All information contained herein is subject to change without notice.

Goodman Manufacturing Company, L.P.I0-148D 2550 North Loop West, Suite 400, Houston, TX 77092 1/04

www.goodmanmfg.com© 2003-2004 Goodman Manufacturing Company, L.P.

C US

®

INSTALLATION & OPERATINGINSTRUCTIONS for

COMBINATION HEATING andCOOLING OUTDOOR UNITS

PGB SERIES

FOR YOUR SAFETYWHAT TO DO

IF YOU SMELL GAS

• Do not try to light any appliance.• Do not touch any electrical switches;

do not use any phones in yourbuilding.

• Immediately call your gas supplierfrom a neighbor's phone. Follow thegas supplier's instructions.

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

DO NOT DESTROY

PLEASE READ CAREFULLYAND KEEP IN A SAFE PLACEFOR FUTURE REFERENCE.

FOR YOUR SAFETYDo not store or use gasoline orother flammable vapors and

liquids in the vicinity of this orany other appliance.

HAVE YOU DISCUSSED WITH YOURINSTALLING CONTRACTOR THE OPTIONAL

$400.00 2ND THROUGH 5TH YEAR COMPRESSORLABOR ALLOWANCE PROGRAM?

For The United States and Canada only

IO-148D 1/042

INDEX

Introduction ........................................................... 2

Replacement Parts ............................................... 2

Important Safety Instructions ................................ 2

Warnings .............................................................. 2

Physical Dimensions ............................................ 4

Specifications ....................................................... 5

Installation Procedure ........................................... 5

Cover Gasket Detail Conversion ........................... 7

Piping.................................................................... 8

Wiring ................................................................... 9

Electronic Ignition System................................... 10

Checkout Procedure ........................................... 10

Lighting Instructions ............................................ 11

wiring Diagrams ................................................. 12

Troubleshooting Chart ......................................... 15

Flowchart ............................................................ 16

THIS PRODUCT CONTAINS ELECTRONIC COMPONENTS,WHICH REQUIRE A DEFINITE GROUND. PROVISIONS AREMADE FOR CONNECTION OF THE GROUND. A DEDICATEDGROUND FROM THE MAIN POWER SUPPLY OR AN EARTHGROUND MUST BE PROVIDED.

INTRODUCTIONThis booklet contains the installation and operatinginstructions for your combination gas-electric year-roundfurnace-air conditioner. All warnings and precautions withinthis booklet must be observed. Improper installation canresult in unsatisfactory operation or dangerous conditionsand void the warranty. Read this booklet and any instructionspackaged with accessories prior to installation. Give thisbooklet to the user and explain its provisions. The user shouldretain this booklet for future reference.

CHECKING PRODUCT RECEIVEDUpon receiving the unit, inspect it for damage from shipment.Claims for damage, either shipping or concealed, should befiled immediately with the shipping company. Check the unitmodel number, specifications, electrical characteristics andaccessories to determine if they are correct. In the event anincorrect unit is shipped, it must be returned to the supplierand must NOT be installed. The manufacturer assumes noresponsibility for installation of incorrectly shipped units.

REPLACEMENT PARTSORDERING PARTSWhen reporting shortages or damages, or ordering repairparts, give the complete unit model and serial numbers asstamped on the unit’s nameplate.

Replacement parts for this appliance are available throughyour contractor or local distributor. For the location of yournearest distributor, consult the white business pages, theyellow page section of the local telephone book or contact:

SERVICE PARTS DEPARTMENTGOODMAN MANUFACTURING COMPANY, L.P.

2550 NORTH LOOP WEST, SUITE 400HOUSTON, TEXAS 77092

(713) 861 – 2500

IMPORTANT SAFETY INSTRUCTIONSRECOGNIZE SAFETY SYMBOLS, WORDS, AND LABELSThe following symbols and labels are used throughout thismanual to indicate immediate or potential hazards. It is theowner’s responsibility to read and comply with all safetyinformation and instructions accompanying these symbols.Failure to heed safety information increases the risk ofproperty damage, product damage, personal injury or death.

DANGERIMMEDIATE HAZARDS WHICH WILL RESULT INPROPERTY DAMAGE, PRODUCT DAMAGE, SEVEREPERSONAL INJURY AND/OR DEATH.

WARNINGHAZARDS OR UNSAFE PRACTICES COULD RESULT INPROPERTY DAMAGE, PRODUCT DAMAGE, SEVEREPERSONAL INJURY AND/OR DEATH.

CAUTIONHAZARDS OR UNSAFE PRACTICES WHICH MAY RESULTIN PROPERTY DAMAGE, PRODUCT DAMAGE, AND/ORPERSONAL INJURY.

WARNINGTHIS FURNACE IS DESIGN CERTIFIED FORINSTALLATION IN BUILDINGS CONSTRUCTED ON SITEONLY.

WARNINGDO NOT USE THIS FURNACE IF ANY PART HAS BEENUNDER WATER. IMMEDIATELY CALL A QUALIFIEDSERVICE TECHNICIAN TO INSPECT THE FURNACE ANDTO REPLACE ANY PART OF THE CONTROL SYSTEM ANDANY GAS CONTROL THAT HAS BEEN UNDER WATER.

IO-148D 1/043

WARNINGCARBON MONOXIDE (REFERRED TO AS CO) CAN CAUSESERIOUS PERSONAL INJURY OR DEATH.

WARNINGWHILE CARBON MONOXIDE DETECTORS DO PROVIDEADDITIONAL PROTECTION, CURRENT LIMITATIONS TOTHEIR EFFECTIVENESS REQUIRE THAT YOUOTHERWISE CONTINUE TO FOLLOW APPROPRIATEINSTRUCTIONS LOCATED IN THE “INSTALLATION &OPERATING INSTRUCTIONS” AND USERS INFORMATION”MANUALS RELATING TO PROTECTING PERSONS FROMTHE RISKS OF CARBON MONOXIDE. REVIEW EACH CODETECTOR’S MANUFACTURERS’ EXPLANATION OF THEIRUNIT’S CAPABILITIES AND FOLLOW THE INSTALLATIONAND OPERATING MANUAL WHEN INSTALLING ANDOPERATING SUCH UNITS.

WARNINGDO NOT CONNECT TO OR USE IN CONJUNCTION WITHTHIS UNIT ANY DEVICES FOR THE PURPOSE OF SAVINGENERGY OR INCREASING OPERATING EFFICIENCIES,WHICH HAVE NOT BEEN TESTED AND APPROVED BY USOR DESIGN CERTIFIED FOR USE WITH THIS UNIT.SERIOUS DAMAGE, REDUCED UNIT PERFORMANCE ANDHAZARDOUS CONDITIONS MAY RESULT FROM THE USEOF DEVICES WHICH HAVE NOT BEEN APPROVED ORCERTIFIED.

WARNINGTO ENSURE PROPER INSTALLATION AND OPERATION OFTHIS PRODUCT, COMPLETELY READ AND UNDERSTANDTHESE INSTRUCTIONS PRIOR TO ATTEMPTING TOASSEMBLE, INSTALL, MAINTAIN, OR REPAIR. IF THESEINSTRUCTIONS ARE NOT FOLLOWED PRECISELY THEREIS A POTENTIAL OF CARBON MONOXIDE POISONING,WHICH CAN RESULT IN SERIOUS ILLNESS OR DEATH.

