Carrier 48VL-19SI Package RTU Gas Heat Elec Cool Instruction Manual
- June 13, 2024
- Carrier
Table of Contents
Turn to the experts
48VL-K
Comfort™13.4 SEER2 Single-Packaged Air
Conditioner and Gas Furnace System with Puron®
(R-410A) Refrigerant
Single Phase 2-5 Nominal Tons (Sizes 24-60)
Three Phase 3-5 Nominal Tons (Sizes 36-60)
Installation Instructions
IMPORTANT: Effective January 1, 2015, all split system and packaged air
conditioners must be installed pursuant to applicable regional efficiency
standards issued by the Department of Energy.
NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Installer: Make sure the Owner’s Manual and Service Instructions
are left with the unit after installation.
Fig. 1 – Unit 48VL
(Low NOx Model Available)
Safety Considerations
Improper installation, adjustment, alteration, service maintenance, or use can
cause explosion, fire, electrical shock, or other conditions which may cause
death, personal injury, or property damage. Consult a qualified installer,
service agency, or your distributor or branch for information or assistance.
The qualified installer or agency must use factory-authorized kits or
accessories when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing, and work
gloves. Have a fire extinguisher available. Read these instructions thoroughly
and follow all warnings or cautions included in literature and attached to the
unit. consult local building codes, the current editions of the National Fuel
Gas Code (NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code (NEC)
NFPA 70.
In Canada refer to the current editions of the National Standards of Canada
CAN/CSA-B149.1 and 2 Natural Gas and Propane Installation codes, and Canadian
Electrical Code CSA C22.1 Recognize safety information. This is the safety-
alert symbol . When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand these
signal words: DAN- GER, WARNING, and CAUTION. These words are used with the
safe- ty-alert symbol. DANGER identifies the most serious hazards which will
result in severe personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or product and property
damage. NOTE is used to highlight suggestions which will result in enhanced
installation, reliability, or operation.
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury and/or death.
Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous gas
that can be fatal when inhaled. Follow all installation, maintenance, and
service instructions. See additional information below regarding the
installation of a CO Alarm.
Most states is the USA and jurisdictions in Canada have laws that require the
use of Carbon Monoxide (CO) alarms with fuel burning products. Examples of
fuel burning products are furnaces, boilers, space heaters, generators, water
heaters, stoves/ranges, clothes dryers, fireplaces, incinerators, automobiles,
and other internal combustion engines. Even if there are no laws in your
jurisdiction requiring a CO Alarm, it’s highly recommended that whenever any
fuel burning product is used in or around the home or business that the
dwelling be equipped with a CO Alarm(s). The Consumer Product Safety
Commission recommends the use of CO Alarm(s). The CO Alarm(s) must be
installed, operated, and maintained according to the CO Alarm manufacturer’s
instructions. For more information about Carbon Monoxide, local laws, or to
purchase a CO Alarm only, please visit the following website
https://www.kidde.com
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing or servicing system, always turn off main power to system
and install lockout tag. There may be more than one disconnect switch. Turn
off accessory heater power switch if applicable.
WARNING
IRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or unit damage.
A qualified installer or agency must use only factory-authorized kits or
accessories when modifying this product.
WARNING
FIRE, INJURY, OR DEATH HAZARD
Failure to follow this warning could result in property damage, personal
injury, or death.
This unit was manufactured to operate with natural gas. When fuel supply is
liquid propane gas (LP), this unit MUST be converted with a factory approved
LP conversion kit. See rating plate for approved conversion kits.
WARNING
PERSONAL INJURY AND PROPERTY DAMAGE HAZARD
For continued performance, reliability, and safety, the only approved
accessories and replacement parts are those specified by the equipment
manufacturer. The use of non-manufacturer approved parts and accessories could
invalidate the equipment limited warranty and result in fire risk, equipment
malfunction, and failure. Please review manufacturer’s instructions and
replacement part catalogs available from your equipment supplier.
Introduction
This unit (see Fig. 1) is a fully self-contained, combination Category I gas
heating/electric cooling unit designed for outdoor installation (See Fig. 3
and Fig. 4 for unit dimensions). All unit sizes have return and discharge
openings for both horizontal and downflow configurations, and are factory
shipped with all downflow duct openings covered. Units may be installed either
on a rooftop or on a cement slab. (See Fig. 5 for roof curb dimensions).
In gas heating mode, this unit is designed for a minimum continuous return-air
temperature of 55°F (13°C) db and a maximum continuous return-air temperature
of 80°F (27°C) db. Failure to follow these return-air temperature limits may
affect reliability of heat exchangers, motors, and other components.
Models with a N in the fifth position of the model number are dedicated that
are Low NOx units designed for California installations. These models meet the
California maximum oxides of nitrogen (NOx) emissions requirements of 40
nanograms/joule or less as shipped from the factory and must be installed in
California Air Quality Management Districts or any other regions in North
America where a Low NOx rule exists.
NOTE: Low NOx requirements apply only to natural gas installations.
NOTICE
If the unit gasketing or insulation must be replaced, ensure the material used
is compliant with the two agency requirements listed.
- Insulation and adhesives shall meet NFPA 90.1 requirements for flame spread and smoke generation.
- Cabinet insulation shall meet ASHRAE Standard 62.2.
Receiving and Installation
Step 1 – Check Equipment
Identify Unit
The unit model number and serial number are stamped on the unit information
plate. Check this information against shipping papers.
Inspect Shipment
Inspect for shipping damage before removing packaging materials. If unit
appears to be damaged or is torn loose from its anchorage, have it examined by
transportation inspectors before removal. Forward claim papers directly to
transportation company. Manufacturer is not responsible for any damage
incurred in transit. Check all items against shipping list. Immediately notify
the nearest equipment distribution office if any item is missing. To prevent
loss or damage, leave all parts in
original packages until installation.
If the unit is to be mounted on a curb in a downflow application, review Step
9 to determine which method is to be used to remove the downflow panels before
rigging and lifting into place. The panel removal process may require the unit
to be on the ground.
Step 2 – Provide Unit Support
For hurricane tie downs, contact distributor for details and PE (Professional
Engineering) Certificate if required.
Roof Curb
Install accessory roof curb in accordance with instructions shipped with curb
(See Fig. 5). Install insulation, cant strips, roofing, and flashing.
Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical for a
water tight seal. Install gasketing material supplied with the roof curb.
Improperly applied gasketing also can result in air leaks and poor unit
performance.
Curb should be level to within 1/4 in. (6 mm). This is necessary for unit
drain to function properly. Refer to accessory roof curb installation
instructions for additional information as required.
Installation on older “G” series roof curbs.
Two accessory kits are available to aid in installing a new “G” series unit on
an old “G” roof curb.
-
Accessory kit number CPADCURB001A00, (small chassis) and accessory kit number CPADCURB002A00, (large chassis) includes roof curb adapter and gaskets for the perimeter seal and duct openings. No additional modifications to the curb are required
when using this kit. -
An alternative to the adapter curb is to modify the existing curb by removing the outer horizontal flange and use accessory kit number CPGSKTKIT001A00 which includes spacer blocks (for easy alignment to existing curb) and gaskets for the perimeter seal and duct openings. This kit is used when existing curb is modified by removing outer horizontal flange.
CAUTION
UNITS/STRUCTURAL DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Ensure there is sufficient clearance for saw blade when cutting the outer
horizontal flange of the roof curb so there is no damage to the roof or
flashing.
Slab Mount
Place the unit on a solid, level pad that is at least 2 in. (51 mm) above
grade. The pad should extend approximately 2 in. (51 mm) beyond the casing on
all 4 sides of the unit. (See Fig. 2.) Do not secure the unit to the pad
except when required by local codes.
Manufacturer reserves the right to change, at any time, specifications and
designs without notice and without obligations.
Fig. 2 – Slab Mounting Details
Step 3 – Field Fabricate Ductwork
Secure all ducts to roof curb and building structure on vertical discharge
units. Do not connect ductwork to unit. For horizontal applications, unit is
provided with flanges on the horizontal openings. All ductwork should be
secured to the flanges. Insulate and weatherproof all external ductwork,
joints, and roof openings with counter flashing and mastic in accordance with
applicable codes.
Ducts passing through an unconditioned space must be insulated and covered
with a vapor barrier.
If a plenum return is used on a vertical unit, the return should be ducted
through the roof deck to comply with applicable fire codes.
Read unit rating plate for any required clearances around ductwork.
Cabinet return-air static shall not exceed -.25 IN. W.C.
Step 4 – Provide Clearances
IMPORTANT: The unit must be secured to the curb by installing screws
through the bottom of the curb flange and into the unit base rails.
When installing large base units onto the common curb, the screws must be
installed before allowing the full weight of the unit to rest on the curb.
A minimum of six screws are required for large base units. Failure to secure
unit properly could result in an unstable unit. See Warning near
Rigging/Lifting information and accessory curb instructions for more details.
The required minimum operating and service clearances are shown in Fig. 3 and
Fig. 4. Adequate combustion, ventilation and condenser air must be provided.
IMPORTANT: Do not restrict outdoor airflow. An air restriction at either
the outdoor-air inlet or the fan discharge may be detrimental to compressor
life.
The condenser fan pulls air through the condenser coil and discharges it
through the top grille. Be sure that the fan discharge does not recirculate to
the condenser coil. Do not locate the unit in either a corner or under an
overhead obstruction. The minimum clearance under a partial overhang (such as
a normal house overhang) is 48-in. (1219 mm) above the unit top. The maximum
horizontal extension of a partial overhang must not exceed 48-in. (1219 mm).
Do not place the unit where water, ice, or snow from an overhang or roof will
damage or flood the unit. Do not install the unit on carpeting or other
combustible materials. Slab-mounted units should be at least 2 in.
(51 mm) above the highest expected water and runoff levels. Do not use unit if
it has been under water.
Step 5 – Rig and Place Unit
WARNING
PERSONAL INJURY OR PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal injury, death or
property damage.
When installing the unit on a rooftop, be sure the roof will support the
additional weight.
Rigging and handling of this equipment can be hazardous for many reasons due
to the installation location (roofs, elevated structures, etc.).
Only trained, qualified crane operators and ground support staff should handle
and install this equipment.
When working with this equipment, observe precautions in the literature, on
tags, stickers, and labels attached to the equipment, and any other safety
precautions that might apply.
Training for operators of the lifting equipment should include, but not be
limited to, the following:
- Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads.
- Instruction in any special operation or precaution.
- Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work gloves.
Inspection
Prior to initial use, and at monthly intervals, all rigging shackles, clevis
pins, and straps should be visually inspected for any damage, evidence of
wear, structural deformation, or cracks. Particular attention should be paid
to excessive wear at hoist hooking points and load support areas.
Materials showing any kind of wear in these areas must not be used and should
be discarded.
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal injury/death or
property damage.
When straps are taut, the clevis should be a minimum of 36 in. (914 mm) above
the unit top cover.
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury or death.
Never stand beneath rigged units or lift over people.
Rigging/Lifting of Unit (See Fig. 6)
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury or death.
Large base units must be secured to common curb before allowing full weight of
unit to rest on curb. Install screws through curb into unit base rails while
rigging crane is still supporting unit.
Lifting holes are provided in base rails as shown in Fig. 3 and Fig. 4.
- Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage.
- Attach shackles, clevis pins, and straps to the base rails of the unit. Be sure materials are rated to hold the weight of the unit (See Fig. 6).
- Attach a clevis of sufficient strength in the middle of the straps. Adjust the clevis location to ensure unit is lifted level with the ground.
After the unit is placed on the roof curb or mounting pad, remove the top skid.
48VL-K: Installation Instructions
UNIT SIZE| CATALOG NUMBER| A
IN.
(mm)
| B (small / common
**base) IN. (mm)***
| B (large
base)
IN. **(mm) ***
| C
IN.
(mm)
| D
IN.
(mm)
| E
IN.
(mm)
| F
IN.
(mm)
| G
IN. (mm)
| H
IN. (mm)
---|---|---|---|---|---|---|---|---|---|---
Small or
Large
| CPRFCURB011B00| 14
(356)
| 10 (254)|
14 (356)
| 16
(406)
| 47.8
(1214)
| 32.4
(822)
|
2.7 (69)
| 30.6 (778)|
46.1 (1170)
Large| CPRFCURB013B00| 14
(356)
| 14 (356)| 43.9
(1116)
| 42.2 (1072)
*. Part Number CPRCURB011B00 can be used on both small and large basepan units. The cross supports must be located based on whether the unit is a small basepan or a large basepan.
NOTES:
- Roof curb must be set up for unit being installed.
- Seal strip must be applied, as required, to unit being installed.
- Roof curb is made of 16-gauge steel.
- Attach ductwork to curb (flanges of duct rest on curb).
- Insulated panels: 1-in. (25.4 mm) thick fiberglass 1 lb. density.
Fig. 5 – Roof Curb Dimensions
CAUTION – NOTICE TO RIGGERS
PRUDENCE – AVIS AUX MANIPULATEUR
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
Use top skid as spreader bar.
| SMALL CABINET | LARGE CABINET | |
|---|---|---|
| Unit | 24 | 30 |
| lb | kg | lb |
| lb | kg | lb |
| Rigging Weight | 339 | 154 |
| 179 | 428 | 194 |
NOTE: See dimensional drawing for corner weights.
Fig. 6 – Unit Suggested Rigging
Table 1 – Physical Data
UNIT SIZE| 24040| 24060| 30040| 30060| 36060|
36090| 42060| 42090
---|---|---|---|---|---|---|---|---
NOMINAL CAPACITY (ton)| 2| 2| 2-1/2| 2-1/2| 3| 3| 3-1/2| 3-1/2
SHIPPING WEIGHT lb. SHIPPING WEIGHT (kg)| 339
154
| 339
154
| 348
158
| 348
158
| 394
179
| 394
179
| 428
194
| 428
194
COMPRESSOR / QUANTITY| Scroll / 1
REFRIGERANT (R-410A)
Quantity lb. Quantity (kg)
| ****
6.4
2.9
| ****
6.4
2.9
| ****
6.0
2.7
| ****
6.0
2.7
| ****
5.75
2.6
| ****
5.75
2.6
| ****
6.0
2.7
| ****
6.0
2.7
REFRIGERANT METERING DEVICE| Orifice
ORIFICE ID in. / mm| .059 / 1.5| .059 / 1.5| .063 / 1.60| .063 / 1.60| .070 /
1.78| .073 / 1.85| .073 /1.85
OUTDOOR COIL
Rows…Fins/in. Face Area (sq ft)
| ****
1..21
11.9
| ****
1…21
11.9
| ****
1…21
13.6
| ****
1…21
13.6
| ****
1…21
13.6
| ****
1…21
13.6
| ****
1…21
13.6
| ****
1…21
13.6
OUTDOOR FAN
Nominal CFM Diameter in. Diameter (mm) Motor Hp (Rpm)
| ****
2500
24
609.6
1/12 (810)
| ****
2500
24
609.6
1/12 (810)
| ****
3200
24
609.6
1/5 (810)
| ****
3200
24
609.6
1/5 (810)
| ****
3500
26
660.4
1/2 (810)
| ****
3500
24
609.6
1/2 (810)
| ****
3500
26
660.4
3/4 (810
| ****
3500
26
660.4
3/4 (810)
INDOOR COIL
Rows…Fins/in. Face Area (sq ft)
| ****
3…17
3.7
| ****
3…17
3.7
| ****
3…17
3.7
| ****
3…17
3.7
| ****
2…17
5.6
| ****
2…17
5.6
| ****
3…17
4.7
| ****
3…17
4.7
INDOOR BLOWER
Nominal Cooling Airflow (CFM) Size in.
