Literature R8GE-ULN Gas Electric Pack Instruction Manual

R8GE-ULN Gas Electric Pack
INSTALLATION INSTRUCTIONS
Single Package Gas Heating/Electric Cooling

R8GE-ULN Gas Electric Pack

This product complies with SJVAPCD 4905 and SCAQMD 1111 with NOx levels below 14ng/J when operated on natural gas.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
– 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 try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a neighbors phone. Follow the gas suppliers instructions.
• If you cannot reach your gas supplier, call the fire department.
  – Installation and service must be performed by a qualified installer, service agency or the gas supplier.

DO NOT DESTROY THIS MANUAL. READ ALL INSTRUCTIONS IN THIS MANUAL AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

IMPORTANT SAFETY INFORMATION

Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored.
WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death.
CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.
WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in 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.
• Verify proper operation after servicing.

WARNING:
These units are fully charged with R-410A refrigerantand ready for installation. When a system is installedaccording to these instructions, no refrigerantcharging is required. If repairs make it necessary for evacuation and charging, it should only be attemptedby qualified, trained personnel thoroughly familiar with this equipment. Some local codes requirelicensed installation service personnel to service this type of equipment. Under no circumstances should the homeowner attempt to install and/or service this equipment. Failure to comply with this warning could result in equipment damage, personalinjury, or death.
WARNING:
Do not place combustible material on or against the unit cabinet. Do not place combustible materials, including gasoline and any other flammable vapors and liquids, in the vicinity of the unit.
WARNING:
PROPOSITION 65 WARNING: This product contains fiberglass wool, a product known to the state of California to cause cancer. Disturbing the insulation of this product during installation, maintenance, or repair will expose you to fiberglass wool.

• Breathing this material may cause respiratory irritations or may cause lung cancer.
• Fiberglass wool may also cause eye irritation, skin sensitization, or other allergic responses in susceptible individuals.
• Always wear goggles, disposable gloves, long sleeved shirt, and appropriate breathing protection when working near this insulation. If contact with skin occurs, wash immediately with soap and water. In case of contact with eyes, flush immediately with water for at least 15 minutes. Contact a physician if needed.

WARNING:
The information listed below and on the next page must be followed during the installation, service, and operation of this unit. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death.

• Before beginning the installation, verify that the unit model is correct for the job. The unit model number is printed on the data label. Follow all precautions in the literature, on tags, and on labels provided with the equipment. Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment.
• Never test for gas leaks with an open flame. Use a commercially available soap solution to check all connections. See page 13.
• Installation of equipment may require brazing operations. Installer must comply with safety codes and wear appropriate safety equipment (safety glasses, work gloves, fire extinguisher, etc.) when performing brazing operations.
• This equipment is NOT to be used for temporary heating of buildings or structures under construction.
• Use caution when handling this appliance or removing components. Personal injury can occur from sharp metal edges present in all sheet metal constructed equipment.
• Follow all precautions in the literature, on tags, and on labels provided with the equipment. Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment.
• The installer should become familiar with the units wiring diagram before making any electrical connections to the unit. See the unit wiring label or Figure 12 (page 24).

REQUIREMENTS & CODES

• This equipment must be installed in accordance with instructions outlined in this manual, all applicable local building codes, and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Installation Code, CAN/CGA B149.1.
• All electrical wiring must be completed in accordance with local, state and national codes and regulations and with the National Electric Code (ANSI/NFPA 70) or in Canada the Canadian Electric Code Part 1 CSA C.22.1.
• The installer must comply with all local codes and regulationswhich govern the installation of this type of equipment. Local codes and regulations take precedence over any recommendations contained in these instructions. Consult local building codes and the National Electrical Code (ANSI CI) for special installation requirements.
• This equipment contains liquid and gaseous refrigerant under high pressure. Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment.
• Install this unit only in a location and position as specified on Figure 1 (page 5). This unit is designed only foroutdoor installations and should be located with considerationof minimizing the length of the supply and return ducts. Consideration should also be given to the accessibility of fuel, electric power, service access, noise, and shade.
• Air Ducts must be installed in accordance with the standards of the National Fire Protection Association “Standards for Installation of Air Conditioning and Ventilation Systems” (NFPA 90A), “Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems” (NFPA 90B), these instructions, and all applicable local codes.
• Consult Table 6 (page 21), Table 7 (page 22), and the rating plate for the proper circulating air flow and temperature rise. It is important that the duct system be designed to provide the correct flow rates and external pressure rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues.
• Use only with the type of gas approved for this unit. Refer to the unit rating plate.
• Provide adequate combustion and ventilation air to the unit. See page 6 & page 7.
• Provide adequate clearances around the combustion air intake louvers. See Figure 1.
• Combustion products must be discharged outdoors. Connect this unit to an approved vent system only, as specified on page 7.
• The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes. Always consult with local authorities before installing any gas appliance.

Combustion & Ventilation Air

• US: National Fuel Gas Code (NFGC), Air for Combustion and Ventilation
• CANADA: Natural Gas and Propane Installation Codes (NSCNGPIC), Venting Systems and Air Supply for Appliances

Duct Systems

• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) Fundamentals Handbook

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70
• CANADA: Canadian Electrical Code CSA C22.1 Gas Piping & Gas Pipe Pressure Testing
• US: NFGC and National Plumbing Codes
• CANADA: NSCNGPIC

General Installation

• US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Association, 400 N. Capitol, N.W., Washington DC 20001 or www.NFPA.org
• CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada

Safety

• US: (NFGC) NFPA 54–1999/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B.
• CANADA: CAN/CGA-B149.1 and .2–M00 National Standard of Canada. (NSCNGPIC)

GENERAL INFORMATION

This single package gas heating/electric cooling unit is designed only for outdoor rooftop or ground level slab installations and can be readily connected to the high static duct system of a home. This unit has been tested for capacity and efficiency in accordance with AHRI standards and will provide many years of safe and dependable comfort, providing it is properly installed and maintained. With regular maintenance, this unit will operate satisfactorily year after year. Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards.
To achieve optimum performance and minimize equipment failure, it is recommended that periodic maintenance be performed on this unit. The ability to properly perform maintenance on this equipment requires certain tools and mechanical skills.
Before you install this unit
√ The cooling load of the area to be conditioned must be calculated and a system of the proper capacity selected. It is recommended that the area to be conditioned be completely insulated and vapor sealed.
√ Check the electrical supply and verify the power supply is adequate for unit operation. Consideration should be given to availability of electric power, service access, noise, and shade. If there is any question concerning the power supply, contact the local power company.
√ All units are securely packed at the time of shipment and upon arrival should be carefully inspected for damage prior to installing the equipment at the job site. Claims for damage (apparent or concealed) should be filed immediately with the carrier.
√ Survey the job site to determine the best location for setting the unit. Choose an appropriate location that minimizes the length of the supply and return air ducts.
√ Please consult your dealer for maintenance information and availability of maintenance contracts. Please read all instructions before installing the unit.
Locating the Equipment

• Clearance in accordance with local installation codes, the requirements of the gas supplier and the manufacturer’s installation instructions.
• A clearance of at least 36 inches from the blower access panel and from the louvered control access panel is recommended for servicing and maintenance. Where accessibility to combustibles clearances are greater than minimum clearances, accessibility clearances must take preference.
• Select a solid, level position, preferably on a concrete slab, slightly above the grade level, and parallel to the home. DO NOT PLACE UNIT UNDER THE HOME.
• Overhead obstructions, poorly ventilated areas, and areas subject to accumulation of debris should be avoided. Do not place the unit in a confined space or recessed area where discharge air from the unit to re-circulate into the condenser air inlet, through the coil.
• Sufficient clearance for unobstructed airflow through the louvered control access panel and outdoor coil must be maintained in order to achieve rated performance. See Figure 1 for minimum clearances to obstructions.
• The hot condenser air must be discharged up and away from the home, and if possible, in a direction with the prevailing wind.
• If practical, place the air conditioner and its ducts in an area where they will be shaded from the afternoon sun, when the heat load is greatest.

