to obtain satisfactory comfort level. COOLING STARTUP NOTE: Check all manual reset limit controls in heating circuit if cooling mode does not operate. Pressure Switch Stuck Open Compressor Protection Devices A pressure switch stuck open can be caused by a faulty pressure switch, faulty wiring, a disconnected or damaged hose, a blocked or restricted flue, or a faulty induced draft blower. If the control senses an open pressure switch during the prepurge cycle, the induced draft blower only will be energized. If the pressure switch opens after ignition has begun the gas valve is deenergized, the circulator blower heat off cycle begins, and the induced draft blower remains on. The diagnostic fault code is two flashes. The compressor includes components which are designed to protect the compressor against abnormal operating conditions. WARNING TO PREVENT PERSONAL INJURY OR DEATH, ALWAYS DISCONNECT ELECTRICAL POWER BEFORE INSPECTING OR SERVICING THE UNIT. ALL COMPRESSOR PROTECTION DEVICES RESET AUTOMATICALLY, ENERGIZING THE CONTACTOR Pressure Switch Stuck Closed A stuck closed pressure switch can be caused by a faulty pressure switch or faulty wiring. If the control encounters a pressure switch stuck closed, the induced draft blower remains off. The diagnostic LED code for this fault is three (3) flashes. AND OUTDOOR FAN. Operating Instructions (Cooling) NOTE: Mechanical cooling cannot be reliably provided at ambient temperatures below 50° F. 1. Turn on the electrical power supply to the unit. 2. Place the room thermostat selector switch in the COOL position (or AUTO if available, and if automatic changeover from cooling to heating is desired). 3. Set the room thermostat to the desired temperature. Open Thermal Protection Device If a primary, auxiliary, or rollout limit switch opens, the gas valve is immediately deenergized, the induced draft and air circulating blowers are energized. The induced draft and air circulator blowers remain energized until the limit switch recloses. The diagnostic fault code for an open limit is four (4) flashes. A primary limit will open due to excessive supply air temperatures. This can be caused by a dirty filter, excessive duct static, insufficient air flow, or a faulty limit. Check filters, total external duct static, blower motor, blower motor speed tap (see wiring diagram), and limit. This limit will automatically reset once the temperature falls below a preset level. An automatic reset auxiliary limit is located on the circulator blower scroll. A dirty filter, excessive duct static, insufficient air flow, a faulty limit, or a failed circulator blower can cause this limit to open. Check filters, total external duct static, circulator blower motor, blower motor speed tap (see wiring diagram), and limit. An interruption in electrical power during a heating cycle may also cause the auxiliary limit to open. The secondary limit is located on top of the circulator blower assembly (see TROUBLESHOOTING ABNORMAL OPERATION - HEATING The following presents probable causes of questionable unit operation. Remove the control box access panel and note the number of diagnostic LED flashes. Refer to Diagnostic Indicator Chart for an interpretation of the signal and to this section for an explanation. Internal Lockout If the integrated ignition control in this unit encounters an internal fault, it will go into a “hard” lockout and turn off the diagnostic 14 Secondary Limit Control figure). If the burner flames are not properly drawn into the heat exchanger, the flame rollout protection device will open. The rollout limit is a manual reset limit located on the burner bracket. The cause of the flame rollout must be determined and corrected before resetting the limit. Possible causes are restricted or blocked flue passages, blocked or cracked heat exchanger, a failed induced draft blower, or insufficient combustion air. Important: If a limit opens five (5) times within a single call for heat, the ignition control will go into a 30-minute lockout. Only the air circulator blower remains on during this lockout. The diagnostic fault code for this condition is “8” flashes and the control automatically resets after 30 minutes. A dirty filter is the most likely cause