Goodman Mfg Commercial Heating and Cooling Gas Unit CPG SERIES User Manual

INSTALLATION INSTRUCTIONS FOR

COMMERCIAL HEATING & COOLING

3 TON - 6 TON PACKAGE GAS UNIT

CPG SERIES

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

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

Prior to installation, thoroughly familiarize yourself with this Installation Manual. Observe all safety warnings.

During installation or repair, caution is to be observed.

It is your responsibility to install the product safely and to educate the customer on its safe use.

All information contained herein is subject to change without notice.

Goodman Manufacturing Company, L.P.

IO-353C

11/10

5151 Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com www.amana-hac.com

WARNING

CARBON MONOXIDE POISONING

HAZARD

DO NOT CONNECT TO OR USE ANY DEVICE THAT IS NOT DESIGN

CERTIFIED BY GOODMAN FOR USE WITH THIS UNIT. SERIOUS

PROPERTY DAMAGE, PERSONAL INJURY, REDUCED UNIT

PERFORMANCE AND/OR HAZARDOUS CONDITIONS MAY RESULT

FROM THE USE OF SUCH NON-APPROVED DEVICES.

FAILURE TO KEEP THIS COMPARTMENT CLOSED

EXCEPT WHEN SERVICING COULD RESULT IN

CARBON MONOXIDE POISONING OR DEATH.

THIS COMPARMENT MUST BE CLOSED EXCEPT

WHEN SERVICING

WARNING

AVERTISSEMENT

T^{HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH}

MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE

S^{TATE OF}C^{ALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER}

REPRODUCTIVE HARM.

RISQUE D'EMPOISONNEMENT AU

MONOXYDE DE CARBONE

SI CE COMPARTMENT N'EST PAS FERME EN

TOUT TEMPS, SAUF EN CAS DE REPARATION, IL Y

A RISQUE D'EMPOISONNEMENT OU MONOXYDE

DE CARBONE OU DE MORT.

CE COMPARTIMENT DOIT ETRE FERME SAUF AU

MOMENT DE L'ENTRETIEN.

WARNING

ADVERTENCIA

T^{O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT USE}

^{THIS UNIT IF ANY PART HAS BEEN UNDER WATER.}I^{MMEDIATELY CALL A}

QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND TO REPLACE

ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL HAVING BEEN

UNDER WATER.

PELIGRO MONOXIDO DE CARBONO

TOXICO

EL FRACASO DE NO MANTENER

COMPARTIMIENTO CERRADO MENOS DURANTE,

ATENDER, PODRIA TENER COMO RESULTADO

ENVENENAR DE MONOXIDO DE CARBONO O

MUERTE.

ESTE COMPARTIMIENTO DEBE CERRADO MENOS

0140L00106

AL ATENDER

THIS UNIT MUST NOT BE USED AS A "CONSTRUCTION HEATER"

DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW

STRUCTURE. THIS TYPE OF USE MAY RESULT IN PREMATURE

FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR

TEMPERATURE AND EXPOSURE TO CORROSIVE OR VERY

DIRTY ATMOSPHERES.

GENERAL INFORMATION

WARNING

T^{O 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.

WARNING

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY

BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH.

This unit is approved for outdoor installation ONLY. 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 B149 Installa-

tion Codes.

WARNING

TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,

DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER

FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

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 withASHRAE Guide

or Manual J - Load Calculations published by the Air Condi-

tioning Contractors of America.

WARNING

HIGH VOLTAGE!

INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE

PERFORMED ONLY BY INDIVIDUALS MEETING THE

REQUIREMENTS OF AN “ENTRY LEVEL TECHNICIAN” AS

SPECIFIED BY THE AIR CONDITIONING AND

REFRIGERATION INSTITUTE (ARI). ATTEMPTING TO

INSTALL OR REPAIR THIS UNIT WITHOUT SUCH

BACKGROUND MAY RESULT IN PRODUCT DAMAGE,

PERSONAL INJURY OR DEATH.

Obtain from:

American National Standards Institute

1430 Broadway

New York, NY 10018

System design and installation should also, where applicable,

follow information presented in accepted industry guides such

as the ASHRAE Handbooks. The manufacturer assumes no

responsibility for equipment installed in violation of any code

or regulation. The mechanical installation of the packaged

roof top units consists of making final connections between

the unit and building services; supply and return duct con-

nections; and drain connections (if required). The internal

systems of the unit are completely factory-installed and tested

prior to shipment.

ALL INSTALLATIONS:

NOTE: Appliance is shipped from factory for vertical duct

application.

Proper installation of the unit ensures trouble-free operation.

Improper installation can result in problems ranging from

noisy operation to property or equipment damages, danger-

ous conditions that could result in injury or personal property

damage and could void the warranty. Give this booklet to the

user and explain it’s provisions. The user should retain these

instructions for future reference.

Units are generally installed on a steel roof mounting curb

assembly which has been shipped to the job site for installa-

tion on the roof structure prior to the arrival of the unit. The

model number shown on the unit’s identification plate identi-

fies the various components of the unit such as refrigeration

tonnage, heating input and voltage.

• For proper flame pattern within the heat exchanger

and proper condensate drainage, the unit must be

mounted level.

• The flue outlet 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.

• 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.

Carefully inspect the unit for damage including damage to

the cabinetry. Any bolts or screws which may have loosened

in transit must be re-tightened. In the event of damage, the

receiver should:

1. Make notation on delivery receipt of any visible

damage to shipment or container.

2. Notify carrier promptly and request an inspection.

3. In case of concealed damage, carrier should be

notified as soon as possible-preferably within 5 days.

4. File the claim with the following supporting documents:

a. Original Bill of Lading, certified copy, or indemnity

bond.

b. Original paid freight bill or indemnity in lieu thereof.

c. Original invoice or certified copy thereof, showing

trade and other discounts or reductions.

d. Copy of the inspection report issued by carrier

representative at the time damage is reported to the

carrier. 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.

• 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.

NOTE: When inspecting the unit for transportation damage,

remove all packaging materials. Recycle or dispose of the

packaging material according to local codes.

PRE-INSTALLATION CHECKS

Carefully read all instructions for the installation prior to in-

stalling unit. Ensure each step or procedure is understood

and any special considerations are taken into account be-

fore starting installation. Assemble all tools, hardware and

supplies needed to complete the installation. Some items may

need to be purchased locally.

• Allow minimum clearances from the enclosure for fire

protection, proper operation, and service access (see

unit clearances). These clearances must be

permanently maintained.

• The combustion air inlet and flue outlet on the unit

must never be obstructed. If used, do not allow the

economizer/manual fresh air damper/ motorized fresh

air damper to become blocked by snow or debris. In

some climates or locations, it may be necessary to

elevate the unit to avoid these problems.

UNIT LOCATION

WARNING

• When the unit is heating, the temperature of the return

air entering the unit must be between 50° F and 100°

T^{O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL}

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED

WHEN INSTALLING THE UNIT.

GROUND LEVEL INSTALLATIONS ONLY:

IMPORTANT NOTE: Remove wood shipping rails prior to

• When the unit is installed on the ground adjacent to

the building, a level concrete (or equal) base is

recommended. Prepare a base that is 3” larger than

the package unit footprint and a minimum of 3” thick.

installation of the unit.

Full perimeter roof curbs are available from the factory and

are shipped unassembled. Field assembly, squaring, level-

ing and mounting on the roof structure are the responsibility

of the installing contractor. All required hardware necessary

for the assembly of the sheet metal curb is included in the

curb accessory.

• The base should also be located where no runoff of

water from higher ground can collect in the unit.

ROOF TOP INSTALLATIONS ONLY:

• To avoid possible property damage or personal injury,

the roof must have sufficient structural strength to carry

the weight of the unit(s) and snow or water loads as

required by local codes. Consult a structural engineer

to determine the weight capabilities of the roof.

WARNING

• The unit may be installed directly on wood floors or

on ClassA, Class B, or Class C roof covering material.

• To avoid possible personal injury, a safe, flat surface

for service personnel should be provided.

• As indicated on the unit data plate, a minimum

clearance of 36” to any combustible material is

required on the furnance access side of the unit. All

combustible materials must be kept out of this area.

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED

WHEN INSTALLING THE UNIT.

• Sufficient structural support must be determined prior

to locating and mounting the curb and package unit.

• Ductwork must be constructed using industry

guidelines. The duct work must be placed into the

roof curb before mounting the package unit. Our full

perimeter curbs include duct connection frames to be

assembled with the curb. Cantilevered type curbs

are not available from the factory.

• This 36” clearance must also be maintained to insure

proper combustion air and flue gas flow. The

combustion air intake and furance flue discharge must

not be blocked for any reason, including blockage by

snow.

• Curb insulation, cant strips, flashing and general

roofing material are furnished by the contractor.

The curbs must be supported on parallel sides by roof mem-

bers. The roof members must not penetrate supply and re-

turn duct opening areas as damage to the unit might occur.

• Adequate clearances from the furnace flue discharge

to any adjacent public walkways, adjacent buildings,

building openings or openable windows must be

maintained in accordance with the latest edition of

the National Fuel Gas Code (ANSI Z223.1)

NOTE: The unit and curb accessories are designed to allow

vertical duct installation before unit placement. Duct

installaton after unit placement is not recommended.

• Minimum horizontal clearance of 48” from the furnace

flue discharge to any electric meters, gas meters,

regulators and relief equipment is required.

CAUTION

UNIT PRECAUTIONS

ALL CURBS LOOK SIMILAR. TO AVOID INCORRECT CURB

POSITIONING, CHECK JOB PLANS CAREFULLY AND VERIFY MARKINGS

ON CURB ASSEMBLY. INSTRUCTIONS MAY VARY IN CURB STYLES AND

SUPERSEDES INFORMATION SHOWN.

•

Do not stand or walk on the unit.

Do not drill holes anywhere in panels or in the base

frame of the unit. Unit access panels provide

structural support.

Do not remove any access panels until unit has been

installed on roof curb or field supplied structure.

Do not roll unit across finished roof without prior

approval of owner or achitect.

Do not skid or slide on any surface as this may

damage unit base. The unit must be stored on a

flat, level surface. Protect the condenser coil

because it is easily damaged.

See the manual shipped with the roof curb for assembly and

installation instructions.

•

CLEARANCES

ROOF CURB INSTALLATIONS ONLY:

48”

Curb installatons must comply with local codes and should

be done in accordance with the established guidelines of the

National Roofing Contractors Association.

48”

Proper unit installation requires that the roof curb be firmly

and permanently attached to the roof structure. Check for

adequate fastening method prior to setting the unit on the

curb.

75”

Unit Clearances

Adequate clearance around the unit should be kept for safety,

service, maintenance, and proper unit operation. Atotal clear-

ance of 75” on the main control panel side of the unit is rec-

ommended to facilitate possible fan shaft, coil, electric heat

and gas furnace removal. Aclearance of 48” is recommended

on all other sides of the unit to facilitate possible compressor

removal, to allow service access and to insure proper venti-

lation and condenser airflow. The unit must not be installed

beneath any obstruction. The unit should be installed re-

mote from all building exhausts to inhibit ingestion of exhaust

air into the unit fresh air intake.

CAUTION

IF PROTRUSIONS EXIST, DO NO ATTEMPT TO SET UNIT ON CURB.

ROOF TOP DUCT CONNECTIONS

Install all duct connections on the unit before placing the unit

on rooftop.

HORIZONTAL DISCHARGE

For horizontal discharge, remove the supply and return duct

covers and place them over the vertical discharge return and

supply openings. Install with insulation facing up, using the

longer screws provided in the literature package.

Ensure that the top of the duct connection frame is flush with

the top of the roof curb.

Flexible duct connectors between the unit and ducts are rec-

ommended. Insulate and weatherproof all external ductwork

and joints as required and in accordance with local codes.

11”

4 7/8””

REMOVE

COVERS

INSULATED

PANELS

17”

7 3/8”

25”

12”

SUPPLY

Roof Curb Installation

6 3/16”

Horizontal Discharge Duct Connections

ROOF CURB POST-INSTALLATION CHECKS

After installation, check the top of the curb, duct connection

frame and duct flanges to make sure gasket has been ap-

plied properly. Gasket should be firmly applied to the top of

the curb perimeter, duct flanges and any exposed duct con-

nection frame. If gasket is loose, re-apply using strong

weather resistant adhesive.

PROTRUSION

Inspect curb to ensure that none of the utility services (elec-

tric) routed through the curb protrude above the curb.

RIGGING DETAILS

WARNING

T^{O PREVENT PROPERTY DAMAGE, THE UNIT SHOULD REMAIN IN AN UPRIGHT}

^{POSITION DURING ALL RIGGING AND MOVING OPERATIONS.}T^{O FACILITATE}

LIFTING AND MOVING WHEN A CRANE IS USED, PLACE THE UNIT IN AN

ADEQUATE CABLE SLING.

CAUTION

IF UNITS ARE LIFTED TWO AT A TIME, THE FORK HOLES ON THE

CONDENSER END OF THE UNIT MUST NOT BE USED. MINIMUM FORK

LENGTH IS 42” TO PREVENT DAMAGE TO THE UNIT; HOWEVER, 48”

IS RECOMMENDED.

Provisions for forks have been included in the unit base frame. No other fork locations are approved.

WARNING

T^{O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL}

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED

WHEN INSTALLING THE UNIT.

•

Unit must be lifted by the four lifting holes located at the base frame corners.

Lifting cables should be attached to the unit with shackles.

The distance between the crane hook and the top of the unit must not be less than 60”.

Two spreader bars must span over the unit to prevent damage to the cabinet by the lift cables. Spreader bars must

be of sufficient length so that cables do not come in contact with the unit during transport. Remove wood struts

mounted beneath unit base frame before setting unit on roof curb. These struts are intended to protect unit base

frame from fork lift damage. Removal is accomplished by extracting the sheet metal retainers and pulling the struts

through the base of the unit. Refer to rigging label on the unit.

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.

To assist in determining rigging requirements, unit weights are shown as follows:

RETURN

CONDENSER

COIL

EVAPORATOR COIL

SUPPLY

COMPRESSOR

Corner & Center of Gravity Locations

Shipping Operating

Corner Weights ( lbs )

(in)

Model

Weight

(lbs)

Weight

(lbs)

CPG036045*

CPG036090*

CPG048090*

CPG048115*

CPG060090*

CPG060140*

CPG072140*

550

560

600

605

645

655

715

525

535

575

580

620

630

690

100

110

115

120

130

165

170

180

190

195

215

100

110

120

130

165

170

180

195

215

* Weights shown are belt drive with no accessories.

CAUTION

TO PREVENT SEVERE DAMAGE TO THE BOTTOM OF THE UNIT, DO NOT

FORK LIFT UNIT AFTER WOOD STRUTS HAVE BEEN REMOVED.

Bring condenser end of unit into alignment with the curb. With condenser end of the unit resting on curb member and using

curb as a fulcrum, lower opposite end of the unit until entire unit is seated on the curb. When a rectangular cantilever curb

is used, care should be taken to center the unit. Check for proper alignment and orientation of supply and return openings

with duct.

RIGGING REMOVAL

CAUTION

TO PREVENT DAMAGE TO THE UNIT, DO NOT ALLOW CRANE HOOKS

AND SPREADER BARS TO REST ON THE ROOF OF THE UNIT.

Remove spreader bars, lifting cables and other rigging equipment.

Electrical Code. If long wires are required, it may be neces-

sary to increase the wire size to prevent excessive voltage

drop. Wires should be sized for a maximum of 3% voltage

drop.

