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Published by Eric Lowber, 2015-10-30 16:13:51

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Johnson Controls Unitary Products Residential Package Unit Technical TrainingThis manual presents information and guidelines for proper installation, adjustment, operation,and maintenance of Johnson Controls Unitary Products residential package units.Read the Installation Manual, Technical Guide, and all available product information beforeattempting assembly, installation, start up, adjustment, or operation of any system.This information is NOT for unqualified personnel. It is intended for HVAC service and installationtechnicians that have had the proper industry training, as well as safety and operations trainingregarding electrical and gas systems.This manual is intended as a general guide, and may not reflect exactly the current designs,or all of the options available to our customers. Please contact your local technical supportrepresentative regarding specific details of a particular model, configuration, or installation. Everyeffort has been made to ensure the accuracy of the information in this manual. The informationand specifications contained in this manual are subject to change without notice. JohnsonControls Unitary Products reserves the right to change such specifications at any time withoutincurring obligation. REV. 04 040715 1

AcknowledgmentsAUTHORSTravis Keyser - Instructor Technical Services Johnson ControlsTECHNICAL ADVICE, REVIEW, FORMATTING AND PROOF READING:Scott Nelmark - Senior Manager, Training Services Johnson ControlsEric Lowber - Training Specialist, Johnson ControlsTom Tasker - Engineer, Johnson ControlsTed Foy - Technical Services, Johnson ControlsAlan Dukes - Technical Services, Virginia Air 2

CTaobnlteeonftsContentsChapter 1 - Introduction 7Nomenclature 8Chapter 2 - Safety 9Danger 9Warning 9Caution 9Specific Safety Rules 10Safety Requirements 11General Awareness 12Job Site Safety 12Hazardous Materials 12Confined spaces 12Pressure 12Electrical Safety 12Lock-Out Tag-Out 13Fire Safety and Burns 13Personal Safety 13Personal Protection Devices (PPD) 13Clothing 14Jewelry 14Lifting 14Chapter 3 - Component Familiarization 15Air Conditioning Cycle 15Compressor 16Condenser Coil 16Metering Device 17 17 TXV Operating Forces 19Evaporator 20Schrader Valves 21Liquid Line Filter-Drier 21High Pressure Switch (HP) 22Transformer 22Contactor 23Dual Run Capacitor 23Start Capacitor 23Hard Start Kit 24Blower Motor (Standard ECM) 31Gas Heating Components 32 32 1) Induced Draft Motor (DM) 2) Gas Valve 32 Inlet Gas Pressure 32 Outlet Gas Pressure 33 3) Spark Ignitor 33 4) Burners 3

5) Flame Sensor 34 6) Rollout Switch (RS) 34 7) Inducer Pressure Switch (PS) 35 8) Unit Control Board (see Figure 3-17) 35 Limit Switch (LS) 35 Accessories 36 Propane Conversion Kit 37 Economizers 37 Dry Bulb Operation 38 Single Enthalpy Kit 38 Dual Enthalpy Kit 38 Manual Fresh Air Damper Kit 38 39 Motorized Fresh Air Damper Kit 39 Filter Frame Kit 40 Roof Curb Kit 40Chapter 4 - Installation 41 Thermostat 41 Electrical Wiring 42 Control Wiring 42 Duct work Installation 42 Location and Clearances 43 Condensate Drain 44 Filters 44 Sizing of Equipment 44 Gas Piping 45 Flue Vent Hood 45 Accessories 45Chapter 5 – Start Up 47 Introduction 47 Job Data 47 General Information 47 Equipment Data 47 Additional Kits & Accessories Installed 47 Unit Location and Connections 47 Electrical Inspection 48 Airflow Setup 48 External Static Pressure (ESP) 48 Using the Magnehelic© 49 Supply Static Pressure Measurement 49 Return Static Pressure Measurement 49 Total External Static Pressure (ESP) Measurement 49 Temperature Rise 50 Temperature Drop 50 Airflow Calculation 52 Calculating Gas Heat Input and Output (Clocking the Meter) 52 4

Total Amperes 53 Compressor Amperes 53 Gas Pipe Leak Testing 53 Gas Line Pressure Measurement 54 Manifold Pressure Verification and Adjustments 54Chapter 6 - Sequence of Operation 55 Standby Mode 55 Blower Motor Control 55 Fan Only Operation 55 Compressor Only Operation 55 Gas Heating Operation 55 56 Full Heat Sequence 57 Retrial Sequence 57 Entering Lockout 57 Sensing Flame 57 Steady Heat State 58 Pressure Switch Open Mid-Cycle 58 Flame Loss Mid-Cycle 58 Shut Down Sequence 59Chapter 7 - Troubleshooting 59 Diagnostic Codes 59 Flash Definitions 59 Display of Fault/Status Code 59 Fault/Status Code Table 60 Fault Code History 60 Fault Descriptions 60 Pressure Switch Closed with Inducer Off 61 Pressure Switch Open During Pressure Switch Proving 61 Pressure Switch Open During Pre-Purge/Inter-Purge 61 Pressure Switch Open During Trial For Ignition 61 Pressure Switch Open During Steady Heat 61 Multiple Pressure Switch Openings During Single Call for Heat 62 High Limit Fault 62 Open High Limit Longer Than 5 Minutes 62 Open High Limit Longer Than 15 Minutes 62 Multiple High Limit Openings During Single Call for Furnace Heating 63 Rollout Switch Fault 63 Flame Faults/Warnings 63 Weak Flame Warning 63 Runaway Flame 64 Multiple Failed Ignitions 64 Multiple Losses of Flame During Single Call for Furnace Heating 64 Gas Valve Fault 65 Wiring Faults 65 Y Present Without a G 65 Incorrect Line Polarity 5

Control Fault 65 Power Up Operation 65 Lockout Modes 65 65 Soft Lockout 66 Hard Lockout 66 High Limit Open Longer than 5 Minutes 66 High Limit Open Longer than 15 Minutes 67 Runaway Flame 67 Gas Valve Fault 68 Power Interruption 69Chapter 8 - Maintenance 69 General Maintenance 69 Thermostats 70 Indoor Coil 70 Outdoor Coil 70 Fan Motors 71 Natural Gas and Propane (LP) Heating Systems 71 71 Burners 71 Heat Exchanger 72 Flame Sensor Cleaning Flue Passages 73Appendix A - Wiring Diagrams 77Appendix B - Accessory Installation and Parts 6

Chapter 1 - IntroductionFigure 1-1: Residential Gas-Electric This manual contains technical information regarding Package System Unitary Products residential gas electric package systems equipped with single stage cooling and single stage gas heat. Follow all local, state and federal laws, codes, rules and regulations when performing work on any of the equipment described in this manual. This manual is not to replace the installation and maintenance documentation provided with the equipment. For model specific information, reference the installation manuals and technical guides during installation and service of any air conditioning equipment.Safety is always a concern when working on HVAC equipment. In Chapter 2 (Safety), manyfactors regarding workplace safety are reviewed. This is not an all inclusive safety document.It is the responsibility of the employer and the technician to identify potential safety hazards thatmay change from one job site to the next. The procedures in this manual provide additional basicsafety awareness tips when installing and servicing gas electric residential package units. Onlyqualified technicians with proper safety training should install, service or maintain the equipmentdescribed in this manual.Proper installation and service of air conditioning systems requires a thorough understandingof electrical and mechanical components and system operation. In Chapter 3 (ComponentFamiliarization), the refrigeration cycle, electrical components and field installed accessories arereviewed. In Chapter 4 (Installation) and Chapter 5 (Start Up), basic installation and start upprocedures are discussed. This document is not intended to replace the installation instructionsand other documentation provided with the equipment. Always fully read and understand theprovided instructions prior to installation, startup, or service of any HVAC product.In Chapter 6 (Sequence of Operation), a detailed sequence of operation for cooling and gasheating operations is provided.Chapter 7 (Troubleshooting) provides common techniques to help identify problems within therefrigeration cycle, electrical components, airflow problems, and flash codes.Chapter 8 (Maintenance) gives an overview of maintenance procedures for the variouscomponents within the residential gas electric package units. 7

