Rheem RKKN-B Installation Manual

INSTALLATION INSTRUCTIONS

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!

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DO NOT DESTROY THIS MANUAL

PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN

WARNING

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THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

ISO 9001:2008

PACKAGE GAS ELECTRIC FEATURING NEW INDUSTRY STANDARD R-410A REFRIGERANT

RKKL-B SERIES 15 & 20 TON [52.8 & 70.3 kW]

COMPLIES WITH ASHRAE 90.1-2007

[ ] INDICATES METRIC CONVERSIONS

SUPERSEDES 92-23577-113-00

92-23577-113-01

TABLE OF CONTENTS

I. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

R410A Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

II. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Outside Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Exhaust & Combustion Hoods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cover Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Rooftop Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Return Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

III. GAS SUPPLY, CONDENSATE DRAIN AND PIPING. . . . . . . . . . . . . . 22

Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

LP Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Adjusting or Checking Furnace Input. . . . . . . . . . . . . . . . . . . . . . . . . . 24

Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

IV. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Hook-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

V. FURNACE SECTION CONTROLS AND IGNITION SYSTEM. . . . . . . 28

Normal Furnace Operating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 28

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Burners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Manual Reset Overtemperature Control . . . . . . . . . . . . . . . . . . . . . . . 31

Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

VI. COOLING SECTION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cooling Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Continuous Fan Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

VII. SYSTEM OPERATING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . 32

Advise the Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Furnace Section Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Cooling Section Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

VIII. AIRFLOW PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-36

IX. ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-38

X. TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-41

XI. WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-45

XII. CHARGE CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47

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Recognize this symbol as an

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indication of Important Safety Information!

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▲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

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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

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

CHECKING PRODUCT RECEIVED

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.

EQUIPMENT PROTECTION FROM THE ENVIRONMENT

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 character- istics, and accessories to determine if they are correct.

I. SPECIFICATIONS

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 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.

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, condenser fans, 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.

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. 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.

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• 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/ Expansion Device

The capillary tubes are specifically designed to operate with R-410A. DO NOT use an R22 expansion device. The existing evaporator must be replaced with the factory specified 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

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

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SAFETY INFORMATION

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▲WARNING

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

▲WARNING

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

▲WARNING

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

▲WARNING

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NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS.

▲WARNING

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

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▲WARNING

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

▲WARNING

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COMBUSTION PRODUCTS MUST BE DISCHARGED OUTDOORS. CONNECT THIS UNIT TO AN APPROVED VENT SYSTEM ONLY, AS SPECIFIED IN VENT PIPE INSTALLATION SECTION OF THESE INSTRUCTIONS.

▲WARNING

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

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

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

• MEANS OF PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION;

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

• INSTALLATION OF EXHAUST AND COMBUSTION AIR INLET HOODS COMPLETED;

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

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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.

FIGURE 1

BOTTOM VIEW

Typical Dimensions Shown in Inches

ST-A1182-02A-00

FIGURE 2

SUPPLY AND RETURN DIMENSIONS FOR DOWNFLOW APPLICATIONS – BOTTOM VIEW

ST-A1182-09A-00

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FIGURE 3

COMPONENT LOCATIONS & DIMENSIONS

FRONT VIEW

Typical Dimensions Shown in Inches

FIGURE 4

COMPONENT LOCATIONS & DIMENSIONS

ST-A1182-06A-00

FIGURE 5

COMPONENT LOCATIONS

ST-A1182-01A-00

POWER ENTRY

ST-A1182-04A-00

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FIGURE 6

DIMENSIONS

FIGURE 7

COMPONENT ACCESS LOCATIONS & DIMENSIONS

ST-A1182-08A-00

FIGURE 8

COMPONENT LOCATIONS

POWER ENTRY

ST-A1182-03-00

ST-A1182-05-00

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GENERAL DATA - RKKL

CONTINUED

NOM. SIZES 7.5-10 TON [26.4 & 35.2 kW] ENERGYSTAR COMPLIANT MODELS

Model RKKL-Series B180CL25E B180CL35E B180CM25E B180CM35E Cooling Performance

Gross Cooling Capacity Btu [kW] 174,000 [50.98] 174,000 [50.98] 174,000 [50.98] 174,000 [50.98] EER/SEER

1

2

10.9/NA 10.9/NA 10.9/NA 10.9/NA Nominal CFM/AHRI Rated CFM [L/s] 6000/5500 [2931/2595] 6000/5500 [2931/2595] 6000/5500 [2931/2595] 6000/5500 [2931/2595] AHRI Net Cooling Capacity Btu [kW] 170,000 [49.81] 170,000 [49.81] 170,000 [49.81] 170,000 [49.81] Net Sensible Capacity Btu [kW] 125,400 [36.74] 125,400 [36.74] 125,400 [36.74] 125,400 [36.74] Net Latent Capacity Btu [kW] 44,600 [13.07] 44,600 [13.07] 44,600 [13.07] 44,600 [13.07]

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IEER

11.1 11.1 11.1 11.1 Net System Power kW 15.6 15.6 15.6 15.6

Heating Performance (Gas)

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Heating Input Btu [kW] (1st Stage / 2nd Stage) 125,000/250,000 [36.62/73.25] 175,000/350,000 [51.27/102.55] 125,000/250,000 [36.62/73.25] 175,000/350,000 [51.27/102.55] Heating Output Btu [kW] (1st Stage / 2nd Stage) 101,500/203,000 [29.74/59.48] 142,000/284,000 [41.61/83.21] 101,500/203,000 [29.74/59.48] 142,000/284,000 [41.61/83.21] Temperature Rise Range °F [°C] (1st Stage / 2nd Stage) 15-45 [8.3-25] / 15-45 [8.3-25] 30-60 [16.7-33.3] / 30-60 [16.7-33.3] 15-45 [8.3-25] / 15-45 [8.3-25] 30-60 [16.7-33.3] / 30-60 [16.7-33.3] Steady State Efficiency (%) 81 81 81 81 No. Burners 10 14 10 14 No. Stages 22 2 2 Gas Connection Pipe Size in. [mm] 0.75 [19] 0.75 [19] 0.75 [19] 0.75 [19]

Compressor

No./Type 2/Scroll 2/Scroll 2/Scroll 2/Scroll

Outdoor Sound Rating (dB)

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91 91 91 91

Outdoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type MicroChannel MicroChannel MicroChannel MicroChannel MicroChannel Depth in. [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4] Face Area sq. ft. [sq. m] 27.46 [2.55] 27.46 [2.55] 27.46 [2.55] 27.46 [2.55] Rows / FPI [FPcm] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9]

Indoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] Rows / FPI [FPcm] 2 / 18 [7] 2 / 18 [7] 2 / 18 [7] 2 / 18 [7] Refrigerant Control Capillary Tubes Capillary Tubes Capillary Tubes Capillary Tubes Drain Connection No./Size in. [mm] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4]

Outdoor Fan—Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 10000 [4719] 10000 [4719] 10000 [4719] 10000 [4719] No. Motors/HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP Motor RPM 1075 1075 1075 1075

Indoor Fan—Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] Drive Type/No. Speeds Belt/Variable Belt/Variable Belt/Variable Belt/Variable No. Motors 11 1 1 Motor HP 33 5 5 Motor RPM 1725 1725 1725 1725 Motor Frame Size 56 56 184 184

Filter—Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508]

Refrigerant Charge Oz. (Sys. 1/Sys. 2) [g] 115/119 [3260/3374] 115/119 [3260/3374] 115/119 [3260/3374] 115/119 [3260/3374] Weights

Net Weights lbs. [kg] 1799 [816] 1812 [823] 1828 [829] 1841 [835] Ship Weights lbs. [kg] 1926 [874] 1939 [880] 1955 [887] 1968 [893]

NOTES:

1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. AHRI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to 20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on AHRI Standard 210/240 or 360.