WARNINGTHIS FURNACE WAS EQUIPPED AT THE FACTORY FORUSE WITH NATURAL GAS ONLY. LIQUID PETROLEUM (L.P.)CONVERSION, IF REQUIRED, MUST BE PERFORMED BYA QUALIFIED TECHNICIAN FAMILIAR WITH PERFORMINGTHIS TYPE OF CONVERSION. IF L.P. CONVERSION ISREQUIRED, ALL INSTRUCTIONS INCLUDED WITH THEFACTORY AUTHORIZED KIT MUST BE FOLLOWED. THEONLY KIT THAT MUST BE USED FOR THIS CONVERSIONIS THE FACTORY AUTHORIZED LPT-01. FAILURE TOFOLLOW THOSE INSTRUCTIONS EXPLICITLY MAY CAUSEFIRE, EXPLOSION, PROPERTY DAMAGE, PERSONALINJURY OR DEATH.

WARNINGTHE GAS SUPPLY PIPE MUST NEVER BE USED FORGROUNDING PURPOSES.

WARNINGNEVER LAY THIS FURNACE ON ITS FRONT OR REAR.

WARNINGHEATING UNIT SHOULD NOT BE UTILIZED WITHOUTREASONABLE, ROUTINE, INSPECTION, MAINTENANCEAND SUPERVISION. IF THE BUILDING IN WHICH ANYSUCH DEVICE IS LOCATED WILL BE VACANT, CARESHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELYINSPECTED, MAINTAINED AND MONITORED. IN THEEVENT THAT THE BUILDING MAY BE EXPOSED TOFREEZING TEMPERATURES AND WILL BE VACANT, ALLWATER-BEARING PIPES SHOULD BE DRAINED, THEBUILDING SHOULD BE PROPERLY WINTERIZED, ANDTHE WATER SOURCE CLOSED. IN THE EVENT THAT THEBUILDING MAY BE EXPOSED TO FREEZINGTEMPERATURES AND WILL BE VACANT, ANY HYDRONICCOIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCHCASE, ALTERNATIVE HEAT SOURCES SHOULD BEUTILIZED.

CARBON MONOXIDE POISONING HAZARD

B10259-216

Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode.

CO can cause serious illness including permanent brain damage or death.

Special Warning for Installation of Furnaces or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

IO-148D 1/044

PHYSICAL DIMENSIONS - FIGURE 1

A 31 1/8 31 1/8 33 5/8B 52 52 55 3/8C 38 3/4 43 3/4 58 1/8D 13 3/8 16 3/4 24 5/8E 18 3/8 20 3/8 26 5/8F 15 15 17G 15 1/4 15 1/4 17 1/4H 13 3/4 16 3/4 25I 18 3/4 20 3/4 27K 30 30 32 1/2L 16 3/8 18 3/8 27 3/4M 7 7 7 1/4N 7 5/8 7 5/8 10 1/8O 12 3/8 12 3/8 14 7/8

B

E

C

D

F

G

2 1/4"

2 1/4"

1 1/2"H

I

5"

2 5/16"

2 1/4"

A

FRESH AIRDAMPER OPENING

DISCHARGE PRESSURE SERVICE PORTSUCTION PRESSURE SERVICE PORT

POWER WIRE ENTRANCECONTROL WIRE ENTRANCE

O

L M K

N

2 1/8"

CONDENSATE DRAINCONNECTION (3/4" NPT) FEMALE

SUPPLY GAS ENTRANCE

FLUE EXHAUST

BLOWER & CONDENSER ACCESS PANEL

SUPPLY

RETURN

PGB024050PGB024075PGB030050PGB030075PGB036050PGB036075

DIMENSIONS(INCHES) PGB030100

PGB036100PGB042075PGB042100

PGB042125PGB042150PGB048075PBG048100PGB048125PGB048150PGB060100PGB060125PGB060150

ALL PGB MODELS MODEL NUMBERS

LP Conversion KitHoneywell HSP

Room Thermostat CHT 18-60

High and Low Pressure Kit HLPK-01

Low Ambient Kit LA-01

LPM-01

ACCESSORY MODEL NUMBERS

IO-148D 1/045

SPECIFICATIONSGENERALThese Combination Gas Heating/Electric Cooling Rooftopsare available in 46, 69, 92, 115, and 140,000 Btu/Hr. heatinginputs and cooling capacities of 2, 2½, 3, 3½, 4, and 5nominal tons of cooling. Units are convertible from horizontalsupply and return to bottom supply and return by relocationof cap panels.

The units are weatherized for installing outside of the building.Units are not to be installed inside the structure.

The information on the rating plate is in compliance with theFTC and DOE rating for single phase units in the U.S.A.The following information is for three phase units which arenot covered under the DOE certification program in the U.S.A.

1. The energy consumption of the ignition system usedwith the unit is 9 watts.

2. The efficiency rating of this unit is a product thermalefficiency rating determined under continuous operatingconditions independent of any installed system.

IMPORTANT: The United States EnvironmentalProtection Agency (EPA) has issued various regulationsregarding the introduction and disposal of refrigerants inthis unit. Failure to follow these regulations may harmthe environment and can lead to the imposition ofsubstantial fines. Because these regulations may varydue to the passage of new laws, we suggest that anywork on this unit be done by a certified technician.Should you have any questions, please contact the localoffice of the EPA.

MAJOR COMPONENTSThe unit includes a hermetically-sealed refrigerating system(consisting of a compressor, condenser coil, evaporator coilwith flowrator assembly), an indoor blower, a condenser fan,a heat exchanger assembly, gas furnace burner and controlassembly, combustion air motor and blower, and allnecessary internal electrical wiring. The cooling system ofthese units is factory-evacuated, charged and performancetested. Refrigerant amount and type are indicated on ratingplate.

INSTALLATION PROCEDUREGENERALIn the U.S.A., installation must conform with local buildingcodes or, in the absence of local codes, with the NationalFuel Gas Code, ANSI Z223.1.

Before attempting any installation, the following points shouldbe considered:

• Structural strength of supporting members• (Rooftop installation)• Clearances and provision for servicing• Power supply and wiring• Gas supply and piping• Air duct connections• Drain facilities and connections• Location for minimum noise

The air deflector plates and shields are in a box located inthe return air compartment for shipping. Secure one to theupper gas panel as shown in Figure 2 and secure the othertwo as shown in Figure 3. Air deflector plates are used on allPGB units equipped with a shield.

AIRDEFLECTOR

PLATE

CGAS PANEL

B

D

A

2"

4"

CHASSIS A B C DSMALL 10" 2 3/16" 16" 2 1/4"

MEDIUM 10" 2 3/16" 16" 3 3/4"LARGE 20" 5 7/16" 13 1/2" 4"

SHIELD DETAIL

(Shield Required on Small, Medium and Large Chassis)

FIGURE 2

B

CA

D

INNER SHIELD

OUTER SHIELD

E

CHASSIS A B C D ESMALL 1" 10" 2 1/2" 8 1/4" 2"

MEDIUM 1" 10" 2 1/2" 8 1/4" 2"LARGE 1" 10" 2 1/2" 8 1/4" 2 3/8"

FIGURE 3

IO-148D 1/046

This unit is designed for outdoor installations. It can bemounted on a slab or rooftop. It is not to be installed withinany part of a structure such as an attic, crawl space, closet,or any other place where condenser air flow is restricted orother than outdoor ambient conditions prevail. Since theunit is to be installed outdoors, it is important to consultyour local code authorities at the time of first installation.Many local codes prohibit the use of a combination gas-electric unit having the heat exchanger downstream of theevaporator. The design of this unit meets this coderequirement in that the return air passes over the heatexchanger first before coming into contact with the evaporatorcoil preventing condensation from taking place within the heatexchanger.

