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Contents
1. 5 Installation Procedure 5 Cover Gasket Detail Conversion 7 PP UNG ce arrest ee ode Shu uh Ska Cuasi 8 cee OR sa 9 Electronic Ignition System 10 Checkout Procedure 10 Lighting Instructions 11 wiring Diagrams 12 Troubleshooting Chart 15 OW GAIN sissies enact iver voce ianea i 16 THIS PRODUCT CONTAINS ELECTRONIC COMPONENTS WHICH REQUIREA DEFINITE GROUND PROVISIONSARE MADE FOR CONNECTION OF THE GROUND A DEDICATED GROUND FROM THE MAIN POWER SUPPLY ORAN EARTH GROUND MUST BE PROVIDED INTRODUCTION This booklet contains the installation and operating instructions for your combination gas electric year round furnace air conditioner All warnings and precautions within this booklet must be observed Improper installation can result in unsatisfactory operation or dangerous conditions and void the warranty Read this booklet and any instructions packaged with accessories prior to installation Give this booklet to the user and explain its provisions The user should retain this booklet for future reference CHECKING PRODUCT RECEIVED Upon receiving the unit inspect it for damage from shipment Claims for damage either ship2. 2 TON 370 3 TON 395 3 1 2 TON 4 TON 5 TON IO 148D 2 Referto Figure 5 for roof curb details UNIT REMOVE BOTH RAILS BEFORE INSTALLING DUCT RETURN GASKET FULL PERIMETER AND ON DIVIDERS SUPPLIED WITH CURB SUPPLY DUCT DUCT FLANGE ROOF CURB NAILER GASKET NAILER STRIP ROOF CURB INSULATION DUCT COUNTER FLASHING CANT STRIP ROOF FELT INSULATION ROOF DECK ROOF STRUCTURAL MEMBER BY CONTRACTOR ROOF CURB DETAIL FIGURE 5 3 Refer to Figure 6 for rigging details RIGGING DETAIL FIGURE 6 1 04 4 The unit should be placed on a solid level platform of adequate strength The mounting structure must be constructed as to support the unit a minimum of 3 above the roof deck An angle iron stand of proper strength may be used to provide level support for the unit See Figure 7 for unit bottom rail constructions BASE PAN 2 13 16 J l l FIGURE 7 Sr anoen sine Fara 2 RELOCATION DIM FOR BASE CHANNEL IN DOWN DISCHARGE OPTION 5 The location of the unit on the roof should be such as to provide proper access for inspection and servicing FOR OUTDOOR INSTALLATION ONLY The venting as supplied with the unit must be used without alterati
3. Thats why we know There s No Better Quality Visit our web site at www goodmanmfg com for information on IO 148D Goodman products Warranties Customer Services Parts Contractor Programs and Training Financing Options 2003 2004 Goodman Manufacturing Company L P 16 1 04
4. 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 65 F Install or check low ambient control should be open outdoor temperature below 65 F outdoor temperature IO 148D 15 1 04 FLOWCHARTS THERMOSTAT CALL FOR HEAT VENT MOTOR END SWITCH OPEN VENT MOTOR END SWITCH CLOSED OPEN GAS VALVE FLAME SENSOR DETECTS FLAME HTG OPERATIONS ACTIVATE VENT MOTOR ACTIVATE SPARK IGNITOR TURN BOTH VENT BLOWERS amp EVAPORATORS ON DISPLAY ERROR CODE GO INTO SOFT LOCKOUT 60 MIN AFTER 5 MIN 15 SECOND VENT MOTOR INTER PURGE 3RD IGNITOR ATTEMPT START EVAPORATOR BLOWER AFTER 30 SEC TIME DELAY DISPLAY ERROR CODE GO INTO SOFT LOCKOUT TERMINATION OF HTG OPERATION T STAT SATISFIED TURN VENT MOTOR OFF AFTER 30 SEC DELAY TURN EVAPORATOR BLOWER OFF AFTER PRESET OFF DELAY 60 MIN 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 to service and forgiving to operate We use quality materials and components Finally every unit is run tested before it aves the factory
5. OFF NO POWER OR CHECK INPUT POWER INTERNAL CONTROL CHECK FUSE ON CONTROL FAULT REPLACE CONTROL 1 BLINK IGNITION FAILURE GAS FLOW OR GAS PRESSURE INSTALLER SERVICEMAN ee eWincH E RME SENEC SWITCH FLAME SENSOR THE STATUS LIGHT ON THE FURNACE CONTROL MAY OR FLAME ROLLOUT BE USED AS A GUIDE TO TROUBLESHOOTING THIS OPEN AUX LIMIT BAD SWITCH APPLIANCE STATUS LIGHT CODES ARE AS FOLLOWS SWITCH AUX LIMIT OPEN 2 BLINKS END SWITCH VENTER OPEN END SWITCH 3 BLINKS END SWITCH CLOSED VENTER WITHOUT INDUCER ON END SWITCH LABEL MAT L WHITE VINYL 4 BLINKS OPEN LIMIT SWITCH MAIN LIMIT OPEN LABEL SIZE 6 X 11 BAD SWITCH B29120 02D IS ADHESIVE BACKED LABEL 5 BLINKS FALSE FLAME SENSED STICKING GAS VALVE B29121 02D IS 8 5 X 11 0 PAPER LABEL 6 BLINKS COMPRESSOR 3 MIN COMP OUTPUT DELAY ANTI CYCLE TIMER B29121 02D IO 148D 12 1 04 IO 148D HONEYWELL WIRING DIAGRAM THREE PHASE SUPPLY VOLTAGE 208 230 3 60 HONEYWELL HSP GAS VALVE IGNITION CONTROL PILOT SENSOR ASSEMBLY NOTE 4 13 NOTE 2 HONEYWELL HSP GAS VALVE IGNITION CONTROL PILOT SENSOR ASSEMBLY THOFELDWRING THC NO ECONOMZER THC WITH ECONOMIZER OPTION 1 STAGE COOLING w G POWER 208 230 3 60 PLUG FURNISHED SUPPLY WITH ECONOMIZER Y ECONOMIZER 5 OPTIONAL 4 COMPONENT LEGEND WIRE SPLICE ALS AUXILLARY LIMIT SWITCH MARKED TERMINAL BJB BLOWER JUNCTION BOX UNMARKED TERMINAL CAP CAPACIT
