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HEAT CONTROLLER INSTALLATION INSTRUCTIONS PACKAGE GAS ELECTRIC FEATURING EARTH-FRIENDLY R-410A REFRIGERANT TGC***A-13 SEER (3-5 TONS) SERIES efrigerant 92-21916-38-00 I.TABLE OF CONTENTS I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. 2 Table of Contents ..................................................................................................2 Introduction ............................................................................................................3 Checking Product Received ..................................................................................3 Specifications.........................................................................................................3 A. General .............................................................................................................3 B. Major Components............................................................................................3 C. R-410A Refrigerant ...........................................................................................3 1. Specifications of R-410A...............................................................................3 2. Quick Reference Guide for R-410A ..............................................................4 3. Evaporator Coil/TXV .....................................................................................4 4. Tools Required for Installing and Servicing R-410A Models.........................4 Safety Information..................................................................................................4 Unit Dimensions.....................................................................................................5 Installation..............................................................................................................7 A. General .............................................................................................................7 1. Pre-Installation Check ..................................................................................7 2. Location Considerations...............................................................................7 B. Outside Installation............................................................................................8 C. Attaching Exhaust and Combustion Air Inlet Hoods .........................................9 D. Cover Panel Installation/Conversion Procedure ...............................................9 E. Clearances ........................................................................................................9 F. Rooftop Installation .........................................................................................10 G. Ductwork .........................................................................................................10 H. Return Air ........................................................................................................11 Gas Supply, Condensate Drain and Piping .........................................................13 A. Gas Connection ..............................................................................................13 B. LP Conversion.................................................................................................14 C. NOx Models ....................................................................................................14 D. Adjusting or Checking Furnace Input ..............................................................15 E. Condensate Drain ...........................................................................................16 Wiring...................................................................................................................16 A. Power Supply ..................................................................................................16 B. Hook Up ..........................................................................................................18 C. Internal Wiring .................................................................................................18 D. Thermostat ......................................................................................................18 Furnace Section Controls and Ignition System....................................................19 Normal Furnace Operating Sequence.................................................................19 Operating Instructions .........................................................................................20 Burners ................................................................................................................21 Manual Reset Overtemperature Control..............................................................21 Pressure Switch...................................................................................................21 Limit Control ........................................................................................................21 System Operating Information .............................................................................21 Advise the Customer ...........................................................................................21 Furnace Section Maintenance.............................................................................22 Lubrication ...........................................................................................................23 Cooling Section Maintenance..............................................................................23 Replacement Parts ..............................................................................................24 Troubleshooting...................................................................................................24 Wiring Diagrams ..................................................................................................24 Charging ..............................................................................................................24 Blower Motor Speed Taps ...................................................................................24 General Data ..................................................................................................27-31 Miscellaneous ......................................................................................................32 Electrical and Physical Data ................................................................................32 Airflow Performance .......................................................................................33-39 Wiring Diagrams.............................................................................................40-46 Charge Charts ................................................................................................47-50 Troubleshooting..............................................................................................51-53 ! Recognize this symbol as an indication of Important Safety Information! ! WARNING THE MANUFACTURER’S WARRANTY DOES NOT COVER ANY DAMAGE OR DEFECT TO THE AIR CONDITIONER CAUSED BY THE ATTACHMENT OR USE OF ANY COMPONENTS, ACCESSORIES OR DEVICES (OTHER THAN THOSE AUTHORIZED BY THE MANUFACTURER) INTO, ONTO OR IN CONJUNCTION WITH THE AIR CONDITIONER. YOU SHOULD BE AWARE THAT THE USE OF UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES MAY ADVERSELY AFFECT THE OPERATION OF THE AIR CONDITIONER AND MAY ALSO ENDANGER LIFE AND PROPERTY. THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES. ! WARNING INSTALL THIS UNIT ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS. PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE UNIT SPACE AS SPECIFIED IN THE VENTING SECTION OF THESE INSTRUCTIONS. ! WARNING PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE UNIT SPACE AS SPECIFIED IN THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS. II. INTRODUCTION This booklet contains the installation and operating instructions for your combination gas heating/electric cooling unit. There are some precautions that should be taken to derive maximum satisfaction from it. Improper installation can result in unsatisfactory operation or dangerous conditions. Read this booklet and any instructions packaged with separate equipment required to make up the system prior to installation. Give this booklet to the owner and explain its provisions. The owner should retain this booklet for future reference. III. CHECKING PRODUCT RECEIVED Upon receiving the unit, inspect it for any damage from shipment. Claims for damage, either shipping or concealed, should be filed immediately with the shipping company. IMPORTANT: Check the unit model number, heating size, electrical characteristics, and accessories to determine if they are correct. IV. SPECIFICATIONS A. GENERAL The Combination Gas Heating/Electric Cooling Rooftop is available in 80,000, 100,000, 120,000 and 135,000 BTU/Hr. heating inputs and cooling capacities of 3, 31⁄2, 4, and 5 nominal tons of cooling. Units are convertible from bottom supply and return to side supply and return by relocation of supply and return air access panels. See cover installation detail. The units are weatherized for mounting outside of the building. ! WARNING UNITS ARE NOT DESIGN CERTIFIED TO BE INSTALLED INSIDE THE STRUCTURE. DOING SO CAN CAUSE INADEQUATE UNIT PERFORMANCE AS WELL AS PROPERTY DAMAGE AND CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH. The information on the rating plate is in compliance with the FTC and DOE rating for single phase units. The following information is for three phase units which are not covered under the DOE certification program. 1. The energy consumption of the ignition system used with this unit is 9 watts. 2. The efficiency rating of this unit is a product thermal efficiency rating determined under continuous operating conditions independent of any installed system. B. MAJOR COMPONENTS The unit includes a hermetically-sealed refrigerating system (consisting of a scroll compressor, condenser coil, evaporator coil with thermostatic expansion valve), a circulation air blower, a condenser fan, a heat exchanger assembly, gas burner and control assembly, combustion air motor and fan, and all necessary internal electrical wiring. The cooling system of these units is factory-evacuated, charged with R-410A refrigerant and performance tested. Refrigerant amount and type are indicated on rating plate. C. R410A REFRIGERANT All units are factory charged with R-410A refrigerant. 1. Specification of R-410A: Application: R-410A is not a drop-in replacement for R-22; equipment designs must accommodate its higher pressures. It cannot be retrofitted into R-22 units. Pressure: The pressure of R-410A is approximately 60% (1.6 times) greater than R22. Recovery and recycle equipment, pumps, hoses and the like need to have design pressure ratings appropriate for R-410A. Manifold sets need to range up to 800 psig high-side and 250 psig low-side with a 550 psig low-side retard. Hoses need to have a service pressure rating of 800 psig. Recovery cylinders need to have a 400 psig service pressure rating. DOT 4BA400 or DOT BW400. Combustibility: At pressures above 1 atmosphere, mixture of R-410A and air can become combustible. R-410A and air should never be mixed in tanks or supply 3 lines, or be allowed to accumulate in storage tanks. Leak checking should never be done with a mixture of R-410A and air. Leak checking can be performed safely with nitrogen or a mixture of R-410A and nitrogen. 