NomenclatureEvery digit in the model number has significance. Please review the following structure tounderstand the capabilities of the residential gas electric package unit by model:PCG 4 A 24 050 2 X 1 AModel Family Revision LevelPackaged A/C A = Original Releasewith Gas Heat B = Second ReleaseNominal Cooling Gas Heating Input Generation LevelEfficiency BTU/Hr x 1000 1 = First Gen.4 = 14 SEER6 = 16 SEER 50= 50,000 NOx Approval 65= 65,000 X = Low-NOx,Cabinet Size 75= 75,000 Blank = Not Low-NOx)A = Small 34 x 50 100= 100,000B = Large 44 x 50 125= 125,000Nominal Cooling Capacity Voltage-Phase-FrequencyBTUx1000 2 = 208/230-1-6024 = 24,000 BTU 2 Ton30 = 30,000 BTU 2.5 Ton36 = 36,000 BTU 3 Ton42 = 36,000 BTU 3.5 Ton48 = 48,000 BTU 4 Ton60 = 60,000 BTU 5 Ton8

Chapter 2 - SafetyReminder - use this manual in conjunction with the technical literature for each product. Thismanual Does Not Supersede the Installation Manual and Technical Guide provided with theequipment. Always read and follow all instructions before installing equipment. Understand andpay particular attention to the signal words DANGER, WARNING, or CAUTION.Danger - DANGER indicates an imminently hazardous situation, which, if not avoided, willresult in death or serious injury. An overpressure protection device, such as a pressure regulator, must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0.5 PSI (14\" w.c. (3.48 kPa). Pressures exceeding 0.5 PSI (14” w.c. (3.48 kPa) at the gas valve will cause damage to the gas valve, resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life.Figure 2-1: Danger SymbolWarning - WARNING indicates a potentially hazardous situation which could result in death orserious injury. Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.Figure 2-2: Warning SymbolCaution - CAUTION indicates a potentially hazardous situation, which, if not avoided, mayresult in minor or moderate injury. It is also used to alert against unsafe practices and hazardsinvolving only property damage. TThhiiss ssyysstteemm uusseess RR--441100AA RReeffrriiggeerraannttwwhhicichhooppeerraatetessaat t hhiigghheerr pprreessssuurreessththaannRR-2-22.2N. oNoothoetrhererfrriegferrigaenrtamnat ymbaey bueseudsiendthinis tshyisstesmys.teGmag. eGsaeutgse, hsoestess, ,hroesfreigse,rraenftrigerant ccoonnttaaiinneerrss aannddrreeccoovveeryrysyssytsetmemssmmusutsbtebdeedseigsnigendetdo to hhaannddllee RR--441100AA.. IIff yyoouu aarree uunnssuurree,, ccoonnssuulltt tthhee eeqquuiippmmeenntt mmaannuuffaaccttuurreerr.. Failure to use R-410A compatible servicing equipment may result in property damage or injury.Figure 2-3: Caution Symbol 9

Specific Safety RulesFollow these specific safety rules for a safe application. ● Package systems utilizing gas heating can only use natural gas or propane (LP) gases as an approved fuel. LP applications require installation of the appropriate LP conversion kit. Refer to the package unit rating plate or Installation Manual for information on proper inlet and manifold pressures. ● Install package systems only in a location and position as specified in the Installation Manual. ● Installation in a residential application must be installed exactly as specified in the Installation Manual. ● Provide adequate clearances for service, combustion and ventilation air to the package unit when natural gas or propane (LP) gases are the fuels utilized for heating. The recommended clearances should be specified in the Installation Manual. ● Test for gas leaks as specified in the Installation Manual. When this symbol is identified within the literature, on labels or in this manual, the technician should be alert to the potential for personal injury.Figure 2-4: Safety Alert Symbol ● Only connect the equipment to a duct system which has an external static pressure within the allowable range as specified in the Installation Manual and on the equipment rating plate. ● These package units are not to be used for temporary heating or cooling of buildings or structures under construction. Improper installation will shorten equipment life, reduce product efficiency, and void the warranty. ● Always install the system to operate within the equipment’s intended temperature and operating ranges. ● The size of the unit should be based on an acceptable and approved heat load calculation for the structure being conditioned. 10

Safety RequirementsFollow these safety requirements for a safe application. ● All equipment should be installed in accordance with all national and local building/ safety codes and requirements, local plumbing or waste water codes, and other applicable codes. In the absence of local codes, install in accordance with the most recent National Electrical Code, National Fuel Gas Code, and/or Natural Gas and Propane Installation Code (latest editions). Furnaces have been certified to the latest edition of standard ANSI and CSA standards. ● Refer to the unit rating plate for the equipment model number, and refer to the Installation Manual for proper air plenum dimensions. ● Provide clearances from combustible materials as listed under Clearances to Combustibles in the Installation Manual and the equipment rating plate. ● Provide clearances for servicing ensuring that service access is allowed for both the burners and indoor fan motor. ● Failure to carefully read and follow all instructions in this manual and the equipment Installation Manual can result in equipment malfunction, death, personal injury and/ or property damage. ● Check the rating plate and power supply to be sure that the electrical characteristics match. All models of the 2 to 5 ton dual fuel package units use nominal 208/230 volts AC, 1 Phase only, 60-Hertz power supply. DO NOT CONNECT THIS APPLIANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE GREATER THAN THE NOMINAL RATED VOLTAGE +/-10% unless it has been specifically identified for such use. ● The equipment shall be installed so the access panels are readily available and the electrical components are protected from water infiltration. ● Installing and servicing heating equipment can be hazardous due to the electrical and the gas fired components. Only trained and qualified personnel should install, repair, or service gas heat equipment. When working on heating equipment, observe precautions in the manuals and on the labels attached to the unit and other safety precautions that may apply. ● The Installation Manual covers minimum requirements needed to conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances; especially those who have not kept up with changing residential and non-HUD modular home construction practices. These instructions are required as a minimum for a safe installation and operation. 11