6. chemical known by the State of California to cause cancer Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 11 B14933 239 1 04 WIRING DIAGRAM SINGLE PHASE I HONEYWELL ALT W R ARS GAS VALVE GAS VALVE NOTE 2 B B lt 8 w w w TM R lt E ahs P TRANS w 2 c 1 w NOTE 3 BL BL es BR P o IGN R BL R BR FS J M OO es THC FIELD WIRING 3 THC NO ECONOMIZER w e w R e v 6 R LS THC WITH ECONOMIZER OPTION 1 STAGE COOLING e 1 r t vo LS 2 STAGE COOLING NOTE 5 s G 1 6 LO rq Y1 1 MI D LO 1 B RW ISRD BIB Y H T i PLUG FURNISHED B R R G WITH ECONOMIZER i BL BR B CRD I y B R PU i s gt PLE Bo 4 ECONOMIZER a 5 eO a OPTIONAL BR i t
7. loose The glass inspection port allows observation of the burner operation with panel in place IO 148D WIRING All wiring should be made in accordance with the National Electrical Code in the U S A Determine the availability of sufficient power to operate the unit The voltage at power supply should be checked to make sure it corresponds to the unit s RATED VOLTAGE REQUIREMENT Install a branch circuit disconnect near the unit in accordance with the N E C or local codes Wire sizes should be determined from the unit nameplate ampacity and in accordance with Table 2 the National Electrical Code Under no circumstances should wiring be sized smaller than is recommended by either of these two sources See wiring diagram for maximum fuse or HACR breaker size TABLE 2 BRANCH CIRCUIT AMPACITY SUPPLY WIRE LENGTH FEET 2 a ee A 8 6 6 4 4 4 3 3 sf tof 8 Bi ol oto 4 a4 _75___ 12 10 8 8 6 6 4 4 _ 5_ 14 12 18 10 8 8 6 6 exterior wiring must be within approved weatherproof conduit The unit must be permanently grounded in accordance with local codes or in the absence of local codes with the N E C ANSI NFPA NO 70 1987 or latest edition in the U S A NOTE Some single phase units are equipped with a single pole contactor Caution must be exercised when servicing as only one leg of the power supply is broken with the contactor To wire units make the following high and low voltage c
8. B29121 04C POWER SUPPLY 460 3 60 14 ALT W R GAS VALVE 75 G 2 HONEYWELL GAS VALVE C7 w 2 TRANS2 THC FIELD WIRING THC NO ECONOMIZER w G R y THC WITH ECONOMIZER OPTION 1 STAGE COOLING ECONOMIZER OPTIONAL Y R W G Y2 Y1 TO THERMOSTAT COMPONENT LEGEND WIRE SPLICE ALS AUXILLARY LIMIT SWITCH MARKED TERMINAL BJB BLOWER JUNCTION BOX UNMARKED TERMINAL CAP CAPACITOR WIRING COMP COMPRESSOR LINE VOLTAGE CM CONDENSER MOTOR LOW VOLTAGE CC CONTRACTOR FIELD INSTALLED POWER CH CRANKCASE HEATER FIELD INSTALLED CONTROL ES END SWITCH EM EVAPORATOR MOTOR WIRE CODE EMR EVAPORATOR MOTOR RELAY B BLACK FS FLAME SENSOR BL BLUE GV GAS VALVE BR BROWN IDMR INDUCED DRAFT MOTOR RELAY GREEN IC INTEGRATED IGNITION CONTROL IGN IGNITOR LS LIMIT SWITCH PL PLUG RS ROLLOUT SWITCH SA START ASSIST THC THERMOSTAT HEAT amp COOL TRANS TRANSFORMER VM VENT MOTOR YELLOW NOTES 1 REPLACEMENT WIRE MUST BE THE SAME SIZE AND TYPE OF INSULATION AS ORIGINAL USE COPPER CONDUCTOR ONLY 2 460V UNITS ARE SINGLE SPEED TO CHANGE FROM LOW TO HIGH SPEED REPLACE YELLOW MOTOR LEAD AT EMR 2 WITH BLACK MOTOR LEAD 3 CRANKCASE HEATER OPTIONAL MAX FUSE SIZE MAX HACR BREAKER SIZE 5TON 20 5TON 20 STATUS LIGHT L u _ OFF 1 BLINK 2 BLINKS 3 BLINKS 4 BLINKS 5 BLINKS 6 BLINKS EQUIP STATUS NO POWER OR INTERNAL CONTROL IGNITION FA
9. CASING MANUAL SHUT OFF WITHIN 4 VERTICAL OF ROOF SLAB 1 8 NPT PLUG FOR MEASURING SUPPLY GAS PRESSURE DRIP LEG 4 8 LONG NOTE DRIP LEG A MUST BE CAPPED UNIT GAS SUPPLY CONNECTION MUST BE TIGHT ROOF OR GROUND LEVEL INSTALLATION Suggested Gas Piping FIGURE 9 CHECKING INPUT TO UNIT 1 Gas input must never exceed the figure shown on the rating plate 2 Manifold pressure can be measured with a manometer attached 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 input using a gas meter proceed as follows a Turn off gas supply to all appliances except furnace With furnace burning time the two cubic foot hand on the gas meter dial plate for one revolution in seconds and divide this reading by two This will give seconds per cubic foot of gas being delivered to the furnace 1 04 b Assuming natural gas with heating value of Btu Cu Ft and Sec Cu Ft being determined from step 2a then 4000x3600 Sec Cu Ft 3 To adjust the regulator remove the cap on top of the gas valve To decrease the pressure decrease input to furnace turn the screw below the cap counterclockwise To increase the pressure increase input to furnace turn the screw clockwise The manifold pressure should not vary more than plus or minus 0 3 W C minimum 3 2 W C maximum 3 8 W C for natural gas Input Btu Hr N
