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Air Conditioner

Installation, operation,

maintenance

INSTRUCTIONS for . . .

IIMKrORTAkllT Installing Engineer

LEAVE THIS BOOKLFF WITH THE HOMEOWNER

To the Homeowner This booklet contains valuable infoma- tion and is intended as a pemanent part of your installation. Keep it in a safe ancl convenient location for handy reference in relation to operating and maintenance instmctions.

TO THE lklSTALLER Before installing this unit please read t.his manual to familiarize yourself on t.he specific items which must be adhered to such as correct supply air texnperature, external static pressure to unit and air temperature rise.

Printed in U.S.A. Part No. A3325M

SUPPLY AiR

RETURN AIR

-- -- -- - -- -- -- -- P

UNIT DES

i\-- L K.O. ELECTRICAL UNIT POWER

3#4 MIPS ' DRAIN

(oi All dvctwork should b e desiqned lo handle the CFM which a r e shown in the shaded area i f the unit is to operate on high fire. Ductwork on the EG5 Series should be designed for cooling CFM.

1 Electrical Datax Characteristics (60 cycle;

Weighis (ibs.1 (Approx.? Net Shipping

*IMWRTANT: While t h e above data 1s preserlted as a guide, it is bmportant to electrically connect, properly size fuses ancl condnctor wlres In accor (lance with the National Electrical Code and all ex~sting locai codes

"Type RW" wlre o i equal Operating tolerance minus 5": on 20SV, plcis 10% on 208, 231 and 2 4 0 V , inanus 10% on 230 and 2 4 0 V

(a) Refrigerant charges subject to change Refer to nameplate an unlt

Specificatior~s subject $0 change without notice

3

7.0 THE HOMEOWNER

TRUE CENTRAL SYSTEM AIR CONDITIONING coolingi, healing, dehumidifying and air filtering Yorw new Central System Air Conditioner has been mreFulJy and precisely engilleerecf for top performance even under the most severe conditions. I t has been designed to meet your needs, your pattern of living in your area. ?he air conditioning system has been installed will.: duct work by your specialist. The unit provides cooling, dehumidification and heated air when you need it, and cIons it autolnatically in accordance with yoslr roonl tl~ermostat setting. When cooling is needed, your hozne is filled with cool, crisp and dehumidified air. Dirt, dust and pollen are filtered out and a gentle flow of refreshing air lets you

I 1 live in n. "controlled climate'". 1 As the outdoor temperature goes up and your ho~ne

*quires cooling, the Central System Air Conditioner will. serve you with a welcome and constant Aow of cool air.

~ The thermostat, with a wide range of settings, is your control center. IS is here where you control b b a ~ heating and cooling. The therz~~ltostat may he one of the typical types sl-rotvn. The thcri-r~ostat will give you full control for ""per- sonalized" 'climate. Know the operation of the tl-rermo- stat thoroughly. Here" !-row your CENTRAL SYSTEM PACKAf2E AIR CONDITIONER provides cooling: The Central Systenl Package Air Conditioner operates on a s ~ r p simple principfe. During the cooling cycle, the unit absorhs heat from the air inside your home and transfers that heat to the outside coil. ONE PACICAGE UNIT. It cools, dehunlidifies and beats the air, Inside the unit are two large coils, an inside coil evapcrrator) and oulside coil f condenser), which are inter-connected to the cmpressor. The compressor, which is the heart of the cooling system, causes the refrigerant to flow through the coils. TNSXDE COIT, IEVAPORATOR). A11 inside air in your home is circulated through the fin spacing of this coil. Xt absorbs heat and condenses out the ~noisture from the inside air during the cooling cycle. OUTSIDE COIL r CONDENSER). This coil has outside air Aovirillg through the fin spacing. Outside air does not enter your hon~e through the operation of the unit. The function of this coil is to release heak which is ahsorbed by the rcfrigemnl Aowing through the inside coil. into the outside air.

COQLINiG CYCLE The cooling cycle is a direct expansion system. Liquid refrigerant enters the indoor coil through capillary tubes where it vaporizes and absorbs heat from the air returned fronn the space cooled which is drawn through the coil. The air is cooled and dehumidified and retr~rxl- ed to the space. The refrigerant is expanded into a gas and warmed. I t is then draw11 into the compressor where it is compressed, thus raising its temperature. The gas is cooled in the condenser where it condenses back info a liquid. Tl-re heat of the gas is absorbed by the ntrtside air, which is hlom by the condenser fan illrougtl the condenser coil. The unit operates in response to the rooln themostat.

NlEATlFIG CYCLE

The heating is acmn-rnlishec2 bv an inclirect method. - Gas Aames heat a circulatil~g liquid in the heat transfer module. h pump moves the heated Kquid through tubes in the illdoor coil. Air returned fron~ the space to he heated is drawn across the coil by a blower where iC i s warmed and then returned to the space. The liquid is thus cooled ancl enters the pump wllich returns it to the module to hr reheated. The n2odule is extremely efficient and colmpact using a rrnique rnethod of heahwchange. Thr liquid to bc heated is circulated at a velodty that will give turbu- lent flow in the module tubes for a high rate of l l ~ a t tmnsfer, The burner is designed for high heat reIpas~ with qliiet opemtiorl. It handles a mixture of air and gas. All of tht. combustion air goes through the b~lrner as part of the mixture with no secondary set-ation. The co111bu~- tion A L I ~ gas is expelled under positive pressure and therefore no other flue extension is required. The heat exd-rangr between the solution heated by the module and the circulating air takes place in a fir1 tube coil. T1w sdution circulates through the tubes. Air circulatcs through the fills and ahsorl3s the heat. The cooling evaporator coil has extra rows of tubes to carry the Ileal-ing solution in thc 2, 2.5 and 3 h.p. units. In the 3.5, 4 and 5 l1.p. urlits, tberc is a separate heatii~g coil in tile supply air plenum. The air circulating biower(s) is dired drive with a multi speed P.S.C. motor, The solution is circulated hy a small motor driven wntrifngal pump. The system pressure drop and pump

* are designed and selected to give the proper velocity through thc moclule and fin tube coil for optimum heat transfer. The system operates at essentially atlnospheric pressure. Since the solution expands when heated and contracts when it cools, an expansion tank is provided that is open to the atmoc:phere. This also provides a point where any air that is in {he syste~n escapes during the lreafing up period. Rc-lween cycles, as the solution cools, it is siphoned olat of thc ~xpansion tank hack into the syste~n. The heating solution is a mixture of 509; es~ylent. glycol i with corrosion inhibitor) and distilled watcr. This is an automotive type anfi-frwze and sumlner coolant liquid. It does not, however, cmtain anv ccrrli- c

leak mcal~rml. THIS THERMOSTAT is your colltrol enter for one stage lleating (120,000 or 80,000 btuh illput) and one

*.

st age cooling.

This sensitive thermostat provides you wit11 a wide selection ar~d range of settings. Yot~ call have only the fan operating to circt~late and filter tile air without

iseating or cooling. You can set the thermostat to actuate the heating system only, or set it to control the cooling system only. Cooling and heating can't be on at the same t h e . Before changing from the cooling to the heating seasol? be sure all dampers in the duct sb~stem are correctly positioned. To set the thermostat for your home, you will want to be thoroughly familiar with the settings. Thp temperature control dial should be set to the temperature you desfrr far your home in the cooiing or heating season. The heating and cooling system will automatically turn on and OR to satisfy the setting.

Position selector switches for type of operation desired. Set temperature dial for desired room temperature. The type of system operation for the various switch positims is shown below:

Cooling and healing system remains off regardless of rooin temperafirre. Fan (blower) doe::

IU i'i 13N nrAi no: operate.

Cooling system remains off reuardless of room tempera-

s,.. tuk. Heatino will cvcli on ,". and off according to ietnpera-

Co@l lure dial setting. Blnwer will cycle with heating.

Cooling system cycles to tnain- iain selecied roorm iempera-

c,, lure. Cooling unit fan (blower] operation constant. Heating remains off regardless of roori? temperature.

Cooling system cycles io main-

0 toin selected room temperature. Cool~ng unit ian (blower) cycles with compressor. Heat-

056 ing off.

