Maytag iQ Drive R6GI Installation Instructions Manual

Maytag iQ Drive R6GI Installation Instructions Manual

Multi-stage, variable speed, inverter driven system with gas heating / electric cooling
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R6GI / PPG2GI
INSTALLATION INSTRUCTIONS
Multi-Stage, Variable Speed, Inverter Driven System with Gas Heating / Electric Cooling
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.
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
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the
fire department.
DO NOT DESTROY THIS MANUAL. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
Premium Model Shown
AVERTISSEMENT
RISQUE D'INCENDIE OU D' EXPLOSION
• Le non-respect des avertissements de
sécurité pourrait entraîner des blessures
graves, la mort ou des dommages matériels.
• L'installation et l'entretien doivent être
effectués par un installateur qualifié, un
organisme de service ou le fournisseur de
gazstaller, service agency or the gas supplier.
• Ne pas entreposer ni utiliser de l'essence ni
d'autres vapeurs ou liquides inflammables
dans le voisinage de cet appareil, ni de tout
autre appareil.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
• Ne pas tenter d'allumer aucun appareil.
• Ne toucher à aucun interrupteur électrique;
n'utiliser aucun téléphone dans le bâtiment.
• Évacuer l'immeuble immédiatement.
• Appeler immédiatement le fournisseur de
gaz en employant le téléphone d'un voisin.
Respecter à la lettre les instructions du
fournisseur de gaz.
• Si personne ne répond, appeler le service des
incendies.
20 SEER / 81% AFUE

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Summary of Contents for Maytag iQ Drive R6GI

  • Page 1 R6GI / PPG2GI 20 SEER / 81% AFUE INSTALLATION INSTRUCTIONS Multi-Stage, Variable Speed, Inverter Driven System with Gas Heating / Electric Cooling Premium Model Shown WARNING: AVERTISSEMENT RISQUE D’INCENDIE OU D’ EXPLOSION FIRE OR EXPLOSION HAZARD • Le non-respect des avertissements de •...
  • Page 2: Table Of Contents

    TAbLE OF CONTENTS IMPORTANT SAFETY INFORMATION .......3 Verifying Over-Temperature Limit Control Operation ............18 REQUIREMENTS & CODES ........4 Verifying Burner Operation ........18 Manifold Pressure Adjustment ........18 GENERAL INFORMATION ..........5 Before You Install this Unit .........5 OPERATING SEQUENCE .........19 Locating the Equipment..........5 Heating Mode ............19 Heating Load ............5 Cooling Mode ............20...
  • Page 3: Important Safety Information

    IMPORTANT SAFETY INFORMATION WARNING: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special PROPOSITION 65 WARNING: This product notes highlighted in the manual. Safety markings are contains fiberglass wool, a product known used frequently throughout this manual to designate a to the state of California to cause cancer.
  • Page 4: Requirements & Codes

    • Use caution when handling this appliance or removing • Additional codes listed below are for reference purposes components. Personal injury can occur from sharp only and do not necessarily have jurisdiction over metal edges present in all sheet metal constructed local or state codes.
  • Page 5: General Information

    • A clearance of at least 36 inches from the blower access GENERAL INFORMATION panel and from the louvered control access panel is This Single Package Gas Heating / Electric Cooling Units recommended for servicing and maintenance. are designed only for outdoor rooftop or ground level Where accessibility clearances are greater installations and can be readily connected to the duct than clearances to combustibles, accessibility...
  • Page 6: Combustion Air & Venting Requirements

    COMbUSTION AIR & VENTING REQUIREMENTS WARNING: AVERTISSEMENT: RISQUE D’EMPOISONNEMENT AU CARbON MONOXIDE POISONING HAZARD MONOXYDE DE CARbONED Failure to follow the steps outlined below for each appliance connected to the venting system Le non-respect des consignes suivantes portant being placed into operation could result in carbon sur chacun des appareils raccordés au système monoxide poisoning or death.The following steps d’évacuation mis en service pourrait entraîner...
  • Page 7: General Information