10. CT DAMAGE SEVERE PERSONAL INJURY AND OR DEATH AA WARNING HAZARDS OR UNSAFE PRACTICES COULD RESULT IN PROPERTY DAMAGE PRODUCT DAMAGE SEVERE PERSONAL INJURY AND OR DEATH AACAUTION HAZARDS OR UNSAFE PRACTICES WHICH MAY RESULT IN PROPERTY DAMAGE PRODUCT DAMAGE AND OR PERSONAL INJURY AA WARNING THIS FURNACE IS DESIGN CERTIFIED FOR INSTALLATION IN BUILDINGS CONSTRUCTED ON SITE ONLY AA WARNING DO NOT USE THIS FURNACE IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL THAT HAS BEEN UNDER WATER 1 04 AA WARNING CARBON MONOXIDE REFERRED TOAS CO CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH AA WARNING WHILE CARBON MONOXIDE DETECTORS DO PROVIDE ADDITIONAL PROTECTION CURRENT LIMITATIONS TO THEIR EFFECTIVENESS REQUIRE THAT YOU OTHERWISE CONTINUE TO FOLLOW APPROPRIATE INSTRUCTIONS LOCATED IN THE INSTALLATION amp OPERATING INSTRUCTIONS AND USERS INFORMATION MANUALS RELATING TO PROTECTING PERSONS FROM THE RISKS OF CARBON MONOXIDE REVIEW EACH CO DETECTOR S MANUFACTURERS EXPLANATION OF THEIR UNIT S CAPABILITIES AND FOLLOW THE INSTALLATION AND OPERATING MANUAL WHEN INSTALLING AND OPERATING SUCH UNITS AA WARNING DO NOT CONNECT TO OR USE IN CONJUNCTION WITH THIS UNIT ANY DEVICES FORTHE PURPOSE OF SAVING ENERGY OR INCREASING OPERATING EFFICI
11. D WILL BE VACANT CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED MAINTAINED AND MONITORED IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT ALL WATER BEARING PIPES SHOULD BE DRAINED THE BUILDING SHOULD BE PROPERLY WINTERIZED AND THE WATER SOURCE CLOSED INTHE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURESAND WILL BE VACANT ANY HYDRONIC COIL UNITS SHOULD BE DRAINEDAS WELLAND IN SUCH CASE ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED A Panger PELIGRO CARBON MONOXIDE POISONING HAZARD Special Warning for Installation of Furnaces or Air Handling Units in Enclosed Areas such as Garages Utility Rooms or Parking Areas 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 struct
12. E INCH GAUGE OR THE SYSTEM MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BY CLOSING ITS INDIVIDUAL MANUAL SHUT OFF VALVE DURING ANY PRESSURE TESTING OF THIS GAS SUPPLY SYSTEM AT PRESSURES EQUAL TO OR LESS THAN 1 2 PSIG To check for leaks in piping use a soap and water solution or other approved method DO NOT USE AN OPEN FLAME IO 148D 5 A1 8 N P T plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the furnace Capacity of gas pipe of different diameters and length in ft hr with a pressure drop of 0 3 W C and a specific p p gravity of 0 60 natural gas Pipe 1 1 ieee ee A I Ce a BU Length 30 73 152 285 590 890 4 63 130 245 500 760 5 56 115 215 440 670 in Feet 60 50 105 195 400 610 70 46 96 180 370 560_ s0 43 90 170 350 I 530_ Nominal size of iron pipe in inches After the length of pipe has been determined select the pipe size which will provide the cubic feet per hour required for the gas input rating of the furnace By formula Cubic feet of _ gas required Gas input of appliance BTU hr Heating value of gas B TU ft 3 The gas input of the appliance is marked on the specification plate The heating value of the gas may be determined by contacting the gas utility or gas supplier GROUND UNION JOINT INSTALLED EXTERIOR TO
13. ENCIES WHICH HAVE NOT BEEN TESTED AND APPROVED BY US OR DESIGN CERTIFIED FOR USE WITH THIS UNIT SERIOUS DAMAGE REDUCED UNIT PERFORMANCEAND HAZARDOUS CONDITIONS MAY RESULT FROMTHE USE OF DEVICES WHICH HAVE NOT BEEN APPROVED OR CERTIFIED AA WARNING TO ENSURE PROPER INSTALLATION AND OPERATION OF THIS PRODUCT COMPLETELY READ AND UNDERSTAND THESE INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE INSTALL MAINTAIN OR REPAIR IF THESE INSTRUCTIONS ARE NOT FOLLOWED PRECISELY THERE IS A POTENTIAL OF CARBON MONOXIDE POISONING WHICH CAN RESULT IN SERIOUS ILLNESS OR DEATH AA WARNING THIS FURNACE WAS EQUIPPED AT THE FACTORY FOR USE WITH NATURAL GAS ONLY LIQUID PETROLEUM L P CONVERSION IF REQUIRED MUST BE PERFORMED BY A QUALIFIED TECHNICIAN FAMILIAR WITH PERFORMING THIS TYPE OF CONVERSION IF L P CONVERSION IS REQUIRED ALL INSTRUCTIONS INCLUDED WITH THE FACTORY AUTHORIZED KIT MUST BE FOLLOWED THE ONLY KIT THAT MUST BE USED FORTHIS CONVERSION IS THE FACTORY AUTHORIZED LPT 01 FAILURE TO FOLLOW THOSE INSTRUCTIONS EXPLICITLY MAY CAUSE FIRE EXPLOSION PROPERTY DAMAGE PERSONAL INJURY OR DEATH IO 148D AA WARNING THE GAS SUPPLY PIPE MUST NEVER BE USED FOR GROUNDING PURPOSES WARNING NEVER LAY THIS FURNACE ON ITS FRONT OR REAR AA WARNING HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE ROUTINE INSPECTION MAINTENANCE AND SUPERVISION IF THE BUILDING IN WHICH ANY SUCH DEVICE IS LOCATE
