INSTALLATION
INSTRUCTIONS
Litho U.S.A.
©2006
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
personal injury or loss of life. Installation and service must be performed by a qualified installer, service agency or the gas supplier
TGA/TCA090
TGA/TCA102
TGA/TCA120
TGA/TCA150
(7.5 Ton)
(8.5 Ton)
(10 Ton)
(12−1/2 Ton)
Table Of Contents
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rigging Unit For Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Altitude Derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
3
3
4
4
4
5
5
6
6
GAS AND COOLING PACKAGED UNITS
504,814M
10/2006
Supersedes 8/2005
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unit Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Blower Operation and Adjustments . . . . . . . . . . . . . . . . . . 8
Cooling Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Gas Heat Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Heating Operation and Adjustments . . . . . . . . . . . . . . . . . . 16
Electric Heat Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
TGA SHOWN
10/06
*2P0805*
504,814M
*P504814M*
TGA/TCA090, 102, 120, & 150 DIMENSIONS − Gas heat section shown
OPTIONAL
OUTDOOR
AIR HOOD
CONDENSER COIL
INTAKE AIR
CONDENSER
COIL FAN (2)
4 (102)
4 (102)
28
(711)
CONDENSER
COIL
INTAKE
AIR
EVAPORATOR COIL
BLOWER
28
(711)
20
(508)
5-1/2
(140)
BOTTOM
SUPPLY AIR
OPENING
6-1/4 20
(159) (508)
CENTER OF
GRAVITY
BOTTOM
RETURN AIR
OPENING
BOTTOM
POWER/GAS ENTRY
5 x 8 inches
(127 x 203 mm)
COMPRESSORS
BOTTOM
POWER/GAS ENTRY
3-1/2 (89)
BLOWER
MOTOR
31-1/4
(794)
CONDENSER
COILS
TOP VIEW
Base Section
TOP VIEW
CONDENSER COIL
EXHAUST AIR
CONDENSER COIL
EXHAUST AIR
99-1/4
(2521)
CONTROL
BOX
99-1/4
(2521)
CONDENSER
COIL FAN
BLOWER
BLOWER
CONDENSER
COIL
INTAKE
AIR
15 (381)
1/2
(13)
ELECTRIC INLETS
35
(889)
GAS
INLET
HEAT
EXCHANGER
FORKLIFT
SLOTS
LIFTING HOLES
(For Rigging)
28
(711)
HORIZONTAL
RETURN AIR
OPENING
HORIZONTAL
SUPPLY AIR
OPENING
21-3/4
(552)
OPTIONAL OUTDOOR AIR HOOD
Required with Economizer or
Outdoor Air Damper
EVAPORATOR
COIL
FILTERS
58
(1473)
EVAPORATOR
COIL
CONTROL
BOX
FILTER
FILTER
50
(1270)
OUTDOOR
AIR
46-3/4
(1187)
OPTIONAL OUTDOOR
AIR HOOD
5-1/2
(140)
SIDE VIEW (Horizontal Openings)
58
(1473)
FILTERS
20
(508)
5
(127)
FLUE
OUTLET
SIDE VIEW
21-3/4
(552)
6-1/4
(159)
28
(711)
OUTDOOR
*OPTIONAL BAROMETRIC AIR
RELIEF DAMPERS
CONDENSATE
DRAIN
*OPTIONAL EXHAUST
HOOD
EXHAUST
AIR
OPTIONAL POWER
EXHAUST FANS
Down-flow Applications Only
OPTIONAL OUTDOOR
AIR DAMPERS
(Manual or Automatic)
3-1/4
(83)
OPTIONAL ECONOMIZER
DAMPERS
END VIEW
(Outdoor Air Dampers)
5
(127)
21-1/4
(540)
END VIEW
(Economizer/Barometric Relief / Power Exhaust)
*NOTE Installed in Return Air Duct for Horizontal Applications.
Page 1
TGA090, 102, 120, & 150 PARTS ARRANGEMENT
ECONOMIZER
(OPTIONAL)
FILTERS
(FOUR − 18 X 24 X 2")
EVAPORATOR
COIL
CONDENSER
FANS
BLOWER
MCC MAIN
CONTROL (A45)
CONDENSER
COIL
FILTER DRIERS
CONDENSER
ACCESS PANEL
CONDENSATE
DRAIN
GAS VALVE
COMBUSTION
AIR INDUCER
BURNERS
BLOWER
MOTOR
COMPRESSORS
TCA090, 102, 120, & 150 PARTS ARRANGEMENT
ECONOMIZER
(OPTIONAL)
FILTERS
(FOUR − 18 X 24 X 2")
EVAPORATOR
COIL
CONDENSER
FANS
BLOWER
MCC MAIN
CONTROL (A45)
FILTER DRIERS
CONDENSATE
DRAIN
ELECTRIC HEAT
(Optional)
COMPRESSORS
Page 2
BLOWER
MOTOR
CONDENSER
COIL
CAUTION
WARNING
Danger of sharp metallic edges. Can cause injury.
Take care when servicing unit to avoid accidental
contact with sharp edges.
Electric shock hazard and danger of
explosion. Can cause injury, death or
product or property damage. Turn off
gas and electrical power to unit before
performing any maintenance or
servicing operations on the unit. Follow
lighting instructions attached to unit
when putting unit back into operation
and after service or maintenance.
Shipping and Packing List
Package 1 of 1 contains:
1− Assembled unit
Check unit for shipping damage. Receiving party should
contact last carrier immediately if shipping damage is found.
General
These instructions are intended as a general guide
and do not supersede local codes in any way.
Authorities having jurisdiction should be consulted
before installation.
The TGA units are available in three heating inputs.
The TCA cooling packaged rooftop unit is the same
basic design as the TGA unit except for the heating
section. Optional electric heat is available for TCA
units. TGA and TCA units have identical refrigerant
circuits with respective 7−1/2, 8-1/2, 10, and 12−1/2 ton
cooling capacities.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFC’s and HCFC’s) as of July 1,
1992. Approved methods of recovery, recycling or
reclaiming must be followed. Fines and/or incarceration may be levied for non−compliance.
Use of this unit as a construction heater or air conditioner
is not recommended during any phase of construction.
Very low return air temperatures, harmful vapors and
operation of the unit with clogged or misplaced filters will
damage the unit.
If this unit has been used for heating or cooling of
buildings or structures under construction, the following
conditions must be met or the warranty will be void:
Availability of units and options varies by brand.
Requirements
The vent hood must be installed per these installation
instructions.
See figure 1 for unit clearances.
UNIT CLEARANCES
A room thermostat must control the unit. The use of
fixed jumpers that will provide continuous heating or
cooling is not allowed.
Outdoor
Air Hood C
A pre−filter must be installed at the entry to the return
air duct.
D
B
The return air duct must be provided and sealed to
the unit.
Return air temperature range between 55°F (13°C)
and 80°F (27°C) must be maintained.
A
Air filters must be replaced and pre−filters must be
removed upon construction completion.