2. Quick Reference Guide For R-410A • R-410A refrigerant operates at approximately 60% higher pressure (1.6 times) than R22. Ensure that servicing equipment is designed to operate with R-410A. • R-410A refrigerant cylinders are pink. • R-410A, as with other HFC’s is only compatible with POE oils. • Vacuum pumps will not remove moisture from POE oil. • R-410A systems are to be charged with liquid refrigerants. Prior to March 1999, R410A refrigerant cylinders had a dip tube. These cylinders should be kept upright for equipment charging. Post March 1999 cylinders do not have a dip tube and should be inverted to ensure liquid charging of the equipment. • Do not install a suction line filter drier in the liquid line. • A liquid line filter drier is standard on every unit. • Desiccant (drying agent) must be compatible for POE oils and R-410A 3. Evaporator Coil / TXV The thermostatic expansion valve is specifically designed to operate with R-410A. DO NOT use an R-22 TXV. The existing evaporator must be replaced with the factory specified TXV evaporator specifically designed for R-410A. 4. Tools Required For Installing & Servicing R-410A Models Manifold Sets: -Up to 800 PSIG High side -Up to 250 PSIG Low Side -550 PSIG Low Side Retard Manifold Hoses: -Service Pressure Rating of 800 PSIG Recovery Cylinders: -400 PSIG Pressure Rating -Dept. of Transportation 4BA400 or BW400 ! CAUTION R-410A systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment. V. SAFETY INFORMATION ! WARNING USE ONLY WITH TYPE OF GAS APPROVED FOR THIS UNIT. REFER TO THE UNIT RATING PLATE. 4 VI. UNIT DIMENSIONS FOR CLEARANCES SEE FIGURE 7. IMPORTANT: THIS UNIT MUST BE MOUNTED LEVEL IN BOTH DIRECTIONS TO ALLOW WATER TO DRAIN FROM THE CONDENSER SECTION AND CONDENSATE PAN. FIGURE 1 BOTTOM VIEW I316 FIGURE 2 CABINET DIMENSIONS AND ACCESS LOCATIONS I281 5 FIGURE 3 CABINET DIMENSIONS AND ACCESS LOCATIONS I282 FIGURE 4 SUPPLY AND RETURN DIMENSIONS I288 6 ! WARNING NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS. VII. INSTALLATION A. GENERAL Install this unit in accordance with The American National Standard Z223.1-latest edition booklet entitled “National Fuel Gas Code,” and the requirements or codes of the local utility or other authority having jurisdiction. Additional helpful publications available from the “National Fire Protection Association” are: NFPA-90A - Installation of Air Conditioning and Ventilating Systems 1985 or latest edition. NFPA-90B - Warm Air Heating and Air Conditioning Systems 1984. These publications are available from: ! WARNING ALWAYS INSTALL UNIT TO OPERATE WITHIN THE UNIT'S INTENDED TEMPERATURE-RISE RANGE WITH A DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED IN DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO UNIT RATING PLATE. ! WARNING WHEN A UNIT IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BY THE UNIT TO AREAS OUTSIDE THE SPACE CONTAINING THE UNIT, THE RETURN AIR SHALL ALSO BE HANDLED BY DUCT(S) SEALED TO THE UNIT CASING AND TERMINATING OUTSIDE THE SPACE CONTAINING THE UNIT. National Fire Protection Association, Inc. 1 Batterymarch Park Quincy, MA 02169-7471 www.nfpa.org 1. PRE-INSTALLATION CHECK-POINTS — Before attempting any installation, carefully consider the following points: Structural strength of supporting members (Rooftop Installation) Clearances and provision for servicing Power supply and wiring Gas supply and piping Air duct connections and sizing Drain facilities and connections Location for minimum noise and vibration - away from bedroom windows 2. LOCATION CONSIDERATIONS The metal parts of this unit may be subject to rust or deterioration in adverse environmental conditions. This oxidation could shorten the equipment’s useful life. Salt spray, fog or mist in seacoast areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such as paper mills and petroleum refineries are especially corrosive. If the unit is to be installed in an area where contaminants are likely to be a problem, give special attention to the equipment location and exposure. 1. Avoid having lawn sprinkler heads spray directly on the unit cabinet. 2. In coastal areas locate the unit on the side of the building away from the waterfront. 3. Shielding by a fence or shrubs may give some protection. ! WARNING DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. REGULAR MAINTENANCE WILL REDUCE THE BUILDUP OF CONTAMINANTS AND HELP TO PROTECT THE UNIT’S FINISH. 1. Frequent washing of the cabinet, fan blade and coil with fresh water will remove most of the salt or other contaminants that build up on the unit. 2. Regular cleaning and waxing of the cabinet with a good automobile polish will provide some protection. 3. A good liquid cleaner may be used several times a year to remove matter that will not wash off with water. Several different types of protective coatings are offered in some areas. These coatings may provide some benefit, but the effectiveness of such coating materials cannot be verified by the equipment manufacturer. The best protection is frequent cleaning, maintenance and minimal exposure to contaminants. 7 ! WARNING FIGURE 5 OUTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOOR CONSTRUCTION. THIS UNIT MAY BE USED TO HEAT THE BUILDING OR STRUCTURE DURING CONSTRUCTION IF THE FOLLOWING INSTALLATION REQUIREMENTS ARE MET. INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING: • PROPER VENT INSTALLATION; • FURNACE OPERATING UNDER THERMOSTATIC CONTROL; • RETURN AIR DUCT SEALED TO THE FURNACE; • AIR FILTERS IN PLACE; • SET FURNACE INPUT RATE AND TEMPERATURE RISE PER RATING PLATE MARKING; • MEANS OF PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION; • RETURN AIR TEMPERATURE MAINTAINED BETWEEN 55°F (13°C) AND 80°F (27°C); AND • INSTALLATION OF EXHAUST AND COMBUSTION AIR INLET HOODS COMPLETED; • CLEAN FURNACE, DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE, TEMPERATURE RISE AND VENTING, ACCORDING TO THE INSTRUCTIONS. I298 B. OUTSIDE SLAB INSTALLATION ! WARNING THESE UNITS ARE DESIGNED CERTIFIED FOR OUTDOOR INSTALLATION ONLY. INSTALLATION INSIDE ANY PART OF A STRUCTURE CAN RESULT IN INADEQUATE UNIT PERFORMANCE AS WELL AS PROPERTY DAMAGE. INSTALLATION INSIDE CAN ALSO CAUSE RECIRCULATION OF FLUE PRODUCTS INTO THE CONDITIONED SPACE RESULTING IN PERSONAL INJURY OR DEATH. (Typical outdoor slab installation is shown in Figure 5.) 1. Select a location where external water drainage cannot collect around unit. 2. Provide a level slab sufficiently high enough above grade to prevent surface water from entering the unit 3. The location of the unit should be such as to provide proper access for inspection and servicing as shown in Figure 7. 4. Locate unit where operating sounds will not disturb owner or neighbors. 5. Locate unit so roof runoff water does not pour directly on the unit. Provide gutter or other shielding at roof level. Do not locate unit in an area where excessive snow drifting may occur or accumulate. 6. Where snowfall is anticipated, the height of the unit above the ground level must be considered. Mount unit high enough to be above anticipated maximum area snowfall and to allow combustion air to enter the combustion air inlet. 7. Select an area which will keep the areas of the vent, air intake, and A/C condenser fins free and clear of obstructions such as weeds, shrubs, vines, snow, etc. Inform the user accordingly. 8. Remove compressor shipping supports (if so equipped) after installation. 8 C. ATTACHING EXHAUST AND COMBUSTION AIR INLET HOODS IMPORTANT: Do not operate this unit without the exhaust/combustion air inlet hood properly installed. This hood is shipped in a carton in the blower compartment inside the unit and must be attached when the unit is installed. See Figure 3. To attach exhaust/combustion air inlet hood: 1. Remove screws securing blower access panel and remove access panel. For location of blower access panel, see Figure 2. 2. Remove exhaust/combustion air inlet hood from the carton, located inside the blower compartment. 3. Attach blower access panel. 4. Attach the combustion air inlet/exhaust hood with screws. Reference Figure 3 for proper location. Screws are in carton with the hood. 5. Vent the unit using the flue exhaust hood, as supplied from the factory, without alteration or addition. D. COVER PANEL INSTALLATION/CONVERSION PROCEDURE DOWNFLOW TO HORIZONTAL 1. Remove the screws and covers from the outside of the supply and return sections. 2. Install the covers in the bottom supply and return openings with the painted side up. See Figure 6. Use the existing gasket to seal the covers. 3. Secure the supply cover to the base of the unit with 1 screw, engaging prepunched tab in unit base. 4. Secure the return cover to the base of the unit with screws engaging prepunched holes in the unit base. This unit is provided with 2 - 25 X 16 X 1 disposable filters. When replacing filters, ensure they are inserted fully to the back to prevent bypass. Recommended Clearance 48 18 12 * 36 60 Location A - Front B - Condenser Coil C - Duct Side D - Evaporator End E - Above E. CLEARANCES The following minimum clearances must be observed for proper unit performance and serviceability. Reference Figure 7. NOTE: Supply duct may be installed with “0’ inch clearance to combustible materials, provided 1 minimum Fiberglass insulation is applied either inside or on the outside of the duct. *Without Economizer. 57 With Economizer FIGURE 6 COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW APPLICATION BEING CONVERTED TO HORIZONTAL I631 9 FIGURE 7 CLEARANCES I297 F. ROOFTOP INSTALLATION 1. Before locating the unit on the roof, make sure that the roof structure is adequate to support the weight involved. (See Electrical & Physical Tables in this manual.) THIS IS VERY IMPORTANT AND THE INSTALLER’S RESPONSIBILITY. 2. For rigging and roofcurb details, see Figures 8, 9, 10 and 11. 3. The location of the unit on the roof should be such as to provide proper access for inspection and servicing. 4. Remove compressor shipping supports (if so equipped) after installation. IMPORTANT: If unit will not be put into service immediately, block off supply and return air openings to prevent excessive condensation. G. DUCTWORK The installing contractor should fabricate ductwork in accordance with local codes. Use industry manuals as a guide when sizing and designing the duct system. Contact Air Conditioning Contractors of America, 2800 Shirlington Road, Suite 300, Arlington, VA 22206, http://www.acca.org. ! WARNING DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN DUCTWORK TO ANY OTHER HEAT PRODUCING DEVICE SUCH AS FIREPLACE INSERT, STOVE, ETC. UNAUTHORIZED USE OF SUCH DEVICES MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY, PROPERTY DAMAGE OR DEATH. 10 FIGURE 8 FLAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. MOUNTED ON ROOFCURB. CURB MUST BE LEVEL. I299 Place the unit as close to the conditioned space as possible allowing clearances as indicated. Run ducts as directly as possible to supply and return outlets. Use of non-flammable weatherproof flexible connectors on both supply and return connections at unit to reduce noise transmission is recommended. On ductwork exposed to outside temperature and humidity, use a minimum of 2 of insulation and a vapor barrier. Distribution system in attic, furred space or crawl space should be insulated with at least 2 of insulation. 1⁄2 to 1 thick insulation is usually sufficient for ductwork inside the air conditioned space. Provide balancing dampers for each branch duct in the supply system. Properly support ductwork from the structure. IMPORTANT: In the event that the return air ducts must be run through an “unconfined” space containing other fuel burning equipment, it is imperative that the user/homeowner must be informed against future changes in construction which might change this to a “confined space.” Also, caution the user/homeowner against any future installation of additional equipment (such as power ventilators, clothes dryers, etc., within the existing unconfined and/or confined space which might create a negative pressure within the vicinity of other solid, liquid, or gas fueled appliances. H. RETURN AIR ! WARNING NEVER ALLOW PRODUCTS OF COMBUSTION OR THE FLUE PRODUCTS TO ENTER THE RETURN AIR DUCTWORK, OR THE CIRCULATING AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS, AND JOINTS TAPED. ALL OTHER DUCT JOINTS MUST BE SECURED WITH APPROVED CONNECTIONS AND SEALED AIRTIGHT. FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR DEATH. 