Heat Controller Refrigerator A 13 User Manual

HEAT CONTROLLER

INSTALLATION INSTRUCTIONS

PACKAGE GAS ELECTRIC FEATURING

EARTH-FRIENDLY R-410A REFRIGERANT

TGC***A-13 SEER (3-5 TONS) SERIES

e f r i g e r a n t

92-21916-38-00

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Recognize this symbol as an indi-

cation of Important Safety

Information!

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.

WARNING

THE MANUFACTURER’S WARRAN-

TY DOES NOT COVER ANY DAM-

AGE OR DEFECT TO THE AIR CON-

DITIONER CAUSED BY THE

ATTACHMENT OR USE OF ANY

COMPONENTS, ACCESSORIES OR

DEVICES (OTHER THAN THOSE

AUTHORIZED BY THE MANUFAC-

TURER) INTO, ONTO OR IN CON-

JUNCTION WITH THE AIR CONDI-

TIONER. YOU SHOULD BE AWARE

THAT THE USE OF UNAUTHO-

RIZED COMPONENTS, ACCES-

SORIES OR DEVICES MAY

ADVERSELY AFFECT THE OPERA-

TION OF THE AIR CONDITIONER

AND MAY ALSO ENDANGER LIFE

AND PROPERTY. THE MANUFAC-

TURER DISCLAIMS ANY RESPON-

SIBILITY FOR SUCH LOSS OR

INJURY RESULTING FROM THE

USE OF SUCH UNAUTHORIZED

COMPONENTS, ACCESSORIES OR

DEVICES.

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 sup-

ply and return by relocation of supply and return air access panels. See cover installa-

tion detail.

The units are weatherized for mounting outside of the building.

WARNING

UNITS ARE NOT DESIGN CERTIFIED TO BE INSTALLED INSIDE THE STRUC-

TURE. DOING SO CAN CAUSE INADEQUATE UNIT PERFORMANCE AS WELL

AS PROPERTY DAMAGE AND CARBON MONOXIDE POISONING RESULTING

IN PERSONAL INJURY OR DEATH.

WARNING

INSTALL THIS UNIT ONLY IN A

LOCATION AND POSITION AS

SPECIFIED IN THE LOCATION

REQUIREMENTS AND CONSIDER-

ATIONS SECTION OF THESE

INSTRUCTIONS. PROVIDE ADE-

QUATE COMBUSTION AND VENTI-

LATION AIR TO THE UNIT SPACE

AS SPECIFIED IN THE VENTING

SECTION OF THESE INSTRUC-

TIONS.

The information on the rating plate is in compliance with the FTC and DOE rating for sin-

gle 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 com-

pressor, condenser coil, evaporator coil with thermostatic expansion valve), a circulation

air blower, a condenser fan, a heat exchanger assembly, gas burner and control assem-

bly, combustion air motor and fan, and all necessary internal electrical wiring. The cool-

ing system of these units is factory-evacuated, charged with R-410A refrigerant and per-

formance tested. Refrigerant amount and type are indicated on rating plate.

WARNING

PROVIDE ADEQUATE COMBUS-

TION AND VENTILATION AIR TO

THE UNIT SPACE AS SPECIFIED IN

THE COMBUSTION AND VENTILA-

TION AIR SECTION OF THESE

INSTRUCTIONS.

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 R-

22. 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

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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 R-

22. 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, R-

410A 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.

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VI. UNIT DIMENSIONS

FOR CLEARANCES

SEE FIGURE 7.

FIGURE 1

BOTTOM VIEW

IMPORTANT: THIS UNIT

MUST BE MOUNTED

LEVEL IN BOTH DIREC-

TIONS TO ALLOW WATER

TO DRAIN FROM THE CON-

DENSER SECTION AND

CONDENSATE PAN.