FIGURE 1
1Unit
Clearance
A
in.(mm)
B
in.(mm)
C
in.(mm)
D
in.(mm)
Top
Clearance
Service
Clearance
60
(1524)
36
(914)
36
(914)
36
(914)
Unobstructed
Clearance to
Combustibles
36
(914)
1
(25)
1
(25)
1
(25)
Unobstructed
Minimum Operation Clearance
36
(914)
36
(914)
36
(914)
36
(914)
Unobstructed
The input rate and temperature rise must be set per
the unit rating plate.
The heat exchanger, components, duct system, air
filters and evaporator coil must be thoroughly
cleaned following final construction clean−up.
Note − Entire perimeter of unit base requires support when elevated above
mounting surface.
1 Service Clearance − Required for removal of serviceable parts.
Clearance to Combustibles − Required clearance to combustible material
(gas units).
Minimum Operation Clearance − Required clearance for proper unit operation.
Page 3
The unit operating conditions (including airflow,
cooling operation, ignition, input rate, temperature
rise and venting) must be verified according to these
installation instructions.
run−off water from higher ground can collect around
the unit.
Unit Support
In downflow discharge installations, install the unit on a
non−combustible surface only. Unit may be installed on
combustible surfaces when used in horizontal discharge
applications or in downflow discharge applications when
installed on an LARMF10/15 roof mounting frame.
4− Units require support along all four sides of unit base.
Supports must be constructed of steel or suitably
treated wood materials.
Duct Connection
NOTE − Securely fasten roof frame to roof per local codes.
A−Downflow Discharge Application
Roof Mounting with LARMF10/15
1− The LARMF roof mounting frame must be installed,
flashed and sealed in accordance with the
instructions provided with the frame.
All exterior ducts, joints and openings in roof or building
walls must be insulated and weather−proofed with
flashing and sealing compounds in accordance with
applicable codes. Any duct passing through an
unconditioned space must be insulated.
2− The LARMF roof mounting frame should be square
and level to 1/16" per linear foot (5mm per linear
meter) in any direction.
CAUTION
In downflow applications, do not drill or punch
holes in base of unit. Leaking in roof may occur if
unit base is punctured.
3− Duct must be attached to the roof mounting frame
and not to the unit; supply and return plenums must
be installed before setting the unit.
Installer’s Roof Mounting Frame
Many types of roof frames can be used to install the unit
depending upon different roof structures. Items to keep
in mind when using the building frame or supports are:
Rigging Unit For Lifting
Rig unit for lifting by attaching four cables to holes in unit
base rail. See figure 2.
1− The base is fully enclosed and insulated, so an
enclosed frame is not required.
2− The frames or supports must be constructed with
non−combustible materials and should be square and
level to 1/16" per linear foot (5mm per linear meter) in
any direction.
3− Frame or supports must be high enough to prevent
any form of moisture from entering unit.
Recommended minimum frame height is 14"
(356mm).
RIGGING
UNIT
TGA
TCA
*WEIGHT
LBS.
1615
1530
KG.
733
694
*Maximum weight with all available installed accessories.
LIFTING POINT SHOULD
BE DIRECTLY ABOVE
CENTER OF GRAVITY
4− Duct must be attached to the roof mounting frame
and not to the unit. Supply and return plenums must
be installed before setting the unit.
IMPORTANT − ALL
PANELS MUST BE IN
PLACE FOR RIGGING.
5− Units require support along all four sides of unit base.
Supports must be constructed of steel or suitably
treated wood materials.
NOTE−When installing a unit on a combustible surface for
downflow discharge applications, an LARMF10/15 roof
mounting frame is required.
B−Horizontal Discharge Applications
1− Units installed in horizontal airflow applications must
use a horizontal conversion kit.
2− Specified installation clearances must be maintained
when installing units. Refer to figure 1.
3− Top of support slab should be approximately 4"
(102mm) above the finished grade and located so no
Page 4
CAUTION − Do not
walk on unit.
FIGURE 2
1− Detach wooden base protection before rigging.
2− Connect rigging to the unit base using both holes in
each corner.
3− All panels must be in place for rigging.
4− Place field-provided H-style pick in place just above
top edge of unit. Frame must be of adequate
strength and length. (H−style pick prevents damage
to unit.)
Heating Start−Up section for tap location. Install a ground
joint union between the gas control manifold and the
main manual shut−off valve. See figure 4 for gas supply
piping entering outside the unit. Figure 5 shows
complete bottom gas entry piping.
Compounds used on threaded joints of gas piping shall be
resistant to the action of liquified petroleum gases.
OUTSIDE OF UNIT GAS PIPE CONNECTION
Condensate Drains
Remove cap and make drain connection to the 1" N.P.T.
drain coupling provided on unit. A trap must be installed
between drain connection and an open vent for proper
condensate removal. See figure 3. It is sometimes
acceptable to drain condensate onto the roof or grade;
however, a tee should be fitted to the trap to direct
condensate downward. The condensate line must be
vented. Check local codes concerning condensate disposal.
Refer to pages 1 and 2 for condensate drain location.
CONDENSATE DRAIN CONNECTION
TO GAS
VALVE
GROUND
JOINT UNION
TO GAS
SUPPLY
CAULK AROUND CONDENSATE COUPLING
DRIP LEG
NOTE − Allow clearance to
open doors when installing
condensate piping.
Minimum Pitch
1" (25 mm) per
10’ (3 m) of line
UNIT
GAS PIPING
SUPPORT
MANUAL MAIN
SHUT−OFF VALVE
(REFER TO
LOCAL CODES)
OPEN VENT
ÁÁ
ÁÁ
ÁÁ
ÁÁ
FIGURE 4
MOUNTING
FRAME
BOTTOM ENTRY GAS PIPING COMPLETED
GROUND
JOINT UNION
FIGURE 3
Connect Gas Piping (Gas Units)
Before connecting field−provided piping, check with gas
company or authorities having jurisdiction for local code
requirements. When installing gas supply piping, length
of run from gas meter must be considered in determining
pipe size for 0.5" w.c. (.12kPa) maximum pressure drop.
Do not use supply pipe smaller than unit gas connection.
For natural gas units, operating pressure at the unit gas
connection must be a minimum of 4.7" w.c. (1.19kPa)
and a maximum of 10.5" (2.60kPa) w.c. For LP/propane
gas units, operating pressure at the unit gas connection
must be a minimum of 11" w.c. (2.74kPa) and a maximum
of 13.5" w.c. (3.36kPa).
When making piping connections a drip leg should be
installed on vertical pipe runs to serve as a trap for
sediment or condensate. A 1/8" N.P.T. plugged tap is
located on gas valve for test gauge connection. Refer to
Page 5
CLOSE NIPPLE
TO GAS
VALVE
10" NIPPLE
12" NIPPLE
TO GAS
SUPPLY
4" NIPPLE
CLOSE
NIPPLE
MANUAL MAIN
SHUT−OFF VALVE
DRIP LEG
Grommets for both gas pipe openings are field provided.
FIGURE 5
Pressure Test Gas Piping (Gas Units)
High Altitude Derate
When pressure testing gas lines, the gas valve must
be disconnected and isolated. Gas valves can be
damaged if subjected to more than 0.5 psig (3.48kPa).