SLAB INSTALLATION - FIGURE 41. Select a location where external water drainage cannot

collect around unit.

2. Provide a level concrete slab (min. flush with all four sidesof the unit). The slab should be isolated from thefoundation wall. Ensure that there is no obstruction tocondenser or combustion air by fences, shrubs, etc.

3. The location of the unit should be such as to provideproper access for inspection and servicing.

4. Bottom rails are supplied for slab installation.

CLEARANCES TO COMBUSTIBLE MATERIALSAND OUTSIDE SLAB INTALLATION

FIGURE 4

12"48" SERVICE

12"

3"

12"

ROOFTOP INSTALLATION1. Before locating the unit on the roof, make sure that the

strength of the roof and beams is adequate at the pointto support the weight involved. This is very importantand installer’s responsibility. The following list showsapproximate weight of unit.

SIZE WEIGHT (lb.)2 TON 370

2 1/2 TON 3853 TON 395

3 1/2 TON 4654 TON 5005 TON 545

2. Refer to Figure 5 for roof curb details.

UNIT

REMOVE BOTH RAILSBEFORE INSTALLING

DUCT RETURN

GASKET (FULLPERIMETER ANDON DIVIDERS)(SUPPLIED WITHCURB)

SUPPLY DUCT

DUCT FLANGE

ROOF CURB

NAILER

ROOF CURB DETAIL

FIGURE 5

GASKET

ROOF CURB

INSULATION*

COUNTER FLASHING*

CANT STRIP*ROOF FELT*

INSULATION*

ROOF DECK*

ROOF STRUCTURALMEMBER*

*BY CONTRACTOR

UNIT

NAILER STRIP

DUCT*

14"

3. Refer to Figure 6 for rigging details.

RIGGING DETAIL

FIGURE 6

IO-148D 1/047

4. The unit should be placed on a solid level platform ofadequate strength. The mounting structure must beconstructed as to support the unit a minimum of 3"above the roof deck. An angle iron stand of properstrength may be used to provide level support for theunit. See Figure 7 for unit bottom rail constructions.

BASE PAN

2 13/16"

1 3/4"

BD*

C

A

FIGURE 7

3"

UNIT A B C D*2 - 3 TON (Small) 51 7/8" 9" 31 3/4" 21 1/16"

3 - 3 ½ TON( Medium) 51 7/8" 9" 31 3/4" 21 1/16"

3 ½ - 5 TON (Large) 55 1/4" 9" 35 1/4" 23"

BASE RAIL DETAIL

*RELOCATION DIM. FOR BASE CHANNEL IN DOWN DISCHARGE OPTION.

5. The location of the unit on the roof should be such as toprovide proper access for inspection and servicing.

FOR OUTDOOR INSTALLATION ONLYThe venting as supplied with the unit must be used withoutalteration or addition. Consult your local utility BEFOREinstalling.

DUCTINGDuct work should be fabricated by the installing contractorin accordance with local codes. Industry manuals, suchas NESCA (National Environmental Systems ContractorsAssociation, 1501 Wilson Blvd., Arlington, Virginia 22209),may be used as a guide when sizing and designing theduct system

WARNINGDO NOT, UNDER ANY CIRCUMSTANCES, CONNECTDUCT WORK TO ANY OTHER HEAT PRODUCING DEVICESUCH AS FIREPLACE INSERT, STOVE, ETC.UNAUTHORIZED USE OF SUCH DEVICES MAY RESULTIN FIRE, CARBON MONOXIDE POISONING, EXPLOSION,PROPERTY DAMAGE PERSONAL INJURY OR DEATH.

This unit should be placed as close to the space to be airconditioned as possible. Adequate clearance must bemaintained as indicated in the Section called “Clearances”.Ducts should be run as directly as possible to supply andreturn outlets. Use of non-flammable weatherproof flexibleconnectors on both supply and return connections at unit toreduce noise transmission is recommended.

It is preferable to install the unit on the roof of the structure ifthe registers or diffusers are located on the wall or in theceiling. A slab installation could be considered when theregisters are low on a wall or in the floor.

On duct work exposed to outside air conditions of temperatureand humidity, use a minimum of 2" of insulation with a goodR factor, and vapor barrier. Distribution system in attic furredspace, or crawl space should be insulated with at least 2" ofinsulation. Usually, 1/2" to 2" thickness of insulation issufficient for duct work inside the air conditioned space.

Balancing dampers should be provided for each branch ductin the supply system. Duct work should be properlysupported from the structure.

FILTERSFilters are not provided with unit, and must be supplied andinstalled in the return air system by the installer. A fieldinstalled filter grille is recommended for easy and convenientaccess to the filters, for periodic inspection and cleaning.Filters must have adequate face area for the rated air quantityof the unit. See table below for recommended filter size.

3 1/2 /4 TON

Min. Filter (1) (1) (1) (2) (2)Size 20x20x1 20x25x1 25x25x1 20x20x1 20x25x1

5 TONUNIT 2 TON 2 1/2 TON 3 TON

CLEARANCESThe following minimum clearances must be observed for properunit performance and serviceability.

1. Provide 60" minimum clearance between top of unit andmaximum 3 foot overhang.

2. Unit is design certified for application on combustibleflooring with base rails in place as shown on Figure 4.

3. See Figure 4 for illustration of minimum installationcombustible material clearances.

4. The unit may be installed directly on wood flooring or on(Class A, Class B, or Class C, in U.S.A.) roof coveringmaterials if the bottom rails are in place.

COVER GASKET DETAIL CONVERSION1. Remove screws and covers from bottom of supply and

return sections.

2. Using covers as a template drill 1/8” diameter holes inunit from around the duct openings.

IO-148D 1/048

FOAM TAPEAROUND FLANGE

SUPPLY/RETURNAIR COVER

INSULATION

SUPPLY AIRCOVER RETURN AIR COVER

FIGURE 8IMPORTANT NOTE: When casing panels, other than accesspanels, are removed for service, any insulation that isdamaged or torn must be replaced by identical material.

PIPINGGAS CONNECTION1. The gas line connection to the unit must be made through

the gas pipe opening provided into the 1/2" inlet valveopening. See Figure 9 for typical piping.

2. The gas line to the furnace should be of adequate sizeto prevent undue pressure drop and should never be lessthan 1/2". A trap should be installed in the gas supplyline as close to the unit as possible. An outside groundjoint union should be installed to connect the gas supplyto the control assembly gas valve.

3. Gas controls have been factory installed. Anothermanual shut off valve should be installed where localcodes specify a shut-off valve is to be located outsidethe unit casing. (See Figure 9.)

4. Piping should be tight. A pipe compound resistant tothe action of liquefied petroleum gases must beused at all threaded pipe connections.