    General Information If this control must be replaced, use only factory authorized replacement parts. See the Replacement Parts List on WARNING: page 25. Installation methods other than those described Vent Termination in the following sections must comply with the This unit has been equipped with an integral venting system and designed to operate only with this venting National Fuel Gas Code and all applicable local codes for providing sufficient combustion air...
  • Page 8: Circulating Air Supply

    • The unit installation shall avoid areas where condensate • Duct work should be attached directly to the unit flanges drainage may cause problems by dropping on planters for horizontal applications. • If roof curb is installed, the ducts must be attached to or patios, etc.
  • Page 9: Unconditioned Spaces

    • If using bottom discharge with return air ducts a roof Unconditioned Spaces curb must be installed prior to unit installation. See All duct work passing through unconditioned space must Rigging and Hoisting section for setting of the unit. be properly insulated to minimize duct losses and prevent •...
  • Page 10: Horizontal To Downflow Conversion

    Horizontal to Downflow Conversion ELECTRICAL WIRING The unit is shipped ready for horizontal duct connections. If down flow ducts are required, the unit must be converted WARNING: following the steps below for both the supply and return ducts. ELECTRICAL SHOCK, FIRE OR EXPLOSION 1.
  • Page 11: Pre-Electrical Checklist

    Voltage Range Compressor Single Circuit Nominal Maximum Model Nominal Indoor Cooling Heating Electrical Motor blower Number Capacity Input Supply (R6GI / PPG2GI) (Tons) E24K080X 80,000 208-230/60/1 11.6 2.60 3.80 20.9 30.0 E36K100X 100,000 208-230/60/1 16.2 2.60 3.80 26.7 40.0 E48K120X 120,000 208-230/60/1 17.6...
  • Page 12: Heat / Cool Thermostat

    thermostat on an outside wall or any other location (Recommended): For highest efficiency a 2 Stage where its operation may be adversely affected by radiant Heating/Cooling thermostat is recommended for this heat from fireplaces, sunlight, or lighting fixtures, and unit. A 2 Stage Cool thermostat is required for control of convective heat from warm air registers or electrical the special variable speed compressor.
  • Page 13: Configuring The Variable Speed Blower

    thermostat is not satisfied before the timer activates, the NOTES: • The CFM values listed in Tables 13 & 14 (page 27) furnace will stage to high fire. The inducer motor and blower will ramp to a higher speed until the thermostat is satisfied. are not dependent on duct static pressure.
  • Page 14: Gas Supply & Piping

    • All gas piping must be installed in compliance with GAS SUPPLY & PIPING local codes and utility regulations. In the absence of local codes the gas line installation must comply WARNING: with the latest edition of the National Fuel Gas Code ANSI Z223.1 or CAN/CGA b149 Installation Codes.
  • Page 15: Leak Check

    If installing this unit above 2,000 feet, the input rate must AVERTISSEMENT: be reduced 4% per 1,000 feet of altitude (Example: 12% at 3,000 feet, 16% at 4,000 feet, etc). NOTE: Deration is necessary to compensate for low atmospheric pressure RISQUE D’INDENDIE OU D’EXPLOSION at high altitudes.
  • Page 16 Shut-Off Valve with 1 /8 NPT Automatic Gas Valve plugged tap (with manual shut-off) Some utilities require Shut-Off Valve to be 4 to 5 feet above floor Burner Ground Assembly Dripleg Joint Union Manifold Figure 7. Typical Gas Hookup - Right Side Entry ALTITUDE AbOVE SEA LEVEL Natural Gas Heating Value of...
  • Page 17: Startup & Adjustments

    START UP & ADJUSTMENTS 2. Feel the air being circulated by the indoor blower and verify that it is cooler than ambient temperature. Listen for Pre-Start Check List any unusual noises. If unusual sounds occur, determine √ Verify the unit is level and allows proper condensate the source of the noise and correct as necessary.
  • Page 18: Verifying & Adjusting Firing Rate