ELECTRICAL WIRING

WARNING

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY

BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH.

CAUTION

O AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE

ONLY COPPER CONDUCTORS.

WARNING

CAUTION

HIGH VOLTAGE!

T^{O PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING ERRORS,}

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

V^{ERIFY PROPER OPERATION AFTER SERVICING.}

TO AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DO NOT TAMPER WITH FACTORY

WIRING. THE INTERNAL POWER AND CONTROL WIRING

OF THESE UNITS ARE FACTORY-INSTALLED AND HAVE

BEEN THOROUGHLY TESTED PRIOR TO SHIPMENT.

CONTACT YOUR LOCAL REPRESENTATIVE IF

ASSISTANCE IS REQUIRED.

NOTE: A weather-tight disconnect switch, properly sized for

the unit total load, must be field installed. An external field

supplied disconnect may be mounted on the exterior panel.

Ensure the data plate is not covered by the field-supplied

disconnect switch.

CAUTION

•

Some disconnect switches are not fused. Protect the

power leads at the point of distribution in accordance

with the unit data plate.

TO PREVENT DAMAGE TO THE WIRING, PROTECT WIRING FROM

SHARP EDGES. FOLLOW NATIONAL ELECTRICAL CODE AND ALL

LOCAL CODES AND ORDINANCES. DO NOT ROUTE WIRES THROUGH

REMOVABLE ACCESS PANELS.

•

The unit must be electrically grounded in accordance

with local codes or, in the absence of local codes,

with the latest edition of the National Electrical Code

(ANSI-NFPA 70). A ground lug is provided for this

purpose. Size grounding conductor in accordance

with Table 250-95 of the National Electrical Code. Do

not use the ground lug for connecting a neutral

conductor.

CAUTION

CONDUIT AND FITTINGS MUST BE WEATHER-TIGHT TO PREVENT

WATER ENTRY INTO THE BUILDING.

For unit protection, use a fuse or HACR circuit breaker that is

in excess of the circuit ampacity, but less than or equal to the

maximum overcurrent protection device. DO NOT EXCEED

THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN

ON UNIT DATA PLATE.

•

Connect power wiring to the compressor contactor

closest to the entrance located within the main control

box.

MAIN POWER

LOW VOLTAGE

BLOCK

All line voltage connections must be made through weather-

proof fittings. All exterior power supply and ground wiring

must be in approved weatherproof conduit.

The main power supply wiring to the unit and low voltage

wiring to accessory controls must be done in accordance with

these instructions, the latest edition of the National Electriacl

Code (ANSI/NFPA 70), and all local codes and ordinances.

All field wiring shall conform with the temperature limitations

for Type T wire (63°F/35°C rise).

LOW VOLTAGE

ENTRANCE

POWER THRU

THE CURB

The main power supply for the CPG036XXX3,4,7 through

CPG072 shall be three-phase, three wire. The power sup-

ply for the CPG036XXX1 through CPG060 shall be single-

phase, two wire. The unit is factory wired for the voltage shown

on the unit’s data plate.

Power and Low Voltage Block Connections

WARNING

FAILURE OF UNIT DUE TO OPERATION ON IMPROPER LINE VOLTAGE

OR WITH EXCESSIVE PHASE UNBALANCE CONSTITUTES PRODUCT

ABUSE AND WILL VOID YOUR WARRANTY AND MAY CAUSE SEVERE

DAMAGE TO THE UNIT ELECTRICAL COMPONENTS.

NOTE: If supply voltage is 208V, lead on primary of trans-

former TRANS1 must be moved from the 230V to the 208V

tap.

Main power wiring should be sized for the minimum wire

ampacity shown on the unit’s database. Size wires in accor-

dance with the ampacity tables in Article 310 of the National

Areas Without Convenience Outlet

2. Locate thermostat or remote sensor in the conditioned

space where it will sense average temperature. Do

not locate the device where it may be directly exposed

to supply air, sunlight or other sources of heat. Follow

installation instructions packaged with the thermostat.

3. Use #18 AWG wire for 24V control wiring runs not

exceeding 75 feet. Use #16AWG wire for 24V control

wiring runs not exceeding 125 feet. Use #14 AWG

wire for 24V control wiring runs not exceeding 200

feet. Low voltage wiring may be National Electrical

Code (NEC) Class 2 where permitted by local codes.

4. Route thermostat wires from sub-base terminals to

the unit. Control wiring should enter through the

condenser end of unit or through curb. Connect

thermostat and any accessory wiring to low voltage

terminal block TB1 in the main control box.

It is recommended that an independant 115V power source

be brought to the vicinity of the roof top unit for portable lights

and tools used by the service mechanic.

UNITS INSTALLED ON ROOF TOPS

Main power and low voltage wiring may enter the unit through

the condenser end of unit or through the roof curb. Install

conduit connectors at the desired entrance locations. Exter-

nal connectors must be weatherproof. All holes in the unit

base must be sealed (including those around conduit nuts)

to prevent water leakage into building. All required conduit

and fittings are to be field supplied.

Supply voltage to roof top unit must not vary by more than

10% of the value indicated on the unit data plate. Phase

voltage unbalance must not exceed 2%. Contact your local

power company for correction of improper voltage or phase

unbalance.

NOTE: Field-supplied conduit may need to be installed

depending on unit/curb configuration. Use #18 AWG solid

conductor wire whenever connecting thermostat wires to

terminals on sub-base. DO NOT use larger than #18 AWG

wire. A transition to #18 AWG wire may be required before

entering thermostat sub-base.

HIGH VOLTAGE ENTRANCE

(REMOVE PLUG)

12 3/8”

LEAD

Red

THERMOSTAT

R (24V)

Green

Yellow

Purple

Blue

White

Brown

G (Fan)

30 1/4”*

Y1 (High Cool)

Y2 (Low Cool)

Common (if req'd)

W1 (Heat)

W2 (High Heat)

CPG 036 Thru 072 (Gas Heat)

1:4

* (6 Ton - 34 1/4”)

LOW VOLTAGE ENTRANCE

GAS SUPPLY PIPING

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER

INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR

MAINTENANCE, REFER TO THIS MANUAL. FOR ADDITIONAL

ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER,

SERVICE AGENCY OR THE GAS SUPPLIER.

3.5 DIA.

POWER THRU

THE CURB

IMPORTANT NOTE: This unit is factory set to operate on

natural gas at the altitudes shown on the rating plate.

41/2”

WARNING

47 1/2”

7 1/2”

TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH WHEN

EITHER USING PROPANE GAS ALONE OR AT HIGHER ALTITUDES,

OBTAIN AND INSTALL THE PROPER CONVERSION KIT(S). FAILURE TO

DO SO CAN RESULT IN UNSATISFACTORY OPERATION AND/OR

EQUIPMENT DAMAGE. HIGH ALTITUDE KITS ARE FOR U.S.

Electrical Entrance and Thru Curb

Unit is equipped with a Low Voltage Terminal Block and has

Single Point wiring to the contactor.

INSTALLATIONS ONLY AND ARE NOT APPROVED FOR USE IN CANADA.

LOW VOLTAGE CONTROL WIRING

The rating 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. Conversion to propane

1. A24V thermostat must be installed for unit operation.

It may be purchased with the unit or field -supplied.

Thermostats may be programmable or

electromechanical as required.

(LP) gas is permitted with the use of the factory authorized

conversion kit (see the unit Technical Manual for the appro-

priate kit). For HighAltitude derates, refer to the latest edition

of the National Fuel Gas Code NFPA 54/ANSI Z223.1.

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.

INLET GAS PRESSURE

6. Install a manual shut-off valve in a convenient location

(within six feet of unit) between the meter and the

unit.

Min. 5.0" W.C., Max. 10.0" W.C.

Min. 11.0" W.C., Max. 14.0" W.C.

NATURAL

PROPANE

7. Tighten all joints securely.

8. The unit must be connected to the building piping by

one of the following methods:

IInlet Gas Pressure Must Not Exceed the Maximum Value Shown in Table

Above.

•

Rigid metallic pipe and fittings

The minimum supply pressure should not vary from that

shown in the table above because this could prevent the unit

from having dependable ignition. In addition, gas input to the

burners must not exceed the rated input shown on the rating

plate. Overfiring of the unit could result in premature heat

exchanger failure.

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).

•

PIPING

IMPORTANT NOTE: To avoid possible unsatisfactory opera-

tion or equipment damage due to under firing of equipment,

do not undersize the natural/propane gas piping from the

meter/tank to the unit. When sizing a trunk line, include all

appliances on that line that could be operated simultaneously.

The rating 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. 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.

BURNER

DOOR

Natural Gas Connection

Natural Gas Capacity of Pipe

in Cubic Feet of Gas Per Hour (CFH)

TBD

Nominal Black Pipe Size (inches)

Length of

Pipe in Feet

1/2

132

3/4

278

190

152

130

115

105

1/4

1050

730

590

500

440

400

370

350

320

305

1/2

1600

1100

980

760

670

610

560

530

490

460

100

520

350

285

245

215

195

180

170

160

150

MANUAL

SHUT-OFF

DRIP

LEG

GROUND JOINT

UNION

Pressure = .50 PSIG or less and Pressure Drop of 0.3" W.C. (Based

on 0.60 Specific Gravity Gas)

Proper Piping Practice

BTUH Furnace Input

NOTE: The unit gas supply entrance is factory sealed with

plugs. Keep plugs in place until gas supply is ready to be

installed. Once ready, replace the plugs with the supplied

grommets and install gas supply line.

CFH =

Heating Value of Gas (BTU/Cubic Foot)

Refer to the Proper Piping Practice drawing for the general

layout at the unit. The following rules apply:

1. Use black iron pipe and fittings for the supply piping.

The use of a flex connector and/or copper piping is

permitted as long as it is in agreement with local

codes.

2. Use pipe joint compound on male threads only. Pipe

joint compound must be resistant to the action of the

fuel used.

3. Use ground joint unions.

1. Vaporization rate, which depends on (a) temperature

of the liquid, and (b) wetted surface area of the

container or containers.

GAS PIPING CHECKS

CAUTION

2. Proper pressure regulation.

T_{O PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, THE}

FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS

CONNECTIONS AND PRESSURE TESTING:

3. Pressure drop in lines between regulators, and

between second stage regulator and the appliance.

Pipe size required will depend on length of pipe run

and total load of all appliances.

^•T^{HE UNIT AND ITS GAS CONNECTIONS MUST BE LEAK TESTED BEFORE}

^{PLACING IN OPERATION.}B^{ECAUSE OF THE DANGER OF EXPLOSION OR}

^{FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.}N^EVER

^{EXCEED SPECIFIED PRESSURES FOR TESTING.}H^{IGHER PRESSURE MAY}

DAMAGE GAS VALVE AND CAUSE OVERFIRING WHICH MAY RESULT IN

PREMATURE HEAT EXCHANGE FAILURE.

TANKS AND PIPING

Complete information regarding tank sizing for

vaporization, recommended regulator settings and pipe

sizing is available from most regulator manufacturers and

propane gas suppliers.

^•T^{HIS UNIT AND ITS SHUT-OFF VALVE MUST BE DISCONNECTED FROM}

THE GAS SUPPLY DURING ANY PRESSURE TESTING OF THAT SYSTEM AT

^{TEST PRESSURES IN EXCESS OF 1/2}PSIG ^{(3.48 K}P^A).

Since propane gas will quickly dissolve white lead or most

standard commercial compounds, special pipe dope

must be used. Shellac base compounds resistant to the

actions of liquefied petroleum gases such as Gasolac^®,

Stalactic^®, Clyde’s^®or John Crane^®are satisfactory.

See below for typical propane gas piping.

^•T^{HIS UNIT MUST BE ISOLATED FROM THE GAS SUPPLY SYSTEM BY}

CLOSING ITS MANUAL SHUT-OFF VALVE DURING ANY PRESSURE

TESTING OF THE GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES

^{EQUAL TO OR LESS THAN 1/2}PSIG ^{(3.48 K}P^A).

WARNING

, BE SURE THERE IS

T^{O AVOID PROPERTY DAMAGE OR PERSONAL INJURY}

5 to 15 PSIG

(20 PSIG Max.)

First Stage

Regulator

NO OPEN FLAME IN THE VICINITY DURING AIR BLEEDING.

Continuous

11" W.C.

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 by loosening the ground joint union until pure gas is

expelled. Tighten union and wait for five minutes until all gas

has been dissipated in the air. Be certain there is no open

flame in the vicinity during air bleeding procedure. The unit is

placed in operation by closing the main electrical disconnect

switch for the unit.

200 PSIG

Maximum

Second Stage

Regulator

Typical Propane Gas Piping

ROOF TOP LOCATION AND INSTALLATION

PROPANE GAS INSTALLATIONS

The gas supply piping location and installation for roof top

units must be in accordance with local codes or, in the ab-

sence of locals codes, with ordinances of the latest edition of

the National Fuel Gas Code (ANSI Z223.1).

WARNING

T^{O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE}

A manual gas shutoff valve must be field installed external to

the roof top unit. In addition, a drip leg must be installed near

the inlet connection. A ground joint union connection is re-

quired between the external shutoff valve and the unit con-

nection to the gas valve to permit removal of the burner as-

sembly for servicing.

OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS

DETECTING WARNING DEVICE. INCE 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.

ONTACT A LOCAL PROPANE GAS SUPPLIER ABOUT INSTALLING A

GAS DETECTING WARNING DEVICE.

1. Route gas piping to unit so that it does not interfere

with the removal of access panels. Support and align

piping to prevent strains or misalignment of the

manifold assembly.

IMPORTANT NOTE: Propane gas conversion kits must be

installed to convert units to propane gas. NOx screens must

be removed before converting to LP. Remove burner

assembly and pull NOx screens from each burner tube. When

all the screens are out, reassemble the burner assembly

without the screens.

2. All units are furnished with standard female NPT pipe

connections. Connection pipe sizes for CPG036

through 072 units is 1/2" NPT on 045 to 140 mBH

units. The size of the gas supply piping to the unit

must be based on length of run, number of units on

the system, gas characteristics, BTU requirement and

available supply pressure. All piping must be done in

accordance with local codes or, in the absence of local

codes, with the latest edition of the National Fuel Gas

Code (ANSI Z223.1).

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 within 9.7 - 10.3 inches W.C. at the manifold with all gas

appliances in operation. Maintaining proper gas pressure

depends on three main factors:

NOTE: The gas connection size at the unit does NOT

establish the size of the supply line.

CIRCULATING AIR AND FILTERS

3. These units are designed for either natural or propane

(LP) gas and are specifically constructed at the factory

for only one of these fuels. The fuels are NOT

interchangeable. However, the furnace can be

converted in the field from natural gas to LP gas with

the appropriate factory kit (see unit Technical Manual

for the appropriate kit). Only a qualified contractor,

experienced with natural and propane gas systems,

should attempt conversion. Kit instructions must be

followed closely to assure safe and reliable unit

operation.

4. With all units on a common line operating under full

fire, natural gas main supply pressure should be

adjusted to approximately 7.0" w.c., measured at the

unit gas valve. If the gas pressure at the unit is greater

than 10.5" w.c., the contractor must furnish and install

an external type positive shutoff service pressure

regulator. The unit will not function satisfactorily if

supply gas pressure is less than 5.5" w.c. or greater

than 10.5" w.c..

DUCTWORK

The supply duct should be provided with an access panel

large enough to inspect the air chamber downstream of the

heat exchanger. A cover should be tightly attached to pre-

vent air leaks.

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.