Size (mm.) Motor HP (RPM)
| ****
750
10×10
254×254
1/2 (1050)
| ****
750
10×10
254×254
1/2 (1050)
| ****
950
10×10
254×254
1/2 (1050)
| ****
950
10×10
254×254
1/2 (1050)
| ****
1150
11×10
279.4×254
3/4 (1000)
| ****
1150
11×10
279.4×254
3/4 (1000)
| ****
1350
11×10
279.4×254
1/2 (1050)
| ****
1350
11×10
279.4×254
1/2 (1050)
FURNACE SECTION*
Burner Orifice No. (Qty…Drill Size) Natural Gas (Factory Installed) Propane Gas
| ****
2…44
2…55
| ****
3…44
3…55
| ****
2…44
2…55
| ****
3…44
3…55
| ****
3…44
3…55
| ****
3…38
3…53
| ****
3…44
3…55
| ****
3…38
3…53
HIGH-PRESSURE SWITCH
(psig) Cut-out Reset (Auto)
| 650 +/- 15
420 +/- 25
LOSS-OF-CHARGE / LOW-PRESSURE
SWITCH (Liquid Line) (psig) cut-out Reset (auto)
| ****
NA
RETURN-AIR FILTERS† ‡
Throwaway Size in. (mm)
| ****
2 each 20x12x1 508x305x25
| 1 each 24x16x1 610x406x25
24x18x1
610x457x25
| 1 each 24x14x1 610x356x25
24x16x1
610x406x25
*. Based on altitude of 0 to 2000 ft (0-610 m).
†. Required filter sizes shown are based on the larger of the AHRI (Air
Conditioning Heating and Refrigeration Institute) rated cooling airflow or the
heating airflow velocity of 300 to 350 ft/minute for throwaway type. Air
filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.
‡. If using accessory filter rack refer to the filter rack installation
instructions for correct filter sizes and quantity
UNIT SIZE| 48090| 48115| 48130| 60090| 60115|
60130
---|---|---|---|---|---|---
NOMINAL CAPACITY (ton)| 4| 4| 4| 5| 5| 5
SHIPPING WEIGHT lb SHIPPING WEIGHT kg| 481
218
| 481
218
| 481
218
| 495
225
| 495
225
| 495
225
COMPRESSOR / QUANTITY| Scroll / 1
REFRIGERANT (R-410A)
Quantity lb Quantity (kg.)
| ****
9.0
4.1
| ****
9.0
4.1
| ****
9.0
4.1
| ****
10.75
4.9
| ****
10.75
4.9
| ****
10.75
4.9
REFRIGERANT METERING DEVICE| Orifice| TXV
ORIFICE ID in./mm| .080 / 2.03| N/A
OUTDOOR COIL
Rows…Fins/in. Face Area (sq ft)
| ****
1…21
23.3
| ****
1…21
23.3
| ****
1…21
23.3
| ****
2…21
17.5
| ****
2…21
17.5
| ****
2…21
17.5
OUTDOOR FAN
Nominal CFM Diameter in. Diameter (mm) Motor Hp (Rpm)
| ****
3500
26
660.4
1/5 (810)
| ****
3500
26
660.4
1/5 (810)
| ****
3500
26
660.4
1/5 (810)
| ****
3500
26
660.4
1/5 (810)
| ****
3500
26
660.4
1/5 (810)
| ****
3500
26
660.4
1/5 (810)
INDOOR COIL
Rows…Fins/in. Face Area (sq ft)
| ****
3…17
5.6
| ****
3…17
5.6
| ****
3…17
5.6
| ****
3…17
5.6
| ****
3…17
5.6
| ****
3…17
5.6
INDOOR BLOWER
Nominal Cooling Airflow (CFM) Size in.
Size (mm) Motor HP (RPM)
| ****
1600
11×10
279.4×254
1.0 (1075)
| ****
1600
11×10
279.4×254
1.0 (1075)
| ****
1600
11×10
279.4×254
1.0 (1075)
| ****
1750
11×10
279.4×254
1.0 (1040)
| ****
1750
11×10
279.4×254
1.0 (1040)
| ****
1750
11×10
279.4×254
1.0 (1040)
FURNACE SECTION*
Burner Orifice No. (Qty…Drill Size) Natural Gas (Factory Installed) Propane Gas
| ****
3…38
3…53
| ****
3…33
3…51
| ****
3…31
3…49
| ****
3…31
3…49
| ****
3…31
3…49
| ****
3…31
3…49
HIGH-PRESSURE SWITCH
(psig) Cut-out Reset (Auto)
| 650 +/- 15
420 +/- 25
LOSS-OF CHARGE / LOW-PRESSURE
SWITCH (Liquid Line) (psig) cut-out Reset (auto)
| ****
N/A
RETURN-AIR FILTERS Throwaway† ‡in.
mm
| 1 each 24x16x1 610x406x25
24x18x1
610x457x25
*. Based on altitude of 0 to 2000 ft (0-610 m).
†. Required filter sizes shown are based on the larger of the AHRI (Air
Conditioning Heating and Refrigeration Institute) rated cooling airflow or the
heating airflow velocity of 300 to 350 ft/minute for throwaway type. Air
filter pressure drop for non-standard filters must not exceed 0.08 IN. W.C.
‡. If using accessory filter rack refer to the filter rack installation
instructions for correct filter sizes and quantity.
Step 6 – Connect Condensate Drain
NOTE: When installing condensate drain connection be sure to comply with
local codes and restrictions.
This unit disposes of condensate water through a 3/4 in. NPT fitting which
exits through the base on the evaporator coil access side. See Fig. 3 and Fig.
4 for location.
Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground level
installations. Install a field-supplied 2-in. (51 mm) condensate trap at the
end of condensate connection to ensure proper drainage. Make sure that the
outlet of the trap is at least 1 in. (25 mm) lower than the drain-pan
condensate connection to prevent the pan from overflowing (See Fig. 7). Prime
the trap with water. When using a gravel apron, make sure it slopes away from
the unit.
Connect a drain tube using a minimum of 3/4-in. PVC or 3/4-in. copper pipe
(all field-supplied) at the outlet end of the 2-in. (51 mm) trap. Do not
undersize the tube. Pitch the drain tube downward at a slope of at least 1-in.
(25 mm) for every 10 ft (3.1 m) of horizontal run. Be sure to check the drain
tube for leaks.
Step 7 – Install Flue Hood
The flue assembly is secured and shipped in the return air duct. Remove duct
cover to locate the assembly (See Fig. 9).
NOTE: Dedicated low NOx models MUST be installed in California Air
Quality Management Districts where a Low NOx rule exists.
These models meet the California maximum oxides of nitrogen (NOx) emissions
requirements of 40 nanograms/joule or less as shipped from the factory.
NOTE: Low NOx requirements apply only to natural gas installations.
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or death.
The venting system is designed to ensure proper venting. The flue hood
assembly must be installed as indicted in this section of the unit
installation instructions.
Install the flue hood as follows:
-
This installation must conform with local building codes and with NFPA 54/ANSI Z223.1 National Fuel Gas Code (NFGC), (in Canada, CAN/CGA B149.1, and B149.2) latest revision. Refer to Provincial and local plumbing or wastewater codes and other
applicable local codes. -
Remove flue hood from shipping location (inside the return section of the blower compartment-see Fig. 9). Remove the return duct cover to locate the flue hood. Place flue hood assembly over flue panel. Orient screw holes in flue hood with holes in the flue panel.
-
Secure flue hood to flue panel by inserting a single screw on the top flange and the bottom flange of the hood.
Step 8 – Install Gas Piping
The gas supply pipe enters the unit through the access hole provided.
The gas connection to the unit is made to the 1/2-in. (12.7 mm) FPT gas inlet
on the gas valve.
Install a gas supply line that runs to the heating section. Refer to the NFGC
for gas pipe sizing. Do not use cast-iron pipe. It is recommended that a black
iron pipe is used. Check the local utility for recommendations concerning
existing lines. Size gas supply piping for 0.5 IN. W.C. maximum pressure drop.
Never use pipe smaller than the 1/2-in. (12.7 mm) FPT gas inlet on the unit
gas valve.
For natural gas applications, the gas pressure at unit gas connection must not
be less than 4.0 IN. W.C. or greater than 13 IN. W.C. while the unit is
operating. For propane applications, the gas pressure must not be less than
11.0 IN. W.C. or greater than 13 IN. W.C. at the unit connection. A 1/8-in.
(3.2 mm) NPT plugged tapping, accessible for test gauge connection, must be
installed immediately upstream of the gas supply connection to the gas valve.
When installing the gas supply line, observe local codes pertaining to gas
pipe installations. Refer to the NFPA 54/ANSI Z223.1 latest edition (in
Canada, CAN/CGA B149.1).
NOTE: In the state of Massachusetts:
- Gas supply connections MUST be performed by a licensed plumber or gas fitter.
- When flexible connectors are used, the maximum length shall not exceed 36 in. (915 mm).
- When lever handle type manual equipment shutoff valves are used, they shall be T-handle valves.
- The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.
In the absence of local building codes, adhere to the following pertinent recommendations:
-
Avoid low spots in long runs of pipe. Grade all pipe 1/4 in. (6.35 mm) for every 15 ft (4.6 m) of length to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter.
-
Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one hanger every 6 ft (1.8 m). For pipe sizes larger than 1/2 in., follow recommendations of national codes.
-
Apply joint compound (pipe dope) sparingly and only to male threads of joint when making pipe connections. Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and/or national codes. Never use Teflon tape.
-
Install sediment trap in riser leading to heating section (See Fig. 8).
This drip leg functions as a trap for dirt and condensate. -
Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft (1.8 m) of heating section.
-
Install ground-joint union close to heating section between unit manual shutoff and external manual main shut-off valve.
-
Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit. NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig. Pressure test the gas supply piping system at pressures equal to or less than 0.5 psig. The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground-joint union.
Table 2 – Gas Flow Capacity *** NOMINAL IRON PIPE SIZE (IN.)| INTERNAL DIAMETER (IN.)| LENGTH OF PIPE FT (m) †
---|---|---
10**
(3)
| 20
(6)
| 30
(9)
| 40
(12)
| 50
(15)
| 60
(18)
| 70
(21)
| 80
(24)
| 90
(27)
| 100
(30)
| 125
(38)
| 150
(46)
| 175
(53)
| 200
(61)
1/2| .622| 175| 120| 97| 82| 73| 66| 61| 57| 53| 50| 44| 40| —| —
3/4| .824| 360| 250| 200| 170| 151| 138| 125| 118| 110| 103| 93| 84| 77| 72
1| 1.049| 680| 465| 375| 320| 285| 260| 240| 220| 205| 195| 175| 160| 145| 135
1-1/4| 1.380| 1400| 950| 770| 600| 580| 530| 490| 460| 430| 400| 360| 325|
300| 280
1-1/2| 1.610| 2100| 1460| 1180| 990| 900| 810| 750| 690| 650| 620| 550| 500|
460| 430
*. Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5-IN. W.C. (based on a 0.60 specific gravity gas). Refer to Table 2 and National Fuel Gas Code NFPA 54/ANSI Z223.1.
†. This length includes an ordinary number of fittings.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death and/or
property damage.
– Connect gas pipe to unit using a backup wrench to avoid damaging gas
controls.
– Never purge a gas line into a combustion chamber. 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.
– Use proper length of pipe to avoid stress on gas control manifold.
– If a flexible connector is required or allowed by authority having
jurisdiction, black iron pipe shall be installed at furnace gas valve and
extend a minimum of 2 in. (51 mm) outside furnace casing.
– If codes allow a flexible connector, always use a new connector. Do not use
a connector which has previously serviced another gas appliance.
- Check for gas leaks at the field-installed and factory-installed gas lines after all piping connections have been completed. Use a commercially available soap solution (or method specified by local codes and/or regulations).
Step 9 – Install Duct Connections
The unit has duct flanges on the supply- and return-air openings on the side
and bottom of the unit. For downshot applications, the ductwork connects to
the roof curb (See Fig. 3 and Fig. 4 for connection sizes and locations).
Configuring Units for Downflow (Vertical) Discharge
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing or servicing system, always turn off main power to system
and install lockout tag. There may be more than one disconnect switch.
-
Open all electrical disconnects before starting any service work.
-
Remove horizontal (metal) duct covers to access vertical (downflow) discharge duct knockouts in unit basepan. (See Fig. 9.)
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Collect ALL screws that were removed. Do not leave screws on rooftop as permanent damage to the roof may occur. -
For single-phase models only, on the discharge side only, remove the insulation covering the downshot (plastic) knockout. Insulation is held in place with aluminum tape. Please note that large chassis units have 2 pieces of insulation, and only the piece over the downshot knockout needs to be removed. Discard insulation.
-
To remove the downshot (plastic) knockouts for both supply and returns, break front and right side connecting tabs with a screwdriver and hammer. Push cover down to break rear and left side tabs. These plastic knockouts are held in place with tabs
similar to an electrical knockout. Discard plastic knockout covers. -
Set unit on roof curb.
-
Verify that the downshot ducts are aligned with the downshot knockout areas.
-
Re-install horizontal (metal) covers as needed to seal unit. Ensure openings are air and watertight.
NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence- type air conditioning and ventilating systems, NFPA 90A or residence-type, NFPA 90B; and/or local codes and ordinances.
Adhere to the following criteria when selecting, sizing, and installing the duct system:
- Units are shipped for horizontal duct installation (by removing duct covers).
- Select and size ductwork, supply-air registers, and return-air grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations.
- Use flexible transition between rigid ductwork and unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure weather-tight and airtight seal.
- All units must have field-supplied filters or accessory filter rack installed in the return-air side of the unit. Recommended sizes for filters are shown in Table 1.
- Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases or performance may be affected.
- Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors of America (ACCA) minimum installation standards for heating and air conditioning systemsSecure all ducts to building structure.