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

3. IEER is rated in accordance with AHRI standard 340/360.

4. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level.

5. Outdoor Sound Rating shown is tested in accordance with AHRI Standard 270.

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GENERAL DATA - RKKL

CONTINUED

NOM. SIZES 7.5-10 TON [26.4 & 35.2 kW] ENERGYSTAR COMPLIANT MODELS

Model RKKL-Series B180DL25E B180DL35E B180DM25E B180DM35E Cooling Performance

Gross Cooling Capacity Btu [kW] 174,000 [50.98] 174,000 [50.98] 174,000 [50.98] 174,000 [50.98] EER/SEER

1

2

10.9/NA 10.9/NA 10.9/NA 10.9/NA Nominal CFM/AHRI Rated CFM [L/s] 6000/5500 [2931/2595] 6000/5500 [2931/2595] 6000/5500 [2931/2595] 6000/5500 [2931/2595] AHRI Net Cooling Capacity Btu [kW] 170,000 [49.81] 170,000 [49.81] 170,000 [49.81] 170,000 [49.81] Net Sensible Capacity Btu [kW] 125,400 [36.74] 125,400 [36.74] 125,400 [36.74] 125,400 [36.74] Net Latent Capacity Btu [kW] 44,600 [13.07] 44,600 [13.07] 44,600 [13.07] 44,600 [13.07]

3

IEER

11.1 11.1 11.1 11.1 Net System Power kW 15.6 15.6 15.6 15.6

Heating Performance (Gas)

4

Heating Input Btu [kW] (1st Stage / 2nd Stage) 125,000/250,000 [36.62/73.25] 175,000/350,000 [51.27/102.55] 125,000/250,000 [36.62/73.25] 175,000/350,000 [51.27/102.55] Heating Output Btu [kW] (1st Stage / 2nd Stage) 101,500/203,000 [29.74/59.48] 142,000/284,000 [41.61/83.21] 101,500/203,000 [29.74/59.48] 142,000/284,000 [41.61/83.21] Temperature Rise Range °F [°C] (1st Stage / 2nd Stage) 15-45 [8.3-25] / 15-45 [8.3-25] 30-60 [16.7-33.3] / 30-60 [16.7-33.3] 15-45 [8.3-25] / 15-45 [8.3-25] 30-60 [16.7-33.3] / 30-60 [16.7-33.3] Steady State Efficiency (%) 81 81 81 81 No. Burners 10 14 10 14 No. Stages 22 2 2 Gas Connection Pipe Size in. [mm] 0.75 [19] 0.75 [19] 0.75 [19] 0.75 [19]

Compressor

No./Type 2/Scroll 2/Scroll 2/Scroll 2/Scroll

Outdoor Sound Rating (dB)

5

91 91 91 91

Outdoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type MicroChannel MicroChannel MicroChannel MicroChannel MicroChannel Depth in. [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4] Face Area sq. ft. [sq. m] 27.46 [2.55] 27.46 [2.55] 27.46 [2.55] 27.46 [2.55] Rows / FPI [FPcm] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9]

Indoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] Rows / FPI [FPcm] 2 / 18 [7] 2 / 18 [7] 2 / 18 [7] 2 / 18 [7] Refrigerant Control Capillary Tubes Capillary Tubes Capillary Tubes Capillary Tubes Drain Connection No./Size in. [mm] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4]

Outdoor Fan—Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 10000 [4719] 10000 [4719] 10000 [4719] 10000 [4719] No. Motors/HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP Motor RPM 1075 1075 1075 1075

Indoor Fan—Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] Drive Type/No. Speeds Belt/Variable Belt/Variable Belt/Variable Belt/Variable No. Motors 11 1 1 Motor HP 33 5 5 Motor RPM 1725 1725 1725 1725 Motor Frame Size 56 56 184 184

Filter—Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508]

Refrigerant Charge Oz. (Sys. 1/Sys. 2) [g] 115/119 [3260/3374] 115/119 [3260/3374] 115/119 [3260/3374] 115/119 [3260/3374] Weights

Net Weights lbs. [kg] 1799 [816] 1812 [823] 1828 [829] 1841 [835] Ship Weights lbs. [kg] 1926 [874] 1939 [880] 1955 [887] 1968 [893]

NOTES:

1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. AHRI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to 20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on AHRI Standard 210/240 or 360.

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

3. IEER is rated in accordance with AHRI standard 340/360.

4. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level.

5. Outdoor Sound Rating shown is tested in accordance with AHRI Standard 270.

10

GENERAL DATA - RKKL

CONTINUED

NOM. SIZES 7.5-10 TON [26.4 & 35.2 kW] ENERGYSTAR COMPLIANT MODELS

Model RKKL-Series B180YL35E B180YM35E B240CL30E B240CL40E Cooling Performance

Gross Cooling Capacity Btu [kW] 174,000 [50.98] 174,000 [50.98] 250,000 [73.25] 250,000 [73.25] EER/SEER

1

2

10.9/NA 10.9/NA 10.5/NA 10.5/NA Nominal CFM/AHRI Rated CFM [L/s] 6000/5500 [2931/2595] 6000/5500 [2931/2595] 8000/7825 [3775/3693] 8000/7825 [3775/3693] AHRI Net Cooling Capacity Btu [kW] 170,000 [49.81] 170,000 [49.81] 240,000 [70.32] 240,000 [70.32] Net Sensible Capacity Btu [kW] 125,400 [36.74] 125,400 [36.74] 175,000 [51.27] 175,000 [51.27] Net Latent Capacity Btu [kW] 44,600 [13.07] 44,600 [13.07] 65,000 [19.04] 65,000 [19.04]

3

IEER

11.1 11.1 10.5 10.5 Net System Power kW 15.6 15.6 22.88 22.88

Heating Performance (Gas)

4

Heating Input Btu [kW] (1st Stage / 2nd Stage) 175,000/350,000 [51.27/102.55] 175,000/350,000 [51.27/102.55] 150,000/300,000 [43.95/87.9] 200,000/400,000 [58.6/117.2] Heating Output Btu [kW] (1st Stage / 2nd Stage) 142,000/284,000 [41.61/83.21] 142,000/284,000 [41.61/83.21] 121,500/243,000 [35.6/71.2] 162,000/324,000 [47.47/94.93] Temperature Rise Range °F [°C] (1st Stage / 2nd Stage) 30-60 [16.7-33.3] / 30-60 [16.7-33.3] 30-60 [16.7-33.3] / 30-60 [16.7-33.3] 15-45 [8.3-25] / 15-45 [8.3-25] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] Steady State Efficiency (%) 81 81 81 81 No. Burners 14 14 12 14 No. Stages 2222 Gas Connection Pipe Size in. [mm] 0.75 [19] 0.75 [19] 0.75 [19] 0.75 [19]

Compressor

No./Type 2/Scroll 2/Scroll 2/Scroll 2/Scroll

Outdoor Sound Rating (dB)

5

91 91 91 91

Outdoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type MicroChannel MicroChannel MicroChannel MicroChannel MicroChannel Depth in. [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4] Face Area sq. ft. [sq. m] 27.46 [2.55] 27.46 [2.55] 50.8 [4.72] 50.8 [4.72] Rows / FPI [FPcm] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9]

Indoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] Rows / FPI [FPcm] 2 / 18 [7] 2 / 18 [7] 3 / 13 [5] 3 / 13 [5] Refrigerant Control Capillary Tubes Capillary Tubes Capillary Tubes Capillary Tubes Drain Connection No./Size in. [mm] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4]

Outdoor Fan—Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 10000 [4719] 10000 [4719] 10000 [4719] 10000 [4719] No. Motors/HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP Motor RPM 1075 1075 1075 1075

Indoor Fan—Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] Drive Type/No. Speeds Belt/Variable Belt/Variable Belt/Variable Belt/Variable No. Motors 1111 Motor HP 3555 Motor RPM 1725 1725 1725 1725 Motor Frame Size 56 184 184 184

Filter—Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508]

Refrigerant Charge Oz. (Sys. 1/Sys. 2) [g] 115/119 [3260/3374] 115/119 [3260/3374] 200/219 [5670/6209] 200/219 [5670/6209] Weights

Net Weights lbs. [kg] 1827 [829] 1856 [842] 2021 [917] 2035 [923] Ship Weights lbs. [kg] 1954 [886] 1983 [899] 2147 [974] 2162 [981]

NOTES:

1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. AHRI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to 20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on AHRI Standard 210/240 or 360.

