Heat Controller A-13 User Manual

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HEAT CONTROLLER

efrigerant

INSTALLATION INSTRUCTIONS

PACKAGE GAS ELECTRIC FEATURING EARTH-FRIENDLY R-410A REFRIGERANT TGC***A-13 SEER (3-5 TONS) SERIES

92-21916-38-00

I.TABLE OF CONTENTS

I. Table of Contents ..................................................................................................2

II. Introduction............................................................................................................3

III. Checking Product Received ..................................................................................3

IV. Specifications.........................................................................................................3

A. General .............................................................................................................3

B. Major Components............................................................................................3

C.R-410A Refrigerant ...........................................................................................3

1. Specifications of R-410A...............................................................................3

2. Quick Reference Guide for R-410A ..............................................................4

3. Evaporator Coil/TXV .....................................................................................4

4. Tools Required for Installing and Servicing R-410A Models.........................4

V. Safety Information..................................................................................................4

VI. Unit Dimensions.....................................................................................................5

VII. Installation..............................................................................................................7

A. General .............................................................................................................7

1. Pre-Installation Check..................................................................................7

2. Location Considerations...............................................................................7

B. Outside Installation............................................................................................8

C.Attaching Exhaust and Combustion Air Inlet Hoods .........................................9

D.Cover Panel Installation/Conversion Procedure ...............................................9

E. Clearances........................................................................................................9

F. Rooftop Installation .........................................................................................10

G.Ductwork .........................................................................................................10

H.Return Air ........................................................................................................11

VIII. Gas Supply, Condensate Drain and Piping .........................................................13

A. Gas Connection ..............................................................................................13

B. LP Conversion.................................................................................................14

C.NOx Models ....................................................................................................14

D.Adjusting or Checking Furnace Input ..............................................................15

E. Condensate Drain ...........................................................................................16

IX. Wiring...................................................................................................................16

A. Power Supply..................................................................................................16

B. Hook Up ..........................................................................................................18

C.Internal Wiring .................................................................................................18

D.Thermostat......................................................................................................18

X. Furnace Section Controls and Ignition System....................................................19

Normal Furnace Operating Sequence.................................................................19

Operating Instructions .........................................................................................20

Burners................................................................................................................21

Manual Reset Overtemperature Control..............................................................21

Pressure Switch...................................................................................................21

Limit Control ........................................................................................................21

XI. System Operating Information.............................................................................21

Advise the Customer ...........................................................................................21

Furnace Section Maintenance.............................................................................22

Lubrication...........................................................................................................23

Cooling Section Maintenance..............................................................................23

Replacement Parts..............................................................................................24

Troubleshooting...................................................................................................24

Wiring Diagrams ..................................................................................................24

Charging..............................................................................................................24

Blower Motor Speed Taps...................................................................................24

XII. General Data..................................................................................................27-31

XIII. Miscellaneous......................................................................................................32

Electrical and Physical Data................................................................................32

Airflow Performance.......................................................................................33-39

Wiring Diagrams.............................................................................................40-46

Charge Charts................................................................................................47-50

Troubleshooting..............................................................................................51-53

Recognize this symbol as an indi-

cation of Important Safety Information!

WARNING

THE MANUFACTURER’S WARRANTY DOES NOT COVER ANY DAMAGE OR DEFECT TO THE AIR CONDITIONER CAUSED BY THE ATTACHMENT OR USE OF ANY COMPONENTS, ACCESSORIES OR DEVICES (OTHER THAN THOSE AUTHORIZED BY THE MANUFACTURER) INTO, ONTO OR IN CONJUNCTION WITH THE AIR CONDITIONER. YOU SHOULD BE AWARE THAT THE USE OF UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES MAY ADVERSELY AFFECT THE OPERATION OF THE AIR CONDITIONER AND MAY ALSO ENDANGER LIFE AND PROPERTY. THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES.

WARNING

INSTALL THIS UNIT ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS. PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE UNIT SPACE AS SPECIFIED IN THE VENTING SECTION OF THESE INSTRUCTIONS.

WARNING

PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE UNIT SPACE AS SPECIFIED IN THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS.

II. INTRODUCTION

This booklet contains the installation and operating instructions for your combination gas heating/electric cooling unit. There are some precautions that should be taken to derive maximum satisfaction from it. Improper installation can result in unsatisfactory operation or dangerous conditions.

Read this booklet and any instructions packaged with separate equipment required to make up the system prior to installation. Give this booklet to the owner and explain its provisions. The owner should retain this booklet for future reference.

III. CHECKING PRODUCT RECEIVED

Upon receiving the unit, inspect it for any damage from shipment. Claims for damage, either shipping or concealed, should be filed immediately with the shipping company. IMPORTANT: Check the unit model number, heating size, electrical characteristics, and accessories to determine if they are correct.

IV. SPECIFICATIONS

A. GENERAL

The Combination Gas Heating/Electric Cooling Rooftop is available in 80,000, 100,000, 120,000 and 135,000 BTU/Hr. heating inputs and cooling capacities of 3, 3 nominal tons of cooling. Units are convertible from bottom supply and return to side supply and return by relocation of supply and return air access panels. See cover installation detail.

The units are weatherized for mounting outside of the building.

WARNING

UNITS ARE NOT DESIGN CERTIFIED TO BE INSTALLED INSIDE THE STRUCTURE. DOING SO CAN CAUSE INADEQUATE UNIT PERFORMANCE AS WELL AS PROPERTY DAMAGE AND CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH.

The information on the rating plate is in compliance with the FTC and DOE rating for single phase units. The following information is for three phase units which are not covered under the DOE certification program.

1. The energy consumption of the ignition system used with this unit is 9 watts.

2. The efficiency rating of this unit is a product thermal efficiency rating determined under continuous operating conditions independent of any installed system.

B. MAJOR COMPONENTS

The unit includes a hermetically-sealed refrigerating system (consisting of a scroll compressor, condenser coil, evaporator coil with thermostatic expansion valve), a circulation air blower, a condenser fan, a heat exchanger assembly, gas burner and control assembly, combustion air motor and fan, and all necessary internal electrical wiring. The cooling system of these units is factory-evacuated, charged with R-410A refrigerant and performance tested. Refrigerant amount and type are indicated on rating plate.

C. R410A REFRIGERANT

All units are factory charged with R-410A refrigerant.

⁄2, 4, and 5

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

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, R410A refrigerant cylinders had a dip tube. These cylinders should be kept upright for equipment charging. Post March 1999 cylinders do not have a dip tube and should be inverted to ensure liquid charging of the equipment.

• Do not install a suction line filter drier in the liquid line.

• A liquid line filter drier is standard on every unit.

• Desiccant (drying agent) must be compatible for POE oils and R-410A

3. Evaporator Coil / TXV

The thermostatic expansion valve is specifically designed to operate with R-410A. DO NOT use an R-22 TXV. The existing evaporator must be replaced with the factory specified TXV evaporator specifically designed for R-410A.

4. Tools Required For Installing & Servicing R-410A Models

Manifold Sets:

-Up to 800 PSIG High side

-Up to 250 PSIG Low Side

-550 PSIG Low Side Retard

Manifold Hoses:

-Service Pressure Rating of 800 PSIG

Recovery Cylinders:

-400 PSIG Pressure Rating

-Dept. of Transportation 4BA400 or BW400

CAUTION

R-410A systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment.

V. SAFETY INFORMATION

WARNING

USE ONLY WITH TYPE OF GAS APPROVED FOR THIS UNIT. REFER TO THE UNIT RATING PLATE.

VI. UNIT DIMENSIONS

FOR CLEARANCES SEE FIGURE 7.

IMPORTANT: THIS UNIT MUST BE MOUNTED LEVEL IN BOTH DIRECTIONS TO ALLOW WATER TO DRAIN FROM THE CONDENSER SECTION AND CONDENSATE PAN.

FIGURE 1

BOTTOM VIEW

FIGURE 2

CABINET DIMENSIONS AND ACCESS LOCATIONS

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FIGURE 3

CABINET DIMENSIONS AND ACCESS LOCATIONS

FIGURE 4

SUPPLY AND RETURN DIMENSIONS

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I288

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.

WARNING

ALWAYS INSTALL UNIT TO OPERATE WITHIN THE UNIT'S INTENDED TEMPERATURE-RISE RANGE WITH A DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED IN DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO UNIT RATING PLATE.

WARNING

WHEN A UNIT IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BY THE UNIT TO AREAS OUTSIDE THE SPACE CONTAINING THE UNIT, THE RETURN AIR SHALL ALSO BE HANDLED BY DUCT(S) SEALED TO THE UNIT CASING AND TERMINATING OUTSIDE THE SPACE CONTAINING THE UNIT.

VII.INSTALLATION

A. GENERAL

Install this unit in accordance with The American National Standard Z223.1-latest edition booklet entitled “National Fuel Gas Code,” and the requirements or codes of the local utility or other authority having jurisdiction.

Additional helpful publications available from the “National Fire Protection Association” are: NFPA-90A - Installation of Air Conditioning and Ventilating Systems 1985 or latest edition. NFPA-90B - Warm Air Heating and Air Conditioning Systems 1984.

These publications are available from: National Fire Protection Association, Inc.

1 Batterymarch Park Quincy, MA 02169-7471 www.nfpa.org

1. PRE-INSTALLATION CHECK-POINTS — Before attempting any installation, carefully consider the following points:

Structural strength of supporting members

(Rooftop Installation) Clearances and provision for servicing Power supply and wiring Gas supply and piping Air duct connections and sizing Drain facilities and connections Location for minimum noise and

vibration - away from bedroom

windows

2. LOCATIONCONSIDERATIONS 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 petroleum refineries are especially corrosive.

If the unit is to be installed in an area where contaminants are likely to be a problem, give special attention to the equipment location and exposure.

1. Avoid having lawn sprinkler heads spray directly on the unit cabinet.

2. In coastal areas locate the unit on the side of the building away from the waterfront.

3. Shielding by a fence or shrubs may give some protection.

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. REGULAR MAINTENANCE WILL REDUCE THE BUILDUP OF CONTAMINANTS AND HELP TO PROTECT THE UNIT’S FINISH.

1. Frequent washing of the cabinet, fan blade and coil with fresh water will remove most of the salt or other contaminants that build up on the unit.

2. Regular cleaning and waxing of the cabinet with a good automobile polish will provide some protection.

3. A good liquid cleaner may be used several times a year to remove matter that will not wash off with water.

Several different types of protective coatings are offered in some areas. These coatings may provide some benefit, but the effectiveness of such coating materials cannot be verified by the equipment manufacturer.

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

WARNING

THIS UNIT MAY BE USED TO HEAT THE BUILDING OR STRUCTURE DURING CONSTRUCTION IF THE FOLLOWING INSTALLATION REQUIREMENTS ARE MET. INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATE AND TEMPERATURE RISE PER RATING PLATE MARKING;

• MEANS OF PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION;

• RETURN AIR TEMPERATURE MAINTAINED BETWEEN 55°F (13°C) AND 80°F (27°C); AND

• INSTALLATION OF EXHAUST AND COMBUSTION AIR INLET HOODS COMPLETED;

• CLEAN FURNACE, DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE, TEMPERATURE RISE AND VENTING, ACCORDING TO THE INSTRUCTIONS.