11 FIGURE 9 B LIFTING DETAIL SPREADER BAR LIFTING BEAM CABLE OR CHAIN A C.G. 38 D .25 25 .7 5 5/8 SHACKLE (EACH CORNER) CORNER WEIGHTS BY PERCENTAGE A B C D 22% 27% 23% 28% C FIGURE 10 I296 FIGURE 11 UNIT ROOFCURB ROOFCURB HOLD DOWN BRACKET TYP. (4) PLCS. ROOFTOP UNIT ROOFTOP UNI GASKET GASKET NAILER STRIP NAILER STRIP DUCT* DUCT* GASKET (FULL PERIMETER AND ON DIVIDERS, MUST BE ABOVE DUCT AND INSULATION PANEL FLANGES.) COUNTER FLASHING* COUNTER FLA INSULATION* INSULATION* CANT STRIP* CANT STRIP* ROOF FELT* ROOF FE ROOFCURB ROOFCURB INSULATION* INSULATI SUPPLY ROOF DECK* ROOF DE RETURN INSULATION PANELS (2) SUPPLIED ROOF STRUCTURAL TURAL MEMBER* NAILING STRIP SUPPLY DUCT* ER* RETURN DUCT* 12 ST-A0801-19-01 *BY CONTRACTOR ST-A0801-19-01 VIII. GAS SUPPLY, CONDENSATE DRAIN AND VIII. PIPING A. GAS CONNECTION IMPORTANT: Connect this unit only to gas supplied by a commercial utility. 1. Install gas piping in accordance with local codes and regulations of the local utility company. In the absence of local codes, the installation must conform to the specifications of the National Fuel Gas Code, ANSI Z223.1 - latest edition. NOTE: The use of flexible gas connectors is not permitted. If local codes allow the use of a corrugated stainless steel flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance. NOTE: The Commonwealth of Massachusetts requires the gas shut-off valve to be a T-handle gas cock. 2. Connect the gas line to the gas pipe inlet opening provided into the 1/2 inlet valve. See Figure 5 or 8 for typical piping. 3. Size the gas line to the furnace adequate enough to prevent undue pressure drop and never less than 1/2 nominal pipe size. 4. Install a drip leg or sediment trap in the gas supply line as close to the unit as possible. 5. Install an outside ground joint union to connect the gas supply to the control assembly at the burner tray. 6. Gas valves have been factory installed. Install a manual gas valve where local codes specify a shut-off valve outside the unit casing. (See Figure 13.) 7. Make sure piping is tight. A pipe compound resistant to the action of liquefied petroleum gases must be used at all threaded pipe connections. 8. IMPORTANT: any additions, changes or conversions required for the furnace to satisfactorily meet the application should be made by a qualified installer, service agency or the gas supplier, using factory-specified or approved parts. In the commonwealth of Massachusetts, installation must be performed by a licensed plumber or gas fitter for appropriate fuel. IMPORTANT: Disconnect the furnace and its individual shutoff valve from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch gauge or isolate the system from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of this gas supply system at pressures equal to or less than 1/2 PSIG. TO CHECK FOR GAS LEAKS, USE A SOAP AND WATER SOLUTION OR OTHER APPROVED METHOD. DO NOT USE AN OPEN FLAME. ! WARNING CHECK FOR LEAKS. THE USE OF AN OPEN FLAME CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. IMPORTANT: Check the rating plate to make certain the appliance is equipped to burn the type of gas supplied. Care should be taken after installation of this equipment that the gas control valve not be subjected to high gas supply line pressure. FIGURE 13 SUGGESTED GAS PIPING ROOF OR GROUND LEVEL INSTALLATION FROM GAS METER UNIT GAS SUPPLY CONNECTION * MANUAL GAS SHUT-OFF VALVE TABLE 1 NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.) Nominal Iron Pipe Size, Inches ⁄2 3 ⁄4 1 11⁄4 11⁄2 1 Equivalent Length of Pipe, Feet 10 20 132 92 278 190 520 350 1,050 730 1,600 1,100 30 40 50 60 70 80 73 152 285 590 890 63 130 245 500 760 56 115 215 440 670 50 105 195 400 610 46 96 180 370 560 43 90 170 350 530 *Factory supplied grommet must be utilized. 13 In making gas connections, avoid strains as they may cause noise and damage the controls. A backup wrench is required to be used on the valve to avoid damage. The capacities of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas) are shown in Table 1. After determining the pipe length, select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the furnace. By formula: Gas Input of Furnace (BTU/HR) Cu. Ft. Per Hr. Required = Heating Value of Gas (BTU/FT3) The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may be determined by consulting the local natural gas utility or the L.P. gas supplier. B. LP CONVERSION ! WARNING FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT SUPPLIED BY THE DISTRIBUTOR OR MANUFACTURER. MAILING ADDRESSES ARE LISTED ON THE FURNACE RATING PLATE, PARTS LIST AND WARRANTY. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY, PROPERTY DAMAGE OR DEATH. Convert the valve to use liquefied petroleum (LP) gas by replacing the pressure regulator spring with the conversion kit spring. This LP kit spring allows the regulator to maintain the proper manifold pressure for LP gas. The correct burner LP orifices are included in the kit. See Figure 14. IMPORTANT: To remove the gas valve, remove the four screws securing the manifold pipe to the burner tray. Remove the manifold pipe with gas valve attached. See Figure 15. NOTE: Order the correct LP conversion kit from the furnace manufacturer. See Conversion Kit Index shipped with unit for proper LP kit number. Furnace conversion to LP gas must be performed by a qualified technician. C. NOx MODELS When converting units equipped with NOx inserts to LP gas, the stainless steel screen mesh inserts in the entrance of the tubular exchangers are not required to meet SCAQMD NOx emission levels. These inserts and 1/8 diameter retaining rod should be carefully removed before firing this furnace on LP gas. IMPORTANT: This furnace is not designed to operate on LP gas with the NOx inserts in place. Step by step instructions on removing the NOx inserts and retaining rod are included in the Conversion Kit Installation Instructions. TABLE 2 LP GAS PIPE CAPACITY TABLE (CU. FT./HR.) Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column inlet pressure). (Based on a Pressure Drop of 0.5 Inch Water Column) Nominal Length of Pipe, Feet Iron Pipe 10 20 30 40 50 60 70 80 90 100 125 150 Size, Inches 1/2 3/4 1 1-1/4 1-1/2 2 275 189 152 129 114 103 96 89 83 78 69 63 567 393 315 267 237 217 196 182 173 162 146 132 1,071 732 590 504 448 409 378 346 322 307 275 252 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496 Example (LP): Input BTU requirement of unit, 150,000 Equivalent length of pipe, 60 ft. = 3/4 IPS required. 14 FIGURE 15 FIGURE 14 MANIFOLD PIPE D. ADJUSTING OR CHECKING FURNACE INPUT – Natural Gas Line Pressure 5 - 10.5 W.C. – LP Gas Line Pressure 11 - 13 W.C. – Natural Gas Manifold Pressure 3.5 W.C – LP Gas Manifold Pressure - 10 W.C. Supply and manifold pressure taps are located on the gas valve body 1/8 N.P.T. and on the manifold. Use a properly calibrated manometer gauge for accurate gas pressure readings. Only small variations in the gas flow should be made by means of the pressure regulator adjustment. Furnaces functioning on LP gas must be set by means of the tank or branch supply regulators. The furnace manifold pressure should be set at 10 W.C. at the gas control valve. To adjust the pressure regulator, remove the regulator cap and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure. Then replace the regulator cap securely. Any necessary major changes in the gas flow rate should be made by changing the size of the burner orifices. To change orifice spuds, shut off the manual main gas valve and remove the gas manifold. For elevations up to 2,000 feet, rating plate input ratings apply. For high altitudes (elevations over 2,000 ft.), see conversion kit index 92-21519-XX for derating and orifice spud sizes. Check of input is important to prevent over-firing of the furnace beyond its designrated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE. Use the following table or formula to determine input rate. Heating Value of Gas (BTU/Cu. Ft.) x 3600 Cu. Ft. Per Hr. Required = Time in Seconds (for 1 Cu. Ft.) of Gas Start the furnace and measure the time required to burn one cubic foot of gas. Prior to checking the furnace input, make certain that all other gas appliances are shut off, with the exception of pilot burners. Time the meter with only the furnace in operation. IMPORTANT NOTE FOR ALTITUDES ABOVE 2,000 FEET (610 METERS): The main burner orifices in your furnace and in these kits are sized for the nameplate input and intended for installations at elevations up to 2,000 feet in the USA or Canada, or for elevations of 2,000 - 4,500 feet (610 -1,373 meters) in Canada if the unit has been derated at the factory. For elevations above 2,000 feet (610 meters) IN THE USA ONLY (see ANSI-Z223.1), the burner orifices must be sized to reduce the input 4% for each 1,000 feet (305 meters) above sea level. 15 TABLE 3 METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS INPUT BTU/HR 40,000 60,000 80,000 100,000 FIGURE 16 CONDENSATE DRAIN METER HEATING VALUE OF GAS BTU PER CU. FT. SIZE 900 1000 1040 1100 2500 CU. FT. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. ONE 1 21 1 30 1 34 1 39 3 45 TEN 13 30 15 0 15 36 16 30 37 30 ONE 0 54 1 0 1 3 1 6 2 30 TEN 9 0 10 0 10 24 11 0 25 0 ONE 0 41 0 45 0 47 0 50 1 53 TEN 6 45 7 30 7 48 8 15 18 45 ONE 0 33 0 36 0 38 0 40 1 30 TEN 5 24 6 0 6 15 6 36 15 0 DO NOT OVERTIGHTEN DRAIN FITTING NOTICE: DERATING OF THE HEATING INPUT FOR HIGH ALTITUDE IN THE FIELD IS UNLAWFUL IN CANADA (REFER TO CAN/CGA 2.17). UNITS INSTALLED IN ALTITUDES GREATER THAN 2,000 FEET (610 METERS) MUST BE SHIPPED FROM THE FACTORY OR FROM A FACTORY AUTHORIZED CONVERSION STATION WITH THE HEATING INPUT DERATED BY 10% SO AS TO OPERATE PROPERLY IN ALTITUDES FROM 2,000 - 4,500 FEET (610 - 1,373 METERS). E.CONDENSATE DRAIN The condensate drain connection of the evaporator is threaded 3/4 nominal P.V.C. pipe. IMPORTANT: Install a condensate trap to ensure proper condensate drainage. See Figure 16. IX. WIRING A. POWER SUPPLY ! WARNING TURN OFF THE MAIN ELECTRICAL POWER AT THE BRANCH CIRCUIT DISCONNECT CLOSEST TO THE UNIT BEFORE ATTEMPTING ANY WIRING. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. 1. All wiring should be made in accordance with the National Electrical Code. Consult the local power company to determine the availability of sufficient power to operate the unit. Check the voltage at power supply to make sure it corresponds to the unit’s RATED VOLTAGE REQUIREMENT. Install a branch circuit disconnect near the rooftop, in accordance with the N.E.C., C.E.C. or local codes. A bracket is provided with the unit for mounting of the disconnect. See Figure 17. 2. It is important that proper electrical power is available at the unit. Voltage should not vary more than 10% from that stamped on the unit nameplate. On three phase units, phases must be balanced within 3%. 3. For branch circuit wiring (main power supply to unit disconnect), the minimum wire size for the length of run can be determined from Table 3 using the circuit ampacity found on the unit rating plate. Use the smallest wire size allowable in Table 4 from the unit disconnect to unit. NOTE: A bracket is provided with the unit for mounting the branch circuit disconnect to the unit. This is the recommended location for the disconnect. See Figure 17. 4. For through the base wiring entry reference Figure 18. All fittings and conduit are field supplied for this application. Reference the chart with Figure 18 for proper hole and conduit size. 16 FIGURE 17 RECOMMENDED BRANCH CIRCUIT DISCONNECT LOCATION TABLE 4 BRANCH CIRCUIT COPPER WIRE SIZE (Based on 1% Voltage Drop)* 200 150 100 50 6 8 10 14 15 4 6 8 12 20 4 6 8 10 25 4 4 6 10 30 3 4 6 8 35 3 4 6 8 40 2 2 3 3 4 4 6 6 45 50 BRANCH CIRCUIT AMPACITY SUPPLY WIRE LENGTH-FEET *Taken from National Electric Code BRANCH CIRCUIT DISCONNECT TO POWER TO THERMOSTAT I317A NOTES: 1. Wire size based on 60°C rated wire insulation and 30°C Ambient Temp. (86°F). 