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

3. IEER is rated in accordance with AHRI standard 340/360.

4. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level.

5. Outdoor Sound Rating shown is tested in accordance with AHRI Standard 270.

11

GENERAL DATA - RKKL

CONTINUED

NOM. SIZES 7.5-10 TON [26.4 & 35.2 kW] ENERGYSTAR COMPLIANT MODELS

Model RKKL-Series B240CM30E B240CM40E B240CN30E B240CN40E Cooling Performance

Gross Cooling Capacity Btu [kW] 250,000 [73.25] 250,000 [73.25] 250,000 [73.25] 250,000 [73.25] EER/SEER

1

2

10.5/NA 10.5/NA 10.5/NA 10.5/NA Nominal CFM/AHRI Rated CFM [L/s] 8000/7825 [3775/3693] 8000/7825 [3775/3693] 8000/7825 [3775/3693] 8000/7825 [3775/3693] AHRI Net Cooling Capacity Btu [kW] 240,000 [70.32] 240,000 [70.32] 240,000 [70.32] 240,000 [70.32] Net Sensible Capacity Btu [kW] 175,000 [51.27] 175,000 [51.27] 175,000 [51.27] 175,000 [51.27] Net Latent Capacity Btu [kW] 65,000 [19.04] 65,000 [19.04] 65,000 [19.04] 65,000 [19.04]

3

IEER

10.5 10.5 10.5 10.5 Net System Power kW 22.88 22.88 22.88 22.88

Heating Performance (Gas)

4

Heating Input Btu [kW] (1st Stage / 2nd Stage) 150,000/300,000 [43.95/87.9] 200,000/400,000 [58.6/117.2] 150,000/300,000 [43.95/87.9] 200,000/400,000 [58.6/117.2] Heating Output Btu [kW] (1st Stage / 2nd Stage) 121,500/243,000 [35.6/71.2] 162,000/324,000 [47.47/94.93] 121,500/243,000 [35.6/71.2] 162,000/324,000 [47.47/94.93] Temperature Rise Range °F [°C] (1st Stage / 2nd Stage) 15-45 [8.3-25] / 15-45 [8.3-25] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] 15-45 [8.3-25] / 15-45 [8.3-25] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] Steady State Efficiency (%) 81 81 81 81 No. Burners 12 14 12 14 No. Stages 2222 Gas Connection Pipe Size in. [mm] 0.75 [19] 0.75 [19] 0.75 [19] 0.75 [19]

Compressor

No./Type 2/Scroll 2/Scroll 2/Scroll 2/Scroll

Outdoor Sound Rating (dB)

5

91 91 91 91

Outdoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type MicroChannel MicroChannel MicroChannel MicroChannel MicroChannel Depth in. [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4] Face Area sq. ft. [sq. m] 50.8 [4.72] 50.8 [4.72] 50.8 [4.72] 50.8 [4.72] Rows / FPI [FPcm] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9]

Indoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] Rows / FPI [FPcm] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] Refrigerant Control Capillary Tubes Capillary Tubes Capillary Tubes Capillary Tubes Drain Connection No./Size in. [mm] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4]

Outdoor Fan—Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 10000 [4719] 10000 [4719] 10000 [4719] 10000 [4719] No. Motors/HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP Motor RPM 1075 1075 1075 1075

Indoor Fan—Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] Drive Type/No. Speeds Belt/Variable Belt/Variable Belt/Variable Belt/Variable No. Motors 1111 Motor HP 7 1/2 7 1/2 7 1/2 7 1/2 Motor RPM 1725 1725 1725 1725 Motor Frame Size 213 213 213 213

Filter—Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508]

Refrigerant Charge Oz. (Sys. 1/Sys. 2) [g] 200/219 [5670/6209] 200/219 [5670/6209] 200/219 [5670/6209] 200/219 [5670/6209] Weights

Net Weights lbs. [kg] 2059 [934] 2073 [940] 2057 [933] 2072 [940] Ship Weights lbs. [kg] 2185 [991] 2200 [998] 2184 [991] 2198 [997]

NOTES:

1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. AHRI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to 20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on AHRI Standard 210/240 or 360.

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

3. IEER is rated in accordance with AHRI standard 340/360.

4. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level.

5. Outdoor Sound Rating shown is tested in accordance with AHRI Standard 270.

12

GENERAL DATA - RKKL

CONTINUED

NOM. SIZES 7.5-10 TON [26.4 & 35.2 kW] ENERGYSTAR COMPLIANT MODELS

Model RKKL-Series B240DL30E B240DL40E B240DM30E B240DM40E Cooling Performance

Gross Cooling Capacity Btu [kW] 250,000 [73.25] 250,000 [73.25] 250,000 [73.25] 250,000 [73.25] EER/SEER

1

2

10.5/NA 10.5/NA 10.5/NA 10.5/NA Nominal CFM/AHRI Rated CFM [L/s] 8000/7825 [3775/3693] 8000/7825 [3775/3693] 8000/7825 [3775/3693] 8000/7825 [3775/3693] AHRI Net Cooling Capacity Btu [kW] 240,000 [70.32] 240,000 [70.32] 240,000 [70.32] 240,000 [70.32] Net Sensible Capacity Btu [kW] 175,000 [51.27] 175,000 [51.27] 175,000 [51.27] 175,000 [51.27] Net Latent Capacity Btu [kW] 65,000 [19.04] 65,000 [19.04] 65,000 [19.04] 65,000 [19.04]

3

IEER

10.5 10.5 10.5 10.5 Net System Power kW 22.88 22.88 22.88 22.88

Heating Performance (Gas)

4

Heating Input Btu [kW] (1st Stage / 2nd Stage) 150,000/300,000 [43.95/87.9] 200,000/400,000 [58.6/117.2] 150,000/300,000 [43.95/87.9] 200,000/400,000 [58.6/117.2] Heating Output Btu [kW] (1st Stage / 2nd Stage) 121,500/243,000 [35.6/71.2] 162,000/324,000 [47.47/94.93] 121,500/243,000 [35.6/71.2] 162,000/324,000 [47.47/94.93] Temperature Rise Range °F [°C] (1st Stage / 2nd Stage) 15-45 [8.3-25] / 15-45 [8.3-25] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] 15-45 [8.3-25] / 15-45 [8.3-25] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] Steady State Efficiency (%) 81 81 81 81 No. Burners 12 14 12 14 No. Stages 2222 Gas Connection Pipe Size in. [mm] 0.75 [19] 0.75 [19] 0.75 [19] 0.75 [19]

