Johnson Controls SUNLINE 2000 BQ 036, SUNLINE 2000 BQ 060, SUNLINE 2000 BQ 048 User Manual

INSTALLATION

MANUAL

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 4 APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 35 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 35 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 38

See the following page for a complete Table of Contents.

NOTES, CAUTIONS AND WARNINGS

The installer should pay particular attention to the words: NOTE, CAUTION, and WARNING. Notes are intended to clarify or make the installation easier. Cautions are given to prevent equipment damage. Warnings are given to alert installer that personal injury and/or equipment damage may result if installation procedure is not handled properly.

CAUTION: READ ALL SAFETY GUIDES BEFORE YOU

BEGIN TO INSTALL YOUR UNIT.

SAVE THIS MANUAL

SUNLINE 2000™

SINGLE PACKAGE HEAT PUMP

BQ 036, 048 & 060

EXPORT ONLY

ISO 9001

Certified Quality

Management System

364985-XIM-B-0508

364985-XIM-B-0508

TABLE OF CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 4 APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION SAFETY INFORMATION: . . . . . . . . 6 LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . 7 CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . 7 COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SERVICE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . 8 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 POWER AND CONTROL WIRING . . . . . . . . . . . . . . 10 OPTIONS/ACCESSORIES . . . . . . . . . . . . . . . . . . . . 10

ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ECONOMIZER/MOTORIZED DAMPER AND

RAIN HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

POWER EXHAUST/BAROMETRIC RELIEF

DAMPER AND RAIN HOOD . . . . . . . . . . . . . . . . . . . 11

ECONOMIZER AND POWER EXHAUST DAMPER SET POINT ADJUSTMENTS AND

INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MINIMUM POSITION ADJUSTMENT . . . . . . . . . . . . 12 ENTHALPY SET POINT ADJUSTMENT . . . . . . . . . . 12

POWER EXHAUST DAMPER SETPOINT (WITH

OR WITHOUT POWER EXHAUST) . . . . . . . . . . . . . 12 INDOOR AIR QUALITY . . . . . . . . . . . . . . . . . . . . . . . 12

PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SUPPLY AIR BLOWERS . . . . . . . . . . . . . . . . . . . . . 30 CHECKING SUPPLY AIR CFM . . . . . . . . . . . . . . . . 30

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SEQUENCE OF OPERATIONS OVERVIEW . . . . . . 31

COOLING SEQUENCE OF OPERATION . . . . . . . . 31

CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . 31 INTERMITTENT BLOWER . . . . . . . . . . . . . . . . . . . . 31 NO OUTDOOR AIR OPTIONS . . . . . . . . . . . . . . . . . 31

ECONOMIZER WITH SINGLE ENTHALPY

SENSOR - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

ECONOMIZER WITH DUAL ENTHALPY

SENSORS - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

ECONOMIZER (SINGLE OR DUAL) WITH POWER EXHAUST - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

MOTORIZED OUTDOOR AIR DAMPERS - . . . . . . . 32

COOLING OPERATION ERRORS . . . . . . . . . . . . . 32

HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . 32 LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . 32 FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . 33

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 33 COMPRESSOR PROTECTION . . . . . . . . . . . . . . . 33 FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 HEATING SEQUENCE OF OPERATIONS . . . . . . . 33

WITH OR WITHOUT ELECTRIC HEAT . . . . . . . . . . . 33 DEFROST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FORCED DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . 34

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 34 HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . 34

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . 35

PRESTART CHECK LIST . . . . . . . . . . . . . . . . . . . . 35 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . 35 POST START CHECK LIST . . . . . . . . . . . . . . . . . . 35 SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 35

COOLING TROUBLESHOOTING GUIDE . . . . . . . . 35 UNIT FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . 37