I316

FIGURE 2

CABINET DIMENSIONS AND ACCESS LOCATIONS

I281

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FIGURE 3

CABINET DIMENSIONS AND ACCESS LOCATIONS

I282

FIGURE 4

SUPPLY AND RETURN DIMENSIONS

I288

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VII.INSTALLATION

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.

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:

National Fire Protection Association, Inc.

1 Batterymarch Park

Quincy, MA 02169-7471

www.nfpa.org

WARNING

ALWAYS INSTALL UNIT TO OPER-

ATE WITHIN THE UNIT'S INTEND-

ED TEMPERATURE-RISE RANGE

WITH A DUCT SYSTEM WHICH

HAS AN EXTERNAL STATIC PRES-

SURE WITHIN THE ALLOWABLE

RANGE, AS SPECIFIED IN DUCT-

ING SECTION OF THESE INSTRUC-

TIONS. SEE ALSO UNIT RATING

PLATE.

1. PRE-INSTALLATION CHECK-POINTS — Before attempting any installation, care-

fully 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

WARNING

2. LOCATION CONSIDERATIONS

WHEN A UNIT IS INSTALLED SO

THAT SUPPLY DUCTS CARRY AIR

CIRCULATED BY THE UNIT TO

AREAS OUTSIDE THE SPACE CON-

TAINING THE UNIT, THE RETURN

AIR SHALL ALSO BE HANDLED BY

DUCT(S) SEALED TO THE UNIT

CASING AND TERMINATING OUT-

SIDE THE SPACE CONTAINING

THE UNIT.

The metal parts of this unit may be subject to rust or deterioration in adverse envi-

ronmental 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 petrole-

um 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 water-

front.

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 PER-

SONAL 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 pro-

vide 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 ver-

ified by the equipment manufacturer.

The best protection is frequent cleaning, maintenance and minimal exposure to

contaminants.

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FIGURE 5

WARNING

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 RAT-

ING PLATE MARKING;

• MEANS OF PROVIDING OUT-

DOOR AIR REQUIRED FOR COM-

BUSTION;

• 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 SUB-

STANTIAL COMPLETION OF THE

CONSTRUCTION PROCESS, AND

VERIFY FURNACE OPERATING

CONDITIONS INCLUDING IGNI-

TION, INPUT RATE, TEMPERA-

TURE RISE AND VENTING,

ACCORDING TO THE INSTRUC-

TIONS.

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 PROD-

UCTS 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.

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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

E. CLEARANCES

Location

A - Front

The following minimum clearances must be observed for proper unit performance and

serviceability. Reference Figure 7.

48؆

18؆

12؆*

36؆

60؆

B - Condenser Coil

C - Duct Side

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.

D - Evaporator End

E - Above

*Without Economizer. 57 With Economizer

FIGURE 6

COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW APPLICATION

BEING CONVERTED TO HORIZONTAL

I631

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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, PROP-

ERTY DAMAGE OR DEATH.

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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 indi-

cated. Run ducts as directly as possible to supply and return outlets. Use of non-flam-

mable 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 suffi-

cient 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 CIRCU-

LATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS

CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT COULD

RESULT IN PERSONAL INJURY OR DEATH.

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FIGURE 9

LIFTING DETAIL

SPREADER BAR

LIFTING BEAM

CABLE OR CHAIN

C.G.

5/8؆ SHACKLE

(EACH CORNER)

CORNER WEIGHTS BY PERCENTAGE

22%

27%

23%

28%

I296

FIGURE 10

ROOFCURB

FIGURE 11

ROOFCURB

UNIT

ROOFTOP UNIT

ROOFTOP UNI

HOLD

DOWN

BRACKET

TYP. (4) PLCS.

GASKET

COUNTER FLASHING*

COUNTER FLA

NAILER STRIP

INSULATION*

DUCT*

GASKET

(FULL PERIMETER

AND ON DIVIDERS,

MUST BE ABOVE DUCT

AND INSULATION

PANEL FLANGES.)

