Carrier 48KHA User Manual

Page 1
48KHA,KLA
Packaged Heating/Cooling Units
Installation, Start-Up and Service Instructions
NOTE TO INSTALLER: After installation, leave these instructions, Owner’s Manual and Peurts Replace
ment Guide with equipment owner.

CONTENTS

Page

SAFETY CONSIDERATIONS

GENERAL..........................................................................1,2
INSTALLATION
Step 1—Rig and Place Unit..............................................2-4
.................................................................
1
2-8
• ROOFTOP INSTALLATION
• GROUND LEVEL INSTALLATION
• CLEARANCES
• CONDENSATE DISPOSAL
• VENTING
Step 2—Make Gas Piping Connections
Step 3—Make Duct Connections........................................6
Step 4—Make Wiring Connections
..........................
.................................
5,6 6,7
• HIGH-VOLTAGE CONNECTIONS
• SPECIAL PROCEDURES FOR 208-V OPERATION
• LOW-VOLTAGE CONNECTIONS
• HEAT ANTICIPATOR SETTING
START-UP........................................................................9-16
SERVICE........................................................................16-19
TROUBLESHOOTING CHARTS
SAFETY CONSIDERATIONS
...................................
20,21

A WARNING

Improper installation, adjustment, eJteration, service, maintenance or use can cause carbon monoxide poison ing, explosion, fire, electric shock or other occurrences which may injure you or damage your property. Con sult a qualified instedler, service agency or the gas sup
plier for information or assistance.
NOTE: Installation of this unit must conform to the guide
lines presented in these Installation Instructions. Read and become familiar with this publication before starting installation.
Only trained, qualified installers and service mechanics should install, start-up and service this equipment. Consult the User’s Manual for routine maintenance. All other opera tions should be performed by tredned service personnel,
personnel.
• Follow all safety codes.
• Wear safety glasses and work gloves.
• Use care in handling, rigging and setting bulky equip ment.
• Observe precautions in these instructions and on equip ment tags, stickers and labels.
* •

A WARNING

Do not disconnect electric power to this appliance with out first turning off gas supply. Be sure power to equip ment is shut off before meuntenance or service.
Fig. 1—Model 48KHA,KLA
GENERAL
Models 48KHA,KLA packaged gas/electric units (Fig. 1) eire design certified in accordance with ANSI Z21.47B-1986, ARI Standeird 210-81 and ARI Stemdard 270-84. The units are design certified by the American Gas Association (AGA) for use with natural or propane gases with appropri ate controls or orifices. See Table 1 for heating input rat ings. Models 48KHA,KLA units are fully self-contedned, combination gas-heating/electric-cooling units designed for outdoor installation on either a rooftop or ground-level slab. May be instedled directly on wood flooring or on Class A, Class B or Class C roof covering materials.
These units are equipped with an energy-saving automatic, intermittent, electric spark ignition system that does not have a continuously burning pilot. All units are manufac tured with natural gas controls.
Units with number 1 in the 4th digit location of model num ber in Table 1 meet California oxides of nitrogen (NOx) max imum emission requirements.
Units are factory charged with R-22 refrigerant. To install: connect gas supply, air ducts, high- and low-voltage wiring and condensate drain, and install a field-supplied air filter in the return-air ductwork.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.
BookI 1 I 4 PC 101 Cataiog No 534-862 Printed in USA Form 48KH,KL-19Si Pg 1 1-88 Replaces: 48KH,KL-17SI Tab ila 11a For replacement items contact distributor.
Page 2
Table 1—Performance Data
COOLING
MODEL 48-
KLA118310BE KLA124310BE
KHA024310BF KLA130310BE
KHA030310BF KLA136310BE
KLA136510CE KLA136610CE KHA136310BE KHA136S10CE KHA036310BF
KHA036510CF KLA142310BE
KLA142510CE KHA042310BF KHA042510CF
KLA148310BE KLA148510CE KLA148610CE KHA048310BE KHA048510CF
KLA160310BE KHA060310BF
♦Rated in accordance with U S. Government D.O.E. test procedures and/
or ARI Standard 210-81.
tSound rating per ARi 270-84. tThe capacity ratings of singie-phase units are in accordance with U.S.
Government D.O.E. test procedures and/or AGA certification require ments. For 3-phase units, the efficiency rating is a product thermai effi ciency rating determined under continuous operating conditions, inde pendent of any installed system.
CAPACITY
(Btuh)*
17,800 40,000 32,000 23,800 40,000
24,000 75,000 29,600
29,600 75,000 58,000 36,000 60,000
36,000 36,000 60,000 36,000 36,000 36,000 36,000
42,000 60,000 42,000 60,000 42,000 42,000 125,000
49,000 49,000 49,000 49,000
49,000 60,000
60,000
RATED
HEATING
INPUT (Btuh)
40,000 32,000
60,000
100,000 79,000 100,000 75,000 125,000 125,000
125,000 97,000
80,000 63,000 80,000 60,000
80,000 60,000 125,000 97,000 125,000 93,750 8.4*
100,000* 79,000* 8.4* 150,000* 116,000* 8.4*
OUTPUT
CAPACITY
(Btuh)
32,000 58,000
47,000 45,000 45,000
97,000 93,750
47,000 45,000
93,750
ARI* SOUND RATING
(Bels)
7.8
7.8
8.0
7.8
7.8
8.0
8.0
8.0
8.0
8.0
8.0
8.0 78
7.8
7.8
7.8
8.4*
8.4*
8.4*
8.4*
SPREADER OARS' ^
(2)2x4xUNIT LENGTH PLUS 10"WITH
11 DEEP 90° NOTCHES EACH END
(2) 2x4xUNIT WIDTH WITH l^
DEEP 90° NOTCHES
EACH END
LOCATE CHAINS THROUGH HOLES IN BASE
CHANNELS
Fig. 2—48KHA,KLA Suggested Rigging
INSTALLATiON
Step 1—Rig and Place Unit

A CAUTION

SPREADER BARS
TWO OR THREE BASE CHANNELS ATTACHED TO BOTTOM OF UNIT
CHAIN
All units can be connected into existing duct systems that are properly sized and designed to handle an airflow of 350
to 450 cfm per each 12,000 Btuh of rated cooling capacity.
See Table 8 for cooling euid heating airflow requirements.
NOTE: When insteJling any accessory item, see Installation
Instructions packaged with accessory.
IMPORTANT-
READ BEFORE INSTALLING
1. This instEdlation must conform with all applicable local and nationed codes.
2. Power supply (volts, hertz and phase) must corre spond to that specified on unit rating plate.
3. Electrical supply provided by utility must be suffi cient to handle load imposed by unit.
4. Refer to Fig. 4 for locations of gas inlet, electrical inlets, condensate drain, duct connections, and required clearances before setting unit in place.
5. Locate unit where vent cap will be a minimum of 4 ft from openable windows or doors.
6. Installation must conform with local building codes and with National Fuel Gas Code, NFPA 54-1984/ ANSI Z223.1-1984.
IMPORTANT: On some models, the high-voltage igni tion cable is not connected to the spark generator termi nal on the control head/gas valve assembly when shipped from the factory. The cable is fastened to the manifold on these models. Push the boot toward center of the cable to expose the connector on the end of the cable. Attach the connector securely to the terminal on the end of the con trol head/gas vedve assembly. Push the boot over connec tor to insulate the high-voltage connection.
When rigging unit to be hfted, use spreader bars to pro tect top and sides. Rig unit as shown in Fig. 2. Use extreme caution to prevent damage when moving unit. Unit must remain in upright position during all rigging and moving operations. Unit must be level for proper condensate drainage; therefore, the ground-level pad or accessory roof-mounting curb must be level before set
ting unit in place. When a field-fabricated support is used, ensure that support is level and properly supports unit and plenum.
ROOFTOP INSTALLATION

A CAUTION

When installing a unit on a rooftop, be sure roof will
support the additioneil weight. Refer to Fig. 4 to obtain
total weight and corner weight information.
When installing a Model 48KHA,KLA end discharge unit with a field-supplied downflow plenum, a field-supplied roof mounting curb must be installed on emd flashed into roof before unit installation. When installing a Model 48KHA,KLA end discharge unit without a downflow ple num, place unit on a level base that provides proper sup port. On flat roofs be sure unit is located at least 4 in. above highest expected water level on roof to prevent flooding. Consult local codes for additional installation requirements.
GROUND LEVEL INSTALLATION-Place unit on a solid, level concrete pad that is a minimum of 4 in. thick and that extends approximately 2 in. beyond casing on all sides of unit. Do not secure unit to pad except when required by local codes.
CLEARANCES—Required minimum operating and service clearances are shown in Fig. 4 for providing adequate com bustion, ventilation emd condenser edr.
Page 3

