Goodman DCG036090 Installation Manual

DCG SERIES

LIGHT COMMERCIAL PACKAGED GAS UNIT

3 to 6 TON

ATTENTION INSTALLING PERSONNEL:

Prior to installation, thoroughly familiarize yourself with this Installation Manual. Observe all safety warnings. During installation or repair, caution is to be observed.

It is your responsibility to install the product safely and to educate the customer on its safe use.

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

These installation instructions cover the outdoor installation of single package heating and cooling units. See the Specification Sheet applicable to your model for information regarding accessories.

*NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.

This Forced Air Central Unit Design Complies With Requirements Embodied In The American National Standard / National Standard of Canada Shown Below.

Replacement Parts................................................................ 2

Safety Instructions................................................................ 2

General Information ............................................................. 3

Unit Location ........................................................................ 4

Clearances ............................................................................ 5

Roof Curb Post-Installation Checks ....................................... 6

Roof Top Duct Connections................................................... 6

Rigging Details ...................................................................... 6

Electrical Wiring.................................................................... 7

Gas Supply Piping ................................................................. 9

Propane Gas Installations ................................................... 10

Circulating Air and Filters.................................................... 11

Venting ............................................................................... 12

Condensate Drain Connection ............................................ 12

Startup, Adjustments, and Checks ...................................... 12

Air flow Adjustments .......................................................... 13

Motor Sheave Adjustments ................................................ 14

Gas System Check ............................................................... 15

Normal Sequence Of Operation.......................................... 17

Maintenance ...................................................................... 20

Troubleshooting.................................................................. 21

Appendix A Blower Performance Tables ............................. 23

Direct Drive .................................................................... 23

DCG036 Down Shot and Horizontal ............................ 23

DCG048 Down Shot and Horizontal ............................ 24

DCG060 Down Shot .................................................... 25

DCG060 Horizontal ..................................................... 26

Belt Drive ....................................................................... 27

Standard Down Shot .................................................. 27

High Static Down Shot................................................ 28

Standard Horizontal ................................................... 29

High Static Horizontal................................................. 30

Appendix B Electrical Data.................................................. 31

Appendix C Unit Dimensions............................................... 32

Appendix D Wiring Diagrams .............................................. 33

Start-Up Checklist ............................................................... 55

INSTALLATION INSTRUCTIONS

Index

ANSI Z21.47•CSA-2.3 Central Furnaces

Our continuing commitment to quality products may mean a change in specifications without notice.

IOD-1004B 2/2015

5151 San Felipe St., Suite 500, Houston, TX 77056

www.daikincomfort.com

REPLACEMENT PARTS

ORDERING PARTS

When reporting shortages or damages, or ordering repair parts, give the complete unit model and serial numbers as stamped on the unit’s nameplate.

Replacement parts for this appliance are available through your contractor or local distributor. For the location of your nearest distributor, consult the white business pages, the yellow page section of the local telephone book or contact:

CONSUMER AFFAIRS

DAIKIN NORTH AMERICA LLC

7401 SECURITY WAY

HOUSTON, TEXAS 77040

855-770-5678

SAFETY INSTRUCTIONS

TO THE INSTALLER

Before installing this unit, please read this manual to familiarize yourself on the specific items which must be adhered to, including maximum external static pressure to unit, air temperature rise, minimum or maximum CFM and motor speed connections.

WARN ING

NOT CONNECT TO OR USE ANY DEVICE THAT IS NOT DESIGN CERTIFIED BY DAIKIN FOR USE WITH THIS UNIT DAMAGE, PERSONAL INJURY, REDUCED UNIT PERFORMANCE AND HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF SUCH NON APPROVED DEVICES

. S

ERIOUS PROPERTY

/OR

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE

TATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER

REPRODUCTIVE HARM.

WARNING

O AVOID PROPERTY DAMAGE , PERSONAL INJURY OR DEATH, DO NOT USE

THIS UNIT IF ANY PART HA S BEEN UNDER WATER. QUALIFIED SERVICE TECHNICIAN T O INSPECT THE FURNACE AND TO RE PLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL HAVING BEEN UNDER WATER.

MMEDIATELY CALL A

Keep this literature in a safe place for future reference.

WARN ING

THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE

- D

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS

AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

- WHAT T O D O IF YO U SMELL GA S:

* D

O NOT TRY TO LIGHT ANY APPLIANCE O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE

- I

* D

ANY PHONE IN YOUR BUILDING

* I

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBORS PHONE INSTRUCTIONS

* I

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED

INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

FIRE DEPARTMENT

. F

OLLOW THE GAS SUPPLIERS

WARNING

HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN

OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF T HE ELECTRI CAL SUPPLY.

CAUTION

HIS UNIT MUST NOT BE USED AS A "CONSTRUCTION HEATER DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TEMPERATURE AND EXPOSURE TO CORROSIVE OR VERY DIRTY

. T

HIS TYPE OF USE MAY RESULT IN PREMATURE

ATMOSPHERES

WARNING

HIGH VOLTAGE!

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWER SOURCES MAY

WARNING

TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,

DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

WARNING

HIGH VOLTAGE!

INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED MINIMUM) THE REQUIREMENTS OF AN

ECHNICIAN” AS SPECIFIED BY THE AIR CONDITIONING

HEATING AND REFRIGERATION INSTITUTE

TTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH

ONLY BY

INDIVIDUALS MEETING(AT A

“E

NTRY LEVEL

(AHRI).

HEET METAL PARTS, SCREWS, CLIPS AND SIMILAR ITEMS INHERENTLY HAVE SHARP EDGES, AND IT IS NECESSARY THAT THE INSTALLER AND SERVICE PERSONNEL EXERCISE CAUTION

GENERAL INFORMA TION

WARNING

O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DUE TO FIRE,

EXPLOSIONS, SMOKE, SOOT, CONDENSATION, ELECTRIC SHOCK OR CARBON MONOXIDE, THIS UNIT MUST BE PROPERLY INSTALLED, REPAIRED, OPERATED, AND MAINTAINED.

This unit is approved for outdoor installation ONLY . Rate d perf ormance is achieved aft er 72 hours of opera tion. Rated performance is delivered at the specified airflow. See product specification sheet for light commercial models. Specification sheets can be found at www.daikincomfort.com for Daikin brand products. Within the website, please select the commercial products menu and then select the submenu for the type of product to be installed, such as air conditioners or heat pumps, to access a list of product pages that each contain links to that model’s specification sheet.

To assure that your unit operates safely and efficiently, it must be installed, operated, and maintained in accordance with these installation and operating instructions, all local building codes and ordinances, or in their absence, with the latest edition of the National Fuel Gas Code NFPA54/ANSI Z223.1 and National Standard of Canada CAN/CSA B149 Installation Codes.

EPA REGULATIONS

IMPORTANT: THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY (EPA)

HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION AND DISPOSAL OF

REFRIGERANTS IN THIS UNIT. FAILURE TO FOLLOW THESE REGULATIONS MAY HARM

THE

ENVIRONMENT AND CAN LEAD TO THE IMPOSITION OF SUBSTANTIAL FINES.

ECAUSE REGULATIONS MAY VARY DUE TO PASSAGE OF NEW LAWS, WE SUGGEST A

CERTIFIED

TE CHNICIAN PERFORM ANY WORK DONE ON THIS UNIT. SHOULD YOU HAVE

ANY

QUESTIONS PLEASE CONTACT THE LOCAL OFFICE OF THE EPA.

NATIONAL CODES

This product is designed and manufactur ed to permit installation in accordance with National Codes. It is the inst aller’ s r e sponsibility to install the product in accordance with National Codes and/ or prevailing local codes and regulations.