FIGURE 5

OUTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOOR CONSTRUCTION.

B. OUTSIDE SLAB INSTALLATION

WARNING

THESE UNITS ARE DESIGNED CERTIFIED FOR OUTDOOR INSTALLATION ONLY. INSTALLATION INSIDE ANY PART OF A STRUCTURE CAN RESULT IN INADEQUATE UNIT PERFORMANCE AS WELL AS PROPERTY DAMAGE. INSTALLATION INSIDE CAN ALSO CAUSE RECIRCULATION OF FLUE PRODUCTS INTO THE CONDITIONED SPACE RESULTING IN PERSONAL INJURY OR DEATH.

I298

(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.

C. ATTACHING EXHAUST AND COMBUSTION AIR INLET HOODS

IMPORTANT: Do not operate this unit without the exhaust/combustion air inlet hood properly installed. This hood is shipped in a carton in the blower compartment inside the unit and must be attached when the unit is installed. See Figure 3.

To attach exhaust/combustion air inlet hood:

1. Remove screws securing blower access panel and remove access panel. For location of blower access panel, see Figure 2.

2. Remove exhaust/combustion air inlet hood from the carton, located inside the blower compartment.

3. Attach blower access panel.

4. Attach the combustion air inlet/exhaust hood with screws. Reference Figure 3 for proper location. Screws are in carton with the hood.

5. Vent the unit using the flue exhaust hood, as supplied from the factory, without alteration or addition.

D. COVER PANEL INSTALLATION/CONVERSION PROCEDURE

DOWNFLOW TO HORIZONTAL

1. Remove the screws and covers from the outside of the supply and return sections.

2. Install the covers in the bottom supply and return openings with the painted side up. See Figure 6. Use the existing gasket to seal the covers.

3. Secure the supply cover to the base of the unit with 1 screw, engaging prepunched tab in unit base.

4. Secure the return cover to the base of the unit with screws engaging prepunched holes in the unit base.

This unit is provided with 2 - 25 X 16 X 1 disposable filters. When replacing filters, ensure they are inserted fully to the back to prevent bypass.

Recommended

Clearance

48 A - Front 18 B - Condenser Coil 12* C - Duct Side 36 D - Evaporator End 60 E - Above

*Without Economizer. 57 With Economizer

Location

FIGURE 6

COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW APPLICATION BEING CONVERTED TO HORIZONTAL

E. CLEARANCES

The following minimum clearances must be observed for proper unit performance and serviceability. Reference Figure 7.

NOTE: Supply duct may be installed with “0’ inch clearance to combustible materials, provided 1 minimum Fiberglass insulation is applied either inside or on the outside of the duct.

I631

FIGURE 7

CLEARANCES

I297

F. ROOFTOP INSTALLATION

1. Before locating the unit on the roof, make sure that the roof structure is adequate to support the weight involved. (See Electrical & Physical Tables in this manual.) THIS

IS VERY IMPORTANT AND THE INSTALLER’S RESPONSIBILITY.

2. For rigging and roofcurb details, see Figures 8, 9, 10 and 11.

3. The location of the unit on the roof should be such as to provide proper access for inspection and servicing.

4. Remove compressor shipping supports (if so equipped) after installation.

IMPORTANT: If unit will not be put into service immediately, block off supply and return air openings to prevent excessive condensation.

G. DUCTWORK

The installing contractor should fabricate ductwork in accordance with local codes. Use industry manuals as a guide when sizing and designing the duct system. Contact Air Conditioning Contractors of America, 2800 Shirlington Road, Suite 300, Arlington, VA 22206, http://www.acca.org.

WARNING

DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN DUCTWORK TO ANY OTHER HEAT PRODUCING DEVICE SUCH AS FIREPLACE INSERT, STOVE, ETC. UNAUTHORIZED USE OF SUCH DEVICES MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY, PROPERTY DAMAGE OR DEATH.

FIGURE 8

FLA T R OOFTOP IN STALLAT ION, ATTIC O R D ROP CE ILI NG DISTRI BUTING SY STEM. M OUN TED ON ROOFCURB. CURB MUST BE LEVEL.

I299

Place the unit as close to the conditioned space as possible allowing clearances as indicated. Run ducts as directly as possible to supply and return outlets. Use of non-flammable weatherproof flexible connectors on both supply and return connections at unit to reduce noise transmission is recommended.

On ductwork exposed to outside temperature and humidity, use a minimum of 2 of insulation and a vapor barrier. Distribution system in attic, furred space or crawl space should be insulated with at least 2 of insulation. 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.

⁄2 to 1 thick insulation is usually suffi-

H. RETURN AIR

WARNING

NEVER ALLOW PRODUCTS OF COMBUSTION OR THE FLUE PRODUCTS TO ENTER THE RETURN AIR DUCTWORK, OR THE CIRCULATING AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS, AND JOINTS TAPED. ALL OTHER DUCT JOINTS MUST BE SECURED WITH APPROVED CONNECTIONS AND SEALED AIRTIGHT.

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

ROOFTOP UNI

COUNTER FLA

GASKET

NAILER STRIP

DUCT*

INSULATION*

CANT STRIP*

ROOF FE INSULATI

ROOF DE

TURAL

RETURN DUCT*

SUPPLY DUCT*

NAILING STRIP

INSULATION PANELS (2) SUPPLIED

GASKET (FULL PERIMETER AND ON DIVIDERS, MUST BE ABOVE DUCT AND INSULATION PANEL FLANGES.)

HOLD DOWN BRACKET TYP. (4) PLCS.

UNIT

FIGURE 9

LIFTING DETAIL

FIGURE 10

ROOFCURB

SPREADER BAR

38.25

5/8 SHACKLE

(EACH CORNER)

CORNER WEIGHTS BY PERCENTAGE

A BCD

22% 27% 23% 28%

LIFTING BEAM

CABLE OR CHAIN

C.G.

25.75

I296

FIGURE 11

ROOFCURB

ROOFTOP UNIT

SUPPLY

RETURN

ST-A0801-19-01

GASKET

NAILER STRIP

DUCT*

ROOFCURB

ROOF STRUCTURAL MEMBER*

*BY CONTRACTOR

COUNTER FLASHING*

INSULATION*

CANT STRIP*

ROOF FELT*

INSULATION*

ROOF DECK*

ST-A0801-19-01

VIII. GAS SUPPLY, CONDENSATE DRAIN AND

VIII. PIPING

A. GAS CONNECTION

IMPORTANT: Connect this unit only to gas supplied by a commercial utility.

1. Install gas piping in accordance with local codes and regulations of the local utility company. In the absence of local codes, the installation must conform to the specifications of the National Fuel Gas Code, ANSI Z223.1 - latest edition.

NOTE: The use of flexible gas connectors is not permitted. If local codes allow the use of a corrugated stainless steel flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance.

NOTE: The Commonwealth of Massachusetts requires the gas shut-off valve to be a T-handle gas cock.

2. Connect the gas line to the gas pipe inlet opening provided into the 1/2 inlet valve. See Figure 5 or 8 for typical piping.

3. Size the gas line to the furnace adequate enough to prevent undue pressure drop and never less than 1/2 nominal pipe size.

4. Install a drip leg or sediment trap in the gas supply line as close to the unit as possible.

5. Install an outside ground joint union to connect the gas supply to the control assembly at the burner tray.

6. Gas valves have been factory installed. Install a manual gas valve where local codes specify a shut-off valve outside the unit casing. (See Figure 13.)

7. Make sure piping is tight. A pipe compound resistant to the action of liquefied

petroleum gases must be used at all threaded pipe connections.

8. IMPORTANT: any additions, changes or conversions required for the furnace to satisfactorily meet the application should be made by a qualified installer, service agency or the gas supplier, using factory-specified or approved parts. In the commonwealth of Massachusetts, installation must be performed by a licensed plumber or gas fitter for appropriate fuel.

IMPORTANT: Disconnect the furnace and its individual shutoff valve from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch gauge or isolate the system from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of this gas supply system at pressures equal to or less than 1/2 PSIG.

TO CHECK FOR GAS LEAKS, USE A SOAP AND WATER SOLUTION OR OTHER APPROVED METHOD. DO NOT USE AN OPEN FLAME.

FIGURE 13

SUGGESTED GAS PIPING

ROOF OR GROUND LEVEL INSTALLATION

FROM GAS METER

MANUAL GAS SHUT-OFF VALVE

Factory supplied grommet must be utilized.

UNIT GAS SUPPLY CONNECTION

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.

TABLE 1

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

Nominal

Iron Pipe

Size,

Inches

⁄2 132 92 73 63 56 50 46 43

⁄4 278 190 152 130 115 105 96 90

1 520 350 285 245 215 195 180 170 11⁄4 1,050 730 590 500 440 400 370 350 11⁄2 1,600 1,100 890 760 670 610 560 530

10 20 30 40 50 60 70 80

Equivalent Length of Pipe, Feet

In making gas connections, avoid strains as they may cause noise and damage the controls. A backup wrench is required to be used on the valve to avoid damage.

The capacities of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas) are shown in Table 1.

After determining the pipe length, select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the furnace. By formula:

Gas Input of Furnace

Cu. Ft. Per Hr. Required =

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT

(BTU/HR) Heating Value of Gas

(BTU/FT

) may be determined by consulting the local natural gas utility or the

)

L.P. gas supplier.

B. LP CONVERSION

WARNING

FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT SUPPLIED BY THE DISTRIBUTOR OR MANUFACTURER. MAILING ADDRESSES ARE LISTED ON THE FURNACE RATING PLATE, PARTS LIST AND WARRANTY. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY, PROPERTY DAMAGE OR DEATH.

Convert the valveto use liquefied petroleum(LP) gas by replacingthe pressureregulator spring with the conversionkit spring. ThisLP kit springallows the regulator to maintain the proper manifold pressure for LP gas. The correctburner LP orificesare includedin the kit. SeeFigure 14.

IMPORTANT: Toremove the gas valve,remove the four screwssecuringthe manifoldpipe to the burnertray. Removethe manifoldpipewith gas valve attached. See Figure15.

NOTE: Order the correctLP conversion kit from the furnacemanufacturer.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

Whenconverting unitsequippedwithNOx inserts to LP gas, the stainless steel screen meshinsertsin the entrance of the tubularexchangersare not requiredto meetSCAQMD NOxemissionlevels. Theseinserts and 1/8 diameter retainingrodshould be carefully removed beforefiringthisfurnace on LP gas. IMPORTANT: This furnace is not designedto operate on LP gas with the NOx inserts in place.

Stepby stepinstructions on removing the NOx insertsand retainingrod are includedin the Conversion Kit InstallationInstructions.

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

1/2 3/4

1-1/4 1-1/2

Example (LP): Input BTU requirement of unit, 150,000

10 20 30 40 50 60 70 80 90 100 125 150

275 189 152 129 114 103 96 89 83 78 69 63 567 393 315 267 237 217 196 182 173 162 146 132

1,071 732 590 504 448 409 378 346 322 307 275 252

2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

Equivalent length of pipe, 60 ft. = 3/4 IPS required.