See figure 6.
Units may be installed at altitudes up to 2000 feet (610 m)
above sea level without any modification. At altitudes
above 2000 feet (610 m), units must be derated to match
the gas manifold pressures shown in table 1.
NOTE−Codes may require that manual main shut−off
valve and union (furnished by installer) be installed in
gas line external to unit. Union must be of the ground
joint type.
NOTE - This is the only permissible derate for these units.
TABLE 1
(m)*
Altitude − ft. (m)
After all connections have been made, check all piping
connections for gas leaks. Also check existing unit gas
connections up to the gas valve; loosening may occur
during installation. Use a leak detection solution or other
preferred means. Do not use matches candles or other
sources of ignition to check for gas leaks.
CAUTION
Some soaps used for leak detection are corrosive
to certain metals. Carefully rinse piping thoroughly
after leak test has been completed. Do not use
matches, candles, flame or othe sources of ignition
to check for gas leaks.
Natural
LP (Propane)
2001 − 3000 ( 610 − 915)
3.6 (0.90)
10.2 (2.54)
3001 − 4000 ( 915 − 1220)
3.5 (0.87)
9.9 (2.46)
4001 − 5000 (1220 − 1525)
3.4 (0.85)
9.6 (2.39)
5001 − 6000 (1525 − 1830)
3.3 (0.82)
9.4 (2.34)
6001 − 7000 (1830 − 2135)
3.2 (0.80)
9.1 (2.26)
7001 − 8000 (2135 − 2440)
3.1 (0.77)
8.8 (2.19)
*Contact Technical Support for altitudes higher than 8000 ft. (2400m).
Electrical Connections
POWER SUPPLY
Do not apply power or close disconnect switch until
installation is complete. Refer to start−up directions.
Refer closely to unit wiring diagram.
WARNING
Danger of explosion. Can cause injury
or product or property damage. Do not
use matches, candles, flame or other
sources of ignition to check for leaks.
NOTE−In case emergency shut down is required, turn off
the main manual shut−off valve and disconnect main
power to unit. These devices should be properly labeled
by the installer.
PRESSURE TEST GAS LINE
Gas Manifold Pressure
in. w.g. (kPa)
Refer to unit nameplate for minimum circuit ampacity
and maximum fuse size.
1− 230/460/575 volt units are factory wired. For 208V
supply, disconnect the orange wire (230V) at all
control power transformer(s). Reconnect the red
wire (208V). Tape the exposed end of the 230V
orange wire.
2− Route power through the bottom power entry area
and connect to L1, L2, and L3 on the top of K2 in
control area. Route power to TB2 on units
equipped with electric heat. Secure power wiring
with factory−installed wire ties provided in control
box. See unit wiring diagram.
CONTROL WIRING
MANUAL MAIN
A−Thermostat Location
SHUT−OFF VALVE
Room thermostat mounts vertically on a standard 2" X 4"
handy box or on any non−conductive flat surface.
Locate thermostat approximately 5 feet (1524mm)
above the floor in an area with good air circulation at
average temperature. Avoid locating the room
thermostat where it might be affected by:
GAS VALVE
−drafts or dead spots behind doors and in corners
CAP
−hot or cold air from ducts
−radiant heat from sun or appliances
FIGURE 6
−concealed pipes and chimneys
Page 6
B−Control Wiring
Unit Power−Up
1− Route thermostat cable or wires from subbase to
control box (refer to unit dimensions to locate bottom
and side power entry).
IMPORTANT − Unless field thermostat wires are rated
for maximum unit voltage, they must be routed away
from line voltage wiring. Use wire ties located to the left of
the MCC board (A45) to secure thermostat cable.
Use18 AWG wire for all applications using remotely
installed
electro−mechanical
and
electronic
thermostats.
2− Install thermostat assembly in accordance with
instructions provided with thermostat.
3− Connect thermostat wiring to TB1 terminal on MCC
(A45) control board as shown in figure 7 for
electro−mechanical and electronic thermostats. If
using other temperature control devices or energy
management systems see instructions and wiring
diagram provided by manufacturer.
IMPORTANT−Terminal connections at the wall plate or
subbase must be made securely. Loose control wire
connections may allow unit to operate but not with proper
response to room demand.
24 VOLT FIELD WIRING WITH ELECTRONIC AND
ELECTRO−MECHANICAL THERMOSTATS
A2 THERMOSTAT
A−General
1− Make sure that unit is installed in accordance with the
installation instructions and applicable codes.
2− Inspect all electrical wiring, both field- and
factory-installed, for loose connections. Tighten as
required.
3− Check to ensure that refrigerant lines do not rub
against the cabinet or against other refrigerant lines.
4− Check voltage at K2 contactor. Voltage must be
within range listed on nameplate. If not, consult
power company and have voltage condition
corrected before starting unit.
5− Make sure filters are in place before start-up.
B−MCC (A45) Control Board
1− Make sure there is no heating, cooling, or blower
demand from thermostat. Apply power to unit.
2− Locate green heartbeat LED on MCC board. See
figure 8. LED should flash slowly to indicate normal
operation. Refer to table 2 if the heartbeat LED is not
flashing normally.
A45 MCC
CONTROL
MCC CONTROL BOARD (A45)
TB1
UNIT TYPE
DIP SWITCH
TB1
(THERMOSTAT
CONNECTIONS)
GREEN
HEARTBEAT
LED
PUSHBUTTON
A45
KA
NOT ALL TERMINALS
ARE FOUND ON ALL
THERMOSTATS
Note − On electro−mechanical thermostats set anticipator at 0.1 amps.
Jumper terminals A1 and
A2 when thermostat has
no night setback terminals.
KB
P113
FIGURE 8
FIGURE 7
Page 7
KC
KD
P118
TABLE 2
MCC HEARTBEAT LED STATUS
LED
Status
Indicates
Blower Operation and Adjustments
IMPORTANT
Action
Off
No power to
board.
Check field wiring. If problem
persists refer to service manual.
On
Processor error.
Press MCC pushbutton and
hold for three seconds to reset processor.*
Three phase scroll compressors must be phased
sequentially for correct compressor and blower
rotation. Follow COOLING START−UP" section of
installation instructions to ensure proper compressor and blower operation.
A−Blower Operation
Flashing
Normal.
Slowly
None.
Flashing Invalid unit DIP
Rapidly switch selected.
Make sure switches are set
correctly. Refer to figure 9.
Simultaneous
Flashing
heat and cool
Rapidly
demands.
Check thermostat and wiring.
Initiate blower demand at thermostat according to
instructions provided with thermostat. Unit will cycle on
thermostat demand. The following steps apply to
applications using a typical electro−mechanical
thermostat.
*Press pushbutton and immediately release to override
the 4−minute compressor minimum run time.
UNIT TYPE DIP SWITCH (FACTORY−SET)
1− Blower operation is manually set at the thermostat
subbase fan switch. With fan switch in ON position,
blowers will operate continuously.
