Rooftop Unit

Installation manual New Released Form:

60Hz Commercial Gas

Rooftop R410A

Model No. YMMRZC090BAAKBLX YMMRZC090BAJKBLX

YMMRZC090BAAKBMX YMMRZC090BAJKBMX
YMMRZC090BAAKBHX YMMRZC090BAJKBHX
YMMRZC120BAAKBLX YMMRZC120BAJKBLX
YMMRZC120BAAKBMX YMMRZC120BAJKBMX
YMMRZC120BAAKBHX YMMRZC120BAJKBHX
YMMRZC150BAAKBLX YMMRZC150BAJKBLX
YMMRZC150BAAKBMX YMMRZC150BAJKBMX
YMMRZC150BAAKBHX YMMRZC150BAJKBHX

Issue Date
Jan. 15, 2023
Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . 1
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit Foundation . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Unit Requirements. . . . . . . . . . . . . . . 10
Main Unit Power. . . . . . . . . . . . . . . . . . . . . . . . . 12
External Unit Power Supply . . . . . . . . . . . . . . 16
Through the Base Gas Utility
Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pre Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Verifying Proper Air Flow (Units with
Belt Drive Indoor Fan) . . . . . . . . . . . . . . . . . . . . 18
Electromechanical Controls – Test
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fan Belt Adjustment-Belt Drive
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Monthly Maintenance. . . . . . . . . . . . . . . . . . . . 20

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Standard Troubleshooting . . . . . . . . . . . . . . . 23
Resetting Cooling and Heating
Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General Information
Warnings and Cautions appear at appropriate locations WARNING
throughout this manual.
Read these carefully. Keep away from the following places:
A place where it is full of oil, gas; places where salty air
WARNING: Indicates a potentially hazardous situation surrounding(near the coast); and a place where is caustic
which, if not avoided, could result in death or serious gas(the sulfide in hotspring). Location in above places
injury. may cause malfunction or shorten the life span of the
manchine.
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate In the cace of extremely strong wind, please prevent the
injury.It may also be used to alarm against unsafe air from flowing backwards into the outdoor unit.
practices and where property-damage-only accidents
Snow canopy is necessary in sonwfall places on the
could occur.
outdoor unit. Please consult the local dealer for details.
In the frequent thunderstruck place, lightning proof
CAUTION actions should be taken.

To prevent refrigerant leak, contact your dealer.

Read this entire manual before beginning installation
procedures. When the system is installed and runs in a small room, it is
required to keep the concentration of the refrigerant, if by
Bodily injury can result from high voltage electrical any chance coming out, below the limit. Otherwise, oxygen
components, fast moving fans. For protection from these in the room may be affected, resulting in a serious
inherent hazards during installation and servicing, the accident.
electrical supply must be disconnected. The refrigerant in the air conditioner is safe and normally
does not leak.
If operating checks must be performed with the unit If the refrigerant leaks in the room, contact with a fire of a
operating, it is the technicians responsibility to recognize burner, a heater or a cooker may result in a harmful gas.
these hazards and proceed safely.
Turn off any combustible heating devices, ventilate the
room, and contact the dealer where you purchased the
unit.
WARNING Do not use the air conditioner until a service person
confirms that the portion where the refrigerant leaks is
repaired.
Ask your dealer for installation of the air conditioner.
If the supply cord is damaged, it must be replaced by the
Incomplete installation performed by yourself may result
manufacturer or its service agent or a similarly qualified
in a water leakage, electric shock, and fire.
person in order to avoid a hazard.
Ask your dealer for improvement, repair, and maintenance. The temperature of refrigerant circuit will be high, please
Incomplete improvement, repair, and maintenance may keep the interconnection cable away from the copper
result in a water leakage, electric shock, and fire. tube.
The appliance should not be used by children without
In order to avoid electric shock, fire or injury, or if you
supervision.
detect any abnormality such as smell of fire, turn off the
power supply and call your dealer for instructions.

Never replace a fuse with that of wrong rated current or

other wires when a fuse blows out.
Use of wire or copper wire may cause the unit to break
WARNING
down or cause a fire.
Check the electric wire, water and gas pipeline layout
Do not insert fingers, rods or other objects into the air inside the wall, floor and ceiling before installation. Do not
inlet or outlet. implement drilling unless confirm safety with the user,
When the fan is rotating at high speed, it will cause injury. especially for the hidden power wire. An electroprobe can
be used to test whether a wire is passing by at the drilling
location, to prevent physical injury or death caused by
Never use a flammable spray such as hair spray, lacquer insulation broken cords.
or paint near the unit. It may cause a fire.
Check the power supply before installation. Ensure that the
Never inspect or service the unit by yourself. power supply must be reliably grounded following local,
Ask a qualified service person to perform this work. state and National Electrical Codes. If not, for example, if
the ground wire is detected charged, installation is
Keep far away from high-frequency equipment. prohibited before it is rectified. Otherwise, there is a risk of
fire and electric shock, causing physical injury or death.

1
 CAUTION CAUTION

Do not dry out the air filter under direct sunshine or heat. Do not operate the unit without the evaporator fan access
panel in place. Reinstall the access panel after performing
Re-install the air filter any maintenance. Operating the unit without the access
panel may result in severe personal injury or death.
Condenser coil
Unfiltered air circulates through the unit's condenser coil This unit is not intended for use by persons (including
can cause the coil's surface to become clogged with children) with reduced physical, sensory or mental
dust, etc. Clean the coil, vertically (i.e., with the fins), and capabilities, or lack of experience and knowledge, unless
stroke the coil surface with a soft brush. Be sure to keep they have been given supervision or instruction
all vegetation away from the condenser coil area. concerning use of the appliance by a person responsible
for their safety. Children should be supervised to ensure
Maintenance performed by serviceman. that they do not play with the unit.
To keep your unit operating safely and efficiently, the
manufacturer recommends that a qualified serviceman Disconnect the power supply before cleaning and
check the entire system at least once each year and any maintenance.
other time that you feel one is needed. Your serviceman
should examine these areas of your unit: The unit shall be installed in accordance with national
wiring regulations.
Filters
DISPOSAL: Do not dispose this product as
Motors and drive system components unsorted municipal waste. Collection of such waste
separately for special treatment is necessary.
Economizer gaskets (for possible replacement)
Do not dispose of electrical appliances as unsorted
Safety controls (for mechanical cleaning)
municipal waste, use separate collection facilities.
Electrical components and wiring (for possible
Contact you local government for information regarding
replacement and connection tightness) Condensate drain
the collection systems available.
(for cleaning)
If electrical appliances are disposed of in landfills or
Unit duct connections (to see that they are physically
dumps, hazardous substances can leak into the
sound and sealed to the unit casing)
groundwater and get into the food chain, damaging your
health and well-being.
Unit mounting support (for structural integrity)

The unit (for obvious unit deterioration)

2
Unit Description Variable Frequency Drive (VFD)
Before shipment, each unit is leak tested, dehydrated, Variable Frequency Drive (VFD) can automatically
charged with refrigerant and compressor oil, and run adjust the indoor fan motor speed in sequence with the
tested for proper control operation. unit’s ventilation, cooling and heating operation.
Direct-drive, vertical discharge condenser fans are During the first stage of cooling operation the VFD will
provided with built-in thermal overload protection. adjust the fan motor to provide 100%/70%/65% of the
design airflow rate for the unit, according to the
System Input Devices and Functions outdoor ambient temperature. When the call for the
second stage of cooling is required, the VFD will allow
The unit must have a thermostat input in order to
the design airflow rate for the unit established (100%).
operate.
During the heating mode, the VFD will allow total
The descriptions of the following basic input devices design airflow rate (100%) operation. During
used within the unit are to acquaint the operator with ventilation mode, the VFD will allow total design
their function as they interface with the various airflow rate (100%) operation.
features. Refer to the unit’s electrical schematic for the
specific device connections. The following controls are
available from the factory for field installation.

