AE-Air IOM8601 Vertical Packaged Gas Heat Instruction Manual
- June 9, 2024
- AE-Air
Table of Contents
IOM8601 Vertical Packaged Gas Heat
Installation, Operation, & Maintenance Manual
IOM 8601 Rev. A 04/2022
Vertical Packaged Gas Heat / Electric Cooling Unit
CATEGORY III TYPE MSP 11 EER
ATTENTION:
Installer: Affix these instructions on or adjacent to the furnace. Consumer:
Read these instructions thoroughly and retain all manuals for future
reference.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow all safety warning exactly may result in property damage,
serious personal injury, or death.
DO NOT store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS: DO NOT attempt to ignite any appliance. DO NOT
touch any electrical switch DO NOT use a phone Leave the building immediately.
Immediately call gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions. If you cannot contact your gas supplier, call the
fire department.
Installation and service must be performed by either a qualified installer,
a service agency, or the gas supplier.
THERMA-PAK IOM
COPYRIGHT
AE-Air works to continually improve its products. It reserves the right to
change design and specifications without notice. The warranty may be void
unless the Startup & Performance Checklist is completed and returned to the
warrantor. If the THERMA-PAK unit is not installed properly, the warranty will
be void, as the manufacturer cannot be held accountable for problems that stem
from improper installation. ©2022 AE-Air, 8273 Moberly Lane, Dallas, TX 75227
WARNING TO INSTALLER, SERVICE PERSONNEL AND OWNER Altering the product
or replacing parts with non-authorized factory parts voids all warranty or
implied warranty and may result in adverse operational performance and/or a
possible hazardous safety condition to service personnel
and occupants. Company employees and/or contractors are not authorized to
waive this warning.
Therma PAK Series IOM (Rev. A 04/21)
Page2 of 57
THERMA-PAK IOM
TABLE OF CONTENTS
SAFETY CONSIDERATIONS MODEL NOMENCLATURE GENERAL INFORMATION INTRODUCTION
STORAGE SHIPPING & PACKAGE LIST UNIT INSPECTION CHECKLIST UNIT DIMENSIONAL
DATA UNIT PHYSICAL DATA ELECTRICAL DATA INSTALLATION
REQUIREMENTS INSTALLATION PRECAUTIONS UNIT LOCATION UNIT CLEARANCE
REQUIREMENTS VENT CLEARANCES REMOVAL OF A UNIT FROM A COMMON VENTING SYSTEM
WALL SLEEVE INSTALLATION PACKAGED UNIT INSTALLATION DUCTWORK CONDENSATE DRAIN
VENTING AIR FILTER COMBUSTION AIR GAS PIPING & CONNECTION LEAK TESTING
ELECTRICAL CONTROLS AIRFLOW HEATING OPERATIONS COOLING OPERATIONS LOCATION OF
MAJOR COMPONENTS REPLACEMENT PARTS WIRING DIAGRAMS CIRCUIT SCHEMATIC STARTUP
INSTRUCTIONS TROUBLESHOOTING HEATING COOLING MAINTENANCE & SERVICE HEATING
COOLING STARTUP & PERFORMANCE CHECKLIST NOTES
Therma PAK Series IOM (Rev. A 04/21)
4-6 7 8 8 8 9
10 11 12 13 13-25 13 13-14 14 15 16 17 18 19-20 21 21 22 23 24 25 25 26 27-29
30-31 32-35 36 37-38 39 40-41 42 42-43 44-47 44-46 48 49-54 49-52 53 54-55 56
Page3 of 57
THERMA-PAK IOM
SAFETY CONSIDERATIONS
1. READ THE ENTIRE MANUAL BEFORE STARTING THE INSTALLATION. 2. These
instructions are intended as a general guide and DO NOT supersede national,
state, or local codes in any way. 3. Altering the product, improper
installation, or the use of unauthorized parts voids all warranty or implied
warranty and may
result in adverse operation and/or performance or may result in hazardous
conditions to service personnel and occupants. Company employees or
contractors are not authorized to waive this warning. 4. This product should
only be installed and serviced by a qualified, licensed, and factory
authorized installer or service agency. 5. All “kits” and “accessories” used
must be factory authorized when modifying this product. Refer and follow
instructions packaged with the kits or accessories when installing.
RECOGNIZE THE FOLLOWING SAFETY NOTATIONS THROUGHOUT THIS MANUAL AND POSTED ON THE EQUIPMENT:
DANGER
Indicates an imminently hazardous situation, which, if not avoided, will
result in death or serious injury.
IMPORTANT
Suggests important procedure steps to insure proper installation, reliability,
or operation.
WARNING
Indicates a potentially hazardous situation or unsafe practices that could
result in severe personal injury or death and/or damage to property.
WARNING
ELECTRIC SHOCK HAZARD
This warning signifies potential electrical shock hazards that could result in
personal injury or death.
CAUTION
Indicates a potentially hazardous situation that may result in minor or
moderate injury.
NOTE
Used to highlight suggestions, which may result in enhanced installation,
reliability or operation.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in dangerous operation,
serious injury, death or property damage.
Improper servicing could result in dangerous operation, serious injury, death
or property damage.
Before servicing, disconnect all electrical power to furnace.
When servicing controls, label all wires prior to disconnecting. Reconnect
wires correctly.
ALWAYS verify the unit is operating properly after servicing.
SAFETY RULES
1. This furnace is approved for use with Natural Gas only. Refer to the
furnace rating plate.
2. Install this furnace ONLY in a location and position as specified in the
INSTALLATION section of this manual.
3. Provide adequate combustion and ventilation air to the furnace space as
specified in the COMBUSTION AIR section of this manual.
4. Products of combustion must be discharged outdoors, refer to the
INSTALLATION section of this manual.
5. Never test for gas leaks with an open flame. Use a commercially available
soap solution made specifically for the detection of leaks to check all
connections as specified in the LEAK TESTING section of this manual.
6. Always install this furnace to operate within the furnace’s intended
temperature rise range with a duct system which has an external static
pressure within the allowable range, as specified on the unit rating plate and
in the HEATING OPERATIONS section.
Therma PAK Series IOM (Rev. A 04/21)
Page4 of 57
THERMA-PAK IOM
SAFETY CONSIDERATIONS (continued)
7. When this furnace is installed so that the supply air
duct supplies air to areas outside the space containing the furnace, the
return air duct must be sealed to the furnace casing and terminate outside the
space containing the furnace as specified in the DUCT CONNECTIONS section of
this manual.
WARNING
For your safety, do not store or use any combustible materials, gasoline, and
other flammable vapors and liquids in the vicinity of this or any other
appliance as described in the
COMBUSTION AIR section of this manual. The material may ignite by spontaneous
combustion creating a fire hazard resulting in property damage, personal
injury, or death.
8. If installed in a residential garage, this furnace must be installed as
specified in the INSTALLATION section.
WARNING
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow ALL instructions could result in combustion products
infiltrating into the building which may cause severe
personal injury or death.
Check that all openings in the outside wall around the vent and air intake
pipe(s) are sealed to prevent infiltration of
combustion products into the building.
Check that furnace vent and air intake terminal(s) are not obstructed in any
way during all seasons.
12. The user shall annually inspect the furnace installation to verify the
following safety related items: a. All flue-gas carrying areas external to the
furnace (i.e., chimney, vent connector) are clear and free of obstructions. b.
The vent connector is in place, slopes upward,
For your safety, do not store or use any insulating material in the vicinity
of this or any other appliance as specified in the COMBUSTION AIR section of
this manual. Such actions could
result in property damage, personal injury, or death. Inspect the furnace area
after installation and after anytime
insulation has been added to the structure.
and is physically sound without holes or excessive corrosion. c. The return- air duct connection(s) is physically sound, is sealed to the furnace casing, and terminates outside the space containing the furnace.
9. For proper and safe operation, the furnace needs air for combustion and
ventilation. Do not block or obstruct air openings on the furnace, air
openings to the area in which the furnace is installed, and the spacing around
the furnace.
10. This furnace is equipped with a blocked vent shutoff system. If the
furnace fails to operate, contact a qualified service agency for repair.
11. Should the gas supply fail to shut off or if
d. The physical support of the furnace is sound without sagging, cracks, gaps,
etc., around the base to provide a seal between the support and the base.
e. There are no obvious signs of furnace deterioration.
f. The burner flames are in good adjustment, refer to FIGURE 40- BURNER FLAMES
to illustrate proper flame appearance for comparison.
overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.
WARNING
See the HEATING OPERATIONS section for more details.
DO NOT OPERATE UNIT IN BUILDINGS UNDER CONSTRUCTION
WARNING
DO NOT use this furnace if any part has been submerged under water. A flood-
damaged furnace is extremely
dangerous. Attempts to use a furnace in this condition can result in fire or
explosion. A qualified service agency must inspect the furnace and to replace
all gas controls, control system parts, electrical parts that have been wet or
replace
the entire furnace if deemed necessary.
Therma PAK Series IOM (Rev. A 04/21)
Page5 of 57
THERMA-PAK IOM
SAFETY CONSIDERATIONS (continued)
13. The following items should be inspected annually (minimum) before each heating season by a qualified service agency: a. HEAT EXCHANGER TUBES; make sure they are free from blockages, signs of carbon buildup or
16. In regions where snow and ice accumulations are possible, check the outdoor grilled areas, it must be kept free from any obstructions to air flow. The flue vent must be free from snow and ice or any obstruction to assure the products of combustion
heavy corrosion. b. GAS BURNERS; make sure they are free of
blockages, signs of carbon buildup or heavy corrosion. The burner carry-over
slots should be clean and of uniform size. c. VENT PIPE; check for excessive
corrosion or perforations. d. VENT TERMINAL; check that it is free from
blockages and restrictions. e. COMBUSTION AIR OPENINGS; check that they are
clean & free from debris or blockages of any kind. f. INDOOR AIR; the blower
wheel and blower housing must be free from debris. Check that supply and
return air registers, grilles, and dampers are positioned properly, filters
are in place and clean. g. INSPECT & WASH THE CONDENSER AND EVAPORATOR COILS
do not use high pressure as damage to the finned surfaces may occur.
are safely discharged outdoors.
CAUTION
Use care when handling compressors. Some surfaces may be hot.
CAUTION
Compressors must not be used to evacuate the air conditioning system. Vacuums
at this level may cause internal
electrical arcing which may result in a damaged or failed compressor.
WARNING
Improper installation, adjustment, alteration, service, or maintenance can
cause property damage, personal injury or loss of life. Refer to the user’s
information manual provided with this furnace. Service must be performed by a
qualified
installer, service agency or the gas supplier.
14. If any of the original wires supplied with the furnace must be replaced, they must be replaced with wiring material having a temperature rating of at least 90°C. a. This furnace must be installed so there are provisions for ventilating air. b. Should overheating occur, or the gas supply fail
WARNING
Installation and service must be performed by a licensed professional
installer (or equivalent), service agency or the gas supplier. Attempting to
install or repair this unit without proper proficiency may result in product
damage, personal
injury or death.
to shut off, shut off the manual gas valve to the furnace before shutting off the electrical supply.
WARNING
WARNING
USE COPPER SUPPLY WIRES ONLY
WARNING
These instructions are intended as an aid to qualified, licensed service
personnel for proper installation, adjustment and operation of this unit. Read
these instructions thoroughly before attempting installation or operation.
Failure to follow
these instructions may result in improper installation, adjustment, service or
maintenance possibly resulting in fire, electrical shock, property damage,
personal injury or death.
HIGH VOLTAGE
Disconnect all power before servicing. Failure disconnect power may result in
property damage, personal injury, or
death.