Compressor

No./Type 2/Scroll 2/Scroll 2/Scroll 2/Scroll

Outdoor Sound Rating (dB)

5

91 91 91 91

Outdoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type MicroChannel MicroChannel MicroChannel MicroChannel MicroChannel Depth in. [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4] Face Area sq. ft. [sq. m] 50.8 [4.72] 50.8 [4.72] 50.8 [4.72] 50.8 [4.72] Rows / FPI [FPcm] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9]

Indoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] Rows / FPI [FPcm] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] Refrigerant Control Capillary Tubes Capillary Tubes Capillary Tubes Capillary Tubes Drain Connection No./Size in. [mm] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4]

Outdoor Fan—Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 10000 [4719] 10000 [4719] 10000 [4719] 10000 [4719] No. Motors/HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP Motor RPM 1075 1075 1075 1075

Indoor Fan—Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] Drive Type/No. Speeds Belt/Variable Belt/Variable Belt/Variable Belt/Variable No. Motors 1111 Motor HP 557 1/2 7 1/2 Motor RPM 1725 1725 1725 1725 Motor Frame Size 184 184 184 213

Filter—Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508]

Refrigerant Charge Oz. (Sys. 1/Sys. 2) [g] 200/219 [5670/6209] 200/219 [5670/6209] 200/219 [5670/6209] 200/219 [5670/6209] Weights

Net Weights lbs. [kg] 2021 [917] 2073 [940] 2059 [934] 2073 [940] Ship Weights lbs. [kg] 2147 [974] 2200 [998] 2185 [991] 2200 [998]

NOTES:

1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. AHRI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to 20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on AHRI Standard 210/240 or 360.

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

3. IEER is rated in accordance with AHRI standard 340/360.

4. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level.

5. Outdoor Sound Rating shown is tested in accordance with AHRI Standard 270.

13

GENERAL DATA - RKKL

CONTINUED

NOM. SIZES 7.5-10 TON [26.4 & 35.2 kW] ENERGYSTAR COMPLIANT MODELS

Model RKKL-Series B240DN30E B240DN40E B240YL40E B240YM40E Cooling Performance

Gross Cooling Capacity Btu [kW] 250,000 [73.25] 250,000 [73.25] 250,000 [73.25] 250,000 [73.25] EER/SEER

1

2

10.5/NA 10.5/NA 10.5/NA 10.5/NA Nominal CFM/AHRI Rated CFM [L/s] 8000/7825 [3775/3693] 8000/7825 [3775/3693] 8000/7825 [3775/3693] 8000/7825 [3775/3693] AHRI Net Cooling Capacity Btu [kW] 240,000 [70.32] 240,000 [70.32] 240,000 [70.32] 240,000 [70.32] Net Sensible Capacity Btu [kW] 175,000 [51.27] 175,000 [51.27] 175,000 [51.27] 175,000 [51.27] Net Latent Capacity Btu [kW] 65,000 [19.04] 65,000 [19.04] 65,000 [19.04] 65,000 [19.04]

3

IEER

10.5 10.5 10.5 10.5 Net System Power kW 22.88 22.88 22.88 22.88

Heating Performance (Gas)

4

Heating Input Btu [kW] (1st Stage / 2nd Stage) 150,000/300,000 [43.95/87.9] 200,000/400,000 [58.6/117.2] 200,000/400,000 [58.6/117.2] 200,000/400,000 [58.6/117.2] Heating Output Btu [kW] (1st Stage / 2nd Stage) 121,500/243,000 [35.6/71.2] 162,000/324,000 [47.47/94.93] 162,000/324,000 [47.47/94.93] 162,000/324,000 [47.47/94.93] Temperature Rise Range °F [°C] (1st Stage / 2nd Stage) 15-45 [8.3-25] / 15-45 [8.3-25] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] 25-55 [13.9-30.6] / 25-55 [13.9-30.6] Steady State Efficiency (%) 81 81 81 81 No. Burners 12 14 14 14 No. Stages 2222 Gas Connection Pipe Size in. [mm] 0.75 [19] 0.75 [19] 0.75 [19] 0.75 [19]

Compressor

No./Type 2/Scroll 2/Scroll 2/Scroll 2/Scroll

Outdoor Sound Rating (dB)

5

91 91 91 91

Outdoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type MicroChannel MicroChannel MicroChannel MicroChannel MicroChannel Depth in. [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4] Face Area sq. ft. [sq. m] 50.8 [4.72] 50.8 [4.72] 50.8 [4.72] 50.8 [4.72] Rows / FPI [FPcm] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9] 1 / 23 [9]

Indoor Coil—Fin Type Louvered Louvered Louvered Louvered

Tube Type Rifled Rifled Rifled Rifled Tube Size in. [mm] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] 0.375 [9.5] Face Area sq. ft. [sq. m] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] 26.67 [2.48] Rows / FPI [FPcm] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] 3 / 13 [5] Refrigerant Control Capillary Tubes Capillary Tubes Capillary Tubes Capillary Tubes Drain Connection No./Size in. [mm] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4] 1/1 [25.4]

Outdoor Fan—Type Propeller Propeller Propeller Propeller

No. Used/Diameter in. [mm] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] 3/24 [609.6] Drive Type/No. Speeds Direct/1 Direct/1 Direct/1 Direct/1 CFM [L/s] 10000 [4719] 10000 [4719] 10000 [4719] 10000 [4719] No. Motors/HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP 3 at 1/2 HP Motor RPM 1075 1075 1075 1075

Indoor Fan—Type FC Centrifugal FC Centrifugal FC Centrifugal FC Centrifugal

No. Used/Diameter in. [mm] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] 2/18x9 [457x229] Drive Type/No. Speeds Belt/Variable Belt/Variable Belt/Variable Belt/Variable No. Motors 1111 Motor HP 7 1/2 7 1/2 5 7 1/2 Motor RPM 1725 1725 1725 1725 Motor Frame Size 184 213 184 213

Filter—Type Disposable Disposable Disposable Disposable

Furnished Yes Yes Yes Yes (NO.) Size Recommended in. [mm x mm x mm] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508] (8)2x25x20 [51x635x508]

Refrigerant Charge Oz. (Sys. 1/Sys. 2) [g] 200/219 [5670/6209] 200/219 [5670/6209] 200/219 [5670/6209] 200/219 [5670/6209] Weights

Net Weights lbs. [kg] 2057 [933] 2072 [940] 2055 [932] 2093 [949] Ship Weights lbs. [kg] 2184 [991] 2198 [997] 2182 [990] 2220 [1007]

NOTES:

1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. AHRI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to 20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on AHRI Standard 210/240 or 360.

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

3. IEER is rated in accordance with AHRI standard 340/360.

4. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level.

