Owners Manual RGAD SGAD R410a Gas Heating - Enviro-Tec
Contents
1. FORM 145 25 O1 908 SKYPAK R SERIES REPLACEMENT PARTS LIST R410 A 4018 6018 4024 6024 CONDENSER BLOWERS BLOWER 10 5 8 X 6 CCW AIRDEX 6817175 EVAPORATOR BLOWERS BLW 1060TL BLOWER 10 X 6 CCW AIRDEX 6837225 X X CONDENSER MOTORS CAPACITORS MTR 106R 1 6HP 208 230 1 60 1 SPD 825 RPM F48 MTR 103R 1 4HP 208 230 1 60 1 SPD 1075 RPM F48 CPC K5B MOTOR RUN CAPACITOR 5MF 370V EVAPORATOR MOTORS CAPACITORS MTR 107R 1 6HP 230 1 60 3 SPD 1075 RPM F48 X X MTR 104R 1 4HP 208 230 1 60 3 SPD 1075 RPM F48 X X CPC K5B MOTOR RUN CAPACITOR 5MF 370V X X X X POWER VENTOR BLOWER MOTOR PVG 66 POWER VENTOR GASKET X X X X COMPRESSORS CAPACITORS CMP 016K5E SCROLL 208 230 1 60 COPELAND ZP16K5E PFV 130 CPC K30B RUN CAPACITOR 30MF 370V CMP 021K5E SCROLL 208 230 1 60 COPELAND ZP21K5E PFV 130 CPC K40B RUN CAPACITOR 40MF 370V PTC 05 COMP START DEVICE COPELAND 014 0035 05 PLG 016PK COMPRESSOR WIRING PLUG CCL S017 4 CONDENSER COIL 14 X 32 SKYMARK R 410A CCL S023 4 CONDENSER COIL 14X32 I R 410A EVAPORATOR COILS ECL SO17L 4 EVAP COIL 14X21 R 410A ECL S023L 4 EVAP COIL 18X21 R 410A ELECTRICAL CONTROLS CTC 012PK CONTACTOR 2 POLE 30 AMP 24V TRF 502 TRANSFORMER 24 230V 50VA BCM 2032B MODULE HONEYWELL ST9120G2032B or G4038 GVI 2603PK GAS VALVE HONEYWELL SV9500M2603B HSPB 1003PK IGNITION PILOT HONEYWELL Q3450C1029B VLV 015 410 THERMAL EXPANSION VALVE ALCO BAE 1 1 22W 1952. REK Emi e riyri MM M PSW PK01 VACUUM SWITCH SKYMARK PSW 610 MAN RESET HIGH PRESS SWITCH 610PSIG SWI 180PK HIGH LIMIT SWITCH 180o LIMIT d FLM PKO1 FLAME ROLL OUT SWITCH SKYP HAX 02 X HEAT EXCHANGER ASSEMBLY 3 TUBE MBA 500P MAIN BURNER NOZZLE OBN 000P ORIFICE BURNER NAT 2 15MM LPKIT 40 PROPANE CONVERSION KIT 40 MBH LPKIT 60 PROPANE CONVERSION KIT 60 MBH PVEXTUBE POWER VENTOR EXTENSION TUBE ECDA 018PK REFRIGERANT DISTRIBUTOR 1 amp 1 5 TON 2 PIPE ECDA 024PK REFRIGERANT DISTRIBUTOR 2 TON 3 PIPE FDY 053PK FILTER DRIER 3 8 gt gt gt gt gt gt gt gt A gt gt gt gt gt gt gt gt gt X gt x 10 JOHNSON CONTROLS FORM 145 25 01 908 SKYPAK S SERIES REPLACEMENT PARTS LIST R410A LEGEND X COMMON MODEL USAGE L LEFT HAND CONFIGURATION UNITS eg SGAD401812 LC A R RIGHT HAND CONFIGURATION UNITS eg SGAD602412 RC A PART NUMBER DESCRIPTION SGAD 2012 4012 4018 6018 4024 6024 6030 8030 CONDENSER BLOWERS BLW 916R BLOWER 9 X6 CCW AIRDEX 6837025 L L BLW 1020R BLOWER 10 X 6 CCW AIRDEX 6837165 L L L L BLW 704 BLOWER 10 X 7 CCW AIRDEX 6837175 L L BLW 916CW JBLOWER 9 X6 CW AIRDEX R R BLW 1020CW BLOWER 10 X6 CW AIRDEX R R R R BLW 704CW JBLOWER 10 X6 CW AIRDEX R R EVAPORATOR BLOWERS BLW 416E BLOWER 9 X4 CCW AIRDEX 6837015 L L BLW 916R BLOWER 9 X6 CCW
3. A qualified service agency should be contacted to inspect the furnace and to replace all gas controls control system parts electrical parts that have been wet or the furnace if deemed necessary Inspect and replace return air filters as recom mended in Section 7B of this manual The furnace is equipped with both temperature and pressure switches to shut off the furnace if unsafe operating conditions occur These safety switches must not be altered in any way Call a qualified service agency if problems occur Prior to each heating season the following specific items should be checked annually a The flue gas exhaust duct outlet visible behind the upper right corner of the exterior wall grille is clear and free of obstruction b The return air duct connection s is physically sound is sealed to the furnace casing and terminates outside the space containing the furnace c The physical support of the furnace is sound without sagging cracks gaps etc around the base so as to provide a seal between the support and the base d An overall physical inspection confirms that there are no obvious signs of deterioration corroded electrical connections fluid stains signs of rust excess accumulation of dirt or debris e The pilot and burner flames are in good adjust ment as described in Section 7E SECTION 3 UNDERSTANDING HOW YOUR HEATING SYSTEM WORKS When your indoor temperature drops below the tem perature s
4. AIRDEX 6837025 L L BLW 1060TL BLOWER 10 X 6 CCW AIRDEX 6837225 L L BLW 1020R BLOWER 10 X6 CCW AIRDEX 6837165 L L BLW 416R BLOWER 10 X 4 CCW AIRDEX 6827015 R R BLW 916CW JBLOWER 9 X6 CW AIRDEX 6817205 R R BLW 1060TR BLOWER 10 X6 CW AIRDEX 6827225 R R BLW 1020CW JBLOWER 10 X6 CW AIRDEX 6817175 R R CONDENSER MOTORS CAPACITORS MTR 106R 1 6HP 208 230 1 60 1 SPD 825 RPM F48 X X X X MTR 103R 1 4HP 208 230 1 60 1 SPD 1075 RPM F48 X X MTR 1037S 1 3HP 208 230 1 60 1 SPD 1075 RPM F48 X X CPC K5B MOTOR RUN CAPACITOR 5MF 370V X X X X X X X X EVAPORATOR MOTORS CAPACITORS 1 10 1 15 1 20 1 25HP 4 SPD MITRI 208 230 1 60 1075 RPM F48 X MTR 107R 1 6HP 230 1 60 3 SPD 1075 RPM F48 X X X MTR 104R 1 4HP 208 230 1 60 3 SPD 1075 RPM F48 X X X X CPC K5B MOTOR RUN CAPACITOR 5MF 370V X X X X X X X X POWER VENTOR BLOWER MOTOR MTR 136PK 1 1 AMP 208 230 1 60 FASCO 7021 9136 L L L L L L L PVENT 02R 1 1 AMP 208 230 1 60 FASCO 7021 10599 R R R R R R R PVG 66 POWER VENTOR GASKET X X X X X X X COMPRESSORS CAPACITORS CMP 092T 410 ROTARY 208 230 1 60 TECHUMSEH RGA5510BXD X X CPC K20B RUN CAPACITOR 20MF 440V X X CMP 016K5E SCROLL 208 230 1 60 COPELAND ZP16K5E PFV 130 X X CPC K30B RUN CAPACITOR 30MF 370V X X CMP 021K5E SCROLL 208 230 1 60 COPELAND ZP21K5E PFV 130 X X CPC K40B RUN CAPACITOR 40MF 370V X X CMP 025K5E SC
5. ever suspect a malfunction in your furnace you will need to turn the furnace OFF The following procedures must be followed Should overheating occur or the gas valve fail to shut off the gas supply turn off the manual gas valve See Fig 2 to the furnace BEFORE turning off the electrical supply Failure to follow these instructions exactly may result in a fire or explosion causing property damage personal injury or death 1 Setthe room thermostat to the lowest temperature setting 2 The gas supply to the furnace can be turned off at the manual shut off valve in the gas pipe just before where the pipe enters the furnace JOHNSON CONTROLS FORM 145 25 O1 908 LD13411 Figure 3 Typical Furnance External Manual Gas Valve NOTE IN THE COMMONWEALTH OF MASSACHUSETTS A T HANDLE GAS COCK MUST BE INSTALLED If you are not able to turn off the external manual shut off valve outside the furnace turn off the gas supply with the main shut off valve at the gas meter outside the house Figure 4 If the furnace operates on propane close the shut off valve on the propane cylinder The following illustration shows a typical shut off valve in the open and closed positions LD13412 Figure 4 Typical Gas Meter Gas Valve 3 Turn OFF all electrical power to the furnace If you are unable to turn off the electrical supply using the disconnect switch near the furnace turn off the electrical power to the furnace by u
6. grille at the outside wall The furnace must not be operated without this exhaust duct extension If possible verify the condition of the vent pipe by visual inspection through the outside wall grille If excessive rust is observed call your dealer for service The exhaust outlet from the Skypak furnace must not be connected to any other vent pipe or chimney All access doors must be installed for this direct vent furnace to operate properly and safely B FILTER MAINTENANCE Never operate your furnace without a filter in place Doing so may damage the furnace blower motor An accumulation of dust and lint on internal parts of your furnace can cause a loss of efficiency A dirty filter will cause excessive stress on the furnace heat exchanger and blower motor and can cause it to overheat and automatically shut down The furnace filter should be checked every 4 weeks or so and cleaned or replaced as necessary STANDARD FACTORY SUPPLIED FILTER TYPE All furnace models are shipped with an internally sus pended wire frame style filter rack hammock type The unitis supplied complete with a 1 inch thick replace able media filter See Figure 5 The universal wire frame rack has been designed to provide filtration in either side return or bottom return applications JOHNSON CONTROLS sg 4 LD13383 Turn off electrical power supply to your furnace before removing any of the access doors to service or perform maintenan
7. system FORM 145 25 O1 908 SECTION 4 OPERATING YOUR FURNACE If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life WARNING A This appliance is equipped with an electric ignition device which automatically lights the pilot and the main burners Do nottry to light the pilot and main burners by hand BEFORE OPERATING smell all around the ap pliance area for gas Be sure to smell next to the floor because some gas is heavier than air and may have settled on the floor STARTING YOUR FURNACE 6 STOP Read the safety information above on this page Set the thermostat to its lowest setting Close GAS OFF the external manual gas valve located in the gas supply pipeline adjacent to the furnace Figure 3 Turn OFF all electrical power to the furnace This furnace is equipped with an electric ignition device which automatically lights the pilot and the main burners Do not try to light the pilot and main burners by hand Remove the largest of the access doors on the furnace 7 Locate the gas control valve in the gas pipe and move the Ignition System Control Switch to the OFF position as shown in Figure 2 PRESSURE REGULATOR e K3NITER ADJUSTMENT U CAP SCREW INLET PRESSURE E NDER CONNECTOR P L OT ADJUSTMENT IGNITION SYSTEM UNDER CAP SCREW CONTROL SWITCH Figure 2
8. using brushes and a vacuum cleaner Significant buildups on the main burners can cause faulty firing Delayed ignition is characterized by a loud noise when the main burners are ignited This condi tion indicates that a service call is required as soon as possible LD13413 Figure 7 Main Bruner JOHNSON CONTROLS SECTION 8 BEFORE REQUESTING A SERVICE CALL If your furnace is operating but not heating your house 1 2 3 4 9 Check your air filter for excessive dirt build up by following the instructions in the air filter section of this manual Check for blocked supply air registers and return air grilles They should be open clean and unob structed Make sure your thermostat is set above the room temperature Make sure your thermostat is not near a heat source such as a lamp television computer direct sunlight or a fireplace If your furnace still fails to provide sufficient heat call a qualified service technician Have your fur nace model and serial number ready JOHNSON CONTROLS FORM 145 25 O1 908 If your furnace does not operate at all Make sure your thermostat is in the HEAT posi tion Make sure your thermostat is set above the room temperature Check for blown fuses or tripped circuit breakers Make sure your gas is ON If your furnace still fails to operate call a qualified service technician Have your furnace model num ber and serial number ready
9. ATION Model Number Serial Number Date Installed Installer Service Agency Address City State Zip Code Telephone Number A WARNING Improper servicing could result in dangerous operation serious injury death or property damage ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to the furnace e When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing SECTION 2 IMPORTANT SAFETY PRECAUTIONS Read Before Operating 1 The Skypak gas furnace is a DIRECT VENT ap pliance which is equipped with a built in ventor blower The products of combustion are exhausted directly to the outdoors through a small rectangular duct 2 3 4 in X 1 3 4 in which extends through the wall sleeve from the back of the unit and ter minates 1 to 1 1 4 in from the back of the grille at the outside wall Ask the installer to verify that the exhaust duct extension is properly installed as described above if you cannot see it by looking through the top right corner of the wall grille JOHNSON CONTROLS 2 3 4 9 6 T 8 9 10 N 11 12 FORM 145 25 O1 908 Never allow the furnace to be operated without all the access doors installed Thes
10. Furnace Gas Control LD13370 JOHNSON CONTROLS 8 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow the safety instructions on the front of this manual What to do if you smell gas If you do not smell gas go to the next step 9 Move the Ignition System Control Switch to the ON position 10 Replace the access door on the furnace 11 Turn ON the electrical power to the furnace 12 Open GAS ON the external manual gas valve 13 Set room thermostat to a setting slightly above room temperature This will automatically signal the furnace to start 14 Furnace operation begins with the starting of the small ventor blower which induces the flow of com bustion air through your furnace s heat exchanger The hot surface igniter will glow bright orange to light the small pilot flame Once the ignition system detects that the pilot flame has been established the gas valve permits gas to flow to the main burn ers where it is ignited by the pilot flame If the main burners fail to ignite on the first trial the furnace control system will go through 2 more ignition cycles If the burners fail to ignite after 3 trials the sys tem will lockout If lockout occurs or the main circulating air blower fails to turn on shut down your furnace and call your quali fied service technician or gas supplier SECTION 5 SHUTTING OFF YOUR FURNACE Should you
11. Models RGAD amp SGAD R410A User s Information Maintenance And Service Manual Supersedes 145 25 O1 708 Form 145 25 O1 908 MODELS RGAD amp SGAD R410A USER S INFORMATION MAINTENANCE AND SERVICE MANUAL CATEGORY III GAS HEATING ELECTRIC COOLING UNITS Model RGAD Capacities 18 000 24 000 Btu Hr Cooling 40 000 60 000 Btu Hr Heating Model SGAD Capacities 12 000 18 000 24 000 amp 30 000 Btu Hr Cooling 20 000 40 000 60 000 amp 80 000 Btu Hr Heating Not all cooling capacities available in all heating capacities FIRE OR EXPLOSION HAZARD A Failure to follow safety warnings exactly could result in serious injury death or property damage Do not store or use gasoline or other flammable vapors and iquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier ATTENTION USER Before operating this appliance read all the instructions contained within this manual Retain this manual for future reference FORM 145 25 O1 908 SECTION No TABLE OF CONTENTS PAGE WARNING What to do if you smell
12. ROLL 208 230 1 60 COPELAND ZP25K5E PFV 130 X X CPC K45B RUN CAPACITOR 45MF 370V X X PTC 05 COMP START DEVICE COPELAND 014 0035 05 X X X X X X X X PLG 016PK COMPRESSOR WIRING PLUG X X X X X X X X CONDENSER COILS CCL S011 4 CONDENSER COIL 14X32 R410A SKYMARK X X CCL S017 4 CONDENSER COIL 14X32 R410A i X X CCL S023 4 CONDENSER COIL 14X32 R410A X X CCL S029 4 CONDENSER COIL 14X32 R410A X X JOHNSON CONTROLS 11 FORM 145 25 O1 908 NUMBER 2012 4012 4018 6018 4024 6024 6030 8030 EVAPORATOR COILS ECL S011L 4 JEVAP COIL 14X21 R410A SKYMARK ECL S017L 4 JEVAP COIL 14X21 R410A ECL S023L 4 JEVAP COIL 18X21 R410A ECL S029 4 EVAP COIL 20X21 R410A ECL SO11R 4 JEVAP COIL 14X21 R410A ECL S017R 4 EVAP COIL 14X21 R410A ECL S023R 4A JEVAP COIL 18X21 R410A ECL SO29R 4 JEVAP COIL 20X21 R410A ELECTRICAL CONTROLS CTC 012PK CONTACTOR 2 POLE 30 AMP 24V TRF 503PK TRANSFORMER 24 230V 50VA BCM 2032B MODULE HONEYWELL ST92032G2032B or G4038 GVI 2603PK GAS VALVE HONEYWELL SV9500M2603B HSPB 1003PK JIGNITOR PILOT HONEYWELL Q3450C1029B REFRIGERANT CONTROL VALVES VLV 001 410 THERMAL EXPANSION VALVE ALCO ANE1ZW195 X X VLV 015 410 THERMAL EXPANSION VALVE ALCO BAE 1 1 22W 195 VLV 002 410 THERMAL EXPANSION VALVE ALCO BAE 22W 195 VLV 003 410 THERMAL EXPANSION VALVE ALCO BAE 3 ZW195 X X MISCELLANEOUS PSW PKO01 VACUUM SWITCH SKYMARK PSW 610 MAN RESET HIGH PRESS SWITCH 610P
13. SIG SWI 180PK HIGH LIMIT SWITCH 1800 LIMIT FLM PKO1 FLAME ROLL OUT SWITCH SKYP HAX 01 X HEAT EXCHANGER ASSEMBLY LEFT HAND 2 TUBE SKYP HAX 02 X HEAT EXCHANGER ASSEMBLY LEFT HAND 3 TUBE SKYP HAR 01 X HEAT EXCHANGER ASSEMBLY RIGHT HAND 2 TUBE SKYP HAR 02 X HEAT EXCHANGER ASSEMBLY RIGHT HAND 3 TUBE HTE 002P HEAT EXCHANGER ASSEMBLY 4 TUBE MBA 500P MAIN BURNER NOZZLE OBN 000P ORIFICE BURNER NAT 2 15MM GAKT 034P SKYPAK WEATHER GASKET LPKIT 40 PROPANE CONVERSION KIT 40 MBH LPKIT 60 PROPANE CONVERSION KIT 60 MBH LPKIT 80 PROPANE CONVERSION KIT 80 MBH PVEXTUBE POWER VENTOR EXTENSION TUBE ECDA 018PK REFRIGERANT DISTRIBUTOR 1 amp 1 5 TON ECDA 024PK REFRIGERANT DISTRIBUTOR 2 TON FDY 033PK FILTER DRIER 3 8 REPLACEMENT PARTS CAN BE OBTAINED FROM YOUR LOCAL SKYPAK DISTRIBUTOR 12 FDY 053PK FILTER DRIER 3 8 JOHNSON CONTROLS FORM 145 25 O1 908 LIMITED WARRANTY RGAD SGAD FURNACE AIR CONDITIONER Johnson Controls warrants this product to be free from defects in workmanship or material for a period of one year from date of original installation or 18 months from date of shipment whichever comes first Johnson Controls obligation under this Warranty is LIMITED to repairing or replacing at our sole option at our factory any part thereof which shall be returned to our factory transportation charges prep
14. aid and which on examination proves to have been thus defective under normal domestic use not exceeding the fuel rating The defective part should be returned through a qualified servicing dealer Upon warranty determination the replacement part will be shipped freight collect and assumes the unexpired portion of this Limited Warranty When a defective part can be repaired or replaced Johnson Controls shall not be obligated to repair the entire unit or any part thereof other than the defective part This warranty applies only to the original homeowner and is subject to the terms and conditions hereof COMPRESSOR FIVE YEAR LIMITED WARRANTY In addition to the One Year Limited Warranty Johnson Controls warrants the compressor to be free from defects in workmanship or material for a period of five 5 years from the date of original installation If a compressor fails during this five year period a new com pressor will be supplied The customer will be responsible for freight costs from our factory for delivery of the replacement compres sor and also for the return of the defective compressor which may be required under the terms of the Warranty Labor and any other expense involved in replacing the compressor is not covered by this Warranty HEAT EXCHANGER TEN YEAR LIMITED WARRANTY In addition to the One Year Limited Warranty Johnson Controls warrants the heat exchanger to be free from defects in workmanship for a period of ten 10 years f
15. ce Failure to follow this warning could result in personal injury WARNING or death LD134382 Figure 5 Standard Factory supplied Filter The filter and rack assembly must be inspected and replaced through the evaporator blower access door The four door retaining screws must be removed to access the filter Squeeze the side of the wire frame together and slide the rack assembly off of the support rails The filter media is fastened to the wire frame by means of the two side clamping brackets Unhook the clamp brackets and remove the used media JOHNSON CONTROLS FORM 145 25 O1 908 Replacement filter media must be the same size and type as the original The replaceable media size is 24 in X 34 in Fasten the new media under one clamping bracket lightly stretch over the frame and secure un der the opposite clamping bracket Re install the rack assembly into the blower compartment and securely fasten the blower access door OPTIONAL FLAT FILTER RACK INSTALLATION SIDE RETURN APPLICATION ONLY This accessory filter rack allows the use of flat panel fil ters High efficiency high capacity or chemically treated filters may be used in this optional filter rack FROM LD13226 The flat panel filter will be positioned over the side return air opening immediately external to the furnace casing The filter required is a disposable fiberglass filter having a nominal size of 16in X 25in X 1 in thick The
16. e furnaces draw air for combustion through the exterior wall grille For proper and safe operation make sure the exterior grille is kept clear of any obstructions to airflow This furnace requires an adequate ventilation air supply for proper and safe operation Do not block or obstruct any air openings connecting to the area in which the furnace is installed The furnace area must be kept clear and free of combustible materials gasoline and other flam mable vapors and liquids These include kerosene cleaning fluids solvents paint thinner or paint Keep the clearance spaces around the furnace free and clear of insulating material Examine the furnace area after the initial installation and re examine if additional insulation is added in the furnace area Some insulating materials may be combustible Become familiar with the sequence of operation and how to safely turn on and turn off your furnace as described in Sections 3 4 amp 5 Should the gas supply fail to shut off or if overheat ing occurs shut off the gas valve to the furnace be fore shutting off the electrical supply Learn where and how to shut off the gas and the electric power to the furnace Ask the installer to show you how to do this Further details on how to do this are given In Section 5 Do not use this furnace if any part has been under water A flood damaged furnace is extremely dangerous Attempts to use the furnace can result in fire or explosion
17. et on your thermostat the thermostat turns your furnace on as follows 1 Furnace operation begins with the starting of the small ventor blower which induces the flow of combustion air through your furnace s heat ex changer 2 When the flow of combustion air is sufficient for proper combustion a pressure switch turns on the ignition system The ignition system ignites a pilot flame which in turn lights the main burners The flames from the main burners are pulled through the inside of the heat exchanger heating the serpentine tube assembly 3 Thirty seconds after the main the main burners light a computerized control turns on your circulating blower The circulating blower pulls air through your cold air return and your air filter and then pushes it across the outside of the heat exchanger 4 Asthe air passes over the heat exchanger the heat transfers from the heat exchanger to the air being blown across it The heated air is then returned to your house through your registers 5 During operation your furnace is monitored con stantly by a series of safety controls and tempera ture limit switches which act to turn off the furnace if any unsafe condition occurs 6 The furnace s burners operate until your room temperature reaches the setting on the thermostat After the burners turn off the circulating blower con tinues to operate for one minute in order to remove the remaining heat from the heat exchanger and duct
18. filter can be slid into or out of the rack from the front of the unit Tools are not required to examine or replace this filter type If the air filter has been installed in another location contact your service dealer for instructions NOTE It is recommended that filters be inspected monthly until it is found how long it takes for the filter to become dirty enough to require replacing It is a good policy to replace filters at least twice a year C GENERAL INSPECTION Examine the furnace installation for the following items It is recommended that the furnace be inspected once a year by a qualified service technician An nual inspections should include checking the fol lowing i The wall grille must be clear of any obstructions that could restrict airflow into the unit or cause exhaust to be recirculated i The exhaust vent extension pipe must be in place and terminating within 1 1 4 inch from the back of the wall grille The vent pipe and vent pipe exten sion must be physically sound without holes or excessive corrosion ii The return air duct should be physically sound sealed to the furnace casing and terminate outside the space containing the furnace iv The physical support of the furnace must be sound without sagging cracks gaps etc around the base so as to provide a seal between the support and the base v There must be no obvious signs of deterioration of the furnace D BLOWERS The blowe
19. gas Front Cover SECTION 1 Recording rating plate and other information 3 SECTION 2 Important safety precautions Read before operating 3 SECTION 3 Understanding how your heating system works 4 SECTION 4 Operating your furnace 4 SECTION 5 Shutting OFF your furnace 5 SECTION 6 Operating your air conditioning 6 SECTION 7 Maintenance of your unit 6 TA Combustion Air amp Venting 6 7B Filter Maintenance 6 7C General Inspection 8 7D Blower 8 7E Igniter amp Burners 8 SECTION 8 Before requesting a service call 9 SECTION 9 Parts Lists 10 SUPPLY WALL SLEEVE EVAPORATOR COIL ACCESS DOOR CONDENSER SECTION MAIN ELECTRICAL ACCESS DODFE GAS HEAT SECTION ACCESS DOOR SIDE RETURN AIF FIELD SELECTABLE l LEFT Peri JUHIT SHIA RETURN AIR FIELD SELECTABLE Ev PORATOR BLOWER t BOTTOM ACCESS DOOR LD13376 2 JOHNSON CONTROLS SECTION 1 RECORDING RATING PLATE amp OTHER INFORMATION Record the furnace model number and serial number in the space provided below This information is displayed on your furnace rating plate located on the upper sec tion of the blower door Also record the installation date which is important for warranty purposes Also fill in the installer s name address and telephone number This will be handy if you have questions later Some companies install an identification tag on furnaces they install or service If not ask for the information YOUR FURANCE INFORM
20. p until the next cycle begins SECTION 7 MAINTENANCE OF YOUR UNIT A furnace is not a simple household appliance It is a complex mechanical assembly and requires profes sional maintenance and repair Other than performing the simple maintenance recommended in this manual you should not attempt to make any mechanical adjust ments to your furnace A periodic inspection of your furnace should be made by a qualified service agency at the start of each heating season NOTE With proper maintenance and care your furnace will operate economically and dependably Basic main tenance procedures which can be accomplished by someone who follows directions are found on the fol lowing pages FORM 145 25 O1 908 A COMBUSTION AIR amp VENTING The Skypak gas furnace is a DIRECT VENT appliance which is equipped with a built in ventor blower All air required for proper combustion is drawn in from the outdoors through the wall sleeve and grille to which the furnace is attached Air for combustion must NOT be contaminated by halo gen compounds which include fluoride chloride bro mide and iodide Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products The products of combustion are exhausted directly to the outdoors through a small rectangular duct which extends through the wall sleeve and terminates 1 to 1 1 4 in from the back of the
21. r size and speed determine the air volume delivered by the furnace Both the indoor and outdoor blower motors and the exhaust vent blower motor all feature permanently lubricated that do not require oil ing Annual cleaning of the blower wheel and housing is recommended for maximum air output this should be performed only by a qualified servicer or service agency E IGNITER amp BURNERS These furnaces use a special hot surface igniter to light the pilot burner Please note that this assembly is very fragile and should only be handled with care Do not touch igniter It can be extremely I hot CAUTION FORM 145 25 O1 908 z 3 8 TO 1 2 IN Pk 10 TO 13 MM 4 PROPER FLAME ADJUSTMENT hm GROUND ELECTRODE FLAME ROD HOT SURFACE IGNITER NOTE GROUND ELECTRODE MUST NOT TOUCH FLAME ROD 050 IN MINIMUM CLEARANCE BEND GROUND ELECTRODE IF NECESSARY DO NOT BEND FLAME ROD M33504 Figure 6 Pilot Burner Gas burners do not normally require scheduled servic ing However accumulations of dirt soot or rust and result in a loss of efficiency and improper performance The pilot and burner flames should be in good adjust ment as shown in figures 6 and 7 The main burner flames should be clear blue and centered within the heat exchanger openings Any yellowing of the burner flames indicates that cleaning and or adjustment of the burners is required For best operation burners should be cleaned annually
22. rom the date of original installation During this time a new replacement heat exchanger will be furnished or at our sole option a credit for the replacement heat exchanger may be allowed Labor and other expenses involved in replacing the heat exchanger are not covered by this warranty This Warranty applies only to the heat exchanger and not to other parts of the furnace and only to the original homeowner and is subject to the terms and conditions hereof LABOR AND COST NOT COVERED This Warranty provides only replacement parts or credits and does not provide for or cover any labor shipping handling or other costs for service travel servicing removing or installing any parts EXCLUSIONS This Warranty shall be void if 1 The unitis not installed by a licensed or otherwise qualified or contractor and in compliance with the Installation Manual applicable installation and good trade practices 2 The defect or damage is caused by accident abuse negligence of any person or company misuse riot flood fire or Acts of God 3 The unit is not operated and regularly serviced and maintained as called for in the Users Manual Damages are caused by operating the unit in a commercial or corrosive atmosphere containing any damaging or dangerous chemicals 5 The unit is modified or services in a manner not in accordance with the Installation Manual and Users Manual 6 Components replacement parts or other accessories not compatible
23. sing the circuit breaker that supplies the furnace from the main electrical panel 4 Remove the largest access door on the furnace which is nearest to where the gas pipe enters the furnace 5 Move the slide switch on the gas control valve to the OFF position See Fig 2 6 Replace the access door 7 If the furnace is being shut down because of a malfunction call your qualified service technician or gas supplier as soon as possible SECTION 6 OPERATING YOUR AIR CONDITIONING The Air Conditioning section of this equipment is charged with R 410A a hi pressure refrigerant Only qualified technicians using appropriately pres sure rated test instruments should perform troubleshooting or service on this equipment 1 Make sure the electric power is turned on at the disconnect 2 Set the room thermostat to the desired tempera ture 3 Move the system selector switch on the thermostat to the COOL position 4 Move the fan switch on the thermostat to the AUTO position The compressor and condenser fan should then start as soon as the thermostat is calling for cooling 5 After a short delay of four seconds the blower will start to circulate cool air When the room tempera ture drops to the setting on the room thermostat the compressor and condenser fan will stop im mediately 6 The blower will continue running or another 100 seconds to extract all of the cooling available from the cooling coil and then sto
24. with the unit or not approved by Johnson Controls have been used with or attached to the unit The defect or damage is not caused by Johnson Controls or it arises from circumstances beyond the control of Johnson Controls The unit is installed outside the United States or Canada or has been removed from the place where it was originally installed THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES OBLIGATIONS OR LIABILITIES EXPRESSED OR IMPLIED BY EMPLOYEES OR REPRESENTATIVES OF JOHNSON CONTROLS ALL STATUTORY EXPRESSED OR IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY NEGATED AND EXCLUDED ANY CLAIMS FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES OR ANY OTHER DAMAGES OR EXPENSES BEYOND THE TERMS OF THIS LIMITED WARRANTY ARE HEREBY EXPRESSLY NEGATED AND EXCLUDED JOHNSON CONTROLS 13 Subject to change without notice Printed in U S A Copyright 2008 by Unitary Products Group All rights reserved Engineered Systems P O Box 1592 Products York PA Group 17405 Form 145 25 01 908 Supersedes 145 25 O1 708 York PA 17405
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