installation and operating instructions thru-the …€¦ · a qualified service agency should be...

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9700539

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE

CAN CAUSE INJURY OR PROPERTY DAMAGE. REFER TO THIS MANUAL.

INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY, OR THE GAS SUPPLIER.

Wolf Steel Ltd�, 24 Napoleon Rd�, Barrie, ON, L4M 0G8 Canada / 103 Miller Drive, Crittenden, Kentucky, USA, 41030

Phone(866)820-8686•Fax(705)725-1150•www.napoleonheatingandcooling.com •[email protected]

MANUFACTURERRESERVESTHERIGHTTODISCONTINUE,ORCHANGEATANYTIME,SPECIFICATIONSORDESIGNSWITHOUTNOTICEANDWITHOUTINCURRINGOBLIGATIONS.

INSTALLATION AND OPERATING INSTRUCTIONS

THRU-THE-WALL PACKAGED UNIT

THE HIGHEST EFFICIENCY THRU-THE-WALL SELF CONTAINED HEATING & COOLING UNIT

CONFORMSTOANSI/ULSTD.1995,ANSISTD.Z21.47CERTIFIEDTOCAN/CSASTD.C22.2NO.236,CAN/CSASTD.2.3ANDCAN/CGASTD.2.17

INSTALLATION SHALL BE MADE IN ACCORDANCE WITH THE REQUIREMENTS OF

THE LOCAL AUTHORITIES HAVING JURISDICTION, AND WITH THE NATIONAL

FUEL GAS CODE, ANSI Z223.1 (LATEST EDITION) AND THE NATIONAL ELECTRICAL

CODE IN THE UNITED STATES OR CAN/CGA-B149.1 & .2 AND THE CANADIAN

ELECTRICAL CODE CSA C22.1 PART 1 (LATEST EDITION) IN CANADA.

ANY ALTERATION OF INTERNAL WIRING WILL VOID CERTIFICATION AND WARRANTIES.

UNIT CONTAINS R-410A REFRIGERANT AND POE COMPRESSOR OIL.

USE ONLY R-410A REFRIGERANT AND APPROVED POE COMPRESSOR OIL.

PROPER SERVICE EQUIPMENT IS REQUIRED. USE ONLY R-410A APPROVED

SERVICE EQUIPMENT.

FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE

VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. SUCH ACTIONS COULD RESULT IN PROPERTY

DAMAGE, PERSONAL INJURY, OR DEATH.

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

FAILURE TO FOLLOW SAFETY WARNINGS AND INSTRUCTIONS EXACTLY COULD

RESULT IN SERIOUS INJURY, DEATH OR PROPERTY DAMAGE.

• Installationandservicemustbeperformedbyaqualifiedinstaller,serviceagencyorthegassupplier.

• Beforeservicing,disconnectallelectricalpowertounit.• Whenservicingcontrols,labelallwirespriortodisconnecting.Reconnectwirescorrectly.

• Verifyproperoperationafterservicing.• Donotstoreorusegasolineorotherflammablevaporsandliquidsinthevicinityofthisoranyotherappliance.

• Afterinstallingtheunit,showuserlocationsofmainelectri-calDisconnectSwitchtoCondopackandhowtheunitcanbede-energizedusingswitch.

CAUTION! !

! IMPORTANT!

WHAT TO DO IF YOU SMELL GAS: ■ Donottrytolightanyappliance. ■ Donottouchanyelectricalswitch;donotuseanyphoneinyourbuilding.

■ Leavethebuildingimmediately. ■ Immediatelycallyourgassupplierfromaneighbor’sphone.Followthegassupplier’sinstructions.

■ Ifyoucannotreachyourgassupplier,callthefiredepartment.

Powered By:

WARNING !!

INSTALLER: PLEASEFAMILIARIZEYOURSELFWITHTHISMANUALBEFOREPROCEEDINGWITHTHEINSTALLATION.LEAVETHISMANUALWITHTHEAPPLIANCEFORFUTUREREFERENCE.

CONSUMER:RETAINTHISMANUALFORFUTUREREFERENCE.

HIGH EFFICIENCY GAS HEAT & ELECTRIC COOLING

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TABLE OF CONTENTS1. MODEL NOMENCLATURE ........ ................................................................................................................. 32. OVERVIEW ................................. ................................................................................................................. 33. SAFETY ...................................... ................................................................................................................. 4

3.1 SAFETYSYMBOLSANDWARNINGS ��43.2 SAFETYRULES ��73.3 CODES ��8

4. INSTALLATION .......................... ................................................................................................................. 94.1 UNITDIMENSIONS ��104.2 UNITLOCATIONANDCLEARANCES �� 114.3 PACKAGEDUNITPREPARATION ��164.4 WALLSLEEVEASSEMBLY ��174.5 UNITSUPPORT ��234.6 PACKAGEDUNITINSTALLATION ��244.7 DUCTWORK ��254.8 CONDENSATEDRAINCONNECTION ��274.9 VENTINGANDCOMBUSTIONPIPING ��284.10 GASSUPPLYANDPIPING ��284.11 GASCONNECTIONS ��284.12 GASINLETPRESSURE ��294.13 LEAKTESTING ��304.14 PURGINGGASLINES ��304.15 CONVERSIONS ��304.16 ELECTRICAL ��33

5. STARTUP AND SHUTDOWN .... ............................................................................................................... 415.1 FURNACESTARTUP ��415.2 FURNACESHUTDOWN ��425.3 AIRCONDITIONINGSTARTUP ��425.4 AIRFLOW ��43

6. MAINTENANCE ......................... ............................................................................................................... 456.1 GENERALSAFETYRULES ��456.2 COOLINGCHASSIS ��466.3 AIRFILTER ��466.4 LUBRICATION ��466.5 GASMETER ��476.6 ROUTINEMAINTENANCE ��47

7. TROUBLESHOOTING ............... ............................................................................................................... 487.1 FURNACETROUBLESHOOTINGCHART ��487.2 AIRCONDITIONINGTROUBLESHOOTING ��497.3 ADJUSTINGSYSTEMCHARGE ��507.4 DIAGNOSTICCODESFORSTATUSLED ��517.5 FAULTCODEHISTORY ��51

8. OWNER’S SERVICE INFORMATION .................................................................................................... 529. WARRANTY ............................... ............................................................................................................... 53

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1. MODEL NOMENCLATURE

P=Condo Pack A, B, C

Gas Condensing

030 - 30 000 Btu/h 015 - 15 000 Btu/h

040 - 40 000 Btu/h 050 - 50 000 Btu/h

000 - No Heat

012 - 12 800 Btu/h / 1.0 Ton018 - 16 500 Btu/h / 1.5 Ton024 - 19 500 Btu/h / 2.0 Ton030 - 24 400 Btu/h / 2.5 Ton

000 - No CoolingAir Conditioning

P S C A A040 018HEAT

CAPACITYHEAT TYPE

COOLING CAPACITYMODELBRAND

COOLINGTYPE REVISION

S=Single Packaged Vertical

C - Gas CondensingS - Gas StandardE - ElectricalH - HydronicD - Duct only (No heat)

Hydronic Heat

030 - 30 000 Btu/h 000 - Duct Only 000 - Duct Only

042 - 42 000 Btu/h

E lectr ic Heat

005 - 5.0 kW 007 - 7.5 kW010 - 10 kW015 - 15 kW

Gas Standard(80%)

038 - 38 000 Btu/h 026 - 26 000 Btu/h

051 - 51 000 Btu/h 064 - 64 000 Btu/h

000 - Duct Only

Heat designation Heat designation

Heat designationHeat designation

A - Air Conditioning Standard Efficiency C - Air Conditioning High EfficiencyH - Heat Pump Standard Efficiency P - Heat Pump High EfficiencyF - Blower Only (No Cool) i.e. PSC040F000A

Example: PSC040A018A - Condo Pack- Single Packaged Vertical- Condensing Gas heating 40k Btu/h- AC 1.5 ton- Rev A

TheseinstructionscovertheinstallationoftheCondoPack,whichconsistsoffourseparatesections:thewallsleeve,thecabinet,theairconditioning(AC)andthefurnacemodules.Insteadofreplacingthecompletesystem,theACandfurnacemodulescanbepartiallyorfullyremovedforservicing.Allcontrolharnessesareseparatedwithmodularquickdisconnects,somodulereplacementsdonotrequirerewiring.Bothmoduleshavebeenfactoryrun-testedandreadyforeasyinstallationasacompletepackage.Thisunit,equippedwithahighefficiencyfurnacemodule,iscertifiedasaCategoryIVdirectventcentralforcedair furnace� Theseinstructionsareintendedasanaidtothelicensedservicetechnician.Improperinstallationmaydamageequipment,voidthewarranty,andcancreateahazard,resultingininjuryordeath.OurHVACsystemsandcomponentsaredesignedtobeinstalledbyqualifiedHVACtechniciansONLY.TheinstallationofHVACsystemsincludeselectrical,gas,andrefrigerantconnectionsandisregulatedbyamultiplesetoflaws,codesandguidelines,atthefederal,stateandlocallevels.Itistheinstaller’sresponsibilitytoinstalltheproductinaccordancewithallapplicablecodesandregulations.Itisthehomeowner’sresponsibilitytoproperlymaintaintheequipment.NOWARRANTYisofferedfortheproductsthatwereinstalledbyunlicensed/unauthorizedpersons.Failuretocomplywiththispolicycouldleadtoviolationsofapplicablelawsthatarepunishable.Documentationandspecificationsarecontinuouslyupdatedandsubjecttochange.Pleasedownloadthelatestversionofspecificationsandmanualsathttp://www.napoleonheatingandcooling.com.

2. OVERVIEW

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Onlytrainedservicetechniciansfamiliarwithstandardserviceinstructionsandtrainingmaterialsshouldattemptinstallation,service,andrepairoftheseunits.Improperinstallation,adjustment,alteration,service,maintenance,orusecancauseexplosion,fire,electricalshock,orotherconditionswhichmaycausedeath,personalinjury,orpropertydamage.Forinformationandassistance,consultaqualifiedinstaller,serviceagency,yourdistributororbranch.Followallsafetycodes.Wearsafetyglasses,protectiveclothing,andworkgloves.Havefireextinguisheravailable.Readinstructionsthoroughlyandfollowallwarningsorcautionsincludedinliteratureandattachedtotheunit.Consultfederal,provincial,state,andlocalcodesforspecialrequirements.

3. SAFETY

3.1 SAFETY SYMBOLS AND WARNINGS

UnderstandandpayparticularattentiontothewordsDANGER,WARNING,andCAUTIONandthefollowingdefinedsymbolsareusedthroughoutthismanualtonotifythereaderofpotentialhazardsofvaryingrisklevels.

HIGHLIGHTSSUGGESTIONSWHICHWILLRESULTINENHANCEDINSTALLATION,RELIABILITY,OROPERATION.

NOTE

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

WARNING !!

SUGGESTS IMPORTANT PROCEDURE STEPS TO INSURE PROPER INSTALLATION, RELIABILITY, OR OPERATION.

IMPORTANT! !

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

DANGER! !

INDICATESAPOTENTIALHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,MAYRESULTINMINORORMODERATEINJURY.ITMAYALSOBEUSEDTOALERT

AGAINSTUNSAFEPRACTICES.

CAUTION! !

H3.3.2.SafetySymbols

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IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FOR YOUR SAFETYDO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS, OR

OTHER COMBUSTIBLE MATERIALS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.WHAT TO DO IF YOU SMELL GAS

•DO NOT TRY TO LIGHT ANY APPLIANCE.•DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR

BUILDING.• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE, OR

A CELLULAR PHONE FROM A LOCATION WELL AWAY FROM THE BUILDING. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.

• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.•DO NOT RE-ENTER THE BUILDING UNTIL AUTHORIZED TO DO SO BY THE GAS

SUPPLIER OR THE FIRE DEPARTMENT.IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN

CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. REFER TO THIS MANUAL.INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SER-

VICE AGENCY OR THE GAS SUPPLIER.H3.3.3. GS_CP

WARNING! !

SHOULD THE GAS SUPPLY FAIL TO SHUT OFF OR IF OVERHEATING OCCURS, SHUT OFF THE GAS VALVE TO THE FURNACE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY.

WARNING! !

DO NOT USE THIS FURNACE IF ANY PART HAS BEEN UNDER WATER. A FLOOD DAMAGED FURNACE IS EXTREMELY DANGEROUS. ATTEMPTS TO USE THE FURNACE

CAN RESULT IN FIRE OR EXPLOSION. A QUALIFIED SERVICE AGENCY SHOULD BE CONTACTED TO INSPECT THE FURNACE AND TO REPLACE ALL GAS CONTROLS,

CONTROL SYSTEM PARTS, ELECTRICAL PARTS THAT HAVE BEEN WET OR THE FURNACE IF DEEMED NECESSARY.

WARNING! !

FOR PROPER AND SAFE OPERATION THE FURNACE NEEDS AIR FOR COMBUSTION AND VENTILATION. DO NOT BLOCK OR OBSTRUCT AIR OPENINGS ON THE FURNACE, AIR

OPENINGS TO THE AREA IN WHICH THE FURNACE IS INSTALLED, AND THE SPACINGS AROUND THE FURNACE.

WARNING! !

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THIS INFORMATION IS INTENDED FOR USE BY QUALIFIED HVAC TECHNICIANS. ANY ATTEMPT TO REPAIR A CENTRAL AIR CONDITIONING PRODUCT MAY RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE. THE MANUFACTURER OR SELLER CANNOT BE RESPONSIBLE FOR THE INTERPRETATION OF THIS INFORMATION, NOR

CAN IT ASSUME ANY LIABILITY IN CONNECTION WITH ITS USE.

UNITCONTAINSR-410AREFRIGERANTANDPOECOMPRESSOROIL.USEONLYR-410AREFRIGERANTANDAPPROVED POE COMPRESSOR OIL. REFRIGERANT LINES MUSTBEBRAZEDANDRATEDFORR410PRESSURES!PROPERSERVICEEQUIPMENTISRE-QUIRED.USEONLYR-410AAPPROVEDSERVICEEQUIPMENT.FAILURETOUSEPROPER

SERVICETOOLSMAYRESULTINEQUIPMENTDAMAGEORPERSONALINJURY.

DURINGTHE INSTALLATION,TESTING,SERVICING,ANDTROUBLESHOOTINGOFTHISPRODUCT,ITMAYBENECESSARYTOWORKWITHELECTRICALCOMPONENTS.THERE

ISARISKOFELECTRICSHOCKWHICHCANCAUSEINJURYORDEATH:DISCONNECTALLREMOTEELECTRICPOWERSUPPLIESBEFORESERVICING!

HOT SURFACE! DO NOT TOUCH TOP OF COMPRESSOR. COMPRESSOR AND DIS-CHARGE PIPES MAY BE EXTREMELY HOT. THIS MAY CAUSE MINOR TO SEVERE BURNS.

ALLR-410ASYSTEMSUSEPOEOIL.POEOILEASILYABSORBSMOISTUREFROMTHEAIR.ASYSTEMWHICHHASBEENEXPOSEDTOTHEATMOSPHEREFORMORETHAN4HOURS

REQUIRESTHATTHECOMPRESSOROILBEREPLACED.NEVERBREAKAVACUUMWITHAIRANDALWAYSCHANGETHEFILTERDRIERWHENOPENINGTHE

SYSTEMFORCOMPONENTREPLACEMENT.

WARNING! !

WARNING! !

CAUTION ! !

CAUTION ! !

H3.3_AC

H3.4.2_CP

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT.

READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER

INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION,

PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING! !

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3.2 SAFETY RULES

H3.6.1

WHEN THIS UNIT IS INSTALLED IN A STORAGE GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18” (457 mm)

ABOVE THE FLOOR TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN THE GARAGE.

THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES.

FAILURE TO HEED THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

WARNING !!

1� Usethisunitonlywithtypeofgasapprovedforthefurnacemodule.Refertotheunitratingplate.2� Storethisunitonlyindryindoorlocations(protectedfromweather).3� DONOTinstallthisunitoutdoorsorinamobilehome,trailerorrecreationalvehicle.Thisapplianceis

notdesigned/certifiedfortheseinstallations.4� DONOTinstallunitinacorrosiveorcontaminatedatmosphere.5. ForlightingandshuttingdownthefurnacerefertoFurnace Start Up and Furnace Shut Down,

section5ofthismanual.6� Installthisunitonlyindryindoorlocations(protectedfromweather).7. Provideadequatecombustionandventilationairtotheunitspaceasspecifiedinsection4.9

“VentingandCombustionPiping”.8� Combustionproductsmustbedischargedoutdoorsusingfactoryinstalledventsystemonly,as

specifiedinsection4.9“VentingandCombustionPiping”.9. Nevertestforgasleakswithanopenflame.Useacommerciallyavailablesoapsolutionmade

specificallyforthedetectionofleakstocheckallconnectionsasspecifiedin“GasSupplyandPiping”sectionofthismanual.