- Flash, weatherproof, and vibration isolate all openings in building structure in accordance with local codes and good building practices.
Step 10 – Install Electrical Connections
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
The unit cabinet must have an uninterrupted, unbroken electrical ground. This
ground may consist of an electrical wire connected to the unit ground screw in
the control compartment, or conduit approved for electrical ground when
installed in accordance with NFPA 70 (NEC) (latest edition) (in Canada,
Canadian Electrical Code CSA C22.1) and local electrical codes.
CAUTION
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the unit being
installed.
- Make all electrical connections in accordance with NFPA 70 (NEC) (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.
- Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.
- Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate. On 3-phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.
- Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are in same conduit as high-voltage wires.
- Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.
- Route field power supply(s) away from areas that could be damaged by lawn and garden equipment or other accidental damage.
High-Voltage Connections
When routing power leads into unit, use only copper wire between disconnect
and unit. The high voltage leads should be in a conduit until they enter the
duct panel; conduit termination at the duct panel must be watertight.
The unit must have a separate electrical service with a field-supplied,
waterproof disconnect switch mounted at, or within sight from, the unit. Refer
to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker
size and minimum circuit amps (ampacity) for wire sizing.
The field-supplied disconnect switch box may be mounted on the unit over the
high-voltage inlet hole when the standard power and low-voltage entry points
are used (See Fig. 3 and Fig. 4 for acceptable location).
NOTE: Field supplied disconnect switch box should be positioned so that
it does not cover up any of the unit gas combustion supply air louvers.
See unit wiring label (Fig. 14 – Fig. 19) and Fig. 10 for reference when
making high voltage connections. Proceed as follows to complete the high-
voltage connections to the unit. Single phase units:
- Run the high-voltage (L1, L2) and ground lead into the control box.
- Connect ground lead to chassis ground connection.
- Locate the black and yellow wires connected to the line side of the contactor (if equipped).
- Connect field L1 to black wire on connection 11 of the compressor contactor.
- Connect field wire L2 to yellow wire on connection 23 of the compressor contactor.
Three-phase units:
- Run the high-voltage (L1, L2, L3) and ground lead into the control box.
- Connect ground lead to chassis ground connection.
- Locate the black and yellow wires connected to the line side of the contactor (if equipped).
- Connect field L1 to black wire on connection 11 of the compressor contactor.
- Connect field wire L3 to yellow wire on connection 13 of the compressor contactor.
- Connect field wire L2 to blue wire from compressor.
Special Procedures for 208-v Operation
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Make sure the power supply to the unit is switched OFF and install lockout tag
before making any wiring changes. With disconnect switch open, move black wire
from transformer (3/16 in. [4.8mm]) terminal marked 230 to terminal marked
208. This retaps transformer to primary voltage of 208 vac.
WARNING
ELECTRICAL SHOCK FIRE/EXPLOSION HAZARD
Failure to follow this warning could result in personal injury or death and
property damage.
Before making any wiring changes, make sure the gas supply is switch off
first. Then switch off the power supply to the unit and install lockout tag.
Control Voltage Connections
Do not use any type of power-stealing thermostat. Unit control problems may
result.
Use no. 18 American Wire Gage (AWG) color-coded, insulated (35°C minimum)
wires to make the control voltage connections between the thermostat and the
unit. If the thermostat is located more than 100 ft (30.5 m) from the unit (as
measured along the control voltage wires), use no. 16 AWG color-coded,
insulated (35°C minimum) wires.
Standard Connection
Run the low-voltage leads from the thermostat, through the inlet hole, and
into unit low-voltage splice box.
Locate six (seven for 3-phase) 18-gage wires leaving control box. These low-
voltage connection leads can be identified by the colors red, green, yellow,
brown, blue, and white (See Fig. 10). A gray wire is standard on 3-phase units
for connection to an economizer. Ensure the leads are long enough to be routed
into the low-voltage splice box (located below right side of control box).
Route leads through hole in bottom of control box and make low-voltage
connections (See Fig. 10). Secure all cut wires, so that they do not interfere
with operation of unit.
Heat Anticipator Setting (Electro-Mechanical Thermostats only)
The room thermostat heat anticipator must be properly adjusted to ensure
proper heating performance. Set the heat anticipator, using an ammeter between
the W and R terminals to determine the exact required setting.
NOTE: For thermostat selection purposes, use 0.18 amp for the approximate
required setting. Failure to make a proper heat anticipator adjustment will
result in improper operation, discomfort to the occupants of the conditioned
space, and inefficient energy utilization; however, the required setting may
be changed slightly to provide a greater degree of comfort for a particular
installation.
Transformer Protection
The transformer is of the energy-limiting type, however a direct short will
likely blow a secondary fuse. If an overload or short is present, correct
overload condition and check for blown fuse on Indoor Fan board or Integrated
Gas Controller. Replace fuse as required with correct size and rating.
Pre-Start-up
WARNING
ENVIRONMENTAL, FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
- Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.
- Do not operate compressor or provide any electric power to unit unless compressor plug is in place and secured.
- Do not remove compressor plug until all electrical sources are disconnected and tagged.
- Relieve and recover all refrigerant from system before touching or disturbing compressor plug if refrigerant leak is suspected around compressor terminals.
- Never attempt to repair soldered connection while refrigerant system is under pressure.
- Do not use torch to remove any component. System contains oil and refrigerant under pressure.
To remove a component, wear protective goggles and proceed as follows:
-Shut off electrical power to unit and install lockout tag.
-Relieve and reclaim all refrigerant from system using both high- and low-pressure ports.
-Cut component connecting tubing with tubing cutter and remove component from unit.
-Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame.
Use the Start-Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start-up:
-
Remove access panels (see Fig. 22).
-
Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION labels attached to, or shipped with unit. -
Make the following inspections:
a. Inspect for shipping and handling damage, such as broken lines, loose parts, disconnected wires, etc.
b. Inspect all field- and factory-wiring connections. Be sure that connections are completed and tight.
c. Ensure wires do not touch refrigerant tubing or sharp sheet metal edges.
d. Inspect coil fins. If damaged during shipping and handling, carefully straighten fins with a fin comb.
WARNING
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death or property damage.
Do not purge gas supply into the combustion chamber. Do not use a match or other open flame to check for gas leaks.
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. -
Verify the following conditions:
a. Make sure gas line is free of air. Before lighting the unit for thfirst time, perform the following with the gas valve in the OFFposition:
NOTE: If the gas supply pipe was not purged before connecting the unit,
it will be full of air. It is recommended that the ground joint union be
loosened, and the supply line be allowed to purge until the odor of gas is
detected. Never purge gas lines into a combustion chamber. Immediately upon
detection of gas odor, retighten the union. Allow 5 minutes to elapse, then
light unit.
b. Ensure fan hub is positioned correctly with respect to motor housing.
c. Make sure that air filter(s) is in place.
d. Make sure that condensate drain trap is filled with water to ensure proper
drainage.
e. Make sure that all tools and miscellaneous loose parts have been removed.
Start-up
WARNING
FIRE, INJURY, OR DEATH HAZARD
Failure to follow this warning could result in property damage, personal
injury, or death.
Do not bypass any of the safety controls in the unit, including but not
limited to the main limit switch, rollout or burner rollout switch, and
pressure switch/pressure transducer.
Step 1 – Check for Refrigerant Leaks
WARNING
EXPLOSION HAZARD
Failure to follow this warning could result in death, serious personal injury,
and/or property damage.
Never use air or gases containing oxygen for leak testing or operating
refrigerant compressors. Pressurized mixtures of air or gases containing
oxygen can lead to an explosion.
Proceed as follows to locate and repair a refrigerant leak and to charge the
unit:
-
Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high- and low-pressure ports.
-
Repair leak following accepted practices.
NOTE: Install a filter drier whenever the system has been opened for repair. -
Add a small charge of Puron (R-410A) refrigerant vapor to system and leak-test unit.
-
Recover refrigerant from refrigerant system and evacuate to 500 microns if no additional leaks are found.
-
Charge unit with Puron (R-410A) refrigerant, using an accurate scale. Refer to unit rating plate for required charge.
Step 2 – Start-up Heating and Make Adjustments
Complete the required procedures given in the Pre-Start-Up section before starting the unit. Do not jumper any safety devices when operating the unit. Make sure that burner orifices are properly aligned. Unstable operation my occur when the burner orifices in the manifold are misaligned.
Follow the lighting instructions on the heating section operation label (located on the inside of the control access panel) to start the heating section.
NOTE: Make sure that gas supply has been purged, and that all gas piping has been checked for leaks.
Check Heating Control
Start and check the unit for proper heating control operation as follows (see
furnace lighting instructions located on the inside of the control access
panel):
- Place room thermostat SYSTEM switch in the HEAT position and the fan switch is placed in AUTO position.
- Set the heating temperature control of the thermostat above room temperature.
- The induced-draft motor will start.
- On a call for heating, the main burner should light within 5 sec. of the spark being energized. If the burners do not light, there is a 22-sec. delay before another 5-sec. try. If the burners still do not light, this sequence is repeated. For 3-phase models if the burners do not light within 15 minutes from the initial call for heat, there is a lockout. For single phase models, if the burners do not light on the 4th ignition attempt, there is a lockout. To reset the control, break the 24-v power to W.
- For 3-phase models the evaporator fan will turn on 45 sec. after the flame has been established. The evaporator fan will turn off 45 sec. after the thermostat has been satisfied. For single phase models the evaporator fan will turn on 30 sec. after the flame has been established. The evaporator fan will turn off 90 sec. After the thermostat has been satisfied. Please note that the integrated gas unit controller (IGC) has the capability to automatically reduce the evaporator “ON” delay and increase the evaporator “OFF” delay in the event of high duct static and/or partially-clogged filter.
Check Gas Input
Check gas input and manifold pressure after unit start-up (See Table 5).
If adjustment is required proceed as follows:
- The rated gas inputs shown in Table 5 are for altitudes from sea level to 2000 ft (610 m) above sea level. These inputs are based on natural gas with a heating value of 1025 Btu/ft at 0.60 specific gravity, or propane gas with a heating value of 2500 Btu/ft 3
at 1.5 specific gravity. 3 IN THE U.S.A.:
The input rating for altitudes above 2,000 ft (610 m) must be reduced by 4% for each 1,000 ft (305 m) above see level.
For installations below 2,000 ft (610 m), refer to the unit rating plate.
For installations above 2,000 ft (610 m). multiply the input on the rating plate by the derate multiplier in Table 3 for correct input rate.
Table 3 – Altitude Derate Multiplier for U.S.A. *
Altitude ft (m)| Percent of Derate| Derate Multiplier
Factor †
---|---|---
0-2000
(0-610)
| 0| 1.00
2001-3000* (610-914)| 8-12| 0.90
3001-4000
(915-1219)
| 12-16| 0.86
4001-5000
(1220-1524)
| 16-20| 0.82
5001-6000
(1524 -1829)
| 20-24| 0.78
6001-7000
(1829-2134)
| 24-28| 0.74
7001-8000
(2134-2438)
| 28-32| 0.70
8001-9000
(2439-2743)
| 32-36| 0.66
9001-10,000
(2744-3048)
| 36-40| 0.62
*. In Canada see Canadian Altitude Adjustment.
†. Derate multiplier factors are based on midpoint altitude for altitude
range.
IN CANADA:
The input rating for altitudes from 2,000 (610 m) to 4,500 ft (1372 m)
above sea level must be derated 10% by an authorized Gas Conversion
Station or Dealer.
EXAMPLE: 90,000 Btu/hr Input Furnace Installed at 4300 ft.
When the gas supply being used has a different heating value or specific gravity, refer to national and local codes, or contact your distributor to determine the required orifice size.
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in reduced unit and/or component
life.
Do Not redrill an orifice. Improper drilling (burrs, out-of-round holes, etc.)
can cause excessive burner noise and misdirection of burner flame. If orifice
hole appears damaged or it is suspected to have been redrilled, check orifice
hole with a numbered drill bit of correct size.
Adjust Gas Input
The gas input to the unit is determined by measuring the gas flow at the meter
or by measuring the manifold pressure. Measuring the gas flow at the meter is
recommended for natural gas units. The manifold pressure must be measured to
determine the input of propane gas units.
Measure Gas Flow (Natural Gas Units)
Minor adjustment to the gas flow can be made by changing the manifold
pressure. The manifold pressure must be maintained between 3.2 and 3.8 IN.
W.C.
If larger adjustments are required, change main burner orifices following the
recommendations of national and local codes.
NOTE: All other appliances that use the same meter must be turned off when gas
flow is measured at the meter.
Proceed as follows:
- Turn off gas supply to unit.
- Remove pipe plug on manifold (See Fig. 11) and connect manometer. Turn on gas supply to unit.
- Record number of seconds for gas meter test dial to make one revolution.
- Divide number of seconds in Step 3 into 3600 (number of seconds in one hr).
- Multiply result of Step 4 by the number of cubic feet (cu ft) shown for one revolution of test dial to obtain cubic feet (cu ft) of gas flow per hour.
- Multiply result of Step 5 by Btu heating value of gas to obtain total measured input in Btuh. Compare this value with heating input shown in Table 5 (Consult the local gas supplier if the heating value of gas is not known).
EXAMPLE: Assume that the size of test dial is 1 cu ft, one revolution takes 32 sec, and the heating value of the gas is 1050 Btu/ft . Proceed as follows:
- 32 sec. to complete one revolution.
- 3600 ¸ 32 = 112.5.
- 112.5 x 1 =112.5 ft3 of gas flow/hr.
- 112.5 x 1050 = 118,125 Btuh input.
If the desired gas input is 115,000 Btuh, only a minor change in the manifold
pressure is required.
Observe manifold pressure and proceed as follows to adjust gas input:
-
Remove regulator cover screw over plastic adjustment screw on gas valve (See Fig. 13).
-
Turn plastic adjustment screw clockwise to increase gas input, or turn plastic adjustment screw counterclockwise to decrease input (See Fig. 13). Manifold pressure must be between 3.2 and 3.8 IN. WC.
WARNING
FIRE AND UNIT DAMAGE HAZARD
Failure to follow this warning could result in personal injury or death and/or property damage.
Unsafe operation of the unit may result if manifold pressure is outside this range. -
Replace regulator cover screw on gas valve (See Fig. 13).
-
Turn off gas supply to unit. Remove manometer from pressure tap and replace pipe plug on gas valve. (See Fig. 11.) Turn on gas to unit and check for leaks.
Measure Manifold Pressure (Propane Units)
Refer to propane kit installation instructions for properly checking gas input.
NOTE: For installations below 2,000 ft (610 m), refer to the unit rating plate for proper propane conversion kit. For installations above 2,000 ft (610 m), contact your distributor for proper propane conversion kit.
