R6GI / PPG2GI 20 SEER / 81% AFUE INSTALLATION INSTRUCTIONS Multi-Stage, Variable Speed, Inverter Driven System with Gas Heating / Electric Cooling Premium Model Shown WARNING: FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury or property damage. • Installation and service must be performed by a qualified installer, service agency or the gas supplier.
TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION......................3 REQUIREMENTS & CODES......................................4 GENERAL INFORMATION.........................................5 Before you install this unit........................................5 Locating the Equipment...........................................5 Heating Load............................................................5 COMBUSTION AIR & VENTING REQUIREMENTS...6 General Information................................................
IMPORTANT SAFETY INFORMATION Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death.
• The installer should become familiar with the units wiring diagram before making any electrical connections to the unit. See the unit wiring label or Figure 17 (page 34) & Figure 18 (page 35). REQUIREMENTS & CODES • This equipment must be installed in accordance with instructions outlined in this manual, all applicable local building codes, and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Installation Code, CAN/CGA B149.1.
This Single Package Gas Heating / Electric Cooling Units are designed only for outdoor rooftop or ground level installations and can be readily connected to the duct system of a home. This unit has been tested for capacity and efficiency in accordance with AHRI Standards and will provide many years of safe and dependable comfort, providing it is properly installed and maintained. With regular maintenance, this unit will operate satisfactorily year after year.
COMBUSTION AIR & VENTING REQUIREMENTS WARNING: CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation: 1.
General Information WARNING: Installation methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes for providing sufficient combustion air to the furnace. Provisions must be made during the installation of this unit that provide an adequate supply of air for combustion. • Instructions for determining the adequacy of an installation can be found in the current revision of the NFGC (ANSI Z223.1 / NFPA54).
• The unit installation shall avoid areas where condensate drainage may cause problems by dropping on planters or patios, etc. Also verify exhaust gases will not impinge on windows or building surfaces, which may be compromised or damaged by condensation. • Do not install the unit such that exhaust from the vent termination is directed into window wells, stairwells, under decks, or in alcoves or similarly recessed areas. The vent termination must not be located above any public walkways.
Unconditioned Spaces All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation. Use insulation with an outer vapor barrier. Refer to local codes for insulation material requirements. Acoustical Duct Work Certain installations may require the use of acoustical lining inside the supply duct work.
Horizontal to Downflow Conversion The unit is shipped ready for horizontal duct connections. If down flow ducts are required, the unit must be converted following the steps below for both the supply and return ducts. 1. Remove both horizontal duct caps. 2. Locate the duct cap inside the duct openings and remove the screw holding it in place. 3. Lift the cap out of the unit. (Hint: The cap can be pushed up from the bottom by reaching through the fork slot). 4.
Table 2RANGE VOLTAGE COMPRESSOR MODEL NUMBER (R6GI / PPG2GI) NOMINAL COOLING CAPACITY (TONS) MAXIMUM HEATING INPUT NOMINAL ELECTRICAL SUPPLY MIN MAX RLA E24K080X 2 80,000 208-230/60/1 187 253 E36K100X 3 100,000 208-230/60/1 187 E48K120X 4 120,000 208-230/60/1 187 E60K120X 5 120,000 208-230/60/1 187 SINGLE CIRCUIT LRA FAN MOTOR FLA INDOOR BLOWER FLA MCA MOP 11.6 N/A 2.60 3.80 20.9 30.0 253 16.2 N/A 2.60 3.80 26.7 40.0 253 17.6 N/A 3.80 7.00 32.8 50.
on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces, sunlight, or lighting fixtures, and convective heat from warm air registers or electrical appliances. Refer to the thermostat manufacturer’s instruction sheet for detailed mounting information.
NOTE: When low fire on the gas valve is energized, the furnace operates in low fire mode at a lower blower speed and the timer begins its delay function. If the room thermostat is not satisfied before the timer activates, the furnace will stage to high fire. The inducer motor and blower will ramp to a higher speed until the thermostat is satisfied.
GAS SUPPLY & PIPING WARNING: FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury or property damage. • Installation and service must be performed by a qualified installer, service agency or the gas supplier. • 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.