Drain Pan Condensate Overflow Switch

(Optional)
This input incorporates the Condensate Overflow
Switch (COF) mounted on the drain pan. When the
condensate level reaches the trip point, the COF relay
energizes and opens the 24 Vac control circuit,
disabling the unit. A delay timer prevents the unit from
starting for 7 minutes.
Discharge Line Thermostat Control
The high pressure controls and the discharge line
thermostat signals are wired in series and connected to
the safety input of the LSD. The compressor contactor
coil is connected to the ‘CC’ terminal of the LSD. If the
high pressure control switch or the discharge line
thermostat is open, the 24 Vac signal to the SI input of
the LSD is interrupted and the compressor contactor
coil supply is disabled by the LSD. It has an automatic
lockout.
The high pressure controls and discharge line
thermostats are wired in the system protection
detection port. If the high pressure control switch or the
discharge line thermostat is open, the main control
board will turn off the compressor of the
corresponding system. There is no automatic lockout.

Evaporator Frost Control

This input incorporates the Evaporator Frost Control
mounted in the indoor coil and can be activated by
closing a field supplied contact installed in parallel with
the Frost Control.
If this circuit is open before the compressor is started,
the compressor will not be allowed to operate. Anytime
this circuit is opened for 5 continuous seconds during
compressor operation, the compressor for that circuit
is immediately turned “Off”. The compressor will not
be allowed to restart for a minimum of 3 minutes
should the Frost Control close.

3
Dimensional Data
Below figure illustrates the minimum operating and Providing less than the recommended clearances may
service clearances for either a single or multiple unit result in condenser coil starvation, “short-circuiting” of
installation. These clearances are the minimum exhaust and economizer airflows, or recirculation of
distances necessary to assure adequate serviceability, hot condenser air.
cataloged unit capacity, and peak operating efficiency.

Figure 1. Typical installation clearance for single and multiple unit applications (in inches)

END TO END
NOTE 2,3

SIDE BY SIDE
NOTE 2

NOTES:
1.FOR HORIZONTAL DISCHARGE UNIT,
THIS MEASURE IS REDUCED TO 1’ 6” NOTE 1
TO MINIMIZE DUCT EXTENSIONS.
4’ 0”
2.WHEN EQUIPPED WITH ECONOMIZER
OR BAROMETRIC RELIEF DAMPER, 1’ 6” Minimum clearance
CLERANCE DISTANCE IS TO BE 3’ 0” Side condensate drain is used
MEASURE FROM PROTRUDING HOOD
INSTEAD OF BASE. 1’ 6” Recommended service clearance
SINGLE UNIT 4’ 0” Unit disconnect is mounted on panel

3.CLEARANCE IS THE SAME IF ANY

UNIT IS ROTATED 180
0
5’ 0” WITH ECONOMIZER
3’ 0” WITHOUT ECONOMIZER

3.ADDITIONAL CLEARANCE REQUIRED

WHEN BAROMETRIC DAMPER OR
ECONOMIZER IS INSTALLED.

4
 Figure 2. Gas/electric units — overview

CONDENSATE
GAS CONNECTION DRAIN
INSIDE CONNECTION

Figure 3. Gas/electric units — front and side views (in inches)

2-3/4”
Ø2
Ø1-3/8”

2-3/4”
48-5/16”

Ø2
48-3/4”

44-3/16”
Ø1-3/8”

30-3/16”
6-5/16”

Ø7/8”

14-7/16”
2-5/16”
7-3/4” 23-3/4” 7-3/4”

7-3/4” 23-3/4” 7-3/4” 9-7/8”

37-15/16”
(GBC UNIT ONLY) 58-7/8”
88-7/16”

5
Figure 4. Electric units — bottom view (in inches)
88-7/16”

25-5/8”
29-5/8” 14” 3-7/16”

12-7/16”

37-5/8”

40-11/16”
27-5/16”

12-3/8”
36-7/16” 3-7/16”

NOTES:
1.THROUGH THE BASE GAS AND ELECTRICAL IS NOT STANDARD ON ALL UNITS.
2.VERIFY WEIGHT, CONNECTION, AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION.

Figure 5. Foundation units — back view (horizontal configuration) (in inches)

SUPPLY RETURN
36-7/16”
14”

5-5/8”
4-15/16”

27-5/16” 12-3/8” 4-9/16”

23”

53-3/16”

6
Figure 6. Roof curb (in inches)

15 1/2”

32 1/4” 3.000 84 13/16”

54 9/16”
19 3/8”
3.000 SUPPLY

15 13/16” 45 1/8”

37 15/16”
RETURN
3 9/16”
14.000

1 3/4”

54 9/16”
84 13/16”

Figure 7. Downflow unit clearance (in inches)

CLEARANCE 68” CLEARANCE 48”

UNIT OUTLINE

39 11/16” 54 5/8”

CLEARANCE 48”
CLEARANCE 60”

7
Weights
Table 1. Maximum unit and corner weights (lb) and center of gravity dimensions (in.)

Weights (lb)(a) , (b) Corner Weights(c) Center of Gravity (in.)

Tons
Shipping Net A B C D Length Width

7.5 1087 1012 248 181 334 249 45 34

8.5 1111 1036 236 176 340 283 44 36

10 1133 1058 237 190 273 358 39 34

12.5 1235 1172 264 194 299 416 39 35

(a) Weights are approximate. Horizontal and downflow unit and corner weights may vary slightly.
(b) Weights do not include additional factory or field installed options/accessories.
(c) Corner weights are given for information only. 7.5–12.5 ton models mstube supported continuously by a curb or equivalent frame support.

Figure 8. Corner weights WARNING

CENTER OF GRAVITY
LENGTH Improper Unit Lift!
A B
Failure to properly lift unit in a LEVEL position
could result in unit dropping and possibly
crushing operator/technician which could result in
CENTER OF
GRAVITY
death or serious injury, and equipment or
WIDTH property-only damage.
Test lift unit approximately 24 inches (61 cm) to
verify proper center of gravity lift point. To avoid
dropping of unit, reposition lifting point if unit is
not level.