for the fault. operation, the ignition control will delay output to the compressor contactor for three minutes from the time power is restored. (Compressor is off a total of three minutes). The diagnostic LED will flash six (6) times to indicate the compressor contactor output is being delayed. NOTE: Some electronic thermostats also have a built-in compressor short cycle timer that may be longer than the three minute delay given above. If you are using an electronic thermostat and the compressor has not started after three minutes, wait an additional five minutes to allow the thermostat to complete its short cycle delay time. MAINTENANCE Flame Detected with Gas Valve Closed Have the gas heating section of the unit checked at least once a year before the heating season begins, to be sure that the combustion air inlet and flue outlet hoods are not blocked by debris, which would prevent adequate combustion air and a properly operating vent system. If flame is sensed with the gas valve deenergized, the combustion and air circulator blowers are energized. The diagnostic fault code is five (5) flashes for this condition. The control can be reset by removing the power supply to the unit or it will automatically reset after one hour. Miswiring is the probable cause for this fault. WARNING Low Flame Sensor Current If the flame sense current drops below approximately one microamp DC, the diagnostic LED will flash seven (7) times. The control will function normally until it can no longer sense flame. If this fault code is encountered, have a qualified service technician remove the sensor and clean it with steel wool. TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE. REPLACING OR CLEANING FILTER A return air filter is not supplied with this unit; however, there must be a means of filtering all of the return air. The filter(s) may be located in the return air duct(s), or return air filter grille(s). Consult with your installing dealer for the actual location of the return air filter(s) for your unit. Dirty filters are the most common cause of inadequate heating or cooling performance. Filter inspection should be made at least every two months; more often if necessary because of local conditions and usage. Dirty throwaway filters should be discarded and replaced with a new, clean filter. Dirty permanent filters should be washed with water, thoroughly dried and sprayed with a filter adhesive before being reinstalled. (Filter adhesives may be found at many hardware stores.) Permanent filters should last several years. However, should one become torn or uncleanable, it should be replaced. Gas Valve Energized When It Should Be OFF Some models utilize an ignition control that recognizes voltage present at the gas valve when the gas valve should be off. If the ignition control senses this fault, it will lockout all functions except continuous fan. This fault is indicated by (9) flashes. Possible causes are miswiring, shorts in the wire harness, or corrosion at the burners. Check and correct wiring if required. Inspect and clean burners if required. Power to the unit must be removed in order to reset the control from lockout. ABNORMAL OPERATION - COOLING Short Cycle Compressor Delay The automatic ignition control has a built-in feature that prevents damage to the compressor in short cycling situations. In the event of intermittent power losses or intermittent thermostat IGNITION CONTROL DIAGNOSTIC INDICATOR CHART Light Signal Off 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes 9 Flashes Refer to Abnormal Heating or Cooling Operation Sections of this Manual Internal Lockout External Lockout Pressure Switch Stuck Open Pressure Switch Stuck Closed Open Thermal Protection Device Flame Sensed with Gas Valve Closed Short Cycle Compressor Delay (Cooling) Low Flame Sense Current Thermal Protection Device Open Gas Valve Energized When It Should Be OFF (DSI-1 Control Only) 15 MAINTAINING CABINET FINISH MAIN BURNER FLAME (QUALIFIED SERVICER ONLY) Use a fine grade automotive wax on the cabinet finish to maintain the finish’s original high luster. This is especially important in installations with extended periods of direct sunlight. Flames should be stable, soft and blue (dust may cause