Rheem RKNAA036CK08E, RKNAA036CL12E, RKNAA036CK12E, RKNAA036CL08E, RKNAA036CM08E Installation Instructions Manual

...

92-23577-72-04

SUPERSEDES 92-23577-72-03

INSTALLATION INSTR UCTIONS

PA CKAGE GAS ELECTRIC

RKNA SERIES (3-5 TONS)

ARI Standard 210/240 UAC

™

I.TABLE OF CONTENTS

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

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

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

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

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

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

V. Safety Information .................................................................................................3

VI. Unit Dimensions ....................................................................................................4

VII. Installation .............................................................................................................6

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

1. Pre-Installation Check..................................................................................6

2. Location Considerations...............................................................................6

B. Outside Installation............................................................................................7

C.Attaching Exhaust and Combustion Air Inlet Hoods .........................................8

D.Cover Panel Installation/Conversion Procedure ...............................................8

E. Clearances........................................................................................................8

F. Rooftop Installation ...........................................................................................9

G.Ductwork ...........................................................................................................9

H.Return Air........................................................................................................10

VIII. Gas Supply, Condensate Drain and Piping.........................................................12

A. Gas Connection ..............................................................................................12

B. LP Conversion.................................................................................................13

C.NOx Models ....................................................................................................13

D.Adjusting or Checking Furnace Input..............................................................14

E. Condensate Drain...........................................................................................15

IX. Wiring ..................................................................................................................15

A. Power Supply..................................................................................................15

B. Hook Up..........................................................................................................17

C.Internal Wiring.................................................................................................17

D.Thermostat......................................................................................................17

X. Furnace Section Controls

and Ignition System ...................................................18

Normal Furnace Operating Sequence.................................................................18

Operating Instructions .........................................................................................19

Burners................................................................................................................20

Manual Reset Overtemperature Control..............................................................20

Pressure Switch...................................................................................................20

Limit Control ........................................................................................................20

XI. System Operating Information.............................................................................20

Furnace Section Maintenance.............................................................................21

Lubrication...........................................................................................................22

Cooling Section Maintenance..............................................................................22

Replacement Parts..............................................................................................23

Troubleshooting...................................................................................................23

Wiring Diagrams..................................................................................................23

Charging..............................................................................................................23

Blower Motor Speed Taps...................................................................................23

XII. General Data ..................................................................................................26-43

XIII. Miscellaneous......................................................................................................44

Electrical and Physical Data...........................................................................44-47

Airflow Performance.......................................................................................48-54

Wiring Diagrams.............................................................................................55-61

Charge Charts................................................................................................62-65

Troubleshooting..............................................................................................66-68

II. INTRODUCTION

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

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

III. CHECKING PRODUCT RECEIVED

Upon receiving the unit, inspect it for any damage from shipment. Claims for damage, either shipping or concealed, should be filed immediately with the shipping company.

IMPORTANT: Check the unit model number, heating size, electrical characteristics, and accessories to determine if they are correct.

IV. SPECIFICATIONS

A. GENERAL

The Combination Gas Heating/Electric Cooling Rooftop is available in 80,000, 100,000, 120,000 and 135,000 BTU/Hr. heating inputs and cooling capacities of 3, 3

⁄2, 4, and 5 nominal tons of cooling. Units are convertible from bottom supply and return to side supply and return by relocation of supply and return air access panels. See cover installa- tion detail.

The units are weatherized for mounting outside of the building.

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

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

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

B. MAJOR COMPONENTS

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

V. SAFETY INFORMATION

WARNING

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

WARNING

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

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

Recognize this symbol as an indication of Importa nt Sa fety Information!

WARNING

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

WARNING

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

WARNING

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.

FIGURE 1

BOTTOM VIEW

FIGURE 2

CABINET DIMENSIONS AND ACCESS LOCATIONS

VI. UNIT DIMENSIONS

FOR CLEARANCES SEE FIGURE 7.

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

I316

I281

FIGURE 3

CABINET DIMENSIONS AND ACCESS LOCATIONS

FIGURE 4

SUPPLY AND RETURN DIMENSIONS

I282

I288

VII.INSTALLATION

A. GENERAL

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

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

These publications are available from: National Fire Protection

Association, Inc. Batterymarch Park Quincy, MA 02269

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

Structural strength of supporting members

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

vibration - away from bedroom

windows

2. LOCATION CONSIDERATIONS The metal parts of this unit may be subject to rust or deterioration in adverse envi-

ronmental conditions. This oxidation could shorten the equipment’s useful life. Salt spray, fog or mist in seacoast areas, sulphur or chlorine from lawn watering systems,

and various chemical contamin

ants from industries such as paper mills and petrole-

um 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 water-

front.