10� BothSupplyandReturnAirmustbeductedtotheappliancefromroomsseparatetotheenclosurehousingtheappliance.Besurethatductsystemhasexternalstaticpressurewithinallowableoperatingrange(aslistedonunit’sRatingPlate).Completelysealsupplyandreturnairductstounitcasing.SeeSection4.7“Ductwork”formoredetail.

11� Alwaysinstallunittooperatewithinthetemperature-riserangeandanexternalstaticpressurerange(ducting),aslistedontheunitratingplate.

12� Agas-firedunitforinstallationinastoragegaragemustbeinstalledsothattheignitionsources,includingblowersandcontactors(Seepage 15, “IMPORTANT”, 1a.),arenolessthan18”(457mm)abovethefloor.Theunitmustbelocated,orprotectedtoavoidphysicaldamagebyvehicles.Seesafetywarnings.

13� Returnairtemperaturerangethatmustbemaintainedis:• between55°F(13°C)and80°F(27°C)forgasheatand• between65°F(18°C)and90°F(32°C)forairconditioning.

14� Thefurnacemustbekeptfreeandclearofinsulatingmaterial.Carefullyexaminethefurnaceareawhenthefurnaceisinstalledor/wheninsulationisadded.Insulatingmaterialmaybecombustible.

15. DO NOT USE FOR HEATING AND COOLING BUILDINGS OR STRUCTURES UNDER CONSTRUCTION! Unitsthataredamagedorentrainedwithconstructiondebriswillnotbecoveredunderwarranty.

16� Beforeinstallingunit,makesureyouknowallapplicablecodes.National,stateandlocalcodesmaytakeprecedenceoveranyinstructionsinthismanual.Besuretoconsult:• AuthoritieshavingjurisdictionoverHVACsysteminstallations;• Localcodeauthoritiesforinformationonelectricalwiring.

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H3.5.1. GS_FMW

DO NOT INSTALL THIS UNIT IN A MOBILE HOME! THIS UNIT IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, PROPERTY

DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.THE FURNACE CONTAINS FOIL COVERED FIBERGLASS INSULATION. INHALATION OF FIBERGLASS PARTICLES IS ASSOCIATED WITH RESPIRATORY DISEASE INCLUDING

CANCER.NATURAL GAS AND PROPANE ARE NORMALLY ODORIZED BY THE FUEL SUPPLIER. IN SOME CASES, THE ODORANT MAY NOT BE PERCEIVABLE. INSTALLATION OF UL AND ULC RECOGNIZED FUEL GAS DETECTORS INSTALLED IN ACCORDANCE WITH THEIR MANUFACTURER’S INSTRUCTIONS ARE RECOMMENDED AS AN ADDITIONAL

MARGIN OF SAFETY.THE EXHAUST GASES FROM THIS FURNACE CONTAIN CHEMICALS WHICH ON

SOME OCCASIONS MAY INCLUDE CARBON MONOXIDE. CARBON MONOXIDE IS AN ODORLESS, TASTELESS, CLEAR COLORLESS GAS WHICH IS HIGHLY TOXIC. EVEN

LOW CONCENTRATIONS ARE SUSPECTED OF CAUSING BIRTH DEFECTS AND OTHER REPRODUCTIVE HARM.

UL AND ULC RECOGNIZED CO DETECTORS ARE REQUIRED FOR ALL BUILDINGS EQUIPPED WITH FOSSIL FUEL BURNING APPLIANCES. ALL CO DETECTORS SHOULD BE INSTALLED IN ACCORDANCE WITH THEIR MANUFACTURER’S INSTRUCTIONS AND

APPLICABLE LOCAL BUILDING CODES.FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD!

FAILURE TO REPLACE WITH PROPER CONTROL COULD RESULT IN FIRE, EXPLOSION OR CARBON MONOXIDE POISONING.

REPLACE GAS VALVE ONLY WITH THE SAME MODEL NUMBER OR AS SPECIFIED BY THE MANUFACTURER.

WARNING! !

3.3 CODES

H6.4

1. This unit must be installed:a� Inaccordancewithalllocalcodes,by-lawsandregulationsbythoseauthoritieshavingjurisdiction.b. InCanada,thisfurnacemustbeinstalledinaccordancewiththecurrentCAN/CGA-B149.1and B149.2NaturalGasandPropaneCode.c� IntheUnitedStates,thisfurnacemustbeinstalledinaccordancewiththecurrentANSIZ223.1 (NFPA54)NationalFuelGasCode.

2. Electrical connections must be made in accordance with:a� Anyapplicablelocalcodes,by-lawsandregulations.b. Canada:currenteditionofCAN/CSAC22.1andC22.2,CanadianElectricalCode(Part1and2).c� UnitedStates:currenteditionofANSI/NFPA70,NationalElectricalCode.

3. Codes and additional information may be obtained from:

CanadianStandardsAssociation5060SpectrumWayMississauga,Ontario,L4W5N6Phone:(416)747-4000website:www.csa.ca

NationalFireProtectionAssociation1BatterymarchParkQuincy,MA,02169-7471Phone:(617)770-3000website:www.nfpa.org

AmericanGasAssociation400 North Capitol Street, NW, Suite450WashingtonDC,20001Phone:(202)824-7000website:www.aga.org

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SUPPLY OUTLET

PRIMARY HEAT EXCHANGER

RETURNINLET

FURNACE MODULE

GAS CONNECTION

FILTER

THERMOSTAT WIRING SLOT

ELECTRICAL BOX

CHASSIS CABINET

ACCESSPANEL

WALL SLEEVE

ACDRAIN

FURNACEDRAIN

COOLINGMODULE

CONTROL BOARD INSPECTION WINDOW

COMBUSTION DISCHARGE TERMINAL

FLAME INSPECTION WINDOW

4. INSTALLATIONTheunitisshippedinonepackage,completelyassembledandwired.Theairconditioningandfurnacecondensatedrainsareshippedseparatelywiththeunitforfieldinstall.

Ifanydamageisfound,propernotationshouldbemadeonthecarrier’sfreightbill.Damageclaimsshouldbefiledwiththecarrierasquicklyaspossible.

Checktheratingplate(atthefrontoftheaccesspanel)toconfirmheatingandcoolingcapacities.Theunitshouldbeoperatedonlywiththetypeofgasandelectricalsupplynotedontheratingplate.

H8.2.1

1� Thefurnacemustnotbelocatedinanareawherethecombustionairisladenwithchemicalcompoundssuchasbromine,chlorineorfluorine,asmaybefoundinswimmingpoolchemicals,laundrydetergents,etc.Thesecompoundswhenexposedtoflame,formacidswhichattacktheheatexchangerandothercomponents.Exposuretothefollowingsubstancesinthecombustionairsupply(butnotlimitedtothefollowing)arenotallowed,andwillaffectwarrantyclaims:• Aerosols,particularlyCFCbasedorpropelledaerosols• Airfresheners• “AirplaneGlue”andsimilaradhesivesandcements• Ammonia,ascommonlyfoundinpermanentwavesolutionsusedinhairdressingsalons• Anti-staticfabricsoftenersusedinclothesdryers• Carbontetrachloride• Chlorinatedcleanersandwaxes• Chlorineandbrominebasedswimmingpoolchemicals• De-icingsaltsorchemicals(rocksalt,etc.)• Drycleaningfluidssuchasperchloroethylene• Fumesfromcuringpolyurethaneandsimilarsubstances• HalogenbasedrefrigerantsincludingR-12andR-22• Hydrochloricacid,muriaticacidandotheracidbasedmasonrywashingandcuringmaterials• Printer’sinks,paintremovers,varnishes,varsol,toluene,etc.• Watersoftenersaltandchemicals

2� Ifthefurnaceisinstalledinanareawherefreezingmayoccur,agarage,anattic,acrawlspaceoranyunconditionedspace,stepsmustbetakentoprotectthecondensatetrapanddrainlinefromfreezing.

BEFORE INSTALLATION, REMOVE THE CHASSIS SHIPPING BRACKETS AND REPLACE THE SCREWS BACK TO THE UNIT.

IMPORTANT! !

FIG. 4.0

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20 1516 "

25 116 "

24 18 " 1 15

16"

1 116 "

7 18 "

1 1516 "

RETURN INLET

8" MIN

FLOOR

3 12 "

8"

20 12 "

1516 " 16"

28 14 "

5 38 "

24 14 " 3 1

8 "

GAS CONNECTIONELECTRICAL CONNECTION

SUPPLY OUTLET

*When flexible connectors are used, the maximum length shall not exceed 36”.

Control Board Inspection Window

Combustion discharge terminal

Flame inspection window

FURNACEDRAIN

ACDRAIN

29" 28"

28 78 "

32 18

45 38 "

43

45

18 "

4.1 UNIT DIMENSIONS

FIG. 4.1

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4.2 UNIT LOCATION AND CLEARANCES

The general location considerations are:• EachwallwithCondoPackunitinstalledshouldbeatleast2ftaway(for

everyfloor)fromtheoppositebuildingwallfacingtheunit.IffacingwallalsohasaCondoPackunitinstalled,thosetwowallsshouldbeatleast4ftapart� See “Minimum Distance to the Opposite Wall ”Table1bellow.

• AsixstorybuildingwithsixCondoPackunitsinstalledinaverticalarray,shouldbeatleast12ftawayfromtheoppositebuildingwallandatleast24ftawayiftheoppositebuildingwallalsocontainsCondoPackunits.

• Buildingstallerthansixstorieswillhavethesamedistanceparametersassix-storybuildings.• IfthreeormoreadjacentwallsformanairshaftwithCondoPackunitsfacingeach

otherineachwall,thedistancebetweenoppositewallsshouldbeincreasedby20%.

• Atleast32”ofunobstructedspaceshouldbeprovidedinfrontoftheindoorside,whetherenclosedornot,inordertochangefilters,forunitinspectionandtopermitremovalofthecoolingmoduleshouldrepairberequired.

• Donotinstalldirectlyoncarpeting,tile,orothercombustiblematerialotherthanwoodflooring.Thegrillesideoftheunitshouldprotrudeminimum1/2”butnomorethan1”(maximum)fromthefaceofthebuildingandshouldnotbeobstructedbyforeignobjects.RefertoFIG.4.2.2.

• Iftheunitisinstalledinanoutsidewallofastoragegarage,itmustbelocatedorprotectedtoavoidphysicaldamagebyvehicles.Thisunitmustbeinstalledsothatnoelectricalcomponentsareexposedtowater.

NUMBER OF FLOORS WITH THE UNITS

MINIMUM DISTANCE TO THE OPPOSITE BUILDING WALL WITHOUT an unit installed

in the opposite building wall WITH an unit installed

in the opposite building wall 1 2 feet 4 feet 2 4 feet 8 feet 3 6 feet 12 feet 4 8 feet 16 feet 5 10 feet 20 feet

6 or more 12 feet 24 feet

TABLE 1

Drain holes

Sleeve Flange

INSIDE

OUTSIDE

Tominimizetheeffectofinteractionbetweenmultipleunitsinabuildingtherearesomegenerallocationconsiderationsthatneedtobetakenintoaccount.Theinstallermustverifythattheseconditionshavebeenmetbeforeinstallingtheunit.Installationofunitsinlocationsthatdonotfollowtheserulesmayleadtoabnormaloperationandprematurefailure.Theuseofthesegeneralrulesmaydifferdependingoneachindividualapplication.Pleasecontactthemanufactureroryourdealerforalternativesandapplicationassistance.

ALTHOUGHITISNOTPOSSIBLETODETAILALLOFCONSTRUCTIONPARAMETERSTHATCOULDBEENCOUNTERED,THEFOLLOWINGGUIDELINESANDPRECAUTIONSARERECOMMENDED:

NOTE

• MASONRY WALLS MUST HAVE A LINTEL TO SUPPORT THE WALL.

• DURING THE WALL SLEEVE ASSEMBLY PAY ATTENTION THAT THE SIDE PANEL FLANGES AND THE BASE PANEL DRAIN HOLES ARE ON THE SAME SIDE OF WALL SLEEVE, SEE FIG 4.2. FIG. 4.2

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4.2.1 Venting Guidelines

H14.3.1_CPACK

Inadditiontothegeneralguidelines,intheUnitedStates,theventexhaustshallbeinstalledinaccordancewiththefollowing:• Theclearancefromthebottomoftheterminaltogradeshallbe12”(305mm).• Theventshallnotterminateoverpublicwalkwaysoroveranareawherecondensateorvaporcould

createanuisanceorhazard.• Theventterminalshallbeinstalled4feet(1.2m)below,4feet(1.2m)horizontallyfrom,or1foot(305mm)

aboveanydoor,window,soffit,undereaveventorgravityairinlettothebuilding.• Theventterminalshallhaveaminimumhorizontalclearanceof4feet(1.2m)fromelectricmeters,gas

meters,regulatorsandreliefequipment.• Locatetheventterminal3feet(0.91m)aboveanyforcedairinletlocatedwithin10feet(3m).Anyfreshair

ormake-upairinlet,suchasforadryerorfurnaceareaisconsideredaforcedairinlet.

H15.5.1_CP

Avoidlocatingtheterminalswherethefluegascouldbecomestagnantandallowrecirculationintothecombustionairintake.Avoidlocatingtheterminalinlocationswheredrippingcondensatemaycauseproblemssuchassidewalks,patios,aboveplanters,nearwindowswhereexhaustgasesmaycausefogging,icing,etc.Avoidlocatingtheterminationtooclosetoshrubsandothervegetation.Thecondensatemaystuntorkillthem.Caulkallcracks,seamsorjointswithina6foot(1.8m)radiusofthetermination.Donotterminateunderadeckunlessthereisadequateclearancetopreventdamagefromthefluegases.Aterminationmaybelocatedattheendofapatiodeck.Pipingrunningbeneaththedeckmustbesuitablyinsulatedandsuspendedinamannertopreventcondensatefromcollectingandfreezing.Whenlocatingventterminations,considerationmustbegiventoprevailingwinds,location,andotherconditionswhichmaycauserecirculationofthecombustionproductsofadjacentvents.Check local codes for distance between vent terminal and a inside corner formed by two exterior walls. If not specifiedbylocalcode,minimumdistancebetweenventterminalandaninsidecornerformedbytwo exterior walls is 6 inches (0.15m).

IMPROPERLOCATIONORINSTALLATIONCANRESULTINSTRUCTURALDAMAGETOTHEBUILDING,DAMAGETOTHEEXTERIORFINISHOFTHEBUILDING,ORMAYALLOWRECIRCULATIONORFREEZINGOFTHEFLUEGASESONTOORINTOTHECOMBUSTIONAIRINTAKE.MOISTUREINTHEFLUEGASESCONDENSESASITLEAVESTHETERMINALS.THISMOISTURECANFREEZEONEXTERIORWALLS,

SOFFITS,ANDOTHERNEARBYOBJECTS.SOMEDISCOLORATIONISTOBEEXPECTED.

CAUTION ! !

Recommendedverticalclearanceofaventterminalandoverhangingstructureshouldbemaximizedtopreventcondensateproductsfromdepositingandfreezingonoverhang.Thispracticehelpspreventdegradationofbuildingmaterials.Recommendedpractice(wherepracticable)istomaintainthesameverticalclearancebetweentheventandtheoverhangasthehorizontallydistancetheoverhangprotrudesfromthebuilding.Unlessgoverningbodieshavinglocaljurisdictionspecifyaminimumclearancelarger,theminimumclearancebetweenaventterminalandaoverhangingstructureshallbe40inches(1m).Anyadjacentpaintedsurfacesshouldbeingoodcondition;nocracks,peelingpaint,etc.Ifwoodensurfacesthatmaybeperiodicallyexposedtofluegasesarepresent,considertreatingwithasealer.

H14.2A_AC

Inadditiontothegeneralguidelines,inCanada,theventexhaustshallnotterminate:• Directlyaboveapavedsidewalkorpaveddrivewaywhichislocatedbetweentwosingle-familydwellings

andservesbothdwellings;• Lessthan7feet(2.1m)aboveapavedsidewalkorpaveddrivewaylocatedonpublicproperty;• Within6feet(1.8m)ofamechanicalairsupplyinlettoanybuilding;• Aboveameter/regulatorassemblywithin3feet(.91m)horizontallyofthecenterlineoftheregulator;• Within3feet(.91m)ofanyserviceregulatorventoutlet;• Lessthan12”(305mm)abovegradeleveloranticipatedsnowlevel;• Within12”(305mm)ofanydoor,windowthatcanbeopened,ornon-mechanicalairsupplyinlettoany

building;• Within12”(305mm)ofthecombustionairinletofanyotherappliance;• Recommendedpractice(wherepracticable)istomaintainthesameverticalclearancebetweenthevent

andtheoverhangasthehorizontallydistancetheoverhangprotrudesfromthebuilding.• Unlessgoverningbodieshavinglocaljurisdictionspecifyaminimumclearancelarger,theminimum

clearancebetweenaventterminalandaoverhangingstructureshallbe40inches(1m).