orange tips but must not be yellow). The flames must extend directly outward from the burner without curling, floating or lifting off. CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY) The coil with the outside air flowing over it should be inspected annually and cleaned as frequently as necessary to keep the finned areas free of lint, hair and debris. CONDENSER, EVAPORATOR, AND INDUCED DRAFT MOTORS Bearings on the air circulating blower motor, condenser motor and the combustion fan motor are permanently lubricated. No additional oiling is required. Check the burner flames for: 1. Good adjustment 2. Stable, soft and blue 3. Not curling, floating, or lifting off. FLAME SENSOR (QUALIFIED SERVICER ONLY) A drop in the flame sensing signal can be caused by a nearly invisible coating on the flame sensor. This coating, created by the fuel or combustion air supply, can be removed by carefully cleaning the flame sensor with steel wool. NOTE: After cleaning, the microamp signal should be stable and in the range of 4 - 6 microamps DC. Burner Flame WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY Flame Sensor ADJUSTMENT. CONTACT A QUALIFIED SERVICER AT ONCE IF AN ABNORMAL FLAME SHOULD DEVELOP. At least once a year, prior to or during the heating season, make a visual check of the burner flames. NOTE: This will involve removing and reinstalling the heat exchanger door on the unit, which is held by two screws. If you are uncertain about your ability to do this, contact a qualified servicer. If a strong wind is blowing, it may alter the airflow pattern within the unit enough that an inspection of the burner flames is not possible. Flame Sensor Location FLUE PASSAGES (QUALIFIED SERVICER ONLY) At the start of each heating season, inspect and, if necessary, clean the unit flue passage. CLEANING BURNERS 1. Shut off electric power and gas supply to the unit. 2. Remove the screws holding the burner retention bracket in place. NOTE: On some models it will be necessary to remove the manifold instead of a burner retention bracket. In such a case, remove the manifold and rotate each burner counterclockwise to remove. Cleaning Flue Passages (Qualified Servicer Only) 1. Shut off electric power and gas supply to the unit. 2. Remove burner assembly by disconnecting the gas line and removing the manifold bracket from the partition panel. 3. Remove the flue from the induced draft blower and the collector box from the partition panel. 4. The primary heat exchanger tubes can be cleaned using a round wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the spring cable. Slowly rotate the cable with the drill and insert it into one of the primary heat exchanger tubes. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Use a large cable for the large tube, and then repeat the operation with a small cable for the smaller tube. Repeat for each tube. 5. When all heat exchanger tubes have been cleaned, replace the parts in the reverse order in which they were removed. 6. To reduce the chances of repeated fouling of the heat exchanger, perform the steps listed in “Startup, Adjustments, and Checks”. Burner Manifold Burner Bracket and Manifold 16 Burner Bracket 3. Remove the burners. 4. Use a bottle brush to clean burner insert and inside of the burners. 5. Replace burners and burner retention bracket or manifold, inspect the burner assembly for proper seating of burners in retention slots. 6. Reconnect electrical power and gas supply. ACCESSORIES AND FUNCTIONAL PARTS SHEET METAL ACCESSORIES Additional accessories, as described below can be purchased to fit specific application needs. Parts and instructions are available from your distributor. CAUTION Accessory Over/Under Duct Cover Kit LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. Horizontal Duct Covers* Compressor Sound Blanket Propane Gas Conversion Kit CAUTION High Altitude Kit Roof Curbs ALWAYS VERIFY PROPER OPERATION AFTER SERVICING. For further information on the yearly inspection, consult the User Manual. It is recommended that a qualified servicer inspect and service the unit at least once each year. Turn the unit on at the thermostat. Wait a few minutes, since any dislodged dust will alter the normal flame appearance. Flames should be predominantly blue and directed into the tubes. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports. FUNCTIONAL PARTS Functional Parts Auxiliary Limit Switch Blower Housing Circulator Blower Motor Blower Wheel Burner Capacitor Compressor Condenser Coil Condenser Fan Blade Condenser Fan Motor Contactor Manifold Evaporator Coil Flame Roll-Out Switch Flame Sensor Gas Orifice Gas Valve Heat Exchanger High Limit Switch Ignitor Ignition Control Inducted Draft Motor Pressure Switch Pressure Switch Hose Transformer Although only functional parts are shown, all sheet metal parts, doors, etc. may be ordered by description. Parts are available from your distributor. Be sure to provide the unit model, manufacturing, and serial numbers with the order. 17 18 1 9 7 2 CAP CC W CC R 1 G 2X 4F M VR OD C N 1 COMP C NC T2 N0 L2 PS C 6 DSI 8 T 1 F S 3 L I M I T A U X L I M I T C M RL FS GV 5 N 4 4 BU-23 BK-26 BK-26 MED HI HI HI 4 4 2 PGA36C0702F PGA36C0902F PGA42C0902F BU-23 MED HI 4 PGA30C0702F BU-23 MED HI MOTOR TO "HEAT" 4 SPEED * HEATING BLOWER SPEED PGA24C0702F MOTOR SPEEDS 6 COO L HEA T L2 WH WH FACTORY WIRED MOTOR CONNECTIONS WARNING:DISCONNECT POWER BEFORE SERVICING. S R C O M N 2 COMB BLOWER 2 2 0 3 8 0 D I L2 L2 L1 120 60 90 L1 D1 FS VT-47 COMBUSTION BLOWER (CB) 12 9 6 3 2 11 8 5 10 BU-23 BK-26 HI BU-23 RD-24 YL-27 MOTOR TO "COOL" MED HI MED HI MED LOW LOW SPEED 7 4 1 208 5. 7. 6. BU-36 GY 25 RD 1 6 GY-25 1 OR YL 4 SPEED BLOWER G C GN WH R Y W NO COM 6 AMANA SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING. IFANYORIGINALWIREISREPLACED, 105° CWIREMUST BEUSED.USECOPPERCONDUCTORSONLY. EQUIPPED FOR 230 VOLT OR 208 VOLT. HEAT ON/OFF FAN DELAY FACTORY SETTINGS: 30 SECONDS ON AND 120 SECONDS OFF. UNUSED BLOWERMOTORLEADS MUSTBEPLACEDON UNUSED MOTOR TERMINALSOFCONTROLOR TAPED. IFHEATINGANDCOOLINGBLOWERSPEEDSARENOTTHE SAMEDISCARDJUMPERBEFORECONNECTINGBLOWERLEADS. COOLING/FAN ONLY ON/OFF FAN DELAY SETTING: 7 SECONDS ON AND 30 SECONDS OFF. READ BEFORE OPERATING OR SERVICING THIS UNIT WARNING: DISCONNECT POWER BEFORE SERVICING. 2 1 AIR CIRCULATION BLOWER (ACB) FLAME SENSOR AUX LIMIT CONTROL OR-19 CAPACITOR (CAP) 3 4 5 GAS VALVE (GV) GY-25 VT-34 BR RD 13 L1 S R C YL-12 PTCR (WHEN REQUIRED) COMPRESSOR 1Ø WIRING 120 GND L1 L2 60 VT BR 90 BK RD 10 FAN VT 20 HERM COM GN GREEN HI VOLTAGE FIELD HI VOLTAGE LOW VOLTAGE FIELD LOW VOLTAGE RD RED BU BLUE GY GRAY VT VIOLET BK BLACK BR BROWN WH WHITE VT 16 YL YELLOW OR ORANGE COLOR CODE 20351601 REV. 2 RD 15 C A P A C I T O R O.D. FAN MOTOR WARNING:DISCONNECT POWER BEFORE SERVICING. GND T1 T2 DETAIL 2 CUSTOM CONTROLS, INC 180 ADJUSTABLE FAN SETTING (FACTORY SETTING AS SHOWN) DETAIL 1 UTEC FIELDCONNECTION 208/230VAC1Ø L2 VT 37 BR 8. DIAGNOSTICLIGHT: STEADYON=STANDBYMODE; STEADYOFF=INTERNALFAULTORNOPOWER;1 FLASH=LOCKOUT; 2FLASHES=PSSTUCKOPEN; 3FLASHES=PSSTUCKCLOSED; 4FLASHES= OPENHIGHLIMITSWITCH, AUXLIMITSWITCH, OROPENROLLOUT; 5FLASHES=FLAME DETECTEDWITHGASVALVECLOSED;6 FLASHES=COMPRESSORDELAYEDONSHORT CYCLETIMER;7FLASHES=LOWFLAMESENSE CURRENT; 8FLASHES=5LIMITTRIPS WITHINASINGLECALLFORHEAT; 9FLASHES=GASVALVESENSEDONINERROR (CUSTOMCONTROLS, INC. ONLY) 9. COMPRESSORSHORT CYCLEDELAY: 3MIN. STARTUPDELAY AFTERPOWERLOSS. 10. OPTIONALTHERMOSTATTERMINAL STRIP ISNOTPRESENTONALLMODELS. THERMOSTAT DIRECT SPARK IGNITOR (DSI) RD-29 OR-22 LIMIT YL-27 RD-24 BU-23 BK-26 RD YL-11 NC VT-18 PRIMARYROLLOUT LIMIT(RL) OR-49 (OPTIONAL, SEE NOTE 10) GY-70 2 AIR CIRCULATION BLOWER (ACB) VT-14 3 4 5 AIR PRESSURE SWITCH (PS) BR-21 LOAD YL-27 BK-26 2 SPEED BLOWER IMPORTANT: 3. 4. 2. 1. T1 DETAIL 1 230 LINE COM TRANSFORMER ** COOLING BLOWER SPEED 180 DETAIL 2 UNUSE D L2 BK 17 VT (COM) RD (230) BK (208V) FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGES MUST BE MADE: MOVE BK17 WIRE FROM TRANSFORMER 230 TERMINAL TO 208 TERMINAL. UNPLUG RED COMBUSTION BLOWER LEAD FROM CONTROL BOARD TERMINAL (DI) AND ATTACH BLACK BLOWER LEAD TO TERMINAL. TAPE UNUSED RED LEAD. M 1 ACB C A P FAN 2 208/230 VAC 1Ø GND THERMOSTAT Y C O M HERM MODELS L1 T1 2 0 8 L 1 H E A T C 2 2 3 0 FAN N 3 COM PTCR (WHEN REQ'D) L 11 10 1 C O O L P 3 208 VOLT INSTALLATION 090 CONTROL BOARD (TERMINAL ORDER REARRANGED) TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT ELECTRICAL POWER TO THIS FURNACE