CAUTIONTHE FURNACE AND ITS INDIVIDUAL SHUT-OFF VALVEMUST BE DISCONNECTED FROM THE GAS SUPPLYPIPING DURING ANY PRESSURE TESTING OF THATSYSTEM AT TEST PRESSURES IN EXCESS OF 1/2 POUNDPER SQUARE INCH GAUGE OR THE SYSTEM MUST BEISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BYCLOSING ITS INDIVIDUAL MANUAL SHUT-OFF VALVEDURING ANY PRESSURE TESTING OF THIS GAS SUPPLYSYSTEM AT PRESSURES EQUAL TO OR LESS THAN 1/2PSIG.

To check for leaks in piping, use a soap and water solutionor other approved method. DO NOT USE AN OPEN FLAME.

5. A 1/8" N.P.T. plugged tapping, accessible for test gaugeconnection, must be installed immediately upstream ofthe gas supply connection to the furnace.

Pipe Size* ½ ¾ 1 1 ¼ 1 ½

10 132 278 520 1050 160020 92 190 350 730 1100

Length 30 73 152 285 590 890of 40 63 130 245 500 760Pipe 50 56 115 215 440 670in Feet 60 50 105 195 400 610

70 46 96 180 370 56080 43 90 170 350 530

*Nominal size of iron pipe in inches.

Capacity of gas pipe of different diameters and length in ft3/hr. with a pressure drop of 0.3" W.C. and a specific

gravity of 0.60 (natural gas).

After the length of pipe has been determined, select thepipe size which will provide the cubic feet per hour requiredfor the gas input rating of the furnace. By formula:

Gas input of appliance (BTU/hr)

Heating value of gas (BTU/ft.3)=Cubic feet of

gas required

The gas input of the appliance is marked on the specificationplate. The heating value of the gas may be determined bycontacting the gas utility or gas supplier.

UNIT GAS SUPPLY CONNECTIONMUST BE TIGHT

DRIP LEG 4"-8"LONG

NOTE: DRIP LEGMUST BE CAPPED

1/8" NPT PLUGFOR MEASURING

SUPPLY GASPRESSURE

MANUAL SHUT-OFFWITHIN 4' (VERTICAL)

OF ROOF/SLAB

GROUND UNIONJOINT-INSTALLED

EXTERIOR TO CASING

ROOF OR GROUND LEVEL INSTALLATIONSuggested Gas Piping

FIGURE 9

CHECKING INPUT TO UNIT1. Gas input must never exceed the figure shown on the

rating plate.

2. Manifold pressure can be measured with a manometerattached to the 1/8" pipe tap provided in the gas valve.Manifold pressure for Natural Gas should be 3 1/2" W.C.and for L.P./Prop. gas 10" W.C. To measure the inputusing a gas meter, proceed as follows:

a. Turn off gas supply to all appliances except furnace.With furnace burning, time the two cubic foot handon the gas meter dial plate for one revolution inseconds and divide this reading by two. This willgive seconds per cubic foot of gas being deliveredto the furnace.

IO-148D 1/049

b. Assuming natural gas with heating value of Btu/Cu.Ft. and Sec./Cu. Ft. being determined from step 2a,then

1000x3600Sec./Cu. Ft.

Input Btu/Hr=

3. To adjust the regulator, remove the cap on top of the gasvalve. To decrease the pressure (decrease input tofurnace), turn the screw below the cap counterclockwise.To increase the pressure (increase input to furnace), turnthe screw clockwise. The manifold pressure should notvary more than plus or minus 0.3" W.C. (minimum 3.2"W.C.; maximum 3.8" W.C. for natural gas).

Note: For elevations up to 2,000 feet, full input ratingsapply. In U.S.A., for elevations over 2,000 feet, reduceinput 4% for each 1,000 feet above sea level by changingthe burner orifices. ( See appropriate marking on theunit for input.)

4. The furnace is to be adjusted to obtain a temperaturerise within the range specified on the appliance ratingplate.

BURNERSBurners for these units have been designed so that fieldadjustment is not required. Burners are accessible for easycleaning when required.

CONDENSATE DRAINThe condensate drain connection of the evaporator is a halfcoupling of 3/4" N.P.T. A trap must be provided to have propercondensate drainage.

Install condensate drain trap as shown in Figure 10. Use 3/4" drain connection size or larger. Do not operate withouttrap. Unit must be level or slightly inclined toward drain. Anauxiliary drain is also provided.

DRAIN CONNECTION

UNIT

FLEXIBLETUBING - HOSEOR PIPE

A POSITIVE LIQUIDSEAL IS REQUIRED

2" MINIMUM

3" MINIMUM

FIGURE 10COMBUSTION AIR FANInspect fan motor blower housing prior to each heating seasonto see that both are clear of obstructions and turn freely.NOTE: Some motors are dual voltage and require wiringchange for 208V operation. See wiring diagram.

FURNACE ACCESS PANELDesign of this system requires that the combustioncompartment be sealed for proper furnace operation. Neveroperate furnace with access panel removed or screws loose.The glass inspection port allows observation of the burneroperation with panel in place.

WIRINGAll wiring should be made in accordance with the NationalElectrical Code in the U.S.A. Determine the availability ofsufficient power to operate the unit. The voltage at powersupply should be checked to make sure it corresponds tothe unit’s RATED VOLTAGE REQUIREMENT. Install abranch circuit disconnect near the unit, in accordance withthe N.E.C. or local codes. Wire sizes should be determinedfrom the unit nameplate ampacity and in accordance withTable 2, the National Electrical Code. Under nocircumstances should wiring be sized smaller than isrecommended by either of these two sources. See wiringdiagram for maximum fuse or HACR breaker size.

TABLE 2

SUPPLY WIRELENGTH - FEET

200 6 4 4 4 3 3 2 2150 8 6 6 4 4 4 3 3100 10 8 8 6 6 6 4 475 12 10 8 8 6 6 4 450 14 12 18 10 8 8 6 6

BRANCH CIRCUIT AMPACITY

15 20 25 30 35 40 45 50

All exterior wiring must be within approved weatherproofconduit. The unit must be permanently grounded inaccordance with local codes, or in the absence of local codes,with the N.E.C. ANSI/NFPA NO. 70-1987 or latest edition inthe U.S.A.

NOTE: Some single phase units are equipped with a singlepole contactor. Caution must be exercised when servicingas only one leg of the power supply is broken with thecontactor.

To wire units, make the following high and low voltageconnections.

HIGH VOLTAGE WIRINGSingle phase

Two leads should be connected to terminals L1 and L2 inthe electrical control section, using wire sizes specifiedin wiring table.

Three phaseThree leads should be connected to terminals L1, L2, andL3 in the electrical control section, using wire sizesspecified in wiring table.

LOW VOLTAGE WIRINGConnect 24 V. wires from the thermostat to the correspondingwires in control box using No. 18 AWG as follows:

LEAD THERMOSTAT NOTESWhite W (Heat) -

Green G (Fan) -

Yellow Y (Cool) -

Red R(24V) -

Orange Y1 Only when economizer is utilizedPink Y2 Only when economizer is utilized

IO-148D 1/0410

INTERNAL WIRINGA diagram of the internal wiring of this unit is located on theinterior of the electrical box cover. If any of the original wire,which was supplied with the appliance, must be replaced,the wire gauge and insulation must be the same as originalwiring.

Transformer and combustion air motor are factory wired for230 volts on 208/230 volt models. See wiring diagram for208 volt wiring.1. For branch circuit wiring (main power supply to unit

disconnect), the minimum wire size for the length of runcan be determined from Table 2 using the circuit ampacityfound on the unit rating plate. From the disconnect tothe unit, the smallest wire size allowable in Table 2 maybe used, as the disconnect must be within the sight ofthe unit.