VENTING

NOTE: Venting is self-contained.

CONDENSATE DRAIN CONNECTION

NOTE: A minimum horizontal distance of 48"

between the regulator and the furnace flue discharge

is required.

A 3/4” NPT drain connection is supplied for condensate pip-

ing. An external trap must be installed for proper condensate

drainage.

5. With all units on a common line operating under full

LP gas main supply pressure should be at least 11.0"

w.c. and must be no greater than 13.0" w.c., measured

at the unit gas valve. Unit will not function satisfactorily

if supply gas pressure is less than 11.0" w.c. or greater

than 13.0" w.c..

DRAIN

CONNECTION

UNIT

2" MINIMUM

6. All pipe connections should be sealed with a pipe

thread compound, which is resistant to the fuel used

with the furnace. A soapy water solution should be

used to check all joints for leaks. A tap is located on

the entering side of the gas valve for test gauge

connection to measure supply (main) gas pressure.

Another tap is provided on the manifold side of the

gas valve for checking manifold pressure.

FLEXIBLE

TUBING-HOSE

OR PIPE

3" MINIMUM

A POSITIVE LIQUID

SEAL IS REQUIRED

Drain Connection

Install condensate drain trap as shown. Use 3/4" drain line

and fittings or larger. Do not operate without trap.

WARNING

HORIZONTAL DRAIN

THIS UNIT AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE

DISCONNECTED FROM THE GAS SUPPLY SYSTEM DURING ANY

PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN

Drainage of condensate directly onto the roof may be ac-

ceptable; refer to local code. It is recommended that a small

drip pad of either stone, mortar, wood or metal be provided to

prevent any possible damage to the roof.

EXCESS OF 1/2 PSIG (13.8”

W.C.).

CAUTION

CLEANING

Due to the fact that drain pans in any air conditioning unit

will have some moisture in them, algae and fungus will

grow due to airborne bacteria and spores. Periodic clean-

ing is necessary to prevent this build-up from plugging the

drain.

THIS UNIT MUST BE ISOLATED FROM THE GAS SUPPLY PIPING

SYSTEM BY CLOSING ITS INDIVIDUAL MANUAL SHUTOFF VALVE

DURING ANY PRESSURE TESTING EQUAL TO OR LESS THAN 1/2

PSIG.

7. There must be no obstruction to prevent the flow of

combustion and ventilating air. A vent stack is not

required and must never be used. The power venter

will supply an adequate amount of combustion air as

long as the air passageways are kept free of any

obstructions and the recommended external unit

clearances are maintained.

TOOLS REQUIRED

STARTUP, ADJUSTMENTS, AND CHECKS

Refrigeration gauge and manifold

Voltmeter

Clamp-on ammeter

WARNING

Ohmmeter

Test lead

HIGH VOLTAGE!

TO AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, BOND THE FRAME OF THIS UNIT TO

THE BUILDING ELECTRICAL GROUND BY USE OF THE

GROUNDING TERMINAL PROVIDED OR OTHER

ACCEPTABLE MEANS. DISCONNECT ALL POWER BEFORE

SERVICING OR INSTALLING THIS UNIT.

(Minimum #16 AWG with insulated alligator clips)

Manometer for verifying gas pressure 0 to 20" w.c.

Air temperature measuring device

General refrigeration mechanics’ tools

TEMPORARY HEATING OR COOLING

PRE-STARTUP INSTRUCTIONS

If the unit is to be used for temporary heating or cooling, a

“Startup, Adjustments, and Checks” must first be performed

in accordance with this manual. Failure to comply with this

requirement will void the warranty. After the machines are

used for temporary heating or cooling, inspect the coils, fans,

and motors for unacceptable levels of construction dust and

dirt and install new filters.

CAUTION

TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY, DO NOT

START THE UNIT UNTIL ALL NECESSARY PRE-CHECKS AND TESTS

HAVE BEEN PERFORMED.

Prior to the beginning of Startup, Adjustments, and Checks

procedures, the following steps should be completed in the

building.

CONTRACTOR RESPONSIBILITY

The installing contractor must be certain that:

THERMOSTAT. Set the thermostat in the conditioned

space at a point at least 10°F below zone temperature.

Set the thermostat system switch on COOL and the

fan switch on AUTO.

•

All supply and return air ductwork is in place and

corresponds with installation instructions.

All thermostats are mounted and wired in accordance

with installation instructions.

All electric power, all gas, hot water or steam line

connections, and the condensate drain installation

have been made to each unit on the job. These main

supply lines must be functional and capable of

operating all units simultaneously.

WARNING

MOVING MACHINERY HAZARD!

TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH, DISCONNECT

POWER TO THE UNIT AND PADLOCK IN THE “OFF” POSITION BEFORE

SERVICNG FANS.

ROOF CURB INSTALLATION CHECK

HEATING STARTUP

Inspect the roof curb for correct installation. The unit and curb

assembly should be level. Inspect the flashing of the roof

mounting curb to the roof, especially at the corners, for good

workmanship. Also check for leaks around gaskets. Note any

deficiencies in a separate report and forward to the contrac-

tor.

This unit is equipped with an electronic ignition device to au-

tomatically 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 re-

placed, 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 ob-

structions in or near the blower motors. Duct covers must

be removed before operating unit.

OBSTRUCTIONS, FAN CLEARANCE AND WIRING

Remove any extraneous construction and shipping materi-

als that may be found during this procedure. Rotate all fans

manually to check for proper clearances and that they rotate

freely. Check for bolts and screws that may have jarred loose

The Startup, Adjustments, and Checks procedure provides a during shipment to the jobsite. Retighten if necessary. Re-

step-by-step sequence which, if followed, will assure the tighten all electrical connections.

proper startup of the equipment in the minimum amount of

time. Air balancing of duct system is not considered part of

this procedure. However, it is an important phase of any air

conditioning system startup and should be performed upon

completion of the Startup, Adjustments, and Checks proce-

dure. The Startup, Adjustments, and Checks procedure at

outside ambients below 55°F should be limited to a readi-

ness check of the refrigeration system with the required final

check and calibration left to be completed when the outside

ambient rises above 55°F.

PRE-STARTUP PRECAUTIONS

It is important to your safety that the unit has been properly

grounded during installation. Check ground lug connection

in main control box for tightness prior to closing circuit breaker

or disconnect switch. Verify that supply voltage on line side

of disconnect agrees with voltage on unit identification plate

and is within the utilization voltage range as indicated in

Appendix C Electrical Data.

System Voltage - That nominal voltage value assigned to a

circuit or system for the purpose of designating its voltage

class.

SET EVAPORATOR FAN RPM

Actual RPM’s must be set and verified with a tachometer or

strobe light. Refer to Appendices A and B for basic unit fan

RPM. Refer also to “Airflow” section of this manual. With

disconnect switch open, disconnect thermostat wires from

terminals Y and W. This will prevent heating and mechanical

cooling from coming on. Place a jumper wire across termi-

nals R and G at TB1 terminal block. Close disconnect switch;

evaporator fan motor will operate so RPM can be checked.

Nameplate Voltage - That voltage assigned to a piece of

equipment for the purpose of designating its voltage class

and for the purpose of defining the minimum and maximum

voltage at which the equipment will operate.

Utilization Voltage - The voltage of the line terminals of the

equipment at which the equipment must give fully satisfac-

tory performance. Once it is established that supply voltage

will be maintained within the utilization range under all sys-

tem conditions, check and calculate if an unbalanced condi-

tion exists between phases. Calculate percent voltage un-

balance as follows.

For gas heat units, the airflow must be adjusted so that the

air temperature rise falls within the ranges given stated on

Data Plate (see Appendix A - Blower Performance).

TENSION AND ALIGNMENT ADJUSTMENT

Correct belt tension is very important to the life of your belt.

Too loose a belt will shorten its life; too tight, premature mo-

tor and bearing failure will occur. Check you belt drive for

adequate “run-in” belt tension by measuring the force required

to deflect the belt at the midpoint of the span length. Belt

tension force can be measured using a belt tension gauge,

available through most belt drive manufacturers.

Three Phase Models Only

2) MAXIMUM VOLTAGE DEVIATIONS

FROM AVERAGE VOLTAGE

3) PERCENT VOLTAGE

UNBALANCE

= 100 X

1) AVERAGE VOLTAGE

HOW TO USE THE FORMULA:

EXAMPLE: With voltage of 220, 216, and 213

1) Average Voltage = 220+216+213=649 / 3 = 216

2) Maximum Voltage Deviations from Average Voltage = 220 - 216 = 4

216

400

216

3) Percent Voltage Unbalance = 100 x

= 1.8%

Percent voltage unbalance MUST NOT exceed 2%

FIELD DUCT CONNECTIONS

Verify that all duct connections are tight and that there is no

air bypass between supply and return.

CONTROL VOLTAGE CHECK

With disconnect switch in the open “OFF” position, discon-

nect blue wire from low voltage transformer TRANS1. Close

Belt Tension Adjustment

the disconnect switch to energize TRANS1 control trans- t = Span length, inches

former. Check primary and secondary (24V) of control trans-

former TRANS1.

C = Center distance, inches

D = Larger sheave diameter, inches

d = Smaller sheave diameter, inches

THERMOSTAT PRELIMINARY CHECK

h = Deflection height, inches

With disconnect switch open and blue wire disconnected from

TRANS1 transformer, attach one lead of ohmmeter to termi-

nal R on TB1 terminal block. Touch, in order, the other ohm-

meter lead to terminals Y1, Y2 and G at TB1 terminal block.

There must be continuity from terminal R to terminals Y and

G. R to Y indicates cool. R to G indicates fan (auto). Replace

blue wire on TRANS1 transformer.

SMALL

DEFLECTION

FORCE (lbs)

TYPE

SHEAVE

DIAMETER

(in)

DEFLECTION

(in)

BELT DRIVE

USED

NEW

Standard 3.0 to 4.0 4.2 ± 0.5 5.5 ± 0.5

0.313

Recommended Pounds of Force Per Belt

New V-belts will drop rapidly during the first few hours of use.

Check tension frequently during the first 24 hours of opera-

tion. Tension should fall between the minimum and maximum

force. To determine the deflection distance from a normal

position, measure the distance from sheave to sheave using

a straightedge or a cord. This is your reference line. On mul-

tiple belt drives, an adjacent undeflected belt can be used as

a reference.

FILTER SECTION CHECK

Remove filter section access panels and check that filters

are properly installed. Note airflow arrows on filter frames.

BELT DRIVE MODELS ONLY

BEARING CHECK

Prior to energizing any fans, check and make sure that all

setscrews are tight so that bearings are properly secured to

shafts.

EVAPORATOR FAN ROTATION CHECK (THREE PHASE MODELS

ONLY)

If the power to the unit is interrupted during the heating cycle,

it may cause the secondary limit to trip. Once the blower com-

partment temperature drops below the limit reset tempera-

ture, the limit will automatically reset. The unit will restart

after one (1) hour.

Check that fan rotates clockwise when viewed from the drive

side of unit and in accordance with rotation arrow shown on

blower housing. If it does not, reverse any two incoming power

cables at Single Point Power Block. In this case, repeat bear-

ing check.

Pre-Operation Checks

1. Close the manual gas valve external to the unit.

2. Turn off the electrical power supply to the unit.

3. Set the room thermostat to its lowest possible setting.

4. Remove the heat exchanger door on the side of the

unit by removing screws.

Do not attempt to change load side wiring. Internal wiring

assures all motors and compressors will rotate in correct di-

rection once evaporator fan motor rotation check has been

made.

5. This unit is equipped with an ignition device which

automatically lights the main burner. DO NOT try to

light burner by any other method.

6. Move the gas control valve switch to the OFF position.

Do not force.

7. Wait five minutes to clear out any gas.

8. 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 3 of

this manual. If having waited for five minutes and no

gas smell is noted, move the gas control valve switch

to the ON position.

ELECTRICAL INPUT CHECK

Make preliminary check of evaporator fan ampere draw and

verify that motor nameplate amps are not exceeded. A final

check of amp draw should be made upon completion of air

balancing of the duct system (see Appendix C).

RESTORING CONNECTIONS

With disconnect switch open, remove jumper wire from ter-

minals R and G at TB1 terminal block, and reconnect ther-

mostat wires to terminals Y and W.

REFRIGERATION SYSTEM CHECKS

9. Replace the heat exchanger door on the side of the

unit.

10. Open the manual gas valve external to the unit.

11. Turn on the electrical power supply to the unit.

12. Set the thermostat to desired setting.

Ensure the hold-down bolts on the compressor are secure

and have not vibrated loose during shipment. Check that vi-

bration grommets have been installed. Visually check all pip-

ing and clamps. The entire refrigeration system has been

factory charged and tested, making it unnecessary to field

charge. Factory charges are shown in Appendix C and on

the unit nameplate.

Gas Supply And Manifold Check

Gas supply pressure and manifold pressure with the burners

operating must be as specified on the rating plate.

Install service manifold hoses. Gauges should read satura-

tion pressure corresponding to ambient temperature. Charge

should be checked to obtain 12° to 15° of sub-cooling per

system (i.e. compressor circuits).

Gas Inlet Pressure Check

Gas inlet pressure must be checked and adjusted in accor-

dance to the type of fuel being consumed.

With Power And Gas Off:

Rollout Protection Control

1. Connect a water manometer or adequate gauge to

the inlet pressure tap of the gas valve.

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. The reason for

elevated temperatures at the control should be

determined and repaired prior to resetting this manual

reset control.

Inlet gas pressure can also be measured by removing

the cap from the dripleg and installing a predrilled cap

with a hose fitting.

With Power And Gas On:

2. Put unit into heating cycle and turn on all other gas

consuming appliances.

WARNING

INLET GAS PRESSURE

T^{O 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.

Min. 5.0" W.C., Max. 10.0" W.C.

Min. 11.0" W.C., Max. 14.0" W.C.

NATURAL

PROPANE

Secondary Limit Control

NOTE: Inlet Gas Pressure Must Not Exceed the Maximum

Value Shown.

The secondary limit control is located on the top of the blower

scroll assembly. This control opens when elevated tempera-

tures are sensed. Elevated temperatures at the control are

normally caused by blower failure. The reason for the open-

ing should be determined and repaired prior to resetting.

If operating pressures differ from above, make necessary

pressure regulator adjustments, check piping size, etc., and/

or consult with local utility.

Manifold Pressure Check

4. Relight all other appliances turned off in step 1. Be

sure all pilot burners are operating.

The gas valve has a tapped opening to facilitate measure-

ment of the manifold pressure. A “U” Tube manometer hav-

ing 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.

Main Burner Flame Check

Flames should be stable, soft and blue (dust may cause or-

ange tips but they must not be yellow) and extending directly

outward from the burner without curling, floating or lifting off.

1. With disconnect switch open, remove field connected

thermostat wire from terminal R, W1 and W2 on TB1.

Place jumper wire between R, W1 and W2 to engage

high stage heat. (note on 045 kbtu/hr units W2 is not

used, only jumper R to W1).

NOx Screen Check

Verify that the alignment of the NOx screens is at 6 o' clock.

In jurisdictions that do not require low NOx emissions, NOx

screens may be removed.

2. See Figure in input rating section for gas valve

adjustment.

Temperature Rise Check

Check the temperature rise through the unit by placing ther-

mometers 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.

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 rat-

ing plate.

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.

For natural gas, the high stage manifold pressure must be

between 3.2 and 3.8 inches water column (3.5 nominal). Low

stage manifold pressure must be between 1.7 to 2.3 inches

water column (2.0 nominal).

