Rheem A180DL25E, A180CL35E, A180DL35E, A180DM25E, A180DM35E Installation Instructions Manual
...Page 1
92-23577-56-01
SUPERSEDES 92-23577-56-00
INSTALLATION INSTRUCTIONS
FOR COMBINATION HEATING
AND COOLING ROOFTOP UNITS
15, 20 & 25 TON (-)KKB
AND 15 & 20 TON (-)KMB UNITS
!
If the information in these instructions is not followed exactly, a
fire or explosion may result, causing property damage, personal
injury or death.
THESE INSTRUCTIONS ARE
INTENDED AS AN AID TO
QUALIFIED SERVICE
PERSONNEL FOR PROPER
INST ALLATION, ADJUSTMENT
AND OPERATION OF THIS
UNIT. READ THESE
INSTRUCTIONS THOROUGHLY
BEFORE A TTEMPTING
INSTALLATION OR
OPERATION. FAILURE TO
FOLLOW THESE
INSTRUCTIONS MAY RESULT
IN IMPROPER INSTALLATION,
ADJUSTMENT, SERVICE OR
MAINTENANCE, POSSIBLY
RESULTING IN FIRE,
ELECTRICAL SHOCK, CARBON
MONOXIDE POISONING,
EXPLOSION, PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
WARNING
Recognize this symbol as an indication of Important Safety Information!
!
— Do not store or use gasoline or other
flammable vapors and liquids, or other
combustible materials in the vicinity of this
or any other appliance.
— WHAT TO DO IF YOU SMELLGAS
• Do not try to light any appliance.
• Do not touch any electrical 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.
• Do not return to your home until
authorized by the gas supplier or fire
department.
— DO NOTRELYON SMELLALONE TO
DETECT LEAKS. DUE TO VARIOUS
FACTORS, YOU MAY NOT BE ABLE T O
SMELL FUEL GASES.
• U.L. recognized fuel gas and CO
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
— Improper installation, adjustment, alteration,
service or maintenance can cause injury ,
property damage or death. Refer to this
manual. Installation and service must be
performed by a qualified installer, service
agency or the gas supplier.
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
!
FOR YOUR SAFETY
!
DO NOT DESTROY.
PLEASE READ CAREFULLY AND KEEP
IN A SAFE PLACE FOR FUTURE
REFERENCE BYA SERVICEMAN OR
USER OF THIS APPLIANCE.
Page 2
2
INTRODUCTION
I. SPECIFICATIONS
TABLE OF CONTENTS
!
WARNING
Page No.
I. SPECIFICATIONS
Components 2
Unit Dimensions 3-5
Electrical & Physical Data 6-10
II. INSTALLATION
General 11
Location Considerations 11
Exhaust & Combustion
Hoods 12
Cover Panel Installation 12
Clearances 13
Rooftop 14
Ducting 14-15
Return Air 15
III. GAS SUPPLY & PIPING 16-18
IV. ELECTRICAL WIRING
Power Supply 19
Hook-up 20
Internal Wiring 20
Thermostat 20
V. FURNACE CONTROLS 21-23
VI. OPERATION INFO 23-24
VII. AIRFLOW 25-26
VIII. TROUBLESHOOTING 27-29
IX. WIRING DIAGRAMS 30-33
X. CHARGE CHARTS 34-36
XI. WARRANTY 40
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 MAYALSO
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.
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.
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.
A. GENERAL
The Combination Gas Heating/Electric
Cooling Rooftop is available in 250,000
AND 350,000 BTUH heating input with
nominal cooling capacity of 15 tons.
300,000 and 400,000 BTUH heating inputs
are available in nominal cooling capacity of
20 & 25 tons. Units are convertible from
bottom supply and return to side supply
and return by relocation of supply and
return air cover panels. See cover
installation detail and Figures 10 &11.
The units are weatherized for mounting
outside of the building.
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.
B. MAJOR COMPONENTS
The unit includes a hermetically-sealed
refrigerating system consisting of a scroll
compressor, condenser coil, evaporator
coil with capillary tube assembly or TXV, a
circulation air blower, a condenser fan, a
heat exchanger assembly, gas burner and
control assembly, combustion air motors
and fan, and all necessary internal
electrical wiring. The cooling system of
these units is factory-evacuated, charged
and performance tested. Refrigerant
amount and type are indicated on rating
plate.
!
WARNING
Page 3
3
FIGURE 1. BOTTOM VIEW
FIGURE 2. SUPPLY AND
RETURN DIMENSIONS FOR
DOWNFLOW APPLICA TIONS
Unit
Dimensions
FOR CLEARANCES
SEE PAGE 12, FIGURE 12.
IMPORTANT: THIS
UNIT MUST BE
MOUNTED LEVEL IN
BOTH DIRECTIONS TO
ALLOW WATER TO
DRAIN FROM THE
CONDENSER
SECTION AND
CONDENSATE PAN.
ST-A0886-02
ST-A0886-07
Page 4
FIGURE 3.
COMPONENT
LOCATIONS &
DIMENSIONS
ST-A0886-04
FIGURE 4.
COMPONENT LOCATIONS
& DIMENSIONS
ST-A0886-06
FIGURE 5.
COMPONENT LOCATIONS
ST-A0886-27
4
GAS SUPPLY
(SIDE ENTRY)
3/4” INLET
Page 5
5
FIGURE 7.
COMPONENT ACCESS
LOCATIONS &
DIMENSIONS
FIGURE 6. DIMENSIONS
ST-A0886-05
ST-A0886-03
FIGURE 8.
COMPONENT
LOCATIONS
ST-A0886-28
Page 6
6
A180CL25E 3-60-208-230 12.4/12.4 88 2.4 11.5 74/74 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1790 2010
[51 X 457 X 457] [3.345] [7551] [2325]/ [811.9] [911.7]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180CL35E 3-60-208-230 12.4/12.4 88 2.4 11.5 74/74 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1817 2037
[51 X 457 X 457] [3.345] [7551] [2325]/ [824.2] [924.0]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180CM25E 3-60-208-230 12.4/12.4 88 2.4 14.7 77/77 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1820 2040
[51 X 457 X 457] [3.345] [7551] [2325]/ [825.5] [925.3]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180CM35E 3-60-208-230 12.4/12.4 88 2.4 14.7 77/77 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1847 2067
[51 X 457 X 457] [3.345] [7551] [2325]/ [837.8] [937.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DL25E 3-60-460 6.4 44 2.0 7.0 43 45 45 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1806 2026
[51 X 457 X 457] [3.345] [7551] [2325]/ [819.2] [919.0]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DL35E 3-60-460 6.4 44 2.0 7.0 43 45 45 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1841 2061
[51 X 457 X 457] [3.345] [7551] [2325]/ [835.1] [934.9]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DM25E 3-60-460 6.4 44 2.0 10.0 46 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1836 2056
[51 X 457 X 457] [3.345] [7551] [2325]/ [832.8] [932.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DM35E 3-60-460 6.4 44 2.0 10.0 46 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1871 2091
[51 X 457 X 457] [3.345] [7551] [2325]/ [848.7] [948.5]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180YL25E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1806 2026
[51 X 457 X 457] [3.345] [7551] [2325]/ [819.2] [919.0]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180YL35E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1817 2037
[51 X 457 X 457] [3.345] [7551] [2325]/ [824.2] [924.0]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180YM25E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1836 2056
[51 X 457 X 457] [3.345] [7551] [2325]/ [832.8] [932.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
SHIPPING
LBS.
[KG]
TABLE 1
15, 20 & 25 TON (-)KKB – ELECTRICAL& PHYSICAL DATA
ELECTRICAL
MODEL
NUMBER
PHASE
FREQUENCY
VOLTAGE
(HZ)
(VOLTS)
RATED
LOAD
AMPERES
(RLA)[EA.]
COMPRESSOR
LOCKED
ROTOR
AMPERES
(LRA)[EA.]
FULL LOAD
AMPERES
(FLA)
FAN
MTR
[EA.]
BLWR
MTR
MINIMUM
CIRCUIT
AMPACITY
AMPERES
MIN.
AMPS
MAX.
AMPS
FUSE OR HACR
CIRCUIT
BREAKER
DRIVE
TYPE
RECOMMENDED
NO. AND SIZE
[mm x mm x mm]
AREA
SQ. FT.
[SQ. M]
NO.
ROWS
CFM
[L/s]
R22
OZ.
[G]
SYSTEM
PER
CIRCUIT
1,2/3,4
NET
LBS.