AVERTISSEMENT: RISQUE D’INDENDIE OU D’EXPLOSION Le non-respect des avertissements de sécurité pourrait d’entraîner des blessures graves, la mort ou des dommages matériels. Ne jamais utiliser une flamme nue por vérifier la présence des fuites de gaz. Pour la vérification de tous les joints, utiliser plutôt une solution savonneuse commerciale fabriquée spécifiquement pur la détection des fuites de gaz. Un incendie ou une explosion peut entraîner des dommages matériels, des blessures ou la mort.
Figure 7 Automatic Gas Valve (with manual shut-off) Shut-Off Valve with 1/8 NPT plugged tap Some utilities require Shut-Off Valve to be 4 to 5 feet above floor Burner Assembly Ground Joint Union Dripleg Manifold Figure 7. Typical Gas Hookup - Right Side Entry Table ALTITUDE 5 ABOVE SEA LEVEL NATURAL GAS HEATING VALUE OF 800 TO 899 BTU/ CU.FT. ZERO TO 1,999 2,000 TO 4,999 5,000 TO 5,999 6,000 TO 7,999 8,000 TO 10,000 3.5 3.5 3.5 3.5 3.0 NATURAL GAS HEATING VALUE OF 900 TO 999 BTU/ CU.FT.
START UP & ADJUSTMENTS Pre-Start Check List √ Verify the unit is level and allows proper condensate drainage. √ Verify all clearance requirements are met and there is free airflow to and from the outdoor coil. √ Verify that the duct work is sealed to prevent air leakage. √ Verify that the line voltage power leads are securely connected and the unit is properly grounded. √ Verify that the low voltage wires are securely connected to the correct leads on the low voltage terminal strip.
to change the blower speed. Lowering the blower speed increases the temperature rise and a higher speed decreases the temperature rise. The unit is equipped with a variable speed motor. Heating and cooling speed selection is made by changing the dip switch settings on the blower control board located in the unit control box. Refer to Configuring the Variable Speed Blower Section (page 13) for additional information.
OPERATING SEQUENCE The operating sequences for the heating, cooling, and fan modes are described below. Refer to the field and furnace wiring diagrams: Figure 17 (page 34) & Figure 18 (page 35). Heating Mode 1. On a call for 1st stage heat, the thermostat closes and applies 24 VAC to terminal W1 on the control board. 2. Safety Circuit Proving - The control board verifies continuity through the 24VAC limit control circuit.
11. The inducer motor is de-energized after a 30 second post purge. 12. The circulating air blower will remain energized for approximately 120 - 150 seconds after the demand for heat is no longer present. 13. Abnormal Conditions - If a limit switch opens during heating operation the gas valve is de-energized immediately.The control de-energizes the induced draft motor and runs the indoor blower motor continuously while the limit switch is open.
AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE OU D’EXPLOSION Le non-respect des avertissements de sécurité pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages matériels. Un entretein incorrect pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages matériels • Couper toute alimentation électrique au générateur d’air chaud avant de prodéder aux travaux d’entretein.
10. Remove the piping between the gas valve and the ground-joint union, if necessary. 11. Carefully remove the four screws inside the burner box (2 at each end), securing the complete burner box assembly to the heat exchanger panel as shown in Figure 8 (page 23). BE EXTREMELY CAREFUL NOT TO DAMAGE THE IGNITOR WHILE REMOVING THE BURNER ASSEMBLY. NOTE: The burner box may have hooks near the top on both ends. To remove this type of burner box, lift the burner box upwards and then remove the box from the unit.
Figure 8 Heat Exchanger Panel Flame Sensor Flame Roll-Out Switch Gas Valve Terminals Burner Box Gas Valve ON/OFF Switch Ignitor NOx Baffle Retainer Clip & Screw Per Tube (If equipped) NOx Baffle Per Tube (If Equipped) Gas Valve Gas Valve Inlet Orifices Burner Gas Manifold Screws (X4) Screws (X4) Figure 8. Burner & Manifold Assembly Figure 9 2-STAGE GAS VALVE Model VR9205Q ON / OFF Switch Manifold pressure Tap Lo Input Adjusting Screw High Input Adjusting Screw Inlet Pressure Tap Figure 9.