With a properly designed system, the proper amount of tem-

perature rise will normally be obtained when the unit is oper-

ated at rated input with the recommended blower speed.

3. To set low fire rate on 090, 115 and 140 kbtu/hr: Open

disconnect switch, and remove jumper from R to W2.

To set low fire manifold pressure, repeat steps above.

Refer to Figure in input rating section for location of

high and low stage adjustment.

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.Aslower blower

speed will increase the temperature rise.

For propane gas, the manifold pressure must be between

9.7 and 10.3 inches water column (10.0 nominal). Low stage

manifold must be between 5.7 and 6.3 inches water column

(6.0 nominal).

NOTE: Blower speed MUST be set to give the correct air

temperature rise through the unit as marked on the rating

plate.

REFRIGERATION SEQUENCE CHECK

Gas Input (Natural Gas Only) Check

With the disconnect switch open, remove the field connected

thermostat wire from terminal R on TB1 terminal block. Place

a jumper across terminals R and G, and across R and Y on

TB1 terminal block. Close the disconnect switch. The follow-

ing operational sequence should be observed.

To measure the gas input use a gas meter and 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:

1. Current through primary winding of transformer

TRANS1 energizes the 24-volt control circuit.

2. To simulate a mechanical call for cooling from the wall

thermostat, place a jumper across terminals R and Y

of terminal block TB1. The cooling is energized when

the room temperature is above the thermostat set-

point for cooling. The thermostat makes R to Y.

3. UNIT WITH ECONOMIZER OPTION: The

compressor circuit is interlocked through terminals 3

and 4 of the economizer module. If the outdoor air

enthalpy (temperature and humidity) is not suitable

for cooling, the economizer terminals will be closed

permitting compressor to be energized.

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.

4. The belt drive blower contactor closes its contacts L1,

L2 and L3 to T1, T2 and T3 to provide power to the

supply fan motor.

7. Disconnecting the jumper wire between R and Y and

between R and G on TB1 terminal block will simulate

a satisfied thermostat. The compressor will cycle off

and IIC (pin 12) will initiate its time delay cycle. The

compressor and the supply fan will cycle off.

8. After a time delay of approximately 3 minutes, the

compressor control circuits will be ready to respond

to a subsequent call for cooling from the wall

thermostat.

PSC Motor

Adjust the CFM for the unit by changing the speed

tap of the indoor blower motor at the EBTDR “com”

connection with one of the speed taps on “M1” or “M2”.

(Black-High Speed, Blue-Medium Speed, Red-Low

Speed.)

9. Open disconnect switch. Reconnect the field

thermostat wire at terminal R on terminal block TB1.

EEM Motor

Adjust the CFM for the unit by changing the position

of the low voltage leads on the motor terminal block.

White is for fan only and gas heat, Yellow is for cooling.

Refer to Appendix A for blower performance at each

speed tap. NOTE: If more than one lead is energized

simultaneously, the motor will run at the higher speed.

5. Check supply fan rotation. If the supply fan is rotating

in the wrong direction, disconnect and lock off Single

Point Power Block. Do not attempt to change load

side wiring. Internal wiring is set at the factory to assure

that the supply fan and compressors all rotate in the

proper direction. Verification of correct supply fan

rotation at initial startup will also indicate correct

compressor rotation. Reconnect power and check for

proper operation.

REFRIGERATION PERFORMANCE CHECK

Under normal summertime (full load) operating conditions,

superheat should be between 8°F and 12°F and sub-cooling

measured at the condenser outlet should be 15°F (nominal).

A 25°F to 35°F temperature difference should exist between

the entering condenser air and the temperature correspond-

ing to the compressor saturated discharge pressure. Check

that compressor RLA corresponds to values shown in Ap-

pendix C. RLA draw can be much lower than values listed at

low load conditions and low ambient condensing tempera-

tures. Values in Appendix C can slightly exceed at high load

conditions and high ambient condensing temperatures.

GAS SUPPLY PRESSURES & REGULATOR ADJUSTMENTS

6. Compressor contactor closes its contacts L1, L2 and

L3 to T1, T2 and T3 to provide power to the

compressor motor COMP. 1. In addition, contactor C1

closes its contact L3 to T3 , energizing the condenser

fan motor.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT

OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE

UNIT BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

WARNING

BURN HAZARD!

DO NOT TOUCH! DISCHARGE LINE MAY BE HOT!

WARNING

TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO

NOT FIRE GAS UNIT WITH FLUE BOX COVER REMOVED.

7. Check that the compressor is operating correctly. The

scroll compressors in these units MUST operate in

the proper rotation. To ensure the compressors are

operating in the correct direction, check the

compressor discharge line pressure or temperature

after the compressor is started.

NOTE: Except during brief periods when gas pressures are

being measured by qualified service personnel, the furnace

access panel must always be secured in place when the

furnace is in operation.An inspection port in the access panel

is provided to monitor the flame.

The discharge pressure and discharge line

temperature should increase. If this does not occur

and the compressor is producing an exceptional

amount of noise, perform the following checks.

• Ensure all compressors and the supply fan motor

are operating in the proper direction. If a single motor

is operating backwards, check the power wiring for

that motor and correct any leads that have been

interchanged at the contactor or at the motor.

• If all of the motors are operating backward,

disconnect the unit power supply and lock it in the

“OFF” position. Switch two leads of the power supply

at the unit Single Point Power Block. Reconnect

power and check for compressor and supply fan

motor operation.

The first step in checking out the gas-fired furnace is to test

the gas supply piping to the unit for tightness and purge the

system of air using methods outlined in the latest edition of

the National Fuel Gas Code ANSI Z223.1. Verify that the

disconnect switch is in the “OFF” position. A soapy water

solution should be used to check for gas leaks. Since the unit

is subject to considerable jarring during shipment, it is ex-

tremely important that all gas connections and joints be tested

for tightness. Gas piping downstream from the unit inlet should

be checked for leaks during the subsequent sequence check.

The supply gas pressure should be adjusted to 7.0" w.c. on

natural gas and 11.0" on LP gas with the gas burners operat-

ing. If there is more than one unit on a common gas line, the

pressures should be checked with all units under full fire. A

6. With all safety devices closed, the system will continue

cooling operation until the thermostat is satisfied.

supply pressure tap is provided on the upstream side of the

gas valve. A manifold pressure tap is provided on the gas

valve. The normal manifold pressure for full input is 3.5" w.c.

on natural gas and 9.5" w.c. for propane gas. Low fire natu-

ral gas 2.0” w.c., 6.0” low fire propane gas. Minimum gas

supply pressure is 5.5" w.c. for natural gas and 11.0" for pro-

pane gas. In order to obtain rating, gas supply pressure must

be 11.0" w.c. for propane gas.

3. Remove the heat exchanger door on the side of the

unit by removing screws.

4. Move the gas control valve switch to the OFF position.

Do not force.

5. Close manual gas shutoff valve external to the unit.

6. Replace the heat exchanger door on the unit.

7. If cooling and/or air circulation will be desired, turn

ON the electrical power.

The pressure regulator on LP gas models is adjusted for 9.5"

w.c. manifold pressure and is intended to prevent over-firing

only. Do not attempt adjustment of the built-in pressure regu-

lator unless the supply pressure is at least 7.0" w.c. on natu-

ral gas or 13.0" w.c. on propane gas. Check the location of

the ignition electrode and the flame sensor for correct gap

setting.

NORMAL SEQUENCE OF OPERATION

HEATING

This unit has one (RS) Manual Reset Limit Control Switch.

Check the limit to make sure it has not tripped. The limit may

arrive at the job site tripped as a result of shipping shock.

If the ventermotor comes on, but the unit does not attempt

ignition, check if theALS (Auxiliary High Limit Control Switch)

requires resetting.

1. With electricity and gas turned on, the system switch

in the “HEAT” or “AUTO” position and the fan switch

in the “AUTO” position, the thermostat will close the

circuit between unit terminals R and W (R-W) when

the temperature falls below the thermostat setting.

2. D1 on IIC energizes relay IDMR.

3. Relay IDMR energizes the ventermotor IDM.

4. Operation of the ventermotor closes the pressure

switch PS located in the burner compartment. Unless

excessive temperatures or shipping shock have

opened high limit control ALS, power is fed to the

integrated ignition control, which then initiates a 15-

second pre-purge time delay. During this period, the

ventermotor will clear the combustion chamber of any

residual gas.

5. After the pre-purge period, the ignition control

energizes the Wl-C gas valve and simultaneously

initiates a “three (3)-try” spark ignition sequence.

6. When the burners are ignited, a minimum one (1)

micro-amp DC current will flow through the flame

between the sensor electrode and the grounded

burner.

Flame Sensor and Ignition Electrode Location

GAS ORIFICES

MAXIMUM NUMBER

MAXIMUM

INPUT

BTUH/BURNER NATURAL PROPANE (LP)

(BTUH)

BURNERS

(Dia)

45,000

23,000

#43

#55

115,000

140,000

90,000

23,000

#43

#55

7. When the controller proves that the flame has been

established, it will keep the gas valve energized and

discontinue the ignition spark. High stage manifold

pressure will be approximately 3.5" w.c. for natural

gas and 10.0" w.c. for propane (LP). Low fire natural

gas is 2.0” w.c.; low fire propane 6.0” w.c.

8. If the control is unable to ignite the burners after its

initial attempt, it will initiate another purge and spark

sequence. A third purge and spark sequence will be

initiated if the second attempt is unsuccessful. If the

third attempt is unsuccessful, the controller will close

the gas valve and lock itself out. It may be reset by

momentarily interrupting power. This may be

accomplished by briefly lowering the room thermostat

set-point below room temperature, or by shutting off

the main power to the unit. (See TP-105 for more

details.)

Heat Exchanger and Burner Orifice Specifications

NOTE: Gas appliances located more than 2000 feet above

sea level must be derated 4% per 1000 feet of total elevation

and that variance in gas heating value and specific gravity

require change in manifold pressure to obtain rating, it is

mandatory that the input be adjusted at the installation site.

All installations should be made as outlined in the latest edition

of the National Fuel Gas Code ANSI Z223.1,section

“Procedures To Be Followed To Place An Appliance in

Operation”. Refer also to the “User’s Information Manual”

supplied with the unit for additional information on the gas

furnace.

Unit Shutdown

1. Set the thermostat to lowest setting.

2. Turn off the electrical power supply to the unit.

External Lockout

9. Integrated ignition control will close its normally open

contacts after a delay of approximately 30 seconds.

This action energizes contactor BC and starts the

supply fan motor. Operation of the supply fan

circulates air across the heat exchanger and delivers

heated air to the conditioned space.

10. When the space temperature rises, the thermostat

will open R-W. Opening R-W will cause the gas valve

to close, and the furnace to shut down.

An external lockout occurs if the integrated ignition control

determines that a measurable combustion cannot be estab-

lished within three (3) consecutive ignition attempts. If flame

is not established within the seven (7) second trial for igni-

tion, the gas valve is deenergized, 15 second inter-purge cycle

is completed, and ignition is reattempted. 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.

11. The furnace has three high temperature limit controls,

which can shut down the burner. They do not shut

down the ventermotor.

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 subse-

quent attempts, the control will recycle for four (4) consecu-

tive ignition attempts (five attempts total) before locking out.

AUTOMATIC RESET HIGH LIMIT CONTROL (LS)

Located in the burner compartment on the heat exchanger,

its sensing element projects through the blower section bulk-

head and senses the temperature at the rear of the furnace.

It will cycle the furnace off if the temperature exceeds 100°F

plus maximum rise.

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 electri-

cal power supply for over five seconds. If the diagnostic LED

indicates an external lockout, perform the following checks:

AUXILIARY HIGH LIMIT CONTROL (ALS)

Located in the blower compartment on the blower housing, it

senses air temperature within the blower compartment and

protects the filters from excessive temperature. It will shut

down the furnace if it senses excessive temperatures.

•

Check the supply and manifold pressures

Check the gas orifices for debris

Check gas valve for proper operation

Check secondary limit

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 automatic reset secondary limit is located on

top of the circulator blower assembly.

MANUAL RESET FLAME ROLLOUT CONTROL (RS)

Located in the burner compartment at the top of the burner

assembly, it senses high temperature that could occur if the

heat exchanger tubes were plugged and the flame was roll-

ing out instead of entering the tubes. It has a manual push-

button reset that cannot be actuated until the limit control has

cooled.

•

Check rollout limit

If the burner flames are not properly drawn into

the heat exchanger, the flame rollout protection

device will open. Possible causes are restricted

or blocked flue passages, blocked or cracked heat

exchanger, a failed induced draft blower, or

insufficient combustion air. The rollout protection

device 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.

Check flame sensor

A drop in flame signal can be caused by nearly

invisible coating on the sensor. Remove the sensor

and carefully clean with steel wool.

Check wiring

Check wiring for opens/shorts and miswiring.

TROUBLESHOOTING

IGNITION CONTROL ERROR CODES

The following presents probable causes of questionable unit

operation. Refer to Diagnostic Indicator Chart for an inter-

pretation of the signal and to this section for an explanation.

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.

•

ABNORMAL OPERATION - HEATING

Internal Control Failure

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.

If the integrated ignition control in this unit encounters an in-

ternal fault, it will go into a “hard” lockout and turn off the

diagnostic LED. If diagnostic LED indicates an internal fault,

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, re-

place control.

Pressure Switch Stuck Open

INPUT RATING

A pressure switch stuck open can be caused by a faulty pres-

sure switch, faulty wiring, a disconnected or damaged hose,

a blocked or restricted flue, or a faulty induced draft blower.

It is the responsibility of the contractor to adjust the gas input

to the unit. The input rate can be calculated by using the

formula:

If the control senses an open pressure switch during the pre-

purge 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 be-

gins, and the induced draft blower remains on. The diagnos-

tic fault code is two flashes.

3600 x HV

NPUT Btu/Hr =

WHERE:

HV = Heating value of fuel = Btu/ft³of gas

T = Time in seconds per ft³of gas flow as read from gas meter

Adjust input rate by varying the adjustment of the gas pres-

sure regulator on the gas valve.All adjustments must be made

with furnace operating at high fire and at normal operating

temperature. Clockwise (P) rotation of the pressure regula-

tor screw increases pressure and gas flow rate. Turn screw

counterclockwise (Q) to decrease pressure and gas flow rate.

After adjustment the furnace temperature rise must be within

the range specified on the unit data plate. NOTE: Thermal

efficiency of the furnace is a product efficiency rating deter-

mined under continuous operating conditions independent

of any installed system.

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 re-

mains off. The diagnostic LED code for this fault is three (3)

flashes.

Open Thermal Protection Device

If the primary 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 diag-

nostic fault code for an open limit is four (4) flashes.

Pressure Regulator

Adjustment

(Under Cap Screw)

Outlet Pressure

Tap

A primary limit will open due to excessive supply air tempera-

tures. 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.

OUTLET

INLET

Inlet Pressure

Tap

Flame Detected with Gas Valve Closed

Gas Valve

On/Off

Selector

If flame is detected with the gas valve deenergized, the com-

bustion and air circulator blowers are energized. The diag-

nostic 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.

Switch

White-Rodgers 36G22 - Single Stage

Open to

Atmosphere

nometer

ose

ABNORMAL OPERATION - COOLING

High Fire Regulator

Adjust

Outlet

Pressure Boss

Regulator

Vent

Short Cycle Compressor Delay

The automatic ignition control has a built-in feature that pre-

vents damage to the compressor in short cycling situations.

In the event of intermittent power losses or intermittent ther-

mostat 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 com-

pressor contactor output is being delayed.