Refer to Figure 9, p. 9 and for typical unit operating

D C weights rigging before proceeding.
1. Remove the shipping crate from around the unit.
Rigging Do not remove the crating from the top of the unit.
2. Rig the unit as shown in Figure 9, p. 9 . Attach
WARNING adequate strength lifting slings to all four lifting
brackets in the unit base rail. Do not use cables,
Heavy Object! chains, or slings except as shown.
Failure to follow instructions below could result in
unit dropping which could result in death or 3. Install a lifting bar, as shown in Figure 9, p. 9 , to
serious injury, and equipment or property-only protect the unit and to facilitate a uniform lift. The
damage. minimum distance between the lifting hook and the
top of the unit should be 7 feet.
Ensure that all the lifting equipment used is
pro pe rly ra ted for th e we igh t o f the unit bei ng 4. Test-lift the unit to ensure it is properly rigged and
lifted. Each of the cables (chains or slings), hooks, balanced, make any necessary rigging adjustments.
and shackles used to lift the unit must be capable 5. Lift the unit and position it into place.
of supporting the entire weight of the unit. Lifting
cables (chains or slings) may not be of the same 6. w units; align the base rail of the unit with
length. Adjust as necessary for even unit lift. the curb rail while lowering the unit onto the curb.
Make sure that the gasket on the curb is not
damaged while positioning the unit.

8
Figure 9. Rigging and center of gravity data Installation
Unit Foundation
WARNING
Risk of Roof Collapsing!
Failure to ensure proper structural roof support
could cause the roof to collapse, which could
result in death or serious injury and property
damage.
C o n ffiir m w i t h a s t r u c t u r a l e n g i n e e r t h a t t h e r o o f
structure is strong enough to support the
combined weight of the roofcurb, the unit, and any
accessories.

NOTICE
Water Damage!
Failure to follow instructions below could result in
equipment and property damage.
Non-factory penetrations through the base of this
unit are not allowed. Any penetration in the base
CENTER OF GRAVITY CENTER OF GRAVITY of the unit may affect the water tight integrity of
LENGTH WIDTH
the unit and lead to water leaks into the
conditioned space.

Notes:
• For units with optional Condensate
Overflow Switch (COF) accessory kit, the
switch will not work properly if unit is not
level or slightly sloped toward switch.
• To assure proper condensate flow during
operation the unit and the curb must be
level.
If the unit is installed at ground level, elevate it above
the snow line. Provide concrete footings at each
support location with a “full perimeter” support
structure or a slab foundation for support. Refer to for
the unit’s operating and point loading weights when
constructing a footing foundation.
If anchoring is required, anchor the unit to the slab
using hold down bolts or isolators. Isolators should be
installed to minimize the transmission of vibrations
into the building.
For rooftop applications, if anchoring is required,
anchor the unit to the roof with hold-down bolts or
isolators.
Check with a roofing contractor for proper
waterproofing procedures.
Use only with type of gas approved for this furnace.
Refer to the furnace rating plate.
Install this furnace only in a location and position as
specified in page 1011 151617 of these
instructions.
Provide adequate combustion and ventilation air to
the furnace space as specified in page 13 of these
instructions.

9
 Ductwork
Elbows with turning vanes or splitters are ☐ Assemble and install the roof curb (if applicable).
recommended to minimize air noise due to turbulence Refer to the latest edition of the curb installers
and to reduce static pressure. guide that ships with each curb kit.
When attaching the ductwork to the unit, provide a ☐ Fabricate and install ductwork; secure ductwork to
watertight flexible connector at the unit to prevent curb.
operating sounds from transmitting through the
☐ Rigging the unit.
ductwork.
☐ Set the unit onto the curb; check for levelness.
All outdoor ductwork between the unit and the
structure should be weather proofed after installation is ☐ Ensure unit-to-curb seal is tight and without buckles
completed. or cracks.
N o t e : For sound consideration, cut only the holes in the ☐ Install and connect a condensate drain line to the
roof deck for the ductwork penetrations. Do not evaporator drain connection.
cut out the entire roof deck within the curb
perimeter. Main Electrical Power Requirements
If a Curb Accessory Kit is not used: ☐ Verify that the power supply complies with the unit
1. The ductwork can be attached directly to the nameplate specifications.
factory-provided flanges around the unit’s supply ☐ Inspect all control panel components; tighten any
and return air openings. Be sure to use flexible duct loose connections.
connections at the unit. ☐ Connect properly sized and protected power supply
2. For “built-up” curbs supplied by others, gaskets wiring to a field-supplied/ installed disconnect
must be installed around the curb perimeter flange switch and to the main power terminal block in the
and the supply and return air opening flanges. unit control panel.
☐ Install proper grounding wires to an earth ground.
General Unit Requirements N o t e : All field-installed wiring must comply with
applicable local codes.
WARNING
Proper Field Wiring and Grounding
Required! External Vent Hood Installation
Failure to follow code could result in death or WARNING
serious injury.
A l l ffiie l d w i r i n g M U S T b e p e r f o r m e d b y q u a l i ffiie d Hazardous Voltage!
personnel. Improperly installed and grounded Failure to disconnect power before servicing could
ffiie l d w i r i n g p o s e s F I R E a n d E L E C T R O C U T I O N result in death or serious injury.
hazards. To avoid these hazards, you MUST follow Disconnect all electric power, including remote
r e q u i r e m e n t s f o r ffiie l d w i r i n g i n s t a l l a t i o n a n d disconnects before servicing. Follow proper
grounding as described in your local/ lockout/tagout procedures to ensure the power
st e l e c t r i c a l c o d e s . can not be inadvertently energized. Verify that no
power is present with a voltmeter.
The checklist listed below is a summary of the steps
required to successfully install a commercial unit. This 1. Remove and discard the cover plate located on the
checklist is intended to acquaint the installing gas heat panel.
personnel with what is required in the installation
Important:
process. It does not replace the detailed instructions
called out in the applicable sections of this manual. • Make sure you read the label
located on the cover plate before
☐ Check the unit for shipping damage and material
you discard it.
shortage; file a freight claim and notify appropriate
sales representative. • Do not discard the fastening screws!
They will be needed to install the
☐ Verify correct model, options and voltage from vent hood.
nameplate.

☐ Verify that the installation location of the unit will

provide the required clearance for proper
operation.

10
Figure 10. Vent hood installation A condensate drain line must be connected to the P-
Trap. Pitch the drain lines at least 0.5-inch for every 10
feet of horizontal run to assure proper condensate flow.
Do not allow the horizontal run to sag causing a
possible doubletrap condition which could result in
condensate backup due to “air lock”.