General AwarenessSafety is ALWAYS the primary concern for everyone. On the job injuries can be significantlyreduced when proper guidelines are followed. Always be aware of all company, local, state and/orOSHA (Occupational Safety and Health Administration) regulations.Job Site SafetyKeeping the job site clean of trash, extra tools and equipment will significantly reduce the chancefor injuries. Since each job is unique and has its own hazards, all new workers to the area shouldbe made aware of the location of fire and first-aid equipment, fire escape routes, and otherdangers.Hazardous MaterialsMany different chemicals and compounds are used in the service and installation of HVACsystems. Please read the directions and use caution along with PPDs whenever handling thesematerials. Read and understand the MSDS (Material Safety Data Sheets) for all materials used.Confined spacesNever enter or work in a confined space without taking the appropriate precautions. Havesomeone available outside the space ready to assist or summon help if necessary. Even spacesthat seem relatively safe can quickly become hazardous if a pipe were to break and fill the spacewith refrigerant, steam, poisonous fumes or other gases. Welding or brazing in a confined spaceis especially hazardous.PressureHigh pressures have always been part of the HVAC profession. With the new refrigerants, suchas R-410A, it is even more crucial that technicians realize the dangers of these gases. Wear theproper personal protective devices including safety glasses and gloves. Proper hose ratings andmanifolds are required for the new high pressure refrigerants.Electrical SafetyJewelry should be removed prior to any electrical work being performed. Ensure that theequipment disconnect switch removes the primary power source prior to taking resistancereadings or disconnecting any wires or connections. Removal of system power should be verifiedwith the voltage function of a multi-meter. All electrical safety guidelines should be followed at alltimes.Electrocution occurs when as small as 6 to 200mA of current flows through the heart disrupting itsnormal operation and causing death.Electrical shock is an injury that occurs as a result of exposure to an electrical current. Inspect allextension cords and power tools regularly.Fuses and circuit breakers are designed to protect equipment, not people. For personal electricalprotection, GFCI or Ground Fault Circuit Interrupters are highly recommended. 12

Lock-Out Tag-Out OSHA Standards cover the servicing and maintenance of machines and equipment in which unexpected energizing or start up of the machines or equipment, or release of stored energy could cause injury to employees. These standards establish minimum requirements for the control of such hazardous energy. To ensure safety, put a lock that is tagged with the technician’s name on the electrical disconnect or breaker of the equipment or circuit which is being serviced. Be aware of others who may be working on the same circuit or other circuits served by the same electrical panel. The technician should also be aware that other technicians may not have used the proper Lock-Out, Tag-Out procedures.Figure 2-5: Lockout DeviceFire Safety and BurnsWhile brazing, keep combustible material away or use a heat shield to help reduce risk of fire.Check equipment regularly and never try to modify or repair regulators.First-degree burns affect the outer layer of the skin, causing pain, redness, and swelling. Second-degree burns affect both the outer and underlying layer of the skin, causing pain, redness,swelling, and blistering. Third degree burns extend into deeper tissues, causing brown orblackened skin that may be numb.When servicing the refrigeration cycle, improper use of equipment and tools can result in seriousburns that are associated with refrigerants. This may include frostbite, which is a deep tissueinjury. Proper PPDs must be in use when servicing the refrigeration system.Personal SafetyPersonal safety includes remaining aware of the surroundings at all times, using properlymaintained tools, and correct use of items designed for personal protection.Personal Protection Devices (PPD)Hard Hat: Must be worn when there is a danger of head injury.Safety Glasses: Eye protection should be worn at all times while on a job site. 13

Gloves: Assist in the prevention of serious injury to the hands from serious cuts as well as injuriesfrom high pressure gases such as refrigerants. Rubber gloves can protect the technician’s handsfrom chemicals when inspected and worn properly.Safety Shoes: Work shoes with steel toes for foot protection. There are also electrical safetyshoes that can aid in protecting the technician against electrical shock and/or electrocution. At aminimum, leather work shoes with rubber soles are required.Respirator: Used in a confined space where the air can be dissipated by refrigerant which cancause asphyxiation.Safety Harness: Used when working above grade level. Ladders must be tied down. Ensurethat PPDs provide the intended protection. They should be inspected regularly, used properly andnever altered or modified in any way.ClothingRotating and moving components pose a serious risk. Loose fitting clothing, ties, and jewelryshould be avoided when servicing rotating equipment. If any clothing or jewelry is caught or ametal item encounters an energized circuit, serious injury or death is a likely result.JewelryJewelry is a potential safety hazard and should be avoided as previously stated in the precedingsection. Since jewelry and gold are conductors of electricity, technicians should keep these itemsin their service bag or in their service vehicle.LiftingTo avoid back injuries, always adhere to proper lifting techniques. Be aware of personallimitations and seek help with items that are too heavy to safely lift. A back support belt mayprovide additional protection.Only trained, qualified technicians should perform electrical maintenance, installation, inspectionsand troubleshooting of electrical equipment. 14

Chapter 3 - Component Familiarization Gas/electric residential package units combine the operational characteristics of a gas furnace, evaporator coil, and outdoor condensing unit into a single, convenient product. Within each system, the components and their operation are similar to those found in split systems. The following provides detail on the air conditioning and gas heating components.Figure 3-1: Residential Package UnitAir Conditioning Cycle CompressorDischarge Line Sensing Bulb Suction Line Liquid Line Filter TXV Drier Condenser Coil Evaporator CoilFigure 3-2: Air Conditioning CycleSimply stated, the air conditioning cycle provides cooling by moving heat from indoors to outdoors.The evaporator coil absorbs heat from the return air from the interior of the structure and thecondenser coil rejects heat outside of the structure. The reduced temperature, reduced humiditysupply air is then reintroduced into the structure. 15

There are four major components within the air conditioning system: ●● Compressor ●● Condenser ●● Metering Device ●● EvaporatorCompressor The compressor transforms refrigerant from low pressure vapor to high pressure vapor and moves the refrigerant through the system. The pressure of the refrigerant entering the inlet (“suction”) side of the compressor is referred to as low side pressure (suction pressure). The low pressure vapor refrigerant is compressed and discharged from the compressor as high pressure discharge gas. Scroll and reciprocating compressors are used on residential gas electric package units. Condenser Coil Residential package units contain a traditional fin and tube condenser coil. The condenser coil rejects heat from the refrigerant and changes the state of the refrigerant from a high pressure vapor to a high pressure liquid. Refrigerant enters the condenser coil as high pressure vapor.Figure 3-3: CompressorThis vapor is much higher in temperature than the ambient air. The heat contained in therefrigerant is then rejected through the coil surface to the ambient air. As heat is rejected from therefrigerant, the refrigerant condenses to a high pressure liquid.A clean, unobstructed condenser coil is critical to maintaining heat transfer capabilities andoverall efficiency of the system. Ensure the condenser coil remains free of debris and restriction.During installation, follow all recommendations regarding minimum spacing from the structure,obstructions, and other equipment.16

Metering Device Residential package units utilize a thermostatic expan- sion valve (TXV) for refrigerant metering. The TXV reduces refrigerant pressure from a high pressure liquid to a low pressure liquid while maintaining constant superheat in the evaporator, adapting to varying load conditions. TXV Operating Forces The TXV has three operating forces: one opening force and two closing forces 1) Sensing Bulb Pressure (Opening): The sensing bulb is the “Opening Force” of the TXV. It is located at the outlet of the coil, on the suction line, as close to the coil as possible downstream of the header. It is mounted as close to the top of the suction line as possible and measures the temperature of the suction line. As the load increases on the coil, the superheat will increase. As the load increases, the suction line temperature rises.Figure 3-4: Metering Device The sensing bulb pressure increases as the suction line temperature rises.When the sensing bulb pressure increases, pressure is exerted on the TXV diaphragm. Thisopens the valve and allows more refrigerant to flow into the coil as required; thus, maintaining theproper amount of superheat.Figure 3-5: Diagram of TXV and Evaporator Assembly2) Spring Pressure (Closing):Spring pressure a “closing force” on the TXV. The TXV assemblies have a factory adjustedspring. This spring is non-adjustable. It is installed in the body of the valve and exerts pressure 17

on a set of pushrods which are in direct contact with the diaphragm. The pressure of the springopposes the sensing bulb pressure.3) Coil Pressure (Closing):Coil pressure is a “closing force” on the TXV. The externally equalized TXV has three connections: ● The liquid line - inlet port: The liquid line port is attached to the liquid line leaving the liquid line filter drier. ● The distributor connection: The distributor connection has multiple feeder tubes at the outlet of the TXV which provides refrigerant to each refrigerant circuit of the coil. ● The external equalizer line: The external equalizer line is a small capillary line which is attached to the top of the line at the outlet of the coil and downstream of the sensing bulb. The eternal equalizer references coil pressure at the outlet of the evaporator coil. The pressure of the coil opposes the sensing bulb pressure. 18