2. Wire size based on 60oC rated wire insulation and 30oCAmbient Temp. (86oF).

3. For more than three( 3) conductors in a raceway or cable,see the N.E.C. for derating the ampacity of eachconductor.

ELECTRONIC IGNITION SYSTEM

MODE OF OPERATIONSee the Sequence of Operation Flowchart for Mode ofOperation.

OPERATING INSTRUCTIONSInstructions to start and shut off the furnace are in the “lightinginstructions” on the unit and in the user’s manual.

The initial start up on a new installation may require thecontrol system to be energized for some time until any airhas bled through the pilot burner and fuel gas is available atthe pilot.

CHECK OUT PROCEDUREBefore leaving the installation, three (3) complete operatingcycles should be observed. Carefully follow the lightinginstructions. Run the unit through a normal operating cycleand observe the operation.

SERVICEService should only be conducted by qualified servicepersonnel. See TroubleShooting Flowchart.

MAINTENANCEThe heat exchanger should operate for many years withoutexcessive scale buildup in the flue passageways. However,it is recommended that the user have a qualified service manto inspect the flue passageways, the vent system, andburners for continued safe operation, paying particularattention to deterioration from corrosion or other sources.

The flue passageways and vent system should be inspectedand cleaned (if required) by a qualified serviceman after thesecond year of service and annually thereafter using thisprocedure. Combustion air motor and blower should bechecked for obstructions prior to each heating season.

1. Turn off all power to the furnace and set the thermostatlever to the lowest temperature.

2. Shut off the gas supply to the furnace either at the meteror at a manual valve in the supply piping.

3. Remove the control door from the furnace.4. Turn the gas control knob to the “off” position.5. Mark the individual wires to the gas control for identifying

purposes when they are to be re-connected.6. Remove wires from the gas valve.7. Using wrenches, separate the ground-joint union in the

supply piping at the furnace.8. Remove piping between the control valve and the ground-

joint union.9. Remove the burner assembly from the furnace by

removing the (4) screws securing the burner box and liftthe burner cover off.

10. Each heating section has a flue collector box cover inthe flue outlet. Remove the screws in the collector boxand wires from the combustion motor.

11. The furnace sections can now be cleaned by the use ofa wire brush with a flexible handle. Slide brush througheach section. Sweeping back and forth through eachsection will loosen any scale allowing it to fall to thebottom of the sections. The debris can now be brushedout of the bottom sections or cleaned with the nozzle ofa vacuum cleaner.

12. Check the ports on the gas burners to make certain thatthey are clean. Brushing or jarring may loosen anyaccumulation. Standing the burner assembly on endwill allow any scale to fall out of the entrance end of theburners.

13. Reinstall the flue collector box & combustion motor.14. Replace the burner assembly and secure in position.15. Reinstall the gas supply piping between the gas control

and the ground joint union.16. Re-connect all wiring that was previously disconnected.17. Turn on the gas supply and check for leaks.18. Turn on the electric power.19. Follow the lighting procedure. Due to the cleaning

operation, the system will contain air. Therefore, thesystem may have to be cycled a couple of times beforethe pilot gas will ignite.

IO-148D 1/0411

LIGHTING INSTRUCTIONS

installed, operatedautomatically lights the burners. Do not try to light the burners by hand. 10. Turn on all electric power to the

TO TURN OFF GAS TO APPLIANCE

other flammable vapors and liquids in the vicinity of this Do not store or use gasoline or

4. Move the gas control switch or knob

follow the instructions "To Turn Off Gas

to "OFF". Do not force.

5. Replace control access panel.

To Appliance" and call your service

12. If the appliance will not operate,

11. Set the thermostat to the desired

technician or gas supplier.

FOR YOUR SAFETY

or any other appliance.

GAS CONTROLGAS CONTROL

3. Remove control access panel.

1. Set the thermostat to its lowest setting.

appliance if service is to be performed.2. Turn off all electric power to the

KNOBSWITCH SHOWN IN "ON" POSITION

6. Move the gas control switch or knob

5. Remove control access panel.

SWITCH SHOWN IN "ON" POSITION

GAS CONTROL

to "OFF".

ON

OF

F

setting.

appliance.

B14933-239

cause cancer, birthdefects or other

known by the State of

cancer.California to cause

reproductive harm.This product contains

Fiberglass insulationcontains a chemical

fiberglass insulation.

in fuel combustionyou to substances

death or seriouswhich can cause

State of California toare known to theillness and which

accordance with theand maintained in

instructions, thisproduct could expose

manufacturer's

call a qualified service technician. will not operate, don't try to repair it,

gas. If you then smell gas, STOP!

gas, go to the next step.

8. Move the gas control switch or knob

above on this label. If you don't smellFollow "B" in the safety information

7. Wait five (5) minutes to clear out any

the control system and any gas controlthe appliance and to replace any part ofa qualified service technician to inspect has been under water. Immediately callD. Do not use this appliance if any part

tools. If the gas control switch or knobcontrol switch or knob. Never useC. Use only your hand to move the gas

which has been under water.

If you do not follow these instructions exactly, a fire or explosion may result causing property

If you cannot reach your gas supplier,

damage, personal injury or loss of life.

call the fire department.

FOR YOUR SAFETY READ BEFORE OPERATING

Force or attempted repair may result in

9. Replace control access panel.

try to light the burners by hand.

the gas suppliers instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the

4. This appliance is equipped with an automatic ignition system which

appliance.

above on this label.

to "ON".

B. BEFORE OPERATING smell aroundthe appliance area for gas. Be sure to smell next to the floor because some gasis heavier than air and will settle on the

do not use any telephone in yourDo not touch any electric switch;Do not try to light any appliance.

WHAT TO DO IF YOU SMELL GAS

from a neighbor's phone. FollowImmediately call your supplierbuilding.

floor. a fire or explosion.

A. This appliance does not have a pilot. Itis equipped with an ignition device whichautomatically lights the burners. Do not

furnace. For assistance

the National Fuel Gas

installation only.For outdoorPGB & PGJ

WARNING: If not

Code, ANSI Z223.1.

For indoor installation.

installed in accordanceThis furnace must be

of local codes, follow

instructions and localwith the manufacturers

codes. In the absence

consult a qualified

or the gas supplier.installer, service agency

or additional information

alteration, service ormaintenance cancause injury or

Refer to the user'sinformation manualprovided with this

property damage.

installation, adjustment,WARNING: Improper

WARNING

IO-148D 1/0412

( O P T I O N A L )

C H E C KS T A T U S L I G H T E Q U I P . S T A T U S

E M

C M

B J B

C O M P

RSC

W I T H E C O N O M I Z E RP L U G F U R N I S H E D

E C O N O M I Z E R

P L 1

5

4

3

2

1

5

1

2

1

2

1

2 - S T A G E C O O L I N G

1 - S T A G E C O O L I N G

THC-FIELD WIRING THC-NO ECONOMIZER

THC-WITH ECONOMIZER OPTION

Y

R

G

W

W

G

R

Y

W

GR

Y

Y Y

W

Y

R

G

Y

R

G

W

Y

R

G

W

4

3

2

1

P L E

C C

RR

L 2L 1

T 2T 1

3212 4 0 2 0 8

2 4 VT R A N S

V M

B R W HCF

R

B

P U

B R

B RB R

C A P 2

L S

A L S

R

RR

BB

W

B L

Y

Y

B B

R

Y

B

BB

Y Y E L L O WW W H I T ER R E DP U P U R P L EP K P I N KO O R A N G EG G R E E NB R B R O W NB L B L U EB B L A C K

W I R E C O D E

F I E L D I N S T A L L E D C O N T R O L F I E L D I N S T A L L E D P O W E R L O W V O L T A G E L I N E V O L T A G E

W I R I N G

U N M A R K E D T E R M I N A L

M A R K E D T E R M I N A L

W I R E S P L I C E

B 2 9 1 2 1 - 0 2 D

2 0 8 - 2 3 0 / 1 / 6 05 T O N 6 04 T O N 5 03 . 5 T O N 5 03 T O N 4 02 . 5 T O N 3 52 T O N 2 5

M A X F U S E S I Z E

F R O M T E R M I N A L 1 T O T E R M I N A L 2 O N T R A N S F O R M E R .