Check Burner Flame
With control access panel (see Fig. 22) removed, observe the unit heating operation. Watch the burner flames to see if they are light blue and soft in appearance, and that the flames are approximately the same for each burner. Propane will have blue flame (See Fig. 12). Refer to the Maintenance section for information on burner removal.
Table 4 – High Altitude Compensation, Natural Gas – All Models
Nameplate Input (Btu/hr)| **Rated Heating Input (Btu/hr), Natural Gas at
Installation Altitude Above Sea Level, U.S.A. *
---|---
0 to 2000 ft**
(0-610 m)
| **2001 to 3000 ft***
(611 to 914 m)
| 3001 to 4000 ft
(915 to 1219 m)
| 4001 to 5000 ft
(1220 to 1524 m)
| 5001 to 6000 ft
(1524 to 1829 m)
40000| 40000| 36000| 34400| 32800| 31200
60000| 60000| 54000| 51600| 49200| 46800
90000| 90000| 81000| 77400| 73800| 70200
115000| 115000| 103500| 98900| 94300| 89700
127000| 127000| 114300| 109200| 104100| 99100
*. In the U.S.A., the input rating for altitudes above 2000 ft (610m) must be reduced by 4% for each 1000 ft (305 m) above sea level.
In Canada, the input rating for altitudes from 2001 to 4500 ft (611 to 1372 m)
above sea level must be derated by 10% by an authorized gas conversion station
or dealer.
For Canadian Installations from 2000 to 4500 ft (610-1372 m), use U.S.A.
column 2001 to 3000 ft (611 to 914 m).
Table 5 – Heating Inputs
HEATING INPUT (BTUH)| NUMBER OF ORIFICES| GAS SUPPLY
PRESSURE (IN. W.C.)| MANIFOLD PRESSURE (IN. W.C.)
---|---|---|---
Natural | Propane †
Min| Max| Min| Max| Natural{| Propane*†
40,000| 2| 4.0| 13.0| 11.0| 13.0| 3.2~3.8| 10.0~11.0
60,000| 3| 4.0| 13.0| 11.0| 13.0| 3.2~3.8| 10.0~11.0
90,000| 3| 4.5| 13.0| 11.0| 13.0| 3.2~3.8| 10.0~11.0
115,000| 3| 4.5| 13.0| 11.0| 13.0| 3.2~3.8| 10.0~11.0
130,000| 3| 4.5| 13.0| 11.0| 13.0| 3.2~3.8| 10.0~11.0
*. Based on altitudes from sea level to 2000 ft (610 m) above sea level. In U.S.A. for altitudes above 2000 ft (610 m), reduce input rating 4 percent for each additional 1000 ft (305 m) above sea level. In Canada, from 2000 ft (610 m) above sea level to 4500 ft (1372 m) above sea level, derate the unit 10 percent.
†. When a unit is converted to propane, different size orifices must be used.
See separate, natural-to-propane conversion kit instructions.
| 
---|---
| 
| 
Normal Operation
An LED (light-emitting diode) indicator is provided on the integrated gas unit
controller (IGC) to monitor operation. The IGC is located by removing the
control access panel (see Fig. 22). During normal operation, the LED is
continuously on (See Table 6 for error codes).
Airflow and Temperature Rise
The heating section for each size unit is designed and approved for heating
operation within the temperature-rise range stamped on the unit rating plate.
Table 9 show the approved temperature rise range for each heating input, and
the air delivery CFM at various temperature rises for a given external static
pressure. The heating operation airflow must produce a temperature rise that
falls within the approved range. For single phase units only, “High” blower
speed is for high static cooling only and must not be used for gas heating
speed.
Refer to Indoor Airflow and Airflow Adjustments section to adjust heating
airflow when required.
Heating Sequence of Operation
(See Fig. 14, Fig. 15 and unit wiring label)
On a call for heating, terminal W of the thermostat is energized, starting the
induced-draft motor for a 5 second pre-purge. When the pressure switch senses
that the induced-draft motor is moving sufficient combustion air, the burner
sequence begins. This function is controlled by the integrated gas unit
controller (IGC). The indoor (evaporator) –fan motor is energized 30 seconds
after flame is established. When the thermostat is satisfied and W is de-
energized, the burners stop firing and the indoor (evaporator) fan motor shuts
off after a 90 second time-off delay. Please note that the IGC has the
capability to automatically reduce the indoor fan motor on delay and increase
the indoor fan motor off delay in the event of high duct static and/or a
partially-clogged filter.
Limit Switches
Normally closed limit switch (LS) completes the control circuit. Should the
leaving-air temperature rise above the maximum allowable temperature, the
limit switch opens and the control circuit “breaks.” Any interruption in the
control circuit instantly closes the gas valve and stops gas flow to the
burners. The blower motor continues to run until LS resets.
When the air temperature at the limit switch drops to the low-temperature
setting of the limit switch, the switch closes and completes the control
circuit. The direct-spark ignition system cycles and the unit returns to
normal heating operation.
Table 6 – LED Indications
| STATUS CODE | LED INDICATION |
|---|---|
| Normal Operation* | On |
| No Power or Hardware Failure | Off |
| Check fuse, low voltage circuit | 1 Flash |
| Limit Switch Fault | 2 Flashes |
| Flame Sense Fault | 3 Flashes |
| Four Consecutive Limit Switch Faults | 4 Flashes |
| Ignition Lockout Fault | 5 Flashes |
| Pressure Switch Fault | 6 Flashes |
| Rollout Switch Fault | 7 Flashes |
| Internal Control Fault | 8 Flashes |
| Temporary 1 hr auto reset† | 9 Flashes |
*. LED indicates acceptable operation. Do not change ignition control board.
†. This code indicates an internal processor fault that will reset itself in
one hr.
Fault can be caused by stray RF signals in the structure or nearby. This is a
UL requirement.
NOTES:
1. When W is energized the burners will remain on for a minimum of 60 sec.
2. If more than one error code exists they will be displayed on the LED in
Rollout Switch
The function of the rollout switch is to close the main gas valve in the event
of flame rollout. The switch is located above the main burners.
When the temperature at the rollout switch reaches the maximum allowable
temperature, the control circuit trips, closing the gas valve and stopping gas
flow to the burners. The indoor (evaporator) fan motor (IFM) and induced draft
motor continue to run until switch is reset. The IGC LED will display FAULT
CODE 7. Step 3 – Start-up Cooling and Make Adjustments sequence.
Complete the required procedures given in the Pre-Start-Up section before
starting the unit. Do not jumper any safety devices when operating the unit.
Do not operate the compressor when the outdoor temperature is below 40°F
(4.4°C) (unless accessory low-ambient kit is installed). Do not rapid-cycle
the compressor. Allow 5 minutes between on cycles to prevent compressor
damage.
Checking Cooling Control Operation
Start and check the unit for proper cooling control operation as follows:
- Place room thermostat SYSTEM switch in OFF position. Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FAN switch is placed in AUTO position.
- Place SYSTEM switch in COOL position and FAN switch in AUTO position. Set cooling control below room temperature. Observe that compressor, condenser fan, and evaporator blower motors start. Observe that cooling cycle shuts down when control setting is satisfied. The evaporator fan will continue to run for 90 sec.
- When using an auto-changeover room thermostat, place both SYSTEM and FAN switches in AUTO positions. Observe that unit operates in Heating mode when temperature control is set to call for heating (above room temperature) and operates in Cooling mode when temperature control is set to call for cooling (below room temperature).
IMPORTANT: Three-phase, scroll compressors are direction oriented. Unit must be checked to ensure proper compressor 3-phase power lead orientation. If not corrected within 5 minutes, the internal protector will shut off the compressor. The 3-phase power leads to the unit must be reversed to correct rotation. When turning backwards, the difference between compressor suction and discharge pressures will be minimal. Checking and Adjusting Refrigerant Charge
The refrigerant system is fully charged with Puron (R-410A) refrigerant and is tested and factory sealed. Allow system to operate a minimum of 15 minutes before checking or adjusting charge.
WARNING
EXPLOSION HAZARD
Failure to follow this warning could result in death, serious personal injury,
and/or property damage.
Never use air or gases containing oxygen for leak testing or operating
refrigerant compressors. Pressurized mixtures of air or gases containing
oxygen can lead to an explosion.
NOTE: Adjustment of the refrigerant charge is not required unless the
unit is suspected of not having the proper Puron (R-410A) charge.
NOTE: Some units have fixed orifice refrigerant metering devices.
There is a different charging procedure for both expansion devices.
Refer to the correct procedure for your unit.
The charging label and the tables shown refer to system temperatures and
pressures in cooling mode only. A refrigerant charging label is attached to
the inside of the compressor access panel. (See Table 8 Subcool chart for
units with TXV and superheat chart for units with fixed orifice.) The chart
includes the required liquid line temperature at given discharge line
pressures and outdoor ambient temperatures. A superheat chart is attached to
the inside of the compressor access panel for the unit with fixed metering
device. Refer to the charging procedure on the label.
An accurate thermocouple- or thermistor-type thermometer, and a gauge manifold
are required when using the subcooling charging method for evaluating the unit
charge. Do not use mercury or small dial-type thermometers because they are
not adequate for this type of measurement.
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit damage.
When evaluating the refrigerant charge, an indicated adjustment to the
specified factory charge must always be very minimal. If a substantial
adjustment is indicated, an abnormal condition exists somewhere in the cooling
system, such as insufficient airflow across either coil or both coils.
Proceed as follows:
-
Remove caps from low- and high-pressure service fittings.
-
Using hoses with valve core depressors, attach low- and high-pressure gauge hoses to low- and high-pressure service fittings, respectively.
-
Start unit in Cooling Mode and let unit run until system pressures stabilize.
-
Measure and record the following:
a. Outdoor ambient-air temperature (°F [°C] db).
b. Liquid line temperature (°F [°C]).
c. Discharge (high-side) pressure (psig).
d. Suction (low-side) pressure (psig) (for reference only). -
Using “Cooling Charging Charts,” compare outdoor-air temperature (°F [°C] db) with the discharge line pressure (psig) to determine desired system operating liquid line temperature (See Table 8).
-
Compare actual liquid line temperature with desired liquid line temperature. Using a tolerance of ± 2°F (±1.1°C), add refrigerant if actual temperature is more than 2°F (1.1°C) higher than proper liquid line temperature, or remove refrigerant if actual temperature is more than 2°F (1.1°C) lower than required liquid linetemperature.
NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to the Check for Refrigerant Leaks section. Indoor Airflow and Airflow Adjustments
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airflow is 350 to 450 cfm for each
12,000 Btuh of rated cooling capacity. For heating operation, the airflow must
produce a temperature rise that falls within the range stamped on the unit
rating plate.
NOTE: Be sure that all supply-and return-air grilles are open, free from
obstructions, and adjusted properly.
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Disconnect electrical power to the unit and install lockout tag before
changing blower speed.
This unit has independent fan speeds for gas heating and cooling modes.
Single phase models also have a dedicated continuous fan speed. All models (1
phase and 3 phase), have a field-selectable capability to run two different
cooling speeds: A normal cooling fan speed (350-450 CFM/Ton) and an enhanced
dehumidification fan speed (As low as 320 CFM/Ton) for use with either a
dehumidistat or a thermostat that supports dehumidification.
This unit is factory-set for use with a single cooling fan speed. For single
phase models, the cooling speed is marked “COOL” on the IGC (See Fig. 20). For
3-phase models, the cooling speed is marked “LOW” on the interface board (IFB)
(See Fig. 20). The factory-shipped settings are noted in Table 9. There are up
to 3 additional speed tap wires available for use in either gas heating mode,
cooling mode, or continuous fan mode (For color coding on the indoor fan motor
leads, see Table 7). For single phase models, one of the additional speed tap
wires is connected to the continuous fan, with the other 2 wires shipped loose
in the control box near the IGC. For three phase models, the additional 3
speed tap wires are shipped loose with vinyl caps and are located in the
control box near the interface fan board (IFB) (See Fig. 20).
Gas Heating Fan Speed Set-up:
To change the gas heating speed:
- Remove existing speed tap wire from the “HEAT” terminal on the IGC.
- Connect the desired speed tap wire on the “HEAT” terminal on the IGC board. Make sure that the speed chosen delivers temperature rise within the rise range listed on the unit. “High” speed is for high static cooling only, and must not be used for gas heating. “High” blower speed is for high static cooling only and must not be used for gas heating speed.
Cooling Fan Speed Set-up (Dehumidification feature not used):
To change cooling speed:
- Remove existing speed tap wire from the “COOL” terminal on the IGC board. Add the wet coil pressure drop in Table 10 to the system static to determine the correct cooling airflow speed in Table 7 that will deliver the nominal cooling airflow listed in Table 1 for each size.
- Connect the desired speed tap wire on the “COOL” terminal on the IGC board.
Dehumidification Cooling Fan Speed Set-up :
IMPORTANT: Dehumidification control must open control circuit on humidity
rise above set point.
Use of the dehumidification cooling fan speed requires use of either a 24 VAC
dehumidistat or a thermostat which includes control of a 24 VAC dehumidistat
connection. In either case, the dehumidification control must open the control
circuit on humidity rise above the dehumidification set point.
- Move shunt jumper on IGD board to “DH” (See Fig. 20).
- Refer to airflow table (Table 9) to determine allowable speeds for the dehumidification cooling fan speed. Speeds that are not allowed are shaded in Table 9.
- Connect selected speed tap wire to “DHUM” terminal on the IGC board. Verify that static pressure is in the acceptable range for the speed tap to be used for dehumidification cooling.
Continuous Fan Speed Set-up:
To change continuous fan speed:
- Remove existing speed tap wire from the “FAN” terminal on the IGC.
- Connect the desired speed tap wire on the “FAN” terminal on the IGC board.
Table 7 – Color Coding for Indoor Fan Motor Leads
Black = High Speed
Orange = Med-High Speed
Red = Med Speed
Pink = Med-Low Speed
Blue = Low Speed
Cooling Sequence of Operation
With the room thermostat SYSTEM switch in the COOL position and the FAN switch
in the AUTO position, the cooling sequence of operation is as follows:
- When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat, the thermostat completes the circuit between thermostat terminal R to terminals Y and G.
- The normally open contacts of energized contactor (C) close and complete the circuit through compressor motor (COMP) to condenser (outdoor) fan motor (OFM). Both motors start instantly.
- The set of normally open contacts on the interface fan board (IFB) are closed which energizes a circuit to the indoor fan motor (IFM).
NOTE: Once the compressor has started and then stopped, it should not be started again until 5 minutes have elapsed. The cooling cycle remains on until the room temperature drops to a point that is slightly below the cooling control setting of the room thermostat. At this point, the thermostat breaks the circuit between thermostat terminal R to terminals Y and G. These open circuits deenergize contactor coil C. The condenser and compressor motors stop. After a 60-sec. delay, the blower motor
stops. The unit is in a standby condition, waiting for the next call for cooling from the room thermostat.