Filter Installation
Each unit ships with 2-inch filters installed. The
quantity of filters is determined by unit size. Access to
the filters is obtained by removing the filter access
panel.
N o t e : Do not operate the unit without filters.
Field Installed Power Wiring
An overall dimensional layout for the standard field
installed wiring entrance into the unit is illustrated in
“Dimensional Data,” p. 4. To insure the unit’s supply
power wiring is properly sized and installed, follow the
guidelines outlined below.
N o t e : All field installed wiring must conform to
Local codes.
Verify that the power supply available is compatible
Vent hood in the picture is for reference,please make with the unit’s nameplate ratings. The available supply
the object as the standard. And it has the function of power must be within 10 percent of the rated voltage
preventing rain and foreign bodies, and should not be stamped on the nameplate. Use only copper
changed without consultation. conductors to connect the power supply to the unit.

Condensate Drain Configuration

An evaporator condensate drain connection is NOTICE
provided on each unit. Refer to “Dimensional Data,” p.
4 for the appropriate drain location.
Use Copper Conductors Only!
Failure to use copper conductors could result in
equipment damage as the equipment was not
N o t e : Use 1-inch PVC pipe to connect to the drain pan d e s i g n e d o r q u a l i ffiie d t o a c c e p t o t h e r t y p e s o f
outlet provided in the unit. This is a slip fit joint conductors.
(no threads). Do not use PVC glue to connect
condensate drain, thread sealing compound or I m p o r t a n t : A field supplied disconnect switch must be
Teflon tape may be used. installed at or near the unit in accordance
with the Local Electrical Code
A condensate trap must be installed at the unit due to
the drain connection being on the “negative pressure”
side of the fan.

Table 2. electrical data

COMPRESSOR A COMPRESSOR B CONDENSER FAN INDOOR FAN MAIN POWER SUPPLY

VOLTS MODEL
RLA-VOLTS LRA RLA-VOLTS LRA FLA-VOLTS HP FLA-VOLTS HP MCA MOP
7.5T 11.6-208 123 10.4-208 73 1.5-208 0.34 7.2-208 2 36 45
8.5T 15.6-208 93 11.6-208 123 1.5-208 0.34 7.2-208 2 42 50
230V
10T 15.6-208 93 18.6-208 137 1.5-208 0.34 12-208 3 54 70
12.5T 23.2-208 164 15.6-208 93 4.5-208 0.76 12-208 3 66 80
7.5T 6.0-460 60 6.4-460 38 0.87-460 0.34 3.5-460 2 20 25
8.5T 6.5-460 60 6.0-460 60 0.87-460 0.34 3.5-460 2 20 25
460V
10T 6.5-460 60 7.8-460 52 0.87-460 0.34 8.7-460 3 27 30
12.5T 11.2-460 75 6.5-460 60 2.1-460 0.76 8.7-460 3 34 40

11
Main Unit Power
Controls using 24 Vac
Standard Wiring Before installing any connecting wiring, refer to
“Dimensional Data,” p. 4 for the electrical access
The electrical service must be protected from over locations provided on the unit and for AC conductor
current and short circuit conditions in accordance with sizing guidelines.
local requirements.
Protection devices must be sized according to the NOTICE
electrical data on the nameplate.
Use Copper Conductors Only!
• A field supplied disconnect switch must be installed Failure to use copper conductors could result in
at or near the unit in accordance with the Local equipment damage as the equipment was not
Electrical Code . d e s i g n e d o r q u a l i ffiie d t o a c c e p t o t h e r t y p e s o f
• Location of the applicable electrical service conductors.
entrance is illustrated in “Dimensional Data,” p. 4.
1. Use copper conductors unless otherwise specified.
Complete the unit’s power wiring connections onto
either; the main terminal block inside the unit 2. Ensure that the AC control wiring between the
control panel, or the electric heat terminal block. controls and the unit’s termination point does not
Refer to the customer connection diagram that exceed three (3) ohms/conductor for the length of
shipped with the unit for specific termination the run.
points.
N o t e : Resistance in excess of 3 ohms per conductor
• Provide proper grounding for the unit in accordance could cause component failure due to
with Local codes. insufficient AC voltage supply.

3. Be sure to check all loads and conductors for

Control Power Transformer grounds, shorts, and mis-wiring.

The 24-volt control power transformers are to be used 4. Do not run the AC low voltage wiring in the same
only with the accessories called out in this manual. conduit with the high voltage power wiring.

Table 3. Electromechanical thermostat 24V AC conductors with electromechanical unit

Distance from Unit to Control Recommended Wire Size

0 - 30 feet 22 gauge

0 - 9.1 m 0.33 mm^2

31 - 50 feet 20 gauge

9.5 - 15.2 m 0.50 mm^2

51 - 75 feet 18 gauge

15.5 - 22.9 m 0.75 mm^2

76 - 125 feet 16 gauge

23.1 - 38.1 m 1.3 mm^2

126 - 200 feet 14 gauge

38.4 - 60.9 m 2.0 mm^2

12
Figure 11. Conventional thermostat field wiring diagram

Voltage Imbalance % Voltage Imbalance =

Three phase electrical power to the unit must meet
stringent requirements for the unit to operate properly.
Measure each leg (phase-to-phase) of the power
AV (Average Voltage) =
supply.
Each reading must fall within the utilization range
stamped on the unit nameplate. If any of the readings
do not fall within the proper tolerances, notify the • V1, V2, V3 = Line Voltage Readings
power company to correct this situation before • VD = Line Voltage reading that deviates the farthest
operating the unit. from the average voltage.
Excessive three phase voltage imbalance between Example: If the voltage readings of the supply power
phases will cause motors to overheat and eventually measured 221, 230, and 227, the average volts would
fail. be:
The maximum allowable voltage imbalance is 2
percent. Measure and record the voltage between
phases 1, 2, and 3 and calculate the amount of
imbalance as follows: • VD (reading farthest from average) = 221
• The percentage of Imbalance equals:

13
The 2.2 percent imbalance in this example exceeds the 4. Observe the ABC and CBA phase indicator lights on
maximum allowable imbalance of 2.0 percent. This the face of the sequencer. The ABC indicator light
much imbalance between phases can equal as much as will glow if the phase is ABC. If the CBA indicator
a 20 percent current imbalance with a resulting light glows, open the disconnect switch or circuit
increase in motor winding temperatures that will protection switch and reverse any two power wires.
decrease motor life. 5. Restore the main electrical power and recheck the
If the voltage imbalance is over 2 percent, notify the phasing. If the phasing is correct, open the
proper agencies to correct the voltage problem before disconnect switch or circuit protection switch and
operating this equipment. remove the phase sequence indicator.

Electrical Phasing (Three Phase Motors) Checklist

The compressor motor(s) and the supply fan motor are Use the following checklist in conjunction with the
internally connected for the proper rotation when the general checklist (“General Unit Requirements,” p. 10)
incoming power supply is phased as A, B, C. to ensure that the unit is properly installed and ready
for operation.
Proper electrical supply phasing can be quickly
determined and corrected before starting the unit by
using an instrument such as an Associated Research
WARNING
Model 45 Phase Sequence Indicator and following the Hazardous Voltage!
steps below: Failure to disconnect power before servicing could
result in death or serious injury.
WARNING Disconnect all electric power, including remote
Hazardous Voltage! disconnects before servicing. Follow proper
lockout/tagout procedures to ensure the power
Failure to disconnect power before servicing could can not be inadvertently energized. Verify that no
result in death or serious injury. power is present with a voltmeter.
Disconnect all electric power, including remote
disconnects before servicing. Follow proper ☐ Check all electrical connections for tightness and
lockout/tagout procedures to ensure the power “point of termination” accuracy.
can not be inadvertently energized. Verify that no
power is present with a voltmeter. ☐ Verify that the condenser airflow is unobstructed.
☐ Verify that the condenser fan and indoor blower
1. Turn the field supplied disconnect switch that turn freely without rubbing and are properly
provides power to the main power terminal block or tightened on the shafts.
to the “Line” side of the optional factory mounted ☐ Check the supply fan belts for proper tension and
disconnect switch to the “Off” position. the fan bearings for sufficient lubrication except
2. Connect the phase sequence indicator leads to the exhaust gas fan. If the belts require adjustment,
terminal block or to the “Line” side of the optional or if the bearings need lubricating, refer to the
factory mounted disconnect switch as follows: maintenance section of this manual for instructions.
• Black (phase A) to L1 ☐ Verify that a condensate trap is installed and the
• Brown (phase B) to L2 piping is properly sized and pitched.

• Gray (phase C) to L3 ☐ Verify that the correct size and number of filters are
in place.
3. Close the field supplied main power disconnect
switch or circuit protector switch that provides the ☐ Inspect the interior of the unit for tools and debris
supply power to the unit. and install all panels in preparation for starting the
unit.
WARNING
Live Electrical Components!
Failure to follow all electrical safety precautions
when exposed to live electrical components could
result in death or serious injury.
When it is necessary to work with live electrical
c o m p o n e n t s , h a v e a q u a l i ffiie d l i c e n s e d e l e c t r i c i a n
or other individual who has been properly trained
in handling live electrical components perform
these tasks.

14
Gas Heat Data
Table 4. Gas heater operating data
Heating Input Rate
125,000 180,000 225,000 250,000
—Btu/h
Minimum and Maxmum Inlet Supply Gas Pressure Natural/LP 4.5/11.0 4.5/11.0 4.5/11.0 4.5/11.0
Manifold Gas Pressure(a) 3.5 3.9 3.6 3.5
Combustion Blower Suction Pressure (1st Stage) -1.3 to -1.7 -1.3 to -1.7 -1.1 to -1.5 -1.1 to -1.5
Combustion Blower Suction Pressure (2nd Stage) -1.3 to -1.7 -1.3 to -1.7 -1.1 to -1.5 -1.1 to -1.5
Minimum Flame Sensing Current(b) 5.0 Micro Amps DC
Normal Sensing Current Range 8.0 to 16 Micro Amps DC
Flue Gas Temperature Rise Above Ambient 230 to 300 F
7.0% to 8.0% (Natural Gas)
Flue Gas Content - % CO2
7.5% to 9.0% (Propane)
Minimum Supply Air Temperature Across Heat Exchanger 40° F
(a) Staged gas heat units have a positive pressure gas valve. Never adjust the staged gas pressure valve to a negative pressure.
(b) A voltage reading across pens (V+) and (V-) is equatable to the flame sensing current. One volt equals one micro amp.

Table 5. Piping
Iron Pipe Size (IPS) Inches
Length of Pipe (ft)
1/2" Pipe 3/4" Pipe 1" Pipe 1¼” Pipe 1½” Pipe
15 76 176 345 750 1220

30 52 120 241 535 850

45 43 99 199 435 700

60 38 86 173 380 610

75 35 77 155 345 545

Note: Capacity of Pipe of Different Diameters and Lengths in Cu. Ft. Per Hr. with Pressure Drop of 0.3" and Specific Gravity of 0.60.

Table 6. Specific gravity multipliers

Specific Gravity Multipliers
0.50 1.10

0.55 1.04

0.60 1.00

0.65 0.96

Figure 12. Schematic diagram for field gas piping to units

1/8” NPT Test Plug 6” MIN

Field supplied ground
Union

To Gas Train
Gas Supply Line
Gas shuttoff (Field Supplied Unit Access Hole
outside unit cabinet.)
Drip Leg

15
 Figure 13. Typical unit gas train configuration
Field Installed Connections
WARNING
Hazardous Voltage w/Capacitors!
Failure to disconnect power and discharge
capacitors before servicing could result in death or
serious injury.
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper
lockout/ tagout procedures to ensure the power
cannot be inadvertently energized. Verify with a
CAT III or IV voltmeter rated per NFPA 70E that all
capacitors have discharged.

WARNING
Combustion Airflow Path and Exhaust Path should
keep open for heating
Proper Field Wiring and Grounding
Required!
Failure to follow code could result in death or
External Unit Power Supply serious injury.

Unit Disconnect Wiring Plan personnel. Improperly installed and grounded

1. Field connections are made by first removing the hazards. To avoid these hazards, you MUST follow
compressor access panel on the front of the unit.
Unscrew the assembly around the outside of the grounding as described in your local electrical codes.
disconnect switch. This assembly is located in the
condenser section of the unit. I m p o r t a n t : All phases of this installation must comply
Both high and low voltage power can be routed
1. Field
through the base or through the front corner post
access panel for the heat section on the front of the
where the disconnect enclosure is mounted. The
unit.
hole is sized for 1 1/2–in. conduit.
2. The gas piping assembly ships inside this section
2. If the conduit required for your application is larger
and includes the shut-off valve, a pressure tap for
than 1 1/2–in., remove the termination plate and
connect to the larger hole using field supplied
connection. For through the base access, remove
reducing washers.
the factory-provided cap from the base pan
3. Route the power wires and ground conductor opening. See Figure 14, p. 17.
through conduit and into the bottom of a field-
installed disconnect switch. Connect the power
dimension shown in Table 7, p. 16.
conductors to the lugs provided. Connect the
ground wire to the unit ground lug. 4. Place the assembly through the cabinet opening as
shown in Figure 14, p. 17 and make the union
4. Route low voltage (class II), control wiring through
hole in base of unit but not through high voltage
conduit. Feed control wiring through bushing
provided on side panel. Route wires through loose Table 7. Through the base gas piping dimension
wire ties provided.
Tons Dimension
5. Tighten the wire ties. Secure the excess wire bundle
7.5-12.5 1 3/16–in.
under the wire ties in the outdoor section. Do not
leave excess wire in the electrical enclosure. Use
the unit wiring diagram to make the low voltage
connections.

Through the Base Gas Utility

Option
connections to the Through the Base Gas Utility
Option.
16
 Figure 14. Through the base gas piping installation

Flue gas temperature is highshall avoid high temperature flue gas directly blowing to the
gas pipelines when installing gas pipelines.

17
Pre Start Start Up
Verifying Proper Air Flow (Units
with Belt Drive Indoor Fan) Before starting unit
Much of the systems performance and reliability is
closely associated with, and dependent upon having ● Is the unit properly located and level with the proper
the proper airflow supplied both to the space that is clearance?
being conditioned and across the evaporator coil.
● Is the duct work correctly sized, run, taped, insulated, and
The indoor fan speed is changed by opening or closing weatherproofed with proper unit arrangement? See Ductwork
the adjustable motor sheave. Installation section.
Before starting the SERVICE TEST, set the minimum
● Is the wiring properly sized and run according to the unit wiring
position setpoint for the economizer to 0% using the
diagram?
setpoint potentiometer located on the Economizer
Control (ECA), if applicable. ● Are all the wiring connections, including those in the unit,
tight?
Electromechanical Controls – ● Has the unit been properly grounded and fused with the
Test Procedure recommended fuse size? See Wiring Data.

F a n T e s t a n d M i n i m u m V e n t i l a t i o n . Connect the ● Have the air conditioning systems been checked at the
short circuit between R and G. service ports for charge and leak tested if necessary?
Connect the short circuit between R and Y1.
● Does the condenser fan and indoor blower fan free without
C o o l 1 . Connect the short circuit between R and Y1. rubbing, and are they tight on the shafts?
C o o l 2 . Connect the short circuit between R and Y2.
● Are all covers and access panels in place to prevent air loss
H e a t 1 . Connect the short circuit between R and W1. and safety hazards?
H e a t 2 . Connect the short circuit between R and W2.
Starting the unit in the cooling mode

Voltage
WARNING With the unit operating, check the line voltage of the unit. The
FIRE OR EXPLOSION HAZARD voltage should be within the range shown on the unit
nameplate.
Failure to follow the safety warnings If low voltage is encountered, check the size and length of
exactly could result in serious injury, the supply line from the main disconnect to the unit. The line
may be undersized for the length of the run.
death or property damage.
Cooling shut down
Place the system selector in the OFF position or reset
Never test for gas leaks with an open thermostat at a setting above room temperature.
flame. Use a commercially available Do not de-energize the main power disconnect except when
unit is to be serviced.
soap solution made specifically for the
detection of leaks to check all
connections. A fire or explosion may
result causing property damage,
personal injury or loss of life.

18
Maintenance
WARNING deflection value determined in Step 1b.

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD 3. Set the small O-ring at zero on the force scale of the
gauge plunger.
Failure to follow safety warnings exactly could
result in dangerous 4. Place the large end of the gauge at the center of the
belt span; then depress the gauge plunger until the
operation, serious injury, death or property damage.
large O-ring is even with the top of the next belt or
Improper servicing could result in dangerous even with a straightedge placed across the fan and
operation, serious injury, motor sheaves.
death or property damage.
5. Remove the belt tension gauge. The small O-ring
• Before servicing, disconnect all electrical power now indicates a number other than zero on the
to unit. plunger’s force scale. This number represents the
• When servicing controls, label all wires prior to force (in pounds) required to give the needed
disconnecting. Reconnect wires correctly. deflection.
• Verify proper operation after servicing. 6. Compare the “force” scale reading (Step 5) with the
Make sure all personnel are standing clear of the unit appropriate “force” value listed in the Belt tension
before proceeding. The system components will start table. If the “force” reading is outside the range,
when the power is applied. readjust the belt tension.
N o t e : Actual belt deflection “force” must not
Fan Belt Adjustment-Belt Drive exceed the maximum “force” value shown in
the Belt tension measurement and deflection
Units ranges table.
7. Recheck the belt tension at least twice during the
WARNING first 2 to 3 days of operation. Belt tension may
Rotating Components! decrease until the new belts are “run in”.
Failure to disconnect power before servicing could
Figure 15. Belt tension gauge
result in rotating components cutting and slashing
technician which could result in death or serious
injury.
Disconnect all electric power, including remote
disconnects before servicing. Follow proper
lockout/tagout procedures to ensure the power
can not be inadvertently energized.

The fan belts must be inspected periodically to assure

proper unit operation. Replacement is necessary if the
belts appear frayed or worn. Units with dual belts
require a matched set of belts to ensure equal belt
length.
When removing or installing the new belts, do not The exhaust gas fan is that lubrication of motor,
stretch them over the sheaves. Loosen the belts using blower, or fan bearings should not be doneand
the belt tension adjustment bolts on the motor others should Check the supply fan belts for proper
mounting base. tension and the fan bearings for sufficient lubrication.
Once the new belts are installed, using a Browning or
Gates tension gauge (or equivalent), adjust the belt
tension as follows:
1. To determine the appropriate belt deflection:
a. Measure the center-to-center shaft distance (in
inches) between the fan and motor sheaves.
b. Divide the distance measured in Step 1a by 64;
the resulting value represents the amount of
belt deflection that corresponds to the proper
belt tension.
2. Set the large O-ring on the belt tension gauge at the

19
 Table 8. Belt tension measurement and deflection ranges (in/lb)

Deflection Force (lb)

Belts Cross Small P.D Range Steel Cable Gripbelts

Super Gripbelts (in) Gripnotch (in)
Section (in) (in)

Min. Max. Min. Max Min. Max.

3.0–3.6 3.00 4.50 3.87 5.50 3.25 4.00

A 3.8–4.8 3.50 5.00 4.50 6.25 3.75 4.75

5.0–7.0 4.00 5.50 5.00 6.87 4.25 5.25

3.4–4.2 4.00 5.50 5.75 8.00 4.50 5.50

B 4.4–5.6 5.12 7.12 6.50 9.12 5.75 7.25

5.8–8.8 6.37 8.75 7.37 10.12 7.00 8.75

Table 9. Belt tension measurement and deflection ranges (mm/kg)

Deflection Force (kg)

Belts Cross Small P.D Range Steel Cable Gripbelts

Super Gripbelts (mm) Gripnotch (mm)
Section (mm) (mm)

Min. Max. Min. Max. Min. Max

13.3–16.0 13.3 20.0 17.2 24.5 14.5 17.8

A 16.9–21.4 15.6 22.2 20.0 27.8 16.7 21.1

22.0–31.1 17.8 24.5 22.2 30.6 18.9 23.4

15.1–18.7 17.8 24.5 25.6 35.6 20.0 24.5

B 19.6–24.9 22.8 31.7 28.9 40.6 25.6 32.3

25.8–39.1 28.4 38.9 32.8 45.0 31.1 38.9

Monthly Maintenance Cooling Season

Before completing the following checks, turn the unit ☐ Check the unit’s drain pans and condensate piping
OFF and lock the main power disconnect switch open. to ensure that there are no blockages.
☐ Inspect the evaporator and condenser coils for dirt,
WARNING bent fins, etc. If the coils appear dirty, clean them
Hazardous Voltage! according to the instructions described in “Coil
Cleaning” later in this section.
Failure to disconnect power before servicing could
result in death or serious injury. ☐ Manually rotate the condenser fans to ensure free
Disconnect all electric power, including remote movement and check motor bearings for wear.
disconnects before servicing. Follow proper Verify that all of the fan mounting hardware is tight.
lockout/tagout procedures to ensure the power ☐ Inspect the F/A-R/A damper hinges and pins to
can not be inadvertently energized. Verify that no ensure that all moving parts are securely mounted.
power is present with a voltmeter. Keep the blades clean as necessary.

Filters
Inspect the return air filters. Clean or replace them if
necessary.

Condensate Overflow Switch

During maintenance, the switch float (black ring) must
be checked to ensure free movement up and down.

20
 WARNING Heating Season
Rotating Components! The furnace system shall be inspected at least once a
Failure to disconnect power before servicing year by a qualified service person.
could result in rotating components cutting
and slashing technician which could result in ☐ Inspect the unit’s air filters. If necessary, clean or
death or serious injury. replace them.
During installation, testing, servicing and ☐ Check supply fan motor bearings; repair or replace
troubleshooting of this product it may be the motor as necessary.
necessary to work with live and exposed ☐ Inspect both the main unit control panel and heat
r o t a t i n g c o m p o n e n t s . H a v e a q u a l i ffiie d o r section control box for loose electrical components
licensed service individual who has been and terminal connections, as well as damaged wire
properly trained in handling exposed rotating insulation. Make any necessary repairs.
components, perform these tasks.
☐ Verify that the electric heat system operates
properly.
NOTICE
Equipment Damage!
Forcibly turning the motor shaft can damage Coil Cleaning
the gear train and motor beyond repair.
Regular coil maintenance, including annual cleaning
Never turn the motor shaft by hand or with a enhances the unit’s operating efficiency by minimizing
wrench. the following:
☐ Verify that all damper linkages move freely; • Compressor head pressure and amperage draw
lubricate with white grease, if necessary.
• Evaporator water carryover
☐ Check supply fan motor bearings; repair or replace
• Fan brake horsepower
the motor as necessary.
• Static pressure losses
☐ Check the fan shaft bearings for wear. Replace the
bearings as necessary. • Airflow reduction
☐ Check the supply fan belt(s). If the belts are frayed At least once each year, or more often if the unit is
or worn, replace them. Refer to the “Fan Belt located in a “dirty” environment, clean the condenser
Adjustment-Belt Drive Units,” p. 19 for belt coils using the instructions outlined below. Be sure to
replacement and adjustments. follow these instructions as closely as possible to avoid
damaging the coils.
☐ Verify that all wire terminal connections are tight.
☐ Remove any corrosion present on the exterior WARNING
surfaces of the unit and repaint these areas.
Hazardous Chemicals!
☐ Generally inspect the unit for unusual conditions (e.
Coil cleaning agents can be either acidic or highly
g., loose access panels, leaking piping connections,
alkaline and can burn severely if contact with skin
etc.)
or eyes occurs.
☐ Make sure that all retaining screws are reinstalled in Handle chemical carefully and avoid contact with
the unit access panels once these checks are skin. ALWAYS wear Personal Protective
complete. Equipment (PPE) including goggles or face shield,
☐ With the unit running, check and record the chemical resistant gloves, boots, apron or suit as
following: required. For personal safety refer to the cleaning
agent manufacturer’s Materials Safety Data Sheet
– ambient temperature
and follow all recommended safe handling
– compressor oil level (each circuit) practices.
– compressor suction and discharge pressures
(each circuit)
– superheat and subcooling (each circuit)
Record this data on an “operator’s maintenance log”
like the one shown in Sample maintenance log table in
Final Process Section. If the operating pressures
indicate a refrigerant shortage, measure the system
superheat and system subcooling.

21
Microchannel (MCHE) Coils

NOTICE
Coil Damage!
Failure to follow instructions below could result in
coil damage.
DO NOT use any detergents with microchannel
condenser coils.
Use pressurized water or air ONLY, with pressure
no greater than 600psi.
For additional information regarding the proper
microchannel coil cleaning procedure.

Due to the soft material and thin walls of the MCHE

coils, the traditional field maintenance method
recommended for Round Tube Plate Fin (RTPF) coils
does not apply to microchannel coils. Moreover,

chemical cleaners are a risk factor to MCHE due to the

material of the coil. The manufacturer does not
recommend the use of chemical cleaners to clean
microchannel coils. Using chemical cleaners could lead
to warranty claims being further evaluated for validity
and failure analysis.
The recommended cleaning method for microchannel
condenser coils is pressurized water or air with a non-
pinpoint nozzle and an ECU of at least 180 with
pressure no greater than 600 psi. To minimize the risk
of coil damage, approach the cleaning of the coil with
the pressure washer aimed perpendicular to the face of
the coil during cleaning. Optimum clearance between
the sprayer nozzle and the microchannel coil is 1”–3”.

Final Process
For future reference, record the unit data below in the
blanks provided.

Variable Frequency Drive (VFD)

If installed in an appropriate environment, the VFD
requires very little maintenance.

Note: Do not perform wiring, inspection or repair

operations while the power is on. Before starting work,
be sure to switch off the power of all machines. After
the power is switch off, there is still residual voltage in
the capacitor inside the inverter. It is necessary to
confirm that the main circuit voltage has dropped to a
safe level, and wait 5 minutes before performing
related operations to avoid personal accidents.

22
Troubleshooting
and verify operation of all outputs, controls, and
WARNING modes. Refer to the sequence of operations for
each mode, to assist in verifying proper operation.
Hazardous Service Procedures! Make the necessary repairs and proceed to Step 5
Failure to follow all precautions in this manual and and Step 6.
on the tags, stickers, and labels could result in
death or serious injury. 6. If no abnormal operating conditions appear in the
test mode, exit the test mode by turning the power
Technicians, in order to protect themselves from
“Off” at the main power disconnect switch and
potential electrical, mechanical, and chemical
removing the test mode connections.
hazards, MUST follow precautions in this manual
and on the tags, stickers, and labels, as well as the
f o l l o w i n g i n s t r u c t i o n s : U n l e s s s p e c i ffiie d o t h e r w i s e ,
Failures
disconnect all electrical power including remote
disconnect and discharge all energy storing Heating Failure
devices such as capacitors before servicing. Verify Heat Failure by Ignition Module (IGN) LED
Follow proper lockout/tagout procedures to indicator:
ensure the power can not be inadvertently Slow Flash: Normal, Call for heat
energized. When necessary to work with live
e l e c t r i c a l c o m p o n e n t s , h a v e a q u a l i ffiie d l i c e n s e d 2 Flash: System Lockout (failed to detect or sustain flame)
electrician or other individual who has been 3 Flash: Pressure Switch Problem Detected
trained in handling live electrical components
4 Flash: High limit switch protection device open
perform these tasks.
5 Flash: Flame sensed and gas valve not energized or flame
sensed and no “W” signal
Standard Troubleshooting 6 Flash: Flame rollout switch open
To prevent injury or death from electrocution, it is the 7 Flash: Thermostat miswired (W1 and W2 swapped)
responsibility of the technician to recognize this hazard
and use extreme care when performing service Simultaneous Heat and Cool Failure
procedures with the electrical power energized.
Emergency Stop is activated.
1. Verify LED on face of the phase monitor is green. If
LED is red, correct supply power fault. To Clear an Alarm
2. Verify that the Digital Display on the mainboard is Once the alarm has been identified and the cause has
displaying “–”. If the Digital Display is right, go to been removed (for example, replaced faulty sensor),
Step 4. the alarm can be cleared from the display.
3. If the LED is not lit, verify that 24 Vac is present
between R and C. If the LED is not lit and 24 Vac is
present replace the IGN. If the Digital Display is not
Resetting Cooling and Heating
lit and 24 Vac is present replace the mainboard. If Lockouts
24 Vac is not present, check fuse 2 on the
Cooling Failures and Heating Lockouts are reset in an
mainboard and check transformer (TNS1). Proceed
identical manner.
to Step 4 if necessary.
Method 1 section explains resetting the system from
4. If no failures are indicated, use the TEST mode
the space; Method 2 section explains resetting the
procedures described in the “Unit Start-Up” section
system at the unit.
or thermostat to start the unit. This procedure will
allow you to check all of the external controls N o t e : Before resetting Cooling Failures and Heating
(relays, contactors, etc) and the IGN. Lockouts check the Failure Status Diagnostics by
the methods previously explained. Diagnostics
5. Test the system through all of the available modes,
will be lost when the power to the unit is
disconnected.

Method 1
To reset the system from the space, turn the “Mode”
After approximately 30 seconds, turn the “Mode”
selection switch at the thermostat to the “Off” position.
selection switch to the desired mode, i.e. Heat, Cool or
Auto.

23
Method 2
To reset the system at the unit, cycle the unit power by
turning the disconnect switch “Off” and then “On”.

Table 10. Troubleshooting chart

Symptom Possible Cause Remedy
Check for correct voltage at compressor contactor in
Power off or loose electrical connection
control box
Thermostat out of calibration-set too high Reset
Check for 24 volts at contactor coil - replace if contacts are
Failed contactor
Unit will not run open
Blown fuses Replace fuses

Transformer defective Check wiring - replace transformer

Interconnecting low voltage wiring damaged Replace thermostat wiring

Run or start capacitor failed (single phase only) Replace

Check for correct voltage at compressor - check and
Loose connection
tighten all connection
Condenser fan runs, compressor Compressor stuck, grounded or open motor Wait at least 2 hours for overload to reset. If still open,
doesn't winding open internal overload replace the compressor.
Determine cause and correct. At compressor terminals,
Low voltage condition voltages must be within 10% of rating plate volts when
unit is operating.
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.
Insufficient cooling
Air, non-condensible or moisture in system Recover refrigerant, evacuate & recharge, add filter drier

Determine cause and correct. At compressor terminals,

Incorrect voltage voltages must be within 10% of rating plate volts when
unit is operating.
At compressor terminals, voltage must be ±10% or
Incorrect voltage
nameplate marking when unit is operating.
Compressor short cycles Defective overload protector Replace - check for correct voltage

Refrigerant undercharge Add refrigerant

Dirty air filter Replace filter

Unit undersized for load Decrease load or increase unit size

Compressor operates Thermostat temperature set too low Reset thermostat

continuously Low refrigerant charge Locate leak, repair, and recharge

Air in system Recover refrigerant, evacuate system, and recharge

Outdoor coil dirty or restricted Clean coil or remove restriction

Registers sweat Low evaporator airflow Increase speed of blower or reduce restriction - replace air
filter
Restriction in liquid line, expansion device or filter
Remove or replace defective component
drier
High head-low vapor pressure Flow check piston size too small Change to correct size piston

Incorrect capillary tubes Change coil assembly

Dirty condenser coil Clean coil

High head-high or normal vapor Refrigerant overcharge Correct system charge

pressure - Cooling mode Condenser fan not running Repair or replace

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

Defective compressor valves Replace compressor

Low head-high vapor pressures

Incorrect capillary tubes Replace coil assembly

Table 10. Troubleshooting chart (continued)

Symptom Possible Cause Remedy

Increase speed of blower or reduce restriction - replace air
Low evaporator airflow
Low vapor - cool compressor - filter
iced evaporator coil
Moisture in system Recover refrigerant - evacuate & recharge - add filter drier

Excessive load Recheck load calculation

High vapor pressure
Defective compressor Replace

Fluctuating head and vapor hunting Check air distribution on coil -replace Throttle
pressure
Air or non-condensible in system Recover refrigerant - evacuate and recharge
Gurgle or pulsing noise at
Air or non-condensible in system Recover refrigerant - evacuate and recharge
expansion device or liquid line
Circulating air blower and Manual reset overtemperature control tripped Reset or replace
inducer run continuously,
compressor will not start Wire loose in limit circuit Check wiring

Water in gas line Drain. Install drip leg.

No power to furnace Check power supply fuses, wiring or circuit breaker.

No 24 volts power supply to control circuit Check transformer.

Miswired or loose connections Check all wiring and wire nut connections
Burners will not ignite
Check flame ignition and sense electrode positioning.
Misaligned spark electrodes
Adjust as necessary
Check gas line for air. Purge as necessary. NOTE: After
purging gas line of air, wait at least 5 minutes for any gas to
No gas at main burners dissipate before attempting to light unit.
Check gas valve.

Dirty air filter Clean or replace filter as necessary

Check gas pressure at manifold with that on unit
Gas input to furnace too low
nameplate
Unit undersized for application Replace with proper unit or add additional unit
Inadequate heating
Restricted airflow Clean or replace filter, remove any restriction

Check rotation of blower, temperature rise of unit. Adjust

Limit switch cycles main burners
as necessary.

Tighten all screws around burner compartment

Cracked heat exchanger. Replace as necessary.

Incomplete combustion results in: Aldehyde odors, Unit over-fired. Reduce input (change orifices or adjust gas
Poor flame characteristics line
carbon monoxide, sooting flame, floating flame
or manifold pressure).

Check burner alignment

Inspect heat exchanger for blockage. Clean as necessary.

Both condenser fan and

compressor startup and Abnormal high discharge pressure caused the high Reference to the remedy of ‘High head-high or normal
shutdown frequently (about pressure switch act vapor pressure-cooling mode’.
three minutes per cycle)
Johnson Controls, Inc. Milwaukee, USA www.johnsoncontrols.com Form:
Middle East and Africa Customer Care Email : [email protected]

Johnson Controls reserve the right to change product features without prior notice.