2 . F O R 2 0 8 V O L T T R A N S F O R M E R O P E R A T I O N M O V E W H I T E W I R E

4 . C R A N K C A S E H E A T E R ( O P T I O N A L ) .

I N P L A C E O F R E D L E A D A T I I C ( D 1 ) .

3 . F O R 2 0 8 C O M B U S T I O N M O T O R O P E R A T I O N C O N N E C T B L A C K L E A D

I N S U L A T I O N A S O R I G I N A L . ( U S E C O P P E R C O N D U C T O R O N L Y ) .

1 . R E P L A C E M E N T W I R E M U S T B E T H E S A M E S I Z E A N D T Y P E O F

N O T E S

V M V E N T M O T O R

T H C T H E R M O S T A T H E A T & C O O L

R S R O L L O U T S W I T C HP L P L U GL S L I M I T S W I T C H

I I C I N T E G R A T E D I G N I T I O N C O N T R O LG V G A S V A L V E

E M E V A P O R A T O R M O T O RE S E N D S W I T C HC H C R A N K C A S E H E A T E RC C C O N T R A C T O R

C M C O N D E N S E R M O T O R

C O M P C O M P R E S S O RC A P C A P A C I T O R

B J B B L O W E R J U N C T I O N B O X

C O M P O N E N T L E G E N D

N O T E # 2

N O T E # 4

T O T H C

L2

Y

L 1

C A P 2COMP

CAP1

C M

C C

T 2

L 2L 1

A L S

L S

E S

Y 2Y 1WG

C C

4

3 2 1

V M

E M

T 1C C

F

CHS

RC

C H

2 0 8 - 2 3 0 / 1 / 6 0

S U P P L Y V O L T A G E

C

H

( H I G H )

( L O W )

P L 1

B R P U

C A P 1

P O W E R S U P P L Y2 0 8 - 2 3 0 / 1 / 6 0

G

P K

O

YB L

R

C

D1

B L

S A S T A R T A S S I S T

56

W

B L

G V

9

R

1

7 1 0

8

2

IICG V

W

E S

A L S A U X I L L A R Y L I M I T S W I T C H

M A X H A C R B R E A K E R S I Z E

2 . 5 T O N 3 03 T O N 4 03 . 5 T O N 5 04 T O N 5 05 T O N 6 0

2 T O N 2 0

L 1

L 1

L 1

5

4

3

L1L2

B

W

B LR

W

B

G Y 1Y 2WRY

T O T H E R M O S T A T

F S

G R D

1 0

1 1

1 2

14

2

3

5

6

L1

D1

L1

I G N

W

M V

M V

O

B R

O

Y

R

R

R

R

B L

G

W

W

R

W

W

B R

R

B

IIC

WY

R G

R S

6

1 2

F S F S

I G N

I G N I G N I T O R

F S F L A M E S E N S O R

R E P L A C E C O N T R O L

STICKING GAS VALVE

G A S F L O W

V E N T E RE N D S W I T C H

A U X . L I M I T O P E N

M A I N L I M I T O P E N

G A S V A L V E

B A D S W I T C HF L A M E R O L L O U TF L A M E S E N S O R

G A S P R E S S U R E

T H E S T A T U S L I G H T O N T H E F U R N A C E C O N T R O L M A YB E U S E D A S A G U ID E T O T R O U B L E S H O O T I N G T H I SA P P L I A N C E . S T A T U S L I G H T C O D E S A R E A S F O L L O W S :

I N S T A L L E R /S E R V IC E M A N

5 B L I N K S

4 B L I N K S

F A U L T

F A L S E F L A M E S E N S E D

O P E N L I M I T S W I T C H

I N T E R N A L C O N T R O LN O P O W E R O R

2 B L I N K S

6 B L I N K S

O N

1 B L I N K

S W I T C H

O P E NE N D S W I T C H

O P E N R O L L O U T

N O R M A L O P E R A T I O N

I G N I T I O N F A I L U R E

-O F F CHECK INPUT POWER

OO

OO

9

8

7

R SW

HEAT

COOL

F S

W

E C O N G

B R

1 1

ECON

F U S E

B A D S W I T C H

O R

O P E N A U X . L I M I TO R

S W I T C H

C O M P R E S S O RO U T P U T D E L A Y

3 M I N . C O M P .A N T I - C Y C L E T I M E R

UNUS

EDL2

L2L2

L2 R

BB R

N O T E # 3

B

L2

L2

CHECK FUSE ON CONTROL

3 B L I N K S V E N T E RE N D S W I T C H

E N D S W I T C H C L O S E DW I T H O U T I N D U C E R O N

LABEL S IZE: 6 X 11B 2 9 1 2 0 - 0 2 D I S A D H E S I V E B A C K E D L A B E LB29121-02D IS 8 .5 X 11 .0 PAPER LABEL

LABEL MAT 'L : WHITE V INYL

N O T E # 5

R

Y

S A

T R A N S T R A N S F O R M E R

G V

M1

P

C

3

2

H O N E Y W E L LG A S V A L V E G A S V A L V E

( A L T . ) W . R .

B L

W

5 . S T A R T A S I S S T U S E D O N M O D E L S W I T H I N E R T I A " A " S H E L L

C O M P R E S S O R S O N L Y .

MV MV

WIRING DIAGRAM - SINGLE PHASE

IO-148D 1/0413

WIRING DIAGRAM - THREE PHASE

(OPTIONAL)

I

HONEYWELL HSP

EM

CM

BJB

COMP

RSC

WITH ECONOMIZERPLUG FURNISHED

ECONOMIZER

PL1

5

4

3

2

1

5

1

2

1

2

1

2-STAGE COOLING

1-STAGE COOLING

THC-FIELD WIRING THC-NO ECONOMIZER

THC-WITH ECONOMIZER OPTION

Y

R

G

W

W

G

R

Y

W

GR

Y

Y Y

W

Y

R

G

Y

R

G

W

Y

R

G

W

4

3

2

1

PLE

CC

R

L2L1

T2T1

321240 208

24VTRANS

POWER

SUPPLY

VM

W B Y

G W

Y R

GO

PK

R

B

PU

BR

BR

BR

CAP 2

LS

ALS

O

O

BR

B

R

RR

BB

B

Y

BL

BL

B B

R

Y

B

BB

G W

Y R Y2

Y1

TO THC

Y YELLOWW WHITER REDPU PURPLEPK PINKO ORANGEG GREENBR BROWNBL BLUE

B BLACK

WIRE CODE

FIELD INSTALLED CONTROL FIELD INSTALLED POWER LOW VOLTAGE

LINE VOLTAGE

WIRING

UNMARKED TERMINAL

MARKED TERMINAL

WIRE SPLICE

B29121-03B208-230/3/60

5 TON 404 TON 353.5 TON 303 TON 25

MAX FUSE SIZE

FROM TERMINAL 1 TO TERMINAL 2 ON TRANSFORMER.