A CAUTION

Do not restrict condenser airflow. An air restriction at either outdoor-edr inlet (the entire surface of the outdoor coil) or fan discharge can be detrimental to compressor life.
Condenser fan discharges through top of unit. Ensure that fan discharge does not recirculate to condenser coil. Do not locate unit in either a corner or under a complete overhead obstruction. Minimum clearance under a partial overhang (such as a typical house roof overhang) is 3 ft above vent cap. Maximum horizontal extension of a partial overhang must not exceed 4 feet.
Do not locate unit where water, falling ice or snow from an
overhang or roof will damage or flood the unit. Do not locate
unit where grass, shrubs, or other plants will interfere with
the airflow either into or out of unit. Do not install unit on carpeting, tile or other combustible material other than wood flooring.
CONDENSATE DISPOSAL
NOTE: Be sure condensate water disposed methods comply
with local codes, restrictions and practices. Models 48KHA,KLA dispose of condensate water through
a %-in. MPT drain fitting. See Fig. 4 for location.
Install a 3-in. trap at the drain fitting to ensure proper drainage. See Fig. 3. Make sure trap outlet is at least 2 in. lower than unit dredn pan connection to prevent pan from overflowing. Prime trap with water.
TO DRAIN
Fig. 3—Condensate Trap
If installation requires draining the condensate water away from unit, connect a dredn tube using a minimum of 7s-in. OD copper tubing, %-in. galvanized pipe or 7s-in. plastic pipe. Do not undersize the tube. Pitch drain tube downward at a slope at least one in. for every 10 ft of horizontal run. Be sure to check drain tube for leaks.
Condensate water can be drained directly onto roof in roof
top installations (where permitted) or onto a gravel apron in ground level installations. When using a gravel apron, make
sure it slopes away from the unit.
VENTING—The vent cap, combustion air shroud and flue
assembly are shipped in either the blower or control com
partment. Vent screen is taped to blower housing. Remove
access doors to locate assemblies. See Fig. 4 for door
locations.
A CAUTION
Venting system is designed to ensure proper venting. Vent cap assembly must be installed as indicated below.
NOTE: Screw holes in flue assembly and unit top eire posi
tioned to ensure proper orientation when installed. Refer to
Fig. 5 emd instedl vent cap as follows:
1. Place combustion air shroud over combustion air open ing in unit top, and line up screw holes in shroud with holes in top. Secure shroud to top, using screws with
rubber washers (provided).
2. The flue gasket is shipped in the literature assembly envelope. Place gasket and flue assembly through hole in combustion air shroud, orient screw holes in base of flue assembly with holes in unit top, and secure gasket
and flue assembly to unit top, using screws provided.
3. Form flat wire screen (provided) into circular shape around protruding lip of combustion-air shroud and bend wire ends through holes of screen mesh to secure screen in place. Make sure that no sharp edges are left exposed.
4. Place vent cap sleeve inside flue assembly. Orient spring chp of vent cap with slot in assembly. Be sure clip snaps into slot to secure clip onto assembly.
Page 4
i MPT / U-—G
DRAIN CONN
PLUGGED ACCESS HOLE FOR REFRIGERANT PRESSURE GAGE HOSES
*NOTON MODELS48KLAII8THROUGH
I36i KHA024 THROUGH 030
CONTROL ACCESS DOOR
BLOWER ACCESS DOOR
I LOW VOLTAGE
INLET
K HIGH VOLTAGE INLET
T-4Í
C> EVAPORATION AIRFLOW ^CONDENSER AIRFLOW
VENT CAP COMBUSTION AIR INLET BOX
■NOT ON MODELS 48KLAII8 THROUGH 136; KHA024 THROUGH 030
MODEL 48-
Dimensions
(ft-in.)
A B C D E F G H J K
L M N
MODEL
48-
KLA118 82 KLA124 KHA024 KLA130 KHA030 97 KLA136 KHA136 122 KHA036 KLA142 KHA042 KLA148 130 135 137 KHA048 134 139 144 KLA160 KHA060
KLA118 KLA124
4-5% 4-5% 5-5% 2-6% 3-4% 3-8%
3-2'/a
1-4 1-7 2-0 1-4 1-4
0-7'/4
0-11% 0-10% 0-10%
1-3’A
0-1 %2 0-1% 0-1% 0-1%
0-1%
0-47,6
1-10 2-4 2-4
CORNER WT (ib)
A B
83 81 96 94 97 93
98 97 92
122 120 116 117 475 485 108 105 102 113 111 107
148 144 139 155 151
C D
79
93 91 94 375 385
120 116 117
148 151 605
KHA024
KLA130
KHA030
KLA136
3-57s 3-107e
0-8?8 1-374 1-874
0-17e 0-67,6
79 81 320 330
82
79 91 94 375 385 90 92 372 382
93 380
105 420 109 440 133 535 138 555 144 575
KHA136 KHA036 KLA142 KHA042
1-174 0-8%
1-1 O'732
1-4
0-87,6 0-87,6
TOTAL
OPERATiNG
WT (ib)
325 335
475
KLA148 KHA048 KLA160 KHA060
6-0% 3-8% 4-6%
2-8
1-174 0-8%
0-11%
1-8%
2-0=»/32
1-5
2-4
TOTAL
SHiPPING
WT (ib)
390 485
430 450 545 565 585 615
Above flue vent........................................................................................................3-0
Duct side of unit .....................................................................................................0-6
Side opposite ducts................................................................................................2-6
Biower access panel side. Side opposite biower access panel.
Bottom of unit.................................................
NOTE: Provision must be made for fresh ambient air to reach the
outdoor coil without recirculation of the air from the outdoor fan discharge

Weight Data

VIEW AA
CLEARANCES (ft-in.)
2-6 2-6
0

Fig. 4—Dimensions and Ciearances (ft-in.)

Page 5
Fig. 5—Vent Cap Assembly
COMBUSTION-AIR SHROUD
CONTROL TRANSFORMER
COMPRESSOR CONTACTOR
GAS INLET PRESSURE TAP (BACK SIDE)
‘GAS PIPE
ENTRANCE HOLE
REGULATOR
LOW VOLTAGE SECONDARY p. pf'TpoNIC \
WIRES air SHIELD ^^)n7rOL GAS VALVE
HEAD
ADJUSTING SCREW
Fig. 6—Model 48KLA136—Side View
(Partiai) with Access Doors Removed
2. Protect all segments of piping system against physiceJ and thermal deimage. Support all piping with appropri ate hangers, etc. Use a minimum of one hanger in every 6 feet. For pipe sizes larger them V2-in., follow recom mendations of national codes.
Apply joint compound (pipe dope) speiringly and only
3. to male threads of joint when meiking pipe connections. Use only pipe dope that is resistant to action of lique fied petroleum gases as specified by local and/or nationeJ codes. Never use pipe thread tape.
InsteJl a sediment trap in riser leading to the heating
4. section. See Fig. 7. This drip leg functions as a trap for dirt and condensate. Install trap where condensate can not freeze. Install this sediment trap by connecting a piping tee to riser leading to heating section, so that straight-through section of tee is vertical. Then, con nect capped nipple into lower end of tee. Extend capped nipple below level of gas controls.
Step 2—Make Gas Piping Connections—A manual shutoff
vedve is shipped loose in the burner compartment or blower compartment. Connect one end of a field-supplied V2-in. streught nipple to the gas valve inlet. Connect the other end of the nipple to the manual shutoff valve as shown in Pig. 6. The gas supply pipe enters unit through access hole pro vided. See Fig. 4 for location. The gas connection to unit is made to the V2-in. FPT gas inlet on manual shutoff. See Fig. 6 for inlet location.
Install a separate gas supply line that runs directly from meter to heating section. Do not use cast-iron pipe. Check local utility for recommendations concerning existing lines. Choose a supply pipe that is large enough to keep pressure loss as low as practical. Never use pipe smaller than the ^¡¿-in.
FPT gas inlet on unit manual shutoff.
When installing gas supply line, observe local codes pertain ing to gas pipe installations. Refer to National Fuel Gas Code, NFPA 54-1984/ANSI Z223.1-1984 in absence of local building codes. Adhere to following pertinent recom mendations:
1. Avoid low spots in long runs of pipe. Grade all pipe %- in. in every 15 ft to prevent traps. Grade all horizonteJ runs downward to risers. Use risers to connect to heat ing section and to meter.
Fig. 7—Sediment Trap
5. Install an accessible, external, manual shutoff valve in gas supply pipe within 6 ft of heating section.
NOTE: The unit manual shutoff valve has a Vs-in. tap
ping on the inlet side of this shutoff for measuring gas input pressure.
6. Install ground-joint union close to heating section between unit manual shutoff and external manual main shutoff valve.
Page 6
7. Pressure-test all gas piping in accordance with loceil and national plumbing and gas codes before connecting
piping to unit.
NOTE: When pressure-testing the gas supply system
after the gas supply piping has been connected to the unit gas valve, the supply piping must be disconnected from the gas valve during any pressure testing of the piping systems at test pressures in excess of 0.5 in. psig. When pressure testing the gas supply piping sys tem at test pressures equal to or less than 0.5 in. psig, the unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening ground-joint union.

A CAUTION

Unstable operation may occur, peirticularly under high­wind conditions, when gas valve and manifold assembly are forced out of position while connecting improperly routed, rigid gas piping to gas valve. Use a backup wrench when making connection to avoid strain on, or distortion of, gas control piping.
2. Use a flexible transition between rigid ductwork and unit to prevent transmissions of vibration. The transi tion may be screwed or bolted to duct flanges. Use suit able gaskets to ensure a weathertight and air-tight
seal.
3. Install external, field-supplied air filter(s) in return-air ductwork where it is easily accessible for service. Rec ommended filter sizes are shown in Table 2.
4. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases.
5. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through an unconditioned space, and use a vapor barrier in accord ance with the latest issue of SMACNA and NE SC A minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure.
6. Flash, weatherproof and vibration-isolate all openings in building structure in accordance with local codes and good building practices.
8. Where permitted by local codes, use an approved corru gated metal tubing gas connector between rigid gas
piping and unit manual shutoff.

A WARNING

Never use a match or other open flame when checking for leaks. Failure to adhere to this warning may cause an explosion.
9. Check for gas leeiks at eJl field-installed and factory­installed gas lines after all piping connections have been completed. Use soap-and-water solution (or method specified by local codes and/or regulations).
Step 3—Make Duct Connections—Model 48KHA,KLA
has duct flanges on the supply- and return-air openings on side of unit. See Fig. 4 for connection sizes and locations.

A WARNING

The design and installation of duct system must be in
accordance with standards of National Fire Protection Association for installation of non-residence type air conditioning and ventilating systems. NFPA No. 90; or residence-type NFPA No. 90B; and/or local codes and ordinances.
Table 2—Filter Sizes (Field Supplied),
(Sq In.)*
MODEL 48-
KLA118310BE KHA024310BF KLA124310BE
KHA030310BF
KLA130310BE KHA036310BF
KHA136510CE KHA036510CF KHA136310BE KLA136510CE
KLA136610CE KLA136310BE
KHA042310BF 694 KHA042510CF 694 KLA142510CE KLA142310BE 672
KHA048310BF 768 KHA048510CF 768 KLA148510CE 768 KLA148610CE KLA148310BE
KHA060310BF 960 KLA160310BE 960
*Required air filter areas shown are based on the ARI-rated cooling air
flow or the heating airflow at a velocity of 300 fpm depending on whichever value is larger. Air filter pressure drop should not exceed 0 08
, in wg
STANDARD CLEANABLEOR
DISPOSABLE HIGH CAPACITY
TYPE
302 202 454 384 257
480 320 480 320
694 576 694 576 576 576 384 576 384
672
768 512 768 512
TYPE
303
462 384 462 384 384
462 462 448 448
512 512 512
640 640

Step 4—Make Wiring Connections

Adhere to the following requirements when selecting, sizing tmd installing duct system;
1. Select and size ductwork, supply-air registers and return-£ur grilles according to ASHRAE recommenda tions emd as presented in Carrier System Design Man ual, Part 2.

A CAUTION

When duct system fastening holes are drilled into side
of Model 48KHA,KLA instead of the unit duct flanges,
use extreme care to avoid puncturing coil or coil tubes.

A WARNING

Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personeil injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with National Electrical Code ANSI/NFPA 70-1984 and local electriced codes. Do not use gas piping as an elec
trical ground. Failure to follow this warning could result in the installer being held liable for personal injury of others.
Page 7
A CAUTION
Feiilure to follow these precautions could result in dam age to unit being installed.
1. Make all electrical connections in accordance with National Electrical Code ANSI/NFPA 70-1984 and local electrical codes governing such wiring.
2. Use only copper conductor for connections between the field-supplied electrical disconnect switch and the unit.
Do not use aluminum or copper-clad aluminum wire.
3. Ensure that high-voltage power to unit is within oper ating voltage range indicated on unit rating plate. On 3-phase units, ensure that phases are balanced within 2%. Consult local power company for correction of improper voltage and/or phase balance.
4. When low-voltage control wires are run in same conduit as high-voltage wires, insulate low-voltage wires for highest voltage contained within conduit.
5. Do not damage internal components when drilling through any panel to mount electrical hardware, con duit, etc.
HIGH-VOLTAGE CONNECTIONS-Unit must have a sepeirate electriceil service with a field-supplied, waterproof, fused disconnect switch per NEC mounted near, and within
sight from, the unit. Refer to unit rating plate for maximum fuse size and minimum circuit amps (ampacity) for wire siz ing. Table 3 shows recommended wire sizes and lengths based on rating plate data.
The field-supplied disconnect switch box may be mounted
on unit over the high-voltage inlet hole in control corner pemel. See Fig. 4.