14. HAVE YOU DISCUSSED WITH YOUR INSTALLING CONTRACTOR THE OPTIONAL 400 00 2 THROUGH 5 YEAR COMPRESSOR LABOR ALLOWANCE PROGRAM US tiste For The United States and Canada only INSTALLATION amp OPERATING INSTRUCTIONS for COMBINATION HEATING and COOLING OUTDOOR UNITS PGB SERIES FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance DO NOT DESTROY FOR YOUR SAFETY e Do not touch any electrical switches Bo notietoreorus qasolineop do not use any phones in your g building PLEASE READ CAREFULLY other flammable vapors and e Immediately call your gas supplier AND KEEP IN A SAFE PLACE from neighbor s phone Follow the 4 1 0 el m any other appliance gas supplier s instructions e Ifyou cannot reach your gas supplier call the fire department All information contained herein is subject to change without notice Goodman Manufacturing Company L P 10 148D 2550 North Loop West Suite 400 Houston TX 77092 1 04 www goodmanmfg com 2003 2004 Goodman Manufacturing Company L P INDEX Introduction 2 Replacement Parts 2 Important Safety Instructions 2 Wear nln _ 2 Physical Dimensions a 4 Specifications
15. ILURE OR OPEN ROLLOUT SWITCH OR OPEN AUX LIMIT END SWITCH OPEN END SWITCH CLOSED WITHOUT INDUCER ON OPEN LIMIT SWITCH FALSE FLAME SENSED COMPRESSOR OUTPUT DELAY 460 3 60 CHECK INPUT POWER CHECK FUSE ON CONTROL GAS FLOW GAS PRESSURE GAS VALVE FLAME SENSOR FLAME ROLLOUT BAD SWITCH AUX LIMIT OPEN VENTER END SWITCH VENTER END SWITCH MAIN LIMIT OPEN BAD SWITCH STICKING GAS VALVE 3 MIN COMP ANTI CYCLE TIMER 1 04 COOLING TROUBLESHOOTING CHART A WARNING DISCONNECT 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 b Defective compressor valves b Replace compressor it wi 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 con
16. O gt lt P POWER SUPPLY Y R W G Y2 Y1 208 230 1 60 TO THERMOSTAT L1 SUPPLY VOLTAGE L2 ii COMPONENT LEGEND WIRE SPLICE ALS AUXILLARY LIMIT SWITCH MARKED TERMINAL BJB BLOWER JUNCTION BOX UNMARKED TERMINAL CAP CAPACITOR WIRING CAP 2 COMP COMPRESSOR LINE VOLTAGE H CM CONDENSER MOTOR LOW VOLTAGE CC CONTRACTOR FIELD INSTALLED POWER HIGH CH CRANKCASE HEATER FIELD INSTALLED CONTROL Tow a ES END SWITCH EM EVAPORATOR MOTOR WIRE GODE FS FLAME SENSOR B BLACK GV GAS VALVE BL BLUE IIC INTEGRATED IGNITION CONTROL BR BROWN IGN IGNITOR G GREEN LS LIMIT SWITCH O ORANGE PL PLUG PK PINK RS ROLLOUT SWITCH PU PURPLE SA START ASSIST R RED THC THERMOSTAT HEAT amp COOL W WHITE TRANS TRANSFORMER Y YELLOW VM VENT MOTOR 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 WHITE WIRE FROM TERMINAL TO TERMINAL 2 gt 0N TRANSFORMER 3 FOR 208 COMBUSTION MOTOR OPERATION CONNECT BLACK LEAD IN PLACE OF RED LEAD AT IIC D1 4 CRANKCASE HEATER OPTIONAL 5 START ASISST USED ON MODELS WITH INERTIA A SHELL COMPRESSORS ONLY MAX FUSE SIZE MAX HACR BREAKER SIZE 2 TON 25 2TON 20 2 5 TON 35 2 5 TON 30 3 TON 40 3 TON 40 3 5 TON 50 3 5 TON 50 4 TON 50 4 TON 50 5 TON 60 5 TON 60 208 230 1 60 STATUS LIGHT EQUIP STATUS CHECK ON NORMAL OPERATION
17. OR WIRING COMP COMPRESSOR LINE VOLTAGE CM CONDENSER MOTOR LOW VOLTAGE CC CONTRACTOR FIELD INSTALLED POWER CH CRANKCASE HEATER FIELD INSTALLED CONTROL CLT COMP LOCKOUT TIMER ES END SWITCH EM EVAPORATOR MOTOR GV GAS VALVE IC IGNITION CONTROL LS LIMIT SWITCH PL PLUG O ORANGE RS ROLLOUT SWITCH PK PINK SA START ASSIST PU PURPLE TFC TIMED FAN CONTROL R RED THC THERMOSTAT HEAT amp COOL W WHITE VM VENT MOTOR Y YELLOW WIRE CODE B BLACK BL BLUE BR BROWN G GREEN 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 WHITE WIRE FROM TERMINAL TO TERMINAL 2 ON TRANSFORMER 3 FOR 208 COMBUSTION MOTOR OPERATION CONNECT BLACK LEAD IN PLACE OF RED LEAD AT TFC D1 4 CRANKCASE HEATER OPTIONAL 5 COMP LOCKOUT TIMER USED ONLY ON MODELS EQUIPPED WITH SCROLL COMPERSSORS MAX FUSE SIZE MAX HACR BREAKER SIZE 3TON 25 3TON 20 3 5 TON 30 3 5 TON 30 4TON 35 4TON 30 STON 40 STON 40 208 230 3 60 B29121 03B 1 04 IO 148D WIRING DIAGRAM 460V NOTE 3 SUPPLY VOLTAGE 460 3 60 CH GX XD IDMR GX ov XD INSTALLER SERVICEMAN THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUIDE TO TROUBLESHOOTING THIS APPLIANCE STATUS LIGHT CODES ARE AS FOLLOWS LABEL MAT L WHITE VINYL LABEL SIZE 6 X 11 5 B29120 04C IS ADHESIVE BACKED LABEL B29121 04C IS 8 5 X 11 0 PAPER LABEL