EvaporatorThe evaporator removes heat from the return air flowing through it. Under normal operatingconditions, the evaporator coil temperature is approximately 40 degrees Fahrenheit. The warmerreturn air passing through the coil rejects heat into the coil surface and into the refrigerant. Whenairflow and refrigerant charge is correct, the air temperature (discharge) leaving the evaporator isapproximately 15-20 degrees Fahrenheit less than the air entering the evaporator. Proper airflowsetup (350-450 CFM/ton of cooling capacity) is critical for system performance and customercomfort. Excessive airflow may not allow proper dehumidification of the air, leading to discomfortin the conditioned space. Insufficient airflow may lead to coil icing and eventual compressorfailure.Figure 3-6: Evaporator Coil (Bottom Left) 19

Refrigerant R-410A R-410A pressures are approximately 60% higher than a comparable R-22 system. All components in the system must be rated to handle higher pressure. This includes a manifold gauge set and refrigerant recovery machine designed to handle the higher pressures of R-410A. Due to the higher pressures, all field connections should be made with brazing rod that has a minimum of 5% silver content. Soft solder must not be used for connections in R-410A systems. Components designed for use with R-410A are usually tagged with a rose pink label the same color as a cylinder of R-410A.Figure 3-7: R-410A Refrigerant Cylinder R-410A is not compatible with mineral based refrigerant oil as used in R-22 systems. R-410A systems use polyolester (POE) synthetic oil.POE is not compatible with mineral oil as used in R-22 systems; therefore, service tools thattouch the refrigerant side of the system (such as the manifold gauge set, recovery cylinders andrecovery machine) should be dedicated to a single refrigerant only.POE oil is very hygroscopic, which means that it has a great affinity for water. Any moisture in thesystem may cause system problems. Do not leave the system open to the atmosphere.Accurate charging on package systems is best conducted by weighing in the exact chargeas indicated on the unit data plate. Systems are shipped factory charged and should notrequire charge modification except in the instance of a leak or component replacement within therefrigeration system.When adding refrigerant to an R-410A system, R-410A must be taken out of the cylinder in liquidform. This eliminates any possibility for the refrigerant to fractionate (separate into its individualcomponents). A quick-charge adapter will flash the liquid R-410A into a vapor before it entersthe suction line. Alternately, the liquid may be “throttled” into the suction line. Use caution whenallowing the liquid refrigerant to enter into the suction line while throttling the low side manifoldvalve. Throttling the valve properly allows the refrigerant to flash to vapor prior to entering thesuction side of the compressor.Schrader ValvesThe residential gas electric package units have Schrader valves to provide access to both the highand low side of the system. These valves should only be attached to the appropriate pressuregauge on the manifold gauge set. Improper installation of the manifold gauge set can causedamage to the gauges.20

Liquid Line Filter-DrierThe liquid line filter drier traps moisture, acid and small particles; effectively stopping thecontaminants from traveling through the system and causing damage.The liquid line filter drier is located in the liquid line between the indoor and outdoor meteringdevices. Filter driers are designed for specific refrigerants and pressures. Do not install a drierthat is not designed for use on the system being serviced. To determine if a liquid line filter drier is restricted, take a temperature reading on both sides of the drier. If there is a temperature difference (greater than 5 degrees Fahrenheit) between the inlet and outlet of the filter drier, the drier should be replaced.Figure 3-8: Liquid Line Filter Drier The high pressure switch protects the system against excessive high side orHigh Pressure Switch (HP) discharge pressures. There are multiple conditions which could cause Figure 3-9: High Pressure Switch this switch to open and de-energize the compressor. Excessive head pressure is most commonly caused by poor air flow across the high side coil. This may be the result of a dirty filter, dirty coil, a failed fan motor, or improper fan speed. It is also possible for the excessive discharge pressure caused by overcharging the system and / or a non-condensable such as air or nitrogen in the system. The high pressure switch opens at 625 +/- 25 psig and resets at 500 +/- 25 psig. 21

Transformer The supplied transformer is wired for 230 volts AC line voltage. If the unit is installed in a location that uses 208 volts AC, the primary voltage tap must be moved to the 208 volt AC connection.Figure 3-10: TransformerContactor Contactors are heavy duty relays that are energized on a call for cooling by a 24 volt AC signal from “Y” (cooling call) on the thermostat. When 24 volts AC is applied to the contactor coil, the contactor’s contacts close (“pull in”). This allows L1 of line voltage to pass through to T1 and energize the compressor and condenser fan. There are no contacts between L2 and T2, indicating that L2 line voltage is always present at the compressor and condenser fan though the T2 connection.Figure 3-11: Contactor If 24 volts AC is present at the contactor coil and the contactor does not pull in, further evaluation of the contactor coil should be completed. The unit should be locked out at the equipment disconnect before any resistance readings are taken. Use an ohmmeter to measure the resistance across the contactor coil. An infinite reading indicates the coil is open, while a reading of zero ohms indicates a shorted coil.If either of these readings is present, the contactor must be replaced. The line voltage on the loadside of the contactor should match the line voltage on the line side of the contactor. If it does not,check the contacts for pitting, dirt or corrosion.22

Dual Run Capacitor The dual run capacitor provides enhanced running torque to the compressor and condenser fan motor. The terminals are marked “Fan” (condenser fan), “Herm” (compressor), and “C” common.Figure 3-12: Dual Run CapacitorStart CapacitorThe start capacitor provides additional starting torque to the compressor and is only in the circuiton start up; therefore, the start capacitor must have a relay to remove the capacitor from thecircuit. Collectively, the start capacitor and start relay are referred to as a “hard start kit”.Hard Start Kit The hard start kit consists of a potential relay and a start capacitor. The hard start kit may be factory or field installed. 25 Start When the motor is energized, 1 Capacitor supply voltage is applied to the Potential Relay start capacitor. The start capacitor increases the starting torque of theFigure 3-13: Hard Start Kit motor and the rotor begins to turn. When the rotor has reached 75% of running speed, the potential relay coil is energized and the normally closed set of points opens; thus removing the start capacitor from the circuit. 23

Be aware that the capacitor may have stored energy even though the electrical disconnect has been locked out and line voltage has been removed from the sys- tem. A resistor should be used to bleed the stored voltage from the capacitor. The recommended resistor is a 20,000 ohm 2 watt resistor. The technician should not use a screwdriver to bleed the capacitor. Improper bleeding of the capacitor can cause damage to the capacitor and to the motor itself.Blower Motor (Standard ECM) The Standard ECM (S-ECM) motor is used in the indoor fan section. This motor operates with 208/240 volts AC line voltage. The allowable voltage range on these motors is 196-264 volts AC. The Standard ECM motor is programmed to provide constant torque. If the static pressure changes, the motor will only maintain the factory programmed torque. This should not be confused with constant airflow. Even though the Standard ECM can maintain torque, if static pressure increases, airflow will decrease. This is similar to a PSC motor. However, airflow will not decrease as dramatically as with a PSC motor, since torque is being maintained.Figure 3-14: S-ECM Blower24