[KG]
FILTER OUTDOOR COIL WEIGHT
PHYSICAL
Page 7
7
A180YM35E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1871 2091
[51 X 457 X 457] [3.345] [7551] [2325]/ [848.7] [948.5]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240CL30E 3-60-208-230 17.8/17.8 124 2.4 14.7 100/100 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1884 2104
[51 X 457 X 457] [3.345] [7551] [2183]/ [854.6] [954.4]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240CL40E 3-60-208-230 17.8/17.8 124 2.4 14.7 100/100 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1900 2120
[51 X 457 X 457] [3.345] [7551] [2183]/ [861.8] [961.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240CM30E 3-60-208-230 17.8/17.8 124 2.4 22.3 108/108 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1906 2126
[51 X 457 X 457] [3.345] [7551] [2183]/ [864.5] [964.3]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240CM40E 3-60-208-230 17.8/17.8 124 2.4 22.3 108/108 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1922 2142
[51 X 457 X 457] [3.345] [7551] [2183]/ [871.8] [971.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240DL30E 3-60-460 9.3 59.6 2.0 10.0 58 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1908 2128
[51 X 457 X 457] [3.345] [7551] [2183]/ [865.5] [965.2]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240DL40E 3-60-460 9.3 59.6 2.0 10.0 58 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1932 2152
[51 X 457 X 457] [3.345] [7551] [2183]/ [876.3] [976.1]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240DM30E 3-60-460 9.3 59.6 2.0 11.2 59 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1930 2150
[51 X 457 X 457] [3.345] [7551] [2183]/ [875.4] [975.2]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240DM40E 3-60-460 9.3 59.6 2.0 11.2 59 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1954 2174
[51 X 457 X 457] [3.345] [7551] [2183]/ [886.3] [986.1]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240YL30E 3-60-575 7.7 49.4 1.0 8.0 45 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1908 2128
[51 X 457 X 457] [3.345] [7551] [2183]/ [865.5] [965.2]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240YL40E 3-60-575 7.7 49.4 1.0 8.0 45 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1932 2152
[51 X 457 X 457] [3.345] [7551] [2183]/ [876.3] [976.1]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240YM30E 3-60-575 7.7 49.4 1.0 8.8 46 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1930 2150
[51 X 457 X 457] [3.345] [7551] [2183]/ [875.4] [975.2]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240YM40E 3-60-575 7.7 49.4 1.0 8.8 46 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 77/72 1954 2174
[51 X 457 X 457] [3.345] [7551] [2183]/ [886.3] [986.1]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
SHIPPING
LBS.
[KG]
TABLE 1 – CONTINUED
15, 20 & 25 TON (-)KKB – ELECTRICAL& PHYSICAL DATA
ELECTRICAL
MODEL
NUMBER
PHASE
FREQUENCY
VOLTAGE
(HZ)
(VOLTS)
RATED
LOAD
AMPERES
(RLA)[EA.]
COMPRESSOR
LOCKED
ROTOR
AMPERES
(LRA)[EA.]
FULL LOAD
AMPERES
(FLA)
FAN
MTR
[EA.]
BLWR
MTR
MINIMUM
CIRCUIT
AMPACITY
AMPERES
MIN.
AMPS
MAX.
AMPS
FUSE OR HACR
CIRCUIT
BREAKER
DRIVE
TYPE
RECOMMENDED
NO. AND SIZE
[mm x mm x mm]
AREA
SQ. FT.
[SQ. M]
NO.
ROWS
CFM
[L/s]
R22
OZ.
[G]
SYSTEM
PER
CIRCUIT
1,2/3,4
NET
LBS.
[KG]
FILTER OUTDOOR COIL WEIGHT
PHYSICAL
Page 8
8
A300CL30E 3-60-208-230 21.0/21.0 156 2.3 14.7 114/114 125/125 125/125 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2037 2257
[51 X 457 X 457] [3.345] [7551] [3317]/ [940.3] [1023.8]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300CL40E 3-60-208-230 21.0/21.0 156 2.3 14.7 114/114 125/125 125/125 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2053 2273
[51 X 457 X 457] [3.345] [7551] [3317]/ [931.2] [1031.0]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300CM30E 3-60-208-230 21.0/21.0 156 2.3 22.3 122/122 125/125 125/125 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2059 2279
[51 X 457 X 457] [3.345] [7551] [3317]/ [933.9] [1033.7]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300CM40E 3-60-208-230 21.0/21.0 156 2.3 22.3 122/122 125/125 125/125 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2075 2295
[51 X 457 X 457] [3.345] [7551] [3317]/ [941.2] [1041.0]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300DL30E 3-60-460 10.4 70 1.5 10.0 61 70 70 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2061 2281
[51 X 457 X 457] [3.345] [7551] [3317]/ [934.8] [1034.6]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300DL40E 3-60-460 10.4 70 1.5 10.0 61 70 70 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2085 2305
[51 X 457 X 457] [3.345] [7551] [3317]/ [945.7] [1045.5]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300DM30E 3-60-460 10.4 70 1.5 11.2 67 70 70 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2083 2303
[51 X 457 X 457] [3.345] [7551] [3317]/ [944.8] [1044.6]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300DM40E 3-60-460 10.4 70 1.5 11.2 67 70 70 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2107 2327
[51 X 457 X 457] [3.345] [7551] [3317]/ [955.7] [1055.5]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300YL30E 3-60-575 8.5 54 1.0 8.0 49 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2061 2281
[51 X 457 X 457] [3.345] [7551] [3317]/ [934.8] [1034.6]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300YL40E 3-60-575 8.5 54 1.0 8.0 49 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2085 2305
[51 X 457 X 457] [3.345] [7551] [3317]/ [945.7] [1045.5]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300YM30E 3-60-575 8.5 54 1.0 8.8 50 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2083 2303
[51 X 457 X 457] [3.345] [7551] [3317]/ [944.8] [1044.6]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A300YM40E 3-60-575 8.5 54 1.0 8.8 50 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2107 2327
[51 X 457 X 457] [3.345] [7551] [3317]/ [955.7] [1055.5]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
SHIPPING
LBS.
[KG]
TABLE 1 – CONTINUED
15, 20 & 25 TON (-)KKB – ELECTRICAL& PHYSICAL DATA
ELECTRICAL
MODEL
NUMBER
PHASE
FREQUENCY
VOLTAGE
(HZ)
(VOLTS)
RATED
LOAD
AMPERES
(RLA)[EA.]
COMPRESSOR
LOCKED
ROTOR
AMPERES
(LRA)[EA.]
FULL LOAD
AMPERES
(FLA)
FAN
MTR
[EA.]
BLWR
MTR
MINIMUM
CIRCUIT
AMPACITY
AMPERES
MIN.
AMPS
MAX.
AMPS
FUSE OR HACR
CIRCUIT
BREAKER
DRIVE
TYPE
RECOMMENDED
NO. AND SIZE
[mm x mm x mm]
AREA
SQ. FT.
[SQ. M]
NO.
ROWS
CFM
[L/s]
R22
OZ.
[G]
SYSTEM
PER
CIRCUIT
1,2/3,4
NET
LBS.
[KG]
FILTER OUTDOOR COIL WEIGHT
PHYSICAL
Page 9
9
A180CL25E 3-60-208-230 12.4/12.4 88 2.4 11.5 74/74 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1790 2010
[51 X 457 X 457] [3.345] [7551] [2325]/ [811.9] [911.7]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180CL35E 3-60-208-230 12.4/12.4 88 2.4 11.5 74/74 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1817 2037
[51 X 457 X 457] [3.345] [7551] [2325]/ [824.2] [924.0]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180CM25E 3-60-208-230 12.4/12.4 88 2.4 14.7 77/77 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1820 2040
[51 X 457 X 457] [3.345] [7551] [2325]/ [825.5] [925.3]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180CM35E 3-60-208-230 12.4/12.4 88 2.4 14.7 77/77 80/80 80/80 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1847 2067
[51 X 457 X 457] [3.345] [7551] [2325]/ [837.8] [937.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DL25E 3-60-460 6.4 44 2.0 7.0 43 45 45 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1806 2026
[51 X 457 X 457] [3.345] [7551] [2325]/ [819.2] [919.0]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DL35E 3-60-460 6.4 44 2.0 7.0 43 45 45 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1841 2061
[51 X 457 X 457] [3.345] [7551] [2325]/ [835.1] [934.9]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DM25E 3-60-460 6.4 44 2.0 10.0 46 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1836 2056
[51 X 457 X 457] [3.345] [7551] [2325]/ [832.8] [932.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180DM35E 3-60-460 6.4 44 2.0 10.0 46 50 50 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1871 2091
[51 X 457 X 457] [3.345] [7551] [2325]/ [848.7] [948.5]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180YL25E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1806 2026
[51 X 457 X 457] [3.345] [7551] [2325]/ [819.2] [919.0]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180YL35E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1841 2061
[51 X 457 X 457] [3.345] [7551] [2325]/ [835.1] [934.9]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A180YM25E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1836 2056
[51 X 457 X 457] [3.345] [7551] [2325]/ [832.8] [932.6]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
SHIPPING
LBS.
[KG]
TABLE 2
15 & 20 TON (-)KMB – ELECTRICAL& PHYSICAL DATA
ELECTRICAL
MODEL
NUMBER
PHASE
FREQUENCY
VOLTAGE
(HZ)
(VOLTS)
RATED
LOAD
AMPERES
(RLA)[EA.]
COMPRESSOR
LOCKED
ROTOR
AMPERES
(LRA)[EA.]
FULL LOAD
AMPERES
(FLA)
FAN
MTR
[EA.]
BLWR
MTR
MINIMUM
CIRCUIT
AMPACITY
AMPERES
MIN.
AMPS
MAX.
AMPS
FUSE OR HACR
CIRCUIT
BREAKER
DRIVE
TYPE
RECOMMENDED
NO. AND SIZE
[mm x mm x mm]
AREA
SQ. FT.
[SQ. M]
NO.
ROWS
CFM
[L/s]
R22
OZ.
