92-21916-27 rev. 09 rrka 3 phase only gas/electric package...

92-21916-27-09SUPERSEDES 92-21916-27-08

INSTALLATION INSTRUCTIONSFOR COMBINATION HEATING AND COOLING ROOFTOPUNITS EQUIPPED WITH INTERMITTENT IGNITIONRRKA/RRMA/RRNA SERIES

ISO 9001:2000

RRKA 3-5 TON (3 PHASE MODELS ONLY)

(carbon monoxide)

Standard 380Standard 210/240 UAC

2

USE ONLY WITH TYPE OF GASAPPROVED FOR THIS UNIT.REFER TO THE UNIT RATINGPLATE.

INSTALL THIS UNIT ONLY IN ALOCATION AND POSITION ASSPECIFIED IN THE LOCATIONREQUIREMENTS ANDCONSIDERATIONS SECTION OFTHESE INSTRUCTIONS. PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR TO THE UNITSPACE AS SPECIFIED IN THEVENTING SECTION OF THESEINSTRUCTIONS.

PROVIDE ADEQUATECOMBUSTION AND VENTILATIONAIR TO THE UNIT SPACE ASSPECIFIED IN THE COMBUSTIONAND VENTILATION AIR SECTIONOF THESE INSTRUCTIONS.

COMBUSTION PRODUCTS MUSTBE DISCHARGED OUTDOORS.CONNECT THIS UNIT TO ANAPPROVED VENT SYSTEM ONLY,AS SPECIFIED IN VENT PIPEINSTALLATION SECTION OFTHESE INSTRUCTIONS.

NEVER TEST FOR GAS LEAKSWITH AN OPEN FLAME. USE ACOMMERCIALLY AVAILABLESOAP SOLUTION MADESPECIFICALLY FOR THEDETECTION OF LEAKS TO CHECKALL CONNECTIONS, ASSPECIFIED IN GAS SUPPLY ANDPIPING SECTION OF THESEINSTRUCTIONS.

ALWAYS INSTALL UNIT TOOPERATE WITHIN THE UNIT'SINTENDED TEMPERATURE-RISERANGE WITH A DUCT SYSTEMWHICH HAS AN EXTERNALSTATIC PRESSURE WITHIN THEALLOWABLE RANGE, ASSPECIFIED IN DUCTING SECTIONOF THESE INSTRUCTIONS. SEEALSO UNIT RATING PLATE.

WHEN A UNIT IS INSTALLED SOTHAT SUPPLY DUCTS CARRY AIRCIRCULATED BY THE UNIT TOAREAS OUTSIDE THE SPACECONTAINING THE UNIT, THERETURN AIR SHALL ALSO BEHANDLED BY DUCT(S) SEALEDTO THE UNIT CASING ANDTERMINATING OUTSIDE THESPACE CONTAINING THE UNIT.

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING! WARNING

! WARNING

! WARNING

SAFETY INFORMATION

THIS UNIT MAY BE USED TOHEAT THE BUILDING OR STRUC-TURE DURING CONSTRUCTION IFTHE FOLLOWING INSTALLATIONREQUIREMENTS ARE MET.INSTALLATION MUST COMPLYWITH ALL INSTALLATIONINSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDERTHERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TOTHE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATE ANDTEMPERATURE RISE PER RAT-ING PLATE MARKING;

• MEANS OF PROVIDING OUT-DOOR AIR REQUIRED FORCOMBUSTION;

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

• INSTALLATION OF EXHAUSTAND COMBUSTION AIR INLETHOODS COMPLETED;

• CLEAN FURNACE, DUCT WORKAND COMPONENTS UPON SUBSTANTIAL COMPLETION OFTHE CONSTRUCTION PROCESS,VERIFY FURNACE OPERATINGCONDITIONS INCLUDING IGNITION, INPUT RATE, TEM-PERATURE RISE AND VENTING,ACCORDING TO THE INSTRUC-TIONS.

3

A. GENERALThe Combination Gas Heating/ElectricCooling Rooftop is available in 40, 60, 80and 100 BTU/Hr. heating inputs andcooling capacities of 3, 31/2, 4 and 5 nominal tons of cooling. Units areconvertible from end supply and return tobottom supply and return by relocation ofsupply and return air access panels. Seecover installation detail.The units are weatherized for mountingoutside of the building.

UNITS ARE NOT DESIGN CERTIFIEDTO BE INSTALLED INSIDE THESTRUCTURE. DOING SO CAN CAUSEINADEQUATE UNIT PERFORMANCEAS WELL AS PROPERTY DAMAGEAND CARBON MONOXIDE POISONINGRESULTING IN PERSONAL INJURY ORDEATH.The information on the rating plate is incompliance with the FTC and DOE ratingfor single phase units. The followinginformation is for three phase units whichare not covered under the DOEcertification program.1. The energy consumption of the

ignition system used with this unit is 9watts.

2. The efficiency rating of this unit is aproduct thermal efficiency ratingdetermined under continuousoperating conditions independent ofany installed system.

B. MAJOR COMPONENTSThe unit includes a hermetically-sealedrefrigerating system (consisting of acompressor, condenser coil, evaporatorcoil with capillary tube assembly), acirculation air blower, a condenser fan, aheat exchanger assembly, gas burner andcontrol assembly, combustion air motorand fan, and all necessary internalelectrical wiring. The cooling system ofthese units is factory-evacuated, chargedand performance tested. Refrigerantamount and type are indicated on ratingplate.

INTRODUCTION I. SPECIFICATIONSTABLE OF CONTENTS

Recognize this symbol as anindication of Important SafetyInformation!

!

! WARNING

! WARNING

Page No.SAFETY INFORMATION 2

I. SPECIFICATIONSComponents 3Unit Dimensions 5-6Access Locations 6

II. INSTALLATIONGeneral 7Location Considerations 7Exhaust & Combustion

Hoods 8Cover Panel Installation 8,9Clearances 10Rooftop 11Ducting 11,12Return Air 12

III. GAS SUPPLY & PIPING 14-16IV. ELECTRICAL WIRING

Power Supply 17Hook-up 18Internal Wiring 18Thermostat 18

V. FURNACE CONTROLS 19,20VI. OPERATION INFO 21,22VII. AIRFLOW 23,24VIII. TROUBLESHOOTING 25,26IX. WIRING DIAGRAMS 27,28X. CHARGE CHARTS 29-35

THE MANUFACTURER’S WARRANTYDOES NOT COVER ANY DAMAGE ORDEFECT TO THE AIR CONDITIONERCAUSED BY THE ATTACHMENT ORUSE OF ANY COMPONENTS,ACCESSORIES OR DEVICES (OTHERTHAN THOSE AUTHORIZED BY THEMANUFACTURER) INTO, ONTO OR INCONJUNCTION WITH THE AIRCONDITIONER. YOU SHOULD BEAWARE THAT THE USE OFUNAUTHORIZED COMPONENTS,ACCESSORIES OR DEVICES MAYADVERSELY AFFECT THE OPERATIONOF THE AIR CONDITIONER AND MAYALSO ENDANGER LIFE ANDPROPERTY. THE MANUFACTURERDISCLAIMS ANY RESPONSIBILITY FORSUCH LOSS OR INJURY RESULTINGFROM THE USE OF SUCHUNAUTHORIZED COMPONENTS,ACCESSORIES OR DEVICES.This booklet contains the installation andoperating instructions for your combinationgas heating/electric cooling unit. There aresome precautions that should be taken toderive maximum satisfaction from it.Improper installation can result inunsatisfactory operation or dangerousconditions.Read this booklet and any instructionspackaged with separate equipmentrequired to make up the system prior toinstallation. Give this booklet to the ownerand explain its provisions. The ownershould retain this booklet for futurereference.

CHECKING PRODUCTRECEIVEDUpon receiving the unit, inspect it for anydamage from shipment. Claims fordamage, either shipping or concealed,should be filed immediately with theshipping company. IMPORTANT: Checkthe unit model number, heating size,electrical characteristics, and accessoriesto determine if they are correct.

Installation Instructions are updated on aregular basis. This is done as productchanges occur or if new informationbecomes available. In this publication, anarrow () denotes changes from theprevious edition or additional newmaterial.

26, 2728

29-30

The following information is for threephase units which are not covered underthe DOE certification program.

1. The energy consumption of theignition system used with this unit is 9watts.

2. The efficiency rating of this unit is aproduct thermal efficiency ratingdetermined under continuousoperating conditions independent ofany installed system.

B. MAJOR COMPONENTSThe unit includes a hermetically-sealedrefrigerating system (consisting of acompressor, condenser coil, evaporatorcoil with capillary tube assembly), acirculation air blower, a condenser fan, aheat exchanger assembly, gas burner andcontrol assembly, combustion air motorand fan, and all necessary internalelectrical wiring. The cooling system ofthese units is factory-evacuated, chargedand performance tested. Refrigerantamount and type are indicated on ratingplate.

4

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5

Unit DimensionsFOR CLEARANCESSEE PAGE 9, FIGURE 12.

FIGURE 1BOTTOM VIEW

I616

153 /83

1 /4

11 /8

11 /8

451 /8

INSIDE491 /2

INSIDE

47 /8

33 /4

33 /4

21 /2

191 /2141 /8

TYP.

