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ATTENTION INSTALLERS:

It is your responsibility to know this product better than your customer. This includes being able to install the product according 
to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. 
Safety should always be the deciding factor when installing this product and using common sense plays an important role as 
well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the unit 
or failure to follow safety warnings could result in serious injury, death, or property damage. These instructions are primarily 
intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require 
licensed installation/service personnel for this type of equipment. After completing the installation, return these instructions to 
the customer’s package for future reference.

15 SEER / 8.0 HSPF / 80% AFUE

DF6SF / PDF2SF - REV. A SERIES

Premium Model Shown

INSTALLATION INSTRUCTIONS

DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

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.

•  Leave the building immediately.
•  Immediately  call  your  gas  supplier  from  a 

neighbors phone. Follow the gas suppliers 

instructions.

•  If you cannot reach your gas supplier, call 

the fire department.

WARNING:

FIRE OR EXPLOSION HAZARD

• Failure  to  follow  safety  warnings  exactly 

could  result  in  serious  injury  or  property 
damage.

• Installation  and  service  must  be  performed 

by a qualified installer, service agency or the 
gas supplier.

•  Do  not  store  or  use  gasoline  or  other 

flammable vapors and liquids in the vicinity 
of this or any other appliance.

 Dual Fuel Heating & Cooling Packaged System

Summary of Contents for DF6SF

Page 1: ...l for this type of equipment After completing the installation return these instructions to the customer s package for future reference 15 SEER 8 0 HSPF 80 AFUE DF6SF PDF2SF REV A SERIES Premium Model Shown INSTALLATION INSTRUCTIONS DO NOT DESTROY PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any elect...

Page 2: ...Heat Pump Mode 18 System Heating Emergency Heat Mode 19 Verifying Adjusting Temperature Rise 19 Verifying Adjusting Firing Rate 19 Verifying Over Temperature Limit Control Operation 19 Manifold Pressure Adjustment 20 Verifying Burner Operation 20 Refrigerant Charging 20 Charging R 410A Unit in AC Mode 20 Charging R 410A Unit in Heating Mode 20 OPERATING SEQUENCE 21 2 Stage Heating Mode Heat Pump 2...

Page 3: ...the literature on tags and on labels provided with the equipment Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment Never test for gas leaks with an open flame Use a commercially available soap solution to check all connections See page 17 Installation of equipment may require brazing operations...

Page 4: ... provide the correct flow rates and external pressure rise An improperlydesignedductsystemcanresultinnuisance shutdowns and comfort or noise issues This unit is designed for outdoor installations only and should be located in a position as shown on page 5 Use only with the type of gas approved for this unit Refer to the unit rating plate Provide adequate combustion and ventilation air to the unit ...

Page 5: ...pment Survey the job site to determine the best location for the packaged unit The unit should be located with consideration of minimizing the length of the supply and return ducts If practical place the equipment and its ducts in an area where they will be shaded from the afternoon sun when the heat load is greatest Consideration should also be given to the accessibility offuel electricpower serv...

Page 6: ... Le non respect des consignes suivantes portant sur chacun des appareils raccordés au système d évacuation mis en service pourrait entraîner l empoisennement au monoxyde de carbone ou la mort Les consignes suivantes doivent être observéespourchaqueappareilraccordéausystème d évacuation mis en service si les autres appareils raccordés au système ne sont pas en service 1 Scellertouteouverturenonutil...

Page 7: ... air to the furnace Provisions must be made during the installation of this unit that provide an adequate supply of air for combustion Instructions for determining the adequacy of an installation can be found in the current revision of the NFGC ANSI Z223 1 NFPA54 Consult local codes for special requirements These requirements are for US installations as found in the NFGC The requirements in Canada...

Page 8: ... leaks If outside air is utilized as return air to the unit for ventilation or to improve indoor air quality the system must be designed so that the return air to the unit is not less than 50 F 10 C during heating operation If a combination of indoor and outdoor air is used the ductsanddampersystemmustbedesignedsothatthe return air supply to the furnace is equal to the return air supply under norm...

Page 9: ...e must be properly insulated to minimize duct losses and prevent condensation Use insulation with an outer vapor barrier Refer to local codes for insulation material requirements Acoustical Duct Work Certain installations may require the use of acoustical lining inside the supply duct work Acoustical insulation must be in accordance with the currentrevisionoftheSheetMetalandAirConditioning Contrac...