[G]
SYSTEM
PER
CIRCUIT
1,2,3,4
NET
LBS.
[KG]
FILTER OUTDOOR COIL WEIGHT
PHYSICAL
Page 10
10
A180YM35E 3-60-575 5.0 34 1.0 8.0 34 35 35 BLT (3) 2 X 18.0 X 18.0 36.0 1.00 16000 82/72 1871 2091
[51 X 457 X 457] [3.345] [7551] [2325]/ [848.7] [948.5]
(3) 2 X 18.0 X 24.0 [2041]
[51 X 457 X 610]
A240CL30E 3-60-208-230 17.5/17.5 123 2.4 14.7 99/99 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 1972 2192
[51 X 457 X 457] [3.345] [7551] [3317]/ [894.5] [994.3]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240CL40E 3-60-208-230 17.5/17.5 123 2.4 14.7 99/99 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 1988 2208
[51 X 457 X 457] [3.345] [7551] [3317]/ [901.7] [1001.5]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240CM30E 3-60-208-230 17.5/17.5 123 2.4 22.3 107/107 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 1994 2214
[51 X 457 X 457] [3.345] [7551] [3317]/ [904.5] [1004.3]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240CM40E 3-60-208-230 17.5/17.5 123 2.4 22.3 107/107 110/110 110/110 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2010 2230
[51 X 457 X 457] [3.345] [7551] [3317]/ [911.7] [1011.5]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240DL30E 3-60-460 9.0 62 2.0 10.0 57 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 1996 2216
[51 X 457 X 457] [3.345] [7551] [3317]/ [905.4] [1005.2]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240DL40E 3-60-460 9.0 62 2.0 10.0 57 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2020 2240
[51 X 457 X 457] [3.345] [7551] [3317]/ [916.3] [1016.0]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240DM30E 3-60-460 9.0 62 2.0 11.2 58 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2018 2238
[51 X 457 X 457] [3.345] [7551] [3317]/ [915.3] [1015.1]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240DM40E 3-60-460 9.0 62 2.0 11.2 58 60 60 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2042 2262
[51 X 457 X 457] [3.345] [7551] [3317]/ [926.2] [1026.0]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240YL30E 3-60-575 7.1 50 1.0 8.0 43 45 45 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 1996 2216
[51 X 457 X 457] [3.345] [7551] [3317]/ [905.4] [1005.2]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240YL40E 3-60-575 7.1 50 1.0 8.0 43 45 45 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2020 2240
[51 X 457 X 457] [3.345] [7551] [3317]/ [916.3] [1016.0]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240YM30E 3-60-575 7.1 50 1.0 8.8 43 45 50 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2018 2238
[51 X 457 X 457] [3.345] [7551] [3317]/ [915.3] [1015.1]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
A240YM40E 3-60-575 7.1 50 1.0 8.8 43 45 50 BLT (3) 2 X 18.0 X 18.0 36.0 2.00 16000 117/107 2042 2262
[51 X 457 X 457] [3.345] [7551] [3317]/ [926.2] [1026.0]
(3) 2 X 18.0 X 24.0 [3033]
[51 X 457 X 610]
SHIPPING
LBS.
[KG]
TABLE 2 – CONTINUED
15 & 20 TON (-)KMB – ELECTRICAL& PHYSICAL DATA
ELECTRICAL
MODEL
NUMBER
PHASE
FREQUENCY
VOLTAGE
(HZ)
(VOLTS)
RATED
LOAD
AMPERES
(RLA)[EA.]
COMPRESSOR
LOCKED
ROTOR
AMPERES
(LRA)[EA.]
FULL LOAD
AMPERES
(FLA)
FAN
MTR
[EA.]
BLWR
MTR
MINIMUM
CIRCUIT
AMPACITY
AMPERES
MIN.
AMPS
MAX.
AMPS
FUSE OR HACR
CIRCUIT
BREAKER
DRIVE
TYPE
RECOMMENDED
NO. AND SIZE
[mm x mm x mm]
AREA
SQ. FT.
[SQ. M]
NO.
ROWS
CFM
[L/s]
R22
OZ.
[G]
SYSTEM
PER
CIRCUIT
1,2,3,4
NET
LBS.
[KG]
FILTER OUTDOOR COIL WEIGHT
PHYSICAL
Page 11
11
II. INSTALLATION
A. GENERAL
1. INSTALLATION — 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: NFPA90A - 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.
Batterymarch Park
Quincy, MA 02269
2. PRE-INSTALLATION CHECKPOINTS — 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
IMPORTANT: Before operating unit,
remove compressor shipping
supports from the compressor base.
Failure to remove supports will casue
noise and vibration.
LOCATION CONSIDERATIONS
The metal parts of this unit may be
subject to rust or deterioration in adverse
environmental 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.
3. A 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.
B. OUTSIDE INSTALLATION
THESE UNITS ARE DESIGNED
CERTIFIED FOR OUTDOOR
INSTALLATION ONLY. INSTALLATION
INSIDE ANY P ART 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.
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.
DISCONNECT ALL POWER TO UNIT
BEFORE STARTING MAINTENANCE.
FAILURE TO DO SO CAN CAUSE
ELECTRICAL SHOCK RESULTING IN
PERSONAL INJURYOR DEATH.
REGULAR MAINTENANCE WILL
REDUCE THE BUILDUP OF
CONT AMINANTS 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 an automobile polish will
provide some protection.
!
WARNING
!
WARNING
FIGURE 9. Outside Slab Installation. Closet Distribution System.
Slab Floor Construction
ST-A0886-25
Page 12
12
(Typical outdoor slab installation is
shown in Figure 9.)
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. Locate the unit to provide proper
access for inspection and servicing
as shown in Figure 12.
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.
C. A TTACHING EXHAUST AND
COMBUSTION AIR INLET
HOODS
IMPORTANT: Do not operate this unit
without the exhaust/combustion air inlet
hood properly installed. These hoods
are shipped in cartons in the blower
compartment inside the unit and must
be attached when the unit is installed.
See Figure 4.
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 3.
2. Remove exhaust/combustion air inlet
hoods from the cartons, located inside
the blower compartment.
3. Attach blower access panel.
4. Attach the combustion air inlet/exhaust
hoods with screws. Reference Figure 4
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. The only
exception is with factory approved
additions.
D.
COVER PANEL
INSTALLATION/
CONVERSION PROCEDURE
DOWNFLOW TO HORIZONT AL
1. Remove the screws and covers from
the outside of the supply and return
sections. Also remove and discard
cover plate. See Figure 7.
2. Install the covers over the bottom
supply and return openings, painted
side up, inserting the leading flange
under the bracket provided. Place
the back flange to top of the front
bracket provided. See Figures 10
and 11.
3. Secure the return and supply cover to
front bracket with two (2) screws.
E.
FILTER REPLACEMENT
This unit is provided with 3 - 18” X 18” X 2”
and 3 - 18” X 24” X 2” disposable filters.
When replacing filters, ensure they are
inserted fully to the back to prevent
bypass. See Figure 5.
Recommended supplier of this filter is
Glassfloss Industries, Inc. or
AAF International
215 Central Avenue
P.O. Box 35690
Louisville, KY 40232
Phone: 1-800-501-3146
Part #: 54-42541-01 (18" x 18" x 2")
54-42541-03 (18" x 24" x 2")
FIGURE 10. HORIZONTAL
CONVERSION DETAIL
ST-A0886-30
FIGURE 11. HORIZONTAL
CONVERSION DETAIL
ST-A0886-31
Page 13
13
E.
CLEARANCES
The following minimum clearances must
be observed for proper unit performance
and serviceability. Reference Figure 12.
FIGURE 12. CLEARANCES
ST-A0886-09
Page 14
14
G.
ROOFTOPINSTALLATION
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 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.
H.DUCTING
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.
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.
Place the unit as close to the conditioned
!
WARNING
FIGURE 13A. Flat Rooftop Installation, Attic or Drop Ceiling Distributing
System. Mounted on Roofcurb. Curb must be level.
ST-A0886-10
FIGURE 13B. Flat Rooftop Installation, Attic or Drop Ceiling Distributing
System. Mounted on Roofcurb. Curb must be level.
ST-A0886-26
Page 15
15
FIGURE 15. ROOFCURB
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.
1
/2”
to 1” thick insulation is usually sufficient
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/building owner must be
informed against future changes in
construction which might change this to
a “confined space.” Also, caution the
user/building owner 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.
FIGURE 14. LIFTING DETAIL
!
WARNING
RETURN AIR
NEVER ALLOW PRODUCTS OF
COMBUSTION OR THE FLUE
PRODUCTS TO ENTER THE RETURN
AIR DUCTWORK, OR THE
CIRCULA TING AIR SUPPL Y. ALL
RETURN DUCTWORK MUST BE
ADEQUA TELY 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 INJURYOR DEATH.
ST-A0886-12
ST-A0888-02
ST-A0888-02
FIGURE 16. ROOFCURB
Page 16
16
III. GAS SUPPLY, CONDENSATE DRAIN AND 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.
2. Connect the gas line to the gas valve
supplied with unit. Routing can be
through the gas pipe opening shown
in Figures 9 or 13A or 13B or
through the base as shown in
Figure 21.
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 17.)
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.
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.