The heating and cooling capacities of the unit should be greater than or equal to the design heating and cooling loads of the area to be conditioned. The loads should be c alculat ed b y an appr o ve d method or in accordance with ASHRAE Guide or Manual J - Load Calculations published by the Air Conditioning Contractors of America.

Obtain from:

American National Standards Institute

1430 Broadway

New York, NY 10018

System design and installation should also, where applicable, follow information pre sented in accept ed industry guides such as the ASHRAE Handbooks. The manufacturer assumes no r esponsibility for equipment installed in viola tion of an y c ode or r egula tion. The mechanical installation of the packaged roof top units consists of making final connections between the unit and building services; supply and return duct connections; and drain connections (if required). The internal systems of the unit are completely factoryinstalled and tested prior to shipment.

Units are g ener ally ins t alled on a steel roof mounting curb assembly which has been shipped to the job site for installation on the roof structure prior to the arrival of the unit. The model number shown on the unit’s identification plate iden tifies the various components of the unit such as refrigeration tonnage, heating input and voltage.

Carefully inspect the unit for damage including damage to the cabinetry . Any bolt s or screws which ma y have loosened in tr ansit must be re-tightened. In the even t of damage, the receiver should:

1. Make notation on delivery receipt of any visible damage to shipment or container.

2. Notify carrier promptly and request an inspection.

3. In case of concealed damage, c arrier should be notified as soon as possible-preferably within 5 days.

4. File the claim with the following supporting documents:

a. Original Bill of Lading, certified copy , or indemnity bond. b. Original paid freight bill or indemnity in lieu thereof. c. Original invoice or certified copy thereof, showing trade

and other discounts or reductions.

d. Copy of the inspection report issued by carrier

representative at the time damage is reported to the carrier. The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

NOTE: When inspecting the unit for transportation damage, remove all packaging materials. R ecycle or dispose of the pack aging material according to local codes.

PRE-INSTALLATION CHECKS

Carefully rea d all instructions for the ins tallation prior t o installing unit. Ensure each step or proce dur e is under stood and an y special considerations are taken into account before starting installation. Assemble all tools, hardware and supplies nee ded to complet e the installation. Some items may need to be purchased locally.

UNIT LOCA TION

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

IMPORTANT NOTE: Remove wood shipping rails prior to installation of the unit.

ALL INSTALLATIONS: IMPORTANT NOTE: Unit should be energized 24 hours prior to

compressor start up to ensure crankcase heater has sufficiently warmed the compressors. Compressor damage may occur if this step is not followed.

• T o avoid possible illness or death of the building occupant s,

do NOT locate outside air intake device (economizer, manual fresh air intake, motorized fresh air intake) too close to an exhaust outlet, gas vent termination, or plumbing vent outlet. For specific distances required, consult local codes.

• Allow minimum clearances from the enclosure for fire

protection, proper opera tion, and service access (see unit clearances). These clearances must be permanently maintained.

• The combustion air inlet and flue outlet on the unit must

never be obstructe d. If used, do not allow the economizer/ manual fresh air damper/ motorized fresh air damper to become blocked by snow or debris. In some climates or locations, it may be necessary to elev at e the unit to avoid these problems.

• When the unit is heating, the temperature of the return

air entering the unit must be a minimum of 55° F.

GROUND LEVEL INSTALLATIONS ONLY:

• When the unit is installed on the ground adjacent to the

building, a level concrete (or equal) base is recommended . Prepare a base that is 3” larger than the package unit footprint and a minimum of 3” thick.

• The base should also be located where no runof f of wa ter

from higher ground can collect in the unit.

ROOF TOP INSTALLATIONS ONLY:

NOTE: Appliance is shipped from factory for vertical duct

application. Proper installation of the unit ensure s tr ouble-free operation. Im-

proper installation can result in problems ranging from noisy operation to property or equipment damages, dangerous conditions that could result in injury or personal property damage and that are not cov ered by the w arranty. Give this booklet to the user and explain it’s provisions. The user should retain these instructions for future reference.

• For proper flame pattern within the heat exchanger and

proper condensate drainage, the unit must be mounted level.

• The flue outlet must be at least 12 inches fr om any opening

through which flue gases could enter a building, and at least three feet above any forced air inlet located within ten feet. The economizer/manual fresh air intake/ motorized fresh air intake and combustion air inlet mounted on the unit are not affected by this restriction.

• To avoid possible corrosion of the heat exchanger, do not

locate the unit in an area where the outdoor air (i.e. combustion air for the unit) will be frequently contaminated by compounds containing chlorine or fluorine. Common sources of such compounds include swimming pool chemicals and chlorine bleaches, paint stripper , adhesives, p aints, varnishe s, sealers, wax es (which are not yet dried) and solvents used during construction and remodeling. Various commercial and industrial processes may also be sources of chlorine/fluorine compounds.

• To avoid possible property damage or personal injury, the

roof must have sufficient structural strength to carry the weight of the unit(s) and snow or water loads as required by local codes. Consult a structur al engineer to determine the weight capabilities of the roof.

• The unit may be installed directly on wood floors or on

Class A, Class B, or Class C roof covering material.

• To avoid possible personal injury, a safe, flat surface for

service personnel should be provided.

• As indicated on the unit data plate, a minimum clearance

of 36” to any combustible material is required on the furnace access side of the unit. All combustible materials must be kept out of this area.

• This 36” clearance must also be maintained to insure

proper combustion air and flue gas flo w. The combustion air intake and furnace flue dischar ge mus t not be block ed for any reason, including blockage by snow.

• Adequate clearances from the furnace flue discharge to

any adjacent public w alkways, adjacen t buildings, building openings or openable windows must be maintained in accordance with the latest e dition of the National Fuel Gas Code (ANSI Z223.1)

• Minimum horizontal clearance of 48” from the furnace

flue discharge to any electric me ters, ga s meters, regulat ors and relief equipment is required.

UNIT PRECAUTIONS

• Do not stand or walk on the unit.

• Do not drill holes anywhere in panels or in the base fr ame of the unit except where indicated. Unit access panels provide structural support.

• Do not remove any access panels until unit has been installed on roof curb or field supplied structure.

• Do not roll unit across finished roof without prior approval of owner or architect.

• Do not skid or slide on any surface as this may damage unit base. The unit must be store d on a flat, level surf ace. Protect the condenser coil because it is easily damaged.

ROOF CURB INSTALLATIONS ONLY:

Curb installations must c omply with local codes and should be done in accordance with the est ablished guidelines of the National R oofing Contractors Association.

Proper unit installation requires that the roof curb be firmly and permanently attached to the roof structure. Check for adequate fastening method prior to setting the unit on the curb.

Full perimeter roof curbs are available from the factory and are shipped unassembled. Field assembly, squaring, leveling and mounting on the roof structure are the responsibility of the installing contractor. All required hardware necessary for the assembly of the sheet metal curb is included in the curb accessory.

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

• Sufficient structural support mus t be determined prior to

locating and mounting the curb and package unit.

• Ductwork must be constructed using industry guidelines.

The duct work must be placed into the roof curb before mounting the package unit. Our full perimeter curbs include duct connection frames to be assemble d with the curb. Cantilevered type curbs are not available from the factory.

• Curb insulation, cant strips, flashing and general roofing

material are furnished by the contractor. The curbs must be supported on parallel sides by roof members. The roof members must not penetrate supply and return duct opening areas as damage to the unit might occur.

See the manual shipped with the roof curb for assembly and installation instructions.

CLEARANCES

24”

Min.*

36” Min.

Unit Clearances

*In situations that have multiple units, a 48” minimum clearance is required between the condenser coils.