15. Do not attempt to light this furnace manually. Refer to the HEATING
OPERATIONS section for instructions for lighting and shutting down the
furnace.
Therma PAK Series IOM (Rev. A 04/21)
Page6 of 57
THERMA-PAK IOM
MODEL NOMENCLATURE
FIGURE 1 – MODEL NOMENCLATURE
MODEL NUMBER DESCRIPTION
DIGITS 1-2 SERIES
E Eco Series
DIGIT 9 REVISION LEVEL A, B, C
DIGIT 2 HEAT TYPE
C Cooling Only H Heat Pump F Cooling with ERV P Heat Pump with ERV
DIGIT 3 HEAT TYPE
E Electric Heat W AquaTherm HW Coil G Gas Heat
DIGITS 10-11 GAS HEAT
20 20,000 BTUH 30 30,000 BTUH 40 40,000 BTUH 50 50,000 BTUH 60
60,000 BTUH
DIGIT 12 CABINET
B 20 x 26 x (66-74)
DIGITS 4-5 TONNAGE
09 9,000 Btu/Hr 12 12,000 Btu/Hr 18 18,000 Btu/Hr 24 24,000 Btu/Hr 30
30,000 Btu/Hr
DIGIT 6 VOLTAGE
2 208/230V 1Ph
DIGITS 7-8 HEAT CAPACITY (KW/ROWS/GAS TYPE & EFFICIENCY)
00 No Heat E1 Single Stage Electric Heat R2 2 Row HW Coil R3 3 Row HW
Coil N8 Nat. Gas 80+% N9 Nat. Gas 90+%
DIGIT 13 ERV SUPPLY / HW CONNECTIONS
0 None R Right L Left
DIGITS 14-15 OPTIONS
00 None
DIGIT 16 BRAND
F First Co. A AE Air
Therma PAK Series IOM (Rev. A 04/21)
Page7 of 57
THERMA-PAK IOM
GENERAL INFORMATION
These instructions are provided for the installation of the THERMA-PAK gas
furnace specifically. For any other related equipment, refer to the
appropriate manufacturer’s instructions.
Clear surrounding area of all tools, equipment, and debris before operating
this unit.
CAUTION
DO NOT use units during the construction process. Mechanical components and
filters may become clogged with dirt and debris, which can cause damage to the
system. The
manufacturer does not warrant equipment subjected to abuse.
WARNING
ELECTRIC SHOCK HAZARD
Before servicing equipment, ALWAYS turn off all power to the unit. There may
be more than one DISCONNECT switch. Electrical shock can cause personal injury
or death.
WARNING
This furnace is certified for through-the-wall indoor installation only. This
furnace is NOT approved for mobile homes, recreational vehicles or outdoor
applications. Such use could result in property damage, personal injury, or
death.
CAUTION
DO NOT operate furnace without an air filter in place.
CAUTION
Extreme caution must be taken to ensure that no damage to the unit results
from screws that are drilled into the cabinet.
This furnace is designed for through-the-wall indoor installation only.
Installation of this equipment, wiring, ducts, and any related components must
conform to current agency codes, state laws, and local codes. Such regulations
take precedence over general instructions contained in this manual.
INTRODUCTION
THERMA-PAK ECG series are self-contained units with gas-fired heating and
electric cooling. The unit design has been certified by Intertek Testing
Services for compliance with the latest edition of the American National
Standard ANSI Z21.47 for direct vent central furnaces. The ECG models are
certified to be in compliance with the latest edition of A.H.R.I. Standard
390. All models are design certified for heating operation when fired with
natural gas.
These installation instructions are intended as a general guide only, for use
by an experienced, qualified contractor.
STORAGE
Equipment should be stored in a clean dry, conditioned area with maximum
temperatures up to 120°F [48.89°C] and minimum temperatures to 32°F [0°C].
Units should be stored upright and in an indoor environment. It is recommended
to leave packaging on the unit until the installation is to begin.
NOTE
DO NOT stack units for any purpose. Stacking can damage the units and may
cause property
damage, personal injury, or death.
Therma PAK Series IOM (Rev. A 04/21)
Page8 of 57
THERMA-PAK IOM
SHIPPING & PACKAGING LIST
SHIPPING INSTRUCTIONS
ECG units must remain in the upright position throughout the shipping and
handling process to maintain the correct compressor oil level.
FIGURE 2 – Standard Packaging
PACKAGING LIST
ECG units are shipped with the following items: 1. Shipping bracket 2. Screws
(4) 3. Top mounting bracket 4. Screws (4) 5. Literature package (IOM –
Installation & Operations Manual Warranty certificate)
Vent Kit – (vent pipe, bracket, screws)
Check the unit for shipping damage. If any damage is found, immediately
contact the shipping carrier
NOTE
All components in this shipment have been inspected at the factory and
released to the transportation agency in good condition. When received, a
visual inspection of all cartons should be made immediately. Any evidence of
rough handling or apparent damage should be noted on the delivery receipt in
the presence of the carrier’s representative. If damage is found, a claim
should be immediately filed against the shipping carrier.
Therma PAK Series IOM (Rev. A 04/21)
Page9 of 57
THERMA-PAK IOM
UNIT INSPECTION CHECKLIST
Complete the inspection procedures below before preparing unit for
installation: 1) Visually inspect unit for any shipping
damage. Damage must be reported immediately to the shipping company to make a
claim. 2) Ensure that the carrier makes proper notation of any shortages or
damage on all copies of the freight bill and completes a common carrier
inspection report. 3) Verify that unit nameplates on the data label match the
sales order or bill of lading (including, unit configuration, size and
voltage). 4) Immediately before installation, remove unit front panel and
verify that all electrical connections are tight. 5) Check to make sure that
the refrigerant piping is free from any kinks and there is no interference
between unit piping and sheet metal or electrical wires. 6) Check that the
blower spins freely within the housing and that there are no obstructions
between the wheel and housing. The wheel can sometimes come loose in shipping.
7) Ensure that the evaporator distributor tubes are not touching one in
another and that they are over the drain pan. 8) Check the air-coil fins for
any damage during shipping. 9) Ensure that the shipping brackets and screws
are removed from the chassis section. Refer to FIGURE 3 – Standard Packaging
with Brackets – Front View & FIGURE 4 – Standard Packaging with Brackets –
Back View for more information. 10) Inspect the gas heat section: a. Check
that the gas manifold is firmly in
place on the burner box and secured with the provided screws (4). b. Check
that burners are securely in place on each gas orifice and properly aligned
with each heat exchanger tube. c. Check that wiring connections are in place
on rollout switches, limit switch, pressure switch, gas valve, draft inducer,
ignitor, and flame sensor.
FIGURE 3 – Standard Packaging with Brackets – Front View
NOTE
Check the unit nameplate for correct voltage before installing the equipment.
Ensure that all electrical ground connections
are made in accordance with local code.
FIGURE 4 – Standard Packaging with Brackets – Back View
Therma PAK Series IOM (Rev. A 04/21)
Page10 of 57
THERMA-PAK IOM
UNIT DIMENSIONAL DATA
6 BURNER UNITS TOP VIEW
15.90 0.74
3.08
22.27 11.90
3.77
1.49
2-5 BURNER UNITS TOP VIEW
15.90 0.74
3.08
22.2711.90
4.49 2.14
22.27 19.48
FILTER 18″ X 24″
24.22
18.04 0.78
6.48 69.95
FLUE EXHAUST OUTLET
34.56
32.94
39.19
20.09 SIDE VIEW
26.09 FRONT VIEW
FIGURE 5 – Unit Dimensions
BACK VIEW
Therma PAK Series IOM (Rev. A 04/21)
Page11 of 57
THERMA-PAK IOM
UNIT PHYSICAL DATA
ECG MODELS UNIT INFORMATION Compressor Qty/Type Compressor Capacitor Condenser Fan HP [kW] Indoor Fan HP [kW] Blower Size (D x W) in. [cm] Condenser Dimension (H x W) in. [cm] Evaporator Dimension (H x W) in. [cm] Filter Size (H x W) in. [cm] Input BTU/h [kW] Output BTU/h [kW] Thermal Efficiency No. of Burners Orifice Size in. [mm] Max. Outlet Air Temp. °F [°C] Max. Static Pressure IWC [pa] Gas Piping Connection in. [cm] Operating Weight lb. [kg] Shipping Weight lb. [kg] Notes: FPT = Female Pipe Thread
PHYSICAL DATA
092N8A20B 122N8A20B 122N8A30B 122N8A40B 182N8A30B 182N8A40B 182N8A50B
182N8A60B
Rotary (1) 35MFD/370V
1/4 [.19] 1/4 [.19] 20,000 [5.9] 16,200 [4.7] 81 2 .061 [1.55] 155 [68] 283
[129] 303 [138]
Rotary (1) 40MFD/370V
1/4 [.19] 1/4 [.19] 20,000 [5.9] 16,200 [4.7] 81 2 .061 [1.55] 155 [68] 283
[129] 303 [138]
Rotary (1) 40MFD/370V
1/4 [.19] 1/4 [.19] 30,000 [8.8] 24,300 [7.1] 81 3 .061 [1.55] 160 [71] 285
[130] 305 [139]
Rotary (1)
Scroll (1)
40MFD/370V 30MFD/370V
1/4 [.19]
1/3 [.25]
1/4 [.19]
1/3 [.25]
10 x 6 [25.4 x 15.24]
26 x 22.5 [66.04 x 57.15]
18 x 22 [47.72 x 55.88]
18 x 24 [45.72 x 60.96]
40,000 [11.7] 30,000 [8.8]
32,400 [9.5] 24,400 [7.1]
81
81
4
3
.061 [1.55] .061 [1.55]
165 [74]
160 [71]
0.5 [125]
1/2″ [12.7]
287 [130]
347 [158]
307 [140]
367 [167]
Scroll (1) 30MFD/370V
1/3 [.25] 1/3 [.25] 40,000 [11.7] 32,400 [9.5] 81 4 .061 [1.55] 165 [74] 350
[159] 370 [168]
Scroll (1) 30MFD/370V
1/3 [.25] 1/2 [.25] 50,000 [14.7] 40,500 [11.9] 81 5 .061 [1.55] 165 [74] 364
[165] 384 [175]
Scroll (1) 30MFD/370V
1/3 [.25] 1/2 [.25] 60,000 [17.6] 48,600 [14.2] 81 6 .061 [1.55] 170 [77] 367
[167] 387 [ 176]
Table 1 – Physical Data
ECG MODELS UNIT INFORMATION Compressor Qty/Type Compressor Capacitor Condenser Fan HP [kW] Indoor Fan HP [kW] Blower Size (D x W) in. [cm] Condenser Dimension (H x W) in. [cm] Evaporator Dimension (H x W) in. [cm] Filter Size (H x W) in. [cm] Input BTU/h [kW] Output BTU/h [kW] Thermal Efficiency No. of Burners Orifice Size in. [mm] Max. Outlet Air Temp. °F [°C] Max. Static Pressure IWC [pa] Gas Piping Connection in. [cm] Operating Weight lb. [kg] Shipping Weight lb. [kg] Notes: FPT = Female Pipe Thread
PHYSICAL DATA
242N8A30B 242N8A40B 242N8A50B 242N8A60B 302N8A40B 302N8A50B 302N8A60B
Scroll (1) 40MFD/370V
1/3 [.25] 1/3 [.37] 30,000 [8.8] 24,300 [7.1] 81 3 .061 [1.55] 160 [71] 347
[158] 367 [167]
Scroll (1) 40MFD/370V
1/3 [.25] 1/3[.37] 40,000 [11.7] 32,400 [9.5] 81 4 .061 [1.55] 165 [74] 361
[164] 381 [173]
Scroll (1)
Scroll (1)
Scroll (1)
40MFD/370V 1/3 [.25] 1/2 [.37]
40MFD/370V 1/3 [.25] 1/2 [.37]
35MFD/370V 1/3 [.25] 1/2 [.37]
10 x 6 [25.4 x 15.24] 26 x 22.5 [66.04 x 57.15] 18 x 22 [47.72 x 55.88]
18 x 24 [45.72 x 60.96] 50,000 [14.7] 60,000 [17.6] 40,000 [11.7] 40,500 [11.9] 48,600 [14.2] 32,400 [9.5]
81
5 .061 [1.55]
81
6 .061 [1.55]
81
4 .061 [1.55]
165 [74]
170 [77]
165 [74]
364 [165]
0.5 [1.25] 1/2″ [12.7] 367 [167]
361 [164]
384 [175]
387 [176]
381 [173]
Scroll (1) 35MFD/370V
1/3 [.25] 1/2 [.37] 50,000 [14.7] 40,500 [11.9] 81 5 .061 [1.55] 165 [74] 364
[165] 384 [175]
Scroll (1) 35MFD/370V
1/3 [.25] 1/2 [.37] 60,000 [17.6] 48,600 [14.2] 81 6 .061 [1.55] 170 [77] 367
[167] 387 [176]
Table 2 – Physical Data Continued
Therma PAK Series IOM (Rev. A 04/21)
Page12 of 57
THERMA-PAK IOM
ELECTRICAL DATA
MODEL NUMBER VOLTAGE-PH-HZ
ECG092N8A20B ECG122N8A20B ECG122N8A30B ECG122N8A40B ECG182N8A30B ECG182N8A40B ECG182N8A50B ECG182N8A60B ECG242N8A30B ECG242N8A40B ECG242N8A50B ECG242N8A60B ECG302N8A40B ECG302N8A50B ECG302N8A60B