DO NOT USE AN OPEN FLAME TO
CHECK FOR LEAKS. THE USE OF AN
OPEN FLAME CAN RESULT IN FIRE,
EXPLOSION, PROPERTY DAMAGE,
PERSONAL INJURYOR DEATH.
!
WARNING
FIGURE 17. SUGGESTED GAS PIPING
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. Abackup 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 3.
After determining the pipe length, select
the pipe size which will provide the
minimum cubic feet per hour required for
the gas input rating of the furnace. By
formula:
Gas Input of Furnace
(BTU/HR)
Cu. Ft. Per Hr. Required =
Heating Value of Gas
(BTU/FT
3
)
The gas input of the furnace is marked on
the furnace rating plate. The heating value
of the gas (BTU/FT
3
) may be determined
by consulting the local natural gas utility or
the L.P. gas supplier.
Nominal
Iron Pipe
Size,
Inches
Equivalent Length of Pipe, Feet
10 20 30 40 50 60 70 80
1
/2 132 92 73 63 56 50 46 43
3
/4
278 190 152 130 115 105 96 90
1 520 350 285 245 215 195 180 170
1
1
/4 1,050 730 590 500 440 400 370 350
11/2
1,600 1,100 890 760 670 610 560 530
TABLE 3
GAS PIPE CAPACITY TABLE (CU. FT./HR.)
FROM GAS
METER
*
Factory supplied grommet must be utilized.
MANUAL GAS
SHUT-OFF
VALVE
UNIT GAS SUPPLY
CONNECTION
*
ROOF OR GROUND LEVEL INSTALLATION
Page 17
17
B. LPCONVERSION
THIS UNIT IS EQUIPPED AT THE
FACTORY FOR USE ON NATURALGAS
ONLY. CONVERSION TO LPGAS
REQUIRES A SPECIAL KIT SUPPLIED
BY THE DISTRIBUTOR OR
MANUFACTURER. MAILING
ADDRESSES ARE LISTED ON THE
FURNACE RA TING PLATE, PARTS LIST
AND WARRANTY. FAILURE TO USE
THE PROPER CONVERSION KIT CAN
CAUSE FIRE, CARBON MONOXIDE
POISONING, EXPLOSION, PERSONAL
INJURY, PROPERTY DAMAGE OR
DEA TH.
Convert the unit to use liquefied petroleum
(LP) gas by replacing with the stem/spring
assembly supplied in the conversion kit.
The LP gas valve maintains the proper
manifold pressure for LP gas. The correct
burner LP orifices are included in the kit.
See Figure 18Afor component locations.
NOTE: Order the correct LP conversion kit
from the furnace manufacturer. See
Conversion Kit Index shipped with unit
for proper LP kit number. Furnace
conversion to LP gas must be
performed by a qualified technician.
C. ADJUSTING OR CHECKING
FURNACE INPUT
– Natural Gas Line Pressure 5” - 10.5”
W.C.
– LP Gas Line Pressure 11” - 13” W.C.
– Natural Gas Manifold Pressure 3.5”
W.C
– LP Gas Manifold Pressure - 10” W.C.
!
WARNING
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)
TABLE 4
LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)
Nominal
Iron Pipe
Size, Inches
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
1/2
3/4
1
1-1/4
1-1/2
2
Length of Pipe, Feet
Example (LP): Input BTU requirement of unit, 150,000
Equivalent length of pipe, 60 ft. = 3/4” IPS required.
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.
FIGURE 18A. HEAT EXCHANGER COMPONENT IDENTIFICATION
ST-A0886-29
Supply and manifold pressure taps are
located on the gas valve body 1/8” N.P.T .
and on the manifold. See Figure 18B.
Use a properly calibrated manometer gauge
for accurate gas pressure readings.
FIGURE 18B. HONEYWELL VR8305Q4120 TWO STAGE GAS VALVE
OUTLET PRESSURE
TAP-1/8 NPT
2-STAGE
OPERATOR
INLET PRESSURE
TAP-1/8 NPT
GROUND
TERMINAL
LOW STAGE ADJUSTMENT
UNDER VENT CAP
HIGH STAGE ADJUSTMENT
UNDER VENT CAP
Page 18
18
250,000 ONE 13.0 14.4 15.0 15.8 36.0
TEN 2 10 2 24 2 30 2 38 6 0
ONE 10.8 12.0 12.5 13.2 30.0
300,000
TEN 14820 2521250
ONE 9.3 10.3 10.7 1.3 25.7
350,000
TEN 1 33 1 43 1 47 1 53 4 17
ONE 8.1 9.0 9.36 9.9 22.5
400,000
TEN 1 21 1 30 1 36 1 39 3 45
To adjust the pressure regulator, remove
the regulator vent cover and turn the
adjustment screw clockwise to increase
pressure or counterclockwise to decrease
pressure. See Figure 18B. Then replace
the regulator vent cover securely .
Any necessary major changes in the gas
flow rate should be made by changing the
size of the burner orifices. To change orifice
spuds, shut off the manual main gas valve
and remove the gas manifold.
For elevations up to 2,000 feet, rating plate
input ratings apply . For high altitudes
(elevations over 2,000 ft.), see conversion
kit index 92-21519-XX for derating and
orifice spud sizes.
Check of input is important to prevent
over-firing of the furnace beyond its
design-rated input. NEVER SET INPUT
ABOVE THA T SHOWN ON THE RATING
PLA TE. Use the following table or
formula to determine input rate.
Heating Value of Gas
(BTU/Cu. Ft.) x 3600
Cu. Ft. Per Hr. Required =
Time in Seconds
(for 1 Cu. Ft.) of Gas
METER TIME IN MINUTES AND SECONDS FOR NORMAL
INPUT RATING OF FURNACES EQUIPPED FOR NATURAL
OR LP GAS
INPUT
BTU/HR
METER
SIZE
CU. FT.
HEATING VALUE OF GAS BTU PER CU. FT.
900 1000 1040 1100 2500
MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.
TABLE 5
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 ANSIZ223.1), the burner orifices must be
sized to reduce the input 4% for each
1,000 feet (305 meters) above sea level.
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 FACTORYAUTHORIZED
CONVERSION STATION WITH THE
HEATING INPUT DERATED BY10% SO
AS TO OPERATE PROPERLY IN
ALTITUDES FROM 2,000 - 4,500 FEET
(610 - 1,373 METERS).
D.CONDENSATE DRAIN
The condensate drain connection of the
evaporator is threaded 1” -11
1
/2” NPT.
IMPORTANT: Install a condensate trap to
ensure proper condensate drainage. See
Figure 19.
FIGURE 19. CONDENSATE DRAIN
DO NOT OVERTIGHTEN DRAIN FITTING
Page 19
19
A.POWER SUPPLY
TURN OFF THE MAIN ELECTRICAL
POWER AT THE BRANCH CIRCUIT
DISCONNECT CLOSEST TO THE UNIT
BEFORE A TTEMPTING ANY WIRING.
FAILURE TO DO SO CAN CAUSE
ELECTRICAL SHOCK RESULTING IN
PERSONAL INJURYOR 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.
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 6
using the circuit ampacity found on the
unit rating plate. Use the smallest wire
size allowable from the unit
disconnect to unit.
IV. WIRING
!
WARNING
4. For through the base wiring entry
reference Figure 21. All fittings and
conduit are field supplied for this
application. Reference the chart with
Figure 21 for proper hole and conduit
size.
NOTES:
1. For branch circuit wiring (main power
supply to unit disconnect), the
minimum wire size for the length of
run can be determined from this
table using the circuit ampacity
found on the unit rating plate. From
the unit disconnect to unit, the
smallest wire size allowable in Table
1 may be used, as the disconnect
must be in sight of the unit.
2. Wire size based on 75°C rated wire
insulation for 1% voltage drop.
3. For more than 3 conductors in a
raceway or cable, see the N.E.C.
(C.E.C. in Canada) for derating the
ampacity of each conductor.
IMPORTANT: THIS UNIT IS APPROVED FOR USE WITH COPPER
CONDUCTORS ONL
Y CONNECTED
TO UNIT CONTACTOR.
WARRANTY MAY BE JEOPARDIZED
IF ALUMINUM WIRE IS CONNECTED
TO UNIT CONTACTOR.
Special instructions apply for power
wiring with aluminum conductors:
Warranty is void if connections are not
made per instructions.
Attach a length (6” or more) of
recommended size copper wire to the unit
contactor terminals 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.
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
TABLE 6
FIGURE 20.
TABLE 7
Recommended Branch Circuit
Disconnect Location
ST-A0886-11
COPPER
WIRE SIZE—AWG
SUPPLYWIRE LENGTH—FEET
50 100 150 200 250 300
20 10 8 6 4 4 4
25 10 8 6 4 4 3
30864432
35864321
40864321
45843211/0
50643211/0
60 6 4 2 1 1/0 2/0
70 4 3 2 1/0 2/0 3/0
80 4 3 1 1/0 2/0 3/0
90 3 2 1/0 2/0 3/0 4/0
100 3 2 1/0 2/0 3/0 4/0
110 2 1 2/0 3/0 4/0 250
125 1 1 2/0 3/0 4/0 25
UNIT
MCA
Page 20
20
WIRE SIZE, AWG
lamps, televisions, radios or air streams
from registers. Refer to instructions packed
with the thermostat for “heater” selection or
adjustment.