Low Fire

Regulator Adjust

Inlet

Pressure Boss

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.

Manometer

White-Rodgers 36G54 (2-Stage) Connected to Manometer

Pressure Adjustments

To connect manometer to gas valve:

EEM Motor

1. Back outlet pressure test screw (inlet/outlet pressure

boss) out one turn (counterclockwise, not more than

one turn).

2. Attach a hose and manometer to the outlet pressure

boss of the valve.

Adjust the CFM for the unit by changing the position of the

low voltage leads on the motor terminal block. Green is for

Fan Only. Yellow is for Cooling and Heat Pump Heating. Re-

fer to Appendix A for blower performance at each speed tap.

NOTE: If more than one lead is energized simultaneously,

the motor will run at the higher speed.

To remove manometer from gas valve:

1. Remove manometer hose from outlet pressure boss.

2. Turn outlet pressure test screw in to seal pressure

port (clockwise, 7 in-lb. minimum).

3. Turn on electrical power and gas supply to the system.

4. Turn on system power and energize valve.

5. Using a leak detection solution or soap suds, check

for leaks at pressure boss screw. Bubbles forming

indicate a leak. SHUT OFF GASAND FIXALLLEAKS

IMMEDIATELY.

MOTOR SHEAVE ADJUSTMENTS

VL, VM, & 2VP VARIABLE PITCH KEY TYPE MOTOR SHEAVES

The driving and driven motor sheaves should be in align-

ment with each other and the shafts parallel.

VL & VM SHEAVES ADJUSTMENT

1. Loosen set screw “B” using a 5/32" Allen key.

2. Making half or full turns from closed position, adjust

sheave pitch diameter for desired speed. DO NOT

OPEN MORE THAN FIVE FULL TURNS.

CAUTION

3. Tighten set screw “B” securely over flat.

4. Carefully put on belts and adjust belt tension. DO NOT

FORCE BELTS OVER GROOVES.

5. Ensure all keys are in place and the set screws tight

before starting drive. Recheck set screws and belt

tension after 24 hours service.

TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE

GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT

RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY

ADJUSTING THE GAS VALVE PRESSURE REGULATOR.

AIR FLOW ADJUSTMENTS

The drive on the supply fan is typically set in the middle of the

RPM range. The drive motor sheave pitch diameter is field

adjustable for the required airflow. Refer to “Drive

Adjustments” section below.

NOTE: Future adjustments should be made by loosening the

belt tension and increasing or decreasing the pitch diameter

of the sheave by half or full turns as required. Readjust belt

tension before starting drive.

When the final adjustments are complete, the current draw

of the motor should be checked and compared to the full

load current rating of the motor. The amperage must not ex-

ceed the service factor stamped on the motor nameplate.

The total airflow must not be less than that required for op-

eration of the electric heaters or the furnace.

If an economizer is installed, check the unit operating bal-

ance with the economizer at full outside air and at minimum

outside air. Upon completion of the air flow balancing, we

recommend replacing the variable pitched motor sheave with

a properly-sized fixed sheave. A matching fixed sheave will

provide longer belt and bearing life and vibration free opera-

tion. Initially, it is best to have a variable pitched motor sheave

for the purpose of airflow balancing, but once the balance

has been achieved, fixed sheaves maintain alignment and

minimize vibration more effectively. For direct drive units, move

fan speed wire.

VL & VM

Sheave

NOTE: Do NOT operate sheave with flange projecting

beyond the hub end.

MAINTENANCE

NOTE: Never run CFM below 350 CFM per ton, evaporator

freezing or poor unit performance is possible.

WARNING

PSC MOTOR

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY

BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH.

Adjust the CFM for the unit by changing the speed tap of the

indoor blower motor at the heat or cool tap on the control

board connection with the one of the speed taps on “M1” or

“M2” (Black-High Speed, Blue-Medium Speed, Red-Low

Speed).

Disposable return air filters are supplied with this unit. See

the unit Specification Sheet or Technical Manual for the cor-

rect size and part number. To remove the filters, remove the

filter access panel on return side of the unit.

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER

INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR

MAINTENANCE, REFER TO THIS MANUAL. FOR ADDITIONAL

ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER,

SERVICE AGENCY OR THE GAS SUPPLIER.

CABINET FINISH MAINTENANCE

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 sun-

light.

CAUTION

SHEET METAL PARTS, SCREWS, CLIPS AND SIMILAR ITEMS INHERENTLY

HAVE SHARP EDGES, AND IT IS NECESSARY THAT THE INSTALLER AND

SERVICE PERSONNEL EXERCISE CAUTION.

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.

Preventive maintenance is the best way to avoid unneces-

sary expense and inconvenience. Have this system inspected

at regular intervals by qualified service personnel, at least

twice a year. Routine maintenance should cover the follow-

ing items:

CONDENSER, EVAPORATOR, AND INDUCED DRAFT MOTORS

Bearings on the air circulating blower motor, condenser mo-

tor and the combustion fan motor are permanently lubricated.

No additional oiling is required.

1. Tighten all belts, set screws, and wire connections.

2. Clean evaporator and condenser coils mechanically

or with cold water, if necessary. Usually any fouling is

only matted on the entering air face of the coil and

can be removed by brushing.

3. Lubricate motor bearings.

4. Align or replace belts as needed.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

A drop in the flame current can be caused by a nearly invis-

ible 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.

5. Replace filters as needed (see below).

6. Check for blockage of condensate drain.

7. Check power and control voltages.

NOTE: After cleaning, the microamp signal should be stable

and in the range of 4 - 6 microamps DC.

8. Check running amperage.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

9. Check operating temperatures and pressures.

10. Check and adjust temperature and pressure controls.

11. Check and adjust damper linkages.

12. Check operation of all safety controls.

13. Examine gas furnaces (see below and the User’s

Information Manual).

At the start of each heating season, inspect and, if neces-

sary, clean the unit flue passage.

LUBRICATION

The fan shaft bearings, the 1 to 2 HP supply fan motors the

condenser fan motors and compressors are permanently lu-

bricated.

14. Check condenser fans and tighten set screws.

FILTERS

INSPECTION & CLEANING

All flue product carrying areas of the furnace, its vent sys-

tem, and main burners should be examined by a qualified

service agency before the start of each heating season. This

examination is necessary for continued safe operation. Par-

ticular attention should be given to deterioration from corro-

sion or other sources. This examination is accomplished in

the following manner.

CAUTION

T_{O PREVENT PROPERTY DAMAGE DUE TO FIRE AND LOSS OF}

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.

Every application may require a different frequency of replace-

ment of dirty filters. Filters must be replaced at least every

three (3) months during operating seasons.

1. Disconnect power to the unit and remove furnace

section access panel.

2. Remove burner assembly:

a. Disconnect the wires from the gas valve after noting

which wires are connected to each terminal.

Dirty filters are the most common cause of inadequate heat-

ing 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.

b. Disconnect wires from the flame rod and ignition

electrode.

WARNING

c. Disconnect the gas piping at the union.

d. The entire burner assembly can now be removed

from the unit.

T^{O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK,}

DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY

^ADJUSTMENT.C^{ONTACT A QUALIFIED SERVICER AT ONCE IF AN ABNORMAL}

FLAME SHOULD DEVELOP.

NOTE: Use all screws that were removed; they are

necessary for safe and proper operation of the unit.

At least once a year, prior to or during the heating season,

make a visual check of the burner flames.

3 Inspect and periodically clean the vent outlet (bird

screen) on the access panel.

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.

NOTE: Periodic observation of the flame and a log of C0₂

measurements are recommended. This will aid in determining

whether the furnace is operating efficiently or if the furnace

requires cleaning.

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.

Flames should be stable, soft and blue (dust may cause or-

ange tips but must not be yellow). The flames must extend

directly outward from the burner without curling, floating or

lifting off.

FUNCTIONAL PARTS

Refer to the unit Parts Catalog for a list of functional parts.

Parts are available from your distributor.

Check the burner flames for:

1. Good adjustment

2. Stable, soft and blue

3. Not curling, floating, or lifting off.

Burner Flame

APPENDIX A BLOWER PERFORMANCE TABLES

DIRECT DRIVE

CPG036 DOWN SHOT AND HORIZONTAL

CPG036 DIRECT DRIVE DOWN SHOT

EXTERNAL STATIC

STANDARD

SPEED TAP

PRESSURE (ESP)

in w.c.

AMPS

WATTS

RPM

CFM

0.10

0.20

1313

1247

1.68

1.63

356

344

748

786

0.30

0.40

0.50

0.60

1178

1094

1002

919

1.59

1.55

1.50

1.45

334

324

312

296

832

869

913

940

LOW

0.10

0.20

0.30

0.40

0.50

0.60

0.70

1471

1400

1354

1271

1188

1083

955

2.11

2.06

2.02

1.95

1.90

1.82

1.74

454

440

432

416

398

378

356

830

863

896

929

957

984

1012

MED

0.30

0.40

0.50

0.60

0.70

0.80

1470

1390

1310

1206

1098

966

2.37

2.31

2.25

2.17

2.09

1.99

510

492

476

454

436

412

935

957

978

HIGH

1000

1023

1045

CPG036 DIRECT DRIVE HORIZONTAL

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

STANDARD

CFM

SPEED TAP

AMPS

WATTS

RPM

0.10

0.20

0.30

0.40

0.50

0.60

1293

1235

1173

1124

1056

978

1.72

1.67

1.62

1.58

1.54

1.47

364

354

342

330

316

298

715

759

803

841

880

913

LOW

0.10

0.20

0.30

0.40

0.50

0.60

0.70

1500

1434

1381

1318

1238

1163

1055

2.13

2.10

2.04

2.00

1.94

1.88

1.80

462

448

436

424

406

392

370

808

838

869

902

929

951

990

MED

0.80

0.40

0.50

0.60

0.70

0.80

0.90

936

1441

1355

1264

1157

1027

840

1.72

2.35

2.28

2.21

2.13

2.03

1.90

350

504

484

468

446

418

388

1017

940

962

HIGH

989

1012

1034

1067

NOTES:

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P. SCFM

correction for wet coil = 4 %.

3 Ton models are shipped from the factory with speed tap set on LOW.

APPENDIX A BLOWER PERFORMANCE TABLES

DIRECT DRIVE

CPG048 DOWN SHOT AND HORIZONTAL

CPG048 DIRECT DRIVE DOWN SHOT

EXTERNAL STATIC

STANDARD

SPEED TAP

PRESSURE (ESP)

in w.c.

AMPS

WATTS

RPM

CFM

0.10

0.20

1592

1528

2.54

2.43

543

521

815

858

LOW

0.30

0.40

0.50

1464

1380

1296

2.32

2.21

2.10

499

475

451

901

930

959

0.10

0.20

0.30

0.40

0.50

0.60

0.70

1828

1700

1606

1531

1401

1287

1123

3.08

2.75

2.61

2.48

2.32

2.22

2.05

665

601

563

537

503

477

441

892

924

966

MED

990

1023

1045

1073

0.10

0.20

0.30

0.40

0.50

0.60

1926

1825

1712

1598

1482

1357

3.34

3.18

3.03

2.87

2.76

2.62

740

700

660

626

596

564

937

965

989

HIGH

1015

1032

1049

CPG048 DIRECT DRIVE HORIZONTAL

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

STANDARD

CFM

SPEED TAP

AMPS

WATTS

RPM

0.10

0.20

0.30

0.40

0.50

1612

1548

1484

1400

1316

2.60

2.49

2.38

2.27

2.16

554

532

510

486

462

789

832

875

904

933

LOW

0.10

0.20

0.30

0.40

0.50

0.60

0.70

1846

1718

1624

1549

1419

1305

1141

3.14

2.81

2.67

2.54

2.38

2.28

2.11

676

612

574

548

514

488

452

866

898

940

MED

964

997

1019

1047

0.10

0.20

0.30

0.40

0.50

0.60

1954

1853

1740

1626

1510

1385

3.43

3.27

3.12

2.96

2.85

2.71

758

718

678

644

614

582

924

952

976

HIGH

1002

1019

1036

NOTES:

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P. SCFM

correction for wet coil = 4 %.

4 Ton models are shipped from the factory with speed tap set on MED.

APPENDIX A BLOWER PERFORMANCE TABLES

DIRECT DRIVE

CPG060 DOWN SHOT

CPG060 DIRECT DRIVE DOWN SHOT

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

SPEED

TAP

STANDARD

CFM

AMPS

WATTS

RPM

0.10

0.20

0.30

1237

1191

1127

1.64

1.75

1.80

180

194

200

638

682

715

0.40

0.50

1065

994

1.89

1.97

214

220

753

797

0.10

0.20

0.30

0.40

0.50

1437

1384

1312

1245

1185

2.13

2.24

2.29

2.42

2.54

248

254

262

280

294

687

726

759

803

847

0.10

0.20

0.30

0.40

0.50

0.60

0.70

1988

1942

1882

1847

1784

1762

1688

4.49

4.58

4.69

4.80

4.87

4.97

5.05

558

574

582

600

612

626

642

885

907

935

962

990

1008

1039

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

2106

2050

1993

1960

1920

1880

1810

1760

1694

5.14

5.26

5.32

5.47

5.54

5.61

5.73

5.81

5.84

650

670

678

696

706

726

736

750

752

924

951

969

1001

1021

1041

1072

1093

1122

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

2199

2146

2121

2066

2010

1978

1919

1837

1738

5.87

5.96

6.06

6.15

6.21

6.32

6.28

6.22

6.04

762

772

788

804

814

834

830

814

786

968

989

1012

1039

1056

1084

1102

1122

1127

NOTES:

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P. SCFM

correction for wet coil = 4 %. 5 Ton models are shipped from the factory with speed tap set on T4.

APPENDIX A BLOWER PERFORMANCE TABLES

DIRECT DRIVE

CPG060 HORIZONTAL

CPG060 DIRECT DRIVE HORIZONTAL

EXTERNAL STATIC

PRESSURE (ESP)

in w.c.

SPEED

TAP

STANDARD

CFM

AMPS

WATTS

RPM

0.10

0.20

0.30

1416

1295

1200

1.63

1.61

1.68

176

174

186

588

621

660

0.40

0.50

1133

1045

1.79

1.90

196

208

704

753

0.10

0.20

0.30

0.40

0.50

1543

1485

1425

1352

1304

2.00

2.12

2.20

2.26

2.39

220

236

250

258

274

627

671

698

748

786

0.10

0.20

0.30

0.40

0.50

0.60

0.70

2107

2031

1980

1954

1887

1839

1782

4.02

4.13

4.27

4.37

4.48

4.58

4.72

502

518

536

554

572

582

602

797

819

858

880

913

940

968

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

2224

2165

2123

2079

2029

1978

1926

1872

1817

4.73

4.79

4.91

5.01

5.14

5.26

5.38

5.48

5.58

592

612

630

642

666

676

698

712

722

832

860

891

913

946

969

1001

1028

1056

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

2318

2296

2228

2193

2145

2097

2054

1991

1952

5.42

5.55

5.66

5.76

5.90

5.99

6.10

6.15

6.26

700

720

734

748

766

784

798

810

826

874

903

929

950

979

1012

1034

1050

1079

NOTES:

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P. SCFM

correction for wet coil = 4 %. 5 Ton models are shipped from the factory with speed tap set on T4.