208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60
ELECTRICAL DATA
COMPRESSOR
CONDENSOR MOTOR
INDOOR MOTOR
RLA LRA FLA HP FLA HP 4.4 20 2.3 1/4 2.3 1/4
4.7 26 2.3 1/4 2.3 1/4
4.7 26 2.3 1/4 2.3 1/4
4.7 26 2.3 1/4 2.3 1/4
9 56.3 2.8 1/3 2.8 1/3
9 56.3 2.8 1/3 2.8 1/3 9 56.3 2.8 1/3 4.1 1/2
9 56.3 2.8 1/3 4.1 1/2
10.1 61.6 2.8 1/3 2.8 1/3 10.1 61.6 2.8 1/3 2.8 1/3
10.1 61.6 2.8 1/3 4.1 1/2
10.1 61.6 2.8 1/3 4.1 1/2
12.8 65 12.8 65
2.8 1/3 4.1 1/2 2.8 1/3 4.1 1/2
12.8 65 2.8 1/3 4.1 1/2
Table 3 – Electrical Data
MIN. CIRCUIT AMPACITY
MAX. CIRCUIT PROTECTION
MIN. VOLTAGE
MAX. VOLTAGE
11
15
197
253
11
15
197
253
11
15
197
253
11
15
197
253
17
25
197
253
17
25
197
253
19
25
197
253
19
25
197
253
19
30
197
253
19
30
197
253
20
30
197
253
20
30
197
253
23
35
197
253
23
35
197
253
23
35
197
253
INSTALLATION
REQUIREMENTS
Follow manufacturer’s installation instructions, as well as local and
municipal building codes. In addition, the installation shall conform to the
following Fire Protection Association (NFPA) Standards:
NFPA No. 90A Standard for Installation of Air Conditioning and Ventilation
Systems
NFPA No. 90B Standard for Installation of Residence Type Warm Air Heating
and Air Conditioning Systems.
This unit is approved for installation clearance to combustible material as
stated on the unit rating plate. However, stated minimum clearances to
combustibles may be inadequate for future accessibility and service needs
which must be considered when planning the installation.
INSTALLATION PRECAUTIONS
Observe the following precautions for typical installation: Always use proper
tools and equipment No wiring or any work should be attempted without
first ensuring the unit is completely disconnected from the power source and
locked out. Also, verify that a proper permanent and uninterrupted ground
connection exists prior to energizing power to the unit. Review unit nameplate
and wiring diagram for proper voltage and control configurations. This
information may vary from unit to unit.
Therma PAK Series IOM (Rev. A 04/21)
CAUTION
Always wear all appropriate Personal Protection Equipment (PPE) when
installing and servicing units.
WARNING
Use multiple people when moving and installing units. Failure to do so could
result in personal injury or death.
CAUTION
Contact with metal edges and corners may result in injury. Protective gloves
should be worn when handling. Exercise
caution when installing and servicing unit.
CAUTION
When the unit is in operation, components are rotating at high speeds.
NOTE
When soldering and brazing, it is recommended to have a fire extinguisher
readily available. When soldering and brazing close to valves or sensitive
components, heat shields and/or wet rags are required to prevent damage to the
valves or components.
Page13 of 57
THERMA-PAK IOM
INSTALLATION (continued)
NOTE
Insulation in the unit provides a barrier between varying atmospheres outside
and within the unit. If insulation is damaged, condensation can occur and can
lead to corrosion, component failure, and possible property damage. Damaged
insulation must be repaired prior to the operation of the unit. Insulation
will lose its effectiveness and value when wet, torn,
separated, and/or damaged.
CAUTION
When servicing this equipment, because of the high pressures present in the
unit, make sure the reversing valve,
expansion device, filter drier and other components are specifically designed
for R-410A refrigerant.
ONLY USE service equipment specifically designated for use with R-410A.
WARNING
R-410A can become combustible if mixed with air at elevated temperature and/or
pressure. Failure to follow this warning
could result in property damage, and personal injury or death.
UNIT LOCATION
This furnace is certified for through-the-wall, indoor, upflow vertical
position installation only. This appliance is not design certified for
installation in mobile homes, recreational vehicles, or outdoors. An approved
wall sleeve must be used to install the ECG unit.
This is a direct vent appliance which uses outside air for combustion and
discharges the products of combustion to the outdoors. Do not install this
unit in close proximity to exhaust from clothes dryer vents, kitchen vents,
corrosive fumes, or steam vents.
Do not install directly on carpeting, tile, or other combustible material
other than wood flooring. Proper distances must be maintained between the
appliance vent pipe and operable windows, building openings, public walkways,
electric meters, gas meters, gas regulators and gas relief equipment. Flue
products must not be permitted to damage building surfaces.
The Installation must conform with local building codes or, in the absence of
local codes, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the
Natural Gas and Propane Installation Code, CSA B149.1 If unit is installed in
a garage, the furnace must be installed so the burner(s) and the ignition
source are located not less than 18″ [45.72cm] above the floor. The furnace
must be protected from physical damage from vehicles.
2″ MIN.
30″ MIN. CLEARANCE FROM PLANTS
FIGURE 6 – Typical Floorplan with THERMA-PAK on Exterior Wall
Therma PAK Series IOM (Rev. A 04/21)
Page14 of 57
THERMA-PAK IOM
INSTALLATION (continued)
UNIT CLEARANCE REQUIREMENTS
The Therma Pak unit may be installed with zero clearances to adjacent
combustible surfaces. This furnace shall not be installed directly on
carpeting, tile, or other combustible material, other than wood flooring.
Service clearance must be provided for future maintenance and service. A
minimum of 32″ [81.28cm] open area must be left unobstructed in front of the
access panels.
The grille side must be kept free from any obstructions to air flow. The unit
must be installed at least 4 feet [1.2192m] from electric meters, gas meters,
regulators, and relief equipment. Products of combustion are discharged
outside from the vent outlet located at the front grille; therefore, all
distances from adjacent public walkways, adjacent buildings, openable windows,
and building openings must be compliant with those called for in the National
Fuel Gas Code ANSI Z223.1 and installation codes, as well as local codes.
FIGURE 7 – Required Exterior Building Clearance
CLEARANCE REQUIREMENTS
MINIMUM CLEARANCE
INCHES
Horizontal distance between units
12
Vertical distance between units
60
Distance above ground level
6
Distance above finished floor
6
Distance above a garage floor
18
Table 4 – Dimensional Clearance Requirements
WH W/D
THERMA PAK UNIT FIGURE 8 – Typical Floor Plan
WARNING
CARBON-MONOXIDE POISIONING HAZARD
Failure to follow instructions could result in severe personal injury or death
due to carbon-monoxide poisoning, if combustion products infiltrate into the
building.
Check that all openings in the outside wall around the vent (and air intake)
pipe(s) are sealed to prevent infiltration of
combustion products into the building. Check that furnace vent (and air
intake) terminal(s) are not
obstructed at during all seasonal weather patterns.
CAUTION
A masonry wall opening must be properly constructed with a lintel for wall
support. Wall openings must be flashed and sealed. The unit must be level,
front to back, side to side. Refer to VENTING section and UNIT CLEARANCE
REQUIREMENTS section of this manual for more information.
Therma PAK Series IOM (Rev. A 04/21)
Page15 of 57
THERMA-PAK IOM
INSTALLATION (continued)
VENT CLEARANCES
FIGURE 9 – Location of Vent Termination Clearances
VENT TERMINATION CLEARANCES
CLEARANCE
US INSTALLATIONS²
A = Clearance above grade, veranda, porch, deck, or balcony (see 1.23.5-i(9)b)
12 in (30 cm)
B = Clearance to window or door that may be opened
4 ft. (1.2 m) below or to the side of opening 1 foot (300 m) above opening
C = Clearance to permanently closed window
D = Vertical clearance to ventilated soffit located above
the terminal within a horizontal distance of 2 ft. (61
cm) from the center line of the terminal
E = Clearance to unventilated soffit
F = Clearance to outside corner
G = Clearance to inside corner
H = Clearance to each side of center line
I = Clearance to service regulator vent outlet
J = Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance
4 ft. (1.2 m) below or to the side of opening 1 ft. (300 m) above opening
K = Clearance to a mechanical air supply inlet
3 ft. (91 cm) above if within 10 ft. (3 m) horizontally
L = Clearance above paved sidewalk or paved driveway located on public property
7 ft. (2.13 m)
M = Clearance under veranda, porch, deck, or balcony
NOTES: 1) In accordance with the current Natural Gas Installation Code. 2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code. *Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single-family dwellings and serves both dwellings. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
Table 5 – Vent Termination Clearances Dimensions
Therma PAK Series IOM (Rev. A 04/21)
Page16 of 57
THERMA-PAK IOM
INSTALLATION (continued)
REMOVAL OF UNIT FROM COMMON VENTING SYSTEM
When an existing furnace is removed from a common venting system serving other
appliances, the venting system is likely to be too large to properly vent the
remaining attached appliances. The following test shall be conducted with each
appliance while the other appliances connected to the common venting system
are not in operation. An improperly sized venting system may cause
condensation or flue gas spillage to occur.
IMPORTANT
DO NOT use the THERMA-PAK unit within a Common Venting System
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch
and determine there is no blockage or restriction, leakage, corrosion, or
other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows between the
space in which the appliances remaining connected to the common venting system
are located and other spaces in the building. Turn on clothes dryers and any
appliance not connected to the common venting system. Turn on exhaust fans,
such as range hoods and bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Following the lighting instructions, place the unit being inspected into
operation. Adjust the thermostat so the appliance will operate continuously.
5. Test for spillage at the draft control relief opening after 5 minutes of
main burner operation. Use the flame of a match or candle.
6. Follow the preceding steps for each appliance connected to the common
venting system.
7. After it has been determined that each appliance remaining connected to
the common venting system properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers, and any other fuel burning
appliance to their previous condition of use.