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

NORMAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 38 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 OUTDOOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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	LIST OF FIGURES
Fig. #		Pg. #
1	RECOMMENDED DRAIN PIPING . . . . . . . . . . . .	. . . . 7
2	COMPRESSOR RESTRAINING BRACKET . . . .	. . . . 8
3	TYPICAL FIELD POWER & CONTROL WIRING	. . . . 9
4	ENTHALPY SETPOINT ADJUSTMENT . . . . . . .	. . . 13
5	HONEYWELL ECONOMIZER CONTROL W7212	. . . 13
6	FOUR AND SIX POINT LOADING . . . . . . . . . . . .	. . . 14
7	UNIT DIMENSIONS (3 - 5 TON HEAT PUMP)
	FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 22
8	UNIT WITH ECONOMIZER RAINHOOD . . . . . . .	. . . 23
9	UNIT WITH FIXED OUTDOOR AIR/MOTORIZED
	DAMPER RAINHOOD . . . . . . . . . . . . . . . . . . . . .	. . . 23
10	UNIT DIMENSIONS (REAR VIEW) . . . . . . . . . . .	. . . 24
11	DISCONNECT/BLOWER ACCESS LOCATION . . . . 24
12	BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .	. . . 30
13	PRESSURE DROP ACROSS COIL . . . . . . . . . . .	. . . 31
	LIST OF TABLES
Tbl. #		Pg. #
1	UNIT APPLICATION DATA (BQ) . . . . . . . . . . . . .	. . . . 6
2	CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . .	. . . 10
3	ELECTRIC HEATER CFM LIMITATIONS . . . . . .	. . . 11
4	CENTER OF GRAVITY (ALL MODELS) . . . . . . .	. . . 14

5BQ 4 POINT LOADS WEIGHT DISTRIBUTION . . . . 14

6BQ 6 POINT LOADS WEIGHT DISTRIBUTION . . . . 14

7 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 8 OPERATING WEIGHTS (LBS.) . . . . . . . . . . . . . . . . . 15

9 ELECTRICAL DATA - BQ036-060 DIRECT DRIVE

W/O POWERED CONVENIENCE OUTLET . . . . . . . 16

10 ELECTRICAL DATA - BQ036-060 BELT DRIVE

W/O POWERED CONVENIENCE OUTLET . . . . . . . 17

11 ELECTRICAL DATA - BQ036-060 BELT DRIVE HIGH STATIC W/O POWERED CONVENIENCE

OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Tbl. #

Pg. #

12 ELECTRICAL DATA - BQ036-060 DIRECT DRIVE W/POWERED CONVENIENCE OUTLET . . . . . . . . . 19

13 ELECTRICAL DATA - BQ036-060 BELT DRIVE W/POWERED CONVENIENCE OUTLET . . . . . . . . . 20

14ELECTRICAL DATA - BQ036-060 BELT DRIVE HIGH STATIC W/POWERED CONVENIENCE

OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 15 ELECTRIC HEAT CORRECTION FACTORS . . . . . . 22 16 VOLTAGE LIMITATIONS . . . . . . . . . . . . . . . . . . . . . 22 17 UTILITIES ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18 MINIMUM CLEARANCES . . . . . . . . . . . . . . . . . . . . . 24

19 SUPPLY AIR BLOWER PERFORMANCE (BQ036 BELT DRIVE) - SIDE DUCT APPLICATION . . . . . . . 25

20SUPPLY AIR BLOWER PERFORMANCE (BQ036 BELT DRIVE) - BOTTOM DUCT APPLICATION . . . 25

21SUPPLY AIR BLOWER PERFORMANCE (BQ048

BELT DRIVE) - SIDE DUCT APPLICATION . . . . . . . 25

22SUPPLY AIR BLOWER PERFORMANCE (BQ048 BELT DRIVE) - BOTTOM DUCT APPLICATION . . . 25

23SUPPLY AIR BLOWER PERFORMANCE (BQ060

BELT DRIVE) - SIDE DUCT APPLICATION . . . . . . . 26

24SUPPLY AIR BLOWER PERFORMANCE (BQ060 BELT DRIVE) - BOTTOM DUCT APPLICATION . . . 26

25SUPPLY AIR BLOWER PERFORMANCE (BQ036, 048 & 060 DIRECT DRIVE) - SIDE DUCT

APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

26 SUPPLY AIR BLOWER PERFORMANCE (BQ036,

048 & 060 DIRECT DRIVE) - BOTTOM DUCT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