18. as supplier call the fire department C Use only your hand to move the gas control switch or knob Never use tools If the gas control switch or knob will not operate don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an automatic ignition system which automatically lights the burners Do not try to light the burners by hand 5 Remove control access panel 6 Move the gas control switch or knob to OFF GAS CONTROL SWITCH SHOWN IN ON POSITION GAS CONTROL KNOB 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 8 Move the gas control switch or knob to ON 9 Replace control access panel 10 Turn on all electric power to the appliance 11 Set the thermostat to the desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appl
19. ding the burner assembly on end will allow any scale to fall out of the entrance end of the burners 13 Reinstall the flue collector box amp 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 the system may have to be cycled a couple of times before the pilot gas will ignite 1 04 LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand B BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any telephone in your building e Immediately call your supplier from a neighbor s phone Follow the gas suppliers instructions lf you cannot reach your g
20. ed space or crawl space should be insulated with at least 2 of insulation Usually 1 2 to 2 thickness of insulation is sufficient for duct work inside the air conditioned space Balancing dampers should be provided for each branch duct in the supply system Duct work should be properly supported from the structure FILTERS Filters are not provided with unit and must be supplied and installed in the return air system by the installer A field installed filter grille is recommended for easy and convenient access to the filters for periodic inspection and cleaning Filters must have adequate face area for the rated air quantity of the unit See table below for recommended filter size unit 2 2 TON 2 2 2 Ton TON 3TON 312 5 TON 4 TON Size 20x20x1 20x25x1 25x25x1 20x20x1 20x25x1 CLEARANCES The following minimum clearances must be observed for proper unit performance and serviceability 1 Provide 60 minimum clearance between top of unit and maximum 3 foot overhang 2 Unit is design certified for application on combustible flooring with base rails in place as shown on Figure 4 3 See Figure 4 for illustration of minimum installation combustible 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 covering materials if the bottom rails are in place COVER GASKET DETAIL CONVERSION 1 Remove screws and covers from bottom of suppl
21. hree 3 conductors in a raceway or cable see the N E C for derating the ampacity of each conductor ELECTRONIC IGNITION SYSTEM MODE OF OPERATION See the Sequence of Operation Flowchart for Mode of Operation OPERATING INSTRUCTIONS Instructions to start and shut off the furnace are in the lighting instructions on the unit and in the user s manual The initial start up on a new installation may require the control system to be energized for some time until any air has bled through the pilot burner and fuel gas is available at the pilot CHECK OUT PROCEDURE Before leaving the installation three 3 complete operating cycles should be observed Carefully follow the lighting instructions Run the unit through a normal operating cycle and observe the operation SERVICE Service should only be conducted by qualified service personnel See TroubleShooting Flowchart MAINTENANCE The heat exchanger should operate for many years without excessive scale buildup in the flue passageways However itis recommended that the user have a qualified service man to inspect the flue passageways the vent system and burners for continued safe operation paying particular attention to deterioration from corrosion or other sources IO 148D 10 The flue passageways and vent system should be inspected and cleaned if required by a qualified serviceman after the second year of service and annually thereafter using this procedure Comb
22. iance and call your service technician or gas supplier GAS CONTROL SWITCH SHOWN IN ON POSITION TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to its lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel FOR YOUR SAFETY IO 148D 4 Move the gas control switch or knob to OFF Do not force 5 Replace control access panel cause inju property da Improper installation adjustment alteration service or maintenance can ry or mage Refer to the user s information manual provided with this furnace For assistance or additional information consult a qualified installer service agency or the gas supplier This furnace must be installed in accordance with the manufacturers instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI Z223 1 For indoor installation PGB amp PGJ For outdoo r installation only WARNING If not installed operated and maintained in accordance with the manufacturer s instructions this product could expose you to substances in fuel combustion which can cause death or serious illness and are known which to the State of California to cause cancer birth defects or other reproductive harm This product contains fiberglass i Fiberglass contains a nsulation insulation