CANT STRIP*

ROOF FELT*

ROOF FE

ROOFCURB

INSULATION*

INSULATI

SUPPLY

RETURN

ROOF DECK*

ROOF DE

INSULATION PANELS

(2) SUPPLIED

ROOF

NAILING STRIP

SUPPLY DUCT*

STRUCTURAL

MEMBER*

ER*

TURAL

RETURN DUCT*

*BY CONTRACTOR

ST-A0801-19-01

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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 specifi-

cations 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 possi-

ble.

5. Install an outside ground joint union to connect the gas supply to the control assem-

bly 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 sat-

isfactorily meet the application should be made by a qualified installer, service

agency or the gas supplier, using factory-specified or approved parts. In the com-

monwealth 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 sup-

ply 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 sup-

ply 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

TABLE 1

ROOF OR GROUND LEVEL INSTALLATION

NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Nominal

Equivalent Length of Pipe, Feet

FROM GAS

METER

Iron Pipe

Size,

UNIT GAS SUPPLY

CONNECTION

Inches

⁄

132

MANUAL GAS

SHUT-OFF

VALVE

⁄

278 190 152 130 115 105

520 350 285 245 215 195 180 170

1,050 730 590 500 440 400 370 350

1,600 1,100 890 760 670 610 560 530

1¹⁄

Factory supplied grommet must be utilized.

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In making gas connections, avoid strains as they may cause noise and damage the con-

trols. 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 pres-

sure 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 MANUFAC-

TURER. 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, PER-

SONAL 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

Iron Pipe

Size, Inches

Length of Pipe, Feet

10 20

50 60

80 90 100 125 150

1/2

3/4

1-1/4

1-1/2

275 189 152 129 114 103

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.

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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 con-

trol 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 design-

rated 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

Time in Seconds

(for 1 Cu. Ft.) of Gas

Cu. Ft. Per Hr. Required =

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 ele-

vations 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.

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TABLE 3

FIGURE 16

CONDENSATE DRAIN

METER TIME IN MINUTES AND SECONDS FOR NORMAL

INPUT RATING OF FURNACES EQUIPPED FOR NATURAL

OR LP GAS

METER

SIZE

CU. FT.

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500

MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

INPUT

BTU/HR

ONE

TEN

40,000

60,000

80,000

100,000

13 30 15

15 36 16 30 37 30

ONE

TEN

10 24 11

ONE

TEN

15 18 45

DO NOT OVERTIGHTEN DRAIN FITTING

ONE

TEN

36 15

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 DIS-

CONNECT CLOSEST TO THE UNIT BEFORE ATTEMPTING ANY WIRING. FAIL-

URE 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 dis-

connect 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.

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FIGURE 17

RECOMMENDED BRANCH CIRCUIT DISCONNECT LOCATION

TABLE 4

BRANCH CIRCUIT COPPER WIRE SIZE

(Based on 1% Voltage Drop)*

200

150

100 10

50 14 12 10 10

15 20 25 30 35 40 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 ter-

minals 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 copper-

aluminum 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

AWG Aluminum

Wire Size

Connector Type and Size

(or equivalent)

T & B Wire Nut

#12

#10

# 8

# 6

# 4

#10

# 8

# 6

# 4

# 2

PT2

T & B Wire Nut

PT3

Sherman Split Bolt

TSP6

TSP4

TSP2

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FIGURE 18

FIGURE 19

TYPICAL THERMOSTAT WIRING

I658

WIRE SIZE, AWG

000

CONDUIT SIZE

HOLE SIZE

1/2؆

7/8؆

1/2؆

7/8؆

1/2؆

7/8؆

3/4؆

1؆

1-1/4؆

1-1/2؆

2؆

1-31/32؆ 1-23/64؆ 1-23/64؆ 1-23/32؆ 1-23/32؆ 1-31/32؆ 1-31/32؆ 2-15/32؆ 2-15/32؆

NOTES: 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

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

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TABLE 6

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.0

2.5

2.0

100

150

200

250

300

Length of Run – Feet (1)

(1) The total wire length is the distance from the furnace to the thermo-

stat 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 sec-

ond 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 moni-

tored 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.