TROUBLESHOOTING - COOLING MODE Diagnostic Display The interface board located inside the control panel has a two character display which provides information regarding operational status and fault history. When 24VAC control power is provided to the board, the display will show some combination of characters. In order to diagnose a problem with the unit, or to determine its operational status, remove the control panel cover, then observe the 2-character lighted display on the interface board.
Table 9 DIAGNOSTIC DESCRIPTION GREEN LED RED LED Control Fault (No Power) Off Off L1/Neutral Polarity Fault Flash Flash 1 Hour Lockout Alternating Flash Normal Operation Pressure Switch Closed Fault On On On Flash Pressure Switch Open Fault Flash On Open Limit Switch Fault Flash Off On Off Motor Fault DIAGNOSTIC DESCRIPTION YELLOW LED Low Flame Sensor Signal Continuous Flash Flame Present On Table 9.
FIGURES & TABLES Dimensions shown in inches (mm) Figure 10 3/4" NPT FEMALE DRAIN CONNECTOR 31.5 INSIDE PERIMETER OF BASE RAIL (IF USED) 2.63 DOWNFLOW SUPPLY DUCT OPENING Top View 47.50 CG 45.75 13.50 16 16 B 13.50 13.31 12 12 C 16.0 16.0 8.75 13.5 13.5 DOWNFLOW RETURN DUCT OPENING CONDENSING COIL HORIZONTAL SUPPLY DUCT OPENING 1.75 23.50 A 4.0 HORIZONTAL RETURN DUCT OPENING 12.45 12.45 4.0 9.75 1.8 24.
Airflow Data MODEL NUMBER Table 12 HEATING INPUT (BTUH) HEATING OUTPUT (BTUH) HEATING RANGE 80,000 52,000 100,000 65,000 120,000 78,000 120,000 78,000 64,800 42,100 81,000 52,650 97,200 63,180 97,200 63,180 1025 - 1375 800 - 1050 1150 - 1500 875 - 1200 1550 - 2000 1200 - 1575 1550 - 2000 1200 - 1575 E24K080X E36K100X E48K120X E60K120X HEATING RISE RANGE (°F) BLOWER SIZE MOTOR (HP) 35-65 11 X 8 1/2 40-70 11 X 8 1/2 40-70 11 X 10 1 40-70 11 X 10 1 NOTE: CFM and Rise are independent of
Gas Information Table 15 CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR) FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60) LENGTH OF PIPE RUN (FEET) NOMINAL PIPE DIAMETER (IN.) 10 1/2 130 90 75 65 3/4 280 190 150 130 1 520 350 285 245 1 1/4 1,050 730 590 1 1/2 1,600 1,100 890 20 30 Cubic Feet Per Hour Required = 40 50 60 70 80 55 50 45 40 115 105 95 90 215 195 180 170 500 440 400 370 350 760 670 610 Input To Furnace (Btu/hr) Heating Value of Gas (Btu/Cu. Ft.
FOR YOUR SAFETY READ BEFORE OPERATING Figure 11 WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. POUR VOTRE SÉCURITÉ. À LIRE AVANT L’EMPLOI ATTENTION! L’inobservation de ces instructions peut entraîner un incendie ou une explosion pouvant causer des dammages à votre propriété à votre personne, ou la mort. A. This appliance does not have a pilot.
Electrical Information Ignition Control Fault Red & Green LED’s (See OPERATING SEQUENCE & Table 9) Figure 12 Yellow = Flame Sense (See OPERATING SEQUENCE & Table 9) Heating Mode Blower Off Delay Blower Interface Connection Automatic Heat Staging (Used with Single Stage Heating Thermostat Only) Low Voltage Control Circuit (3 Amp Fuse) Figure 12.
Figure 14 2-Character Display Test Pins Figure 14. Interface Board in Control Panel Table 17 2 CHARACTER DISPLAY C1 C2 C3 C4 C5 0L - CAPACITY STAGE Cooling, Stage One Call, Low Cooling, Stage One Call, Intermediate Cooling, Stage One Call, Low High Cooling, Stage Two Call, Nominal High Cooling, Two Call, Boost Startup Delay (5 Minutes) System Powered but Idle Table 17.
Figure 15 Reactor Inverter Board Interface Board Thermistors Compressor Terminal Board Contactor * 5 Ton inverter assembly has additional components: Contactor, PTCR, and Fan Terminal Block Figure 15.
