Heatcontroller TGRG User Manual

INSTALLATION INSTRUCTIONS

ISO 9001:2008

Seasonal Energy Efficiency Ratio (SEER)

Annual Fuel Utilization Efficiency - AFUE

HIGHMID

13.0 14.0

80.0%

RRNL RRPL

THIS MODEL

10.6

—

Uses least energy

➞

16.05

78% 82% 88% 97%

PACKAGE GAS ELECTRIC

FEATURING EARTH-FRIENDLY R-410A REFRIGERANT TGRG**C/TGRG**E (2-5 TONS) TGRG**D- 14 SEER (2-5 TONS)

(14 SEER &

ABOVE)

U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

92-21916-34-02

SUPERSEDES 92-21916-34-01

TABLE OF CONTENTS

I. Safety Information .................................................................................................3

I. Introduction ............................................................................................................6

III. Checking Product Received ..................................................................................6

IV. Specifications ........................................................................................................6

A. General .............................................................................................................6

B. Major Components............................................................................................6

C. R-410A Refrigerant ...........................................................................................6

V. Unit Dimensions ....................................................................................................8

VI. Installation ...........................................................................................................10

A. General ...........................................................................................................10

. Pre-Installation Check ................................................................................10

2. Location Considerations.............................................................................10

B. Outside Installation..........................................................................................10

C. Attaching Exhaust and Combustion Air Inlet Hoods .......................................11

D. Cover Panel Installation/Conversion Procedure .............................................12

1. Horizontal to Downflow ...............................................................................12

2. Downflow to Horizontal ...............................................................................12

E. Clearances ......................................................................................................12

F. Rooftop Installation .........................................................................................14

G. Ductwork .........................................................................................................14

H. Return Air ........................................................................................................16

I. Filters ..............................................................................................................17

VII. Gas Supply, Condensate Drain and Piping .........................................................19

A. Gas Connection ..............................................................................................19

B. LP Conversion.................................................................................................20

C. NOx Models ....................................................................................................21

D. Adjusting or Checking Furnace Input ..............................................................21

E. Condensate Drain ...........................................................................................22

VIII. Wiring ..................................................................................................................22

A. Power Supply ..................................................................................................22

B. Hook Up ..........................................................................................................24

C. Internal Wiring .................................................................................................24

D. Thermostat ......................................................................................................24

IX. Furnace Section Controls and Ignition System ...................................................25

A. Normal Furnace Operating Sequence ............................................................25

B. Operating Instructions .....................................................................................26

C. Burners............................................................................................................27

D. Manual Reset Overtemperature Control .........................................................27

E. Pressure Switch ..............................................................................................27

F. Limit Control ....................................................................................................27

X. System Operating Information .............................................................................27

A. Advise the Customer.......................................................................................27

B. Furnace Section Maintenance ........................................................................28

C. Lubrication.......................................................................................................29

D. Cooling Section Maintenance .........................................................................29

E. Replacement Parts..........................................................................................30

F. Charging..........................................................................................................30

G. Blower Motor Speed Adjustments ...................................................................30

XI. General Data ..................................................................................................33-38

XII. Miscellaneous.................................................................................................39-42

XIII. Airflow Performance Data ..............................................................................43-46

XIV. Wiring Diagrams .............................................................................................47-51

XV. Charge Charts ................................................................................................52-59

XVI. Troubleshooting..............................................................................................60-61

I. SAFETY INFORMATION

WARNING

PROPOSITION 65: THIS FURNACE CONTAINS FIBERGLASS INSULATION. RESPIRABLE PARTICLES OF FIBERGLASS ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER. EXHAUST GAS FROM THIS FURNACE CONTAINS CHEMICALS, INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF CALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

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

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.

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

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.

WARNING

THIS UNIT MUST NOT BE INSTALLED DIRECTLY ON WOOD FLOORING, CLASS A, CLASS B OR CLASS C ROOF COVERING MATERIALS, OR ANY OTHER COMBUSTIBLE STRUCTURE EXCEPT AS SPECIFIED IN FIGURE 13. FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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, OR PROPERTY DAMAGE.

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 CAROBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

WARNING

O NOT USE AN OPEN FLAME TO CHECK FOR LEAKS. THE USE OF AN OPEN

D FLAME CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

THIS UNIT IS EQUIPPED AT THE 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.

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.

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.

WARNING

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

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.

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!

WARNING

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

WARNING

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPER-

TION RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PER-

A SONAL INJURY OR DEATH.