Heating Load
This unit should be sized to provide the design heating load requirement. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air Conditioning Engineers; or other approved engineering methods. For installations above 2,000 ft., the unit should have a sea level input rating large enough that it will meet the heating load after deration for altitude.

COMBUSTION AIR & VENTING REQUIREMENTS

WARNING:
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes.
9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

General Information
WARNING:

Installation methods other than those described in the following sections must comply with the NationaFuel Gas Code and all applicable local codes for providing sufficient combustion air to the unit.

• Provisions must be made during the installation of this unit that provide an adequate supply of air for combustion.
• Instructions for determining the adequacy of an installation can be found in the current revision of the NFGC (ANSI Z223.1/ NFPA54). Consult local codes for special requirementsThese requirements are for US installations as found in the NFGC.
• The requirements in Canada (B149.1) are structureddifferently. Consult with B149.1 and local code officials for Canadian installations.

WARNING:
Combustible air must not be drawn from a contaminated atmosphere. Excessive exposure to contaminated combustion air will result in safety and performance related problems.

• To maximize heat exchanger life, the combustion air must be free of chemicals that can form corrosive acidic compounds in the combustion gases. The recommended source of combustion air is to use clean air from outside. DO NOT place any chemicals with flammable or caustic vapors or these other corrosive chemicals near the vent termination:
  • Gasoline/Kerosene
  • 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
  • Cements, glues, paint removers, varnishes, etc.
  • Hydrochloric acid
  • Masonry acid washing materials
  • Plumbing Stack

Vent Termination
This unit has been equipped with an integral venting system and designed to operate only with this venting system. No additional venting shall be used. This unit must be vented to the outdoors.
WARNING:
This unit is intended for outdoor installation only. Do not vent the unit through a conventional venting system.
A vent cover assembly has been supplied with the unit. and can be found secured to the gas controls within the control area of this unit. The vent cover assembly must be installed to assure proper operation of the unit.
Figure 2 shows the proper installation of the vent cover assembly over the vent outlet on the exterior of the corner panel. The fasteners used to secure the vent cover assembly have been included in the owner’s package. The following list summarizes the requirements for the location of the vent system termination:

• The location of the vent termination must be consistent with the National Fuel Gas Code (ANSI Z223.1) or CAN/CGA-B149 Installation Codes.
• The vent termination must be located at least 4 feet horizontally from any electric meters, gas meters, regulators, and relief equipment.
• The vent termination must be located at least 3 feet above any forced air inlet located within 10 feet.
• The vent termination must be located at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.
• The vent termination must be located at least 1 foot above grade.
• The unit should be installed in a way that prevents any obstruction of the vent termination during accumulating snow.
• The unit installation shall avoid areas where condensate drainage may cause problems by dropping on planters or patios, etc. Also verify exhaust gases will not impinge on windows or building surfaces, which may be compromised or damaged by condensation.
• Do not install the unit such that exhaust from the vent termination is directed into window wells, stairwells, under decks, or in alcoves or similarly recessed areas. The vent termination must not be located above any public walkways.

CIRCULATING AIR SUPPLY

WARNING:
Products of combustion must not be allowed to enter the return air ductwork or the circulating air supply. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.
All return ductwork must be adequately sealed, all joints must be taped, and the ductwork must be secured to the unit with sheet metal screws. When return air is provided through the bottom of the unit, the joint between the unit and the return air plenum must be air tight.
The roof curb or cement pad on which the unit is mounted must provide sound physical support of the unit with no gaps, cracks, or sagging between the unit and the curb or pad.
Return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert, stove, etc. Doing so may result in fire, explosion, carbon monoxide poisoning, personal injury, or property damage.
Air Ducts
This unit is designed only for use with a supply and return duct. Air ducts should be installed in accordance with the standards of the National Fire Protection Association “Standard for Installation of Air Conditioning Systems” (NFPA 90A), “Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems” (NFPA 90B), and all applicable local codes.
NFPA publications are available by writing to: National Fire Protection Association, Batterymarch Park, Quincy, ME 02269 or visit www.NFPA.org on the web.

• Design the duct work according to Manual D by the Air Conditioning Contractors of America (ACCA).
• The ducts must be properly sized not to exceed 0.30 inches WC pressure drop per 100 feet of equivalent duct at 400 SCFM per nominal ton of cooling capacity.
• Duct work should be attached directly to the unit flanges for horizontal applications.
• If roof curb is installed, the ducts must be attached to the curb duct supports, not the unit.
• It is recommended that the outlet duct be provided with a removable access panel. The opening should be accessible when the unit is installed in service and shall be sizes so that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover for the opening shall be attached in a way that will prevent leaks.
• If outside air is utilized as return air to the unit for ventilation or to improve indoor air quality, the system must be designed so that the return air to the unit is not less than 50° F (10° C) during heating operation.

Air Filter Requirements
WARNING:
Never operate the unit without a filter in place. Dust and lint could accumulate on internal parts, resulting in loss of efficiency, equipment damage and possible fire.
NOTE TO INSTALLER: After installing or replacing the filtration system for this unit, add the following statement on or adjacent to the filter service panel: “Replace filter(s) installed in your system only with the same dimensional size filters that are being replaced.”

EXTERNAL FILTER SIZES

NOMINAL COOLING (TONNAGE)| FILTER SIZE (IN. X IN.)| APPROXIMATE AIR FLOW RANGE (CFM)| APPROXIMATE **FILTER AREA (SQ. IN.)*
2.0| 20 x 25| 600-900| 450
2.5| 20 x 30| 750-1200| 550
3.0| 25 x 25| 1100-1300| 625
3.5| 24 x 30| 1200-1600| 750
4.0| 18 x 24 (2 required)| 1400-1800| 850
5.0| 20 x 25 (2 required)| 1700-2200| 1000
INTERNAL FILTER SIZES**

CABINET HEIGHT| OUTDOOR FAN DIAMETER| FILTER SIZE (IN. X IN.)| APPROXIMATE AIR FLOW RANGE (CFM)| APPROXIMATE **FILTER AREA (SQ. IN.)***
30”| 20| (2) 14”x25”| 700 – 1300| 700
24”| (1) 12”x20” and (1) 16”x25”| 640
34”| 20| (2) 16”x25”| 900 – 1400| 800
24”| (1) 12”x20” and (2) 10”x25”| 740
38”| 20”| (2) 18”x25”| 1100 – 1600| 900
24”| (1) 12”x20” and (2) 12”x25”| 840
42”| 20”| (2) 20”x25”| 1300 – 1800| 1000
24”| (1) 12”x20” and (2) 14”x25”| 940

• Based on velocity of 300 ft/min for disposable filters.
  Table 1. Recommended External Air Filter Sizes

  • A suitable air filter must be installed upstream of the evaporator coil of the return air system. Refer to Table 1 for recommended external filter sizes.
  • All return air must pass through the filters before entering the evaporator coil. It is important that all filters be kept clean and replaced frequently to ensure proper operation of unit. Dirty or clogged filters will reduce the efficiency of the unit and result in unit shutdowns.
  • Air filter pressure drop must not exceed 0.08 inches WC.