Cooling and heating systenr off regardless of room temperature. Cooling uni t fan (blower) operotes continuouslv.

The thermostat shown below will provide two stage healing i SO,(K70 input 1st stage, 120,000 input second stage i and one stage cooling. Heating Temperature Control Lever Cooling Temperature

Control Lever

Room Temperature

nermorneter

Coal/Hea* Swiieh

This sensitive thermostat gives you a wide selection and range of settings . . . you car-\ have only the fan

opern"cng to circulate and filter the air without heating or cmling . . . it can be set to act only as a cooling or heating unit . . . or you can gct i t to oy~erak automatically to provide heating or emling as needed to mainbin preset Temperature Cox~trol settings. To set the thermoskt for your home, you will want to be tl-roroughly familiar ivith the settings. Heating Temperature Control should be set to the desired temperature for yorrr home when heating is required. The unit will antomatically turn an and off to satisfy the setting. The Heating Temperature Cm- troi operates the unit only during the heating cycle. Cooling Temperature Control should be set to the temperature you desire for your home when cooling is required. The unit will automatically turn on and off to satisfy the setting. The Cooling Temperature Co11- trol operates the tlnit only during the coding cycle. Cool/Heat Switch. When the "CBOL/HEAT SWITCT-T"' is on the "OFF'" pmition, the cooling and heating is completely shut off. However, you still can use the ""FAN" to circulate air in your home. For completely automatic operation, the "COOL/ NEAT SWITCH" shor~ld be set on "AUTO". On this setting, the unit will either heat or cool whichever is required to satisfy your comfort settings of the two Temperature Contmls. Optional settings: "COOLING ONLY" or "HIEAT- ING ONLY*, Ebv summer cooling, you may want to set the "COOL1 HEAT SWITCK" on position "COOL"" The unit will automaticnliy provide cool dehumidified air as needed. The unit will not cycle to heating as long as the setting is on the ""COOL" position. When the setting is on ""NEATYthe unit will automatically heat, as needed, and will ncrt cycle into cooling as long as the setting is on the ""EAT" positim. Fan Switch. When the CooliHeat switch is set in the "OFF" pmifion, the cooling and heating is completely shut off. However, you still ran me the fan to circulate air in your home by settii~g the fan switch to the "ON" position. FOR MOST EFFICIENT OPERATION. When in the height of your heating or cooling seasons, it is reco~nmended that you do not reset the thermostat for night operation. Once the thermostat is set for the desired temperatr~rcs, it will give you the most em- notnical operation.

RESETTING PROCEDURE - MODULE WRAPPER OVERHEAT LIM1"TCONltRQL

(The entire ~ u u t \v111 become in- opelative. heat~ng or coollng cycle, lf t h ~ c control opens). T h i s conbol 1s morinted on the module Aur gas wmp- per on the opposite stde of ihe ,nodule Aue gas outlet. Its ftmcbon IS to provide oreiheat protection for the heat transfer rnodule 1x1 case ihe solution 1mit eo~>trol fails to funct to~~. It IS n manna1 reset eontml. CATITION: T h i s eontrol sl~ould not he reset rf the solution ts below the safe operat~rlg Ie%{eicl ~x~arked oil the expan- slon t a l k or if a large amount of .;elution rs obvious in the base pnn. THE blAXN ELECTRICAL DISCON- NECT SWITCFI FOR THE UNIT MUST BE PULLED BEFORE THE COPJTROI, I W E S E T -

The following roilipimentl or otaatloixr co?ild cause the contml to open dnd srop ol?emtloii of the uint.

fnol3erat1vr rolotion pump or motor, ~ndoor blower motor, losr of solu- rlol~ or the filtel ( s ) In the leturn alr dnct or return air filter gnllel.;) 1.; blot Lecl 1i1Ch die and rtc~hri- NOTE Kesrl the controt oilly O"16 TIME If the unrt doc$ not con- tmuc h, ( I Q P T . I ~ ~ I ifte~ 50111 have cleaneti the filtei(s), GALL A COhl- PETENT SERVICEMAN TO CHECK OUT TNE UNIT.

WARRANTY Your Warranty Certificate is in the envelope in which the warranty registration cards were remiv~d. Read the Warranty carefully. Note exactly what is covered. Re sure the m d e l , mfg. and serial numbers and installation date are filled in. Keep this Warranty Certif- icate in a safe place so you Gar1 Iind it if necessry. h3anufaeturers Warranty Registration Card. You will find this card in the envelope in which you remived the warranty certificate. Be sure to include the model number, serial number, manufacturing number. date of installation and dealer from svhom purchased, in addition to your full name and address on the return card.

TAKE CARE.. . for top performance

There are some periodic checks you must perform from time to time to assure you of top performance. If you make these cllecks as suggested your eentral system will always serve you with top efficiency. C m A N OUTSIDE COIL. The coil wit11 the outside air flowing over it should be cleaned as frequently as necessary to keep it free of dirt and debris. Be sure you pull the unit electrical switch before starting to clean the coi 1. OIL BLOVITER MOTORS. The bearings on the fan and bImer nlotors should be oiled at the start of each season. The photographs will show you where the oil ports are located. Use SAE No. 20 motor oil. DO NOT USE A DETERGENT m P E OIL, CAUTION: Pull the unit electrical switch before attempting to oil the motors. The motors have a built-in prokction against excessive current or werheating. These safety devices save Inany expensive repairs. CLEAN FILTER. The filter($) are located in your return air duct or in a return air filter grille i s ) , If you have a permanent type filter(s) it should be washed with warm water, dried and sprayed with an adhesive according to recommendations. The frequency which is required for this depends on your locality and usage of the wi t .

DO NOT QBERATE UNIT WiTWOUT FILTERS COMPRESSOR. The compressor is permanently lubricated and requires no oiling. ilDD ETHYLENE GLYCOL, SOLZITION. At the annual inspectiol-1 observe the solution level in the expansion tank, when the unit is cold. I t should be be-

tween one llalf and three quarters full. It inay be necessary to add solution due to evaporation losses. It is recommended tha"rar6Ponf T ~ l a r be used in a 50% mixture with distilled water. Telar is ethylene glycol with a corrosion inhibitor. Do not u3c anttjreesc liq-lids that eoalnirz anti-leak i n g r ~ d k n f s . To add solution proceed as follows:

I. Mix 50% solution. 2. Remove expansion tank cap and cap from top of

unit. 3. Use ?hP"exible tubing and a funnel to adcii solu-

tion. 4. Fill tank to lower edge of upper band. 5. RcpIacc expansion fank rap and cap on the top

oJ ~ J E P unit ccrbinet.

BEFORE 1'017 CALL, YOUR SERVICEMAN. Thcre are several built-in safety featnl-es that may a~itomaticallg shut 03% the unit nnder abnomlal cii~erating conilitions. IC your tiirit should slmt off, here are soime things you should elleek hefore you call the sen,icc~?i;.an:

I. Wait a fcw mimiles (15 to 30 minutes) to see if it will restline operation.

2. Check thennostat to see i f it is properly set. 3. Check fuses on electrical supply in the home. 4. C11eck the filter to ~ c e i f it is clean 5. Pull main electrical switch for tinit (for heating) or lower themostat

setting helow roolii ternI>erature. Wail 5 ~ninntes. Engage electrical switch. Set rooin thermostat to above room tcmper;?ture. Set to heat, fan s\vitch to auto. Gas nus st be on.

6. Reset nloduie flue gawvrapper tempemture limit control. See page 5. SOhIE THINGS YOU SFlOULD DO: Kerp radios, dectric lamp%, or other supez$cinl I ~ m t solrees away from thennostat. Too murll lmat 01% the tliem>ostat will give you false control. Do not rovei- up thenlrostnt. . . . Allow Prcr air in flow- over it. Do not let outside air inlet Io~~vcrs gct hlocked witli shrubs, leaves, or othcr ohjech. A rrce circ~ilalion of air to and from the unit is ahsoltitely necessary. Keep clonrs and winclows cloiiecl when operating unit. You w-ill w live irr a coillrollecl "c)irnate" in tnnperntures just right for your o1%m personal comfort.