2− With fan switch in AUTO position, the blowers will
cycle with demand. Blowers and entire unit will be off
when system switch is in OFF position.
B−Blower Access
TGA UNITS
OFF/ON
The blower assembly is secured to a sliding base which
allows the entire assembly to be pulled out of the unit. See
figure 10.
1− Remove the clamp which secures the blower wiring
to the blower motor base.
TCA UNITS
OFF/OFF
2− Remove and retain screws on either side of sliding
base. Pull base toward outside of unit.
3− Slide base back into original position when finished
servicing. Replace the clamp and blower wiring in the
previous location on the blower motor base.
THA UNITS
ON/OFF
4− Replace retained screws on either side of the sliding
base.
C−Determining Unit CFM
UNUSED
SETTING
ON/ON
(HEARTBEAT LED
WILL FLASH
RAPIDLY IN ERROR)
FIGURE 9
1− The following measurements must be made with a
dry indoor coil. Run blower without a cooling demand.
Measure the indoor blower shaft RPM. Air filters must
be in place when measurements are taken.
2− With all access panels in place, measure static
pressure external to unit (from supply to return).
3− Referring to table 4, use static pressure and RPM
readings to determine unit CFM. Use table 5 when
installing units with any of the optional accessories
listed.
Page 8
BLOWER ASSEMBLY
TO INCREASE BELT TENSION
1−Loosen four bolts securing motor base to mounting
frame.
MOTOR BASE
ADJUSTMENT SCREWS
− 2 EACH SIDE
2−Turn adjusting bolt to the right, or clockwise, to
move the motor outward and tighten the belt.
ALIGN TOP EDGES
PARALLEL BEFORE
TIGHTENING MOTOR
IN PLACE
3−Tighten two bolts on motor pulley side.
IMPORTANT − Align top edges of blower motor base
and mounting frame base parallel before tightening
two bolts on the other side of base. Motor shaft and
blower shaft must be parallel.
BLOWER MOTOR
MOUNTING FRAME
BLOWER
MOTOR BASE
4−Tighten two bolts on other side of base.
TO INCREASE CFM
LOOSEN ALLEN SCREW &
TURN PULLEY CLOCKWISE
BELT TENSION
ADJUSTING BOLT − TURN
CLOCKWISE TO TIGHTEN BELT
TO DECREASE CFM
TURN PULLEY
COUNTERCLOCKWISE
SIDE VIEW
MOTOR
ALLEN
SCREW
PULLEY
REMOVE TWO SCREWS FROM
BOTH SIDES BEFORE SLIDING
BLOWER ASSEMBLY OUT OF UNIT
FIGURE 10
4− The blower RPM can be adjusted at the motor pulley.
Loosen Allen screw and turn adjustable pulley
clockwise to increase CFM. Turn counterclockwise to
decrease CFM. See figure 10. Do not exceed
minimum and maximum number of pulley turns as
shown in table 3.
TABLE 3
MINIMUM AND MAXIMUM PULLEY ADJUSTMENT
Belt
Minimum
Turns Open
Maximum
Turns Open
A Section
No minimum
5
B Section
1*
6
PULLEY ALIGNMENT
ALIGNED
MOTOR
PULLEY
BELT
BLOWER
PULLEY
NOT ALIGNED
FIGURE 11
*No minimum number of turns open when B belt is used on
pulleys 6" O.D. or larger.
1− Loosen four bolts securing motor base to mounting
frame. See figure 10.
D−Blower Belt Adjustment
Maximum life and wear can be obtained from belts only
if proper pulley alignment and belt tension are
maintained. Tension new belts after a 24−48 hour
period of operation. This will allow belt to stretch and
seat grooves. Make sure blower and motor pulley are
aligned as shown in figure 11.
2− To increase belt tension −
Turn adjusting bolt to the right, or clockwise, to move
the motor outward and tighten the belt. This
increases the distance between the blower motor and
the blower housing.
Page 9
To loosen belt tension −
Turn the adjusting bolt to the left, or counterclockwise
to loosen belt tension.
3− Tighten two bolts on motor pulley side.
IMPORTANT − Align top edges of blower motor base and
mounting frame base parallel before tightening two bolts
on the other side of base. Motor shaft and blower shaft
must be parallel.
3− Measure belt deflection force. For a used belt, the
deflection force should be 5 lbs. (35kPa). A new belt
deflection force should be 7 lbs. (48kPa).
4− Tighten two bolts on other side of base.
A force below these values indicates an
undertensioned belt. A force above these values
indicates an overtensioned belt.
MEASURE BELT TENSION
E−Check Belt Tension
Overtensioning belts shortens belt and bearing life.
Check belt tension as follows:
1− Measure span length X. See figure 12.
2− Apply perpendicular force to center of span (X) with
enough pressure to deflect belt 1/64" for every inch
of span length or 1.5mm per 100mm of span length.
Example: Deflection distance of a 40" span would be
40/64" or 5/8".
Example: Deflection distance of a 400mm span
would be 6mm.
Page 10
FORCE
DEFLECTION 1/64" PER INCH OF SPAN
OR 1.5mm PER 100mm OF SPAN
FIGURE 12
TABLE 4
090, 102, 120, 150 BASE UNIT BLOWER PERFORMANCE
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL & AIR FILTERS IN PLACE.
FOR ALL UNITS ADD:
1 − Wet indoor coil air resistance of selected unit.
2 − Any factory installed options air resistance (heat section, economizer, etc.).
3 − Any field installed accessories air resistance (duct resistance, diffuser, etc.).
Then determine from blower table blower motor output and drive required.
See table 5 for wet coil and option/accessory air resistance data.
MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT
TCA090, 102 requires 3000 cfm (1415 M/s) minimum air with electric heat.
TCA120 & TCA150 models require 4000 cfm (1890 L/s) minimum air with electric heat.