2. For more than 3 conductors in a raceway or cable, see the N.E.C. for derating the ampacity of each conductor. When installed, the unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, if an external electrical source is utilized. IMPORTANT: THIS UNIT IS APPROVED FOR USE WITH COPPER CONDUCTORS ONLY CONNECTED TO UNIT CONTACTOR. WARRANTY MAY BE JEOPARDIZED IF ALUMINUM WIRE IS CONNECTED TO UNIT CONTACTOR. Special instructions apply for power wiring with aluminum conductors: Warranty is void if connections are not made per instructions. Attach a length (6 or more) of recommended size copper wire to the unit contactor terminals L1 and L3 for single phase, L1, L2 and L3 for three phase. Select the equivalent aluminum wire size from the tabulation below: Splice copper wire pigtails to aluminum wire with U.L. recognized connectors for copperaluminum splices. Please exercise the following instructions very carefully to obtain a positive and lasting connection: 1. Strip insulation from aluminum conductor. 2. Coat the stripped end of the aluminum wire with the recommended inhibitor, and wire brush the aluminum surface through inhibitor. INHIBITORS: Brundy-Pentex “A”; Alcoa-No. 2EJC; T & B-KPOR Shield. 3. Clean and recoat aluminum conductor with inhibitor. 4. Make the splice using the above listed wire nuts or split bolt connectors. 5. Coat the entire connection with inhibitor and wrap with electrical insulating tape. TABLE 5 AWG Copper Wire Size #12 #10 # 8 # 6 # 4 AWG Aluminum Wire Size #10 # 8 # 6 # 4 # 2 Connector Type and Size (or equivalent) T & B Wire Nut PT2 T & B Wire Nut PT3 Sherman Split Bolt TSP6 Sherman Split Bolt TSP4 Sherman Split Bolt TSP2 17 FIGURE 18 FIGURE 19 TYPICAL THERMOSTAT WIRING I658 WIRE SIZE, AWG CONDUIT SIZE HOLE SIZE NOTES: 14 1/2 7/8 12 1/2 7/8 10 1/2 7/8 8 3/4 1-31/32 6 1 1-23/64 4 1 1-23/64 3 1-1/4 1-23/32 2 1-1/4 1-23/32 1 1-1/2 1-31/32 0 1-1/2 1-31/32 00 2 2-15/32 000 2 2-15/32 1. DETERMINE REQUIRED WIRE SIZE FROM MINIMUM CIRCUIT AMPACITY SHOWN IN INSTALLATION & OPERATING INSTRUCTION. 2. BOTTOM POWER ENTRY WILL NOT ACCOMMODATE WIRE LARGER THAN #2 AWG (SHADED AREA). B. HOOK-UP To wire unit, refer to the following hook-up diagram. Refer to Figures 3 and 18 for location of wiring entrances. Wiring to be done in the field between the unit and devices not attached to the unit, or between separate devices which are field installed and located, shall conform with the temperature limitation for Type T wire [63°F rise (35°C)] when installed in accordance with the manufacturer’s instructions. C. INTERNAL WIRING IMPORTANT: Some single phase units are equipped with a single pole contactor. Caution must be exercised when servicing as only one leg of the power supply is broken with the contactor. Some models are equipped with electronically commutated blower motors which are constantly energized, unless the main unit disconnect is in the off position. A diagram of the internal wiring of this unit is located under the electrical box cover and this manual. If any of the original wire as supplied with the appliance must be replaced, the wire gauge and insulation must be same as original wiring. Transformer is factory wired for 230 volts on 208/230 volt models and must be changed for 208 volt applications. See unit wiring diagram for 208 volt wiring. D. THERMOSTAT The room thermostat must be compatible with the spark ignition control on the unit. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control. The low voltage wiring should be sized as shown in Table 6. Install the room thermostat in accordance with the instruction sheet packed in the box with the thermostat. Run the thermostat lead wires inside the compressor access panel compartment and connect to low voltage terminals as shown on the wiring diagram. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes or ducts, lighting fixtures, radiation from fireplace, sun 18 TABLE 6 Thermostat Load Amps FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS 3.0 2.5 2.0 16 16 18 50 SOLID COPPER WIRE - AWG. 14 12 10 10 14 12 12 12 16 14 12 12 100 150 200 250 Length of Run – Feet (1) 10 10 10 300 (1) The total wire length is the distance from the furnace to the thermostat and back to the furnace. NOTE: DO NOT USE CONTROL WIRING SMALLER THAN NO. 18 AWG. rays, lamps, televisions, radios or air streams from registers. Refer to instructions packed with the thermostat for “heater” selection or adjustment. X. FURNACE SECTION CONTROLS AND IGNITION SYSTEM NORMAL FURNACE OPERATING SEQUENCE This unit is equipped with an integrated direct spark ignition control. 1. The thermostat calls for heat. 2. The control board will run a self check to verify that the limit control and manual reset overtemperature control are closed and that the pressure switch is open. 3. Upon closure of the pressure switch, the control board energizes the induced draft blower for a 15 second prepurge. 4. After the 15 second prepurge, the gas valve opens and the spark is initiated for 7 second trial for ignition. 5. Burners ignite and flame sensor proves all burners have lit. 6. The circulating air blower is energized after 30 seconds. 7. The control board enters a normal operation loop in which all safety controls are monitored continuously. 8. Thermostat is satisfied and opens. 9. The gas valve is de-energized and closes, shutting down the burner flame. 10. The control board will de-energize the inducer after a five second post purge. 11. The circulating air blower is de-energized after 90 seconds. The integrated control is a three ignition system. After a total of three cycles without sensing main burner flame, the system goes into a 100% lockout mode. After one hour, the ignition control repeats the prepurge and ignition cycles for 3 tries and then go into 100% lockout mode again. It continues this sequence of cycles and lockout each hour until ignition is successful or power is interrupted. During the lockout mode, neither the ignitor or gas valve will be energized until the system is reset by turning the thermostat to the “OFF” position or interrupting the electrical power to the unit for 3 seconds or longer. The induced draft blower and main burner will shut off when the thermostat is satisfied. The circulating air blower will start and run on the heating speed if the thermostat fan switch is in the “ON” position. The integrated furnace control is equipped with diagnostic LED. The LED is lit continuously when there is power to the control, with or without a call for heat. If the LED is not lit, there is either no power to the control or there is an internal component failure within the control, and the control should be replaced. 19 If the control detects the following failures, the LED will flash on for approximately 1/4 second, then off for 3/4 second for designated failure detections. 1 Flash: Failed to detect flame within the three tries for ignition. 2 Flash: Pressure switch or induced draft blower problem detected. 3 Flash: High limit or auxiliary limit open. 4 Flash: Flame sensed and gas valve not energized or flame sensed with no “W” signal. 5 Flash: Overtemperature switch open. OPERATING INSTRUCTIONS This appliance is equipped with integrated furnace control. This device lights the main burners each time the room thermostat (closes) calls for heat. See operating instructions on the back of the furnace/controls access panel. ! WARNING DO NOT ATTEMPT TO MANUALLY LIGHT THIS FURNACE WITH A MATCH OR ANY OPEN FLAME. ATTEMPTING TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. TO START THE FURNACE 1. STOP! Read the safety information on the Operating Instructions label located on this appliance. ! WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. 2. Set the thermostat to its lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT try to light the burner by hand. 5. Remove control door/access panel. 6. Move switch to the “OFF” position. 7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • 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. If you don’t smell gas, go to the next step. 8. Move “OFF” position to “ON” position. 9. Replace the control door. 10. Turn on all electric power to the appliance. 11. Set the thermostat to the desired setting. 12. If the appliance will not operate, follow the instructions below on how to shut down the furnace. ! WARNING THE SPARK IGNITOR AND IGNITION LEAD FROM THE IGNITION CONTROL ARE HIGH VOLTAGE. KEEP HANDS OR TOOLS AWAY TO PREVENT ELECTRICAL SHOCK. SHUT OFF ELECTRICAL POWER BEFORE SERVICING ANY OF THE CONTROLS. FAILURE TO ADHERE TO THIS WARNING CAN RESULT IN PERSONAL INJURY OR DEATH. The initial start-up on a new installation may require the control system to be energized for some time until air has bled through the system and fuel gas is available at the burners. TO SHUT DOWN FURNACE 1. Set the thermostat to the lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Remove control door. 4. Move switch to the “OFF” position. 5. Replace control door. 20 ! WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, SHUT OFF THE MANUAL GAS VALVE TO THE APPLIANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN RESULT IN AN EXPLOSION OR FIRE CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH! BURNERS Burners for these units have been designed so that field adjustment is not required. Burners are tray-mounted and accessible for easy cleaning when required. MANUAL RESET OVERTEMPERATURE CONTROL Two manual reset overtemperature controls (one on 80,000 BTUH) are located on the burner shield. These devices senses blockage in the heat exchanger or insufficient combustion air. This shuts off the main burners if excessive temperatures occur in the burner compartment. Operation of this control indicates an abnormal condition. Therefore, the unit should be examined by a qualified installer, service agency, or the gas supplier before being placed back into operation. ! WARNING DO NOT JUMPER THIS DEVICE! DO NOT reset the overtemperature control without taking corrective action to assure that an adequate supply of combustion air is maintained under all conditions of operation. Failure to do so can result in carbon monoxide poisoning or death. Replace this control only with the identical replacement part. PRESSURE SWITCH This furnace has a pressure switch for sensing a blocked exhaust or a failed induced draft blower. It is normally open and closes when the induced draft blower starts, indicating air flow through the combustion chamber. LIMIT CONTROL The supply air high temperature limit cut-off is set at the factory and cannot be adjusted. It is calibrated to prevent the air temperature leaving the furnace from exceeding the maximum outlet air temperature. ! WARNING DO NOT JUMPER THIS DEVICE! DOING SO CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. IMPORTANT: Replace this control only with the identical replacement part. XI. SYSTEM OPERATING INFORMATION ADVISE THE CUSTOMER 1. Change the air filters regularly. The heating system operates better, more efficiently and more economically. 2. Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed. 3. Close doors and windows. This reduces the heating and cooling load on the system. 4. Avoid excessive use of exhaust fans. 5. Do not permit the heat generated by television, lamps or radios to influence the thermostat operation. 6. Except for the mounting platform, keep all combustible articles three feet from the unit and exhaust system. 21 7. IMPORTANT: Replace all blower doors and compartment cover after servicing the unit. Do not operate the unit without all panels and doors securely in place. 