®
CONTENTS
USER’S, MAINTENANCE
and
SERVICE INFORMATION
MANUAL
SAFETY INFORMATION
FOR YOUR SAFETY . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . 2
THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTERMITTENT IGNITION DEVICE . . . . . . . . . . 2
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 3
TO SHUT DOWN THE FURNACE: . . . . . . . . . . . 3
TO LIGHT THE FURNACE:. . . . . . . . . . . . . . . . . . 3
VENT SAFETY SYSTEM: . . . . . . . . . . . . . . . . . . . 3
100% SHUT OFF: . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLAIN UNIT FUNCTION . . . . . . . . . . . . . . 4
GENERAL MAINTENANCE . . . . . . . . . . . . . . 4
HEATING SYSTEM INSPECTION . . . . . . . . . . . . 4
BURNER AND PILOT CHECK . . . . . . . . . . . . . . . 5
CLEANING BURNERS . . . . . . . . . . . . . . . . . . . . . 5
CLEANING FLUE PASSAGES AND
HEATING ELEMENTS. . . . . . . . . . . . . . . . . . . . . . 5
AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 6
MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONDENSER COIL. . . . . . . . . . . . . . . . . . . . . . . . 7
REGISTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SINGLE PACKAGE
AIR CONDITIONER
GAS/ELECTRIC
The manufacturer recommends that the “User” read all sections of this
manual and keep the manual for future reference.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 7
BEFORE CALLING A SERVICE
TECHNICIAN: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRE OR EXPLOSION HAZARD
REPLACEMENT PARTS . . . . . . . . . . . . . . . . 8
Failure to follow safety warnings exactly
could result in serious injury, death, or
property damage.
- Do not store or use gasoline or other
flammable vapors and liquids in the vicin-
ity of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not
use any phone in your building.
Leave the building immediately.
Immediately call your gas supplier from a
neighbor’s phone. Follow the gas sup-
plier’s instructions.
•
•
•
If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be per-
formed by a qualified installer, service
agency or the gas supplier.
035-18843-000-A-0402
035-18843-000-A-0402
When the room thermostat is satisfied, the electrical
circuit to the gas valve is opened, closing off both main
burner and pilot gas simultaneously. If the pilot burner
should fail to light, contact your heating contractor or
gas utility for service to insure that proper operating
conditions are restored.
VENT SAFETY SYSTEM:
This gas furnace is equipped with an automatic reset
high temperature sensor or rollout switch which in the
unlikely event of a sustained main burner flame rollout
will shut off the flow of gas by closing the main gas
valve. The ignition modules will also be disabled, pre-
venting the flow of gas to the valves. The switch is
located inside the gas heat access panel above the
burner inlet. Flame rollout can be caused by blockage
of the power vent system, improper gas pressure or
adjustment. If this event occurs the furnace will not
operate properly, gas supply to the furnace should be
shut off and no attempt should be made to place the
furnace in operation. The system should be inspected
by a qualified service technician. Refer to Figure 2 for a
typical installation.
INPUT
The correct heat capacity of the furnace is regulated by
the burner orifices and the gas pressure. The proper
orifices are furnished but the gas pressure regulator
must be adjusted by the installer or gas utility service
technician.
OPERATING INSTRUCTIONS
TO SHUT DOWN THE FURNACE:
100% SHUT OFF:
1. Close the main gas shutoff valve(s).
2. Turn off the electric power supply.
The ignition modules are designed for 100% shut-off. If
the furnace fails to ignite within 85 seconds after a call
for heat, the flow of gas (including pilot) will be shut off
and the ignition module will lock out. The module can
be reset by:
TO LIGHT THE FURNACE:
1. Do not attempt to light manually.
2. Open the main gas shutoff valve(s).
A. Turning the system switch on the room thermostat
to the “OFF” position and back to the “HEAT” posi-
tion.
3. Adjust the set point of the room thermostat above
the temperature in the space.