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

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

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

3. A good liquid cleaner may be used several times a year to remove matter tha

t will

not wash off with water.

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

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

B. OUTSIDE SLAB INSTALLATION

(Typical outdoor slab installation is shown in Figure 5.)

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

2. Provide a level slab sufficiently high enough above grade to prevent surface water from entering the unit

3. The location of the unit should be such as to provide proper access for inspection and servicing as shown in Figure 7.

4. Locate unit where operating sounds will not disturb owner or neighbors.

5. Locate unit so roof runoff water does not pour directly on the unit. Provide gutter or other shielding at roof level. Do not locate unit in an area where excessive snow drifting may occur or accumulate.

6. Where snowfall is anticipated, the height of the unit above the ground level must be considered. Mount unit high enough to be above anticipated maximum area snowf

all

and to allow combustion air to enter the combustion air inlet.

7. Select an area which will keep the areas of the vent, air intake, and A/C condenser fins free and clear of obstructions such as weeds, shrubs, vines, snow, etc. Inform the user accordingly.

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

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

FIGURE 5

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

I298

WARNING

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

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

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

• MEANS OF PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION;

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

• INSTALLATION OF EXHAUST AND COMBUSTION AIR INLET HOODS COMPLETED;

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

C. ATTACHING EXHAUST AND COMBUSTION AIR INLET HOODS

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

To attach exhaust/combustion air inlet hood:

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

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

3. Attach blower access panel.

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

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

D. COVER PANEL INSTALLATION/CONVERSION PROCEDURE

DOWNFLOW TO HORIZONTAL

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

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

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

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

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

E. CLEARANCES

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

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

Recommended

Clearance

Location

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

*Without Economizer. 57 With Economizer

FIGURE 6

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

I631

FIGURE 7

CLEARANCES

I297

F. ROOFTOP INSTALLATION

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

IS VERY IMPORTANT AND THE INSTALLER’S RESPONSIBILITY.

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

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

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

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

G. DUCTWORK

The installing contractor should fabricate ductwork in accordance with local codes. Use industry manuals as a guide when sizing and designing the duct system. Contact Air Conditioning Contractors of America, 1513 16th St. N.W., Washington, D.C. 20036.

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

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.

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.

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

cient for ductwork inside the air conditioned space. Provide balancing dampers for each branch duct in the supply system. Properly support

ductwork from the structure. IMPORTANT: In the event that the return air ducts must be run through an “unconfined”

space containing other fuel burning equipment, it is imperative that the user/homeowner must be informed against future changes in construction which might change this to a “confined space.” Also, caution the user/homeowner against any future installation of additional equipment (such as power ventilators, clothes dryers, etc., within the existing unconfined and/or confined space which might create a negative pressure within the vicinity of other solid, liquid, or gas fueled appliances.

H. RETURN AIR

FIGURE 8

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

I299

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 11

ROOFCURB

FIGURE 10

ROOFCURB

RETURN DUCT*

SUPPLY DUCT*

NAILING STRIP

INSULATION PANELS (2) SUPPLIED

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

HOLD DOWN BRACKET TYP. (4) PLCS.

UNIT

I296

ST-A0801-19-01

CORNER WEIGHTS BY PERCENTAGE

ABC D

22% 27% 23% 28%

SPREADER BAR

LIFTING BEAM

CABLE OR CHAIN

5/8 SHACKLE

(EACH CORNER)

38.25

25.75

C.G.

ST-A0801-19-01

ROOFTOP UNIT

COUNTER FLASHING*

INSULATION*

CANT STRIP*

ROOF FELT*

INSULATION*

ROOF DECK*

*BY CONTRACTOR

ROOF STRUCTURAL MEMBER*

ROOFCURB

DUCT*

NAILER STRIP

GASKET

RETURN

SUP-

FIGURE 9

LIFTING DETAIL

ROOFTOP UN

GASKET

NAILER STRIP

DUCT*

OOFCURB

COUNTER FL

INSULATION*

CANT STRIP*

ROOF F INSULAT

ROOF D

TURAL

VIII. GAS SUPPLY, CONDENSATE DRAIN AND

VIII. PIPING

A. GAS CONNECTION

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

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

NOTE: The use of flexible gas connectors is not permitted.

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

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

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 a

ssem-

bly at the burner tray.

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

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

handle gas lock.

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

petroleum gases must be used at all threaded pipe connections.

8. IMPORTANT: any additions, changes or conversions required for the furnace to satisfactorily meet the application should be made by a qualified installer, service agency or the gas supplier, using factory-specified or approved parts. In the commonwea

lth of Massachusetts, installation must be performed by a licensed plumber

or gas fitter for appropriate fuel.

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

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

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.

FIGURE 13

SUGGESTED GAS PIPING

FROM GAS METER

Factory supplied grommet must be utilized.

MANUAL GAS SHUT-OFF VALVE

UNIT GAS SUPPLY CONNECTION

ROOF OR GROUND LEVEL INSTALLATION

WARNING

CHECK FOR LEAKS. THE USE OF AN OPEN FLAME CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Nominal

Iron Pipe

Size,

Inches

Equivalent Length of Pipe, Feet

10 20 30 40 50 60 70 80

⁄2 132 92 73 63 56 50 46 43

⁄4 278 190 152 130 115 105 96 90

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

TABLE 1

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

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

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

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

Gas Input of Furnace (BTU/HR)

Cu. Ft. Per Hr. Required =

Heating Value of Gas (BTU/FT

)

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

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

L.P. gas supplier.

B. LP CONVERSION

Convert the valve to use liquefied petroleum (LP) gas by replacing the pressure regulator spring with the conversion kit spring. This LP kit spring allows the regulator to maintain the proper manifold pressure for LP gas. The correct burner LP orifices are included in the kit. See Figure 14.

IMPORTANT: To remove the gas valve, remove the four screws securing the manifold pipe to the burner tray. Remove the manifold pipe with gas valve attached. See Figure 15.

NOTE: Order the correct LP conversion kit from the furnace manufacturer.

See Conversion Kit Index shipped with unit for proper LP kit number. Furnace conversion to LP gas must be performed by a qualified technician.

C. NOx MODELS

When converting units equipped with NOx inserts to LP gas, the stainless steel screen mesh inserts in the entrance of the tubular exchangers are not required to meet SCAQMD NOx emission levels. These inserts and 1/8 diameter retaining rod should be carefully removed before firing this furnace on LP gas. IMPORTANT: This furnace is not designed to operate on LP gas with the NOx inserts in place.

Step by step instructions on removing the NOx inserts and retaining rod are included in the Conversion Kit Installation Instructions.

WARNING

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

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

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

TABLE 2

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

Nominal Iron Pipe Size, Inches

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

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

567 393 315 267 237 217 196 182 173 162 146 132 1,071 732 590 504 448 409 378 346 322 307 275 252 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,6061,496

1/2 3/4

1 1-1/4 1-1/2

Length of Pipe, Feet

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

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

D. 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.

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

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

 W.C. at the gas con-

trol valve. To adjust the pressure regulator, remove the regulator cap and turn the adjustment screw

clockwise to increase pressure or counterclockwise to decrease pressure. Then replace

the regulator cap securely.

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

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

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

Heating Value of Gas

(BTU/Cu. Ft.) x 3600

Cu. Ft. Per Hr. Required =

Time in Seconds

(for 1 Cu. Ft.) of Gas

Start the furnace and measure the time required to burn one cubic foot of ga

s. 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.

FIGURE 14

FIGURE 15

MANIFOLD PIPE

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

E.CONDENSATE DRAIN

The condensate drain connection of the evaporator is threaded 3/4 nominal P.V.C. pipe. IMPORTANT: Install a condensate trap to ensure proper condensate drainage. See Figure 16.

IX. 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 the unit’s RATED VOLTAGE REQUIREMENT. Install a branch circuit disconnect near the rooftop, in accordance with the N.E.C., C.E.C. or local codes. A bracket is provided with the unit for mounting of the disconnect. See Figure 17.

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

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

allowable in Table 4 from the unit dis-

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

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

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

ONE 121130134139345

40,000

TEN 13 30 15 0 15 36 16 30 37 30

ONE 054101 31 6230

60,000

TEN 9 0 10 0 10 24 11 0 25 0 ONE 041045047050153

80,000

TEN 6 45 7 30 7 48815 18 45 ONE 0 33 0 36 0 38 040 130

100,000

TEN 524 6 0 615 63615 0

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

OR LP GAS

INPUT

BTU/HR

METER

SIZE

CU. FT.

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500

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

TABLE 3

FIGURE 16 CONDENSATE DRAIN

DO NOT OVERTIGHTEN DRAIN FITTING

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.

NOTES:

1. Wire size based on 60°C rated wire insulation and 30°C Ambient Temp. (86°F).

2. For more than 3 conductors in a raceway or cable, see the N.E.C. for derating the ampacity of each conductor.

When installed, the unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code,

ANSI/NFPA 70, if an external electrical source is utilized.

IMPORTANT: THIS UNIT IS APPROVED FOR USE WITH COPPER CONDUCTORS ONLY

CONNECTED TO UNIT CONTACTOR.

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

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

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

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

aluminum splices. Please exercise the following instructions very carefully to obtain a positive and lasting connection:

1. Strip insulation from aluminum conductor.

2. Coat the stripped end of the aluminum wire with the recommended inhibitor, and wire brush the aluminum surface through inhibitor. INHIBITORS: Brundy-Pentex “A”; Alcoa-No. 2EJC; T & B-KPOR Shield.

3. Clean and recoat aluminum conductor with inhibitor.

4. Make the splice using the above listed wire nuts or split bolt connectors.

5. Coat the entire connection with inhibitor and wrap with electrical insulating tape.

FIGURE 17

RECOMMENDED BRANCH CIRCUIT DISCONNECT LOCATION

TO POWER

TO THERMOSTAT

BRANCH CIRCUIT DISCONNECT

I317A

AWG Copper AWG Aluminum Connector Type and Size

Wire Size Wire Size (or equivalent)

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

TABLE 5

200 6 4 4 4 3 3 2 2 150 8 6644433 100 10 8866644

50 14 12 10 10 8866

15 20 25 30 35 40 45 50

BRANCH CIRCUIT AMPACITY

SUPPLY WIRE LENGTH-FEET

*Taken from National Electric Code

TABLE 4

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

B. HOOK-UP

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

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

C. INTERNAL WIRING

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

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

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

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

D. THERMOSTAT

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

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

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

WIRE SIZE, AWG

FIGURE 18

FIGURE 19

TYPICAL THERMOSTAT WIRING

1/2 7/8

3/4

1-31/32

1

1-23/64

1

1-23/64

1-1/4

1-23/32

1-1/4

1-23/32

1-1/2

1-31/32

1-1/2

1-31/32

2

2-15/32

000

2

2-15/32

CONDUIT SIZE

HOLE SIZE

I658

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).

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

The following is a list of recommended thermostats to be used with or without an economizer:

X. FURNACE SECTION CONTROLS AND

IGNITION SYSTEM

NORMAL FURNACE OPERATING SEQUENCE

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

1. The thermostat calls for heat.

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

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

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

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

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

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

8. Thermostat is satisfied and opens.

9. The gas v

alve is de-energized and closes, shutting down the burner flame.

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

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

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

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

The integrated furnace control is equipped with diagnostic LED. The LED is lit continuously when there is power to the control, with or without a ca

ll for heat. If the LED is not lit, there

Single Stage Cool Two Stage Cool

W/O Economizer W/Economizer

Maple Chase - Honeywell -

Model #0970 Model #T7300-A1005

Honeywell - Honeywell -

Model #T8602C Model #T874D-1959

Maple Chase -

Model #0960

White Rodgers -

Model #1F91-59

Robertshaw -

Model #CM64A-USAJ

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.0 16 14 12 10 10 10

2.5 16 14 12 12 12 10

2.0 18 16 14 12 12 10 50 100 150 200 250 300

Length of Run – Feet (1)

Thermostat Load -

Amps

TABLE 6

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

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

is either no power to the control or there is an internal component failure within the control, and the control should be replaced.

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

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

OPERATING INSTRUCTIONS

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

TO START THE FURNACE

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

2. Set the thermostat to its lowest setting.

3. Turn off all electric power to the appliance.

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

try to light the burner by hand.

5. Remove control door/access panel.

6. Move switch to the “OFF” position.

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

• Do not try to light any appliance.

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

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

er’s instructions.

• If you cannot reach your gas supplier, call the fire department. If you don’t smell gas, go to the next step.

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

9. Replace the control door.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

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

The initial start-up on a new installation may require the control system to be energized for some time until

air has bled through the system and fuel gas is available at the burners.

TO SHUT DOWN FURNACE

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove control door.

4. Move switch to the “OFF” position.

5. Replace control door.

WARNING

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

WARNING

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

WARNING

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

BURNERS

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

MANUAL RESET OVERTEMPERATURE CONTROL

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

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

PRESSURE SWITCH

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

LIMIT CONTROL

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

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

XI. SYSTEM OPERATING INFORMATION

ADVISE THE CUSTOMER

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

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

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

4. Avoid excessive use of exhaust fans.

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

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

WARNING

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

WARNING

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

WARNING

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

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

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

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

FURNACE SECTION MAINTENANCE

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

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

agency, or gas supplier):

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

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

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 dra

ft blower motor, gas valve, flame sensor, and flame roll-out control, and ignitor cable. Mark all wires disconnected for proper reconnection.

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

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

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

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

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

11. Direct a water hose into the outlet of the he

at exchanger top. Flush the inside of each heat exchanger tube with water. Blow out each tube with air to remove excessive moisture.

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

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

The manufacturer recommends that a qualified installer, service agency or the gas suppli- er 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 sea

son.

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.

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