If improper venting is observed during any of the above tests, the venting
system must be corrected. See National Fuel Gas Code, ANSI Z223.1 (latest
edition) to correct improper operation of common venting system.
Therma PAK Series IOM (Rev. A 04/21)
WARNING
ELECTRIC SHOCK HAZARD
Disconnect all power supplies before servicing. Lock out/tag out equipment to
prevent electrical shock.
WALL SLEEVE INSTALLATION
Refer to installation instruction packed with the wall sleeve to assemble and
mount into the wall. Before unit installation, make sure sleeve components are
not damaged; drain line is not obstructed and is leak free. Check that all
seals are in position and free of damage. Securely fasten the Architectural
grille to the front of the sleeve using the supplied hardware.
RETURN AIR
1/2″ [1.27cm]
6″ [15.24cm]
30″ [76.2cm] ANY EXTERIOR OBSTRUCTION 1/4″ [0.635cm]
FIGURE 10 – Wall Sleeve Mounting
IMPORTANT
After sleeve installation, ensure that the gap between the wall and seal is
insulated and is in contact with the sleeve
sides.
IMPORTANT
Make sure a high grade non-hardening sealant approved for exterior use has
been applied between edge of the sleeve and the structure, on the inside and
outside walls, to prevent
air and water from migrating inside
Page17 of 57
THERMA-PAK IOM
INSTALLATION (continued)
WALL SLEEVE INSTALLATION
REAR INSTALLATION & DIMENSIONS
FIGURE 11 – Rear Installation Dimensions The Therma Pak unit can be installed in a closet with the following clearances; to combustibles 0″ clearance on the sides, 2″ [5.08cm] clearance from the top, and 1″ [2.54cm] from the front and the plenum. Adequate clearance must be provided to install a gas line and manual shutoff valve while also providing access for installing field wiring. Do not install directly on any combustible material (such as carpet, tile, etc.) other than wood flooring.
SIDE INSTALLATION & DIMENSIONS
Installed Wall Sleeve
6″ MIN.
6″ MIN. [15.24cm] 30″ MIN. [76.2cm] Service Opening
12″ MIN.
10″ MIN. [25.4cm]
FIGURE 12 – Side Installation Dimensions
NOTE
Sleeve dimensions differ across models.
Therma PAK Series IOM (Rev. A 04/21)
Page18 of 57
THERMA-PAK IOM
INSTALLATION (continued)
PACKAGED UNIT INSTALLATION
FIGURE 13 – THERMA-PAK Unit Installation
NOTE
Locate unit in an area that provides minimum clearance to all service access
panels. Consider all additional clearances
needed for water connections, electrical connections, duct connections and
sufficient return airflow.
IMPORTANT
UNIT INTENDED FOR INDOOR INSTALLATION ONLY
NOTE
DO NOT locate unit in areas subject to freezing temperatures or with high
humidity levels which may cause cabinet
condensation. Units should be mounted on the sleeve with a pitch to the
outside of the building.
Insulation in the unit provides a barrier between the different atmospheres
present outside and within the unit. If the insulating barrier is damaged, the
surrounding ambient air will affect the inside surface temperature of the
cabinet, this may lead to sheet metal corrosion and subsequently, component
failure.
IMPORTANT
Damaged insulation must be repaired or replaced before the unit can be placed
back into operation. Insulation is damaged
when wet, perforated, or torn.
The installer must adhere strictly to all local and national code requirements
pertaining to the installation of this equipment including the cabinet,
discharge plenum and connecting ducts. Therma-Pak units are for indoor use
only, and are agency listed for installation with clearances specified in on
the furnace rating plate.
Therma PAK Series IOM (Rev. A 04/21)
Page19 of 57
THERMA-PAK IOM
INSTALLATION (continued)
PACKAGED UNIT INSTALLATION (Continued)
NOTE
Remove the four shipping brackets holding the unit to the shipping pallet and
remove unit from the shipping pallet. Check nameplate voltage, amperage and
fuse size for proper
power supply.
5. Inspect the sleeve seal, which is supplied with the sleeve, to ensure that
it is properly secured and aligned.
6. Slide the THERMA-PAK unit toward the sleeve seal until the sleeve and
cabinet brackets are nested and almost making contact.
7. Center the THERMA-PAK unit in the sleeve. 8. Use screw fasteners to attach
the cabinet bracket to
wall sleeve.
SLEEVE BRACKET
FIGURE 14 – Side Bracket Installation on Sleeve 1. Ensure that properly sized
ductwork is in place
to mate to the connections on the THERMA-PAK. 2. Remove front access panel and
verify all
electrical connections are secure and check the condenser fan to see it turns
freely. 3. If an air filter is to be applied to the unit remove the top flange
on the filter rack to replace filter. (FIGURE 21 – Air Filter Location). Place
the filter into the filter bracket. 4. Ensure that the wall sleeve is
installed squarely and is secured before installing the unit.
NUT
UNIT
3 PLACES
FIGURE 15 – Wall Sleeve Installation 9. Use a high-grade, non-hardening sealant to close
any gaps that may exist between the seal and the
wall of the sleeve.
10. Check that the unit is completely settled on all four sides against the wall sleeve seals.
WARNING
If unit is not properly sealed, water, outside air, and/or products of
combustion will infiltrate into the closet.
Infiltration of elements to inside air may cause improper unit operation,
damage to the unit, or property damage.
Infiltration of combustion products may cause personal injury or death.
Therma PAK Series IOM (Rev. A 04/21)
Page20 of 57
THERMA-PAK IOM
INSTALLATION (continued)
DUCTWORK
IMPORTANT
The supply duct connection must be sized to a minimum of the same size as the
unit discharge air opening.
IMPORTANT
All ductwork must be installed in accordance with National Fire Protection
Assoc. Codes 90A and 90B.
DISCHARGE DUCTING
Discharge (supply) air ductwork must be used and must be adequately sized to
provide airflow within the specified total external static pressure of 0.5″
w.c. Ductwork should be adequately insulated to prevent condensation and loss
of efficiency. Flexible duct connections may be used.
RETURN AIR DUCTING
If permitted by local codes and the local authority having jurisdiction,
Therma-Pak units may use free-air return. For installations using return air
ductwork, it must be adequately sized to provide airflow within the specified
total external static pressure of 0.5″ w.c. Ductwork should be adequately
insulated to prevent loss of efficiency. Flexible duct connections may be
used. When this furnace is installed so that the supply air duct supplies air
to areas outside the space containing the furnace, the return air duct must be
sealed to the furnace casing and terminate outside the space containing the
furnace. Installer must ensure that the doors are sealed properly to avoid
combustion air recirculation. Condensate drain lines must be properly
installed with adequate slope away from unit to ensure proper drainage. A
minimum trap of 1.5 inches [3.81cm] must be installed to isolate the negative
pressures of the drain pan from the drain line. Refer to for schematic
information on the condensate drain lines.
WARNING
Never allow the products of combustion from the flue pipe to enter the supply
or return ducts.
Therma PAK Series IOM (Rev. A 04/21)
FIGURE 16 – Unit Return Ducting CONDENSATE DRAINAGE
FIGURE 17 – Condensate Drain Layout .
Page21 of 57
THERMA-PAK IOM
INSTALLATION (continued)
VENTING
The venting system exhausts the products of combustion to the outdoors. The
Therma Pak unit ships with the vent pipe un-installed. The installer must
install the vent pipe before the unit is placed into operation. Follow all
local & National codes when selecting an installation location. Observe all
clearance requirements pertaining to vent termination. Perform regularly
scheduled maintenance checks to assure venting of flue products to the
outdoors is unobstructed.
Draft Inducer
EVAP FAN MOTOR FLUE PIPE
Vent Pipe (Field Installed)
FIGURE 18 – Venting Location
WARNING
CARBON MONOXIDE POISONING HAZARD Failure to follow instructions could result
in severe personal injury or death due to carbon monoxide poisoning. This unit
is equipped with safety switches that disable operation if access panels are
not in place. Do NOT defeat safety switches. Do NOT operate this unit in any
mode without all factory provided access panels secured in place.
The Therma-Pak is equipped with three door switches as shown in the figure to
the right. This is to ensure that the appliance does not function, if these
key access doors are not replaced back. There are four more access doors on
the sides and it is necessary to ensure they are closed or put back on, after
any service is performed.
Vent Pipe Bracket (Field Installed with 4 Screws)
FIGURE 19 – Venting Location (Detail)
Therma PAK Series IOM (Rev. A 04/21)
FIGURE 20 Door Switch Locations
Page22 of 57
THERMA-PAK IOM
INSTALLATION (continued)
AIR FILTER
The Therma Pak unit must not be operated without an air filter in place. The
unit is equipped with a factory installed 2″ filter rack and a disposable
filter. A permanent washable filter may also be used provided it has the same
or greater surface area as the original filter. As an alternative to the
factory provided filter location, a filter rack may be field installed
elsewhere in the return duct system. Do not use filters which are highly
restrictive to air flow. The total external static pressure, including ducts,
grilles, registers, and filters must not exceed 0.5″ w.c.
AIR FILTER MINIMUM DIMENSIONS
Model Series
Minimum Area
ECG**2N8*****
432 sq. inches [0.278 sq. meter]
Table 6 – Air Filter Minimum Dimensions
SIDE RAIL 2 PLACES
FILTER TOP FILTER
FILTER RACK
FIGURE 21 – Air Filter Location
Therma PAK Series IOM (Rev. A 04/21)
Page23 of 57
THERMA-PAK IOM
INSTALLATION (continued)
COMBUSTION AIR
This is a direct vent furnace, which receives its combustion air from outside
and discharges the products of combustion outside. Do not restrict air
openings on the ECG unit or any other appliances. Do not store any insulating
material in the vicinity of the ECG unit or any other appliances.
WARNING
DO NOT block any louvered sections of the furnace, inside or outside.
Inadequate combustion air will cause improper
combustion and lead to the production of carbon monoxide.
WARNING
The area surrounding the furnace must be kept free of all combustible
materials, gasoline, insulating materials and
other flammable materials.
Inspect the furnace area after the furnace is installed and after anytime
insulation has been added to the structure.
CAUTION
Avoid contamination of the furnace area and the combustion air supply,
exposure to the following substances may cause premature heat exchanger
failure:
Permanent wave solutions Chlorinated waxes and cleaners Chlorine based
swimming pool chemicals Water softening chemicals De-icing salts or chemicals
Carbon tetrachloride Halogen type refrigerants Cleaning solvents (such as
perchloroethylene) Printing inks Paint removers Varnishes, etc. Hydrochloric
acid Antistatic fabric softeners for clothes dryers Masonry acid washing
materials
All gas piping and connections to this furnace must be performed by a
qualified installer. Installation methods and materials must comply with local
building codes or, in the absence of local codes, to the National Fuel Gas
Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation
Code, CSA B149.1.
Therma PAK Series IOM (Rev. A 04/21)
MANUAL GAS SHUT-OFF VALVE
PIPE UNION
DRIP LEG WITH CAP CONNECTION TO FURNACE
FIGURE 22 – Gas Supply Piping
Page24 of 57
THERMA-PAK IOM
INSTALLATION (continued)
GAS PIPING & CONNECTION
WARNING
In the State of Massachusetts:
This product must be installed by a licensed Plumber or Gas Fitter. When
flexible connectors are used, the maximum
length shall not exceed 36″ [91.44cm]. When lever-type gas shutoffs are used,
they shall be T-handle type.