Unconditioned Spaces
All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation. Use insulation with an outer vapor barrier. Refer to local codes for insulation material requirements.
Acoustical Duct Work
Certain installations may require the use of acoustical lining inside the supply duct work.

• Acoustical insulation must be in accordance with the current revision of the Sheet Metal and Air Conditioning Contractors National Association (SMACNA) application standard for duct liners.
• Duct lining must be UL classified batts or blankets with a fire hazard classification of FHC-25/50 or less.
• Fiber duct work may be used in place of internal duct liners if the fiber duct work is in accordance with the current revision of the SMACNA construction standard on fibrous glass ducts. Fibrous duct work and internal acoustical lining must be NFPA Class 1 air ducts when tested per UL Standard 181 for Class 1 ducts.

UNIT INSTALLATION

Packaging Removal
Remove the shipping carton and User’s Manual from the equipment. For rooftop installations, remove and discard the two supports attached beneath the unit.
Rigging & Hoisting
WARNING:
To avoid the risk of property damage, personal injury,or death, it is the rigger’s responsibility to ensure that whatever means are used to hoist the unit are safe and adequate:

• The lifting equipment must be adequate for the load. Refer to Table 4 (page 19) for unit weights.
• The unit must be lifted from the holes in the base rails using cables or chains.
• Spreader bars are required to protect the unit and ensure even loading.
• Keep the unit in an upright position at all times. The rigging must be located outside the units center of gravity. Refer to Figure 10 (page 19) for locating the center of gravity.
• All panels must be securely in place during rigging and hoisting.

Clearances to Combustible Materials
These units are certified as combination heating and cooling equipment for outdoor rooftop or ground level installations. Units may be installed on combustible flooring or Class A, B, or C roofing material when used with bottom supply and return air ducts as long as the following requirements are met:

• If using bottom discharge with return air ducts a roof curb must be installed prior to unit installation. See Rigging and Hoisting section for setting of the unit.
• Sufficient clearance for unobstructed airflow through the outdoor coil must also be maintained in order to achieve rated performance. See page 5 for information about locating the equipment.

Rooftop
Rooftop installations must be located according to local building codes or ordinances and these requirements:

• The roof must be capable of handling the weight of the unit. For unit weights, see Table 4. Reinforce the roof if necessary.
• The appropriate accessory roof curb must be installed prior to unit installation. The roof curb must be square and level to ensure proper condensate drainage. Please follow all instructions provided with the kit. See Figure 3 (page 10).
• Secure roof curb or frame to roof using acceptable mechanical methods per local codes.
  NOTE: Make sure the two supports beneath the unit have been removed.

Ground Level
Ground level installations must be located according to local building codes or ordinances and these requirements:

• Clearances must be in accordance with those shown in Figure 1 (page 5).
• A suitable mounting pad must be provided and be separate from the building foundation. The pad must be level to ensure proper condensate disposal and strong enough to support the unit’s weight. The slab height must be a minimum of 2” (5cm) above grade and with adequate drainage. See Figure 4 (page 10).
• Remove and discard the horizontal Supply and Return duct covers located on the rear of the unit. Form duct attachment flanges by bending the sheet metal outward 90 degrees along the perforated lines.
• Firmly attach ductwork directly to these flanges with screws or other approved mechanical connections and not to the Supply/Return air panels to avoid damage to internal components of the equipment. Once completed use approved duct sealing methods to ensure an air and watertight seal is achieved.

Horizontal to Downflow Conversion
The unit is shipped ready for horizontal duct connections. If down flow ducts are required, the unit must be converted following the steps below for both the supply and return ducts.

1. Remove the horizontal duct cap.
2. Locate the duct cap inside the duct openings and remove the screw holding it in place.
3. Lift the cap out of the unit. (Hint: The cap can be pushed up from the bottom by reaching through the fork slot).
4. Cover the horizontal duct opening with the horizontal duct cap. The insulation will be on the indoor side.
5. Fasten the cover with screws to seal.
6. Remove and discard the two wood supports beneath the unit.

Condensate Drain
Condensate is removed from the unit through the 3/4” female pipe fitting located on the front side of the unit. See Figure 5 (page 10).
Install a 2 inch condensate trap in the drain line of the same size and prime with water. When connecting rigid drain line, hold the female fitting with a wrench to prevent twisting. Do not over tighten! Refer to local codes and restrictions for proper condensate disposal requirements.

ELECTRICAL WIRING

WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in 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.
• Verify proper operation after servicing.
• Electrical connections must be in compliance with all applicable local codes and ordinances, and with the current revision of the National Electric Code (ANSI/NFPA 70).
• For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code (CSA C22.1 and/or local codes).

IMPORTANT NOTE:
If replacing any of the original wires supplied with the furnace, the replacement wire must be copper wiring having the same guage, voltage, and temperature rating.
Pre-Electrical Checklist
√ Verify the voltage, frequency, and phase of the supply sourcematch the specifications on the unit rating plate.
√ Verify that the service provided by the utility is sufficient to handle the additional load imposed by this equipment. See Table 2 (page 11) and Table 9 (page 25) (or the unit rating label) for proper high voltage wiring requirements.
√ Verify factory wiring is in accordance with the unit wiring diagram. See Figure 12 (page 24). Make sure theconnections didn’t loosen during shipping or installation.
Grounding
WARNING:
The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur. Do not use gas piping as an electrical ground!
This unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code (ANSI/NFPA 70) or the CSA C22.1 Electrical Code. Grounding of the unit is accomplished by using the grounding lug provided in the control box.
Line Voltage

• The line voltage to the unit should be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the unit.
• An electrical disconnect must be located within sight of and readily accessible to the unit. This switch shall be capable of electrically de-energizing the outdoor unit. See unit data label for proper incoming field wiring. Any other wiring methods must be acceptable to authority having jurisdiction.
• Use only copper wire for the line voltage power supply to this unit as shown in Table 2. Use proper code agency listed conduit and a conduit connector for connecting the supply wires to the unit. Use of rain tight conduit is recommended.
• Provide power supply for the unit in accordance with the unit wiring diagram and the unit rating plate.