    Verifying Over-Temperature Limit Control the blower speed. Lowering the blower speed increases the temperature rise and a higher speed decreases the Operation temperature rise. 1. Verify the louvered control access panel is in place and The unit is equipped with a variable speed motor. Heating that there is power to the unit.
  • Page 19: Operating Sequence

    OPERATING SEQUENCE general, whenever ignition failure occurs the warm-up interval is increased by 3 seconds on the next try. And The operating sequences for the heating, cooling, and fan if successful, it remains there. Minimum and maximum modes are described below. Refer to the field and furnace warm-up time limits are set at 9 and 54 seconds.
  • Page 20: Cooling Mode

    11. The inducer motor is de-energized after a 30 second When performing startup tests or troubleshooting, the post purge. 5 minutes startup delay can be skipped by shorting the 12. The circulating air blower will remain energized for two J4 Test pins indicated in Figure 14 for about 1 second approximately 120-150 seconds after the demand while the compressor is off and waiting to start.
  • Page 21: Cleaning Of Heat Exchanger

    Cleaning of Heat Exchanger CAUTION: WARNING: Use care when removing parts from this unit. Personal injury can result from sharp metal Holes in the heat exchanger can cause products edges present in all equipment of sheet metal of combustion to enter the home. Replace the construction.
  • Page 22: Cleaning Of Burners

    12. Remove the screw securing the NOx baffle retainer CAUTION: clip to the heat exchanger panel, then pull the baffle straight forward to remove. Repeat these steps for each additional tube assembly. Keep components for To prevent damage to the unit or internal components, it is recommended that two reuse aftercleaning.
  • Page 23 Heat Exchanger Panel Flame Sensor Flame Ignitor Roll-Out Switch Burner NOx Ba e Gas Valve Gas Valve Retainer Clip Terminals ON/OFF Switch & Screw Per Tube (If equipped) NOx Ba e Per Tube (If Equipped) Valve Gas Valve Inlet Ori ces Screws Burner (X4)
  • Page 24: Troubleshooting-Cooling Mode

    TROUbLESHOOTING - COOLING MODE Instrumentation The 20 SEER iQ Drive split air conditioner includes Diagnostic Display instrumentation as listed in Table 8. All items listed are The interface board located inside the control panel has a connected to the interface board except for the high two character display which provides information regarding pressure switch.
  • Page 25: Replacement Parts

    HEATING COMPONENT FUNCTIONS Diagnostic Description Green LED Red LED Flame Roll-Out Control - The flame roll-out control acts to Control Fault (No Power) verify that the burner flame is being drawn into the heat L1/Neutral Polarity Fault Flash Flash exchanger tubes. If the burner flame is not being drawn into the heat exchanger tubes, the roll-out control will 1 Hour Lockout Alternating Flash...
  • Page 26: Unit Dimensions & Weights

    UNIT DIMENSIONS & WEIGHTS INSIDE PERIMETER 3/4" NPT OF BASE RAIL FEMALE DRAIN 31.5 (IF USED) CONNECTOR 2.63 DOWNFLOW SUPPLY DUCT OPENING Top View 47.50 45.75 13.50 13.50 13.31 23.50 DOWNFLOW RETURN DUCT OPENING HORIZONTAL HORIZONTAL RETURN DUCT 1.75 SUPPLY DUCT OPENING OPENING 16.0...
  • Page 27: Airflow Data

    AIRFLOW DATA Heating Input Heating Output Heating Heating Rise blower Motor Model Number (btuh) (btuh) Range Range (°F) Size (HP) 80,000 64,800 1025 - 1375 E24K080X 11 X 8 35-65 52,000 42,100 800 - 1050 100,000 81,000 1150 - 1500 E36K100X 11 X 8 40-70...
  • Page 28: Gas Information

    GAS INFORMATION GAS PIPE CAPACITIES Length of Pipe Run (Feet) Nominal Pipe Diameter (IN.) 1 1/4 1,050 1 1/2 1,600 1,100 Input To Furnace (Btu/hr) Cubic Feet Per Hour Required = Heating Value of Gas (Btu/Cu. Ft.) NOTE: The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace.
  • Page 29: Figure 11. Gas Valve Label