1 /2

1 /2

FIGURE 2CABINET DIMENSIONS 1.5-4 TONS

I258

475/8 507/8

31/2

85/8

13/4

41/2

47/8

15

FLUEEXHAUSTHOOD

GASSUPPLYENTRANCE

BLOWER /EVAPORATORACCESSPANEL

SIDE SUPPLYDUCT OPENING

SIDE RETURNDUCT OPENING

191/8133/4

335/8

31/8

4

BOTTOM

RETURN

DUCT

OPENING

BOTTOM

SUPPLY

DUCT

OPENING

FLUEEXHAUSTHOOD

GASSUPPLYENTRANCE

50 7/847 5/8

1 3/4

8 5/8

3 1/2

15

4 7/819 1/8

3 1/8

13 3/4

33 5/8

4

4 1/2


SIDE SUPPLY DUCT OPENING

SIDE RETURN DUCT OPENING

6

FIGURE 4ACCESS LOCATIONS

FIGURE 3CABINET DIMENSIONS

I259

A0940-01-00

OUTDOOR FAN GRILLEAND COMPRESSOR ACCESS

FURNACE/CONTROLSACCESS PANEL

COMBUSTION AIRINLET HOOD

FIELD POWERWIRE ENTRANCE

FIELD CONTROLWIRE ENTRANCE

LIQUID PRESSURESERVICE PORT

SUCTION PRESSURESERVICE PORT

THREADED PVC CONDENSATEDRAIN CONNECTION (3/4 NPT)

OUTDOOR COILPROTECTIVE GRILLE

FILTER ACCESSPANEL (FOR UNITMOUNTED FILTERACCESSORY)

FLUE EXHAUST

205/115/ 5

223/4

207/8

FLUEEXHAUSTHOOD

GASSUPPLYENTRANCE

BLOWER /EVAPORATORACCESS PANEL

SIDE SUPPLYDUCT OPENING

SIDE RETURNDUCT OPENING

Unit Dimensions(continued)

205/8

115/8

5

FLUEEXHAUSTHOOD

GASSUPPLYENTRANCE

50 7/847 5/8

1 3/4

8 5/8

3 1/2

15

4 7/819 1/8

3 1/8

13 3/4

33 5/84

4 1/2


SIDE SUPPLY DUCT OPENING

SIDE RETURN DUCT OPENING

OUTDOOR COILPROTECTIVE GRILLE

OUTDOOR FAN GRILLE AND COMPRESSOR ACCESS

FIELD CONTROL WIRE ENTRANCE

FLUE EXHAUSTHOOD

COMBUSTION AIRINLET HOOD

FIELD POWERWIRE ENTRANCE

LIQUID PRESSURESERVICE PORT

THREADEDPVC CONDENSATEDRAIN CONNECTION(3/4 NPT) SUCTION PRESSURE

SERVICE PORT

FURNACE/CONTROLSACCESS PANEL

FLUE EXHAUST

20 5/8

20 7/8

22 3/4

11 5/8

5

7

II. INSTALLATION2. Regular cleaning and waxing of the

cabinet with a good automobile polishwill provide some protection.

3. Use a good liquid cleaner severaltimes a year to remove matter that willnot wash off with water.

Several different types of protectivecoatings are offered in some areas. Thesecoating may provide some benefit, but theeffectiveness of such coating materialscannot be verified by the equipmentmanufacturer.The best protection is frequentcleaning, maintenance and minimalexposure to contaminants.

B. OUTSIDE INSTALLATION

THESE UNITS ARE DESIGNEDCERTIFIED FOR OUTDOORINSTALLATION ONLY. INSTALLATIONINSIDE ANY PART OF A STRUCTURECAN RESULT IN INADEQUATE UNITPERFORMANCE AS WELL AS

1. Avoid having lawn sprinkler headsspray directly on the unit cabinet.

2. In coastal areas locate the unit on theside of the building away from thewaterfront.

3. Shielding by a fence or shrubs maygive some protection.

4. Elevate the unit off its slab or baseenough to allow air circulation andavoid holding water against thebasepan.

DISCONNECT ALL POWER TO UNITBEFORE STARTING MAINTENANCE.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTING INPERSONAL INJURY OR DEATH.REGULAR MAINTENANCE WILLREDUCE THE BUILDUP OFCONTAMINANTS AND HELP TOPROTECT THE UNIT’S FINISH.1. Frequent washing of the cabinet, fan

blade and coil with fresh water willremove most of the salt or othercontaminants that build up on the unit.

A. GENERAL1. INSTALLATION — Install this unit in

accordance with The AmericanNational Standard Z223.1-latestedition booklet entitled “National FuelGas Code,” and the requirements orcodes of the local utility or otherauthority having jurisdiction.Additional helpful publicationsavailable from the “National FireProtection Association” are: NFPA-90A - Installation of Air Conditioniongand Ventilating Systems 1985 orlatest edition. NFPA-90B - Warm AirHeating and Air ConditioningSystems 1984.These publications are availablefrom:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

NOTE: Remove wood shipping basebefore installing unit.2. PRE-INSTALLATION CHECK-

POINTS — Before attempting anyinstallation, carefully consider thefollowing points:Structural strength of supportingmembers

(Rooftop Installation)Clearances and provision forservicingPower supply and wiringGas supply and pipingAir duct connectionsDrain facilities and connectionsLocation for minimum noise and

vibration

LOCATION CONSIDERATIONSThe metal parts of this unit may besubject to rust or deterioration in adverseenvironmental conditions. This oxidationcould shorten the equipment’s useful life.Salt spray, fog or mist in seacoast areas,sulphur or chlorine from lawn wateringsystems, and various chemicalcontaminants from industries such aspaper mills and petroleum refineries areespecially corrosive.If the unit is to be installed in an areawhere contaminants are likely to be aproblem, give special attention to theequipment location and exposure.

! WARNING

! WARNING

FIGURE 5OUTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOORCONSTRUCTION

SUPPLYDUCT ATCLOSETCEILING

FILTERGRILLE

SLABFLOOR

BRANCHCIRCUITDISCONNECT

UNIONTRAP

GAS SHUT-OFF VALVE

GAS SUPPLY

SERVICE ACCESS PANELS.DO NOT BLOCK ACCESS.

POWERSUPPLYCONDUIT

THERMOSTATWIRECONDUIT

I251

IMPORTANT: PITCH UNIT TOWARD DRAINTO ALLOW FOR PROPER WATERDRAINAGE. SEE FIGURE 5.

FIGURE 5OUTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOORCONSTRUCTION

2. PRE-INSTALLATION CHECK-POINTS — Before attempting anyinstallation, carefully consider thefollowing points:Structural strength of supportingmembers

(Rooftop Installation)Clearances and provision forservicingPower supply and wiringGas supply and pipingAir duct connectionsDrain facilities and connectionsLocation for minimum noise and

vibration

LOCATION CONSIDERATIONSThe metal parts of this unit may besubject to rust or deterioration in adverseenvironmental conditions. This oxidationcould shorten the equipment’s useful life.Salt spray, fog or mist in seacoast areas,sulphur or chlorine from lawn wateringsystems, and various chemicalcontaminants from industries such aspaper mills and petroleum refineries areespecially corrosive.If the unit is to be installed in an areawhere contaminants are likely to be aproblem, give special attention to theequipment location and exposure.

8

PROPERTY DAMAGE. INSTALLATIONINSIDE CAN ALSO CAUSERECIRCULATION OF FLUEPRODUCTS INTO THE CONDITIONEDSPACE RESULTING IN PERSONALINJURY OR DEATH.(Typical outdoor slab installation isshown in Figure 5.)1. Select a location where external

water drainage cannot collect aroundunit.

2. Provide a slab sufficiently highenough above grade to preventsurface water from entering the unit.Where snowfall is anticipated, mountthe unit above the anticipatedmaximum snow depth for your area.The slab should be isolated from thefoundation wall.

3. Pitch the slab approximately 1/2” sothat the unit will be pitched towardthe drain. See Figure 6.

4. The location of the unit should besuch as to provide proper access forinspection and servicing as shown inFigure 12.

5. Locate unit where operating soundswill not disturb owner or neighbors.

6. Locate unit so roof runoff water doesnot pour directly on the unit. Providegutter or other shielding at roof level.Do not locate unit in an area whereexcessive snow drifting may occur oraccumulate.

7. Where snowfall is anticipated, theheight of the unit above the groundlevel must be considered. Mount unithigh enough to be above averagearea snowfall and to allowcombustion air to enter thecombustion air inlet.

C. ATTACHING EXHAUST ANDCOMBUSTION AIR INLETHOODSIMPORTANT: Do not operate this unitwithout the exhaust and combustion airinlet hood properly installed. These hoodsare shipped in a carton in the return aircompartment inside the unit and must beattached when the unit is installed. SeeFigure 6.To attach exhaust and combustion air inlethoods:

1. Remove 3 screws securing filter accesspanel and remove filter access panel.For location of filter access panel, seeFigure 4.

2. Remove both exhaust and combustionair inlet hoods from their carton, locatedinside the return air compartment.

3. Attach filter access panel.4. Attach the combustion air inlet hood and

the exhaust hood each with 4 screws asshown in Figure 7. Screws are in partsbag shipped in the burner compartment.

5. Vent the unit using the flue exhausthood, as supplied from the factory,without alteration or addition. The onlyexception is with factory approvedadditions. Consult your local utility orother authority having jurisdiction foraccepted venting techniques.

D. COVER PANELINSTALLATION/CONVERSION PROCEDURE

1. HORIZONTAL TO DOWNFLOWa. Remove screws and covers from

the supply and return bottomsections. NOTE: Rotate the supplycover 90° and remove.

b. Install gasket (supplied with partsbag) around perimeter of cover onthe insulated side. See Figure 9.

c. Secure covers to the side of the unitusing existing screws and thosesupplied in the parts bag.

2. DOWNFLOW TO HORIZONTALa. Remove screws and covers from

the outside of the supply and returnsections.

b. Install gasket (supplied with partsbag) around perimeter of cover asillustrated in Figure 8.

c. Install covers in the unit bottom withthe insulated side up. NOTE: Supplycover must be inserted through supplyopening with narrow side toward unit.Once cover is through opening, rotate90° and slip back flange of coverunder tab at the back of bottom ductopening. See Figure 11.

d. Secure supply cover to base of unitwith 2 screws, engaging prepunchedholes in raised duct opening flange.

e. Secure return covers to base of unitwith screws engaging prepunchedholes in raised duct opening flange.

FIGURE 6PITCHING UNIT TO INSURE PROPER CONDENSATE DRAINAGE.