• Overcurrent protection must be provided at the branch circuit distribution panel and sized as shown on the unit rating label and according to applicable local codes. See Table 9 (or the unit rating plate) for minimum circuit ampacity and maximum overcurrent protection limits.
  COPPER WIRE SIZE — AWG (1% VOLTAGE DROP)

  SUPPLY WIRE LENGTH-FEET| SUPPLY CIRCUIT AMPACITY
  200| 150| 100| 50
  6| 8| 10| 14| 15
  4| 6| 8| 12| 20
  4| 6| 8| 10| 25
  4| 4| 6| 10| 30
  3| 4| 6| 8| 35
  3| 4| 6| 8| 40
  2| 3| 4| 6| 45
  2| 3| 4| 6| 50
  2| 3| 4| 6| 55
  1| 2| 3| 4| 60

NOTE: Wire Size based on N.E.C. for 60° type copper conductors.
Table 2. Copper Wire Size

• A wiring diagram is located on the inside cover of the control access panel of the outdoor unit. The installer should become familiar with the wiring diagram before making any electrical connections to the outdoor unit. See Figure 12.
• Units are shipped from the factory wired for 230 volt transformer operation.
• Connect the line-voltage leads to the terminals on the contactor inside the control compartment.

Thermostat / Low Voltage Connections

• This unit is designed to operate from a 24 VAC Class II control circuit. A single stage cooling / single stage heating thermostat should be used with this unit. A 2-stage cooling / 2-stage heating thermostat is recommended for economizer operation. See Figure 6 (page 11) for typical thermostat connection.
• The control circuit wiring must comply with the current provisions of the NEC (ANSI/NFPA 70) and with applicable local codes having jurisdiction. Thermostat connections should be made in accordance with the instructions supplied with the thermostat and the indoor equipment.
• The low voltage wires must be properly connected. Route 24V control wires through the sealing grommet near the power entrance.
• Several thermostat options are available depending on the accessories installed with the unit. Select a thermostat that operates in conjunction with the installed accessories.
• The thermostat should be mounted about 5 feet above the floor on an inside wall. DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces, sunlight, or lighting fixtures, and convective heat from warm air registers or electrical appliances. Refer to the thermostat manufacturer’s instruction sheet for detailed mounting information.

Checking Heat Anticipator Settings

• Add the current draw of the system heating components.
  OR

• Measure the current flow on the thermostat R-W circuit after the circulating blower motor has started. Set the heat anticipator according to the thermostat manufacturer’s instructions for heat anticipator settings.

Blower Speed
The blower speed is preset at the factory for fan only, heating, and cooling operation. These factory settings are listed in Table 5 (page 20) and Table 6 (page 21). For optimum system performance and comfort, it may be necessary to change the factory set speed.
CAUTION:
To avoid personal injury or property damage, make sure the motor leads do not come into contact with any uninsulated metal components of the unit.
5-Speed ECM Motor

• Shut off all electrical power to the unit and remove the control panel.
  NOTE: The furnace board has slide switches to select between blower speeds that are preset from the factory. The heat, cool, and fan speed can be changes by sliding the switch from the available options of L-Low. MLMedium Low, MH-Medium High, H-High. The blower motor speeds increase as the switch is moved from Low to High.

• A movable jumper beside the blower speed slide switches change fan speed(G call). The fan speed is preset from the factory for the Lowest blower speed L. Changing this position of the jumper one setting at a time will increase the fan speed.

Optional Furnace Control Board Connections
Electronic Air Cleaner
The furnace control board provides output terminals for an optional electronic air cleaner (EAC) that can be installed in the return air duct of your system. THE EAC output is energized any time the HEAT or COOL blower speed is energized. Control ratings are 1.0 Amp. @ 240 VAC. Output connections are made via board terminals labeled EAC and NEUTRAL.
Humidifier
The furnace control board provides output terminals for an optional humidifier (HUM) that can be installed on your system. The HUM output is energized any time the furnace inducer motor is energized. Control ratings are 1.0 Amp. @ 240 VAC. Output connections are made via board terminals labeled HUM and NEUTRAL.
Check all factory wiring to the units wiring diagram. Inspect the factory wiring connections to be sure none loosened during shipping or installation.

GAS SUPPLY & PIPING

WARNING:
FIRE OR EXPLOSION HAZARD

• Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
• Installation and service must be performed by a qualified installer, service agency or the gas supplier.
• 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 try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
• All gas piping must be installed in compliance with local codes and utility regulations. In the absence of local codes the gas line installation must comply with the latest edition of the National Fuel Gas Code ANSI Z223.1 or CAN/CGA B149 Installation Codes.
• Some local codes require the installation of a manual main shut-off valve and ground joint union external to the unit. The shut-off valve should be readily accessible for service and/or emergency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off. See Figure 7 (page 13).
• The manifold pressure must be set to the appropriate value for your installation. Refer to the Manifold Pressure Adjustment section (page 15) for adjustment instructions.
• Gas piping must never run in or through air ducts, chimneys, gas vents, or elevator shafts.
• The main gas shutoff valve and main power disconnect to the unit must be properly labeled by the installer in case emergency shutdown is required.
• An 1/8 inch NPT plugged tap must be installed in the gas line immediately upstream of the gas supply connection to the unit for use when measuring the gas supply pressure. The plug should be readily accessible for service use.
• A drip leg should be installed in the vertical pipe run to the unit. See Figure 7.

This unit only has right side gas entry. When connecting the gas, provide clearance between the gas supply line and the entry hole in the unit’s casing to avoid unwanted noise and/or damage to the unit. A typical gas service hookup is shown in Figure 7.
Table 7 (page 22) lists gas pipe capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.
Leak Check
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
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. A fire or explosion may result causing property damage, personal injury or loss of life.
After the gas piping to the unit is complete, all connections must be tested for gas leaks. This includes pipe connections at the main gas valve, emergency shutoff valve and other gas connectors. A soap and water solution can be applied on each joint or union using a small paintbrush. If any bubbling is observed, the connection is not sealed adequately and must be retightened. Repeat the tightening and soap check process until bubbling ceases.

• If pressure testing the gas supply lines at pressures greater than 1/2 psig (14 inches WC), the unit must be disconnected from the gas supply piping system to prevent damage to the gas valve.
• If the test pressure is less than or equal to 1/2 psig (14 inches WC), the unit must be isolated from the gas supply line by closing the manual shut-off valve.

High Altitude Conversion – Natural Gas
High altitude conversion with this furnace depends on the installation altitude and the heating value of the gas. Installation of this furnace at altitudes above 2,000 feet shall be in accordance with local codes, or in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1/NFPA 54. Please consult your local code authority.
WARNING:
The reduction of input rating necessary for high altitude installation may only be accomplished with factory supplied orifices. Do not attempt to drill out orifices in the field. Improperly drilled orifices may cause fire, explosion, carbon monoxide poisoning, personal injury or death.
The furnaces are shipped from the factory with orifices and gas regulator settings for natural gas operation at sea level altitudes. At 2,000 feet, the NFGC requires that this appliance be derated 4% for each 1,000 feet of altitude. For example, at 2,000 feet the input needs to be reduced 8%, at 3,000 feet (12%), etc. This deration is in reference to the input rate and gas heating value at sea level.
To derate the furnace requires knowing the heating value of the gas at the installation site. Heating values at particular job sites vary for two reasons:

1. The chemical mixture of the gas varies across regions and is expressed as the “sea level heating value”.
2. The heating value varies by altitude. For this reason, especially in high altitude areas, the local gas utility specifies the heating value at the residence’s gas meter as the “local value”.