Figure 3-15: S-ECM Motor ConnectionsThe Standard ECM motor has a 10 pin connector, but only utilizes nine of the pins. The linevoltage terminals are labeled “L”, “G” and “N”. The “L” terminal is line 1, and the “N” terminal isthe line 2 for 230 volts AC. The “G” terminal is the ground terminal. A reading of 230 volts AC ismeasured between the “L” and “N” terminals.The control terminals are labeled “C”, “1”, “2”, “3”, “4” and “5”. The terminal labeled “C” is commonfor the 24 volts AC control voltage, while terminals labeled “1” through “5” are pre programmedtorque settings. 24 volt AC signals are sent from the control board to engage the proper fantorque for the mode of operation.If the motor is wired improperly, the control module and / or the motor module may be permanentlydamaged.The speed of the motor must be adjusted within the minimum and maximum limits approvedfor the evaporator coil, electric heat, and outdoor unit. The settings and blower capacities areprovided in the air flow data tables listed in the unit Installation Manual. To adjust the motor speed for heating, cooling, and continuous fan, the blower motor wire for each mode is connected to the selected terminal (1-5). For cooling mode airflow establishment, consult the airflow performance tables in the Installation Instructions to select the blower speed that provides 350-450 CFM/Ton of airflow. In heating mode, the proper blower speed selection is one that will deliver the rated temperature rise (as specified on the unit data plate) when in steady state heating.Figure 3-16: S-ECM ConnectorContinuous fan speed is dependent on customer preference, though is often selected as thelowest available speed. 25

Unit Control Board1 9 10 8 72 63 5 4 Figure 3-17: Unit Control Board26

1) Thermostat Connections (24vac)R – 24 volts AC HotC – 24 volts AC CommonW – Heat CallY – Cooling CallG – Continuous Indoor FanO – Reversing Valve (not used) The plug above the thermostat connections is for the defrost control board and is not used for a gas electric package unit.2) Nine Pin PlugPin 1 High (temperature) Limit Switch inputPin 2 24VAC from Transformer (hot)Pin 3 24VAC from Transformer (common)Pin 4 24VAC to Pressure Switch (tied to P1, Pin1)Pin 5 24VAC to HLS/ROS circuitPin 6 Gas Valve CommonPin 7 24VAC to Gas ValvePin 8 Pressure Switch InputPin 9 Chassis Ground3) Motor Control ConnectionThe control provides 24VAC output to control the operational speed of the Standard ECM motor(S-ECM). The Y SPD output is energized when the control has a request for cooling speed bloweroperation. The W SPD output is energized when the control has a request for heating speedblower operation. The G SPD output is energized when the control has a request for fan speedblower operation.4) Flame Current PadThe control provides access to the Flame Current reading for troubleshooting purposes. Thecontrol has two solder pads labeled ‘+’ and ‘–‘, suitable for field connection of a multimeter. Theoutput from these terminals is 1 volt DC per 1 microamp of flame current.5) Three Pin Plug208/230 volt connection to the Induced Draft Motor (Pins 1 and 2) and Flame Sensor (Pin 3)6) Spark Generator (Ignition Coil)Provides energy for spark generation during the trial for ignition. 27

7) Fault and Status LEDProvides flash codes indicating system status and faults if present. Flash types and related codesare illustrated below.Heartbeat 2 seconds ON, 2 seconds OFFFlash 1/3 second ON, 1/3 second OFFRapid Flash 1/10 second ON, 1/10 second OFFDescription Flash CodeNormal OperationStandby mode Green HeartbeatCall for furnace heat active Amber HeartbeatCall for cool active Green HeartbeatCall for fan active Green HeartbeatControl in Factory Test mode Rapid Green FlashOperational FaultsControl failure ON (any color)Low flame current Rapid Amber FlashFlame sensed with gas valve off 1 Red FlashPressure switch closed with inducer off 2 Red FlashesPressure switch open with inducer on 3 Red FlashesLimit/Rollout switch open 4 Red FlashesLimit/Rollout switch open >15 minutes 5 Red FlashesPressure switch cycle lockout 6 Red FlashesLockout due to failed ignition 7 Red FlashesLockout due to too many flame dropouts 8 Red FlashesGas valve fault code 10 Red FlashesLimit/Rollout switch open between 5 and 15 minutes 11 Red FlashesWiring Related FaultsIncorrect line voltage polarity 9 Red FlashesY thermostat demand without a G 4 Amber Flashes8) LAST ERROR ButtonWhen the LAST ERROR pushbutton is pressed for longer than 1/5 second and no thermostatsignals are currently active, the control will sequentially flash, on the Status LED, the series ofstored error codes (up to the last 5 active error codes since they were last cleared or 30 days,whichever is shorter) starting with the most recent. There will be a 2 second delay between errorcodes. The series may be repeated by pressing LAST ERROR push button again. If one of thethermostat signals becomes active while the control is flashing stored error codes, the error codeflashing mode will immediately terminate and normal operation of the control will resume. Thecontrol will ignore the LAST ERROR pushbutton during any mode with the exception of Standbymode. If there are no error codes stored in memory, the LED shall give a 2 Green Flash code.28

If the LAST ERROR push button is pressed for longer than 5 seconds, the control immediatelyclears the stored error codes and flashes the green LED 3 times to indicate that the error memoryhas been cleared.9) BLOWER DELAY JumperThe control provides a 4 position movable shunt jumper to provide adjustment to the furnaceheating off delay time. The positions are labeled “60”, “90, “120”, and “180”. A jumper notconnected in any of the 4 positions defaults to the “120” position. The control is shipped from thefactory with the jumper in the “60” position.10) Fuse ConnectorConnection point for the 3 amp automotive style fuse.Control Board Terminal DesignationsInput Description Connection TypeGW Call for fan operation from tstat P3, Pin1Y Call for first stage furnace P3, Pin2 operation from tstatO Call for first stage compressor P3, Pin3HLS-In from tstatTR Call for reversing valve P3, Pin4TC (convenience terminal) from tstatGas CommonPS-In High (temperature) Limit P1, Pin1LINE Switch inputFSF1 24VAC from Transformer (hot) P1, Pin2LAST ERROR 24VAC from Transformer P1, Pin3BL DL (common)Output From Gas Valve P1, Pin6RC Pressure Switch Input P1, Pin8PS-Out Line Voltage (115 VAC) Input P2, Pin1 Flame sensor connection P2, Pin3 3 Amp fuse connection (Low F1 female q.c. Voltage) Button to display fault codes Pushbutton Blower off Delay P5, 4 position jumper (60,90,120,180) Description Connector 24VAC to Thermostat P3, Pin5 24VAC Common to Thermostat P3, Pin6 (also common with GND) 24VAC to pressure Switch (tied P1, Pin4 to P1, Pin1) 29