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 NJURY OR DEATH.

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.

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.

WARNING

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

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.

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.

WARNING

IMPORTANT: ALL MANUFACTURER PRODUCTS MEET CURRENT

EDERAL OSHA GUIDELINES FOR

F SAFETY. CALIFORNIA PROPOSITION 65 WARNINGS ARE REQUIRED FOR CERTAIN PRODUCTS, WHICH ARE NOT COVERED BY THE OSHA STANDARDS.

CALIFORNIA'S PROPOSITION 65 REQUIRES WARNINGS FOR PRODUCTS SOLD IN CALIFORNIA THAT CONTAIN, OR PRODUCE, ANY OF

VER 600 LISTED CHEMICALS

O KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER OR BIRTH DEFECTS SUCH AS FIBERGLASS INSULATION, LEAD IN BRASS, AND COMBUSTION PRODUCTS FROM NATURAL GAS.

ALL “NEW EQUIPMENT” SHIPPED FOR SALE IN CALIFORNIA WILL HAVE LABELS STATING THAT THE PRODUCT CONTAINS AND/OR PRODUCES PROPOSITION 65 CHEMICALS. ALTHOUGH WE HAVE NOT CHANGED OUR PROCESSES, HAVING THE SAME LABEL ON ALL OUR PRODUCTS FACILITATES MANUFACTURING AND SHIPPING. WE CANNOT ALWAYS KNOW “WHEN, OR IF” PRODUCTS WILL BE SOLD IN THE CALIFORNIA MARKET.

YOU MAY RECEIVE INQUIRIES FROM CUSTOMERS ABOUT CHEMICALS FOUND IN, OR PRODUCED BY, SOME OF OUR HEATING AND AIR-CONDITIONING EQUIPMENT, OR FOUND IN NATURAL GAS USED WITH SOME OF OUR PRODUCTS. LISTED BELOW ARE THOSE CHEMICALS AND SUBSTANCES COMMONLY ASSOCIATED WITH SIMILAR EQUIPMENT IN OUR INDUSTRY AND OTHER MANUFACTURERS.

• GLASS WOOL (FIBERGLASS) INSULATION

• CARBON MONOXIDE (CO)

• FORMALDEHYDE

• BENZENE

MORE DETAILS ARE AVAILABLE AT THE WEBSITES FOR OSHA (OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION), AT WWW.OSHA.GOV OF CALIFORNIA'S OEHHA (OFFICE OF ENVIRONMENTAL HEALTH HAZARD ASSESSMENT), AT WWW.OEHHA.ORG. EDUCATION IS IMPORTANT SINCE THE CHEMICALS AND SUBSTANCES ON THE LIST ARE FOUND IN OUR DAILY LIVES. MOST CONSUMERS ARE AWARE THAT PRODUCTS PRESENT SAFETY AND HEALTH RISKS, WHEN IMPROPERLY USED, HANDLED AND MAINTAINED.

AND THE STATE

CONSUMER

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

ccessories to determine if they are correct.

IV. SPECIFICATIONS

A. GENERAL

The Combination Gas Heating/Electric Cooling Rooftop is available in 40,60, 80 and 100 BTU/Hr. heating inputs and cooling capacities of 2, 2 cooling. Units are convertible from end supply and return to bottom 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

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 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 is indicated on rating plate.

C. R410A REFRIGERANT

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

1. Specification of R-410A:

Application: R-410A is not a drop-in replacement for R-22; equipment designs must accommodate its higher pressures. It cannot be retrofitted into R-22 units.

Pressure: The pressure of R-410A is approximately 60% (1.6 times) greater than 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, 3, 31⁄2 , 4 and 5 nominal tons of

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. UNIT DIMENSIONS

FOR CLEARANCES SEE FIGURE 9.

FIGURE 1

OUTDOOR COIL

ROTECTIVE GRILLE

UTDOOR FAN GRILLE

O AND COMPRESSOR ACCESS

29% ± 2%

LUE

XHAUST

0% ± 2%

21% ± 2%

SIDE RETURN DUCT

PENING

THREADED PVC CONDENSATE DRAIN CONNECTION (3/4 NPT)

SUCTION PRESSURE SERVICE PORT

LIQUID PRESSURE SERVICE PORT

TOP VIEW

479⁄16”

FIELD CONTROL WIRE ENTRANCE

FLUE EXHAUST HOOD

COMBUSTION AIR INLET HOOD

5013⁄16”

FIELD POWER WIRE ENTRANCE

BOTTOM RETURN DUCT OPENING

BLOWER/EVAPORATOR ACCESS PANEL

CORNER WEIGHTS

% OF TOTAL UNIT

BOTTOM VIEW

451⁄16” INSIDE

191⁄2”

141⁄4”

TYP.