WARNING:
This unit was equipped at the factory for use with natural gas only. LP/Propane cannot be used with this unit. Failure to follow safety warnings exactly could result in serious injury, death or property damage.

START UP & ADJUSTMENTS

Pre-Start Check List
√ Verify the unit is level and allows condensate to drain.
√ Verify all clearance requirements are met and there is free airflow to and from the outdoor coil.
√ Verify that the duct work is sealed to prevent air leakage and air filter is installed.
√ Verify that the line voltage power leads are securely connected and the unit is properly grounded.
√ Verify that the low voltage wires are securely connected to the correct terminals in the low voltage area of the control box.
√ Verify that the gas line service pressure does not exceed 10.0 inches WC (0.36 psig), and is not less than 4.5 inches WC (0.16 psig) for natural gas.
√ Verify that the burner limit control is closed. If necessary, press the red button to reset the control. DO NOT install a jumper wire across the control to defeat its function. If the control reopens upon start-up, DO NOT reset the control without identifying and correcting the fault condition which caused the control to trip.
√ Verify that the gas line has been purged and all connections are leak tight.
√ Verify that all exterior panels are replaced and securely fastened.
√ Verify that the outdoor fan turns freely.
√ Verify that the power supply branch circuit overcurrent protection is sized properly.
√ Verify that the thermostat is wired correctly. The thermostat function switch should be set to OFF and the thermostat fan switch should be set to AUTO.
Start-Up Procedure
WARNING:
If this unit is equipped with crankcase heaters, allow 24 hrs for heating of the refrigerant compressor crankcase prior to start up or anytime the power has been removed for more than 12 hrs. Failure to comply may result in damage or cause premature failure of the system.
Air Circulation
Leave the thermostat system mode on OFF, and set the fan mode to ON. Blower should run continuously. Check the air delivery at the supply registers and adjust register openings for balanced air distribution. Examine ductwork for leaks or obstruction if insufficient air is detected. Set the thermostat fan mode to AUTO. The blower should stop running.
System Cooling

1. Set the thermostat’s system mode to COOL and the fan mode to AUTO. Gradually lower the thermostat temperature setpoint below room temperature and verify the compressor, fan and indoor blower energize.
2. Feel the air being circulated by the indoor blower and verify that it is cooler than ambient temperature. Listen for any unusual noises. If unusual sounds occur, determine the source of the noise and correct as necessary.
3. Allow the cooling system to operate for several minutes and then set the temperature selector above room temperature. Verify the fan and compressor cycle off with the thermostat.
   NOTE: The blower will also stop after a 60 second delay.

System Heating

1. Set the thermostat to the lowest setting.
2. Follow the procedures given on the operating instruction label, this manual or attached inside the louvered control access panel.
3. Set the thermostat above room temperature and verify the Operating Sequence. See page 16.
4. Verify that the compressor and outdoor fan motor are not energized.
5. After the unit has run for approximately five minutes, set the thermostat below room temperature and verify the shutdown sequence; steps 10, 11, & 12 in the Operating Sequence section on page 16.

Verifying & Adjusting Temperature Rise
Verify the temperature rise through the unit is within the range specified on the unit data label. Temperature rises outside the specified range could result in premature heat exchanger failure.

1. Place thermometers in the return and supply air stream as close to the unit as possible. The thermometer on the supply air side must be shielded against direct radiation from the heat exchanger to avoid false readings.
2. Adjust all registers and duct dampers to the desired position. Run the unit for 10 to 15 minutes before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures.

NOTE: For typical duct systems, the temperature rise will fall within the range specified on the data label (with the blower speed at the factory recommended setting) shown in Table 5 (page 20) or Table 6 (page 21). If the measured temperature rise falls outside the specified range, it may be necessary to change the blower speed. Lowering the blower speed increases the temperature rise and a higher speed decreases the temperature rise.
Verifying & Adjusting Firing Rate
CAUTION:
Do not re-drill the burner orifices. If the orifice size must be changed, use only new orifices.
The firing rate must be verified for each installation to prevent over-firing of the unit. The firing rate must not exceed the rate shown on the unit data label. To determine the firing rate, follow the steps below:

1. Obtain the gas heating value (HHV) from the gas supplier.

2. Shut off all other gas fired appliances.

3. Start the unit in heating mode and allow it to run for at least 3 minutes.

4. Measure the time (in seconds) required for the gas meter to complete one revolution.

5. Convert the time per revolution to cubic feet of gas per hour using Table 8 (page 22).

6. Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btu per hour. See Example.
   Example:
   • Time for 1 revolution of a gas meter with a 1 cubic foot dial = 40 seconds.
   • From Table 8, read 90 cubic feet gas per hour.
   • Local heating value of the gas (obtained from gas supplier) = 1,040 Btu per cubic foot.
   • Input rate = 1,040 x 90 = 93,600 Btuh.

7. Adjust the manifold pressure if necessary. See Manifold Pressure Adjustment below. For additional information about elevations above 2,000 feet, see page 13.

Manifold Pressure Adjustment
The manifold pressure must be set to the appropriate value for your installation. To adjust the manifold pressure:

1. Obtain the required manifold pressure setting
   NOTE: The values listed in the tables are based on sea level values. At higher altitudes, the heating value of gas is lower than the sea level heating value.

2. Remove the regulator capscrew (Figure 8) from the INLET side of the regulator.

3. Slowly turn the adjustment screw inside the regulator to obtain the appropriate manifold pressure. NOTE: Turning the screw clockwise increases the pressure and turning the screw counter-clockwise decreases the pressure. To prevent backing the screw all the way out from the valve, turn the screw slowly.

4. Replace and tighten the regulator capscrew over the adjustment screw.

Verifying Over-Temperature Limit Control Operation

1. Verify the louvered control access panel is in place and that there is power to the unit.

2. Block the return airflow to the unit by installing a close-off plate in place of or upstream of the filter.

3. Set the thermostat above room temperature and verify the units operating sequence on page 16.
   NOTE: The over-temperature limit control should turn off the gas valve within approximately four minutes (exact time depends on the efficiency of the close-off when blocking the return air). The circulating air and combustion blowers should continue to run when the over-temperature limit control switch opens.

4. Remove the close-off plate immediately after the over- temperature limit control opens. If the unit operates for more than four minutes with no return air, set the thermostat below room temperature, shut off power to the unit, and replace the over-temperature limit control.

Verifying Burner Operation
CAUTION:
The door over the burners may only be open for inspection purposes only. The door must be installed during unattended operation.

1. Remove the burner compartment door and note the location of the sightglass on burner head.

2. Set the thermostat above room temperature and observe the ignition sequence.
   NOTE: The burner flame should be present by seeing a glow through the sightglass.

3. After validating the flame, change the thermostat setting to below room temperature.

4. Verify the burner flame is completely extinguished.

5. Replace the burner compartment door.

Verify Operation of the Supply Air Limit Switch
A properly functioning limit switch should turn off the gas valve when the return is blocked (time depends on how well the return air is blocked). The circulating air and combustion blowers should continue to run when the limit switch opens.