BOLD ITALIC INDICATES FIELD FURNISHED DRIVE
Total Static Pressure − in. w.g. (Pa)
Air
Ai
Volume
cfm
(L/s)
.20 (50)
.40 (100)
.60 (150)
.80 (200) 1.00 (250) 1.20 (300) 1.40 (350) 1.60 (400) 1.80 (450) 2.00 (495) 2.20 (545) 2.40 (595) 2.60 (645)
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
2250
(1060)
455 0.30 555 0.45 640 0.60 720 0.80 790 1.00 855 1.20 915 1.40 975 1.60 1030 1.85 1080 2.05 1130 2.30 1175 2.55 1220 2.80
(0.22)
(0.34)
(0.45)
(0.60)
(0.75)
(0.90)
(1.04)
(1.19)
(1.38)
(1.53)
(1.72)
(1.90)
(2.09)
2500
(1180)
475 0.40 575 0.55 660 0.70 735 0.90 805 1.10 870 1.30 930 1.55 985 1.75 1040 2.00 1090 2.25 1140 2.50 1185 2.75 1230 3.00
(0.30)
(0.41)
(0.52)
(0.67)
(0.82)
(0.97)
(1.16)
(1.31)
(1.49)
(1.68)
(1.87)
(2.05)
(2.24)
2750
(1300)
495 0.45 595 0.65 675 0.85 750 1.05 820 1.25 885 1.45 940 1.70 995 1.90 1050 2.20 1100 2.45 1145 2.65 1195 2.95 1240 3.25
(0.34)
(0.48)
(0.63)
(0.78)
(0.93)
(1.08)
(1.27)
(1.42)
(1.64)
(1.83)
(1.98)
(2.20)
(2.42)
3000
(1415)
525 0.55 615 0.75 695 0.95 770 1.20 835 1.40 895 1.60 955 1.85 1010 2.10 1060 2.35 1110 2.65 1160 2.90 1205 3.20 1250 3.45
(0.41)
(0.56)
(0.71)
(0.90)
(1.04)
(1.19)
(1.38)
(1.57)
(1.75)
(1.98)
(2.16)
(2.39)
(2.57)
3250
(1535)
550 0.65 640 0.90 715 1.10 790 1.35 855 1.60 915 1.80 970 2.05 1025 2.35 1075 2.60 1125 2.85 1170 3.15 1215 3.40 1260 3.70
(0.48)
(0.67)
(0.82)
(1.01)
(1.19)
(1.34)
(1.53)
(1.75)
(1.94)
(2.13)
(2.35)
(2.54)
(2.76)
3500
(1650)
580 0.80 665 1.05 740 1.25 810 1.50 870 1.75 930 2.00 985 2.25 1040 2.55 1090 2.85 1135 3.10 1185 3.40 1230 3.70 1270 4.00
(0.60)
(0.78)
(0.93)
(1.12)
(1.31)
(1.49)
(1.68)
(1.90)
(2.13)
(2.31)
(2.54)
(2.76)
(2.98)
3750
(1770)
605 0.95 690 1.20 760 1.45 830 1.70 890 1.95 950 2.25 1005 2.50 1055 2.80 1105 3.10 1150 3.35 1195 3.65 1240 3.95 1285 4.30
(0.71)
(0.90)
(1.08)
(1.27)
(1.45)
(1.68)
(1.87)
(2.09)
(2.31)
(2.50)
(2.72)
(2.95)
(3.21)
4000
(1890)
635 1.10 715 1.40 785 1.65 850 1.90 910 2.20 965 2.45 1020 2.75 1070 3.05 1120 3.35 1165 3.65 1210 3.95 1255 4.30 1295 4.60
(0.82)
(1.04)
(1.23)
(1.42)
(1.64)
(1.83)
(2.05)
(2.28)
(2.50)
(2.72)
(2.95)
(3.21)
(3.43)
4250
(2005)
665 1.30 740 1.60 810 1.85 870 2.15 930 2.45 985 2.75 1040 3.05 1090 3.35 1135 3.65 1185 4.00 1225 4.30 1270 4.65 1310 4.95
(0.97)
(1.19)
(1.38)
(1.60)
(1.83)
(2.05)
(2.28)
(2.50)
(2.72)
(2.98)
(3.21)
(3.47)
(3.69)
4500
(2125)
695 1.50 770 1.80 835 2.10 895 2.40 955 2.70 1005 3.00 1060 3.35 1105 3.65 1155 4.00 1200 4.30 1245 4.65 1285 5.00 1325 5.30
(1.12)
(1.34)
(1.57)
(1.79)
(2.01)
(2.24)
(2.50)
(2.72)
(2.98)
(3.21)
(3.47)
(3.73)
(3.95)
4750
(2240)
725 1.75 795 2.05 860 2.40 920 2.70 975 3.00 1030 3.35 1080 3.65 1125 3.95 1175 4.35 1215 4.65 1260 5.00 1300 5.35 1340 5.70
(1.31)
(1.53)
(1.79)
(2.01)
(2.24)
(2.50)
(2.72)
(2.95)
(3.25)
(3.47)
(3.73)
(3.99)
(4.25)
5000
(2360)
760 2.05 825 2.35 885 2.65 945 3.00 1000 3.35 1050 3.65 1100 4.00 1145 4.35 1190 4.70 1235 5.05 1280 5.45
(1.53)
(1.75)
(1.98)
(2.24)
(2.50)
(2.72)
(2.98)
(3.25)
(3.51)
(3.77)
(4.07)
−−−−
−−−−
5250
(2475)
790 2.30 855 2.65 910 2.95 970 3.35 1020 3.65 1070 4.00 1120 4.35 1165 4.70 1210 5.10 1255 5.45
(1.72)
(1.98)
(2.20)
(2.50)
(2.72)
(2.98)
(3.25)
(3.51)
(3.80)
(4.07)
−−−−
−−−−
−−−−
5500
(2595)
820 2.60 880 2.95 940 3.30 995 3.70 1045 4.05 1095 4.40 1145 4.80 1190 5.15 1230 5.50
(1.94)
(2.20)
(2.46)
(2.76)
(3.02)
(3.28)
(3.58)
(3.84)
(4.10)
−−−−
−−−−
−−−−
−−−−
5750
(2715)
850 2.95 910 3.30 965 3.70 1020 4.05 1070 4.45 1120 4.80 1165 5.20 1210 5.60
(2.20)
(2.46)
(2.76)
(3.02)
(3.32)
(3.58)
(3.88)
(4.18)
−−−−
−−−−
−−−−
−−−−
−−−−
6000
(2830)
885 3.35 940 3.70 995 4.10 1045 4.45 1095 4.85 1145 5.25 1190 5.65
(2.50)
(2.76)
(3.06)
(3.32)
(3.62)
(3.92)
(4.21)
−−−−
−−−−
−−−−
−−−−
−−−−
Page 11
−−−−
F−Field−Furnished Blower Drives
determine the drive number and table 7 to determine the
For field−furnished blower drives, use tables 4 and 5 to
manufacturer’s model number.