SIDE SUPPLY DUCT OPENING

WEIGHT

13⁄16”

TYP.

153⁄8”

11⁄2”

TYP.

497⁄16” INSIDE

BOTTOM SUPPLY DUCT OPENING

OUTDOOR FAN GRILLE & COMPRESSOR ACCESS

313⁄16”

49⁄10”

33⁄16”

FIGURE 1 (CONTINUED)

MODELS

TGRG**C/

TGRG**E

024, 030,

036

042, 048,

060, 060

FRONT VIEW

471⁄2”

MODEL

TGRG**D

024

036, 048,

060

207⁄8”

⁄16”

“A”

HEIGHT

⁄16”

75⁄16”

227⁄8”

⁄16”

21⁄2”

IDE

S SUPPLY

UCT

PENING

3515⁄16”

BACK VIEW

39⁄16”

15”

191⁄8”

47⁄8”

131⁄4”

47⁄16”

81⁄2”

TYP.

SHOWN WITH DUCT COVERS REMOVED.

143⁄16”

TYP.

133⁄4”

TYP.

IDE

S RETURN DUCT OPENING

FILTER ACCESS PANEL (FOR UNIT MOUNTED FILTER ACCESSORY)

SIDE VIEW

527⁄16”

OUTDOOR COIL PROTECTIVE GRILLE

SIDE VIEW

FLUE EXHAUST HOOD

GAS SUPPLY ENTRANCE

1015⁄16”

111⁄16”

BLOWER/ EVAPORATOR ACCESS PANEL

VI. INSTALLATION

A. GENERAL

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

tructural 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

2. LOCATION CONSIDERATIONS (CORROSIVE ENVIRONMENT)

The metal parts of this unit may be subject to rust or deterioration if exposed to a corrosive environment. This oxidation could shorten the equipment’s useful life. Corrosive elements include, but are not limited to, 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.

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

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

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

front.

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

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

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. Use a good liquid cleaner 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.

B. OUTSIDE INSTALLATION

WARNING

(Typical outdoor slab installation is shown in Figure 2.)

1. Select a location where external water drainage cannot collect around unit.

FIGURE 2

UTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOOR

ONSTRUCTION

2. Provide a slab sufficiently high enough above grade to prevent surface water from entering the unit. Where snowfall is anticipated, mount the unit above the anticipated maximum snow depth for your area. Do not locate unit in an area where excessive snow drifting may block combustion air inlet.

3. Pitch the slab approximately

⁄2” so that the unit will be pitched toward the drain. See

Figure 3.

4. The location of the unit should be such as to provide proper access for inspection and servicing as shown in Figure 9.

5. Locate unit where operating sounds will not disturb owner or neighbors. The slab should be isolated from the foundation wall.

6. Locate unit so roof runoff water does not pour directly on the unit. Provide gutter or other shielding at roof level.

C. ATTACHING EXHAUST AND COMBUSTION AIR INLET HOODS

IMPORTANT: Do not operate this unit without the exhaust and combustion air inlet hood properly installed. These hoods are shipped in a carton in the return air compartment inside the unit and must be attached when the unit is installed. See Figure 4.

To attach exhaust and combustion air inlet hood:

1. Remove 3 screws securing filter access panel and remove filter access panel. For location of filter access panel, see Figure 1.

2. Remove both exhaust and combustion air inlet hoods from their carton, located inside the return air compartment.

3. Attach filter access panel.

4. Attach the combustion air inlet hood and the exhaust hood each with 4 screws as shown in Figure 4. Screws are in parts bag shipped in the burner compartment.

5. Vent the unit using the flue exhaust hood, as supplied from the factory, without alteration or addition. The only exception is with factory approved additions. Consult your local utility or other authority having jurisdiction for accepted venting techniques.

FIGURE 3

ITCHING UNIT TO INSURE PROPER CONDENSATE DRAINAGE.