1. Verify the blower door is securely mounted in place and that there is power to the furnace.
2. Block the return airflow to the furnace by installing a closeoff plate in place of or upstream of the filter(s).
3. Set the thermostat above room temperature and observe the Operating Sequence.
4. Remove the close-off immediately after the limit switch opens. If the furnace continues to operate with no return air, set the thermostat below room temperature, shut off power to the furnace, and replace the limit switch.

OPERATING SEQUENCE

The operating sequences for the heating, cooling, and fan modes are described below. Refer to the field and unit wiring diagram. See Figure 12 (page 24).
Heating Cycle

1. The thermostat calls for heat by energizing the W terminal with 24VAC.
2. The control verifies the safety circuit pressure switch is open and high temperature limit switch circuit is closed.
3. If the pressure switch is open, the control energizes the inducer and waits for the pressure switch to close. The pressure switch must close within 10 seconds.
4. The control runs the inducer for a 30 second pre-purge.
5. The control energizes the igniter output for a 30 second warm-up period.
6. The control energizes the main gas valve for 3 seconds.
7. If the flame is proved after igniting the gas, the control deenergizes the igniter. The gas valve and inducer remain energized. The control goes to blower on delay.
8. If flame is present, the control energizes the blower on the selected HEAT speed 30 seconds after the gas valve opened. The gas valve remains energized while the inducer ramps to Max. RPM over a programmed time period.
9. When the thermostat demand for heat is satisfied, the control de-energizes the gas valve. The inducer output remains on for a 90 second post-purge period.
10. Blower off timing of 60, 90, 120, & 180 seconds (depending on the movable jumper setting) begins when the thermostat is satisfied. See Figure 14 (page 16). The control will operate at the selected HEAT speed of 60 seconds, then change to FAN speed for the remaining off delay time. If the blower off delay jumper is not present, the fan should still operate for 120 seconds at the selected HEAT speed. The indoor blower motor is de-energized after a blower off delay as selected by the movable jumper.

Cooling Cycle

1. The thermostat calls for cooling by energizing the Y & G terminal with 24VAC.
2. The control energizes the blower in the cooling speed and sends 24VAC to the contactor in the condensing section.
3. When the thermostat removes the call for cooling, the contactor in the outdoor condensing section is de-energized and the control continues to run the fan for a period of 60 seconds.

Fan Mode

• When the thermostat energizes the G terminal for continuous fan (without calling for heat or cooling), the indoor fan is energized on the selected FAN speed. See Figure ## (Page ##). The control defaults to MEDIUM HIGH if the movable jumper is not attached.
• If a call for cooling occurs during continuous fan, the blower will switch over to the selected COOL speed.
• If the W terminal receives a call for heat during continuous fan, the blower will de-energize and reset to delayed ON timing.
• A call for fan is ignored while in lockout.

EQUIPMENT MAINTENANCE

WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in 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.
• Verify proper operation after servicing.

CAUTION:
Use care when removing parts from this unit. Personal injury can result from sharp metal edges present in all equipment of sheet metal construction.
Proper maintenance is important to achieve optimum performance from the system. The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools. If you do not possess these skills, contact your dealer for maintenance. Consult your local dealer about the availability of maintenance contracts. Routine maintenance should include the following:
CAUTION:
The unit should never be operated without a filter in the return air system. Replace disposable filters with the same type and size.

• Inspect, clean or replace air filters at the beginning of each heating and cooling season, or more frequently if required. Refer to Table 1 (page 8) for recommended external filter sizes
• Inspect the condensate drain and outdoor coil at the beginning of each cooling season. Remove any debris. Clean the outdoor coil and louvers as necessary using a mild detergent and water. Rinse thoroughly with water.
• Inspect the electrical connections for tightness at the beginning of each heating and cooling season.
• The blower compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor. Buildup of dirt and lint on the blower and motor can create excessive loads on the motor resulting in higher than normal operating temperatures and possible shortened service life.
• Maintain heat exchanger and burners. The unit should operate for many years without excessive scale buildup in the heat exchanger, however, the heat exchanger, the vent system, and the burners should be inspected and cleaned (if required) by a qualified serviceman annually to ensure continued safe operation. Particular attention must be given to identify deterioration from corrosion or other sources.
• The motors for the circulating air blower, outdoor fan, and combustion blower are pre-lubricated at the factory. No further oiling is required for the life of this product.
• Inspect and clean the screen of the vent cover assembly at the beginning of each heating and cooling season.

Heat Exchanger & Burner Maintenance – The furnace should operate for many years without soot buildup in the flue passageways, however, the flue and vent system should be inspected and cleaned (if required) by a qualified service technician annually to ensure continued safe operation. Pay attention to any deterioration from corrosion or other sources.
Lubrication – The bearings in the blower motor and inducer blower used in these furnaces are pre-lubricated and sealed by the manufacturer. No further oiling of the bearings is required for the life of the motor.
Cleaning of Flame Sensor – If the flame sensor is suspect for Loss of Flame fault code, the sensor can be cleaned to see if that remedies the issue. Follow steps 1 – 10. See Figure 14 (page 29) for component location.
CAUTION:
Due to igniter/flame sensor assembly location, a new gasket should be on hand before servicing this part. One new gasket is provided in the furnace extra parts package. Failure to re-seal the assembly after service can result in abnormal furnace operation.

1. Shut off gas supply to the furnace at the meter or at a manual valve in the supply piping.

2. Turn off all power to the furnace and set the thermostat to its lowest setting.

3. Remove the louvered door from the unit.

4. Turn the gas control switch to the OFF position.

5. Remove the 2 screws securing the combustion air orifice plate to the air/fuel mixing tube (if needed to access the ignitor/flame sensor assembly cover on smaller models).

6. Remove 8 screws from perimeter of access cover plate.

7. Lift the assembly and bracket straight up out of the burner box and off the HX panel.
   NOTE: Use of a flat blade screwdriver between assembly bracket and top of burner mounting bracket to help leverage bracket off may be required. See Figure 9.

8. Clean the flame sensor using steel wool being careful not to damage the igniter.

9. Replace old gasket with new gasket ensuring correct orientation, with adhesive side to the bracket.

10. Replace igniter/flame sense assembly in reverse order they were removed.

Vent System – Check the vent pipe and/or chimney for corrosion or debris. Any corroded section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace.
WARNING:
Holes in the vent pipe or heat exchanger can cause combustion products to enter the home. Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

TROUBLESHOOTING

If the unit does not operate in the cooling mode, check the following:

• Is the thermostat operating properly?

• Is the blower compartment doors in place?

• Is the furnace disconnect closed?

• Has the circuit breaker tripped or did any of the control board fuses burn open?
  NOTE: There are 2 fuses, one on the control board (3-amp) and one in a fuse holder (1.5-amp) to the right of the control board.

• Is the gas turned on?

• Are any manual reset switches open?

• Is the filter dirty or plugged?

• Is the flame sensor coated? (Remove and clean with steel wool. New gasket is required) See Cleaning of Flame Sensor sectionon page 17.

• Are all the LED’s on the furnace control board constantly ON? If not, refer to Table 3 or the wiring diagram (Figure 12 (page 24)) to determine fault condition.
  IMPORTANT NOTE: The furnace will lock out after 5 failed attempts for ignition and will try again every hour if the call for heat remains.