BEFORE SERVICING OR PERFORMING MAINTENANCE. WARNING 120 150 19 1 9 7 2 2 0 8 W CC R 1 G 2X 4F M VR 2 C A P C S R COMP C C O M N 2 N0 NC L2 T2 PS COMB BLOWER 2 3 0 D I C 6 DSI 8 T 1 F S 3 RL L I M I T A U X L I M I T FS GV C M 5 N 4 4 COOL HEAT L2 WH WH 6 L2 LOW MED LOW 3 3 3 3 PGA48C0902F PGA48C1152F PGA60C0902E PGA60C1152F MED SPEED MODELS 90 D1 FS 11 10 7 12 4 8 9 HI HI RD-24 BU-23 BK-26 BK-26 BU-23 BU-23 MED MED MOTOR TO "COOL" ** COOLING BLOWER SPEED 120 L1 1 2 5 6 3 T1 DETAIL 1 LINE 208 230 COM TRANSFORMER SPEED 180 60 DETAIL 2 L1 BU-23 RD-24 MOTOR TO "HEAT" * HEATING BLOWER SPEED L2 BK 17 VT-47 COMBUSTION BLOWER (CB) VT (COM) RD (230) UNUSED L2 FACTORY WIRED MOTOR CONNECTIONS WARNING:DISCONNECT POWER BEFORE SERVICING. 208/230 VAC 1Ø GND FAN OD N 1 ACB THERMOSTAT HERM CAP CC L 1 Y L P S C O M 2 3 0 FAN N 3 H E A T MOTOR SPEEDS L1 T1 COM PTCR (WHEN REQ'D) L 1 11 10 C O O L GY 25 OR BU-36 WH GN YL RD R Y W G C NO COM 1 FLAME SENSOR AUX LIMIT CONTROL OR-19 CAPACITOR (CAP) 2 AIR CIRCULATION BLOWER 3 (ACB) THERMOSTAT DIRECT SPARK IGNITOR (DSI) GAS VALVE (GV) 6 BR GY-25 VT-34 BR L1 PTCR (WHEN REQUIRED) 120 60 GND L1 L2 90 BK DETAIL 2 CUSTOM CONTROLS, INC 180 VT BR VT 20 RD 15 C A P A C I T O R LOW PRESSURE SWITCH (OPTIONAL) RD 10 FAN HERM COM O.D. FAN MOTOR VT 16 LOW VOLTAGE LOW VOLTAGE FIELD HI VOLTAGE HI VOLTAGE FIELD COLOR CODE YL YELLOW BR BROWN OR ORANGE WH WHITE VT VIOLET BU BLUE GN GREEN GY GRAY BK BLACK RD RED 20351501 REV. 0 WARNING:DISCONNECT POWER BEFORE SERVICING. YL/BK GND T1 T2 ADJUSTABLE FAN SETTING (FACTORY SETTING AS SHOWN) DETAIL 1 UTEC FIELD CONNECTION 208/230 VAC 1Ø L2 VT 37 RD 13 R C COMPRESSOR 1Ø WIRING S YL-12 READ BEFORE OPERATING OR SERVICING THIS 8. DIAGNOSTIC LIGHT: STEADY ON= STANDBY MODE; UNIT WARNING: DISCONNECT POWER BEFORE STEADY OFF= INTERNAL FAULT OR NO POWER; 1 SERVICING. FLASH= LOCKOUT; 2 FLASHES= PS STUCK OPEN; 1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE 3 FLASHES= PS STUCK CLOSED; 4 FLASHES= USED WHEN SERVICING OPEN HIGH LIMIT SWITCH, AUX LIMIT SWITCH, 2. IF ANY ORIGINAL WIRE IS REPLACED, 105 °C WIRE MUST ° OR OPEN ROLL OUT; 5 FLASHES= FLAME BE USED.USE COPPER CONDUCTORS ONLY. DETECTED WITH GAS VALVE CLOSED; 6 3. EQUIPPED FOR 230 VOLT OR 208 VOLT. FLASHES= COMPRESSOR DELAYED ON SHORT 4. HEAT ON/OFF FAN DELAY FACTORY SETTINGS: 30 CYCLE TIMER;7 FLASHES = LOW FLAME SENSE SECONDS ON AND 120 SECONDS OFF. CURRENT; 8 FLASHES = 5 LIMIT TRIPS WITHIN A 5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON SINGLE CALL FOR HEAT. UNUSED MOTOR TERMINALS OF CONTROL OR TAPED. 9. COMPRESSOR SHORT CYCLE DELAY: 3 MIN. 6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE STARTUP DELAY AFTER POWER LOSS. SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS. 10. OPTIONAL THERMOSTAT TERMINAL STRIP 7. COOLING /FAN ONLY ON/OFF FAN DELAY SETTING: 7 SECONDS ON IS NOT PRESENT ON ALL MODELS. AND 30 SECONDS OFF. IMPORTANT: (OPTIONAL, SEE NOTE 10) GY-70 YL-11 NC VT-18 OR-22 LIMIT RD-29 PRIMARY ROLLOUT RD LIMIT (RL) 1 OR-49 AIR PRESSURE SWITCH (PS) BR-21 LOAD GY-25 VT-14 RD-24 BU-23 BK-26 5 4 M 1 208 VOLT INSTALLATION P 3 FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGES MUST BE MADE: MOVE BK17 WIRE FROM TRANSFORMER 230 TERMINAL TO 208 TERMINAL. C 2 CONTROL BOARD (TERMINAL ORDER REARRANGED) TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT ELECTRICAL POWER TO THIS FURNACE BEFORE SERVICING OR PERFORMING MAINTENANCE. WARNING 090 120 150 20 2 0 8 COM R G 2X 4F M VR FAN 208/230 VAC 1Ø GND C S R ACB C A P OD 2 N 1 COMP C C O M N 2 L2 T2 N0 PS NC COMB BLOWER 2 2 0 3 8 0 D I C 6 DSI 8 T 1 F S 3 RL L I M I T A U X L I M I T FS GV C M 5 N 4 4 COOL HEAT L2 WH WH 6 L2 BK-26 BU-23 BK-26 BU-23 BK-26 MED HI HI MED HI HI MED HI HI 4 4 4 4 4 4 4 2 PGB24C0902E PGB30C0702E PGB30C0902E PGB36C0702E PGB36C0902E PGB42C0902E HI LOW BK-26 BU-23 YL-27 MOTOR TO "HEAT" PGB24C0702E SPEED PGB24C0452E * HEATING BLOWER SPEED L2 L1 D1 FS 4 12 11 10 7 1 8 2 5 6 9 3 BU-23 BU-23 MED HI MED HI BK-26 RD-24 MED LOW HI YL-27 YL-27 LOW RD-24 YL-27 LOW MED LOW MOTOR TO "COOL" T1 DETAIL 1 SPEED LOW COM LINE 208 230 ** COOLING BLOWER SPEED L1 BK 17 VT-47 COMBUSTION BLOWER (CB) VT (COM) RD (230) UNUSED L2 FACTORY WIRED MOTOR CONNECTIONS WARNING:DISCONNECT POWER BEFORE