COMBUSTION AIR MOTOR CONDENSER FAN MOTOR BLOWER MOTOR EG2, BLOWER MOTOR E63 5, 2.5, 3/12 UNITS 4, 5/12 UNITS

6

DESCRIPTION This unit is a year-round air conditioner. I t col~sists of conveniently located tern~inals. The 24V room thermo- a self-contained hermetically sealed refrigeration sys- stat is an optional item and is not srrpplied with the tern for cooline and a gas fired hvdronic heating svs- unit. . . :< ,?I) ~ ~ ~ i i i ~ i : ~ c .> l ; r .~t rr.~!;cfi>r II~(OCILIIY for l~c.:~tii\c. '1'11t-

s I ~ I I - ! ,K I -- it: ' i.< in! i T: I . : I I \T ql-irl~ni~ . ?~ ld n ~ c , ~ ~ l l t c c j 011 1.111,- I+'iltctrs are not supplied with the unit. Therefore, the ! X I . i - , - t i !,>. =. . \ i r 1.i th( . s t? 11z1ul-(3 i>t.ing co~rclitionc~d filter i s t must he iilstslled in the return air duct or :. t#,'r<tiI,::< rl '1). (':I: l.:tiir l ~ ~ l ~ n v ~ r : ~ ~ i c l i . ~ 11~;1tc<l or co%>lt-(l filter grills I s J . DO NOT OPERA'I'E UNIT WITH- . - 1. ~ ; ~ : i ! . i ( l . . i l l h t : t i lnn ;in<] coolinc coi3i.lcto1.q. r14ny;. O'CJ'I' 2JILTERS.

1 , - I ! : I ? , t 1 ; I o r - - 1 in

RECEIVING 3. The unit must be installed on a level and solid Upon receipt of the unit, the equipment sho11ld be in- platform. Tlte platfortn should be approximately spected for any danlage which may have occurrecl in 6 inches above the roof deck. "ransit, If danlage is obvious, it should be noted on the 4. An angle iron frame or stand of suitable strength carrier's freight hill and a request for inspection and may also he e~nploved to support the unit. settiemeni- of claim lnade at on*. Units are usually 5. It is desirable for the condenser to face away from shipped F.0.B. factory, and it is the consignee's re- prevailing winds. sr~onsibilii-$7 to 61e damage claims. -

AS A REMINDER LOCATEON The unit must he accessible for servicing and gen- The electric-gas package unit is designed for o~~tdoor era1 maintenan=. Consult your local codes for fixed instaliation oniy and mrist not be ilzsta2led in a b ~ ~ i l d - ladders to the roof top when n unit is insblled on IF79 Or ̂P ~ ~ C ~ O S U T C ~ . the roof. The duct conneciiar~ end may be placed as close to the building as Inay be required to make the duct connec- CONDENSATE DRAIN tlons. Adeqtrate dearance must be allowed on both sides of The unit cot~densate drain has a $/$" n~ale X.P.5. outlet

the unit far service access. AiIorri cr rninitrzutn clear- fitting. Connect the drain with 3/1F'' galvanized pipe, Th'' O.D. copper tubing or equal non-corrosive piping,

ante of 30 inchfj: 012 fhf left hand side? of unit i left inchding trap lo oltiain proper condensale flow. TIre hnr~d . . . facing rrnii frnnl conditioned air erzd). This trap will also prevent debris, insects and dirt froln clearance is required to remove the blower assembly in

ca* it has to be serviced. Major service, such as re- being drawn into the return air system- Consult all local codes and orclinanee?; in relation to tine termina- placing a compressor or coil. may require the removal

of the unit top. Therefore, suficient clearance sholalcf tion of tile conder~sate drain p i w . illsunlly it can be

be allowed above the unit. run to an oilen drain.

'The co~ndenser air discharge end of the unit should bc so located to ailow the air to discharge frely and unobstrtlded for a minimum of six feet . . . . this should prevent the hot condenser air from being reeir- rulated. The clearance from the top of the unit 111ust be a minimllm of six inci~~.: or six feet above the flue hood. Building codes dimer in all areas of the countq, Please consrllt- on ail local codes in relation to the distance a unit may be instaltlled fron~ the lot line. etc. It is recommended that g~~t te r s or deflectors are installed on the roof to prevent roof water from shedding on the mit,

OUTDOOR CONCRETE SLAB LOCATION 7 . A level concrek slab extending approximately 6

inches i2eyond the cabinet perimeter, n~ust be installed fo provide a proper support for the unit. The srrrface of the slab must terminate at approxi- rxlatcly 4 inches above the finished grade lirte. The slab should also be so located tvhereby no run-off of water from higher ground can collect srouxld or in the unit.

ROOF LOCAT EON 1. The roof rxust have strrrctural strength to earry

the weight of the unit. 2. Normally, the Building Codes or FHA approved

cmsiruction is adeqtzate when loading is properly distributed on the roof joists or rafters.

PANEL REMOVAL There are four removable panels on the unit, two on each side. Each panel slips in underneath the top and is secured by a Ih-turn latch (cmtrol panel side only, plus latch above the unit electrical irrlet) assembly at the bottom. Each pallel can be removed by turning the latch ttrm (refer to arrow on latch button for locking arm locationj, pull the bnttoin of panel ot~tward and then move the panel do~7rltvard to allow the top portim to disengage from the unit top mver. Reverse procedure to re-install.

SHlPP1NG PROTECTION After the unit has been rrloved into ids proper location and seeulrrd (unit needs to be bolted down only if it is mounted on an elevated frarne), pmcwd as follows:

1. Remove the compressor compart- ment access door and cut the cnnlpressor hold down stmp. Use extreme care when cutting strap; it could easilg back-lash and cause injury.

2. Remove access door which expo~m the indoor hlower. Remove any shipping protection which may holcl t h ~ blower wheels in location during shipping, and the support pad under the blower hous- nng.

3. Attach the vent cap and cover on the door over the Auc outlet with four screws. The opening of vent cap and rover must allow ~ombu~tio~i gases to be discharged uptvard.

MOTE. BE SURE THE GASKET IS LOCATED BETWEEN HTM AND CONDENSER AIR INLET PANEL

ELECTRICAL CONNECRIQNS AND FCISETRQN SIZING All electrical wiring m s t be made in accordance with existing focal codes or the National Electrical Code An electrical power supply plus ground is required from the service box through a fused disconnect to the unit. Refer to the unit nameplate for the Fusetron size. DO NOT MOUNT THE ELECTRICAL FUSED DISCONNECT SWITCH ON THE UNIT becailse the outer case panels may have to be rentoxred to properly service the unit. Be sure both line and low voltage cnnneeticms are made throt~gh weatherproof fittings, All exterior wiring rnust be in approved weatherproof conduit. Low voltage from the unit control panel to the thert~~ostat requires a four wire color coded cable for one stage cooling and m e stage heating. A five wire cable is required for one stage cooliillg and two stage heating. Please refer to the unit wiring diagram for connecting terminal nomenclature (208-230-"4V) and color/number coded control wires for the room thermostat.

DUCT SYSTEM Use a recognized standard method for calculating heat loss and heat gain, room by room, as a basis for dcsign- ing the duct system. ARI 230, NESCA Manual J, or the ASNRAE Guide and Data Book illustrade sucl.3 methods.

approved as a Class I Air Dt~ct wit11 a minimuin wall thickness of I" and a 32/1 pound density.