HLS-Out 24VAC to HLS/ROS circuit P1, Pin5GASGND 24VAC to Gas Valve P1, Pin724V COM Chassis Ground P1, Pin9Y SPDG SPD 24 VAC Motor Speed P6, Pin1W SPD (Common)C 24VAC Cool Motor Speed P6, Pin2RO 24VAC Fan Motor Speed P6, Pin3Y 24VAC Hot Motor Speed P6, Pin4W 24VAC Common to Thermostat P4, Pin1IND (also common with GND)IGNFAULT/STATUS 24VAC to HP P4, Pin2FLAME CURRENT Call for reversing valve P4, Pin3 (convenience terminal) to HP Call for compressor to HP P4, Pin4 Call for furnace operation from P4, Pin5 HP 208/230VAC Inducer (Hot) P2, Pin2 17kVAC Ignition Coil (Hot) ¼” Quick Connect on ign coil 1 two-color LED N/A Field Connection points 2 solder pads for measurement of Flame Current30

Gas Heating Components Improper servicing of gas heating equipment can result in property damage, personal injury and/or loss of life. Only qualified service technicians should install, service, or repair gas heating equipment. 8 7 1 53 6 2 4Figure 3-18: Gas Heating Components 31

1) Induced Draft Motor (DM) The induced draft motor, also referred to as an inducer motor or combustion blower motor, provides two functions: bringing air for combustion into the burner box and moving the products of combustion through the heat exchanger and expels them to the outdoors. The induced draft motors are 208/230 volts AC single phase. Induced draft operation is proven with the inducer pressure switch, which may be verified with a Magnehelic gauge or incline manometer.Figure 3-19: Inducer Draft Motor The induced draft motor must be energized and proven prior to fuel and ignition being introduced to the burners. This is proven with the inducer pressure switch (PS).2) Gas ValveOUTLET VENT PORTPRESSUREPORT OUTLET INLET OFFWRENCH ON MAIN REGULATORBOSS ADJUSTMENT ON/OFF SWITCH INLET (Shown in ON position) PRESSURE PORTFigure 3-20: Gas ValveInlet Gas PressureThe gas valve must have a minimum of 4.5” W.C. for natural gas and 11” W.C. for propane (LP)available at the inlet of the gas valve, and should not exceed an inlet pressure of ½ PSI. If theinlet fuel pressure is not sufficient or exceeds the maximum ½ PSI inlet pressure, the local utilityshould be notified or a regulator must be installed.Outlet Gas PressureThe gas valves are shipped configured for natural gas and require a conversion kit for use withpropane (LP) gas. Follow all installation instructions and applicable codes when installing orconverting a gas heating system from natural gas to LP gas.The outlet manifold pressure must be set to 3.5” W.C. for natural gas and 10” W.C. for propaneas measured at the outlet manifold pressure tap. The manifold pressure adjustment (3/32” allen32

screw) is located underneath the main regulator adjustment screw cap. This cap must be re-moved to adjust manifold pressure, and put back in place following adjustment.3) Spark IgnitorDirect spark ignition is used in the gas electric residential package units. After proof of induced draft motor operation and each of the safety limits are identified, the ignition control board energizes the spark ignitor to directly light the main burner and provide 24 volts AC to the gas valve to initiate the flow of gas. After flame is detected (minimum 1.5 uA), the flame sensor detects that a flame is present, and the spark is interrupted.Figure 3-21: Spark Ignitor The inshot burners mix fuel from the gas valve and primary air for4) Burners combustion.Figure 3-22: Inshot Burner Proper manifold pressure (3.5” w.c. for natural gas, 10” w.c. for propane gas) must be provided for establishment of a stable, blue flame. If the flame is lazy or is yellow in color, the manifold pressure and gas input value/orifice size must be verified. 33

5) Flame Sensor Through flame rectification, the flame sensor proves that main burner flame has been established. The sensor is energized with 120 volts AC. This is rectified to DC though the burner flame when present. Current flow in DC microamperes (µA) indicates that flame has been established, and may be measured at the flame current pad on the ignition control board. A standard voltmeter may be used to measure the DC voltage as 1 VDC being equal to the minimum flame value of 1 microamp. The minimum permitted value is .5 micro amps DC. A standard volt meter may be used to measure the DC voltage as 1 VDC being equal to the minimum flame value of 1 microamp. The threshold for a “weak flame” as indicated on the unit control board is 1.5µA.Figure 3-23: Flame Sensor6) Rollout Switch (RS)Figure 3-24: Rollout SwitchThe rollout switch halts system operation when the flame rolls outside of the heat exchanger orcombustion chamber It is a normally closed temperature actuated switch that opens when aflame is sensed and the switch exceeds the system design operating temperatures. Unlike thelimit switch, the rollout switch is manually reset. The switch is in series with the heating controlcircuit and will de-energize the gas valve when opened. Should the switch open, the the problemcondition must be identified and resolved before further operation. Possible causes include: ● Cracked heat exchanger ● Improper panel installation ● Restriction in the flue stack ● Restricted combustion air intake 34

7) Inducer Pressure Switch (PS) The inducer pressure switch provides proof of inducer motor operation prior to introduction of gas and energization of the direct spark ignitor. The closure point of the switch is typically indicated on the switch label. More than 90% of pressure switches returned under warranty have no defect found... before changing a switch the switch circuit must be diagnosed with an incline manometer or Magnehelic gauge. The manometer is “teed” into the pressure switch circuit in parallel to determine the pressure present at the switch. A fault code indicating that the pressure switch did not close RARELY suggests that the switch is defective.Figure 3-25: Inducer Pressure SwitchRather, there is a condition present that is reducing the combustion airflow, such as a restriction inthe combustion air or flue gas pathway.8) Unit Control Board (see Figure 3-17)Limit Switch (LS)The limit switch (LS), also known as the high temperature limit, is the primary temperature safetycontrol. The LS senses air temperature in the heat exchanger section. The LS is a temperatureactuated switch that interrupts the heating cycle if exposed to excessive air temperatures, suchas burner operation without blower operation, or greatly restricted airflow (plugged air filter,restrictions in the air delivery system).Figure 3-26: Limit SwitchThe LS is a normally closed switch wired in the 24 volt AC heating control circuit and whenoverheated, will open and de-energize the gas valve. The LS automatically resets (closes) uponcooldown and has approximate temperature settings that can be identified in the temperaturecontrols table of the unit wiring diagram. 35

An open limit switch may be caused by the following: ●● Dirty return air filter ●● Blocked supply air ducts ●● Blocked return air ducts ●● Dirty evaporator ●● Excessive manifold pressure ●● Debris deflecting airflow away from the limit switchHeat ExchangerThe heat exchanger allows the heat from combustion to conduct through the steel and transfer tothe air within the conditioned space.It is important that the proper air flow across the heat exchanger is achieved.Obtaining the optimal airflow during the heating cycle (maintaining a temperature rise within therange on the unit data plate) will allow the equipment to perform at peak efficiency.Be aware that if the supply air is too low, the heat exchanger will be damaged due to excessiveheat stress on the metal.If the supply air is moving to quickly, the air will feel cool to the customer and flue gases can beginto condense and produce destructive acids within the heat exchanger. These problems may beavoided by establishing proper manifold gas pressure and heating mode airflow.Figure 3-27: Heat ExchangerAccessoriesAccessory descriptions are provided here. For initial release, available accessory instructions areincluded in Appendix B of this manual. 36

Propane Conversion KitThe kit may be field installed on new equipment to convert a system from natural gas to propanegas. ! WARNINGImproper installation, adjustment, service or maintenance can cause injury or property damage;therefore only a qualified installer or qualified service personnel should perform this conversion.Figure 3-28: Propane Conversion Kit WarningEconomizers ECONOMIZER ASSEMBLYHORIZONTAL RETURN BOTTOM RETURN AIR OPENING AIR OPENINGFigure 3-29: EconomizerThe economizer kits are equipped with a 24 volt AC controller, a modulating damper actuator, andeither a single blade or a interposing blade damper configuration. If installation of an economizer is going to occur on a package unit on a roof with burglar bars, then an economizer equipped with interposing blades must be used. The burglar bars will obstruct the single blade economizer damper and the economizer will not operate properly.The economizer has two main modes of operation. The economizer can provide minimum outsideair positioning for fresh air ventilation. This introduces fresh air into the building and can assist inmaintaining indoor air quality. 37