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If the control detects the following failures, the LED will flash on for approximately 1/4 sec-

ond, 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 EXPLO-

SION 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 auto-

matically 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 suppli-

er’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 ELECTRI-

CAL 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.

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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 com-

bustion 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 combus-

tion 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 maxi-

mum 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 ther-

mostat operation.

6. Except for the mounting platform, keep all combustible articles three feet from the unit

and exhaust system.

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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 suppli-

er 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.

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WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPT-

ING 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 instruc-

tions, 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 ATTEMPT-

ING 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 solu-

tion. 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.

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4. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solu-

tion. 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.

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SPEED TAP BLOCK

FIGURE 22

FIGURE 20

FIGURE 21

INTEGRATED FURNACE

CONTROL

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FIGURE 22 (Continued)

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XII. GENERAL DATA - TGC MODELS

NOMINAL SIZES 3-5 TONS [10.6-17.6 kW]

Model TGC-Series

Cooling Performance¹

036A3K-080

036A-3K-120

036A-1K-080

036A-1K-120

Continued ->

Gross Cooling Capacity Btu [kW]

EER/SEER²

36,800 [10.78]

11.4/13

36,800 [10.78]

11.4/13

36,800 [10.78]

11.4/13

36,800 [10.78]

11.4/13

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

1200/1200 [566/566]

35,400 [10.37]

26,200 [7.68]

9,200 [2.7]

1200/1200 [566/566]

35,400 [10.37]

26,200 [7.68]

9,200 [2.7]

1200/1200 [566/566]

35,400 [10.37]

26,200 [7.68]

9,200 [2.7]

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 %

80,000 [23.44]

64,800 [18.99]

30-60 [16.7/33.3]

120,000 [35.16]

97,200 [28.48]

50-80 [27.8/44.4]

80,000 [23.44]

62,500 [18.31]

30-60 [16.7/33.3]

120,000 [35.16]

94,500 [27.69]

50-80 [27.8/44.4]

Steady State Efficiency (%)

No. Burners

No. Stages

Gas Connection Pipe Size in. [mm]

0.5 [12.7]

Compressor

No./Type

Outdoor Sound Rating (dB)⁴

1/Scroll

1/Copeland Scroll

Outdoor Coil - Fin Type

Tube Type

Louvered

Rifled

Louvered

Rifled

Louvered

Rifled

Louvered

Rifled

Tube Size in. [mm] OD

Face Area sq. ft. [sq. m]

Rows / FPI [FPcm]

0.375 [9.5]

16.91 [1.57]

1 / 22 [9]

0.375 [9.5]

16.91 [1.57]

1 / 22 [9]

0.375 [9.5]

16.91 [1.57]

1 / 22 [9]

0.375 [9.5]

16.91 [1.57]

1 / 22 [9]

Indoor Coil - Fin Type

Tube Type

Corrugated

Rifled

Corrugated

Rifled

Corrugated

Rifled

Corrugated

Rifled

Tube Size in. [mm]

Face Area sq. ft. [sq. m]

Rows / FPI [FPcm]

0.375 [9.5]

5.17 [0.48]

2 / 17 [7]

0.375 [9.5]

5.17 [0.48]

2 / 17 [7]

0.375 [9.5]

5.17 [0.48]

2 / 17 [7]

0.375 [9.5]

5.17 [0.48]

2 / 17 [7]

Refrigerant Control

Drain Connection No./Size in. [mm]

TX Valves

1/0.75 [19.05]

TX Valves

1/0.75 [19.05]

TX Valves

1/0.75 [19.05]

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

FC Centrifugal

1/10x10 [254x254]

Direct/3

FC Centrifugal

1/10x10 [254x254]