    FOR YOUR SAFETY READ POUR VOTRE SÉCURITÉ. BEFORE OPERATING À LIRE AVANT L’EMPLOI ATTENTION! L’inobservation de ces instructions WARNING: If you do not follow these instructions peut entraîner un incendie ou une explosion pouvant exactly, a fi re or explosion may result causing property causer des dam mages à...
  • Page 30: Electrical Information

    ELECTRICAL INFORMATION Ignition Control Fault Yellow = Flame Sense Heating Mode Red & Green LED’s (See Operating Sequence & Table 9) Blower Off Delay (See Operating Sequence & Table 9) Blower Interface Connection Automatic Heat Staging (Used with Single Stage Heating Thermostat Only) Low Voltage Control Circuit (3 Amp Fuse)
  • Page 31: Figure 14. Interface Board

    2-Character Display Test Pins Figure 14. Interface Board in Control Panel 2 CHARACTER CAPACITY STAGE DISPLAY Cooling, Stage One Call, Low Cooling, Stage One Call, Intermediate Cooling, Stage One Call, Low High Cooling, Stage Two Call, Nominal High Cooling, Stage Two Call, Boost Startup Delay (5 minutes) —...
  • Page 32: Figure 15. R6Gi Inverter

    Reactor Inverter Board Interface Board Thermistors Compressor Terminal Board Contactor * 5 Ton inverter assembly has additional components: Contactor, PTCR, and Fan Terminal Block Figure 15. R6GI Inverter Assembly (2, 3 & 4 Ton*)
  • Page 33 Hot Surface Ignition Control Board with 24V Secondary 3-Amp Fuse Protection Blower Low Voltage Control Thermostat Board Connections Branch Circuit Ground Connection Branch Circuit High Voltage Draft Connection Inducer Motor Dual Vent Pressure Switch High Temperature Limit (Auto Reset) 2-Stage Gas Valve Flame Sensor...
  • Page 34 LINE- N LINE- N XMFR-N DHUM Y1 L2-IN MODE SPEED LINE FAULT L2-OUT LINE COMMON XMFR OPEN GREEN OPEN Y/Y2 Figure 17. Two Stage Cool, Two Stage Heat (2, 3, & 4 Ton Models)
  • Page 35 LINE- N LINE- N XMFR-N DHUM Y1 L2-IN MODE SPEED LINE FAULT L2-OUT LINE COMMON XMFR OPEN GREEN OPEN Y/Y2 Figure 18. Two Stage Cool, Two Stage Heat (5 Ton Models)
  • Page 36: Refrigerant Charging

    REFRIGERANT CHARGING 5. Using the temperature value recorded, determine the corresponding liquid refrigerant pressure from the curve in the appropriate charging chart. See Figures 19 - 22 WARNING: pages 37 & 38. These units are shipped fully charged with 6. If the pressure measured in step 3 is less than the R-410A refrigerant and ready for installation.
  • Page 37: Figure 19. Charging Chart For 2 Ton Units

    Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (° F) Figure 19. Charging Chart for 2 Ton Units Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (° F) Figure 20. Charging Chart for 3 Ton Units...
  • Page 38: Figure 21. Charging Chart For 4 Ton Units

    Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (° F) Figure 21. Charging Chart for 4 Ton Units Remove refrigerant when above curve Add refrigerant when below curve Liquid Temperature (° F) Figure 22. Charging Chart for 5 Ton Units...
  • Page 39 Temperature vs. Resistance for All Thermistors (Part 1) k Ω Temperature vs. Resistance for All Thermistors (Part 2) k Ω Figure 23. Temperature Sensor Resistance Charts...
  • Page 40: Installation / Performance Checklist

    INSTALLATION / PERFORMANCE CHECK LIST 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.

This manual is also suitable for:

Iq drive ppg2gi

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