Use 1/2″ N.P.T. gas piping to make field installed connections to the furnace
gas valve. A manual gas shutoff valve must be provided and installed external
to the furnace casing. A ground joint union and a drip leg must also be
provided. A field provided gas supply pressure 1/8″ N.P.T. test port must be
installed. Use a high quality approved pipe thread compound on all pipe thread
joints. A flexible gas connector may be used to connect the furnace if
permitted by local codes. If a flexible connector is used, it must be a listed
connector in new condition. Do not use a connector that has been previously
used to service another appliance. A flexible connector must not pass through
the furnace cabinet; Black steel gas piping must be used between the gas valve
and a location outside the furnace cabinet to connect the flexible gas
connector.
Gas piping must connect to the furnace through the top of the cabinet. Gas
piping must be adequately supported external to the furnace cabinet. The
furnace gas valve, manifold, and burner assembly are not designed or intended
to support the weight of the gas line external to the furnace cabinet. The gas
piping connecting the furnace must be properly aligned with the gas valve to
prevent binding and distortion of the gas manifold and burner assembly.
The furnace and its external gas shut-off valve must be disconnected from the
piping system before any gas line pressure test exceeding ½ PSI (14″ [35.56cm]
W.C.) is performed. Do not expose the gas valve to any pressure higher than
14″ [35.56cm] W.C. or gas valve failure may occur.
The gas valve is equipped with 1/8″ N.P.T. pressure test ports for measuring
gas supply pressure and gas manifold pressure. Refer HEATING OPERATIONS for
locations of pressure test ports. Refer to Table 11 – Gas Pressure Table for
proper gas supply and manifold pressures.
Therma PAK Series IOM (Rev. A 04/21)
LEAK TESTING
Gas piping must be thoroughly checked and proven to be leak free before
placing the furnace in operation. Follow all local code requirements in place
or National Fuel Gas Code, ANSI Z223.1/NFPA 54 requirements for leak checking.
Never test for gas leaks using an open flame. Use a commercially available
soap solution made specifically for the detection of leaks.
WARNING
FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could
result in property damage, or serious personal injury or death.
NEVER test for leaks using an open flame. Use a commercially available
solution formulated specifically for the detection of leaks to check all
connections.
Page25 of 57
THERMA-PAK IOM
ELECTRICAL
HIGH VOLTAGE
All wiring must comply with local and national code requirements. Units are
provided with wiring diagrams and nameplate data to provide information
required for necessary field wiring.
Units are provided with a class 2 transformer for 24VAC control circuits.
Should any add-on accessory or component also have a class 2 transformer
furnished, care must be taken to prevent interconnecting outputs of the two
transformers by using a thermostat with isolating contacts.
WARNING
ELECTRIC SHOCK HAZARD
Disconnect all power supplies before servicing. Lock out/tag out to prevent
accidental electrical shock.
NOTE
There may be multiple power sources supplying the unit.
WARNING
Use copper conductors only. Install all parts and panels before operation of
unit. Failure to follow these warnings can
result in personal injury or death.
WARNING
Connect ground wire to ground terminal marked “GND”. Failure to properly
ground the unit may result in personal
injury or death.
CAUTION
Any device that has been furnished by the factory for field installation must
be wired in strict accordance with the
associated wiring diagram. Failure to properly wire the unit may damage
components and void warranties.
208-230 VOLT OPERATION
All 208-230 Volt units are factory wired for 230 Volt operation. For 208 Volt
operation, rewiring the line voltage tap on the 24 Volt control transformer is
required.
LOW VOLTAGE
THERMOSTAT A standard 24 VAC single state heating and cooling thermostat is
required to control this unit. A thermostat with a “C” common terminal is
preferred. Thermostat connections and their functions are below in FIGURE 21 –
Thermostat Connections as follows.
Abbr. Y C W R G
THERMOSTAT CONNECTIONS KEY
Color
Function
Yellow Compressor Contactor
Brown Transformer 24VAC Common
White Call for Heating
Red Evaporator Blower
Green Transformer 24VAC Hot
Table 7 – Thermostat Connections Key
FIGURE 21 – Thermostat Connections
THERMOSTAT INSTALLATION
The Thermostat should be located on an interior wall in a larger room, away
from supply duct draft. Position the thermostat back plate against the wall so
that it appears level and so the thermostat wires protrude through the middle
of the back plate mounting holes and drill holes with a 3/16″ [5mm] bit.
Install supplied anchors and secure plate to the wall. Thermostat wire must be
18 AWG wire.
Therma PAK Series IOM (Rev. A 04/21)
Page26 of 57
THERMA-PAK IOM
CONTROLS
FIGURE 22 – Control Board
CONTROL BOARD L.E.D. TABLE
SIGNAL
PROBLEM
POSSIBLE CAUSE
Slow Flash
No heat request from room thermostat Stand-by mode; does not indicate fault condition
RAPID FLASH Room thermostat is requesting heat
Thermostat requesting heat; does not indicate condition
CONSTANT OFF Internal fault or No power
Main power is off or control has failed
2 FLASHES
3 FLASHES
4 FLASHES 5 FLASHES 6 FLASHES
Control does not respond
Control does not respond
Unexpected pressure switch condition Contacts are open with inducer on or closed with inducer off
Limit switch or rollout switch is open Flame sensed while gas valve is off
On-Board microprocessor conflict
Table 8 – Control Board L.E.D. Table
CHECKS & CORRECTIONS
Check circuit breaker / circuit fuse, external power switch.
COOLING OPERATION When the unit is given a “Y” input it will operate in cooling mode. The compressor will immediately come on after a “Y” input. After a 5 second time delay the indoor fan will be energized. The system will remain in cooling mode as long as the “Y” input is present.
CONTINUOUS FAN OPERATION When the unit is given a “G” input, without an additional “Y” or “W” call, the unit will operate in continuous fan mode. The fan remains energized as long as the “G” input is present.
When the “Y” input is removed from the system the control immediately de- energizes the compressor contactor. The indoor blower de-energizes after a cooling off delay period of 90 seconds.
Therma PAK Series IOM (Rev. A 04/21)
Page27 of 57
THERMA-PAK IOM
CONTROLS (continued)
BLOWER CONTROL
ECG gas heat units are equipped with a direct drive indoor blower motor.
ECG09 and ECG12 have 4 speed blower motors: o Either T2 or T3 may be used
for heating mode providing the speed selection allows the unit to operate
within specified temperature rise range. o T1 is the constant fan speed. o T4
is used for cooling mode. All other models have 5 fan speeds: o Either T2 or
T3 may be used for heating mode providing the speed selection allows the unit
to operate within specified temperature rise range. o T1 is the constant fan
speed. o T4 or T5 may be used for cooling mode.
See wiring diagram located on the unit.
FIGURE 23 – Blower Control Tap
CAUTION
In heating mode, the unit must operate within its rated temperature rise range
and static range. Refer to Tables 9 & 10 ECG AIRFLOW PERFORMANCE DATA.
Failure to operate within the designed temperature rise range will cause
unreliable operation and damage the heat exchanger may occur.
NOTE
High efficiency brushless DC motors are wired with line voltage power applied
at all times. Low voltage thermostat demand and board algorithms will control
its use.
Therma PAK Series IOM (Rev. A 04/21)
Page28 of 57
THERMA-PAK IOM
CONTROLS (continued)
FIGURE 24- Electrical Components
LED LIGHT
FIGURE 25 – Control Bracket Detail
Therma PAK Series IOM (Rev. A 04/21)
Page29 of 57
THERMA-PAK IOM
AIRFLOW
ECG AIRFLOW PERFORMANCE DATA
IWC STATIC PRESSURE
MODEL
MOTOR MID RISE
0.1
SPEED
RISE °F RANGE °F SCFM
TEMP RISE °F
0.2
SCFM
TEMP RISE °F
0.3
SCFM
TEMP RISE °F
0.4
SCFM
TEMP RISE °F
T1
25-55
300
50
260
–
210
–
170
–
ECG092N8A20B
T2H T3
40.0
25-55 25-55
370 450
40 33
330 410
45 36
280 360
53 41
240 320
46
T4C
25-55
360
41
320
46
270
55
230
–
T1
25-55
300
50
260
–
210
–
170
–
ECG122N8A20B
T2H T3
40.0
25-55 25-55
370 530
40 28
330 490
45 30
280 440
53 33
240 400
37
T4C
25-55
460
32
420
35
370
40
330
45
T1
30-60
410
55
370
59
320
290
–
ECG122N8A30B
T2H T3
45.0
30-60 30-60
520 620
46 36
490 590
46 38
430 540
51 41
400 500
56 44
T4C
30-60
460
49
420
52
370
–
340
–
T1
35-65
410
–
370
–
320
–
290
–
ECG122N8A40B
T2H T3
50.0
35-65 35-65
620 650
48 46
590 620
50 48
540 560
55 53
500 530
59 56
T4C
35-65
460
–
420
–
370
–
340
–
T1
30-60
490
45
470
48
410
54
380
59
T2H
30-60
560
39
540
42
480
47
440
50
ECG182N8A30B
T3
45.0
30-60
640
35
610
36
550
40
520
43
T4C
30-60
680
33
650
34
600
37
560
39
T5
30-60
750
30
720
31
660
34
630
35
T1
35-65
530
56
510
58
450
–
410
–
T2H
35-65
620
48
610
49
550
54
510
58
ECG182N8A40B
T3
50.0
35-65
840
35
820
36
760
39
720
41
T4C
35-65
690
43
670
44
610
48
580
51
T5
35-65
740
40
730
41
670
44
630
47
T1
35-65
650
57
610
61
560
–
530
–
T2H
35-65
730
50
700
53
650
57
610
60
ECG182N8A50B
T3
50.0
35-65
920
40
880
42
830
44
800
46
T4C
35-65
680
54
650
57
600
62
560
T5
35-65
750
50
710
52
660
56
630
59
T1
40-70
580
–
560
–
490
–
450
–
T2H
40-70
880
50
860
52
790
56
750
59
ECG182N8A60B
T3
55.0
40-70
1090
41
1070
41
1000
44
960
46
T4C
40-70
690
64
670
–
600
–
560
–
T5
40-70
750
59
730
61
660
630
–
NOTE:
Airflow data shown is with a dry coil at 70ºDB EAT with Standard 1″ filter Do not operate unit outside of blower operating range
C indicates default cooling tap H indicates default heating tap
Table 9 – ECG AIRFLOW PERFORMANCE DATA
0.5
SCFM
TEMP RISE °F
120
–
190
–
270
54
180
–
120
–
190
–
360
41
280
52
240
–
350
–
460
48
290
–
240
–
460
–
490
–
290
–
330
–
400
56
470
47
510
43
580
38
370
–
460
–
680
44
530
56
580
51
480
–
560
–
750
50
510
–
580
64
410
–
710
63
920
48
520
–
580
–
Therma PAK Series IOM (Rev. A 04/21)
Page30 of 57
THERMA-PAK IOM
AIRFLOW
ECG AIRFLOW PERFORMANCE DATA CONTINUED
IWC STATIC PRESSURE
MODEL
MOTOR MID RISE
0.1
SPEED
RISE °F RANGE °F SCFM
TEMP RISE °F
0.2
SCFM
TEMP RISE °F
0.3
SCFM
TEMP RISE °F
0.4
SCFM
TEMP RISE °F
T1
30-60
490
48
470
48
410
54
380
59
T2H
30-60
560
39
540
42
480
47
440
50
ECG242N8A30B
T3
45.0
30-60
640
35
610
36
550
40
520
43
T4C
30-60
770
29
740
30
690
32
650
34
T5
30-60
940
24
910
24
850
26
820
27
T1
35-65
530
56
510
58
450
NA
410
NA
T2H
35-65
620
48
610
49
550
54
510
58
ECG242N8A40B
T3
50.0
35-65
840
35
820
36
760
39
720
41
T4C
35-65
790
37
780
38
720
41
680
44
T5
35-65
920
32
910
33
850
35
810
36
T1
35-65
650
57
610
61
560
–
530
–
T2H
35-65
730
50
700
53
650
57
610
60
ECG242N8A50B
T3
50.0
35-65
920
40
880
42
830
44
800
46
T4C
35-65
790
47
760
49
710
52
670
55
T5
35-65
930
40
890
41
840
44
810
46
T1
40-70
650
–
630
–
560
–
520
–
T2H
40-70
880
50
860
52
790
56
750
59
ECG242N8A60B
T3
55.0
40-70
1090
41
1070
41
1000
44
960
46
T4C
40-70
790
56
770
58
700
64
660
–
T5
40-70
930
48
910
49
840
53
800
56
T1
35-65
780
38
740
40
700
43
660
45
T2H
35-65
650
45
610
49
560
52
530
56
ECG302N8A40B
T3
50.0
35-65
990
30
950
31
900
33
870
34
T4C
35-65
950
31
900
33
860
35
820
36
T5
35-65 1030
29
990
30
940
31
900
33
T1
35-65
770
48
740
50
690
54
650
57
T2H
35-65
730
50
700
53
650
57
610
60
ECG302N8A50B
T3
50.0
35-65
970
38
940
40
890
42
850
44
T4C
35-65
940
39
910
41
860
43
820
45
T5
35-65 1010
37
980
38
920
40
890
42
T1
40-70
780
57
760
59
690
65
650
–
T2H
40-70
880
50
860
52
790
56
750
59
ECG302N8A60B
T3
55.0
40-70
970
46
940
47
880
51
840
53
T4C
40-70
940
47
920
48
850
52
810
55
T5
40-70 1000
44
980
45
910
49
870
51
NOTE:
Airflow data shown is with a dry coil at 70ºDB at dry coil conditions Do not operate unit at static ranges outside of the temperature rise range
C indicates default cooling tap H indicates default heating tap
Table 10 – ECG AIRFLOW PERFORMANCE DATA CONTINUED
0.5
SCFM
TEMP RISE °F
330
400
56
470
47
600
37
770
29
370
NA
460
–
680
44
630
47
770
39
480
–
560
–
750
50
620
59
760
49
480
710
63
920
48
620
–
750
59
620
48
490
–
820
36
780
38
860
34
600
62
560
–
800
46
780
48
840
44
610
–
710
63
790
56
770
58
830
54
Therma PAK Series IOM (Rev. A 04/21)
Page31 of 57
THERMA-PAK IOM
HEATING OPERATIONS
FIGURE 26 – Heating Sequence of Operations
Therma PAK Series IOM (Rev. A 04/21)
Page32 of 57
THERMA-PAK IOM
HEATING OPERATIONS (continued)
LIGHTING BURNERS
1. Turn off electrical power to the unit. 2. Turn the room thermostat to the
lowest setting. 3. Check that the position of the gas valve switch is
in the “on” position 4. Check that the position of the manual gas shut-
off valve is in the “on” position (see FIGURE 30 Manual Gas Shutoff Valve). 5.