Adequate clearance around the unit should be k ept f or safe ty , ser vice, maintenance, and proper unit operation. A total clearance of 75” on the main control panel side of the unit is r ecommende d to facilitate possible fan shaft, coil, electric heat and gas furnace removal. A clear ance of 48” is rec ommended on all other side s of the unit to facilitate possible compressor removal, to allow service access and to insure proper ventilation and condenser airflow. The unit must not be installe d beneath an y obstruction. The unit should be installed remote from all building exhausts to inhibit ingestion of exhaust air into the unit fresh air intake.

NOTE: If the 48” minimum is used on the control panel side of a DCG unit, a flue extension (MF# 220-GX-01) needs be to installed to prevent flue gas recirculation.

24”

Min.*

NOTE: The unit and curb accessories are de signed to allow v ertical duct installation before unit placement. Duct inst allation after unit placement is not recommended.

CAUTION

ALL

CURBS LOOK SIMILAR

POSITIONING, CHECK JOB PLANS CAREFULLY AND VERIFY MARKINGS ON CURB ASSEMBLY SUPERSEDES INFORMATION SHOWN

. TO

AVOID INCORRECT CURB

. I

NSTRUCTIONS MAY VARY IN CURB STYLES AND

INSULATED PANELS

Roof Curb Installation

ROOF CURB POST -INSTALLA TION CHECK S

After installation, check the top of the curb, duct connection fr ame and duct flanges to make sure gasket has been applied properly. Gasket should be firmly applied to the top of the curb perimeter, duct flanges and any exposed duct connection frame. If gasket is loose, re-apply using strong weather resistant adhesive.

CAUTION

UNITS ARE LIFTED TWO AT A TIME, THE FORK HOLES ON THE CONDENSER END OF THE UNIT MUST NOT BE USED LENGTH IS IS RECOMMENDED

42” TO

PREVENT DAMAGE TO THE UNIT; HOWEVER

. M

INIMUM FORK

, 48”

PROTRUSION

Inspect curb to ensure that none of the utility services (electric) routed through the curb protrude above the curb.

CAUTION

PROTRUSIONS EXIST, DO NO ATTEMPT TO SET UNIT ON CURB

ROOF TOP DUCT CONNECTIONS

Install all duct connections on the unit before placing the unit on rooftop.

HORIZONTAL DISCHARGE

Refer t o IOD-7006 included in the litera ture pack for inst alling horizontal duct covers.

Flexible duct connectors between the unit and ducts are recommended. Insulate and weatherproof all external ductwork and joints as required and in accordance with local codes.

11” 4 7/8””

REMOVE

COVERS

Provisions for fork s have been include d in the unit base frame. No other fork locations are approved.

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

• Unit must be lifted by the four lifting holes located at the base frame corners.

• Lifting cables should be at tached to the unit with shackle s.

• The distance between the crane hook and the top of the unit must not be less than 60”.

• Two spreader bars must span over the unit to prevent damage to the cabinet by the lift cables. Spreader bars must be of sufficient length so that cables do not come in contact with the unit during transport. Remove wood struts mounted beneath unit base frame before setting unit on roof curb. These struts are intended to protect unit base frame from fork lift damage. Removal is accomplished by extracting the sheet met al r etainer s and pulling the struts through the base of the unit. Refer to rigging label on the unit.

Important: If using bottom discharge with roof curb, ductwork should be attached to the curb prior to ins talling the unit. Ductwork dimensions are shown in Roof Curb Installation Instructions.

17” 7 3/8”

12”

SUPPL Y

6 3/16”

Horizontal Discharge Duct Connections

RIGGING DET AILS

WARNING

O PREVENT PROPERTY DAMAGE, THE UNIT SHOULD REMAIN IN AN UPRIGHT

POSITION DURING ALL RIGGING AND MOVING OPERATIONS. LIFTING AND MOVING WHEN A CRANE IS USED, PLACE THE UNIT IN AN ADEQUATE CABLE SLING.

O FACILITATE

25”

Refer to the Roof Curb Installation Instructions for proper curb installation. Curbing must be installed in compliance with the National Roofing Contractors Association Manual.

Lower unit carefully onto roof mounting curb. While rigging unit, center of gravity will cause condenser end t o be lower than supply air end.

To assist in determining rigging requirements, unit weights are shown as follows:

ELECTRICAL WIRING

WARN ING

CONDENSER

COIL

COMPRESSOR

RETURN

EVAPO RATOR COIL

SUPPLY

Corner & Center of Gravity Locations

Model

DCG036045* 37 30 550 525 100 165 100 165 DCG036090* 37 30 560 535 100 170 100 170 DCG048090* 37 30 600 575 110 180 110 180 DCG048115* 37 30 605 580 110 180 110 180 DCG060090* 37 30 635 610 113 187 118 192 DCG060140* 37 30 645 620 118 192 118 192 DCG072140* 37 30 700 675 127 210 127 211

* Weights shown are belt drive with no accessories.

(in)Y(in)

Shipping

Weight

(lbs)

Operating

Weight

(lbs)

Corner Weights ( lbs )

ABCD

HIGH VOLTAGE!

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT BE PRESENT DAMAGE, PERSONAL INJURY OR DEATH

. F

. M

AILURE TO DO SO MAY CAUSE PROPERTY

ULTIPLE POWER SOURCES MAY

WARN ING

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DO NOT TAMPER WITH FACTORY WIRING

. THE

OF THESE UNITS ARE FACTORY-INSTALLED AND HAVE BEEN THOROUGHLY TESTED PRIOR TO SHIPMENT

ONTACT YOUR LOCAL REPRESENTATIVE IF

ASSISTANCE IS REQUIRED

INTERNAL POWER AND CONTROL WIRING

CAUTION

PREVENT DAMAGE TO THE WIRING, PROTECT WIRING FROM SHARP EDGES LOCAL CODES AND ORDINANCES REMOVABLE ACCESS PANELS

. F

OLLOW NATIONAL ELECTRICAL CODE AND ALL

. DO

NOT ROUTE WIRES THROUGH

CAUTION

ONDUIT AND FITTINGS MUST BE WEATHER-TIGHT TO PREVENT

WATER ENTRY INTO THE BUILDING

CAUTION

PREVENT SEVERE DAMAGE TO THE BOTTOM OF THE UNIT, DO NOT

FORK LIFT UNIT AFTER WOOD STRUTS HAVE BEEN REMOVED

Bring condenser end of unit into alignment with the curb. With condenser end of the unit resting on curb member and using curb as a fulcrum, lower opposite end of the unit until entire unit is seated on the curb. When a rectangular cantilever curb is used, care should be taken to center the unit. Check for proper alignment and orientation of supply and return openings with duct.

RIGGING REMOVAL

CAUTION

PREVENT DAMAGE TO THE UNIT, DO NOT ALLOW CRANE HOOKS

AND SPREADER BARS TO REST ON THE ROOF OF THE UNIT

Remove sprea der bars, lifting cable s and other rigging equipment.

For unit protection, use a fuse or HACR circuit breaker that is in excess of the circuit ampacity, but less than or equal to the maximum overcurrent protection device. DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON UNIT DATA PLATE.

All line voltage connections must be made through weatherproof fittings. All exterior power supply and ground wiring must be in approved weatherproof conduit.

The main power supply wiring to the unit and low voltage wiring to accessory controls must be done in accordance with these instructions, the latest edition of the Na tional Electrical Code (ANSI/ NFP A 7 0), and all local codes and ordinances. All field wiring shall conform with the temperature limitations for Type T wire (63°F/ 35°C rise).

The unit is factory wired for the voltage shown on the unit’s data plate. Refer to model nomenclature in Appendix B for voltage requirement for your unit.

NOTE: If supply voltage is 208V, lead on primary of transformer must be moved from the 230V to the 208V tap. Refer to wiring diagram on unit for details.

Main power wiring should be sized f or the minimum wire ampacity shown on the unit’s database. Size wires in accordance with the ampacity tables in Article 310 of the National Electrical Code. If long wires are required, it may be necessary to increase the wire size to prevent e xce ssive volt age drop. Wires should be sized f or a maximum of 3% voltage drop.