The economizer can also be installed to provide outdoor air for cooling when ambient conditionspermit. When the outdoor air temperature or the enthalpy (total heat content) is at a sufficientlevel, the air can be used for cooling the conditioned space. This can reduce the demand formechanical cooling and limit compressor run time.The standard economizer kits are shipped with an ambient dry bulb temperature sensor. Theeconomizers have optional enthalpy kits which will convert the system with single or dual enthalpysensing capabilities.Dry Bulb OperationThe dry bulb temperature sensor, which is shipped standard with the economizer kit, sensesambient air temperatures. When the ambient air is within the temperature range setting on thecontrol module, the economizer will use the ambient air to condition the space.Single Enthalpy KitThe single enthalpy kit contains an enthalpy sensor only. The enthalpy sensor replaces the drybulb sensor and is capable of not only measuring the temperature, but also the humidity of theambient air. The enthalpy sensor is providing the controller with the total heat content of theoutside air. If the heat content of the outside air is within the range setting on the control module,the economizer will introduce fresh air to be used to cool the conditioned space.Dual Enthalpy KitThe dual enthalpy kit contains an enthalpy sensor, electrical wires, and self drilling screws. Theenthalpy sensor will be installed to sense the total heat content of the return air. The total heatof the return air is compared to the total heat of the outside air. When the controller senses theenthalpy of the return and outside air, the economizer will modulate to use the air with the leastamount of heat content. If the economizer is to be used with dual enthalpy control, both the single and dual enthalpy kit must be installed to provide both the ambient and return air enthalpy sensors. Each kit has only one enthalpy sensor.Manual Fresh Air Damper KitThe manual fresh air damper may be installed on both downflow and side return air applications.The slide damper can be adjusted to allow zero to 50% outside air to mix with the return air thatis being supplied to the conditioned space. This kit can be installed to provide minimum fresh air.The intake panel is insulated and has a protective screen at the inlet of the damper.In some applications, it may be desirable to close off the outside air when the unit is not inoperation. To achieve this, a motorized fresh air damper kit may be more suitable for theapplication. 38


The motorized fresh air damper is available for downflow and side return air applications. Thedamper can be installed to allow zero to 50% outside air and provide fresh air to the conditionedspace. The damper has a two position damper motor that is actuated when the indoor fan is inoperation. The two positions are either open or closed. The kit has a fixed slide damper that canbe adjusted to regulate the volume of outside air flow entering the return air stream. The dampermotor can be field wired to provide fresh air during the heating mode, fan on, or cooling operation.The damper closes on a loss of power. The intake panel is insulated and has a protective screenat the inlet of the damper.Filter Frame KitThe filter frame kits available for installation installed on downflow and horizontal units. Thefilter kits are available in more than one size (large and small footprint). The filter kits may beinstalled on units with or without economizers and should be installed according to the installationinstructions provided with the kit.Roof Curb KitRoof curbs for residential package units (8” and 14”) must be installed according to the InstallationManual and should meet all National Roofing Contractors Associations (NRCA) standards. Thesefield installed kits must be matched to the equipment model being installed. The roof curbs areshipped unassembled and have corner hinge pin construction for easy assembly. The kit providesunit duct supports for both supply and return air duct connections. The curb is also constructedwith a full perimeter wood nailer that will allow the base flashing to be tied back into the roofingsystem.It is the responsibility of the contractor to ensure that the building construction can accommodatethe additional weight load of the equipment being installed. If care is not taken to ensure that the building will provide proper support for the equipment, damage to property, personal injury, or death may occur. 40

Chapter 4 - Installation Figure 4-1: Package Unit InstallationResidential package units shall be installed in accordance with all current local, city, state andnational laws and code requirements. If the equipment is installed outside of the United States, alllaws and codes within the country of origin shall be adhered to. The technician shall also followthe installation procedures specified in the Installation Manual. If the manufacturer’s specificationsare exceeded by code, or if code is exceeded by the manufacturer’s specifications, the mostrestrictive code requirements must be used.ThermostatThe thermostat is an important component within the electrical system. If the thermostat is notselected to match the equipment’s operating requirements or if the thermostat is not installedproperly, the system cannot provide adequate comfort within the structure.Thermostats should be mounted on an interior wall. Thermostats mounted on walls around theperimeter of a structure will not sense accurate temperatures and the length of the run cycles willincrease. This will cause overshooting of the thermostat settings, decreased comfort levels andinefficient system operation.The thermostat should be approximately eye level and away from supply air registers. Athermostat that is in the supply air stream will short cycle the equipment and result inuncomfortable space temperatures and equipment failure. 41

If the thermostat is equipped with a heat anticipator, the anticipator should be set according tothe value specified in the unit Installation Instructions. Some electronic thermostats do not haveadjustable heat anticipators. They may have cycle rate adjustment settings rather than anticipatorsettings. The cycle rate adjustment setting should be set to six cycles per hour.Electrical WiringAll electrical connections and components shall be installed in accordance with current nationalelectrical code requirements within the United States, or current national codes within the countryin which the equipment is being installed.The power supply should be a dedicated circuit with the proper equipment grounding and circuitprotection. Failure to provide adequate wire sizing, circuit protection and equipment grounding willresult in improper system operation, property damage, personal injury and / or loss of life.All electrical conduits entering the controls section of the package unit should be sealed with anapproved, non-conducting electrical sealant. This will prevent moisture from being pulled thru theconduit and corroding electrical components within the controls section.Prior to connecting the main power supply to the unit, verify that the primary voltage taps to thetransformer are wired properly for 208/230 volts AC. If the transformer is not wired properly,electrical component failure can occur.Control WiringInstall the field supplied thermostat by following the installation instructions that accompany thethermostat. With the thermostat and the electrical disconnect set to the OFF position and locked-out, connect the thermostat wiring from the wiring connections on the thermostat to the electrical connections in the control section of the package unit. Electronic thermostats may require the common wire from the transformer’s 24 volts AC secondary side to be connected to the “C” terminal. The digital display and electronics within the thermostat are powered by the transformer at the “R” and “C” terminals of the thermostat. All control wiring should be a minimum of 18 gauge wire.Figure 4-2: Low Voltage Thermostat ConnectionsDuct work InstallationTo properly design the duct work for the structure, refer to the ASHRAE Fundamentals Handbookchapter on “DUCT DESIGN”, or Air Conditioning Contractors of America (ACCA) “Manual D”. 42