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE

STANDARD DOWN SHOT

CPG036 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

1524 0.32 1340 0.25

1628 0.41 1396 0.32 1171 0.24 900

1541 0.43 1284 0.32 1024 0.23 714 0.14

1444 0.45 1193 0.33 936 0.24

0.16

1111 0.34

744 0.22

806

0.23

CPG048 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

1800 0.47 1556 0.35

2002 0.65 1708 0.49 1438 0.36 1167 0.22

1910 0.67 1612 0.50 1330 0.37 1030 0.23

1813 0.69 1571 0.54 1222 0.36

1478 0.56 1142 0.32

1107 0.41

989 0.25

CPG060 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

2460 0.96 2251 0.80 2073 0.65 1862 0.51

2408 1.00 2206 0.84 1982 0.68 1808 0.55 1572 0.41

2402 1.08 2173 0.89 1943 0.72 1701 0.55 1511 0.43

2153 0.95 1917 0.77 1667 0.59

1888 0.82 1634 0.63

1601 0.67

CPG072 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

2625 1.18 2486 1.02 2322 0.83 2152 0.68

2765 1.52 2596 1.28 2476 1.09 2327 0.94 2159 0.75 1938 0.59

2650 1.43 2452 1.18 2325 1.00 2070 0.80 1898 0.64

2443 1.29 2251 1.06 2068 0.86 1868 0.71

2258 1.17 2040 0.94 1806 0.73

2021 1.02

NOTE

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P.

SCFM correction for wet coil = 4 %.

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE

STANDARD HORIZONTAL

CPG036 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

1524 0.32 1340 0.25

1628 0.41 1396 0.32 1171 0.24 900

1541 0.43 1284 0.32 1024 0.23 714 0.14

1444 0.45 1193 0.33 936 0.24

0.16

1111 0.34

744 0.22

806

0.23

CPG048 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

1800 0.47 1556 0.35

2002 0.65 1708 0.49 1438 0.36 1167 0.22

1910 0.67 1612 0.50 1330 0.37 1030 0.23

1813 0.69 1571 0.54 1222 0.36

1478 0.56 1142 0.32

1107 0.41

989 0.25

CPG060 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

2460 0.96 2251 0.80 2073 0.65 1862 0.51

2408 1.00 2206 0.84 1982 0.68 1808 0.55 1572 0.41

2402 1.08 2173 0.89 1943 0.72 1701 0.55 1511 0.43

2153 0.95 1917 0.77 1667 0.59

1888 0.82 1634 0.63

1601 0.67

CPG072 STANDARD BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.2

0.4

0.6

0.8

1.0

1.2

2749 1.18 2573 0.96 2402 0.79

2680 1.22 2544 1.06 2346 0.84 2164 0.68

2655 1.31 2498 1.10 2306 0.92 2094 0.72 1890 0.57

2703 1.47 2486 1.20 2263 0.97 2076 0.81

2515 1.34 2272 1.07 2002 0.83

2253 1.16 2028 0.93

NOTE

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P.

SCFM correction for wet coil = 4 %.

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE

HIGH STATIC DOWN SHOT

CPG036 HIGH STATIC BELT DRIVE DOWN SHOT

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

0.8

1.0

1.2

1.4

1.6

1.8

1655 0.526 1389 0.395 1103 0.275

1640 0.571 1342 0.426 1035 0.289 775

0.19

1638 0.632 1326 0.471 1002 0.317 713 0.192

1638 0.692 1307 0.519 984 0.362

1307 0.579 1002 0.416

1002 0.476 717 0.319

717 0.379

CPG048 HIGH STATIC BELT DRIVE DOWN SHOT

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

0.8

1.0

1.2

1.4

1.6

1.8

1989 0.769 1712 0.594 1433 0.441

1929 0.788 1662 0.631 1384 0.469 1106 0.329

1952 0.876 1622 0.665 1335 0.494 1056 0.345

1897 0.93 1611 0.726 1315 0.543 1008 0.357

1616 0.80 1298 0.588 1007 0.419

1316 0.659 1007 0.46

CPG060 HIGH STATIC BELT DRIVE DOWN SHOT

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

2262 1.161 2051 0.948 1851 0.763 1657 0.60

2277 1.271 2070 1.048 1852 0.837 1646 0.656

2304 1.387 2089 1.153 1872 0.931 1647 0.722

2104 1.255 1893 1.029 1668 0.811

0.8

1.0

1.2

1.4

1.6

1912 1.129 1690 0.90

1720 1.00

CPG072 HIGH STATIC BELT DRIVE DOWN SHOT

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

2793 1.645 2575 1.367 2407 1.155 2250 0.963

2775 1.762 2638 1.526 2407 1.253 2226 1.045 2011 0.835

2821 1.894 2660 1.668 2407 1.358 2194 1.116 2012 0.923

2696 1.787 2497 1.54 2228 1.235 1977 0.985

2455 1.591 2236 1.346 2013 1.10

0.8

1.0

1.2

1.4

1.6

1.8

2262 1.44 2032 1.20

2069 1.30

NOTE

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P.

SCFM correction for wet coil = 4 %.

APPENDIX A BLOWER PERFORMANCE TABLES

BELT DRIVE - HIGH STATIC HORIZONTAL

CPG036 HIGH STATIC BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

0.8

1.0

1.2

1.4

1.6

1.8

1568 0.45 1266 0.32

1492 0.47 1194 0.34 922

1476 0.52 1163 0.37 856 0.24

1458 0.57 1146 0.41 802 0.25

1458 0.63 1139 0.46 782 0.30

0.23

1139 0.52

844.3 0.42

844

0.36

CPG048 HIGH STATIC BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

0.8

1894 0.66 1585 0.49

1839 0.71 1532 0.53 1223 0.37

1782 0.73 1477 0.55 1170 0.39

1786 0.80 1445 0.59 1115 0.40

1764 0.86 1426 0.64 1107 0.46

1446 0.72 1098 0.50

1.2

1.4

1.6

1.8

1099 0.56

CPG060 HIGH STATIC BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

2219 0.95 1970 0.75

2215 1.04 1956 0.82 1697 0.62

2240 1.15 1957 0.90 1681 0.67

2260 1.26 1983 1.00 1683 0.74

2288 1.38 2009 1.10 1711 0.84

2032 1.21 1741 0.93

0.8

1.0

1.2

1.4

1.6

1.8

1776 1.04

CPG072 HIGH STATIC BELT DRIVE HORIZONTAL

TURNS OPEN

ESP, In

H₂O

CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2677 1.29 2486 1.07

2690 1.42 2529 1.20 2263 0.94

2740 1.60 2471 1.27 2246 1.02 1972 0.79

2748 1.74 2518 1.44 2255 1.13 1970 0.87

2797 1.87 2562 1.59 2273 1.27 2025 0.99

2556 1.67 2314 1.40 2035 1.11

2342 1.50 2037 1.21

2137 1.35

NOTE

Tables represent dry coil without filter, to compensate for filter add 0.08" to measured E.S.P.

SCFM correction for wet coil = 4 %.

APPENDIX B ELECTRICAL DATA

ELECTRICAL DATA

OUTDOOR

FAN MOTOR

VOLTAGE

LIMITATION

COMPRESSOR

INDOOR

FAN MOTOR

INDOOR

MOTOR

VOLTAGE

(NAMEPLATE)

MODELS

APPLICATION

MIN.

MAX.

QTY

RLA

LRA

QTY

RLA

FLA

208/230-60-1

208/230-60-3

187

253

16.67

1/4

1.40

DD STD STATIC

BD STD STATIC

DD STD STATIC

BD STD STATIC

DD STD STATIC

BD STD STATIC

1/3

2.5

1/3

1.0

1.5

1/2

1.0

1.5

1.0

1.5

2.5

3.8

1.9

2.3

2.9

3.8

1.9

2.3

7.6

3.8

1.9

2.3

5.0

2.5

2.3

187

253

10.45

73.0

1/4

1.40

3 TON

460-60-3

575-60-3

414

518

187

506

633

253

5.77

3.8

38.0

37.0

109

1/4

0.80

0.60

1.40

208/230-60-1

19.87

208/230-60-3

187

253

13.14

83.1

1/4

1.40

4 TON

460-60-3

575-60-3

414

518

187

506

633

253

6.09

4.4

41.0

33.0

134

1/4

0.80

0.60

1.40

208/230-60-1

26.41

208/230-60-3

187

253

15.96 110.0

1/4

1.40

5 TON

460-60-3

575-60-3

414

518

187

414

518

506

633

253

506

633

7.76

5.71

52.0

38.9

123

1/4

1/3

0.80

0.60

1.92

1.20

0.90

208/230-60-3

460-60-3

6 TON

9.70

7.4

62.0

50.0

575-60-3

APPENDIX C UNIT DIMENSIONS

47 1/2”

73 1/4”

38 13/16”*

74 1/16”

*6 Ton - 42 13/16

48 3/16”

11”

4 7/8”

17”

7 3/8”

19 7/16”

RETURN

25”

SUPPLY

12”

RETURN

DRAIN

THRU CURB

LOCATION

EMBOSS

FOR

THRU THE

BASE

5 7/8”

UTILITIES

6 1/4”

SUPPLY

27 3/8”

Horizontal Discharge

4 1/2”

7 1/2”

8 3/16”

NOTE

For horizontal discharge, remove the

supply and return duct covers and place

47 1/2”

them over the vertical discharge return and

supply openings. Install with insulation

facing up, using the longer screws

provided in the literature package.

BOTTOM VIEW OF UNIT

Vertical Discharge

APPENDIX D WIRING DIAGRAMS

CPG036(48)0451D SINGLE PHASE 240V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

208-240/1/60

SEE NOTE 5

3 SPEED

208

240

FOR

24V

ALTERNATE

MOTOR

6-WIRES

SMOKE/FIRE

DETECTOR

REPLACE

JUMPER

YL RD

SEE NOTE 6 & 7

3 SPEED

TB1

SEE NOTE 7

ALS

IIC

NOTE 4

PLF

W. R.

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

LPS

YL/PK

BL/PK

R G

Y1W1

SEE NOTE 8

GREEN JUMPER

TB1

IGN

RCCF

HPS

208-240/1/60 0140L00510 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(48)0451D SINGLE PHASE 240V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FAC TORY WIRING

SUPPLY VOLTAGE

208-240/1/60

COMPONENT LEGEND

AUXILIARY LIMIT SWITCH

LINE VOLTAGE

LOW VOLTAGE

ALS

COMP

COMPRESSOR

CONDENSER MOTOR

CONTACTOR

OPTIONAL

HIGH VOLTAGE

EVAPORATOR MOTOR

FUSE

FIELD WIRING

FLAME SENSOR

HIGH VOLTAGE

LOW VOLTAGE

GND

EQUIPMENT GROUND

GAS VALVE

HPS

HIGH PRESSURE SWITCH

HEAT

PCB

WIRE CODE

IIC

IGN

LPS

PLF

INTEGRATED IGNITION CONTROL

IGNITOR

LIMIT SWITCH

LOW PRESSURE SWITCH

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

RUN CAPACITOR FOR CONDENSER FAN

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

VENT MOTOR

VENT MOTOR RELAY

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

PK PINK

PU PURPLE

RD RED

PCB

COOL

RCCF

TB1

VMR

TB1

WH WHITE

YL YELLOW

IIC

IGN

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

BLOWER CAPACITOR

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION

MOVE BLACK WIRE FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

ALS

THERMOSTAT

FIELD WIRING

IIC

3. FOR DIFFERENT THAN FACTORY SPEED TAP.

CHANGE COOLING SPEED AT COOL

TERMINAL. CHANGE HEATING SPEED AT

HEAT TERMINAL ON CONTROL BOARD

3 SPEED MOTOR

NO ECONOMIZER

LPS

HPS

RD - LOW SPEED

BL - MED. SPEED

BK - HIGH SPEED

NOTE

Y/Y2

4. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURNAIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO ECONOMIZER

ACCESSORY.

PLF

TB1

TO THERMOSTAT

TERMINAL BLOCK

STAT

TB1

5. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

6. PURPLE WIRE CONNECTS TO TRANSFORMER

(PIN 1).

7. SPEED TAP TERMINATIONS SHOWN ON

DIAGRAM ARE REPRESENTATIVE, BUT ACTUAL

FACTORY SETTING MAY BE DIFFERENT BASED

ON HEATING VALUE AND CAPACITY OF UNIT.

CHECK

EQUIP. STATUS

STATUS LIGHT

NORMAL OPERATION

Y/Y2

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OFF

8. TO RUN DIFFERENT SPEED FOR HEATING AND

COOLING, DISCONNECT GEEEN JUMPER FROM

"COOL" TERMINAL AND REPLACE WITH

APPROPRIATE SPEED TAP. THEN PLACE

DISCONNECTED END OF JUMPER ON

"UNUSED" TERMINAL LEFT OPEN BY MOVING

THE SPEED TAP.

GAS FLOW

1 BLINK

STAT

GAS PRESSURE

TB1

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

2 STAGE COOLING

OPEN AUX. LIMIT

SWITCH

2 BLINKS

3 BLINKS

4 BLINKS

PRESSURE SWITCH

OPEN

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF

OVERCURRENT PROTECTION.

CHECK

PRESSURE SWITCH

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

Y/Y2

MAIN LIMIT OPEN

BAD SWITCH

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

STAT

TB1

208-240/1/60 0140L00510 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0901D SINGLE PHASE 240V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

208-240/1/60

SEE NOTE 5

3 SPEED

208

240

FOR

24V

ALTERNATE

MOTOR

6-WIRES

SMOKE/FIRE

DETECTOR

REPLACE

JUMPER

YL RD

SEE NOTE 6 & 7

3 SPEED

TB1

SEE NOTE 7

ALS

IIC

NOTE 4

PLF

W. R.

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

LPS

YL/PK

RY1W1G

Y2 W2

SEE NOTE 8

GREEN JUMPER

TB1

SEE

NOTE 9

IGN

BL/PK

RCCF

HPS

208-240/1/60 0140L00506 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0901D SINGLE PHASE 240V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

COMPONENT LEGEND

FACTORY WIRING

SUPPLY VOLTAGE

208-240/1/60

AUXILIARY LIMIT SWITCH

COMPRESSOR

CONDENSER MOTOR

CONTACTOR

ALS

COMP

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL

HIGH VOLTAGE

EVAPORATOR MOTOR

FUSE

FIELD WIRING

FLAME SENSOR

EQUIPMENT GROUND

GAS VALVE

HIGH VOLTAGE

LOW VOLTAGE

GND

HPS

HIGH PRESSURE SWITCH

IIC

IGN

LPS

INTEGRATED IGNITION CONTROL

IGNITOR

LIMIT SWITCH

LOW PRESSURE SWITCH

FEMALE PLUG/CONNECTOR

HEAT

PCB

WIRE CODE

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

PK PINK

PU PURPLE

RD RED

WH WHITE

YL YELLOW

BL/PK BLUE WITH PINK STRIP

PCB

PLF

COOL

RCCF RUN CAPACITOR FOR CONDENSER FAN

TB1

VMR

PRESSURE SWITCH

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

VENT MOTOR

VENT MOTOR RELAY

BLOWER CAPACITOR

TB1

IIC

IGN

YL/PK YELLOW WITH PINK STRIP

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION

MOVE BLACK WIRE FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

ALS

THERMOSTAT

FIELD WIRING

IIC

3. FOR DIFFERENT THAN FACTORY SPEED TAP.

CHANGE COOLING SPEED AT COOL

TERMINAL. CHANGE HEATING SPEED AT

HEAT TERMINAL ON CONTROL BOARD

3 SPEED MOTOR

NO ECONOMIZER

LPS

HPS

RD - LOW SPEED

BL - MED. SPEED

BK - HIGH SPEED

NOTE

Y/Y2

4. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO ECONOMIZER

ACCESSORY.