determine BHP and RPM required. Reference table 6 to
TABLE 5
OPTIONAL ACCESSORY AIR RESISTANCE
Wet Indoor
Coil
Air Volume
Gas Heat Exchanger
(TGA Models)
Electric Heat
(TCA
Models)
Economizer
cfm
L/s
090H,
102S, 102H,
120S
120H
150S
2250
2500
1060
1180
.06 (15)
.08 (20)
.10 (25)
.12 (30)
.05 (12)
.05 (12)
.07 (17)
.09 (22)
.09 (22)
.11 (27)
.01 (2)
.01 (2)
.035 (9)
.04 (10)
2750
1300
.09 (22)
.14 (35)
.06 (15)
.10 (25)
.13 (32)
.01 (2)
.045 (11)
3000
1415
.10 (25)
.16 (40)
.07 (17)
.12 (30)
.16 (40)
.02 (5)
.05 (12)
3250
1535
.11 (27)
.19 (47)
.08 (20)
.15 (37)
.19 (47)
.02 (5)
.06 (15)
3500
1650
.13 (32)
.21 (52)
.09 (22)
.17 (42)
.22 (55)
.03 (7)
.07 (17)
3750
1770
.14 (35)
.23 (57)
.10 (25)
.20 (50)
.26 (65)
.03 (7)
.075 (19)
4000
1890
.16 (40)
.26 (65)
.11 (27)
.22 (55)
.30 (75)
.04 (10)
.08 (20)
4250
2005
.17 (42)
.28 (70)
.12 (30)
.25 (63)
.34 (85)
.04 (10)
.09 (22)
4500
2125
.18 (45)
.31 (77)
.13 (32)
.28 (70)
.38 (94)
.05 (12)
.10 (25)
4750
2240
.20 (50)
.33 (82)
.14 (35)
.31 (77)
.42 (104)
.05 (12)
.11 (27)
5000
2360
.22 (55)
.36 (90)
.16 (40)
.35 (87)
.47 (117)
.06 (15)
.12 (30)
5250
2475
.24 (60)
.39 (97)
.18 (45)
.38 (94)
.52 (129)
.06 (15)
.13 (32)
5500
2595
.26 (65)
.42 (104)
.20 (50)
.42 (104)
.57 (142)
.07 (17)
.14 (35)
5750
2715
.28 (70)
.45 (112)
.22 (55)
.46 (115)
.62 (154)
.07 (17)
.15 (37)
6000
2830
.30 (75)
.68 (169)
.24 (60)
.50 (124)
.68 (169)
.08 (20)
.16 (40)
Std. Heat
130,000
Med Heat
180,000
High Heat
240,000
TABLE 6
DRIVE KIT SPECIFICATIONS
Motor
Drive1
hp
kW
2
3
Std.
Drive 2
RPM Range
Drive 4
Drive 3
Drive 5
Drive 6
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
1.5
680−925
562−764
−−−
−−−
850−1120
739−925
−−−
−−−
−−−
917−1152
−−−
−−−
2.2
680−925
−−−
−−−
850−1120
−−−
−−−
750−938
1110−1395
−−−
−−−
930−1169
3 Hi
Eff
2.2
−−−
−−−
680−925
−−−
−−−
−−−
895−1120
−−−
−−−
−−−
1110-1395
−−−
5
3.7
−−−
−−−
−−−
561−776
−−−
−−−
895−1120
739−924
−−−
−−−
1110-1395
916−1151
In Canada, nominal motor output is also maximum usable motor output. If motors of comparable output are used, be sure to keep within
the service factor limitations outlined on the motor nameplate.
TABLE 7
MANUFACTURER’S NUMBERS
DRIVE
NO.
NO
ADJUSTABLE SHEAVE
BROWNING NO.
DRIVE COMPONENTS
FIXED SHEAVE
BELT
OEM PART NO.
BROWNING NO.
OEM PART NO.
BROWNING NO.
OEM PART NO.
1
1VP40x7/8
79J0301
AK69x1
36K4701
AX46
31K7101
2
1VP44x1−1/8
36C0701
BK85x1
49K4101
BX52
P−8−8094
3
1VP44x7/8
53J9601
AK64x1
12L2501
AX46
31K7101
4
1VP60x1−1/8
41C1301
BK95x1
79J2701
BX56
P−8−10082
5
1VP50x7/8
P−8−2187
AK59x1
31K6801
AX46
31K7101
6
1VP60x1−1/8
41C1301
BK77x1
49K4001
BX53
49K3801
Page 12
1− Observe suction and discharge pressures and
blower rotation on unit start−up.
Cooling Start−Up
A−Operation
1− Initiate first and second stage cooling demands
according to instructions provided with thermostat.
2− No Economizer Installed in Unit −
A first−stage cooling demand (Y1) will energize
compressor 1 and both condenser fans. An
increased cooling demand (Y2) will energize
compressor 2.
Units Equipped With Economizer −
When outdoor air is acceptable, a first−stage
cooling demand (Y1) will energize the economizer.
An increased cooling demand (Y2) will energize
compressor 1 and both condenser fans. When
outdoor air is not acceptable unit will operate as
though no economizer is installed.
3− Units contain two refrigerant circuits or stages. See
figure 13.
REFRIGERANT STAGES
(BOTH FANS ARE ENERGIZED
WITH A Y1 DEMAND)
2− Suction pressure must drop, discharge pressure
must rise, and blower rotation must match rotation
marking.
If pressure differential is not observed or blower rotation is
not correct:
3− Disconnect all remote electrical power supplies.
4− Reverse any two field−installed wires connected to
the line side of K2 contactor. Do not reverse wires at
blower contactor.
5− Make sure the connections are tight.
Discharge and suction pressures should operate at
their normal start-up ranges.
C−Refrigerant Charge and Check
WARNING−Do not exceed nameplate charge under
any condition.
This unit is factory charged and should require no further
adjustment. If the system requires charge, reclaim the
charge, evacuate the system, and add required
nameplate charge.
NOTE − System charging is not recommended below
60°F (15°C). In temperatures below 60°F (15°C) , the
charge must be weighed into the system.
If weighing facilities are not available, or to check the
charge, use the following procedure:
1− Attach gauge manifolds and operate unit in cooling
mode until system stabilizes (approximately five
minutes). Make sure outdoor air dampers are closed.
2− Check each system separately with all stages
operating.
3− Use a thermometer to accurately measure the
outdoor ambient temperature.
2
1
FIGURE 13
4− Each refrigerant circuit is separately charged with
HCFC−22 refrigerant. See unit rating plate for correct
amount of charge.
5− Refer to Cooling Operation and Adjustment section for
proper method to check refrigerant charge.
B−Three Phase Scroll Compressor Voltage Phasing
4− Apply the outdoor temperature to tables 8 through 14
to determine normal operating pressures.
5− Compare the normal operating pressures to the
pressures obtained from the gauges. Minor
variations in these pressures may be expected due
to differences in installations. Significant differences
could mean that the system is not properly charged
or that a problem exists with some component in the
system. Correct any system problems before
proceeding.
6− If discharge pressure is high, remove refrigerant from
the system. If discharge pressure is low, add
refrigerant to the system.
Three phase scroll compressors must be phased
Add or remove charge in increments.
sequentially to ensure correct compressor and blower
rotation and operation. Compressor and blower are
Allow the system to stabilize each time
refrigerant is added or removed.
wired in phase at the factory. Power wires are
color−coded as follows: line 1−red, line 2−yellow, line
7− Use the following approach method along with the
3−blue.
normal operating pressures to confirm readings.