CAUTION

O AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE

ONLY COPPER CONDUCTORS.

CAUTION

O PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING E RRORS,

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

ERIFY PROPER OPERATION AFTER SERVICING.

NOTE: A weather-tight disconnect switch, properly sized for the unit total load, must be field or f actory inst alled. An e xt ernal field supplied disconnect may be mounted on the exterior panel.

Ensure the data plate is not covered by the field-supplied disconnect switch.

• Some disconnect switches are not fused. Protect the power leads a t the point of distribution in accordance with the unit data plate.

• The unit must be electrically grounded in accor dance with local codes or, in the absence of local codes, with the latest edition of the National Electrical Code (ANSI-NFPA 70). A ground lug is provided for this purpose. Size grounding conductor in accordance with T able 250-95 of the National Electrical Code. Do not use the ground lug for c onnecting a neutral conductor.

• Connect power wiring to the compressor co ntactor closest to the entrance located within the main control box or to electrical power block, if equipped.

MAIN POWER

LOW VOLTAGE BLOCK

UNITS INSTALLED ON ROOF TOPS

Main power and low voltage wiring may enter the unit through the condenser end of unit or through the roof curb. Install c onduit connectors at the desired entrance locations. External connectors must be weatherproof. All holes in the unit base must be sealed (including those around conduit nuts) to prevent wat er leakage into building. All required conduit and fittings are to be field supplied.

Supply voltage to roof top unit mus t not vary by more than 10% of the value indicated on the unit data plate. Phase voltage unbalance must not exceed 2%. Contact your local power company for correction of improper voltage or phase unbalance.

HIGH VOLTAGE ENTRANCE

(REMOVE PLUG)

12 3/8”

30 1/4”*

* (6 Ton - 34 1/4”)

1:4

LOW VOLTAGE ENTRANCE

3.5 DIA.

LOW VOLTAGE ENTRANCE

POWER THRU THE CURB

Power and Low Voltage Block Connections

WARN ING

AILURE OF UNIT DUE TO OPERATION ON IMPROPER LINE VOLTAGE OR WITH EXCESSIVE PHASE UNBALANCE CONSTITUTES PRODUCT ABUSE AND WILL VOID YOUR WARRANTY AND MAY CAUSE SEVERE DAMAGE TO THE UNIT ELECTRICAL COMPONENTS

Areas Without Convenience Outlet

It is recommended that an independent 115V power source be brought to the vicinity of the roof top unit for portable lights and tools used by the service mechanic.

NOTE: Refer to local codes for requirements. These outlets can also be factory installed.

POWER THRU THE CURB

4 1/2”

47 1/2”

7 1/2”

Electrical Entrance and Thru Curb

Unit is equipped with a Low Voltage Terminal Block and has Single Point wiring to the contactor or power block, if equipped.

LOW VOLTAGE CONTROL WIRING

1. A 24V thermostat must be installed for unit operation. It may be purchased with the unit or field -supplied. Thermostats may be programmable or electromechanical as required.

2. Locate thermostat or remote sensor in the conditioned space where it will sense average temperature. Do not locate the device where it may be directly exposed to supply air, sunlight or other sources of heat. Follow installation instructions packaged with the thermostat.

3. Use #18 AWG wire for 24V control wiring runs not exceeding 75 feet. U se #16 A WG wire for 24V con trol wiring runs not exceeding 125 feet. Use #14 AWG wire for 24V control wiring runs not exceeding 200 feet. Low voltage wiring may be National Electrical Code (NEC) Class 2 where permitted by local codes.

4. Route thermostat wires from sub-base terminals to the unit. Control wiring should enter through the condenser panel opening or through curb indicated in “Electrical Entrance” figure. Connect thermostat and any accessory wiring to low voltage terminal block TB1 in the main con trol box.

NOTE: Field-supplied conduit may need to be ins talled depending on unit/curb configuration. Use #18 AWG solid conductor wire whenever connecting thermostat wires to terminals on sub-base. DO NOT use larger than #18 AWG wire. A transition to #18 AWG wire may be required before entering thermostat sub-base.

NOTE: Refer to unit wiring diagrams for thermostat hookups.

GAS SUPPLY PIPING

WARN ING

PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER

. FOR

ADDITIONAL

IMPORTANT NOTE: This unit is factory set to operate on natural gas at the altitudes shown on the rating plate.

WARN ING

AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH WHEN EITHER USING PROPANE GAS ALONE OR AT HIGHER ALTITUDES OBTAIN AND INSTALL THE PROPER CONVERSION KIT(S DO SO CAN RESULT IN UNSATISFACTORY OPERATION AND/OR EQUIPMENT DAMAGE

NSTALLATIONS ONLY AND ARE NOT APPROVED FOR USE IN CANADA

. H

IGH ALTITUDE KITS ARE FOR

). F

U.S.

AILURE TO

The rating plate is stamped with the model number, type of gas and gas input rating. Mak e sure the unit is equippe d to oper ate on the type of gas available. Conv ersion to propane (LP) g as is permitted with the use of the factory authorized conversion kit (see the unit Technical Manual for the appropriate kit). For High Altitude derates, refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1.

INLE T GAS PR ESSURE

NATURAL M i n. 5.0" W .C ., Ma x. 10.0" W.C.

PROPANE Min. 1 1.0 " W. C., M ax . 14.0" W.C.

Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in Table Above.

The minimum supply pressure should not vary from that sho wn in the table above because this could prevent the unit from having dependable ignition. In addition, gas input to the burners must not exceed the rated input shown on the rating plate. Overfiring of the unit could result in premature heat exchanger failure.

PIPING

IMPORTANT NOTE: To avoid possible unsatisfactory operation or

equipment damage due to under firing of equipment, do not undersize the natur al/propane gas piping fr om the meter/tank to the unit. When sizing a trunk line, include all appliances on that line that could be operated simultaneously.

The rating plate is stamped with the model number, type of gas and gas input rating. Mak e sur e the unit is equipped to oper ate on the type of gas available. The gas line installation must comply with local codes, or in the absence of local codes, with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1.

Natural Gas Connection

Natural Gas Capacity of Pipe

in Cubic Feet of Gas Per Hour (CFH)

Length of

Pipe in Feet

10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 980 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610 70 46 96 180 370 560 80 43 90 170 350 530 90 40 84 160 320 490

100 38 79 150 305 460

Pressure= .50 PSIG or less and Pressure Drop of 0.3" W.C. (Based on 0.60 Specific Gravity Gas)

CFH =

Refer to the Proper Piping Practice drawing for the general layout at the unit. The following rules apply:

1. Use black iron pipe and fit tings f or the supply piping. The use of a flex connector and/or copper piping is permitted as long as it is in agreement with local codes.

2. Use pipe joint compound on male thre a ds only. Pipe joint compound must be resistan t to the action of the fuel used.

3. Use ground joint unions.

4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.

5. Use two pipe wrenches when making connection to the gas valve to keep it from turning.

6. Install a manual shut-off valve in a convenient location (within six feet of unit) between the meter and the unit.

7. Tighten all joints securely.

8. The unit must be connected to the building piping by one of the following methods:

• Rigid metallic pipe and fittings

Nominal Black Pipe Size (inches)

1/2 3/4 1 1 1/4 1 1 /2

BTUH Furna ce In put

Heating Value of Gas (BT U/Cubic Foot

• Semirigid metallic tubing and metallic fittings (Aluminum alloy tubing must not be used in exterior locations)

• Listed ga s appliance c onnector s used in acc or dance with the terms of their listing that are complet ely in the same room as the equipment

• In the prior two methods above the connector or tubing must be protected from physical and thermal damage. Aluminum alloy tubing and connectors must be coated to protect agains t external corrosion when in cont act with masonry, pla st er or insula tion or are subject t o r epe ate d wettings by liquids (wat er - not rain w a ter, detergents or sewage).