In Canada:

In USA:

Thisapplianceshouldbeinstalledinalocationsuchthattheventoutletislocatedinthefollowingmanner:

13

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Thisdesigniscertifiedforthru-the-wallinstallationonly.Theinteriorportionsoftheunitmaybesurroundedbyaclosetwithclearancestocombustiblematerialaslistedonthenameplate.Adequateclearancemustbeprovidedtoinstalltheunionandmanualshut-offvalveaswellasaccessibilitytofieldwiringjunctionbox.Minimum clearances to combustibles derived from factory testing are shown below and also on the nameplate of the unit:

H15.5_CP

Avoidlocatingtheterminalswherethefluegascouldbecomestagnantandallowrecirculationintothecombustionairintake.Avoidlocatingtheterminalinlocationswheredrippingcondensatemaycauseproblemssuchassidewalks,patios,aboveplanters,nearwindowswhereexhaustgasesmaycausefogging,icing,etc.Avoidlocatingtheterminationtooclosetoshrubsandothervegetation.Thecondensatemaystuntorkillthem.Caulkallcracks,seamsorjointswithina6foot(1.8m)radiusofthetermination.Donotterminateunderadeckunlessthereisadequateclearancetopreventdamagefromthefluegases.Aterminationmaybelocatedattheendofapatiodeck.Pipingrunningbeneaththedeckmustbesuitablyinsulatedandsuspendedinamannertopreventcondensatefromcollectingandfreezing.Whenlocatingventterminations,considerationmustbegiventoprevailingwinds,location,andotherconditionswhichmaycauserecirculationofthecombustionproductsofadjacentvents.

IMPROPERLOCATIONORINSTALLATIONCANRESULTINSTRUCTURALDAMAGETOTHEBUILDING,DAMAGETOTHEEXTERIORFINISHOFTHEBUILDING,ORMAYALLOWRECIRCULATIONORFREEZINGOFTHEFLUEGASESONTOORINTOTHECOMBUSTION

AIRINTAKE.MOISTUREINTHEFLUEGASESCONDENSESASITLEAVESTHETERMINALS.THISMOISTURECANFREEZEONEXTERIORWALLS,SOFFITS,ANDOTHERNEARBY

OBJECTS.SOMEDISCOLORATIONISTOBEEXPECTED.

CAUTION ! !

Checklocalcodesfordistancebetweenventterminalandainsidecornerformedbytwoexteriorwalls.Ifnotspecifiedbylocalcode,minimumdistancebetweenventterminalandaninsidecornerformedbytwoexteriorwallsis6inches(0.15m).Recommendedverticalclearanceofaventterminalandoverhangingstructureshouldbemaximizedtopreventcondensateproductsfromdepositingandfreezingonoverhang.Thispracticehelpspreventdegradationofbuildingmaterials.Recommendedpractice(wherepracticable)istomaintainthesameverticalclearancebetweentheventandtheoverhangasthehorizontallydistancetheoverhangprotrudesfromthebuilding.Unlessgoverningbodieshavinglocaljurisdictionspecifyaminimumclearancelarger,theminimumclearancebetweenaventterminalandaoverhangingstructureshallbe40inches(1m).Anyadjacentpaintedsurfacesshouldbeingoodcondition;nocracks,peelingpaint,etc.Ifwoodensurfacesthatmaybeperiodicallyexposedtofluegasesarepresent,considertreatingwithasealer.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS. DÉGAGEMENTS MINIMAUX PAR RAPPORT AUX MATÉRIAUX COMBUSTIBLES. TOP / DESSUS 2 “ (50.8 mm) PLENUM / PLÉNUM 1 “ (25 mm) FRONT / AVANT 10” (254 mm) BACK / ARRIÈRE 0 RIGHT SIDE / CÔTÉ DROIT 0* LEFT SIDE / CÔTÉ GAUCHE 0 BOTTOM / FOND 0*** FLUE PIPE / TUYAU 0 * RECOMMENDED 2 “ (50.8 mm) CLEARANCE FOR SERVICING *** CERTIFIED FOR CLOSET INSTALATION ON COMBUSTIBLE FLOORING. *** CERTIFIÉ POUR L’INSTALLATION DANS UN PLACARD SUR UN PLANCHER COMBUSTIBLE.

TABLE 2

H3.7. AC

THIS FURNACE IS CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS. THIS SHALL BE INTERPRETED AS A WOOD FLOOR ONLY.

THE FURNACE MUST NOT BE INSTALLED DIRECTLY ON CARPETING, OR OTHER COMBUSTIBLE MATERIAL EXCEPT WOOD.

INSTALLATION ON COMBUSTIBLE MATERIAL OTHER THAN WOOD CAN RESULT IN FIRE, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS

AND LIQUIDS.THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE

USED AS A CLOSET OR FOR ANY OTHER STORAGE PURPOSE.

WARNING ! !

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FIG. 4.2.1 - DIRECT VENT TERMINAL CLEARANCES

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Theminimumclearancesrequiredforinstallationandaccessibilityareshownbelow.Theseclearancesshouldbefollowedunlessotherwiseapprovedbythemanufacturer.

9 5

/8 "

REF.

82"

REF.

A A

A-A

0" M

IN. C

LEA

RAN

CE

* 2"

MIN

. CLE

ARA

NC

E

10" M

IN.

CLE

ARA

NC

E36

" D

OO

R O

PEN

ING

29"

REF

.

1" R

EF.

DRA

IN R

EQUI

RED

(1

.5" Ø

MIN

.)FO

R RE

MO

VA

LO

F FU

RNA

CE

AN

D

AC

CO

ND

ENSA

TE

DRA

IN

32 1

/8"

REF.

*

ROUG

H O

PEN

ING

TO

SUI

T 2

8 7/

8" X

44

7/8"

WA

LL S

LEEV

E

VIE

W O

F O

UTSI

DE

WA

LL

GA

S V

ENT

C C PO

SITIO

N

8" M

IN.

2" M

IN.

CLE

ARA

NC

E TO

CO

MBU

STIB

LE

**SE

CUR

E TO

WA

LL

FABR

ICA

TED

WO

OD

OR

STEE

L SU

PPO

RT

1" R

EF. C

LEA

RAN

CE

BETW

EEN

LEF

T (H

ING

E)

SID

E D

OO

R JA

M

AN

D C

ON

DO

PA

CK

44

7/8

" R

EF.

44

7/8

" R

EF.

28

7/8"

4 3

/4"

3"

2.5"

REF.

G

AS

VEN

T

NO

TE**

Engi

neer

/Arc

hite

ct -

to c

onsu

lt w

ith N

apol

eon

Engi

neer

ing

to d

eter

min

e br

acke

t loc

atio

n fo

r set

ting

the

desi

red

dept

h of

Wal

l Sle

eve

into

wal

l.

CLE

ARA

NC

E FO

R SE

RVIC

ING

) (1

0" R

ECO

MM

END

ED M

IN.

FLO

OR

1.5"

Ø

43

1/8"

Flas

hing

Flas

hing

12

9/16

"

16 "

Sea

l aro

und

Sle

eve

and

OU

TS

IDE

wal

l

Sea

l aro

und

Sle

eve

and

INS

IDE

wal

l

PRO

TRU

DE

1/2”

MIN

.-1” M

AX

.

Bric

k W

all

PRO

TRU

DE

1/2”

MIN

.-1” M

AX

.

40 "

MIN

. C

lear

ance

fro

m th

e G

as V

ent

to e

xter

ior

over

hang

Bric

k W

all

* If

less

then

10”

, se

rvic

ing

may

be

perfo

rmed

by

open

ing

the

front

doo

r pan

els

and

the

gas

mod

ule

may

nee

d to

be

rem

oved

to a

cces

s co

mpo

nent

s.

Spa

ce re

quire

d fo

r R

etur

n A

ir D

uctin

g m

ust b

e co

nsid

ered

.

FIG. 4.2.2.

16

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4.3 PACKAGED UNIT PREPARATION

NOTE

Prior to installing the unit in the wall opening:1� Removethebracketsconnectingtheunittotheskid.2� Removethecoolingmodule.

IMPORTANT! !

• THISUNITMUSTBEINSTALLEDINACCORDANCEWITHALLAPPLICABLECODES.• THISUNITISAPPROVEDFORTHRU-THE-WALLINSTALLATIONONLY.• THESE INSTALLATIONANDMAINTENANCE INSTRUCTIONS SHOULD BE LEFTWITHTHEUNITFORFUTUREREFERENCE.

1. Theunitmustbeinstalledaminimumof8”abovefinishedfloor.a. If unit is installed in a storage garage, all ignition sources (electric contactors and

motorsincluded)mustbepositionedataminimumof18”(457mm)abovethefloor,and it must be protected from physical damage by vehicles, consistent with CAN/CSA-B149.

2. The entire unit must not be installed outside. This unit is designed for indoor installationontoanexteriorwallhavinganopeningforcondenserairflow.

3. The grille side of the unit should extend 1/2” Min. - 1” Max. beyond the exterior wall to allow moisture that may enter the outdoor section to drain.

4. DO NOT install this unit at an exterior wall location that will position the bottom of the wall grille below the exterior grade level. Below grade installation will allow the accumulation of rain or snow into the wall sleeve and unit base, and could result in water penetration into the building interior.

5. The grille side must be:a. Keptfreeofanyobstructionsthatcouldreduceoraltertheairflowpattern.

The unit must be installed at least 3’ (0.92m) from electric meters, gas meters, regulators, and relief equipment in Canada, in accordance with CAN/CSA-B149 or 4’ (1.22 m) in U.S. in accordance to NFPA 54, ANSI Z223 installation codes.

b. The vent of the unit is located at the outside grille. Distances from adjacent public walkways, adjacent buildings, windows, and building openings must be consistent with the National Fuel Gas Code ANSI Z223.1 and/or CAN/CSA-B149 installation codes, as well as local codes.

6. Masonry walls must have a lintel to support the wall, as per National and local building codes.

7. The interior of the unit may be installed with clearances noted on the nameplate to adjacent combustible surfaces.

8. The unit shall not be installed directly on carpeting, tile or other combustible material, exceptwoodflooring.

9. In order to be able to remove the chassis, at least 32” of open area must be left unobstructed in front of the front doors. The drain pan and condensate trap line should beconnectedtothefloordrain.

10. Caulk and seal all spaces around the top, sides and bottom of the exterior grille area, making sure that THE OPENINGS FOR DRAINAGE IN THE BOTTOM EDGE ARE NOT BLOCKED. Refer to “4.2 Unit Location and Clearances”.

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4.4 WALL SLEEVE ASSEMBLY

LEGEND1� TopPanel2� BasePanel3� RightSidePanel4� Left Side Panel 5. Side Support Bracket 6� TopSupportBracket7. Screw#8-32x.315SteelTrilobular8� GasketD-Channel28.9”long9. GasketD-Channel44”long10� SquaringBrace11� SquaringBraceMiddle

ITEM QTY PART NAME MANUFACTURING DESCRIPTION PART NO1 1 Toppanel PANEL,SLEEVETOPPOWDER W475-0978-(colorcode)2 1 Basepanel PANEL,SLEEVEBASEPOWDER W475-0975-(colorcode)3 1 Rightsidepanel PANEL,SLEEVERSPOWDER W475-0977-(colorcode)4 1 Leftsidepanel PANEL,SLEEVELSPOWDER W475-0976-(colorcode)5 2 Sidesupportbracket BRACKET,SIDESUPPORT W080-14446 1 Topsupportbracket BRACKET,TOPSUPPORT W080-14457 25 Screw#8-32x.315SteelTrilobular SCREW,#8-32x.315QUADHEXWASHER W570-0162

10 2 Squaringbrace BRACE,SQUARING W080-143311 1 Squaringbracemiddle BRACE,SQUARING W075-0019

ITEM QTY PART NAME MANUFACTURING DESCRIPTION PART NO8

12.5FGasketD-Channel28.9”long GASKET,D-CHANNELEPDM

(includedinW020-0835CondoPackbaggie) W290-02569 GasketD-Channel44”long

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THE UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. IMPROPER INSTALLATION, ADJUSTMENT, SERVICE,

OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH. CONSULT A QUALIFIED INSTALLER OR SERVICE AGENCY FOR INFORMATION AND ASSISTANCE.

! ! WARNING

6

2

4

1

7

1010

58

11

8

9

3

Thewallsleeveisdesignedtobeinstalledintothewallduringtheconstructionofthebuilding,inordertoprovideanaccurateopeningandeasierinstallationofthru-the-wallpackagedunitlateron,afterbuildingiscompleted.

DIAGRAM (A)

1/4”NUTDRIVER

INCLUDEDINTHECWSMUAKIT:

SHOWNBUTNOTINCLUDEDINTHECWSMUAKIT:

TABLE 3

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1. PlaceBasepart(2)onthefloorandattachRightSidePanel(3):

a� PositionBasePanel(2)toseatbehindflangeson the Side Panel (3)�

b. Bringtogetherpanelclipsandopenings(FIG.1).

2. Pressdownfirmlytolockbasepanelintoplace(FIG.2).

3. AttachLeftSidePanel(4)toBase(2).Repeatprocedurefromstep2(FIG.2).

a

b

3

2

2

Press down

4

3

2

1

a

b

3

2

2

Press down

4

3

2

2

a

b

3

2

2

Press down

4

3

2

3

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4. CheckforparallelpositionofLeftandRightSidePanels(3)and(4).SecureconnectionwithBasePanel(2),see(FIG.4).

5. AttachTopPanel(1)toLeftandRightSidePanels(3)and(4).Alignconnectionopeningsandsecuretheassemblybypushingtheclipsinplace(FIG.5).

6. AttachSquaringBraces(10)totheinnersidesofboth,TopPanelandtheSidePanels,byinsertingthescrewsfrominside.

7. ToattachtheSquaringBrace(10)totheSidePanels(3)and(4)usethe1/8”holeslocated10”downfromthetopand3.5”fromtheoutsideflange(FIG.7).

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

4

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

6

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

5

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8

9

11

810

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

9

NOTE: The following support bracket locations are for installations where the wall sleeve is installed from the OUTSIDE of the building. For installations where the wall sleeve is installed from the INSIDE of the building, the Side Support Brackets (5) need to be mounted on INTERIOR wall, so they will need to be relocated on the wall sleeve (new screw positions may need to be created).

8. AttachtheSideSupportBrackets(5)totheSidePanels(3)&(4)andtoBasePanelwithfourscrewsthroughtheshorterflange(FIG.8).

9. Selectthesetofmountingholesbasedontypeofconstructionwallfaceapplication(brick,stucco,siding,etc.):a� Forbrickorstuccowall,usepre-drilledholes

located3.5”fromoutsideedge(FIG.9).b. Forsidingtypeofwall,useholeslocated1.5”

fromoutsideedge(FIG.9).c� AttachTopSupportBracket(6)totheTopPanel

(1)usingthreescrewsprovided(7),(FIG.9).d� Usingtwomountingscrews(7),installMiddle

SquaringBrace (11) acrossthewallsleeve,asshownintheDIAGRAM(A)andFIG.10.

e� Refer to “Wall Sleeve Installation” ,FIG12andFIG13.f� Do not removeSquaringBraces(10)and(11)

fromthewallsleeveifyoudonotplantoinstalltheCondoPackunitimmediately.

g. Filltheclearancespacebetweenthesleeveandawallframingwithlowexpandinginsulationfoam(thisisforadditionalprotectionagainstairinfiltrationduringtheperiodsofveryhighwinds).

10. Prior to installing CondoPack into the wall sleeve: • Removesquaringbracesfromwallsleeve.• Applyself-adhesiveD-ChannelGasketstrips(8)

&(9)toinsidesurfaceofsleevefrontflanges,asshowninFIG.10.

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

8

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

7

21

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8

9

11

810

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

9

NOTE: The following support bracket locations are for installations where the wall sleeve is installed from the OUTSIDE of the building. For installations where the wall sleeve is installed from the INSIDE of the building, the Side Support Brackets (5) need to be mounted on INTERIOR wall, so they will need to be relocated on the wall sleeve (new screw positions may need to be created).

8. AttachtheSideSupportBrackets(5)totheSidePanels(3)&(4)andtoBasePanelwithfourscrewsthroughtheshorterflange(FIG.8).

9. Selectthesetofmountingholesbasedontypeofconstructionwallfaceapplication(brick,stucco,siding,etc.):a� Forbrickorstuccowall,usepre-drilledholes

located3.5”fromoutsideedge(FIG.9).b. Forsidingtypeofwall,useholeslocated1.5”

fromoutsideedge(FIG.9).c� AttachTopSupportBracket(6)totheTopPanel

(1)usingthreescrewsprovided(7),(FIG.9).d� Usingtwomountingscrews(7),installMiddle

SquaringBrace (11) acrossthewallsleeve,asshownintheDIAGRAM(A)andFIG.10.

e� Refer to “Wall Sleeve Installation” ,FIG12andFIG13.f� Do not removeSquaringBraces(10)and(11)

fromthewallsleeveifyoudonotplantoinstalltheCondoPackunitimmediately.

g. Filltheclearancespacebetweenthesleeveandawallframingwithlowexpandinginsulationfoam(thisisforadditionalprotectionagainstairinfiltrationduringtheperiodsofveryhighwinds).