The following is a list of recommended
thermostats to be used with or without an
economizer:
B. HOOK-UP
To wire unit, refer to the following hookup diagram.
Refer to Figures 2 and 21 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
Adiagram of the internal wiring of this unit
is located on the inside of control access
panel and in 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 7.
Install the room thermostat in accordance
with the instruction sheet packed in the box
with the thermostat. Run the thermostat
lead wires through control entry opening
(Figure 2 or Figure 21) and connect to the
low voltage thermostat connections (see
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 rays,
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
50 100 150 200 250 300
Length of Run – Feet (1)
Thermostat Load -
Amps
TABLE 8
(1) The total wire length is the distance from the unit to the thermostat
and back to the unit.
NOTE: DO NOT USE CONTROL WIRING SMALLER THAN NO. 18
AWG.
FIGURE 21. BASE ENTRY LOCATIONS
FIGURE 22. TYPICAL THERMOSTAT WIRING
14
1/2(
7/8(
12
1/2(
7/8(
10
1/2(
7/8(
8
3/4(
1-31/32(
6
1(
1-23/64(
4
1(
1-23/64(
3
1-1/4(
1-23/32(
2
1-1/4(
1-23/32(
1
1-1/2(
1-31/32(
0
1-1/2(
1-31/32(
00
2(
2-15/32(
000
2(
2-15/32(
CONDUIT SIZE
HOLE SIZE
ST-A0886-14
Two Stage Cool/
Two Stage Heat Part #
W/O Economizer
Robertshaw -
Model #09710
41-32971-01
Honeywell -
Model #T874D1959
41-21444-01
White Rodgers -
Model #1F91-7
41-21015-04
Honeywell -
Model #T7300AORB
41-21615-06
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).
Page 21
21
V. FURNACE SECTION CONTROLS AND IGNITION SYSTEM
thermostat input. If only W1 is called
for, W2 is de-energized and the
control starts a 30 second off delay on
the W2 inducer(s).
1 1. After fixed 30 seconds the W2
inducers is de-energized.
12. Control enters normal operating loop
where all inputs are continuously
checked.
13. Zone thermostat is satisfied.
14. Control de-energizes gas valve.
15. Control senses loss of flame.
16. Control initiates 5 second inducer
postpurge and 90 second indoor
blower delay off.
17. Control de-energizes inducer
blower(s).
18. Control de-energizes indoor blower.
19. Control in the stand by mode with
solid red LED.
B. Call For Second Stage,
After First
Stage Established; Starting from A.1 1:
1. If a call for second stage (high fire) is
initiated after a call for first stage heat
is established, the control verifies W2
pressure switches for normally open
contacts. The control energizes the
W2 inducers and energizes the
second stage of the gas valve.
2. Control enters normal operating loop
where all inputs are continuously
checked.
C. Second Stage Satisfied; First Stage
Still Called For; Starting From B.3:
1. Once the call for second stage is
satisfied, the control starts a 30
second off delay on W2 inducers and
reduces the gas valve to first stage.
2. Control enters normal operating loop
where all inputs are continuously
checked.
D. First Stage Satisfied:
1. Zone thermostat is satisfied.
2. Control de-energizes gas valve.
3. Control senses loss of flame.
4. Control initiates 5 second inducer
postpurge and 90 second indoor
blower delay off.
5. Control de-energizes inducer blower.
6. Control de-energizes indoor blower.
7. Control in the stand by mode with solid
red LED.
E. First Stage and Second Stage Called
Simultaneously:
1. Zone thermostat contacts close, a call
for first stage (low fire) and second
stage (high fire) heat is initiated.
2. Control runs self check.
3. Control checks the high-limit switch for
normally closed contacts, each
pressure switch for normally open
contacts, and all flame rollout switches
for continuity .
4. Control energizes each inducer.
5. Control checks each pressure switch
for closure.
6. If each pressure switch is closed, the
control starts a 30 second prepurge
and energizes W2. If either switch is
still open, the inducers will continue to
be energized until closure.
7. After prepurge timeout, control
energizes W1 and continues to
energize W2, initiates spark for 2
seconds minimum, 7 second maximum
ignition trial, and initiates 120 second
stage warm up timing.
8. Control detects flame, de-energizes
spark and starts a 45 second indoor
blower delay on timing.
9. After a fixed 45 seconds indoor blower
delay on, the control energizes the
indoor blower.
10. After a fixed 120 seconds second stage
warmup period control checks the
thermostat input. If W1 and W2 is
present control enters normal operating
loop where all inputs are continuously
checked.
F. First Stage and Second Stage
Removed Simultaneously:
1. Upon a loss of W1 and W2 the gas
valve is de-energized.
2. Upon a loss of flame, each inducer will
complete a 5 second postpurge and
the indoor blower will complete a 90
second delay off.
3. Control in the stand by mode with solid
red LED.
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 goes 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 circulating air blower will start and run
on the heating speed if the thermostat fan
switch is in the “ON” position.
NORMAL FURNACE
OPERATING SEQUENCE
This unit has a two stage gas furnace
which employs an integrated furnace
control with self diagnostics located in the
control box. The furnace is composed of
induced draft blowers, negative pressures
switches, two stage gas valve, manifold
orifices, inshot burners, direct spark
ignitor, remote flame sense, tubular heat
exchanger, high limit switch and rollout
switches. See Figure 23.
NORMAL HEAT MODE
A. Call For First Stage (low fire) Only:
1. Zone thermostat contacts close, a call
for first stage (low fire) heat is
initiated.
2. Control runs self check.
3. Control checks the high-limit switch
for normally closed contacts, each
pressure switch for normally open
contacts, and all flame rollout
switches for continuity .
4. Control energizes each inducer.
5. Control checks each pressure switch
for closure.
6. If each pressure switch is closed, the
control starts a 30 second prepurge
and energizes W2. If any pressure
switch is still open, the inducers will
continue to be energized until closure.
7. After prepurge timeout, control
energizes W1 and continues to
energize W2, initiates spark for 2
seconds minimum, 7 second
maximum ignition trial, initiates 120
second, second stage (high fire)
warm up timing.
8. Control detects flame, de-energizes
spark and initiates 45 second delay
on blower timing.
9. After a fixed 45 seconds indoor
blower delay on, the control energizes
the indoor blower.
10. After a fixed 120 seconds second
stage warmup period control checks
FIGURE 23.
ST-A0886-29
Page 22
22
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.
DO NOT ATTEMPT TO MANUALLY
LIGHT THIS FURNACE WITH AMATCH
OR ANY OPEN FLAME. A TTEMPTING
TO DO SO CAN CAUSE AN
EXPLOSION OR FIRE RESUL TING IN
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
TO START THE FURNACE
1. Set the thermostat to its lowest
setting.
2. Turn off all electric power to the
appliance.
3. This appliance does not have a pilot.
It is equipped with an ignition device
which automatically lights the burner.
Do not
try to light the burner by hand.
4. Remove control door.
5. Move control knob to the “OFF”
position. Turn the knob by hand only,
do not use any kind of tool.
6. Wait five (5) minutes to clear out any
gas. Then smell for gas, including
near the floor. If you smell gas,
STOP! Follow B in the safety
information on the Operating
Instructions located on the back of the
controls/access panel. If you don’t
smell gas, go to the next step.
7. Move the gas control knob from
“OFF” position to “ON” position.
Operate this appliance with the gas
control knob in the “ON” position only .
Do not use the gas control knob as a
means for throttling the burner input
rate.
MANUAL RESET
OVERTEMPERATURE
CONTROL
Four manual reset overtemperature
controls 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.
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.
PRESSURE SWITCH
This furnace has four pressure switches for
sensing a blocked exhaust or a failed
induced draft blower. They are normally
open and close when the induced draft
blowers start, 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.
DO NOT JUMPER THIS DEVICE! DOING
SO CAN CAUSE AFIRE OR EXPLOSION
RESUL TING IN PROPERTYDAMAGE,
PERSONAL INJUR YOR DEATH.
IMPORTANT: Replace this control only
with the identical replacement part.
8. Replace the control door.
9. Turn on all electric power to the
appliance.
10. Set the thermostat to the desired
setting.
1 1. If the appliance will not operate, follow
the instructions below on how to shut
down the furnace.
THE SP ARK IGNIT OR AND IGNITION
LEAD FROM THE IGNITION CONTROL
ARE HIGH VOL TAGE. KEEP HANDS OR
TOOLS AWAYTO PREVENT
ELECTRICAL SHOCK. SHUT OFF
ELECTRICAL POWER BEFORE
SERVICING ANYOF THE CONTROLS.
FAILURE TO ADHERE TO THIS
WARNING CAN RESULT IN PERSONAL
INJURY OR DEATH.
The initial start-up on a new installation
may require the control system to be
energized for some time until air has bled
through the system and fuel gas is
available at the burners.
TO SHUT DOWN FURNACE
1. Set the thermostat to the lowest
setting.
2. Turn off all electric power to the
appliance if service is to be
performed.
3. Remove control door.
4. Move control knob to the “OFF”
position.
5. Replace control door.
SHOULD OVERHEA TING 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
RESUL T IN AN EXPLOSION OR FIRE
CAUSING PROPERTY DAMAGE,
SEVERE PERSONAL INJUR YOR
DEA TH!