Page 13
TABLE 8
TGA/TCA090S NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
65F
75F
85F
95F
105F
115F
CIRCUIT 1
DIs. +10
psig
175
200
228
260
292
329
Suct. +5
psig
74
76
77
79
80
82
Outdoor
Coil
Entering
Air Temp
65F
75F
85F
95F
105F
115F
CIRCUIT 2
Dis. +10
psig
180
206
236
269
303
343
Suc. +5
psig
73
73
74
75
77
80
TABLE 9
TGA/TCA090H NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
65F
75F
85F
95F
105F
115F
CIRCUIT 1
DIs. +10
psig
152
175
202
231
262
295
Suct. +5
psig
74
77
79
81
81
82
CIRCUIT 2
Dis. +10
psig
156
181
209
239
274
310
Suc. +5
psig
76
78
80
81
83
85
CIRCUIT 1
DIs. +10
psig
170
196
227
260
298
341
Suct. +5
psig
74
75
77
79
81
83
CIRCUIT 1
DIs. +10
psig
156
181
207
234
266
300
Suct. +5
psig
72
75
76
77
78
80
Dis. +10
psig
178
204
237
272
313
360
CIRCUIT 1
DIs. +10
psig
169
195
222
252
283
319
Suct. +5
psig
74
77
79
81
82
84
Suct. +5
psig
72
76
78
80
81
83
Dis. +10
psig
176
201
229
260
294
330
Suct. +5
psig
76
78
80
81
83
84
CIRCUIT 1
DIs. +10
psig
179
205
231
260
293
324
Suct. +5
psig
67
70
72
74
75
77
CIRCUIT 2
Dis. +10
psig
176
200
227
257
291
325
Suc. +5
psig
70
72
73
74
76
77
D−Charge Verification − Approach Method
1− Using the same thermometer, compare liquid
temperature to outdoor ambient temperature.
Suc. +5
psig
73
73
74
76
77
79
CIRCUIT 2
Dis. +10
psig
160
186
213
243
277
313
Suc. +5
psig
75
77
79
81
82
84
TABLE 12
TCA/TGA120S NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
65F
75F
85F
95F
105F
115F
Dis. +10
psig
171
196
222
252
283
318
CIRCUIT 2
CIRCUIT 2
Approach Temperature = Liquid temperature minus
ambient temperature.
TABLE 11
TCA/TGA102H NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
65F
75F
85F
95F
105F
115F
CIRCUIT 1
TABLE 14
TCA/TGA150S NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
65F
75F
85F
95F
105F
115F
TABLE 10
TCA/TGA102S NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
65F
75F
85F
95F
105F
115F
TABLE 13
TCA/TGA120H NORMAL OPERATING PRESSURES
CIRCUIT 2
Dis. +10
psig
176
203
233
264
300
340
Suc. +5
psig
77
79
81
82
83
84
2− Approach temperature should be 7°F + 1 (3.8°C + 0.5).
An approach temperature greater than this value
indicates an undercharge. An approach temperature
less than this value indicates an overcharge.
3− Do not use the approach method if system pressures
do not match pressures in tables 8 through 14. The
approach method is not valid for grossly over or
undercharged systems.
E−Compressor Controls
Most compressor controls are integrated in the A45 MCC
control or are field−installed options. See unit wiring
diagram to determine which controls are used on each
unit. Optional controls are identified on wiring diagrams
by arrows at junction points.
1− Freezestats (S49, S50)
Switches de−energize compressors when evaporator
coil temperature falls below 29°F (−2°C) to prevent
evaporator freeze−up. Switches reset when
evaporator coil temperature reaches 58°F (15°C).
Page 14
This unit is equipped with an automatic spark ignition
system. There is no pilot. In case of a safety shutdown,
move thermostat switch to OFF and return the thermostat
switch to HEAT to reset ignition control.
Gas Heat Start−Up (Gas Units)
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
A−Placing Unit In Operation
Electric shock hazard. Can cause injury
or death. Do not use this unit if any part
has been under water. Immediately call
a qualified service technician to inspect
the unit and to replace any part of the
control system and any gas control
which has been under water.
WARNING
Danger of explosion and fire. Can cause
injury or product or property damage.
You must follow these instructions
exactly.
Gas Valve Operation for White Rodgers 36C (figure 14)
and Honeywell VR8205Q/VR8305Q (figure 15)
WARNING
Danger of explosion. Can cause injury
or product or property damage. If overheating occurs or if gas supply fails to
shut off, shut off the manual gas valve
to the appliance before shutting off
electrical supply.
1− Set thermostat to lowest setting.
2− Turn off all electrical power to appliance.
WHITE RODGERS 36C76 GAS VALVE
INLET
PRESSURE
TAP (SIDE)
WARNING
STAGE 2 MANUAL MANIFOLD
PRESSURE ADJUSTMENT
SCREW UNDER CAP
Electric shock hazard. Can cause
injury or death. Before attempting to
perform any service or maintenance,
turn the electrical power to unit OFF at
disconnect switch(es). Unit may have
multiple power supplies.
MANIFOLD
PRESSURE
TAP (SIDE)
GAS VALVE SHOWN
IN OFF" POSITION
D−1
WARNING
SMOKE POTENTIAL
The heat exchanger in this unit could be a source of
smoke on initial firing. Take precautions with respect to building occupants and property. Vent initial supply air outside when possible.
C−1
C2
GV−1
GV−2
FIGURE 14
BEFORE LIGHTING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
HONEYWELL VR8205Q/VR8305Q SERIES GAS VALVE
Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by
hand, do not try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
WARNING
HIGH FIRE
ADJUSTMENT
LOW FIRE
ADJUSTMENT
MANIFOLD
PRESSURE
TAP
INLET
PRESSURE
TAP
Danger of explosion. Can cause injury or
death. Do not attempt to light manually.
Unit has a direct spark ignition system.
Page 15
Gas valve knob is shown in OFF position.
FIGURE 15
3− This appliance is equipped with an ignition device
which automatically lights the burner. Do not try to
light the burner by hand.
Heating Operation and Adjustments
(Gas Units)
A−Heating Sequence of Operation
4− Open or remove the heat section access panel.
1− On a heating demand the combustion air inducer
starts immediately.
to
5− Turn the knob on the gas valve clockwise
OFF". Depress 36C knob slightly. Do not force.
2− Combustion air pressure switch proves inducer
operation, then allows power to ignition control.
Switch is factory set and requires no adjustment.
7− Turn the knob on the gas valve counterclockwise
to ON". Do not force.
3− After a 30−second prepurge, spark ignitor energizes
and gas valve solenoid opens.
8− Close or replace the heat section access panel.
4− Spark ignites gas, ignition sensor proves the flame
and combustion continues.
9− Turn on all electrical power to appliance.
10− Set thermostat to desired setting.
11− The combustion air inducer will start. The burners will
light within 40 seconds.
12− If the appliance does not light the first time (gas line
not fully purged), it will attempt up to two more
ignitions before locking out.
13− If lockout occurs, repeat steps 1 through 10.
14− If the appliance will not operate, follow the
instructions Turning Off Gas to Appliance" and call
your service technician or gas supplier.
Turning Off Gas to Unit
1− If using an electromechanical thermostat, set to the
lowest setting.
2− Before performing any service, turn off all electrical
power to the appliance.
5− If flame is not detected after first ignition trial, ignition
control will repeat steps 3 and 4 two more times
before locking out the gas valve.
6− For troubleshooting purposes, an ignition attempt
after lock out may be re−established manually. Move
thermostat to OFF" and return thermostat switch to
HEAT" position.
B−Ignition Control Diagnostic LED’s
TABLE 15
IGNITION CONTROL HEARTBEAT LED STATUS
LED
Flashes
Indicates
Slow
Normal operation. No call for heat.