Length of Pipe, Feet

FIGURE 14

FIGURE 15

MANIFOLD PIPE

D. ADJUSTING OR CHECKING FURNACE INPUT

– Natural Gas LinePressure5- 10.5W.C. – LP Gas Line Pressure 11- 1

– Natural Gas Manifold Pressure 3.5

P Gas Manifold Pressure - 10W.C

– L

Supply and manifold pressure taps are located on the gas valve body 1/8 N.P.T. and on the manifold.

Use a properly calibrated manometer gauge for accurate gas pressure readings. Only small variations in the gas flow should be made by means of the pressure regulator

adjustment. Furnaces functioning on LP gas must be set by means of the tank or branch supply regulators. The furnace manifold pressure should be set at 10 W.C. at the gas control valve.

To adjust the pressure regulator, remove the regulator cap and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure. Then replace

the regulator cap securely.

Any necessary major changes in the gas flow rate should be made by changing the size of the burner orifices. To change orifice spuds, shut off the manual main gas valve and remove the gas manifold.

For elevations up to 2,000 feet, rating plate input ratings apply. For high altitudes (elevations over 2,000 ft.), see conversion kit index 92-21519-XX for derating and orifice spud sizes.

Check of input is important to prevent over-firing of the furnace beyond its designrated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE. Use the following table or formula to determine input rate.

Heating Value of Gas

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 elevations of 2,000 - 4,500 feet (610 -1,373 meters) in Canada if the unit has been derated at the factory. For elevations above 2,000 feet (610 meters) IN THE USA ONLY (see ANSI-Z223.1), the burner orifices must be sized to reduce the input 4% for each 1,000 feet (305 meters) above sea level.

(BTU/Cu. Ft.) x 3600 Time in Seconds

(for 1 Cu. Ft.) of Gas

3W.C.



W.C

TABLE 3

INPUT

BTU/HR

40,000

60,000

80,000

100,000

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL

METER

SIZE

CU. FT.

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

ONE 1 21 1 30 1 34 1 39 3 45 TEN 13 30 15 0 15 36 16 30 37 30

ONE 0 54 101 316230 TEN 9010 0 10 24 11 0 25 0

ONE 0 41 0 45 0 47 0 50 1 53 TEN 6 45 7 30 7 48 8 15 18 45

ONE 0 33 0 36 0 38 0 40 1 30 TEN 5 24 60615 6 36 15 0

OR LP GAS

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500

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.

FIGURE 16 CONDENSATE DRAIN

DO NOT OVERTIGHTEN DRAIN FITTING

IX. WIRING

A. POWER SUPPLY

WARNING

TURN OFF THE MAIN ELECTRICAL POWER AT THE BRANCH CIRCUIT DISCONNECT CLOSEST TO THE UNIT BEFORE ATTEMPTING ANY WIRING. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

1. All wiring should be made in accordance with the National Electrical Code. Consult the local power company to determine the availability of sufficient power to operate the unit. Check the voltage at power supply to make sure it corresponds to the unit’s RATED VOLTAGE REQUIREMENT. Install a branch circuit disconnect near the rooftop, in accordance with the N.E.C., C.E.C. or local codes. A bracket is provided with the unit for mounting of the disconnect. See Figure 17.

2. It is important that proper electrical power is available at the unit. Voltage should not vary more than 10% from that stamped on the unit nameplate. On three phase units, phases must be balanced within 3%.

3. For branch circuit wiring (main power supply to unit disconnect), the minimum wire size for the length of run can be determined from Table 3 using the circuit ampacity found on the unit rating plate. Use the smallest wire size allowable in Table 4 from the unit disconnect to unit.

NOTE: A bracket is provided with the unit for mounting the branch circuit disconnect to

the unit. This is the recommended location for the disconnect. See Figure 17.

4. For through the base wiring entry reference Figure 18. All fittings and conduit are field supplied for this application. Reference the chart with Figure 18 for proper hole and conduit size.

FIGURE 17

RECOMMENDED BRANCH CIRCUIT DISCONNECT LOCATION

BRANCH CIRCUIT DISCONNECT

TO THERMOSTAT

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 AP PROVED FOR USE WITH COPPER CONDUCTORS

CONNECTED TO UNIT CONTACTOR.

ONLY

WARRANTY MAY BE JEOPARDIZED IF ALUMINUM WIRE IS CONNECTED TO UNIT CONTACTOR.

Special instructions apply for power wiring with aluminum conductors: Warranty is void if connections are not made per instructions.

Attach a length (6 or more) of recommended size copper wire to the unit contactor terminals L1 and L3 for single phase, L1, L2 and L3 for three phase.

Select the equivalent aluminum wire size from the tabulation below: Splice copper wire pigtails to aluminum wire with U.L. recognized connectors for 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.

TO POWER

I317A

TABLE 4

BRANCH CIRCUIT COPPER WIRE SIZE (Based on 1% Voltage Drop)*

200 64443322 150 86644433 100 10 8866644

50 14 12 10 10 8866

15 20 25 30 35 40 45 50

BRANCH CIRCUIT AMPACITY

SUPPLY WIRE LENGTH-FEET

*Taken from National Electric Code

TABLE 5

AWG Copper AWG Aluminum Connector Type and Size

Wire Size Wire Size (or equivalent)

#12 #10 T & B Wire Nut PT2 #10 # 8 T & B Wire Nut PT3 # 8 # 6 Sherman Split Bolt TSP6 # 6 # 4 Sherman Split Bolt TSP4 # 4 # 2 Sherman Split Bolt TSP2

FIGURE 18

FIGURE 19

TYPICAL THERMOSTAT WIRING

I658

WIRE SIZE, AWG

CONDUIT SIZE

HOLE SIZE

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).

1/2 7/8

3/4

1-31/32

1

1-23/64

1

1-23/64

1-1/4

1-23/32

1-1/4

1-23/32

1-1/2

1-31/32

1-1/2

1-31/32

2-15/32

2

000

2

2-15/32

B. HOOK-UP

To wire unit, refer to the following hook-up diagram. Refer to Figures 3 and 18 for location of wiring entrances. Wiring to be done in the field between the unit and devices not attached to the unit, or

between separate devices which are field installed and located, shall conform with the temperature limitation for Type T wire [63°F rise (35°C)] when installed in accordance with the manufacturer’s instructions.

C. INTERNAL WIRING

IMPORTANT: Some single phase units are equipped with a single pole contactor. Caution must be exercised when servicing as only one leg of the power supply is broken with the contactor.

Some models are equipped with electronically commutated blower motors which are constantly energized, unless the main unit disconnect is in the off position.

A diagram of the internal wiring of this unit is located under the electrical box cover and this manual. If any of the original wire as supplied with the appliance must be replaced, the wire gauge and insulation must be same as original wiring.

Transformer is factory wired for 230 volts on 208/230 volt models and must be changed for 208 volt applications. See unit wiring diagram for 208 volt wiring.

D. THERMOSTAT

The room thermostat must be compatible with the spark ignition control on the unit. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control. The low voltage wiring should be sized as shown in Table

6. Install the room thermostat in accordance with the instruction sheet packed in the box

with the thermostat. Run the thermostat lead wires inside the compressor access panel compartment and connect to low voltage terminals as shown on the wiring diagram. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes or ducts, lighting fixtures, radiation from fireplace, sun

TABLE 6

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.0 16 14 12 10 10 10

2.5 16 14 12 12 12 10

2.0 18 16 14 12 12 10

Amps

Thermostat Load -

(1) The total wire length is the distance from the furnace to the thermostat and back to the furnace.

NOTE: DO NOT USE CONTROL WIRING SMALLER THAN NO. 18 AWG.

50 100 150 200 250 300

Length of Run – Feet (1)

rays, lamps, televisions, radios or air streams from registers. Refer to instructions packed with the thermostat for “heater” selection or adjustment.

X. FURNACE SECTION CONTROLS AND

IGNITION SYSTEM

NORMAL FURNACE OPERATING SEQUENCE

This unit is equipped with an integrated direct spark ignition control.

1. The thermostat calls for heat.

2. The control board will run a self check to verify that the limit control and manual reset overtemperature control are closed and that the pressure switch is open.

3. Upon closure of the pressure switch, the control board energizes the induced draft blower for a 15 second prepurge.

4. After the 15 second prepurge, the gas valve opens and the spark is initiated for 7 second trial for ignition.

5. Burners ignite and flame sensor proves all burners have lit.

6. The circulating air blower is energized after 30 seconds.

7. The control board enters a normal operation loop in which all safety controls are monitored continuously.

8. Thermostat is satisfied and opens.

9. The gas valve is de-energized and closes, shutting down the burner flame.

10. The control board will de-energize the inducer after a five second post purge.

11. The circulating air blower is de-energized after 90 seconds. The integrated control is a three ignition system. After a total of three cycles without sensing main burner flame, the system goes into a

100% lockout mode. After one hour, the ignition control repeats the prepurge and ignition cycles for 3 tries and then go into 100% lockout mode again. It continues this sequence of cycles and lockout each hour until ignition is successful or power is interrupted. During the lockout mode, neither the ignitor or gas valve will be energized until the system is reset by turning the thermostat to the “OFF” position or interrupting the electrical power to the unit for 3 seconds or longer. The induced draft blower and main burner will shut off when the thermostat is satisfied.

The circulating air blower will start and run on the heating speed if the thermostat fan switch is in the “ON” position.

The integrated furnace control is equipped with diagnostic LED. The LED is lit continuously when there is power to the control, with or without a call for heat. If the LED is not lit, there is either no power to the control or there is an internal component failure within the control, and the control should be replaced.

If the control detects the following failures, the LED will flash on for approximately 1/4 second, then off for 3/4 second for designated failure detections.

1 Flash: Failed to detect flame within the three tries for ignition. 2 Flash: Pressure switch or induced draft blower problem detected. 3 Flash: High limit or auxiliary limit open. 4 Flash: Flame sensed and gas valve not energized or flame sensed with no “W” signal. 5 Flash: Overtemperature switch open.

OPERATING INSTRUCTIONS

This appliance is equipped with integrated furnace control. This device lights the main burners each time the room thermostat (closes) calls for heat. See operating instructions on the back of the furnace/controls access panel.

WARNING

DO NOT ATTEMPT TO MANUALLY LIGHT THIS FURNACE WITH A MATCH OR ANY OPEN FLAME. ATTEMPTING TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

TO START THE FURNACE

1. STOP! Read the safety information on the Operating Instructions label located on this appliance.

WARNING

IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

2. Set the thermostat to its lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT

5. Remove control door/access panel.

6. Move switch to the “OFF” position.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP!

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

If you don’t smell gas, go to the next step.

8. Move “OFF” position to “ON” position.

9. Replace the control door.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

12. If the appliance will not operate, follow the instructions below on how to shut down the furnace.

WARNING

THE SPARK IGNITOR AND IGNITION LEAD FROM THE IGNITION CONTROL ARE HIGH VOLTAGE. KEEP HANDS OR TOOLS AWAY TO PREVENT ELECTRICAL SHOCK. SHUT OFF ELECTRICAL POWER BEFORE SERVICING ANY OF THE CONTROLS. FAILURE TO ADHERE TO THIS WARNING CAN RESULT IN PERSONAL INJURY OR DEATH.

try to light the burner by hand.

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.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, SHUT OFF THE MANUAL GAS VALVE TO THE APPLIANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN RESULT IN AN EXPLOSION OR FIRE CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH!