5. Outdoor Sound Rating shown is tested in accordance with AHRI Standard 270.

14

GENERAL DATA - RKKL

NOM. SIZES 7.5-10 TON [26.4 & 35.2 kW] ENERGYSTAR COMPLIANT MODELS

Model RKKL-Series B240YN40E Cooling Performance

Gross Cooling Capacity Btu [kW] 250,000 [73.25] EER/SEER

1

2

10.5/NA Nominal CFM/AHRI Rated CFM [L/s] 8000/7825 [3775/3693] AHRI Net Cooling Capacity Btu [kW] 240,000 [70.32] Net Sensible Capacity Btu [kW] 175,000 [51.27] Net Latent Capacity Btu [kW] 65,000 [19.04]

3

IEER

10.5 Net System Power kW 22.88

Heating Performance (Gas)

4

Heating Input Btu [kW] (1st Stage / 2nd Stage) 200,000/400,000 [58.6/117.2] Heating Output Btu [kW] (1st Stage / 2nd Stage) 162,000/324,000 [47.47/94.93] Temperature Rise Range °F [°C] (1st Stage / 2nd Stage) 25-55 [13.9-30.6] / 25-55 [13.9-30.6] Steady State Efficiency (%) 81 No. Burners 14 No. Stages 2 Gas Connection Pipe Size in. [mm] 0.75 [19]

Compressor

No./Type 2/Scroll

Outdoor Sound Rating (dB)

5

91

Outdoor Coil—Fin Type Louvered

Tube Type MicroChannel MicroChannel Depth in. [mm] 1 [25.4] Face Area sq. ft. [sq. m] 50.8 [4.72] Rows / FPI [FPcm] 1 / 23 [9]

Indoor Coil—Fin Type Louvered

Tube Type Rifled Tube Size in. [mm] 0.375 [9.5] Face Area sq. ft. [sq. m] 26.67 [2.48] Rows / FPI [FPcm] 3 / 13 [5] Refrigerant Control Capillary Tubes Drain Connection No./Size in. [mm] 1/1 [25.4]

Outdoor Fan—Type Propeller

No. Used/Diameter in. [mm] 3/24 [609.6] Drive Type/No. Speeds Direct/1 CFM [L/s] 10000 [4719] No. Motors/HP 3 at 1/2 HP Motor RPM 1075

Indoor Fan—Type FC Centrifugal

No. Used/Diameter in. [mm] 2/18x9 [457x229] Drive Type/No. Speeds Belt/Variable No. Motors 1 Motor HP 7 1/2 Motor RPM 1725 Motor Frame Size 213

Filter—Type Disposable

Furnished Yes (NO.) Size Recommended in. [mm x mm x mm] (8)2x25x20 [51x635x508]

Refrigerant Charge Oz. (Sys. 1/Sys. 2) [g] 200/219 [5670/6209] Weights

Net Weights lbs. [kg] 2092 [949] Ship Weights lbs. [kg] 2218 [1006]

NOTES:

1. Cooling Performance is rated at 95° F ambient, 80° F entering dry bulb, 67° F entering wet bulb. Gross capacity does not include the effect of fan motor heat. AHRI capacity is net and includes the effect of fan motor heat. Units are suitable for operation to 20% of nominal cfm. Units are certified in accordance with the Unitary Air Conditioner Equipment certification program, which is based on AHRI Standard 210/240 or 360.

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

3. IEER is rated in accordance with AHRI standard 340/360.

4. Heating Performance limit settings and rating data were established and approved under laboratory test conditions using American National Standard Institute standards. Ratings shown are for elevations up to 2000 feet. For elevations above 2000 feet, ratings should be reduced at the rate of 4% for each 1000 feet above sea level.

5. Outdoor Sound Rating shown is tested in accordance with AHRI Standard 270.

15

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: NFPA-90A - Installation of Air Conditioning and Ventilating Systems 1985 or latest edition. NFPA-90B - Warm Air Heating and Air Conditioning Systems 1984.

These publications are available from:

National Fire Protection

Association, Inc. 1 Batterymarch Park Quincy, MA 02269-7471 www.nfpa.org

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

Structural strength of supporting members

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

vibration - away from bedroom

windows

IMPORTANT: Before operating unit, remove compressor shipping supports from the compressor base. Failure to remove supports will cause noise and vibration.

▲WARNING

!

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

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.

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.

4. 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.

5. Regular cleaning and waxing of the cabinet with an automobile polish will provide some protection.

6. 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.

16

▲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.

B. OUTSIDE INSTALLATION

(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. ATTACHING 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. Open blower 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.

FIGURE 9

OUTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOOR CONSTRUCTION

ST-A1182-27-00

17

D.

COVER PANEL INSTALLATION / CONVERSION PROCEDURE

DOWNFLOW TO HORIZONTAL

1. Remove the screws and covers from the outside of the supply and return sections. 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 8 – 20” X 25” 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 #: 54-42541-04 (20" x 25" x 2")

FIGURE 10

HORIZONTAL CONVERSION DETAIL

18

ST-A0886-30

FIGURE 11

HORIZONTAL CONVERSION DETAIL

ST-A0886-31

A

B

*D

E

C

VERTICAL

CLEARANCE

FIGURE 12

CLEARANCES

E.

CLEARANCES

The following minimum clearances must be observed for proper unit performance and serviceability. Reference Figure 12.

RECOMMENDED

CLEARANCE

80”

18” 18”/42” 18”/48”

18”

* WITHOUT ECONOMIZER/48” WITH ECONOMIZER

+

WITHOUT HORIZONTAL ECONOMIZER/42” WITH HORIZONTAL ECONOMIZER

LOCATION

A – FRONT B – CONDENSER COIL

+

C – DUCT SIDE

*D – EVAPORATOR END

E – ABOVE

ST-A1128-28-00

FIGURE 13A

FLAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. MOUNTED ON ROOFCURB. CURB MUST BE LEVEL.

ST-A1182-26-00

19

▲WARNING

!

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

G.

ROOFTOP INSTALLATION

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

THIS IS VERY IMPORTANT AND THE INSTALLER’S RESPONSIBILITY.

2. For rigging and roofcurb details, see Figures 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, 2800 Shirlington Road, Suite 300, Arlington, VA 22206, http:/www.acca.org.

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 nonflammable 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. 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.

1

/2” to 1” thick insulation is

FIGURE 13B

FLAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. MOUNTED ON ROOFCURB. CURB MUST BE LEVEL.

20

ST-A1182-26-00

CORNER WEIGHTS MEASURED AT BASE OF UNIT.

FIGURE 14

UNIT BASE FRAME

ROOFTOP UNIT

ROOFCURB

ROOF FLASHING

ROOFING

CANT STRIP

ROOF DECK

INSULATION

DUCT

NAILER STRIP

GASKET

LIFTING DETAIL

RETURN AIR

▲WARNING

!

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

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

FIGURE 15

ROOFCURB

ST-A1182-14-00

ST-A1182-25-00

FIGURE 16

ROOFCURB

ST-A0888-02

21

III. GAS SUPPLY, CONDENSATE DRAIN AND

III. 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.

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 through the base as shown in Figure

21.

3. Size the gas line to the furnace adequate enough to prevent undue pressure drop. Do not use less than 1/2” pipes.

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 and Figure

21.)

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

fied 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.

FIGURE 17

SUGGESTED GAS PIPING

ROOF OR GROUND LEVEL INSTALLATION

FROM GAS METER

MANUAL GAS SHUT-OFF VALVE

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.

UNIT GAS SUPPLY CONNECTION

*

TABLE 1

GAS PIPE CAPACITY TABLE (CU. FT./HR. NATURAL GAS @ 0.30 IWC [INCHES OF WATER COLUMN] PRESSURE DROP)

Nominal

Iron Pipe

Size,

Inches

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 11/4 1,050 730 590 500 440 400 370 350 11/2 1,600 1,100 890 760 670 610 560 530

10 20 30 40 50 60 70 80

Equivalent Length of Pipe, Feet

Factory supplied grommet must be utilized.

*

22

▲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.

▲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.

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

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 damage the gas controls. A backup wrench is required to be used on the valve to avoid damage. Do not overtighten the connection.

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

After determining the pipe length, select the pipe size which will provide the minimum cubic feet per hour re quired 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 gas supplier.

(BTU/HR) Heating Value of Gas

3

(BTU/FT

3

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

)

B. LP CONVERSION

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 18A for 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.