PLF

TB1

TO THERMOSTAT

TERMINAL BLOCK

STAT

TB1

5. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

6. PURPLE WIRE CONNECTS TO TRANSFORMER

(PIN 1).

7. SPEED TAP TERMINATIONS SHOWN ON

DIAGRAM ARE REPRESENTATIVE, BUT ACTUAL

FACTORY SETTING MAY BE DIFFERENT BASED

ON HEATING VALUE AND CAPACITY OF UNIT.

CHECK

EQUIP. STATUS

STATUS LIGHT

NORMAL OPERATION

Y/Y2

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OFF

8. TO RUN DIFFERENT SPEED FOR HEATING AND

COOLING, DISCONNECT GEEEN JUMPER FROM

"COOL" TERMINAL AND REPLACE WITH

APPROPRIATE SPEED TAP. THEN PLACE

DISCONNECTED END OF JUMPER ON

"UNUSED" TERMINAL LEFT OPEN BY MOVING

THE SPEED TAP.

GAS FLOW

1 BLINK

STAT

GAS PRESSURE

TB1

GAS VALVE

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

2 STAGE COOLING

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

9. FOR LOW STAGE OPERATION ONLY, REMOVE

WHITE JUMPER. FOR 2 STAGE OPERATION,

REMOVE JUMPER AND CONNECT W2 TO W1

ON THERMOSTAT.

2 BLINKS

3 BLINKS

4 BLINKS

CHECK

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

Y/Y2

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF

OVERCURRENT PROTECTION.

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

STAT

TB1

208-240/1/60 0140L00506 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG0060*1D SINGLE PHASE 240V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWER SUPPLY

240/1/60

SEE NOTE 6

24V

C L G N

VMR

NOTE 3 & 7

WH PU

YL/PK

LPS

TB1

HPS

ALS

YL/PK

PLF

NOTE 4

BR WH

SMOKE/FIRE

DETECTOR

REPLACES

JUMPER

TB1

WIRE

SEE

NOTE 6

W. R.

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

W W2

YL WH

TB1

SEE

NOTE 8

IGN

RCCF

240/1/60 0140L00429 REV B

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG0060*1D SINGLE PHASE 240V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FACTORY WIRING

SUPPLY VOLTAGE

COMPONENT LEGEND

240/1/60

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL

AUXILIARY LIMIT SWITCH

COMPRESSOR

CONDENSER MOTOR

CONTACTOR

EVAPORATOR MOTOR

FUSE

ALS

COMP

HIGH VOLTAGE

FIELD WIRING

FLAME SENSOR

HIGH VOLTAGE

LOW VOLTAGE

EQUIPMENT GROUND

GAS VALVE

HIGH PRESSURE SWITCH

INTEGRATED IGNITION CONTROL

IGNITOR

LOW PRESSURE SWITCH

LIMIT SWITCH

GND

HPS

IIC

IGN

LPS

WIRE CODE

VMR

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

PLF

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

RUN CAPACITOR FOR COMPRESSOR/FAN

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

RCCF

TB1

PK PINK

NOTE 6

TB1

VMR

PU PURPLE

TB1

IGN

IIC

RD RED

WH WHITE

VENT MOTOR

VENT MOTOR RELAY

YL YELLOW

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

VMR

TB1

2. FOR 208 VOLT TRANSFORMER OPERATION

MOVE BLACK WIRE FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

3. FOR DIFFERENT THAN FACTORY SPEED TAP.

CHANGE COOLING SPEED AT MOTOR T4 AND

T5 TERMINALS. CHANGE HEATING SPEED AT

MOTOR T1. T2, AND T3 TERMINALS

ALS

THERMOSTAT

FIELD WIRING

IIC

NO ECONOMIZER

COOLING SPEED (YELLOW WIRE)

T3 - LOW SPEED

T4 - HIGH SPEED

LPS

HPS

NOTE

HEATING SPEED (WHITE WIRE)

T1 - LOW SPEED (070)

T2 - MED. SPEED

T5 - HIGH SPEED (140)

Y/Y2

5 4

PLF

W1 W2

TB1

4. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO ECONOMIZER

ACCESSORY.

TO THERMOSTAT

TERMINAL BLOCK

STAT

TB1

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

5. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

CHECK

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

FAULT

STATUS LIGHT

6. L1 AND L2 ON ICC CONTROL IS 24V INPUT.

7. SPEED TAP TERMINATIONS SHOWN ON

DIAGRAM ARE REPRESENTATIVE, BUT

Y/Y2

OFF

ACTUAL FACTORY SETTINGS MAY BE

DIFFERENT BASED ON THE HEATING VALUE

IGNITION FAILURE

GAS FLOW

GAS PRESSURE

GAS VALVE

1 BLINK

OF THE UNIT.

STAT

8. FOR LOW STAGE OPERATION ONLY, REMOVE

TB1

OPEN ROLLOUT

SWITCH

WHITE JUMPER. FOR 2 STAGE OPERATION,

REMOVE JUMPER AND CONNECT W2 TO W2

ON THERMOSTAT.

FLAME SENSOR

2 STAGE COOLING

FLAME ROLLOUT

OPEN AUX. LIMIT

BAD SWITCH

SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

2 BLINKS

3 BLINKS

4 BLINKS

PRESSURE SWITCH

OPEN

CHECK

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

PRESSURE SWITCH

Y/Y2

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER

CURRENT PROTECTION .

MAIN LIMIT OPEN

BAD SWITCH

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

STAT

TB1

240/1/60 0140L00429 REV B

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG060*3D THREE PHASE 208-230V/60HZ DIRECT

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWER SUPPLY

240/3/60

SEE NOTE 5

208

24V

240

YL RD

VMR

C L G N

GR PK

OR BR YL

TB1

OR BR

NOTE 3 & 7

ALS

TB1

NOTE 4

PLF

BR WH

FOR

SMOKE/FIRE

DETECTOR

REPLACE

JUMPER

SEE

NOTE 6

LPS

IIC

YL/PK

W. R.

(ALT.) HONEYWELL

GAS VALVE

Y2 C R Y1 W W2 G

TB1

YL WH

SEE

NOTE 8

BL/PK

HPS

IGN

230/3/60 0140L00980 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG060*3D THREE PHASE 208-230V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SUPPLY VOLTAGE

240/3/60

FACTORY WIRING

COMPONENT LEGEND

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL

AUXILIARY LIMIT SWITCH

ALS

COMP

COMPRESSOR

CONDENSER MOTOR

CONTACTOR

HIGH VOLTAGE

EVAPORATOR MOTOR

FUSE

FIELD WIRING

GND

HPS

FAN CAPACITOR

FLAME SENSOR

EQUIPMENT GROUND

GAS VALVE

HIGH VOLTAGE

LOW VOLTAGE

WIRE CODE

BK BLACK

HIGH PRESSURE SWITCH

VMR

IIC

INTEGRATED IGNITION CONTROL

BL BLUE

IGN

IGNITOR

IIC

BR BROWN

GR GREEN

OR ORANGE

LIMIT SWITCH

LOW PRESSURE SWITCH

LPS

PLF

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

ROLLOUT SWITCH

PK PINK

TB1

NOTE 6

PU PURPLE

TB1

TERMINAL BLOCK (24V SIGNAL)

RD RED

WH WHITE

IGN

TRANSFORMER

VMR

VENT MOTOR

VENT MOTOR RELAY

EM C

YL YELLOW

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

NOTE 3

TB1

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

VMR

2. FOR 208 VOLT TRANSFORMER OPERATION

MOVE BLACK WIRES FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

3. FOR DIFFERENT THAN FACTORY SPEED TAP.

CHANGE COOLING SPEED AT MOTOR T3 AND

T4 TERMINALS. CHANGE HEATING SPEED AT

MOTOR T1. T2, AND T5 TERMINALS

ALS

THERMOSTAT

FIELD WIRING

IIC

NO ECONOMIZER

COOLING SPEED (YELLOW WIRE)

T3 - LOW SPEED

T4 - HIGH SPEED

LPS

HPS

NOTE 4

PLF

HEATING SPEED (WHITE WIRE)

T1 - LOW SPEED (070)

T2 - MED. SPEED

Y/Y2

T5 - HIGH SPEED (140)

TB1

4. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO ECONOMIZER

ACCESSORY.

STAT

TO THERMOSTAT

TERMINAL BLOCK

TB1

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

5. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

6. L1 AND L2 ON ICC CONTROL IS 24V INPUT.

7. SPEED TAP TERMINATIONS SHOWN ON

DIAGRAM ARE REPRESENTATIVE, BUT

ACTUAL FACTORY SETTINGS MAY BE

DIFFERENT BASED ON THE HEATING VALUE

OF THE UNIT.

8. FOR LOW STAGE OPERATION ONLY, REMOVE

WHITE JUMPER. FOR 2 STAGE OPERATION,

REMOVE JUMPER AND CONNECT W2 TO W2

ON THERMOSTAT.

EQUIP. STATUS

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

FAULT

CHECK

STATUS LIGHT

Y/Y2

OFF

IGNITION FAILURE

GAS FLOW

GAS PRESSURE

GAS VALVE

1 BLINK

STAT

TB1

OPEN ROLLOUT

SWITCH

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

2 STAGE COOLING

OPEN AUX. LIMIT

SWITCH

AUX. LIMIT OPEN

CHECK

2 BLINKS

3 BLINKS

4 BLINKS

PRESSURE SWITCH

OPEN

CHECK

PRESSURE SWITCH

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER

CURRENT PROTECTION

Y/Y2

MAIN LIMIT OPEN

BAD SWITCH

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

STAT

TB1

230/3/60 0140L00980 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)*3D THREE PHASE 208-230V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWERSUPPLY

208-240/3/60

SEE NOTE 5

3 SPEED

208

240

FOR

24V

ALTERNATE

MOTOR

6-WIRES

SMOKE/FIRE

DETECTOR

REPLACE

JUMPER

YL RD

SEE NOTE 6 & 7

3 SPEED

TB1

SEE NOTE 7

ALS

IIC

NOTE 4

PLF

W. R.

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

LPS

YL/PK

RY1W1

SEE NOTE 8

GREEN JUMPER

TB1

IGN

BL/PK

HPS

208-240/3/60 0140L00512 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)*3D THREE PHASE 208-230V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

COMPONENT LEGEND

SUPPLY VOLTAGE

208-240/3/60

FACTORY WIRING

ALS

COMP

AUXILIARY LIMIT SWITCH

COMPRESSOR

CONDENSER MOTOR

CONTACTOR

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL

HIGH VOLTAGE

EVAPORATOR MOTOR

FUSE

FIELD WIRING

GND

HPS

FAN CAPACITOR

FLAME SENSOR

EQUIPMENT GROUND

GAS VALVE

HIGH VOLTAGE

LOW VOLTAGE

HIGH PRESSURE SWITCH

WIRE CODE

IIC

IGN

INTEGRATED IGNITION CONTROL

IGNITOR

HEAT

PCB

BK BLACK

BL BLUE

LIMIT SWITCH

BR BROWN

GR GREEN

OR ORANGE

PK PINK

PU PURPLE

RD RED

LPS

LOW PRESSURE SWITCH

PCB

PLF

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

ROLLOUT SWITCH

COOL

TB1

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

TB1

VMR

VENT MOTOR

VENT MOTOR RELAY

BLOWER CAPACITOR

WH WHITE

YL YELLOW

IIC

IGN

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION

MOVE BLACK WIRE FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

ALS

THERMOSTAT

FIELD WIRING

IIC

3. FOR DIFFERENT THAN FACTORY SPEED TAP.

CHANGE COOLING SPEED AT COOL

TERMINAL. CHANGE HEATING SPEED AT

HEAT TERMINAL ON CONTROL BOARD

3 SPEED MOTOR

NO ECONOMIZER

LPS

HPS

RD - LOW SPEED

BL - MED. SPEED

BK - HIGH SPEED

NOTE

Y/Y2

4. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO ECONOMIZER

ACCESSORY.

PLF

TB1

TO THERMOSTAT

TERMINAL BLOCK

STAT

TB1

5. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

6. PURPLE WIRE CONNECTS TO TRANSFORMER

(PIN 1).

7. SPEED TAP TERMINATIONS SHOWN ON

DIAGRAM ARE REPRESENTATIVE, BUT ACTUAL

FACTORY SETTING MAY BE DIFFERENT BASED

ON HEATING VALUE AND CAPACITY OF UNIT.

CHECK

EQUIP. STATUS

STATUS LIGHT

NORMAL OPERATION

Y/Y2

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OFF

8. TO RUN DIFFERENT SPEED FOR HEATING AND

COOLING, DISCONNECT GEEEN JUMPER FROM

"COOL" TERMINAL AND REPLACE WITH

APPROPRIATE SPEED TAP. THEN PLACE

DISCONNECTED END OF JUMPER ON

"UNUSED" TERMINAL LEFT OPEN BY MOVING

THE SPEED TAP.

GAS FLOW

1 BLINK

STAT

GAS PRESSURE

TB1

GAS VALVE

FLAME SENSOR

2 STAGE COOLING

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

2 BLINKS

3 BLINKS

4 BLINKS

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF

OVERCURRENT PROTECTION.

CHECK

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

Y/Y2

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

STAT

TB1

208-240/3/60 0140L00512 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)*3D THREE PHASE 230V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWERSUPPLY

208-240/3/60

SEE NOTE 5

3 SPEED

208

240

FOR

24V

ALTERNATE

MOTOR

6-WIRES

SMOKE/FIRE

DETECTOR

REPLACE

JUMPER

YL RD

SEE NOTE 6 & 7

3 SPEED

TB1

SEE NOTE 7

ALS

IIC

NOTE 4

PLF

W. R.

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

LPS

YL/PK

RY1W1

Y2 W2

SEE NOTE 8

GREEN JUMPER

TB1

SEE

NOTE 9

IGN

BL/PK

HPS

208-240/3/60 0140L00507 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)*3D THREE PHASE 230V/60HZ DIRECT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

COMPONENT LEGEND

SUPPLY VOLTAGE

208-240/3/60

FACTORY WIRING

ALS

COMP

AUXILIARY LIMIT SWITCH

COMPRESSOR

CONDENSER MOTOR

CONTACTOR

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL

HIGH VOLTAGE

EVAPORATOR MOTOR

FUSE

FIELD WIRING

GND

HPS

FAN CAPACITOR

FLAME SENSOR

EQUIPMENT GROUND

GAS VALVE

HIGH VOLTAGE

LOW VOLTAGE

HIGH PRESSURE SWITCH

WIRE CODE

IIC

IGN

INTEGRATED IGNITION CONTROL

IGNITOR

HEAT

PCB

BK BLACK

BL BLUE

LIMIT SWITCH

BR BROWN

GR GREEN

OR ORANGE

PK PINK

PU PURPLE

RD RED

LPS

LOW PRESSURE SWITCH

PCB

PLF

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

ROLLOUT SWITCH

COOL

TB1

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

TB1

VMR

VENT MOTOR

VENT MOTOR RELAY

BLOWER CAPACITOR

WH WHITE

YL YELLOW

IIC

IGN

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

NOTES

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. FOR 208 VOLT TRANSFORMER OPERATION

MOVE BLACK WIRE FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

ALS

THERMOSTAT

FIELD WIRING

IIC

3. FOR DIFFERENT THAN FACTORY SPEED TAP.

CHANGE COOLING SPEED AT COOL

TERMINAL. CHANGE HEATING SPEED AT

HEAT TERMINAL ON CONTROL BOARD

3 SPEED MOTOR

NO ECONOMIZER

LPS

HPS

RD - LOW SPEED

BL - MED. SPEED

BK - HIGH SPEED

NOTE

Y/Y2

4. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO ECONOMIZER

ACCESSORY.