Direct/3

FC Centrifugal

1/10x10 [254x254]

Direct/3

FC Centrifugal

1/10x10 [254x254]

Direct/3

Motor HP

1/2

Motor RPM

Motor Frame Size

1075

Filter - Type

Disposable

Furnished

Yes

(NO.) Size Recommended in. [mm x mm x mm]

(1)1x16x25 [25x406x635]

Refrigerant Charge Oz. [g]

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

GENERAL DATA - TGC MODELS

NOMINAL SIZES 3-5 TONS [10.6-17.6 kW]

Model TGC-Series

Cooling Performance¹

042A-3K-080

042A-3K-120

042A-1K-080

042A-1K-120

Continued ->

Gross Cooling Capacity Btu [kW]

EER/SEER²

42,500 [12.45]

11.2/13

42,500 [12.45]

11.2/13

42,500 [12.45]

11.2/13

42,500 [12.45]

11.2/13

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

1400/1450 [661/684]

40,500 [11.87]

30,600 [8.97]

9,900 [2.9]

1400/1450 [661/684]

40,500 [11.87]

30,600 [8.97]

9,900 [2.9]

1400/1450 [661/684]

40,500 [11.87]

30,600 [8.97]

9,900 [2.9]

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 %

80,000 [23.44]

64,800 [18.99]

30-60 [16.7/33.3]

120,000 [35.16]

97,200 [28.48]

50-80 [27.8/44.4]

80,000 [23.44]

62,500 [18.31]

30-60 [16.7/33.3]

120,000 [35.16]

94,500 [27.69]

50-80 [27.8/44.4]

Steady State Efficiency (%)

No. Burners

No. Stages

Gas Connection Pipe Size in. [mm]

0.5 [12.7]

Compressor

No./Type

Outdoor Sound Rating (dB)⁴

1/Copeland Scroll

1/Scroll

Outdoor Coil - Fin Type

Tube Type

Louvered

Rifled

Louvered

Rifled

Louvered

Rifled

Louvered

Rifled

Tube Size in. [mm] OD

Face Area sq. ft. [sq. m]

Rows / FPI [FPcm]

0.375 [9.5]

16.91 [1.57]

1.53 / 22 [9]

0.375 [9.5]

16.91 [1.57]

1.53 / 22 [9]

0.375 [9.5]

16.91 [1.57]

1.53 / 22 [9]

0.375 [9.5]

16.91 [1.57]

1.53 / 22 [9]

Indoor Coil - Fin Type

Tube Type

Corrugated

Rifled

Corrugated

Rifled

Corrugated

Rifled

Corrugated

Rifled

Tube Size in. [mm]

Face Area sq. ft. [sq. m]

Rows / FPI [FPcm]

0.375 [9.5]

5.17 [0.48]

3 / 13 [5]

0.375 [9.5]

5.17 [0.48]

3 / 13 [5]

0.375 [9.5]

5.17 [0.48]

3 / 13 [5]

0.375 [9.5]

5.17 [0.48]

3 / 13 [5]

Refrigerant Control

Drain Connection No./Size in. [mm]

TX Valves

1/0.75 [19.05]

TX Valves

1/0.75 [19.05]

TX Valves

1/0.75 [19.05]

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

FC Centrifugal

1/10x10 [254x254]

Direct/3

FC Centrifugal

1/10x10 [254x254]

Direct/3

FC Centrifugal

1/10x10 [254x254]

Direct/3

FC Centrifugal

1/10x10 [254x254]

Direct/3

Motor HP

1/2

Motor RPM

Motor Frame Size

1075

1725

Filter - Type

Disposable

Furnished

Yes

(NO.) Size Recommended in. [mm x mm x mm]

(1)1x16x25 [25x406x635]

Refrigerant Charge Oz. [g]

125 [3544]

Weights

Net Weight lbs. [kg]

Ship Weight lbs. [kg]

570 [259]

577 [262]

579 [263]

586 [266]