Superheat charging table is derived from optimum performance point. (95°F
[35°C] outdoor ambient and (80°F [27°C] dry bulb; 67°F [19°C] wet bulb indoor
condition.)
Where a dash (-) appears do not attempt to check charge or charge unit under
these conditions using the superheat method. (Weigh in method should be used.)
A150625
Table 9 – Dry Coil Air Delivery* – Horizontal and Downflow Discharge Sizes 24-60
Unit Size
| Heating
Rise
o F ( o C)
| ****
Motor Speed
| ****
Tap
| Allowable Functions| ESP (in. W.C.)
---|---|---|---|---|---
| 0.1| 0.2| 0.3| 0.4| 0.5| 0.6| 0.7|
0.8| 0.9| 1
24040
| ****
25 – 55
(14 – 31)
| ****
Low†
| ****
Blue
| ****
Alternate Heating
| CFM| 640| 553| 454| 310| —| —| —| —| —| —
BHP| 0.07| 0.08| 0.08| 0.09| —| —| —| —| —| —
Gas Heat Rise (oF)| 47| 54| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 26| 30| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low‡
| ****
Pink
| ****
Heating Alternate Cooling
| CFM| 830| 758| 688| 607| 514| 393| 254| —| —| —
BHP| 0.12| 0.13| 0.13| 0.13| 0.14| 0.14| 0.15| —| —| —
Gas Heat Rise (oF)| 36| 39| 43| 49| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 20| 22| 24| 27| NA| NA| NA| NA| NA| NA
Medium**
| ****
Red
| ****
Cooling Alternate Heating
| CFM| 1080| 1025| 969| 910| 852| 787| 718| 638| 541| 457
BHP| 0.21| 0.22| 0.23| 0.23| 0.24| 0.24| 0.25| 0.25| 0.26| 0.27
Gas Heat Rise (oF)| 28| 29| 31| 33| 35| 38| 41| 47| 55| NA
Gas Heat Rise (oC)| 15| 16| 17| 18| 19| 21| 23| 26| 31| NA
Med-High
| ****
Orange
| ****
Alternate Cooling Alternate Heating
| CFM| 1101| 1046| 993| 936| 878| 816| 749| 676| 599| 498
BHP| 0.22| 0.23| 0.24| 0.24| 0.25| 0.26| 0.26| 0.27| 0.27| 0.28
Gas Heat Rise (oF)| 27| 28| 30| 32| 34| 36| 40| 44| 50| NA
Gas Heat Rise (oC)| 15| 16| 17| 18| 19| 20| 22| 24| 28| NA
High| Black| High Static Cooling
Only
| CFM| 1222| 1173| 1123| 1072| 1021| 967| 912| 853| 787| 712
BHP| 0.29| 0.29| 0.30| 0.31| 0.31| 0.32| 0.33| 0.34| 0.34| 0.34
24060
| ****
25 – 55
(14 – 31)
| ****
Low†
| ****
Blue
| | CFM| 640| 553| 454| 310| —| —| —| —| —| —
BHP| 0.07| 0.08| 0.08| 0.09| —| —| —| —| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
| ****
Pink
| ****
Alternate Cooling Alternate Heating
| CFM| 830| 758| 688| 607| 514| 393| 254| —| —| —
BHP| 0.12| 0.13| 0.13| 0.13| 0.14| 0.14| 0.15| —| —| —
Gas Heat Rise (oF)| 54| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 30| NA| NA| NA| NA| NA| NA| NA| NA| NA
Medium**
| ****
Red
| ****
Cooling Alternate Heating
| CFM| 1080| 1025| 969| 910| 852| 787| 718| 638| 541| 457
BHP| 0.21| 0.22| 0.23| 0.23| 0.24| 0.24| 0.25| 0.25| 0.26| 0.27
Gas Heat Rise (oF)| 41| 44| 46| 49| 52| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 23| 24| 26| 27| 29| NA| NA| NA| NA| NA
Med-High‡
| ****
Orange
| ****
Heating Alternate Cooling
| CFM| 1101| 1046| 993| 936| 878| 816| 749| 676| 599| 498
BHP| 0.22| 0.23| 0.24| 0.24| 0.25| 0.26| 0.26| 0.27| 0.27| 0.28
Gas Heat Rise (oF)| 41| 43| 45| 48| 51| 55| NA| NA| NA| NA
Gas Heat Rise (oC)| 23| 24| 25| 26| 28| 30| NA| NA| NA| NA
High| Black| High Static Cooling
Only
| CFM| 1222| 1173| 1123| 1072| 1021| 967| 912| 853| 787| 712
BHP| 0.29| 0.29| 0.30| 0.31| 0.31| 0.32| 0.33| 0.34| 0.34| 0.34
Unit Size
| Heating
Rise
o F ( o C)
| ****
Motor Speed
| ****
Tap
| Allowable Functions| ESP (in. W.C.)
---|---|---|---|---|---
| 0.1| 0.2| 0.3| 0.4| 0.5| 0.6| 0.7|
0.8| 0.9| 1
30040
| ****
25 – 55
(14 – 31)
| ****
Low†
| ****
Blue
| ****
Alternate Heating
| CFM| 643| 552| 455| 348| 225| —| —| —| —| —
BHP| 0.09| 0.10| 0.11| 0.11| 0.11| —| —| —| —| —
Gas Heat Rise (oF)| 46| 54| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 26| 30| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low‡
| ****
Pink
| ****
Heating Alternate Cooling
| CFM| 817| 744| 673| 597| 516| 431| 325| 190| —| —
BHP| 0.14| 0.15| 0.15| 0.16| 0.17| 0.17| 0.18| 0.18| —| —
Gas Heat Rise (oF)| 36| 40| 44| 50| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 20| 22| 25| 28| NA| NA| NA| NA| NA| NA
Medium
| ****
Red
| ****
Alternate Cooling Alternate Heating
| CFM| 1159| 1104| 1045| 990| 937| 878| 821| 759| 693| 618
BHP| 0.31| 0.32| 0.33| 0.33| 0.34| 0.35| 0.36| 0.37| 0.37| 0.38
Gas Heat Rise (oF)| 26| 27| 28| 30| 32| 34| 36| 39| 43| 48
Gas Heat Rise (oC)| 14| 15| 16| 17| 18| 19| 20| 22| 24| 27
Med-High**
| ****
Orange
| ****
Cooling Alternate Heating
| CFM| 1201| 1147| 1095| 1037| 987| 934| 877| 818| 755| 671
BHP| 0.34| 0.35| 0.36| 0.37| 0.37| 0.38| 0.39| 0.40| 0.41| 0.40
Gas Heat Rise (oF)| 25| 26| 27| 29| 30| 32| 34| 36| 39| 44
Gas Heat Rise (oC)| 14| 14| 15| 16| 17| 18| 19| 20| 22| 25
High| Black| High Static Cooling
Only
| CFM| 1291| 1236| 1181| 1131| 1080| 1033| 978| 909| 792| 661
BHP| 0.41| 0.42| 0.43| 0.43| 0.44| 0.45| 0.46| 0.45| 0.43| 0.40
30060
| ****
25 – 55
(14 – 31)
| ****
Low†
| ****
Blue
| | CFM| 643| 552| 455| 348| 225| —| —| —| —| —
BHP| 0.09| 0.10| 0.11| 0.11| 0.11| —| —| —| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
| ****
Pink
| ****
Alternate Cooling Alternate Heating
| CFM| 817| 744| 673| 597| 516| 431| 325| 190| —| —
BHP| 0.14| 0.15| 0.15| 0.16| 0.17| 0.17| 0.18| 0.18| —| —
Gas Heat Rise (oF)| 55| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 30| NA| NA| NA| NA| NA| NA| NA| NA| NA
Medium‡
| ****
Red
| ****
Heating Alternate Cooling
| CFM| 1159| 1104| 1045| 990| 937| 878| 821| 759| 693| 618
BHP| 0.31| 0.32| 0.33| 0.33| 0.34| 0.35| 0.36| 0.37| 0.37| 0.38
Gas Heat Rise (oF)| 39| 40| 43| 45| 48| 51| 54| NA| NA| NA
Gas Heat Rise (oC)| 21| 22| 24| 25| 26| 28| 30| NA| NA| NA
Medium-High**
| ****
Orange
| ****
Cooling Alternate Heating
| CFM| 1201| 1147| 1095| 1037| 987| 934| 877| 818| 755| 671
BHP| 0.34| 0.35| 0.36| 0.37| 0.37| 0.38| 0.39| 0.40| 0.41| 0.40
Gas Heat Rise (oF)| 37| 39| 41| 43| 45| 48| 51| 55| NA| NA
Gas Heat Rise (oC)| 21| 22| 23| 24| 25| 27| 28| 30| NA| NA
High| Black| High Static Cooling
Only
| CFM| 1291| 1236| 1181| 1131| 1080| 1033| 978| 909| 792| 661
BHP| 0.41| 0.42| 0.43| 0.43| 0.44| 0.45| 0.46| 0.45| 0.43| 0.40
Unit Size
| Heating
Rise
o F ( o C)
| ****
Motor Speed
| ****
Tap
| Allowable Functions| ESP (in. W.C.)
---|---|---|---|---|---
| 0.1| 0.2| 0.3| 0.4| 0.5| 0.6| 0.7|
0.8| 0.9| 1
36060
| ****
25 – 55
(14 – 31)
| ****
Low†
| ****
Blue
| Alternate Cooling, Alternate Gas Heating| CFM| 1096| 1044| 994| 945| 892|
837| 780| 717| 664| 612
BHP| 0.14| 0.15| 0.16| 0.18| 0.19| 0.19| 0.20| 0.21| 0.22| 0.23
Gas Heat Rise (oF)| 41| 43| 45| 47| 50| 53| NA| NA| NA| NA
Gas Heat Rise (oC)| 23| 24| 25| 26| 28| 30| NA| NA| NA| NA
Med-Low‡
| ****
Pink
| ****
Gas Heating, Alternate Cooling
| CFM| 1151| 1103| 1056| 1002| 953| 897| 845| 788| 729| 678
BHP| 0.16| 0.17| 0.18| 0.19| 0.20| 0.21| 0.22| 0.23| 0.24| 0.25
Gas Heat Rise (oF)| 39| 40| 42| 45| 47| 50| 53| NA| NA| NA
Gas Heat Rise (oC)| 22| 22| 23| 25| 26| 28| 29| NA| NA| NA
Medium
| ****
Red
| Alternate Cooling, Alternate Gas Heating| CFM| 1299| 1252| 1204| 1155| 1106|
1059| 1007| 959| 905| 844
BHP| 0.22| 0.23| 0.24| 0.25| 0.26| 0.27| 0.28| 0.29| 0.30| 0.31
Gas Heat Rise (oF)| 34| 36| 37| 39| 40| 42| 44| 47| 49| 53
Gas Heat Rise (oC)| 19| 20| 21| 21| 22| 23| 25| 26| 27| 29
Med-High**
| ****
Orange
| Cooling, Alternate Gas Heating| CFM| 1382| 1335| 1292| 1246| 1202| 1152|
1106| 1058| 1007| 957
BHP| 0.26| 0.27| 0.28| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35
Gas Heat Rise (oF)| 32| 33| 35| 36| 37| 39| 40| 42| 44| 47
Gas Heat Rise (oC)| 18| 19| 19| 20| 21| 22| 22| 23| 25| 26
High| Black| High Static Cooling
Only
| CFM| 1530| 1485| 1442| 1398| 1354| 1309| 1263| 1217| 1169| 1120
BHP| 0.33| 0.35| 0.36| 0.37| 0.38| 0.39| 0.40| 0.41| 0.42| 0.43
36090
| ****
35 – 65
(19 – 36)
| ****
Low†
| ****
Blue
| Alternate Cooling, Alternate Gas Heating| CFM| 1096| 1044| 994| 945| 892|
837| 780| 717| 664| 612
BHP| 0.14| 0.15| 0.16| 0.18| 0.19| 0.19| 0.20| 0.21| 0.22| 0.23
Gas Heat Rise (oF)| 61| 64| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 34| 36| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
| ****
Pink
| Alternate Cooling, Alternate Gas Heating| CFM| 1151| 1103| 1056| 1002| 953|
897| 845| 788| 729| 678
BHP| 0.16| 0.17| 0.18| 0.19| 0.20| 0.21| 0.22| 0.23| 0.24| 0.25
Gas Heat Rise (oF)| 58| 61| 63| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 32| 34| 35| NA| NA| NA| NA| NA| NA| NA
Medium‡
| ****
Red
| ****
Gas Heating, Alternate Cooling
| CFM| 1299| 1252| 1204| 1155| 1106| 1059| 1007| 959| 905| 844
BHP| 0.22| 0.23| 0.24| 0.25| 0.26| 0.27| 0.28| 0.29| 0.30| 0.31
Gas Heat Rise (oF)| 52| 53| 56| 58| 61| 63| NA| NA| NA| NA
Gas Heat Rise (oC)| 29| 30| 31| 32| 34| 35| NA| NA| NA| NA
Med-High**
| ****
Orange
| Cooling, Alternate Gas Heating| CFM| 1382| 1335| 1292| 1246| 1202| 1152|
1106| 1058| 1007| 957
BHP| 0.26| 0.27| 0.28| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35
Gas Heat Rise (oF)| 48| 50| 52| 54| 56| 58| 61| 63| NA| NA
Gas Heat Rise (oC)| 27| 28| 29| 30| 31| 32| 34| 35| NA| NA
High| Black| High Static Cooling
Only
| CFM| 1530| 1485| 1442| 1398| 1354| 1309| 1263| 1217| 1169| 1120
BHP| 0.33| 0.35| 0.36| 0.37| 0.38| 0.39| 0.40| 0.41| 0.42| 0.43
Unit Size
| Heating
Rise
o F ( o C)
| ****
Motor Speed
| ****
Tap
| Allowable Functions| ESP (in. W.C.)