SERVICING. HERM CAP CC W CC 1 THERMOSTAT Y C O M L 1 GY 25 RD 1 GY-25 1 OR GN RD YL WH R Y W G C NO COM 1 FLAME SENSOR AUX LIMIT CONTROL OR-19 CAPACITOR (CAP) 2 THERMOSTAT DIRECT SPARK IGNITOR (DSI) GAS VALVE (GV) BR VT-34 RD 13 L1 R C COMPRESSOR 1Ø WIRING S VT 16 BR 11 GND L1 L2 BK 27 RD 10 FAN VT 20 HERM COM RD 15 C A P A C I T O R O.D. FAN MOTOR VT 16 LOW VOLTAGE LOW VOLTAGE FIELD HI VOLTAGE HI VOLTAGE FIELD COLOR CODE BR BROWN YL YELLOW WH WHITE OR ORANGE BU BLUE VT VIOLET GY GRAY GN GREEN RD RED BK BLACK 20261301 REV. 1 WARNING:DISCONNECT POWER BEFORE SERVICING. GND T1 T2 ADJUSTABLE FAN SETTING (FACTORY SETTING AS SHOWN) DETAIL 1 FIELD CONNECTION 208/230 VAC 1Ø L2 VT 37 BR YL-12 8. DIAGNOSTIC LIGHT: STEADY ON= STANDBY MODE; STEADY OFF= INTERNAL FAULT OR NO POWER; 1 FLASH= LOCKOUT; 2 FLASHES= PS STUCK OPEN; 3 FLASHES= PS STUCK CLOSED; 4 FLASHES= OPEN HIGH LIMIT SWITCH, AUX LIMIT SWITCH, OR OPEN ROLL OUT; 5 FLASHES= FLAME DETECTED WITH GAS VALVE CLOSED; 6 FLASHES= COMPRESSOR DELAYED ON SHORT CYCLE TIMER;7 FLASHES= LOW FLAME SENSE CURRENT; 8 FLASHES= 5 LIMIT TRIPS WITHIN A SINGLE CALL FOR HEAT. 9. COMPRESSOR SHORT CYCLE DELAY: 3 MIN. STARTUP DELAY AFTER POWER LOSS. GY-25 6 AIR 5 CIRCULATION BLOWER 4 (ACB) 3 READ BEFORE OPERATING OR SERVICING THIS UNIT WARNING: DISCONNECT POWER BEFORE SERVICING. 1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING. 2. IF ANY ORIGINAL WIRE IS REPLACED, 105 ºC WIRE MUST BE USED.USE COPPER CONDUCTORS ONLY. 3. EQUIPPED FOR 230 VOLT OR 208 VOLT. 4. HEAT ON/OFF FAN DELAY FACTORY SETTINGS: 30 SECONDS ON AND 120 SECONDS OFF. 5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON UNUSED MOTOR TERMINALS OF CONTROL OR TAPED. 6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS. 7. COOLING ON/OFF FAN DELAY SETTING: 7 SECONDS ON AND 30 SECONDS OFF. IMPORTANT: GY-70 YL-11 NC VT-18 RD-29 OR-22 LIMIT YL-27 RD-24 BU-23 BK-26 4 SPEED BLOWER PRIMARY ROLLOUT LIMIT (RL) OR-49 VT-14 2 6 AIR 5 CIRCULATION BLOWER 4 (ACB) 3 AIR PRESSURE SWITCH (PS) BR-21 BU-36 LOAD YL-27 BK-26 2 SPEED BLOWER M 1 FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGES MUST BE MADE: MOVE BK17 WIRE FROM TRANSFORMER 230 TERMINAL TO 208 TERMINAL. UNPLUG RED COMBUSTION BLOWER LEAD FROM CONTROL BOARD TERMINAL (DI) AND ATTACH BLACK BLOWER LEAD TO TERMINAL. TAPE UNUSED RED LEAD. BK TRANSFORMER (208V) C 2 2 3 0 FAN N 3 MOTOR SPEEDS L1 T1 1 9 7 2 H E A T MODELS L 11 10 1 C O O L P 3 208 VOLT INSTALLATION 090 120 CONTROL BOARD (TERMINAL ORDER REARRANGED) TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT ELECTRICAL POWER TO THIS FURNACE BEFORE SERVICING OR PERFORMING MAINTENANCE. WARNING 150 21 2 0 8 COM R G 2X 4F M VR 2 C C A P S COMP C C O M N 2 N0 NC L2 T2 PS COMB BLOWER 2 3 0 D I C 6 DSI 8 T 1 F S 3 RL L I M I T A U X L I M I T FS GV C M 5 N 4 4 COOL HEAT L2 WH WH 6 L2 MED LOW MED HI MED HI 3 3 3 3 3 3 3 PGB48C0902E PGB48C1152E PGB48C1402E PGB60C0902E PGB60C1152E PGB60C1402E LOW SPEED BK-26 BU-23 RD-24 BK-26 BU-23 RD-24 BU-23 MOTOR TO "HEAT" * HEATING BLOWER SPEED L2 MED MED MED LOW SPEED HI HI HI L1 D1 FS 10 7 9 11 4 8 6 12 1 2 5 3 BK-26 BK-26 BK-26 BU-23 BU-23 BU-23 RD-24 MOTOR TO "COOL" T1 DETAIL 1 LINE 208 230 COM TRANSFORMER ** COOLING BLOWER SPEED L1 BK 17 VT-47 COMBUSTION BLOWER (CB) VT (COM) RD (230) UNUSED L2 FACTORY WIRED MOTOR CONNECTIONS WARNING:DISCONNECT POWER BEFORE SERVICING. 208/230 VAC 1Ø GND FAN OD R ACB N 1 PGB42C1152E CC HERM CAP W CC 1 THERMOSTAT Y L P S C O M L 1 GY 25 OR BU-36 WH GN YL RD R Y W G C NO COM 1 FLAME SENSOR AUX LIMIT CONTROL OR-19 CAPACITOR (CAP) 2 AIR CIRCULATION BLOWER 3 (ACB) THERMOSTAT DIRECT SPARK IGNITOR (DSI) GAS VALVE (GV) 6 BR GY-25 VT-34 BR L1 VT 16 BR 11 GND L1 L2 BK 27 VT 20 RD 15 C A P A C I T O R LOW PRESSURE SWITCH RD 10 FAN HERM COM O.D. FAN MOTOR VT 16 LOW VOLTAGE LOW VOLTAGE FIELD HI VOLTAGE HI VOLTAGE FIELD COLOR CODE YL YELLOW BR BROWN OR ORANGE WH WHITE VT VIOLET BU BLUE GN GREEN GY GRAY BK BLACK RD RED 20261201 REV. 2 WARNING:DISCONNECT POWER BEFORE SERVICING. YL/BK GND T1 T2 ADJUSTABLE FAN SETTING (FACTORY SETTING AS SHOWN) DETAIL 1 FIELD CONNECTION 208/230 VAC 1Ø L2 VT 37 RD 13 R C COMPRESSOR 1 WIRING S YL-12 READ BEFORE OPERATING OR SERVICING THIS UNIT WARNING: DISCONNECT POWER BEFORE SERVICING. 