8. Do not allow snow or other debris to accumulate in the vicinity of the appliance. FURNACE SECTION MAINTENANCE The unit’s furnace should operate for many years without excessive scale build-up in flue passageways; however, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect the flue passageways, the exhaust system and the burners for continued safe operation, paying particular attention to deterioration from corrosion or other sources. If during inspection the flue passageways and exhaust system are determined to require cleaning, the following procedures should be followed (by a qualified installer, service agency, or gas supplier): 1. Turn off the electrical power to the unit and set the thermostat to the lowest temperature. 2. Shut off the gas supply to the unit either at the meter or at manual valve in the supply piping. ! WARNING LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 3. Remove the furnace controls access panel and the control box cover. 4. Disconnect the gas supply piping from the gas valve. 5. Disconnect the wiring to the induced draft blower motor, gas valve, flame sensor, and flame roll-out control, and ignitor cable. Mark all wires disconnected for proper reconnection. 6. Remove the screws (4) connecting the burner tray to the heat exchanger mounting panel. 7. Remove the burner tray and the manifold assembly from the unit. 8. Remove the screws (5) connecting the induced draft blower to the collector box and screws (18) connecting the collector box to the heat exchanger center panel. Remove the induced draft blower and the collector box from the unit. 9. Remove the screws (3) connecting the divider plate to the heat exchanger center panel. 10. Remove the turbulators from inside the heat exchangers by inserting the blade of a screwdriver under the locking tabs. Pop the tabs out of the expanded grooves of the heat exchanger. Slide the turbulators out of the heat exchangers. 11. Direct a water hose into the outlet of the heat exchanger top. Flush the inside of each heat exchanger tube with water. Blow out each tube with air to remove excessive moisture. 12. Reassemble (steps 1 through 10 in reverse order). Be careful not to strip out the screw holes used to mount the collector box and inducer blower. Replace inducer blower gasket and collector box gasket with factory replacements if damaged. ! WARNING HOLES IN THE EXHAUST TRANSITION OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME. THE EXHAUST TRANSITION OR HEAT EXCHANGER MUST BE REPLACED IF THEY HAVE HOLES OR CRACKS IN THEM. FAILURE TO DO SO CAN CAUSE CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH. The manufacturer recommends that a qualified installer, service agency or the gas supplier visually inspect the burner flames for the desired flame appearance at the beginning of the heating season and approximately midway in heating season. The manufacturer also recommends that a qualified installer, service agency or the gas supplier clean the flame sensor with steel wool at the beginning of the heating season. 22 ! WARNING DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING MAINTENANCE. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK OR SEVERE PERSONAL INJURY OR DEATH. LUBRICATION IMPORTANT: DO NOT attempt to lubricate the bearings on the blower motor or the induced draft blower motor. Addition of lubricants can reduce the motor life and void the warranty. The blower motor and induced draft blower motor are prelubricated by the manufacturer and do not require further attention. A qualified installer, service agency or the gas supplier must periodically clean the motors to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior. And, as suggested elsewhere in these instructions, the air filters should be kept clean because dirty filters can restrict air flow and the motor depends upon sufficient air flowing across and through it to prevent overheating. COOLING SECTION MAINTENANCE ! WARNING DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. It is recommended that at the beginning of each cooling season a qualified installer or service agency inspect and clean the cooling section of this unit. The following areas should be addressed: evaporator coil. condenser coil, condenser fan motor and venturi area. To inspect the evaporator coil: 1. Remove the filter access panel and the blower/evaporator coil access panel. Remove the filters. ! WARNING LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING THE UNIT. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH. 2. Shine a flashlight on the evaporator coil (both sides) and inspect for accumulation of lint, insulation, etc. 3. If coil requires cleaning, follow the steps shown below. Cleaning Evaporator Coil 1. The coil should be cleaned when it is dry. If the coil is coated with dirt or lint, vacuum it with a soft brush attachment. Be careful not to bend the coil fins. 2. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solution. Rinse the coil thoroughly with water. IMPORTANT: Do not use excessive water pressure. Excessive water pressure can bend the fins and tubing of the coil and lead to inadequate unit performance. Be careful not to splash water excessively into unit. 3. Inspect the drain pan and condensate drain at the same time the evaporator coil is checked. Clean the drain pan by flushing with water and removing any matters of obstructions which may be present. 4. Go to next section for cleaning the condenser coil. Cleaning Condenser Coil, Condenser Fan, Circulation Air Blower and Venturi 1. Remove the compressor access panel. Disconnect the wires to the condenser fan motor in the control box (see wiring diagram). Remove the wires from the opening in the bottom of the control box. 2. Remove the screws securing the condenser top panel and remove the panel with condenser fan motor and grille attached. 3. The coil should be cleaned when it is dry. If the coil is coated with dirt or lint, vacuum it with a soft brush attachment. Be careful not to bend the coil fins. 23 4. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solution. Rinse the coil thoroughly with water. IMPORTANT: Do not use excessive water pressure. Excessive water pressure can bend the fins and tubing of the coil and lead to inadequate unit performance. Be careful not to splash water excessively into unit. 5. The venturi should also be inspected for items of obstruction such as collections of grass, dirt or spider webs. Remove any that are present. 6. Inspect the circulating air blower wheel and motor for accumulation of lint, dirt or other obstruction and clean it necessary. Inspect the blower motor mounts and the blower housing for loose mounts or other damage. Repair or replace if necessary. Re-assembly 1. Place the condenser top panel back on the unit and replace all screws. 2. Run the fan motor wires through the hole in the bottom of the control box. Reconnect fan motor wires per the wiring diagram attached to the back of the cover. 3. Replace the filter and blower/evaporator coil access panels. 4. Replace the control box cover and controls access panel. 5. Restore electrical power to the unit and check for proper operation, especially the condenser fan motor. REPLACEMENT PARTS Contact your local distributor for a complete parts list. TROUBLESHOOTING Refer to Troubleshooting Chart included in this manual. WIRING DIAGRAMS Refer to the appropriate wiring diagram included in this manual. CHARGING Refer to the appropriate charge chart included in this manual. BLOWER MOTOR SPEED TAPS After determining necessary CFM and speed tap data from the Airflow Performance Data, follow the steps below to change speeds. 1. Remove the blower access panel. 2. Reference Figure 20 for location of the speed tap block on the blower. 3. Remove the furnace control access panel. 4. Remove the control box cover. See Figure 21 for location of the integrated furnace control board. 5. Reference Figure 22 for the proper location of the red and black wires on the speed tap block and on the furnace integrated control board to obtain the speed tap you have chosen. 6. After adjusting the wires accordingly, attach the control box cover, furnace control access panel and the blower access panel to the unit. 24 SPEED TAP BLOCK FIGURE 22 FIGURE 20 INTEGRATED FURNACE CONTROL FIGURE 21 25 FIGURE 22 (Continued) 26 XII. GENERAL DATA - TGC MODELS NOMINAL SIZES 3-5 TONS [10.6-17.6 kW] Model TGC-Series 036A3K-080 036A-3K-120 036A-1K-080 Cooling Performance1 Gross Cooling Capacity Btu [kW] EER/SEER2 Nominal CFM/ARI Rated CFM [L/s] ARI Net Cooling Capacity Btu [kW] Net Sensible Capacity Btu [kW] Net Latent Capacity Btu [kW] Net System Power kW 36,800 [10.78] 11.4/13 1200/1200 [566/566] 35,400 [10.37] 26,200 [7.68] 9,200 [2.7] 3.1 36,800 [10.78] 11.4/13 1200/1200 [566/566] 35,400 [10.37] 26,200 [7.68] 9,200 [2.7] 3.1 36,800 [10.78] 11.4/13 1200/1200 [566/566] 35,400 [10.37] 26,200 [7.68] 9,200 [2.7] 3.1 036A-1K-120 Continued -> 36,800 [10.78] 11.4/13 1200/1200 [566/566] 35,400 [10.37] 26,200 [7.68] 9,200 [2.7] 3.1 Heating Performance (Gas)3 Heating Input Btu [kW] Heating Output Btu [kW] Temperature Rise Range °F [°C] AFUE % Steady State Efficiency (%) No. Burners No. Stages Gas Connection Pipe Size in. [mm] 80,000 [23.44] 64,800 [18.99] 30-60 [16.7/33.3] 80 81 4 1 0.5 [12.7] 120,000 [35.16] 97,200 [28.48] 50-80 [27.8/44.4] 80 81 6 1 0.5 [12.7] 80,000 [23.44] 62,500 [18.31] 30-60 [16.7/33.3] 80 81 4 1 0.5 [12.7] 120,000 [35.16] 94,500 [27.69] 50-80 [27.8/44.4] 80 81 6 1 0.5 [12.7] Compressor No./Type 1/Scroll 1/Scroll 1/Copeland Scroll 1/Copeland Scroll Outdoor Sound Rating (dB)4 78 78 78 78 Outdoor Coil - Fin Type Tube Type Tube Size in. [mm] OD Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1 / 22 [9] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1 / 22 [9] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1 / 22 [9] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1 / 22 [9] Indoor Coil - Fin Type Tube Type Tube Size in. [mm] Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Refrigerant Control Drain Connection No./Size in. [mm] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 2 / 17 [7] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 2 / 17 [7] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 2 / 17 [7] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 2 / 17 [7] TX Valves 1/0.75 [19.05] Outdoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds CFM [L/s] No. Motors/HP Motor RPM Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Indoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds No. Motors Motor HP Motor RPM Motor Frame Size FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 Filter - Type Furnished (NO.) Size Recommended in. [mm x mm x mm] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Refrigerant Charge Oz. [g] 96 [2722] 96 [2722] 96 [2722] 96 [2722] Weights Net Weight lbs. [kg] Ship Weight lbs. [kg] 543 [246] 550 [249] 543 [246] 550 [249] 543 [246] 550 [249] 543 [246] 550 [249] NOTES: 1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. ARI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to ±20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on ARI Standard 210/240 or 360. 2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures. 3. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level. 4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270. 