B. Decreasing the set point of the room thermostat
below the temperature in the conditioned space
and returning it to its original setting.
4. Turn on the electric power supply.
5. The draft fan will operate. After an adequate purge
time, the electric spark igniter will light the burners.
C. Opening and closing the unit's main disconnect
switch.
6. The burners will extinguish and relight automatically
upon the demand of the room thermostat.
FIGURE 2: TYPICAL INSTALLATION
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035-18843-000-A-0402
If the furnace continues to lock out, a qualified service
technician should be called to determine the cause of
the problem.
bustion air inlets or vent outlets on your unit. These
provide air for combustion and ventilation. Adequate air
is important to the safe and proper operation of the
unit.
HEATING SYSTEM INSPECTION
It is the owner's responsibility to insure that an annual
inspection of the entire heating portion of the unit is
made by a qualified service technician. This should
include inspection of the burner, heating element and
flue for any corrosion or soot accumulation which may
require cleaning and also checking of burner and con-
trols for proper operation.
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result
in dangerous operation, serious injury, death or prop-
erty damage.
Improper servicing could result in dangerous opera-
tion, serious injury, death or property damage.
In addition, at least once during the heating season,
the owner shall make a visual inspection of the flue out-
let for evidence of black soot or blockage of flue outlet
by leaves or other debris. If any soot is found, it is rec-
ommended a qualified service technician be called
immediately. If any blockage is found, it must be
cleared immediately.
•
•
•
Before servicing, disconnect all electrical power
to furnace.
When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.
Verify proper operation after servicing.
Check for obvious signs of deterioration of the unit.
Check that the return and supply ducts attached to the
unit are sound and air tight. Check that the unit's physi-
cal support, concrete slab or roof curb, is sound and
not in need of repair. Make sure there are no gaps
between the roof curb and the unit where rain could
leak into the building.
PRIOR TO ANY OF THE FOLLOWING MAINTE-
NANCE PROCEDURES, SHUT OFF ALL POWER
TO THE UNIT, TO AVOID PERSONAL INJURY.
Start the furnace. The vent motor should start, the
igniter will start to spark and ignite the pilot flame. After
a short delay the main burner should ignite. If it does
not, contact a qualified service technician for assis-
tance. Check the appearance of the main burner flame.
Adjust burner shutters so no yellow flame is observed
in the heat exchanger tubes. (See Figure 3.) If flame
adjustment cannot be made, obtain the assistance of a
qualified service technician and refer to the PILOT
CHECKOUT and BURNER AIR SHUTTER ADJUST-
MENT sections in the UNIT INSTALLATION INSTRUC-
TION.
EXPLAIN UNIT FUNCTION
When the system is functioning properly, show the
owner the location of all disconnect switches and the
thermostat. Explain how to start and stop the unit and
how to adjust temperature settings within the limitations
of the system. Advise that the flue exhaust hood sur-
face and the immediate area will experience high tem-
peratures during the heating cycle, and that all
unauthorized personnel and debris must be kept away
from this area.
GENERAL MAINTENANCE
In order to insure long and trouble free service from
your system, we recommend periodic inspection,
cleaning, lubrication and adjustment by your installing
Dealer/Contractor. Be sure to ask about this service.
For those who prefer to do-it-yourself, please follow the
instructions listed below to care for your system.
FIGURE 3: TYPICAL FLAME APPEARANCE
BURNER AND PILOT CHECK
Snow or debris should not be allowed to accumulate in
or around the unit. Do not permit overhanging struc-
tures or shrubs to obstruct outdoor air discharge, com-
Periodically (at least annually at the beginning of each
heating season) make a visual check of the pilot and
main burner flame. If necessary, adjust main burner pri-
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Unitary Products Group
035-18843-000-A-0402
mary air shutters to give a distinct, sharp blue flame as
explained under BURNER AIR SHUTTER ADJUST-
MENT. If it is not possible to adjust for the proper flame,
the burners may need cleaning.