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.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
Page 23
23
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.
LABEL ALL WIRES PRIOR TO
DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN
CAUSE IMPROPER AND DANGEROUS
OPERA TION RESULTING IN FIRE,
ELECTRICAL SHOCK, PROPERTY
DAMAGE, PERSONAL INJUR YOR
DEA TH.
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 motors, 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 (10) connecting
the two induced draft blowers to the
collector box and screws (12)
connecting the inducer mounting plate
to the heat exchanger center panel.
Remove the induced draft blowers
and the collector box from the unit.
9. 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.
10. 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.
1 1. Reassemble (steps 1 through 9 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.
HOLES IN THE EXHAUST TRANSITION
OR HEA T EXCHANGER CAN CAUSE
TOXIC FUMES TO ENTER THE HOME.
THE EXHAUST TRANSITION OR HEA T
EXCHANGER MUST BE REPLACED IF
THEY HAVE HOLES OR CRACKS IN
THEM. FAILURE TO DO SO CAN CAUSE
CARBON MONOXIDE POISONING
RESUL TING IN PERSONALINJURY OR
DEA TH.
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.
DISCONNECT MAIN ELECTRICAL
POWER TO THE UNIT BEFORE
ATTEMPTING MAINTENANCE.
FAILURE TO DO SO MAY RESULT IN
ELECTRICAL SHOCK OR SEVERE
PERSONAL INJURYOR DEATH.
!
WARNING
!
WARNING
!
WARNING
VI. COOLING SECTION OPERATION
COOLING MODE
A. Call for first stage cooling
1. Zone thermostat contacts close and
a call for cooling is initiated.
2. Inputs ‘Y1’ and ‘G’to the control are
energized.
3. Control senses ‘Y1’ and ‘G’. After 1
sec. delay , control energizes indoor
blower and first stage compressor.
4. Control enters normal operating loop
where all inputs are continuously
checked.
5. Zone thermostat is satisfied.
6. Control de-energizes indoor blower
relay after 80 second indoor blower
delay off.
7. Control in the stand by mode with
solid red LED.
B. Call for second stage cooling. After
first stage cooling established:
starting from A4.
1. If a call for second stage cooling is
initiated after a call for first stage
cooling is established, the control
energizes Y2 and energizes the
second stage compressor.
2. Control enters normal operating loop
where all inputs are continuously
checked.
C. Second stage satisfied: first stage
still called for: starting from B2.
1. Y2 is de-energized and second
stage compressor is de-energized.
D. First stage and second stage called
simultaneously .
1. Zone thermostat contacts close, a
call for first and second stage cooling
is initiated.
2. Inputs Y1, Y2 and G to the control are
energized.
3. Control senses Y1, Y2 and G, after 1
second delay , control energizes
indoor blower, first and second stage
compressor are energized.
E. First stage and second stage
removed simultaneously .
1. Upon a loss of Y1 and Y2 each
compressor is de-energized. Control
either de-energizes indoor blower
relay after 80 second indoor blower
delay off.
2. Control in the stand by mode with
solid red LED.
CONTINUOUS F AN MODE
A‘G’ input only indicates a zone thermostat
call for continuous indoor blower operation.
VII. SYSTEM OPERATING INFORMATION
Page 24
24
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
DISCONNECT MAIN ELECTRICAL
POWER TO THE UNIT BEFORE
ATTEMPTING MAINTENANCE.
FAILURE TO DO SO CAN CAUSE
ELECTRICAL SHOCK RESULTING IN
SEVERE PERSONAL INJURYOR
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. Open the control/filter access panel
and remove filters. Also, remove
blower access panel. In downflow
applications remove the horizontal
return to gain access.
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 INJURYOR
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-andwater solution. Rinse the coil
thoroughly with water. IMPORTANT:
Do not
use excessive water
pressure. Excessive water pressure
can bend the fins and tubing of the
coil and lead to inadequate unit
performance. Be careful not to splash
water excessively into unit.
3. Inspect the drain pan and
condensate drain at the same time
the evaporator coil is checked. Clean
the drain pan by flushing with water
and removing any matters of
obstructions which may be present.
4. Go to next section for cleaning the
condenser coil.
Cleaning Condenser Coil, Condenser
Fan, Circulation Air Blower and
Venturi
1. Remove the condenser access end
panel and/or compressor access
louver panel. Disconnect the wires to
the condenser fan motor in the
control box (see wiring diagram).
2. 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.
3. If the coil is coated with oil or grease,
clean it with a mild detergent-andwater solution. Rinse the coil
thoroughly with water. IMPORTANT:
Do not
use excessive water
pressure. Excessive water pressure
can bend the fins and tubing of the
coil and lead to inadequate unit
performance. Be careful not to splash
water excessively into unit.
4. The venturi should also be inspected
for items of obstruction such as
collections of grass, dirt or spider
webs. Remove any that are present.
5. 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. Reconnect fan motor wires per the
wiring diagram attached to the back of
the control cover.
2. Replace the control box cover.
3. Close the filter/control access panel
and replace the blower/evaporator coil
access panels.
4. Restore electrical power to the unit
and check for proper operation,
especially the condenser fan motor.
REPLACEMENT PARTS
Contact your local distributor for a
complete parts list.
TROUBLESHOOTING
Refer to Figures 24 and 25 for determining
cause of unit problems.
WIRING DIAGRAMS
Figures 26, 27, 28 and 29 are complete
wiring diagrams for the unit and its power
sources. Also located on back of
compressor access panel.
CHARGING
See Figures 30 and 31 for proper charging
information.
!
WARNING
!
WARNING
Page 25
25
E.S.P. - Inches of Water
15 TON PACKAGE UNIT - 60 Hz
———
—
637
653
669
685
701
717
733
749
765
———
—
1494
1738
1981
2224
2468
2711
2955
3198
3442
AIR-FLOW PERFORMANCE – 15 TON MODELS
TABLE 9
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3
1.4
1.5 1.6 1.7 1.8 1.9 2.0
STD
CFM
RPM RPM
WATTS WATTS
RPM
WATTS
RPM RPM
WATTS WATTS
RPM
WATTS
RPM
WATTS
RPM RPM
WATTS WATTS
RPM
WATTS
RPM
WATTS
RPM
WATTS
RPM
WATTS
RPM
WATTS
RPM RPM
WATTS WATTS
RPM RPM RPM RPM
WATTS WATTS WATTS WATTS
4800
5000
5200
5400
5600
5800
6000
6200
6400
6600
6800
7000
7200
———
640
656
672
688
704
720
736
752
768
784
———
1394
1638
1881
2125
2368
2611
2855
3098
3342
3585
—
—
644
660
676
692
708
724
740
756
772
788
804
—
—
1294
1538
1781
2025
2268
2512
2755
2998
3242
3485
3729
631
647
663
679
695
711
727
743
759
775
791
807
877
951
1194
1438
1681
1925
2168
2412
2655
2899
3142
3385
3629
3821
650
666
682
698
714
731
747
763
779
795
811
881
890
1095
1338
1581
1825
2068
2312
2555
2799
3042
3286
3529
3695
4000
670
686
702
718
734
750
766
782
798
814
885
894
903
1238
1482
1725
1968
2212
2455
2699
2942
3186
3429
3569
3874
4179
689
705
721
737
753
769
785
801
817
889
898
907
916
1382
1625
1869
2112
2355
2599
2842
3086
3329
3442
3748
4053
4358
709
725
741
757
773
789
805
821
893
920
911
902
929
1525
1769
2012
2256
2499
2742
2986
3229
3316
3622
3927
4232
4538
728
744
760
776
792
808
888
897
906
915
924
933
942
1669
1912
2156
2399
2643
2886
2885
3190
3495
3801
4106
4411
4717
747
764
780
796
812
892
901
910
919
928
937
946
955
1812
2056
2299
2543
2786
2759
3064
3369
3675
3980
4285
4591
4896
767
783
799
815
896
905
914
923
932
941
950
959
968
1956
2199
2443
2686
2632
2938
3243
3548
3854
4159
4464
4770
5075
786
802
818
900
909
918
927
936
945
954
963
972
—
2100
2343
2586
2506
2812
3117
3422
3727
4033
4338
4643
4949
—
806
822
904
913
922
931
940
949
958
967
976
—
—
2243
2487
2380
2685
2991
3296
3601
3907
4212
4517
4823
—
—
899
908
917
926
935
944
953
962
971
980
989
—
—
1949
2254
2559
2864
3170
3475
3780
4086
4391
4696
5002
—
—
912
921
929
936
947
956
965
974
983
992
———
2128
2433
2738
3044
3349
3654
3960
4265
4570
4876
———
924
933
942
951
960
969
978
987
996
1005
———
2307
2612
2917
3223
3528
3833
4139
4444
4749
5055
———
937
946
955
964
973
982
991
1000
1009
———
—
950
959
968
977
986
995
1004
1013
—————
963
972
981
990
999
1008
1017
—————
—
976
985
994
1003
1012
1021
———————
2486
2791
3097
3402
3707
4012
4318
4623
4928
———
—
2665
2970
3276
3581
3886
4192
4497
4802
—————
2844
3149
3455
3760
4065
4371
4876
—————
—
3023
3329
3634
3939
4245
4550
———————
DRIVE PACKAGE L
3.0
BK-90
1VP-44
123 456
823 787 750 710 670 629
MOTOR HP
BLOWER SHEAVE
MOTOR SHEAVE
TURNS OPEN
RPM
NOTES: 1. Factory sheave settings shown in bold type.