5. Other recommendations for proper ductwork de- sigrt ar~d installation are as fallows:

NOTE: It is not rctbotnmc~ndrd th:~t two unit\ dih charge thc supply a ir into :I common dutst. E:~t.t\ unit should late its own hupply :lnd rcturn air duct systt-nt

a. When ducts have insulation internally, the duct size m s t be increased by two thick- nesses of insulation. All seams and joints shall be airtight, smooth fitting and taped.

b. No abrupt increases, decreases, oEfiets or 90" t t~ms without turning vanes.

c. Large ducts sliiall not have dimensions where- by the larger dimensions are greater than 4 times the sllorter dimensions, Stiflenil~g of ducts should have standing seams or addi- tional reinforcing angles.

cl. Air velocities in maill ducts for residential applicatio~il should not exceed 1000 FPM a11d for branches 840 FPM.

e. Branell ducts must have volulne control dampers, with outside locking devices, to ab- low the system to be properly balanced. Be sure to use proper take-off fittings for 13ranch runs.

f. Supply and return air grilles must be of suf- ficient size, llumber and location to prevei~l objectioi~able drafts, plus providing balanced air circulation.

g. Supply and return air branch ducts shall have a

a min^imum dimension of 6'9o11nd or ewal. h. All ductwclrk must be supported with rnetal

straps to pwvent sagging. 6. An asbestos clot11 connection should be employed

on both the supply and retmn air duct 21; the unit. AJI connections to t l~e tlnit must be weather tiglilt.

7. The duct installation shall be adjusted to obbin a

in the ductworE.

D U C T W O R K BlUSULAlFlQN Indoor supl3ly and ret,um ducts exposed to near outdoor temperature must be insulated wit.t7 a minixnurn

The following generd considerations should be taken into account:

I. The unit should be as close as possible to those areas which are to be conditioned.

2. A11 duct cvork exposed to the weatl~er and where attached to the duct connections on the unit must be sealed rain and weather tight.

3. The m r m air supply duct from the unit through a wall fabricated of combustible material must have a clearance of one inch. A sheet nletal il~imble must be installed to provide the correct clearance. One inch of fiber glass may be employed instead of the one inch clearance; however, weather and waterproof itlashing must be installed on -the exterior wall to the duct.

4~ If fibrolls glass ductwork is used, it must be TJ.?;.

of 2'~ fifibrglas or equal. Ductwork exposed to the outdoor elements must have two inches of insulation arld a weatherproof barrier. Inside ductwork within the conditional space may be insulated wit11 $4" fiberglas internal or externally with a vapor barrier, Vapor barriers, such as aluminum foil, or equal, shall lap a minimum of three inches at all longitudinal and butt joinls. These joints must be securely sealed and stapled. All punctul.es, tears, or imperfections in vapor barrier must be patched with same material and adhesive. Ductwork in or below a slab Aoor mt~st be eon~pletely encased in not less than 2 inches of concrete and shall be insulaited and vapor-sealed in addition to the slab perimeter insulation. Insulation shall be a lni~limum of 1". one porind density, fiberglas or qual .

All insulating must be perforzned in a workmanlike manner and installed in a fashioll as recommended by the manufacturer of the insulation and vapor barrier manufacturer.

FILTERS -. [ D O N O T OPERATE UWlT VVlWWOUT AIR FILTERS) Air filters are not supplied with this unit. Air filters must he installed behind the return air grille(§) or pros;isians must be made in the return air ductwork for filters in an accessible loratioxl where they may be readily changed. Refer to unit specifications on page 3 for recommellded filter size.

ELECTRiCAL W I R I N G All wiring to electrically connect the ullit must con- fom to the National Electrical Code and all local existing codes and ordinances. A wiring diagram is f~~rr~ished wit11 each unit which illustrates the inters-lal wiring. It is lwated on the unit control panel cover.

NOTE: A gr0~112d toire must be connected to the ground lernzinni of tthc unit control panel' and rozrted fa n defirrifc grouizd,

ALUMlNUM CONDUCTOR, FBELD WERING Install the electrical concluit to the package unit into the appropriate knwk-out and size wires in accordallce to the National Electric Code and/or the existing local codes. When using afurninum conductors proceed as Gotlo\vs:

1. Select the equivalent aluminum wire size from the tabrzlation below:

C o n n e c t o r T u o e and size

2. Attach a length t 6" or more) of recommended size copper wire to the unit coznpressor contactor terminals L1 and L3 for single phase, LI. L2 and L3 for three phase.

3. Splice copper wire pigtails to aluminum wire wit11 U. L. recognized connectors for copper aluminuli-r splices. c See hbt~lation). Please exercise the following instructions very carefully to obtain a positive and lasting connection: a. Strip insulation frorn alruninum conductor. b. Coat the stripped end of the aluminum wire

with the recommended inhibitor (See tabula- tion below) and wire brusi~ alun7inun-r s~~rface through inhibitor. @ e Clean and recoat aluminum conductor with inhibitor.

d. Make the splice using the above listed wire nuts or split bolt connectors,

e. Coat entire connection with inhibitor and wrap with electrical insulating hpe.

INHIBITORS: Brundy - Pentex "A: AAlcoa - No. 2EJC; 7' i?i B -- KOPR-Shield

Warranty void i f connections are not made per above instructions or label on ur~it. For additimal infoma- dion refer to sli~cet on field wiring of aluminum wires. furnished with unit.

R O O M THERMOSTAT " n ~ e room thern-rostat must be located in the spa= to be air conditioned. It should be approximately 4 feet above the floor and must not be subjected to cold or war-m air frorn tile supply grilles or exposed to the sun or superficial heat and wdue vibration. P leas refer to the installation instructions of the room thermostat for more explicit information.

R O O M THERMOSTAT HEAT ANTICIPATOR The 17~512 anticipator in the room thermostat must be adjusted to obtain the proper number of heating cycles per ljoilr. For one stage eleating the heat anticipator must be set at .'7 amps. i TSlF and Q539A 1 . For two stage 11eating the first stage heat anticipator must be s r t at .55 amps. The second stage anticipator setthlg must he .I5 allws. i T872 ) .

GAS CONNECTIONS Local codes and the National Fire Protection Associa- liw Code (PU'FPAB4) must be followed in installing the gas piping. Size t h ~ gas piping using the infor~~~aiion on page 10. When two or more appliances are connected to the same supply, znake a system layotit and size to give adequate capacity in each branch Never use a pipe smaller than *Aff I.P.S. or y8" 0.D. semi-rigid tubing. Use proper pipe "t~read cornpound resistant to liqtlified petroleum gases on a11 threaded joints. Locate a grotmd joint mion just outside the unit axld a sl~ut otifl w l v ~ in a convenient locatio~l (within 6 feet) between the meter and the illlit. When a new gas piping system is placed in service, it should b teskd for tightness under pressure. After the gas is turned on a leakage check shall be made with the mekr. Look for Ieaks ttsing soapy water and a brush. NEVER USE A FLAME. After piping has been checked, purge a11 air fron~ t l ~ e system.

PROPANE UNlT CQNVERSiONl KITS MNKS AND PIPiFJIG The unik referred to ix-r this manual are n~anufactured for operation on natural gas. To operate the units on propane . . . . . a eonvers2on kit must be field installed. Refer to installation ins"tuctions supplied with kit. All pmpane gas qnipment must conforln to the safety standards of the National Board of Fire Underwriters

See NBFLT Manual 58). For satisfactory operation, propane gas presstxre must be 11 inch W.C. at the unit valve inlet under full load. Nlaintainhlg proper gas pmssure depends on three xnain factors:

1. Vaporization rate, which depends o~a ( a ) k m p r - ature of the liquid, and ( b ) "wetted surface" area of the container or containers.

2. Proper pressure rclgulation. ( Two-shge regulation

is recommended -from the standpoi~~t of bo& cost CT = 0.o. size Copper Tubing

and efificienq. I.P.S. = B I B C ~ Iron Pipe Size

3. Pressure drop in lines between regulators, and *These two tables are meant to be a

between second stage regulator and the appliance. Fo"fur"@""nformaiion refer to NFPA Manual No, 54"

Pipe size required will depend on length of piise run and total load of all appliances.

Complete information regarding tank sizing for vapori- ~at-ion, recommended regulator settings, and pipe sizing is available fro111 no st regulator manufactrrrers and t.P gas suppliers. Pmpam is an excellent solvent a ~ l d special pipe dope must be ~ ~ s p d wllen assenthling piping for this gas as it will qrricBIy dissolve white lead or most standard tomti~crcia~ compounds. Shellac base compounds sr~ch as G:~solac, Stalactic, Clyde's or Joi-rn Crane are satisfactory for this type of gas. Please refer to the following illustration for typical ~~"ropane gas installations.

PLUMBING Proper sizing of gas piping depends 0x1 the cubic feel per Itour of gas flow required, specific gravity of the gas and the length of the run. ""ANSI Installation of Gas App1isnec.s and Gas Piping'" t Z-27.30) should be fal- low-ed in all cases unless superceded by local codes or gas company requirements. Connect gas supply to u ~ ~ i t gas regulator/valve. The piping to the rrnit must jnclucle a manual service shui- off valve and a clrip leg. A union of the grou~lcl joint or Anngr type nus st he installed between the manual sllut- off valve and the urlit servo regulator gas valve. Tight- en connecting ?&" nipple or pipe into the rxnit gas valve with a pipe wrench and a parallel jaw wrencll olr the valve lrex. DO NOT APPLY FORCE THROUGH THE VALVE BODY. Check all connections for leaks wher~ piping is corn- plekd, tising a soap solution - never an ope11 flame.

PPESSURE HERE VARIATION I O W T

11" WATER COLUMN

00 OVER 20 PRESSliRE MEPF l i t THE ',ME

OPERATIONAL INFORMATION

SECOMO STAGE REGULATOR

% 1 a , , - - _ - _ . 1 1 , P 1

I

j -- -

CQOLING A transformer supplies 24 volt pourer to operate the control systern. The roon-r thermostat selector switch is lnaz~untly set lo "COOCa and a second switch set on ""AUTO" operates the air circulating blower with the compressor on cooling. Setting the second switch on "ON" gives continuous operation of the air circi~lating blower. A rise in temperature above the ther~noskt setting places the cooliltg cycle in operation. The contactor is closed by colnpleting the 24 volt circuit throllgh the room thermostat. The contack close the high voltage circuit to the compressor, condenser fan, ancl air circulating blower, Also, it mag

TO GPPLIAWS

VENT TURNED _------ ~- G O W N W R D

COOLlNG BLOWER SPEED

*Line Sizes, Tank Regulator To Building Regulator

125,000 BTUH

50 CFH

3 ~ " O.D.

250,000 BTUH

100 CFM

-Low Speed when compressor IS not lunnlng

actuate the fan relay to change the air circulating blower speed. The compressor has an internal overload built into its motor windit~gs. This control will break the power to the colnpressor in respmse to an overload or excessive motor temperature. Solme compressors may also have e x k r ~ ~ a l overloads. While not a control, the compressor has a crmkcase heater tltat is "on" at all titnes when the power is on. This protects the comppssor by keeping the crankcase warrn so that refrigerant will 11ot go into solution wit11 the oil.

Coppel Tubing

-8'' O.D Copper Tubinn

Copper Tub~ng

Is" O.D. Copper Tublns

Jn" O,D, Copper

?k" O.D. Copper Tubing

3a" 0.D Copper Tubing

'he' 0.D Copper Tubing

"Line Sizes Second Regurator to Appliancejs)

The same 24 volt transformer which ersergizes the cooling col~troX circuit powers the heating control circuit. The room tl-rerrr~astnt, when set on " 'HEAT, actuates the heating syskm whenever the room temprra"cuw falls bclow the temperslr~re setting, Tliis closes the 34 volt circuit to the heatix~g relay and the DST i Direct Spark Ignition, cmtrol system. When the heating relav contacts close, thev in turn -. energize the co~nbustion I~lower and water pump motors. The fan stat. cont,rols the operation of the ilsdoor blower molar, is mountecl 01s the irldoor

ODULE WRAPPER UMIT CONTROL coil tube shcet and closes on a temperature rise. T l ~ e AL RESET BUTTON fan stat will n~onitor a combination fin, tube and solu-

tion temperature. Therefore, when the solulim temperature reacl~es al3proxirnately 130"1", Lire fan stat will clcrse and start the indoor blower mot.or at. a pre- deiemined speed. See below.

T l ~ e DSI control performs several functions. I t operates t.he gas valve, supplies a higls tension spark for ignition alld n~onitors mrnbustim. I t will close the gas valve if a f arne is not established axzd maintained. The DSI cont:~ins a step up transformer, an electrolnic

SIDE VIEW, CONTROL PANEL SIDE

SIDE VIEW, HEATiNG MODULE SIDE

module, an ignition transformer and capacitor. The direct spark ignition is provided by the step up transformer which powers a pulse generator circuit in the module. The ignition transformer increases thc volbge to 39,000 volts ( peak for the spark igniter. The electronic module also pcrvvers thc flame rod. A circ-uit is coml~leted, through the Barne to ground, W ~ F " X I

the burner flame is established. This current Aow mainhins the safety lockout .timer in 111c reset or nornlal o ~ r n l i ~ l g condition and interrupts the spark ignition circuit.

CAPILLARY

The Gas Valve is built especiaily for the heat transfer module, I t must be powered only hy the DSI. It does not operate an a 24 volt circuit. It is of servo valve- regulator construction and listed for operation dokvn to -40'F. The valve regulates at a negative pressure and is non-adjustable. This ineans that the combustion blower must be running and imposing a vactlum on the gas valve outlet for i t to open ancl permit the Aow of gas. This method proves combustion air flow. The comblistion blower assembly col~sists of tile blower. motor and inlet chamber assembly. The gas mal-ri- fold pipe from the valve-reg-~~la"tr and a short air inlet pipe both extend through the wall of the inlet chamher and are uyelded in place. An orifice plate is bolted in place over the ends of the two pipes. The snlialler orifice- meters the high fire gas and the larger orifice meters the supplementary air required for high fire. This orifice plus the low fire air orifice in the disc at the entrance of the inlet chamber control the high fire air. A solenoid operated damper plate rests on the orifice plate body assembly. This covers the air orifice opm- ing and restricts -tile gas orifice to a smaller opening. The plate is d o ~ ~ n in the lotv fire position so that air is drawn througlr the low fire air orifice and gas through the low fire gas orifice in the damper plate. The rlnir always starts with the damper plate down on Jow fire. If the solenoid is energized, the damper plate is lifted opeiling the high fire air and gas orifices. The orifices on either high or tow fire meter the proper pro- portions of gas and air, changes in combustion blower speed because of voltage variation or any other variation in blo\ver capacity have very liltle eRect on the combustion mixture since both gas and air enter the inlet cham\,er at essentialiy zero pressure. The gas and damper body assembly must be changed in converting fronz natural to propane gas. The fan stat will keep the indoor blower r~~otor in operation, after the room thermostat has lreen satisfied, until the fins. tubes and air cools to a predetermined tem~crature. This elinlinates to some extent the blow- ing of cool air from the air distribution system. The solution limit control feeler bulb is immersed in one of the heat transfer module tubes. It has t~zo sets of cmtacts ' one normally closed and the other normally open). The control itself is mounted on the center bulkhead directly above the DSI (direct spark ignition combustion control). Tf the solution is overheated because of dirty air filters, indoor air circulating blower motor failure, loss of solution. reduction of pump- ing rate or any reason for high solution temperature, tlte one set of contacts in the solutiol~ limit control will open. This in turn tviil open the circuit to the and in turn close the gas valve. The other set of contacts will dose and keep the solutio~l pump plus the combustion blower n-totor in operation. The gas valve will ren~ain closed until the solution temperature has been Io~~ered apprmimately 100°F. The indoor blower nlntor will also rtln if the room thermostat FAN switch is set to ON or the fan stat is closed.

a. The heating relay contacts close, thusly starting tlie solution purnp and the cornbustioa-r air blower.

b. The DST control energizes the igniter (spark plug) and opens the gas valve.

Immediately tlpon burner ignition the flame rod ter- minates the trial for ignition period t by resetting the safety lock-out timer) and discontinues the ignition sparh. The DSI syslein and heating relay are de energized when the room thermostat heating circtail is opened Tf-ris in turn closes tlte gas valve. However, the indoor air blower x~~otor will continue to operate until the fan stat contacts open iapprox. 95'F 1. The second heating stage is actuated when the second inercrrry tube contacts close. This in turn energizes the "rime delay relay. The tir-rle delay relay contacts will close in approximately 40 seconds and energize the ilig't~ fire solenoid. Tllis in turn carlses the l2igl1 fire damper plate Lo be pulled upward and, thereby expos- ing the higl-r fire air and gas orifices. t Kring rate 120,000 BTUH , . The illdoor blower motor speed automatically changes to high sl?ieed. ( Except EG5/ 12 Series, blower operation stays on low speed). Whel~ the seconcl stage I-reating mercury tube contacts open, the I-righ fire solenoid will be de-energized in ap- proxiimately 40 seconds, causing the system to operate at the 80,0110 BTLTH rate and the indoor blower motor returns to the lower speed. The firing rate stays at 80,000 BTUH until either the first stage heat mercuw tube colltarts open whicll in turi-r de-energize the BST, heating relay, etc.), or the second stage l~eating mercury tube contt~cts reclose to bring the unit had< to the high fire rab. The systen~ is fail-safe should any malfrtnction or component failure occur. It will either not, start or will sl~ut down as show11 in the shaded areas of the sequence of operation diagra171. The servo-regulator gas valve cannot open until it is energized ancl the comhustio~i air hlower is in operatlim and draws a negative 13resslare on the gas orifice and manifold.

PLACING IN OPERATION FQR WEAWNG There will he air in the gas supply line after testing for leaks on a new installation. Therefore, the air must be bled from the line by cracking open the grouncl joint union until pure gas is expelled. Tighten u~~ioaa and wait for five minutes rlntil all gas has been dis- sipated in the air. BE CERTAIN THERE IS NO OPEN FLAR4E I N THE VICINITY DURING AIR BLEEDING PROCEDURE. The u11it is placed in operatiola by closing the lnain electrical disconnect switch and opening the gas valve. The gas valve control knob i s located under the plastic weather cover.

HEATING CQNf ROLS SEQUENCE QF OPERATION Refer to the sequence of operation diagram. With the thermostat set on NEAT and the fan lever on AUTO, the sequence of operation will be as follows: When the heating contacts on the roam thermostat close c rlpon a drop in temperatul-e) three functiol~s are performed:

This cover must be replaced after the unit is in opera- 1 minute to let the safety switch reset. I t may take tion and has k e n completely cheeked out. several cycles before the flame is established. Turn the room tl~ermostat setting to a point above the The unit must stay in operation for several minutes room temperature, set: the =lector switcii~ to HEAT before lowering the thermostat setting for shtlt off after and the fan switch to AUTO. The solution ptlmp and the initial start-up. The air circulatixlg blower should

j con~bustion blonler motors should a11 start. There k e p running after tile heat transfer mdule is OR, 1 probably is still some air in thc gas supply line if that is, until the fan stat conhets open. Put the unit I I ignition dws not take place. The t ~ n i t will shut of3 through srveral cycles of about 3 minutes cm and 5

in about 15 seconds. I t will he necessary to lnove the minutes off. The resultant expansion and contraction I r m ~ n thermostat system selector switch to OFF or of the solution will expel any air that migllt be in the

1 ciisr~gage the eIeefrieal disconnect switch for at least system.

HlGX AND LOW FIRE DAMPER PLATE OPERATION

LOW FIRE (80,000 BTUH) (Damper Plate Down)

HIGH F I R E (120,000 BTUH) (Damper Plate Up)

TVPlCAL THERMOSTAT AND UNlT 24V WilRlNG HOOK-UP

r Wl.-- - ..i ' I

EG i y ---! 1 un,, : I G - - - - - _ _ - -

W2

One Scge Heal (6RCOO STUH) one 4 s g c coo:

L 6 - - - - - - - - - 2 One Sraoe Near (120.009 %TUN) One Siagr Cool

From / EG

Two Stage Heai Clne Siage Cool

SERVICE PROCEDURES HEATING

lMPORTANT spark to cut-OR. Tliis should be fro111 9 to Before servicing this rtnit, be completely familiar with 3.5 seconds, After ignition spark cut-OR, the unit wiring cliagmm and the Sequence of Heating manually re-open gas valve. No gas should Operation. Please refer to heating sequence diagram flow to the burner. This can best be ob- on page I?. FOR MORE EXPLICIT INFORMA- served at the gas meter. TION REFER TO THE SERVICE MANUAL. d. Tlie systern will rernain in lockout until the elec- The various control components cannot be repaired in trical system is reset by adjusting the room ther- the field and tl~erefore must be replaced, However, the lllostat to the OFF and AUTO position or p~~ll ing emtrols can be checked out electrically to ascerhin the electrical discon11cct switch. Wait one minute, which one is defective. Check out the following before then trim system on. Normal ignition should a restart or a performance check is ntade: occur.

1. Make certain all wiring connections are clc:~n, dry e. VGThen the unit has been in operation for five min- and are not grounded or shorted. Be sure tlie utes, lower the room thermostat setting to below porcelain insulator on the Aarne rod and igniter roonl temperature. The gas valve should close. are clean. The heating relay sltould open and the con2bus-

2. If system is energized but in safety lock-out (call- tion hlower plus the solution pump should stop. ing for heat and burner is off?, proceed as follows: The air circulating blower should continue to

' a ) Set room thermostat systenl lever to OFF operate until the fan stat opens. The air leaving and fan lever to AUTO, or pull the dis- the unit will be approximately 95°F. If the gas connect sjvitch in power supply, valve doesxi't close, c11eck the colitrol wires, heat-

ing relay contacts and the wiring on the room l b> Wait one minute. This allows the elec- thermostat.

tronic network in the DSI control to If the indoar k12ower continues to operate and the ""drain" and reset to the starting condition. heating circuit checks out (check therlnostat fan 3. Makc sure that service cock in gas supply line selector switdl . . . "'ON"' blower operates con-

and maxlual gas cock in the automatic gas valve tinuously. on "AUTO" bblwer should stop) . . . are turned to the ON position. check if the fan stat contacts remain closed by re-

1. With thermostat OFF, close discorl~lect switch in moving one wire from the fan stat. This should line voltage power supply. Use an AC voltmeter drol3 out t11e fail relay. Refer to wiring diagram. to check for pourer at L,I and L3 terminals (230 If the room thermostat is manually lowered, open- volt range) on compressor contactor. Check for ing both first and second stage contacts in the power across the secondary side of the unit trans- mercury tubes. and if the indoor blower motor forn~er at 1-2 on the thermostat terminal strip and has not come 0x1, the solution "iemperature may at a BK-1 wire on the 24V terminal strip. 124 volt rise with a resultant of oper-ring the limit contml range). If line voltage is 2081240 and no low contacts i 1 and 3 and closing I to 2). The clas- voltage, replace transformer. ing of conbets I ar-rd 2 causes the heating relay

RESTART AND PERFORMANCE CHECK Start system by setting room themostat to FTEAT position and the temperature control dial or lever to above room temperature and fan switeIi to AUTO. Observe systern response as follows:

a. Solution pump and combustion blower should start. If they do not, check the heating relay to make sure it is '"filling in" and the circuits arc completed to these co~?.rponents. If the gas valve does not open, jul11pm across the limit control contacts 1 and 3. This controls the law voltage circuit to the DSI conk01 whic11 in turn powers the gas valve. If unit starts, replace control.

b. The igni.tion spark plug shotxld produce a high voltage spark (an a~ldible sound can be noted). The gas valve should be energized sin1ultaneousily. Tl~is in turn should ignite the gas in the l~eat transfer nlodlale within 4 seconds.

c. Cheek safety loclrout as follows: i I) Disengage the electrical disconnect switch

and manually shut off the gas supply at the automatic gas valve.

t 2 ) Engage electrical disconnect switch and simultaneously start timing. Determine the number of secmds it takes for the ignition

to start the solution pump and the combustion blower motors. A power failure (wl~en the unit is in operation) can possibly create the following condition: The residual heat build-up in the heat transfer module could cause some of the sdution to Aash into steam and drive a large quantity into the expansion tank. TE the tank overflows, only the excess solution will be discharged and it should not be necessary lo add solution. The pump seal may also open and discharge a slnall amount of solution. However, the seal should reseal as soon as the heat transfer module cools.

f. If a malfr~nction occt~rs, either the burner failing to igl~ite, or igniting and then going out. a component check must be made. A flame-out and safety lockot~t can occur during operatio11 if there is an interruption of the gas supply.

COMPONENT" CHECKS IMPORTANT

I. If any co~~dit ioi~ exists which wiX1 cause thc system to go into sofety locfiorrt, meter readings iex- cept co~rtrol circuit TI and ground 2-2-V) must be taken qllickly after restart; that is, within the trial for ignitio~r period.

2, Always de-energize the system for at least one

b. E L E C T R I C A L CONNECTIONS, SHORTS, LEAKAGE: Electrical connections at flame rod and DSI must be clean and tight. The leadwire nlust be replaced if it is da~naged or deteriorated. Use only 14 to 18 gauge wire which is lnoisfure resistant and has thermoplastic insulation with 105 C minimum rating.

SPARK IGNITER 1. Examine spark igniter for conform-

ance with the following requirements:

a. Spark gap must he 3/16 inch. Check and adjust by carefully bending the angle tip of outer

ground) electrode. Do not exceed 3,'16 illch gap.

b. Check porcelain for craeks or dirt that can cause a path to ground.

2. Ignition cakde lnust not be in con- 3/16

tact with any metal surface. Con- neetioils to stud terminal on DSI System Control and on igniter milst be clean and tight. Replace cable if damaged or deteriorated.

3. If there is no spark c or weak spark) after corn- pletion of the above steps, recheck for satisfactory power output to the spark ignitiorl circuit at the DSI System Control before replacing the spark igniter.

I I I

COMBIlUATIOIU GAS CONTROL 1. This unit is equipped with a negative pressure

regulating gas valve of a specific type. See information below in regards to replacement of valve componenk. If the gas valve does not open Lo admit- gas to burner and power was proved out between terminals 3 and 5 t 9v DG i of DSI Sys- tem Control, check the gas valve operator coil as follows:

a. Disconnect the gas valve operator leads tRD-5 and BK-3) from terminals 3 and 5 of the DSI System Control.

b. Using ohmmeter, check between valve leads for open circuit in the valve operator coil. If coil is open replace the entire gas valve.

I

I c. Refer to page 30 to check negative rnanifold pressure and rating unit.

THIS IS A NEGATIVE REGULATED GAS CONTROL. IF SERVICE IS REQUIRED, REPLACE WITH SAME MODEL NUMBER

DEVICE ONLY. INDIVIDUAL REGULATOR AND OPERATOR

COMPONENTS ARE NOT REPLACEABLE

LOW-HIGH FIRE DAMPER (for checkout with a two stage heating thermostat)

To check out the low and high fire damper operation proceed as follows with the thermostat setting below room temperature and the unit off:

1. Move ther~nostat setting to a point which is five degrees above room temperature. The unit should start normally. t80,000 BTUH firing rate.) In approximately 40 seconds the solenoid on top of the inlet chaxnber sl~ould operate and lift the damper plate off the orifice plate approximately M".

2. If the soleltoid does not function, check to see if the time delay relay is recriving 24 volts power. Furthermore, check to see if the relay contacts are closecl to provide 230V power to the solenoid. Tllese checks will determine if these components are functional.

3. If the damper plate dws not Lift to its full height or the solenoid is energized and the damper does not lift . . . check the linkage assembly.

4. To check out the low fire da~nper operation . . . . prtlceed by removing the cover from the room tli~ertnostat.

5. Carefully lower the room temperature setting uiltil the second stage heat mercury tuhe contacts open; however, the first stage heat mercury tube cot~tncts must remain in the closed position.

6. With the mercury tubes positioned as explained in par2lgraph 5, the damper plate sl~ould drop in approximately 40 seconds. The burner should eon- h u e to opet;?te as long as the first stage heat mercury tube contacts are closed.

7. The burner will go off when the contacts of both heating mercury tubes open; however, it still will take ahout 40 seconds for the damper plate to drop when the thermostat is adjuskd from high fire to a call for no heat.

MODULE HEATER The module llieater is strapped to the bottom portion of the heat transfer module. I t has a 40 watt element and is energized from L1 and L3. With power ON check as follows:

1. Using a vdtmeter, measure for lille voltage on ter~ninals L1 and L3 to lvhich the heater leads are connected.

3. No volt-age indicates blown fuses, bad wiring to heater. Repair or replace wiring.

3. If voltage is present - tur11 power OFF and disconnect heater leadwires.

4. Using an Fihmmcter, check heater co~~tinuity - should test conti~tuous. If not, replace heater.

SEQUENCE OF T W O STAGE HEATING OPERATION DIAGRAM r I

Thermostat Fan Switch Set to "AUTO" Blower Motor Cycles

With Fan Sta t

De energ~zed Thermostat 1st Stage Heattng Contacts Open, DSI

System De energ~zed, Gas Valve

Gas Valve

Heatrng Relay Contacts

Combusiton Blower and

Solution Pump Continue to

(a) For motor $pee<s, refer to page 11 'Except EG5 37 (low ~ n l y )

Operate

Solution Cools, Module Limit Resets and

System Goes into Normal Ignrtlon

Cycle

ELECTRICAL CHECK CAUTION DO NOT SHORT, TERMINALS 3 AND 5 ON THE DSI IBLACXC BOX) CONTROL OR THE GAS VALVE TERMINALS. A DIRECT SHORT WILL BLOJV AN INTERNAL FUSE. THE DSI CANNOT BE REPAIRED I N THE FIELD, REPLACEMENT OF T H E CONTROL I S NECESSARY.

DSI SYSTEM CONTROL

~ D I S C F N N E C I -..,..-LEADWIRE AND CONNECT TO SLACK METER LEAD (-1

SPARK IGNITER

17

T E FACTCPY FOR 240Y M U T I O N FOR LEAD NO I4 AND TAPE IT'S FEMALE

I EXACT REPLACEMENT WRTS MUST SE USED WHEN SRVICIM: ,

UNIT WIRING DIAGRAM MODELS E62/ "12-1 --- MFG. NO. P55 198-1 3C TEC, E62.5,'12-1 --. MFG, NO. P55198-1 rlC TEC,

P55 198- l6C COPE, P55198-17(% COPE,

i i D55299 REV. I 1 -

UNlli WIRING DIAGRAM MODEL E 6 3 j 12-1 - MFG. NO. P55198-15C TEC.

P55198-18C COPE,

F 855300 REV. 1

@%SIT WIRIAlG DIAGRAM MODEL EG3,5/12-1 K - MFG. NO. P551W-44C TEC*

955 199-49C COPE.

UNfT WlRlNG DIAGRAM MODEL EG4/12-1 - MFG, FJIQ. P95199-45C TEC,

1 055305 REV, I

UNIT WlRllrlG DIAGRAM MODEL EG$/12-1 --. MFG, NO, P55199-5CIC COPE.

i -- - - - - -

LEAD UO 14 AND TAPE IT'$ FEWLE CONNECT IN PLKE OF LE.2D NO 14

UNIT WIRING DIAGRAM MODEL E64/ 12-3 - MEG, NO. 1P55199-51C COPE,

-- . . . .- -. - ... . -

LEAD hh3 14 ANiD TAPE IT'S FEMALE

r 1

7 - 1 055W3 REV. I

1 WTES i THE RED DOT ON THE COMPRESSOR RUN CAPACITOR MUST BE LOCATED AS S W W / 2 THE UNIT TRANSFORMER IS RATED 208 240124Y AND IS CONNECTED AT TNE FACTmY FOR 240Y OPERATION. FOR 208 V CFERATION ON UNITS RATED 2@V, DISCONNECT TRmNSfORMER LEAD NO I 4 @W TAP€ IT'S F E M L E TEPMIt4AL FEMOVE TAPE FROM FEMALE TERMINAL LEAD MO H2 AN@ CONNECT IN P L X E OF LEAD N@ I4

3 SEE ELECTRICAL IhF08NATION ON UNIT MODEL NAMPLATE FOR MAX FUSETRON SIZE FIELD CONNECTIONS OF

UNlT WIRING DlAGRAM MODEL EG5/12-1 - MFG. NQ. P55199-476 TEC,

UNiT W I R I N G DlAGRAlVa MODEL EG5/12-1 -.- MFG, NO, PS5199-52C COPE.

EXACT REPLEEMEMI' PARTS MI1ST iiE

lJNl"FV\IIRING DRAGRAM MODEL EGS/12-3 - MFG, NO" P55199-53C COPE.

CHECKING FlRING RATE In order for this unit to operak as it was designed to, it ms~st ]lave the correct size gas pipe installed to it. On Propane gas operation there sho~lfd be dual regulation of gas pressures i one regulator at the tank and one loeatecl prior to the clistribution piping lo the appfi- ancr 1 s i . With Propane it is very importarlt to have the correct size pipe Crcrnl the tank regulator to the second regulator pllis correct pipe size to the appliance ( s) . Xnpui to this unit should nexer excwd the BTUH as shoivn on the rating platee. Check the gas nleter far input to the ur~it on high fire. Prweed as follows far tlaiurai gas applicatiom:

CU8fC 0 FEET

I. Refer to the one cubic foot dial and observe how long it takes for the dial to make one revolution.

2. If the unit operates normally it should take 32 seconds for the one cubic foot dial to complete one revolution.

3. Refer to the gas rate ellart Lo determine the cuhic feet per hour.

4. Locate 32 seconds on chart. Follorv line across to the columxl under one i 1) cubic foot test dial. There we find the value of 113 cubic feet.

5. ConGact the I m l gas company to obtain the calorific value of the gas supplied.

6. Multiplying the calorific value of the gas x 113 = BTUH input to unit. Example: 1050 x 113 = 118,650. This test con- cludes that the unit is operating satisfactoriig.

On Propane gas installations tI~ere usuaJ1jr is no gas meter to measure the cubic foot per hoslr gas consump- tion. It, tllerefore. becalnes necessary to take a manifold pressure reading.

If the unit I-ms been converted frorn NG to Propane gas, "n certain thc~t danlpcr body gasket scals properly and is l~ullcd down evenly on the high fire gas arid air con~lectione. Proceed as fallows:

I. Shut down unit ( pull electrical s w i t ~ l ~ i . 2. Relnove l/8" i>ipe plug from body of outlet exld

of the valve with a 3,1W hex ""Allen wrench"'. 3. Install a 1,8" IPS male fitting (one end of fitting

lnust be adaptable lo &he manolnetrr hose). 4. Attach hose to fitting and to the llegative end of

the manomet~r.

CAUTION: Pinch the hose to the manometer until unit is in opera ti or^ . . . . also before stopping. I f f his precatllion is not followed, the sol~ltion lnay be drawn out of the gauge at sh r t up and shut d o ~ ~ n .

5 , Start tlte systern in the heating cycle (high fire) in order to take the reading. The negative pressure sl~ould read .20 inches water column.

6. If the reading is higl~er than -05 inches \close to zero) the input will be high. If the reading is lower than .35 (further away fron~ zero), the input will he reduced. Readings witl~in these toler- anees "plus or minus .I5 inches! will allow approximately a t BTU input change from the normal.

7. Replace the gas valve in either ease in item 6 r high or low output).

CHECKING DUCT STATIC PRESSURE: sure the static pressure of the return duct a t the

The maximum and n~inimum allowable duet static inlet of the twit (negative pressure).

pressrlres are follnd in the specification section. 2, Measure the sbt ie pressure of the s ~ ~ p p l y duct The indoor blower is not designed to deliver proper ( positive pressure 1 . air quantities (CF'M) against statics othcr than tho* 3. Add the two readings together. listed. NOTE: Both readings ]nay be taken simultaneously Too greahf an external static pressure will result in insuficient air that car1 cause icing of the coil ( refrig- and read directly on the mallorneter if so desired (See

above illus. I . eration cycle) and/or too high of a temperatme rise illeating cycle:, whereas too much air can cause poor 4. Consult proper tahles for quantity of air. humidity control (refrigeration cycle) andlor too low If the total external static presstire exceeds the mini- temperature rise illeating cycle). Too much air can munl or n~nxinli~lrn allowable statics, check for closed also cause nlotor overloading and in either case this dampere, dirty filters, undersized or poorly laid out constitutes a poorly designed system. duct work. "ro determine prcrper air movement, prowed as fol- Gomeet th<> duct work accordingly by adding addition- lows: a1 branch runs or incwasing the physical size of the

I. Using a draft gauge t inclined manometer) mea- inain supply and/or return ducts.

FINAL CHECK DO"S

a. InsGalt on a concrete pad 4'hbove grade level. Tn- stall on 4 x 4 treated wood beanls or 4" high steel H or I beams whet1 on flat roof.

b. Xnstait gutters or water deflectors on raof so water doesn't shed into unit when on ground level.

t. Install asbestos canvas connectors between unit and duct work.

d. Use a rubber grommet in the %" K.O. before inst:-tl- ling low voltage wiring.

e. Check operation of unit befow leaving the job: 1 i Cut off gas and turn on room thermostat. Unit

si~ould go into forkout in approximately I1 sec. 12) Check same as item 1. Spark will he audible.

(X4ust be checked within 11 sec. ignition period.)

( 3 1 Check gas input as per instruction on page 30. 6 4) Cheek supply and return air temperatures.

1 60°F. temperature rise or max, leaving temperature of 140'F).

f 5 Check module solution limit control electrically, disconnecting indoor blower motor and starting unit. Gas valve should close and heating should discontinue. Limit cut-oE 205^ +- 10°F.

I. Have the shipping blocks or straps been removed froun the intenial sprung compressor?

2. Has the shipping packing been removed from the blower wheel i s) ?

3. Have the blower wheel s ) been checked for position to the orifices and are they tight on the shaft?

4. Do they spin freely? 5. Are the lnotor mounting spiders tight on blower

housing and condenser shroud? 6. Has the tubing been checked to ascertain that it

doesn't touch other tubing or components? 7. Does the condenser motor and fan spin freely? 8. Is the unit level? 9. Is the unit properly supported and secured?

10. Has the evaporator condensate drain been connected and properly trapped?

If. Is the unit proteckd by the correct size fusetrons? 32. Are the high volLqge supply wires of ample size? 13. Are all eteetrieal connectior~s tight? 14, Has the gas piping for heating been sized and in-

stalled proprly? 15. Is the vent cap and cover installed on the unit? 26. Check the volhge wit11 unit in operation at dis-

connect switch and compressor contactor. 1'7. Does it check within the allowable toleranm shwn

in this manual alld /or the unit style serial ~iumber nameplate?

DOHITS a. Don" install on cantilever hangers on a

wall of a wood frame building. * b. Don't inskll unit under a wooden porch

deck or under huilding overhang from the foundation.

c. Don't o strict the path of Aue gas. d. Don't locate the unit in a well to facilikte

unit installation. Surrounding area must have water drainage away from unit.

18. Does the unit run quietly? 19. Has the air distribution system been checked for

Lcalrs? 20. Art. ducts completely insulated and

in required areas? 21. Has the air distriblltion system been balanced? 2 2 Are all grilles, diffusers and dampers properly ad-

justed and locked? 23. Is n filter c s ) insbllcd in the return air syskm ac-

cording to the recommended size? 24. Have the healing and cooling cycles heen checked

out for at least 3 or 4 cycles? 25. Is the operation normal? 33. Has the operation of the unit been ex12lained to the

ocmer? 2'7. Has the operation of the thermostat been explained

to the ocvner? 28. Has the owner been instructed to move the thermo-

stat selector suriich to ""OFF'Yfor one minute in case of ""no heat" problem?

29. Dws the owner know where the filter( s ) are located . . . when and how they are to be cleaned or replaced?

30. Was the owner been alerted in relation to the lubri- cation of the motors. service contracts and preven- tive inaintenance?

31. Have the warrax~ty cards been filled out and mailed? 32. Goes the owner know %,horn to call for service?

Dealer Name lnstallatisn Date

Address Model No. Mfg- No. P

City State Serial No.

Phone No. Service Phone No.

32

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