27 GENERAL DATA - TGC MODELS NOMINAL SIZES 3-5 TONS [10.6-17.6 kW] Model TGC-Series 042A-3K-080 042A-3K-120 042A-1K-080 Cooling Performance1 Gross Cooling Capacity Btu [kW] EER/SEER2 Nominal CFM/ARI Rated CFM [L/s] ARI Net Cooling Capacity Btu [kW] Net Sensible Capacity Btu [kW] Net Latent Capacity Btu [kW] Net System Power kW 42,500 [12.45] 11.2/13 1400/1450 [661/684] 40,500 [11.87] 30,600 [8.97] 9,900 [2.9] 3.62 42,500 [12.45] 11.2/13 1400/1450 [661/684] 40,500 [11.87] 30,600 [8.97] 9,900 [2.9] 3.62 42,500 [12.45] 11.2/13 1400/1450 [661/684] 40,500 [11.87] 30,600 [8.97] 9,900 [2.9] 3.62 042A-1K-120 Continued -> 42,500 [12.45] 11.2/13 1400/1450 [661/684] 40,500 [11.87] 30,600 [8.97] 9,900 [2.9] 3.62 Heating Performance (Gas)3 Heating Input Btu [kW] Heating Output Btu [kW] Temperature Rise Range °F [°C] AFUE % Steady State Efficiency (%) No. Burners No. Stages Gas Connection Pipe Size in. [mm] 80,000 [23.44] 64,800 [18.99] 30-60 [16.7/33.3] 80 81 4 1 0.5 [12.7] 120,000 [35.16] 97,200 [28.48] 50-80 [27.8/44.4] 80 81 6 1 0.5 [12.7] 80,000 [23.44] 62,500 [18.31] 30-60 [16.7/33.3] 80 81 4 1 0.5 [12.7] 120,000 [35.16] 94,500 [27.69] 50-80 [27.8/44.4] 80 81 6 1 0.5 [12.7] Compressor No./Type 1/Copeland Scroll 1/Copeland Scroll 1/Scroll 1/Scroll Outdoor Sound Rating (dB)4 78 78 78 78 Outdoor Coil - Fin Type Tube Type Tube Size in. [mm] OD Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1.53 / 22 [9] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1.53 / 22 [9] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1.53 / 22 [9] Louvered Rifled 0.375 [9.5] 16.91 [1.57] 1.53 / 22 [9] Indoor Coil - Fin Type Tube Type Tube Size in. [mm] Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Refrigerant Control Drain Connection No./Size in. [mm] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 13 [5] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 13 [5] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 13 [5] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 13 [5] TX Valves 1/0.75 [19.05] Outdoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds CFM [L/s] No. Motors/HP Motor RPM Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Indoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds No. Motors Motor HP Motor RPM Motor Frame Size FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1725 48 Filter - Type Furnished (NO.) Size Recommended in. [mm x mm x mm] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Refrigerant Charge Oz. [g] 125 [3544] 125 [3544] 125 [3544] 125 [3544] Weights Net Weight lbs. [kg] Ship Weight lbs. [kg] 570 [259] 577 [262] 579 [263] 586 [266] 570 [259] 577 [262] 579 [263] 586 [266] NOTES: 1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. ARI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to ±20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on ARI Standard 210/240 or 360. 2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures. 3. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level. 4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270. 28 GENERAL DATA - TGC MODELS NOMINAL SIZES 3-5 TONS [10.6-17.6 kW] Model TGC-Series 048A-3K-080 048A-3K-100 048A-3K-135 Cooling Performance1 Gross Cooling Capacity Btu [kW] EER/SEER2 Nominal CFM/ARI Rated CFM [L/s] ARI Net Cooling Capacity Btu [kW] Net Sensible Capacity Btu [kW] Net Latent Capacity Btu [kW] Net System Power kW 50,000 [14.65] 11.45/13 1600/1600 [755/755] 48,000 [14.06] 35,600 [10.43] 12,400 [3.63] 4.19 50,000 [14.65] 11.45/13 1600/1600 [755/755] 48,000 [14.06] 35,600 [10.43] 12,400 [3.63] 4.19 50,000 [14.65] 11.45/13 1600/1600 [755/755] 48,000 [14.06] 35,600 [10.43] 12,400 [3.63] 4.19 048A-1K-080 Continued -> 50,000 [14.65] 11.45/13 1600/1600 [755/755] 48,000 [14.06] 35,600 [10.43] 12,400 [3.63] 4.19 Heating Performance (Gas)3 Heating Input Btu [kW] Heating Output Btu [kW] Temperature Rise Range °F [°C] AFUE % Steady State Efficiency (%) No. Burners No. Stages Gas Connection Pipe Size in. [mm] 80,000 [23.44] 64,800 [18.99] 30-60 [16.7/33.3] 80 81 4 1 0.5 [12.7] 100,000 [29.3] 81,000 [23.73] 40-70 [22.2/38.9] 80 81 5 1 0.5 [12.7] 135,000 [39.56] 109,400 [32.05] 50-80 [27.8/44.4] 80 81 6 1 0.5 [12.7] 80,000 [23.44] 62,500 [18.31] 30-60 [16.7/33.3] 80 81 4 1 0.5 [12.7] Compressor No./Type 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll Outdoor Sound Rating (dB)4 78 78 78 78 Outdoor Coil - Fin Type Tube Type Tube Size in. [mm] OD Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Louvered Rifled 0.375 [9.5] 16.59 [1.54] 2 / 22 [9] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Indoor Coil - Fin Type Tube Type Tube Size in. [mm] Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Refrigerant Control Drain Connection No./Size in. [mm] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Outdoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds CFM [L/s] No. Motors/HP Motor RPM Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Indoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds No. Motors Motor HP Motor RPM Motor Frame Size FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 Filter - Type Furnished (NO.) Size Recommended in. [mm x mm x mm] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Refrigerant Charge Oz. [g] 165 [4678] 165 [4678] 165 [4678] 165 [4678] Weights Net Weight lbs. [kg] Ship Weight lbs. [kg] 580 [263] 587 [266] 580 [263] 587 [266] 585 [265] 592 [269] 580 [263] 587 [266] NOTES: 1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. ARI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to ±20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on ARI Standard 210/240 or 360. 2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures. 3. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level. 4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270. 29 GENERAL DATA - TGC MODELS NOMINAL SIZES 3-5 TONS [10.6-17.6 kW] Model TGC-Series 048A-1K-100 048A-1K-135 060A-3K-100 Cooling Performance1 Gross Cooling Capacity Btu [kW] EER/SEER2 Nominal CFM/ARI Rated CFM [L/s] ARI Net Cooling Capacity Btu [kW] Net Sensible Capacity Btu [kW] Net Latent Capacity Btu [kW] Net System Power kW 50,000 [14.65] 11.45/13 1600/1600 [755/755] 48,000 [14.06] 35,600 [10.43] 12,400 [3.63] 4.19 50,000 [14.65] 11.45/13 1600/1600 [755/755] 48,000 [14.06] 35,600 [10.43] 12,400 [3.63] 4.19 61,000 [17.87] 11.1/13 2000/1900 [944/897] 59,000 [17.29] 42,000 [12.31] 17,000 [4.98] 5.32 060A-3K-135 Continued -> 61,000 [17.87] 11.1/13 2000/1900 [944/897] 59,000 [17.29] 42,000 [12.31] 17,000 [4.98] 5.32 Heating Performance (Gas)3 Heating Input Btu [kW] Heating Output Btu [kW] Temperature Rise Range °F [°C] AFUE % Steady State Efficiency (%) No. Burners No. Stages Gas Connection Pipe Size in. [mm] 100,000 [29.3] 78,500 [23] 40-70 [22.2/38.9] 80 81 5 1 0.5 [12.7] 135,000 [39.56] 106,500 [31.2] 50-80 [27.8/44.4] 80 81 6 1 0.5 [12.7] 100,000 [29.3] 81,000 [23.73] 25-55 [13.9/30.6] 80 81 5 1 0.5 [12.7] 135,000 [39.56] 109,400 [32.05] 40-70 [22.2/38.9] 80 81 6 1 0.5 [12.7] Compressor No./Type 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll Outdoor Sound Rating (dB)4 78 78 83 83 Outdoor Coil - Fin Type Tube Type Tube Size in. [mm] OD Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Louvered Rifled 0.375 [9.5] 16.59 [1.54] 2 / 22 [9] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Indoor Coil - Fin Type Tube Type Tube Size in. [mm] Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Refrigerant Control Drain Connection No./Size in. [mm] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Outdoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds CFM [L/s] No. Motors/HP Motor RPM Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3680 [1737] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3930 [1855] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3930 [1855] 1 at 1/3 HP 1075 Indoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds No. Motors Motor HP Motor RPM Motor Frame Size FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1/2 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1 1075 48 Filter - Type Furnished (NO.) Size Recommended in. [mm x mm x mm] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Refrigerant Charge Oz. [g] 165 [4678] 165 [4678] 160 [4536] 160 [4536] Weights Net Weight lbs. [kg] Ship Weight lbs. [kg] 580 [263] 587 [266] 585 [265] 592 [269] 590 [268] 597 [271] 597 [271] 604 [274] NOTES: 1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. ARI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to ±20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on ARI Standard 210/240 or 360. 2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures. 3. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level. 4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270. 30 GENERAL DATA - TGC MODELS NOMINAL SIZES 3-5 TONS [10.6-17.6 kW] Model TGC-Series 060A-1K-100 060A-1K-135 Cooling Performance1 Gross Cooling Capacity Btu [kW] EER/SEER2 Nominal CFM/ARI Rated CFM [L/s] ARI Net Cooling Capacity Btu [kW] Net Sensible Capacity Btu [kW] Net Latent Capacity Btu [kW] Net System Power kW 61,000 [17.87] 11.1/13 2000/1900 [944/897] 59,000 [17.29] 42,000 [12.31] 17,000 [4.98] 5.32 61,000 [17.87] 11.1/13 2000/1900 [944/897] 59,000 [17.29] 42,000 [12.31] 17,000 [4.98] 5.32 Heating Performance (Gas)3 Heating Input Btu [kW] Heating Output Btu [kW] Temperature Rise Range °F [°C] AFUE % Steady State Efficiency (%) No. Burners No. Stages Gas Connection Pipe Size in. [mm] 100,000 [29.3] 78,500 [23] 25-55 [13.9/30.6] 80 81 5 1 0.5 [12.7] 135,000 [39.56] 106,500 [31.2] 40-770 [22.2/38.9] 80 81 6 1 0.5 [12.7] Compressor No./Type 1/Copeland Scroll 1/Copeland Scroll Outdoor Sound Rating (dB)4 83 83 Outdoor Coil - Fin Type Tube Type Tube Size in. [mm] OD Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Louvered Rifled 0.375 [9.5] 16.56 [1.54] 2 / 22 [9] Indoor Coil - Fin Type Tube Type Tube Size in. [mm] Face Area sq. ft. [sq. m] Rows / FPI [FPcm] Refrigerant Control Drain Connection No./Size in. [mm] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Corrugated Rifled 0.375 [9.5] 5.17 [0.48] 3 / 15 [6] TX Valves 1/0.75 [19.05] Outdoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds CFM [L/s] No. Motors/HP Motor RPM Propeller 1/24 [609.6] Direct/1 3930 [1855] 1 at 1/3 HP 1075 Propeller 1/24 [609.6] Direct/1 3930 [1855] 1 at 1/3 HP 1075 Indoor Fan - Type No. Used/Diameter in. [mm] Drive Type/No. Speeds No. Motors Motor HP Motor RPM Motor Frame Size FC Centrifugal 1/10x10 [254x254] Direct/3 1 1 1075 48 FC Centrifugal 1/10x10 [254x254] Direct/3 1 1 1075 48 Filter - Type Furnished (NO.) Size Recommended in. [mm x mm x mm] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Disposable Yes (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] Refrigerant Charge Oz. [g] 160 [4536] 160 [4536] Weights Net Weight lbs. [kg] Ship Weight lbs. [kg] 590 [268] 597 [271] 597 [271] 604 [274] NOTES: 1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. ARI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to ±20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on ARI Standard 210/240 or 360. 2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures. 3. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level. 4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270. 