2. Do not set sheave below minimum turns open shown.
3. Re-adjustment of sheave required to achieve rated airflow at ARI minimum E.S.P.
4. Drive data shown is for horizontal airflow with dry coil. Add component resistance
to duct resistance to determine total E.S.P.
DRIVE PACKAGE M
5
BK-72
1VP-44
1.5 2 3 4 56
1022 1017 1006 933 860 786
MOTOR HP
BLOWER SHEAVE
MOTOR SHEAVE
TURNS OPEN
RPM
COMPONENT RESISTANCE TABLE
CFM WETCOIL DOWNFLOW
4800 0.020 0.010
5200 0.040 0.020
5600 0.060 0.030
6000 0.080 0.040
6400 0.100 0.050
6800 0.125 0.060
7200 0.150 0.070
Page 26
26
701
717
733
749
765
781
797
813
829
845
861
877
911
920
929
938
947
2468
2711
2955
3198
3442
3685
3929
4172
4415
4659
4902
5146
5726
6032
6337
6642
6948
AIR-FLOW PERFORMANCE – 20 & 25 TON MODELS
TABLE 10
E.S.P. - Inches of Water
20 TON PACKAGE UNIT - 60 Hz
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3
1.4
1.5 1.6 1.7 1.8 1.9 2.0
STD
CFM
RPM RPM
WATTS WATTS
RPM
WATTS
RPM RPM
WATTS WATTS
RPM
WATTS
RPM
WATTS
RPM RPM
WATTS WATTS
RPM
WATTS
RPM
WATTS
RPM
WATTS
RPM
WATTS
RPM
WATTS
RPM RPM
WATTS WATTS
RPM RPM RPM RPM
WATTS WATTS WATTS WATTS
6400
6600
6800
7000
7200
7400
7600
7800
8000
8200
8400
8600
8800
9000
9200
9400
9600
720
736
752
768
784
801
817
833
849
865
881
915
924
933
942
951
960
2611
2855
3098
3342
3585
3829
4072
4316
4559
4802
5046
5600
5905
6211
6516
6821
7127
740
756
772
788
804
820
836
852
868
910
919
928
936
945
954
963
972
2755
2998
3242
3485
3729
3972
4216
4459
4703
5169
5474
5779
6084
6390
6695
7000
7306
759
775
791
807
823
839
855
871
913
922
931
940
949
958
967
976
985
2899
3142
3385
3629
3872
4116
4359
4603
5042
5348
5653
5958
6264
6569
6874
7180
—
779
795
811
827
843
859
875
917
926
935
944
953
962
971
980
989
—
3042
3286
3529
3772
4016
4259
4503
4916
5221
5527
5832
6137
6443
6748
7053
7359
—
798
814
830
846
862
878
921
930
939
948
957
966
975
984
993
—
—
3186
3429
3673
3916
4160
4403
4790
5095
5401
5706
6011
6317
6622
6927
7233
—
—
817
834
850
866
882
925
934
943
952
961
970
979
988
997
1006
—
—
3329
3573
3816
4060
4303
4664
4696
5274
5580
5885
6190
6496
6801
7106
7412
—
—
837
853
869
920
929
938
947
956
965
974
983
992
1001
1010
———
3473
3716
3960
4232
4538
4843
5148
5454
5759
6064
6369
6675
6980
7285
———
856
872
924
933
942
951
960
969
978
987
996
1005
1014
———
—
3616
3860
4106
4411
4717
5022
5327
5633
5938
6243
6549
6854
7159
———
—
876
928
937
946
955
964
973
982
991
1000
1009
1018
1027
———
—
3760
3980
4285
4591
4896
5201
5506
5812
6117
6422
6728
7033
7338
———
—
932
941
950
959
968
977
986
995
1004
1013
1022
1031
—————
3854
4159
4464
4770
5075
5380
5686
5991
6296
6602
6907
7212
—————
945
954
963
972
981
990
999
1008
1017
1026
1035
1044
—————
4033
4338
4643
4949
5254
5559
5865
6170
6475
6781
7086
7391
—————
958
967
976
985
994
1003
1012
1021
1030
1039
1048
—————
—
4212
4517
4823
5128
5433
5739
6044
6349
6655
6960
7265
—————
—
971
980
989
998
1007
1015
1024
1033
1042
1051
———————
4391
4696
5002
5307
5612
5918
6223
6528
6834
7139
———————
983
992
1001
1010
1019
1028
1037
1046
1055
1064
———————
4570
4876
5181
5486
5791
6097
6402
6707
7013
7318
———————
996
1005
1014
1023
1032
1041
1050
1059
1068
———————
—
4749
5055
5360
5665
5971
6276
6581
6887
7192
———————
—
1009
1018
1027
1036
1045
1054
1063
1072
1081
———————
—
1022
1031
1040
1049
1058
1067
1076
1085
—————————
1035
1044
1053
1062
1071
1080
1089
1098
—————————
1048
1057
1066
1075
1084
1093
1102
—————————
—
4928
5234
5539
5844
6150
6455
6760
7066
7371
———————
—
5108
5413
5718
6024
6329
6634
6940
7245
—————————
5287
5592
5897
6203
6508
6813
7119
7424
—————————
5466
5771
6076
6382
6687
6992
7298
—————————
—
DRIVE PACKAGE L
5.0
BK-95
1VP-50
1 23456
882 846 810 773 736 700
MOTOR HP
BLOWER SHEAVE
MOTOR SHEAVE
TURNS OPEN
RPM
NOTES: 1. Factory sheave settings shown in bold type.
2. Do not set sheave below minimum turns open shown.
3. Re-adjustment of sheave required to achieve rated airflow at ARI minimum E.S.P.
4. Drive data shown is for horizontal airflow with dry coil. Add component resistance
to duct resistance to determine total E.S.P.
DRIVE PACKAGE M
7.5
BK-90
1VP-60
1234 56
1102 1075 1047 1006 964 922
MOTOR HP
BLOWER SHEAVE
MOTOR SHEAVE
TURNS OPEN
RPM
COMPONENT RESISTANCE TABLE
CFM WETCOIL DOWNFLOW
6400 0.100 0.030
6800 0.125 0.043
7200 0.150 0.055
7600 0.175 0.068
8000 0.200 0.080
8400 0.225 0.093
8800 0.250 0.105
9200 0.275 0.118
9600 0.300 0.130
Page 27
27
WARNING
!
FIGURE 24
COOLING TROUBLE SHOOTING CHART
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
box
• Thermostat out of calibration-set too high • Reset
• Failed contactor • Check for 24 volts at contactor coil - replace if contacts are
open
• 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
control opens at 450 PSIG
• Interconnecting low voltage wiring damaged • Replace thermostat wiring
Condenser fan runs, compressor • Loose connection • Check for correct voltage at compressor -
doesn’t check & tighten all connections
• 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
plate volts when unit is operating.
• 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
plate volts when unit is operating.
Compressor short cycles • Incorrect voltage • At compressor terminals, voltage must be ± 10% of
nameplate marking when unit is operating.
• 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
filter
High head pressure- • Restriction in liquid line, expansion device or filter drier • Remove or replace defective component
low vapor pressures • Flow check piston size too small • Change to correct size piston
• Incorrect capillary tubes • Change coil assembly
• TXV does not open • Replace TXV
High head pressure-high or • Dirty condenser coil • Clean coil
normal vapor pressure - • Refrigerant overcharge • Correct system charge
Cooling mode • Condenser fan not running • Repair or replace
• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge
Low head pressure-high vapor • Defective Compressor valves • Replace compressor
pressures • Incorrect capillary tubes • Replace coil assembly
Low vapor pressure - • Low evaporator airflow • Increase speed of blower or reduce restriction - replace air
cool compressor - filter
iced evaporator coil • Operating below 65°F outdoors • Add Low Ambient Kit
• Moisture in system • Recover refrigerant - evacuate & recharge - add filter drier
High vapor pressure • Excessive load • Recheck load calculation
• Defective compressor • Replace
Fluctuating head & vapor • TXV hunting • Check TXV bulb clamp - check air distribution on coil - replace
pressures TXV
• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge
Gurgle or pulsing noise at • Air or non-condensibles in system • Recover refrigerant, evacuate & recharge
expansion device or liquid line
Page 28
28
FIGURE 25
FURNACE TROUBLESHOOTING GUIDE
(COMBINATION HEATING AND COOLING UNITS WITH DIRECTSPARK IGNITION)
SET THERMOSTAT TO
CALL FOR HEAT
SET FAN SWITCH TO AUTO
START
WARNING
DISCONNECT POWER BEFORE
SERVICING.
SERVICE MUST BE BY A TRAINED,
QUALIFIED SERVICE TECHNICIAN.
HAZARDOUS VOLTAGE
LINE VOLTAGE
CONNECTIONS
FLOW CHART CONTINUED ON NEXT PAGE
NO
YES
YES
YES
YES
NO
NO
NO
!