10.After brushing is complete, blow all brushed areas
with air or nitrogen. Vacuum as needed.
11.Replace parts in the order they were removed in
Steps 1 thru 5.
CLEANING BURNERS
12.When replacing the center and top of the flue collec-
tor box, be careful not to tear the adjoining insula-
tion.
Remove them from the furnace as explained in
BURNER INSTRUCTIONS section in the Unit Installa-
tion Instructions. Clean burners with wire brush and
vacuum as needed.
13.Ensure that all seams on the vent side of the com-
bustion system are air tight. Apply a high tempera-
ture (+500°F) sealing compound where needed.
CLEANING FLUE PASSAGES AND
HEATING ELEMENTS
With proper combustion adjustment, the heating ele-
ment of a gas fired furnace will seldom need cleaning.
If the element should become sooted, it can be cleaned
as follows:
1. Remove the burner assembly as outlined in
“BURNER INSTRUCTIONS” of the unit installation
instructions.
2. Remove the unit roof from over the gas heat section.
3. Remove the top plate and the top draft blower wheel
from the upper draft blower housing.
FIGURE 4: TYPICAL FLUE BAFFLE
INSTALLATION
4. Remove the screws holding the top of the flue collec-
tor box. Carefully remove the top of the flue collector
box without ripping the adjacent insulation. Then
remove the center divider plate separating the upper
and lower flue boxes.
AIR FILTERS
Units up through 125 MBH input (3-6 Ton) are shipped
with 1" throwaway type air filters. All other units contain
2" filters. The filter racks on 3-6 ton units will receive 1"
or 2" filters. Filters can also be installed in the building
at a suitable return air location if an economizer or out-
side air accessory is not used. Filters must always be
used. They should be inspected once a month and
thoroughly cleaned or replaced if it appears they are
beginning to accumulate excessive dirt. Filter sizes and
quantities are shown in the following table.
5. On the inside of the flue collector box, remove the
flue baffles from the tube interiors. Note the last
bend of the baffle fits tightly against the tube forcing
the end of the baffle to lock into the tube collar. This
collar is formed when the tube is expanded into the
end sheet. To remove, move the end of the baffle
toward the center of the tube releasing the end of the
baffle from the tube collar, then pull straight out of
the tube. Refer to Figure 4.
6. Using a wire brush on a flexible wand, brush out the
inside of each heat exchanger from the burner inlet
and flue outlet ends.
QUANTITY PER UNIT (Nom, Tons)
THROW
15
TON
STD
&
20
TON
STD
&
AWAY
FILTER
SIZES
3 - 6
TON
25 TON STD
EFFICIENCY
15 - 25 TON ULTRA
HIGH EFFICIENCY
7. Brush out the inside of the flue collector box and the
flue baffles.
(Inches)
HIGH
EFF.
HIGH
EFF.
14 x 20
14 x 25
12 x 24
16x 20
16 x 25
18 x 24
2
1
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~
~
~
~
~
~
5
~
~
~
4
4
~
~
~
~
~
8. Run the wire brush down the vent hoods from the
flue collector end.
12
~
12
~
9. If soot build-up is particularly bad, remove the vent
motor and clean the wheel and housings. Run the
wire brush down the flue extensions at the outlet of
the vent housings.
~
~
~
~
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035-18843-000-A-0402
To install the filters, remove the filter access panel
located to the left of the condensate drain connection
as shown in Figure 5.
INDOOR COIL
(2) 14" X 20"
FILTERS
NOTE: Filters must be installed with “Air Flow” arrows
pointing inward -- toward the indoor coil. In the
event the spacers in the filter section are
removed, they must be reinstalled in their origi-
nal position.
CONDENSATE
DRAIN
CONNECTION
(1) 14" X 25"
FILTERS
3 - 6 TON UNIT
Slide filters all the way into the filter racks provided.