• If the inducer blower is operating and items above have been verified, check the limit switch circuit and reset if necessary. See Figure 14 (page 29) for component location.

• If the furnace operates when the limit switch circuit is reset, contact a qualified service technician to identify and repair the problem.

• If the furnace still doesn’t operate, check the flame roll-out switch and reset if necessary. See Figure 14 for component location.

• If the furnace operates when the flame rollout switch is reset, contact a qualified service technician to identify and repair the problem.

Table 3. Diagnostic Codes

FIGURES & TABLES

MODEL NUMBER| UNIT WEIGHT| SHIPPING WEIGHT| CENTER OF GRAVITY| HEIGHT IN INCHES (C)
---|---|---|---|---
A| B| WITH BASE RAILS| WITHOUT BASE RAILS
024K055U1| 390| 406| 26.5| 26.5| 35.0| 31.3
030K070U1| 390| 406| 26.0| 26.5| 35.0| 31.3
036K070U1| 390| 406| 26.5| 26.5| 35.0| 31.3
042K100U1| 438| 455| 27| 26.5| 39.0| 35.3
048K100U1| 438| 455| 27| 26.5| 39.0| 35.3
X60K100U1| 490| 507| 27| 27.5| 47.0| 43.3

Table 4. Center of Gravity & Unit Shipping Weights

Airflow Data

Denotes factory set heating speed Tap 1 is fan only
(†) Part number may contain a C or X.
Data is shown without a filter
Heat rise: Btu/h (Input) = CFM Δ T 1.081
Δ T = (Btu/h 0.83) / (CFM 1.081)
To comply with government mandated efficiency standards, two openings are required for airflows above 1,600 CFM.
Temperature rises in the table are approximate. Actual temperature rises may vary.
Individual cells shaded in gray indicate a temperature rise outside the recommended range.
To comply with government mandated efficiency standards, speed settings which do not have data are not allowed in HEAT mode.
Data is ACFM (Actual Cubic Feet per Minute)
Table 5. Nominal Heating Airflow Rates & Temperature Rises (° F)**

• Denotes factory set cooling speed
  Tap 1 is factory set fan speed.
  Data is with a dry coil.
  Data is SCFM (Standard Cubic Feet per Minute)
  Table 6. Nominal Cooling Airflow Rates & Temperature Rises (° F)

Gas Information

CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR) FOR NATURAL GAS (SPECIFIC GRAVITY – 0.60)

NOMINAL PIPE DIAMETER (IN.)| LENGTH OF PIPE RUN (FEET)
10| 20| 30| 40| 50| 60| 70| 80
1/2| 130| 90| 75| 65| 55| 50| 45| 40
3/4| 280| 190| 150| 130| 115| 105| 95| 90
1| 520| 350| 285| 245| 215| 195| 180| 170
1 1/4| 1,050| 730| 590| 500| 440| 400| 370| 350
1 1/2| 1,600| 1,100| 890| 760| 670| 610| |

NOTE: The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace. To determine the cubic feet per hour of gas flow required by the furnace, divide the input rate of the furnace by the heating value (from gas supplier) of the gas.
Table 7. Gas Pipe Capaacities

GAS FLOW RATES (CUBIC FEET PER HOUR)

TIME FOR ONE REVOLUTION (SECONDS)| CUBIC FEET PER REVOLUTION OF GAS METER
1| 5| 10
10| 360| 1,800| 3,600
12| 300| 1,500| 3,000
14| 257| 1,286| 2,571
16| 225| 1,125| 2,250
18| 200| 1,000| 2,000
20| 180| 900| 1,800
22| 164| 818| 1,636
24| 150| 750| 1,500
26| 138| 692| 1,385
28| 129| 643| 1,286
30| 120| 600| 1,200
32| 113| 563| 1,125
34| 106| 529| 1,059
36| 100| 500| 1,000
38| 95| 474| 947
40| 90| 450| 900
42| 86| 429| 857
44| 82| 409| 818
46| 78| 391| 783
48| 75| 375| 750
50| 72| 360| 720
52| 69| 346| 692
54| 67| 333| 667
56| 64| 321| 643
58| 62| 310| 621
60| 60| 300| 600
62| 58| 290| 581
64| 56| 281| 563
GAS FLOW RATES (CUBIC FEET PER HOUR)

TIME FOR ONE REVOLUTION (SECONDS)| CUBIC FEET PER REVOLUTION OF GAS METER
1| 5| 10
66| 55| 273| 545
68| 53| 265| 529
70| 51| 257| 514
72| 50| 250| 500
74| 49| 243| 486
76| 47| 237| 474
78| 46| 231| 462
80| 45| 225| 450
82| 44| 220| 439
84| 43| 214| 429
86| 42| 209| 419
88| 41| 205| 409
90| 40| 200| 400
92| 39| 196| 391
94| 38| 191| 383
96| 38| 188| 375
98| 37| 184| 367
100| 36| 180| 360
102| 35| 176| 353
104| 35| 173| 346
106| 34| 170| 340
108| 33| 167| 333
110| 33| 164| 327
112| 32| 161| 321
114| 32| 158| 316
116| 31| 155| 310
118| 31| 153| 305
120| 30| 150| 300

Table 8. Gas Flow Rates

FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fi re or explosion may result causing property damage, personal injury, or loss of life.
A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the fl oor because some gas is heavier than air and will settle on the fl oor.
WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fi re department.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or moby hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.
OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. The appliance’s ignition device automatically lights the burner. Do not try to light burner by hand.
5. Remove the control access door/panel (upper door if two-door model).
6. Move the gas control switch to the “OFF” position. (See Figure 1)
7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the fl oor. If you smell gas, STOP! Follow “B” in above information. If you don’t smell gas, go to the next step.
8. Move the gas control switch to the “ON” position. (See Figure 1)
9. Replace the control access door/panel (upper door if two door model).
10. Turn on all electrical power to the appliance.
11. Turn the thermostat to a desired setting.
12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.
2. Turn off all electrical power to the appliance if service is to be performed.
3. Remove the control access door/panel (upper door if two-door model).
4. Move the gas control switch to the “OFF” position. Do not use force. (See Figure 1)
5. Replace the control access door/panel (upper door if two-door model).

Figure 11. Gas Valve Label

Wiring Diagram & Electrical Data

WIRING DIAGRAM
Packaged Ultra Low NOx Single Stage Gas Heat/Electric Air Conditioner
230 Volt
Single Phase
60Hz
NOTES:

1. Disconnect all power before servicing.
2. For supply connection use copper conductors only.
3. Not suitable on systems that exceed 150V to ground.
4. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at lest 105C.
5. for supply wite ampacities and overcurrent protection, see unit rating plate.

Figure 12. Wiring Diagram for 230V / 60 Hz Unit with ECM Motor

NOTE 6:
Fuse Type: MDL
Voltage: 250VAC
Current: 1.5A
Part#: MDL-1-1/2-R

10422350
(NEW)
04/22

NOTE: FLA = Full Load Amps; LRA = Lock Rotor amps; RLA = Rated Load Amps.
Table 9. Electrical Data.