A WARNING

Label Part No. A74191B, which is shipped loose in bag of parts, must be affixed to the disconnect switch box. This label states: "DO NOT DISCONNECT THE ELECTRICAL POWER TO THIS APPLIANCE WITHOUT FIRST TURNING OFF THE GAS SUPPLY.”
Proceed as follows to complete the high-voltage connections
to unit:
1. Connect ground lead to chassis ground connection when using a separate ground wire.
2. Run high-voltage leads into unit control box and con nect to contactor. See unit wiring label and Fig. 6 and 8.
NOTE; On 3-phase units, connect third high-voltage lead to
brown high-voltage pigtail lead. See unit wiring label and Fig. 8.
SPECIAL PROCEDURES FOR 208-V OPERATION
A WARNING
Make sure power supply to unit is switched OFF before making any wiring changes. Electrical power may cause personal injury or death.
For operation on 208 volts, disconnect orange transformer primary lead from contactor. See unit wiring label and Fig. 6. Remove tape emd cover from terminal on end of red transformer-primary lead. Save cover. Connect red lead to contactor terminal from which orange lead was dis connected.
Using cover removed from red lead, insulate loose terminal on orange lead. Wrap cover with electricEd tape so that metal terminal cannot be seen.
NOTE: For some 48KHA,KLA units, the factory-wired
blower-motor speed connections may require changing for 208-v operation to ensure adequate airflow at the rated external static pressure. See unit wiring label. Insulate all unused motor leads following same procedures described for tremsformer leads.
LOW-VOLTAGE CONNECTIONS-Use a suitable room thermostat as specified on unit wiring label.
Locate room thermostat on an inside wall in space to be con ditioned where it will not be subjected to either a cooling or heating source, or direct exposure to sunlight. Mount ther
mostat 4 to 5 ft above floor.
Use no. 18 AWG color-coded, insulated (35 C minimum)
v/ires to make low-voltage connections between thermostat
and unit. If thermostat is located more than 100 ft from unit (as measured along the low-voltage wires), use no. 16
AWG color-coded, insulated (35 C minimum) wires.
A grommeted, low-voltage inlet hole is located in the panel
adjacent to control access panel. See Fig. 4. Run low-voltage
leads from thermostat, through inlet hole and to low-voltage
flagged pigtail leads that run through a hole in bottom of
unit control box. See Fig. 6. Connect thermostat leads to
pigtail leads as shown in Fig. 8
HEAT ANTICIPATOR SETTING—Room thermostat heat
anticipator must be properly adjusted to ensure proper heating performance. Set heat anticipator, using ammeter to determine exact required setting.
NOTE: For thermostat selection purposes, use 1.0 amps for
approximate required setting.
Failure to make a proper heat anticipator adjustment will
result in improper operation, discomfort to occupants of
conditioned space and inefficient energy use; however,
required setting may be changed slightly to provide a
greater degree of comfort for a particular installation.
Page 8
MODEL
48-
KLA118
SERIES
310BE 208/230-1 197
VOLTS­PHASE
KLA124 310BE 208/230-1 KHA024 310BF
KLA130 KHA030 KLA136 KLA136 KLA136 KHA136
KHA036
310BE 208/230-1 310BF 208/230-1 197 310BE 208/230-1 510CE 208/230-3 610CE 310BE
310BF
KHA136 510CE,CF KHA036 510CF KLA142
310BE 208/230-1
208/230-1 197
460-3 414
208/230-1
208/230-3 187 253 208/230-3 187
KLA142 510CE 208/230-3 KHA042
310BF 208/230-1
KHA042 510CF 208/230-3 KLA148 310BE KLA148
510CE 208/230-3
KLA148 610CE KHA048 KHA048 KLA160 KHA060
310BF 510CF 208/230-3 310BE 230-1 310BF
208/230-1 197
460-3 414
208/230-1 197
230-1 207
AWG—American Wire Gage
FLA —Full Load Amps IFM —Indoor Fan Motor LRA —Locked Rotor Amps MCA—Maximum Circuit Ampacity OFM —Outdoor Fan Motor
RLA —Rated Load Amps
Table 3—Electrical Data (60 Hz)
OPERATING
VOLTAGE* COMPR Min Max RLA LRA
253 8.7 49.0 1.2
197 253
197 253
197 253 187 253
197 253
197 253 187 197 253 187
187 253
187 253 207 253
11.7 63.0 1.7 1.0
253 11.7 63.0
13.7
253 13.7 76.0 2.9
506 5.1 32.8 1.9
253
253
253 253
506
253
253
*Voltage limits between which the unit will operate satisfactorily tif other than 75 C copper wire is used, determine size from unit ampacity and the National Elec
trical code. Voltage drop of wire must be less than 2% of unit rated voltage Maximum wire length is for one way along the wire path from unit to service panel
:(;Maximum dual element size
76.0
17.6 88.0 4.6
11.5 65.1 4.7 1.0 20.1
17.6 88.0 3.8 0.8 26.6
65.1 5.6 1.0 21.0 18.1
11.5
11.5 65.1 5.6 1.0 21.0 18.1
95.4 4.1
23.9
15.3 82.0 5.6 1.0 25.8 21.9
95.4 3.9 0.8 34.6 28.6 50
23.9
15.3 82.0 5.0 1.0
23.7 116.0 4.5
14.7 92.0 7.8
7.0
23.7 116.0
14.7
130.0 6.2 1.9 42.9 35.9
27.8
27.8 130.0 6.5
MAX FUSE
FLA
IFM
3.0 1.0
3.1 1.0
46.0 3.3 1.2 13.3 11.5 20
3.7 1.9 35.3 29.3 50 8
92.0 5.8 2.2 26.4 22.7 35
MCAt
OFM
1.0 13.1 10.9
1.0 21.0
1.0 27.6 23.2
0.6 8.9 7.6 15
0.8
1.9 36.1 30.1 50 8
2.2
1.9 43.2 36.2 60
MAX
AMPS
17.4 14.4 25
18.7 15.7 25
21.2 17.8 30 10 115
34.8 28.8 50
25.2 21.3 35 10
28.4
17.6 30 10 116
17.2 25
22 2 40
24.7 35 10
SIZE
(Amps)t
20
40 10
25 10 130 25 10 130
35 10 108
60 8
MIN WIRE
SIZE (AWG)t (75C Copper)
14 12 12
10 14 272 10
8 113
8 114
14 180
10
8 99
MAX
WIRE
LENGTHt
76 89 82
88
137
92
111 108
96
111 104 100
SINGLE-STAGE HEAT S COOL-
MANUAL CHANGEOVER
. Field Low-Voltage Wiring .Field High-Voltage Wiring . Factory Low-Voltage Wiring , Factory High-Voltage Wiring
SINGLE-STAGE HEAT S COOL-
AUTOCHANGEOVER
JUMPER-H
NOTE: For manual changeover applications, use thermostat part no. HH01AD042 with subbase part no HH93AZ042, or thermostat part no HH01AD040 with subbase part no HH93AZ040
For automatic changeover, use thermostat part no. HH07AT174 with subbase part no.
HH93AZ096; or thermostat part no HH10AD041 with subbase part no HH93AZ041.
-------------------
HIGH-VOLTAGE PIGTAIL LEAD
1
—♦frrw^
-------
3-PHASE UNITS ONLY
CONTACTOR TERMINALS (SEE UNIT WIRING LABEL)
---
'

>n-rvri —

FIELD-SUPPLIED DISCONNECT PER NEC

Fig. 8—High- and Low-Voitage Connections

Page 9

STARTUP

Unit Preparation

A WARNING

Failure to observe the following warnings could result in serious personal injury;
1
Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.
Do not operate compressor or provide any electric
2.
power to unit unless compressor terminal cover is in place and secured.
3.
Do not remove compressor terminal cover until all elec trical sources have been disconnected.
4.
Relieve all pressure from system before touching or dis turbing anything inside terminal box if a refrigerant leak is suspected around compressor terminals.
5. Never attempt to repair a soldered connection while refrigerant system is under pressure.
6. Do not use a torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows:
a. Shut off gas supply first, and then electrical power
to unit.
b. Relieve all pressure from system.
c. Use tubing cutter to cut tubing that connects com
ponent, and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to torch flame.
PRE-START-UP PROCEDURES-Proceed as follows to inspect and prepare unit for initial start-up:
Remove edl access panels.
Read and follow instructions on all WARNING, CAU TION and INFORMATION labels attached to or Heating Section Start-Up and Adjustments shipped with the unit.__________________________________________________________________
3.
Make following inspections:
a. Inspect for shipping and handling damages such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections
and on unit base. The presence of oil generally indi cates a refrigerant leeik. Leak-test all refrigerant tubing connections using electronic leak detector, halide torch or liquid soap solution. If refrigerant leak is detected, see Refrigerant Leaks in next
section.
c. Inspect all field- and factory-wiring connections. Be
sure connections are completed and tight.
d. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.
c. Maike sure air filter(s) is in place.
d. Make sure condensate dredn pan is filled with water
to ensure proper drainage.
e. Make sure all tools and miscellaneous loose parts
have been removed.
5. Replace all access panels. Unit is now ready for initial start-up.
REFRIGERANT LEAKS—Proceed as follows to repair a refrigerant leak and to charge the unit.

A WARNING

Never attempt to repair a soldered connection while refrigerant system is under pressure. Severe bodily injury may result. Always wear protective goggles when servicing the refrigerant system.
1. Locate leak and ensure that refrigerant system pres sure has been relieved.
2. Repair leak following accepted practices.
NOTE; Install a filter drier whenever system has been
opened for repair.
3. Add a small cheu-ge of R-22 refrigerant vapor to system and leEik-test unit.
4. Evacuate refrigerant system if additioned leaks are not found.
5. Charge unit with R-22 refrigerant, using a volumetric-
charging cylinder, such as Dial-a-Charge, or accurate scale. Refer to unit rating plate for required charge. Be sure to add extra refrigerant to compensate for interned volume of filter drier.
NOTE: See Cooling Section Start-Up and Adjustments—
Checking and Adjusting Refrigerant Charge.

A CAUTION

Complete required procedures given in Unit Prepara tion section before starting unit.
Do not jumper any safety devices when operating unit. Ensure that burner orifices are properly aligned. Unstable
operation may occur when the burner orifices in the mani fold are misedigned. To ensure correct burner orifice edign­ment, check orifice angle with a machinist’s protractor or other suitable device. The orifice angle must be from hori zontal to 3 degrees down, as measured from unit base.
Follow instructions on heating section operation label (located in unit near the gas valve) or in Owner’s Manual, to start the heating section.