Turn on electrical power to the unit. 6. With the room thermostat to heat
mode, set the temperature above the current room temperature.
SHUTTING DOWN BURNERS
1. Turn off electrical power to the unit. 2. Move the gas valve switch to the
“off” position 3. Turn the manual gas shut-off valve to the “off”
FIGURE 27 – Lighting Instructions Label
GAS INLET
INLET PRESSURE PORT (SET SCREW: 5/32″ HEX HEAD)
GAS INLET
GAS OUTLET
1/4″ MALE SPADE TERMINALS
SWITCH
REGULATOR COVER SCREW (REMOVE TO ACCESS ADJUSTMENT SCREW)
OUTLET PRESSURE PORT (SET SCREW: 5/32″ HEX HEAD)
FIGURE 30 – Gas Valve
NOTE
The White-Rodgers kit ID: F92-1003 is required to measure gas pressure. The
kit consists of a 3/32″ Allen wrench, 5/16″ I.D. tube, and a 5/16″ to 1/4″
hose barb connector.
Therma PAK Series IOM (Rev. A 04/21)
Page33 of 57
THERMA-PAK IOM
HEATING OPERATIONS (continued)
GAS SUPPLY PRESSURE
1. Turn “off” the gas supply to the furnace using the 1/4 turn manual gas
valve.
2. Turn the pressure test screw (3/32″ Hex) in the center of the inlet
pressure boss not more than one turn counterclockwise.
3. Attach the 5/16″ tube from the kit on the gas valve inlet pressure boss.
4. Insert the 5/16″ to 1/4″ hose barb connector from the kit into the 5/16″
tube attached in step 3.
5. Install manometer tubing with manometer on the 1/4″ hose barb connector.
6. Turn “on” the gas supply to the furnace using the 1/4 turn manual gas
valve.
7. Leak check the manometer connections using soap solution made specifically
for the detection of leaks. If a leak is present, shut off the manual valve
and repair the leak. Proceed when no leaks are present.
8. Note the gas supply pressure measured on the manometer. With the burners
not operating, the pressure should be 4.5″ WC minimum and not exceed 10.5″ WC
maximum.
9. Set the room thermostat to call for heat. 10. Terminate the call for heat
at the thermostat. 11. Turn “off” the manual gas valve. 12. Remove the 5/16″
tube, hose barb connector, and
manometer tubing from the inlet pressure boss. 13. Turn the inlet pressure
test screw (3/32″ Hex)
clockwise to seal pressure port. Tighten to 7 in*lb minimum torque.
GAS PRESSURE TABLE
Natural Gas Pressure (inches W.C.)
Min.
Max.
Supply Pressure
4.5
10.5
Nominal 7
Manifold Pressure
3.2
3.8
3.5
Table 11 – Gas Pressure Table
GAS MANIFOLD PRESSURE
1. Turn “off” the gas supply to the furnace using the ¼ turn manual gas
valve.
2. Turn the pressure test screw (3/32″ Hex) in the center of the outlet
pressure boss not more than one turn counterclockwise.
3. Attach the 5/16″ tube from the kit on the gas valve outlet pressure boss.
4. Insert the 5/16″ to ¼” hose barb connector from the kit into the 5/16″
tube attached in step 3.
5. Install manometer tubing with manometer on the ¼” hose barb connector.
FIGURE 28 – Manual Gas Shutoff Valve 6. Turn “on” the gas supply to the
furnace using the
1/4 turn manual gas valve. 7. Set the room thermostat to call for heat. Check
for
leaks on the manometer connections using a commercial solution specifically
formulated for the detection of leaks. If a leak is present, immediately shut
off the manual valve and repair leak. Proceed when no leaks are present. 8.
Note the gas manifold pressure measured on the manometer, with the burners
operating, the gas pressure must maintain 3.2″ WC minimum and not exceed 3.8
WC maximum. 9. To increase gas manifold pressure, remove the regulator cap and
turn the adjustment screw clockwise. To decrease the pressure, turn the
adjustment screw counter-clockwise. 10. Terminate the call for heat at the
thermostat. 11. Turn “off” the manual gas valve. 12. Remove the 5/16″ tube,
hose barb connector, and manometer tubing from the outlet pressure boss. 13.
Turn the outlet pressure test screw (3/32″ Hex) clockwise to seal pressure
port. Tighten to 7 in*lb minimum torque. 14. Turn “on” the manual gas valve.
15. Run the furnace in heat mode by setting the room thermostat to call for
heat. Check for leaks using soap solution formulated for the detection of
leaks.
Therma PAK Series IOM (Rev. A 04/21)
Page34 of 57
THERMA-PAK IOM
HEATING OPERATIONS (continued)
TEMPERATURE RISE
This gas furnace is designed to operate within a specific range of
temperatures while in heating mode. The “Temperature Rise” range is shown on
the rating plate. Temperature rise is defined as the temperature difference
between the air entering the furnace and the air leaving the furnace. Avoid
measuring supply air temperature directly above the heat exchanger as radiant
heat will affect the measurement. The actual temperature rise measured must be
within the range shown on the rating plate. The volume of air (CFM) moved by
the indoor blower may be changed to decrease the actual temperature rise
(increase indoor blower CFM) or increase the actual temperature rise (decrease
the indoor blower CFM) See blower speed section in controls (FIGURE 23 –
Blower Control Tap) page 29 of this manual for information on changing indoor
blower speed.
SUPPLY AIR DUCT
OPTIONAL RETURN DUCT
Therma PAK Series IOM (Rev. A 04/21)
FIGURE 29 – Temperature Rise
Page35 of 57
THERMA-PAK IOM
COOLING OPERATIONS
START
Y = ON
NO
G = ON
NO
STAND BY
NO
YES
YES
FAN MODE
HPS = CLOSED
FAN = ON
Initial Condition
YES
Comp = Off
Fan = Off
COMP ON
LEGEND:
Y = Call for Cooling
G = Call for Fan HPS = High Pressure Switch
FIGURE 30 – Cooling Sequence of Operations
Therma PAK Series IOM (Rev. A 04/21)
Page36 of 57
THERMA-PAK IOM
LOCATION OF MAJOR COMPONENTS
FIGURE 31 – Cabinet Components
Therma PAK Series IOM (Rev. A 04/21)
Page37 of 57
THERMA-PAK IOM
LOCATION OF MAJOR COMPONENTS (continued)
HEAT EXCHANGER TUBES
BURNER BOX GAS BURNERS MANIFOLD
ROLLOUT SWITCH
FLUE COLLECTOR BOX
GAS VALVE FIGURE 32 – Heating Assembly
DRAFT INDUCER
Therma PAK Series IOM (Rev. A 04/21)
Page38 of 57
THERMA-PAK IOM
REPLACEMENT PARTS
Table 12: Replacement Parts For service part inquiries, please contact:
First Co. 8273 Moberly Lane
Dallas, TX 75227 214-388-5751
Therma PAK Series IOM (Rev. A 04/21)
Page39 of 57
THERMA-PAK IOM
WIRING DIAGRAMS
Therma PAK Series IOM (Rev. A 04/21)
ECG(09-12)2N8AB ROTARY 208-230V ECM FIGURE 33 -ECG(09-12)2N8AB 208-230 Volt ECM Wiring Diagram
Page40 of 57
Page41 of 57
ECG(18-30)2N8AB SCROLL 208-230V ECM FIGURE 34 – ECG(18-30)2N8A Scroll 208-230 Volt ECM Wiring Diagram
Therma PAK Series IOM (Rev. A 04/21)
THERMA-PAK IOM
WIRING DIAGRAMS
THERMA-PAK IOM
CIRCUIT SCHEMATIC
FIGURE 35 – Circuit Diagram
STARTUP INSTRUCTIONS
PRE-STARTUP CHECKS
CAUTION
Wire all field installed device such as a fan switch or thermostat furnished
by the factory in strict accordance with
the wiring diagram supplied with the unit. Failure to do so could result in
damage to components and will void all warranties.
Before start-up, thoroughly check all the components. Optimal operation of
equipment requires cleanliness. Often after installation of the equipment,
additional construction activities occur. Protect the equipment from debris
during these construction phases.
PRIOR TO THE STARTUP OF THE UNIT
1. Ensure supply voltage matches nameplate data. 2. Ensure the unit is
properly grounded. 3. With the power off, check blower wheel set
screws for proper tightness and that the blower wheel rotates freely. 4.
Ensure unit will be accessible for servicing. 5. Ensure condensate line is
properly sized, run, trapped, pitched and tested. 6. Ensure all cabinet
grommets and electrical insulating grommets are in place. 7. Ensure clean
filters are in place. 8. Ensure all access panels are in place and secured. 9.