FIGURE 18A

HEAT EXCHANGER COMPONENT IDENTIFICATION

ST-A1125-13

23

FIGURE 18B

HONEYWELL VR8305Q4120 TWO STAGE GAS VALVE

TABLE 2

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

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column inlet pressure).

(Based on a Pressure Drop of 0.5 Inch Water Column)

Nominal Iron Pipe Size, Inches

1/2 3/4

1 1-1/4 1-1/2

2

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

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

275 189 152 129 114 103 96 89 83 78 69 63

567 393 315 267 237 217 196 182 173 162 146 132 1,071 732 590 504 448 409 378 346 322 307 275 252 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

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

Length of Pipe, Feet

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.

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. Only small variations in the gas flow should be made by means of the pressure regula-

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

To adjust the pressure regulator, remove the regulator 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 THAT SHOWN ON THE RATING PLATE. Use the following table or formula to determine input rate.

24

Heating Value of Gas

Cu. Ft. Per Hr. Required =

Start the furnace and measure the time required to burn one cubic foot of gas. Prior to checking the furnace input, make certain that all other gas appliances are shut off, with the exception of pilot burners. Time the meter with only the furnace in operation.

IMPORTANT NOTE FOR ALTITUDES ABOVE 2,000 FEET (610 METERS): The main burner orifices in your furnace and in these kits are sized for the nameplate input and intended for installations at elevations up to 2,000 feet in the USA or Canada, or for elevations of 2,000 - 4,500 feet (610 -1,373 meters) in Canada if the unit has been derated at the factory. For elevations above 2,000 feet (610 meters) IN THE USA ONLY (see ANSI-Z223.1), the burner orifices must be sized to reduce the input 4% for each 1,000 feet (305 meters) above sea level.

NOTICE: DERATING OF THE HEATING INPUT FOR HIGH ALTITUDE IN THE FIELD IS UNLAWFUL IN CANADA (REFER TO CAN/CGA 2.17). UNITS INSTALLED IN ALTITUDES GREATER THAN 2,000 FEET (610 METERS) MUST BE SHIPPED FROM THE FACTORY OR FROM A FACTORY AUTHORIZED CONVERSION STATION WITH THE HEATING INPUT DERATED BY 10% SO AS TO OPERATE PROPERLY IN ALTITUDES FROM 2,000 - 4,500 FEET (610 - 1,373 METERS).

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

(for 1 Cu. Ft.) of Gas

TABLE 3

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

INPUT

BTU/HR

250,000 ONE 13.0 14.4 15.0 15.8 36.0

300,000

350,000

400,000

METER

SIZE

CU. FT.

TEN 2 10 2 24 2 30 2 38 60

ONE 10.8 12.0 12.5 13.2 30.0

TEN 1 48 2025212 50

ONE 9.3 10.3 10.7 11.3 25.7

TEN 1 33 1 43 1 47 1 53 4 17

ONE 8.1 9.0 9.36 9.9 22.5

TEN 1 21 1 30 1 36 1 39 3 45

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

OR LP GAS

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500

D. CONDENSATE DRAIN

IMPORTANT: Install a condensate trap to ensure proper condensate drainage. See Figure 19.

The condensate drain pan has a threaded female 1 inch NPT (11.5 TPI) connection. Consult local codes or ordinances for specific requirements of condensate drain piping and disposal.

• To use the removable drain pan feature of this unit, some of the condensate line joints should assembled for easy removal and cleaning.

• Use a thin layer of Teflon tape or paste on drain pan connections and install only hand tight.

• Do not over tighten drain pan connections as damage to the drain pan may occur.

• Drain line MUST NOT block service access panels.

• Drain line must be no smaller than drain pan outlet and adequately sized to accommodate the condensate discharge from the unit.

• Drain line should slope away from unit a minimum of 1/8” per foot to ensure proper drainage.

• Drain line must be routed to an acceptable drain or outdoors in accordance with local codes.

• Do not connect condensate drain line to a closed sewer pipe.

▲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.

• Drain line may need insulation or freeze protection in certain applications.

IV. WIRING

A. POWER SUPPLY

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

FIGURE 19

CONDENSATE DRAIN

DO NOT OVERTIGHTEN DRAIN FITTING

25

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 3 using the circuit ampacity found on the unit rating plate. Use the smallest wire size allowable from the unit disconnect to unit.

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.

TABLE 4

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

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 4 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 AP PROVED FOR USE WITH COPPER CONDUCTORS

CONNECTED TO UNIT CONTACTOR.

ONLY WARRANTY MAY BE JEOPARDIZED IF ALUMINUM WIRE IS CONNECTED TO

UNIT CONTACTOR. Special instructions apply for power wiring with aluminum conductors:

Warranty is void if connections are not made per instructions.

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

FIGURE 20

RECOMMENDED BRANCH CIRCUIT DISCONNECT LOCATION

26

ST-A1182-26-00

Select the equivalent aluminum wire size from the tabulation below:

R Y1 Y2 G C W1 W2 W3 B

TERM INAL BLOCK

st-A1 125-1 2-00

COOL

POWER

FAN

HEAT

ONLY USED

ON DUAL

FUEL OR HEAT

PUMP

MODELS

LOW VOLTAGE

THERMOSTAT CONNECTIONS

POWER WIRES

FROM DISCONNECT

TO TERMINAL BLOCK

WASHERS

CONTROL VOLTAGE

KNOCKOUT

WIRE FROM

ZONE THERMOSTAT

STRAIGHT CONDUIT

FITTING

CONDUIT FROM

ZONE THERMOSTAT

CONDUIT FROM POWER SUPPLY

SIZED PER CHART

STRAIGHT CONDUIT

FITTING SIZED

PER CHART

WIRE SIZE FROM

MIN. CIRCUIT AMPACITY

CUT HOLE

SIZED PER CHART

OR USE KNOCK OUT

GAS LINE

EXTERNAL MANUAL GAS

SHUT-OFF VALVE

RUN THERMOSTAT

WIRING IN THIS

CHASE TO CONTROL

BOARD

Splice copper wire pigtails to aluminum wire with U.L. recognized connectors for copperaluminum 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.

B. HOOK-UP

To wire unit, refer to the following hook-up diagram. Refer to Figures 2, 7 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

TABLE 5

UNIT MCA

COPPER

WIRE SIZE—AWG

SUPPLY WIRE LENGTH—FEET

FIGURE 21

BASE ENTRY LOCATIONS

50 100 150 200 250 300

20 10 86444 25 10 86443 30 864432 35 864321

40 864321 45 843211/0 50 643211/0 60 64211/0 2/0 70 4321/0 2/0 3/0

80 4311/0 2/0 3/0

90 321/0 2/0 3/0 4/0 100 321/0 2/0 3/0 4/0 110 212/0 3/0 4/0 250 125 112/0 3/0 4/0 250

150 1/0 1/0 3/0 4/0 250 300 175 2/0 2/0 4/0 250 300 350

WIRE SIZE, AWG

14

CONDUIT SIZE

HOLE SIZE

NOTES: 1. DETERMINE REQUIRED WIRE SIZE FROM MINIMUM CIRCUIT AMPACITY SHOWN IN INSTALLATION & OPERATING INSTRUCTION.

2. BOTTOM POWER ENTRY WILL NOT ACCOMMODATE WIRE LARGER THAN #2 AWG (SHADED AREA).

1/2ⴖ 7/8ⴖ

FIGURE 22

TYPICAL THERMOSTAT WIRING

12

1/2ⴖ 7/8ⴖ

10

1/2ⴖ 7/8ⴖ

8

3/4ⴖ

1-31/32ⴖ

6

1ⴖ

1-23/64ⴖ

4

1ⴖ

1-23/64ⴖ

3

1-1/4ⴖ

1-23/32ⴖ

2

1-1/4ⴖ

1-23/32ⴖ

1

1-1/2ⴖ

1-31/32ⴖ

0

1-1/2ⴖ

1-31/32ⴖ

2-15/32ⴖ

00

2ⴖ

ST-A1125-10

000

2ⴖ

2-15/32ⴖ

27

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

A diagram 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 6.