27 BELT DRIVE RPM SELECTION . . . . . . . . . . . . . . . . 27

28 BELT DRIVE BLOWER MOTOR AND DRIVE

DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 29 STATIC RESISTANCES . . . . . . . . . . . . . . . . . . . . . . 27 30 ELECTRIC HEAT LIMIT CONTROL SETTING . . . . . 34 31 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . 35 32 UNIT CONTROL BOARD FLASH CODES . . . . . . . . 37

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GENERAL

YORK Model BQ units are single package heat pumps equipped with optional factory installed electric heaters. These are designed for outdoor installation on a rooftop or slab.

The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested. The units require electric power, gas connection, duct connections, installation of combustion air inlet hood, flue gas outlet hoods and fixed outdoor air intake damper (units without economizer or motorized damper option only) at the point of installation.

The supplemental electric heaters have nickel-chrome elements and utilize single point power connection.

SAFETY CONSIDERATIONS

Due to system pressure, moving parts and electrical components, installation and servicing of air conditioning equipment can be hazardous. Only qualified, trained, service personnel should install, repair, maintain or service this equipment.

Observe all precautions in the literature, on labels and tags accompanying the equipment whenever working on air conditioning equipment. Be sure to follow all other safety precautions that apply.

Wear safety glasses and work gloves, and follow all safety codes. Use a quenching cloth and have a fire extinguisher available for all brazing operations.

INSPECTION

As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier's freight bill. A separate request for inspection by the carrier's agent should be made in writing. Refer to Form 50.15-NM for additional information.

REFERENCE

Additional information on the design, installation, operation and service of this equipment is available in the following reference forms:

•364985 -General Installation

•035-19404-000 -Economizer Accessory

•530.18-N1.13V -Man. Outdoor Air Damper Accessory 0 - 35%

•530.18-N1.14V -Man. Outdoor Air Damper Accy

0 - 100%

•035-07364-000 -Motorized Outdoor Air Damper Accy.

•035-19422-000 –Electric Heat Accessory

•035-19405-000 -Barometric Relief Damper

•530.46-N1.1V -Dual Enthalpy Accessory

•530.18-N1.10V -Power Exhaust Accessory

RENEWAL PARTS

Contact your local York® parts distribution center for authorized replacement parts.

APPROVALS

Design listed by CSA as follows:

•For use as a heat pump only with or without optional electric heat.

•For outdoor installation only.

•For installation on combustible material.

This product must be installed in strict compliance with the enclosed installation instructions and any applicable local, state, and national codes including, but not limited to, building, electrical, and mechanical codes.

Improper installation may create a condition where the operation of the product could cause personal injury or property damage.

The installer should pay particular attention to the words: NOTE, CAUTION and WARNING. Notes are intended to clarify or make the installation easier. Cautions are given to prevent equipment damage. Warnings are given to alert installer that personal injury and/ or equipment damage may result if installation procedure is not handled properly.

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PRODUCT NOMENCLATURE

3-5 Ton Sunline Simplicity Model Number Nomenclature

B Q 048 N04 A 2 A AA 1 0 1 2 4 A

Product Category

B = HP, Single Pkg., R-22

Product Identifier

Q = 10.0 SEER HP

Nominal Cooling Capacity

036 = 3.0 Ton

048 = 4.0 Ton

060 = 5.0 Ton

Heat Type and Nominal Heat Capacity

C00 = Cooling Only. Suitable for Field

Installed Electric Heat

Electric Heat Options

E05 = 5 KW

E07 = 7 KW

E10 = 10 KW

E15 = 15 KW

E20 = 20 KW

E30 = 30 KW

Airflow

A = Direct Drive

B = Direct Drive/Single Input Economizer

D = Direct Drive/Motorized Damper

N = Belt Drive

P = Belt Drive/Single Input Economizer

R = Belt Drive/Motorized Damper

T = Belt Drive High Static

U = Belt Drive High Static/Single Input Economizer

V = Belt Drive High Static/Motorized Damper

Voltage

2 = 208/230-3-60

4 = 460-3-60

5 = 575-3-60

Product Style

A = Style A

Configuration Options (not required for all units)

These four digits will not be assigned until a quote is requested, or an order placed.