31 XIII. MISCELLANEOUS Evaporator Fan Condenser Motor Compressor Motor Unit Information ELECTRICAL DATA – TGC SERIES 036A-3K-080 036A-3K-120 036A-1K-080 036A-1K-120 042A-3K-080 Unit Operating Voltage Range 187-253 187-253 187-253 187-253 187-253 Minimum Circuit Ampacity 19/19 19/19 27/27 27/27 Minimum Overcurrent Protection Device Size 25/25 25/25 35/35 Maximum Overcurrent Protection Device Size 25/25 25/25 40/40 042A-3K-120 042A-1K-080 042A-1K-120 048A-3K-080 187-253 187-253 187-253 187-253 23/23 23/23 28/28 28/28 23/23 35/35 30/30 30/30 35/35 35/35 30/30 40/40 35/35 35/35 45/45 45/45 35/35 No. 1 1 1 1 1 1 1 1 1 Volts 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 Phase 3 3 1 1 3 3 1 1 3 HP 3 3 3 3 3 1/2 3 1/2 3 1/2 3 1/2 4 RPM 3450 3450 3450 3450 3450 3450 3450 3450 3450 Amps (RLA) 10.4/10.4 10.4/10.4 16.7/16.7 16.7/16.7 13.5/13.5 13.5/13.5 17.9/17.9 17.9/17.9 13.7/13.7 Amps (LRA) 88/88 88/88 79/79 79/79 88/88 88/88 112/112 112/112 83.1/83.1 No. 1 1 1 1 1 1 1 1 1 Volts 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 Phase 1 1 1 1 1 1 1 1 1 HP 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3 Amps (FLA) 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Amps (LRA) 3 3 3 3 3 3 3 3 3 No. 1 1 1 1 1 1 1 1 1 Volts 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 Phase 1 1 1 1 1 1 1 1 1 HP 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 Amps (FLA) 4 4 4 4 4 4 4 4 4 Amps (LRA) 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 048A-3K-100 048A-3K-135 048A-1K-080 048A-1K-100 048A-3K-135 060A-3K-100 060A-3K-135 060A-1K-100 060A-1K-135 Unit Operating Voltage Range 187-253 187-253 187-253 187-253 187-253 187-253 187-253 187-253 187-253 Minimum Circuit Ampacity 23/23 23/23 33/33 33/33 33/33 30/30 30/30 43/43 43/43 Minimum Overcurrent Protection Device Size 30/30 30/30 40/40 40/40 40/40 35/35 35/35 50/50 50/50 Maximum Overcurrent Protection Device Size 35/35 35/35 50/50 50/50 50/50 40/40 40/40 60/60 60/60 Evaporator Fan Condenser Motor Compressor Motor Unit Information ELECTRICAL DATA – TGC SERIES 32 No. 1 1 1 1 1 1 1 1 1 Volts 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 Phase 3 3 1 1 1 3 3 1 1 HP 4 4 4 4 4 5 5 5 5 RPM 3450 3450 3450 3450 3450 3450 3450 3450 3450 Amps (RLA) 13.7/13.7 13.7/13.7 21.8/21.8 21.8/21.8 21.8/21.8 15.6/15.6 15.6/15.6 26.3/26.3 26.3/26.3 Amps (LRA) 83.1/83.1 83.1/83.1 117/117 117/117 117/117 110/110 110/110 134/134 134/134 No. 1 1 1 1 1 1 1 1 1 Volts 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 Phase 1 1 1 1 1 1 1 1 1 HP 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3 Amps (FLA) 1.5 1.5 1.5 1.5 1.5 2.2 2.2 2.2 2.2 Amps (LRA) 3 3 3 3 3 4.9 4.9 4.9 4.9 No. 1 1 1 1 1 1 1 1 1 Volts 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 Phase 1 1 1 1 1 1 1 1 1 HP 1/2 1/2 1/2 1/2 1/2 1 1 1 1 Amps (FLA) 4 4 4 4 4 7.6 7.6 7.6 7.6 Amps (LRA) 6.7 6.7 6.7 6.7 6.7 0 0 0 0 Low Med Med Med TGC036A TGC036A TGC036A Cool High Low High 135,000 [39.56] 100,000 [29.31] 100,000 [29.31] 135,000 [39.56] Low Med 80,000 [23.45] Med Low 120,000 [35.17] 80,000 [23.45] Med 80,000 [23.45] Heating Input BTU/hr [kW] 120,000 [35.17] Low Heat Motor Speed From Factory TGC036A Unit Model 1750 / 2250 1400 / 1800 1225 / 1575 1050 / 1350 10x10 1 3 Speed (X-13) 10x10 1/2 3 Speed (PSC) 10x10 1/2 3 Speed (PSC) 10x10 1/2 3 Speed (PSC) Manufacturer Size/ Recommended Blower HP # Air-Flow Range Motor (Min / Max) CFM of Speeds DIRECT-DRIVE BLOWER 208 AIRFLOW PERFORMANCE High Med Low High Med Low High Med Low High Med Low Motor Speed CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts 0.1 1210 450 1515 525 1680 650 1210 450 1515 525 1680 650 1210 450 1515 525 1680 650 1575 297 1985 535 2431 970 0.2 1193 400 1500 515 1650 640 1193 400 1500 515 1650 640 1193 400 1500 515 1650 640 1536 314 1954 553 2372 981 0.3 1175 395 1475 510 1625 630 1175 395 1475 510 1625 630 1175 395 1475 510 1625 630 1496 330 1919 574 2306 964 0.4 1155 385 1450 505 1580 610 1155 385 1450 505 1580 610 1155 385 1450 505 1580 610 1457 347 1876 593 2228 926 0.5 1125 380 1405 490 1530 580 1125 380 1405 490 1530 580 1125 380 1405 490 1530 580 1417 364 1824 606 2138 872 0.6 1075 375 1350 475 1460 560 1075 375 1350 475 1460 560 1075 375 1350 475 1460 560 1377 381 1759 609 2032 806 External Static Pressure-Inches W.C. CFM Air Delivery/RPM/Watts-208 VOLTS 0.7 1015 370 1275 460 1390 545 1015 370 1275 460 1390 545 1015 370 1275 460 1390 545 1338 397 1679 599 1907 736 0.8 925 360 1180 445 1280 515 925 360 1180 445 1280 515 925 360 1180 445 1280 515 1298 414 1581 572 1762 665 INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC DIRECT DRIVE 33 34 Low Med Med Med TGC042A TGC048A TGC060A Cool High Low High Med Low Med Low Med Low Heat Motor Speed From Factory TGC036A Unit Model 135,000 [39.56] 100,000 [29.31] 80,000 [23.45] 100,000 [29.31] 135,000 [39.56] 80,000 [23.45] 120,000 [35.17] 120,000 [35.17] 80,000 [23.45] Heating Input BTU/hr [kW] 1750 / 2250 1400 / 1800 1225 / 1575 1050 / 1350 10x10 1 3 Speed (X-13) 10x10 1/2 3 Speed (PSC) 10x10 1/2 3 Speed (PSC) 10x10 1/2 3 Speed (PSC) Manufacturer Size/ Recommended Blower HP # Air-Flow Range Motor (Min / Max) CFM of Speeds DIRECT-DRIVE 230 AIRFLOW PERFORMANCE High Med Low High Med Low High Med Low High Med Low Motor Speed CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts 0.1 1400 470 1685 635 1870 780 1400 470 1685 635 1870 780 1400 470 1685 635 1870 780 1575 297 1985 535 2431 970 0.2 1375 460 1620 600 1830 760 1375 460 1620 600 1830 760 1375 460 1620 600 1830 760 1536 314 1954 553 2372 981 0.3 1360 455 1580 580 1790 740 1360 455 1580 580 1790 740 1360 455 1580 580 1790 740 1496 330 1919 574 2306 964 0.4 1335 450 1550 570 1730 700 1335 450 1550 570 1730 700 1335 450 1550 570 1730 700 1457 347 1876 593 2228 926 0.5 1305 440 1500 550 1660 660 1305 440 1500 550 1660 660 1305 440 1500 550 1660 660 1417 364 1824 606 2138 872 0.6 1255 435 1430 535 1580 635 1255 435 1430 535 1580 635 1255 435 1430 535 1580 635 1377 381 1759 609 2032 806 External Static Pressure-Inches W.C. CFM Air Delivery/RPM/Watts-230 VOLTS 0.7 1210 425 1350 505 1500 600 1210 425 1350 505 1500 600 1210 425 1350 505 1500 600 1338 397 1679 599 1907 736 0.8 1100 410 1230 475 1375 555 1100 410 1230 475 1375 555 1100 410 1230 475 1375 555 1298 414 1581 572 1762 665 INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC DIRECT DRIVE Low Med High TGC042A TGC048A Cool High Med Low Heat Motor Speed From Factory TGC036A Unit Model 80,000 [23.45] 135,000 [39.56] 80,000 [23.45] 120,000 [35.17] Heating Input BTU/hr [kW] 80,000 [23.45] 120,000 [35.17] 1400 / 1800 1225 / 1575 1050 / 1350 10x10 1/2 3 Speed (PSC) 10x10 1/2 3 Speed (PSC) 10x10 1/2 3 Speed (PSC) Manufacturer Size/ Recommended Blower HP # Air-Flow Range Motor (Min / Max) CFM of Speeds DIRECT-DRIVE 460 AIRFLOW PERFORMANCE High Med Low High Med Low High Med Low Motor Speed Watts CFM Watts CFM 780 1870 635 1685 470 1400 CFM Watts 780 1870 CFM Watts 635 1685 Watts CFM 470 1400 CFM Watts 780 1870 CFM Watts 635 1685 470 1400 Watts CFM Watts CFM 0.1 760 1830 600 1620 460 1375 760 1830 600 1620 460 1375 760 1830 600 1620 460 1375 0.2 740 1790 580 1580 455 1360 740 1790 580 1580 455 1360 740 1790 580 1580 455 1360 0.3 700 1730 570 1550 450 1335 700 1730 570 1550 450 1335 700 1730 570 1550 450 1335 0.4 660 1660 550 1500 440 1305 660 1660 550 1500 440 1305 660 1660 550 1500 440 1305 0.5 635 1580 535 1430 435 1255 635 1580 535 1430 435 1255 635 1580 535 1430 435 1255 0.6 External Static Pressure-Inches W.C. CFM Air Delivery/RPM/Watts-460 VOLTS 0.7 600 1500 505 1350 425 1210 600 1500 505 1350 425 1210 600 1500 505 1350 425 1210 0.8 555 1375 475 1230 410 1100 555 1375 475 1230 410 1100 555 1375 475 1230 410 1100 INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC DIRECT DRIVE 35 36 0.1 0.2 — — 605 620 640 680 1100 1200 1300 1400 1500 340 305 275 250 — — — — 225 255 270 300 340 370 — 615 630 655 675 710 745 920 855 800 750 705 1 2 3 4 5 3.6 - 4.4 PITCH DIAMETER 6 .055 .05 DOWNFLOW ECONOMIZER R. A. DAMPER .06 .060 .07 .066 .060 1400 1600 1800 2000 2200 STANDARD INDOOR AIRFLOW - CFM .08 .072 .09 .080 .085 .10 .086 .100 .11 .093 .110 NOTES: 1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS 2. STANDARD CFM @ .075 LBS./CU. FT. 3. MOTOR EFFICIENCY = 80% 4. BHP = WATTS X MOTOR EFF. 746 5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P. .035 WET COIL .040 1200 .070 1000 MOTOR – 1/2 H.P. - 1750 RPM COMPONENT COMPONENT AIR RESISTANCE 605 1230 1180 1130 1090 1045 1000 940 0 660 590 RESISTANCE - INCHES WATER 665 5 1/2 6.4 PITCH DIAMETER 1090 1080 575 RANGE – 1030 - 1330 MOTOR SHEAVE– 3.4 - 4.4 PITCH DIAMETER BLOWER SHEAVE – 5.7 PITCH DIAMETER “N” DRIVE ( FIELD SUPPLIED) NOTE: Factory sheave settings are shown in bold print. RPM 4 1 3 2.4 - 3.4 PITCH DIAMETER MOTOR SHEAVE TURNS OPEN 2 6.9 PITCH DIAMETER MOTOR H.P. BLOWER SHEAVE “L” 1/2 DRIVE PACKAGE 0 6 .12 .100 .120 2400 .13 .107 .125 2600 .15 .115 .130 2800 905 1290 850 1240 820 1225 760 1185 700 1135 615 1050 565 1005 535 955 490 910 425 845 405 800 “M” 840 1270 810 1230 775 1215 705 1170 650 1125 560 1035 520 990 480 940 440 880 395 825 375 775 1060 540 505 “N” 780 1255 730 1220 680 1195 630 1155 610 1115 530 1025 505 970 455 920 400 855 375 805 340 750 1045 1035 “M” 730 1245 690 1210 655 1180 605 1130 580 1095 495 1005 475 955 415 900 370 835 340 775 305 720 “L” 690 1235 640 1190 615 1170 575 1120 540 1085 485 995 435 940 390 885 345 820 310 760 275 700 485 1330 1320 1300 1290 1270 940 880 825 780 730 715 645 650 1225 605 1180 575 1155 540 1105 515 1075 1025 1260 1240 625 1215 580 1170 555 1140 525 1095 490 1055 470 980 425 925 375 860 320 800 280 740 255 670 470 455 960 400 905 340 845 290 780 260 715 230 650 1010 1.50 RPM WATTS 1.40 RPM WATTS 1.30 RPM WATTS 1.20 RPM WATTS 1.10 RPM WATTS 1.0 0.9 RPM WATTS 0.8 RPM WATTS RPM WATTS 0.7 RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS EXTERNAL STATIC PRESSURE 0.6 0.5 0.4 0.3 NOTE: Bold lines separate L, M and N drives respectively. — 900 RPM WATTS RPM WATTS 1000 AIR FLOW CFM CAPACITY: 3 TON - 13 SEER VOLTAGE: 208/230 - 460 3 TON - 13 SEER MODELS INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC BELT DRIVE 0.1 0.2 — — — — — 725 740 770 1200 1300 1400 1500 1600 1700 1800 500 460 410 — — — — — — — — — — 375 410 445 495 535 — — — — 725 740 765 795 825 875 850 820 795 765 745 725 — — “L” 570 520 470 440 395 360 335 — — RPM WATTS 0.3 958 945 905 865 820 4 2 3 4 5 .055 .05 DOWNFLOW ECONOMIZER R. A. DAMPER .06 .060 .07 .066 .060 1400 1600 1800 2000 2200 STANDARD INDOOR AIRFLOW - CFM .08 .072 .09 .080 .065 .10 .086 .100 .11 .093 .110 NOTES: 1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS 2. STANDARD CFM @ .075 LBS./CU. FT. 3. MOTOR EFFICIENCY = 80% 4. BHP = WATTS X MOTOR EFF. 746 5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P. .035 WET COIL .040 1200 .070 1000 MOTOR – 1/2 H.P. - 1750 RPM COMPONENT COMPONENT AIR RESISTANCE 725 1225 1185 1145 1100 1060 1020 1000 1 4.0 - 5.0 PITCH DIAMETER RESISTANCE - INCHES WATER 770 5 1/2 6.9 PITCH DIAMETER 835 760 700 650 600 RANGE – 1090 - 1365 MOTOR SHEAVE– 4.0 - 5.0 PITCH DIAMETER BLOWER SHEAVE – 6.4 PITCH DIAMETER “N” DRIVE ( FIELD SUPPLIED) NOTE: Factory sheave settings are shown in bold print. RPM 3 1 2 2.8 - 3.8 PITCH DIAMETER MOTOR SHEAVE TURNS OPEN 0 6.9 PITCH DIAMETER MOTOR H.P. BLOWER SHEAVE “L” 1/2 DRIVE PACKAGE 1145 1125 1105 1090 1065 550 .12 .100 .120 2400 .13 .107 .125 2600 .15 .115 .130 2800 — — 1110 1315 1270 960 1225 900 1185 790 1100 750 1045 710 1010 650 980 605 925 6 — 1340 1005 1290 940 1020 1240 865 1205 810 1165 740 1075 690 1020 650 1000 600 945 550 900 0 1005 1325 915 1275 860 1225 800 1185 745 1145 660 1055 640 1015 570 975 540 825 510 875 6 920 1310 860 1260 765 1205 720 1170 690 1135 610 1030 590 1000 540 950 495 905 480 855 “M” 850 1290 790 1245 710 1190 665 1150 640 1120 560 1015 510 965 490 925 460 880 420 830 1050 500 “N” 790 1270 710 1230 650 1180 610 1140 590 1105 510 1005 465 955 445 905 415 860 395 800 1030 “M” 710 1255 650 1215 600 1170 580 1130 540 1090 450 985 440 935 410 885 380 835 350 770 450 — — 1350 1335 1325 1305 1290 — — 1040 980 900 815 760 700 630 640 1240 590 1195 560 1160 520 1120 500 1075 1010 1275 1265 590 1220 550 1185 520 1145 490 1105 455 1060 415 965 400 380 870 355 810 320 750 420 400 945 380 895 915 360 850 325 790 305 735 995 1.50 RPM WATTS 1.40 RPM WATTS 1.30 RPM WATTS 1.20 RPM WATTS 1.10 RPM WATTS 1.0 0.9 RPM WATTS 0.8 RPM WATTS RPM WATTS 0.7 RPM WATTS RPM WATTS RPM WATTS RPM WATTS EXTERNAL STATIC PRESSURE 0.6 0.5 0.4 NOTE: Bold lines separate L, M and N drives respectively. — 1100 RPM WATTS RPM WATTS 1000 AIR FLOW CFM CAPACITY: 3.5 TON - 13 SEER VOLTAGE: 208/230 - 460 3.5 TON - 13 SEER MODELS INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC BELT DRIVE 37 38 CAPACITY: 4 TON - 13 SEER 0.2 — — — — — 775 800 830 1400 1500 1600 1700 1800 1900 2000 595 525 470 — — — — — — — — — — 425 470 515 560 640 — — — — 775 795 820 855 885 940 910 875 850 815 790 770 — — “L” 670 610 555 505 455 425 385 — — RPM WATTS 0.3 1060 1000 955 910 865 4 .055 .05 ECONOMIZER R. A. DAMPER .06 .060 .040 1200 .07 .066 .060 1400 6 1 2 1800 2000 2200 .08 .072 .070 .09 .080 .085 .10 .086 .100 .11 .093 .110 RESISTANCE - INCHES WATER 1600 3 4 5 3.4 - 4.4 PITCH DIAMETER 6 .12 .100 .120 2400 .13 .107 .125 2600 .15 .115 .130 2800 770 1385 1330 1280 1225 1175 1120 1060 0 STANDARD INDOOR AIRFLOW - CFM 825 5 3/4 “M” 5.7 PITCH DIAMETER NOTES: 1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS 2. STANDARD CFM @ .075 LBS./CU. FT. 3. MOTOR EFFICIENCY = 80% 4. BHP = WATTS X MOTOR EFF. 746 5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P. .035 DOWNFLOW 1000 WET COIL COMPONENT COMPONENT AIR RESISTANCE NOTE: Factory sheave settings are shown in bold print. RPM 3 1 2 2.8 - 3.8 PITCH DIAMETER MOTOR SHEAVE TURNS OPEN 0 6.4 PITCH DIAMETER MOTOR H.P. BLOWER SHEAVE “L” 1/2 DRIVE PACKAGE “M” “N” — 950 1160 — 1200 1375 1060 1295 1010 1240 900 1180 860 1115 840 1065 790 1020 710 970 1105 1115 1330 1020 985 1385 870 800 1070 1365 1175 1150 1350 955 1260 920 1220 840 1130 800 1075 755 1035 700 995 650 955 735 1330 890 1235 840 1190 760 1100 740 1050 680 1010 625 960 600 930 1120 680 930 940 1350 915 1305 870 1270 810 1215 770 1165 715 1075 655 1025 605 980 560 940 540 900 1095 640 1010 890 1330 845 1285 800 1235 755 1195 710 1145 660 1050 605 1005 580 960 530 920 495 870 1075 600 1305 825 1315 780 1270 745 1220 700 1175 670 1125 600 1025 550 980 515 940 490 900 475 850 1050 1280 770 1300 730 1245 700 1200 650 1155 615 1105 550 1010 510 960 480 925 445 870 425 825 545 — — — 1385 1370 1355 1345 — — — 1000 935 855 825 775 705 730 1285 685 1235 640 1185 610 1135 590 1085 1030 1335 1320 655 1265 635 1220 600 1170 570 1120 550 1070 510 990 470 450 910 410 855 390 805 505 475 975 440 935 950 410 885 390 835 360 780 1015 1.50 RPM WATTS 1.40 RPM WATTS 1.30 RPM WATTS 1.20 RPM WATTS 1.10 RPM WATTS 1.0 0.9 RPM WATTS 0.8 RPM WATTS RPM WATTS 0.7 RPM WATTS RPM WATTS RPM WATTS RPM WATTS EXTERNAL STATIC PRESSURE 0.6 0.5 0.4 NOTE: Bold lines separate L, M and N drives respectively. — 1300 RPM WATTS RPM WATTS 0.1 VOLTAGE: 208/230 - 460 1200 AIR FLOW CFM 4 TON - 13 SEER MODELS INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC BELT DRIVE 0.2 — — — 780 800 830 860 895 940 970 1015 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 910 825 755 680 615 550 485 455 — — — — — 390 450 470 530 605 655 735 795 880 935 — 780 795 815 850 880 915 945 975 1015 1040 “L” — — 1095 1040 1015 995 955 930 895 870 840 805 795 780 1040 925 830 780 705 655 590 540 490 425 405 370 RPM WATTS 0.3 760 810 875 950 1020 1095 1175 1270 1100 1120 1145 1170 1195 1225 1260 1305 710 775 830 910 980 1050 1140 1215 1055 1070 1105 1130 1155 1180 1225 1260 660 720 790 870 940 1050 1085 1175 1010 1035 1055 1090 1120 1150 1175 1200 615 675 730 820 880 965 1055 1140 965 995 1015 1040 1060 1100 1145 1170 560 640 700 760 830 910 1005 1100 915 945 970 1005 1030 1065 1100 1145 1095 1040 995 2 940 3 890 4 .055 .05 ECONOMIZER R. A. DAMPER .06 .060 .040 1200 .07 .066 .060 1400 2 1800 2000 2200 .08 .072 .070 .09 .080 .085 .10 .086 .100 .11 .093 .110 RESISTANCE - INCHES WATER 1600 3 4 5 .12 .100 .120 2400 .13 .107 .125 2600 .15 .115 .130 2800 780 1405 1360 1305 1250 1195 1145 1095 1 3.4 - 4.4 PITCH DIAMETER - ADJ. 0 STANDARD INDOOR AIRFLOW - CFM 835 5 1 6.4 PITCH DIAMETER NOTES: 1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS 2. STANDARD CFM @ .075 LBS./CU. FT. 3. MOTOR EFFICIENCY = 80% 4. BHP = WATTS X MOTOR EFF. 746 5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P. .035 DOWNFLOW 1000 WET COIL COMPONENT COMPONENT AIR RESISTANCE NOTE: Factory sheave settings are shown in bold print. RPM 1 2.8 - 3.8 PITCH DIAMETER - ADJ. 0 MOTOR SHEAVE TURNS OPEN 6.4 PITCH DIAMETER MOTOR H.P. 6 680 1075 640 1035 605 990 570 940 530 895 BLOWER SHEAVE “L” 3/4 DRIVE PACKAGE 6 640 1060 600 1015 560 965 510 915 470 870 “M” 595 1045 540 995 500 945 440 895 415 840 “M” 1360 1300 1265 1240 1210 1180 1160 1140 1120 1105 1080 540 490 970 460 930 425 875 385 815 1350 1210 1125 1055 995 910 850 785 725 680 615 570 RPM WATTS 1065 RPM WATTS 1030 RPM WATTS RPM WATTS RPM WATTS RPM WATTS 0.9 0.8 0.7 EXTERNAL STATIC PRESSURE 0.6 0.5 0.4 NOTE: Bold lines separate L, M and N drives respectively. — RPM WATTS RPM WATTS 0.1 1400 AIR FLOW CFM CAPACITY: 5 TON - 13 SEER VOLTAGE: 208/230 - 460 — — — — — — — 1390 1400 — — — — — 1375 1315 1370 1255 1340 1400 — — 1320 1405 1260 1230 1350 1175 1310 1375 — — 1225 1385 1180 1140 1320 1100 1275 1360 1200 1400 1150 1370 1060 1290 1020 1250 1100 1120 1385 1075 1350 980 1260 950 1225 1335 1050 1375 1000 1335 915 1245 890 1200 960 985 1365 930 1320 880 1260 850 1225 810 1175 1035 905 1355 855 1300 815 1245 790 1200 755 1160 1320 840 1340 790 1275 750 1225 730 1180 705 1145 1290 775 1320 735 1255 700 1215 675 1165 650 1135 — — — — — — 1405 1390 1375 1365 — — — — — — 1100 1020 940 880 805 745 705 660 645 615 595 1355 RPM WATTS 1340 RPM WATTS 1300 RPM WATTS 1235 RPM WATTS 1195 RPM WATTS 1150 RPM WATTS 1.50 1.40 1.30 1.20 1.10 1.0 1105 5 TON - 13 SEER MODELS INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC BELT DRIVE 39 FIGURE 23 WIRING DIAGRAM 40 FIGURE 24 WIRING DIAGRAM 41 FIGURE 25 WIRING DIAGRAM 42 FIGURE 26 WIRING DIAGRAM 43 FIGURE 27 WIRING DIAGRAM 44 FIGURE 28 WIRING DIAGRAM 45 FIGURE 29 WIRING DIAGRAM 46 FIGURE 30 SYSTEM CHARGE CHARTS 3 TON COOLING - 13 SEER 525 500 115 475 450 425 105 400 95 375 350 85 325 300 75 275 65 250 225 55 200 175 120 125 130 135 140 145 150 155 160 165 170 92-102259-01-01 47 FIGURE 31 SYSTEM CHARGE CHARTS 3.5 TON COOLING - 13 SEER 48 FIGURE 32 SYSTEM CHARGE CHARTS 4 TON COOLING - 13 SEER 49 FIGURE 33 SYSTEM CHARGE CHARTS 5 TON COOLING - 14 SEER SYSTEM CHARGE CHART - REFRIGERANT 410A 5 TON, 14 SEER 525 500 115 475 450 425 105 400 375 95 350 85 325 300 75 275 250 65 225 55 200 175 120 125 130 135 140 145 150 155 160 165 170 92-102259-05-00 50 COOLING TROUBLE SHOOTING CHART ! WARNING DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. SYMPTOM Unit will not run POSSIBLE CAUSE REMEDY • Power off or loose electrical connection • • Thermostat out of calibration-set too high • Failed contactor • • • Blown fuses • Transformer defective • High pressure control open (if provided) • • • • Interconnecting low voltage wiring damaged • • Run or start capacitor failed (single phase only) • Start relay defective 9single phase only) • Loose connection • • • • Compressor stuck, grounded or open motor winding open internal overload. • Low voltage condition • • Low voltage condition • • • • • • • • • • • Recalculate load Check - should be approximately 400 CFM per ton. Charge per procedure attached to unit service panel. Recover refrigerant, evacuate & recharge, add filter drier At compressor terminals, voltage must be within 10% of rating plate volts when unit is operating. • Incorrect voltage • • Defective overload protector • Refrigerant undercharge • • At compressor terminals, voltage must be ± 10% of nameplate marking when unit is operating. Replace - check for correct voltage Add refrigerant • Low evaporator airflow • Increase speed of blower or reduce restriction - replace air filter High head-low vapor pressures • • • • Restriction in liquid line, expansion device or filter drier Flow check piston size too small Incorrect capillary tubes TXV does not open • • • • Remove or replace defective component Change to correct size piston Change coil assembly Replace TXV High head-high or normal vapor pressure - Cooling mode • • • • Dirty condenser coil Refrigerant overcharge Condenser fan not running Air or non-condensibles in system • • • • Clean coil Correct system charge Repair or replace Recover refrigerant, evacuate & recharge Low head-high vapor pressures • Defective Compressor valves • Incorrect capillary tubes • • Replace compressor Replace coil assembly Low vapor - cool compressor iced evaporator coil • Low evaporator airflow • • Operating below 65°F outdoors • Moisture in system • • Increase speed of blower or reduce restriction - replace air filter Add Low Ambient Kit Recover refrigerant - evacuate & recharge - add filter drier • Excessive load • Defective compressor • • Recheck load calculation Replace • TXV hunting • • Air or non-condensibles in system • Check TXV bulb clamp - check air distribution on coil - replace TXV Recover refrigerant, evacuate & recharge Gurgle or pulsing noise at expansion device or liquid line • Air or non-condensibles in system • Recover refrigerant, evacuate & recharge Circulating air blower & inducer run continuously, compressor will not start • Manual reset overtemperature control • tripped • Wire loose in limit circuit • Reset or replace • Check wiring Condenser fan runs, compressor doesn’t Insufficient cooling Compressor short cycles Registers sweat High vapor pressure Fluctuating head & vapor pressures Improperly sized unit Improper airflow Incorrect refrigerant charge Air, non-condensibles or moisture in system Incorrect voltage Check for correct voltage at compressor contactor in control box Reset Check for 24 volts at contactor coil - replace if contacts are open Replace fuses Check wiring-replace transformer Reset-also see high head pressure remedy-The high pressure control opens at 610 PSIG Replace thermostat wiring Replace Replace Check for correct voltage at compressor check & tighten all connections Wait at least 2 hours for overload to reset. If still open, replace the compressor. At compressor terminals, voltage must be within 10% of rating plate volts when unit is operating. Add start kit components 51 FURNACE TROUBLESHOOTING GUIDE (COMBINATION HEATING AND COOLING UNITS WITH DIRECT SPARK IGNITION) ! WARNING HAZARDOUS VOLTAGE DISCONNECT POWER BEFORE LINE VOLTAGE CON- SERVICING. NECTIONS SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN. START SET THERMOSTAT TO CALL FOR HEAT SET FAN SWITCH TO AUTO YES INDUCED DRAFT BLOWER MOTOR STARTS NO • CHECK LINE VOLTAGE TO CONTROL BOARD • CHECK LOW VOLTAGE TRANSFORMER • CHECK WIRING • CHECK FOR 208-230 VAC TO IOM MOTOR REPLACE INTEGRATED CONTROL BOARD (IFC) NO YES YES REPLACE IGNITOR/ CABLE ASSEMBLY REPLACE INDUCED DRAFT BLOWER 15 SECOND PREPURGE YES IGNITOR SPARKS NO YES • CHECK IGNITOR CABLE • CHECK SPARK IGNITOR POSITION AND CONDITION • IS NEGATIVE PRESSURE SWITCH CLOSED? • CHECK FOR OPEN ROLL-OUT CONTROL YES NO NO YES YES • CHECK FOR OPEN LIMIT • CHECK NEGATIVE PRESSURE SWITCH SENSING TUBE • CHECK FOR EXHAUST BLOCKAGE REPLACE NEGATIVE PRESSURE SWITCH • CHECK IGNITION CONTROL CHASSIS GROUND WIRE CHECK FOR EXHAUST, INTAKE OR HEAT EXCHANGER BLOCKAGE AND RESET CONTROL • CHECK WIRING NO REPLACE LIMIT IF UNIT IS COLD REPLACE IGNITION CONTROL NOTE: THE SYSTEM WILL ATTEMPT TO LIGHT 3 TIMES WITH A 60 SECOND INTERPURGE BETWEEN TRIES. IF AFTER THE THIRD TIME THE BURNERS DO NOT LIGHT, THE SYSTEM WILL LOCK OUT. IF THE UNIT IS EQUIPPED WITH A UNITED TECH. OR JOHNSON CONTROLS IGNITION CONTROL, THE SYSTEM WILL ATTEMPT TO LIGHT 3 TIMES EACH HOUR UNTIL THE BURNERS LIGHT OR THE THERMOSTAT IS RESET. MAIN BURNER LIGHTS YES NO • CHECK INLET GAS PRESSURE • CHECK 24 VOLTS TO GAS VALVE • CHECK FOR GAS FLOW TO AND FROM VALVE • CHECK BURNER CARRYOVER YES REPLACE VALVE FLOW CHART CONTINUED ON NEXT PAGE 52 NO REPLACE INTEGRATED CONTROL BOARD (IFC) IF WIRING IS OK NOTE: IF THE SYSTEM GOES INTO LOCKOUT, WAIT 30 SECONDS AND RESET THE SYSTEM. MAIN BURNER FLAME SUSTAINED NO YES • CHECK FLAME SENSOR POSITION AND CONDITION YES REPLACE SENSOR • CLEAN FLAME SENSOR WITH STEEL WOOL • CHECK FLAME SENSOR WIRES AND CONNECTIONS NO REPLACE IGNITION CONTROL INDOOR BLOWER MOTOR STARTS AFTER 30 SECONDS NO • CHECK FOR 208-230 VAC ACROSS BLOWER MOTOR TERMINALS ON CONTROL BOARD NO REPLACE INTEGRATED CONTROL BOARD (IFC) • CHECK CAPACITOR YES YES REPLACE BLOWER MOTOR SYSTEM RUNS UNTIL CALL FOR HEAT ENDS NO • CHECK FOR DIRTY FILTERS • CHECK FOR RESTRICTED AIR-FLOW YES • CHECK FOR OPEN LIMIT • CHECK FOR OPEN ROLL-OUT CONTROL YES YES TURN THERMOSTAT OFF VALVE SHUTS OFF FLAME SHUTS OFF NO • CHECK FOR PROPER THERMOSTAT OPERATION • REMOVE VALVE LEAD AT GAS VALVE IF VALVE CLOSES, RECHECK THE THERMOSTAT AND WIRING. IF OK, THEN REPLACE VALVE CHECK FOR EXHAUST, INTAKE OR HEAT EXCHANGER BLOCKAGE CLEAR BLOCKAGE AND RESET CONTROL YES INDUCED DRAFT MOTOR STOPS AFTER 5 SECOND POSTPURGE NO YES INDOOR BLOWER MOTOR STOPS AFTER 90 SECONDS NO YES TROUBLESHOOTING ENDS • CHECK FOR OPEN LIMIT OR ROLL-OUT CONTROL NO REPLACE INTEGRATED CONTROL BOARD (IFC) YES • CHECK FOR EXHAUST OR INTAKE BLOCKAGE. CLEAR BLOCKAGE AND RESET CONTROL • CHECK FOR DIRTY FILTERS • CHECK FOR RESTRICTED AIRFLOW REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED. 53 54 55 56 CM 0109
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