Make sure that all electrical connections are tight and secure. 10. Check the
electrical overcurrent protection and wiring for the correct size. 11. Verify
that the low voltage wiring between the thermostat and the unit matches the
wiring diagram.
Therma PAK Series IOM (Rev. A 04/21)
Page42 of 57
THERMA-PAK IOM
STARTUP INSTRUCTIONS (continued)
UNIT STARTUP
1. Ensure that power is connected to the unit and the local disconnect is
switched to ON position.
2. Check that there is 24V from the control transformer. The controller
module LED should light up.
3. Set the thermostat to the lowest position. Turn the thermostat system
switch to “COOL” and the fan switch to “AUTO” position. The compressor,
outdoor fan should come on within 5 seconds.
CHECKING GAS INPUT RATE The gas input rate of a furnace is expressed in BTU
per hour (BTUH). Upon installation and startup, the gas input rate of each ECG
unit must be measured and must not exceed the input rate listed on the furnace
rating plate.
To measure the natural gas input rate;
1. The ECG unit must be the only appliance consuming gas during this
measurement, other gas consuming appliances must be turned OFF.
2. Set the room thermostat to call for heat. When the burners are operating,
use a stopwatch and record the number of seconds it takes to complete one
revolution of the 0.5 cu/ft., 1.0 cu/ft or the 2.0 cu/ft. dial at the gas
meter.
3. The heating value may be obtained from the utility company, if unknown use
the typical heating value of 1,000 BTU per cu/ft.
Refer to Table 13 – Gas Meter Clocking Table or see example calculation below.
GAS METER CLOCKING TABLE
SECONDS FOR ONE REVOLUTION
MODEL
0.5
1.0
2.0 CU/FT
CU/FT CU/FT
ECG**2N8A20 90
180
360
ECG**2N8A30 60
120
240
ECG**2N8A40 45
90
180
ECG**2N8A50 36
72
144
ECG**2N8A60 30
60
120
Table 13 – Gas Meter Clocking Table
Example of input rate calculation using the typical heating valve of Natural
Gas of 1,000 BTU cu/ft, and 90 seconds time to complete one revolution of the
1 cu/ft dial on the gas meter.
Heating value = 1,000 BTU per cu/ft. Convert hours to seconds (60 minutes per
hour x
60 seconds per minute) = 3600 seconds in one hour. Example time for one
revolution of the 1 cu/ft dial = 90 seconds Input = Heating Value (1,000) x
seconds per hour (3,600) divided by the time to consume 1 cu/ft of gas (90
secs) = 40,000 BTUH.
NOTE
In the calculation example above, If the 0.5 cu/ft dial was used, you must
multiply the number of seconds recorded for one revolution by two before using
the formula. If the 2 cu/ft
dial was used, you must divide the number of seconds recorded for one
revolution by two before using the formula.
STARTUP & PERFORMANCE CHECKLIST INSTRUCTIONS
The warranty may be void unless the FIGURE 41 Startup and Performance
Checklist & FIGURE 42 Startup and Performance Checklist is completed and
returned to the warrantor. If the ECG unit is not installed properly the
warranty will be void as the manufacturer can’t be held accountable for
problems that stem from improper installation.
Therma PAK Series IOM (Rev. A 04/21)
Page43 of 57
THERMA-PAK IOM
TROUBLESHOOTING
HEATING
PROBLEM
POSSIBLE CAUSE
CHECKS & CORRECTIONS
Open Circuit Fuse (Electrical Panel)
Replace fuse
NO
OPERATION
Open Open
Circuit Breaker (Electrical Unit Power Switch
Panel)
(External disconnect, adjacent to unit)
Active fault locking out heat operation
Re-set circuit breaker / fuse Check position / electrical state of switch
Refer to LED & legend for state of unit / fault code. Correct condition &
reset power
Open Unit Door Switch (Internal)
Furnace design does not permit heat operation with blower door removed
No power to room thermostat (24 vac between P1 terminals 2 & 5)
Improper field wiring Faulty Transformer No transformer ground
No request from room thermostat (24 vac between P1 terminals 2 & 3)
Improper field wiring Faulty thermostat / thermostat wiring Control board relay not closing contact to energize draft inducer
No draft inducer operation
Remove obstruction preventing inducer wheel from turning
Electrically open inducer motor winding or thermal protector – replace inducer
Correct poor chassis to earth ground / transformer to chassis ground / control
board to chassis ground
Correct Improper gap on spark electrode
Weak Spark / No spark
NO HEAT
Clean Insulating carbon buildup from spark electrode & determine cause of poor
combustion
Replace spark electrode assembly for faulty – leaking insulator Faulty
ignition wire leaking voltage – replace ignition wire
Ignition wire not connected / poorly connected to control or spark electrode
Open limit from no indoor blower operation
Remove obstruction preventing indoor blower wheel from turning
Control board relay contact not energizing line voltage to blower motor
replace control
Speed tap not energized at low voltage terminal strip by thermostat wire,
repair connection to thermostat wire or motor speed terminal
Over-heated blower motor with open winding or open thermal protection, correct
restriction causing over-heating condition, replace motor if winding is open
Furnace cycling on pressure switch
Correct inadequate venting, plugged inducer pressure switch port, Check wiring connections to gas valve & control board (P2 terminals 3 & 4)
Gas valve not opening No or inadequate flame signal
Check control board output 24 VAC to gas valve (P2 terminals 3 & 4) control
must energize gas valve and spark electrode for 4 seconds minimum at trial for
ignition.
Correct low gas pressure, clean or replace flame rod
Furnace cycling on limit switch
INADEQUATE
HEAT
Gas pressure too low
Restricted air flow caused by plugged filter, closed registers / grilles Correct gas supply line pressure to 4.5″ – 10″ range while furnace operating in heat mode Correct gas manifold pressure to 3.2″ to 3.8″ range
Table 14 – Gas Heat Troubleshooting Table
Therma PAK Series IOM (Rev. A 04/21)
Page44 of 57
THERMA-PAK IOM
TROUBLESHOOTING (continued)
HEATING
Refer to the LED code definitions in Table 15 – Control Board L.E.D. Table for
definitions used in this section.
Step 1 Thermostat calls for heat by energizing “W” terminal with 24 volts a/c
Description The room thermostat R terminal is constantly powered with 24 volts
a/c by its connection to the control board R
of Normal terminal and the unit transformer. A request for heat will energize
the “W” terminal of the thermostat and the control Operation board. Possible
Causes of Failure: 1. Thermostat mode switch is not set to heat 2. Broken wire
between control board & thermostat 3. Broken wire at thermostat terminal 4.
Improperly connected thermostat wire (W at control is not connected to W at
thermostat) 5. Defective thermostat
a. The control board LED will display a slow flash no call for heat
Step 2 Control board checks for a closed limit switch circuit & an open
pressure switch circuit Description Upon receiving a request for heat, the
control board must verify a safe condition exists before attempting ignition.
of Normal The high temperature limit & rollout switches must be electrically
closed. The pressure switch must be electrically Operation open. Possible
Causes of Failure: 1. Draft inducer relay on control board stuck closed
keeping the draft inducer running & the pressure switch closed
a. The control board L.E.D. will flash 3 times 2. The high limit switch or
rollout switch is electrically open. A wire or connector is broken or
improperly connected
a. The control Board L.E.D. will flash 4 times b. The room thermostat will
lose power as an open limit or rollout switch breaks 24 volts a/c to the R
terminal
Step 3 Control board closes on-board contacts to energize draft inducer
Description The control board relay coil is energized & relay contacts close
to power the draft inducer. The draft inducer must
of Normal function to draw the gas flames into the heat exchanger tubes &
expel the products of combustion outdoors. Operation Possible Causes of
Failure: 1. No power to draft inducer due to control board inducer relay
contracts failing open
a. The control board L.E.D. will flash 3 times 2. The draft inducer motor is
powered but not operating due to an open winding or thermal protector
a. The control board L.E.D. will flash 3 times
Step 4 Draft inducer runs causing pressure switch contacts to close
Description The pressure switch must prove that the draft inducer is running &
that adequate negative pressure is present in the
of Normal heat exchanger. Operation Possible Causes of Failure 1. The draft
inducer motor is running but the pressure switch is not closing due to lack of
negative pressure caused by
a. Blocked flue b. Tubing disconnected from the draft inducer or pressure
switch c. Tubing leaking d. Blocked pressure switch port on draft inducer
housing
i. The control board L.E.D. will flash 3 times
Step 5 Draft inducer purges the heat exchanger for 15 seconds Description
Before trial for ignition, the draft inducer runs to purge the heat exchanger
of any combustible mixture of gas & air
of Normal which may be present Operation Possible Causes of Failure: 1. Power
Failure 2. Draft Inducer Failure 3. Control Board Relay Failure
Therma PAK Series IOM (Rev. A 04/21)
Page45 of 57
THERMA-PAK IOM
TROUBLESHOOTING (continued)
HEATING
Step 6 Control board energizes the spark ignitor & the gas valve (trial for
ignition) Description During trial for ignition, the draft inducer, & gas
valve are energized. After 10 seconds, the spark ignitor is de-
of Normal energized & the control checks for the presence of flame. If flame
is not present, the control will de-energize the gas Operation valve.
Possible Causes of Failure:
1. Internal or external gas valve in off position 2. Inadequate ground
causing no spark or poor spark 3. Inadequate gas supply to furnace 4. Manifold
gas pressure too high or too low causing improper gas / air mixture 5.
Improper spark electrode gap
a. The control board L.E.D. will display 2 flashes if locked out from failed
ignition or flame loss
Step 7 Control board senses flame within 10 seconds of trial for ignition
Description Flame must be sensed by the control board flame rectification
system to maintain gas valve operations
of Normal Operation
Possible Causes of Failure:
1. Inadequate flame 2. Inadequate control ground 3. Flame sensor dirty /
coated with non-conductive buildup 4. Flame sensor insulator is cracked
a. The control board L.E.D. will display 2 flashes if locked out from failed
ignition or flame loss
Step 8 Control board energizes indoor blower motor after 30 seconds
Description After 30 seconds of burner operation the control board energizes
the indoor blower motor
of Normal Operation
Possible Causes of Failure:
1. Control board relay fails to energize blower 2. Indoor blower not
connected to line voltage 240-volt supply 3. Indoor blower speed tap not
connected to low voltage 24-volt supply 4. Indoor blower fan wheel blocked or
restricted
a. The control board L.E.D. will display 4 flashes due to open limit switch if
indoor airflow is inadequate
Step 9 Room temperature increases to satisfy the thermostat Description Heat
cycle continues until the room thermostat temperature set point is met
of Normal Operation
Possible Causes of Failure:
1. Room thermostat request for heat interrupted ending call for heat 2.
Furnace burners cycling on / off due to
a. Open limit switch b. Restricted airflow c. Dirty filter
i. The control board L.E.D. will display 4 flashes due to open limit switch if
indoor airflow is inadequate
Therma PAK Series IOM (Rev. A 04/21)
Page46 of 57
THERMA-PAK IOM
TROUBLESHOOTING (continued)
HEATING
Step 10 Thermostat opens de-energizing the “W” terminal Description The room
thermostat will end the request for heat & de-energize the “W” terminal of the
control board
of Normal Operation
Possible Causes of Failure:
1. Room thermostat contracts staying closed not ending the request for heat
2. Thermostat wires shorted together keeping “W” terminal energized
Step 11 Control board de-energizes the gas valve Description Control board
opens the 24 Volt signal to the gas valve main solenoid shutting off the flow
of gas to the burners
of Normal Operation
Possible Causes of Failure:
1. Electrical short in the gas valve circuit keeping the gas valve energized.
The control board L.E.D. will display 5 flashes if gas flame is detected when
it is not expected. Draft inducer will continue to run
Step 12 Control board continues to energize the indoor blower motor for 2
minutes Description Control boards continues to energize the indoor blower
motor to distribute heat from the heat exchanger to the
of Normal conditioned space Operation
Possible Causes of Failure:
1. The control board time delay blower relay is stuck closed causing blower
to stay on to cool down heat exchanger runs in excess of 2 minutes
Therma PAK Series IOM (Rev. A 04/21)
Page47 of 57
THERMA-PAK IOM
TROUBLESHOOTING (continued)
COOLING
PROBLEM ENTIRE UNIT DOES NOT RUN
BLOWER OPERATES BUT COMPRESSOR DOES NOT RUN UNIT OFF ON HIGH PRESSURE
CONTROL FAULT CODE 12
POSSIBLE CAUSE Power supply off
CHECKS & CORRECTIONS Apply power; close disconnect.