SS Drain Pan

CPC Controller, DFS, APS

Johnson Controller, DFS, APS

Honeywell Controller, DFS, APS

Novar Controller, DFS, APS

Simplicity IntelliComfort Controller

Simplicity IntelliComfort Controller w/ModLinc

2" Pleated Filters

BAS Ready Economizer (2-10 V. D. C. Actuator without a Controller)

Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned

		Product Generation
	1	= First Generation
	2	= Second Generation
			Additional Options

Standard Cabinet	Hinged Filter Door & Toolless Access Cabinet
AA = None	BA = Hinged Filter Door & Toolless Access Panels
AB = Phase Monitor	BA = Hinged Filter Door & Toolless Access Panels
AC = Coil Guard	BB = Phase Monitor, Hinged Filter Door & Toolless
AD = Dirty Filter Switch	Access Panels
AE = Phase Monitor & Coil Guard	BC = Coil Guard, Hinged Filter Door & Toolless
AF = Phase Monitor & Dirty Filter Switch	Access Panels
AG = Coil Guard & Dirty Filter Switch	BD = Dirty Filter Switch, Hinged Filter Door &
AH = Phase Monitor, Coil Guard & Dirty Filter Switch	Toolless Access Panels
AS = Bottom Drain Connection	BE = Phase Monitor & Coil Guard, Hinged Filter
RC = Coil Guard & American Flag	Door & Toolless Access Panels
TA = Technicoat Condenser Coil	BF = Phase Monitor & Dirty Filter Switch, Hinged
TJ = Technicoat Evaporator Coil	Filter Door & Toolless Access Panels
TS = Technicoat Evaporator and Condenser Coil	BG = Coil Guard & Dirty Filter Switch, Hinged Filter
	Door & Toolless Access Panels
	BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
	Hinged Filter Door & Toolless Access Panels

ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be located in digits 15-18.

Installation Options

A = No Options Installed

B = Option 1

C = Option 2

D = Options 1 & 2

E = Option 3

F = Option 4

G = Options 1 & 3

H = Options 1 & 4

J = Options 1, 2 & 3

K = Options 1, 2, & 4

L = Options 1,3 & 4

M = Options 1, 2, 3, & 4

N = Options 2 & 3

P = Options 2 & 4

Q = Options 2, 3, & 4

R = Options 3 & 4

S = Option 5

T = Options 1 & 5

U = Options 1, 3, & 5

V = Options 1, 4, & 5

W = Options 1, 3, 4, & 5

X = Options 3 & 5

Y = Options 4 & 5

Z = Options 3, 4 & 5

Options

1 = Disconnect

2 = Non-Pwr'd Conv. Outlet

3 = Smoke Detector S.A.

4 = Smoke Detector R.A.

5 = Pwr'd Conv. Outlet

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INSTALLATION

INSTALLATION SAFETY INFORMATION:

Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference.

1.Install this unit only in a location and position as specified on page 6 of these instructions.

2.This equipment is not to be used for temporary heating of buildings or structures under construction.

LIMITATIONS

These units must be installed in accordance with the following national and local safety codes:

In U.S.A.:

•National Electrical Code ANSI/NFPA No. 70.

TABLE 1: UNIT APPLICATION DATA (BQ)

In Canada:

•Current Canadian Electrical Code C22.1.

•Local plumbing and waste water codes.

•Other applicable local codes.

Refer to the Unit Application Data Table 1 and the Electrical Data table for the unit.

If components are to be added to a unit to meet local codes, they are to be installed at the dealer's and/or the customer's expense.

Size of unit for proposed installation should be based on heat loss/heat gain calculation made according to the methods of the Air Conditioning Contractors of America (ACCA).