---|---|---|---|---|---
| 0.1| 0.2| 0.3| 0.4| 0.5| 0.6| 0.7|
0.8| 0.9| 1
42060
| ****
25 – 55
(14 – 31)
| ****
Low†
| ****
Blue
| ****
Alternate Heating
| CFM| 956| 899| 843| 786| 729| 676| 621| 558| 504| 435
BHP| 0.13| 0.13| 0.14| 0.15| 0.16| 0.16| 0.17| 0.18| 0.18| 0.19
Gas Heat Rise (oF)| 47| 50| 53| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 26| 28| 29| NA| NA| NA| NA| NA| NA| NA
Med-Low‡
| ****
Pink
| ****
Heating Alternate Cooling
| CFM| 1201| 1153| 1107| 1060| 1012| 965| 917| 871| 828| 782
BHP| 0.21| 0.22| 0.22| 0.23| 0.24| 0.25| 0.26| 0.27| 0.28| 0.29
Gas Heat Rise (oF)| 37| 39| 40| 42| 44| 46| 49| 51| 54| NA
Gas Heat Rise (oC)| 21| 22| 22| 23| 25| 26| 27| 28| 30| NA
Medium
| ****
Red
| ****
Alternate Cooling Alternate Heating
| CFM| 1443| 1402| 1361| 1322| 1284| 1243| 1204| 1164| 1124| 1084
BHP| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38| 0.39| 0.40| 0.42
Gas Heat Rise (oF)| 31| 32| 33| 34| 35| 36| 37| 38| 40| 41
Gas Heat Rise (oC)| 17| 18| 18| 19| 19| 20| 21| 21| 22| 23
Med-High**
| ****
Orange
| ****
Cooling Alternate Heating
| CFM| 1529| 1491| 1451| 1411| 1376| 1338| 1300| 1261| 1223| 1185
BHP| 0.37| 0.39| 0.40| 0.41| 0.42| 0.43| 0.44| 0.45| 0.46| 0.47
Gas Heat Rise (oF)| 29| 30| 31| 32| 32| 33| 34| 35| 36| 38
Gas Heat Rise (oC)| 16| 17| 17| 18| 18| 19| 19| 20| 20| 21
High| Black| High Static Cooling
Only
| CFM| 1604| 1565| 1529| 1490| 1455| 1421| 1385| 1348| 1310| 1274
BHP| 0.42| 0.44| 0.45| 0.46| 0.47| 0.48| 0.49| 0.50| 0.51| 0.52
42090
| ****
35 – 65
(19 – 36)
| ****
Low†
| ****
Blue
| | CFM| 956| 899| 843| 786| 729| 676| 621| 558| 504| 435
BHP| 0.13| 0.13| 0.14| 0.15| 0.16| 0.16| 0.17| 0.18| 0.18| 0.19
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
| ****
Pink
| ****
Alternate Cooling Alternate Heating
| CFM| 1201| 1153| 1107| 1060| 1012| 965| 917| 871| 828| 782
BHP| 0.21| 0.22| 0.22| 0.23| 0.24| 0.25| 0.26| 0.27| 0.28| 0.29
Gas Heat Rise (oF)| 56| 58| 60| 63| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 31| 32| 34| 35| NA| NA| NA| NA| NA| NA
Medium‡
| ****
Red
| ****
Heating Alternate Cooling
| CFM| 1443| 1402| 1361| 1322| 1284| 1243| 1204| 1164| 1124| 1084
BHP| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38| 0.39| 0.40| 0.42
Gas Heat Rise (oF)| 46| 48| 49| 51| 52| 54| 56| 58| 60| 62
Gas Heat Rise (oC)| 26| 27| 27| 28| 29| 30| 31| 32| 33| 34
Med-High**
| ****
Orange
| ****
Cooling Alternate Heating
| CFM| 1529| 1491| 1451| 1411| 1376| 1338| 1300| 1261| 1223| 1185
BHP| 0.37| 0.39| 0.40| 0.41| 0.42| 0.43| 0.44| 0.45| 0.46| 0.47
Gas Heat Rise (oF)| 44| 45| 46| 47| 49| 50| 52| 53| 55| 57
Gas Heat Rise (oC)| 24| 25| 26| 26| 27| 28| 29| 29| 30| 31
High| Black| High Static Cooling
Only
| CFM| 1604| 1565| 1529| 1490| 1455| 1421| 1385| 1348| 1310| 1274
BHP| 0.42| 0.44| 0.45| 0.46| 0.47| 0.48| 0.49| 0.50| 0.51| 0.52
Unit Size
| Heating
Rise
o F ( o C)
| ****
Motor Speed
| ****
Tap
| Allowable Functions| ESP (in. W.C.)
---|---|---|---|---|---
| 0.1| 0.2| 0.3| 0.4| 0.5| 0.6| 0.7|
0.8| 0.9| 1
48090
| ****
35 – 65
(19 – 36)
| ****
Low†
| ****
Blue
| | CFM| 641| 551| 462| 385| 289| 216| 163| 115| —| —
BHP| 0.05| 0.06| 0.06| 0.07| 0.07| 0.08| 0.08| 0.09| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low‡
| ****
Pink
| ****
Heating Alternate Cooling
| CFM| 1437| 1395| 1351| 1307| 1265| 1221| 1176| 1132| 1084| 1039
BHP| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38
Gas Heat Rise (oF)| 47| 48| 50| 51| 53| 55| 57| 59| 62| 64
Gas Heat Rise (oC)| 26| 27| 28| 28| 29| 30| 32| 33| 34| 36
Medium**
| ****
Red
| ****
Cooling Alternate Heating
| CFM| 1771| 1735| 1699| 1664| 1627| 1592| 1557| 1522| 1486| 1450
BHP| 0.51| 0.52| 0.53| 0.55| 0.56| 0.57| 0.58| 0.59| 0.61| 0.62
Gas Heat Rise (oF)| 38| 39| 39| 40| 41| 42| 43| 44| 45| 46
Gas Heat Rise (oC)| 21| 21| 22| 22| 23| 23| 24| 24| 25| 26
Med-High
| ****
Orange
| ****
Alternate Cooling Alternate Heating
| CFM| 1928| 1897| 1862| 1830| 1796| 1764| 1732| 1698| 1620| 1512
BHP| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.73| 0.71| 0.66
Gas Heat Rise (oF)| 35| 35| 36| 37| 37| 38| 39| 39| 41| 44
Gas Heat Rise (oC)| 19| 20| 20| 20| 21| 21| 21| 22| 23| 25
High| Black| High Static Cooling
Only
| CFM| 2212| 2167| 2124| 2061| 1976| 1892| 1794| 1699| 1567| 1438
BHP| 0.97| 0.99| 1.00| 0.97| 0.95| 0.91| 0.86| 0.82| 0.77| 0.71
48115
| ****
30 – 60
(17 – 33)
| ****
Low†
| ****
Blue
| | CFM| 641| 551| 462| 385| 289| 216| 163| 115| —| —
BHP| 0.05| 0.06| 0.06| 0.07| 0.07| 0.08| 0.08| 0.09| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
| ****
Pink
| ****
Alternate Cooling Alternate Heating
| CFM| 1437| 1395| 1351| 1307| 1265| 1221| 1176| 1132| 1084| 1039
BHP| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38
Gas Heat Rise (oF)| 60| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 33| NA| NA| NA| NA| NA| NA| NA| NA| NA
Medium**
| ****
Red
| ****
Cooling Alternate Heating
| CFM| 1771| 1735| 1699| 1664| 1627| 1592| 1557| 1522| 1486| 1450
BHP| 0.51| 0.52| 0.53| 0.55| 0.56| 0.57| 0.58| 0.59| 0.61| 0.62
Gas Heat Rise (oF)| 48| 49| 50| 51| 53| 54| 55| 56| 58| 59
Gas Heat Rise (oC)| 27| 27| 28| 29| 29| 30| 31| 31| 32| 33
Med-High‡
| ****
Orange
| ****
Heating Alternate Cooling
| CFM| 1928| 1897| 1862| 1830| 1796| 1764| 1732| 1698| 1620| 1512
BHP| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.73| 0.71| 0.66
Gas Heat Rise (oF)| 44| 45| 46| 47| 48| 49| 49| 50| 53| 57
Gas Heat Rise (oC)| 25| 25| 26| 26| 26| 27| 27| 28| 29| 31
High| Black| High Static Cooling
Only
| CFM| 2212| 2167| 2124| 2061| 1976| 1892| 1794| 1699| 1567| 1438
BHP| 0.97| 0.99| 1.00| 0.97| 0.95| 0.91| 0.86| 0.82| 0.77| 0.71
Unit Size
| Heating
Rise
o F ( o C)
| ****
Motor Speed
| ****
Tap
| Allowable Functions| ESP (in. W.C.)
---|---|---|---|---|---
| 0.1| 0.2| 0.3| 0.4| 0.5| 0.6| 0.7|
0.8| 0.9| 1
48130
| ****
35 – 65
(19 – 36)
| ****
Low†
| ****
Blue
| | CFM| 641| 551| 462| 385| 289| 216| 163| 115| —| —
BHP| 0.05| 0.06| 0.06| 0.07| 0.07| 0.08| 0.08| 0.09| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
| ****
Pink
| ****
Alternate Cooling
| CFM| 1437| 1395| 1351| 1307| 1265| 1221| 1176| 1132| 1084| 1039
BHP| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Medium**
| ****
Red
| ****
Cooling Alternate Heating
| CFM| 1771| 1735| 1699| 1664| 1627| 1592| 1557| 1522| 1486| 1450
BHP| 0.51| 0.52| 0.53| 0.55| 0.56| 0.57| 0.58| 0.59| 0.61| 0.62
Gas Heat Rise (oF)| 53| 54| 56| 57| 58| 59| 61| 62| 64| 65
Gas Heat Rise (oC)| 30| 30| 31| 32| 32| 33| 34| 34| 35| 36
Med-High‡
| ****
Orange
| ****
Heating Alternate Cooling
| CFM| 1928| 1897| 1862| 1830| 1796| 1764| 1732| 1698| 1620| 1512
BHP| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.73| 0.71| 0.66
Gas Heat Rise (oF)| 49| 50| 51| 52| 53| 54| 55| 56| 58| 62
Gas Heat Rise (oC)| 27| 28| 28| 29| 29| 30| 30| 31| 32| 35
High| Black| High Static Cooling
Only
| CFM| 2212| 2167| 2124| 2061| 1976| 1892| 1794| 1699| 1567| 1438
BHP| 0.97| 0.99| 1.00| 0.97| 0.95| 0.91| 0.86| 0.82| 0.77| 0.71
60090
| ****
35 – 65
(19 – 36)
| ****
Low†
| ****
Blue
| ****
Alternate Heating
| CFM| 641| 551| 462| 385| 289| 216| 163| 115| —| —
BHP| 0.05| 0.06| 0.06| 0.07| 0.07| 0.08| 0.08| 0.09| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low‡
| ****
Pink
| ****
Heating Alternate Cooling
| CFM| 1437| 1395| 1351| 1307| 1265| 1221| 1176| 1132| 1084| 1039
BHP| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38
Gas Heat Rise (oF)| 47| 48| 50| 51| 53| 55| 57| 59| 62| 64
Gas Heat Rise (oC)| 26| 27| 28| 28| 29| 30| 32| 33| 34| 36
Medium**
| ****
Red
| ****
Cooling Alternate Heating
| CFM| 1914| 1881| 1848| 1814| 1780| 1748| 1716| 1681| 1619| 1512
BHP| 0.62| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.71| 0.66
Gas Heat Rise (oF)| 35| 36| 36| 37| 38| 38| 39| 40| 41| 44
Gas Heat Rise (oC)| 19| 20| 20| 21| 21| 21| 22| 22| 23| 25
Med-High
| ****
Orange
| ****
Alternate Cooling Alternate Heating
| CFM| 1928| 1897| 1862| 1830| 1796| 1764| 1732| 1698| 1620| 1512
BHP| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.73| 0.71| 0.66
Gas Heat Rise (oF)| 35| 35| 36| 37| 37| 38| 39| 39| 41| 44
Gas Heat Rise (oC)| 19| 20| 20| 20| 21| 21| 21| 22| 23| 25
High| Black| High Static Cooling
Only
| CFM| 2212| 2167| 2124| 2061| 1976| 1892| 1794| 1699| 1567| 1438
BHP| 0.97| 0.99| 1.00| 0.97| 0.95| 0.91| 0.86| 0.82| 0.77| 0.71
Unit Size
| Heating
Rise
o F ( o C)
|
Motor Speed
|
Tap
| Allowable Functions| ESP (in. W.C.)
---|---|---|---|---|---
| 0.1| 0.2| 0.3| 0.4| 0.5| 0.6| 0.7|
0.8| 0.9| 1
60115
|
30 – 60
(17 – 33)
|
Low†
|
Blue
| | CFM| 641| 551| 462| 385| 289| 216| 163| 115| —| —
BHP| 0.05| 0.06| 0.06| 0.07| 0.07| 0.08| 0.08| 0.09| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
|
Pink
|
Alternate Cooling Alternate Heating
| CFM| 1437| 1395| 1351| 1307| 1265| 1221| 1176| 1132| 1084| 1039
BHP| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38
Gas Heat Rise (oF)| 60| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| 33| NA| NA| NA| NA| NA| NA| NA| NA| NA
Medium**
|
Red
|
Cooling Alternate Heating
| CFM| 1914| 1881| 1848| 1814| 1780| 1748| 1716| 1681| 1619| 1512
BHP| 0.62| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.71| 0.66
Gas Heat Rise (oF)| 45| 45| 46| 47| 48| 49| 50| 51| 53| 57
Gas Heat Rise (oC)| 25| 25| 26| 26| 27| 27| 28| 28| 29| 31
Med-High‡
|
Orange
|
Heating Alternate Cooling
| CFM| 1928| 1897| 1862| 1830| 1796| 1764| 1732| 1698| 1620| 1512
BHP| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.73| 0.71| 0.66
Gas Heat Rise (oF)| 44| 45| 46| 47| 48| 49| 49| 50| 53| 57
Gas Heat Rise (oC)| 25| 25| 26| 26| 26| 27| 27| 28| 29| 31
High| Black| High Static Cooling
Only
| CFM| 2212| 2167| 2124| 2061| 1976| 1892| 1794| 1699| 1567| 1438
BHP| 0.97| 0.99| 1.00| 0.97| 0.95| 0.91| 0.86| 0.82| 0.77| 0.71
60130
|
35 – 65
(19 – 36)
|
Low†
|
Blue
| | CFM| 641| 551| 462| 385| 289| 216| 163| 115| —| —
BHP| 0.05| 0.06| 0.06| 0.07| 0.07| 0.08| 0.08| 0.09| —| —
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Med-Low
|
Pink
|
Alternate Cooling
| CFM| 1437| 1395| 1351| 1307| 1265| 1221| 1176| 1132| 1084| 1039
BHP| 0.29| 0.30| 0.31| 0.32| 0.33| 0.34| 0.35| 0.36| 0.37| 0.38
Gas Heat Rise (oF)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Gas Heat Rise (oC)| NA| NA| NA| NA| NA| NA| NA| NA| NA| NA
Medium**
|
Red
|
Cooling Alternate Heating
| CFM| 1914| 1881| 1848| 1814| 1780| 1748| 1716| 1681| 1619| 1512
BHP| 0.62| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.71| 0.66
Gas Heat Rise (oF)| 49| 50| 51| 52| 53| 54| 55| 56| 58| 62
Gas Heat Rise (oC)| 27| 28| 28| 29| 29| 30| 31| 31| 32| 35
Med-High‡
|
Orange
|
Heating Alternate Cooling
| CFM| 1928| 1897| 1862| 1830| 1796| 1764| 1732| 1698| 1620| 1512
BHP| 0.64| 0.65| 0.67| 0.68| 0.69| 0.71| 0.72| 0.73| 0.71| 0.66
Gas Heat Rise (oF)| 49| 50| 51| 52| 53| 54| 55| 56| 58| 62
Gas Heat Rise (oC)| 27| 28| 28| 29| 29| 30| 30| 31| 32| 35
High| Black| High Static Cooling
Only
| CFM| 2212| 2167| 2124| 2061| 1976| 1892| 1794| 1699| 1567| 1438
BHP| 0.97| 0.99| 1.00| 0.97| 0.95| 0.91| 0.86| 0.82| 0.77| 0.71
|
Shaded areas indicate speed/static combinations that are not permitted for dehumidification speed.