I655

FIGURE 7COMBUSTION AIR INLET HOOD & EXHAUST HOODINSTALLATION

I250

EXHAUSTHOOD W/(4)SCREWS

COMBUSTIONAIR INLETHOOD W/(4)SCREWS

LEVEL FRONT OF UNIT

LEVEL PLANECONDENSATE DRAIN CONNECTION

1/8 BUBBLE OFF LEVEL

THIS END APPROX.1/2” HIGHER THAN FRONT

EXHAUSTHOOD W/(4)SCREWS

COMBUSTIONAIR INLETHOOD W/(4)SCREWS

9

FIGURE 10DUCT COVER INSTALLATION SIDE MOUNTING

I264

FIGURE 9COVER GASKET DETAIL FOR UNITS SHIPPED FOR SIDE DISCHARGEAPPLICATION BEING CONVERTED TO DOWNFLOW

TAPEAROUND FLANGE

SUPPLY/RETURNAIR COVER

FIGURE 8COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOWAPPLICATION BEING CONVERTED TO SIDE DISCHARGE

TAPEAROUND FLANGE

SUPPLY/RETURNAIR COVER

RETURNDUCT COVER

(ATTACH WITH 6 SCREWS)

SUPPLYDUCT COVER


I654


I264

RETURNDUCT COVER


SUPPLYDUCT COVER



10

THIS UNIT MUST NOT BE INSTALLEDDIRECTLY ON WOOD FLOORING,CLASS A, CLASS B OR CLASS C ROOFCOVERING MATERIALS, OR ANYOTHER COMBUSTIBLE STRUCTUREEXCEPT AS SPECIFIED IN FIGURE 13.FAILURE TO ADHERE TO THIS WARINGCAN CAUSE A FIRE OR EXPLOSIONRESULTING IN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

FIGURE 11DUCT COVER INSTALLATION BASE PAN MOUNTING

I265

BASE PAN

SUPPLY DUCTCOVER *(INSULATIONSIDE UP),ATTACH WITHTWO SCREWS.

RETURNDUCTCOVER(INSULATIONSIDE UP,ATTACHWITH 4SCREWS)

SUPPLY DUCTCOVER

*ROTATE SUPPLY COVER 90° AFTER IT IS INSERTEDTHROUGH OPENING. SLIP FLANGE OF COVERUNDER LANCE AT BACK OF BOTTOM SUPPLY DUCTOPENING. SEE DETAIL AT LEFT. THEN SECURECOVER BY INSTALLING 2 SCREWS USING HOLENEAREST THE OUTSIDE OF UNIT.

LANCE AT BACK OF BOTTOMSUPPLY DUCT OPENING

E. CLEARANCESThe following minimum clearances mustbe observed for proper unit performanceand serviceability. See Figure 12.1. Provide 48” minimum clearance at

front of the unit. Provide 24”minimum clearance on right side ofunit. If economizer is used, a 24”minimum clearance is required onleft side of unit. (See Figure 12.) If noeconomizer is required, then a 12”clearance is required on left side ofunit.

2. Provide 60” minimum clearancebetween top of unit and maximum 3foot overhang.

3. Unit is design certified for 2”minimum clearance between supplyduct and a combustible structure forthe first 3 feet of duct. 0” clearance isallowed after 3 feet.

FIGURE 12CLEARANCES

I252

60” MINIMUMOVERHEADCLEARANCE

12” MINIMUMCLEARANCEWITHOUTECONOMIZER24” MINIMUMCLEARANCEWITHECONOMIZER ORINTERNALFILTER KIT

NON-COMBUSTIBLESTRUCTURE ONLY.SEE FIG. 4 FOREXCEPTION

48” MINIMUMCLEARANCE TOSERVICE CONTROLS

24” MINIMUM CLEARANCETO SERVICE BLOWER &

EVAPORATOR

2” CLEARANCEAROUND SUPPLY

PLENUM TOCOMBUSTIBLE

STRUCTURE, FORFIRST 3 FEET.

0” AFTER 3 FEET.

2” MINIMUMCLEARANCETO WALL

! WARNING


I265

BASE PAN

SUPPLY DUCTCOVER *(INSULATIONSIDE UP),ATTACH WITHTWO SCREWS.

RETURNDUCTCOVER(INSULATIONSIDE UP,ATTACHWITH 4SCREWS)

SUPPLY DUCTCOVER

*ROTATE SUPPLY COVER 90° AFTER IT IS INSERTEDTHROUGH OPENING. SLIP FLANGE OF COVERUNDER LANCE AT BACK OF BOTTOM SUPPLY DUCTOPENING. SEE DETAIL AT LEFT. THEN SECURECOVER BY INSTALLING 2 SCREWS USING HOLENEAREST THE OUTSIDE OF UNIT.

LANCE AT BACK OF BOTTOMSUPPLY DUCT OPENING


FIGURE 12CLEARANCES

11

G. ROOFTOP INSTALLATION1. Before locating the unit on the roof,

make sure that the roof structure isadequate to support the weightinvolved. (See electrical and physicaltables in this book for weight of unit.)THIS IS VERY IMPORTANT ANDTHE INSTALLER’SRESPONSIBILITY.

2. For rigging and roofcurb details, seeFigures 17, 18 and 19.

3. The location of the unit on the roofshould be such as to provide properaccess for inspection and servicing.

IMPORTANT: If unit will not be put intoservice immediately, block off supply andreturn air openings to prevent excessivecondensation.

H. DUCTINGThe installing contractor should fabricateductwork in accordance with local codes.Use industry manuals as a guide whensizing and designing the duct system.Contact Air Conditioning Contractors ofAmerica, 1513 16th St. N.W.,Washington, D.C. 20036.

DO NOT, UNDER ANYCIRCUMSTANCES, CONNECTRETURN DUCTWORK TO ANY OTHERHEAT PRODUCING DEVICE SUCH ASFIREPLACE INSERT, STOVE, ETC.UNAUTHORIZED USE OF SUCHDEVICES MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURY ORPROPERTY DAMAGE.

FIGURE 13EXCEPTION TO NON-COMBUSTIBLE FLOORING REQUIREMENT

I458

BOTH ENDSMUST BEOPEN FORDOWNFLOWOR SIDEFLOWDUCTWORKTO PROVIDEVENTILATION

COMBUSTIBLESTRUCTURE

1” MIN.

NOMINAL4 x 4 TIMBER(SIDES ONLY)

SIDEFLOWSUPPLYPLENUM

CONNECTION

SUPPLYPLENUM

(DOWNFLOW)RETURN PLENUM

(DOWNFLOW)

SIDEFLOWRETURN PLENUM

CONNECTION

! WARNING

3-1/2” MIN.

FIGURE 14FLAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. MOUNTED ONROOFCURB. PITCH UNIT TOWARD DRAIN. SEE FIGURE 5.

I256

SERVICE ACCESSPANELS. DO NOTBLOCK ACCESS.

BRANCHCIRCUITDISCONNECT

GAS SUPPLY

TRAPGAS SHUT-OFF VALVE

UNION

THERMOSTATWIRE CONDUITCONDENSATE

INTOROOFDRAIN

IF REQ’DBY LOCAL

CODES.

POWERSUPPLYCONDUIT

I257

SERVICE ACCESSPANELS. DO NOTBLOCK ACCESS.

SUPPLY PLENUM

GASSHUT-OFFVALVE

GAS SUPPLY

TRAP

UNION

THERMOSTATWIRE CONDUIT

BRANCH CIRCUITDISCONNECT

CONDENSATEDRAIN INTO

ROOFDRAIN IFREQ’D BY LOCAL

CODES

POWER SUPPLYCONDUIT

FIGURE 15PITCHED ROOFTOP INSTALLATION, ON ANGLE-IRON STAND, SIDE FLOW DUCTWORK,ATTIC OR DROP CEILINGDISTRIBUTING SYSTEM.PITCH UNIT TOWARD DRAIN.SEE FIGURE 5.

FIGURE 15PITCHED ROOFTOP INSTALLATION, ON ANGLE-IRON STAND, SIDE FLOW DUCTWORK,ATTIC OR DROP CEILINGDISTRIBUTING SYSTEM.PITCH UNIT TOWARD DRAIN.

12

Place the unit as close to the conditionedspace as possible allowing clearancesas indicated. Run ducts as directly aspossible to supply and return outlets.Use of non-flammable weatherproofflexible connectors on both supply andreturn connections at unit to reducenoise transmission is recommended.On ductwork exposed to outsidetemperature and humidity, use aminimum of 2” of insulation and a vaporbarrier. Distribution system in attic, furredspace or crawl space should beinsulated with at least 2” of insulation. 1/2”to 1” thick insulation is usually sufficientfor ductwork inside the air conditionedspace.Provide balancing dampers for eachbranch duct in the supply system.Properly support ductwork from thestructure.IMPORTANT: In the event that the returnair ducts must be run through an“unconfined” space containing other fuelburning equipment, it is imperative thatthe user/homeowner must be informedagainst future changes in constructionwhich might change this to a “confinedspace.” Also, caution theuser/homeowner against any futureinstallation of additional equipment (suchas power ventilators, clothes dryers, etc.,within the existing unconfined and/orconfined space which might create anegative pressure within the vicinity ofother solid, liquid, or gas fueledappliances.

FIGURE 17LIFTING DETAIL

! WARNINGRETURN AIR

NEVER ALLOW PRODUCTS OFCOMBUSTION OR THE FLUEPRODUCTS TO ENTER THE RETURNAIR DUCTWORK, OR THECIRCULATING AIR SUPPLY. ALLRETURN DUCTWORK MUST BEADEQUATELY SEALED AND SECUREDTO THE FURNACE WITH SHEET

I253

RIGGINGNOT PROVIDED

LIFT BRACKET(4 REQ’D

FIGURE 16PITCHED ROOFTOP INSTALLATION, ON ROOFJACK, DOWNFLOW DUCTWORK, ATTIC ORDROP CEILING DISTRIBUTING SYSTEM. PITCH UNIT TOWARD DRAIN. SEE FIGURE 5.