Page 10: ...al Condensate Drain Condensate is removed from the unit through the 3 4 female pipe fitting Figure 5 located on the front side of the unit Install a 2 inch condensate trap in the drain line of thesamesizeandprimewithwater Whenconnectingrigid drain line hold the female fitting with a wrench to prevent twisting Do not over tighten Refer to local codes and restrictions for proper condensate disposal ...

Page 11: ...mpact frame A 2 stage heat 2 stage cool thermostat with back up fossil fuel heat capability is required with the Dual Fuel iHybrid heat pump packaged system This system is capable of providing two stages of cooling two stages of heating in heat pump mode and an additional 2 stages of secondary gas heating See Figure 12 page 30 The low voltage wires must be properly connected to the units low volta...

Page 12: ...ower is configured by setting the heat cool and adjust jumpers located on the ignition control board as described below Selecting Cooling Airflow The cooling airflow is selected by setting the Cool and Adjust jumpers on the ignition control board Table 11 page27 liststherecommendedairflowvalues CFM and selector tap settings for each nominal system capacity All airflows for other modes of operation...

Page 13: ...F Compressor Delay Function 1 20 40 NO 2 20 40 YES 3 20 75 NO 4 20 75 YES is removed the defrost mode will terminate in 13 7 minutes if the coil temperature is above the terminate set point or when the Y input is removed whichever occurs first NOTE If a demand curve is selected which has a 30 second compressor time delay in defrost the delay is reduced to 10 seconds in TEST mode Ambient Sensor Mou...

Page 14: ... been energized for 5 seconds When the compressor is not running Comfort Alert will not power the solenoid regardless of the state of Y2 If Alert codes 1 or 9 appear while the compressor is running Comfort Alert will turn off the solenoid to prevent solenoid damage from overheating conditions L Terminal Wiring White Rodgers Compatible Thermostats The L connection is used to communicate Comfort Ale...

Page 15: ...voltagetothesolenoidtotheminimumlevelrequiredto keep the solenoid pulled in As the 24VAC supply voltage varies Comfort Alert intelligently changes the solenoid DC voltage supply to minimize power consumption A voltmeter attached to the DC SOL output will measure 4 18VDC whensolenoidshouldbeenergized depending on the level of the 24 VAC supply Interpreting the Diagnostic LED s When an abnormal syst...

Page 16: ...on of length in typical applications based on nominal pressure drop in the line Ground Joint Union Dripleg Shut Off Valve with 1 8 NPT plugged tap Burner Assembly Manifold Some utilities require Shut Off Valve to be 4 to 5 feet above floor Automatic Gas Valve with manual shut off Figure 9 Typical Gas Hookup Right Side Entry GAS SUPPLY PIPING WARNING FIRE OR EXPLOSION HAZARD Failure to follow safet...

Page 17: ...he furnace manifold pressure See Tables 6 or 7 for the correct manifold pressure settings LP Propane Gas Conversion WARNING This unit was equipped at the factory for use with natural gas only A special kit supplied by the manufacturer is required to convert the unit to operate on LP Propane gas Failure to use the proper conversion kit can cause fire explosion property damage carbon monoxide poison...

Page 18: ...ower will run continuously Check the air delivery at the supply registers and adjust register openings for balanced air distribution Examine ductwork for leaks or obstruction if insufficient air is detected Set the thermostat fan mode to AUTO The blower will stop running Short Cycle Protection 1 With the system operating in cooling mode note the temperaturesettingofthethermostatandgraduallyraise t...

Page 19: ...s the difference between the supply and return air temperatures NOTE For typical duct systems the temperature rise will fall within the range specified on the data label with the blower speed at the factory recommended setting shown inTable 9 page 27 If the measured temperature rise falls outsidethespecifiedrange itmaybenecessarytochange the blower speed Lowering the blower speed increases the tem...

Page 20: ... Pressure in W C for Natural Gas Manifold Pressure in W C for Natural Gas Installations Altitude above sea level Heating Value Btu cu ft 800 to 899 900 to 999 1 000 to 1 100 zero to 1 999 FT 3 5 3 5 3 5 2 000 to 4 999 FT 3 5 3 5 3 5 5 000 to 5 999 FT 3 5 3 5 3 0 6 000 to 7 999 FT 3 5 3 2 2 8 8 000 to 10 000 FT 3 0 2 8 2 5 Table 7 Manifold Pressure in W C for LP Gas Manifold Pressure in W C and Ori...