- Air delivery values are without air filter and are for dry coil (See Wet Coil Pressure Drop Table).
† Factory-shipped continuous fan speed
‡ Factory-shipped heating speed
** Factory-shipped cooling speed
“NA” = Not allowed for heating speed
“High Static Cooling” = Only to be used for cooling function (not allowed for heating function)
NOTE: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain static pressure available for ducting.
Table 10 – Wet Coil Pressure Drop (IN. W.C.)
| Unit Size | Standard CFM (SCFM) |
|---|---|
| 600 | 700 |
| 1300 | 1400 |
| 2000 | 2100 |
| 24 | 0.03 |
| 30 | |
| 36 | |
| 42 | |
| 48 | |
| 60 |
Table 11 – Economizer with 1-in. Filter Pressure Drop (IN. W.C.)
Filter Size in. (mm)| Cooling
Tons
| Standard CFM (SCFM)
---|---|---
600| 700| 800| 900| 1000| 1100| 1200|
1300| 1400| 1500| 1600| 1700| 1800| 1900|
2000| 2100| 2200
600-1400 CFM
12x20x1+12x20x1 (305x508x25+305x508x25)
| 2.0,
2.5
| ****
–
| ****
–
| ****
0.09
| ****
0.14
| ****
0.16
| ****
0.18
| ****
0.25
| ****
0.28
| ****
0.30
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
1200-1800 CFM
16x24x1+14x24x1
(406x610x25+356x610x25)
| 3.5| –| –| –| –| –| –| 0.10| 0.11| 0.12| 0.13| 0.14| 0.16| 0.16| –| –| –| –
1500-2200 CFM
16x24x1+18x24x1 (406x610x25+457x610x25)
| 3.0,
4.0,
5.0
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
.08
| ****
.10
| ****
.11
| ****
.13
| ****
0.15
| ****
0.17
| ****
0.18
| ****
0.20
| ****
0.21
| ****
0.22
| ****
0.23
| ****
0.23
Table 12 – Filter Pressure Drop Table (IN. W.C.)
Filter Size in. (mm)| Cooling
Tons
| Standard CFM (SCFM)
---|---|---
600| 700| 800| 900| 1000| 1100| 1200|
1300| 1400| 1500| 1600| 1700| 1800| 1900|
2000| 2100| 2200
600-1400 CFM
12x20x1+12x20x1 (305x508x25+305x508x25)
| 2.0,
2.5
| ****
0.03
| ****
0.05
| ****
0.06
| ****
0.08
| ****
0.10
| ****
0.11
| ****
0.13
| ****
0.14
| ****
0.16
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
1200-1800 CFM
16x24x1+14x24x1
(406x610x25+356x610x25)
| ****
3.5
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
0.07
| ****
0.08
| ****
0.09
| ****
0.09
| ****
0.10
| ****
0.11
| ****
0.12
| ****
–
| ****
–
| ****
–
| ****
–
1100-2200 CFM
16x24x1+18x24x1 (406x610x25+457x610x25)
| 3.0
4.0
5.0
| ****
–
| ****
–
| ****
–
| ****
–
| ****
–
| ****
.02
| ****
.02
| ****
.03
| ****
.03
| ****
0.04
| ****
0.06
| ****
0.08
| ****
0.10
| ****
0.11
| ****
0.13
| ****
0.14
| ****
0.15
Maintenance
To ensure continuing high performance and to minimize the possibility of
premature equipment failure, periodic maintenance must be performed on this
equipment. This unit should be inspected at least once each year by a
qualified service person. To troubleshoot unit, refer to
Table 13, Table 14, Table 15, Troubleshooting Chart.
NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a
maintenance contract.
WARNING
PERSONAL INJURY AND UNIT DAMAGE HAZARD
Failure to follow this warning could result in personal injury or death and
unit component damage.
The ability to properly perform maintenance on this equipment requires certain
expertise, mechanical skills, tools and equipment. If you do not possess
these, do not attempt to perform any maintenance on this equipment, other than
those procedures recommended in the Owner’s Manual.
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow these warnings could result in personal injury or death:
- Turn off electrical power to the unit and install lock out tag before performing any maintenance or service on this unit.
- Use extreme caution when removing panels and parts.
- Never place anything combustible either on or in contact with the unit.
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper operation.
Errors made when reconnecting wires may cause improper and dangerous
operation. Label all wires prior to disconnecting when servicing.
CAUTION
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental pollution.
Remove and re-cycle all components or materials (i.e. oil, refrigerantetc)
before unit final disposal.
The minimum maintenance requirements for this equipment are as follows:
-
Inspect air filter(s) each month. Clean or replace when necessary.
-
Inspect indoor coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.
-
Inspect blower motor and wheel for cleanliness at the beginning of each heating and cooling season. Clean when necessary. For first heating and cooling season, inspect blower wheel bi-monthly to determine proper cleaning frequency.
-
Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary.
-
Ensure electric wires are not in contact with refrigerant tubing or sharp metal edges.
-
Check and inspect heating section before each heating season.
Clean and adjust when necessary. -
Check flue hood and remove any obstructions, if necessary.
Air Filter
IMPORTANT: Never operate the unit without a suitable air filter in the
return-air duct system. Always replace the filter with the same dimensional
size and type as originally installed. See Table 1 for recommended filter
sizes.
Inspect air filter(s) at least once each month and replace (throwaway-type) or
clean (cleanable-type) at least twice during each cooling season and twice
during the heating season, or whenever the filter becomes clogged with dust
and lint.
Indoor Blower and Motor
NOTE: All motors are pre-lubricated. Do not attempt to lubricate these
motors.
For longer life, operating economy, and continuing efficiency, clean
accumulated dirt and grease from the blower wheel and motor annually.
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Disconnect and tag electrical power to the unit before cleaning the blower
motor and wheel.
To clean the blower motor and wheel:
-
Remove and disassemble blower assembly as follows:
a. Remove blower access panel (see Fig. 22).
b. Disconnect 5 pin plug and 4 pin plug from indoor blower motor.
Remove capacitor if required.
c. On all units remove blower assembly from unit. Remove screws securing blower to blower partition and slide assembly out. Be careful not to tear insulation in blower compartment.
d. Ensure proper reassembly by marking blower wheel and motor in relation to blower housing before disassembly.
e. Loosen setscrew(s) that secures wheel to motor shaft, remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing. -
Remove and clean blower wheel as follows:
a. Ensure proper reassembly by marking wheel orientation.
b. Lift wheel from housing. When handling and/or cleaning blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes.
c. Remove caked-on dirt from wheel and housing with a brush.
Remove lint and/or dirt accumulations from wheel and housing with vacuum cleaner, using soft brush attachment. Remove grease and oil with mild solvent.
d. Reassemble wheel into housing.
e. Reassemble motor into housing. Be sure setscrews are tightened on motor shaft flats and not on round part of shaft. Reinstall blower into unit. Reinstall capacitor.
f. Connect 5 pin plug and 4 pin plug to indoor blower motor.
g. Reinstall blower access panel (see Fig. 22). -
Restore electrical power to unit. Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles.
Induced Draft (combustion air) Blower Assembly
The induced-draft blower assembly consists of the inducer motor, the blower
housing, and the induced-draft blower wheel.
Clean periodically to assure proper airflow and heating efficiency.
Inspect blower wheel every fall and periodically during the heating season.
For the first heating season, inspect blower wheel bimonthly to determine
proper cleaning frequency.
To inspect blower wheel, remove draft hood assembly. Shine a flashlight into
opening to inspect wheel. If cleaning is required, remove induced-draft blower
assembly as follows:
- Remove control access panel (See Fig. 22).
- Remove the 5 screws that attach induced-draft blower assembly to the flue collector box cover.
- Slide the assembly out of the unit. (See Fig. 24). Clean the blower wheel. If additional cleaning is required, continue with Steps 4 and
- To remove blower wheel, remove 2 setscrews.
- To remove inducer motor, remove screws that hold the inducer motor to the blower housing.
- To reinstall, reverse the procedure outlined above.
Flue Gas Passageways
To inspect the flue collector box and upper areas of the heat exchanger:
- Remove the induced draft blower assembly according to directions in the Induced Draft Blower Assembly section.
- Remove the 11 screws holding the flue collector box cover (See Fig. 21) to the heat exchanger assembly. Inspect the heat exchangers.
- Clean all surfaces, as required, using a wire brush.
Limit Switch
Remove blower access panel (see Fig. 22). Limit switch is located on the fan
partition.
Burner Ignition
Unit is equipped with a direct spark ignition 100 percent lockout system.
Ignition module (IGC) is located in the control box (See Fig. 19).
Module contains a self-diagnostic LED. During servicing, refer to label
diagram or Table 6 in these instructions for LED interpretation.
If lockout occurs, unit may be reset by either momentarily interrupting power
supply to unit or by turning selector switch to OFF position at the
thermostat.
Main Burners
At the beginning of each heating season, inspect for deterioration or blockage
due to corrosion or other causes. Observe the main burner flames and adjust,
if necessary.
Removal of Gas Train
To remove the gas train for servicing:
-
Shut off main gas valve.
-
Shut off power to unit and install lockout tag.
-
Remove control access panel (See Fig. 22).
-
Disconnect gas piping at unit gas valve.
-
Remove fan partition mounting bracket (2 screws located on the left side of control compartment on the fan partition panel). Slide bracket forward, bottom first, to remove. (See Fig. 21.)
-
Remove wires connected to gas valve. Mark each wire.
-
Remove the mounting screw that attaches the burner rack to the unit base (See Fig. 21).
-
Partially slide the burner rack out of the unit (see Fig. 21 and Fig. 24). Remove ignitor and sensor wires at the burner assembly.
Remove wires to rollout switch. -
Slide the burner rack out of the unit (See Fig. 21 and Fig. 24).
-
To reinstall, reverse the procedure outlined above.
-
Check all connections for leaks.
WARNING
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death or
property damage.
Do not purge gas supply into the combustion chamber. Do not use a match or
other open flame to check for gas leaks.
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.
Outdoor Coil, Indoor Coil, and Condensate Drain Pan
Inspect the condenser coil, evaporator coil, and condensate drain pan at least
once each year.
The coils are easily cleaned when dry; therefore, inspect and clean the coils
either before or after each cooling season. Remove all obstructions, including
weeds and shrubs, that interfere with the airflow through the condenser coil.
Straighten bent fins with a fin comb. If coated with dirt or lint, clean the
coils with a vacuum cleaner, using the soft brush attachment. Be careful not
to bend the fins. If coated with oil or grease, clean the coils with a mild
detergent and water solution. Rinse coils with clear water, using a garden
hose. Be careful not to splash water on motors, insulation, wiring, or air
filter(s). For best results, spray condenser coil fins from inside to outside
the unit. On units with an outer and inner condenser coil, be sure to clean
between the coils. Be sure to flush all dirt and debris from the unit base.
Inspect the drain pan and condensate drain line when inspecting the coils.
Clean the drain pan and condensate drain by removing all foreign matter from
the pan. Flush the pan and drain trough with clear water. Do not splash water
on the insulation, motor, wiring, or air filter(s). If the drain trough is
restricted, clear it with a “plumbers snake” or similar probe device.
WARNING
Outdoor Fan
UNIT OPERATION HAZARD
Failure to follow this caution may result in damage to unit components.
Keep the condenser fan free from all obstructions to ensure proper cooling
operation. Never place articles on top of the unit.
- Remove 6 screws holding outdoor grille and motor to top cover.
- Turn motor/grille assembly upside down on top cover to expose fan blade.
- Inspect the fan blades for cracks or bends.
- If fan needs to be removed, loosen setscrew and slide fan off motor shaft.
- When replacing fan blade, position blade as shown in Fig. 25.
- Insure that setscrew engages the flat area on the motor shaft when tightening.
- Replace grille.
Electrical Controls and Wiring
Inspect and check the electrical controls and wiring annually. Be sure to turn
off the electrical power to the unit.
Remove access panels (see Fig. 22) to locate all the electrical controls and
wiring. Check all electrical connections for tightness. Tighten all screw
connections. If any smoky or burned connections are noticed, disassemble the
connection, clean all the parts, re-strip the wire end and reassemble the
connection properly and securely.
After inspecting the electrical controls and wiring, replace all the panels.
Start the unit, and observe at least one complete cooling cycle to ensure
proper operation. If discrepancies are observed in operating cycle, or if a
suspected malfunction has occurred, check each electrical component with the
proper electrical instrumentation. Refer to the unit wiring label when making
these checks.
Max Distance Between Top of Fan
Grille and Bottom of Fan Blade
| Size | “A” |
|---|---|
| IN. | mm |
| 24 | 9.0 |
| 30 | 8.0 |
| 36 | 7.6 |
| 42 | 7.6 |
| 48 | 7.6 |
| 60 | 7.6 |
Fig. 25 – Fan Blade Position
Refrigerant Circuit
Annually inspect all refrigerant tubing connections.
WARNING
EXPLOSION, SAFETY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could result in personal injury, death or
property damage.
System under pressure. Relieve pressure and recover all refrigerant before
system repair or final unit disposal. Use all service ports and open all flow-
control devices, including solenoid valves.
If low cooling performance is suspected, leak-test all refrigerant tubing
using an electronic leak-detector or liquid-soap solution. If a refrigerant
leak is detected, refer to the Check for Refrigerant Leaks section.
If no refrigerant leaks are found and low cooling performance is suspected,
refer to the Checking and Adjusting Refrigerant Charge section.
Gas Input
The gas input does not require checking unless improper heating performance is
suspected. If a problem exists, refer to the Start-Up section.