BURNER DOOR

There will be air in the gas supply line after testing for leaks on a new installation. Therefore, the air must be bled from the line by loosening the ground joint union until pure ga s is expelled. Tighten union and wait for five minutes until all ga s ha s been dissipa t ed in the air. Be certain there is no open flame in the vicinity during air bleeding procedure. The unit is placed in operation by closing the main electrical disconnect switch for the unit.

PROP ANE GAS INSTALLATIONS

WARNING

O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE

OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETECTING WARNING DE VICE. OF ODORANT IN PROPANE GAS, A GAS DETECTING W ARNING DEVICE IS THE ONLY RELIABLE WAY TO DETECT A PROPANE GAS LEAK.

ONTACT A LOCAL PROPANE GAS SUPPLIER ABOUT INSTALLING A

GAS DETECTING WARNING DEVICE.

INCE RUST CAN REDUCE THE LEVEL

TBD

MANUAL SHUT-OFF

GROUND JOINT UNION

DRIP LEG

Proper Piping Practice

NOTE: The unit gas supply entrance is factory sealed with plugs.

Keep plugs in place until gas supply is ready to be installed. Once ready, replace the plugs with the supplied grommets and install gas supply line.

GAS PIPING CHECKS

CAUTION

O PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, THE FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS CONNECTIONS AND PRESSURE TESTING:

•

HE UNIT AND ITS GAS CONNECTIONS MUST BE LEAK TESTED BEFORE

PLACING IN OPERATION. FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. EXCEED SPECI FIED PRES SURES FOR TESTI NG. DAMAGE GAS VALVE AND CAUSE OVERFIRING WHICH MAY RESULT IN PREMATURE HEAT EXCHANGE FAILURE.

HIS UNIT AND ITS SHUT-OFF VALVE MUST BE DISCONNECTED FROM

•

THE GAS S UPPLY DURING ANY PRESSURE TE STING OF THAT SYSTEM AT TEST PRESSUR E S IN EX CES S OF 1/2

HIS UNI T MU ST BE I SOLAT ED FRO M THE GAS SUPPL Y SYS TEM BY

•

CLOSING ITS MANUAL SHUT-OFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PI PING SYSTEM AT TEST PRESSURE S EQUAL TO OR LESS THAN 1/2

BECAUSE OF THE DANGER OF EXPLOSION OR

IGHER PRESSURE MAY

(3.48 KPA).

PSIG

(3.48 KPA).

PSIG

EVER

IMPORTANT NOTE: Propane gas conversion kits must be installed to convert units to propane gas. NOx screens must be removed before converting to LP. Remove burner assembly and pull NOx screens from each burner tube. When all the screens are out, reassemble the burner assembly without the screens.

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriter s (See NBFU Manual 58).

For satisfactory operation, propane gas supply pressure must be within 9.7 - 10.3 inches W.C. at the manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, which depends on (a) temperature of the liquid, and (b) wetted surf ace area of the c ontainer or containers.

2. Proper pressure regulation.

3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size required will depend on length of pipe run and total load of all appliances.

TANKS AND PIPING

Complete information regarding tank sizing for vaporization, recommended regulator settings and pipe sizing is available from most regulat or manufacturers and pr opane gas suppliers .

Since propane gas will quickly dissolve white lead or most standard commer cial compounds, special pipe dope must be used. Shellac base compounds resistant to the actions of liquefied petroleum ga ses such as Gasolac®, Stalactic®, Clyde’ s or John Crane® are satisfactory.

See the following figure for typical propane gas piping.

WARNING

O AVOID PROPERTY DAMAGE OR PERSONAL INJURY

NO OPEN FLAME IN THE VICINITY DURING AIR BLEEDING.

, BE SURE THERE IS

First Stage Regulator

200 PSIG Maximum

Typical Propane Gas Piping

5 to 15 PSIG (20 PSIG Max.)

Continuous

Second Stage Regulator

11" W.C.

ROOF TOP LOCATION AND INSTALLATION

The gas supply piping location and installation for roof top units must be in accordance with local codes or, in the absence of locals codes, with ordinances of the latest edition of the National Fuel Gas Code (ANSI Z223.1).

A manual gas shut off valve must be field installed e xternal to the roof top unit. In addition, a drip leg must be installed near the inlet connection. A ground joint union connection is required between the external shut off valve and the unit connection to the gas valve to permit removal of the burner assembly for servicing.

1. Route gas piping to unit so that it does not interfere with the removal of access panels. Support and align piping to prevent strains or misalignment of the manif old assembly .

2. All units are furnished with standard female NPT pipe connections. Connection pipe sizes for DCG036 through 072 units is 1/2" NPT on 045 to 140 mBH units. The size of the gas supply piping to the unit must be base d on leng th of run, number of units on the system, g as char acteristics, BTU requirement and av ailable supply pressure. All piping must be done in accordance with local codes or, in the absence of local codes, with the latest edition of the National Fuel Gas Code (ANSI Z223.1).

NOTE: The gas connection size at the unit does NOT establish the size of the supply line.

3. These units are designed for either natural or propane (LP) gas and are specifically constructed at the factory for only one of these fuels. The fuels are NOT int erchangeable. However, the furnace can be converted in the field from natural gas to LP gas with the appropriate factory kit (see unit Technical Manual for the appropriate kit). Only a qualified contractor, experienced with natural and propane gas systems, should attempt conversion. Kit instructions must be followed closely to assure safe and reliable unit operation.

4. With all units on a common line operating under full fire, natural gas main supply pressure should be adjusted to approximately 7.0" w.c., measured at the unit gas valv e. If the gas pressure a t the unit is greater than 10.5" w.c., the contractor must furnish and install an external type positive shut off service pressure regulator. The unit will not function satisfactorily if supply gas pr essure is less than

5.5" w.c. or greater than 10.5" w.c.. NOTE: A minimum horizontal distance of 48" between

the regulator and the furnace flue discharge is required.

5. With all units on a common line operating under full LP gas main supply pressure should be a t leas t 11.0" w .c. and must be no greater than 13.0" w.c., measured at the unit gas valve. Unit will not function satisfactorily if supply gas pressure is less than 11.0" w.c. or greater than 13.0" w.c..

6. All pipe connections should be sealed with a pipe thread compound, which is resistant to the fuel used with the furnace. A soapy water solution should be used to check all joints for leaks. A tap is located on the entering side of the gas valve f or tes t g auge connection t o measure supply (main) gas pressure. Another tap is provided on the manifold side of the gas valve for checking manifold pressure.

WARN ING

HIS UNIT AND ITS INDIVIDUAL SHUTOFF VALVE MUST BE

DISCONNECTED

PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN EXCESS OF

1/2 PSIG (13.8” W.C.).

FROM THE GAS SUPPLY SYSTEM DURING ANY

CAUTION

HIS UNIT MUST BE SYSTEM BY CLOSING ITS INDIVIDUAL MANUAL SHUTOFF VALVE DURING ANY PRESSURE TESTING EQUAL TO OR LESS THAN

PSIG.

ISOLAT ED

FROM THE GAS SUPPLY PIPING

1/2

7. There must be no obstruction to prevent the flow of combustion and ventilating air. A vent stack is not required and must never be used. The power venter will supply an adequate amount of combustion air as long as the air passageways are kept free of any obstructions and the recommended external unit clearances are maintained.

CIRCULA TING AIR AND FIL TERS

DUCTWORK

The supply duct from the unit through a wall may be ins talled without clearance. However, minimum unit clearances must be maintained (see “Clearance s” section). The supply duct should be provided with an access panel large enough to inspect the air chamber downstream of the heat exchanger. A cover should be tightly attached to prevent air leaks.