Page 21: ... control energizes the inducer motor and restarts the 60 second pressure switch proving period 5 Pre Purge If the low pressure switch closes the control runstheinduceronhighspeedfora30secondpre purge time while monitoring the thermostat call for heat limit switch circuit low pressure switch and flame sense High pressure switch is ignored 6 Igniter Warm Up When the 30 second pre purge time has elap...

Page 22: ...thermostat has been satisfied gas valve is de energized 11 The inducer motor is de energized after a 30 second post purge 12 The circulating air blower will remain energized for approximately 120 150 seconds after the demand for heat is no longer present 13 Abnormal Conditions If a limit switch opens during heating operation the gas valve is de energized immediately The control de energizes the in...

Page 23: ...pply to the unit at the meter or at the manual valve in the gas supply piping 2 Turn off all power to the unit and set the thermostat to the lowest temperature setting 3 Remove the louvered access panel from the unit 4 Turn the gas control knob gas valve to the OFF position See Figure 11 page 29 for gas valve shut off instructions 5 Disconnect the wires from the gas valve ignitor flame sensor comb...

Page 24: ...lashing SYSTEM STATUS HI LO DEHUMIDIFY Cooling Mode only LED STATUS GREEN Factory jumper wire R to DEHUM in place or Close on Fall humidistat Low humidity Closed ON Humidistat open High Humidity Low Speed Blower call OFF SYSTEM STATUS CFM LED STATUS YELLOW NOT USED OFF Cleaning of Burners If the burners require cleaning follow the steps below 1 Shut off the gas supply to the unit either at the met...

Page 25: ...igh fire When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold Dual Pressure Switch The dual pressure switch verifies that the inducer motor is drawing the combustion gases through the heat exchanger tubes and venting the gases through the vent system for both high and low fire conditions Over Temperature Limit Control The over temperature limit cont...

Page 26: ... 1 8 4 0 12 45 12 45 4 0 D 8 75 Horizontal Supply Duct Opening Horizontal Return Duct Opening 4 0 1 75 9 75 24 75 16 0 Condensing Coil 13 5 13 5 16 0 16 0 C figures tables Figure 10 Unit Dimensions Model Number Unit Weight Center of Gravity Height in inches C D A B with base rails without base rails X24K080CA 480 26 0 27 0 39 0 35 3 55 8 X36K100CA 599 27 0 26 5 43 0 39 3 55 8 X48K120CA 618 27 0 26...

Page 27: ... ADJUST COOL ADJUST TAP A 10 2 T O N 685 TAP A 10 840 TAP A 10 4 T O N 1485 Normal 760 Normal 3 T O N 930 Normal 5 T O N 1650 10 835 10 1025 10 1815 TAP B 10 840 TAP B 10 975 TAP B 10 1620 Normal 930 Normal 1080 Normal 1800 10 1025 10 1190 10 1980 TAP C 10 975 TAP C 10 1110 TAP C 10 1665 Normal 1080 Normal 1230 Normal 1850 10 1190 10 1350 10 2035 TAP D 10 1110 TAP D 10 1290 TAP D 10 1800 Normal 12...

Page 28: ...4 429 86 42 209 419 88 41 205 409 90 40 200 400 92 39 196 391 94 38 191 383 96 38 188 375 98 37 184 367 100 36 180 360 102 35 176 353 104 35 173 346 106 34 170 340 108 33 167 333 110 33 164 327 112 32 161 321 114 32 158 316 116 31 155 310 118 31 153 305 120 30 150 300 GAS PIPE CAPACITIES Nominal Pipe Diameter IN Length of Pipe Run Feet 10 20 30 40 50 60 70 80 1 2 130 90 75 65 55 50 45 40 3 4 280 1...

Page 29: ...ementetavertirlacompagnie du gaz en utili sant le téléphone d un voisin A défaut de la compagnie du gaz avertir le service des pompiers C Enfoncer ou faire tourner le robinet à gaz à la main seulement Nejamaisutiliserd outils S iln estpaspossible de faire tourner ou d enfoncer le robinet à la main ne pas essayer de le réparer Faire appel à un spécialiste Forcer outenterderéparerlerobinetpourrait ê...