10. Prior to installing CondoPack into the wall sleeve: • Removesquaringbracesfromwallsleeve.• Applyself-adhesiveD-ChannelGasketstrips(8)

&(9)toinsidesurfaceofsleevefrontflanges,asshowninFIG.10.

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

8

3.5”3.5”

10” 10”

Siding

Brick3.5”

1.5”

107

7

2

2

3

3

3

4

4

4

4

5

6

1

1

7

7

10

7 Wall Sleeve Dimensions

32 34 "

26 12 "

12 916 "

"

16"

3 34 "

POSITION A

44 78 "

1" POSITION B

16"

28 78 "

42 14 "

WALL SLEEVE IS DIRECTLY LAGGEDTO WALL SUBSTRUCTURE.

TO IMPROVE RIGIDITY AND REDUCTION IN VIBRATION WALL MOUNTING,BRACKETS CAN BE USED TO AFFIX WALL SLEEVE TO BUILDING SUB STRUCTURE FROM INSIDE OR OUTSIDE BUILDING. ENGINEER/ARCHITECT TO CONSULT WITH NAPOLEON ENGINEERING TO DETERMINE BRACKET LOCATION FOR SETTING THE DESIRED DEPTH OF WALL SLEEVE INTO WALL.

46 78 "

1516

11

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4.4.1 Wall Sleeve Installation

Wallsleevecanbeinstalledfrominside(FIG.12)oroutsidethebuilding(FIG.13).Thesideandtopbrackets’positionneedtobeadjustedtosuitthemethodandbuildingmaterial.1� Withdrainholesfacingoutside,positionthesleeve

towardsthewalluntilthesupportbracketsaresetonwalledge.Leave¼“spaceinbetweenthewallandsleeveforcaulking.

2� EnsureparallelpositionbetweenWallSleeveandwallopening.WallSleevemustbesquarefortheCondoPacktoslideintoit.

3� AttachWallSleevetothebuilding:a� Securethesupportbracketstothewallusingfivescrew

holesoneachside.b. Securesidepanelsintothestructuralwallusing

fasteners.

To install Wall Sleeve into wall opening:

11� Allopeningsaroundthetop,sidesandbottomofwallsleevemustbecaulkedandsealed.ThewallopeningacrossthetopandbottomoftheWallSleevecouldbeflashedifrequired.

12� Allunusedholesneedtobesealed.

INSTALLATION CREW MUST ADHERE TO ALL LOCAL/NATIONAL SAFE WORK PRACTICES INCLUDING EMPLOYING APPROPRIATE FALL ARREST EQUIPMENT

WARNING! !

13

CARE MUST BE TAKEN NOT TO PLUG THE DRAIN OPENINGS IN THE BASE PANEL.

IMPORTANT! !

12

FROMINSIDE:Pushthesleevetowardsthewalluntilthesupportbracketsaresetonwalledge.

FROMOUTSIDE:Pullthesleevetowardsthewalluntilthesupportbracketsaresetonwalledge.

4� CompletelyfillthespacesbetweenthewallsleeveandthewallwithLowExpandingInsulationFoam.

5. Wait8hoursminimumforfoamtocure.6� PreparetheCondoPackunitforinstallation.Forunit

supportguidesreferto“Unit Support” onthenextpage.7. Removewallsleevesquaringbraces(10)and(11),FIG10.8� Installtheunit.9. Caulkallseamsbetweenthewallsleeveandthefinished

exteriorandinteriorwalls.Caulkallseamsbetweenthewallsleeveandthecabinet. Sealthespacesusingnon-hardeningcaulkingcompound.Allsealsmustbeweathertighttoprevententranceofmoistureandwaterintothebuilding.

10� Wheninstalled,theWallSleeveshouldprotrude1/4”to1”beyondtheexteriorfinishedwalltoallowproperwaterevacuationthroughthedrainholesinthebottompanel.

SLEEVE MUST BE FASTENED TO THE STRUCTURAL WALL AND NOT TO THE FINISHED WALL.

IMPORTANT! !

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4.5 UNIT SUPPORT

Wall Sleeve

InsideWall

OutsideWall

29” MIN

2” MIN

WIDTH

DEPTH20” MIN

7”x24” MINOpening

Support Platform

LEVEL

8” MIN

18” Max

Return Air

More then 18” will obstruct the access to the unit through the side panel.

DO NOT OPERATE THE FURNACE FOR PROLONGED PERIODS OF TIME WITHOUT AN AIR FILTER. A ALWAYS

WEAR SAFETY GLASSES WHEN WORKING WITH TOOLS! OVER-TIGHTENING THE SCREWS MAY STRIP

THE RETAINING HOLES. READ ALL OF THE ASSEMBLY INSTRUCTIONS STEPS BEFORE PROCEEDING.

CAUTION! !Thewallsleeveisnotintendedasthesolesupportfortheunit.Therefore,additionalsupportmustbeprovidedbyarigidstructurethatbearstheweightoftheunitandprovidesaninterfacefor“returnair”ducting.

• Minimum height of platform = 8” • Recommended platform width = 29”• Recommended platform depth = 20”

1� Carefullymeasuretheunitandchooseastrongbuildingmaterialforthesupportstructure.

2� Theunitshouldbeadditionallysupportedforlevelingpurposes.

3� Anadditionalvibrationisolationmaterial(mustbenon-combustible)maybeusedifrequired.

4� Ensurethatthe“returnair”openingisatleast7’’x24’’.ItmustbealignedwithreturnairopeningonthebaseoftheinstalledCondoPackappliance.

5. ThesupportstructureandtheWallSleevehavetoprovidesecureandleveledpositionfortheunitandamethodofbringingreturnairviaductingtothespaceundertheappliance.

6� Flashingtheunittoreturnairduct(bellowthesupportstructure)istobedonelaterbyfieldinstallationofSteelSheetExtensions(customcuttolength).See(FIG16).

• First,thesupportingplatformmustbebuilt,see(FIG.14).Itcanbeconstructedofplywoodandframinglumber.(FIG.15)showingalignmentoftheplatformtopwiththebasepanelofthewallsleeve.

Before building support structure, consider the following:

14

B

B

BWall Sleeve

Base Panel Platform Top

B B

These surfaces should be level

15

Return Air DuctFlashing with Steel sheet extension

7”

Wall Sleeve

Unit

16

FLASHING MUST SEAL SPACE BETWEEN THE RE-TURN AIR INLET OF CABINET BASE AND THE RETURN AIR PLENUM TO AVOID DRAWING RETURN AIR FROM THE CLOSET SPACE CONTAINING THE APPLIANCE.

REFER TO SECTION 4.7.

IMPORTANT! !

PAGEFORIOMONLY

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1/4”-20 x 1 1/4” Grommet

Flat Washer

4.6 PACKAGED UNIT INSTALLATIONProcedure

1� Verifythatisolationgrommetsareinstalledinthefiveholesonthetopmountingbracket.

2� BringtheCondoPackascloseaspossibletowallopening(FIG.4�6�A).CarefullyslidetheunitintotheWallSleeve(refertoWallSleeveAssemblyandInstallationInstructions)sothefrontoftheunitisincontactwiththefrontflangesoftheWallSleeve.

For ease of installation (OPTIONAL):a� InstallcabinetintotheWallSleevewithoutcoolingunit.b. Slidecoolingunitin,aftercabinetisinplace(FIG.4�6�B)c� Furnacemodulealsocanberemovedseparately(FIG.4�6�C)�

Refertosection“4.16.4.2FurnaceModuleRemoval”� FIG. 4.6.A

FIG. 4.6.B

FIG. 4.6.C

FIG. 4.6.D

AC Module

Furnace Module

3� Useaflatwasherwitheach1/4”-20x11/4”screw.SecureCondoPackunittotheWallSleeveusingfive11/4”screwsthroughtheisolationgrommetsinthefiveholesontheWallSleevetopmountingbracket(seeFIG.4�6�D)�

OVER-TIGHTENINGTHESCREWSWILLDEFORMTHEISOLATIONGROMMETSAND

REDUCETHEIREFFECTIVENESS.

NOTE

4� Caulkandsealallspacesaroundthetop,sidesandbottomoftheexteriorgrillearea,makingsurethattheopeningsfordrainageinthebottomedgearenotblocked.

5. Shim(FIG.4.6.E)betweenunitsupport(DiagramB)andthebottomrearcornersofcabinettopreventtwistingloadsontostructuralwalls.

Furnace module removal.Furnacemodulecanberemovedfromcabinetseparately.Refer to section“4.16.4.2FurnaceModuleRemoval”� Both modulescanbeinstalledseparatelyandeitheroneofthesecanbereplacedasaservicepart(asthecompletemodules).

FIG. 4.6.E

Air Conditioning module removal.

AirConditioningmodulecanberemovedforeasiercabinetinstallation.Refertosection“4�16�4�1 Air Conditioner Module Removal”�

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The ductwork should be sized and constructed in accordance with accepted industry standards: Theoutletductmaybeprovidedwitharemovableaccesspaneltoviewtheheatexchangerduringunitservicing.Notethatafullinspectionoftheheatexchangerismadepossiblebythefurnacebeinga“pullout”module.Itshallalsospecifythatthecoverattachmentpreventsleaks.

a� Properairflowisrequiredforthecorrectoperationofthisunit.Insufficientairflowmaycauseerraticoperation,couldcausetheunittocycleonthehightemperaturelimit,andmaydamagetheheatexchanger.Excessiveairflowmayresultinanexcessivelynoisyductsystemandmayresultinundesirableconsequencessuchascreatinguncomfortabledrafts.Thetotalstaticpressuredropoftheairdistributionsystem(includingfilters)shouldnotexceed0.5”wc.Itisimportanttoprovideduct(s)thataresizedsufficientlytohandlethelargerairvolumesforheatingorcoolingprovidedbythismodel.

b. AFLEXIBLEDUCTCONNECTORisaneffectivedevicetopreventthetelegraphingofmechanicalnoisefromthefurnacetootherpartsofthehomeviatheductwork.Ifusingflexibleconnectors,ensurethattheadjoiningductisindependentlysupported.

Duct sizing and construction information may be obtained from:

•A.C.C.A.(AirConditioningContractorsofAmerica)• A.S.H.R.A.E.(AmericanSocietyofHeating,RefrigerationandAirConditioningEngineers)•H.R.A.I.(Heating,RefrigeratingandAirConditioningInstitute(Canada)•S.M.A.C.N.A. (SheetMetalandAirConditioningContractors’NationalAssociation(UnitedStates)Alloftheaboveprofessionalorganizationshaveductsizingmanualsavailable.

NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM THE FLUE TO ENTER THE RETURN AIR OR SUPPLY AIR DUCTWORK.

ALL RETURN AIR DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE UNIT WITH SHEET METAL SCREWS. TAPE THE SHEET METAL SEAMS IN THE VICINITY OF THE UNIT WITH FOIL TAPE OR SIMILAR MATERIAL. WHEN THE UNIT IS MOUNTED ON A PLATFORM WITH RETURN AIR THROUGH THE BOTTOM, IT MUST BE SEALED PROPERLY

BETWEEN THE UNIT AND THE RETURN AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT OF THE UNIT WITHOUT SAGGING OR GAPS AROUND THE BASE. IT MUST ALSO BE SEALED BETWEEN

THE SUPPORT AND THE BASE.

4.7 DUCTWORK

4.7.1 Supply Air Ducting

IMPORTANT! !

WARNING! !

BOTH SUPPLY AND RETURN AIR MUST BE DUCTED TO THE APPLIANCE FROM ROOMS SEPARATE TO THE CLOSET ENCLOSURE HOUSING THE APPLIANCE.

IMPORTANT! !

SUPPLY AIR DUCT (PLENUM) CONNECTION MUST BE AT LEAST THE SAME SIZE AS THEUNIT SUPPLY AIR OPENING. SEAL SUPPLY AIR DUCTWORK TO UNIT CASING, WALLS,

CEILINGS OR FLOORS.

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4.7.2 Return Air Ducting

Unit Flashing Tosealtheunittoreturnairduct(bellowthesupportstructure),performfollowingproceduresteps:

1� Cutaholeinthereturnairduct(24”x7”).2� Aligntheunitopeningwithareturnair

duct cut out�3� InsertsteelsheetextensionpartA

throughtheopening.4� Aligntheupperedges,adjustingthe

height.5. Mounttothecondopackusingfourself-

tappingscrewsprovided.6� InsertsecondpartBandmountto

extensionpartAusingtwoscrewsfrominside.SeecrosssectionCCbellow.

A

A

D

B

B

Return Air Duct

24”x7” Return Air Duct Opening

24”

7”Unit Opening

c

c

Providethesupportinsidethebuildingintheareaofthereturnairopening.Thesupportshouldbehighenoughtoallowforreturnairtotheunitasperrequirements.Ifrequired,installaresilientmaterialbetweenthesupportandthebaseoftheunittoreducethepossibletransmissionofsoundandvibration.

1

2

3

4

Return Air Duct

7”

Wall Sleeve

Unit

AB

CC

7. Adjustsheetmetalextensionassemblytotheunitopeningifnecessaryandcutoffextrasheetlength.

8� SecureassemblyusingfourscrewsD�9. UseAluminumfoiltapetosealall

spacesbetweenflashingofreturnairduct and the unit�

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A

A

E

F F

E

F

B

BC C

C

C

D

(1/2”&5/8”)

F

DO NOT drain the condensate outdoors. DO NOT run the condensate line through areas wherew might occur. Freezing of condensate can result in erratic operation and in property damage.CAUTION

WARNING

! !

! !

A A

A - Furnace HoseC - Hose Clamp 2X C - Hose Clamp 1XA - Furnace HoseB - AC Hose 3/4” B - AC Hose

Remove both caps E from the top of T fittings F.

AA Drain extra liquid.

Extra water.

Pull two clamps C over hose A openings.

Connect hose openings to T fittingsand tighten both clamps.

1. Place clamp over hose opening.

2. Attach hose to AC drain.

3. Tighten clamp and secure.

Add water into drain B opening.

AA

A

A

After adding water, PLACE CAPS BACK onto barbed T fittings.

B

B

A

AA

AA

Place hose A INSIDE of support bracket D as shown. Mount bracket D into position and secure it with screw provided.

B

Drain

CAPS COVERING BARBED FITTINGS SHALL ONLY BE REMOVED DURING PRIMING OF THE P-TRAP, THEY MUST BE FIRMLY IN PLACE COVERING BARBED FITTINGS DURING UNIT OPERATION. IN ADDITION, ALL DRAIN TUBES MUST BE TIGHTLY CLAMPED TO THE BARBED FITTINGS. FAILURE TO FOLLOW EITHER OF THESE CONDITIONS DURING UNIT OPERATION COULD CAUSE EXHAUST PRODUCTS TO ENTER THE LIVING SPACEWHICH MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Check drain hoses inside. Ensure the clamps are tightly clamped to fittings.

1. Remove two caps (not shown)from the bottom of barbed T fittings (F).

Prep hose byadding RV grade

plumbing antifreezeinto both A hose openings until liquid starts drippingfrom the other end.

1 2 3

4 5 6

7 8 9

10 11

4.8 CONDENSATE DRAIN CONNECTION Thefurnaceandairconditioningcondensatedrainconnectionsareincluded,butnotinstalled.Bothdrain connectionsarealreadypre-fabricatedwithintegralPtraps.Toconnectcondensatedrainstotheexistingdrainagesystems,refertoillustratedinstallationsteps1-11:

The condensate hose leaving the side of the appliance shall follow a downward slope to the building drain at all times. Condensate from the outlet of the drain trap assembly must be conveyed to a floor drain, or to a condensate pump. If using a condensate pump, be sure that it is approved for furnace condensate.

NOTE

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ALWAYS USE A BACKSTOP WRENCH TO PREVENT TWISTING OF THE GAS VALVE. ANY STRAINS ON THE GAS VALVE CAN AFFECT POSITIONING OF THE ORIFICES REL-

ATIVE TO THE BURNERS. THIS COULD RESULT IN FAULTY BURNER OPERATION.ENSURE THAT THE GAS VALVE IS NOT SUBJECTED TO HIGH PRESSURES.

Theventingsystemisanintegralpartoftheapplianceandisdesignedforproperoperationunderallweatherconditionsandforwindsupto32milesperhour.Theventingsystemmustnotbemodifiedoraddedonto.Theventoutletmustnotbealteredorextended.Theunitcontainsanexhaustblowerwhichdrawsthecombustionproductsoutoftheheatexchangertogetherwithdilutionairandforcesthemixturefromtheunittotheoutside.Nospecialprovisionsarerequiredforsupplyingairforcombustion,norisachimneyrequired.

InCanada,thegaspipingshouldbeinstalledinaccordancewithCAN/CSA-B149.1andB149.2,andinaccordancewithanylocalcodes.IntheUnitedStates,thegaspipingshouldbeinstalledinaccordancewith(NFGC)NFPA54/ANSIZ223.1andanylocalcodes.Iflocalcodesallowtheuseofaflexiblegasapplianceconnector,alwaysuseanewlistedconnector.Donotuseaconnectorwhichhaspreviouslyservicedanothergasappliance.Foralever-typevalveuseonlyashut-offgasvalveapprovedbyCAN/CSAB149.