I257B

SERVICE ACCESS PANELS.DO NOT BLOCK ACCESS.

SUPPLYPLENUM

GAS SUPPLY

TRAP

GAS SHUT-OFF VALVE

UNION

THERMOSTATWIRE CONDUIT

BRANCH CIRCUITDISCONNECT

CONDENSATEDRAIN INTO

ROOFDRAIN IFREQ’D BY LOCAL

CODES.

POWER SUPPLYCONDUIT

METAL SCREWS, AND JOINTS TAPED.ALL OTHER DUCT JOINTS MUST BESECURED WITH APPROVEDCONNECTIONS AND SEALEDAIRTIGHT.FAILURE TO PREVENT PRODUCTS OFCOMBUSTION FROM BEINGCIRCULATED INTO THE LIVING SPACECAN CREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING THAT COULD RESULT INPERSONAL INJURY OR DEATH.

I. FILTERSThe installer must install field suppliedfilters in the return air duct. A field installedfilter grille is recommended for easy andconvenient access to the filters for periodicinspection and cleaning. Filters must haveadequate face area for the rated airquantity of the unit. See air delivery tablesfor recommended filter size. A fieldinstalled internal filter kit RXRY-B01 isavailable.

FIGURE 17LIFTING DETAIL.

ALTERNATE RIGGING HOLES(4 SIDES)

13

FIGURE 20DUCTWORK COVER INSTALLATION DETAIL

FIGURE 21RESIDENTIAL ROOFTOP DUCTWORK INSTALLATION DETAIL

I342

I610A

I610B

RETURN PLENUM161/2MAX.

201/2 MAX.

163/8 MAX.

INSULATIONPANELS

NAILINGSTRIP

CAULK ALLJOINTSWATERTIGHT

SUPPLYPLENUM

DUCTFLANGE(NOT TOEXCEED 1()

ROOFCURB

FIGURE 18ROOFCURB

I255

**BY CONTRACTOR**FOR INSTALLATION OF DUCT AS SHOWN, USE RECOMMENDED

DUCT SIZES FROM ROOFCURB INSTALLATION INSTRUCTIONS. FORDUCT FLANGE ATTACHMENT TO UNIT, SEE UNIT INSTALLATIONINSTRUCTIONS (FIGURE 1) FOR SIZE OF DUCT OPENINGS.

ROOFTOP UNIT

TIE DOWN SCREW *

ROOFCURB

ROOF FLASHING *

ROOFING *CANT STRIP *

ROOF DECK *

GASKET

NAILING STRIP

INSULATION *

INSULATION *

** DUCT *

RECOMMENDED SHEET METALDUCTWORK COVER CAULKED WATERTIGHT

CAULK ALL JOINTSWATERTIGHT

90° FLANGE ON DUCT

SUPPLY AIR DUCT

ATTACH DUCTS TO UNITWITH SCREWS AS SHOWN

RETURN AIR DUCT

INSULATED DUCTWORKINSIDE DUCTWORK COVER

FIGURE 19ROOFCURB

FIGURE 21RESIDENTIAL ROOFTOP DUCTWORK INSTALLATION DETAIL.

FIGURE 20DUCTWORK COVER INSTALLATION DETAIL

14

TO CHECK FOR GAS LEAKS, USE ASOAP AND WATER SOLUTION OROTHER APPROVED METHOD. DO NOTUSE AN OPEN FLAME.

DO NOT USE AN OPEN FLAME TOCHECK FOR LEAKS. THE USE OF ANOPEN FLAME CAN RESULT IN FIRE,EXPLOSION, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.IMPORTANT: Check the rating plate tomake certain the appliance is equipped toburn the type of gas supplied. Care shouldbe taken after installation of thisequipment that the gas control valve notbe subjected to high gas supply linepressure.In making gas connections, avoid strainsas they may cause noise and damage thecontrols. A backup wrench is required tobe used on the valve to avoid damage.

III. GAS SUPPLY, CONDENSATE DRAIN AND PIPINGA. GAS CONNECTIONIMPORTANT: Connect this unit only togas supplied by a commercial utility.1. Install gas piping in accordance with

local codes and regulations of thelocal utility company. In the absenceof local codes, the installation mustconform to the specifications of theNational Fuel Gas Code, ANSIZ223.1 - latest edition.NOTE: The use of flexible gasconnectors is not permitted.NOTE: The Commonwealth ofMassachusetts requires the gasshut-off valve to be a T-handle gascock.

2. Connect the gas line to the gas pipeinlet opening provided into the 1/2”inlet valve. See Figure 5 for typicalpiping.

3. Size the gas line to the furnaceadequate enough to prevent unduepressure drop and never less than1/2(.

4. Install a drip leg or sediment trap inthe gas supply line as close to theunit as possible.

5. Install an outside ground joint unionto connect the gas supply to thecontrol assembly at the burner tray.

6. Gas valves have been factoryinstalled. Install a manual gas valvewhere local codes specify a shut-offvalve outside the unit casing. (SeeFigure 22.)

7. Make sure piping is tight. A pipecompound resistant to the actionof liquefied petroleum gases mustbe used at all threaded pipeconnections.

8. IMPORTANT: any additions,changes or conversions required forthe furnace to satisfactorily meet theapplication should be made by aqualified installer, service agency orthe gas supplier, using factory-specified or approved parts. In thecommonwealth of Massachusetts,installation must be performed by alicensed plumber or gas fitter forappropriate fuel.

IMPORTANT: Disconnect the furnaceand its individual shutoff valve from thegas supply piping during any pressuretesting of that system at test pressuresin excess of 1/2 psig or isolate thesystem from the gas supply pipingsystem by closing its individual manualshutoff valve during any pressure testingof this gas supply system at pressuresequal to or less than 1/2 PSIG.

! WARNING

FIGURE 22SUGGESTED GAS PIPING

The capacities of gas pipe of differentdiameters and lengths in cu. ft. per hr. withpressure drop of 0.3 in. and specificgravity of 0.60 (natural gas) are shown inTable 2.

After determining the pipe length, selectthe pipe size which will provide theminimum cubic feet per hour required forthe gas input rating of the furnace. Byformula:

Gas Input of Furnace(BTU/HR)

Cu. Ft. Per Hr. Required =Heating Value of Gas(BTU/FT3)

The gas input of the furnace is marked onthe furnace rating plate. The heating valueof the gas (BTU/FT3) may be determinedby consulting the local natural gas utility orthe L.P. gas supplier.

NominalIron Pipe

Size,Inches

Equivalent Length of Pipe, Feet

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

11/4 1,050 730 590 500 440 400 370 35011/2 1,600 1,100 890 760 670 610 560 530

TABLE 2GAS PIPE CAPACITY TABLE (CU. FT./HR.)

FROM GASMETER

*Factory supplied grommet must be utilized.

MANUAL GASSHUT-OFFVALVE

UNIT GAS SUPPLYCONNECTION *

ROOF OR GROUND LEVEL INSTALLATION

15

B. LP CONVERSION

THIS UNIT IS EQUIPPED AT THEFACTORY FOR USE ON NATURALGAS ONLY. CONVERSION TO LP GASREQUIRES A SPECIAL KIT SUPPLIEDBY THE DISTRIBUTOR ORMANUFACTURER. MAILINGADDRESSES ARE LISTED ON THEFURNACE RATING PLATE, PARTSLIST AND WARRANTY. FAILURE TOUSE THE PROPER CONVERSION KITCAN CAUSE FIRE, CARBONMONOXIDE POISONING, EXPLOSION,PERSONAL INJURY, PROPERTYDAMAGE OR DEATH.Convert the valve to use liquefiedpetroleum (LP) gas by replacing thepressure regulator spring with theconversion kit spring. This LP kit springallows the regulator to maintain theproper manifold pressure for LP gas.The correct burner LP orifices areincluded in the kit. See Figure 23.NOTE: Order the correct LP conversionkit from the furnace manufacturer. SeeConversion Kit Index shipped withunit for proper LP kit number.Furnace conversion to LP gas mustbe performed by a qualifiedtechnician.

! WARNING

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleumgases (at 11 inches water column inlet pressure).

(Based on a Pressure Drop of 0.5 Inch Water Column)

TABLE 3LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

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

275 189 152 129 114 103 96 89 83 78 69 63

567 393 315 267 237 217 196 182 173 162 146 132

1,071 732 590 504 448 409 378 346 322 307 275 252

2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511

3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787

6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

1/2

3/4

1

1-1/4

1-1/2

2

Length of Pipe, Feet

Example (LP): Input BTU requirement of unit, 150,000

Equivalent length of pipe, 60 ft. = 3/4” IPS required.

NOx MODELSWhen converting units equipped withNOx inserts to LP gas, the stainlesssteel mesh inserts in the entrance of thetubular exchangers are not required tomeet SCAQMD NOx emission levels.Carefully remove these inserts beforefiring this furnace on LP gas. Thisfurnace is not designed to operate on LPgas with the NOx inserts in place.

Step by step instructions on removing theNOx inserts and retaining rod are includedin the Conversion Kit InstallationInstructions.

C. ADJUSTING OR CHECKINGFURNACE INPUT

– Natural Gas Line Pressure 5” - 10.5”W.C.– LP Gas Line Pressure 11” - 13” W.C.– Natural Gas Manifold Pressure 3.5” W.C– LP Gas Manifold Pressure - 10” W.C.Supply and manifold pressure taps arelocated on the gas valve body 1/8” N.P.T.).Use properly calibrated manometer gaugefor accurate gas pressure readings.Only small variations in the gas flow shouldbe made by means of the pressureregulator adjustment. Furnaces functioningon LP gas must be set by means of thetank or branch supply regulators. Thefurnace manifold pressure should be set at10” W.C. at the gas control valve.