23. nstalled inside the structure The information on the rating plate is in compliance with the FTC and DOE rating for single phase units in the U S A The following information is for three phase units which are not covered under the DOE certification program in the U S A 1 The energy consumption of the ignition system used with the unit is 9 watts 2 The efficiency rating of this unit is a product thermal efficiency rating determined under continuous operating conditions independent of any installed system IMPORTANT The United States Environmental Protection Agency EPA has issued various regulations regarding the introduction and disposal of refrigerants in this unit Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines Because these regulations may vary due to the passage of new laws we suggest that any work on this unit be done by a certified technician Should you have any questions please contact the local office of the EPA MAJOR COMPONENTS The unit includes a hermetically sealed refrigerating system consisting of a compressor condenser coil evaporator coil with flowrator assembly an indoor blower a condenser fan a heat exchanger assembly gas furnace burner and control assembly combustion air motor and blower and all necessary internal electrical wiring The cooling system of these units is factory evacuated charged and performance tested Refrigera
24. nt amount and type are indicated on rating plate INSTALLATION PROCEDURE GENERAL In the U S A installation must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 Before attempting any installation the following points should be 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 IO 148D The air deflector plates and shields are in a box located in the return air compartment for shipping Secure one to the upper gas panel as shown in Figure 2 and secure the other two as shown in Figure 3 Air deflector plates are used on all PGB units equipped with a shield AIR DEFLECTOR PLATE GAS PANEL SHIELD DETAIL B cT p 5515 A Shield Required on Small Medium and Large Chassis FIGURE 2 INNER SHIELD OUTER SHIELD CHASSIS E SMALL 242 812 LARGE FIGURE 3 1 04 This unit is designed for outdoor installations It can be mounted on a slab or rooftop It is not to be installed within any part of a structure such as an attic crawl space closet or any other place where condenser air flow is restricted or other than outdoor ambient conditions prevail Since the unit is to be installed outdoors it is im
25. on or addition Consult your local utility BEFORE installing DUCTING Duct work should be fabricated by the installing contractor in accordance with local codes Industry manuals such as NESCA National Environmental Systems Contractors Association 1501 Wilson Blvd Arlington Virginia 22209 may be used as a guide when sizing and designing the duct system AA WARNING DO NOT UNDER ANY CIRCUMSTANCES CONNECT DUCT WORK TO ANY OTHER HEAT PRODUCING DEVICE SUCH AS FIREPLACE INSERT STOVE ETC UNAUTHORIZED USE OF SUCH DEVICES MAY RESULT IN FIRE CARBON MONOXIDE POISONING EXPLOSION PROPERTY DAMAGE PERSONAL INJURY OR DEATH IO 148D This unit should be placed as close to the space to be air conditioned as possible Adequate clearance must be maintained as indicated in the Section called Clearances Ducts should be run as directly as possible to supply and return outlets Use of non flammable weatherproof flexible connectors on both supply and return connections at unit to reduce noise transmission is recommended It is preferable to install the unit on the roof of the structure if the registers or diffusers are located on the wall or in the ceiling A slab installation could be considered when the registers are low on a wall or in the floor On duct work exposed to outside air conditions of temperature and humidity use a minimum of 2 of insulation with a good R factor and vapor barrier Distribution system in attic furr