IMPORTANT! !

DISCONNECT THE MANUAL SHUT-OFF VALVE AND GAS VALVE DURING ANY PRESSURE TESTING THAT EXCEEDS 1/2 P.S.I.G. (3.45 kPA).

4.9 VENTING AND COMBUSTION PIPING

4.10 GAS SUPPLY AND PIPING

4.11 GAS CONNECTIONS

Backstop wrench must remain stationary.

WARNING! !

FIG. 4.11

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4.12 GAS INLET PRESSUREThenaturalgasinletsupplypressureshouldbe5”to7”wc.(7”wcrecommended).TheLPgasinletsupplypressureshouldbe11”to13”wc.(12”wcrecommended).Thesepressuresmustbemaintainedwhileallothergasfiredappliancesareoperatingatmaximumconditions.

Thegasvalvehasanadjustableinternalregulatorforcontrollingburnermanifoldpressure.Burnermanifoldpressureislistedonthefurnaceratingplate.

InCanada,thegaspipingshouldbeinstalledinaccordancewithCAN/CSA-B149.1and2,andinaccordancewithanylocalcodes.IntheUnitedStates,thegaspipingshouldbeinstalledinaccordancewith(NFGC)NFPA54/ANSIZ223.1andanylocalcodes.Iflocalcodesallowtheuseofaflexiblegasapplianceconnector,alwaysuseanewlistedconnector.Donotuseaconnector,whichhaspreviouslyservicedanothergasappliance.

Always use a backstop wrench to prevent twist-ing of the gas valve. Any strains on the gas valve canaffectpositioningoftheorificesrelativetothe burners. This could result in faulty burner operation.

ENSURE THAT THE GAS VALVE IS NOT SUBJECTED TO HIGH PRESSURES.

IMPORTANT! !

To maintain a good seal in the burner area, the gas piping through the top panel into the furnace must be 1/2” Schedule 40 black iron pipe. The pipe passes through a special rubber grommet that is custom manufactured to seal tightly around the gas pipe (FIG 4.12.).

IMPORTANT! !

H3.18_AC

THE 30, 40 AND 50K BTU FURNACES ARE FACTORY EQUIPPED TO BURN NATURAL GAS ONLY.CONVERSION TO LP GAS REQUIRES A NATURAL GAS TO LP CONVERSION KIT (W370-0040) EXCEPT

FOR 15K BTU (CCGM015A) UNITS. THE 15K BTU UNIT COMES FACTORY EQUIPPED TO BURN EITHER NATURAL GAS OR LP GAS. THERE ARE NO CONVERSION KITS FOR THE 15K BTU FURNACE .

FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, EXPLOSION, CARBON MONOXIDE POISONING, PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

WARNING !!

• CONVERSION OF THE 30, 40, 50 KBTU FURNACES REQUIRES SPECIALIZED EQUIPMENT. CONVERSION MUST BE COMPLETED BY A TRAINED AND QUALIFIED INSTALLER, SERVICE AGENCY OR GAS SUPPLIER. CONVERSION FROM NATURAL TO LP GAS FOR 15K BTU/H UNITS IS ONLY DONE AT FACTORY.

• CONNECT THIS FURNACE ONLY TO GAS SUPPLIED BY A COMMERCIAL UTILITY OR SUPPLIER. PRIVATE GAS WELLS DO NOT GENERALLY PROVIDE GAS WITH CONSISTENT, UNIFORM AND PREDICTABLE HEATING VALUES AND DENSITIES. MANY NON-COMMERCIAL WELLS CONTAIN IMPURITIES SUCH AS SULFUR, WHICH MAY DAMAGE THE FURNACE. THIS FURNACE CANNOT OPERATE PROPERLY OR SAFELY USING FUELS OUTSIDE NORMAL COMMERCIAL STANDARDS.

IMPORTANT! !

DO NOT EXCEED 13” WC INLET PRESSURE FOR LP GAS AND 10.5” WC FOR NATURAL GAS.

FIG. 4.12

! IMPORTANT!

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FIRE OR EXPLOSION HAZARD! NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME.

NEVER USE A MATCH, TAPER, CIGARETTE LIGHTER, FLAME OR ANY OTHER IGNITION SOURCE TO CHECK FOR LEAKS IN A GAS LINE.

USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLYFOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS.

FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.

4.13 LEAK TESTING

4.14 PURGING GAS LINES

4.15 CONVERSIONS4.15.1 High altitude conversion

4.15.2 Natural to LP Gas Conversion

4.15.3 Checking the Inlet Gas Pressure

Both,theunitanditsmanualgasshut-offvalvemustbedisconnectedfromthegassupplypipingsystemduringanypressuretestingofthatsystem,iftestpressureexceeds1/2psi(3.5kPa).

InCanada,unitiscertifiedupto4500feetwithnode-rateforNaturalgasonly.LP(propane)requiresa10%reductionofinputcapacityforelevatingfrom2000-4500feet(610m-1372m).IntheUnitedStates,themodificationsforhighaltitudearebasedona4%reductionofinputcapacityforevery1000feet(305m)above2000feet(610m)abovesealevel.Consultwithlocalfuelsuppliersorauthoritiestodeterminelocalregulationsorcustoms.

ThisunitismanufacturedasanaturalgasappliancethatmaybeconvertedtoLPgasthroughtheuseofthe Conversion Kit (W370-0040).Thiskitcontainstheconversionkitinstructions,orificesneededforallmodels,theregulatorspringforthegasvalve,andalabeltoaffixadjacenttotheapplianceratingplatetoalertsubsequentservicetechniciansoftheconversion.Thepartsremovedforthisconversionmustremainwiththefurnaceforanyfutureconversionbacktonaturalgas.

WARNING! !

H17.4

AllnewgaspipinginstallationsshouldbepressuretestedasspecifiedbyCAN/CSA-B149.1&2,orNFPA54ANSIZ223.1orANSI/NFPA58,“Standard for the Storage and Handling of Liquefi ed Petroleum Gases.”Gaspipingthathasnotbeenpressuretested,fromthemanualshut-offvalvetothefurnacegasvalveforexample,shouldbeleaktestedusinganelectroniccombustiblegasdetector,acommerciallypreparedleakdetector,orotherlocallyapprovedmethod.

H18.4.1A

WHITE-RODGERS 36J24-214 / 36J24-218P1 SINGLE STAGE GAS VALVE 1� Turnoffthegasandelectricalsupplytothefurnace.2� Backoffinletpressuretestscrew(inletpressureboss,seeFIGURE28&29)counterclockwiseoutone

turnmaximum,witha3/32”Allenwrench.AttachahoseandcalibratedU-tubeordigitalmanometertotheinletpressureboss.Hoseshouldoverlapboss3/8”.Themanometermusthaveascalerangeofatleast0”to15”ofwatercolumn.

3� TurnONthegasandelectricalsupplyandoperatethefurnaceandallothergasconsumingappliancesonthesamegassupplyline.Usingaleakdetectionsolution,checkforleaksaroundthegasvalve/manifoldconnectionandtheburnerorifices.Repairanyleaksbeforecontinuing.

4� Measurefurnacegasinletpressurewithburnersfiring.Inletpressuremustbewithintherangespecifiedonthefurnaceratingplate.5-7”w.c.(NaturalGas)or11-13”w.c.(LP).Iftheinletpressurediffersfromtheratingplate,checkthegaspipingsizeand/orconsultwithlocalgasutility.Ifworkingonanaturalgassystem,contactthegasutility.Theymayinsistonanyserviceregulatoradjustmentsbeingmadebytheirownstaff.

5. Turnoffgasandelectricalsupplytofurnace,removethemanometerhosefromtheinletpressuretapboss,andtightentheinletpressuretapscrewusingthe3/32”Allenwrench.(Clockwise,7in-lbminimum).

6� Turnonthegassupplyandelectricalpowertothefurnace.7. Usingaleakdetectionsolution,checkforleaksatpressurebossscrew.Bubblesformingindicatealeak.

SHUTOFFGASANDFIXALLLEAKSIMMEDIATELY!8� Turngasbackonandtestinletpressurebosswithleakdetector.Ifproblemswereencounteredwithobtainingenoughpressure,firstexaminethegaspipingsystemtoensurethatitiscorrectlysized.PipesizingisspecifiedinCAN/CSA-B-149.1&2,andinNFPA54/ANSIZ223.1.Besuretocheckforrestrictions,partiallyclosedvalves,etc.Insomecircumstances,highinletpressurecanberemediedwiththeuseofaninlineapplianceregulator.Ifaninlineapplianceregulatorisused,ensurethatithasthecapacitytoadequatelyhandlethegasvolumerequiredbythefurnaceandanyotherappliancesreceivinggasfromtheheaderservingthefurnace.

NOTE• THISPROCEDUREDOESNOTAPPLYTO15KBTU/hUNITS(CCGM015A).

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FIG. 28. - WHITE RODGERS 36J24-214 GAS VALVE FIG. 29. VALVE PRESSURE CHECK KIT

H18.4.1A

WHITE-RODGERS 36J24-214 / 36J24-218P1 SINGLE STAGE GAS VALVE 1� Turnoffthegasandelectricalsupplytothefurnace.2� Backoffinletpressuretestscrew(inletpressureboss,seeFIGURE28&29)counterclockwiseoutone

turnmaximum,witha3/32”Allenwrench.AttachahoseandcalibratedU-tubeordigitalmanometertotheinletpressureboss.Hoseshouldoverlapboss3/8”.Themanometermusthaveascalerangeofatleast0”to15”ofwatercolumn.

3� TurnONthegasandelectricalsupplyandoperatethefurnaceandallothergasconsumingappliancesonthesamegassupplyline.Usingaleakdetectionsolution,checkforleaksaroundthegasvalve/manifoldconnectionandtheburnerorifices.Repairanyleaksbeforecontinuing.

4� Measurefurnacegasinletpressurewithburnersfiring.Inletpressuremustbewithintherangespecifiedonthefurnaceratingplate.5-7”w.c.(NaturalGas)or11-13”w.c.(LP).Iftheinletpressurediffersfromtheratingplate,checkthegaspipingsizeand/orconsultwithlocalgasutility.Ifworkingonanaturalgassystem,contactthegasutility.Theymayinsistonanyserviceregulatoradjustmentsbeingmadebytheirownstaff.

5. Turnoffgasandelectricalsupplytofurnace,removethemanometerhosefromtheinletpressuretapboss,andtightentheinletpressuretapscrewusingthe3/32”Allenwrench.(Clockwise,7in-lbminimum).

6� Turnonthegassupplyandelectricalpowertothefurnace.7. Usingaleakdetectionsolution,checkforleaksatpressurebossscrew.Bubblesformingindicatealeak.

SHUTOFFGASANDFIXALLLEAKSIMMEDIATELY!8� Turngasbackonandtestinletpressurebosswithleakdetector.Ifproblemswereencounteredwithobtainingenoughpressure,firstexaminethegaspipingsystemtoensurethatitiscorrectlysized.PipesizingisspecifiedinCAN/CSA-B-149.1&2,andinNFPA54/ANSIZ223.1.Besuretocheckforrestrictions,partiallyclosedvalves,etc.Insomecircumstances,highinletpressurecanberemediedwiththeuseofaninlineapplianceregulator.Ifaninlineapplianceregulatorisused,ensurethatithasthecapacitytoadequatelyhandlethegasvolumerequiredbythefurnaceandanyotherappliancesreceivinggasfromtheheaderservingthefurnace.

4.15.4 Setting the manifold pressure

H18.5.1.1

Whentheinstallationiscompletedtothe“Start-up & Setup”stage,testthegasmanifoldpressurebyfollowingthesesteps:WHITE-RODGERS 36J24-214 SINGLE STAGE GAS VALVE1� Turnoffthegasandelectricalsupplybeforeproceeding.2� Backoffoutletpressuretestscrew(outletpressureboss,seefig.28&29)counterclockwiseoutonemore

turnmaximum,witha3/32”Allenwrench.AttachahoseandacalibratedU-tubeordigitalmanometertotheoutletpressureboss.Hoseshouldoverlapboss3/8”.Themanometermusthaveascalerangeofatleast0”to15”ofwatercolumn.

3� TurnonthegassupplyandelectricalpowertothefurnaceandenergizemainsolenoidbyconnectingRtoWontheintegratedcontrolboard.

4� Removescrewfromtheoutletpressureregulatoradjusttower(fig.28)andturntheplasticregulatoradjustmentscrewclockwisetoincreasemanifoldpressureorcounterclockwisetoreducemanifoldpressure.Manifoldpressureshouldbesetto3.5”w.cfornaturalgas,10.5”w.c.forLPgas.Alwaysadjustregulatoraccordingtooriginalequipmentmanufacturer’sspecificationslistedontheapplianceratingplate.Whenthecorrectpressurehasbeenestablished,securelyreplacetheregulatorcoverscrew.FAILURE TO DO SO LEADS TO FIRE DANGER!

5. Turnoffthegasandelectricalsupplytothefurnace.6� Removethemanometerhosefromtheoutletpressuretapboss,andtightentheoutletpressuretapscrew

usingthe3/32”Allenwrench.(Clockwise,7in-lbminimum).7. Turnonthegassupplyandelectricalpowertothefurnace.8� Turnonsystempowerandenergizevalve.9. Usingaleakdetectionsolution,checkforleaksatpressurebossscrew.Bubblesformingindicatealeak.

SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY!

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4.15.5 Checking furnace input

H3.21

ALL REGULATOR ADJUSTMENTS MUST BE DONE BY A TRAINED, QUALIFIED TECHNICIAN. IMPROPER MODIFICATIONS OR ADJUSTMENTS CAN RESULT IN FIRE OR EXPLOSION

CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR LOSS OF LIFE.

WARNING ! !

H18.6.1_AC

Thenaturalgassupplypressureshouldbeamaximumof7”wcandminimumof5”wc.Theburnermanifoldpressureisfactorysetto3.5”wc.Theinputratingofthefurnaceisbasedon1000Btu/ft³gas.Sinceheatingvaluesforthegasvarygeographically,theactualfurnaceinputandoutputwillvaryaccordingly.Forexample,naturalgaswitha900Btu/ft³heatingvaluewillreducetheinputto90%oftheratedinput.Naturalgaswitha1100Btu/ft³heatingvaluewillincreasetheinputtoapproximately110%oftheratedinput.Thisisnotusuallyaproblem;however,adjustmentstocompensateforthiscanbemadebyminoradjustmentstotheburnermanifoldpressureorbychangingtheburnerorificesize.Contactthefuelsupplierforspecificheatingcontentvalues.AnyadjustmentstotheburnermanifoldpressureshouldbecarriedoutwiththeuseofamanometerorcalibratedMagnehelic®gauge.Donotadjustthegasvalvepressureregulatormorethan±0.3”wc.Referto:Setting The Manifold Gas Pressure and Figure 30.

• INPUT is expressed in btu/hr• HEATING value of the gas is expressed in btu/ft3• and TIME is the number of seconds required for the test dial to indicate 1 cubic foot.

HEATING value of gas X 3600TIME in sec. for 1 CU. FT.

INPUT =

where:

• 1 cubic foot = 0.0283 cubic meters• 1 cubic meter = 35.315 cubic feet• 0.01 cubic meter = 0.3531 cubic feet• 0.5 cubic meter = 1.766 cubic feet

If using a gas meter with SI (metric) units:

NEVER ADJUST THE INPUT OF THE FURNACE TO EXCEED THE INPUT SHOWN ON THE RATING PLATE.

IMPORTANT! !

H18.5.1.1








H18.5.1.1








FIG. 30. - MANOMETER MEASURING GAS MANIFOLD PRESSURE

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4.16 ELECTRICAL

4.16.1 Electrical Wiring And Connections

4.16.1.1 Main Disconnect Switch

• InCanada,allelectricalworkandgroundingmustbeinaccordancewiththelatesteditionofCSA-C22.1,CanadianElectricalCodePart1,andanyapplicablelocalcode.IntheUnitedStates,allelectricalworkmustbeinaccordancewiththelatesteditionoftheNationalElectricalCode,ANSI/NFPA70.

• Theoperatingvoltageoftheunitisfrom197to253volts.Operatingtheequipmentoutsideoftheselimitswillvoidthewarranty.

• ThewiringdiagramIslocatedbehindthefurnaceaccesspanel.• Ensurethatelectricalcomponentsintheindoorsectionareprotectedfromwater.Theratingplateindicatestheoperatingvoltage,phase,ampacity,maximumfusesize,andminimumvoltageRefertotheratingplatelocatedontheunitforproperfuseorbreakersize.

Beforeproceedingwiththeelectricalconnections,ensurethattheavailableelectricalsupplyiscompatiblewiththevoltage,frequencyandphaselistedontheapplianceratingplate.ItisNOTpermissibletoconnectunittoaccessoriessuchashumidifiertransformers,condensatepumpsandelectronicaircleaners.