A WARNING

Do not purge gas supply into combustion chamber. Do not use a match or other open flame to check for gas leaks. Failure to adhere to this warning may cause an explosion.
4. Verify the following conditions: a. Meike sure gas supply has been purged, and all gas
piping has been checked for leaks.
b. Make sure outdoor fan blade is correctly positioned
in fan orifice. Blades should clear fan motor by no
more than % inch.
CHECKING HEATING CONTROL OPERATION-Start
and check unit for proper heating control operation as follows:
Place room thermostat selector switch in HEAT position and fan switch in AUTO, position. Set heating temperature control of thermostat above room temperature. Observe that after built-in time delays, the pilot automatically
lights, burners light and blower motor starts. Observe that
burners and pilot are extinguished, and that after a built-in delay, blower motor stops when heating control setting of thermostat is satisfied.
_____
_
Page 10
GAS INPUT

A CAUTION

These units are designed to consume the rated gas inputs using the fixed orifices at specified manifold pressures as shown in Table 4. DO NOT REDRILL ORIFICES UNDER ANY CIRCUMSTANCES.
The rated gas inputs shown in Table 4 are for altitudes from sea level up to 2000 ft above sea level. These inputs are based on natureJ gas with a heating value of 1050 Btu/cu ft at 0.65 specific gravity, or propane gas with a heating value of 2500 Btu/cu ft at 1.5 specific gravity. For elevations above 2000 ft, reduce input 4% for each 1000 ft above sea level. When gas supply being used has a different heating value or specific gravity, refer to Carrier training manuals, national and local codes, or contact your Carrier distributor or dealer to determine required orifice size.
ADJUSTING GAS INPUT-The gas input to unit is deter mined by measuring the gas flow at the meter or by measur ing the manifold pressure. Measuring the gas flow at the meter is recommended for natured gas units. Manifold pres sure must be measured to determine the input of propane gas units.
Measuring Gas Flow at Meter Method—Natural Gas Units—Minor adjustment can be made by changing mani fold pressure. Manifold pressure must be maintained between 3.2 and 3.8 in. wg. If larger adjustments are required, change main burner orifices following recommen dations of national and loced codes.
NOTE: All other appliances that use the same meter must
be turned off when gas flow is measured at meter. Proceed as follows:
1. Turn off gas supply to unit.
2. Remove pipe plug on bottom of gas vedve, then connect water manometer at this point. Turn on gas to unit.
3. Record number of seconds for gas meter test dial to make one revolution.
4. Divide number of seconds in step 3 into 3600 (number of seconds in one hour).
5. Multiply result of step 4 by the number of cu ft shown for one revolution of test dial to obtain cu ft of gas flow per hour.
6. Multiply result of step 5 by Btu heating value of gas to obtain toted measured input in Btuh. Compare this
value with heating input shown in Table 4. Consult local gas supplier if the heating value of gas is not known.
Example: Assume that the size of test dial is one cu ft, one revolution takes 30 seconds and the heating value of the gas is 1050 Btu per cu ft, then proceed as follows;
a. 30 seconds to complete one revolution.
b. 30 divided into 3600 equals 120.
c. 120 times one equals 120 cu ft of gas flow per hour.
d. 120 times 1050 equals 126,000 Btuh input.
If the desired gas input is 125,000 Btuh, only a minor change in the manifold pressure is required.
Observe manifold pressure and proceed as follows to adjust gas input:
1. Remove cover screw over REG ADJ screw on gas valve.
2. Turn regulator adjustment screw clockwise to increase gas input, or turn regulator adjustment screw counter clockwise to decrease input. Manifold pressure must be between 3.2 and 3.8 in. wg. UNSAFE OPERATION OF THE UNIT MAY RESULT IF MANIFOLD
PRESSURE IS OUTSIDE THIS RANGE.
3. Replace vented seal on gas valve.
4. Turn off gas supply to unit. Remove manometer from pressure tap. Replace pipe plug on gas valve. Turn on gas to unit. Check for leaks.
Measuring Manifold Pressure—Propane Gas Units—The main burner orifices on a propane gas unit are sized for the unit rated input when manifold pressure is 10.5 in. wg.
Proceed as follows to adjust gas input on propane gas unit:
1. Turn off gas to unit.
2.
Remove pipe plug on gas valve outlet identified as PRESS. TAP, then connect manometer at this point.
3.
Turn on gas to unit.
4. Remove cover screw over REG ADJ screw on gas valve.
5.
Adjust regulator adjustment screw for a manifold pres sure reading of 10.5 in. wg. Turn adjusting screw clock wise to increase manifold pressure, or turn adjusting screw counterclockwise to decrease manifold pressure.
Replace cover screw.
6.
7.
Turn off gas to unit. Remove manometer from pressure tap. Replace pipe plug on gas valve, then turn on gas to unit. Check for leaks.
Table 4—Rated Gas Inputs at Indicated Manifold Pressures
GAS SUPPLY NATURAL GAS PROPANE GAS
NUMBER
MODEL 48-
KLA118,124,130 KLA136,142 3 5.0 KHA024,030 KLA148 KHA136,KLA160 KHA036,042,048 5 5.0 KHA060 6 5.0
♦Based on altitudes from sea level up to 2000 ft above sea level. For alti
tudes above 2000 ft, reduce input rating 4% for each 1000 ft above sea levei
OF Natural
ORIFICES Min Max
2 5.0 13.6 11.0
3 5,0 4 5.0 13.6 5 5.0 13.6
PRESSURE (in. wg) PRESSURE
13.6 11.0
13.6 11.0
13.6 11.0
13.6 11.0 13.0 3.5 10.5
Propane (in. wg)
Max Natural
Min
13.0 3.5 10.5
13.0 3.5 10.5
13.0 3.5
13.0 3.5
11.0
11.0 13.0 3.5 10.5
13.0 3.5
Orifice
Propane
10.5 LH32DB207(42) 75,000 LH32DB060(53) 75,000
10.5 LH32DB205(45) 80,000 LH32DB201(55)
10.5
fWhen KLA is converted to propane, all
See kit instructions
Part No. Input Part No. input
(Size)
LH32DB204(45) 40,000 LH32DB201(55) LH32DB205(45) 60,000 LH32DB201(55)
LH32DB205(45) LH32DB207(42) 125,000
LH32DB207(42) 150,000
Heating
(Btuh)* (Size) (Btuh)*
100,000 LH32DB201(55)
Orifice
LH32DB060(53) LH32DB060(53)
NOx burners must be modified
10
Heating
40,000t 60,000t
80,000t
ioo,ooot 125,000 150,000
Page 11
ADJUSTING BURNER AIR SHUTTERS-After burners have operated at full input for at least 10 minutes, adjust primary air to each burner to ensure optimum heating per formance. Make these adjustments when unit is being installed and during routine maintenance inspections at beginning of each heating season. Be sure each burner is
clean and free of deposits before adjusting primary air.
Primary air to each burner is regulated by burner air shut ter on each burner. See Fig. 9 (Burner Flames, Standard) for location of burner air shutter. With all burners operating, adjust primary air to each burner as follows:
1. Loosen locking screw that secures air shutter in place on burner, then partially close air shutter until a slight
yellow tip appears on top of burner flames.
2. Open air shutter very slowly until yellow tip just disap pears, then secure air shutter in place with locking
screw.
3. Repeat steps 1 and 2 for each burner.
After air shutter adjustments have been completed, observe that flames on each burner are light blue and soft in appear ance, and that flames are same height along entire length of each burner. See Fig. 9.
CARRYOVER
AIR
SHUTTER

STANDARD

MANIFOLD

Fig. 9—Burner Flames

BLOWER HEAT-RELAY OPERATION-Heating relay (see Fig. 6 and unit wiring diagram) is located in the control box and adjusts to permit either longer or shorter OFF cycles. The ON cycle automatically adjusts as OFF cycle changes. Adjusting level on relay is factory-set at center position to provide optimum performance for most installa tions. On unusual installations, or where line voltage is con siderably above or below rated voltage, an increase or decrease may be required for length of time blower remains on. To increase blower operation time, move adjusting lever toward right-hand position. To decrease blower operation time, move lever toward left-hand position.
AIRFLOW AND TEMPERATURE RISE-The heating
section of each size of unit is designed and approved for heating operation within temperature rise range stamped on unit rating plate.
Table 5 shows approved temperature rise range for each unit and air delivery (cfm) at various temperature rises.
Heating operation airflow must produce a temperature rise
that falls within the approved range. Refer to Cooling Sec
tion Start-Up and Adjustments—Indoor Airflow emd Air
flow Adjustments to adjust heating airflow when required.
HEATING SEQUENCE OF OPERATION—See Fig. 10
Models 48KHA,KLA have an intermittent electric-spark
ignition system without a standing flame. When manual
shutoff is opened, gas flows to gas valve. On a call for heat
ing by the thermostat, unit terminal R makes to unit termi
nal W. Pilot veJve solenoid of gas valve and spark generator
are energized. Gas flows to pilot and the pilot is ignited
within 4 seconds. The flame sensor proves the presence of
pilot flame within 0.8 seconds after pilot ignition. The inter
nal switching of gas valve de-energizes spark generator,
energizes meun valve solenoid and energizes heating delay
relay. Gas flows to medn burners and is ignited by pilot
flame. Contacts of heating relay close between 60 and 90
seconds after burners are ignited, and blower motor starts.
Heating cycle is now in normeil operation. Unit will continue
operating in heating cycle until thermostat is satisfied.
When this occurs, the thermostat switching removes 24-volt
control circuit voltage instantly; however, contacts of de
energized heating relay remain closed and keep blower
motor running for an additional 2 to 3 minutes. Contacts of
heating relay open after 2- to 3-minute delay and blower
motor stops. Heating section is now in a standby condition
wmting for another call for heating from thermostat.
Table 5—Air Delivery (cfm) at Indicated Temperature
MODEL 48-
KLA118 KLA124 40,000 794 751 712 678 646 KHA024 75,000 KLA130 KHA030 KLA136 KHA036/136 KHA036 125,000 KLA142 60,000 1190 KHA042 125,000 KLA148 80,000 KHA048 KLA160 100,000 KHA060 150,000
NOTE: Bolder ratings in table fall
range of the unit Dashed areas of
HTG
INPUT TEMPERATURE RISE(F)
(Btuh)
40,000 794 751 712 678
40,000 794 751 712 75,000 60,000 1190 1126
100,000
125,000
35 37 39 41 43 45 47
1212 1158
1984 1877 1781 1694 1615
1128
~
1502
1587
1877
1984
-
678
1271 1016 969
1068
2117
1068 1016
1355
1425 2326 2117 1781 1694
below the approved temperature rise the tabie faii beyond the air delivery
Rise and Rated Heating Input
49
646 617
617
617
646
1212 1158
926 887
1543
2019 1930 1846 1771
926
969
_
1930 1846
1292 1235 1182
1930
2019 1815 1543 1478
2325 2226
567 545 524
591 591 567 545
1063 1022 983
1109
591 567
1063 1022 983 947 914 883
1109
850
1417 1362 1310
1478
850 817 786 758 731 706 683 661
887
1771 1702 1638 1579 1523 1134 1089 1048 1010 975 1771 1702
1846
1417 1362 2135 2051
51 53
545 524
817 786
1701 1638
1638 1310 1974
capabiiity of the unit within the operating voitage range for aii voltage
options for each size unit.
57 59 61 63 65 67
55 505 487 471
947 914 883 854 827 809 505 487 471
758 731 1263 1218 1579 1523
1579 1263 1902
706 1177 1472
1482
942 911 1472
1523
1177
1218 1835 1773 1715 1660
441
455
455 854 683
1102 1068 1036 1006 978 951 926
1138
1378 1336 1296 1258 1223 1189 1158
1423
1378 1326 1296 1258 1223
1423
1423 1378
1102
1138
71 73 75
69
_
427
778
641 622 604 587 571 556
1336 1296
1561
1609
— —
_
1493 1483 1395
1516
11
1189
— —
— —
Page 12
C — Contactor Cap. — Capacitor Comp — Compressor GV — Gas Valve IFM — Indoor Fan Motor IFMC — Indoor Fan Motor Capacitor IFR — Indoor Fan Relay (Cooling) IFSS — Indoor Fan Safety Switch
LS — Limit Switch OFM — Outdoor Fan Motor P — Pilot (Safety, Flame Sensing) PI — Pilot Igniter QT — Quadruple Terminal ST — Start Thermistor TDR — Time-Delay Relay (Adjustable) (Heating)
Tran — Transformer