PLF

TB1

TO THERMOSTAT

TERMINAL BLOCK

STAT

TB1

5. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

6. PURPLE WIRE CONNECTS TO TRANSFORMER

(PIN 1).

7. SPEED TAP TERMINATIONS SHOWN ON

DIAGRAM ARE REPRESENTATIVE, BUT ACTUAL

FACTORY SETTING MAY BE DIFFERENT BASED

ON HEATING VALUE AND CAPACITY OF UNIT.

CHECK

EQUIP. STATUS

STATUS LIGHT

NORMAL OPERATION

Y/Y2

NO POWER OR

INTERNAL CONTROL

FAULT

IGNITION FAILURE

OPEN ROLLOUT

SWITCH

OFF

8. TO RUN DIFFERENT SPEED FOR HEATING AND

COOLING, DISCONNECT GEEEN JUMPER FROM

"COOL" TERMINAL AND REPLACE WITH

APPROPRIATE SPEED TAP. THEN PLACE

DISCONNECTED END OF JUMPER ON

"UNUSED" TERMINAL LEFT OPEN BY MOVING

THE SPEED TAP.

9. FOR LOW STAGE OPERATION ONLY, REMOVE

WHITE JUMPER. FOR 2 STAGE OPERATION,

REMOVE JUMPER AND CONNECT W2 TO W1

ON THERMOSTAT.

GAS FLOW

1 BLINK

STAT

GAS PRESSURE

TB1

GAS VALVE

FLAME SENSOR

2 STAGE COOLING

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

2 BLINKS

3 BLINKS

4 BLINKS

CHECK

PRESSURE SWITCH

MAIN LIMIT OPEN

BAD SWITCH

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

Y/Y2

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF

OVERCURRENT PROTECTION.

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

STAT

TB1

208-240/3/60 0140L00507 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(48)0904B(7B)/CPG060*4B(7B)/CPG072*4B(7B) THREE PHASE 460V/575V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWER SUPPLY

460/3/60

575/3/60

SEE NOTE 4

460/575

460

575

240

VMR

24V

BC GR

SMOKE/FIRE

DETECTOR

REPLACES JUMPER

TB1

WIRE

ALS

NOTE 2

PLF

IIC

YL/PK

SEE

NOTE 3

W. R.

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

R W

LPS

SEE

NOTE 5

IGN

HPS

BL/PK

460-575/3/60 0140L00870 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(48)0904B(7B)/CPG060*4B(7B)/CPG072*4B(7B) THREE PHASE 460V/575V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SUPPLY VOLTAGE

COMPONENT LEGEND

460-575/3/60

AUXILIARY LIMIT SWITCH

BLOWER CONTACTOR

ALS

FACTORY WIRING

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL HIGH

VOLTAGE

COMP COMPRESSOR

CONDENSER MOTOR

CONTACTOR

EVAPORATOR MOTOR

FUSE

FIELD WIRING

FAN CAPACITOR

HIGH VOLTAGE

LOW VOLTAGE

FLAME SENSOR

GND

HPS

IBR

IIC

IGN

LPS

PLF

TB1

EQUIPMENT GROUND

GAS VALVE

HIGH PRESSURE SWITCH

INDOOR BLOWER RELAY

INTEGRATED IGNITION CONTROL

IGNITOR

VMR

WIRE CODE

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

PK PINK

LOW PRESSURE SWITCH

LIMIT SWITCH

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

NOTE 3

PU PURPLE

RD RED

IGN

IIC

WH WHITE

YL YELLOW

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

VMR

VENT MOTOR

VENT MOTOR RELAY

VMR

THERMOSTAT

FIELD WIRING

ALS

NOTES

NO ECONOMIZER

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO THE ECONOMIZER

ACCESSORY.

IIC

Y/Y2

3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.

LPS

HPS

4. USE COPPER CONDUCTORS ONLY.

NOTE 2

PLF

STAT

TB1

USE NEC CLASS 2 WIRE.

5. FOR LOW STAGE OPERATION ONLY, REMOVE

WHITE JUMPER. FOR 2 STAGE OPERATION,

REMOVE JUMPER AND CONNECT W2 TO W2

ON THERMOSTAT.

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

Y/Y2

CHECK

EQUIP. STATUS

STATUS LIGHT

STAT

NORMAL OPERATION

TB1

NO POWER OR

INTERNAL CONTROL

OFF

2 STAGE COOLING

IGNITION FAILURE

GAS FLOW

1 BLINK

GAS PRESSURE

GAS VALVE

OPEN ROLLOUT

SWITCH

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

Y/Y2

SEE UNIT RATING PLATE FOR TYPE AND

SIZE OF OVER CURRENT PROTECTION.

2 BLINKS

3 BLINKS

4 BLINKS

CHECK

PRESSURE SWITCH

STAT

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

TB1

MAIN LIMIT OPEN

BAD SWITCH

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

460-575/3/60 0140L00870 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0903B/CPG060*3B/CPG072*3B THREE PHASE 208-230V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWER SUPPLY

208-240/3/60

SEE NOTE 4

240

208

24V

VMR

SMOKE/FIRE DETECTOR

REPLACES JUMPER

WIRE

TB1

ALS

IIC

NOTE 2

PLF

YL/PK

SEE

NOTE 3

W. R.

(ALT.) HONEYWELL

GAS VALVE

GR BL

Y Y1 C R W W2 G

LPS

HPS

TO THERMOSTAT

SEE NOTE 6

BL/PK

IGN

208-240/3/60 0140L00981 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0903B/CPG060*3B/CPG072*3B THREE PHASE 208-230V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

COMPONENT LEGEND

SUPPLY VOLTAGE

208-240/3/60

FACTORY WIRING

AUXILIARY LIMIT SWITCH

BLOWER CONTACTOR

ALS

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL

COMP

COMPRESSOR

CONDENSER MOTOR

CONTACTOR

EVAPORATOR MOTOR

FUSE

FAN CAPACITOR

HIGH VOLTAGE

FIELD WIRING

HIGH VOLTAGE

LOW VOLTAGE

FLAME SENSOR

EQUIPMENT GROUND

GAS VALVE

GND

HPS

IBR

IIC

IGN

LPS

WIRE CODE

HIGH PRESSURE SWITCH

INDOOR BLOWER RELAY

INTEGRATED IGNITION CONTROL

IGNITOR

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

VMR

LOW PRESSURE SWITCH

PLF

TB1

LIMIT SWITCH

PK PINK

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

NOTE 3

PU PURPLE

NOTE 3

RD RED

WH WHITE

IGN

IIC

YL YELLOW

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

H C

VMR

VENT MOTOR

VENT MOTOR RELAY

VMR

THERMOSTAT

FIELD WIRING

ALS

NOTES

NO ECONOMIZER

1. REPLACEMENT WIRE MUST BE THE SAME

IIC

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO THE ECONOMIZER

ACCESSORY.

Y/Y2

3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.

LPS

HPS

4. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

5. FOR 208 VOLT TRANSFORMER OPERATION,

MOVE BLACK WIRE FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

6. FOR LOW STAGE OPERATION ONLY, REMOVE

WHITE JUMPER. FOR 2 STAGE OPERATION,

REMOVE JUMPER AND CONNECT W2 TO W2

ON THERMOSTAT.

NOTE 2

STAT

TB1

PLF

WITH ECONOMIZER OPTION

Y/Y2

TO THERMOSTAT

INSTALLER/SERVICEMAN

CHECK

EQUIP. STATUS

STATUS LIGHT

STAT

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

TB1

OFF

2 STAGE COOLING

IGNITION FAILURE

GAS FLOW

GAS PRESSURE

GAS VALVE

1 BLINK

OPEN ROLLOUT

SWITCH

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

CHECK

PRESSURE SWITCH

OPEN AUX. LIMIT

SWITCH

Y/Y2

PRESSURE SWITCH

2 BLINKS

3 BLINKS

4 BLINKS

OPEN

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER

CURRENT PROTECTION

STAT

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

TB1

MAIN LIMIT OPEN

BAD SWITCH

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

208-240/3/60 0140L00981 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0454B THREE PHASE 575V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWER SUPPLY

460/3/60

575/3/60

SEE NOTE 4

460/575

460

575

240

VMR

24V

BC GR

SMOKE/FIRE

DETECTOR

REPLACES JUMPER

WIRE

TB1

ALS

NOTE 2

PLF

IIC

YL/PK

SEE

NOTE 3

W. R.

GAS VALVE

(ALT.) HONEYWELL

GAS VALVE

R W1

LPS

HPS

BL/PK

IGN

460-575/3/60 0140L00871 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0454B THREE PHASE 575V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SUPPLY VOLTAGE

460-575/3/60

COMPONENT LEGEND

AUXILIARY LIMIT SWITCH

BLOWER CONTACTOR

ALS

FACTORY WIRING

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL HIGH

VOLTAGE

COMP COMPRESSOR

CONDENSER MOTOR

CONTACTOR

EVAPORATOR MOTOR

FUSE

FIELD WIRING

FAN CAPACITOR

HIGH VOLTAGE

LOW VOLTAGE

FLAME SENSOR

GND

HPS

IBR

IIC

IGN

LPS

EQUIPMENT GROUND

GAS VALVE

HIGH PRESSURE SWITCH

INDOOR BLOWER RELAY

INTEGRATED IGNITION CONTROL

IGNITOR

VMR

WIRE CODE

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

PK PINK

PU PURPLE

RD RED

WH WHITE

LOW PRESSURE SWITCH

LIMIT SWITCH

PLF

TB1

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

NOTE 3

IGN

IIC

YL YELLOW

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

VMR

VENT MOTOR

VENT MOTOR RELAY

VMR

THERMOSTAT

FIELD WIRING

ALS

NOTES

NO ECONOMIZER

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

2. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO THE ECONOMIZER

ACCESSORY.

IIC

Y/Y2

3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.

LPS

HPS

4. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

NOTE 2

PLF

STAT

TB1

WITH ECONOMIZER OPTION

INSTALLER/SERVICEMAN

Y/Y2

CHECK

EQUIP. STATUS

STATUS LIGHT

STAT

NORMAL OPERATION

TB1

NO POWER OR

INTERNAL CONTROL

OFF

2 STAGE COOLING

IGNITION FAILURE

GAS FLOW

1 BLINK

GAS PRESSURE

GAS VALVE

OPEN ROLLOUT

SWITCH

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

OPEN AUX. LIMIT

SWITCH

PRESSURE SWITCH

OPEN

Y/Y2

SEE UNIT RATING PLATE FOR TYPE AND

SIZE OF OVER CURRENT PROTECTION.

2 BLINKS

3 BLINKS

4 BLINKS

CHECK

PRESSURE SWITCH

STAT

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

TB1

MAIN LIMIT OPEN

BAD SWITCH

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

460-575/3/60 0140L00871 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0453B THREE PHASE 240V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

GND

COMP

POWER SUPPLY

208-240/3/60

SEE NOTE 4

240

208

24V

VMR

SMOKE/FIRE DETECTOR

REPLACES JUMPER

WIRE

TB1

ALS

IIC

NOTE 2

PLF

YL/PK

SEE

NOTE 3

W. R.

(ALT.) HONEYWELL

GAS VALVE

R W1

LPS

HPS

BL/PK

IGN

208-240/3/60 0140L00979 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

CPG036(048)0453B THREE PHASE 240V/60HZ BELT DRIVE

HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

COMPONENT LEGEND

SUPPLY VOLTAGE

208-240/3/60

FACTORY WIRING

AUXILIARY LIMIT SWITCH

BLOWER CONTACTOR

ALS

LINE VOLTAGE

LOW VOLTAGE

OPTIONAL

COMP COMPRESSOR

CONDENSER MOTOR

HIGH VOLTAGE

CONTACTOR

EVAPORATOR MOTOR

FUSE

FAN CAPACITOR

FLAME SENSOR

FIELD WIRING

HIGH VOLTAGE

LOW VOLTAGE

GND

HPS

IBR

IIC

IGN

LPS

EQUIPMENT GROUND

GAS VALVE

HIGH PRESSURE SWITCH

INDOOR BLOWER RELAY

INTEGRATED IGNITION CONTROL

IGNITOR

WIRE CODE

BK BLACK

BL BLUE

BR BROWN

GR GREEN

OR ORANGE

VMR

LOW PRESSURE SWITCH

LIMIT SWITCH

PK PINK

PLF

TB1

VMR

FEMALE PLUG/CONNECTOR

PRESSURE SWITCH

ROLLOUT SWITCH

TERMINAL BLOCK (24V SIGNAL)

TRANSFORMER

VENT MOTOR

VENT MOTOR RELAY

NOTE 3

PU PURPLE

NOTE 3

RD RED

WH WHITE

IGN

IIC

YL YELLOW

BL/PK BLUE WITH PINK STRIP

YL/PK YELLOW WITH PINK STRIP

H C

VMR

THERMOSTAT

FIELD WIRING

ALS

NOTES

NO ECONOMIZER

1. REPLACEMENT WIRE MUST BE THE SAME

SIZE AND TYPE OF INSULATION AS ORIGINAL.

(USE COPPER CONDUCTOR ONLY).

IIC

2. ACCESSORY ECONOMIZER PLUG ADJACENT

TO BLOWER HOUSING IN RETURN AIR

COMPARTMENT. REMOVE MALE PLUG AND

ATTACH FEMALE PLUG TO THE ECONOMIZER

ACCESSORY.

Y/Y2

3. L1 AND L2 ON IIC CONTROL IS 24V INPUT.

LPS

HPS

4. USE COPPER CONDUCTORS ONLY.

USE NEC CLASS 2 WIRE.

5. FOR 208 VOLT TRANSFORMER OPERATION,

MOVE BLACK WIRE FROM TERMINAL 3 TO

TERMINAL 2 ON TRANSFORMER.

NOTE 2

PLF

STAT

TB1

WITH ECONOMIZER OPTION

Y/Y2

INSTALLER/SERVICEMAN

CHECK

EQUIP. STATUS

STATUS LIGHT

STAT

NORMAL OPERATION

NO POWER OR

INTERNAL CONTROL

TB1

OFF

2 STAGE COOLING

IGNITION FAILURE

GAS FLOW

GAS PRESSURE

GAS VALVE

1 BLINK

OPEN ROLLOUT

SWITCH

FLAME SENSOR

FLAME ROLLOUT

BAD SWITCH

AUX. LIMIT OPEN

CHECK

PRESSURE SWITCH

OPEN AUX. LIMIT

SWITCH

Y/Y2

PRESSURE SWITCH

2 BLINKS

3 BLINKS

4 BLINKS

OPEN

SEE UNIT RATING PLATE FOR TYPE AND SIZE OF OVER

CURRENT PROTECTION

CHECK

PRESSURE SWITCH

STAT

WITHOUT INDUCER ON

OPEN LIMIT SWITCH

TB1

MAIN LIMIT OPEN

BAD SWITCH

5 BLINKS

6 BLINKS

FALSE FLAME SENSED

COMPRESSOR

OUTPUT DELAY

3 MIN. COMP.

208-240/3/60 0140L00979 REV A

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

Goodman Manufacturing Company, L.P.

5151 Felipe, Suite 500, Houston, TX 77056

www.goodmanmfg.com

www.amana-hac.com

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