Ductwork dimensions are shown in the roof curb installation manual.

If desired, supply and return duct connections to the unit may be made with flexible connections to reduce possible unit operating sound transmission.

VENTING

PRE-STARTUP INSTRUCTIONS - GENERAL

NOTE: Venting is self-contained.

The indoor motor on DCG units are dual voltag e motor s. They ar e factory wired for 230 volts. If field supply power is 208V, the installer must swap the connections to the black and red loads (located in the blower compartment) to ensure correct inductor motor operation.

CONDENSA TE DRAIN CONNE CTION

CONDENSATE DRAIN CONNECTION

A 3/4” female NPT drain connection is supplied on the end of the unit and bottom of the drain pan f or condensat e piping. An ext ernal trap must be installed for proper condensate drainage.

DRAIN CONNECTION

UNIT 2" MINIMUM

FLEXIBLE TUBING-HOSE OR PIPE

A POSITIVE LIQUID SEAL IS REQUIRED

Drain Connection

3" MIN IMUM

Install condensate drain trap as shown. Use 3/4" drain line and fittings or larger. Do not operate without trap.

HORIZONTAL DRAIN

Drainage of condensate directly on to the r oof ma y be accept able; refer to local code. It is recommended that a small drip pad of either stone, mortar, wood or metal be provided to prevent any possible damage to the roof.

CLEANING

Due to the fact that drain pans in any air conditioning unit will have some moisture in them, algae and fungus will grow due to airborne bacteria and spores. Periodic cleaning is necessary to prevent this build-up from plugging the drain.

ST ARTUP, ADJUSTMENTS, AND CHECK S

WARN ING

CAUTION

PREVENT PROPERTY DAMAGE OR PERSONAL INJURY START THE UNIT UNTIL ALL NECESSARY PRE-CHECKS AND TESTS HAVE BEEN PERFORMED

, DO

NOT

Prior to the beginning of Startup, Adjustments, and Checks pr ocedures, the following steps should be completed in the building.

WARN ING

MOVING MACHINERY HAZA RD!

O PREVENT POSSIBLE PERSONAL INJURY OR DEATH, DISCONNECT

POWER TO THE UNIT AND PADLOCK IN THE SERVICNG FANS

“OFF”

POSITION BEFORE

This unit is equipped with an electronic ignition device to automatically light the main burners. It also has a power vent blower to exhaust combustion products.

On new installations, or if a major component has been replaced, the operation of the unit must be checked.

Check unit operation as outlined in the following instructions. If any sparking, odors, or unusual sounds are encountered, shut off electrical power and recheck for wiring errors, or obstructions in or near the blower motors. Duct cover s must be removed before

operating unit.

The Startup, Adjustments, and Checks procedure provides a s tepby-step sequence which, if follow ed, will assure the proper st artup of the equipment in the minimum amount of time. Air balancing of duct system is not considered part of this procedure. However, it is an important phase of any air c onditioning syst em startup and should be performed upon completion of the Startup, Adjustments , and Checks procedure. The St artup, Adjustment s, and Checks procedure at outside ambients below 55°F should be limit ed to a readiness check of the refrigera tion system with the requir ed final check and calibration left to be completed when the outside ambient rises above 55°F.

TEMPORARY HEATING OR COOLING

If the unit is to be used for tempor ary heating or cooling, a “Startup, Adjustments, and Checks” must first be performed in accordance with this manual. Failure to comply with this requir ement will void the warranty. After the machines are used for temporary heating or cooling, inspect the coils, fans, and motors for unacceptable levels of construction dust and dirt and install new filters.

HIGH VOLTAGE!

O AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, B THE BUILDING ELECTRICAL GROUND BY USE OF THE GROUNDING TERMINAL PROVIDED OR OTHER ACCEPTABLE MEANS SERVICING OR INSTALLING THIS UNIT

OND THE FRAME OF THIS UNIT TO

. D

ISCONNECT ALL POWER BEFORE

CONTRACTOR RESPONSIBILITY

The installing contractor must be certain that:

• All supply and return air ductwork is in place, properly sealed, and corresponds with installation instructions.

• All thermostats are mounted and wired in accordance with installation instructions.

• All electric power, all gas, hot water or steam line connections, and the condensate drain installation have been made to each unit on the job. These main supply lines must be functional and capable of operating all unit s simultaneously.

• Requirements are met for venting and combution air.

• Air filters are in place.

• Input rate and temperature rise are adjusted per rating plate.

ROOF CURB INSTALLATION CHECK

Inspect the roof curb for correct installation. The unit and curb assembly should be level. Inspect the flashing of the roof mounting curb to the roof, especially at the corners, for good workmanship. Also check for leaks around g a s kets. Note any deficiencie s in a separate report and forward to the contractor.

OBSTRUCTIONS, FAN CLEARANCE AND WIRING

Remove any extraneous construction and shipping materials that may be found during this procedure. Rotate all fans manually to check for proper clearances and that they rotate freely. Check for bolts and screws that may have jarred loose during shipment to the job site. Retighten if necessary. Re-tighten all electrical connections.

Three Phase Models Only

2) MAXIMUM VOLTAGE DEVIATIONS

3) PERCENT VOLTAGE UNBALANCE

HOW TO USE THE FORMULA: EXAMPLE: With voltage of 220, 216, and 213

1) Average Voltage = 220+216+213=649 / 3 = 216

2) Maximum Voltage Deviation s fro m Average Voltage = 220 - 216 = 4

3) Percent Voltage Unbalance = 100 x = = 1.8%

Percent voltage unbalance MUST NOT exceed 2%

= 100 X

FROM AVERAGE VOLT AG E

1) AVERAGE VOLTAGE

216

400 216

AIR FLOW ADJUSTMENTS

When the final adjustments are comple te, the curren t draw of the motor should be checked and compared to the full load current rating of the motor. The amperage must not exceed the service factor stamped on the motor nameplate. The total airflow must not be less than that required f or oper ation of the electric heat ers or the furnace.

If an economizer is installe d, check the unit operating balance with the economizer at full outside air and at minimum outside air.

NOTE: Never run CFM below 350 CFM per ton, evapor ator freezing or poor unit performance is possible.

FIELD DUCT CONNECTIONS

Verify that all duct connections are tight and that there is no air bypass between supply and return.

FILTER SECTION CHECK

Remove filter section access panels and check that filter s are properly installed. Note airflow arrows on filter frames.

PRE-STARTUP PRECAUTIONS

It is important to your safety that the unit has been properly grounded during installation. Check gr ound lug connection in main control box for tightness prior to closing circuit break er or disconnect switch. Verify that supply voltage on line side of disconnect agrees with voltage on unit identification plate and is within the utilization voltage rang e as indicate d in Appendix B Electrical Data.

System Voltage - That nominal voltage value assigned to a circuit or system for the purpose of designating its voltage class.

Nameplate Voltage - That voltage assigned to a piece of equipment for the purpose of designating its voltage class and for the purpose of defining the minimum and maximum voltage at which the equipment will operate.

Utilization Voltage - The voltag e of the line terminals of the equipment at which the equipment must give fully satisfactory performance. Once it is established that supply voltage will be maintained within the utilization range under all system conditions, check and calculate if an unbalanced condition exists between phases. Calculate percent voltage unbalance as follows.

PSC MOTOR

Adjust the CFM for the unit by changing the speed tap of the indoor blower motor at the heat or cool tap on the control board connection with the one of the speed taps on “M1” or “M2” (Black High Speed, Blue-Medium Speed, Red-Low Speed).

EEM Motor

Adjust the CFM for the unit by changing the position of the low voltage leads on the motor terminal block. Green is for Fan Only. Y ello w is for Cooling and Heat Pump Heating. Refer to Appendix A for blower performance at each speed tap. NOTE: If more than one lead is energized simultaneously, the motor will run at the higher speed.