Fig. 10—Typical Wiring Diagram (48KHA030310 shown)

H— Wire Sleeve
O Component Connection (Unmarked)
o Component Connection (Marked)
------
— — Field Wiring
________
Field Ground Wiring
--------------Field Power Wiring
-Pl- Field Splice
■ Junction
-----
®— Junction (Thermostat to Subbase)
— ——— Alternate Start Thermistor Wiring
12
NOTES: 1 Use copper conductors only. 2 Compressor and fan motors thermally protected 3 Transformer pigtails: red208v; orange 230v;
insulate unused lead
4 Neutral for 240/416-v system for Canada only
5 If any of the original wire furnished must be
replaced, it should be replaced with wire of the
same type or its equivalent
6 Fan motor pigtails; red low, black high, insulate
unused lead
Page 13
UNIT
MODEL
48-
KLA118
KLA124
KHA024 208-
KLA130
KHA030
KLA136
KLA136
KHA036 KHA136
KHA036 KHA136 230-3
KLA142
KHA042
KLA148 208-
KLA148
KHA048
(See next page for applicable notes )
VOLTS- MOTOR
PHASE (60 Hz) SPEED
208- Coolt
230-1 High Heat):
208-
230-1 High Heat
230-1
208-
230-1
208-
230-1
208-
230-1
208/
230-3
460-3 Cool 1165
208- Coolf:
230-1
208/
208-
230-1
208/ Cool 965 960 955 940 930
230-3 High Heat
208-
230-1 High Heat 1705
208/ Cool
230-3 High Heat
230-1 High Heat
208/ Med Heat 1805 1800 1785 1765 1735
230-3
460-3 Cool 1490
208-
230-1
BLOWER EXTERNAL STATIC PRESSURE (in. wg)
Low
Low
Low Heat
High Highf:
Low Heatf:
High Heat
Low
High Heat
Low Heatf:
High Heat
Low Heatf:
High
Low Heat): 1185
High Heat 1535
Low Heat
High HeatL
Low Heat
Med Heat
High Heatf:
Low Heatt
High Heat
Low
Low Heat
Low Heatf:
Low HeatL
Low Heat):
High Heat
Low Heatt 1500
High Heat 2040
Low
High Heat
Table 6—Model 48KHA,KLA Air Delivery (cfm)*
at Indicated External Static Pressure and Voltage
COILt
0.0 0.1
Heat
740 700 660 700 665 625
795 750 705
Cool
745
Heatf:
895 850
Cool
865 980 930 875
Coolt
940 995 925 890
Cool);
935
1125
Cool
1080 1035 990
700
Cool
690 670 650 630 605 580
1325 1270 1210
Coolf:
1270 1220 1165
Heatt
1125
Cool
1085 1225 1165 1105
Cool
1175 1120 1065
950 945 940 930 915 900
Cool
945 940 935 925 910 890
1570 1500 1425
Coolf:
1475 1410 1345 1165 1155 1140
Cool
1155 1145 1125 1110 1085 1050 1015 960 855
Heat
1525
Cool):
1475
Cool): 1485
1280 1260 1240 1265 1245
1825 1765 1700 1630
Cool
1735 1670
1275 1270 1260 1240 1220 1195 1165 1135 1100
Coolf:
1270 1260 1625 1605 1575 1540 1500 1455 1400 1350 1295
Cool
1590 1565 1530 1490 2035 1980 1920 1855 1785
Cool
1915 1860 1800 1740 1675
855 850 835
Cool
855 845 830
1700 1635 1565 1495 1425
Cool):
1635 1575 1505 1440
Heatf: 970 965 960 945 935
2040 1980 1915 1850
Coolf:
1950 1890 1835 1410 1385 1355 1315 1255 1175
Cool
1390 1365 1330 1280 1215 1120 1535
Cool):
1650 1590 1535 1465 1405 1400 1395 1385 1365
1400 1395 1725 1710 1685 1655 1615
Cool):
1705 1685 1655 1615 1570 1515 1455 1390 1320 1870 1180 1170
Cool
1175 1165 1780
Coolf: 1770 1710 1645 1590 1525
1200 1195
Cool
1195 1190 1180 1170 1160
Cool
1800 1790 1770 1745 1715
2200 2155 2110 2055 2000 1940 1880 1815 1755 2325 2275 2220 2160
Coolf:
2155 2110
Cooli|: 2000 1960 1910 1855 Heatt
1690
Cool
1685 1640 1585 1890 1820
CoolL
1880
0.2
705 665
800 750 700 645
820 775 725 675 620
895 845 790 730 665
900 870
1075 1030 980 930 880
680 655
1070 1015 1035 985
1490 1450 1415 1375 1440 1405 1370 1325
1220 1195 1165
1595 1515 1410
1245 1225 1205
1650
1590 1525 1450
1385 1370 1345
1160 1155 1130 1075
1720 1660 1610 1550
1190 1180 1170
2060 2005 1950
1650 1600 1545
1760 1690 1625 1560
1810 1745 1670 1600 1530
208V
0.3 0.4 0.5 0.6 0.7 615 565 510
580 535 480 660 610 555
620 570
820 760
855 815 835 800
950 900 635 610
1150 1090 1020 1110 1045
955 900 925 870
1040 980 1005 945
1355 1280 1275 1205
1125
1100 1075 1040 995 930 1365 1345 1320 1295 1265 1225
1215 1190
1540
1445
820 795 815 790
1375
1785
1770 1705
1390
1090
1140
1480
1525 1455
_
_ — — — — —
520
700
780
766
855 585
975 840
815
915 885
1200
1140
1330 1280 1225
1160 1130
1425 1270
1175 1145 1110
1395 1350 1300 1245 1715
1610 1545
760 750
1355 1305
910 880 835 780 905 870
1715 1640 1550 1450 2145 1635 1555 1465 1380 2030 1970 1905 1840
1365
1300 1705 1640 1580 1510 1435
1335 1295 1240 1310 1260 1205 1145 1630 1605 1575 1540 1495
1565 1505 1440
980
960
1500 1470
1150 1145 1135 1115 1145
1700 1665 1680
1890 1835 1775 1710
1420 1390
— _
__
920 _
_ —
— — — —
_
— _
— _
_ —
_
_
_
_
— —
_
1280 1220 1135 1620
1155 1045 1560
_
_ — _
1790
1645 1570 1495 2130
1480 1410 1995
1030
_
_
__
1695 1630 1560 1480 1405
820 765 1190
_
_
_
_
_
_ —
1140 1130 1110 1415
1625 1585 2080
1640 1605 1565 2050
_ _ —
1750 1690 1630
— “
0.0 0.1 0.2 0.3
0.8
_
805
— — —
— — 985 935 885 835
_
— —
_
_
— —
_
_ —
_
1075 1490
_
1175 1650
1370 1935
_
765 725
760 720 870 825 780
810 775 730 690 950
1030 975 920 865
1030 990 955 920 880 840 1000
1160 1120 1075 1030 980 935
850 835
1370 1310 1245 1180 1305 1245 1190 1125
1175 1130
1260 1205
1250 1210
1610 1510
1345
1510 1475
1905
1505
1845 1770
1035
1770
1190
1580
1770
1350 1340 1330 1310 1345
1920 1860
1420
2265
1790
1975 1915
680
905 855 875 825
965 935
1115 1065
795 765 735 705
820 810 785
1115 1050 1070 1010
1140 1080 1020 955
1200 1155 1100
1205 1160 1115 1165 1125 1080 1035 990
1540 1470 1400 1450 1390
1320 1295 1265
1540 1495 1450 1405
1580
1475 1435
1520
1160 1135 1110 1095
1175
1135 1120 1095 1060
1155 1500 1460
1450 1415
1445 1400 1340 1275
1480 1440 1395
1845 1775 1725 1655
1490 1470
1470 1445 1805 1760 1710
1725 1675
2010 1940
2070
1875 1815 1745
1940 1025 1010
1020 1005 990
1635 1555
1705
1185 1175
1170 1155 1135 1105
1180
2010 1940
2080
1475 1420 1360
1530
1435 1380 1315 1240
1485 1710 1645
1635 1610
1885 1835
1770 1720 1665 1610 1550 1470 1360
1820
1335 1325 1300 1255 1120
1845 1770 1790 1725 1655
1410 1400 1390
1395 1385 1380 1365 1350 1320 1285
1405
2015 1970 1920 1865 1805
2050
1975 1930 1880 1820 1765 1705 1640
2020
2215 2160
1480 1460
1450 1425 1395 1370
1470
1950 1895 1835 1775
1995
1665 1600
1730
1820
1900 1845 1770
230V or 460V
0.4
675 625 565
635 585 525
735 685 630
640 590
800 745 680 770 715 650
810 755 780 725
890 860 820
1015 965 915
755 725 695
1110 1035 1060 990
985 925 855 950 890 830
1040 985 925
1065 1015
1330 1255
1325 1260 1190
1235 1190 1135
1390 1345 1295
1425 1385 1340 1290 1230 1145 1380 1335 1290
1345 1280 1210
1700 1595 1475
1565 1455 1320
1445 1415 1375 1330 1415 1375 1330 1285 1235 1185
1655 1595 1535
1625 1575 1520 1465
1870 1800 1725
995 975 950
965 935
1470 1385
1165 1145
1865 1790 1705 1770 1695 1610
1575 1500 1415
1585 1545 1500 1445 1380 1305
1780 1730 1670
1275 1190
1696 1625 1550
1585 1515
1385 1370 1355
2095 2030 1965
2100 2040 1975 1910 1840 1770
1435 1410 1380 1350 1325 1295
1795 1735 1670 1530 1450
1565 1495 1410 1745 1665 1590
1696 1625
0.6
0.5
_ — — —
— —
_
— —
885
— —
_ — — — — — _
— —
_
1180
1355
1060 1015
1235
1680 1615
_ — _
1325
1120 1080
1055
1290
__
1345
1445 1385
1610
— _ _ _
1340 1710
— —
1550
0.7 0.8
_
_
_
_
_
_
_
_
_
_
_
_
1120 1020 1060 900
1300 1230 1235 1155
1005 940
970 895
1165 1055
_
_
1230
1280
1415
1480
1350
1405 1645 1570
1545 1475
1020 940
990 910
1610 1500 1515 1400
_
_ _
1320 1250 1540 1455
_
_
1330 1300
1745 1680
1895 1825
1310 1280
1580
1645
1540
1610
— —
13
Page 14
Table 6—Model 48KHA,KLA Air Delivery (cfm)*
at Indicated External Static Pressure and Voltage (cont)
MODEL
48-
KHA048 208/
KLA160
KHA060
*Air delivery values are without air filter. Deduct field-supplied air filter
pressure drop to obtain external static pressure available for ducting
tHeating airflow values are with a dry coil Cooling airflow values are with
a wet coil.
frThese airflow values are at the factory heating and cooling motor speed
setting.
A dash (—) indicates portions of the table that are beyond the blower motor capability or that are not applicable
UNIT
VOLTS—
PHASE (60 Hz)
230-3
230-1
230-1
BLOWER
MOTOR
SPEED
Low Heat
Med Heat
High
Low
High
Low
Med
High
COILt
Cool
Cooli Heat
Cool Heatt
Cool Heat
Coolj: Heat
Cool Heat^:
Cool Heat
Coolj:
0.0
1440 1435
1755 1745
1950 1925
0.1
1435 1430
1740 1730
1920 1890
0.2
1425 1420
1725 1710
1880 1850
0.3 0.4
1415 1410
1700 1680
1940 1810
208V
1400 1395
1665 1645
1795 1765
EXTERNAL STATIC PRESSURE (in. wg)
0.6 0.7
0.5 1365
1385
1355
1380 1625
1580 1550
1600
1700
1750 1715
1665
NOTE: Do not operate the unit at a cooling airflow that is less than 350
fpm per each 12,000 Btuh of rated cooling capacity Indoor coil frosting
may occur at airflows below this point.
1340 1330
1530 1500
1645 1615
0.8
0.0 0.1 0.2 0.3
1305
1730
1290
1725
1470
1970
1440
1950
1590
2175
1560
2130 1610
1595 2375
2270 1880
1875 2130
2075 2345
2255
1720 1710
1945 1920
2130 2085
1600 1585
2280 2185
1875 1865
2075 2025
2260 2175
1700 1685
1910 1880
2085 2035
1580 1575
2185
2100
1860 1840
2015
1965
2180
2100
230V or 460V
0.4
1675
1645
1660
1625
1875
1825
1840
1790
2030
1970
1980
1920
1560
1530
1550
1515
2095
2000
2015
1930
1825
1770
1790
1725
1955
1890
1900
1835
2095
2010
2020
1945
0.5
1601 1585
1775 1735
1905 1855
1495 1475
1905 1840
1700 1650
1810 1760
1930 1865
0.6 0.7
1560 1545
1720 1685
1840 1790
1520 1495
1660 1625
1765 1720
0.8
1470 1445
1600 1570
1695 1650
NOTE: The igniter continues to spark for approximately 10
seconds after burners are ignited. LIMIT AND PRESSURE SWITCHES-Furnace limit
switch (see Fig. 10) closes gas valve if leaving-air tempera ture exceeds 175 F.
Normally closed limits switch completes control circuit through pigtail lead W to gas valve 5F. See Fig. 10. Should leaving-air temperature rise to 175 F, switch opens and W control circuit breaks. Any interruption in W control circuit instantly closes gas valve and stops gas flow to burners and pilot. Blower motor continues to run until time-delay sequence of heat relay is completed.
When air temperature at limit switch drops to the low-tem perature setting of limit switch, switch closes and com pletes W control circuit. Electric-spark ignition system cycles emd unit returns to normeil heating operation.
BLOWER SAFETY SWITCH-BIower safety switch is a temperature-actuated switch connected in parallel with con tacts of heat relay. Function of switch is to activate blower
should gas valve fail to close when thermostat is satisfied.
Safety switch is mounted on blower divider panel. When temperature at safety switch reaches approximately 175 F, switch closes to start blower. Switch opens when tempera ture at switch drops to approximately 116 F.
Cooling Section Start-Up and Adjustments