2. FOR 208 VOLT TRANSFORMER OPERATION MOVE WHITE WIRE

4. CRANKCASE HEATER (OPTIONAL).

IN PLACE OF RED LEAD AT TFC (D1).

3. FOR 208 COMBUSTION MOTOR OPERATION CONNECT BLACK LEAD

INSULATION AS ORIGINAL.(USE COPPER CONDUCTOR ONLY).

1. REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF

NOTES

VM VENT MOTORTHC THERMOSTAT HEAT & COOL

RS ROLLOUT SWITCHPL PLUGLS LIMIT SWITCHIC IGNITION CONTROLGV GAS VALVE

EM EVAPORATOR MOTORES END SWITCH

CH CRANKCASE HEATERCC CONTRACTOR

CM CONDENSER MOTOR

COMP COMPRESSORCAP CAPACITOR

BJB BLOWER JUNCTION BOX

COMPONENT LEGEND

TFC TIMED FAN CONTROL

NOTE #2

NOTE #4

TO THC

N1

Y

S2N4

CAP 2

COMP

CM

CC

T2

L2L1

ALS

LS

ES

Y2Y1WG

CC

4

3 2 1

VM

EM

T1CC

S

RC

CH

208-230/3/60

SUPPLY VOLTAGE

C

H

(HIGH)

(LOW) TFC

PL1

PU B Y/R

CAP1

208-230/3/60

G

PK

O

YBL

O

O

NOTE #3

C

D1

Y

SA START ASSIST

R

Y

56

2413

BRR

WBL

PILOT/SENSORASSEMBLY

GAS VALVE/IGNITION CONTROL

R

R

LIMIT

LIMIT

X

G

ASSEMBLYSENSORPILOT/

HONEYWELL HSPGAS VALVE/IGNITION CONTROL

12

34MV

W

3

C

TFC

GV&IC

BY

ES

RS

W

ALS AUXILLARY LIMIT SWITCH

RS

MAX HACR BREAKER SIZE

3 TON 203.5 TON 304 TON 305 TON 40

N

OFF U P

DELAY

SPEED

LE

AD

S

MO

TO

R

UN

US

ED

N

TW

Z2

Z1

K1 K2

1 2

DI

YC C G Y W R

SE

C

XF

MR

K3

COOLHEAT

1

21 3 4 C X

S1

S1

S1

6

1

54 2

HONEYWELL

N3

N2

S

B

B

W

R

W BW

BR

RBL

W

R

BL

RBR

O

BL

O

W

W

O

W

W

W

BBR

B

Y

BL

L3

T3

Y

L3

CC

T3S1

1

CLT

2 3 4

NOTE #5

5. COMP. LOCKOUT TIMER USED ONLY ON MODELS EQUIPPED WITHSCROLL COMPERSSORS.

CLT COMP. LOCKOUT TIMER

43 21

CLT CLT

IO-148D 1/0414

WIRING DIAGRAM - 460V

( O P T I O N A L )

C H E C KS T A T U S L I G H T E Q U I P . S T A T U S

H O N E Y W E L LG A S V A L V E

M V

M V

G V

( A L T . ) W . R .

G A S V A L V E

W 1

B L

3

2

M

G VP

C

E M

C M

BJB

C O M P

RSC

W I T H E C O N O M I Z E RP L U G F U R N I S H E D

E C O N O M I Z E R

P L 1

5

4

3

2

1

5

1

2

1

2

1

2 - S T A G E C O O L I N G

1 - S T A G E C O O L I N G

THC-FIELD WIRING THC-NO ECONOMIZER

THC-WITH ECONOMIZER OPTION

Y

R

G

W

W

G

R

Y

WG

R

Y

Y Y

W

Y

R

G

Y

R

G

W

Y

R

G

W

4

3

2

1

P L E

460

2 4 VT R A N S

V M

B Y W

R

B

P U

B R

B RB R

C A P 2

L S

A L S

R

RR

BB

BL

Y

Y

B B

R

Y

B

B

B

Y Y E L L O WW W H I T E

R R E DP U P U R P L EPK P INKO O R A N G EG G R E E NB R B R O W NB L B L U EB B L A C K

W I R E C O D E

F I E L D I N S T A L L E D C O N T R O L F I E L D I N S T A L L E D P O W E R L O W V O L T A G E

L I N E V O L T A G E

W I R I N G

U N M A R K E D T E R M I N A L

M A R K E D T E R M I N A L

W I R E S P L I C E

B 2 9 1 2 1 - 0 4 C

4 6 0 / 3 / 6 0

5 T O N 2 0

M A X F U S E S I Z E

H I G H S P E E D R E P L A C E Y E L L O W M O T O R L E A D A T E M R # 2 W I T H

2 . 4 6 0 V U N I T S A R E S I N G L E S P E E D , T O C H A N G E F R O M L O W T O

3 . C R A N K C A S E H E A T E R ( O P T I O N A L ) .

B L A C K M O T O R L E A D .

I N S U L A T I O N A S O R I G I N A L . ( U S E C O P P E R C O N D U C T O R O N L Y ) .