SET EVAPORATOR FAN RPM

Actual RPM’s mus t be set and verified with a tachomet er or strobe light. Refer to Appendices A and B for basic unit fan RPM. Refer also to “Airflow ” section of this manual. W ith disconnect switch open, disconnect thermostat wires from terminals Y and W. This will prevent heating and mechanic al cooling from coming on. Place a jumper wire across terminals R and G at TB1 terminal block. Close disconnect switch; evaporator fan motor will operate so RPM can be checked.

For gas heat units, the airflow must be adjusted so that the air temperature rise f alls within the r ange s given s tated on Data Plate (see Appendix A - Blower Performance).

EVAPORATOR FAN ROTATION CHECK (THREE PHASE MODELS ONLY)

Check that fan rotate s clockwise when viewe d fr om the driv e side of unit and in accordance with rotation arrow shown on blower housing. If it does not, reverse any two incoming power cables at Single Point Power Block. In this case, repeat bearing check.

Do not attempt to change load side wiring. In ternal wiring assur es all motors and compressors will rotate in correct direction once evaporator fan motor rotation check has been made.

ELECTRICAL INPUT CHECK

Make preliminary check of evapor ator f an ampere dra w and verify that motor nameplate amps are not exceeded. A final check of amp draw should be made upon completion of air balancing of the duct system (see Appendix C).

BELT DRIVE MODELS ONLY

The drive on the supply fan is typically set in the middle of the RPM range. The drive motor sheave pitch diameter is field adjustable for the required airflow. Refer to “Motor Shea ve Adjustmens” section.

Upon completion of the air flow balancing, we recommend replacing the variable pitched motor sheave with a properly-sized fixed sheav e. A ma tching fix e d she a v e will provide longer belt and bearing life and vibration fr ee oper ation. Initially, it is best to have a variable pitched motor sheav e for the purpose of airflow balancing, but once the balance has been achieved, fixed sheaves maintain alignment and minimize vibra tion mor e e f fectively. For direct drive units, move fan speed wire.

BEARING CHECK

Prior to energizing any f ans, check and make sure tha t all setscrews are tight so that bearings are properly secured to shafts.

TENSION AND ALIGNMENT ADJUSTMENT

Correct belt tension is very important to the life of your belt. Too loose a belt will shorten its life; too tight, premature motor and bearing failure will occur. Check you belt drive for adequate “runin” belt tension by measuring the force required to deflect the belt at the midpoint of the span length. Belt tension force can be measured using a belt tension gauge, available through most belt drive manufacturers.

t = Span length, inches C = Center distance, inches D = Larger sheave diameter, inches

d = Smaller sheave diameter, inches h = Deflection height, inches

SMALL

TYPE DEFLECTION

BELT DRIVE USED NEW

AX Standard 3.0 to 4.0 4.2 ± 0.5 5.5 ± 0.5 0.313

SHEAVE

DIAMETER

(in)

Recommended Pounds of Force Per Belt

DEFLECTION

FORCE (lbs)

(in)

New V-belts will drop rapidly during the first few hours of use. Check tension frequently during the first 24 hours of operation. T ension should f all between the minimum and maximum f orce. To determine the deflection distance from a normal position, measure the distance from sheave to sheave using a straightedge or a cord. This is your reference line. On multiple belt drives, an adjacent undeflected belt can be used as a reference.

MOTOR SHEAVE AD JUSTMENTS

VL, VM, & 2VP VARIABLE PITCH KEY TYPE MOTOR SHEAVES

The driving and driven motor sheave s should be in alignment with each other and the shafts parallel.

VL & VM SHEAVES ADJUSTMENT

1. Loosen set screw “B” using a 5/32" Allen key.

2. Making half or full turns from closed position, adjust

sheave pitch diameter for desired speed. DO NOT OPEN MORE THAN FIVE FULL TURNS.

3. Tighten set screw “B” securely over flat.

4. Carefully put on belts and adjust belt tension. DO NOT

FORCE BELTS OVER GROOVES.

5. Ensure all keys are in place and the se t screws tigh t befor e

starting drive. Recheck set screws and belt tension after 24 hours service.

NOTE: Future adjustments should be made by loosening the belt tension and increasing or decreasing the pitch diameter of the sheave by half or full turns as r equired. R eadjust belt tension be fore starting drive.

*Apply force to the center of the span.

Belt Tension Adjustment

W ARNING

AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO

NOT FIRE GAS UNIT WITH FLUE BOX COVER REMOVED

VL & VM

NOTE: Do NOT operate sheave with flange projecting beyond the hub end.

GAS SYSTEM CHECK

Pre-Operation Checks

1. Close the manual gas valve external to the unit.

2. Turn off the electrical power supply to the unit.

3. Set the room thermostat to its lowest possible setting.

4. Remove the heat exchanger door on the side of the unit by removing screws.

5. This unit is equipped with an ignition device which automatically lights the main burner. DO NOT try to light burner by any other method.

6. Move the gas contr ol v alv e switch t o the OFF position. Do not force.

7. Wait five minutes to clear out any gas.

8. Smell for gas, including near the gr ound. This is important because some types of gas ar e heavier than air. If you have waited five minutes and you do smell gas, immediately follow the warnings on page 3 of this manual. If having waited for five minutes and no gas smell is noted, move the gas control valve switch to the ON position.

9. Replace the heat exchanger door on the side of the unit.

10. Open the manual gas valve external to the unit.

11. Turn on the electrical power supply to the unit.

12. Set the thermostat to desired setting.

NOTE: Except during brief periods when gas pr essure s are being measured by qualifie d service personnel, the furnace access panel must always be secur ed in place when the furnace is in opera tion. An inspection port in the access panel is provided to monitor the flame.

The first step in checking out the gas-fired furnace is to test the gas supply piping to the unit for tigh tness and pur ge the s ys tem of air using methods outlined in the latest edition of the National Fuel Gas Code ANSI Z223.1. Verify that the disc onnect swit ch is in the “OFF” position. A soapy water solution should be use d to check for gas leaks. Since the unit is subject to considerable jarring during shipment, it is extremely important that all gas connections and joints be tested for tightness. Gas piping downstream from the unit inlet should be checked for leaks during the subsequent sequence check.

The supply gas pressure should be a djust ed t o 7.0" w.c. on natural gas and 11.0" on LP gas with the gas burners operating. If there is more than one unit on a common gas line, the pressures should be checked with all units under full fire. A supply pressure tap is provided on the upstream side of the gas valve. A manifold pressure tap is provided on the gas valve. The normal manifold pressure for full input is 3.5" w.c. on natural gas and 9.5" w.c. for propane gas. Low fire natur al ga s 2.0” w .c., 6.0” low fire pr opane g as. Minimum gas supply pressure is 5.5" w.c. for natural gas and 11.0" for propane g as. In order to obt ain rating, gas supply pr essure must be 11.0" w.c. for propane gas.

The pressure regulator on LP gas models is adjusted for 9.5" w.c. manifold pressure and is intended to prevent over-firing only. Do not attempt adjustment of the built-in pressure regulator unless the supply pressure is at le ast 7.0" w.c. on natural gas or 13.0" w .c. on propane gas. Check the loc ation of the ignition electrode and the flame sensor for correct gap setting.

FLAME

SENSOR

GAS SUPPLY PRESSURES & REGULATOR ADJUSTMENTS

W ARNING

HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE UNIT BEFORE TURNING OFF THE ELECTRICAL SUPPLY

Flame Sensor and Ignition Electrode Location

MAXIMUM

INPUT

(BTUH)

45,000 2 23,000 #43 # 55

NUMBER

BURNERS

MAXIMUM

BTUH/BURNER

GAS ORIFICES

NATURAL

(Dia)

PROPANE (LP)

(Dia)

Manifold Pressure Check

The gas valve has a tapped opening to facilitate measurement of the manifold pressur e. A “U” Tube manomet er having a scale range from 0 to 12 inches of water should be used for this measurement. The manifold pressure must be measured with the burners operating.