Hot Surface Ignition Control Board with 24V Secondary 3-Amp Fuse Protection Figure 16 Blower Control Board *Draft Inducer Motor Low Speed Resistor (See 208V Operation page 11) Low Voltage Thermostat Connections Branch Circuit Ground Connection Branch Circuit High Voltage Connection Draft Inducer Motor Dual Vent Pressure Switch High Temperature Limit (Auto Reset) 2-Stage Gas Valve Flame Sensor Hot Surface Igniter Flame RollOut Limit (Manual Reset) Figure 16.
OUT N AC BLACK L RED L N RED BLACK 3X LPS L1 L2 CONTACTOR T1 T2 RED YELLOW BLACK 8X V YELLOW U 8X V 2X BROWN YELLOW BLUE W TO 208/230-1-60 POWER SUPPLY L2 C BLACK BROWN G BLACK HPS YELLOW COVER POST W1 RED BLUE L Y2 E YELLOW R RED YELLOW FLAME ROLL-OUT LIMIT HIGH TEMP LIMIT COMPRESSOR SHELL (TOP VIEW) WHITE YELLOW RED TERMINAL BLOCK L1 RED BLACK GREEN 1 2 3 4 5 6 7 COMPRESSOR U W GND BK/WH STRIPE 4X 2X OUTDOOR FAN MOTOR PWM FAN CONTROL 1X BLAC
WIRING DIAGRAM FIELD WIRING LOW VOLTAGE HIGH VOLTAGE Line Voltage 208/230 VAC U W V W EXV DRIVER LPS INTERFACE BOARD 8X PWM FAN CONTROL 1X BLACK BROWN GREEN 2X 8X PTC TO 208/230-1-60 POWER SUPPLY RED BROWN L2 L1 RED L2 4X RELAY T2 TERMINAL BLOCK GND BLACK L1 T1 N L N 4X BK/WH STRIPE YELLOW AC IN POWER LINE FILTER AC L OUT 2x25A RED BLUE G C BLACK BROWN CONTACTOR L1 L2 T1 T2 RED BLUE BLACK YELLOW WHITE YELLOW RED W1 Y2 E YELLOW R RED YELLOW RED BL
REFRIGERANT CHARGING WARNING: These units are shipped fully charged with R-410A refrigerant and ready for installation. When a system is installed according to these instructions, no refrigerant charging is required. If repairs make it necessary for evacuation and charging, it should only be done by qualified, trained personnel thoroughly familiar with this equipment. Some local codes require licensed installation/service personnel to service this type of equipment.
Figure 19 550 500 Liquid Pressure (psig) Remove refrigerant when above curve 450 400 350 300 Add refrigerant when below curve 250 200 50 60 70 80 90 100 Liquid Temperature (° F) 110 120 130 Figure 19. Charging Chart for 2 Ton Units Figure 20 550 500 Liquid Pressure (psig) Remove refrigerant when above curve 450 400 350 300 Add refrigerant when below curve 250 200 50 60 70 80 90 100 Liquid Temperature (° F) 110 120 130 Figure 20.
Figure 21 550 500 Liquid Pressure (psig) Remove refrigerant when above curve 450 400 350 300 Add refrigerant when below curve 250 200 50 60 70 80 90 100 Liquid Temperature (° F) 110 120 130 Figure 21. Charging Chart for 4 Ton Units Figure 22 550 500 Liquid Pressure (psig) Remove refrigerant when above curve 450 400 350 300 Add refrigerant when below curve 250 200 50 60 70 80 90 100 Liquid Temperature (° F) Figure 22.
Figure 23 Temperature vs. Resistance for All Thermistors (Part 1) 170 160 150 Deg F 140 130 120 110 100 90 80 70 1 2 3 4 5 6 7 8 9 10 kΩ Temperature vs. Resistance for All Thermistors (Part 2) 80 70 60 Deg F 50 40 30 20 10 0 -10 10 20 30 40 50 60 70 80 90 100 kΩ Figure 23.
INSTALLATION / PERFORMANCE CHECK LIST ATTENTION INSTALLERS: VENTING SYSTEM It is your responsibility to know this product better than your customer. This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. Safety should always be the deciding factor when installing this product and using common sense plays an important role as well.