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 through the thermostat wiring chase on the unit (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, lamps, televisions, radios or air streams from registers. Refer to instructions packed with the thermostat for “heater” selection or adjustment.

See Thermostat Specification Sheet for recommended thermostats.

TABLE 6

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.0 16 14 12 10 10 10

2.5 16 14 12 12 12 10

2.0 18 16 14 12 12 10

Amps

Thermostat Load -

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

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

50 100 150 200 250 300

Length of Run – Feet (1)

28

V. FURNACE SECTION CONTROLS AND

V. IGNITION SYSTEM

NORMAL FURNACE OPERATING SEQUENCE

This unit is equipped with a two stage integrated direct spark ignition control.

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 low-fire inducer.

5. Control checks each low-fire pressure switch for closure.

6. If each low-fire pressure switch is closed, the control starts a 30 second prepurge. If either low-fire pressure switch is still open after 180 seconds, the high-fire inducers will be energized until closure.

7. After prepurge timeout, control initiates spark for 2 seconds minimum, 7 second maximum ignition trial, initiates 45 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 the 45 second second stage warmup period control checks thermostat input. If only W1 is called for, W2 is de-energized and the control starts a 5 second off delay on the W2 inducer.

11. After fixed 5 seconds the W2 inducer is de-energized.

12. Control enters normal operating loop where all inputs are continuously checked.

FIGURE 23

ST-A1125-13

B. Call For Second Stage, After First Stage Established; Starting from A.11:

1. If a call for second stage (high fire) is initiated after a call for first stage heat is established, the control energizes the W2 inducer assures the high-fire pressure switch is closed 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.2:

1. Once the call for second stage is satisfied, the control starts a 30 second off delay on W2 inducer 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 low-fire inducer.

5. Control checks each pressure switch for closure.

6. If each low-fire pressure switch is closed, the control starts a 30 second prepurge. If either switch is still open after 180 seconds, the high-fire inducers will be energized until closure.

7. After prepurge timeout, control initiates spark for 2 seconds minimum, 7 second maximum ignition trial, and initiates 45 second 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 the 45 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 four-ignition system. After a total of four 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 4 tries and then go into 100% lockout mode again. It continues this sequence of cycles and lockout each hour until ignition is successful or power is interrupted. During the lockout

29

mode, neither the ignitor or gas valve will be energized until the system is reset by turning the thermostat to the “OFF” position or interrupting the electrical power to the unit for 3 seconds or longer. The induced draft blower and main burner will shut off when the thermostat is satisfied.

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

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

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

1 Flash: Failed to detect flame within the four tries for ignition. 2 Flash: Pressure switch or induced draft blower problem detected.

▲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.

3 Flash: High limit or auxiliary limit open. 4 Flash: Flame sensed and gas valve not energized or flame sensed with no “W” sig-

5 Flash: Overtemperature switch open.

nal.

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.

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

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.

8. Replace the control door.

9. Turn on all electric power to the appliance.

10. Set the thermostat to the desired setting.

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

▲WARNING

!

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

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.

try to light the burner by hand.

30

▲WARNING

!

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

BURNERS

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

MANUAL RESET OVERTEMPERATURE CONTROL

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.

▲WARNING

!

DO NOT JUMPER THIS DEVICE! DO NOT RESET THE OVER TEMPERATURE CONTROL WITHOUT TAKING CORRECTIVE ACTION TO ASSURE THAT AN ADEQUATE SUPPLY OF COMBUSTION AIR IS MAINTAINED UNDER ALL CONDITIONS OF OPERATION. FAILURE TO DO SO CAN RESULT IN CARBON MONOXIDE POISONING OR DEATH. REPLACE THIS CONTROL ONLY WITH THE IDENTICAL REPLACEMENT PART.

PRESSURE SWITCH

This furnace has two sets of pressure switches for sensing a blocked exhaust or a failed induced draft blower. They are normally open and close when the induced draft blower starts, indicating air flow through the combustion chamber.

LIMIT CONTROL

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

▲WARNING

!

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

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

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.

31

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 de-energizes indoor blower relay after 80 second indoor blower delay off.

2. Control in the stand by mode with solid red LED.

CONTINUOUS FAN MODE

A ‘G’ input only indicates a zone thermostat call for continuous indoor blower operation.

VII. SYSTEM OPERATING INFORMATION

ADVISE THE CUSTOMER

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

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

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

4. Avoid excessive use of exhaust fans.

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

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

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

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

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

▲WARNING

!

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

▲WARNING

!

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

32

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.

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.

▲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.

8. Remove the screws (10) connecting the four 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.

11. 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.

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.

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.

▲WARNING

!

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

▲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.

COOLING SECTION MAINTENANCE

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.

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

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

Cleaning Evaporator Coil

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

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

use exces-

33

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

use exces-

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 control access panel.

CHARGING

See Figures 30, 31 and 32 for proper charging information.

34

RKKL-B180

VIII. AIRFLOW PERFORMANCE

35

36

IX. ELECTRICAL DATA - RKKL

B180CL B180CM B180DL B180DM B180YL B180YM B240CL B240CM B240CN

Unit Operating Voltage

Range

187-253 187-253 414-506 414-506 518-632 518-632 187-253 187-253 187-253

ELECTRICAL DATA - RKKL SERIES

Minimum Circuit

Ampacity

Minimum Overcurrent

Protection Device Size

Unit Information

Maximum Overcurrent

Protection Device Size

HP, Compressor 1

Amps (RLA), Comp. 1

Compressor Motor

Amps (LRA), Comp. 1

HP, Compressor 2

Amps (RLA), Comp. 2

Amps (LRA), Comp. 2

Volts

No.

Volts

Phase

RPM

208/230 208/230 460 460 575 575 208/230 208/230 208/230

75/75 78/78 38 40 28 30 94/94 102/102 102/102

90/90 90/90 45 45 30 35 110/110 110/110 110/110

90/90 100/100 50 50 35 35 125/125 125/125 125/125

222222 222

200/230 200/230 460 460 575 575 200/230 200/230 200/230

333333 333

3450 3450 3450 3450 3450 3450 3450 3450 3450

77777710 10 10

25/25 25/25 12.2 12.2 9933.6/33.6 33.6/33.6 33.6/33.6

164/164 164/164 100 100 78 78 239/239 239/239 239/239

6666668 1/2 8 1/2 8 1/2

25/25 25/25 12.8 12.8 9.6 9.6 30.1/30.1 30.1/30.1 30.1/30.1

164/164 164/164 100 100 78 78 225/225 225/225 225/225

Condenser Motor

Evaporator Fan

No.

Volts

Phase

HP

Amps (FLA, each)

Amps (LRA, each)

No.