To adjust the pressure regulator, removethe regulator cap and turn the adjustmentscrew clockwise to increase pressure orcounterclockwise to decrease pressure.Then replace the regulator capsecurely.Any necessary major changes in the gasflow rate should be made by changing thesize of the burner orifices. To changeorifice spuds, shut off the manual maingas valve and remove the gas manifold.For elevations up to 2,000 feet, ratingplate input ratings apply. For highaltitudes (elevations over 2,000 ft.), seeconversion kit index 92-21519-XX forderating and orifice spud sizes.Check of input is important to preventover-firing of the furnace beyond itsdesign-rated input. NEVER SET INPUTABOVE THAT SHOWN ON THE RATINGPLATE. Use the following table orformula to determine input rate.

FIGURE 23

16

ONE 1 21 1 30 1 34 1 39 3 4540,000 TEN 13 30 15 0 15 36 16 30 37 30ONE 0 54 1 0 1 3 1 6 2 3060,000 TEN 9 0 10 0 10 24 11 0 25 0ONE 0 41 0 45 0 47 0 50 1 5380,000 TEN 6 45 7 30 7 48 8 15 18 45ONE 0 33 0 36 0 38 0 40 1 30100,000 TEN 5 24 6 0 6 15 6 36 15 0

Heating Value of Gas(BTU/Cu. Ft.) x 3600

Cu. Ft. Per Hr. Required =Time in Seconds(for 1 Cu. Ft.) of Gas

Start the furnace and measure the timerequired to burn one cubic foot of gas.Prior to checking the furnace input, makecertain that all other gas appliances areshut off, with the exception of pilotburners. Time the meter with only thefurnace in operation.IMPORTANT NOTE FOR ALTITUDESABOVE 2,000 FEET (610 METERS): Themain burner orifices in your furnace andin these kits are sized for the nameplateinput and intended for installations atelevations up to 2,000 feet in the USA orCanada, or for elevations of 2,000 - 4,500feet (610 -1,373 meters) in Canada if theunit has been derated at the factory. For

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

OR LP GAS

INPUTBTU/HR

METERSIZE

CU. FT.

HEATING VALUE OF GAS BTU PER CU. FT.900 1000 1040 1100 2500

MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

TABLE 4

elevations above 2,000 feet (610meters) IN THE USA ONLY (see ANSI-Z223.1), the burner orifices must besized to reduce the input 4% for each1,000 feet (305 meters) above sea level.NOTICE: DERATING OF THEHEATING INPUT FOR HIGH ALTITUDEIN THE FIELD IS UNLAWFUL INCANADA (REFER TO CAN/CGA 2.17).UNITS INSTALLED IN ALTITUDESGREATERS THAN 2,000 FEET (610METERS) MUST BE SHIPPED FROMTHE FACTORY OR FROM A FACTORYAUTHORIZED CONVERSION STATIONWITH THE HEATING INPUT DERATEDBY 10% SO AS TO OPERATEPROPERLY IN ALTITUDES FROM2,000 - 4,500 FEET (610 - 1,373METERS).

D. CONDENSATE DRAINThe evaporator coil condensate drain endswith an threaded 3/4” nominal PVC stub. Atrap is built in for proper condensatedrainage and to prevent debris from beingdrawn into the unit. Do not connect thedrain to a closed sewer line. Connection toa vented sewer line is allowed. It isrecommended that a PVC cement not beused so that the drain line can be easilycleaned in the future.IMPORTANT: DO NOT INSTALL ANEXTERNAL TRAP. DOING SO CANCAUSE IMPROPER DRAINAGE OF THECONDENSATE AND RESULT INFLOODING WITHIN THE UNIT.

17

A. POWER SUPPLY

TURN OFF THE MAIN ELECTRICALPOWER AT THE BRANCH CIRCUITDISCONNECT CLOSEST TO THE UNITBEFORE ATTEMPTING ANY WIRING.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTING INPERSONAL INJURY OR DEATH.1. All wiring should be made in

accordance with the NationalElectrical Code. Consult the localpower company to determine theavailability of sufficient power tooperate the unit. Check the voltageat power supply to make sure itcorresponds to the unit’s RATEDVOLTAGE REQUIREMENT. Install abranch circuit disconnect near therooftop, in accordance with theN.E.C. or local codes.

2. It is important that proper electricalpower is available at the unit.Voltage should not vary more than10% from that stamped on the unitnameplate. On three phase units,phases must be balanced within 3%.

3. For branch circuit wiring (main powersupply to unit disconnect), theminimum wire size for the length ofrun can be determined from Table 5using the circuit ampacity found on theunit rating plate. Use the smallest wiresize allowable in Table 5 from the unitdisconnect to unit. The disconnectmust be in sight and readilyaccessible of the unit.

NOTES:

IV. WIRING

! WARNING

1. Wire size based on 60°C rated wireinsulation and 30°C Ambient Temp.(86°F).

2. For more than 3 conductors in araceway or cable, see the N.E.C. forderating the ampacity of eachconductor.When installed, the unit must beelectrically grounded in accordancewith local codes or, in the absence oflocal codes, with the NationalElectrical Code, ANSI/NFPA 70, if anexternal electrical source is utilized.

IMPORTANT: THIS UNIT IS AP-PROVED FOR USE WITH COPPERCONDUCTORS ONLY CONNECTEDTO UNIT CONTACTOR.WARRANTY MAY BE JEOPARDIZEDIF ALUMINUM WIRE IS CONNECTEDTO UNIT CONTACTOR.Special instructions apply for powerwiring with aluminum conductors:Warranty is void if connections arenot made per instructions.

Attach a length (6” or more) ofrecommended size copper wire to the

200 6 4 4 4 3 3 2 2150 8 6 6 4 4 4 3 3100 10 8 8 6 6 6 4 450 14 12 10 10 8 8 6 6

15 20 25 30 35 40 45 50

TABLE 5BRANCH CIRCUIT COPPER WIRE SIZE(BASED ON 1% VOLTAGE DROP)*

unit contactor terminals L1 and L3 forsingle phase, L1, L2 and L3 for threephase.Select the equivalent aluminum wire sizefrom the tabulation below:Splice copper wire pigtails to aluminumwire with U.L. recognized connectors forcopper-aluminum splices. Please exercisethe following instructions very carefully toobtain a positive and lasting connection:1. Strip insulation from aluminum

conductor.2. Coat the stripped end of the aluminum

wire with the recommended inhibitor,and wire brush the aluminum surfacethrough inhibitor. INHIBITORS:Brundy-Pentex “A”; Alcoa-No. 2EJC; T& B-KPOR Shield.

3. Clean and recoat aluminum conductorwith inhibitor.

4. Make the splice using the above listedwire nuts or split bolt connectors.

5. Coat the entire connection withinhibitor and wrap with electricalinsulating tape.

AWG Copper AWG Aluminum Connector Type and SizeWire Size Wire Size (or equivalent)

#12 #10 T & B Wire Nut PT2#10 # 8 T & B Wire Nut PT3# 8 # 6 Sherman Split Bolt TSP6# 6 # 4 Sherman Split Bolt TSP4# 4 # 2 Sherman Split Bolt TSP2

TABLE 6

SUPPLY WIRELENGTH-FEET

*Taken from National Electric Code

BRANCH CIRCUIT AMPACITY

18

B. HOOK-UPTo wire unit, refer to the following hook-up diagram.Refer to Figure 3 for location of wiringentrances.Wiring to be done in the field betweenthe unit and devices not attached to theunit, or between separate devices whichare field installed and located, shallconform with the temperature limitationfor Type T wire [63°F rise (35°C)] wheninstalled in accordance with themanufacturer’s instructions.

C. INTERNAL WIRINGIMPORTANT: Some single phase unitsare equipped with a single polecontactor. Caution must be exercisedwhen servicing as only one leg of thepower supply is broken with thecontactor.A diagram of the internal wiring of thisunit is located under the electrical boxcover. If any of the original wire assupplied with the appliance must bereplaced, the wire gauge and insulationmust be same as original wiring.Transformer is factory wired for 230 voltson 208/230 volt models and must bechanged for 208 volt applications. Seeunit wiring diagram for 208 volt wiring.

D. THERMOSTATThe room thermostat must be compatiblewith the spark ignition control on the unit.Generally, all thermostats that are not ofthe “current robbing” type are compatiblewith the integrated furnace control. Thelow voltage wiring should be sized asshown in Table 7.Install the room thermostat in accordancewith the instruction sheet packed in thebox with the thermostat. Run thethermostat lead wires inside the blowercompartment and connect to low voltageterminals as shown on the wiring diagram.

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.3.0 16 14 12 10 10 102.5 16 14 12 12 12 102.0 18 16 14 12 12 10

50 100 150 200 250 300Length of Run – Feet (1)Th

erm

osta

t Loa

d - A

mps

TABLE 7

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

Never install the thermostat on an outsidewall or where it will be influenced by drafts,concealed hot or cold water pipes orducts, lighting fixtures, radiation fromfireplace, sun rays, lamps, televisions,radios or air streams from registers. Referto instructions packed with the thermostatfor “heater” selection or adjustment.The following is a list of recommendedthermostats to be used with and withoutan economizer:

*

*L2 connection 3Phase only

SINGLE STAGE COOL W/OECONOMIZER

MAPLE CHASE - MODEL #0970HONEYWELL - MODEL #T8602CMAPLE CHASE - MODEL #0960WHITE RODGERS - MODEL #1F91-59ROBERTSHAW - MODEL #CM64A-USAJ

TWO STAGE COOL W/ECONOMIZER

HONEYWELL - MODEL #T7300-A1005HONEYWELL - MODEL #T874D-1959

19

V. FURNACE SECTION CONTROLS AND IGNITION SYSTEM• The induced draft blower and main

burner will shut off when the thermostat

is satisfied.

• The circulating air blower will start and

run on the heating speed if the

thermostat fan switch is in the “ON”

position.