Sizing, installation and insulating the duct work shall also be provided in accordance withindustry recognized procedures identified by the equipment specifications and duct manufacturerspecifications. The residential gas electric package units may be ducted horizontally as shipped, or converted to downflow by relocating the blankoff panels from the down discharge openings to the side discharge openings. It is imperative that the duct system is designed properly per approved methods and matched to the equipment being installed. Improperly sized duct systems will result in loss of efficiency, equipment damage, structural damage and indoor air quality problems.Figure 4-3: Down and Side Discharge ConnectionsResidential package systems are designed to deliver their rated airflow at up to .5” external static pressure. Restrictive duct will increase external static pressureand will cause operational issues and customer discomfort. At all times, the equipmentmust be permitted to operate within stated design tolerances to ensure operation per thepublished performance ratings.Location and ClearancesThe package units are designed to be installed outdoors only. Proper clearances for airflow andservicing shall be provided in accordance with the Installation Manual that accompanied the unit.All package systems installed at ground level shall be on a level pad or slab designed to withstandthe equipment’s weight and dimensions. The pad or slab location and dimensions shall also meetlocal code requirements.Some installations may require additional clearances from ground or roof level to the bottom of theunit. This would be dependant on local code requirements regarding snow line data which couldaffect the defrost capabilities of the unit. 43

Condensate Drain Residential package units must be installed with a condensate drain plumbed from the unit and piped to an open drain. The condensate drain must have a condensate trap in the line. If an open drain is not available when installed on a roof, contact the local authority having jurisdiction and identify local requirements for the condensate drain. Equipment installed at grade level must have a condensate drain piped to an open drain or an approved drain which meets local code requirements. The con- densate drain should be sized properly and all fittings and con- nections sealed with an approved sealing compound. After installation, the trap should be primed with water.Figure 4-4: Drain Connection B “A” = ½ of “B” A “B” Must be at least 1 Inch plus fan total static pressureFigure 4-5: Proper Condensate DrainFiltersFilters may be installed with an approved filter kit that is properly sized for the system. Filtersizes should be entered on the start-up sheet when the system is installed. Never operate theunit without a suitable air filter system. Additionally, the equipment owner must be instructedconcerning the importance of regular filter cleaning or replacement as appropriate.Sizing of EquipmentSizing of equipment must be based on heat loss and heat gain calculations made in accordancewith industry recognized procedures identified by the Air Conditioning Contractors of America(ACCA).44

Gas Piping Gas piping must be completed in accordance with the National Fuel Gas Code unless superseded by local codes or the local authority having jurisdiction. Equipment installed outside of the United States should follow all local codes, rules and regulations within the origin of the installation. Proper pipe sizing will depend on BTU content, the type of fuel and the required cubic feet per hour of fuel. The gas piping supplying the unit should also meet the natural gas or propane (LP) gas pipe sizing charts in the Installation Manual.Figure 4-6: Gas Piping ConfigurationThe gas electric residential package units should have a shutoff valve, union, and drip leginstalled. The drip leg shall be a minimum of 3” in length. All gas piping should be sealed with anapproved pipe thread dope at each joint. The pipe dope should be applied to the male threadsonly, not to the inside of fittings or gas valve.Flue Vent HoodThe flue vent hood is shipped with the gas electric package unit and must be field installedaccording to the Installation Manual to provide proper discharge of flue gases.Proper clearances must be kept to prevent the hot hood and flue gas temperaturesfrom damaging property or causing personal injury. Caution the equipment owneras to the location and temperatures that may be present.AccessoriesAll of the accessories and any future accessories that may become available shall be installedin accordance with the provided installation instructions to ensure safe operation and customersatisfaction. Accessory installation instructions are provided in Appendix B of this manual. 45

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Chapter 5 – Start UpIntroductionPrior to start up, all of the installation procedures outlined in the equipment Installation Manualmust be completed. This includes gas piping, electrical wiring, any accessory kits installed, andcondensate drain connections. In the appendix, a start up sheet is provided that can be used as astart-up checklist and to maintain an equipment service record.Job DataThe job data section of the start up sheet has important information that will assist in maintaininga record of the customer’s name, address, contact information, and the date the installation wascompleted.General InformationThe general information section of the start-up sheets provides a location to log basic informationregarding the type of installation. This section includes information such as if the installation iscommercial, residential, roof installation or if the unit is at grade level and also what direction theunit is set to deliver the air to the conditioned space.Equipment DataThe equipment data section of the start-up sheets provides an area to log the unit model andserial number.Additional Kits & Accessories InstalledThe additional kits & accessories section of the start-up sheets provides a checklist to log anyadditional accessories that were field installed and may require service or repair in the future. Unit Location and Connections The unit location and connections section of the start-up sheets provides a checklist to verify that the equipment was leveled, mounted properly and that all duct work and drain lines were attached. It also provides a location to log the filter type and dimensions.Figure 5-1: Unit Installation 47

Electrical InspectionThe electrical inspection section provides a checklist on the start-up sheet with key electricalpoints that should be evaluated on any equipment installation. This section provides a checklistthat will help to protect the equipment, property, tenants and technician when used in associationwith the Installation Manual.Airflow Setup Airflow in all modes of operation MUST be established upon installation in all instances. Do not assume anything is “factory set”. Each job varies and as such, blower speed selections must be properly established in the field for each mode of system operation without exception.Figure 5-2: Speed Selection PlugProper airflow establishment involves measurement of external static pressure (ESP) in coolingmode and selection of appropriate blower speed taps that provide 350-450 CFM per ton of coolingin the cooling mode, and provide a temperature rise within the range listed on the unit data platein the heating mode. Refer to the airflow tables in the Installation Instructions that correspond withthe duct configuration (side or down discharge).External Static Pressure (ESP)As with most all residential equipment, residential gas electric package systems are designedto provide their rated airflow at up to .5” w.c. total external static pressure. External staticpressures greater than .5” w.c. will cause a reduction in indoor airflow volume and maylead to comfort and operational issues. Be sure to locate and correct the source(s) ofairflow restriction prior to leaving the jobsite.Understanding airflow configuration and limitations is a critical element of HVAC servicework. This knowledge must be at the forefront of service and installation activities.All systems, including those that utilize the ECM indoor fan motors, have airflow limitations. If asystem does not have the proper ductwork, the unit will not meet the designed seasonal energyefficiency ratings, system operation will be louder than expected, and the system may alsoexperience component failures.The measurement of external static pressure (ESP) and proper adjustment is of the utmostimportance if the system is going to operate to design conditions.On the supply side of the indoor fan, the pressure is pushing out in all directions on the interior ofthe supply system. 48

On the return side of the indoor fan, the pressure is pulling inward on the interior of the returnsystem.Restrictions in the duct system—such as undersized duct, dirty filters, dirty evaporator coil andclosed or blocked registers—will cause the external static pressure to increase. As the externalstatic pressure increases, the unit’s ability to move air decreases.Common tools of choice for measuring ESP are the Magnehelic© gauge or incline manometer.The example in Figure 5-1, illustrates the use of the Magnehelic© gauge. High Pressure Tap Using the Magnehelic© Low Pressure Tap The Magnehelic© gauge has two ports, labeled “High” and “Low”. The “High” port registers positive pressure, and is connected to the supply side of the system. The port marked “Low” registers negative pressure, and is connected to the return side of the system as close to the unit as possible.Figure 5-3: Magnehelic© Gauge Side ViewSupply Static Pressure MeasurementTo measure the supply static pressure, connect the Magnehelic© gauge probe to the port marked“high”. The probe should be inserted immediately off the supply duct connection or as close to thetake off as possible.Return Static Pressure MeasurementTo measure the return static pressure, connect the Magnehelic© probe to the port marked “low”.The probe should be inserted in the return air duct as close to the unit as possible.Total External Static Pressure (ESP) MeasurementTo measure the total external static pressure, add the supply air static pressure to the return airstatic pressure. Example: Supply Air Static: .3” W.C. + -.2” W.C. Return Air Static: =.5” W.C. = Total ESP 49

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