BURNERS

Burners for these units have been designed so that field adjustment is not required. Burners are tray-mounted and accessible for easy cleaning when required.

MANUAL RESET OVERTEMPERATURE CONTROL

Two manual reset overtemperature controls (one on 80,000 BTUH) are located on the burner shield. These devices senses blockage in the heat exchanger or insufficient combustion air. This shuts off the main burners if excessive temperatures occur in the burner compartment.

Operation of this control indicates an abnormal condition. Therefore, the unit should be examined by a qualified installer, service agency, or the gas supplier before being placed back into operation.

WARNING

DO NOT JUMPER THIS DEVICE! DO NOT reset the over temperature control without taking corrective action to assure that an adequate supply of combustion air is maintained under all conditions of operation. Failure to do so can result in carbon monoxide poisoning or death. Replace this control only with the identical replacement part.

PRESSURE SWITCH

This furnace has a pressure switch for sensing a blocked exhaust or a failed induced draft blower. It is normally open and closes when the induced draft blower starts, indicating air flow through the combustion chamber.

LIMIT CONTROL

The supply air high temperature limit cut-off is set at the factory and cannot be adjusted. It is calibrated to prevent the air temperature leaving the furnace from exceeding the maximum outlet air temperature.

WARNING

DO NOT JUMPER THIS DEVICE! DOING SO CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

IMPORTANT: Replace this control only with the identical replacement part.

XI. SYSTEM OPERATING INFORMATION

ADVISE THE CUSTOMER

1. Change the air filters regularly. The heating system operates better, more efficiently and more economically.

2. Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed.

3. Close doors and windows. This reduces the heating and cooling load on the system.

4. Avoid excessive use of exhaust fans.

5. Do not permit the heat generated by television, lamps or radios to influence the thermostat operation.

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

7. IMPORTANT: Replace all blower doors and compartment cover after servicing the

unit. Do not operate the unit without all panels and doors securely in place.

8. Do not allow snow or other debris to accumulate in the vicinity of the appliance.

FURNACE SECTION MAINTENANCE

The unit’s furnace should operate for many years without excessive scale build-up in flue passageways; however, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect the flue passageways, the exhaust system and the burners for continued safe operation, paying particular attention to deterioration from corrosion or other sources.

If during inspection the flue passageways and exhaust system are determined to require cleaning, the following procedures should be followed (by a qualified installer, service

agency, or gas supplier):

1. Turn off the electrical power to the unit and set the thermostat to the lowest temperature.

2. Shut off the gas supply to the unit either at the meter or at manual valve in the supply piping.

WARNING

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

3. Remove the furnace controls access panel and the control box cover.

4. Disconnect the gas supply piping from the gas valve.

5. Disconnect the wiring to the induced draft blower motor, gas valve, flame sensor, and flame roll-out control, and ignitor cable. Mark all wires disconnected for proper reconnection.

6. Remove the screws (4) connecting the burner tray to the heat exchanger mounting panel.

7. Remove the burner tray and the manifold assembly from the unit.

8. Remove the screws (5) connecting the induced draft blower to the collector box and screws (18) connecting the collector box to the heat exchanger center panel. Remove the induced draft blower and the collector box from the unit.

9. Remove the screws (3) connecting the divider plate to the heat exchanger center panel.

10. Remove the turbulators from inside the heat exchangers by inserting the blade of a screwdriver under the locking tabs. Pop the tabs out of the expanded grooves of the heat exchanger. Slide the turbulators out of the heat exchangers.

11. Direct a water hose into the outlet of the heat exchanger top. Flush the inside of each heat exchanger tube with water. Blow out each tube with air to remove excessive moisture.

12. Reassemble (steps 1 through 10 in reverse order). Be careful not to strip out the

screw holes used to mount the collector box and inducer blower. Replace inducer blower gasket and collector box gasket with factory replacements if damaged.

WARNING

HOLES IN THE EXHAUST TRANSITION OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME. THE EXHAUST TRANSITION OR HEAT EXCHANGER MUST BE REPLACED IF THEY HAVE HOLES OR CRACKS IN THEM. FAILURE TO DO SO CAN CAUSE CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH.

The manufacturer recommends that a qualified installer, service agency or the gas supplier visually inspect the burner flames for the desired flame appearance at the beginning of the heating season and approximately midway in heating season.

The manufacturer also recommends that a qualified installer, service agency or the gas supplier clean the flame sensor with steel wool at the beginning of the heating season.

WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING MAINTENANCE. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK OR SEVERE PERSONAL INJURY OR DEATH.

LUBRICATION

IMPORTANT: DO NOT attempt to lubricate the bearings on the blower motor or the induced draft blower motor. Addition of lubricants can reduce the motor life and void the warranty.

The blower motor and induced draft blower motor are prelubricated by the manufacturer and do not require further attention.

A qualified installer, service agency or the gas supplier must periodically clean the motors to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior. And, as suggested elsewhere in these instructions, the air filters should be kept clean because dirty filters can restrict air flow and the motor depends upon sufficient air flowing across and through it to prevent overheating.

COOLING SECTION MAINTENANCE

WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

It is recommended that at the beginning of each cooling season a qualified installer or service agency inspect and clean the cooling section of this unit. The following areas should be addressed: evaporator coil. condenser coil, condenser fan motor and venturi area.

To inspect the evaporator coil:

1. Remove the filter access panel and the blower/evaporator coil access panel. Remove the filters.

WARNING

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING THE UNIT. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.

2. Shine a flashlight on the evaporator coil (both sides) and inspect for accumulation of lint, insulation, etc.

3. If coil requires cleaning, follow the steps shown below.

Cleaning Evaporator Coil

1. The coil should be cleaned when it is dry. If the coil is coated with dirt or lint, vacuum it with a soft brush attachment. Be careful not to bend the coil fins.

2. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solution. Rinse the coil thoroughly with water. IMPORTANT: Do not 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.

use excessive

4. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solution. Rinse the coil thoroughly with water. IMPORTANT: Do not 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.

use excessive

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.

FIGURE 20

SPEED TAP BLOCK

FIGURE 22

INTEGRATED FURNACE CONTROL

FIGURE 21

FIGURE 22 (Continued)

XII. GENERAL DATA - TGC MODELS

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

Model TGC-Series 036A3K-080 036A-3K-120 036A-1K-080 036A-1K-120 Cooling Performance

Gross Cooling Capacity Btu [kW] 36,800 [10.78] 36,800 [10.78] 36,800 [10.78] 36,800 [10.78] EER/SEER Nominal CFM/ARI Rated CFM [L/s] 1200/1200 [566/566] 1200/1200 [566/566] 1200/1200 [566/566] 1200/1200 [566/566] ARI Net Cooling Capacity Btu [kW] 35,400 [10.37] 35,400 [10.37] 35,400 [10.37] 35,400 [10.37] Net Sensible Capacity Btu [kW] 26,200 [7.68] 26,200 [7.68] 26,200 [7.68] 26,200 [7.68] Net Latent Capacity Btu [kW] 9,200 [2.7] 9,200 [2.7] 9,200 [2.7] 9,200 [2.7] Net System Power kW 3.1 3.1 3.1 3.1

Heating Performance (Gas)

Heating Input Btu [kW] 80,000 [23.44] 120,000 [35.16] 80,000 [23.44] 120,000 [35.16] Heating Output Btu [kW] 64,800 [18.99] 97,200 [28.48] 62,500 [18.31] 94,500 [27.69] Temperature Rise Range °F [°C] 30-60 [16.7/33.3] 50-80 [27.8/44.4] 30-60 [16.7/33.3] 50-80 [27.8/44.4] AFUE % 80 80 80 80 Steady State Efficiency (%) 81 81 81 81 No. Burners 4646 No. Stages 1111 Gas Connection Pipe Size in. [mm] 0.5 [12.7] 0.5 [12.7] 0.5 [12.7] 0.5 [12.7]

Compressor

No./Type 1/Scroll 1/Scroll 1/Copeland Scroll 1/Copeland Scroll

Outdoor Sound Rating (dB) Outdoor Coil - Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] OD 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 16.91 [1.57] 16.91 [1.57] 16.91 [1.57] 16.91 [1.57] Rows / FPI [FPcm] 1 / 22 [9] 1 / 22 [9] 1 / 22 [9] 1 / 22 [9]

Indoor Coil - Fin Type Corrugated Corrugated Corrugated Corrugated

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] Rows / FPI [FPcm] 2 / 17 [7] 2 / 17 [7] 2 / 17 [7] 2 / 17 [7] Refrigerant Control TX Valves TX Valves TX Valves TX Valves Drain Connection No./Size in. [mm] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05]

Outdoor Fan - Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 1/24 [609.6] 1/24 [609.6] 1/24 [609.6] 1/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 3680 [1737] 3680 [1737] 3680 [1737] 3680 [1737] No. Motors/HP 1 at 1/3 HP 1 at 1/3 HP 1 at 1/3 HP 1 at 1/3 HP Motor RPM 1075 1075 1075 1075

Indoor Fan - Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 1/10x10 [254x254] 1/10x10 [254x254] 1/10x10 [254x254] 1/10x10 [254x254] Drive Type/No. Speeds Direct/3 Direct/3 Direct/3 Direct/3 No. Motors 1111 Motor HP 1/2 1/2 1/2 1/2 Motor RPM 1075 1075 1075 1075 Motor Frame Size 48 48 48 48

Filter - Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Refrigerant Charge Oz. [g] 96 [2722] 96 [2722] 96 [2722] 96 [2722] Weights

Net Weight lbs. [kg] 543 [246] 543 [246] 543 [246] 543 [246] Ship Weight lbs. [kg] 550 [249] 550 [249] 550 [249] 550 [249]

11.4/13 11.4/13 11.4/13 11.4/13

78 78 78 78

(1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Continued ->

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.

GENERAL DATA - TGC MODELS

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

Model TGC-Series 042A-3K-080 042A-3K-120 042A-1K-080 042A-1K-120 Cooling Performance

Gross Cooling Capacity Btu [kW] 42,500 [12.45] 42,500 [12.45] 42,500 [12.45] 42,500 [12.45] EER/SEER Nominal CFM/ARI Rated CFM [L/s] 1400/1450 [661/684] 1400/1450 [661/684] 1400/1450 [661/684] 1400/1450 [661/684] ARI Net Cooling Capacity Btu [kW] 40,500 [11.87] 40,500 [11.87] 40,500 [11.87] 40,500 [11.87] Net Sensible Capacity Btu [kW] 30,600 [8.97] 30,600 [8.97] 30,600 [8.97] 30,600 [8.97] Net Latent Capacity Btu [kW] 9,900 [2.9] 9,900 [2.9] 9,900 [2.9] 9,900 [2.9] Net System Power kW 3.62 3.62 3.62 3.62

Heating Performance (Gas)

Compressor

No./Type 1/Copeland Scroll 1/Copeland Scroll 1/Scroll 1/Scroll

Outdoor Sound Rating (dB) Outdoor Coil - Fin Type Louvered Louvered Louvered Louvered

Indoor Coil - Fin Type Corrugated Corrugated Corrugated Corrugated

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] Rows / FPI [FPcm] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] Refrigerant Control TX Valves TX Valves TX Valves TX Valves Drain Connection No./Size in. [mm] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05]

Outdoor Fan - Type Propeller Propeller Propeller Propeller

Indoor Fan - Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

Filter - Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Refrigerant Charge Oz. [g] 125 [3544] 125 [3544] 125 [3544] 125 [3544] Weights

Net Weight lbs. [kg] 570 [259] 579 [263] 570 [259] 579 [263] Ship Weight lbs. [kg] 577 [262] 586 [266] 577 [262] 586 [266]

11.2/13 11.2/13 11.2/13 11.2/13

78 78 78 78

(1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Continued ->

NOTES:

2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures.