FIGURE 4

OMBUSTION AIR INLET HOOD & EXHAUST HOOD

C INSTALLATION

EXHAUST HOOD W/(4) SCREWS

I655

COMBUSTION AIR INLET

OOD W/(4)

H SCREWS

D. COVER PANEL INSTALLATION/CONVERSION PROCEDURE

1. HORIZONTAL TO DOWNFLOW

a. Remove screws and covers from the supply and return bottom sections. NOTE:

Rotate the supply cover 90° and remove.

b. Install gasket (supplied with parts bag) around perimeter of cover on the insulated

side. See Figure 6.

c. Secure covers to the side of the unit using existing screws and those supplied in

the parts bag.

2. DOWNFLOW TO HORIZONTAL

a. Remove screws and covers from the supply and return bottom sections.

b. Install gasket (supplied with parts bag) around perimeter of cover as illustrated in

Figure 5.

c. Install covers in the unit bottom with the insulated side up. NOTE: Supply cover

must be inserted through supply opening with narrow side toward unit. Once cover is through opening, rotate 90° and slip back flange of cover under tab at the back of bottom duct opening. See Figure 8.

d. Secure supply cover to base of unit with 2 screws, engaging prepunched holes in

raised duct opening flange.

e. Secure return covers to base of unit with screws engaging prepunched holes in

raised duct opening flange.

WARNING

E. CLEARANCES

The following minimum clearances must be observed for proper unit performance and serviceability. See Figure 9.

1. Provide 48” minimum clearance at front of the unit. Provide 24” minimum clearance on right side of unit. If economizer is used, a 24” minimum clearance is required on

FIGURE 5

COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW APPLICATION BEING CONVERTED TO SIDE DISCHARGE

TAPE AROUND FLANGE

UPPLY/RETURN

IR COVER

FIGURE 6

COVER GASKET DETAIL FOR UNITS SHIPPED FOR SIDE DISCHARGE APPLICATION BEING CONVERTED TO DOWNFLOW

TAPE A

ROUND FLANGE

SUPPLY/RETURN AIR COVER

654

FIGURE 7

DUCT COVER INSTALLATION SIDE MOUNTING

I264

RETURN

DUCT COVER

(ATTACH WITH 6 SCREWS)

SUPPLY

DUCT COVER

(ATTACH WITH 6 SCREWS)

FIGURE 8

DUCT COVER INSTALLATION BASE PAN MOUNTING

I265

BASE PAN

SUPPLY DUCT COVER

(INSULATION SIDE UP), ATTACH WITH TWO SCREWS.

RETURN DUCT COVER (INSULATION SIDE UP, ATTACH WITH 4 SCREWS)

SUPPLY DUCT COVER

*ROTATE SUPPLY COVER 90° AFTER IT IS INSERTED

THROUGH OPENING. SLIP FLANGE OF COVER UNDER LANCE AT BACK OF BOTTOM SUPPLY DUCT OPENING. SEE DETAILAT LEFT. THEN SECURE COVER BY INSTALLING 2 SCREWS USING HOLE NEAREST THE OUTSIDE OF UNIT.

LANCE AT BACK OF BOTTOM SUPPLY DUCT OPENING

FIGURE 5

OVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW

PPLICATION BEING CONVERTED TO SIDE DISCHARGE

FIGURE 6

COVER GASKET DETAIL FOR UNITS SHIPPED FOR SIDE DISCHARGE APPLICATION BEING CONVERTED TO DOWNFLOW

FIGURE 7

DUCT COVER INSTALLATION SIDE MOUNTING

FIGURE 8

DUCT COVER INSTALLATION BASE PAN MOUNTING

FIGURE 9

CLEARANCES

left side of unit. (See Figure 9.) If no economizer is required, then a 12” clearance is required on left side of unit.

2. Provide 60” minimum clearance between top of unit and maximum 3 foot overhang.

3. Unit is design certified for 2” minimum clearance between supply duct and a combustible structure for the first 3 feet of duct. 0” clearance is allowed after 3 feet.

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 book for weight of unit.) THIS IS VERY IMPORTANT AND THE INSTALLER’S RESPONSIBILITY.

2. For rigging and roofcurb details, see Figures 14, 15, and 16.

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

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, 1513 16th St. N.W., Washington, D.C. 20036.

WARNING

FIGURE 10

XCEPTION TO NON-COMBUSTIBLE FLOORING REQUIREMENT

I458

BOTH ENDS MUST BE OPEN FOR DOWNFLOW OR SIDEFLOW DUCTWORK TO PROVIDE VENTILATION

COMBUSTIBLE STRUCTURE

1” MIN.