Blown Fuse
Replace fuse or reset circuit breaker. Check for correct fuses.
Voltage supply low Thermostat
If voltage is below minimum voltage specified on unit data plate, contact lower power company. (Fault Code Ou & 17). Set the fan to “ON”, the fan should run. Set thermostat to “COOL” and lowest temperature setting, the unit should run in the cooling mode. If neither the blower nor compressor run with the thermostat set to “COOL”, check that the unit is wired correctly.
Thermostat
Check setting, calibration and wiring.
Wiring Safety Controls
Check for loose or broken wires at compressor, capacitor or contractor. Check control board fault LED for fault code.
Compressor overload open Compressor motor grounded
If the compressor is cool and the overload will not reset, replace the compressor. Internal wiring grounded to the compressor shell. Replace compressor. If compressor burnout, install new filter dryer.
Compressor windings open Discharge pressure too high
Refrigerant charge
High pressure switch
After compressor has cooled, check continually of compressor windings. If the windings are open, replace the compressor. In “COOLING” mode: Lack of adequate airflow rate. Air temperature too warm. Scaled or restricted condenser coil. The unit is overcharged with refrigerant. Reclaim refrigerant, evacuate and recharge with factory recommended charge. Check for defective or improperly calibrated high-pressure switch.
Table 16 – Cooling Troubleshooting Table
Therma PAK Series IOM (Rev. A 04/21)
Page48 of 57
THERMA-PAK IOM
MAINTENANCE & SERVICE- HEATING
FLAME SENSOR ROLLOUT SWITCH
GAS VALVE INLET
IGNI TOR BURNERS
ORIFICES SCREWS
MANIFOLD ASSEMBLY
GAS VALVE
FIGURE 36 – Burner Components
PREVENTATIVE MAINTENANCE
Examine the furnace after installation and periodically thereafter to
determine that:
1. The furnace flue is clear and free of obstructions.
2. The furnace flue is in place and is physically sound without holes or
excessive corrosion.
3. The return-air duct connection(s) is physically sound, is sealed to the
furnace casing, and terminates outside the space containing the furnace.
4. The physical support of the furnace is sound without sagging, cracks,
gaps.
5. There are no obvious signs of deterioration of the furnace.
6. The burner flames are proper (see FIGURE 37 Burner Flames) being drawn
into the heat exchanger tubes, not lifting, blue in color, not being distorted
by fan operation
AIR FILTER(S)
Furnace filters should be checked monthly and replaced as necessary. Do not
operate the furnace without filters in place. The Interval of filter
replacement will vary with environmental factors and the size and type of
filters used. It is extremely important to replace filters before they become
a restriction to air flow.
Therma PAK Series IOM (Rev. A 04/21)
FIGURE 38 – Burner Flames
DRAFT INDUCER
The draft inducer creates a negative pressure condition in the gas heat
exchanger and discharges the products of combustion to the outdoors. Check the
ventilation openings on the end of the inducer draft motor to make sure they
are not blocked and free from debris. The draft inducer motor contains
permanently sealed ball bearings and requires no lubrication.
COMBUSTION AIR PROVING SWITCH
The combustion air-proving switch is a safety device which verifies operation
of the draft inducer.
Page49 of 57
THERMA-PAK IOM
MAINTENANCE & SERVICE- HEATING (continued)
FLAME ROLL OUT SWITCHES
Flame roll-out switches are electrically normally closed safety switches that
assure burner flames are drawn properly into the heat exchanger tubes. In the
event of improper burner flames or overheating of the burner section, the
flame roll-out switch opens the electrical circuit shutting off the flow of
gas to the burners. Flame roll-out switches require manual reset if tripped.
FLAME SENSOR ASSEMBLY
The flame sensor assembly consists of a conductive rod surrounded by an
insulator attached to a mounting plate. The flame sensor may be cleaned as
needed with steel wool. A slight coating developing on the flame sensor over
time is normal and to be expected, however; the presence of heavy black carbon
is an indication of improper combustion and requires immediate attention to
determine the cause and to correct. Exercise care when handling to protect the
insulator from damage.
INTEGRATED CONTROL
The integrated control handles inputs from the room thermostat, spark ignition
& flame sensing functions, controlling power to the gas valve, fan timing
functions, and monitors all safety circuits of the furnace. There are no
serviceable parts in the integrated control module other than a 5A fuse. Do
not handle the integrated control module unless necessary, before touching the
integrated control module, touch the unit frame to discharge any static
electricity which could damage the integrated control.
SPARK IGNITOR ASSEMBLY
The spark igniter assembly consists of a spark electrode with insulator and a
ground electrode attached to a mounting plate. Take care not to damage the
insulator. The spark and ground electrodes may be cleaned as needed with steel
wool.
GAS BURNERS
The gas burners allow combustion air to mix with the natural gas and direct
the gas / air mixture to each heat exchanger tube.
GAS ORIFICES
The gas orifices are precisely sized to deliver the proper amount of natural
gas to each burner. Exercise caution when handling orifices to prevent the
creation of burrs.
GAS VALVE
The gas valve is an integral part of unit safety. Never use a gas valve that
has been under water. The gas valve is energized by the control board to
establish the flow of natural gas to the burners when heat is requested by the
thermostat and all safety devices are in their proper state.
HIGH TEMPERATURE LIMIT SWITCH
The high temperature limit switch is an electrically normally closed safety
that limits temperature within the furnace. If heating mode airflow through
the furnace becomes inadequate, the high temperature limit switch will open,
shutting off the flow of gas to the burners. The high temperature limit switch
is auto reset.
WARNING
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings may cause property damage, personal injury,
or death.
Improper servicing could result in dangerous operation death or property
damage.
Before servicing, disconnect all electrical power to furnace.
When servicing controls, label all wires prior to disconnecting. Reconnect
wires correctly.
Verify proper operation after servicing.
INDOOR BLOWER MOTOR
Check the openings on the end of the indoor blower motor to make sure they are
not blocked and free from debris. The indoor blower motor contains permanently
sealed ball bearings and requires no lubrication.
Therma PAK Series IOM (Rev. A 04/21)
Page50 of 57
THERMA-PAK IOM
MAINTENANCE & SERVICE- HEATING (continued)
PERIODIC INSPECTIONS
The following additional items should be inspected annually (minimum) before
each heating season by a qualified service agency:
HEAT EXCHANGER TUBES Make sure they are free from blockages, signs of carbon
buildup, heavy corrosion or cracks. GAS BURNERS Make sure they are free of
blockages, signs of carbon buildup or heavy corrosion. The burner carry-over
slots should be clean and of uniform size. VENT PIPE Check for excessive
corrosion or perforations. VENT TERMINAL Check that it is free from blockages
and restrictions. COMBUSTION AIR OPENINGS Check that they are clean & free
from debris or blockages of any kind. INDOOR AIR The blower wheel and blower
housing must be free from debris. Check that supply and return air registers,
grilles, and dampers are positioned properly, filters are in place and clean.
CONDENSER AND EVAPORATOR COILS Inspect and wash the condenser and evaporator
coils. DO NOT use high pressure as damage to the finned surfaces may occur.
HIGH ALTITUDE OPERATIONS
ECG*2N8 units are certified for installation at altitudes of 0 – 4,500 ft.
SPECIAL NOTES FOR EXTREMELY COLD WEATHER AREAS
Periodically check the outside louvered grill for ice that may form and
obstruct the flue and combustion air inlet.
Therma PAK Series IOM (Rev. A 04/21)
Page51 of 57
THERMA-PAK IOM
MAINTENANCE & SERVICE- HEATING (continued)
HEATING MODULE REMOVAL
The entire gas heat section may be removed as a unit for service if required.
Turn off electrical power to furnace.
- Turn off electrical power to furnace. 2) Remove heating section access panels shown in FIGURE 39- Heating Access Panel Removal
FIGURE 39 – Heating Access Panel Removal 3) Disconnect gas union and necessary
piping to allow heat section module to slide out of cabinet, see FIGURE 40 –
Disconnection of Gas Union & Piping
PIPE UNION GROMMET
FIGURE 40 – Disconnection of Gas Union & Piping
Therma PAK Series IOM (Rev. A 04/21)
Page52 of 57
THERMA-PAK IOM
MAINTENANCE & SERVICE- COOLING
PREVENTIVE MAINTENANCE
To achieve maximum performance and service life of equipment, a formal
schedule of regular maintenance should be established and followed.
AIR FILTER
The air filter should be cleaned or replaced every 30 days or more frequently
if severe operating conditions exist. Always replace the filter with the same
type and size as originally furnished.
WARNING
It is a violation of federal law to discharge refrigerant into the atmosphere.
Use proper reclaiming methods and equipment when installing or servicing this
unit. Service should be performed by a QUALIFIED service agency. The
refrigerant system contained in the unit normally requires no maintenance
since it is a closed, self-contained system.
CAUTION
All appropriate personal protection equipment should be worn when servicing or
maintaining this unit. Personal injury can result from sharp metal edges,
moving parts, and hot or cold surfaces.
WARNING
COIL
Clean all heat transfer surfaces and remove all dirt, dust, and contaminates
that potentially impairs air flow using industry accepted practices. Care
should be taken not to bend coil fin material.
CONDENSATE DRAIN PAN AND PIPE
Check and clean all dirt and debris from pan. Ensure drain line is free
flowing and unobstructed.
UNIT PERFORMANCE
Record performance measurements of volts, amps, and air temperature
differences. A comparison of logged data with start-up and other annual data
is useful as an indicator of general equipment condition.
ELECTRIC SHOCK HAZARD
Check motor connections to ensure they are secure and in accordance with the
unit wiring diagram.
ECM motors have line voltage power applied at all times. ALWAYS VERIFY THAT
POWER IS DISCONNECTED BEFORE
SERVICING.
Therma PAK Series IOM (Rev. A 04/21)
Page53 of 57
THERMA-PAK IOM
STARTUP & PERFORMANCE CHECKLIST
FIGURE 41 – Startup and Performance Checklist (1 of 2)
Therma PAK Series IOM (Rev. A 04/21)
Page54 of 57
THERMA-PAK IOM
STARTUP & PERFORMANCE CHECKLIST (continued)
FIGURE 42 – Startup and Performance Checklist (2 of 2)
Therma PAK Series IOM (Rev. A 04/21)
Page55 of 57
THERMA-PAK IOM
NOTES
Therma PAK Series IOM (Rev. A 04/21)
Page56 of 57
Vertical Packaged Gas Heat / Electric Cooling Unit
CATEGORY III TYPE MSP 11 EER
Manufactured by: AE Air.
8273 Moberly Lane Dallas, TX 75227 www.ae-air.com
The manufacturer works to continually improve its products. It reserves the
right to change design and specifications without notice. ©2022 AE Air, 8273
Moberly Lane, Dallas, TX 75227
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