4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270.

GENERAL DATA - TGC MODELS

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

Model TGC-Series 048A-3K-080 048A-3K-100 048A-3K-135 048A-1K-080 Cooling Performance

Gross Cooling Capacity Btu [kW] 50,000 [14.65] 50,000 [14.65] 50,000 [14.65] 50,000 [14.65] EER/SEER Nominal CFM/ARI Rated CFM [L/s] 1600/1600 [755/755] 1600/1600 [755/755] 1600/1600 [755/755] 1600/1600 [755/755] ARI Net Cooling Capacity Btu [kW] 48,000 [14.06] 48,000 [14.06] 48,000 [14.06] 48,000 [14.06] Net Sensible Capacity Btu [kW] 35,600 [10.43] 35,600 [10.43] 35,600 [10.43] 35,600 [10.43] Net Latent Capacity Btu [kW] 12,400 [3.63] 12,400 [3.63] 12,400 [3.63] 12,400 [3.63] Net System Power kW 4.19 4.19 4.19 4.19

Heating Performance (Gas)

Heating Input Btu [kW] 80,000 [23.44] 100,000 [29.3] 135,000 [39.56] 80,000 [23.44] Heating Output Btu [kW] 64,800 [18.99] 81,000 [23.73] 109,400 [32.05] 62,500 [18.31] Temperature Rise Range °F [°C] 30-60 [16.7/33.3] 40-70 [22.2/38.9] 50-80 [27.8/44.4] 30-60 [16.7/33.3] AFUE % 80 80 80 80 Steady State Efficiency (%) 81 81 81 81 No. Burners 4564 No. Stages 1111 Gas Connection Pipe Size in. [mm] 0.5 [12.7] 0.5 [12.7] 0.5 [12.7] 0.5 [12.7]

Compressor

No./Type 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll

Outdoor Sound Rating (dB) Outdoor Coil - Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] OD 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 16.59 [1.54] 16.56 [1.54] 16.56 [1.54] 16.56 [1.54] Rows / FPI [FPcm] 2 / 22 [9] 2 / 22 [9] 2 / 22 [9] 2 / 22 [9]

Indoor Coil - Fin Type Corrugated Corrugated Corrugated Corrugated

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] Rows / FPI [FPcm] 3 / 15 [6] 3 / 15 [6] 3 / 15 [6] 3 / 15 [6] Refrigerant Control TX Valves TX Valves TX Valves TX Valves Drain Connection No./Size in. [mm] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05]

Outdoor Fan - Type Propeller Propeller Propeller Propeller

Indoor Fan - Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

Filter - Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Refrigerant Charge Oz. [g] 165 [4678] 165 [4678] 165 [4678] 165 [4678] Weights

Net Weight lbs. [kg] 580 [263] 580 [263] 585 [265] 580 [263] Ship Weight lbs. [kg] 587 [266] 587 [266] 592 [269] 587 [266]

11.45/13 11.45/13 11.45/13 11.45/13

78 78 78 78

(1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Continued ->

NOTES:

2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures.

4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270.

GENERAL DATA - TGC MODELS

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

Model TGC-Series 048A-1K-100 048A-1K-135 060A-3K-100 060A-3K-135 Cooling Performance

Gross Cooling Capacity Btu [kW] 50,000 [14.65] 50,000 [14.65] 61,000 [17.87] 61,000 [17.87] EER/SEER Nominal CFM/ARI Rated CFM [L/s] 1600/1600 [755/755] 1600/1600 [755/755] 2000/1900 [944/897] 2000/1900 [944/897] ARI Net Cooling Capacity Btu [kW] 48,000 [14.06] 48,000 [14.06] 59,000 [17.29] 59,000 [17.29] Net Sensible Capacity Btu [kW] 35,600 [10.43] 35,600 [10.43] 42,000 [12.31] 42,000 [12.31] Net Latent Capacity Btu [kW] 12,400 [3.63] 12,400 [3.63] 17,000 [4.98] 17,000 [4.98] Net System Power kW 4.19 4.19 5.32 5.32

Heating Performance (Gas)

Heating Input Btu [kW] 100,000 [29.3] 135,000 [39.56] 100,000 [29.3] 135,000 [39.56] Heating Output Btu [kW] 78,500 [23] 106,500 [31.2] 81,000 [23.73] 109,400 [32.05] Temperature Rise Range °F [°C] 40-70 [22.2/38.9] 50-80 [27.8/44.4] 25-55 [13.9/30.6] 40-70 [22.2/38.9] AFUE % 80 80 80 80 Steady State Efficiency (%) 81 81 81 81 No. Burners 5656 No. Stages 1111 Gas Connection Pipe Size in. [mm] 0.5 [12.7] 0.5 [12.7] 0.5 [12.7] 0.5 [12.7]

Compressor

No./Type 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll 1/Copeland Scroll

Outdoor Sound Rating (dB) Outdoor Coil - Fin Type Louvered Louvered Louvered Louvered

Indoor Coil - Fin Type Corrugated Corrugated Corrugated Corrugated

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] 5.17 [0.48] Rows / FPI [FPcm] 3 / 15 [6] 3 / 15 [6] 3 / 15 [6] 3 / 15 [6] Refrigerant Control TX Valves TX Valves TX Valves TX Valves Drain Connection No./Size in. [mm] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05] 1/0.75 [19.05]

Outdoor Fan - Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 1/24 [609.6] 1/24 [609.6] 1/24 [609.6] 1/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 3680 [1737] 3680 [1737] 3930 [1855] 3930 [1855] No. Motors/HP 1 at 1/3 HP 1 at 1/3 HP 1 at 1/3 HP 1 at 1/3 HP Motor RPM 1075 1075 1075 1075

Indoor Fan - Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 1/10x10 [254x254] 1/10x10 [254x254] 1/10x10 [254x254] 1/10x10 [254x254] Drive Type/No. Speeds Direct/3 Direct/3 Direct/3 Direct/3 No. Motors 1111 Motor HP 1/2 1/2 11 Motor RPM 1075 1075 1075 1075 Motor Frame Size 48 48 48 48

Filter - Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Refrigerant Charge Oz. [g] 165 [4678] 165 [4678] 160 [4536] 160 [4536] Weights

Net Weight lbs. [kg] 580 [263] 585 [265] 590 [268] 597 [271] Ship Weight lbs. [kg] 587 [266] 592 [269] 597 [271] 604 [274]

11.45/13 11.45/13 11.1/13 11.1/13

78 78 83 83

(1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Continued ->

NOTES:

2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures.

4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270.

GENERAL DATA - TGC MODELS

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

Model TGC-Series 060A-1K-100 060A-1K-135 Cooling Performance

Gross Cooling Capacity Btu [kW] 61,000 [17.87] 61,000 [17.87] EER/SEER Nominal CFM/ARI Rated CFM [L/s] 2000/1900 [944/897] 2000/1900 [944/897] ARI Net Cooling Capacity Btu [kW] 59,000 [17.29] 59,000 [17.29] Net Sensible Capacity Btu [kW] 42,000 [12.31] 42,000 [12.31] Net Latent Capacity Btu [kW] 17,000 [4.98] 17,000 [4.98] Net System Power kW 5.32 5.32

Heating Performance (Gas)

Heating Input Btu [kW] 100,000 [29.3] 135,000 [39.56] Heating Output Btu [kW] 78,500 [23] 106,500 [31.2] Temperature Rise Range °F [°C] 25-55 [13.9/30.6] 40-770 [22.2/38.9] AFUE % 80 80 Steady State Efficiency (%) 81 81 No. Burners 56 No. Stages 11 Gas Connection Pipe Size in. [mm] 0.5 [12.7] 0.5 [12.7]

Compressor

No./Type 1/Copeland Scroll 1/Copeland Scroll

Outdoor Sound Rating (dB) Outdoor Coil - Fin Type Louvered Louvered

Tube Type Rifled Rifled Tube Size in. [mm] OD 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 16.56 [1.54] 16.56 [1.54] Rows / FPI [FPcm] 2 / 22 [9] 2 / 22 [9]

Indoor Coil - Fin Type Corrugated Corrugated

Tube Type Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 5.17 [0.48] 5.17 [0.48] Rows / FPI [FPcm] 3 / 15 [6] 3 / 15 [6] Refrigerant Control TX Valves TX Valves Drain Connection No./Size in. [mm] 1/0.75 [19.05] 1/0.75 [19.05]

Outdoor Fan - Type Propeller Propeller

No. Used/Diameter in. [mm] 1/24 [609.6] 1/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 CFM [L/s] 3930 [1855] 3930 [1855] No. Motors/HP 1 at 1/3 HP 1 at 1/3 HP Motor RPM 1075 1075

Indoor Fan - Type FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 1/10x10 [254x254] 1/10x10 [254x254] Drive Type/No. Speeds Direct/3 Direct/3 No. Motors 11 Motor HP 11 Motor RPM 1075 1075 Motor Frame Size 48 48

Filter - Type Disposable Disposable

Furnished Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

Refrigerant Charge Oz. [g] 160 [4536] 160 [4536] Weights

Net Weight lbs. [kg] 590 [268] 597 [271] Ship Weight lbs. [kg] 597 [271] 604 [274]

11.1/13 11.1/13

83 83

(1)1x16x25 [25x406x635] (1)1x16x25 [25x406x635]

NOTES:

2. EER and/or SEER are rated at ARI conditions and in accordance with DOE test procedures.

4. Outdoor Sound Rating shown is tested in accordance with ARI Standard 270.

XIII. MISCELLANEOUS

036A-3K-080 036A-3K-120 036A-1K-080 036A-1K-120 042A-3K-080 042A-3K-120 042A-1K-080 042A-1K-120 048A-3K-080

Unit Operating Voltage Range

Minimum Circuit

Ampacity

Minimum Overcurrent

Protection Device Size

Unit InformationCompressor MotorCondenser MotorEvaporator Fan

Maximum Overcurrent Protection Device Size

Volts

Phase

RPM Amps (RLA) Amps (LRA)

Volts

Phase

Amps (FLA) Amps (LRA)

Volts

Phase

Amps (FLA) Amps (LRA)

No.