ALL ELECTRICAL WORK MUST BE DONE BY A TRAINED, QUALIFIED TECHNICIAN. IMPROPER MODIFICATIONS OR ADJUSTMENTS CAN RESULT IN FIRE OR EXPLOSION, CAUSING PROP-

ERTY DAMAGE, SEVERE PERSONAL INJURY OR LOSS OF LIFE.

WARNING ! !

SHUT OFF ELECTRICAL POWER AT THE FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE.

• THE FURNACE CABINET MUST HAVE AN UNINTERRUPTED GROUND.• A GROUND WIRE IS PROVIDED IN THE ELECTRICAL JUNCTION BOX.• DO NOT USE GAS PIPING AS A GROUND.

FAILING TO GROUND THE FURNACE PROPERLY CAN RESULT IN ELECTRIC SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

WARNING ! !

PROVIDE EACH CONDOPACK UNIT WITH ITS OWN SEPARATE ELECTRICAL CIRCUIT, MEANS OF CIRCUIT PROTECTION, AND ELECTRICAL DISCONNECT SWITCH. FOLLOW CURRENT NA-TIONAL ELECTRICAL CODE ANSI/NFPA 70, CSA C22.1 C.E.C. PART 1, AND STATE AND LOCAL

CODES. FAILURE TO PROVIDE THESE SHUT-OFF MEANS COULD CAUSE ELECTRICAL SHOCK OR FIRE, RESULTING IN DAMAGE, INJURY OR DEATH.

WARNING ! !

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4.16.2.1 Service Switch

4.16.2 Unit Connection

ItismandatorytosupplyunitwithadisconnectswitchlocatedBEFOREtheunit,makingsurethatonedoesnothavetopasstheunitperimeterinordertodisconnectpowertotheunit.Althoughisnotnecessary,butisrecommendedthatroomswithmorethanoneentranceareequippedwithaseparateunitdisconnectswitch,locatedclosetheroomentrance.

THE SERVICE SWITCH SHOULD BE CLEARLY LABELED AND INSTALLED IN A LOCATION WHERE IT IS NOT LIKELY TO BE MISTAKEN AS BEING A LIGHT SWITCH OR SIMILAR CONTROL.

IMPORTANT! !

H19.3

Theunitisshippedfullywiredexceptfortheconnectionstothehousewiring.Theunitpowerconnectionsaremadeinajunctionboxlocatedonthetopofthecabinet(refertoFigure4.0).ThejunctionboxcontainsaBLACKwiretobeconnectedwithL1(hot),aWHITEwiretobeconnectedwithL2(Neutral),andaGROUNDLUGtobeconnectedtotheground.

NOTEUsegoodqualitywirenutssuchasMarrette®connectors,Ideal®wirenuts,etc.

IMPORTANT! !

USE COPPER CONDUCTORS ONLY.

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4.16.3 Wiring Diagram

Y1

WY/

Y2R

GC

AIR

COND

ITIO

NING

MO

DULE

EC

MX-

13

GAS

FU

RN

ACE

MO

DU

LE

NL

5

4321

GC

24V

CO

M

G PAR

K

L1

NEU

TRAL

S

EXH

AUST

ER

HI COOL

HEAT

INTE

GR

ATED

FUR

NA

CE

CO

NTR

OL

BO

AR

D

SPA

RK

IGN

ITIO

NB

OA

RD

HIG

H H

EA

T TE

MP

ERA

TUR

ES

WIT

CH

GA

SV

ALV

E

GAS

FU

RN

ACE

FRO

NT

MAN

IFO

LDC

OVE

R S

WIT

CH

GAS

PR

ESS

UR

EH

IGH

PR

ES

SUR

E S

WIT

CH

FLA

ME

RO

D

FLA

ME

RO

LLO

UT

240V

AC

208V

AC

24VA

C

THE

RM

OS

TAT

WIR

ING

BK

W

BK W G

O

RR

R YY

Y

RR

VBKW

R BL W B

W54321

W54321

BK W

BK W

BKW W BK

YY

HIG

H P

RES

SU

RE

SW

ITC

H

BK

BK R

W O

R R

Y

OR

BR

CO

MP

RES

SO

RO

UTD

OO

R F

AN

MO

TOR

BR

G

C

SG

R

C

RS

BL

CO

NN

ECTO

R

LOW

AM

BIE

NT

SW

ITC

H

LINEXFMR

LOW COOL

G

SEE

NO

TE 1

WR

GY

208/

230

VAC

L1L2

GN

D

L1L2

CO

NTA

CTO

R

T1T2

CFA

NH

ERM

DU

AL R

UN

CAP

ACIT

OR

W B

Y

IND

OO

R S

EC

TIO

N

OU

TD

OO

R S

EC

TIO

N

G

BK

WG

WR

GY

G

BR

W38

5-07

89

WA

RN

ING

: DIS

CO

NN

ECT

ALL

PO

WER

SU

PPLI

ES B

EFO

RE

SER

VIC

ING

OR

INST

ALL

ING

UN

ITS.

FA

ILU

RE

TO D

O S

O M

AY C

AU

SE P

RO

PER

TYD

AM

AG

E, P

ERSO

NA

L IN

JURY

OR

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TH.

AVER

TISS

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T : D

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AN

CH

EZ T

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OR

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D’A

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N O

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’INST

ALL

ATIO

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ON

-R

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CT

DE

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TE IN

DIC

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ENTR

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ER D

ES D

OM

MA

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MAT

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LS, D

ES B

LESS

UR

ES O

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A M

OR

T.U

SE C

OPP

ER W

IRES

/ U

TILI

SER

DES

FIL

S D

’ALI

MEN

TATI

ON

EN

CU

IVR

E.LE

GEN

D /

LÉG

END

E

CO

LOU

R C

OD

E / C

OD

E D

E C

OU

LEU

RB

K -

BLA

CK

/ N

OIR

BL

- BLU

E /

BLE

UB

R -

BR

OW

N /

BR

UN

G -

GR

EE

N /

VE

RT

O -

OR

AN

GE

/ O

RA

NG

ER

- R

ED

/ R

OU

GE

V -

VIO

LET

/ VIO

LET

W -

WH

ITE

/ B

LAN

CY

- YE

LLO

W /

JAU

NE

THER

MO

STAT

CO

NN

ECTI

ON

S / F

ILA

GE

DU

TH

ERM

OST

ATW

- H

EAT

ING

/ C

HA

UFF

AG

ER

- 24

VA

CG

- FA

N /

VE

NTI

LATE

UR

Y/Y

2 - C

OO

LIN

G /

RE

FRO

IDIS

SE

ME

NT

ECM

MO

TOR

SPE

ED C

OD

E / C

OD

E D

E VI

TESS

E D

U M

OTE

UR

EC

M1

- 100

%2

- 85%

3 - 6

0%4

- 35%

5 - 2

5%N

OTE

S / R

EMA

RQ

UES

NO

TE 1

: C

ON

NE

CT

TO T

HE

CO

RR

ES

PO

ND

ING

SP

EE

D W

IRE

. US

E IN

CLU

DE

D

SP

LITT

ER

FO

R C

OM

MO

N F

AN

SP

EE

DS

.

BR

AN

CH

EZ

AU

FIL

DE

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ES

SE

CO

RR

ES

PO

ND

AN

T. U

TILI

SE

Z LE

CO

UP

LEU

R

INC

LUS

PO

UR

LE

S V

ITE

SS

ES

CO

MM

UN

ES

DE

VE

NTI

LATE

UR

.

TRA

NSL

ATIO

NS

E

NG

LIS

H

FR

EN

CH

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CO

ND

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NIN

G M

OD

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MO

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LE D

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ATIO

NC

OM

PR

ES

SO

R

C

OM

PR

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SE

UR

CO

NN

EC

TOR

RA

CC

OR

DC

ON

TAC

TOR

CO

NTA

CTE

UR

DU

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CIT

OR

CO

ND

EN

SAT

EU

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BLE

EX

HA

US

TER

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LATE

UR

D’É

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UAT

ION

FLA

ME

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D

É

LEC

TRO

DE

DE

DÉ

TEC

TIO

N D

E F

LAM

ME

FLA

ME

RO

LLO

UT

LIM

ITE

UR

DE

RE

TOU

R D

E F

LAM

ME

GA

S F

UR

NA

CE

FR

ON

T M

AN

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LD IN

TER

RU

PTE

UR

DU

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UV

ER

CLE

DU

C

OV

ER

SW

ITC

H

CO

LLE

CTE

UR

AVA

NT

D

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A FO

UR

NA

ISE

AU

GA

ZG

AS

FU

RN

AC

E M

OD

ULE

MO

DU

LE D

E L

A FO

UR

NA

ISE

AU

GA

ZG

AS

PR

ES

SU

RE

HIG

H

IN

TER

RU

PTE

UR

DE

HA

UTE

PR

ES

SIO

N D

U

PR

ES

SU

RE

SW

ITC

H

GA

ZG

AS

VA

LVE

SO

UPA

PE

DE

GA

ZH

IGH

HE

AT T

EM

PE

RAT

UR

E

IN

TER

RU

PTE

UR

DE

SU

RC

HA

UFF

E

SW

ITC

HH

IGH

PR

ES

SU

RE

SW

ITC

H

C

OM

MU

TATE

UR

HA

UTE

PR

ES

SIO

NIN

DO

OR

SE

CTI

ON

CO

MPA

RTI

ME

NT

INTÉ

RIE

UR

INTE

GR

ATE

D F

UR

NA

CE

TAB

LEA

U D

E C

ON

TRÔ

LE IN

TÉG

RÉ

DE

LA

C

ON

TRO

L B

OA

RD

FO

UR

NA

ISE

LOW

AM

BIN

ET

SW

ITC

H

IN

TER

RU

PTE

UR

DE

BA

SS

E T

EM

PÉ

RAT

UR

EO

UTD

OO

R F

AN

MO

TOR

MO

TEU

R D

E S

OU

FFLE

RIE

EX

TÉR

IEU

RO

UTD

OO

R S

EC

TIO

N

CO

MPA

RTI

ME

NT

EX

TÉR

IEU

RS

PAR

K IG

NIT

ION

BO

AR

D

PA

NN

EA

U D

E C

ON

TRÔ

LE D

’ALL

UM

AG

ETH

ER

MO

STA

T W

IRIN

G

FI

LAG

E D

U T

HE

RM

OS

TAT

WIR

ING

DIA

GR

AM

/ S

CH

ÉM

A D

E C

ÂB

LAG

E

OP

TIO

NA

L W

IRIN

G /

FILA

GE

OP

TIO

NN

EL

LOW

VO

LTA

GE

FIE

LD W

IRIN

G /

FIL

BA

SS

E T

EN

SIO

N

36

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A1 B1

C

B2A2

Sparker Board

Transformer

Main Circuit Board

ContactorX13 Molex

1 2 3

1. Turn Main Power disconect OFF.2. Turn Gas Disconnect OFF. AC module: Pull lower door off.

DO NOT TOUCH!

VESTIBULE

AC Molex

Main MolexConnector

Drain

Capacitor

ALL ELECTRICAL WORK MUST BE DONE BY A TRAINED, QUALIFIED TECHNICIAN. IMPROPER MODIFICATIONS OR ADJUSTMENTS CAN RESULT IN FIRE OR EXPLOSION

CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR LOSS OF LIFE.

WARNING! !

AC

D

FURNACEVESTIBULE

Note: *Refer to “4.16.3 Wiring Diagram”.

4.16.4 Removal of Air Conditioner and Furnace Modules

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A1

B1 A2

A2 B2

C

B2

B1

4 5 6

7 8 9

10 11 12

13 1514

Disconnect AC drain hose. Slide the AC unit out.

Disconnect the main Molex Connector C (Optional for AC modul).

Pull out the first set of wiring harness A2.

Pull up the second wiring harness out from the opening.

Take apart blower wiring harness by disconnecting Molex Connector B1 .

Remove 9 screws from the furnace front panel. Pull down and remove the front panel.

Squeeze the two tabs on the Molex connector A1 and take apart AC wiring harness.

Once Molex is separated, rotate A2 plastic block 1/4 turn.

Squeeze the two tabs on the X13 Blower Motor Molex Connector B1 to separate the wiring.

Rotate B2 plastic block 1/4 turn.

4.16.4.1 Air Conditioner Module Removal

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A1

B1 B1 A2

A2

B2

B2

C

16 18

19 20 21

22 23 24

272625

17

Disconnect the main Molex connector C.

Pull out the first wiring harness A2. Pull up the second set of wiring harness out from the opening.

Remove 9 screws from the furnace front panel. Pull down and remove the front panel.

Squeeze the two tabs on the Molex connector A1 and take apart AC wiring harness.

Squeeze the two tabs on the X13 Blower Motor Molex Connector B1 to separate the wiring harness.

Once Molex is separated, rotate A2 plastic block 1/4 turn.

Rotate B2 plastic block 1/4 turn.

Take apart blower wiring harness by disconnecting Molex Connector B1 .

1. Turn gas OFF. 2. Disconnect Union connector. 3. Remove gas piping downflow from Union connector.

Union

Drip Cap

°90 - Connector T - Connector

6” Piping 1/2” Nipple supplied

Gas Shutt OFFvalve

Condo Pack

4. Remove °90 connector from 6” nipple (supplied on GAS module).5. Disconnect drain trap hoses . 6. Disconnect a thermostat.7. Slide the Heating Module out.

4.16.4.2 Furnace Module Removal

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A1 B1

D

C

B2A2

Sparker Board

Transformer

Main Circuit Board

Contactor

Capacitor X3 Molex

Drain

AC Molex

Sparker Board

Transformer

Main Circuit Board

1 23

4

5 6 78

29

28

31

34

Sparker Board

Transformer

Side Screw

Main Circuit Board

1 2

3

4

5 6 7 8

8

30

32 33

Remove all 8 screws holding the furnace module in, as shown inthe this diagram (28).

1. Reconnect both drain trap hoses. 2. Turn the Main Gas Valve ON.3. Turn the Main Power Disconnect ON.

Secure furnace module by replacing the 8 screws on the front.Make sure not to forget side screw #8. Reconnect wiring harnesses.

Once everything is disconnected, slide the furnace out.

When sliding furnace into the cabinet, make sure the module slides UNDER the rail.

Do not forget to remove the side screw #8.

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Theunitcontainsadirect-drive,multi-speedblower.Theproperspeedshavebeenpresetatthefactoryforheatingandcooling.Forrecommendedheating/coolingspeedsforspecificmodelsrefertoTable4.in“5.4.1 Temperature Rise Check” section.Direct-driveblowermotorsarepermanentlylubricatedanddonotrequireoiling.

H53.2

Thethermostatshouldbelocatedapproximately5feet(1524mm)abovethefloor,onaninsidewallwherethereisgoodnaturalaircirculation,andwherethethermostatwillbeexposedtoaverageroomtemperatures.Avoidlocationswherethethermostatwillbeexposedtocolddrafts,heatfromnearbylampsorappliances,exposuretosunlight,heatfrominsidewallstacks,etc.

H53.1

Thethermostatandcontrolwiringshouldbeaminimumof18AWGcopper.Excessivelengthsofwiremayresultinenoughvoltagedroptoimpairtheproperfunctioningofthefurnace.Forthermostatwiresinexcessof25feet(7.6m),use16AWG;50feet(15.2m),use14AWG.

4.16.5 Low Voltage Wiring

4.16.6 Thermostat

4.16.7 Blower

4.16.8 Limit Control

4.16.9 Installation and Operation in Extremely Cold Weather Areas

Afixedtemperaturelimitcontrolisprovidedwhichwillshutoffthegastothemainburnersiftheunitisoverheatedforanyreason.Thecontrolmustnotbeadjustedorrelocated.

Inareaswhereextremelycold(below20°F)outdoortemperaturescanbeexpected,someadditionalinstallationandoperatingprecautionsshouldbetaken.Thefollowingprecautionsaretakentopreventpossibleventsystemiceblockagethatcouldresultinsafetyshutdownoftheburners:

1� Adjusttothehighestachievabletemperaturerisewithintheriseandstaticpressurerangesspecifiedontheratingplate.Dependingonspecificmodel,itmaybepossibletochangetoalowerheatingblowerspeedtaptogetahighertemperaturerise.

2� Makesuretherearenoleaksofoutsideairintothereturnairsystem.3� Keeptheoutsidelouvergrilleasfreeaspossibleofanyicethatmayformandobstructtheflue

outlet�

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1� Shutofftheelectricalpowertotheunitandsettheroomthermostattoitslowestsetting.2� TurnthethermostattoHEATmode.3� Removetheburnercompartmentaccessdoor.

5. STARTUP AND SHUTDOWNTheCondoPackisdesignedtobeusedwithresidentialsingle-stagecoolingandsingle-stageheatingwallthermostatswithautomaticormanualmodechangeover.Automaticchangeoverthermostatsmustincludeadeadbandtopreventcyclingbetweencoolingandheatingmodes.Single-pole,single-throwthermostatsarenotsuitableforusewithCondoPack.Theunitincorporatesa90-secondtimedelaytokeeptheindoorbloweroperatingaftercoolingissatisfiedtoreduceoperatingcosts.IndoorblowermotorspeedforcoolingandheatingmodescanbealteredbychangingthemotorspeedtapsontheEnduraProMotorharness.