This unit is not to be used for temporary heating of buildings or structures under construction.

UNIT MODEL NUMBER		036	048		060
Voltage Variation,	208/230		187	/ 253
	460		414	/ 506
Min. / Max.1
	575		518	/ 630
Supply Air CFM, Nom.		1200	1600		2000
Wet Bulb Temperature (ºF) of Air on			57	/ 72
Evaporator Coil, Min. / Max
Dry Bulb Temperature (ºF) of Air on			0 /	120
Condenser Coil, Min. / Max.

1. Utilization range “A” in accordance with ARI Standard 110.

LOCATION

Use the following guidelines to select a suitable location for these units.

1.Unit is designed for outdoor installation only.

2.Condenser coils must have an unlimited supply of air.

3.Where a choice of location is possible, position the unit on either north or east side of building.

4.For ground level installation, use a level concrete slab with a minimum thickness of 4 inches. The length and width should be at least 6 inches

greater than the unit base rails. Do not tie slab to the building foundation.

5.Roof structures must be able to support the weight of the unit and its options and/or accessories. Unit must be installed on a solid level roof curb or appropriate angle iron frame.

6.Maintain level tolerance to 1/2 inch maximum across the entire length or width of the unit.

If a unit is to be installed on a roof curb or special frame other than a YORK roof curb, gasketing must be applied to all surfaces that come in contact with the unit underside.

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RIGGING AND HANDLING

Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails. Spreader bars, whose length exceeds the largest dimension across the unit, MUST BE USED.

Units may also be moved or lifted with a forklift. Slotted openings in the base rails are provided for this purpose. Fork lengths must be a minimum of 42 inches.

Remove the nesting brackets from the four corners on the top of the unit. All screws that are removed when removing the brackets must be replaced on the unit.

Refer to Table 8 for unit weights and to the Figure 6 for approximate center of gravity.

Before lifting a unit, make sure that all panels are in place and that its weight is distributed equally on all cables so it will lift evenly.

CLEARANCES

All units require certain clearances for proper operation and service. Installer must make provisions for adequate ventilation air. Refer to Dimensions and Clearances shown in Figures 7 through 10 and Table 18 for the clearances required for combustible construction, servicing, and proper unit operation.

Do not permit overhanging structures or shrubs to obstruct outdoor air discharge outlet, combustion air inlet or vent outlets.

DUCTWORK

Ductwork should be designed and sized according to the methods in Manual Q of the Air Conditioning Contractors of America (ACCA).

A closed return duct system shall be used. This shall not preclude use of economizers or outdoor fresh air intake. The supply and return air duct connections at the unit should be made with flexible joints to minimize noise.

The supply and return air duct systems should be designed for the CFM and static requirements of the job. They should NOT be sized to match the dimensions of the duct connections on the unit.

When fastening ductwork to side duct flanges on unit, insert screws through duct flanges only. DO NOT insert screws through casing. Outdoor ductwork must be insulated and waterproofed.

Refer to Figures 7 and 10 for information concerning side and bottom supply and return air duct openings.

CONDENSATE DRAIN

Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install a condensate drain line from the 3/4" NPT female connection on the unit to an open drain.

NOTE: The condensate drain operates in a negative pressure in the cabinet. The condensate drain line MUST be trapped to provide proper drainage. See Figure 1.

FIGURE 1 - RECOMMENDED DRAIN PIPING

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COMPRESSORS

Units are shipped with compressor mountings factoryadjusted and ready for operation.

Units with scroll compressors have a shipping bracket which must be removed after the unit is set in place. See Figure 2.

COMPRESSOR

MOUNTING

BRACKET BASE

REMOVE THESE

SCREWS (2)

MOUNTING BRACKET TOP (REMOVE)

WIRE TIE (CUT AND REMOVE)

FILTERS

One-inch or two-inch filters can be supplied with each unit. Filters must always be installed ahead of the evaporator coil and must be kept clean or replaced with same size and type. Dirty filters will reduce the capacity of the unit and will result in frosted coils or safety shutdown. Minimum filter area and required sizes are shown in Physical Data Table 7.