1 . R E P L A C E M E N T W I R E M U S T B E T H E S A M E S I Z E A N D T Y P E O F

N O T E S

T R A N S T R A N S F O R M E RT H C T H E R M O S T A T H E A T & C O O L

R S R O L L O U T S W I T C HP L P L U G

L S L I M I T S W I T C H

I I C I N T E G R A T E D I G N I T I O N C O N T R O L

G V G A S V A L V E

E M E V A P O R A T O R M O T O RE S E N D S W I T C HC H C R A N K C A S E H E A T E RC C C O N T R A C T O R

C M C O N D E N S E R M O T O R

C O M P C O M P R E S S O RC A P C A P A C I T O R

B J B B L O W E R J U N C T I O N B O X

C O M P O N E N T L E G E N D

N O T E # 3

T O T H C

Y

A L S

L S

ES

Y 2Y 1WG

C C

4

3 2 1P L 1

B R P U

P O W E R S U P P L Y

460/3 /60

G

PK

O

YBL

R

C

B L

S A S T A R T A S S I S T

56

W

B L

9

R

1

7 1 0

8

2

I ICG V

ES

A L S A U X I L L A R Y L I M I T S W I T C H

M A X H A C R B R E A K E R S I Z E

5 T O N 2 0

5

4

3

B

B LR

W

G Y 1Y 2WRY

T O T H E R M O S T A T

FS

G R D

1 0

1 1

1 2

14

2

3

5

6

L1D

1L1

IGN

W

O

B R

O

Y

R

R

R

R

BL

G

W

W

IIC

WY

R G

R S

6

1 2

FS FS

I G N

I G N I G N I T O R

F S F L A M E S E N S O R

REPLACE CONTROL

STICKING GAS VALVE

G A S F L O W

V E N T E RE N D S W I T C H

A U X . L I M I T O P E N

M A I N L I M I T O P E N

G A S V A L V E

B A D S W I T C HF L A M E R O L L O U TF L A M E S E N S O R

G A S P R E S S U R E

IN S T A L L E R / S E R V I C E M A N

5 B L I N K S

4 B L I N K S

F A U L T

F A L S E F L A M E S E N S E D

O P E N L I M I T S W I T C H

I N T E R N A L C O N T R O LN O P O W E R O R

2 B L I N K S

6 B L I N K S

O N

1 BL INK

S W I T C H

O P E NE N D S W I T C H

O P E N R O L L O U T

N O R M A L O P E R A T I O N

I G N I T I O N F A I L U R E

-O F F CHECK INPUT POWER

OO

OO

9

8

7

R SW

HEAT

COOL

F S

W

E C O N G

B R

1 1

ECON

F U S E

B A D S W I T C H

O R

O P E N A U X . L I M I TO R

S W I T C H

C O M P R E S S O RO U T P U T D E L A Y

3 M I N . C O M P .ANTI-CYCLE TIMER

UNUS

EDL2

L2L2

L2 R

CHECK FUSE ON CONTROL

3 B L I N K S V E N T E RE N D S W I T C H

E N D S W I T C H C L O S E DW I T H O U T I N D U C E R O N

Y

C CT1

L 1

R

T 2

L 2

T3

L 3

C A P 1

C

230 460

T R A N S 2

W O

2

B

2I D M R

3 R 1

4

E M R

3 1R

4

WB

G

BB L

W

B L

W

B L

G RG R

B

B

R

B R

B

B R

B

SC A P 2

L 1 S U P P L Y V O L T A G E

4 6 0 / 3 / 6 0

C C T1 R

COMPC

C H

T2

L 2 L 3

C C

E M ( L O W )

( H I G H )

T R A N S 2

VMC

2302

C M

4

4602 4

E M R

T3

C C

I D M R

T R A N S 1

B L

I D M R

CH

D1

E M R

31

31

I D M R I N D U C E D D R A F T M O T O R R E L A Y

E M R E V A P O R A T O R M O T O R R E L A Y

V M V E N T M O T O R

N O T E # 2

MV MV

L A B E L M A T ' L : W H I T E V I N Y LL A B E L S I Z E : 6 X 1 1 . 5B 2 9 1 2 0 - 0 4 C I S A D H E S I V E B A C K E D L A B E LB 2 9 1 2 1 - 0 4 C I S 8 . 5 X 1 1 . 0 P A P E R L A B E L

T H E S T A T U S L I G H T O N T H E F U R N A C E C O N T R O L M A YB E U S E D A S A G U I D E T O T R O U B L E S H O O T I N G T H I SA P P L I A N C E . S T A T U S L I G H T C O D E S A R E A S F O L L O W S :

IO-148D 1/0415

COOLING TROUBLESHOOTING CHART

WARNINGDISCONNECT ALL POWER TO UNIT BEFORE SERVICING.

SYMPTOM POSSIBLE CAUSE REMEDY

High head - low suction a. Restriction in liquid line or capillary tube a. Remove or replace defective components

High head - high or normal suction a. Dirty condenser coil a. Clean coil

b. Overcharged b. Correct System Charge

c. Condenser fan not running c. Repair or replace

Low head - high suction a. Incorrect capillary tube a. Replace evaporator assembly

b. Defective compressor valves b. Replace compressor

Unit will not run a. Power off or loose electrical connection a. Check for unit voltage at contactor in unit

b. Thermostat out of calibration set too high b. Reset

c. Defective contactor c. Check for 24 volts at contactor coil - replace if contacts are open

d. Blown fuses or tripped breaker d. Replace fuse or reset breaker

e. Transformer defective e. Check wiring - replace transformer

f. High or low pressure control open (Optional) f. Reset high pressure control or check unit charge

High pressure control opens at 425 psi

Low pressure control opens at 25 psi

g. Compressor overload contacts open g. Replace compressor NOTE: wait at least 2 hours for overload to reset

Condenser fan runs a. Loose connection a. Check for unit voltage at compressor - checkcompressor doesn't and tighten all connections

b. Compressor stuck, grounded or open winding b. Wait at least 2 hours for overload to reset. open internal overload If still open, replace the compressor

c. Low voltage connection c. At compressor terminals, voltage must be within 10% of nameplate volts when unit is operating

Low suction - cool compressor a. Low indoor airflow a. Increase speed of blower or reduce restrictionIced evaporator coil and replace air filters

Compressor short cycles a. Defective overload protector a. Replace - check for correct voltage

b. Unit cycling on low pressure control b. Check refrigerant charge and/or airflow

Registers sweat a. Low airflow a. Increase speed of blower or reduce restriction - replace air filter

High suction pressure a. Excessive load a. Recheck load calculation

b. Defective compressor b. Replace

Insufficient cooling a. Improperly sized unit a. Recalculate load

b. Improper airflow b. Check - should be approximately 400 CFM per ton

c. Incorrect refrigerant charge c. Charge per procedure attached to unit service panel

d. Incorrect voltage d. At compressor terminals, voltage must be within 10% of nameplate volts when unit is operating

Evaporator coil freezing or frosting a. Low airflow a. Check - should be approximately 400 CFM per ton, dirty air filters, all duct outlets open

b. Low refrigerant charge b. Properly charge unit

c. Operating unit in cooling mode below 65e F c. Install or check low ambient control, should be open outdoor temperature below 65e F outdoor temperature

IO-148D 1/0416

Quality Makes the Difference!All of our systems are designed and manufactured with the same high quality standards regardless of size or efficiency.We have designed these units to significantly reduce the most frequent causes of product failure. They are simple toservice and forgiving to operate. We use quality materials and components. Finally, every unit is run tested before itleaves the factory. That’s why we know . . . There’s No Better Quality.

Visit our web site at www.goodmanmfg.com for information on:• Goodman products• Warranties• Customer Services• Parts• Contractor Programs and Training• Financing Options

© 2003-2004 Goodman Manufacturing Company, L.P.

FLOWCHARTS

LIMIT SWITCHCLOSED

THERMOSTATCALL FOR

HEAT

VENT MOTOREND SWITCH

OPEN

ACTIVATE VENTMOTOR

VENT MOTOREND SWITCH

CLOSED

ACTIVATE SPARKIGNITOR

OPEN GASVALVE

FLAME SENSORDETECTS FLAME

START EVAPORATOR

BLOWER AFTER 30 SEC. TIME

DELAY

3RD IGNITORATTEMPT

TURN BOTH VENT BLOWERS

& EVAPORATORS ON

NO

15 SECOND VENTMOTOR INTER

PURGE

NO

YES

YES

NO

DISPLAY ERRORCODE. GO INTOSOFT LOCKOUT(60 MIN.) AFTER

5 MIN.

NO

NO

HTG OPERATIONS TERMINATION OF HTG OPERATION

T STAT SATISFIED

TURN GAS VALVE OFF

TURN VENT MOTOR OFF AFTER 30 SEC.

DELAY

TURN EVAPORATORBLOWER OFF AFTERPRESET OFF DELAY

DISPLAY ERRORCODE. GO INTOSOFT LOCKOUT

(60 MIN.)