187-253 187-253 187-253 187-253 187-253 187-253 187-253 187-253 187-253

19/19 19/19 27/27 27/27 23/23 23/23 28/28 28/28 23/23

25/25 25/25 35/35 35/35 30/30 30/30 35/35 35/35 30/30

25/25 25/25 40/40 40/40 35/35 35/35 45/45 45/45 35/35

111 111 1 11

208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230

3 31 1 33 1 13

3 33 33 1/2 3 1/2 3 1/2 3 1/2 4

3450 3450 3450 3450 3450 3450 3450 3450 3450

10.4/10.4 10.4/10.4 16.7/16.7 16.7/16.7 13.5/13.5 13.5/13.5 17.9/17.9 17.9/17.9 13.7/13.7

88/88 88/88 79/79 79/79 88/88 88/88 112/112 112/112 83.1/83.1

1 11 1 11 1 11

208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230

1 11 1 11 1 11

1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3

1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

333 333 3 33

111 111 1 11

208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230

111 111 1 11

1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2

444 444 4 44

6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7

ELECTRICAL DATA – TGC SERIES

Unit Operating Voltage Range

Minimum Circuit

Ampacity

Minimum Overcurrent

Protection Device Size

Unit InformationCompressor MotorCondenser MotorEvaporator Fan

Maximum Overcurrent Protection Device Size

Volts

Phase

RPM Amps (RLA) Amps (LRA)

Volts

Phase

Amps (FLA) Amps (LRA)

Volts

Phase

Amps (FLA) Amps (LRA)

No.

ELECTRICAL DATA – TGC SERIES

048A-3K-100 048A-3K-135 048A-1K-080 048A-1K-100 048A-3K-135 060A-3K-100 060A-3K-135 060A-1K-100 060A-1K-135

187-253 187-253 187-253 187-253 187-253 187-253 187-253 187-253 187-253

23/23 23/23 33/33 33/33 33/33 30/30 30/30 43/43 43/43

30/30 30/30 40/40 40/40 40/40 35/35 35/35 50/50 50/50

35/35 35/35 50/50 50/50 50/50 40/40 40/40 60/60 60/60

111 111 1 11

208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230

331 113 3 11

444 445 5 55

3450 3450 3450 3450 3450 3450 3450 3450 3450

13.7/13.7 13.7/13.7 21.8/21.8 21.8/21.8 21.8/21.8 15.6/15.6 15.6/15.6 26.3/26.3 26.3/26.3

83.1/83.1 83.1/83.1 117/117 117/117 117/117 110/110 110/110 134/134 134/134

111 111 1 11

208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230

111 111 1 11

1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3

1.5 1.5 1.5 1.5 1.5 2.2 2.2 2.2 2.2

333 334.9 4.9 4.9 4.9

111 111 1 11

208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230 208/230

111 111 1 11

1/2 1/2 1/2 1/2 1/2 1111

444 447.6 7.6 7.6 7.6

6.7 6.7 6.7 6.7 6.7 0000

INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC

DIRECT DRIVE

External Static Pressure-Inches W.C.

CFM Air Delivery/RPM/Watts-208 VOLTS

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM 1210 1193 1175 1155 1125 1075 1015 925

Motor

Speed

of Speeds

Motor HP #

Blower Size/

Manufacturer

Recommended

Air-Flow Range

(Min / Max) CFM

[kW]

Input

BTU/hr

Heating

Heat

Watts 450 400 395 385 380 375 370 360

Low

10x10

80,000

[23.45]

Low

CFM 1515 1500 1475 1450 1405 1350 1275 1180

CFM 1680 1650 1625 1580 1530 1460 1390 1280

Watts 525 515 510 505 490 475 460 445

Med

High

1/2

(PSC)

3 Speed

1050 / 1350

[35.17]

120,000

Med

Watts 650 640 630 610 580 560 545 515

CFM 1210 1193 1175 1155 1125 1075 1015 925

Watts 450 400 395 385 380 375 370 360

Low

80,000

Low

CFM 1515 1500 1475 1450 1405 1350 1275 1180

Watts 525 515 510 505 490 475 460 445

Med

1/2

10x10

3 Speed

1225 / 1575

[23.45]

CFM 1680 1650 1625 1580 1530 1460 1390 1280

Watts 650 640 630 610 580 560 545 515

High

(PSC)

[35.17]

120,000

Med

CFM 1210 1193 1175 1155 1125 1075 1015 925

Watts 450 400 395 385 380 375 370 360

Low

10x10

80,000

[23.45]

Low

CFM 1515 1500 1475 1450 1405 1350 1275 1180

CFM 1680 1650 1625 1580 1530 1460 1390 1280

Watts 525 515 510 505 490 475 460 445

Med

High

1/2

(PSC)

3 Speed

1400 / 1800

[29.31]

[39.56]

100,000

135,000

Med

High

Watts 650 640 630 610 580 560 545 515

CFM 1575 1536 1496 1457 1417 1377 1338 1298

Watts 297 314 330 347 364 381 397 414

Low

10x10

[29.31]

100,000

Low

CFM 1985 1954 1919 1876 1824 1759 1679 1581

CFM 2431 2372 2306 2228 2138 2032 1907 1762

Watts 535 553 574 593 606 609 599 572

Med

High

(X-13)

3 Speed

1750 / 2250

[39.56]

135,000

High

Watts 970 981 964 926 872 806 736 665

Cool

Motor Speed

From Factory

Unit Model

DIRECT-DRIVE BLOWER 208 AIRFLOW PERFORMANCE

Low

TGC036A

Med

TGC036A

Med

TGC036A

Med

TGC036A

INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC

DIRECT DRIVE

External Static Pressure-Inches W.C.

CFM Air Delivery/RPM/Watts-230 VOLTS

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM 1400 1375 1360 1335 1305 1255 1210 1100

Motor

Speed

of Speeds

Motor HP #

Blower Size/

Manufacturer

Recommended

Air-Flow Range

(Min / Max) CFM

[kW]

Input

80,000

BTU/hr

Heating

Heat

Watts 470 460 455 450 440 435 425 410

Low

10x10

[23.45]

Low

CFM 1685 1620 1580 1550 1500 1430 1350 1230

CFM 1870 1830 1790 1730 1660 1580 1500 1375

Watts 635 600 580 570 550 535 505 475

Med

High

1/2

(PSC)

3 Speed

1050 / 1350

[35.17]

120,000

Med

Watts 780 760 740 700 660 635 600 555

CFM 1400 1375 1360 1335 1305 1255 1210 1100

Watts 470 460 455 450 440 435 425 410

Low

10x10

80,000

[23.45]

Low

CFM 1685 1620 1580 1550 1500 1430 1350 1230

CFM 1870 1830 1790 1730 1660 1580 1500 1375

Watts 635 600 580 570 550 535 505 475

Watts 780 760 740 700 660 635 600 555

Med

High

1/2

(PSC)

3 Speed

1225 / 1575

[35.17]

120,000

Med

CFM 1400 1375 1360 1335 1305 1255 1210 1100

Watts 470 460 455 450 440 435 425 410

Low

10x10

80,000

[23.45]

Low

CFM 1685 1620 1580 1550 1500 1430 1350 1230

CFM 1870 1830 1790 1730 1660 1580 1500 1375

Watts 635 600 580 570 550 535 505 475

Med

High

1/2

(PSC)

3 Speed

1400 / 1800

[29.31]

100,000

135,000

Med

High

CFM 1575 1536 1496 1457 1417 1377 1338 1298

Watts 780 760 740 700 660 635 600 555

Low

[39.56]

100,000

Low

CFM 1985 1954 1919 1876 1824 1759 1679 1581

Watts 297 314 330 347 364 381 397 414

Med

10x10

1750 / 2250

[29.31]

CFM 2431 2372 2306 2228 2138 2032 1907 1762

Watts 535 553 574 593 606 609 599 572

Watts 970 981 964 926 872 806 736 665

High

(X-13)

3 Speed

[39.56]

135,000

High

Cool

Motor Speed

From Factory

Unit Model

DIRECT-DRIVE 230 AIRFLOW PERFORMANCE

Low

TGC036A

Med

TGC042A

Med

TGC048A

Med

TGC060A

INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC

DIRECT DRIVE

External Static Pressure-Inches W.C.

CFM Air Delivery/RPM/Watts-460 VOLTS

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Motor

Speed

of Speeds

Motor HP #

Blower Size/

Manufacturer

Recommended

Air-Flow Range

(Min / Max) CFM

[kW]

Input

80,000

BTU/hr

Heating

Heat

CFM 1400 1375 1360 1335 1305 1255 1210 1100

Low

[23.45]

120,000

Low

Watts 470 460 455 450 440 435 425 410

10x10

[35.17]

CFM 1685 1620 1580 1550 1500 1430 1350 1230

Watts 635 600 580 570 550 535 505 475

Med

1/2

(PSC)

3 Speed

1050 / 1350

CFM 1870 1830 1790 1730 1660 1580 1500 1375

High

Watts 780 760 740 700 660 635 600 555

CFM 1400 1375 1360 1335 1305 1255 1210 1100

Low

Watts 470 460 455 450 440 435 425 410

CFM 1685 1620 1580 1550 1500 1430 1350 1230

Watts 635 600 580 570 550 535 505 475

Med

1/2

10x10

3 Speed

1225 / 1575

80,000

[23.45]

120,000

Med

CFM 1870 1830 1790 1730 1660 1580 1500 1375

(PSC)

[35.17]

Watts 780 760 740 700 660 635 600 555

High

CFM 1400 1375 1360 1335 1305 1255 1210 1100

Low

Watts 470 460 455 450 440 435 425 410

CFM 1685 1620 1580 1550 1500 1430 1350 1230

Watts 635 600 580 570 550 535 505 475

Med

1/2

10x10

3 Speed

1400 / 1800

CFM 1870 1830 1790 1730 1660 1580 1500 1375

(PSC)

80,000

Watts 780 760 740 700 660 635 600 555

High

[23.45]

[39.56]

135,000

High

Cool

Motor Speed

From Factory

Unit Model

DIRECT-DRIVE 460 AIRFLOW PERFORMANCE

Low

TGC036A

Med

TGC042A

High

TGC048A

INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC

BELT DRIVE

RPM WATTS

1240 645

1260 715

1270 730

1290 780

1300 825

1320 880

1330 940

“N”

RPM WATTS

1215 625

1225 650

1235 690

1245 730

1255 780

1270 840

1290 905

RPM WATTS

1170 580

1180 605

1190 640

1210 690

1220 730

1230 810

1240 850

RPM WATTS

1140 555

1155 575

1170 615

1180 655

1195 680

1215 775

1225 820

RPM WATTS

1095 525

1105 540

1120 575

1130 605

1155 630

1170 705

1185 760

“M”

RPM WATTS

1055 490

1075 515

1085 540

1095 580

1115 610

1125 650

1135 700

RPM WATTS

1010 470

1025 485

1035 505

1045 540

1060 575

1080 590

960 455

980 470

905 400

925 425

995 485

940 435

1005 495

955 475

1025 530

970 505

1035 560

990 520

RPM WATTS

EXTERNAL STATIC PRESSURE

RPM WATTS

3 TON - 13 SEER MODELS

845 340

860 375

885 390

900 415

920 455

835 370

775 340

720 305

855 400

805 375

750 340

940 480

880 440

825 395

775 375

RPM WATTS

780 290

RPM WATTS

715 260

RPM WATTS

650 230

RPM WATTS

800 320

740 280

670 255

820 345

760 310

700 275

1090 660

1050 615

1005 565

955 535

910 490

845 425

800 405

“L”

RESISTANCE - INCHES WATER

STANDARD INDOOR AIRFLOW - CFM

.05 .06 .07 .08 .09 .10 .11 .12 .13 .15

COMPONENT 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800

WET COIL .035 .040 .060 .070 .085 .100 .110 .120 .125 .130

DOWNFLOW .055 .060 .066 .072 .080 .086 .093 .100 .107 .115

ECONOMIZER

R. A. DAMPER

NOTES:

1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS

2. STANDARD CFM @ .075 LBS./CU. FT.

3. MOTOR EFFICIENCY = 80%

COMPONENT AIR RESISTANCE

4. BHP = WATTS X MOTOR EFF.

746

5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P.