A CAUTION

Complete required procedures given in Unit Prepara tion section before starting unit.
Do not jumper any safety devices when operating unit. Do not operate compressor when outdoor temperature
is below 55 F (single-phase units) or 40 F (3-phase units).
Do not permit compressor to rapid cycle. Allow 5 min utes between cycles to prevent compressor damage.
CHECKING COOLING CONTROL OPERATION-Start and check unit for proper cooling control operation as follows:
1. Place room thermostat selector switch in OFF position. Observe that blower motor starts when fan switch is placed in ON position and shuts off when fan switch is placed in AUTO, position.
2. Place selector switch in COOL position and fan switch in AUTO, position. Set cooling control below room tem perature. Observe that compressor, condenser fan and evaporator blower motors start. Observe that cooling cycle shuts down when control setting is satisfied.
3. When using an automatic changeover room thermo
stat, place both selector and fan switches in AUTO, positions. Observe that unit operates in heating mode when temperature control is set to call for heating (above room temperature) and operates in cooling mode when temperature control is set to call for cooling (below room temperature).
CHECKING AND ADJUSTING REFRIGERANT CHARGE—Refrigerant system is fully charged with R-22 refrigerant, tested and factory sealed. For most applica tions, factory charge is the correct amount for best perform ance; however, this charge may require a slight adjustment to attain rated performance.
NOTE: Adjustment of refrigerant charge is not required
unless unit is suspected of not having proper R-22 charge. For all applications, correct R-22 charge for best perform ance is charge that results in a suction gas superheat of 5 F at compressor inlet when unit is operating at ARI rating conditions of 95 F db outdoor and 80 F db/67F wb indoor.
A superheat charging label is attached to outside of com pressor access door. Label includes a Field Superheat Charging Table and a Required Suction-Tube (F) tempera ture chart.
Table 7 is intended for use when minor unit charge adjust ments are required. For large adjustments, evacuate unit and weigh in cheirge according to unit rating plate. Use Table 7 to approximate charge if ARI rating conditions can-
14
Page 15
#
#
not be obtained. Refer to required eurflow rates in Table 8. Charge unit with outdoor fan operating only at high speed.
An accurate superheat-, thermocouple-, or thermistor-type thermometer, a sling psychrometer and a gage manifold are required when using superheat cheirging method for evalu ating unit charge. Do not use m ercury o r small dial-typ e
th erm o m eters b eca use they are not ade qua te for this type of m easuremen t.

A CAUTION

When evaluating refrigerant charge, an indicated adjustment to specified factory charge must always be minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in cooling sys tem, such as insufficient airflow across either or both coils.
Proceed as follows:
1. Remove caps from low- and high-pressure service fit tings. See Fig. 4 for location of entrance for refrigerant pressure gage hoses.
2. Using hoses with valve core depressors, attach low-
and high-pressure gage hoses to low- and high-pressure service fittings, respectively.
3. Start unit in cooling mode and let unit run until system
pressures stabilize.
4. Measure and record the following:
a. Outdoor ambient-air temperature (F db).
b. Evaporator inlet-air temperature (F wb).
c. Suction-tube temperature (F) at low-side service
fitting.
d. Suction (low-side) pressure (psig).
5. Using Field Superheat Charging Table, compare outdoor-air temperature (F db) with evaporator inlet-air temperature (F wb) to determine desired system oper
ating superheat temperature.
6. Using Required Suction-Tube (F) table, compare
desired superheat temperature with suction (low-side) operating pressure (psig) to determine proper suction tube temperature.
7. Compare actual suction-tube temperature with proper
suction tube temperature. Using a tolerance of ±3 F, add refrigerant if actual temperature is more than 3 F higher than proper suction tube temperature, or remove refrigerant if actual temperature is more than 3 F lower than required suction-tube temperature.
NOTE: If the problem causing inaccurate readings is a
refrigerant leak, see Unit Preparation, Refrigerant Leaks
section of these instructions.
INDOOR AIRFLOW AND ADJUSTMENTS

A CAUTION

For cooling, recommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For heating, airflow must produce a temperature rise that falls within the range stamped on unit rating plate.
Models 48KHA,KLA end-discharge units have direct-drive blower motors. All motors are factory-connected to deliver proper heating and cooling airflows at normal external static pressures (except for some 208-v applications).

Table 7—Refrigerant Charging Label

DESIRED SUPERHEAT TEMPERATURE (F)
(Measured @ Low-Side Service Port)
OUTDOOR
AMBIENT
EDB (F)
65 70 75 80 85 90
54 56 58 60
10 13 16 19
7 10 13 16 19
_ _
95
100
105 110 115
NOTES: 1 Dashed Areas; Do not attempt to charge system under these condi
tions or refrigerate siugging may occur
2 Add charge if actual superheat temperature is higher than chart value
and remove if lower Allow ± 3 F for tolerance
EVAPORATOR AIR INLET EWB (F)
6 9 12 15
5
__
64 66 68
62
24 27 30 33 36 38
21
21
18 21 15 18
12
8
11 15 19 22 26 30 33
8 5 9
6
70
24 27
13 16 10 14
30
24
28 31
21
25 28 31
20 18
12
8 5 9 13
15
6 11 15 20 25
8
74 76
72
33 36 39
34 37
24 27 31 22 25 29 20 23 27 17 22 26
14
18
41
35
23
REQUIRED SUCTION-TUBE TEMPERATURE (F) vs.
DESIRED SUPERHEAT TEMPERATURE (F)
(Measured @ Low-Side Service Port)
DESIRED
SUPERHEAT
TEMP(F) 61.5
0 2 37 4 6 8
10 45
SUCTION OR LOW-SIDE
64.2
35 37 39 41 43
39 39 41 43 45 41 43 43 45 47 49
47
AT SERVICE
67.1 70
43 45 47 49 51
41
47
45
49 51
12 47 49 51 53 14 16 18 53 20 22 24 26 61 28 30 32 34 36 38 40
NOTE: Measure suction-tube temperature with an accurate superheat thermocouple, or thermistor-type thermometer.
49 51 51 53 55 57
55 57 59 61 57
55 57 59 61 63 59 61 63 65
63 65 67 69 63 65 67 69 65 67 69 71 73 67 69 69 71 73 75 71 73 75 73 75 77 79 81 75 77 79 81
53
59 61
71
55
73 75
77 79 81
PRESSURE PORT
73 76 79.2 82.4
45
47 49 49 51 51 53 53 55 57 59 61 55 57 57 59 59 61
63 63 65 67 69 65 67 67 69 71 73 75
71
71 73 75 77 79
75
77 77 79
83 83 85
(Psig)
47
51 53 55 55
59 61 63 63 65
69
73
77 79 81 81 83 85 87
8S.7
49 51
53 55
57 59
61 63
65 67 67 69
71 73
75 77
79 81
83 85 85 87 89 89 91
53
57
65
71
83
87
Table 5 shows heating airflow at various temperature rises. Table 6 shows both heating and cooling airflows at various external static pressures for Models 48KHA,KLA direct-drive units. Refer to these tables to determine airflow for system being installed. See Table 8 for rated cooling and heating airflows.
NOTE: Be sure all supply- and return-air grilles are open,
free from obstructions and adjusted properly.