The integrated furnace control is

equipped with diagnostic LED. The LED

is lit continuously when there is power to

the control, with or without a call for heat.

If the LED is not lit, there is either no

power to the control or there is an

internal component failure within the

control, and the control should be

replaced.

If the control detects the following

failures, the LED will flash on for

approximately 1/4 second, then off for 3/4

second for designated failure detections.

1 Flash: Failed to detect flame within the

three tries for ignition.

2 Flash: Pressure switch or induced draft

blower problem detected.

3 Flash: High limit or auxiliary limit open.

4 Flash: Flame sensed and gas valve not

energized or flame sensed with

no “W” signal.

5 Flash: Overtemperature switch open.

OPERATING INSTRUCTIONSThis appliance is equipped with a direct

spark intermittent ignition device. This

device lights the main burners each time

the room thermostat (closes) calls for

heat. See operating instructions on the

back of the furnace/controls access

panel.

DO NOT ATTEMPT TO MANUALLYLIGHT THIS FURNACE WITH A MATCHOR ANY OPEN FLAME. ATTEMPTINGTO DO SO CAN CAUSE ANEXPLOSION OR FIRE RESULTING INPROPERTY DAMAGE, PERSONALINJURY OR DEATH.

TO START THE FURNACE

1. Set the thermostat to its lowest

setting.

2. Turn off all electric power to the

appliance.

3. This appliance does not have a pilot. It

is equipped with an ignition device

which automatically lights the burner.

Do not try to light the burner by hand.

4. Remove control door.

5. Depress the control knob and move to

the “OFF” position. Turn the knob by

hand only, do not use any kind of tool.

6. Wait five (5) minutes to clear out any

gas. Then smell for gas, including

near the floor. If you smell gas, STOP!

Follow B in the safety information on

the Operating Instructions located on

the back of the controls/access panel.

step.

7. Move the gas control knob from “OFF”

position to “ON” position. Operate this

appliance with the gas control knob in

the “ON” position only. Do not use the

gas control knob as a means for

throttling the burner input rate.

8. Replace the control door.

9. Turn on all electric power to the

appliance.

10. Set the thermostat to the desired

setting.

11. If the appliance will not operate, follow

the instructions below on how to shut

down the furnace.

THE SPARK IGNITOR AND IGNITIONLEAD FROM THE IGNITION CONTROLARE HIGH VOLTAGE. KEEP HANDS ORTOOLS AWAY TO PREVENTELECTRICAL SHOCK. SHUT OFFELECTRICAL POWER BEFORESERVICING ANY OF THE CONTROLS.FAILURE TO ADHERE TO THISWARNING CAN RESULT IN PERSONALINJURY OR DEATH. The initial start-up

on a new installation may require the

control system to be energized for some

time until any air has bled through the

system and fuel gas is available at the

burners.

NORMAL FURNACEOPERATING SEQUENCEThis unit is equipped with an integrated

direct spark ignition control.

1. The thermostat calls for heat.

2. The control board will run a self

check to verify that the limit control

and manual reset overtemperature

control are closed and that the

pressure switch is open. If so, the

induced draft blower (inducer)

begins a prepurge cycle.

3. The air proving negative pressure

switch closes.

4. 15 seconds after the pressureswitch closes, the gas valve opens

and the spark is initiated for a 7

second trial for ignition.

5. Burners ignite and flame sensor

proves all burners have lit.

6. The circulating air blower is

energized after 30 seconds.

7. The control board enters a normal

operation loop in which all safety

controls are monitored continuously.

8. Thermostat is satisfied and opens.

9. The gas valve is de-energized and

closes, shutting down the burner

flame.

10. The control board will de-energize

the inducer after a five second post

purge.

11. The circulating air blower is de-

energized after 90 seconds.

• The integrated control board has a

three try ignition system.

• After a total of three trials for ignition

without sensing main burner flame, the

system goes into a 100% lockout

mode.

• After one hour, the ignition control

repeats the prepurge and ignition

cycles for 3 tries and then goes into

100% lockout mode again.

• It continues this sequence of cycles

and lockout each hour until igniton is

successful or power is interrupted.

• During the lockout mode, neither the

spark ignition control or gas valve will

be energized until the system is reset

by turning the thermostat to the “OFF”

position or interrupting the electrical

power to the unit for 3 seconds or

longer.

! WARNING! WARNING

If you don’t smell gas, go to the next

1. STOP! Read the safety information onthe Operating Instructions Labellocated on this appliance.

IF YOU DO NOT FOLLOW THESEINSTRUCTIONS EXACTLY, A FIRE OREXPLOSION MAY RESULT CAUSINGPROPERTY DAMAGE, PERSONALINJURY OR LOSS OF LIFE.

2. Set the thermostat to its lowestsetting.

3. Turn off all electric power to theappliance.

4. This appliance does not have a pilot.It is equipped with an ignition devicewhich automatically lights the burner.Do NOT try to light the burner byhand.

5. Remove control door/access panel.

7. Wait five (5) minutes to clear out anygas. Then smell for gas, includingnear the floor. If you smell gas, STOP!Follow ‘B’ in the safety information onthe Operating Instruction Labellocated on this appliance. If you don’tsmell gas, go to the next step.

8. Move the switch from “OFF” positionto “ON” position.


10. Turn on all electric power to theappliance.

11. Set the thermostat to the desiredsetting.

12. If the appliance will not operate, followthe instructions below on how to shutdown the furnace.

THE SPARK IGNITOR AND IGNITIONLEAD FROM THE IGNITION CONTROLARE HIGH VOLTAGE. KEEP HANDS ORTOOLS AWAY TO PREVENTELECTRICAL SHOCK. SHUT OFFELECTRICAL POWER BEFORESERVICING ANY OF THE CONTROLS.FAILURE TO ADHERE TO THISWARNING CAN RESULT IN PERSONALINJURY OR DEATH. The initial start-upon a new installation may require thecontrol system to be energized for sometime until any air has bled through thesystem and fuel gas is available at theburners.

!

!

WARNING

WARNING

6. Move switch to the “OFF” position.








7. Wait five (5) minutes to clear out anygas. Then smell for gas, includingnear the floor. If you smell gas, STOP!If you don’t smell gas, go to the nextstep.

• Do not try to light any appliance.

• Do not touch any electric switch; donot use any phone in your building.

• Immediately call your gas supplierfrom a neighbor’s phone. Follow thegas supplier’s instructions.

• If you cannot reach your gassupplier, call the fire department.







WARNING!

WARNING!








7. Wait five (5) minutes to clear out anygas. Then smell for gas, includingnear the floor.





If you smell gas, STOP! If you don’tsmell gas, go to the next step.







WARNING!

WARNING!








7. Wait five (5) minutes to clear out anygas. Then smell for gas, includingnear the floor. If you smell gas, STOP!





If you don’t smell gas, go to the nextstep.







WARNING!

WARNING!

20

BURNERSBurners for these units have beendesigned so that field adjustment is notrequired. Burners are tray-mounted andaccessible for easy cleaning whenrequired.

MANUAL RESETOVERTEMPERATURECONTROLA manual reset overtemperature controlis located on the burner shield. Thisdevice senses blockage in the heatexchanger or insufficient combustion air.This shuts off the main burners ifexcessive temperatures occur in theburner compartment.Operation of this control indicates anabnormal condition. Therefore, the unitshould be examined by a qualifiedinstaller, service agency, or the gassupplier before being placed back intooperation.

DO NOT JUMPER THIS DEVICE! DONOT reset the overtemperature controlwithout taking corrective action toassure that an adequate supply ofcombustion air is maintained under allconditions of operation. Failure to doso can result in carbon monoxidepoisoning or death. Replace thiscontrol only with the identicalreplacement part.

! WARNING

TO SHUT DOWN FURNACE1. Set the thermostat to the lowest

setting.2. Turn off all electric power to the

appliance if service is to beperformed.

3. Remove control door.

5. Replace control door.

SHOULD OVERHEATING OCCUR ORTHE GAS SUPPLY FAIL TO SHUT OFF,SHUT OFF THE MANUAL GAS VALVETO THE APPLIANCE BEFORESHUTTING OFF THE ELECTRICALSUPPLY. FAILURE TO DO SO CANRESULT IN AN EXPLOSION OR FIRECAUSING PROPERTY DAMAGE,SEVERE PERSONAL INJURY ORDEATH!

PRESSURE SWITCHThis furnace has a pressure switch forsensing a blocked exhaust or a failedinduced draft blower. It is normally openand closes when the induced draft blowerstarts, indicating air flow through thecombustion chamber.

LIMIT CONTROLThe supply air high temperature limit cut-off is set at the factory and cannot beadjusted. It is calibrated to prevent the airtemperature leaving the furnace fromexceeding the maximum outlet airtemperature. WARNING: DO NOTJUMPER THIS DEVICE! Replace thiscontrol only with the identicalreplacement part.

! WARNING


21

ADVISE THE CUSTOMER1. Keep the air filters clean. The

heating system operates better,more efficiently and moreeconomically.

2. Arrange the furniture and drapes sothat the supply air registers and thereturn air grilles are unobstructed.

3. Close doors and windows. Thisreduces the heating load on thesystem.

4. Avoid excessive use of exhaust fans.5. Do not permit the heat generated by

television, lamps or radios toinfluence the thermostat operation.

6. Except for the mounting platform,keep all combustible articles threefeet from the unit and exhaustsystem.

7. IMPORTANT: Replace all blowerdoors and compartment cover afterservicing the unit. Do not operate theunit without all panels and doorssecurely in place.

8. Do not allow snow or other debris toaccumulate in the vicinity of theappliance.

FURNACE SECTIONMAINTENANCEThe unit’s furnace should operate formany years without excessive scalebuild-up in flue passageways; however,it is recommended that a qualifiedinstaller, service agency, or the gassupplier annually inspect the fluepassageways, the exhaust system andthe burners for continued safe operation,paying particular attention todeterioration from corrosion or othersources.If during inspection the fluepassageways and exhaust system aredetermined to require cleaning, thefollowing procedures should be followed(by a qualified installer, service

agency, or gas supplier):

1. Turn off the electrical power to the

unit and set the thermostat to the

lowest temperature.

2. Shut off the gas supply to the unit

either at the meter or at manual

valve in the supply piping.

LABEL ALL WIRES PRIOR TO

DISCONNECTION WHEN SERVICING

CONTROLS. WIRING ERRORS CAN

CAUSE IMPROPER AND DANGEROUS

OPERATION RESULTING IN FIRE,

ELECTRICAL SHOCK, PROPERTY

DAMAGE, PERSONAL INJURY OR

DEATH.

3. Remove the furnace controls accesspanel and the control box cover.

4. Disconnect the gas supply pipingfrom the gas valve.

5. Disconnect the wiring to the induceddraft blower motor, gas valve, flamesensor, and flame roll-out control,and ignitor cable. Mark all wires

disconnected for proper

reconnection.6. Remove the screws (4) connecting

the burner tray to the heat exchangermounting panel.

7. Remove the burner tray and themanifold assembly from the unit.

8. Remove the screws (4) connectingthe induced draft blower to thecollector box and screws (16)connecting the collector box to theheat exchanger mounting panel.Remove the induced draft blower andthe collector box from the unit.

9. Remove the turbulators from insidethe heat exchangers by inserting theblade of a screwdriver under thelocking tabs. Pop the tabs out of theexpanded grooves of the heatexchanger. Slide the turbulators out ofthe heat exchangers.

10. Direct a water hose into the outlet ofthe heat exchanger top. Flush theinside of each heat exchanger tubewith water. Blow out each tube with airto remove excessive moisture.

11. Reassemble (steps 1 through 10 inreverse order). Be careful not to

strip out the screw holes used to

mount the collector box and

inducer blower. Replace inducer

blower gasket and collector box

gasket with factory replacements if

damaged.

HOLES IN THE EXHAUST

TRANSITION OR HEAT EXCHANGER

CAN CAUSE TOXIC FUMES TO ENTER

THE HOME. THE EXHAUST

TRANSITION OR HEAT EXCHANGER

MUST BE REPLACED IF THEY HAVE

HOLES OR CRACKS IN THEM.

FAILURE TO DO SO CAN CAUSE

CARBON MONOXIDE POISONING

RESULTING IN PERSONAL INJURY OR

DEATH.

The manufacturer recommends that aqualified installer, service agency or thegas supplier visually inspect the burnerflames for the desired flame appearance atthe beginning of the heating season andapproximately midway in heating season.The manufacturer also recommends that aqualified installer, service agency or thegas supplier clean the flame sensor withsteel wool at the beginning of the heatingseason.

DISCONNECT MAIN ELECTRICAL

POWER TO THE UNIT BEFORE

ATTEMPTING MAINTENANCE.

FAILURE TO DO SO MAY RESULT IN

ELECTRICAL SHOCK OR SEVERE

PERSONAL INJURY OR DEATH.

LUBRICATIONIMPORTANT: DO NOT attempt tolubricate the bearings on the blower motoror the induced draft blower motor. Additionof lubricants can reduce the motor life andvoid the warranty.The blower motor and induced draftblower motor are prelubricated by themanufacturer and do not require furtherattention.A qualified installer, service agency or thegas supplier must periodically clean themotors to prevent the possibility ofoverheating due to an accumulation ofdust and dirt on the windings or on themotor exterior. And, as suggestedelsewhere in these instructions, the airfilters should be kept clean because dirtyfilters can restrict air flow and the motordepends upon sufficient air flowing acrossand through it to prevent overheating.

COOLING SECTIONMAINTENANCE

DISCONNECT MAIN ELECTRICAL

POWER TO THE UNIT BEFORE

ATTEMPTING MAINTENANCE.

FAILURE TO DO SO CAN CAUSE

ELECTRICAL SHOCK RESULTING IN

SEVERE PERSONAL INJURY OR

DEATH.

VI. SYSTEM OPERATING INFORMATION! WARNING

! WARNING

! WARNING

! WARNING

22

It is recommended that at the beginningof each cooling season a qualifiedinstaller or service agency inspect andclean the cooling section of this unit. Thefollowing areas should be addressed:evaporator coil. condenser coil,condenser fan motor and venturi area.To inspect the evaporator coil:1. Remove the filter access panel and

the blower/evaporator coil accesspanel.

LABEL ALL WIRES PRIOR TODISCONNECTION WHEN SERVICINGTHE UNIT. WIRING ERRORS CANCAUSE IMPROPER ANDDANGEROUS OPERATIONRESULTING IN FIRE, ELECTRICALSHOCK, PROPERTY DAMAGE,SEVERE PERSONAL INJURY ORDEATH.2. Unplug the wires from the circulating

air blower and the limit control.Remove the two screws and slidethe blower out of the unit sideways.

3. Shine a flashlight on the evaporatorcoil (both sides) and inspect foraccumulation of lint, insulation, etc.

4. If coil requires cleaning, follow thesteps shown below.

Cleaning Evaporator Coil1. Remove screws from condenser fan

grille assembly and lay grille over onthe unit top panel.

2. Remove the controls access paneland the control box cover.

3. Disconnect the outdoor fan motorwiring from the compressor contactorand capacitor. Remove the strainrelief in the bulkhead and pull the fanmotor wires through. Set grilleassembly to the side.

4. Remove the screws that secure theunit top to the unit. Remove the topand set the unit top to the side.

5. The coil should be cleaned when it isdry. If the coil is coated with dirt orlint, vacuum it with a soft brushattachment. Be careful not to bendthe coil fins.

6. If the coil is coated with oil or grease,clean it with a mild detergent-and-water solution. Rinse the coilthoroughly with water. IMPORTANT:Do not use excessive waterpressure. Excessive water pressurecan bend the fins and tubing of thecoil and lead to inadequate unitperformance. Be careful not tosplash water excessively into unit.

7. Go to next section for cleaning thecondenser coil.

Cleaning Condenser Coil, Drain Pan,Condensate Drain, Condenser Fan,Circulation Air Blower and Venturi1. Remove the screws from the

condenser coil protective grille andremove the grille from the unit.Ensure the filter access panel is stillremoved to access all of the screwssecuring the grille.

2. The coil should be cleaned when it isdry. If the coil is coated with dirt orlint, vacuum it with a soft brushattachment. Be careful not to bendthe coil fins.

3. If the coil is coated with oil or grease,clean it with a mild detergent-and-water solution. Rinse the coilthoroughly with water. IMPORTANT:Do not use excessive waterpressure. Excessive water pressurecan bend the fins and tubing of thecoil and lead to inadequate unitperformance. Be careful not to splashwater excessively into unit.

4. Inspect the drain pan andcondensate drain at the same timethe condenser coil is checked. Cleanthe drain pan by flushing with waterand removing any matters ofobstructions which may be present.

5. Flush the drain tube with water. If thedrain tube is blocked, it can usuallybe cleared with high pressure water.

6. may cause inadequate unitperformance.

7. The venturi should also be inspectedfor items of obstruction such ascollections of grass, dirt or spiderwebs. Remove any that are present.

8. Inspect the circulating air blowerwheel and motor for accumulation oflint, dirt or other obstruction andclean it necessary. Inspect the blowermotor mounts and the blowerhousing for loose mounts or otherdamage. Repair or replace ifnecessary.

Re-assembly1. Place the condenser coil protective

grille back on unit and replace allscrews.

2. Place top panel back on unit andreplace all screws.

3. Set condenser fan grille assembly ontop of the unit with the fan on top andthe motor wires on the venturi side.run the fan motor wires through thebulkhead and pull wires through thehole on the bottom of the control boxon the left side and into the controlbox. Reconnect fan motor wires perthe wiring diagram attached to theback of the control box cover.

4. Replace wire strain relief in bulkheadafter the slack is pulled out of thewires on the fan side. This will assurewires will not be damaged by the fanduring unit operation.

5. Turn the condenser fan grilleassembly over and into the recess inthe unit top. Secure the grille to theunit with the four long #8 screwsremoved earlier.

6. Replace the circulating air blower,making sure that all wires are properlyreconnected per the unit wiringdiagram.

7. Replace the filter andblower/evaporator coil access panels.

8. Replace the control box cover andcontrols access panel.

9. Restore electrical power to the unitand check for proper operation,especially the condenser fan motor.

REPLACEMENT PARTSContact your local distributor for acomplete parts list.

TROUBLESHOOTINGRefer to Figures 27 and 28 for determiningcause of unit problems.

WIRING DIAGRAMFigures 29 and 30 are complete wiringdiagrams for the unit and its powersources.

CHARGINGSee Figure 31 through 38 for propercharging information.

! WARNING

23

RPM 734 810

3.0 [10.55] LowMed

886

Med

CFM 1222 [577] 1197 [565] 1179 [556] 1162 [548] 1137 [537] 1097 [518] 1033 [488]

923

RPM 765 810 855 890 920 960 995

Inputs

40,000 [11.72]60,000 [17.58]80,000 [23.45]

100,000 [29.31]

10 x 91/2 HP

3 Speed Motor

959

Watts 423 415 407 397 386 370 351

988

RPM 895 930 965 985 1005 1025 1045

1016

Watts 538 514 493 473 454 434 412

Watts 476 468 450 427 403 380 363

Med

CFM 1674 [790] 1620 [765] 1566 [739] 1511 [713] 1451 [685] 1384 [653] 1305 [616]

RPM

3.5 [12.31] LowHigh

997 1019

High

CFM 1514 [715] 1461 [670] 1415 [668] 1370 [647] 1322 [624] 1266 [597] 1197 [565]

1040 1058 1076 1088 11004.0 [14.07] Low

High

SeeNote

Below

AllInputs

60,000 [17.58]80,000 [23.45]

100,000 [29.31]

10 x 93/4 HP

3 Speed Motor

Low

CFM 1204 [568] 1202 [567] 1191 [562] 1171 [553] 1143 [539] 1107 [522] 1065 [503]

Watts 625 596 567 539 512 484 455

RPM 1085 1094 1102 1110 1118 1126 1134

Watts 699 663 632 604 576 548 517

High

CFM �1843 [870] �1763 [832] 1693 [799] 1627 [768] 1560 [736] 1485 [701] 1398 [660]

RPM 674 707 793 841 896 938 977

Watts 501 489 471 463 446 427 406

Med

CFM 1741 [821] 1721 [811] 1693 [798] 1645 [775] 1583 [746] 1521 [717] 1437 [677]

RPM 891 943 978 1004 1029 1047 10705.0 [17.59] LowHigh 100,000 [29.31]10 x 93/4 HP

3 Speed Motor

Low

CFM 1187 [560] 1174 [553] 1161 [547] 1148 [541] 1135 [535] 1105 [521] 1065 [502]

Watts 743 709 674 640 602 566 531

RPM 1036 1050 1064 1083 1092 1102 1116

Watts 831 801 754 716 682 640 605

High

CFM 2062 [972] 1988 [937] 1926 [908] 1832 [864] 1773 [836] 1684 [794] 1578 [744]

NOTE: On 4 ton models, switch to medium speed for cooling if external static pressure is less than 0.4” W.C. at 230 volts or less than 0.3” W.C. at 208 volts.� WARNING: Observe airflow operating limits if operating in area of airflow table shown in bold.

DOWN DISCHARGE PRESSURE DROP (ADD TO EXTERNAL STATIC PRESSURE)

Pressure Drop—Inches W.C. [kPa] .00 .01 [.002] .02 [.005] .03 [.007] .05 [.012] .07 [.017] .08 [.019] .09 [.022]

Nominal Cooling Capacity Tons [kW] 1.5 [5.28] 2.0 [7.03] 2.5 [8.79] – 4.0 [14.07] 5.0 [17.59]

Minimum Filter Size—Inches [mm] 16 x 20 x 1 [406 x 508 x 25] 20 x 20 x 1 [508 x 508 x 25] 24 x 24 x 1 [610 x 610 x 25] 24 x 30 x 1 [610 x 762 x 1]

CFM [L/s] 600 [283] 800 [378] 1000 [472] 1200 [566] 1400 [661] 1800 [850]1600 [755] 2000 [944]

MINIMUM RECOMMENDED FILTER SIZES

[ ] Designates Metric Conversions

AllInputs

40,000 [11.72]60,000 [17.58]80,000 [23.45]

100,000 [29.31]

10 x 91/2 HP

3 Speed Motor

INDOOR AIRFLOW PERFORMANCE—208 VOLTSNominalCoolingCapacity

Tons [kW]

Motor Speedfrom

Factory

HeatingInput

BTU/HR [kW]

Blower Size/Motor HP [W] &

# of Speeds

MotorSpeed External Static Pressure—Inches W.C. [kPa]

CFM [L/s] Air Delivery/RPM/Watts—208 VoltsSide Discharge—Wet Coil

Cool 0.1 [.02] 0.2 [.05] 0.3 [.07] 0.4 [.10] 0.5 [.12] 0.6 [.15] 0.7 [.17]Heat

TABLE 8. AIR-FLOW PERFORMANCE – RRKA MODELS

24

3.0 [10.55] LowMed MedCFM 1411 [666] 1368 [646] 1327 [626] 1285 [606] 1238 [584] 1183 [558] 1116 [527]RPM 865 900 935 970 1000 1020 1035

Inputs

40,000 [11.72]60,000 [17.58]80,000 [23.45]

100,000 [29.31]

10 x 91/2 HP

3 Speed Motor Watts 498 481 464 447 430 411 391

RPM 980 1000 1020 1035 1050 1065 1080Watts 589 565 543 523 503 481 456

3.5 [12.31] LowHigh HighCFM 1641 [774] 1577 [744] 1515 [715] 1455 [687] 1393 [657] 1329 [627] 1262 [596]

RPM 859 905 951 981 1011 1034 1057Watts 557 530 506 483 461 437 409

MedCFM �1793 [846] �1731 [817] 1665 [786] 1594 [752] 1519 [717] 1440 [680] 1356 [640]RPM 1053 1067 1080 1091 1101 1110 11194.0 [14.07] Low

High

SeeNote

Below

AllInputs

60,000 [17.58]80,000 [23.45]

100,000 [29.31]

10 x 93/4 HP

3 Speed Motor

LowCFM 1412 [666] 1395 [658] 1371 [647] 1339 [632] 1296 [612] 1242 [586] 1176 [555]

Watts 667 637 606 574 543 512 483

RPM 1110 1117 1124 1129 1133 1139 1144Watts 736 715 683 646 608 574 551

HighCFM �1889 [892] �1826 [862] �1753 [827] 1672 [789] 1586 [749] 1499 [707] 1413 [667]

RPM 741 794 858 904 947 985 1021Watts 595 583 564 539 510 484 453

MedCFM 1943 [916] 1895 [893] 1840 [867] 1774 [836] 1700 [801] 1618 [763] 1525 [719]RPM 995 1024 1040 1057 1041 1087 11005.0 [17.59] LowHigh 100,000 [29.31]

10 x 93/4 HP

3 Speed Motor

LowCFM 1388 [654] 1380 [651] 1371 [646] 1351 [637] 1325 [625] 1294 [610] 1225 [577]

Watts 785 751 717 674 643 599 561

RPM 1080 1093 1100 1106 1115 1123 1130Watts 889 884 796 768 725 687 651

HighCFM 2150 [1014] 2072 [977] 1991 [939] 1917 [904] 1820 [858] 1722 [812] 1627 [767]

NOTE: On 4 ton models, switch to medium speed for cooling if external static pressure is less than 0.4” W.C. at 230 volts or less than 0.3” W.C. at 208 volts.� WARNING: Observe airflow operating limits if operating in area of airflow table shown in bold.

[ ] Designates Metric Conversions

AllInputs

40,000 [11.72]60,000 [17.58]80,000 [23.45]

100,000 [29.31]

10 x 91/2 HP

3 Speed Motor

NominalCoolingCapacity

Tons [kW]

Motor Speedfrom

Factory

HeatingInput

BTU/HR [kW]

Blower Size/Motor HP [W] &

# of Speeds

MotorSpeed External Static Pressure—Inches W.C. [kPa]

CFM [L/s] Air Delivery/RPM/Watts—230 VoltsSide Discharge—Wet Coil

Cool 0.1 [.02] 0.2 [.05] 0.3 [.07] 0.4 [.10] 0.5 [.12] 0.6 [.15] 0.7 [.17]Heat

INDOOR AIRFLOW PERFORMANCE—230 VOLTS

TABLE 8. AIR-FLOW PERFORMANCE – RRKA MODELS (CONTINUED)

25

BLOWER MOTOR SPEEDTAPSAfter determining necessary CFM andspeed tap data from Table 8, follow thesteps below to change speeds.1. Remove the furnace/control access

panel.2. Remove the control box cover. See

Figure 23 for location of the furnacecontrol board.

3. Reference Figure 24 for the properlocation of the red and black wireson the speed tap block and on thefurnace control board to obtain thespeed tap you have chosen.

4. After adjusting the wires accordingly,attach the control box cover, furnacecontrol access panel and the bloweraccess panel to the unit.

FIGURE 26FACTORY SET BLOWER SPEEDS W/ELEC. HEAT

FACTORY SETBLOWER SPEED

1.5 TON W/40K HEAT LOW LOW1.5 TON W/60K HEAT LOW HIGH2.0 TON W/40K HEAT HIGH LOW2.0 TON W/60K HEAT HIGH HIGH2.0 TON W/80K HEAT HIGH HIGH2.5 TON/ALL HEATS LOW LOW3.0 TON/ALL HEATS MED. LOW3.5 TON/ALL HEATS HIGH LOW4.0 TON/ALL HEATS HIGH LOW5.0 TON/ALL HEATS HIGH LOW

MODELCOOL HEAT

FIGURE 25

FIGURE 24INTEGRATED FURNACE CONTROL BOARD

HEATCOOL

FACTORY SETBLOWER SPEEDMODEL

FIGURE 26FACTORY SET BLOWER SPEEDS W/ELEC. HEAT

3.0 TON/ALL HEATS3.5 TON/ALL HEATS4.0 TON/ALL HEATS5.0 TON/ALL HEATS

MED.HIGHHIGHHIGH

LOWLOWLOWLOW

26

WARNING!

FIGURE 27COOLING TROUBLE SHOOTING CHART

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

SYMPTOM POSSIBLE CAUSE REMEDY

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

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

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

control opens at 450 PSIG• Interconnecting low voltage wiring damaged • Replace thermostat wiring

Condenser fan runs, compressor • Run or start capacitor failed (single phase only) • Replacedoesn’t • Start relay defective 9single phase only) • Replace

• Loose connection • Check for correct voltage at compressor -check & tighten all connections

• Compressor stuck, grounded or open motor winding • Wait at least 2 hours for overload to reset.open internal overload. If still open, replace the compressor.

• Low voltage condition At compressor terminals, voltage must be within 10% of ratingplate volts when unit is operating.

• Low voltage condition • Add start kit components

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

plate volts when unit is operating.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

27

FIGURE 28

15 SECOND PREPURGE

28

FIGURE 29

29

3 TO

N CO

OLI

NG -

(-)RK

A

SYST

EM C

HARG

E CH

ARTS

FIG

UR

E 3

0

30

SYST

EM C

HARG

E CH

ARTS

FIG

URE

364

TON

COO

LING

- (-)

RKA

FIG

URE

353

1/2

TON

COO

LING

- (-)

RKA

FIG

UR

E 3

1F

IGU

RE

32

32 CM 0206

92-21916-27 rev. 09 rrka 3 phase only gas/electric package...

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