115,000 5 23,000 #43 # 55 140,000 6 23,000 #43 # 55

90,000 4 23,000 #43 # 55

Heat Exchanger and Burner Orifice Specifications

NOTE: G as appliances locate d more than 2000 feet abov e sea level

must be derated 4% per 1000 feet of total elevation and that variance in gas heating value and specific gravity require change in manifold pressure to obtain r ating, it is mandatory that the input be adjusted at the installa tion site. All installations should be made as outlined in the latest e dition of the National Fuel Gas Code ANSI Z223.1,section “Procedure s To Be Followed To Place An Appliance in Operation”. Refer also to the “User’s Information Manual” supplied with the unit for additional informa tion on the gas furnace.

Gas Supply And Manifold Check

Gas supply pressure and manif old pressur e with the burners oper ating must be as specified on the rating plate.

Gas Inlet Pressure Check

Gas inlet pressure must be check e d and adjus te d in accor dance to the type of fuel being consumed.

With Power And Gas Off:

1. Connect a water manometer or adequate gauge to the inlet pressure tap of the gas valve. Inlet gas pressure can also be measured by removing the cap from the dripleg and installing a predrilled cap with a hose fitting.

With Power And Gas On:

2. Put unit into heating cycle and turn on all other gas consuming appliances.

INLE T GAS PR ESSURE

NATURAL M i n. 5.0" W .C ., Ma x. 10.0" W.C.

PROPANE Min. 1 1.0 " W. C., M ax . 14.0" W.C.

NOTE: Inlet Gas Pressure Must Not Exceed the Maximum Value

Shown. If operating pressure s diff er fr om above, mak e nece ssary pressur e

regulator adjustmen ts, check piping size, et c., and/ or consult with local utility.

1. With disconnect switch open, remove field connected thermostat wire from terminal R, W1 and W2 on TB1. Place jumper wire between R, W1 and W2 to eng age high stage heat. (note on 045 kbtu/hr units W2 is not used, only jumper R to W1).

2. See Figure in input rating section for g as valve adjustmen t.

To adjust the pressure regulator, remove the adjustment screw or cover on the gas valve. Turn out (counterclockwise) to decrease pressure, turn in (clockwise) to increa se pressure. O nly small variations in gas flow should be made by means of the pr essur e regulator adjustment. In no case should the final manif old pr essur e vary more than plus or minus 0.3 inches water c olumn from the specified nominal pressure. An y major change s in flow should be made by changing the size of the burner orifices. The measured input rate to the furnace must not exceed the rating specified on the unit rating plate.

For natural ga s, the high stage manifold pre ssure must be between

3.2 and 3.8 inches water column (3.5 nominal). Low stage manifold pressure must be between 1.7 to 2.3 inches water column (2.0 nominal).

3. To set low fire rate on 090, 115 and 140 kbtu/hr: Open disconnect switch, and remove jumper from R to W2. To set low fire manifold pressure, repeat steps above. Refer to Figure in input rating section for location of high and low stage adjustment.

For propane gas, the manifold pressure must be between 9.7 and

10.3 inches water column (10.0 nominal). Low st age manifold must be between 5.7 and 6.3 inches water column (6.0 nominal).

Gas Input (Natural Gas Only) Check

It is the responsibility of the contractor to adjust the gas input to the unit.

To measure the gas input use a gas meter and proceed as follows:

1. Turn off g as supply t o all other appliances ex cept the unit.

2. With the unit operating, time the smallest dial on the meter for one complete r evolution. If this is a 2 cubic f oot dial, divide the seconds by 2; if it is a 1 cubic foot dial, use the seconds as is. This gives the seconds per cubic foot of gas being delivered to the unit.

3. INPUT=GAS HTG VALUE x 3600 / SEC. PER CUBIC FOOT

Example: Natural gas with a heating value of 1000 BTU per cubic foot and 34 seconds per cubic foot as det ermined by St ep 2, then:

Input = 1000 x 3600 / 34 = 106,000 BTU per Hour. NOTE: BTU content of the gas should be obtained from the gas supplier. This measured input must not be greater than shown on the unit rating plate.

Adjust input rate by varying the adjustment of the gas pressure

regulator on the gas valve. All adjustments must be made with furnace operating at high fire and at normal operating temperature. A manometer should be connected t o the gas valve to verify pressure is within the specified range (see following figures for manometer connections). Clockwise rotation of the pr essure regulator screw increase s pre ssure and g as flow r at e. Turn screw counterclockwise to decrease pressure and gas flow rate. After adjustment the furnace temperatur e rise must be within the range specified on the unit data plate. NOTE: Thermal efficiency of the furnace is a product efficiency rating determined under continuous operating conditions independent of any installed system.

Outlet Pre ssure

Tap

INLET

Inlet Pressure

Tap

Pressure Regulator

Adjustment

(Under Cap Screw)

OUTLET

Gas Valve

On/Off

Selector

Switch

White-Rodgers 36G22 - Single Stage

Open t

Atmosphere

Outlet

Pressure Boss

High Fire Re gulator

Adjust

Regulator

Vent

5. Using a leak detection solution or soap suds, check for le aks at pressure boss screw. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY.

CAUTION

PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ADJUSTING THE GAS VALVE PRESSURE REGULATOR

. O

NLY MINOR ADJUSTMENTS SHOULD BE MADE BY

4. Relight all other appliances turned off in s t ep 1. Be sur e all pilot burners are operating.

Main Burner Flame Check

Flames should be stable, soft and blue (dust may cause orange tips but they must not be yellow) and extending directly outward from the burner without curling, floating or lifting off.

NOx Screen Check

Verify that the alignment of the NOx screens is at 6 o' clock. In jurisdictions that do not require low NOx emissions, NOx screens may be removed.

Temperature Rise Check

Check the temperature rise through the unit by placing thermometers in supply and return air registers as close to the unit as possible. Thermometers must not be able to sample temperature directly from the unit heat exchangers, or false readings could be obtained.

1. All registers must be open; all duct dampers must be in their final (fully or partially open) position and the unit operated for 15 minutes before taking readings.

2. The temperature rise must be within the range specified on the rating plate.

Low Fire

Regulator Adjust

Inlet

Pressure Boss

Man

White-Rodgers 36G54 (2-Stage) Connected to Manometer

Pressure Adjustments

To connect manometer to gas valve:

1. Back outlet pressure t est screw (inlet/ outlet pressur e boss) out one turn (counterclockwise, not more than one turn).

2. Attach a hose and manometer t o the outlet pre ssure boss of the valve.

To remove manometer from gas valve:

1. Remove manometer hose from outlet pressure boss.

2. Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb. minimum).

3. Turn on electrical power and gas supply to the system.

4. Turn on system power and energize valve.

NOTE: Air temperatur e rise is the temperature dif ference between supply and return air.

With a properly designed system, the proper amount of temperature rise will normally be obtained when the unit is operated at rated input with the recommended blower speed.

If the correct amount of temperature rise is not obtained, it may be necessary to change the blower speed. A higher blower speed will lower the temperature rise. A slower blower speed will increase the temperature rise.

NOTE: Blower speed MUST be set to give the correct air temperature rise through the unit as marked on the rating plate.

NORMAL SEQUENCE OF OPERA TION

HEATING

This unit has one (RS) Manual Reset Limit Control Switch. Check the limit to make sure it has not tripped. The limit may arrive at the job site tripped as a result of shipping shock.

+ 39 hidden pages