NOMINAL 4 x 4 TIMBER (SIDES ONLY)

SIDEFLOW

SUPPLY

PLENUM

CONNECTION

SUPPLY

PLENUM

(DOWNFLOW)

ETURN PLENUM

(

DOWNFLOW)

SIDEFLOW

RETURN PLENUM

CONNECTION

3-1/2” MIN.

FIGURE 10

EXCEPTION TO NON-COMBUSTIBLE FLOORING REQUIREMENT

FIGURE 11

LAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. MOUNTED ON

OOFCURB, PITCH UNIT TOWARD DRAIN.

FIGURE 12

PITCHED ROOFTOP INSTALLATION, ON ANGLE-IRON STAND, SIDE FLOW DUCTWORK, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. PITCH UNIT TOWARD DRAIN.

IGURE 13

ITCHED ROOFTOP INSTALLATION, ON ROOFJACK, DOWNFLOW DUCTWORK, ATTIC OR

ROP CEILING DISTRIBUTING SYSTEM. PITCH UNIT TOWARD DRAIN.

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

FIGURE 14

IFTING DETAIL.

. FILTERS

The installer must install field supplied filters in the return air duct. A field installed filter grille is recommended for easy and convenient access to the filters for periodic inspection and cleaning. Filters must have adequate face area for the rated air quantity of the unit. See air delivery tables for recommended filter size. A field installed internal filter kit RXRY-B01 is available.

I342

ETURN PLENUM

MAX.

/2 MAX.

/8 MAX.

NSULATION

ANELS

NAILING STRIP

CAULK ALL JOINTS WATERTIGHT

SUPPLY PLENUM

UCT

LANGE

(

NOT TO

XCEED 1()

ROOFCURB

FIGURE 15

ROOFCURB

255

**BY CONTRACTOR

FOR INSTALLATION OF DUCT AS SHOWN, USE RECOMMENDED DUCT SIZES FROM ROOFCURB INSTALLATION INSTRUCTIONS. FOR DUCT FLANGE ATTACHMENT TO UNIT, SEE UNIT INSTALLATION INSTRUCTIONS (FIGURE 1) FOR SIZE OF DUCT OPENINGS.

OOFTOP UNIT

IE DOWN SCREW

OOFCURB

ROOF FLASHING

OOFING

CANT STRIP *

ROOF DECK *

ASKET

AILING STRIP

INSULATION

NSULATION

** DUCT *

FIGURE 16

ROOFCURB

FIGURE 15

OOFCURB

FIGURE 16

OOFCURB

FIGURE 17

DUCTWORK COVER INSTALLATION DETAIL

FIGURE 18

RESIDENTIAL ROOFTOP DUCTWORK INSTALLATION DETAIL.

VII.GAS SUPPLY, CONDENSATE DRAIN AND

FIGURE 19

SUGGESTED GAS PIPING

FROM GAS METER

Factory supplied grommet must be utilized.

MANUAL GAS SHUT-OFF VALV E

UNIT GAS SUPPLY CONNECTION

ROOF OR GROUND LEVEL INSTALLATION

Nominal

Iron Pipe

Size,

Inches

Equivalent Length of Pipe, Feet

10 20 30 40 50 60 70 80

/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

TABLE 1

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

VII.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.

OTE: The Commonwealth of Massachusetts requires the gas shut-off valve to be

N 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 2 for typical piping.

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

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 19.)

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 psig 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.

FIGURE 19

SUGGESTED GAS PIPING

TO CHECK FOR GAS LEAKS, USE A SOAP AND WATER SOLUTION OR OTHER

FIGURE 20

APPROVED METHOD. DO NOT USE AN OPEN FLAME.

WARNING

DO NOT USE AN OPEN FLAME TO 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.

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 0.5 in. and specific gravity of 0.60 (natural gas) are shown in Table 2.

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 L.P. gas supplier.

(BTU/HR) Heating Value of Gas

(BTU/FT

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

)

B. LP CONVERSION

WARNING

Convert the valve to use liquefied petroleum (LP) gas by replacing the pressure regulator spring with the conversion kit spring. This LP kit spring allows the regulator to maintain the proper manifold pressure for LP gas. The correct burner LP orifices are included in the kit. See Figure 20.

NOTE: Order the correct LP conversion kit from the furnace manufacturer. See Conversion Kit Index shipped with unit for proper LP kit number. Furnace conversion to LP gas must be performed by a qualified technician.

FIGURE 20

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