26. onnections HIGH VOLTAGE WIRING Single phase Two leads should be connected to terminals L1 and L2 in the electrical control section using wire sizes specified in wiring table Three phase Three leads should be connected to terminals L1 L2 and L3 in the electrical control section using wire sizes specified in wiring table LOW VOLTAGE WIRING Connect 24 V wires from the thermostat to the corresponding wires in control box using No 18 AWG as follows THERMOSTAT NOTES White W Heat Green Yeow Coo Cn s _ 1 04 INTERNAL WIRING A diagram of the internal wiring of this unit is located on the interior 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 original wiring Transformer and combustion air motor are factory wired for 230 volts on 208 230 volt models See wiring diagram for 208 volt wiring 1 For branch circuit wiring main power supply to unit disconnect the minimum wire size for the length of run can be determined from Table 2 using the circuit ampacity found on the unit rating plate From the disconnect to the unit the smallest wire size allowable in Table 2 may be used as the disconnect must be within the sight of the unit 2 Wire size based 60 rated wire insulation 30 Ambient Temp 86 F 3 Formore than t
27. ote For elevations up to 2 000 feet full input ratings apply In U S A for elevations over 2 000 feet reduce input 4 for each 1 000 feet above sea level by changing the burner orifices See appropriate marking on the unit for input 4 The furnace is to be adjusted to obtain a temperature rise within the range specified on the appliance rating plate BURNERS Burners for these units have been designed so that field adjustment is not required Burners are accessible for easy cleaning when required CONDENSATE DRAIN The condensate drain connection of the evaporator is a half coupling of 3 4 N P T A trap must be provided to have proper condensate drainage Install condensate drain trap as shown in Figure 10 Use 3 4 drain connection size or larger Do not operate without trap Unit must be level or slightly inclined toward drain An auxiliary drain is also provided DRAIN CONNECTION UNIT FLEXIBLE i TUBING HOSE 3 MINIMUM OR PIPE i A POSITIVE LIQUID SEAL IS REQUIRED FIGURE 10 COMBUSTION AIR FAN Inspect fan motor blower housing prior to each heating season to see that both are clear of obstructions and turn freely NOTE Some motors are dual voltage and require wiring change for 208V operation See wiring diagram FURNACE ACCESS PANEL Design of this system requires that the combustion compartment be sealed for proper furnace operation Never operate furnace with access panel removed or screws
28. ping or concealed should be filed immediately with the shipping company Check the unit model number specifications electrical characteristics and accessories to determine if they are correct In the event an incorrect unit is shipped it must be returned to the supplier and must NOT be installed The manufacturer assumes no responsibility for installation of incorrectly shipped units IO 148D REPLACEMENT PARTS ORDERING PARTS When reporting shortages or damages or ordering repair parts give the complete unit model and serial numbers as stamped on the unit s nameplate Replacement parts for this appliance are available through your contractor or local distributor For the location of your nearest distributor consult the white business pages the yellow page section of the local telephone book or contact SERVICE PARTS DEPARTMENT GOODMAN MANUFACTURING COMPANY L P 2550 NORTH LOOP WEST SUITE 400 HOUSTON TEXAS 77092 713 861 2500 IMPORTANT SAFETY INSTRUCTIONS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS The following symbols and labels are used throughout this manual to indicate immediate or potential hazards It is the owner s responsibility to read and comply with all safety information and instructions accompanying these symbols Failure to heed safety information increases the risk of property damage product damage personal injury or death QA DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN PROPERTY DAMAGE PRODU
29. portant to consult your 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 the evaporator The design of this unit meets this code requirement in that the return air passes over the heat exchanger first before coming into contact with the evaporator coil preventing condensation from taking place within the heat exchanger SLAB INSTALLATION FIGURE 4 1 Selecta location where external water drainage cannot collect around unit 2 Provide a level concrete slab min flush with all four sides of the unit The slab should be isolated from the foundation wall Ensure that there is no obstruction to condenser or combustion air by fences shrubs etc 3 The location of the unit should be such as to provide proper access for inspection and servicing 4 Bottom rails are supplied for slab installation RON TLL PERRY N S SS S lt lt s L 7 MN P ofl lt 12 48 SERVICE CLEARANCES COMBUSTIBLE MATERIALS AND OUTSIDE SLAB INTALLATION FIGURE 4 ROOFTOP INSTALLATION 1 Before locating the unit on the roof make sure that the strength of the roof and beams is adequate at the point to support the weight involved This is very important and installer s responsibility The following list shows approximate weight of unit
