Heat Controller Refrigerator A-13 Installation instructions

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Heat Controller Refrigerator A-13 Installation instructions | Manualzz
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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