AE-Air IOM8601 Vertical Packaged Gas Heat Instruction Manual

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)

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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
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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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.
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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)

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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.
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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)

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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.

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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.

1. 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)

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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)

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THERMA-PAK IOM
STARTUP & PERFORMANCE CHECKLIST (continued)
FIGURE 42 – Startup and Performance Checklist (2 of 2)

Therma PAK Series ­ IOM (Rev. A 04/21)

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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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