REFRIGERANT CHARGING

WARNING:
These units are shipped fully charged with R-410A refrigerant and ready for installation. When a system is installed according to these instructions, no refrigerant charging is required. If repairs make it necessary for evacuation and charging, it should only be done by qualified, trained personnel thoroughly familiar with this equipment. Some local codes require licensed installation/service personnel to service this type of equipment. Under no circumstances should the owner attempt to install and/or service this equipment. Failure to comply with this warning could result in property damage, personal injury, or death.
CAUTION:
This unit uses R-410A refrigerant. DO NOT use any other refrigerant in this unit. Use of another refrigerant may damage the unit.
The system refrigerant charge can be checked and adjusted through the service ports provided at the front panel. Use only gauge lines which have a “Schrader” depression device present to actuate the valve. Draw a vacuum on gauge lines to remove air before attaching them to the service ports on the unit. Refrigerant charging must be done by qualified personnel familiar with safe and environmentally responsible refrigerant handling procedures.
Application Notes & Charging Charts
(Cooling Mode Only)
This equipments cooling system contains refrigerant under high pressure, always use safe practices when servicing the unit. Always review the factory literature and safety warnings prior to servicing.
These units are shipped from the factory with the proper amount and type of refrigerant. Always inspect the unit rating label to determine the units information prior to working on the system. Do not mix different refrigerants or charge the unit with a refrigerant not listed on the unit rating label.
The charging tables are valid for a variety of indoor, return air conditions and are most highly influenced by the outdoor ambient temperature, outdoor fan operation and the unit operating voltage. Before referencing the charts, always make sure that the compressor circuit is energized on nominal speed (Y1 energized) and has stable operation. As can be seen in the charging charts, the ideal system sub-cooling can vary over the range of operation. Always reference the charts to determine the ideal amount of sub-cooling for a given liquid pressure. Units charged to other values will not perform at the rated unit efficiency (EER). For 2 – 4 ton units, see Table 10 (page 26), Table 11 (page 26), Table 12 (page 27), Table 13 (page 27), & Table 14 (page 28). For 5 ton units see Figure 13 (page 28).
To inspect a systems operation, using quality instruments, match the measured liquid temperature to the units chart. The measured liquid pressure reading should be within 3% of the value shown for most installations.
For systems that are operating with more then a 5% deviation, inspect the unit for leaks. Always use safe and environmentally sound methods for refrigerant handling. When repairing system leakages, always utilize a nitrogen (inert) gas to protect the refrigerant system and pressure check the repair before recharging. Always replace the filter-dryers when performing any repair to the refrigeration system. After completing the repairs, evacuate the system to 350-500 microns and weigh in the refrigerant to the amount specified on the unit rating label.
Refrigerant Charging Tables (Cooling Mode Only)
Shaded boxes indicate flooded conditions.
Rated design values. The suction pressure will be lower than design value if indoor air flow, entering dry bulb, or entering wet bulb temperatures are lower than design.

1. All pressures are listed in psig and all temperatures in ° F
2. Discharge temperatures greater than charted values indicate an undercharged system.

Table 10. Charging Table for 2 Ton Models Table 11. Charging Table for 2.5 Ton Models Table 12. Charging Table for 3 Ton Models Table 13. Charging Table for 3.5 Ton Models Table 14. Charging Table for 4 Ton Models

FURNACE COMPONENTS

The descriptions below are various functional components that affect the operation and shutting down of this furnace. Some of these components and their locations are shown in Figure 14. If any component of the furnace must be replaced, use only factory authorized replacement parts specified in the Replacement Parts List.
Flame Sensor – Verifies when a flame is present. If no flame is detected, the furnace will shut down within 4 seconds.
Gas Valve – Controls the flow of gas to the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold.
Inducer Assembly – Vents products of combustion to the outside.
Pressure Switch – Verifies that the inducer is drawing the combustion gases through the heat exchanger. The pressure switch prevents furnace operation with excessive flue blockage or improper inducer operation.
Main Air Limit Switch – Prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature.
Temperature Limit Switch – Verifies the inducer is drawing combustion gases through the heat exchanger properly. The temperature switch prevents furnace operation in the event of flue or combustion air passageway blockage, or improper inducer operation. If the roll-out switch opens, the gas valve will close and initiate the shutdown cycle. The blower will run continuously due to open limit fault.

INSTALLATION CHECKLIST

INSTALLATION ADDRESS:

CITY:| STATE:
UNIT MODEL #
UNIT SERIAL #
Unit Installed Minimum clearances per Figure 1 (page 5)?| YES| NO
INSTALLER NAME:
CITY:| STATE:
Has the owner’s information been reviewed with the customer?| YES| NO
Has the Literature Package been left with the unit?| YES| NO
ELECTRICAL SYSTEM
Electrical connections tight?| YES| NO
Line voltage polarity correct?| YES| NO
Rated Voltage (VOLTS):
L1-L2 Volts:
Has the thermostat been calibrated?| YES| NO
Is the thermostat level?| YES| NO
Is the heat anticipator setting correct? (If Applicable)| YES| NO
VENTING SYSTEM
Is the vent hood installed?| YES| NO
Is vent hood free from restrictions| YES| NO
Filter(s) secured in place?| YES| NO
Filter(s) clean?| YES| NO

ATTENTION INSTALLERS:
It is your responsibility to know this product better than your customer. This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. Safety should always be the deciding factor when installing this product and using common sense plays an important role as well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the unit or failure to follow safety warnings could result in serious injury, death, or property damage. These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment.

GAS SYSTEM

Gas Type: (circle one)| Natural Gas| Propane
Gas pipe connections leak-tested?| YES| NO
Gas Line Pressure (in – W.C.):
Is there adequate fresh air supply for combustion and ventilation?| YES| NO
Installation Altitude (FT.):
Deration Percentage:
Unit Input (Btuh):
Supply Air Temperature (° F):
Return Air Temperature (° F):
Temperature Rise (° F):
DURING UNIT OPERATION:
Manifold pressure (in – W.C.):
REFRIGERATION SYSTEM
Was unit given 24 hr warm up period for crankcase heaters (if equipped)?| YES| NO
Stage-1 Liquid Pressure (high side):
Stage-1 Suction Pressure (low side):

REPLACEMENT PARTS

Replacement parts are available through your distributor. Please have the complete model and serial number of the unit when ordering replacement parts.

ELECTRICAL:

• Capacitors
• Compressors
• Contactors
• Gas Valves
• Ignition Controls
• Ignitors/Flame Sensors| • Pressure Switches
• Relays
• Temperature Limit Switches
• Thermostats
• Time Delay Relays
• Transformers
---|---

MOTORS:

• Blower Motor
• Fan Motor
• Inducer Blower Motor

COMPONENTS:

• Blower Assembly
• Burner Manifold
• Burners/Orifices
• Cabinet Panels
• Expansion Valves
• Fan Grille
• Filter/Driers
• Gaskets
• Heat Exchanger

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Specifications & illustrations subject to change without notice or incurring obligations (04/22).
O’Fallon, MO, © Nortek Global HVAC LLC 2022. All Rights Reserved. 10422360
(Replaces 1036144A)

References

• NFPA | The National Fire Protection Association

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