8. DIAGNOSTIC LIGHT: STEADY ON= STANDBY MODE; 1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE STEADY OFF= INTERNAL FAULT OR NO POWER; 1 USED WHEN SERVICING FLASH= LOCKOUT; 2 FLASHES= PS STUCK OPEN; 2. IF ANY ORIGINAL WIRE IS REPLACED, 105 °C WIRE MUST 3 FLASHES= PS STUCK CLOSED; 4 FLASHES= BE USED.USE COPPER CONDUCTORS ONLY. OPEN HIGH LIMIT SWITCH, AUX LIMIT SWITCH, 3. EQUIPPED FOR 230 VOLT OR 208 VOLT. OR OPEN ROLL OUT; 5 FLASHES= FLAME 4. HEAT ON/OFF FAN DELAY FACTORY SETTINGS: 30 DETECTED WITH GAS VALVE CLOSED; 6 SECONDS ON AND 120 SECONDS OFF. FLASHES= COMPRESSOR DELAYED ON SHORT 5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON CYCLE TIMER;7 FLASHES = LOW FLAME SENSE UNUSED MOTOR TERMINALS OF CONTROL OR TAPED. CURRENT; 8 FLASHES = 5 LIMIT TRIPS WITHIN A 6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SINGLE CALL FOR HEAT. SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS. 9. COMPRESSOR SHORT CYCLE DELAY: 3 MIN. 7. COOLING /FAN ONLY ON/OFF FAN DELAY SETTING: 7 SECONDS ON STARTUP DELAY AFTER POWER LOSS. AND 30 SECONDS OFF. IMPORTANT: GY-70 YL-11 NC VT-18 OR-22 LIMIT RD-29 PRIMARY ROLLOUT RD LIMIT (RL) 1 OR-49 AIR PRESSURE SWITCH (PS) BR-21 LOAD GY-25 VT-14 RD-24 BU-23 BK-26 5 4 M 1 2 3 0 FAN N 3 MODELS L1 T1 1 9 7 2 H E A T MOTOR SPEEDS L 1 11 10 C O O L P 3 208 VOLT INSTALLATION C 2 FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGES MUST BE MADE: MOVE BK17 WIRE FROM TRANSFORMER 230 TERMINAL TO 208 TERMINAL. 090 120 CONTROL BOARD (TERMINAL ORDER REARRANGED) TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT ELECTRICAL POWER TO THIS FURNACE BEFORE SERVICING OR PERFORMING MAINTENANCE. WARNING 150 22 R G FAN 208/230 VAC 1Ø GND C S R ACB C A P OD 2 COMP C C O M N 2 L2 T2 N0 PS NC COMB BLOWER 2 2 0 3 8 0 D I C 6 DSI 8 T 1 F S 3 RL L I M I T A U X L I M I T FS GV C M 5 N 4 4 COOL HEA T L2 WH WH 6 L2 BK-26 BK-26 BK-26 BK-26 BK-26 HI HI HI HI HI 4 4 4 4 4 2 PGD24C0902E PGD30C0702E PGD30C0902E PGD36C0702E PGD36C0902E PGD42C0902E HI BK-26 YL-27 BU-23 LOW 4 MED HI 4 MOTOR TO "HEAT" SPEED PGD24C0452E * HEATING BLOWER SPEED L2 L1 D1 FS VT-47 COMBUSTION BLOWER (CB) 2 12 11 8 5 9 3 6 1 10 7 4 BU-23 MED HI BK-26 BU-23 MED HI HI RD-24 MED LOW YL-27 LOW YL-27 YL-27 LOW RD-24 MOTOR TO "COOL" MED LOW 230 T1 DETAIL 1 SPEED LOW COM LINE 208 ** COOLING BLOWER SPEED L1 BK 17 VT (COM) RD (230) UNUSED L2 FACTORY WIRED MOTOR CONNECTIONS WARNING:DISCONNECT POWER BEFORE SERVICING. HERM CAP COM CC W CC 2X 4F M VR THERMOSTAT Y L P S C O M 1 N 1 PGD24C0702E L1 T1 2 0 8 L 1 GY 25 RD 1 OR YL R G W Y C THERMOSTAT DIRECT SPARK IGNITER (DSI) GAS VALVE (GV) LOW VOLTAGE TERMINAL STRIP WH GN RD NO COM FLAME SENSOR AUX LIMIT CONTROL OR-19 CAPACITOR (CAP) 6 AIR 5 CIRCULATION BLOWER 4 (ACB) 3 2 1 READ BEFORE OPERATING OR SERVICING THIS UNIT WARNING: DISCONNECT POWER BEFORE SERVICING. 1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING. 2. IF ANY ORIGINAL WIRE IS REPLACED, 105 C WIRE MUST BE USED.USE COPPER CONDUCTORS ONLY. 3. EQUIPPED FOR 230 VOLT OR 208 VOLT. 4. HEAT ON/OFF FAN DELAY FACTORY SETTINGS: 30 SECONDS ON AND 120 SECONDS OFF. 5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON UNUSED MOTOR TERMINALS OF CONTROL OR TAPED. 6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS. 7. COOLING ON/OFF FAN DELAY SETTING: 7 SECONDS ON AND 30 SECONDS OFF. IMPORTANT: GY-70 YL-11 NC VT-18 RD-29 OR-22 LIMIT YL-27 RD-24 BU-23 BK-26 4 SPEED BLOWER PRIMARY ROLLOUT LIMIT (RL) OR-49 GY-25 VT-14 6 AIR 5 CIRCULATION BLOWER 4 (ACB) 3 2 1 AIR PRESSURE SWITCH (PS) BR-21 BU-36 LOAD YL-27 BK-26 2 SPEED BLOWER M 1 FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGES MUST BE MADE: MOVE BK17 WIRE FROM TRANSFORMER 230 TERMINAL TO 208 TERMINAL. UNPLUG RED COMBUSTION BLOWER LEAD FROM CONTROL BOARD TERMINAL (DI) AND ATTACH BLACK BLOWER LEAD TO TERMINAL. TAPE UNUSED RED LEAD. BK TRANSFORMER (208V) C 2 2 3 0 FAN N 3 MODELS W R 1 9 7 2 H E A T MOTOR SPEEDS Y L 1 11 10 C O O L GY-25 RD 13 L1 R C COMPRESSOR 1 WIRING S VT 16 BR 11 GND L1 L2 BK 27 VT 20 RD 15 C A P A C I T O R LOW PRESSURE SWITCH RD 10 FAN HERM COM O.D. FAN MOTOR VT 16 LOW VOLTAGE LOW VOLTAGE FIELD HI VOLTAGE HI VOLTAGE FIELD COLOR CODE YL YELLOW BR BROWN OR ORANGE WH WHITE VT VIOLET BU BLUE GN GREEN GY GRAY BK BLACK RD RED 20261401 REV. 