— —

615 225

— —

900

— —

1000

630 255

— —

1100

RPM WATTS

CAPACITY: 3 TON - 13 SEER

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.10 1.20 1.30 1.40 1.50

VOLTAGE: 208/230 - 460

AIR

CFM

FLOW

RPM WATTS

655 270

605 250

1200

675 300

620 275

1300

710 340

640 305

1400

745 370

680 340

DRIVE PACKAGE “L” “M”

MOTOR H.P. 1/2 1/2

BLOWER SHEAVE 6.9 PITCH DIAMETER 6.4 PITCH DIAMETER

1500

NOTE: Bold lines separate L, M and N drives respectively.

MOTOR SHEAVE 2.4 - 3.4 PITCH DIAMETER 3.6 - 4.4 PITCH DIAMETER

TURNS OPEN 0 1 2 3 4 5 6 0 1 2 3 4 5 6

RPM 920 855 800 750 705 665 605 1230 1180 1130 1090 1045 1000 940

NOTE: Factory sheave settings are shown in bold print.

“N” DRIVE ( FIELD SUPPLIED)

BLOWER SHEAVE – 5.7 PITCH DIAMETER

MOTOR SHEAVE– 3.4 - 4.4 PITCH DIAMETER

RANGE – 1030 - 1330

MOTOR – 1/2 H.P. - 1750 RPM

INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC

BELT DRIVE

— —

RPM WATTS

1265 630

1275 700

1290 760

1305 815

1325 900

1335 980

1350 1040

— —

“N”

RPM WATTS

1220 590

RPM WATTS

1185 550

RPM WATTS

1145 520

RPM WATTS

1105 490

RPM WATTS

1060 455

995 420

RPM WATTS

945 400

RPM WATTS

1240 640

1195 590

1160 560

1120 520

1075 500

1010 450

965 415

1255 710

1215 650

1170 600

1130 580

1090 540

1030 500

985 450

1270 790

1230 710

1180 650

1140 610

1105 590

1050 550

1005 510

1290 850

1245 790

1190 710

1150 665

1120 640

1065 600

1015 560

1310 920

1260 860

1205 765

1170 720

1135 690

1090 650

1030 610

1325 1005

1275 915

1225 860

1185 800

1145 745

1105 700

1055 660

1340 —

1290 1005

1240 940

1205 865

1165 810

1125 760

1075 740

— —

1315 1110

1270 1020

1225 960

“M”

1185 900

1145 835

RESISTANCE - INCHES WATER

STANDARD INDOOR AIRFLOW - CFM

1100 790

EXTERNAL STATIC PRESSURE

3.5 TON - 13 SEER MODELS

CAPACITY: 3.5 TON - 13 SEER

VOLTAGE: 208/230 - 460

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.10 1.20 1.30 1.40 1.50

895 380

RPM WATTS

850 360

RPM WATTS

790 325

RPM WATTS

735 305

RPM WATTS

— —

RPM WATTS

— —

RPM WATTS

— —

RPM WATTS

915 400

870 380

810 355

750 320

— —

935 440

885 410

835 380

770 350

725 335

— —

955 465

905 445

860 415

800 395

745 360

— —

965 510

925 490

880 460

830 420

765 395

725 375

— —

1000 590

950 540

905 495

855 480

795 440

740 410

— —

1015 640

975 570

825 540

875 510

820 470

765 445

725 410

1020 690

1000 650

945 600

900 550

850 520

795 495

740 460

1045 750

1010 710

980 650

925 605

875 570

825 535

770 500

“L”

.05 .06 .07 .08 .09 .10 .11 .12 .13 .15

COMPONENT 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800

WET COIL .035 .040 .060 .070 .065 .100 .110 .120 .125 .130

DOWNFLOW .055 .060 .066 .072 .080 .086 .093 .100 .107 .115

ECONOMIZER

R. A. DAMPER

NOTES:

1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS

2. STANDARD CFM @ .075 LBS./CU. FT.

3. MOTOR EFFICIENCY = 80%

COMPONENT AIR RESISTANCE

4. BHP = WATTS X MOTOR EFF.

746

5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P.

AIR

CFM

FLOW

1000

1100

1200

1300

1400

1500

1600

1700

DRIVE PACKAGE “L” “M”

MOTOR H.P. 1/2 1/2

BLOWER SHEAVE 6.9 PITCH DIAMETER 6.9 PITCH DIAMETER

1800

NOTE: Bold lines separate L, M and N drives respectively.

MOTOR SHEAVE 2.8 - 3.8 PITCH DIAMETER 4.0 - 5.0 PITCH DIAMETER

RPM 958 945 905 865 820 770 725 1225 1185 1145 1100 1060 1020 1000

TURNS OPEN 0 1 2 3 4 5 6 0 1 2 3 4 5 6

“N” DRIVE ( FIELD SUPPLIED)

NOTE: Factory sheave settings are shown in bold print.

BLOWER SHEAVE – 6.4 PITCH DIAMETER

MOTOR SHEAVE– 4.0 - 5.0 PITCH DIAMETER

RANGE – 1090 - 1365

MOTOR – 1/2 H.P. - 1750 RPM

INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC

BELT DRIVE

— —

RPM WATTS

1320 705

1335 775

1345 825

1355 855

1370 935

1385 1000

— —

“N”

RPM WATTS

1265 655

RPM WATTS

1220 635

RPM WATTS

1170 600

RPM WATTS

1120 570

RPM WATTS

1070 550

RPM WATTS

1015 505

975 475

RPM WATTS

1285 730

1235 685

1185 640

1135 610

1085 590

1030 545

990 510

1300 770

1245 730

1200 700

1155 650

1105 615

1050 600

1010 550

1315 825

1270 780

1220 745

1175 700

1125 670

1075 640

1025 600

1330 890

1285 845

1235 800

1195 755

1145 710

1095 680

1050 660

1350 940

1305 915

1270 870

1215 810

1165 770

1120 735

1075 715

1365 1020

1330 985

1280 930

1235 890

1190 840

1150 800

1100 760

1385 1115

1350 1070

1305 1010

1260 955

1220 920

1175 870

1130 840

— —

1375 1160

1330 1105

1295 1060

“M”

1240 1010

1200 950

1180 900

EXTERNAL STATIC PRESSURE

935 440

RPM WATTS

950 470

960 510

980 550

1005 605

1025 655

4 TON - 13 SEER MODELS

885 410

910 450

925 480

940 515

960 580

900 490

850 475

790 425

— —

1500

920 530

870 495

815 455

775 425

— —

1600

980 605

940 560

900 540

850 505

795 470

— —

1700

RPM WATTS

835 390

855 410

780 360

— —

1200

805 390

— —

1300

870 445

825 425

770 385

— —

1400

RPM WATTS

CAPACITY: 4 TON - 13 SEER

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.10 1.20 1.30 1.40 1.50

VOLTAGE: 208/230 - 460

AIR

CFM

FLOW

RPM WATTS

1050 740

1010 680

960 625

930 600

875 555

820 515

775 470

1800

1075 800

1035 755

995 700

955 650

910 610

855 560

800 525

1900

1115 860

1065 840

1020 790

970 710

“L”

940 670

885 640

830 595

DRIVE PACKAGE “L” “M”

MOTOR H.P. 1/2 3/4

BLOWER SHEAVE 6.4 PITCH DIAMETER 5.7 PITCH DIAMETER

2000

NOTE: Bold lines separate L, M and N drives respectively.

MOTOR SHEAVE 2.8 - 3.8 PITCH DIAMETER 3.4 - 4.4 PITCH DIAMETER

TURNS OPEN 0 1 2 3 4 5 6 0 1 2 3 4 5 6

RPM 1060 1000 955 910 865 825 770 1385 1330 1280 1225 1175 1120 1060

NOTE: Factory sheave settings are shown in bold print.

RESISTANCE - INCHES WATER

STANDARD INDOOR AIRFLOW - CFM

.05 .06 .07 .08 .09 .10 .11 .12 .13 .15

COMPONENT 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800

WET COIL .035 .040 .060 .070 .085 .100 .110 .120 .125 .130

DOWNFLOW .055 .060 .066 .072 .080 .086 .093 .100 .107 .115

ECONOMIZER

R. A. DAMPER

NOTES:

1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS

2. STANDARD CFM @ .075 LBS./CU. FT.

3. MOTOR EFFICIENCY = 80%

COMPONENT AIR RESISTANCE

4. BHP = WATTS X MOTOR EFF.

746

5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P.

INDOOR AIRFLOW PERFORMANCE FOR 3-5 TON PACKAGE GAS ELECTRIC UNITS – TGC

BELT DRIVE

— —

1405 1320

— —

RPM WATTS

1340 745

RPM WATTS

1300 705

RPM WATTS

1235 660

1355 805

1320 775

1255 735

1365 880

1340 840

1275 790

1375 940

1355 905

1300 855

1390 1020

1365 985

1320 930

1405 1100

1375 1050

1335 1000

1385 1120

1350 1075

1400 1200

1370 1150

— —

1385 1225

RPM WATTS

1195 645

1215 700

1225 750

1245 815

1260 880

1290 960

RPM WATTS

1150 615

1165 675

1180 730

1200 790

1225 850

1245 915

RPM WATTS

1105 595

1135 650

1145 705

1160 755

1175 810

1200 890

RPM WATTS

1065 570

1080 615

1105 680

1120 725

1140 785

1160 850

RPM WATTS

1030 540

1045 595

1060 640

1075 680

1100 760

1120 810

EXTERNAL STATIC PRESSURE

970 490

RPM WATTS

995 540

1015 600

1035 640

1055 710

1070 775

5 TON - 13 SEER MODELS

930 460

945 500

965 560

RPM WATTS

990 605

1010 660

1035 720

1320 1035

1260 980

1225 950

1180 910

1145 875

1105 830

1055 790

1335 1100

1290 1060

1250 1020

1210 995

1170 950

1130 910

1090 870

1360 1180

1320 1140

1275 1100

1240 1055

1195 1020

1155 980

1120 940

1375 1260

1350 1230

1310 1175

1265 1125

1225 1095

1180 1050

1150 1050

1400 1375

1370 1315

1340 1255

1300 1210

1260 1175

1225 1140

1175 1085

— —

1400 1390

1360 1350

1305 1270

1260 1215

1200 1175

“M”

875 425

895 440

815 385

780 370

— —

1400

840 415

795 405

— —

1500

915 510

870 470

805 425

780 390

— —

1600

RPM WATTS

CAPACITY: 5 TON - 13 SEER

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.10 1.20 1.30 1.40 1.50

VOLTAGE: 208/230 - 460

AIR

CFM

FLOW

RPM WATTS

940 570

895 530

840 490

795 450

— —

1700

965 615

915 560

870 540

815 470

780 455

1800

995 675

945 640

895 590

850 530

800 485

1900

1015 730

970 700

930 655

880 605

830 550

2000

1040 820

1005 760

955 705

915 655

860 615

2100

1060 880

1030 830

995 780

945 735

895 680

2200

1100 965

1065 910

1015 830

975 795

940 755

2300

1145 1055

1100 1005

1040 925

1015 880

970 825

2400

1170 1140

1145 1100

1095 1040

“L”

1040 935

1015 910

DRIVE PACKAGE “L” “M”

MOTOR H.P. 3/4 1

BLOWER SHEAVE 6.4 PITCH DIAMETER 6.4 PITCH DIAMETER

2500

NOTE: Bold lines separate L, M and N drives respectively.