Page 30: ... W2 BLUE BROWN S2 Heat Pump Heat Cool S2 Gas Heat 24VAC Com S1 Gas Heat Fan S1 Heat Pump Heat Cool 24VAC Reversing Valve See Note 1 NOTES 1 Reversing valve energized in cooling mode of operation Refer to the thermostat manual for detailed installation and programming instructions 2 For use with standard heat pump thermostats with defrost control board fault monitoring only E E Emergency Heat O L O...

Page 31: ...p operates in heating mode until the combination of outdoor ambient and outdoor coil temperatures initiate a defrost cycle The outdoor coil temperature must be at or below 32 F before the defrost cycle begins There must be a minimum of 20 minutes between defrost cycles After this time temperature conditions must call for defrost continuously for 4 1 2 minutes before a defrost cycle is initiated Th...

Page 32: ...or heat Excess flame dropouts 5 within one call for heat Not Used Flame present with gas valve Off LED STATUS RED ON 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes 9 Flashes 10 Flashes SYSTEM STATUS 2nd STAGE HEAT DEMAND No demand for 2nd stage heat 2nd stage heat demand Normal operation 2nd stage heat demand high pressure switch not closed LED STATUS GREEN OFF ON Fl...

Page 33: ...d Blower call LED STATUS GREEN ON OFF DEFROST BOARD OPERATION Heat Pump operates in heating mode until the combination of outdoor ambient and outdoor coil temperatures initiate a defrost cycle The outdoor coil temperature must be at or below 32 F before the defrost cycle begins There must be a minimum of 20 minutes between defrost cycles After this time temperature conditions must call for defrost...

Page 34: ...on of outdoor ambient and outdoor coil temperatures initiate a defrost cycle The outdoor coil temperature must be at or below 32 F before the defrost cycle begins There must be a minimum of 20 minutes between defrost cycles After this time temperature conditions must call for defrost continuously for 4 1 2 minutes before a defrost cycle is initiated The defrost cycle ends when either the outdoor c...

Page 35: ...xcessively low thermostat setting Check evaporator airflow coil blockages or return air filter Check ductwork or registers for blockage Faulty metering device Check TXV bulb installation size location and contact Check if TXV fixed orifice is stuck closed or defective Condenser coil is dirty Liquid line restriction filter drier blocked if present in system Thermostat is malfunctioning Solenoid plu...

Page 36: ...mpressor protector reset time due to extreme ambient temperature Compressor windings are damaged Check compressor motor winding resistance ALERT Flash Code 6 Yellow LED Open Start Circuit Current only in run circuit Run capacitor has failed Open circuit in compressor start wiring or connections Check wiring and connectors between supply and the compressor S terminal Compressor start winding is dam...

Page 37: ...scoolingsystemcontainsrefrigerantunder high pressure always use safe practices when servicing the unit Always review the factory literature and safety warnings prior to servicing These units are shipped from the factory with the proper amount and type of refrigerant Always inspect the unit rating label to determine the units information prior to working on the system Do not mix different refrigera...

Page 38: ...ling Remove refrigerant when above curve Add refrigerant when below curve Figure 17 Charging Chart for 2 Ton Units 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 75 80 85 90 95 100 105 110 115 120 125 130 135 Liquid Temperature F Liquid Pressure psig X36K080CA Charging Chart Cooling Remove refrigerant when above curve Add refrigerant when below curve Figure 18 ...

Page 39: ...oling Remove refrigerant when above curve Add refrigerant when below curve Figure 19 Charging Chart for 4 Ton Units 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 75 80 85 90 95 100 105 110 115 120 125 130 135 Liquid Temperature F Liquid Pressure psig X60K120CA Charging Chart Cooling Remove refrigerant when above curve Add refrigerant when below curve Figure 20...

Page 40: ...__ STATE_________________ Has the owner s information been reviewed with the customer YES NO Has the Literature Package been left with the unit YES NO ELECTRICAL SYSTEM Electrical connections tight YES NO Line voltage polarity correct YES NO Rated Voltage ____________________________________ VOLTS L1 L2 Volts ______________________________________ VOLTS Has the thermostat been calibrated YES NO Is...

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