2 WARNING:DISCONNECT POWER BEFORE SERVICING. YL/BK GND T1 T2 ADJUSTABLE FAN SETTING (FACTORY SETTING AS SHOWN) DETAIL 1 FIELD CONNECTION 208/230 VAC 1Ø L2 VT 37 BR VT-34 BR YL-12 8. DIAGNOSTIC LIGHT: STEADY ON= STANDBY MODE; STEADY OFF= INTERNAL FAULT OR NO POWER; 1 FLASH= LOCKOUT; 2 FLASHES= PS STUCK OPEN; 3 FLASHES= PS STUCK CLOSED; 4 FLASHES= OPEN HIGH LIMIT SWITCH, AUX LIMIT SWITCH, OR OPEN ROLL OUT; 5 FLASHES= FLAME DETECTED WITH GAS VALVE CLOSED; 6 FLASHES= COMPRESSOR DELAYED ON SHORT CYCLE TIMER;7 FLASHES= LOW FLAME SENSE CURRENT; 8 FLASHES= 5 LIMIT TRIPS WITHIN A SINGLE CALL FOR HEAT. 9. COMPRESSOR SHORT CYCLE DELAY: 3 MIN. STARTUP DELAY AFTER POWER LOSS. P 3 208 VOLT INSTALLATION 090 120 CONTROL BOARD (TERMINAL ORDER REARRANGED) TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT ELECTRICAL POWER TO THIS FURNACE BEFORE SERVICING OR PERFORMING MAINTENANCE. WARNING 150 N 2 L1 T1 2 0 8 L1 C O M 2 3 0 CC HE RM CAP CO M FAN CC N 10 3 OD 2 FAN 2X 4F M VR GND 1 S C RCOMP L2 T2 N0 PS NC C DSI COMB BLOWER FS C O M H E A F D N T S I 1 W1 EM/W2 C M 8 6 7 3 5 C C C NORMAL NORMAL NORMAL NORMAL NORMAL PGD48C1152E PGD48C1402E PGD60C0902E PGD60C1152E PGD60C1402E B B B C B A C B A * * * NORMAL ***** HEATING BLOWER SPEED RL L I M I T L I M I T A U X N 4 4 COOLING BLOWER SPEED PGD48C0902E ADJUST SETTING BLOWER MOTOR SPEED DETAIL 2 WARNING: DISCONNECT POWER BEFORE SERVICING. 208/230 VAC 1Ø L P S L 1 11 12 C O T O 9 I L CONTROL BOARD (TERMINAL ORDER REARRANGED) BLOWER INTERFACE R2 O R3 C1 C2 HEAT L2 L2 UNUS ED L2 L1 L1 D1 FS 8 11 9 12 2 5 3 6 1 10 7 4 T1 GY-70 YL-11 DETAIL 1 RD-13 VT-37 RD-1 COM LINE 208 230 WH BR-21 GY-25 LOAD READ BEFORE OPERATING OR SERVICING THIS UNIT. WARNING: DISCONNECT POWER BEFORE SERVICING. 1. AMANA SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING. 2. IF ANY ORIGINAL WIRE IS REPLACED, 105ºC WIRE MUST BE USED.USE COPPER CONDUCTORS ONLY. 3. EQUIPPED FOR 230 VOLT OR 208 VOLT. 4. HEAT ON/OFF FAN DELAY FACTORY SETTINGS: 30 SECONDS ON AND 120 SECONDS OFF. 5. UNUSED BLOWER MOTOR LEADS MUST BE PLACED ON UNUSED MOTOR LEADS TERMINALS OF CONTROL OR TAPED. 6. IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS. 7. COOLING / FAN ONLY ON/OFF FAN DELAY SETTING: 7 SECONDS ON AND 30 SECONDS OFF. IMPORTANT: COOL L2 VT-47 BK-17 COMBUSTION BLOWER (CB) VT (COM) RD (230V) RD-31 TRANSFORMER FOR PROPER OPERATION ON 208 VOLT THE FOLLOWING CHANGE MUST BE MADE: MOVE BK17 WIRE FROM TRANSFORMER 230 TERMINAL TO 208 TERMINAL. OR-49 LIMIT YL/BK SEE DETAIL 2 VT-34 AUX LIMIT CONTROL OR-19 AIR CIRCULATION BLOWER (ACB) R Y W G C NORM (+ ) (-) TEST A DJUST CO OL A B C D BLOWER INTERFACE HEAT A B C D CUT TO E NA BLE DEHUM IDIFY VT 20 RD 10 BU-44 RD-23 BR 48 GN-70 YL 27 8. DIAGNOSTIC LIGHT: STEADY ON= STANDBY MODE; STEAD OFF= INTERNAL FAULT OR NO POWER; 1 FLASH= LOCKOUT; 2 FLASHES= PS STUCK OPEN; 3 FLASHES= PS STUCK CLOSED; 4 FLASHES= OPEN HIGH LIMIT SWITCH, AUX LIMIT SWITCH, OR OPEN ROLL OUT; 5 FLASHES= FLAME DETECTED WITH GAS VALVE CLOSED; 6 FLASHES= COMPRESSOR DELAYED ON SHORT CYCLE TIMER;7 FLASHES= LOW FLAME SENSE CURRENT; 8 FLASHES= 5 LIMIT TRIPS WITHIN A SINGLE CALL FOR HEAT. 9. COMPRESSOR SHORT CYCLE DELAY: 3 MIN. STARTUP DELAY AFTER POWER LOSS. THERMOSTAT GN RD AIR PRESSURE SWITCH (PS) FLAME SENSOR GY-25 RD-29 DIRECT SPARK IGNITOR (DSI) VT-18 BU 36 YL VT-14 PRIMARY ROLLOUT LIMIT (RL) OR-22 NO MODELS R Y W G C AIR CIRCULATION BLOWER (ACB) TEST ( -) A B C D A B C D ()+ NORM ADJUST COOL HEAT G M 1 208 VOLT INSTALLATION P 3 Y/Y2 C 2 CUT TO E NA B LE W1 EM/W2 O R2 R3 C1 C2 G Y/Y2 DEHUM IDI FY R C RD 13 L1 L2 T1 T2 FAN HERM COM DETAIL 1 ADJUSTABLE FAN SETTING (FACTORY SETTING AS SHOWN) VT 20 LOW VOLTAGE LOW VOLTAGE FIELD HI VOLTAGE HI VOLTAGE FIELD COLOR CODE YL YELLOW BR BROWN OR ORANGE WH WHITE VT VIOLET BU BLUE GN GREEN GY GRAY BK BLACK RD RED GY 25 VT 16 RD RD 10 15 C A P A C I T O R O.D. FAN MOTOR 20290001 REV. 0 LOW PRESSURE SWITCH (LPS) GND GY 25 BR 11 VT BK 16 27 L2 L1 GND FIELD CONNECTION YL 208/230 VAC 1Ø BK VT 37 COMPRESSOR 1Ø WIRING S YL-12 TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DISCONNECT ELECTRICAL POWER TO THIS FURNACE BEFORE SERVICING OR PERFORMING MAINTENANCE. WARNING COM 090 120 150 23 NC 2002-2004 Goodman Company, L.P. 24 Effective: June 2004