MOTOR SHEAVE 2.8 - 3.8 PITCH DIAMETER - ADJ. 3.4 - 4.4 PITCH DIAMETER - ADJ.

RPM 1095 1040 995 940 890 835 780 1405 1360 1305 1250 1195 1145 1095

TURNS OPEN 0 1 2 3 4 5 6 0 1 2 3 4 5 6

COMPONENT AIR RESISTANCE

NOTE: Factory sheave settings are shown in bold print.

RESISTANCE - INCHES WATER

STANDARD INDOOR AIRFLOW - CFM

.05 .06 .07 .08 .09 .10 .11 .12 .13 .15

COMPONENT 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800

WET COIL .035 .040 .060 .070 .085 .100 .110 .120 .125 .130

DOWNFLOW .055 .060 .066 .072 .080 .086 .093 .100 .107 .115

ECONOMIZER

R. A. DAMPER

NOTES:

1. PERFORMANCE SHOWN WITH DRY COIL & STANDARD 1 FILTERS

2. STANDARD CFM @ .075 LBS./CU. FT.

3. MOTOR EFFICIENCY = 80%

746

4. BHP = WATTS X MOTOR EFF.

5. ADD COMPONENT RESISTANCE TO DUCT STATIC TO DETERMINE TOTAL E.S.P.

FIGURE 23

WIRING DIAGRAM

FIGURE 24

WIRING DIAGRAM

FIGURE 25

WIRING DIAGRAM

FIGURE 26

WIRING DIAGRAM

FIGURE 27

WIRING DIAGRAM

FIGURE 28

WIRING DIAGRAM

FIGURE 29

WIRING DIAGRAM

FIGURE 30

175

200

225

250

275

300

325

350

375

400

425

450

475

500

525

120 125 130 135 140 145 150 155 160 165 170

105

115

92-102259-01-01

SYSTEM CHARGE CHARTS

3 TON COOLING - 13 SEER

FIGURE 31

SYSTEM CHARGE CHARTS

3.5 TON COOLING - 13 SEER

FIGURE 32

SYSTEM CHARGE CHARTS

4 TON COOLING - 13 SEER

FIGURE 33

92-102259-05-00

SYSTEM CHARGE CHART - REFRIGERANT 410A

5 TON, 14 SEER

105

115

175

200

225

250

275

300

325

350

375

400

425

450

475

500

525

120 125 130 135 140 145 150 155 160 165 170

SYSTEM CHARGE CHARTS

5 TON COOLING - 14 SEER

COOLING TROUBLE SHOOTING CHART

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

SYMPTOM POSSIBLE CAUSE REMEDY

Unit will not run • Power off or loose electrical connection • Check for correct voltage at compressor contactor in control

• Thermostat out of calibration-set too high • Reset

• Failed contactor • Check for 24 volts at contactor coil - replace if contacts are

• Blown fuses • Replace fuses

• Transformer defective • Check wiring-replace transformer

• High pressure control open (if provided) • Reset-also see high head pressure remedy-The high pressure

• Interconnecting low voltage wiring damaged • Replace thermostat wiring

Condenser fan runs, compressor • Run or start capacitor failed (single phase only) • Replace

doesn’t • Start relay defective 9single phase only) • Replace

• Loose connection • Check for correct voltage at compressor -

• Compressor stuck, grounded or open motor winding • Wait at least 2 hours for overload to reset. open internal overload. If still open, replace the compressor.

• Low voltage condition At compressor terminals, voltage must be within 10% of rating

• Low voltage condition • Add start kit components

Insufficient cooling • Improperly sized unit • Recalculate load

• Improper airflow • Check - should be approximately 400 CFM per ton.

• Incorrect refrigerant charge • Charge per procedure attached to unit service panel.

• Air, non-condensibles or moisture in system • Recover refrigerant, evacuate & recharge, add filter drier

• Incorrect voltage • At compressor terminals, voltage must be within 10% of rating

Compressor short cycles • Incorrect voltage • At compressor terminals, voltage must be ± 10% of

• Defective overload protector • Replace - check for correct voltage

• Refrigerant undercharge • Add refrigerant

Registers sweat • Low evaporator airflow • Increase speed of blower or reduce restriction - replace air

box

open

control opens at 610 PSIG

check & tighten all connections

plate volts when unit is operating.

nameplate marking when unit is operating.

filter

High head-low vapor pressures • Restriction in liquid line, expansion device or filter drier • Remove or replace defective component

High head-high or normal vapor • Dirty condenser coil • Clean coil

pressure - Cooling mode • Refrigerant overcharge • Correct system charge

Low head-high vapor pressures • Defective Compressor valves • Replace compressor

Low vapor - cool compressor - • Low evaporator airflow • Increase speed of blower or reduce restriction - replace air

iced evaporator coil filter

High vapor pressure • Excessive load • Recheck load calculation

Fluctuating head & vapor • TXV hunting • Check TXV bulb clamp - check air distribution on coil - replace

pressures TXV

Gurgle or pulsing noise at • Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

expansion device or liquid line

Circulating air blower & inducer • Manual reset overtemperature control • Reset or replace

run continuously, • tripped

compressor will not start • Wire loose in limit circuit • Check wiring

• Flow check piston size too small • Change to correct size piston

• Incorrect capillary tubes • Change coil assembly

• TXV does not open • Replace TXV

• Condenser fan not running • Repair or replace

• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

• Incorrect capillary tubes • Replace coil assembly

• Operating below 65°F outdoors • Add Low Ambient Kit

• Moisture in system • Recover refrigerant - evacuate & recharge - add filter drier

• Defective compressor • Replace

• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

FURNACE TROUBLESHOOTING GUIDE

(COMBINATION HEATING AND COOLING UNITS WITH DIRECT SPARK IGNITION)

WARNING

START

SET THERMOSTAT TO

CALL FOR HEAT

SET FAN SWITCH TO AUTO

YES

INDUCED DRAFT BLOWER

MOTOR STARTS

YES

15 SECOND PREPURGE

HAZARDOUS VOLTAGE

LINE VOLTAGE CON-

NECTIONS

• CHECK LINE VOLTAGE TO CONTROL BOARD

• CHECK LOW VOLTAGE TRANSFORMER

• CHECK WIRING

• CHECK FOR 208-230 VAC TO IOM MOTOR

DISCONNECT POWER BEFORE SERVICING. SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN.

YES

REPLACE INDUCED

DRAFT BLOWER

REPLACE INTEGRATED CONTROL BOARD (IFC)

REPLACE IGNITOR/ CABLE ASSEMBLY

YES

IGNITOR SPARKS

YES

MAIN BURNER LIGHTS

YES

• CHECK IGNITOR CABLE

• CHECK SPARK IGNITOR POSITION AND CONDITION

• IS NEGATIVE PRESSURE SWITCH CLOSED?

• CHECK FOR OPEN ROLL-OUT CONTROL

• CHECK FOR OPEN LIMIT

• CHECK IGNITION CONTROL CHASSIS GROUND WIRE

• CHECK WIRING NO

REPLACE IGNITION CON-

TROL

NOTE: THE SYSTEM WILL ATTEMPT TO LIGHT 3 TIMES WITH A 60 SECOND INTER-

PURGE BETWEEN TRIES. IF AFTER THE THIRD TIME THE BURNERS DO NOT LIGHT, THE SYSTEM WILL LOCK OUT. IF THE UNIT IS EQUIPPED WITH A UNITED TECH. OR JOHNSON CONTROLS IGNITION CONTROL, THE SYSTEM WILL ATTEMPT TO LIGHT 3 TIMES EACH HOUR UNTIL THE BURNERS LIGHT OR THE THERMOSTAT IS RESET.

• CHECK INLET GAS PRESSURE

• CHECK 24 VOLTS TO GAS VALVE

• CHECK FOR GAS FLOW TO AND FROM VALVE

• CHECK BURNER CARRYOVER

YES

NO YES YES

• CHECK NEGATIVE PRESSURE SWITCH SENSING TUBE

• CHECK FOR EXHAUST BLOCKAGE

REPLACE NEGATIVE

PRESSURE SWITCH

CHECK FOR EXHAUST,

INTAKE OR HEAT

EXCHANGER BLOCKAGE

AND RESET CONTROL

REPLACE LIMIT IF UNIT IS COLD

REPLACE INTEGRATED CONTROL BOARD (IFC)

IF WIRING IS OK

YES

REPLACE VALVE

FLOW CHART CONTINUED ON NEXT PAGE

MAIN BURNER FLAME SUSTAINED

YES

NOTE: IF THE SYSTEM GOES INTO LOCKOUT, WAIT

30 SECONDS AND RESET THE SYSTEM.

• CHECK FLAME SENSOR POSITION AND CONDITION

• CLEAN FLAME SENSOR WITH STEEL WOOL

• CHECK FLAME SENSOR WIRES AND CONNECTIONS

YES

REPLACE SENSOR

INDOOR BLOWER MOTOR STARTS

AFTER 30 SECONDS

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

YES

TURN THERMOSTAT OFF

VALVE SHUTS OFF FLAME SHUTS OFF

YES

INDUCED DRAFT MOTOR STOPS

AFTER 5 SECOND POSTPURGE

YES

REPLACE IGNITION CON-

TROL

• CHECK FOR 208-230 VAC ACROSS BLOWER MOTOR TERMINALS ON CONTROL BOARD

• CHECK CAPACITOR

YES

REPLACE BLOWER

MOTOR

• CHECK FOR OPEN LIMIT

• CHECK FOR OPEN ROLL-OUT CONTROL

• CHECK FOR PROPER THERMOSTAT OPERATION

• REMOVE VALVE LEAD AT GAS VALVE IF VALVE CLOSES, RECHECK THE THERMOSTAT AND WIRING. IF OK, THEN REPLACE VALVE

YES

REPLACE INTEGRATED CONTROL BOARD (IFC)

• CHECK FOR DIRTY FILTERS

• CHECK FOR RESTRICTED AIR-FLOW

CHECK FOR EXHAUST,

INTAKE OR HEAT EXCHANG-

ER BLOCKAGE

CLEAR BLOCKAGE AND

RESET CONTROL

INDOOR BLOWER MOTOR STOPS

AFTER 90 SECONDS

YES

TROUBLESHOOTING ENDS

REPEAT PROCEDURE UNTIL TROUBLE FREE

OPERATION IS OBTAINED.

• CHECK FOR OPEN LIMIT OR ROLL-OUT CONTROL

YES

• CHECK FOR EXHAUST OR INTAKE BLOCKAGE. CLEAR BLOCKAGE AND RESET CONTROL

• CHECK FOR DIRTY FILTERS

• CHECK FOR RESTRICTED AIRFLOW

REPLACE INTEGRATED CONTROL BOARD (IFC)

535455

CM 010956

Heat Controller A-13 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual