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National Comfort Products COMFORT PACK CPG 41838-U Series Instruction Manual

Gas & electric models
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3rd Edition
C C MF
MF RT PACK
RT PACK
SERVICE
GUIDE
Gas & Electric
Models
National Comfort Products
NATIONAL
Go Thru-the-Wall
®
A Division of National Refrigeration and Air Conditioning Products, Inc.
COMFORT
(800) 523-7138
PRODUCTS
ncpservice @ nrac.com
www.nationalcomfortproducts.com
HEATING & A/C EQUIPMENT

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Summary of Contents for National Comfort Products COMFORT PACK CPG 41838-U Series

  • Page 1 3rd Edition C C MF MF RT PACK RT PACK SERVICE GUIDE Gas & Electric Models National Comfort Products NATIONAL Go Thru-the-Wall ® A Division of National Refrigeration and Air Conditioning Products, Inc. COMFORT (800) 523-7138 PRODUCTS ncpservice @ nrac.com www.nationalcomfortproducts.com...

  • Page 3: Table Of Contents

    Table of Contents Model Number Identification ....................Page 4 Unit Dimensions .......................Page 5 Gas Furnace ........................Page 12 Gas Furnace Specifications A, B, C, D, E-Series Non-Condensing Furnace Models ..Page 12 Gas Furnace Specifications U-Series Non-Condensing Furnace Models ......Page 13 Gas Furnace Specifications U-Series Condensing Furnace Models ........Page 14 Electric Furnace .......................Page 40 Cooling Chassis .......................Page 42 Wiring Diagrams .......................Page 58...

  • Page 4: Model Number Identification

    Comfort Pack Model Number Identification Options, Last 2 Digits if used for factory use Model Number * * * C P G 4 1 8 3 8 - U CP=Comfort = Edition – Factory use Pack G =Gas = Generation – Factory use E =Electric Refrigerant Options...

  • Page 5: Unit Dimensions

    Unit Dimensions Original R22 with Gas Heat (A & B Series) 43" " " " "...
  • Page 6 Unit Dimensions Original R22 with Electric Heat (A & B Series)
  • Page 7 Unit Dimensions Original R410A with Gas Heat (B, C, D, E Series)
  • Page 8 Unit Dimensions Original R410A with Electric Heat (B, C, D, E Series)
  • Page 9 Unit Dimensions U-Series R410A 80% Gas Heat...
  • Page 10 Unit Dimensions U-Series R410A up to 95% Gas Heat...
  • Page 11 Unit Dimensions U-Series R410A Electric Heat...

  • Page 12: Gas Furnace

    Gas Furnace IMPORTANT NOTE! Interlock Door Switch All CPG (GAS MODELS) come equipped with an interlock door switch. This switch is located behind the bottom filter access panel on the left-hand side of the unit. When the filter access panel is removed this switch will open and disconnect all low voltage to the control board.

  • Page 13: Gas Furnace Specifications U-Series Non-Condensing Furnace Models

    Gas Furnace Specifications for U-Series Non-Condensing Furnaces 14208378 14208379 14208380 14208381 Heat Module P/N Input (BTU) 28,000 38,000 51,000 64,000 Output (BTU) 22,400 30,400 40,800 51,200 Max External Static Pressure (in w.c.) Temperature Rise (°F) 45 to 60 40 to 70 40 to 70 55 to 85 Blower Speed Setting...

  • Page 14: Gas Furnace Specifications U-Series Condensing Furnace Models

    Gas Furnace Specifications for U-Series Condensing Furnaces 14208384 14208385 14208386 14208387 Heat Module P/N Input (BTU) (NG) 25,000 32,000 43,000 50,000 Output (BTU) (NG) 23,750 30,400 40,850 47,500 Input (BTU) (LP) 25,000 35,000 50,000 Output (BTU) (LP) 23,750 33,250 47,500 Max External Static Pressure (in w.c.) Temperature Rise (°F) 30 to 60...
  • Page 15 Gas Furnace 4. Heat Blower On Delay – The control waits for 20 seconds from the time the gas valve opened and then energizes the blower motor. The gas valve and venter motor remain energized. The control proceeds to 5. Steady Heat. 5.
  • Page 16 Gas Furnace Slide Out Furnace Instructions All U-Series Models are equipped with a slide out furnace. Instructions for sliding out Non-Condensing Furnace. All Models manufactured after January 2015 feature a Slide-Out Furnace. 1. Remove the (4) screws indicated below. Gas Line Power Cord 2.
  • Page 17 Gas Furnace 3. Remove (2) right side screws and remove the front furnace baffle. Front Furnace Baffle 4. Disconnect (2) molex plugs before sliding out the heat exchanger/furnace assembly. (Not Pictured) 5. Grasp the vertical heat exchanger partition firmly with your left hand. 6.
  • Page 18 Gas Furnace Instructions for Sliding Out Condensing Furnace. 1. Remove the (2) screws indicated below. 2. Remove the patch plate.
  • Page 19 Gas Furnace 3. Remove the (11) screws. 4. Remove the front furnace baffle.
  • Page 20 Gas Furnace 5. Remove the (2) screws from the support leg. 6. Remove support bracket. 7. Disconnect wire harnesses and loosen hose clamp on the flue then proceed with sliding the furnace out. Do Not Use Manifold as Handle. * Note: Once removed, the furnace should remain pitched toward the condensate collector box to keep condensate from leaking out of the...
  • Page 21 Gas Furnace Safety Limit Switches Limit Switch Operation – The limit switches are ignored unless a call for heat is present. If a limit switch is open and a call for heat is present, the control de-energizes the gas valve, turns the blower motor on heat speed, and runs the inducer motor.
  • Page 22 Gas Furnace On Condensing Furnaces, the Main Air (High Temperature Limit) Switch is located above the collector box and is mounted with (2) small phillips head screws. It is wired in series with the flame rollout switch and the inducer limit. Furnace Size (Btuh) Cut Out 165°F...
  • Page 23 Gas Furnace AS CLOSE AS POSSIBLE TO THE EVAPORATOR COIL BEHIND THE FILTER DOOR CFM = BTU Output / (1.08 x ΔT) Series Input Output Nominal ∆T ∆T Range 38,000 30,400 55° 40°F to 70°F A, B, C, D-Series 51,000 40,800 55°...
  • Page 24 Gas Furnace Flame Rollout Limit Switch The flame rollout switch protects the burner area from high temperatures. The switch is normally closed, opens on temperature rise and breaks a circuit back to the DSI Control Board when tripped. These switches are manual reset switches. On Non-Condensing Furnaces the Flame Rollout Switch is located on top of the burner assembly with (2) ¼”...
  • Page 25 Gas Furnace Troubleshooting a Flame Rollout Switch trip. (See page 20 Limit Switch Operation) To prove the roll out switch has failed open, use an ohmmeter and verify there is no continuity across the terminals once the limit has been manually reset from pushing in the red button in between the wire terminals.
  • Page 26 Gas Furnace 0.55” On Non-Condensing Furnaces 0.55” Furnace Size (Btuh) On Condensing furnaces Opens (in w.c.) -0.55 +/- .05 -0.55 +/- 0.05 -0.55 +/- 0.05 -.055 +/- 0.05 Closes (in w.c.) -0.65 Max -0.65 Max -0.65 Max -0.65 Max On Condensing Furnaces On Condensing furnaces BTU Size Furnace Size (Btuh)
  • Page 27 Gas Furnace Furnace Size (Btuh) Opens (in w.c.) -0.15 +/- 0.05 -0.3 +/- 0.05 -0.3 +/- 0.05 -0.6 +/- 0.05 Closes (in w.c.) -0.30 Max -0.45 Max -0.45 Max -0.75 Max Troubleshooting A Pressure Switch Trip To check the pressure switch, first prove that the inducer assembly is pulling adequate static pressure at the pressure switch tubing using a manometer.
  • Page 28 Gas Furnace On Condensing Models the entire inducer assembly must be disconnected from the flue pipe by loosening the the 5/16” screw on the worm gear clamp that attaches the rubber connector to the PVC flue. The (4) ¼” screws will need to be removed to release the housing from the col- On condensing models the entire inducer assmebly must be disconnected from the flue pipe by loosening the the 5/16”...
  • Page 29 Gas Furnace DSI Control - Ignition Module This control module signals all operations of the CPG including spark ignition. The green and yellow LED's (visible through the service window) can aid in troubleshooting different failures. DSI Control Troubleshooting CONTROL GREEN LED STATUS STEADY ON Normal operation, no call for heat...
  • Page 30 Gas Furnace DSI Control Identification Used For All Original Series Equipment INDUCER FAN FAN OUTPUT- FAN OUTPUT- INPUT COOLING HEATING OUTPUT NEUTRALS SPARK IGNITOR OUTPUT 24VAC, 60Hz., .5A MAX. ANSI Z21.20 AUTOMATIC MOLEX TO HEAT COMPONENTS VOLTAGE COMMON EXTENDED FAN TIME DIP SWITCH SETTING VOLTAGE...
  • Page 31 Gas Furnace DSI Control Identification - Used For All U-Series Equipment INDUCER FAN FAN OUTPUT- FAN OUTPUT- INPUT COOLING HEATING RELAY NEUTRALS SPARK IGNITOR OUTPUT MOLEX TO 24VAC, 60Hz., .5A MAX. ANSI Z21.20 AUTOMATIC HEAT COMPONENTS VOLTAGE COMMON All units are equipped with a temperature reset switch.
  • Page 32 Gas Furnace Gas Valve The gas valve receives a gas supply and regulates gas after a call for heat is initiated. In BTU Size both models the gas valve is located in the upper right-hand section of the furnace. Orifice Size 0.462 0.5265 0.62...
  • Page 33 Gas Furnace Gas Valve Relay Fault If the control senses the gas valve as energized for more than one second when the control is not attempting to energize the gas valve, or the gas valve is sensed as not energized when it is supposed to be energized, then the control will lock out with the green LED off.
  • Page 34 Gas Furnace The Flame Sensor reads the flame from the burner and sends a signal back to the control board via flame rectification. To test the flame sensor use a multimeter capable of reading DC microamps ( µA ) between 0-20.
  • Page 35 Gas Furnace Poor Connection • Loose or broken connection on the sensor to the board • Poor ground connection • With an ohmmeter check for continuity between the spark rod and the wire back to the board Grounded Ignitor • Make sure the ignitor rod is not grounded to the furnace assembly or heat exchanger tube. Burner Assembly On Non-Condensing Models the burner is a single orifice ribbon style burner.
  • Page 36 Gas Furnace Heat Exchanger The heat exchanger is located on the left side of the furnaces. The inducer motor pulls fresh air in through the heat exchanger creating a negative pressure. The burner fires creating combustion gases that heat the heat exchanger, collecting and venting them through the flue. The blower motor runs and distributes the heat from the heat exchanger through the ductwork and diffusers.
  • Page 37 Gas Furnace Furnace Support Leg This leg is in place to help support the back end of the furnace and keep the secondary heat exchanger pitched toward the collector box. Internal Drain Tubing There is a drain tube that is located between the flue connector and the top of the collector box. This allows for any drainage that occurs in the flue to pitch back to the collector box.
  • Page 38 Gas Furnace Waterless Trap The waterless trap is provided with the unit can be installed in two different locations. This trap will seal when the inducer motor starts and will hold a small column of water until the inducer motor operation is terminated. At that point the trap will drain completely. It is important to keep the trap mounted in a vertical position at all times.
  • Page 39 Gas Furnace External Draining The condensing furnace external drainage is critical to the furnaces continued operation. Regardless of the desired drainage configuration, all tubing must be secured with the routing clamps provided using the predrilled mounting holes. Downstream of the waterless trap will be a field connected 5/8"...

  • Page 40: Electric Furnace

    Electric Furnace Electric Heat Models Components • Strip Heaters • High Limits • Sequencers • Contactors • Blower Relay • Time Delay • CPE Control Board Sequence of Operations - Electric Heat, Series A, B, C, D Call for Heat – The thermostat sends a call for heat by energizing the “white” wire to the sequencer.
  • Page 41 Electric Furnace CPE Control Board Faults – If multiple inputs are received with a cooling input (Y) then the board will automatically fault and run in cooling. Cooling Blower Operation – Cooling fan will delay 5 seconds on a call for cooling and will delay off when a call is terminated for the duration of the board jumper set point.

  • Page 42: Cooling Chassis

    Chassis (Cooling Section) Cooling Chassis The Comfort Packs most serviceable feature is the slide-out cooling chassis. The cooling chassis consists of a complete refrigeration circuit for cooling and gives the ability of removal from the entire Comfort Pack unit for service and troubleshooting. The integral components of the cooling chassis are as follows: •...
  • Page 43 Chassis (Cooling Section) Once removed from the cabinet, all components for the cooling section including the blower can be easily serviced. (Shipping Bolts are located on both sides of the cabinet and must be removed). Chassis Removal Instructions • Remove the bottom filter access panel and control access panel. •...
  • Page 44 Chassis (Cooling Section) Inducer Blower Motors 14270043 • Permanent Split Capacitor – 1/3 HP • 1120 RPM - 3 Speed • Used on all R22 Comfort Packs (Replaces all PSC blower motors) • Comes with welded bracket for mounting 14270044 •...
  • Page 45 Chassis (Cooling Section) Electronically Commutated Motor Troubleshooting Part# 14270048 DC Controlled Constant Torque Motor 230 Volt, 3.0 Amp , 1120 RPM, 1/3HP, CCW LE, 0-10V DC Controlled To verify motor operations, disconnect all electrical power to the motor. Wait at least 2 minutes to allow the motor control circuits to discharge. Visually inspect the motor for any obstructions and carefully remove if any are found.
  • Page 46 Chassis (Cooling Section)
  • Page 47 Chassis (Cooling Section) DC Motor Control Check Steps 5 Speed Electronically Commutated Motors Part# 14270055 Constant Torque Blower Motor 230 Volt, 3.0 Amp, 1120 RPM, 1/3 HP, CCWLE, 24 Volt AC Controlled To verify motor operations, disconnect all electrical power to the motor. Wait at least 2 minutes to allow the motor control circuits to discharge.
  • Page 48 Chassis (Cooling Section) The harnesses from both the 14270055 and 14270059 connect to the 5 pin motor speed terminal board. The motor speed can be adjusted at this board. Each harness has a color that matches up with a number on the board which determines motor speed. Terminal Wire Color Speed/Torque...
  • Page 49 Chassis (Cooling Section) Blower Motor Removal Instructions The blower motor can be easily accessed once the chassis is slid out of the cabinet. Follow this procedure on how to easily remove the blower assembly. 1. Remove the 4 screws from the control deck and carefully slide all motor wiring through the rubber grommet.
  • Page 50 Chassis (Cooling Section) 3. Slide the motor assembly up and out of the chassis. Be careful to not damage any refrigeration components while removing the blower assembly. PSC Motors Check for proper voltage to the motor. All motors operate at 208/230 Volts AC. Capacitor values for PSC motors: •...
  • Page 51 Chassis (Cooling Section) Condenser Fan Motors 14270044 • Permanent Split Capacitor – 1/4 HP • 1075 RPM – Single Speed • Used on 2 Ton R410A B & C-Series, all D-Series, all 9.2 EER U-Series, and 1.5 ton 12 SEER U-Series 14270045 •...
  • Page 52 Chassis (Cooling Section) VERIFY 24 VOLTS TO THE CONTACTOR COIL VERIFY 240 VOLTS LEAVING THE CONTACTOR VERIFY THAT THE POWER WIRE TO THE COMMON (C) ON THE CAPACITOR COMES FROM THE SAME POINT ON THE CONTACTOR THAT THE WIRE GOING TO THE RUN WINDING (R) ON THE COMPRESSOR IS After verifying the wiring, document the following information and compare to the specification on the compressor's data tag.
  • Page 53 Chassis (Cooling Section) Thermal Expansion Valve (TXV) The TXV is located underneath the control deck. The TXV meters refrigerant based on pressures in the system and temperatures at the bulb location. The spring tension plus the evaporator pressure (which is measured through the external equalizer tube) counter the pressure in the power element.
  • Page 54 Chassis (Cooling Section) Refrigeration Service Easy service port access is available on the right-hand side of the chassis above the control deck. Use these ports to verify system operating pressures along with superheat and subcooling for proper refrigeration system diagnosis. Note –...
  • Page 55 Chassis (Cooling Section) Compressor Contactor The compressor contactor is used to send line voltage to the compressor and condenser fan motor. The 24-volt coil is powered by a call for cooling and wired in series with the high and low pressure switch.
  • Page 56 Chassis (Cooling Section) Transformer The transformer is used to supply low voltage to the Comfort Pack control circuit. Its primary side must be supplied with 208/240 VAC and its secondary side supplies 24 VAC. It is rated at 40 VA. Failure to adjust the transformer in 208 Volt applications will then change low voltage output and can affect low voltage components in the unit.
  • Page 57 Chassis (Cooling Section) Secondary Drainage The secondary drain is an option that offers protection from overflow. The secondary drain feature is piped into the base of the unit and drains through the weep holes outside. Drain Pan Flexible Tubing Secondary Drain Connection Apply Force 1/2”...

  • Page 58: Wiring Diagrams

    Wiring Diagrams Comfort Pack Gas A or B Series R22 BLACK PURPLE YELLOW...
  • Page 59 Wiring Diagrams Comfort Pack Gas B or C Series R410A BLACK PURPLE BLUE BLUE YELLOW...
  • Page 60 Wiring Diagrams Comfort Pack Gas D Series R410A BLACK PURPLE BLUE BLUE ORANGE YELLOW...
  • Page 61 Wiring Diagrams Comfort Pack Gas E Series R410A BLACK PURPLE BLUE BLUE WHITE BLACK YELLOW...
  • Page 62 Wiring Diagrams Comfort Pack Gas U11 Series R410A BLACK PURPLE BLUE BLUE YELLOW...
  • Page 63 Wiring Diagrams Comfort Pack Gas U12 Series R410A BLACK PURPLE BLUE BLUE YELLOW...
  • Page 64 Wiring Diagrams Comfort Pack Gas U33 Series R410A BLACK PURPLE BLUE BLUE YELLOW...
  • Page 65 Wiring Diagrams Comfort Pack Gas - Condensing Furnace U33 95% Series R410A BLACK PURPLE BLUE BLUE YELLOW...
  • Page 66 Wiring Diagrams Comfort Pack Electric A or B Series R22 5-10KW WHITE BLACK PURPLE GREEN WHITE GREEN ORANGE YELLOW...
  • Page 67 Wiring Diagrams Comfort Pack Electric A or B Series R22 15KW WHITE WHITE BLACK PURPLE GREEN WHITE GREEN ORANGE YELLOW...
  • Page 68 Wiring Diagrams Comfort Pack Electric B or C Series R410A 5-10KW WHITE BLACK PURPLE BLUE BLUE GREEN WHITE GREEN ORANGE YELLOW...
  • Page 69 Wiring Diagrams Comfort Pack Electric B or C Series R410A 15KW WHITE WHITE BLACK PURPLE BLUE BLUE GREEN WHITE GREEN ORANGE YELLOW...
  • Page 70 Wiring Diagrams Comfort Pack Electric D Series R410A 5-10KW WHITE BLACK PURPLE BLUE BLUE GREEN BLACK WHITE ORANGE ORANGE YELLOW...
  • Page 71 Wiring Diagrams Comfort Pack Electric D Series R410A 15KW WHITE WHITE BLACK PURPLE BLUE BLUE GREEN BLACK WHITE ORANGE ORANGE YELLOW...
  • Page 72 Wiring Diagrams Comfort Pack Electric E Series R410A 5-10KW WHITE BLACK PURPLE BLUE BLUE GREEN WHITE COIL ORANGE YELLOW...
  • Page 73 Wiring Diagrams Comfort Pack Electric E Series R410A 15KW WHITE WHITE BLACK PURPLE BLUE BLUE GREEN BLACK BLACK BLUE WHITE COIL YELLOW...
  • Page 74 Wiring Diagrams Comfort Pack Electric U11 Series R410A 5-10KW BLACK PURPLE BLUE BLUE ORANGE GREEN BLACK WHITE BLACK YELLOW...
  • Page 75 Wiring Diagrams Comfort Pack Electric U11 Series R410A 15KW WHITE BLACK PURPLE BLUE BLUE ORANGE GREEN BLACK WHITE BLACK YELLOW...
  • Page 76 Wiring Diagrams Comfort Pack Electric U*2 Series R410A 3-10KW WHITE BLACK PURPLE BLUE BLUE...
  • Page 77 Wiring Diagrams Comfort Pack Electric U*2 Series R410A 15KW WHITE BLACK PURPLE BLUE BLUE...
  • Page 78 Abnormal Functions Ignition Retry Ignition Trial Inducer Draft Motor 27, 28 Blower Delay Interlock Door Switch Blower Motor Interrupted Thermostat Call for Heat Blower Motor Removal 49, 50 Blower Off Delay Limit Switches Lockouts Call for Heat Low Pressure Switch Chassis Chassis Removal Compressor Contactor...
  • Page 80 NATIONAL ® COMFORT PRODUCTS HEATING & A/C EQUIPMENT National Comfort Products ® A Division of National Refrigeration & Air Conditioning Products, Inc. 539 Dunksferry Road | Bensalem, PA 19020 1-800-523-7138 | ncpservice@nrac.com www.nationalcomfortproducts.com Service Guide Comfort Pack 3/2023...

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