30. trol 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 check compressor 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 restriction Iced 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 Improperly sized unit Recalculate load Improper airflow Check should be approximately 400 CFM per ton Incorrect refrigerant charge Charge per procedure attached to unit service panel Incorrect voltage At compressor terminals voltage must be within 10 of nameplate volts when unit is operating Evaporator coil freezing or frosting Low airflow
31. ure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death B10259 216 1 04 PHYSICAL DIMENSIONS FIGURE 1 BLOWER amp CONDENSER ACCESS PANEL CONDENSATE DRAIN DISCHARGE PRESSURE SERVICE PORT CONNECTION 3 4 NPT FEMALE SUCTION PRESSURE SERVICE PORT POWER WIRE ENTRANCE CONTROL WIRE ENTRANCE SUPPLY GAS ENTRANCE FRESHAIR DAMPER OPENING WWWX gt PGB042125 PGB042150 PGB048075 PGB024050 PBG048100 DIMENSIONS PGB024075 PGB048125 INCHES PGB030050 PGBO030100 PGB048150 PGBO030075 PGB036100 PGB060100 PGB036050 PGB042075 PGB060125 PGB036075 PGB042100 PGBO060150 S S 5536 D em 1632 2456 15 15 17 G H F s el r T ea 2632 2 7 7 T Ym ACCESSORY MODEL NUMBERS ALL PGB MODELS MODEL NUMBERS LP Conversion Kit Honeywell HSP EPMO Room Thermostat CHT 18 60 High and Low Pressure Kit HLPK 01 Low Ambient Kit LA 01 12 3 8 12 3 8 14 7 8 IO 148D 4 1 04 SPECIFICATIONS GENERAL These Combination Gas Heating Electric Cooling Rooftops are available in 46 69 92 115 and 140 000 Btu Hr heating inputs and cooling capacities of 2 2 3 3 4 4 and 5 nominal tons of cooling Units are convertible from horizontal supply and return to bottom supply and return by relocation of cap panels The units are weatherized for installing outside of the building Units are not to be i
32. ustion air motor and blower should be checked for obstructions prior to each heating season 1 Turn off all power to the furnace and set the thermostat lever to the lowest temperature 2 Shut off the gas supply to the furnace either at the meter or ata 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 lift the burner cover off 10 Each heating section has a flue collector box cover in the flue outlet Remove the screws in the collector box and wires from the combustion motor 11 The furnace sections can now be cleaned by the use of a wire brush with a flexible handle Slide brush through each section Sweeping back and forth through each section will loosen any scale allowing it to fall to the bottom of the sections The debris can now be brushed out of the bottom sections or cleaned with the nozzle of a vacuum cleaner 12 Check the ports on the gas burners to make certain that they are clean Brushing or jarring may loosen any accumulation Stan
33. y and return sections 2 Using covers as a template drill 1 8 diameter holes in unit from around the duct openings 1 04 SUPPLY AIR RETURN AIR COVER INSULATION SUPPLY RETURN AIR COVER FOAM TAPE AROUND FLANGE FIGURE 8 IMPORTANT NOTE When casing panels other than access panels are removed for service any insulation that is damaged or torn must be replaced by identical material PIPING GAS CONNECTION 1 The gas line connection to the unit must be made through the gas pipe opening provided into the 1 2 inlet valve opening See Figure 9 for typical piping 2 The gas line to the furnace should be of adequate size to prevent undue pressure drop and should never be less than 1 2 A trap should be installed in the gas supply line as close to the unit as possible An outside ground joint union should be installed to connect the gas supply to the control assembly gas valve 3 Gas controls have been factory installed Another manual shut off valve should be installed where local codes specify a shut off valve is to be located outside the unit casing See Figure 9 4 Piping should be tight A pipe compound resistant to the action of liquefied petroleum gases must be used at all threaded pipe connections CAUTION THE FURNACE AND ITS INDIVIDUAL SHUT OFF VALVE MUST BE DISCONNECTED FROM THE GAS SUPPLY PIPING DURING ANY PRESSURE TESTING OF THAT SYSTEMAT TEST PRESSURES IN EXCESS OF 1 2 POUND PER SQUAR
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