INDUCED DRAFT BLOWER
MOTOR STARTS
30 SECOND PREPURGE
REPLACE INTEGRATED
CONTROL BOARD (IFC)
REPLACE INDUCED
DRAFT BLOWER(S)
NO
REPLACE NEGATIVE
PRESSURE SWITCH
REPLACE INTEGRATED
CONTROL BOARD (IFC)
IF WIRING IS OK
CHECK FOR EXHAUST,
INTAKE OR HEAT
EXCHANGER BLOCKAGE
AND RESET CONTROL
NO
REPLACE IGNITION
CONTROL
YES
REPLACE VALVE
• CHECK LINE VOLTAGE TO IFC
• CHECK LOW VOLTAGE TRANSFORMER
• CHECK WIRING
• CHECK FOR 208-230 VAC TO IDM MOTOR
• CHECK IGNITOR CABLE
• CHECK SPARK IGNITOR POSITION AND CONDITION
• IS EACH NEGATIVE PRESSURE SWITCH CLOSED?
• CHECK FOR OPEN ROLL-OUT CONTROLS
• CHECK FOR OPEN LIMIT
• CHECK IGNITION CONTROL CHASSIS GROUND WIRE
• CHECK WIRING
• CHECK INLET GAS PRESSURE
• CHECK 24 VOLTS TO GAS VALVE
• CHECK FOR GAS FLOW TO AND FROM VALVE
• CHECK BURNER CARRYOVER
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 WILLLOCK OUT. IF THE UNIT IS EQUIPPED WITH A
UNITED TECH. THE SYSTEM WILL ATTEMPT T O LIGHT 3 TIMES EACH HOUR
UNTIL THE BURNERS LIGHT OR THE THERMOSTAT IS RESET OR POWER IS
REMOVED FOR 3 SECONDS OR GREATER.
YES
YES
IGNITOR SPARKS
MAIN BURNER LIGHTS
NO
• CHECK NEGATIVE PRESSURE
SWITCH SENSING TUBE
• CHECK FOR EXHAUST
BLOCKAGE
YES
YES
YES
REPLACE IGNITOR/
CABLE ASSEMBLY
REPLACE LIMIT
IF UNIT IS COLD
NO
Page 29
29
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
• CHECK FOR 208-230 VAC ACROSS BLOWER
MOTOR TERMINALS ON CONTROL BOARD
• CHECK FOR LINE VOLTAGE AT LOAD SIDE OF
BLOWER CONTACT.
YES
YES
NO
MAIN BURNER FLAME SUSTAINED
YES
NO
INDOOR BLOWER MOTOR STARTS
AFTER 45 SECONDS
REPLACE SENSOR
NO
REPLACE INTEGRATED
CONTROL BOARD (IFC)
NO
REPLACE IGNITION
CONTROL
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
NO
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS
TROUBLESHOOTING ENDS
REPEAT PROCEDURE UNTILTROUBLE FREE
OPERATION IS OBTAINED.
YES
NO
TURN THERMOSTAT OFF
VALVE SHUTS OFF
FLAME SHUTS OFF
YES
INDUCED DRAFT MOTOR(S) STOPS
AFTER 5 SECOND POSTPURGE
YES
YES
• CHECK FOR DIRTY FILTERS
• CHECK FOR RESTRICTED
AIR-FLOW
CHECK FOR EXHAUST,
INTAKE OR HEAT
EXCHANGER BLOCKAGE
CLEAR BLOCKAGE AND
RESET CONTROL
YES
INDOOR BLOWER MOTOR STOPS
AFTER 90 SECONDS
YES
FURNACE STARTS ON HIGH FIRE.
FURNACE SWITCHES TO LOW FIRE
AFTER 120 SECONDS WARMUPIF
THERMOSTAT IS CALLING FOR W1.
FURNACE WILL SWITCH TO HIGH
FIRE IF LOW FIRE DOES NOT SATISFY
THERMOSTAT DEMAND FOR HEAT
LOAD.
Page 30
30
FIGURE 26
Page 31
31
FIGURE 27
Page 32
32
FIGURE 28
Page 33
33
FIGURE 29
Page 34
34
SYSTEM CHARGE CHARTS
FIGURE 30
Page 35
35
SYSTEM CHARGE CHARTS
FIGURE 31
Page 36
36
SYSTEM CHARGE CHARTS
FIGURE 32
Page 37
40
CM 401
Limited Warranty - Parts
COMBINATION GAS HEAT-ELECTRIC COOLING AIR CONDITIONER
GENERAL: The manufacturer warrants ANY PART of this product against failure under normal use and service within the applicable periods specified below, in
accordance with the terms of this Warranty. Under this Warranty, the manufacturer will furnish a replacement part that will be warranted for only the unexpired
portion of the original warranty; if a heat exchanger fails and a replacement is not available, a credit will be allowed for the cost of the heat exchanger towards
the purchase price of a new combination air conditioner as described below.
EFFECTIVE DATE: The effective date of warranty coverage is the date of original installation, if properly documented; otherwise the date of manufacture, plus
six (6) months.
WARRANTY PERIODS:
HEAT EXCHANGER: the manufacturer warrants the heat exchanger for a period of Ten (10) years after the effective date. HOWEVER, A FAILURE OF ANY
HEAT EXCHANGER DUE TO CORROSIVE ELEMENTS IN THE ATMOSPHERE IS EXCLUDED FROM WARRANTY COVERAGE. In the event of heat
exchanger failure during the warranty period, the manufacturer will furnish a replacement heat exchanger. If not available for any reason, the manufacturer shall
have the right to instead allow a credit in the amount of the then current suggested retail selling price of the heat exchanger (or an equivalent heat exchanger)
toward the purchase of any other the manufacturer combination gas heat-electric cooling air conditioner.
COMPRESSOR: If the motor-compressor fails within Five (5) years after the effective date, a replacement compressor will be furnished.
ANY OTHER PART: If any other part fails within One (1) year after the effective date, the manufacturer will furnish a replacement part.
THIS WARRANTY WILL NOT APPLY: a) to defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with the
printed instructions provided; b) to damage from abuse, accident, fire, flood and the like; c) to parts used in connection with normal maintenance, such as
cleaning or replacing air filters; d) to units which are not installed in the United States of America or Canada; e) to units which are not installed in accordance with
applicable local codes, ordinances and good trade practices; or f) to defects or damage caused by the use of any attachment, accessory or component not
authorized by the manufacturer.
SHIPPING COSTS: You will be responsible for the cost of shipping warranty replacement parts from our factory to our the manufacturer distributor and from the
distributor to the location of your product. You also are responsible for any shipping cost of returning the failed part to the distributor and for incidental costs
incurred locally, including handling charges. (If in Alaska, Hawaii or Canada, you also must pay the shipping cost of returning the failed part to the port of entry
into the continental United States.)
SERVICE LABOR RESPONSIBILITY: This Warranty does not cover any labor expenses for service, nor for removing or reinstalling parts. All such expenses are
your responsibility unless a service labor agreement exists between you and your contractor.
HOW TO OBTAIN WARRANTY PERFORMANCE: You must promptly report any failure covered by this Warranty to the installing contractor or distributor.
Normally, the installing contractor from whom the unit was purchased will be able to take the necessary corrective action by obtaining through his air conditioning
distributor any replacement parts. If the contractor is not available, simply contact any other local contractor handling the manufacturer’s air conditioning
products. The name and location of a local contractor can usually be found in your telephone directory or by contacting an air conditioning distributor which
carries the manufacturer’s products. If necessary, the following office can advise you of the nearest distributor.
P.O. Box 17010 (FOR CALIFORNIA ONLY)
5600 Old Greenwood Road 14300 Alondra Boulevard
Fort Smith, Arkansas 72917-7010 LaMirada, California 90638
501-646-4311 310-860-7761
HOWEVER, ANY REPLACEMENTS ARE MADE SUBJECT TO VALIDATION OF IN-WARRANTY COVERAGE. An item to be replaced must be made available
in exchange for the replacement.
MISCELLANEOUS: No one is authorized to make any warranties on behalf of the manufacturer. ANY IMPLIED WARRANTIES, INCLUDING
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECIFIED
ABOVE. THE MANUFACTURER’S SOLE LIABILITY WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS SET FORTH IN THIS WARRANTY, AND ANY
CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARE EXPRESSLY EXCLUDED. Some states do not allow limitations on how long an implied
warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
The manufacturer suggests that you immediately complete the information on the reverse side and retain this Warranty Certificate in the event warranty service
is needed and that you keep proper documentation of the date of installation (e.g., a dated receipt).
Please become familiar with all the provisions of the Limited Warranty. We suggest that your installing contractor either complete the
data listed below, or furnish you with the necessary information so that you can enter this data below. If necessary, you may obtain the
model and serial numbers from the data plate which is affixed to the side of the outdoor unit.
Name of Owner Name of Contractor
Address Address
City/State/Zip Code City/State/Zip Code
Model Number Serial Number
Date of Original Installation
KEEP THIS WARRANTY FOR YOUR RECORDS.
DO NOT MAIL.
RHEEM
AIR CONDITIONING
DIVISION
A Division of Rheem Manufacturing Company
P.O. Box 17010, 5600 Old Greenwood Road, Fort Smith, Arkansas 72917-7010
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