Volts

Phase

HP

Amps (FLA, each)

Amps (LRA, each)

333333 333

208/230 208/230 460 460 575 575 208/230 208/230 208/230

111111 111

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

2.3/2.3 2.3/2.3 1.5 1.5 112.3/2.3 2.3/2.3 2.3/2.3

5.6/5.6 5.6/5.6 3.1 3.1 2.2 2.2 5.6/5.6 5.6/5.6 5.6/5.6

111111 111

208/230 208/230 460 460 575 575 208/230 208/230 208/230

333333 333

353535 57 1/2 7 1/2

11.5/11.5 14.9/14.9 4.6 6.6 3.5 5.3 14.7/14.7 23.1/23.1 23.1/23.1

74.5/74.5 82.6/82.6 38.1 46.3 20 39.4 82.6/82.6 136/136 136/136

37

ELECTRICAL DATA - RKKL (continued)

ELECTRICAL DATA - RKKL SERIES

B240DL B240DM B240DN B240YL B240YM B240YN

Unit Operating Voltage

Range

414-506 414-506 414-506 518-632 518-6323 518-632

Minimum Circuit

Ampacity

Minimum Overcurrent

Protection Device Size

Unit Information

Maximum Overcurrent

Protection Device Size

HP, Compressor 1

Amps (RLA), Comp. 1

Compressor Motor

Amps (LRA), Comp. 1

HP, Compressor 2

Amps (RLA), Comp. 2

Amps (LRA), Comp. 2

Volts

No.

Volts

Phase

RPM

460 460 460 575 575 575

51 54 54 37 39 39

60 60 60 440 45 45

60 70 70 45 50 50

222222

460 460 460 575 575 575

333333

3450 3450 3450 3450 3450 3450

10 10 10 10 10 10

17.9 17.9 17.9 12.8 12.8 12.8

125 125 125 80 80 80

8 1/2 8 1/2 8 1/2 8 1/2 8 1/2 8 1/2

16.7 16.7 16.7 12.2 12.2 12.2

114 114 114 80 80 80

Condenser Motor

Evaporator Fan

No.

Volts

Phase

HP

Amps (FLA, each)

Amps (LRA, each)

No.

Volts

Phase

HP

Amps (FLA, each)

Amps (LRA, each)

333333

460 460 460 575 575 575

111111

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

1.5 1.5 1.5 111

3.1 3.1 3.1 2.2 2.2 2.2

111111

460 460 460 575 575 575

333333

5 7 1/2 7 1/2 5 7 1/2 7 1/2

6.6 9.6 9.6 5.3 7.8 7.8

46.3 67 67 39.4 53.8 53.8

38

X. TROUBLESHOOTING

FIGURE 24

COOLING TROUBLE SHOOTING CHART

!

WARNING

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

SYMPTOM POSSIBLE CAUSE REMEDY

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

• Thermostat out of calibration-set too high • Reset

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

• Blown fuses • Replace fuses

• Transformer defective • Check wiring-replace transformer

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

• Interconnecting low voltage wiring damaged • Replace thermostat wiring

Condenser fan runs, compressor • 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

• Low voltage condition • Increase voltage

Insufficient cooling • Improperly sized unit • Recalculate load

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

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

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

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

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

• Defective overload protector • Replace - check for correct voltage

• Refrigerant undercharge • Add refrigerant

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

box

open

control opens at 610 PSIG

plate volts when unit is operating.

nameplate marking when unit is operating.

filter

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

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

pressures

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

High vapor pressure • Excessive load • Recheck load calculation

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

pressures TXV

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

expansion device or liquid line

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

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

• Defective compressor • Replace

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

39

FIGURE 25 FURNACE TROUBLESHOOTING GUIDE

(COMBINATION HEATING AND COOLING UNITS WITH DIRECT SPARK IGNITION)

WARNING

!

START

SET THERMOSTAT TO

CALL FOR HEAT

SET FAN SWITCH TO AUTO

YES

INDUCED DRAFT BLOWER

MOTOR STARTS

YES

30 SECOND PREPURGE

HAZARDOUS VOLTAGE

LINE VOLTAGE CON-

NECTIONS

NO

• CHECK LINE VOLTAGE TO IFC

• CHECK LOW VOLTAGE TRANSFORMER

• CHECK WIRING

• CHECK FOR 208-230 VAC OR 460V TO IDM MOTOR

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

NO

YES

REPLACE INDUCED DRAFT BLOWER(S)

REPLACE INTEGRATED CONTROL BOARD (IFC)

REPLACE IGNITOR/ CABLE ASSEMBLY

YES

IGNITOR SPARKS

YES

MAIN BURNER LIGHTS

YES

NO

• 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 NO

REPLACE IGNITION CON-

TROL

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

PURGE BETWEEN TRIES. IF AFTER THE THIRD TIME THE BURNERS DO NOT LIGHT, THE SYSTEM WILL LOCK OUT. IF THE UNIT IS EQUIPPED WITH A UNITED TECH. THE SYSTEM WILL ATTEMPT TO LIGHT 3 TIMES EACH HOUR UNTIL THE BURNERS LIGHT OR THE THERMOSTAT IS RESET OR POWER IS REMOVED FOR 3 SECONDS OR GREATER.

• CHECK INLET GAS PRESSURE

• CHECK 24 VOLTS TO GAS VALVE

• CHECK FOR GAS FLOW TO AND FROM VALVE

• CHECK BURNER CARRYOVER

YES

NO YES YES

NO

• CHECK NEGATIVE PRESSURE SWITCH SENSING TUBE

• CHECK FOR EXHAUST BLOCKAGE

REPLACE NEGATIVE

PRESSURE SWITCH

CHECK FOR EXHAUST,

INTAKE OR HEAT

EXCHANGER BLOCKAGE

AND RESET CONTROL

REPLACE LIMIT IF UNIT IS COLD

REPLACE INTEGRATED CONTROL BOARD (IFC)

NO

IF WIRING IS OK

40

YES

REPLACE VALVE

FLOW CHART CONTINUED ON NEXT PAGE

MAIN BURNER FLAME SUSTAINED

YES

NO

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

NO

YES

REPLACE SENSOR

INDOOR BLOWER MOTOR STARTS

AFTER 45 SECONDS

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

YES

FURNACE STARTS ON HIGH FIRE. FURNACE SWITCHES TO LOW FIRE AFTER 120 SECONDS WARMUP IF THERMOSTAT IS CALLING FOR W1. FURNACE WILL SWITCH TO HIGH FIRE IF LOW FIRE DOES NOT SATISFY THERMOSTAT DEMAND FOR HEAT LOAD.

YES

TURN THERMOSTAT OFF

VALVE SHUTS OFF

FLAME SHUTS OFF

YES

NO

REPLACE IGNITION CON-

TROL

• CHECK FOR 24 VAC ACROSS BLOWER MOTOR TERMINALS ON CONTROL BOARD

• CHECK FOR LINE VOLTAGE AT LOAD SIDE OF BLOWER CONTACT.

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

NO

YES

REPLACE INTEGRATED CONTROL BOARD (IFC)

• CHECK FOR DIRTY FILTERS

• CHECK FOR RESTRICTED AIR-FLOW

CHECK FOR EXHAUST,

INTAKE OR HEAT EXCHANG-

ER BLOCKAGE

CLEAR BLOCKAGE AND

RESET CONTROL

INDUCED DRAFT MOTOR(S) STOPS

AFTER 5 SECOND POSTPURGE

YES

INDOOR BLOWER MOTOR STOPS

AFTER 90 SECONDS

YES

TROUBLESHOOTING ENDS

REPEAT PROCEDURE UNTIL TROUBLE FREE

OPERATION IS OBTAINED.

41

XI. WIRING DIAGRAMS

FIGURE 26

RKKL SERIES

42

FIGURE 27

RKKL SERIES

43

FIGURE 28

RKKL SERIES

44

FIGURE 29

RKKL SERIES

45

XII. CHARGE CHARTS

FIGURE 30

RKKL SYSTEM CHARGE CHARTS

46

FIGURE 31

RKKL SYSTEM CHARGE CHARTS

47

CM 091248

Rheem RKKN-B Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual