INSTALLATION INSTRUCTIONSPackage Gas Electric FeaturingIndustry Standard R-410A RefrigerantRKKN-B073 (6 TON) SERIESRKKN-C073 (6 TON) SERIES WITH CLEAR CONTROLTM (DDC)

92-23577-157-03(SUPERCEDES 92-23577-157-02)

ACCREDITED

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I. TABLE OF CONTENTSI. Table of Contents .................................................................................................. 2II. Introduction ........................................................................................................... 3III. Checking Product Received .................................................................................. 3IV. Specifications ........................................................................................................ 3

A. General .............................................................................................................3B. Major Components ...........................................................................................3C. R-410A Refrigerant ...........................................................................................3

1. Specifications of R-410A ..............................................................................32. Quick Reference Guide for R-410A .............................................................. 43. Evaporator Coil/TXV .....................................................................................44. Tools Required for Installing and Servicing R-410A Models ........................ 4

V. Safety Information ................................................................................................. 4VI. Unit Dimensions .................................................................................................... 5VII. Installation ............................................................................................................. 7

A. General .............................................................................................................71. Pre-Installation Check ..................................................................................72. Location Considerations ..............................................................................7

B. Outside Installation ...........................................................................................8C. Attaching Exhaust and Combustion Air Inlet Hoods ......................................... 9D. Cover Panel Installation/Conversion Procedure ............................................... 9E. Clearances ........................................................................................................9F. Rooftop Installation ...........................................................................................9G. Ductwork .........................................................................................................10H. Return Air ........................................................................................................11

VIII. Gas Supply, Condensate Drain and Piping ........................................................ 13A. Gas Connection ..............................................................................................13B. LP Conversion ................................................................................................14C. NOx Models ....................................................................................................14D. Adjusting or Checking Furnace Input ..............................................................15E. Condensate Drain ...........................................................................................17

IX. Wiring .................................................................................................................. 17A. Power Supply ..................................................................................................17B. Hook Up ..........................................................................................................19C. Internal Wiring .................................................................................................19D. Thermostat ......................................................................................................19

X. Furnace Section Controls and Ignition System ................................................... 20Normal Furnace Operating Sequence ................................................................20Operating Instructions .........................................................................................20

Burners................................................................................................................21Manual Reset Overtemperature Control ............................................................. 21Pressure Switch ..................................................................................................21Limit Control ........................................................................................................22

XI. System Operating Information ............................................................................ 22Advise the Customer ...........................................................................................22Furnace Section Maintenance ............................................................................22

Lubrication........................................................................................................... 23Cooling Section Maintenance .............................................................................23Replacement Parts..............................................................................................24

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

Charging.............................................................................................................. 24XII. General Data ..................................................................................................25-27XIII. Miscellaneous ..................................................................................................... 28

Electrical Data .....................................................................................................28Airflow Performance ............................................................................................29Wiring Diagrams.............................................................................................30-34Charge Chart.......................................................................................................35

Troubleshooting .............................................................................................36-38

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II. INTRODUCTIONThis 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 RECEIVEDUpon 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. SPECIFICATIONSA. GENERALThe Combination Gas Heating/Electric Cooling Rooftop is available in 100,000 and 135,000 BTU/Hr. heating inputs and cooling capacity of 6 nominal tons of cooling. Units are convertible from bottom supply and return to side supply and return by relocation of supply and return air access panels. See cover installation detail.The units are weatherized for mounting outside of the building.

The information on the rating plate is in compliance with the FTC and DOE rating for sin-gle 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 COMPONENTSThe unit includes a hermetically-sealed refrigerating system (consisting of a scroll com-pressor, condenser coil, evaporator coil with thermostatic expansion valve), a circula-tion air blower, a condenser fan, a heat exchanger assembly, gas burner and control assembly, combustion air motor and fan, and all necessary internal electrical wiring. The cooling system of these units is factory-evacuated, charged with R-410A refrigerant and performance tested. Refrigerant amount and type are indicated on rating plate.

C. R-410A REFRIGERANTAll 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 designpressure ratings appropriate for R-410A. Manifold sets need to range up to 800 psighigh-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

WARNINGTHE MANUFACTURER’S WAR-RANTY DOES NOT COVER ANY DAMAGE OR DEFECT TO THE AIR CONDITIONER CAUSED BY THE ATTACHMENT OR USE OF ANY COMPONENTS, ACCESSO-RIES 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 OPER-ATION OF THE AIR CONDITIONER AND MAY ALSO ENDANGER LIFE AND PROPERTY. THE MANUFAC-TURER DISCLAIMS ANY RESPON-SIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES.

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

Recognize this symbol as an indication of Important Safety Information!

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WARNINGINSTALL THIS UNIT ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSID-ERATIONS SECTION OF THESE INSTRUCTIONS. PROVIDE ADE-QUATE COMBUSTION AND VENTI-LATION AIR TO THE UNIT SPACE AS SPECIFIED IN THE VENTING SECTION OF THESE INSTRUC-TIONS.

WARNINGPROVIDE ADEQUATE COMBUS-TION AND VENTILATION AIR TO THE UNIT SPACE AS SPECIFIED IN THE COMBUSTION AND VENTI-LATION AIR SECTION OF THESE INSTRUCTIONS.

WARNINGEFFICIENCY TESTING NOTICEFOR PURPOSES OF VERIFYING OR TESTING EFFICIENCY RATINGS, THE TEST PROCE-DURE IN TITLE 10 PART 431 APPENDIX A TO SUBPART F (UNIFORM TEST METHOD FOR MEASURING THE ENERGY CONSUMPTION OF SMALL LARGE AND VERY LARGE COMMERCIAL PACKAGE AIR CONDITIONING AND HEATING EQUIPMENT), TITLE 10 PART 431.76 SUBPART D (UNIFORM TEST METHOD FOR MEASURING ENERGY CONSUMPTION OF COMMERCIAL WARM AIR FURNACES), AND THE CLARIFYING PROVISIONS PROVIDED IN THE AHRI OPERATIONS MANUALS FOR UNITARY LARGE EQUIPMENT 340/360, 365 AND COMMERCIAL FURNACES THAT WERE APPLICABLE AT THE DATE OF MANUFACTURE SHOULD BE USED FOR TEST SET UP AND PER-FORMANCE.

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lines, or be allowed to accumulate in storage tanks. Leak checking should never be done with a mixture of R-410A and air. Leak checking can be performed safely with nitrogen or a mixture of R-410A and nitrogen.

2. Quick Reference Guide For R-410A• R-410A refrigerant operates at approximately 60% higher pressure (1.6 times) than

R-22. Ensure that servicing equipment is designed to operate with R-410A.• R-410A refrigerant cylinders are pink.• R-410A, as with other HFC’s is only compatible with POE oils.• Vacuum pumps will not remove moisture from POE oil.• R-410A systems are to be charged with liquid refrigerants. Prior to March 1999,

R-410A refrigerant cylinders had a dip tube. These cylinders should be kept uprightfor equipment charging. Post March 1999 cylinders do not have a dip tube andshould 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 / TXVThe thermostatic expansion valve is specifically designed to operate with R-410A. DO NOT use an R-22 TXV. The existing evaporator must be replaced with the factory specified TXV evaporator specifically designed for R-410A.

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

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

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

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2-5/32[55]

4-5/8[118]

26[660]

4.502[114]

13-1/8[333]

4-1/2[114]

13-1/8[333]

77-15/32[1968]

20[508]

2-3/8[60]

43-7/32[1098]

2-3/8[60]

2-3/8[60]

RETURNAIR SUPPLY

AIR

[ ] DESIGNATES METRIC CONVERSIONS

TOP VIEW

ST-A1143

FIGURE 2

VI. UNIT DIMENSIONSRKKN 6 TON [21.1 kW] MODELS

FIGURE 1

ST-A1224-01

OUTDOOR FAN

OUTDOOR COIL

6

FIGURE 3

ST-A1148

BACK VIEW

ST-A1224

FRONT VIEWFIGURE 5

ST-A1224

SIDE VIEW

FIGURE 4

WARNINGALWAYS INSTALL UNIT TO OPER-ATE 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 SEC-TION OF THESE INSTRUCTIONS. SEE ALSO UNIT RATING PLATE.

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

WARNINGNEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIF-ICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNEC-TIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS.

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V. SAFETY INFORMATIONVII. INSTALLATIONA. GENERAL Install this unit in accordance with The American National Standard Z223.1-latest edition booklet entitled “National Fuel Gas Code,” and the requirements or codes of the local utility or other authority having jurisdiction.Additional helpful publications available from the “National Fire Protection Association” are: NFPA-90A - Installation of Air Conditioning and Ventilating Systems 1985 or latest edition. NFPA-90B - Warm Air Heating and Air Conditioning Systems 1984.These publications are available from:National Fire Protection Association, Inc.1 Batterymarch Park Quincy, MA 02169-7471www.nfpa.org1. PRE-INSTALLATION CHECK-POINTS — Before attempting any installation, care-

fully consider the following points:Structural strength of supporting members

(Rooftop Installation)Clearances and provision for servicingPower supply and wiringGas supply and pipingAir duct connections and sizingDrain facilities and connectionsLocation for minimum noise and vibration - away from bedroom windows

2. LOCATION CONSIDERATIONSThe 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. Saltspray, fog or mist in seacoast areas, sulphur or chlorine from lawn watering systems,and various chemical contaminants from industries such as paper mills and petro-leum refineries are especially corrosive.If the unit is to be installed in an area where contaminants are likely to be aproblem, 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 removemost 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 pro-vide some protection.

3. A good liquid cleaner may be used several times a year to remove matter that willnot 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 ver-ified by the equipment manufacturer.The best protection is frequent cleaning, maintenance and minimal exposure to contaminants.

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

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B. OUTSIDE SLAB INSTALLATION

(Typical outdoor slab installation is shown in Figure 6.)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 unit3. The location of the unit should be such as to provide proper access for inspection

and servicing as shown in Figure 8.4. 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 snowdrifting may occur or accumulate.

6. Where snowfall is anticipated, the height of the unit above the ground level must beconsidered. Mount unit high enough to be above anticipated maximum area snowfalland 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 condenserfins free and clear of obstructions such as weeds, shrubs, vines, snow, etc. Informthe user accordingly.

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

WARNINGTHIS UNIT MAY BE USED TO HEAT THE BUILDING OR STRUC-TURE DURING CONSTRUCTION IF THE FOLLOWING INSTAL-LATION REQUIREMENTS ARE MET. INSTALLATION MUST COM-PLY 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 RAT-ING PLATE MARKING;

• MEANS OF PROVIDING OUT-DOOR AIR REQUIRED FOR COM-BUSTION;

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

• INSTALLATION OF EXHAUSTAND COMBUSTION AIR INLETHOODS COMPLETED;

• CLEAN FURNACE, DUCT WORKAND COMPONENTS UPON SUB-STANTIAL COMPLETION OFTHE CONSTRUCTION PROCESS,AND VERIFY FURNACE OPER-ATING CONDITIONS INCLUDINGIGNITION, INPUT RATE, TEM-PERATURE RISE AND VENTING,ACCORDING TO THE INSTRUC-TIONS.

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WARNINGTHESE 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 PROD-UCTS INTO THE CONDITIONED SPACE RESULTING IN PERSONAL INJURY OR DEATH.

FIGURE 6OUTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOOR CONSTRUCTION.

SR-A1224

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C. ATTACHING EXHAUST AND COMBUSTION AIR INLET HOODSIMPORTANT: 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 ofblower access panel, see Figure 2.

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

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 HORIZONTAL1. 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 7. 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.

E. CLEARANCESThe following minimum clearances must be observed for proper unit performance and serviceability. Reference Figure 8.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.

F. ROOFTOP INSTALLATION1. 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.) THISIS VERY IMPORTANT AND THE INSTALLER’S RESPONSIBILITY.

2. For rigging and roofcurb details, see Figures 9, 10, 11 and 12.3. 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.

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G. DUCTWORKThe 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.

36“

60“

48“

VERTICALCLEARANCE

18“

12“

ST - A1141 - 13

FIGURE 8CLEARANCES

ST-1224

FIGURE 7COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW APPLICATION BEING CONVERTED TO HORIZONTAL

I631

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

WARNINGDO 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, PROP-ERTY DAMAGE OR DEATH.

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Place the unit as close to the conditioned space as possible allowing clearances as indi-cated. Run ducts as directly as possible to supply and return outlets. Use of non-flam-mable weatherproof flexible connectors on both supply and return connections at unit to reduce noise transmission is recommended.On ductwork exposed to outside temperature and humidity, use a minimum of 2( of insulation and a vapor barrier. Distribution system in attic, furred space or crawl space should be insulated with at least 2( of insulation. 1⁄2( to 1( thick insulation is usually 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

ST - A1141 - 10

FIGURE 9FLAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. MOUNTED ON ROOFCURB. CURB MUST BE LEVEL.

ST-1224

WARNINGNEVER 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 CIRCU-LATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

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RETURN DUCT*

SUPPLY DUCT*

NAILING STRIP

INSULATION PANELS(2) SUPPLIED

GASKET(FULL PERIMETERAND ON DIVIDERS,MUST BE ABOVE DUCTAND INSULATIONPANEL FLANGES.)

HOLDDOWNBRACKETTYP. (4) PLCS.

UNIT

ROOFTOP UNIT

COUNTER FLASHING*GASKETNAILER STRIP

DUCT*

ROOFCURB

INSULATION*

CANT STRIP*

ROOF FELT*

INSULATION*

ROOF DECK*ROOFSTRUCTURALMEMBER*

*BY CONTRACTOR

ATTACHINGSCREW*

HOLDDOWNCLIP

ROOFTOPUNIT

FIGURE 12ROOFCURB

ST-A0801-19-01

ROOFTOP UNIT

COUNTER FLASHING*

INSULATION*

CANT STRIP*

ROOF FELT*

INSULATION*

ROOF DECK*

*BY CONTRACTOR

ROOFSTRUCTURALMEMBER*

ROOFCURB

DUCT*

NAILER STRIP

GASKET

I296

CORNER WEIGHTS BY PERCENTAGE A B C D 22% 27% 23% 28%

SPREADER BAR

A

B

D

C

LIFTING BEAM

CABLE OR CHAIN

5/8( SHACKLE(EACH CORNER)

38.2525.75

C.G.

FIGURE 10LIFTING DETAIL

FIGURE 11ROOFCURB

RETURN DUCT*

SUPPLY DUCT*

NAILING STRIP

INSULATION PANELS(2) SUPPLIED

GASKET(FULL PERIMETERAND ON DIVIDERS,MUST BE ABOVE DUCTAND INSULATIONPANEL FLANGES.)

HOLDDOWNBRACKETTYP. (4) PLCS.

UNIT

ROOFTOP UNIT

COUNTER FLASHING*GASKETNAILER STRIP

DUCT*

ROOFCURB

INSULATION*

CANT STRIP*

ROOF FELT*

INSULATION*

ROOF DECK*ROOFSTRUCTURALMEMBER*

*BY CONTRACTOR

ATTACHINGSCREW*

HOLDDOWNCLIP

ROOFTOPUNIT

ST-A0801-19-01

RETURN

SUPPLY

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VIII. GAS SUPPLY, CONDENSATE DRAIN ANDVIII. PIPINGA. GAS CONNECTIONIMPORTANT: 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 specifi-cations of the National Fuel Gas Code, ANSI Z223.1 - latest edition.

NOTE: The use of flexible gas connectors is not recommended. If local codes allowthe use of a corrugated stainless steel flexible gas appliance connector, always usea new listed connector. Do not use a connector which has previously serviced anoth-er gas appliance.

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

2. Connect the gas line to the gas pipe inlet opening provided into the 1/2( inlet valve.See Figure 6 or 9 for typical piping.

3. Size the gas line to the furnace adequately to prevent undue pressure drop andnever less than 1/2( nominal pipe size.

4. Install a drip leg or sediment trap in the gas supply line as close to the unit as possible.5. Install an outside ground joint union to connect the gas supply to the control assem-

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.)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, serviceagency or the gas supplier, using factory-specified or approved parts. In the com-monwealth of Massachusetts, installation must be performed by a licensed plumberor 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 13SUGGESTED GAS PIPING

FROM GASMETER

*Factory supplied grommet must be utilized.

MANUAL GASSHUT-OFFVALVE

UNIT GAS SUPPLYCONNECTION *

ROOF OR GROUND LEVEL INSTALLATION

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

NominalIron Pipe

Size,Inches

Equivalent Length of Pipe, Feet

10 20 30 40 50 60 70 801⁄2 132 92 73 63 56 50 46 433⁄4 278 190 152 130 115 105 96 901 520 350 285 245 215 195 180 170

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

TABLE 1NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)

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In making gas connections, avoid strains as they may cause noise and damage the con-trols. Use a backup wrench on the valve to avoid damage.The capacities of gas pipe of different diameters and lengths in cu. ft. per hr. with pres-sure 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 (BTU/HR)

Cu. Ft. Per Hr. Required = Heating Value of Gas

(BTU/FT3)

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) 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 regula-tor spring with the conversion kit spring. This LP kit spring allows the regulator to main-tain 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 conver-sion to LP gas must be performed by a qualified technician.

C. NOx MODELSWhen 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.

WARNINGFACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT SUPPLIED BY THE DISTRIBUTOR OR MANUFAC-TURER. 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, PERSON-AL 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 2LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

NominalIron PipeSize, Inches 10 20 30 40 50 60 70 80 90 100 125 150

275 189 152 129 114 103 96 89 83 78 69 63 567 393 315 267 237 217 196 182 173 162 146 132 1,071 732 590 504 448 409 378 346 322 307 275 252 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

1/23/41

1-1/41-1/2

2

Length of Pipe, Feet

Example (LP): Input BTU requirement of unit, 150,000Equivalent length of pipe, 60 ft. = 3/4( IPS required.

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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 control valve.To adjust the pressure regulator, remove the regulator cap and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure. Then replace the regulator cap securely.Any necessary major changes in the gas flow rate should be made by changing the size of the burner orifices. To change orifice spuds, shut off the manual main gas valve and remove the gas manifold.For elevations up to 2,000 feet, rating plate input ratings apply. For high altitudes (eleva-tions 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.

Heating Value of Gas(BTU/Cu. Ft.) × 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 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 ele-vations 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

16

Alternate Method for Canadian High-Altitude Derate for Residential and Light Commercial Gas/Electric Package UnitsIn Canada, unless an orifice change is specifically mandated by local codes, an alter-nate method of altitude deration through a reduction in manifold pressure is acceptable as described in Table 4.The information in Table 1 is based on a heating value of 1000 BTU per cubic feet of natural gas, and 2500 BTU per cubic feet of LP gas.Important: Actual input rates must be measured on-site with manifold pressure adjustment to ensure that an actual 10% reduction in input rate is achieved.Once this field adjustment has been made, the label shown in Figure 17 must be affixed in a conspicuous location on the front of the furnace cabinet.NOTE: This label is supplied in the information package shipped with each unit.

ONE 1 21 1 30 1 34 1 39 3 45 40,000 TEN 13 30 15 0 15 36 16 30 37 30 ONE 0 54 1 0 1 3 1 6 2 30 60,000 TEN 9 0 10 0 10 24 11 0 25 0 ONE 0 41 0 45 0 47 0 50 1 53 80,000 TEN 6 45 7 30 7 48 8 15 18 45 ONE 0 33 0 36 0 38 0 40 1 30 100,000 TEN 5 24 6 0 6 15 6 36 15 0

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

OR LP GAS

INPUTBTU/HR

METERSIZE

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 3FIGURE 16CONDENSATE DRAIN

DO NOT OVERTIGHTEN DRAIN FITTING

Altitude

40,000 32,000 60,000 48,000 80,000 64,000 #45 0’-2000’ 100,000 80,000 3.5” W.C.

120,000 96,000 135,000 108,000 #43 36,000 28,800 54,000 43,200 2001’- 72,000 57,600 #45 4500’ 90,000 72,000 2.9” W.C.

108,000 86,400 121,500 97,200 #43

Input Output OrificeSize

ManifoldPressure

TABLE 4ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATE

NATURAL GAS

Altitude

40,000 32,000 60,000 48,000 80,000 64,000 #55 0’-2000’ 100,000 80,000 10” W.C.

120,000 96,000 135,000 108,000 36,000 28,800 54,000 43,200 2001’- 72,000 57,600 #55 4500’ 90,000 72,000 8.1” W.C.

108,000 86,400 121,500 97,200

Input Output OrificeSize

ManifoldPressure

LP GAS

FIGURE 17MANIFOLD PRESSURE CHANGE LABEL

The manifold pressure of this appliance hasbeen field adjusted to obtain the correct input

rating for installation at altitudes between2,000 feet and 4,500 feet elevation.

La pression du distributeur d’alimentation de cetappareil a ete ajuste sur les lieux afin d’obtenir labonne puissance d’entrée pour une installation

entre 2000 et 4500 pieds d’altitude.

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

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

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

GAS SUPPLY

FIGURE 18RECOMMENDED BRANCH CIRCUIT DISCONNECT LOCATION

ST-1224

AWG Copper AWG Aluminum Connector Type and Size Wire Size Wire Size (or equivalent) #12 #10 T & B Wire Nut PT2 #10 # 8 T & B Wire Nut PT3 # 8 # 6 Sherman Split Bolt TSP6 # 6 # 4 Sherman Split Bolt TSP4 # 4 # 2 Sherman Split Bolt TSP2

TABLE 6

200 6 4 4 4 3 3 2 2 150 8 6 6 4 4 4 3 3 100 10 8 8 6 6 6 4 4 50 14 12 10 10 8 8 6 6 15 20 25 30 35 40 45 50

BRANCH CIRCUIT AMPACITYSUPPLY WIRELENGTH-FEET

*Taken from National Electric Code

TABLE 5BRANCH CIRCUIT COPPER WIRE SIZE(Based on 1% Voltage Drop)*

WARNINGTURN 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.

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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 arefield supplied for this application. Reference the chart with Figure 18 for proper holeand conduit size.

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 localcodes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, if an external electrical source is utilized.

IMPORTANT: THIS UNIT IS AP PROVED FOR USE WITH COPPER CONDUCTORS 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 ter-minals L1 and L3 for single phase, L1, L2 and L3 for three phase.Select the equivalent aluminum wire size from Table 6:Splice copper wire pigtails to aluminum wire with U.L. recognized connectors for cop-per-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.

WIRE SIZE, AWG14

1/2(

7/8(

121/2(

7/8(

101/2(

7/8(

83/4(

1-31/32(

61(

1-23/64(

41(

1-23/64(

31-1/4(

1-23/32(

21-1/4(

1-23/32(

11-1/2(

1-31/32(

01-1/2(

1-31/32(

002(

2-15/32(

0002(

2-15/32(

CONDUIT SIZEHOLE 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).

FIGURE 19

ST-A1141

EXAMPLE FOR CONNECTING THRU-BASE POWER AND CONTROL WIRING. ALL CONNECTIONS TO USE WATER-TIGHT FITTINGS. MAINTAIN CLEARANCE WITH ALL COPPER TUBING.

FIGURE 20TYPICAL THERMOSTAT WIRING (B073)FIGURE 20TYPICAL THERMOSTAT WIRING

HIGH VOLTAGEDISCONNECT

SWITCH

ST-A1294

T1

T2

T3

L1

L2

L3

Y2 Y1 G R W

LOW VOLTAGEWIRE LEADS

CHASSIS GROUND

FOR INTERNAL WIRING SEE WIRING LABEL ATTACHED TO UNIT.

HIGH VOLTAGE POWER WIRING24 VOLT CONTROL WIRING

THERMOSTATSUBBASER W

Y1Y2G

HE

AT

PO

WE

R

FAN

1ST.

STA

GE

CO

OL

2ND

. STA

GE

CO

OL

FIGURE 21TYPICAL THERMOSTAT WIRING

R Y1 Y2 G C

ST-A1125-42-00

RTU-C BOARD LOW VOLTAGETHERMOSTAT CONNECTIONS

OC B LW1 W2

R Y1 Y2 G C W

TMCLEAR CONTROL (DDC) MODELS

FIGURE 21TYPICAL THERMOSTAT WIRING (C073)

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4. Make the splice using the wire nuts or split bolt connectors shown in Table 6.5. Coat the entire connection with inhibitor and wrap with electrical insulating tape.

B. HOOK-UPTo 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 WIRINGA 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. THERMOSTATThe room thermostat must be compatible with the spark ignition control on the unit. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control. The low voltage wiring should be sized as shown in Table 6.Install the room thermostat in accordance with the instruction sheet packed in the box with the thermostat. Run the thermostat lead wires inside the compressor access panel compartment and connect to low voltage terminals as shown on the wiring diagram. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes or ducts, lighting fixtures, radiation from fireplace, sun rays, lamps, televisions, radios or air streams from registers. Refer to instructions packed with the thermostat for “heater” selection or adjustment.The following are the recommended thermostats available through the manufacturer to be used:

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)Ther

mos

tat L

oad

-A

mps

TABLE 7

(1) The total wire length is the distance from the furnace to the thermo-stat and back to the furnace.NOTE: DO NOT USE CONTROL WIRING SMALLER THAN NO. 18 AWG.

W/O Economizer W/Economizer(-)HC-TST213GESS (-)HC-TST213UNMS

(-)HC-TST213UNMS (-)HC-TST305UNMS (-)HC-TST305UNMS (-)HC-TST314UNMS (-)HC-TST314UNMS

FIGURE 22FLUSH MOUNT ROOM TEMPERATURE SENSOR FOR NETWORKED DDC APPLICATIONS(REPLACES THERMOSTAT)

ROOMTEMPERATURESENSOR WITH

TIMED OVERRIDEBUTTON

ZNS-101

10kΩ room tem-perature sensortransmits room tem-perature to DDCsystem. Times over-ride buttons allowstenant to changefrom unoccupiedtemperature setpointto occupied temper-ature setpoint for apreset time.

ROOMTEMPERATURESENSOR WITH

TIMED OVERRIDEBUTTON AND

STATUS INDICATOR

ZNS-102

10kΩ room tem-perature sensortransmits room tem-perature to DDCsystem. Times over-ride button allowstenant to changefrom unoccupiedtemperature setpointto occupied temper-ature setpoint for apreset time. StatusIndicator Light trans-mits ALARM flashcode to occupiedspace.

ROOMTEMPERATURESENSOR WITH

SETPOINTADJUSTMENT ANDTIMED OVERRIDE

BUTTON

ZNS-103

10kΩ room tem-perature sensor withsetpoint adjustmenttransmits room tem-perature to DDCsystem along withdesired occupiedroom temperaturesetpoint. Timedoverride buttonallows tenant tochange from unoc-cupied temperaturesetpoint to occupiedtemperature setpointfor a preset time.

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X. FURNACE SECTION CONTROLS AND IGNITION SYSTEMNORMAL FURNACE OPERATING SEQUENCEThis unit is equipped with an integrated direct spark ignition control. 1. The thermostat calls for heat. 2. The control board will run a self check to verify that the limit control and manual

reset overtemperature control are closed and that the pressure switch is open. 3. Upon closure of the pressure switch, the control board energizes the induced draft

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

second trial for ignition. 5. Burners ignite and flame sensor proves all burners have lit. 6. The circulating air blower is energized after 30 seconds. 7. The control board enters a normal operation loop in which all safety controls are

monitored continuously. 8. Thermostat is satisfied and opens. 9. The gas valve is de-energized and closes, shutting down the burner flame. 10. The control board will de-energize the inducer after a five second post purge. 11. The circulating air blower is de-energized after 90 seconds.The integrated control is a three ignition system.After a total of three cycles without sensing main burner flame, the system goes into a 100% lockout mode. After one hour, the ignition control repeats the prepurge and ignition cycles for 3 tries and then go into 100% lockout mode again. It continues this sequence of cycles and lockout each hour until ignition is successful or power is inter-rupted. 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 continu-ously when there is power to the control, with or without a call for heat. If the LED is not lit, there is either no power to the control or there is an internal component failure within the control, and the control should be replaced.If the control detects the following failures, the LED will flash on for approximately 1/4 second, then off for 3/4 second for designated failure detections.1 Flash: Failed to detect flame within the three tries for ignition.2 Flash: Pressure switch or induced draft blower problem detected.3 Flash: High limit or auxiliary limit open.4 Flash: Flame sensed and gas valve not energized or flame sensed with no “W” signal.5 Flash: Overtemperature switch open.

OPERATING INSTRUCTIONSThis 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.

WARNINGDO 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.

WARNINGIF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJU-RY OR LOSS OF LIFE.

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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.

BURNERSBurners 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 CONTROLTwo 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 com-bustion 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 SWITCHThis 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, indicat-ing air flow through the combustion chamber.

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

WARNINGDO NOT JUMPER THIS DEVICE! DO NOT reset the over temperature control without taking corrective action to assure that an adequate supply of combus-tion 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.

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

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LIMIT CONTROLThe 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.

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

XI. SYSTEM OPERATING INFORMATIONADVISE 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 ther-

mostat operation. 6. Except for the mounting platform, keep all combustible articles three feet from the

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

unit. Do not operate the unit without all panels and doors securely in place. 8. Do not allow snow or other debris to accumulate in the vicinity of the appliance.

FURNACE SECTION MAINTENANCEThe 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.

2.1 Remove the flue hood from the upper access panel, see Figure 1. 2.2 Remove 2 screws connecting the IDB elbow to the upper access panel. 2.3 Remove 2 screws connecting the upper access panel to the unit body. 2.4 Now, remove the upper access panel.3. Remove the bottom furnace controls access panel and the control box cover.4. Disconnect the gas supply piping from the gas valve.5. Disconnect the wiring to the induced draft blower motor, gas valve, flame sensor,

and flame roll-out control, and ignitor cable. Mark all wires disconnected for proper reconnection.

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

7. Remove the burner tray and the manifold assembly from the unit.8. Remove the screws (5) connecting the induced draft blower to the collector box

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

WARNINGLABEL 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.

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

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

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

11. Direct a water hose into the outlet of the heat exchanger top. Flush the insideof 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 thescrew 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 sup-plier visually inspect the burner flames for the desired flame appearance at the begin-ning 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.

LUBRICATIONIMPORTANT: 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 instruc-tions, the air filters should be kept clean because dirty filters can restrict air flow and the motor depends upon sufficient air flowing across and through it to prevent overheating.

COOLING SECTION MAINTENANCEIt is recommended that at the beginning of each cooling season a qualified installer or service agency inspect and clean the cooling section of this unit. The following areas should be addressed: evaporator coil. condenser coil, condenser fan motor and venturi area.To inspect the evaporator coil:1. Remove the filter access panel and the blower/evaporator coil access panel.

Remove the filters.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.

WARNINGDISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPT-ING MAINTENANCE. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK OR SEVERE PERSONAL INJURY OR DEATH.

WARNINGDISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPT-ING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

WARNINGLABEL 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.

WARNINGHOLES 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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Cleaning Evaporator Coil1. 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 solu-

tion. Rinse the coil thoroughly with water. IMPORTANT: Do not use excessive water pressure. Excessive water pressure can bend the fins and tubing of the coil and leadto 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 ischecked. 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 Venturi1. Remove the compressor access panel. Disconnect the wires to the condenser fan

motor in the control box (see wiring diagram). Remove the wires from the opening in the bottom of the control box.

2. Remove the screws securing the condenser top panel and remove the panel withcondenser fan motor and grille attached.

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

4. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solu-tion. Rinse the coil thoroughly with water. IMPORTANT: Do not use excessive water pressure. Excessive water pressure can bend the fins and tubing of the coil and leadto inadequate unit performance. Be careful not to splash water excessively into unit.

5. The venturi should also be inspected for items of obstruction such as collections ofgrass, dirt or spider webs. Remove any that are present.

6. Inspect the circulating air blower wheel and motor for accumulation of lint, dirt orother 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-assembly1. Place the condenser top panel back on the unit and replace all screws.2. Run the fan motor wires through the hole in the bottom of the control box. Reconnect

fan motor wires per the wiring diagram attached to the back of the cover.3. Replace the filter and blower/evaporator coil access panels.4. Replace the control box cover and controls access panel.5. Restore electrical power to the unit and check for proper operation, especially the

condenser fan motor.

REPLACEMENT PARTSContact your local distributor for a complete parts list.

TROUBLESHOOTINGRefer to Troubleshooting Chart included in this manual.

WIRING DIAGRAMSRefer to the appropriate wiring diagram included in this manual.

CHARGINGRefer to the appropriate charge chart included in this manual.

25

XII. GENERAL DATA - RKKN MODELSNOMINAL SIZES 6 TON [21.1 kW]

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 Large Equipment certification program, which is based on AHRI Standard 340/360.

2. EER and IEER are rated at AHRI conditions and in accordance with DOE test procedures and AHRI Standard 340/360.

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

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

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26

GENERAL DATA - RKKN MODELSNOMINAL SIZES 6 TON [21.1 kW]

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 Large Equipment certification program, which is based on AHRI Standard 340/360.

2. EER and IEER are rated at AHRI conditions and in accordance with DOE test procedures and AHRI Standard 340/360.

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

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

27

GENERAL DATA - RKKN MODELSNOMINAL SIZES 6 TON [21.1 kW]

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 Large Equipment certification program, which is based on AHRI Standard 340/360.

2. EER and IEER are rated at AHRI conditions and in accordance with DOE test procedures and AHRI Standard 340/360.

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

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

28

XIII. MISCELLANEOUS

29

AIR

FLO

W P

ERFO

RM

AN

CE

– 6

TON

[21.

10 k

W] T

HR

EE P

HA

SE B

ELT

DR

IVE

DR

IVE

PAC

KAG

E L

MM

OTO

R H

.P. [

W]

1-1/

2 [1

119]

1-

1/2

[111

9]BL

OW

ER S

HEA

VE

6.4(

PIT

CH

DIA

MET

ER

6.4(

PIT

CH

DIA

MET

ERM

OTO

R S

HEA

VE

2.8(

- 3.

8( P

ITC

H D

IAM

ETER

—AD

J.

3.4(

- 4.

4( P

ITC

H D

IAM

ETER

—AD

J.TU

RN

S O

PEN

0

1 2

3 4

5 6

0 1

2 3

4 5

6R

PM

1100

105

0 10

00

945

895

845

780

1295

123

0 11

95

1145

110

0 10

50 1

000

CA

PACI

TY: 6

TON

[21.10

kW]

VO

LTAG

E 20

8/230

-460 &

575—

3 Pha

seEX

TERN

AL S

TATIC

PRE

SSUR

E—IN

CHES

OF W

ATER

[kPA

]

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.2

1.3

1.4

1.5

[.0

2]

[.05

] [.

07]

[.10

] [.

12]

[.15

] [.

17]

[.20

] [.

22]

[.25

] [.

27]

[.30

] [.

32]

[.35

] [.

37]

RPM

W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

RP

M W

—

—

—

—

—

—

785

560

850

605

895

650

930

670

975

720

1010

76

0 10

50

800

1090

85

0 11

20

890

1150

94

0 11

80

980

1210

10

15 —

—

—

—

78

5 58

0 83

0 61

5 87

5 66

0 91

5 70

0 95

5 74

0 99

0 77

0 10

20

815

1070

85

5 11

05

925

1135

96

0 11

65

1015

11

95

1075

12

20

1115

—

—

775

600

815

625

860

675

895

720

930

750

975

800

1015

84

0 10

50

900

1085

94

0 11

20

1000

11

45

1035

11

75

1090

12

05

1150

12

30

1205

—

—

810

650

840

680

880

740

920

870

955

820

995

880

1030

92

0 10

65

960

1100

10

25

1130

10

60

1160

11

30

1190

11

80

1220

12

50

1240

12

95 78

0 66

0 82

5 70

0 86

5 75

0 91

0 81

0 94

5 85

0 98

0 88

0 10

15

930

1050

10

00

1080

10

45

1120

11

00

1145

11

60

1180

12

20

1205

12

60

1230

13

30

1255

13

80 81

5 72

0 85

5 76

0 89

0 83

0 93

0 87

0 96

0 91

0 10

00

960

1035

10

05

1065

10

60

1100

11

30

1135

11

80

1160

12

50

1200

13

25

1220

13

70

1240

14

25

—

— 84

5 78

0 88

0 83

5 92

0 90

0 95

0 94

5 99

0 99

0 10

25

1050

10

55

1110

10

85

1155

11

20

1215

11

50

1335

11

85

1355

12

20

1430

12

35

1470

12

55

1525

—

—

870

855

910

915

945

975

980

1020

10

20

1085

10

45

1140

10

80

1200

11

10

1260

11

35

1300

11

75

1390

12

05

1450

12

30

1530

12

50

1580

12

95

1630

—

—

900

945

940

1005

97

5 10

60

1005

11

05

1040

11

75

1065

12

25

1100

12

95

1135

13

50

1165

14

25

1200

15

05

1225

15

80

1240

16

35

1270

16

65

—

—

—

—93

0 10

75

970

1100

10

00

1145

10

30

1200

10

60

1260

10

90

1335

11

25

1395

11

55

1470

11

85

1540

12

20

1615

12

35

1675

12

55

1730

—

—

—

—

—

—

960

1150

10

00

1195

10

25

1240

10

55

1305

10

85

1350

11

15

1440

11

45

1510

11

80

1560

12

10

1620

12

35

1740

12

50

1775

12

95

1825

—

—

—

—

—

—

1800

[850

]19

00 [8

97]

2000

[944

]21

00 [9

91]

2200

[103

8]23

00 [1

085]

2400

[113

3]25

00 [1

180]

2600

[122

7]27

00 [1

274

2800

[132

1]

AIR

FLOW

CFM

[L/s]

NOTE

: L-D

rive

left o

f bold

line,

M-D

rive

right

of b

old lin

e.

NOTE

S: 1

. Fa

ctory

shea

ve se

ttings

are

show

n in

bold

print

.

2. R

e-ad

justm

ent o

f she

ave

requ

ired

to a

chiev

e ra

ted

airflo

w at

ARI

mini

mum

E.S

.P.

3.

Do

not o

pera

te a

bove

blow

er R

PM sh

own

as m

otor

ove

rload

ing w

ill oc

cur.

[ ]

Des

igna

tes

Met

ric C

onve

rsio

ns

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

.035

.040

.060

.070

.085

.100

.110

120

.125

.130

.055

.060

.066

.072

.080

.086

.093

.100

.107

.115

.05

.06

.07

.08

.09

.10

.11

.12

.13

.15

NO

TES:

4. B

HP

= W

ATT

S X

MO

TOR

EFF.

5. A

DD

CO

MPO

NEN

T RE

SIST

AN

CE T

O D

UCT

STA

TIC

TO D

ETER

MIN

E TO

TAL

E.S.

P.74

6

COM

PON

ENT

RESI

STA

NCE

- IN

CHES

WA

TER

WET

CO

ILD

OW

NFL

OW

ECO

NO

MIZ

ER

STA

ND

ARD

IND

OO

R A

IRFL

OW

- CF

M

COM

PON

ENT

AIR

RES

ISTA

NCE

1. P

ERFO

RMA

NCE

SH

OW

N W

ITH

DRY

CO

IL &

STA

ND

ARD

1"

FILT

ERS

2. S

TAN

DA

RD C

FM @

.075

LBS

./CU

. FT.

3. M

OTO

R EF

FICI

ENCY

= 8

0%

R.A

. DA

MPE

R

30

FIGURE 23WIRING DIAGRAMM

AT

ER

IAL:

PR

INT

ING

INS

TR

UC

TIO

NS

:N

O R

EVIS

ION

TO

DES

IGN

, MAT

ERIA

L, T

OO

LIN

G, O

R P

RO

CES

S IS

AC

CEP

TABL

EW

ITH

OU

T PR

IOR

APP

RO

VAL

FRO

M R

HEE

M T

HR

OU

GH

AN

AU

THO

RIZ

ED C

HAN

GE

NO

TIC

E, A

REV

ISED

EN

GIN

EER

ING

SPE

CIF

ICAT

ION

AN

D A

RES

AMPL

ING

OF

PAR

TS. T

HE

SUPP

LIER

IS R

ESPO

NSI

BLE

FOR

NO

TIFY

ING

RH

EEM

R &

D A

ND

PUR

CH

ASIN

G D

EPAR

TMEN

TS IN

WR

ITIN

G O

F AN

Y C

HAN

GES

AFF

ECTI

NG

PR

OD

UC

T Q

UAL

ITY,

PER

FOR

MAN

CE,

REL

IABI

LITY

, PAC

KAG

ING

, DEL

IVER

Y O

RW

OR

KMAN

SHIP

. “AN

Y D

OC

UM

ENTS

REF

ERR

ED T

O O

N T

HIS

DR

AWIN

G A

RE

INC

LUD

ED IN

TH

E SP

ECIF

ICAT

ION

S FO

R T

HIS

CO

MPO

NEN

T”.

NO

TE

SC

OM

PO

NE

NT

CO

DE

SW

IRE

CO

LO

R C

OD

EBK......BLA

CK

BR......BROWN

BL.......BLU

E

G........G

REEN

GY......GRAY

O........O

RANGE

PR......PURPLE

R........R

ED

W.......W

HITE

Y........YELL

OW

WIR

ING

INFO

RM

AT

ION

WAR

NING

-CAB

INET

MUST

BE

PERM

ANEN

TLY

GRO

UNDED

AND C

ONFO

RM T

O I.E.C.,

N.E.C.,

C.E.C.,

NAT

IONAL

WIRING R

EGULA

TIONS, A

ND L

OCAL

CODES

AS

APPL

ICAB

LE.

REP

LACEM

ENT

WIRE

-MUST

BE

THE

SAME

SIZE

AND T

YPE

OF

INSU

LATION A

S ORIGINAL

(105

C. MIN.)

-FIELD

INST

ALLE

D-FAC

TORY

STAN

DAR

DLO

W VO

LTAG

E

-FIELD

INST

ALLE

D-FAC

TORY

OPT

ION

-FAC

TORY

STAN

DAR

DLINE

VOLT

AGE

ORIG

INAL

RELE

ASE

NO.:

ELE

CTR

ICAL

WIRING D

IAGRAM

MODELE

DBY:

CHECKED:

APPROVED:

REV:

PART

NO.:

DATE

:

AD

S-4

574-

02, P

RE

SS

UR

E

SE

NS

ITIV

E, A

DH

ES

IVE

BA

CK

ED

MA

TER

IAL

MAKE E

XACTL

Y

WITH B

LACK P

RINTING

Y-065

5S36

8

90-235

96-61

09-11-18

03

208

/ 23

0, 2

-STG

3 P

HASE, 60

HZ

BELT

DRIVE

1. CONNECTO

RS S

UITABLE

FOR U

SE W

ITH C

OPPER

CONDUCTO

RS O

NLY

. 2

. COMPRESSOR M

OTO

R T

HERMALL

Y P

ROTE

CTE

D. ALL

3 P

HASE

MODELS

ARE P

ROTE

CTE

D U

NDER P

RIM

ARY S

INGLE

PHASE C

ONDITIO

NS.

3. CONTR

OL

TRANSFO

RMER F

ACTO

RY W

IRED F

OR 2

30 V

OLT

OPERATION. MOVE B

LACK W

IRE T

O 2

08 V

OLT

T TA

P F

OR

20

8 VOLT

OPERATION.

4. CONTA

CTO

R F

ACTO

RY W

IRED. CONNECT

FIELD

WIRE T

O FA

CTO

RY S

UPPLIED C

ONTA

CTO

R IN E

LECTR

ICAL

BOX.

5. LO

W V

OLT

AGE C

IRCUIT IS N

.E.C. CLA

SS 2

WITH A

CLA

SS 2

TR

ANSFO

RMER. 24

V, 50

/60

HZ S

UPPLIED.

6. CONNECT

FIELD

WIRING IN G

ROUNDED R

AIN T

IGHT

CONDUIT

TO

60

HZ F

USED D

ISCONNECT.

7. ONLY

ONE M

RLC

IS N

EEDED O

N T

HE 8

0,00

0 INPUT

UNIT.

8. MOTO

R F

ACTO

RY W

IRED F

OR C

ORRECT

SPEED.

9. WIRED F

ROM P

L2 (6

& 9

) GO T

O T

HE M

IXED A

IR S

ENSOR O

N TH

E O

PTIONAL

ECONOMIZER.

10. REMOVE J

UMPER F

OR F

IELD

INSTA

LLED O

CCUPANCY R

ELA

Y.

ALC

BC

BR

CC

COMP

CT

DISC

FLMS

FT GFC

OGL

GND

GV

HPC

IBM

IDM

IFC

LAC

LC LPC

MRLC

NPC

OFM

PL

RC

SD

SE

TDC

WN

AUX. LIMIT C

ONTR

OL

BLO

WER C

ONTA

CTO

RBLO

WER R

ELA

YCOMPRESSOR C

ONTA

CTO

RCOMPRESSOR

CONTR

OL

TRANSFO

RMER

DISCONNECT

SWITCH

FLAME S

ENSOR

FREEZE S

TAT

GROUND F

AULT

CONVENIENCE O

UTL

ET

GROUND L

UG

GROUND

GAS V

ALV

EHIG

H P

RESSURE C

ONTR

OL

INDOOR B

LOWER M

OTO

R

INDUCED D

RAFT

MOTO

RINTE

GRATE

D F

URNACE C

ONTR

OL

LOW A

MBIENT

COOLING C

ONTR

OL

LIMIT C

ONTR

OL

LOW P

RESSURE C

ONTR

OL

MANUAL

RESET

LIMIT C

ONTR

OL

NEGATIVE P

RESSURE C

ONTR

OL

OUTD

OOR F

AN M

OTO

RPLU

GRUN C

APACITOR

SMOKE D

ETE

CTO

RSPARK E

LECTR

ODE

TIME D

ELA

Y C

ONTR

OL

WIRE N

UT

VYM

(J3)

8.0

IN. x

10.75

IN. WHITE B

ACKGROUND

1 2 3 4 5

PL-

9

1 2 3 4

PL-

101 2 3 4

PL-

11

Y2

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

18O

19O

255

OP

L-7

PL-

825

6

11 12

BR BL

14P

RP

R13

PL-

1

1615

YY

16A

10 RS

EE

NO

TE 7

O2

1

PL3

PL4

246

R

BR

261 R

24V

Y 825

0

249

R

61 GY

LC

RY

1G

W

PR

/WB

RR R

YG

Y

LC

Y1

GW

Y2

Y2

O20B

R

R71

C2 O

PL-

2

PL-

5

GY6

R24V

PL-

62

R/W

SE

EN

OTE

10

PL-

6140

41

SE

EN

OTE

9

OY

R

OO

Y

Y

BL

YY7AP

L-67C

Y

BL

BR

O

185

BR

GN

D

GL

BR

9AY

O267B

2L1

065

Y

2L2

2L3

BL

2T3

2T2

2T1

R

5L1

5L2

5L3

PR

R

L2S

L3R

L1C

237

Y

T2

T3

T1CO

MP

BR

C

GY

GW

WN

9

G

BK

BL

2T3

2T2

2T1

R

GN

D

TO VFD KIT

(OP

T)

PL-

9TO VF

DKI

T(O

PT)

5 4

3

2

1

COM

P24

V

BK

BL

BR

134

2

101

Y

Y

BK

32

101Y

177

R

BR

BR

03DELE

TED N

OTE

10.

VYM

R-107

4S01

310

-15-18

02CORRECTE

D N

UMBER IN B

LOWER R

ELA

Y “2” W

AS “4” A

ND

“4” WAS “2”.

VYM

Y-065

5S37

910

-03-18

01CORRECTE

D C

OMPONENT

CODE

VYM

Y-065

5S37

509

-27-18

31

FIGURE 24WIRING DIAGRAM

03VYM

R-107

4S01

901

-14-19

REVISED P

RINTING INSTR

UCTIONS “8.0

IN X

10.75

IN” WAS

“10.0

IN X

13.0

IN.”

MA

TE

RIA

L:

PR

INT

ING

INS

TR

UC

TIO

NS

:N

O R

EVIS

ION

TO

DES

IGN

, MAT

ERIA

L, T

OO

LIN

G, O

R P

RO

CES

S IS

AC

CEP

TABL

EW

ITH

OU

T PR

IOR

APP

RO

VAL

FRO

M R

HEE

M T

HR

OU

GH

AN

AU

THO

RIZ

ED C

HAN

GE

NO

TIC

E, A

REV

ISED

EN

GIN

EER

ING

SPE

CIF

ICAT

ION

AN

D A

RES

AMPL

ING

OF

PAR

TS. T

HE

SUPP

LIER

IS R

ESPO

NSI

BLE

FOR

NO

TIFY

ING

RH

EEM

R &

D A

ND

PUR

CH

ASIN

G D

EPAR

TMEN

TS IN

WR

ITIN

G O

F AN

Y C

HAN

GES

AFF

ECTI

NG

PR

OD

UC

T Q

UAL

ITY,

PER

FOR

MAN

CE,

REL

IABI

LITY

, PAC

KAG

ING

, DEL

IVER

Y O

RW

OR

KMAN

SHIP

. “AN

Y D

OC

UM

ENTS

REF

ERR

ED T

O O

N T

HIS

DR

AWIN

G A

RE

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TH

E SP

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S FO

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CO

MPO

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NO

TE

SC

OM

PO

NE

NT

CO

DE

SW

IRE

CO

LO

R C

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EBK......BLA

CK

BR......BROWN

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E

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REEN

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ED

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WIR

ING

INFO

RM

AT

ION

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NING

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INET

MUST

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PERM

ANEN

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GRO

UNDED

AND C

ONFO

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O I.E.C.,

N.E.C.,

C.E.C.,

NAT

IONAL

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EGULA

TIONS, A

ND L

OCAL

CODES

AS

APPL

ICAB

LE.

REP

LACEM

ENT

WIRE

-MUST

BE

THE

SAME

SIZE

AND T

YPE

OF

INSU

LATION A

S ORIGINAL

(105

C. MIN.)

-FIELD

INST

ALLE

D-FAC

TORY

STAN

DAR

DLO

W VO

LTAG

E

-FIELD

INST

ALLE

D-FAC

TORY

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ION

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STAN

DAR

DLINE

VOLT

AGE

ORIG

INAL

RELE

ASE

NO.:

ELE

CTR

ICAL

WIRING D

IAGRAM

MODELE

DBY:

CHECKED:

APPROVED:

REV:

PART

NO.:

DATE

:

AD

S-4

574-

02, P

RE

SS

UR

E

SE

NS

ITIV

E, A

DH

ES

IVE

BA

CK

ED

MA

TER

IAL

MAKE E

XACTL

Y8.0

IN X

10.75

IN. WHITE B

ACKGROUND

WITH B

LACK P

RINTING

Y-065

5S36

8

90-235

96-62

09-11-18

03

460

2-STG

, 3

PHASE, 60

HZ

BELT

DRIVE

1. CONNECTO

RS S

UITABLE

FOR U

SE W

ITH C

OPPER

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RS O

NLY

. 2

. COMPRESSOR M

OTO

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D. ALL

3 P

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ARE P

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D U

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INGLE

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3. CONTA

CTO

R F

ACTO

RY W

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SS 2

WITH A

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RMER. 24

V, 50

/60

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5. CONNECT

FIELD

WIRING IN G

ROUNDED R

AIN T

IGHT

CONDUIT

TO 6

0 HZ F

USED D

ISCONNECT.

6. ONLY

ONE M

RLC

IS N

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N T

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0,00

0 INPUT

UNIT.

7. WIRED F

ROM P

L2 (6

& 9

) GO T

O T

HE M

IXED A

IR S

ENSOR O

N

TH

E O

PTIONAL

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8. REMOVE J

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INSTA

LLED O

CCUPANCY R

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Y.

ALC

BC

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COMP

CT

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AN M

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UT

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BL

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OTE

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01CORRECTE

D C

OMPONENT

CODE

VYM

Y-065

5S37

509

-27-18

32

FIGURE 25WIRING DIAGRAM

04

VYM

R-1074S019

01-14-19

REVISED P

RINTING INSTRUCTIO

NS “8.0

IN X

10.75

IN” WAS

“10.0

IN X

13.0

IN.”

03

VYM

Y-0655S391

10-24-18

REVISED W

IRE A

TTACHED T

O IFC T

O S

HOW INSULA

TED Q

.C.

02

VYM

R-1074S007

06-21-18

REMOVED “44

” AND “45

” FROM O

FM W

IRES

MA

TE

RIA

L:

PR

INT

ING

INS

TR

UC

TIO

NS

:N

O R

EVIS

ION

TO

DES

IGN

, MAT

ERIA

L, T

OO

LIN

G, O

R P

RO

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S IS

AC

CEP

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OU

T PR

IOR

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VAL

FRO

M R

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M T

HR

OU

GH

AN

AU

THO

RIZ

ED C

HAN

GE

NO

TIC

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REV

ISED

EN

GIN

EER

ING

SPE

CIF

ICAT

ION

AN

D A

RES

AMPL

ING

OF

PAR

TS. T

HE

SUPP

LIER

IS R

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NSI

BLE

FOR

NO

TIFY

ING

RH

EEM

R &

D A

ND

PUR

CH

ASIN

G D

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WR

ITIN

G O

F AN

Y C

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GES

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NG

PR

OD

UC

T Q

UAL

ITY,

PER

FOR

MAN

CE,

REL

IABI

LITY

, PAC

KAG

ING

, DEL

IVER

Y O

RW

OR

KMAN

SHIP

. “AN

Y D

OC

UM

ENTS

REF

ERR

ED T

O O

N T

HIS

DR

AWIN

G A

RE

INC

LUD

ED IN

TH

E SP

ECIF

ICAT

ION

S FO

R T

HIS

CO

MPO

NEN

T”.

NO

TE

SC

OM

PO

NE

NT

CO

DE

SW

IRE

CO

LO

R C

OD

EBK......BLA

CK

BR......BROWN

BL.......BLU

E

G........G

REEN

GY......GRAY

O........O

RANGE

PR......PURPLE

R........R

ED

W.......W

HITE

Y........YELL

OW

WIR

ING

INFO

RM

AT

ION

WAR

NING

-CAB

INET

MUST

BE

PERM

ANEN

TLY

GRO

UNDED

AND C

ONFO

RM T

O I.E.C.,

N.E.C.,

C.E.C.,

NAT

IONAL

WIRING R

EGULA

TIONS, A

ND L

OCAL

CODES

AS

APPL

ICAB

LE.

REP

LACEM

ENT

WIRE

-MUST

BE

THE

SAME

SIZE

AND T

YPE

OF

INSU

LATION A

S ORIGINAL

(105

C. MIN.)

-FIELD

INST

ALLE

D-FAC

TORY

STAN

DAR

DLO

W VO

LTAG

E

-FIELD

INST

ALLE

D-FAC

TORY

OPT

ION

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STAN

DAR

DLINE

VOLT

AGE

ORIG

INAL

RELE

ASE

NO.:

ELE

CTR

ICAL

WIRING D

IAGRAM

MODELE

DBY:

CHECKED:

APPROVED:

REV:

PART

NO.:

DATE

:

AD

S-4

574-

02, P

RE

SS

UR

E

SE

NS

ITIV

E, A

DH

ES

IVE

BA

CK

ED

MA

TER

IAL

MAKE E

XACTL

Y8.0

IN X

10.75

IN. WHITE B

ACKGROUND

WITH B

LACK P

RINTING

R-107

4S00

1

90-235

96-57

03-05-18

04

575, 2

-STA

GE, 3

PHASE, 60

HZ

BELT

DRIVE

1. C

ONNECTO

RS S

UITABLE

FOR U

SE W

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RS O

NLY

.2. C

OMPRESSOR M

OTO

R T

HERMALL

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MODELS

ARE P

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INGLE

PHASE C

ONDITIO

NS.

3. C

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RMER F

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IRED F

OR 2

30 V

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LACK W

IRE T

O 2

08 V

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TAP F

OR

208

VOLT

OPERATION.

4. C

ONTA

CTO

R F

ACTO

RY W

IRED. CONNECT

FIELD

WIRE T

OFA

CTO

RY S

UPPLIED C

ONTA

CTO

R IN E

LECTR

ICAL

BOX.

5. L

OW V

OLT

AGE C

IRCUIT IS N

.E.C. CLA

SS 2

WITH A

CLA

SS 2

TRANSFO

RMER. 24

V, 50

/60

HZ S

UPPLIED.

6. C

ONNECT

FIELD

WIRING IN G

ROUNDED R

AIN T

IGHT

CONDUIT

TO 6

0 HZ F

USED D

ISCONNECT.

7. O

NLY

ONE M

RLC

IS N

EEDED O

N T

HE 8

0,00

0 INPUT

UNIT.

8. P

OWER T

RANSFO

RMER P

RIM

ARY L

EADS: BLU

E-C

OMMON,

RED-575

V 5

0 HZ / 4

15V 5

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9. W

IRED F

ROM P

L2 (7

& 8

) GO T

O T

HE M

IXED A

IR S

ENSOR O

N TH

E O

PTIONAL

ECONOMIZER.

10. Y2

IS U

SED O

NLY

FOR T

HE O

PTIONAL

ECONOMIZER.

11. REMOVE J

UMPER F

OR F

IELD

INSTA

LLED O

CCUPANCY R

ELA

Y.

ALC

BC

CC

COMP

CT

DISC

FLMS

FT GFC

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GND

GV

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IBM

IDM

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LC LPC

MRLC

NPC

OFM

PL

RC

SD

SE

TDC

WN

AUX. LIMIT C

ONTR

OL

BLO

WER C

ONTA

CTO

RCOMPRESSOR C

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CTO

RCOMPRESSOR

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RMER

DISCONNECT

SWITCH

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ENSOR

FREEZE S

TAT

GROUND F

AULT

CONVENIENCE O

UTL

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UG

GROUND

GAS V

ALV

EHIG

H P

RESSURE C

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INDOOR B

LOWER M

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MOTO

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OL

LOW A

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OL

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MANUAL

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RSPARK E

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TIME D

ELA

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OL

WIRE N

UT

TCJW

(J3)

T2

T3

T1CO

MP

BL

OB

L

WN

9

BL

COM

P24

V

33

FIGURE 26WIRING DIAGRAM - DDC

MAKE E

XACTL

Y8.00

IN X

10.75

IN. WHITE B

ACKGROUND

WITH B

LACK P

RINTING

AD

S-4

574-

02, P

RE

SS

UR

E

SE

NS

ITIV

E, A

DH

ES

IVE

BA

CK

ED

MA

TER

IAL

THE

DO

TTED

BO

X N

EAR

TH

E D

RAW

ING

NU

MBE

R R

EPR

ESEN

TS A

.25

X .2

5 2D

DAT

A M

ATR

IX.

SEE

ADS-

1046

69-0

1 FO

R D

ATA

MAT

RIX

SPE

CS.

NO

TE:

MA

TE

RIA

L:

PR

INT

ING

INS

TR

UC

TIO

NS

:N

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ION

TO

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IGN

, MAT

ERIA

L, T

OO

LIN

G, O

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AC

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ITH

OU

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L FR

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RH

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TH

RO

UG

H A

N A

UTH

OR

IZED

CH

ANG

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OTI

CE,

A R

EVIS

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ION

AN

D A

RES

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OF

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TS. T

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LIER

IS R

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FOR

NO

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RC

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UAL

ITY,

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LITY

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KAG

ING

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R W

OR

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HE

SPEC

IFIC

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NS

FOR

THIS

CO

MPO

NEN

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A

DS

-457

4-02

, PR

ES

SU

RE

S

EN

SIT

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, AD

HE

SIV

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AC

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D M

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WITH B

LACK P

RINTING

NO

TE

SC

OM

PO

NE

NT

CO

DE

SW

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CO

LO

R C

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EBK......BLACK

BR......BROWN

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W.......W

HITE

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WIR

ING

INFO

RM

AT

ION

WAR

NING

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INET

MUST

BE

PERM

ANEN

TLY

GRO

UNDED

AND C

ONFO

RM T

O I.E.C.,

N.E.C.,

C.E.C.,

NAT

IONAL

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EGULA

TIONS, A

ND L

OCAL

CODES

AS

APPL

ICAB

LE.

REP

LACEM

ENT

WIRE

-MUST

BE

THE

SAME

SIZE

AND T

YPE

OF

INSU

LATION A

S ORIGINAL

(105

C. MIN.)

-FIELD

INST

ALLE

D

-FAC

TORY

STAN

DAR

DLO

W VO

LTAG

E

-FIELD

INST

ALLE

D-FAC

TORY

OPT

ION

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STAN

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DLINE

VOLT

AGE

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TORY

OPT

ION

ORIG

INAL R

ELEASE N

O.:

208-230/460V 3

PH, 60HZ.

GAS/ELECTRIC W

/RTU-C

6 T

ON - 2

STAGE

ELECTRICAL W

IRING D

IAGRAM

MODELED B

Y:

CHECKED:

APPROVED:

REV:

PART N

O.:

DATE: 90-23596-60

01

R-1074S009

09-07-18

VYM

BL

BL

BL

BL

GL

G

B AG

ND

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4 3 2 112

34

BR

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R-1074S017

01-07-19

01

ADDED J

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6 TERMINALS

9 A

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0 , 13

AND 1

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DDED R

1

TO T

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3 A

ND 4

.TCJW

34

FIGURE 27WIRING DIAGRAM - DDC

MAKE E

XACTL

Y8.00

IN X

10.75

IN. WHITE B

ACKGROUND

WITH B

LACK P

RINTING

AD

S-4

574-

02, P

RE

SS

UR

E

SE

NS

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DH

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MA

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MBE

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DAT

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IX.

SEE

ADS-

1046

69-0

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R D

ATA

MAT

RIX

SPE

CS.

NO

TE:

MA

TE

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L:

PR

INT

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TO

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ANG

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RES

AMPL

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OF

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TS. T

HE

SUPP

LIER

IS R

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D A

ND

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RC

HAS

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OF

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T Q

UAL

ITY,

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FOR

MAN

CE,

REL

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KAG

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, DEL

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Y O

R W

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DED

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FOR

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A

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4-02

, PR

ES

SU

RE

S

EN

SIT

IVE

, AD

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AC

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WITH B

LACK P

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NO

TE

SC

OM

PO

NE

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WIR

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OR

CO

DE

BK......BLA

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BR......BROWN

BL.......BLU

E

G........G

REEN

GY......GRAY

O........O

RANGE

PR......PURPLE

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ED

W.......W

HITE

Y........YELL

OW

WIR

ING

INFO

RM

AT

ION

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NING

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INET

MUST

BE

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35

FIGURE 28SYSTEM CHARGE CHART

SYSTEM CHARGE CHART - REFRIGERANT 410A

92-104690-04-01

OUTDOOR DRY BULB

115 508 / 143105 443 / 14295 385 / 14185 333 / 13875 281 /65 243 / 13155 205 / 128

1151059585756555

NOTICE:

issue. Refer to unit Installation troubleshooting section for further support.

• Confirm the indoor supply air flow is correct, reference rated CFM in the unit Specification

• Allow the system to run long enough for temperatures and pressures to stabilize.Sheets.

• It is required to fine tune unit charge. Indoor ambient temperature must be between72°F and 82°F dry bulb at the indoor coil.

• Measure liquid line temperature at four (4) inches prior to metering device.

• If obtaining rated sub-cooling values causes liquid/vapor pressures that are significantlydifferent (>20 psig) from those listed on the table, there may be a component or air flow

• Sub-cooling tolerance is +/- 1.5°F

Liquid Pressure / Vapor Pressure

910

6 -TON

171614118

Pressure Requirements - Gross Charge Check ONLY

Sub Cooling Requirements - Final Charge Verification

136

36

WARNING!

COOLING TROUBLESHOOTING CHART

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

SYMPTOM POSSIBLE CAUSE REMEDY

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

• Thermostat out of calibration – set too high • Reset• Failed contactor • Check for 24 volts at contactor coil – replace if contacts are

open• Blown fuses • Replace fuses• Transformer defective • Check wiring-replace transformer• High pressure control open (if provided) • Reset-also see high head pressure remedy –

The high pressure control opens at 610 PSIG• Interconnecting low voltage wiring damaged • Replace thermostat wiring

Condenser fan runs, • Run or start capacitor failed (single phase only) • Replacecompressor doesn’t • Start relay defective (single phase only) • Replace

• Loose connection • Check for correct voltage at compressor –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 ratingplate volts when unit is operating.

• Low voltage condition • Add start kit components

Insufficient cooling • Improperly sized unit • Recalculate load• Improper airflow • Check – should be approximately 400 CFM per ton.• Incorrect refrigerant charge • Charge per procedure attached to unit service panel.• Air, non-condensibles or moisture in system • Recover refrigerant, evacuate & recharge, add filter drier• Incorrect voltage • At compressor terminals, voltage must be within 10% of rating

plate volts when unit is operating.

Compressor short cycles • Incorrect voltage • At compressor terminals, voltage must be ± 10% ofnameplate marking when unit is operating.

• Defective overload protector • Replace – check for correct voltage• Refrigerant undercharge • Add refrigerant

Registers sweat • Low evaporator airflow • Increase speed of blower or reduce restriction – replace airfilter

High head – low vapor pressures • Restriction in liquid line, expansion device or filter drier • Remove or replace defective component• Flow check piston size too small • Change to correct size piston• Incorrect capillary tubes • Change coil assembly• TXV does not open • Replace TXV

High head – high or normal vapor • Dirty condenser coil • Clean coil pressure – Cooling mode • Refrigerant overcharge • Correct system charge

• Condenser fan not running • Repair or replace• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

Low head-high vapor pressures • Defective Compressor valves • Replace compressor• Incorrect capillary tubes • Replace coil assembly

Low vapor – cool compressor – • Low evaporator airflow • Increase speed of blower or reduce restriction – replace airiced evaporator coil filter

• Operating below 65°F outdoors • Add Low Ambient Kit• Moisture in system • Recover refrigerant – evacuate & recharge – add filter drier

High vapor pressure • Excessive load • Recheck load calculation• Defective compressor • Replace

Fluctuating head & vapor • TXV hunting • Check TXV bulb clamp – check air distribution on coil – replacepressures TXV

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

Gurgle or pulsing noise at • Air or non-condensibles in system • Recover refrigerant, evacuate & rechargeexpansion device or liquid line

Circulating air blower & inducer • Manual reset overtemperature control • Reset or replacerun continuously, • tripped

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

37

FURNACE TROUBLESHOOTING GUIDE(COMBINATION HEATING AND COOLING UNITS WITH DIRECT SPARK IGNITION)

SET THERMOSTAT TOCALL FOR HEAT

SET FAN SWITCH TO AUTO

START

WARNINGDISCONNECT POWER BEFORESERVICING.SERVICE MUST BE BY A TRAINED,QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGELINE VOLTAGECONNECTIONS

FLOW CHART CONTINUED ON NEXT PAGE

NO

YESYES

YES

YES

NO

NO

NO

!

INDUCED DRAFT BLOWERMOTOR STARTS

15 SECOND PREPURGE

REPLACE INTEGRATEDCONTROL BOARD (IFC)

REPLACE INDUCED DRAFT BLOWER

NO

REPLACE NEGATIVE PRESSURE SWITCH

REPLACE INTEGRATED CONTROL BOARD (IFC)

IF WIRING IS OK

CHECK FOR EXHAUST, INTAKE OR HEAT

EXCHANGER BLOCKAGE AND RESET CONTROLNO

REPLACE IGNITION CONTROL

YES

REPLACE VALVE

• CHECK LINE VOLTAGE TO CONTROL BOARD• CHECK LOW VOLTAGE TRANSFORMER• CHECK WIRING• CHECK FOR 208-230 VAC TO IOM MOTOR

• CHECK IGNITOR CABLE• CHECK SPARK IGNITOR POSITION AND CONDITION

• IS NEGATIVE PRESSURE SWITCH CLOSED?

• CHECK FOR OPEN ROLL-OUT CONTROL

• CHECK FOR OPEN LIMIT

• CHECK IGNITION CONTROL CHASSIS GROUND WIRE

• CHECK WIRING

• CHECK INLET GAS PRESSURE

• CHECK 24 VOLTS TO GAS VALVE

• CHECK FOR GAS FLOW TO AND FROM VALVE

• CHECK BURNER CARRYOVER

NOTE: THE SYSTEM WILL ATTEMPT TO LIGHT 3 TIMES WITH A 60 SECOND INTER-PURGE BETWEEN TRIES. IF AFTER THE THIRD TIME THE BURNERS

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

YES

YES

IGNITOR SPARKS

MAIN BURNER LIGHTS

NO

• CHECK NEGATIVE PRESSURE SWITCH SENSING TUBE• CHECK FOR EXHAUST BLOCKAGE

YES

YES

YES

REPLACE IGNITOR/CABLE ASSEMBLY

REPLACE LIMITIF UNIT IS COLD

NO

38 *97B0055N23* 97B0055N23 | CM 0218

NOTE: IF THE SYSTEM GOES INTO LOCKOUT, WAIT30 SECONDS AND RESET THE SYSTEM.

• CHECK FLAME SENSOR POSITION AND CONDITION

• CLEAN FLAME SENSOR WITH STEEL WOOL

• CHECK FLAME SENSOR WIRES AND CONNECTIONS

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

• CHECK CAPACITOR

YES

YES

NOMAIN BURNER FLAME SUSTAINED

YES

NOINDOOR BLOWER MOTOR STARTSAFTER 30 SECONDS

REPLACE SENSOR

NO REPLACE INTEGRATED CONTROL BOARD (IFC)

NO REPLACE INTEGRATED CONTROL BOARD (IFC)

NO

REPLACE IGNITION CONTROL

YES

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 THERMOSTATAND WIRING. IF OK, THEN REPLACE VALVE

• CHECK FOR OPEN LIMIT OR ROLL-OUT CONTROL

YES

NOSYSTEM RUNS UNTILCALL FOR HEAT ENDS

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

• CHECK FOR DIRTY FILTERS• CHECK FOR RESTRICTED AIRFLOW

TROUBLESHOOTING ENDS

REPEAT PROCEDURE UNTIL TROUBLE FREEOPERATION IS OBTAINED.

YES

NOTURN THERMOSTAT OFFVALVE SHUTS OFFFLAME SHUTS OFF

YES

NOINDUCED DRAFT MOTOR STOPSAFTER 5 SECOND POSTPURGE

YES

YES

• CHECK FOR DIRTY FILTERS• CHECK FOR RESTRICTED

AIR-FLOW

CHECK FOR EXHAUST, INTAKE OR HEAT

EXCHANGER BLOCKAGE.CLEAR BLOCKAGE AND

RESET CONTROL

YES

NOINDOOR BLOWER MOTOR STOPSAFTER 90 SECONDS