A WARNING

Disconnect electrical power to unit before changing blower speed. Be sure to turn off gas supply before dis connecting electrical power. Fallure to do so may cause personal injury or death.
15
Page 16
Table 8—Rated Cooling and Heating Airfiows
COOLING
MODEL 48-
KLA118310BE 630 0.10 505 KLA12431 QBE
KHA024310BF
KLA13031 QBE KHA030310BF
KLA136310BE KLA136510CE 1200 0.15 758 KLA136610CE KHA136310BE KHA136510CE KHA036310BF KHA036510CF
KLA142310BE 1400 015 695 KLA142510CE KHA042310BF KHA042510CF
KLA148310BE KLA148510CE KLA148610CE KHA048310BF KHA048510CF
KLA160310BE 2000 KHA060310BF 2000
ESP—External Static Pressure
♦Rated in accordance with U.S Government D.O.E. test procedures and/
or ARI Standard 210-81
Rated
Airflow
(dm)*
800 0.10 505 800 0.10 947
1000 015 1000 0.15
1200 0.15 758 1200 0.15 758
1200 0.15 1155 1200 015 1200 0.15 1200 0.15 1445
1400 0.15 1400 0.15 1400 0.15
1600 0 20 1600 0.20 925 1600 0.20 925 1600 0.20 1445 1600 0.20 1445
ESP
(in. wg)
0.20
0.20
Rated
Airflow
(cfm)*
462 947
1155 1445
695 1445 1445
925
1155 1735
HEATING
Maximum
(in. wg)*
ESP
0.30
0.30
0.30
0.30
0.30
0.30
0.65
0.65
0.30
0.65
0.30
0.65
0.30
0.65
0.30
0.65
0.30
0.65
0.65 0 30
0.65
0.30
0.30
NOTE: When operating the 208/230-volt, 3-phase versions
of Model 48KHA048 at 208 volts, lead connections of blower motor must be changed as indicated on unit wiring label to ensure proper airflow.

A CAUTION

Do not change blower-motor lead connections on 460-v units from factory setting.
Heating and/or cooling airflow of 208/230-v direct-drive blower motors can be changed by changing the lead con nections of blower motor. Motor leads are color-coded as follows:
black—high, speed blue —medium speed red —low speed
NOTE: Some direct-drive blower motors do not bave lead
for medium speed. Factory connections and available optional connections are shown in Table 6.
For all units, motor lead connected to heat relay determines heating speed and resulting airflow; and motor lead con nected to cooling relay determines the cooling speed and resulting airflow. See unit wiring label.
To change heating and/or cooling speed, connect appropri ate color-coded lead to appropriate relay. Be sure to prop erly insulate any unused motor lead. See Make Wiring Connections, Special Procedures for 208-v Operation section for proper procedures to insulate an unused electrical lead.
When installing a 208- or 230-v direct-drive unit that is factory-connected for heating and cooling speeds that are not the same, and seune speed for both heating and cooling is required for a particular application, connect appropriate color-coded lead to terminal 2 of cooling relay and connect a field-supplied jumper between heat relay and terminal 2 of cooling relay. Be sure to properly insulate unused motor lead(s).
CONTROLS—All compressors have the following interned-
protection controls:
High-Pressure Relief Valve—This vedve opens when pres sure differential between low and high side becomes excessive.
Compressor Overload—This overload interrupts power to compressor when either current or internal temperature becomes excessive, and automaticedly resets when internal temperature drops to a safe level. This overload may require
up to 60 minutes (or longer) to reset; therefore, if internal
overload is suspected of being open, disconnect electrical
power to unit and check circuit through overload with an
ohmmeter or continuity tester. COOLING SEQUENCE OF OPERATION-The following
sequence of operation pertains to all 208/230-volt, 3-phase
units; however, sequence of operation of single-phase and
460-volt units is very similar. Refer to wiring diagram in Fig. 10.
NOTE: Although actued unit wiring may vary slightly from
that shown in Fig. 10, sequence of operation will not be affected.
With room thermostat selector switch in the COOL position and fan switch in AUTO, position, cooling sequence of oper ation is as follows:
When room temperature rises to a point slightly above cool ing control setting of thermostat, thermostat cooling bulb tilts and completes circuit between thermostat terminal R to terminals Y and G. These completed circuits through the thermostat connect contactor coil (through unit wire Y) and relay coil (through unit wire G) across the 24-volt secondary of transformer.
The 2 sets of normally open contacts of energized contactor
2D close and complete circuit through compressor motor 3F and condenser fan motor 3D1. Both motors start instantly.
The set of normally open contacts of energized relay closes
and completes circuit through evaporator blower motor. Blower motor starts instantly.
NOTE: Three-phase units are equipped with a 2-speed con
denser fan motor and a temperature-actuated switch. Fan motor operates at high speed when outdoor temperature rises to 75 ±3 F and continues to operate at high speed until outdoor temperature drops to 61 ±4 F. At 61 F or lower, fan motor operates at low speed and permits cooling
operation down to 40 F.
Cooling cycle remains on until room temperature drops to a
point slightly below cooling control setting of room thermo
stat. At this point, thermostat cooling bulb tilts and breaks
circuit between thermostat termined R to terminals Y and
G. These open circuits de-energize contactor coil and relay
coil. Condenser, compressor and blower motors stop. Unit is
in a standby condition, waiting for next call for cooling from
room thermostat.

SERVICE

To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic meiinte-
nance must be performed on this equipment. This combina tion heating/cooling unit should be inspected at least once a
year by a qualified service person.
NOTE TO EQUIPMENT OWNER: Consult your local deeder about the availability of a maintenance contract.
16
Page 17
#

A WARNING

The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance on this equip ment other than those procedures recommended in the Owner’s Manual. FAILURE TO HEED THIS WARN
ING COULD RESULT IN SERIOUS PERSONAL INJURY AND EQUIPMENT DAMAGE.
The minimum maintenance requirements for this equipment
are as follows:
1. Inspect air filter(s) each month. Clean or replace when necessary.
2. Inspect cooling coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for cleanliness and check lubrication each heating and cooling season. Service when necessary.
4. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary.
5. Check and inspect heating section before each heating season. Clean and adjust when necessary.

A WARNING

Failure to follow these warnings could result in serious
personal injury.
1. Turn off gas supply, then disconnect electrical power
to unit before performing any maintenance or service.
2. Use extreme caution when removing panels and
parts. As with any mechanical equipment, personal injury can result from sharp edges, etc.
3. Never place anything combustible either on, or in contact with unit.
4. Should overheating occur, or gas supply fail to shut off, first shut off external main manual gas vedve to unit, then shut off electrical supply.

Top Removal

A CAUTION

When removing unit top, use extreme caution to pro tect seal that isolates heat exchanger and flue products from other sections. Removal of top must never be attempted by anyone other than qualified technicians.

A CAUTION

Condenser fan and motor are fastened to unit top. When removing top, use extreme ceire not to pull fan motor leads loose.
NOTE: When performing maintenance or service proce
dures that require removal of unit top, be sure to perform all routine maintenance procedures that require top removal, including: inspection of heat exchanger area, coil inspection and cleaning, and condensate drain pan inspection and cleaning.
When performing mEuntenemce and service procedures that require unit top removal, refer to following top removal procedures:
1. Turn off gas supply, then disconnect electric power to unit.
2. Remove vent cap and combustion-air assemblies. Do not damage gasket. Refer to Venting section and reverse assembly procedures shown.
3. Remove all screws that secure unit top, including screws around 4 sides and those on top that screw into internal divider panels. Save all screws.
4. Tape all side panels at each seam near unit top. Use tape strips that are at least 5 in. long to prevent sides from falling when top is removed.
5. Carefully lift top from unit. Set top on edge and ensure that it is supported by unit side that is opposite duct (or plenum) side. Use extreme care to prevent damage
to either seal that isolates heat exchanger and flue
products, or the fan blades, motor and insulation.

A WARNING

If seal that isolates heat exchanger and flue products is damaged, repair seed, using same type of foil-backed insulation used at time of manufacture, and/or alumi num duct tape, depending on severity of damage. FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY TO OCCUPANTS OF THE CONDITIONED SPACE.
Carefully replace and secure unit top to unit, using
6.
screws removed in step 3 when maintenance and/or
service procedures are concluded. Be sure to use origi nal screws that have rubber washers to seal out water when securing top to internal divider panels.
Reinstall vent cap and combustion-air assemblies.
7. Refer to Venting section.
Air Filter
A CAUTION
Never operate unit without a suitable air filter in return-air duct system. Always replace filter with same
size and type. See Table 2 for filter sizes.
Inspect field-supplied Eur filter(s) at least once each month and replace (disposable type) or clean (cleanable type) at least twice during each heating and cooling season or when ever the filter(s) becomes clogged with dust and lint.
Evaporator Blower Wheel and Motor—For longer life, oper
ating economy and continuing efficiency, clean accumulated dirt and grease from blower wheel and motor annually.
Lubricate motor every 5 years if motor is used intermit tently (thermostat FAN switch in AUTO, position), or every 2 years if motor is used continuously (thermostat FAN switch in ON position).

A WARNING

Turn off gas supply, then disconnect and tag electricEd power to unit before cleaning and lubricating blower motor and wheel. Failure to do so may cause personal injury or death.
Clean and lubricate blower motor and wheel as follows:
1. Remove Emd disassemble blower assembly.
17
Page 18
a. Remove blower and control access panels.
b. Refer to unit wiring label and disconnect blower
motor leads from their termination points in unit control box. Be sure to mark wiring label appropri ately if lead terminations were not previously marked. Pull leads into blower compartment.
c. Remove blower assembly from unit. Be careful not
to tear insulation in blower compartment.
d. Ensure proper reassembly by marking blower wheel
and motor in relation to blower housing before disassembly.
e. Loosen setscrew(s) that secures wheel to motor
shaft, remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing.
2. Lubricate motor. a. Thoroughly clean all accumulations of dirt or grease
from motor housing.
b. Remove dust caps or plugs from oil ports located at
each end of motor.
c. Use a good grade of SAE 20 nondetergent motor oil
and put one teaspoon, 5 cc, ®/ie oz., or 16 to 25 drops in each oil port.
d. Allow time for oil to be absorbed by each bearing,
then wipe excess oil from motor housing.
e. Replace dust caps or plugs in oil ports.
3. Remove and clean blower wheel. a. Ensure proper reassembly by marking wheel orien
tation emd cutoff plate location.
b. Remove screws holding cutoff plate, and remove
plate from housing.
c. Lift wheel from housing. When handling and/or
cleaning blower wheel, be sure not to disturb bal ance weights (clips) on blower wheel vanes.
d. Remove caked-on dirt from wheel and housing with
a brush. Remove lint and/or dirt accumulation from wheel emd housing with vacuum cleaner, using soft brush attachment. Remove grease and oil with mild solvent.
e. Reassemble wheel and cutoff plate into housing.
f. Reassemble motor into housing. Be sure setscrews
are tightened on motor shaft flats and not on round peirt of shaft.
4. Reinstall blower assembly into unit. Route blower
motor leads into control compartment and reconnect
all blower motor leads to proper termination points in
unit control box. Replace panels.
5. Restore electrical power, then gas supply, to unit. Start
unit and check for proper blower rotation and motor
speeds during heating and cooling cycles.
Heating Section—Ensure dependable and efficient heating
operation by inspecting heating section before each heating season and cleaning when necessary. Proceed as follows;
1. Turn off gas supply, then disconnect electrical power to
unit.
2. Inspect emd clean heating section. a. Remove control access door.
b. Remove unit top following procedures under Top
Removal.
c. Remove second£iry-air shield, flue baffles, pilot and
burners. Flue baffles may be removed after partial loosening of collector front panel. Inspect and deem all of these components. Be sure to remove any resi due that may have collected on a component.
d. Clean flue ways with brush and/or vacuum, and
inspect heat exchanger for leгlks and cracks.
e. Inspect indoor-air passages in unit for cleanliness
and check tightness of screws and parts.
f. Replace all components removed in step c, and
replace unit top.
3. Restore electrical power, then gas supply to unit. Start heating cycle and adjust burner air shutters. See Heat ing Section Start-Up and Adjustments—Adjusting Burner Air Shutters.