5.1 FURNACE STARTUPThisfurnaceisequippedwithasparkignition(SI)device.Eachtimethattheroomthermostatcallsforheat,theSIlightsthemainburnersdirectly.Seethelightinginstructionsonthefurnace.Whenthegassupplyisinitiallyconnectedtothefurnace,thegaspipingmaybefullofair.Inordertopurgethisair,theinstallermustusepurgingequipmentandtechniquesaslistedinNationalandLocalGascodes.Allowfiveminutesforanygastodissipatebeforecontinuingwiththestart-upprocedure.Besureproperventilationisavailable.Duringinitialstart-up,itisnotunusualforodortocomeoutofanyroomregister.Toensureproperventilation,itisrecommendedtoopenwindowsanddoors,beforeinitialfiring.Thefurnacehasanegativepressureswitchthatisasafetyduringacallforheat.Theinduceddraftblowermustpullanegativepressureontheheatexchangertoclosethenegativepressureswitch.Theinduceddraftblowermustmaintainat leastthenegativepressureswitchsetpointforthefurnacetooperate.If theinduceddraftblowerfailstocloseormaintaintheclosingofthenegativepressureswitch,a“noheatcall”wouldresult.

H21.0.1

WARNING !!FAILURE TO SEAL DRAIN T-FITTINGS WITH CAPS WILL CAUSE A CARBON

MONOXIDE HAZARD!

It isrequired/mandatorythat thedraintrapassemblybeprimedbeforethe initialstartup.Refer to theinstructionsonhowtoprimethecondensatetraponthedrainpipingsectioninthismanual.Adrytrapwillallowfluegasestoflowthroughtherecoverycoildrain,whichwillpreventthecondensatefromdrainingfromtherecoverycoil.Ifenoughcondensateaccumulatesintherecoverycoil,therecoverycoilpressureswitchwillsensethisconditionandbreakitselectricalcontacts,andextinguishcombustion.Ifthistakesplace,theinducedblowerwillstopafterabriefpost-purgecycle,thecondensatewilldrainoutandfillthetrap.Ifthethermostatisstillcallingforheat,theignitionsequencewillstartagainaftera5minutewait.

NOTE

ENSURE THAT THE MANUAL GAS VALVE SWITCH HAS BEEN IN THE “OFF” POSITION FOR AT LEAST 5 MIN. DO NOT ATTEMPT TO MANUALLY LIGHT THE MAIN BURNERS.

IMPORTANT! !

4� Turnthegasvalveswitchtothe“ON”position.5. Replacetheburnercompartmentaccessdoor.6� Turnonfurnaceapplianceshutoffvalve.7. Restoreelectricalpowertothefurnace.8� Settheroomthermostattoapointaboveroomtemperaturetolightthefurnace.9. Aftertheburnersarelit,settheroomthermostattothedesiredtemperature.

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1� Settheroomthermostattobelowsetpoint.2� Removetheburnercompartmentaccessdoor.3� Turnthegasvalveswitchtothe“OFF”position.4� Thefurnaceapplianceshut-offvalvemaybeclosedifdesired.5. PowertothefurnacemustremainONfortheairconditionertowork.

5.2 FURNACE SHUTDOWN

5.3 AIR CONDITIONING STARTUP

IF YOU INTEND TO BE AWAY FROM HOME FOR LENGTHY PERIODS OF TIME DURING THE NON-HEATING SEASON, IT IS ADVISABLE TO FOLLOW THE FURNACE SHUT DOWN

PROCEDURE.

IMPORTANT! !

H3.24

SHOULD OVERHEATING OCCUR OR THE GAS BURNERS FAIL TO SHUT OFF, CLOSE THE MANUAL GAS VALVE FOR THE FURNACE BEFORE SHUTTING OFF THE ELECTRICAL POWER TO THE FURNACE. FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE

RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

BEFORE RESTARTING THE FURNACE, CHECK ALL PLASTIC VENTS AND WIRES FOR DAMAGE.

WARNING ! !

1� TurntheThermostattoCOOLmode.2� SettheroomthermostattobelowthecurrenttemperaturetoturnonAC.3� Waitforthefanandcompressortoturnonandruntheunitforatleast10minutes.4� Powertotheairconditionermustremainonforthefurnacetowork.

WARNING !!AIR CONDITIONER MUST NOT BE OPERATED WHEN OUTDOOR TEMPERATURE

IS BELOW 55°F.

Whileoperating,theACModulewillremovehumidityfromtheair.Thishumiditywillcondenseontheevapo-ratorcoilandeventuallyfallinthedrain-panbellowthecoil.Thereisarubberhose(“P-Trap”)thattakesthewatercollectedtothebuildingservicedrain.Beforeinitialoperationand/oratthebeginningofeachcoolingseason,itisimportantthatthisP-trapisprimed.IftheP-trapdriesout,aircanbedrawnbackupthehoseknockingcondensateoffthecoil,gettingtheairfilterandothercomponentswet.Onhowtoprimethecon-densatetrap,refertotheinstructions“4.8CondensateDrainConnection”�

NOTE

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Whentheductsystemiscompleteandtheairfilterorfiltersareinplace,determineiftheairflowiscorrect.

1� Insertaductthermometerinthesupplyairduct.Thethermometershouldbeplacedascloseaspracticaltothefurnace,butoutofthe“lineofsight”oftheheatexchanger(thispreventsfalsereadingsowingtoradiantheat).Ensurethatthethermometerlocationiswithintheductairstream.Avoidlocationssuchastheinsideradiusofanelbow,etc.

2� Insertaductthermometerinthereturnairductasclosetothefurnaceaspractical.Ensurethatthethermometerlocationwillbeunaffectedbyhumidifierbypassducts,etc.Choosealocationwellwithinthemainairstream.

3� Operatethefurnacelongenoughtoobtainsteadystateconditionsattheinputlistedonthefurnaceratingplate.

4� Whenthetwothermometershavestabilized,usuallywithin5-8minutes,comparethetworeadings.Subtractthereturnairtemperaturefromthesupplyairtemperature.Thedifferenceisthetemperaturerise,alsocalled∆T.

5. Comparethemeasured∆Ttothetemperatureriserangeshownontheratingplate.6� Unlessstateddifferentlyontheratingplate,thetemperatureriseshouldnormallyrange

between35°to65°F(20°to36°C).Whenadjustingthetemperaturerise,theidealtemperatureriseisapproximately50°F(28°C).

7. Ifthemeasured∆Tisabovetheapprovedtemperaturerange,thereistoolittleairflow.Itmustbeincreasedbyremovingrestrictionsintheductwork,addingsupplyorreturnductwork,orbyselectingahighermotorspeed.

***Ifthemeasured∆Tistoolow,thereistoomuchairflow.

5.4 AIR FLOW

5.4.1 Temperature Rise CheckH22.0

Forproperfurnaceoperation,airflowovertheheatexchangerisofutmostimportance.Insufficientairflowacceleratesmetalfatigueandpossiblefailureintheheatexchanger,aswellasdecreaseefficiency.Excessiveairflowpromotesacceleratedcorrosionoftheheatexchanger.

IMPORTANT: DO NOT BYPASS THIS STEP OF THE START UP PROCEDURES.

TABLE 4.

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Noadjustmentsarerequiredorshouldbeattemptedregardinganyofthecomponentsofthecoolingchassis.Thechassisshouldbecheckedtoseethatnoneofthewiringislooseormissing.CoolingchassisischargedwithR410Arefrigerant.

5.4.2 Calculating air flow / Capacity Check

5.4.3 Adjustments – Cooling H22.2.1

Therearecircumstanceswhereitmaybedesirabletoknowtheairflowdeliverythroughtheductsystem,suchaswhenestimatingtheamountofairflowavailableforairconditioning.Thiscanbedonebydirectmeasurementwithelectronicorslopedmanometersandvelometers,orusetheformulainthenextcolumn.

CFM =Output

1.085 x ∆Twhere:• CFMisairflowincubicfeetperminute;• ∆Tisthetemperaturerise;and• Outputisthefurnaceoutputcapacity

fromtheratingplate�

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6. MAINTENANCE

H3.25

DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN

PERSONAL INJURY OR LOSS OF LIFE.

WARNING ! !

LABELALLWIRESPRIORTODISCONNECTIONWHENSERVICINGCONTROLS.WIRINGERRORSCANCAUSEIMPROPERANDDANGEROUSOPERATION.

ALWAYSVERIFYPROPEROPERATIONAFTERSERVICING.

CAUTION ! !

6.1 GENERAL SAFETY RULES1� Combustiblematerialsshouldnotbestoredagainstoraroundtheunit.Keeptheunitareaclear

andfreefromallcombustiblematerialssuchasnewspapers,rags,cardboard,foam,plastic,paperbackedfiberglassinsulation,clothing,etc.Thisappliesespeciallytogasolineandotherflammablevaporsandliquids.

2� ThisunitisETLcertifiedasaCategoryIVindirectordirectventappliance.Itisdesignedtooperateasatwopipe(outdoorcombustionair)system.Theunitneedsadequateamountsofcombustionairtooperateproperly.Donotblockorobstructtheair-intaketerminalontheunit,orairopeningssupplyingcombustionairtotheareawheretheunitisinstalled.

3� Alldoorsandpanelsmustbeinplaceduringnormalunitoperation.Attemptingtooperatetheunitwithmissingdoorsorpanelscouldleadtothecreationofcarbonmonoxidegas.

4� Iftheunitisinstalledinaconfinedspaceorifyouintendtobuildaunitroomwhereinsulationispresent,beawarethatsomeinsulatingmaterialsarecombustible.Donotallowbuildinginsulatingmaterialstocomeintocontactwiththeunit.

5. Anyadditions,alterationsorconversionsrequiredinorderfortheunittoproperlymatchtheapplicationrequirementsmustbedonebyaqualifiedinstallationcontractor,serviceagencyorgassupplier,usingfactoryspecifiedorapprovedparts.

6� Familiarizeyourselfwiththelocationofthegasmanualshut-offvalveandanyelectricalswitch,fuseorcircuitbreakerassociatedwiththeunit.

7. Donotallowsnow,iceordebristoaccumulatearoundtheoutdoorunitexhaustandcombustionairintaketerminals.Blockageoftheexhaustorcombustionintaketerminalscanresultininadequateperformanceornuisanceshut-downs.

8� Familiarizeyourselfwiththelocationofyourunitfilter.Ablockedairfilterwillreduceefficiency,increasefuelconsumption,raisetheunitoperatingtemperature,andshortenthelifeofunitcomponents.

9. Donotcoverreturnairgrillsandsupplyairregisterswithdrapes,curtains,throwrugs,etc.10� Avoidshuttingoffsupplyairregistersintheinterestsofsavingheat.Whilethereissomevalidity

tothispracticewithspaceheating,thereislittletobegainedincentralheatingsystems.Theunitrequiresaquantityofairpassingovertheheatexchangertooperatewithindesigntemperatures.Reducingthenumberofsupplyairregistersavailableforairdeliverymayhavetheunforeseenconsequenceofraisingtheunitoperatingtemperature,reducingunitefficiency,andshorteningthelifeoftheunitcomponents.

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Boththeexhaustermotorandcirculatingfanmotoraresealedbearingtypemotors.Nolubricationrequired�

Thecoolingchassiscontainsallitemsrelatedtothecoolingfunctionsoftheunit,andalsocontainstheindoorblowerandmotorfortheheatingfunction.Forextensiveservicing,qualifiedpersonnelmaychoosetoremovethecoolingchassisfromtheunitandtakeittoaworkarea.Sparechassisarerecommendedsothatextensiveservicingcanbeperformedoutsidethelivingspace.Thiswillpreventintroducingdirtordoingdamageinthelivingarea,andcouldhelptoeliminatesignificantdisruptionoftheairconditioningandheatingfunctionsinthelivingareas.Theindoorblowermotorandtheoutdoorfanmotorhavepermanentlylubricatedbearingsanddonotrequireroutineservice.TherefrigerationsystemissealedandfactorychargedwithRefrigerantR-410Asothatroutinemaintenanceisnotrequired.Cleaningoftheoutdoorcoil,indoorcoil,drainpan,andinsidethebottomofthechassisarerecommendedatleastonceayear,andmoreofteniftheequipmentisoperatedinadustyorhostileenvironment.Theelectricalcontrolsdonotrequireroutineservice.PowertotheunitshouldalwaysbeturnedOFFbeforeperformingserviceorremovingthecoolingorfurnacemodulefromtheunit.Onepowerconnectorandonecontrolcircuitconnectorareprovidedforeasydisconnectingandre-connectingofthewiresbetweenthecoolingchassisandcabinet.Thefrontfurnacepaneldoormustberemovedtoallowaccesstothewiringharnesses.Afterreinstallingthecoolingchassis,bothpaneldoorsmustbereinstalled.Referto:Air Conditioner Module Removal sectionofthismanual.

6.2 COOLING CHASSIS

6.3 AIR FILTER

6.4 LUBRICATION

Allindoorreturnairmustbefiltered.Apermanent-typefilterispre-installedwiththeunit.Itislocatedontheairconditioningmodule.Theprovidedairfilterisanaturalfiberwashableandshouldbeinspectedfrequentlyandcleanedorreplacedasnecessary.

THE MOTOR BEARINGS WERE PRE-LUBRICATED BY THE MOTOR MANUFACTURER. DO NOT ATTEMPT TO LUBRICATE THEM. EXCESS LUBRICATION WILL VOID THE WARRANTY, SHORT-EN THE SERVICE LIFE OF THE MOTORS, AND WILL ATTRACT THE BUILDUP OF DUST AND DIRT.

IMPORTANT! !

H27.1_AC

DONOTOPERATEYOURHEATINGMODULEORAIRCONDITIONERFOREXTENDEDPERIODSOFTIMEWITHOUTANAIRFILTER.

CAUTION ! !

Aportionofthedustentrainedintheairmaytemporarilylodgeintheairductrunsandthesupplyregisters.Anyrecirculateddustparticleswillbeheatedandcharredbycomingintocontactwiththeheatexchanger.Thisresiduewillsoilceilings,walls,drapes,carpets,furniture,andotherhouseholdarticles.

BESURETHATTHEFILTERISRE-INSTALLEDWITHTHEAIRFLOWDIRECTIONIDENTICALTOITSPREVIOUSUSE.REVERSINGTHEFILTERWILLCAUSEDUSTTRAPPEDWITHINTHEFILTERTOBREAKFREEANDRECIRCULATEWITHINTHEDUCTSYSTEM.CONSULT

YOURINSTALLATIONCONTRACTORORSERVICETECHNICIANIFYOUHAVEANYQUESTIONSONINSTRUCTIONSFORREMOVING/REINSTALLINGTHEAIRFILTER.

CAUTION ! ! H3.25.1.1

DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN

PERSONAL INJURY OR LOSS OF LIFE.

WARNING ! !

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6.5 GAS METER

H3.29_AC GSI

OBSTRUCTION OF THE AIR VENT ON AN LP (PROPANE) CYLINDER OR TANK REGULATOR CAN CAUSE EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE,

SEVERE PERSONAL INJURY OR DEATH.

YOUR GAS SUPPLIER SHOULD PERIODICALLY INSPECT AND CLEAN THE AIR VENT SCREEN TO PREVENT ANY OBSTRUCTION. KEEP PROTECTIVE REGULATOR

COVER IN PLACE, AS EXPOSURE TO THE ELEMENTS CAN CAUSE ICE BUILDUP AND REGULATOR FAILURE.

WARNING ! !

QUARTERLY: • Werecommendamonthlyfilterinspectionatfirst,theneverythreemonthsafterwards.YEARLY: • PrimingTrapneedstobeinspectedateverystartingseason.Addmorewaterifnecessary.• Checkthatbarbedfittingcapsaretightandcondensatelinesremaincleanandsecuredbyhoseclamps.

H27.3.1_AC

Itisgoodpracticetogiveaquickinspectionofyouruniteachtimeyouinspectorcleantheairfilter.Thingstocheck:• Checktheunitforobvioussignsofdeterioration.• Checktheventingandcombustionairpipingtoensurethatitisstillfastenedtotheunit.Itshouldnotsag,

andshouldhavea1/4”(6mm)perfoot(305mm)slopeupwards,totheoutsidewallortermination.• Thereshouldbenowatermarksonthefloorundertheventing.Watermarksmayindicatealeakingpipejoint.• Allductworkshouldbesecuredtotheunit,andallductworkshouldbesolidlysupportedthroughout.• Watershouldfloweasilythroughthecondensatedrainlines.Youmaybeabletoobservethiswhilethe

unitisoperatingifyourcondensatedrainlinefromthedraintrapassemblyterminatesatafloordrain.Ifthedrainlinesareopaque,yourservicetechnicianwillcheckthemduringtheannualservicing.

• Thegasburnershouldbeobservedfromtimetotimeduringtheheatingseasontoensurethattheflamesarecleanandblue.Abitoforangecolorintheflameisnotlikelytobeaproblemandisprobablydustparticlesburning.Ifyouobservelazyyellowflames,callyourheatingorservicecontractorimmediately.Theyellowflamesinevitablyleadtosoot-ups.

• Thecombustionairandexhaustterminalsshouldbeinspectedoccasionallytoensurethattheyarefreeofobstructionsanddebris.

WE RECOMMEND THAT YOUR UNIT AND EXHAUST/COMBUSTION AIR VENTS BE CHECKED BY A QUALIFIED SERVICE TECHNICIAN ONCE A YEAR.

IMPORTANT! !

6.6 ROUTINE MAINTENANCE

H25.0.2

MostnaturalgassystemsandallLPgassystemshaveaserviceregulatorlocatednearthepointwherethegaspipingentersthebuilding.Thepropanetankwillnormallyhaveanadditionalfirststageregulatorlocatedatthetankoutletvalve.Alloftheseregulators(locatedoutdoors)willhaveavent.(Figure 2)Itisimportantfortheseventstoremainclear.Donotallowmoisture,whichcouldfreeze,tobuildupinthevent.Ifyouseemoisturebuildingupintheregulatorvent,contactyourgassupplier.

H25.0.2

MostnaturalgassystemsandallLPgassystemshaveaserviceregulatorlocatednearthepointwherethegaspipingentersthebuilding.Thepropanetankwillnormallyhaveanadditionalfirststageregulatorlocatedatthetankoutletvalve.Alloftheseregulators(locatedoutdoors)willhaveavent.(Figure 2)Itisimportantfortheseventstoremainclear.Donotallowmoisture,whichcouldfreeze,tobuildupinthevent.Ifyouseemoisturebuildingupintheregulatorvent,contactyourgassupplier.

FIG. 2 - GAS REGULATOR VENT

Regulatorvent

Keep free of ice, snow, and debris

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7. TROUBLESHOOTING7.1 FURNACE TROUBLESHOOTING CHART

Apply Power To Furnace

Thermostat Calls For Heat

Air Proving Switches Proved Open & Limit

Circuit Closed

Wait For Air Proving Switch to Open. Flash "3"

Wait For Limit Circuit to Close and/or Reset

of Flame Rollout. Flash "1"

Combustion Air Blower On

Air Proving Switch Proved Closed Within 60 Seconds?

Combustion Air Blower O�Flash "2"

60 Minute Wait Period

Prepurge 15 Seconds

Ignitor Energized 5 Seconds(10 Seconds on Retries)

Main Valve Opens

Ignitor Energized

Main Burner Lights And Is Sensed During Trial For Ignition? Main Valve Closes

Failed Trials For Ignition Less Than Four During

This Ignition Sequence?

Heat Circulating Air Fan On After Programmed Delay

Flame Sense Lost?

Thermostat Call For Heat Ends

Main Valve Closes

Combustion Air Blower O� After PostPurge (5 Seconds)

Circulating Air Fan O� After Blower O� Delay

Wait For Next Call For Heat

Main Valve Closes

Flame Sence Lost More Than FourTimes In This Call For Heat?

Combustion Air Blower O� After Post Purge

Circulating Air Fan O� After Blower O�

Delay

1 Hour Lockout Reset Delay. Flash "4"

30 Seconds Between Trial Purge

NO

NO

YES

YES

YES

NO

YES

NO

YES

SEQUENCE OF OPERATIONTroubleshooting Flowchart

TABLE 6.

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7.2 AIR CONDITIONING TROUBLESHOOTING

POSSIBLE CAUSE CORRECTION

Unit will not operate Power disconnected or loose connection Check voltage at contactor in condensing unit

Blown fuse / breaker tripped Replace fuses / reset breaker

Thermostat out of calibration is set too high Reset

Contactor defective Check for 24VAC at contactor coil, replace if open

Transformer defective Check wiring – replace transformer

High pressure control open (if provided) Reset – see high pressure correction (high pressure control opens at 600 psig)

Outdoor fan on;

Compressor off

Run or start capacitor defective Replace

Start relay defective Replace

Loose wire Check for correct voltage at compressor – check and tighten all connections

Compressor stuck, grounded or open motor winding, open internal overload

Wait at least 2 hours for overload to reset; if still open, replace the compressor

Too little cooling Low voltage condition Add start kit components

Improperly sized unit Recalculate load

Improper indoor airflow Check-should be approximately 400 CFM per ton

Incorrect refrigerant charge Charge per procedure in installation manual

Air, non-condensables or moisture in system

Recover refrigerant

Compressor operates in short cycles

Incorrect voltage At compressor terminals, voltage must be +/10% of nameplate marking when unit is operating

Defective overload protector Replace – check for correct voltage

Refrigerant undercharge Add refrigerant

High head pressure;

Low suction pressure

Restriction in liquid line, expansion device or filter drier

Remove or replace defective component

Lack of sufficient indoor airflow Clean/check filters, registers, or evaporator coil that may cause a restriction.

High head pressure;

Normal suction pressure

Dirty outdoor coil Clean coil

Refrigerant overcharge Correct system charge

Outdoor fan not running Repair or replace

Air or non-condensables in system Recover refrigerant, evacuate and recharge

Low head pressure;

High suction pressure

Expansion device stuck in open position Replace expansion device

Defective compressor valves Replace compressor

Low suction pressure; Compressor cool;

Ice on indoor coil

Low indoor airflow Increase speed of blower or reduce restriction – replace air filter

Operating below 65degF outdoors Add low ambient kit

Moisture in system Recover refrigerant – evacuate and recharge – replace filter drier

High suction pressure;

or �luctuating head and suction pressures

Excessive load Recheck load calculation

Defective compressor Replace

TXV hunting Check TXV bulb clamp – check air distribution on coil – replace TXV

Air or non-condensibles in system Recover refrigerant, evacuate and recharge

Pulsing noise at expansion device or liquid line


Registers sweat Low indoor airflow Increase speed of blower or reduce restriction –

FAULT CONDITION

WARNING! THIS TROUBLESHOOTING GUIDE IS INTENDED FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY!

TABLE 7.

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7.3 ADJUSTING SYSTEM CHARGE








Outdoor fan on;

Compressor off











Recover refrigerant





High head pressure;





High head pressure;






Low head pressure;





Ice on indoor coil













FAULT CONDITION









Outdoor fan on;

Compressor off











Recover refrigerant





High head pressure;





High head pressure;






Low head pressure;





Ice on indoor coil













FAULT CONDITION


Unitscomefromthefactorychargedwiththecorrectamountofrefrigerant.Therearetimes,however,whenthechargemayneedtobeadjusted.Refrigerantleaksandadditionofsystemcomponentsforservicingormonitoring,forexample,willrequirethattherefrigerantchargebeadjustedfortheunittofunctionasintended.NotethatonlyqualifiedHVACtechniciansshalladjustthecharge.

i� Ifsub-coolingandsuperheatarelow,adjusttheTXVto7°Fto9°Fsuperheat.ii� Ifsub-coolingislowandsuperheatishighornormal,addchargetoobtaintherequiredsub-

cooling.iii� Ifsub-coolingandsuperheatarehigh,adjusttheTXVto7°Fto9°Fsuperheat.iv� Ifsub-coolingishighornormalandsuperheatislow,removechargetolower

therequiredsub-cooling.

Procedure:1� OperatetheunitatstandardAHRIconditionsascloseaspossible(80°FDB/67°FWBIndoor,

95°FDBOutdoor).2� Connectcharginghosefromliquidportontherefrigerantbottletochargingserviceport.3� Openrefrigerantbottleandpurgehoseatbottlefitting.4� TemporarilyinstallatemperaturemeasuringdeviceontheliquidlineneartheTXVandoneatthe

suctionlinenearthecompressor.Ensurethatthetemperaturemeasuringdevicemakesadequatecontactandinsulatedforaccuratereadings.

5. Operatethesystemforatleast10minutes.6� Checksub-coolingandsuperheat.Systemsusingthermostaticexpansionvalvesshouldhavea

sub-coolingasperitsnameplate,ifexplicitlystated,or7.5°F+/-1°Fotherwise.Superheatshouldbe7°Fto9°F.

TABLE 7. CONT.

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7.4 DIAGNOSTIC CODES FOR STATUS LED

7.5 FAULT CODE HISTORY

H23.4.1

STATUSFAULT CONDITION

LEDRed LED indicates following codes:

LEDOFF Nopowertocontrolorcontrolhardwarefaultdetected

LEDON Normaloperation

1Flash Highlimitswitchopen

2Flashes Pressureswitchopenwithinduceron

3Flashes Pressureswitchclosedwithinduceroff

4Flashes Lockoutduetotoomanyfailedignitionattempts(1hourlockout)

5Flashes L1/NeutralPolarityproblem

6Flashes Toomanylimittripswithinonecallforheat

7Flashes Pressureswitchcyclelockout

8Flashes Lockoutduetotoomanyflamedropouts

9Flashes Notused

10Flashes Flamepresentwithgasvalveoff

A3colourLEDisprovidedtoindicatesystemfaults.LEDcodesareasfollows:• LEDOff-Nopowertocontrol,pushbuttonswitchpressed,orcontrolfault• LEDSteadyOn(anycolour)-Controlhardwarefaultdetected• SlowGreenFlash-Nocallforheat,noactiveerrors• SlowOrangeFlash-Callforheatpresent,noactiveerrors• Rapidflash-Incorrect24VACphasing/twinningerrors

H23.5

Thecontrolstoresthelast5faultcodesinmemory.Whenthepushbuttonswitchispressed,thecontrolwillflashthestoredfaultcodeswhentheswitchisreleased.Themostrecentfaultcodeisflashedfirst,theoldestlast.Faulthistorymaybeclearedbyholdingthepushbuttonswitchformorethan5seconds.

TABLE 8.

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H28.0

HOMEOWNER’S REFERENCE TABLEModel No�

Serial No�(serial number located on bottom of inside door)

DateInstalled

Contractor

Contact

Address

PostalCode/ZipCode

TelephoneNo.

AfterHoursNo.

If different from Installation Contractor:

ServiceTech.

TelephoneNo.

AfterHoursNo.

Fuel Supplier:

GasSupplier

Contact

TelephoneNo.

AfterHoursNo.

8. OWNER’S SERVICE INFORMATIONTABLE 9.

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9. WARRANTY

ALLSPECIFICATIONSANDDESIGNSARESUBJECTTOCHANGEWITHOUTPRIORNOTICEDUETOON-GOINGPRODUCTIMPROVEMENTS.Napoleon®ISAREGISTEREDTRADEMARKOFWOLFSTEELLTD.

FOR HOMEOWNERS FUTURE REFERENCE

Wolf Steel Ltd. productsaremanufacturedunderthestrictStandardoftheworldrecognizedISO9001:2008QualityAssuranceCertificate.Wolf Steel Ltd. productsaredesignedwithsuperiorcomponentsandmaterialsassembledbytrainedcraftsmenwhotakegreatprideintheirwork.

Thecompleteapplianceisthoroughlyinspectedbyaqualifiedtechnicianbeforepackagingtoensurethatyou,thecustomer,receivesthequalityproductthatyouexpectfrom Wolf Steel Ltd.

LIMITED WARRANTYThisheating/coolingapplianceiswarrantedbyWolfSteelLtd� (Condo Pack) tobefreefromdefectsinmaterialsandworkmanshipundernormaluseandmaintenance.TheStainlessSteelHeatExchanger(GasFurnaceversion)iswarrantedforaperiodof20 years(Partsonly,shippingandwarrantylaborcostarenotcovered.Suchcostaretocoveredbytheownerofappliance)� Forthefirst 10 yearsofthewarrantyperiodWolf Steel Ltd� willreplacetheentirefurnacemoduleiftheHeatExchangerfails(theHeatExchangershallbedefinedasthestainlesssteelcomponentsmakinguptheprimaryandsecondaryexchangesurfacesonly,theplasticfrontmanifoldcoverandgasketareNOTincludedaspartoftheHeatExchanger)andallconditionsandlimitationsofthewarrantyaremet.Forthe11th through 20th year ofthewarranty,replacementcostofthefurnacemodulewillbeprorated.Allothercoveredcomponentswillbewarrantedforaperiodof5 years duringwhichWolf Steel Ltd� willcoverthereplacementofthecomponent(Partsonly,shippingandwarrantylaborcostare not covered.Suchcostare tocoveredbytheownerofappliance).Componentsnotcoveredbythewarrantyincludeconsumablessuchasfilters,fuses,driers,refrigerantandoils.Cabinetrycomponents,grillsandwiringcomponentsarealsoexcludedfromthewarranty.Thewarrantyperiodbeginsatthedateoftheoriginalinstallationandifthisdatecannotbeverified,thewarrantyperiodbegins6monthsafterthemanufacturedateoftheappliance(indicatedbythefirst4numbersoftheserialnumber).Thewarrantyisonlyvalidwhen:• theappliancehasnotbeenmovedfromitslocationoforiginal

install,• hasbeeninstalledbyalicensedorqualifiedHVACtechnician,• wasinstalledinaccordancewiththemanufacturer’sdirectionsin

theInstallationandOperationManual,and• wasinstalledincompliancewithallindustrystandards,national

andlocalcodes.WarrantyclaimsmustbeauthorizedbyWolf Steel Ltd� recognizedrepresentativeoragent;parts/componentsbeingclaimedmayneedtobeanalyzedataWolf Steel Ltd� facility.Recordsofinstallationdateandperiodicmaintenancearerequiredtoprocessclaim.AllwarrantyservicemustbedonebyWolf Steel Ltd� authorizedservicetechniciansusingapprovedcomponents.

Limitations:

Wolf Steel Ltd� isnotresponsiblefor:

1� Damages/Repairs/Costsincurredduetofaultyinstallationorapplication�

2� Damages/Repairs/Costscausedbyaninstallationthatisnotperformedincompliancewithallfederal,provincial/statelawsorregulations,andtheInstallationandOperationManual.

3� Damageasaresultofvandalism,freightdamage,floods,fires,winds,lightening,andaccidents,oranyactofnature.Atmospherescontaminatedbycompoundsofchlorine,halogenatedhydrocarbons,orotherdamagingchemicalscausingdeteriorationofcomponents,orotherconditionsbeyondthecontrolofWolfSteel.

4� Useofcomponentsoraccessoriesnotcompatiblewiththisappliance�

5. ProductsinstalledoutsideofCanadaandtheUnitedStatesanditsterritories.

6� Routinemaintenance,butnotlimitedto,cleaningofthecoils,filtercleaningand/orreplacementandlubrication.

7. Damages/Repairs/CostsincurredbecauseoftheuseofPartsnotsuppliedorpreviouslyauthorizedbyWolfSteel.

8� Damagesorrepairsrequiredasaresultofimproperuse,maintenance,operation,servicing,cleaningorreplacingfilters.

9. Failuretooperateduetointerruptionand/orinadequateelectricalservice.

10� Damages,defectsorfailurescausedbyaccidentsornegligentorunreasonableuseoroperationoftheunitandits’components,includingwithoutlimitation,operationbeyondratedcapacityandoperationofelectricalcomponentsatvoltageotherthanthatspecifiedontheratingplate.

11� WolfSteelwillnotinanyeventextendwarrantycoveragetoanyincidental,consequentialorindirectdamages.

12� Changesintheappearanceoftheunitthatdoesnotaffectitsperformance.

13� Damages,defectsorfailurescausedbyoperationoftheunitinabnormalenvironmentalconditions(i.e.saltair).

14� Damages,defectsorfailurescausedbyconditionedair(returnair)suppliedtothefurnacebeinggreaterthan20%fromoutofdoors(13°C/55°Fmin.returnairtemperature).

15. Damages,defectsorfailurescausedbyoperatingairconditioningmodulesduringperiodswhenoutdoorambienttemperaturesfallbelow13°C/55°F.

Forfurtherinformationaboutthiswarranty,contactWolf Steel Ltd� Technical Service Departmentby•phone(888)721-8324•byemail: [email protected]•ormailtoWOLF STEELLTD, 24 Napoleon Road, Barrie, Ontario L4M 0G8 Canada

w w w . n a p o l e o n h e a t i n g a n d c o o l i n g . c o m

DealerNameDealer’sCity/Province-State/Postal-ZipCode

Telephone/FaxE-mailAddress

ModelandSerialNumber (Serial number located on inside bottom door)

InstallationDate

Condo Pack LIMITED WARRANTY

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Oth

er N

apol

eon®

Pro

duct

s

Fireplace Inserts • Charcoal Grills • Gas Fireplaces • Waterfalls • Wood Stoves Heating & Cooling • Electric Fireplaces • Outdoor Fireplaces • Gas Grills

Fireplaces / Heating & Cooling call: 705-721-1212 • Grills call: 705-726-4278napoleonproducts.com

24 Napoleon Road, Barrie, Ontario, Canada L4M 0G8214 Bayview Drive, Barrie, Ontario, Canada L4N 4Y8103 Miller Drive, Crittenden, Kentucky, USA 410307200 Trans Canada Highway, Montreal, Quebec, Canada H4T 1A3

installation and operating instructions thru-the …€¦ · a qualified service agency should be...

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