When more than one filter in a filter rack is required,
they must butt each other when sliding into position.
Replace the filter access panel.
15 TON
(2) 18" X 24"
FILTERS
20 TON
INDOOR COIL
(4) 16" X 20"
FILTERS
BLOWER ASSEMBLY
CONDENSATE
DRAIN
CONNECTION
20 TON
Even with good filters properly in place, blower wheels
and motors will become dust laden after many months
of operation. The entire blower assembly should be
inspected annually. If the motor and wheel are heavily
coated with dust, they can be brushed and cleaned
with a vacuum cleaner.
(4) 16" X 25"
FILTERS
15 TON
(3) 18" X 24"
FILTERS
15 & 20 TON
STANDARD & HIGH
EFFICIENCY UNITS
These units are supplied with blower shaft bearings
that do not require maintenance but may be relubri-
cated if desired. Every three years, using a low pres-
sure grease gun, pump grease into the bearing grease
fitting until grease just begins to show at the seals. Do
not over lubricate. Use any lithium base grease recom-
mended for ball bearing service.
INDOOR COIL
(6) 12" X 24"
FILTERS
CONDENSATE
DRAIN
CONNECTION
(6) 12" X 24"
FILTERS
25 TON STANDARD EFFICIENCY
15, 17.5, 20, 25 TON ULTRA-HIGH EFFICIENCY UNITS
FIGURE 5: END VIEW LESS FILTER ACCESS
PANEL
Perform all maintenance operations on the blower
motor with electric power disconnected from the unit.
Do not attempt to lubricate bearings with the unit in
operation.
Indoor Blower Motor and Drive - The indoor blower
motor features ball bearings that do not require peri-
odic lubrication. Periodic lubrication of the motor and
bearings can extend the life of components but is
optional.
MOTORS
Outdoor fan motors are permanently lubricated and
require no maintenance.
If desired, every three years, using a low pressure
grease gun, pump grease into the bearing grease fit-
ting until grease just begins to show at the seals. Do
not over lubricate. Use any lithium base grease recom-
mended for ball bearing service.
Ventor motor is factory lubricated for an estimated 10
year life.
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035-18843-000-A-0402
CONDENSER COIL
REGISTERS
An annual check and cleaning, if necessary, of the out-
door coil should be done. Cleaning should be as often
as necessary to keep the coil clean. Clean any debris
and dirt from the outside coil face with a brush being
careful not to damage the fins. If extremely dirty, a hose
can be used to wash the coil from the inside out while
brushing a soapy solution on the outside.
Supply and return air registers must be open when the
unit is in operation. Obstructions must not be allowed
to block airflow in or out of the registers.
TROUBLESHOOTING
BEFORE CALLING A SERVICE PERSON:
A. Check thermostat setting and insure thermostat is
calling for heat or cooling.
B. Check thermostat for lint, etc.
Damage can occur if the bearings are overlubricated.
Use grease sparingly.
C. Check fuses or circuit breakers.
D. Check filters for excessive dust accumulation.
Unitary Products Group
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REPLACEMENT PARTS
OWNER please have your installer fill in the following information immediately after unit has been
installed and properly operating.
Installed by____________________________________________________________________________________________
Installer’s Address ______________________________________________________________________________________
Installation Date________________________________________________________________________________________
Owner’s Name _________________________________________________________________________________________
Owner’s Address _______________________________________________________________________________________
Equipment installed at (address) ___________________________________________________________________________
Model Number ______________________________________ Serial Number _____________________________________
Distributor from whom the equipment was purchased___________________________________________________________
The owner should keep this information in a place where it can be found if needed for warranty purposes.
Subject to change without notice. Printed in U.S.A.
Copyright © by Unitary Products Group 2002. All rights reserved.
035-18843-000-A-0402
Supersedes: Nothing
Unitary
Products
Group
5005
York
Drive
Norman
OK
73069
|