Evaporator Airflow
The heating and/or cooling airflow does not require checking unless improper
performance is suspected. If a problem exists, be sure that all supply- and
return-air grilles are open and free from obstructions, and that the air
filter is clean. When necessary, refer to the Indoor Airflow and Airflow
Adjustments section to check the system airflow.
Puron Items
The indoor metering device is either a TXV or orifice type device depending on
size.
Pressure Switches
Pressure switches are protective devices wired into control circuit (low
voltage). They shut off compressor if abnormally high or low pressures are
present in the refrigeration circuit. These pressure switches are specifically
designed to operate with Puron (R-410A) systems. R-22 pressure switches must
not be used as replacements for the Puron (R-410A) system.
Low Pressure Switch (if used)
This switch is located on the suction line and protects against low suction
pressures caused by such events as loss of charge, low airflow across indoor
coil, dirty filters, etc. It opens at 50 psig. If system pressure is above
this, switch should be closed. To check switch:
- Turn off all power to unit.
- Disconnect leads on switch.
- Apply ohm meter leads across switch. You should have continuity on a closed switch.
NOTE: Because these switches are attached to refrigeration system under pressure, it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists.
If switch must be removed, remove and recover all system charge so that pressure gauges read 0 psig. Never open system without breaking vacuum with dry nitrogen.
High-Pressure Switch
The high-pressure switch is located in the discharge line and protects against
excessive condenser coil pressure. It opens at 650 psig.
High pressure may be caused by a dirty outdoor coil, failed fan motor, or
outdoor air recirculation. To check switch:
- Turn off all power to unit.
- Disconnect leads on switch.
- Apply ohm meter leads across switch. You should have continuity on a closed switch.
Compressor (Puron Refrigerant)
The compressor used in this product is specifically designed to operate with
Puron (R-410A) refrigerant and cannot be interchanged.
The compressor is an electrical (as well as mechanical) device. Exercise
extreme caution when working near compressors. Power should be shut off, if
possible, for most troubleshooting techniques. Refrigerants present additional
safety hazards.
WARNING
FIRE/EXPLOSION HAZARD
Failure to follow this warning could result in personal injury or death and/or
property damage.
Wear safety glasses and gloves when handling refrigerants. Keep torches and
other ignition sources away from refrigerants and oils.
For models that have a scroll compressor, the compressor pumps refrigerant
throughout the system by the interaction of a stationary and an orbiting
scroll. The scroll compressor has no dynamic suction or discharge valves, and
it is more tolerant of stresses caused by debris, liquid slugging, and flooded
starts. The compressor is equipped with a noise reducing shutdown device and
an internal pressure relief port. The pressure relief port is a safety device,
designed to protect against extreme high pressure. The relief port has an
operating range between 550 (26.34 kPa) and 625 psig (29.93 kPa) differential
pressure.
WARNING
EXPLOSION, ENVIRONMENTAL SAFETY HAZARD
Failure to follow this warning could result in personal injury, death or
equipment damage.
This system uses Puron (R-410A) refrigerant which has higher operating
pressures than R-22 and other refrigerants. No other refrigerant may be used
in this system. Gauge set, hoses, and recovery system must be designed to
handle Puron (R-410A). If you are unsure, consult the equipment manufacturer.
Refrigerant System
This information covers the refrigerant system including the compressor oil
needed, servicing systems on roofs containing synthetic materials, the filter
drier and refrigerant charging.
Compressor Oil
The Copeland scroll compressor uses 3MAF POE oil. If additional oil is needed,
use Uniqema RL32-3MAF. If this oil is not available, use Copeland Ultra 32 CC
or Mobil Arctic EAL22 CC. This oil is extremely hygroscopic, meaning it
absorbs water readily. POE oils can absorb 15 times as much water as other
oils designed for HCFC and CFC refrigerants. Take all necessary precautions to
avoid exposure of the oil to the atmosphere.
Servicing Systems on Roofs with Synthetic
Materials
POE (polyolester) compressor lubricants are known to cause long term damage to
some synthetic roofing materials.
Exposure, even if immediately cleaned up, may cause embrittlement (leading to
cracking) to occur in one year or more. When performing any service that may
risk exposure of compressor oil to the roof, take appropriate precautions to
protect roofing. Procedures which risk oil leakage include, but are not
limited to, compressor replacement, repairing refrigerant leaks, replacing
refrigerant components such as filter drier, pressure switch, metering device,
coil, accumulator, or reversing valve.
Synthetic Roof Precautionary Procedure
- Cover extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an approximate 10 X 10 ft. (3.1 m X 3.1 m) area.
- Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components.
- Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant run-offs through the louvered openings in the unit base.
- Perform required service.
- Remove and dispose of any oil contaminated material per local codes.
Liquid Line Filter Drier
This filter drier is specifically designed to operate with Puron (R-410A).
Use only factory-authorized components. Filter drier must be replaced whenever
the refrigerant system is opened. When removing a filter drier, use a tubing
cutter to cut the drier from the system. Do not unsweat a filter drier from
the system. Heat from unsweating will release moisture and contaminants from
drier into system.
Puron (R-410A) Refrigerant Charging
Refer to unit information plate and charging chart. Some R-410A refrigerant
cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder
in upright position. For cylinders equipped with a dip tube, charge Puron
(R-410A) units with cylinder in upright position and a commercial metering
device in manifold hose. Charge refrigerant into suction-line.
Troubleshooting
Use the Troubleshooting Guides (See Table 13, Table 14, and Table 15) if
problems occur with these units.
Start-up Checklist
Use Start-Up checklist to ensure proper start-up procedures are followed.
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Table 13 – Troubleshooting Chart
| SYMPTOM | CAUSE | REMEDY |
|---|
Compressor and condenser fan will not start.
| Power failure| Call power company
Fuse blown or circuit breaker tripped| Replace fuse or reset circuit breaker
Defective contactor, transformer, or high-pressure, loss-of-charge or low-
pressure switch| ****
Replace component
Insufficient line voltage| Determine cause and correct
Incorrect or faulty wiring| Check wiring diagram and rewire correctly
Thermostat setting too high| Lower thermostat temperature setting below room
temperature
Compressor will not start but condenser fan runs
| Faulty wiring or loose connections in compressor circuit| Check wiring and
repair or replace
Compressor motor burned out, seized, or| Determine cause
internal overload open| Replace compressor
Defective run/start capacitor, overload, start relay| Determine cause and
replace
One leg of 3-phase power dead| Replace fuse or reset circuit breaker
Determine cause
Low input voltage| Determine cause and correct
Three-phase scroll compressor makes excessive noise, and there may be a low
pressure differential.| ****
Scroll compressor is rotating in the wrong direction
| Correct the direction of rotation by reversing the
3-phase power leads to the unit. Shut down unit to allow pressures to
equalize.
Compressor cycles (other than normally satisfying thermostat)
| Refrigerant overcharge or undercharge| Recover refrigerant, evacuate system,
and recharge to capacities shown on rating plate
Defective compressor| Replace and determine cause
Insufficient line voltage| Determine cause and correct
Blocked outdoor coil| Determine cause and correct
Defective run/start capacitor| Determine cause and replace
Faulty outdoor fan motor or capacitor| Replace
Restriction in refrigerant system| Locate restriction and remove
Compressor operates continuously
| Dirty air filter| Replace filter
Unit undersized for load| Decrease load or increase unit size
Thermostat temperature set too low| Reset thermostat
Low refrigerant charge| Locate leak, repair, and recharge
Air in system| Recover refrigerant, evacuate system, and recharge
Outdoor coil dirty or restricted| Clean coil or remove restriction
Excessive head pressure
| Dirty air filter| Replace filter
Dirty condenser coil| Clean coil
Refrigerant overcharged| Recover excess refrigerant
Air in system| Recover refrigerant, evacuate system, and
recharge
Condenser air restricted or air short-cycling| Determine cause and correct
Head pressure too low| Low refrigerant charge| Check for leaks, repair, and
recharge.
Restriction in liquid tube| Remove restriction
Excessive suction pressure| Refrigerant overcharged| Recover excess
refrigerant
Suction pressure too low
| Dirty air filter| Replace filter
Low refrigerant charge| Check for leaks, repair and recharge
Metering device or low side restricted| Remove source of restriction
Insufficient evaporator airflow| Increase air quantity
Check filter–replace if necessary
Temperature too low in conditioned area| Reset thermostat
Outdoor ambient below 55ýF (13ýC)| Install low-ambient kit
Filter drier restricted| Replace filter
Table 14 – Troubleshooting Guide–Heating
| SYMPTOM | CAUSE | REMEDY |
|---|
Burners will not ignite
| Water in gas line| Drain. Install drip leg.
No power to furnace| Check power supply fuses, wiring or circuit breaker.
No 24-v power supply to control circuit
| Check transformer.
NOTE: Some transformers have internal over-current protection that requires a cool-down period to reset.
Mis-wired or loose connections| Check all wiring and wire nut connections
Misaligned spark electrodes| Check flame ignition and sense electrode
positioning. Adjust as necessary.
No gas at main burners
| 1. Check gas line for air. Purge as necessary. NOTE: After purging gas line of air, wait at least 5 minutes for any gas to dissipate before attempting to light unit.
2. Check gas valve.
Inadequate heating
| Dirty air filter| Clean or replace filter as necessary
Gas input to furnace too low| Check gas pressure at manifold match with that
on unit nameplate
Unit undersized for application| Replace with proper unit or add additional
unit
Restricted airflow| Clean or replace filter. Remove any restriction.
Limit switch cycles main burners| Check rotation of blower, temperature rise
of unit. Adjust as
necessary.
Poor flame characteristics
| ****
Incomplete combustion results in: Aldehyde odors, carbon monoxide, sooting flame, floating flame
| 1. Tighten all screws around burner compartment
2. Cracked heat exchanger. Replace.
3. Unit over-fired. Reduce input (change orifices or adjust gas line or manifold pressure).
4. Check burner alignment.
5. Inspect heat exchanger for blockage. Clean as necessary.
Table 15 – Troubleshooting Guide–LED Status Codes
| SYMPTOM | CAUSE | REMEDY |
|---|
No Power or Hardware failure (LED OFF)
| ****
Loss of power to control module (IGC)*.
| Check 5-amp fuse son IGC*, power to unit, 24-v circuit breaker, and
transformer. Units without a 24-v circuit breaker have an internal overload in
the 24-v transformer. If the overload trips, allow 10 minutes for automatic
reset.
Check fuse, low voltage circuit (LED 1 flash)| Fuse is blown or missing or
short circuit in secondary (24VAC) wiring.| Replace fuse if needed. Verify no
short circuit in low voltage (24 VAC wiring).
Limit switch faults (LED 2 flashes)| ****
High temperature limit switch is open.
| Check the operation of the indoor (evaporator) fan motor. Ensure
that the supply-air temperature rise is in accordance with the range on the unit nameplate. Clean or replace filters.
Flame sense fault (LED 3 flashes)| The IGC* sensed flame that should not be
present.| Reset unit. If problem persists, replace control board.
4 consecutive limit switch faults (LED 4 flashes)| ****
Inadequate airflow to unit.
| Check the operation of the indoor (evaporator) fan motor and
that supply-air temperature rise agrees with range on unit nameplate information.
Ignition lockout fault (LED 5 flashes)| ****
Unit unsuccessfully attempted ignition for 15 minutes.
| Check ignitor and flame sensor electrode spacing, gaps, etc. Ensure that fame sense and ignition wires are properly terminated. Verify that unit is obtaining proper amount of gas.
Pressure Switch fault (LED 6 flashes)
| ****
Open pressure switch.
| Verify wiring connections to pressure switch and inducer motor. Verify pressure switch hose is tightly connected to both inducer housing and pressure switch. Verify inducer wheel is properly attached to inducer motor shaft. Verify inducer motor shaft is turning.
Rollout switch fault (LED 7 flashes)
| ****
Rollout switch has opened.
| Rollout switch will automatically reset, but IGC* will continue to lockout unit. Check gas valve operation. Ensure that
induced-draft blower wheel is properly secured to motor shaft. Inspect heat exchanger. Reset unit at unit disconnect.
Internal control fault (LED 8 flashes)| Microprocessor has sensed an error in
the software or hardware.| If error code is not cleared by resetting unit
power, replace the IGC*.
Temporary 1 hr auto reset1 (LED 9 flashes)| Electrical interference impeding
IGC software| Reset 24-v. to control board or turn thermostat off, then on
again. Fault will automatically reset itself in one (1) hour.
* WARNING : If the IGC must be replaced, be sure to ground yourself to
dissipate any electrical charge that my be present before handling new control
board. The
IGC is sensitive to static electricity and my be damaged if the necessary
precautions are not taken.
IMPORTANT: Refer to Table 14-Troubleshooting Guide-Heating for additional
troubleshooting analysis.
LEGEND
IGC—Integrated Gas Unit Controller
LED—Light-Emitting Diode
Start-Up Checklist
(Remove and Store in Job Files)
I. PRELIMINARY INFORMATION
MODEL NO.: ____
SERIAL NO.: ____
DATE: __
TECHNICIAN:____
II. PRESTART-UP (Insert check mark in box as each item is completed)
(¦ ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION
INSTRUCTIONS
( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS
( ) CHECK GAS PIPING FOR LEAKS (WHERE APPLICABLE)
( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE
( ) VERIFY THAT UNIT INSTALLATION IS LEVEL
( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND
SETSCREW TIGHTNESS
( ) INSPECT TUBING
III. START-UP
ELECTRICAL
SUPPLY VOLTAGE
COMPRESSOR AMPS ____
INDOOR (EVAPORATOR) FAN AMPS ____
TEMPERATURES
OUTDOOR (CONDENSER) AIR TEMPERATURE __ DB
RETURN-AIR TEMPERATURE__ DB WB
COOLING SUPPLY AIR ____ DB _ WB
GAS HEAT SUPPLY AIR __
PRESSURES
GAS INLET PRESSURE _____ IN. W.C.
GAS MANIFOLD PRESSURE __ IN. W.C.
REFRIGERANT SUCTION____ PSIG,SUCTION LINE TEMP* __
REFRIGERANT DISCHARGE PSIG, _LIQUID TEMP†
( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTSC
GAS HEAT TEMPERATURE RISE
TEMPERATURE RISE (See Literature) RANGE ____
MEASURED TEMPERATURE RISE ___
- Measured at suction inlet to compressor
{Measured at liquid line leaving condenser.
© 2023 Carrier. All rights reserved.
Edition Date: 02/23
Catalog No: 48VL-19SI
Replaces:48VL-18SI
Manufacturer reserves the right to change, at any time, specifications and
designs without notice and without obligations.
References
- Inspiring Confidence | Leading Innovation | Carrier
- Dashboard | My Learning Center
- Kidde Fire Safety Products and Education | Kidde