Fast
Normal operation. Call for heat.
Steady Off
Internal control fault OR no power to
control OR Gas Valve Relay Fault.
Steady On
Control internal failure.
2
Lockout. Failed to detect or sustain flame.
3
Prove switch open or closed or rollout
switch open.
4
Limit switch is open and/or limit has
opened three times.
5
Flame sensed but gas valve solenoid
not energized.
3− Open or remove the heat section access panel.
C−Limit Controls
4− Turn the knob on the gas valve clockwise
to
OFF". Depress 36C knob slightly. Do not force.
Limit controls are factory−set and are not adjustable. The
primary limit is located on the blower deck behind the
blower housing.
D−Heating Adjustment
5− Close or replace the heat section access panel.
Main burners are factory−set and do not require
adjustment.
The following manifold pressures are listed on the gas valve.
Natural Gas Units − Low Fire − 1.6" w.c. (not adjustable)
Natural Gas Units − High Fire − 3.7" w.c.
Danger of explosion. Can cause injury or
death. Do not attempt to light manually.
LP Gas Units − Low Fire − 5.5" w.c. (not adjustable)
Unit has a direct spark ignition system.
LP Gas Units − High Fire − 10.5" w.c.
Page 16
WARNING
Electric Heat Start−Up (TCA Units)
Optional electric heat will stage on and cycle with
thermostat demand. Number of stages of electric heat will
vary depending on electric heat assembly. See electric
heat wiring diagram on unit for sequence of operation.
Service
2− Remove burner compartment access panel.
3− Remove two screws securing burners to burner
support and lift the burners from the orifices. See
figure 17. Clean as necessary.
4− Locate the ignitor under the left burners. Check
ignitor spark gap with appropriately sized twist drills
or feeler gauges. See figure 18.
The unit should be inspected once a year by a qualified
service technician.
REMOVE FILTERS
CAUTION
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
cancer. (Fiberglass wool is known to the State of
California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown on unit nameplate or
contact your supervisor.
A−Filters
Units are equipped with four 18 X 24 X 2" filters. Filters
should be checked and replaced when necessary with
filters of like kind and size. Take note of air flow direction
marking on filter frame when reinstalling filters. See
figure 16.
PULL TO
REMOVE
FILTERS
FIGURE 16
BURNER BOX ASSEMBLY
GAS
VALVE
NOTE−Filters must be U.L.C. certified or equivalent for
use in Canada.
B−Lubrication
All motors are lubricated at the factory. No further
lubrication is required.
BURNERS
C−Burners (Gas Units)
Periodically examine burner flames for proper
appearance during the heating season. Before each
heating season examine the burners for any deposits or
blockage which may have occurred.
GAS MANIFOLD
FLAME
SENSOR
Clean burners as follows:
1− Turn off both electrical power and gas supply to unit.
Page 17
FIGURE 17
TABLE 16
IGNITOR
Length − in. (mm)
Dimension
Unit
Btuh Input
Ignitor
A
130K
7−3/4 (197)
11 (279)
B
180K
5 (127)
5−1/2 (140)
C
240K
2−1/4 (57)
2−3/4 (70)
SPARK GAP
SHOULD BE 1/8"
(3mm)
Sensor
7− Replace access panel.
8− Restore electrical power and gas supply. Follow
lighting instructions attached to unit and use
inspection port in access panel to check flame.
D−Combustion Air Inducer (Gas Units)
FIGURE 18
5− Check the alignment of the ignitor and the sensor as
shown in figure 19 and table 16.
6− Replace burners and screws securing burner.
WARNING
Danger of explosion. Can cause injury or
death. Do not overtighten main burner
mounting screws. Snug tighten only.
A combustion air proving switch checks combustion air
inducer operation before allowing power to the gas
controller. Gas controller will not operate if inducer is
obstructed.
Under normal operating conditions, the combustion air
inducer wheel should be checked and cleaned prior to the
heating season. However, it should be examined
periodically during the heating season to establish an
ideal cleaning schedule. With power supply
disconnected, the condition of the inducer wheel can be
determined by looking through the vent opening.
IGNITOR AND SENSOR POSITION
IGNITOR
SENSOR
A
A
B
B
TOP VIEW
C
C
SIDE VIEW IGNITOR
SIDE VIEW SENSOR
Gas Flow
Gas Flow
1−3/4"
(45mm)
1−3/8"
(35mm)
13/16"
(21mm)
3/8"
(10mm)
BURNER BOX
FIGURE 19
Page 18
Clean combustion air inducer as follows:
6− Clean combustion air inlet louvers on heat access
panel using a small brush.
1− Shut off power supply and gas to unit.
2− Disconnect pressure switch
combustion air inducer port.
air
tubing
from
3− Remove and retain screws securing combustion
air inducer to flue box. Remove and retain two
screws from bracket supporting vent connector.
See figure 20.
E−Flue Passageway and Flue Box (Gas Units)
1− Remove combustion air inducer assembly as
described in section D.
2− Remove flue box cover. Clean with a wire brush as
required.
3− Clean tubes with a wire brush.
HEAT EXCHANGER ASSEMBLY
4− Reassemble the unit. The flue box cover gasket and
combustion air inducer gasket should also be
replaced during reassembly.
HEAT
EXCHANGER
TUBE
F−Evaporator Coil
COMBUSTION
AIR INDUCER
Inspect and clean coil at beginning of each cooling season.
Clean using mild detergent or commercial coil cleaner.
Flush coil and condensate drain with water taking care not
to get insulation, filters and return air ducts wet.
G−Condenser Coil
Clean condenser coil annually with detergent or
commercial coil cleaner and inspect monthly during the
cooling season.
VENT
CONNECTOR
GAS VALVE
BURNER
FIGURE 20
4− Clean inducer wheel blades with a small brush and
wipe off any dust from housing. Clean accumulated
dust from front of flue box cover.
5− Return combustion air inducer motor and vent
connector to original location and secure with
retained screws. It is recommended that the
combustion air inducer gasket be replaced during
reassembly.
Condenser coils are made of single, two, and three
formed slabs. Dirt and debris may become trapped
between the slabs. To clean between slabs, carefully
separate coil slabs and wash them thoroughly. See figure
21. Flush coils with water following cleaning.
Note − Remove all screws and gaskets prior to cleaning
procedure and replace upon completion.
H−Supply Air Blower Wheel
Annually inspect supply air blower wheel for accumulated
dirt or dust. Turn off power before attempting to remove
access panel or to clean blower wheel.
CLEAN CONDENSER COIL
TOP VIEW
ENDPLATE IS SECURED
TO MULLION
1−
Remove unit top panel and condenser section access
panel.
2−
Remove screws securing coil end plate to mullion.
3−
Remove clips connecting coils slabs and separate
slabs 3−4" (76−102mm).
4−
Clean coils with detergent or commercial coil cleaner.
5−
Rinse thoroughly with water and reassemble.
EVAPORATOR COIL
BLOWER
CONDENSER
COILS
CONDENSER ACCESS PANEL
FIGURE 21
Page 19
Download PDF
Similar pages