A WARNING

Never use a match or other flame to check for gas leaks. Failure to adhere to this warning may cause an explosion.
4. Inspect gas control area for gas leaks, using a soap­and-water solution.
5. Replace control access panel.
Pilot—Inspect the pilot and clean (when necessary) at begin
ning of each heating season. Remove accumulation of soot
and carbon from pilot. The pilot flame must be high enough to properly touch flame-sensing element and to light burners.
Condenser Coil, Evaporator Coil and Condensate Drain
Pan—Inspect condenser coil, evaporator coil and conden
sate drain pan at least once each year. Proper inspection
and cleaning requires removal of unit top. See Top Removal
section. Coils are easily cleaned when dry; therefore, inspect and
clean coils either before or after each cooling season.
Remove all obstructions including weeds and shrubs that interfere with edrflow through condenser coil. Straighten bent fins with a fin comb. If coated with dirt or lint, clean coils with a vacuum cleaner, using soft brush attachment. Be careful not to bend fins. If coated with oil or grease, clean coils with mild detergent and water solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring or air filter(s). For best results, spray condenser coil fins from inside to outside of unit. On units with an outer and inner condenser coil, be sure to clean between coils. Be sure to flush all dirt and debris from unit base.
Inspect drain pan and condensate drain line when inspect ing the coils. Clean dreun pan and condensate drain by removing edl foreign matter from pan. Flush pern and drain tube with clear water. Do not splash water on insulation, motor, wiring or ear filter(s). If drain tube is restricted, clear it with a plumber’s snake or similar probe device.
The bottom of dreun tube has a Vs-in. diameter hole. This hole is located in the portion of the dreiin tube that runs through drain pan. Clean this hole with a stiff wire that has a %-in. long, 90 degree bend.

Condenser Fan

A CAUTION

Keep condenser fan free of edl obstructions to ensure proper cooling operation. Never place eu-ticles on top of unit.
Inspect fan blades for cracks or bends each year. Ensure
that blades clear the motor by exactly % inch. If blade
assembly has slipped down motor shaft, adjust fan position
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on motor shaft by loosening setscrew(s), then moving blade assembly up. Be sure setscrew(s) is on flat(s) of shaft before tightening.
Electrical Controls and Wiring—Inspect and check electri
cal controls and wiring annually. Be sure to turn off gas sup
ply and then electrical power to unit.
Remove control, blower and compressor compartment access panels to locate all electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed: disassemble the connection, clean all parts, restrip wire end and reassemble connection properly emd securely.
After inspecting electrical controls and wiring, replace all panels. Start unit and observe at least one complete beating cycle and one complete cooling cycle to ensure proper opera tion. If discrepancies are observed in either or both operat ing cycles, or if a suspected malfunction has occurred, check each electrical component with proper electrical instrumen tation. Refer to unit wiring label when making these checkouts.
NOTE: Refer to heating and/or cooling sequence of opera
tion in this publication as an aid in determining proper con trol operation.
Refrigerant Circuit—Annually inspect all refrigerant tubing
connections and unit base for oil accumulations. Presence of oil generally indicates a refrigerant leak.
If oil is detected or if low-cooling performance is suspected, leeik-test all refrigerant tubing using em electronic leak detector, hedide torch, or liquid-soap solution. If a refriger ant leak is detected, see Unit Preparation—Refrigerant Leeiks.
If no refrigerant leaks are found and low-cooling perform ance is suspected, see Cooling Section Start-Up emd Adjust
ments—Checking and Adjusting Refrigerant Charge
section.
Gas Input—Gas input does not inquire checking unless
improper heating performance is suspected. If a problem exists, refer to Heating Section Start-Up and Adjustments section.
Evaporator Airflow—Heating and/or cooling airflow does
not require checking unless improper performance is sus pected. If a problem exists, be sure all supply- and retum-air
grilles are open and free from obstructions, and air filter is
clean. When necessary, refer to Cooling Section Start-Up
and Adjustments Indoor Airflow and Airflow Adjustments section to check system eiirflow.
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Page 20
TROUBLESHOOTING CHART
Table 9—Heating Service Analysis Chart
SYMPTOM Pilot will not light
Burners will not ignite Water in gas line
Inadequate heating Dirty air filter
Poor flame characteristics Incomplete combustion results in:
PROBABLE CAUSE REMEDY
No spark at electrode
Spark shorting out to main burner
No gas at pilot burner
No power to furnace No 24-volt power supply to control circuit Miswired or loose connections Dirty pilot—yellow flame Pilot burning improperly— sharp blue flame Burned-out heat anticipator in thermostat No gas at main burners
Broken thermostat wire
Gas input to furnace too low
Unit undersized for application Restricted airflow Blower speed too low Limit switch cycles main burners
Aldehyde odors, (CO), sooting flame— floating flame
Check air gap between electrode tip and pilot burner Gap should be as shown in Fig. 11. Readjust as necessary.
Clean moisture or dirt accumulation on electrode ceramic with cloth. Cracked ceramic—replace pilot electrode assembly. Check for loose or broken wiring at and between spark generator and
electrode. Replace wire or tighten connection as necessary. Check fuses or circuit breaker to ensure voltage to unit. Check 24-volt input to spark generator. If reading is 24 volts, and
above steps have been completed, replace electronic control head portion of control head/gas valve assembly.
Realign electrode tip away from main burner but maintain spark gap to pilot burner. See Fig. 11.
Clean pilot orifice. Check for 24 volts between terminals no. 1 and GR of gas valve. If
reading is 24 volts, and above steps have been completed, replace gas valve portion of control head/gas valve assembly.
Drain—install water trap. Check power supply, fuses, wiring, or circuit breaker. Check transformer—replace If necessary. Check all wiring and wirenut connections. Clean pilot orifice. Replace pilot
Replace thermostat.
1. Check for 24 volts between terminals 3 and GR on control head If reading is 24 volts, replace gas valve portion of control head/gas valve assembly
2 If reading is not 24 volts, check flame sensor for cracked ceramic
insulator or shorted sensor cable Replace electronic head if sensor circuit is not defective.
Run continuity check to locate break. Clean or replace filter as necessary. Check gas pressure at manifold Clock gas meter for input If too low,
increase manifold pressure, or replace with correct orifices. Replace with proper unit—or add additional unit. Clean or replace filter—or remove any restriction. Use faster speed tap—or install optional blower. Dirty air filters—clean or replace. Registers closed, restricted ductwork—open or remove restriction. Check heat anticipator setting on thermostat—readjust. Air shutters on burners closed—adjust to soft blue flame. Check all screws around flue outlets and burner compartment— tighten. Lack of combustion air. See Installation section. Cracked heat exchanger—replace. Overfired furnace—reduce input, or change orifices. Check vent for restriction—clean as required. Check orifice to burner alignment.
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Table 10—Cooling Sen/ice Analysis Chart
SYMPTOM Compressor and condenser fan will not start
Compressor will not start but condenser fan runs
Compressor cycle (other than normally satisfying thermostat)
Compressor operates continuously
Excessive head pressure Dirty air filter
Head pressure too low Low refrigerant charge
Excessive suction pressure
Suction pressure too low
PROBABLE CAUSE
Power failure Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker. Defective thermostat, contactor,
transformer, or control relay Insufficient line voltage Determine cause and correct. Incorrect or faulty wiring
Thermostat setting too high
Faulty wiring or loose connections in compressor circuit Compressor motor burned out, seized, or internal overload open Defective run/start capacitor, overload, start relay One leg of 3-phase power dead Refrigerant overcharge or undercharge Defective compressor Determine cause, replace. Insufficient line voltage Blocked condenser Determine cause and correct. Defective run/start capacitor, overload, or start relay Defective thermostat Faulty condenser fan motor or capacitor Replace. Restriction in refrigerant system Locate restriction and remove. Dirty air filter Unit undersized for load Thermostat set too low Reset thermostat. Low refrigerant charge Leaking valves in compressor Air in system Condenser coil dirty or restricted Clean coil or remove restriction.
Dirty condenser coil Clean coil. Refrigerant overcharged Air in system Condenser air restricted or air short-cycling
Compressor valves leaking Replace compressor.
Restriction in liquid tube High heat load Check for source and eliminate.
Compressor valves leaking Replace compressor.
Refrigerant overcharged Purge excess refrigerant. Dirty air filter Replace filter. Low refrigerant charge Check for leaks, repair, and recharge. Metering device or low side restricted Remove source of restriction.
Insufficient evaporator airflow Increase air quantity. Check filter—replace if necessary. Temperature too low in conditioned area Reset thermostat. Outdoor ambient below 55 F Install accessory low-ambient kit.
Field-installed filter drier restricted
TROUBLESHOOTING CHART
REMEDY
Call power company.
Replace component
Check wiring diagram and rewire correctly. Lower thermostat setting below room temperature. Check wiring and repair or replace.
Determine cause Replace compressor.
Determine cause and replace.
Determine cause. Replace fuse or reset circuit breaker. Blow refrigerant, evacuate system, and recharge to nameplate.
Determine cause and correct.
Determine cause and replace.
Replace thermostat.
Replace filter. Decrease load or increase unit size.
Locate leak, repair, and recharge. Replace compressor. Blow refrigerant, evacuate system, and recharge.
Replace filter.
Purge excess refrigerant. Blow refrigerant, evacuate system, and recharge. Determine cause and correct.
Check for leaks, repair, and recharge.
Remove restriction.
Replace.
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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations
_Book| 1 I 4 PC 101 Catalog No. 534-862 Printed in U S.A Form 48KH,KL-19SI Pg 24 1-88 Replaces: 48KH,KL-17SI Tab haha
For replacement items contact distributor.
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