SERVICE ACCESS

The following removable panels provide access to all serviceable components:

•Compressor compartment

•Electric Heat compartment

•Blower compartment

•Main control box

•Filter compartment

Refer to the Dimensions and Clearances shown in Figures 7 and 11 for location of these access panels.

FIGURE 2 - COMPRESSOR RESTRAINING BRACKET

Do not loosen compressor mounting bolts.

Make sure that all screws and panel latches are replaced and properly positioned on the unit to maintain an airtight seal.

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TYPICAL POWER WIRING

REFER TO THE ELECTRICAL DATA

TABLES TO SIZE THE DISCONNECT

SWITCH, OVERCURRENT PROTEC-

TION AND WIRING.

TYPICAL CONTROL WIRING

COOLING / HEATING (24 VOLT THERMOSTAT)

THERMOSTAT1

TERMINALS

	RH	UNIT TERMINAL
ADD		STRIP TB1
JUMPER	RC	R
	Y	Y1	24 VOLT
		Y2	TRANSFORMER

WW1

W2

GG

C

124 VOLT THERMOSTAT 2ET07701024. TO CONTROL THE ECONOMIZER ON THE SECOND STAGE COOLING OR TO HAVE AN ELECTRIC HEAT ACCESSORY WITH TWO STAGES OF HEAT, USE THERMOSTAT 2TH0471024.

COOLING / HEATING (ELECTRONIC THERMOSTAT)	COOLING / HEATING (ELECTRONIC THERMOSTAT)
MULTI STAGE	SINGLE STAGE

THERMOSTAT1						THERMOSTAT1
TERMINALS			UNIT TERMINAL				UNIT TERMINAL
						TERMINALS
	RC		STRIP TB1	24 VOLT
ADD						RH	STRIP TB1
	RH		R	TRANSFORMER
JUMPER						RC	R
	Y1		Y1		ADD
		2				Y	Y1
	Y2		Y2		JUMPER
						W	W1
	W1		W1
4						G	G
	W2	3	W2
							C
	G		G
							24 VOLT
	B		C
							TRANSFORMER

	LED 1		X
	LED 2	NOT	OCC	1ELECTRONIC PROGRAMMABLE THERMOSTAT 2ET07701024 (INCLUDES SUBBASE).
		USED 4
	COM
				TO CONTROL THE ECONOMIZER ON SECOND STAGE COOLING, USE THERMOSTAT
ADD	A1			2TH04700224.
JUMPER	A2

T TO REMOTE SENSOR

T 2TH040702224 IF USED

1 ELECTRONIC PROGRAMMABLE THERMOSTAT 2ET04700224 (INCLUDES SUBBASE). 2 SECOND STAGE COOLING IS NOT REQUIRED ON UNITS LESS ECONOMIZER.

3SECOND STAGE HEATING IS ONLY REQUIRED ON UNITS WITH A TWO STAGE ELECTRIC HEATER OR 2 STAGE GAS HEAT.

4REMOVE JUMPER J2 FROM TERMINALS 4 AND 9 ON JUMPER PLUG CONNECTOR P6 ON UNITS WITH ECONOMIZER. TERMINALS A1 AND A2 PROVIDE A RELAY OUT-PUT TO CLOSE THE OUTDOOR ECONOMIZER DAMPERS WHEN THE THERMOSTAT SWITCHES TO THE SET-BACK POSITION.

FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING

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THERMOSTAT

The room thermostat should be located on an inside wall approximately 56 inches above the floor where it will not be subject to drafts, sun exposure or heat from electrical fixtures or appliances. Follow the manufacturer's instructions enclosed with the thermostat for general installation procedure. A minimum of seven color-coded insulated wires (#18 AWG) should be used to connect the thermostat to the unit.

POWER AND CONTROL WIRING

Field wiring to the unit must conform to provisions of the National Electrical Code, ANSI / NFPA No. 70 (in U.S.A.), current Canadian Electrical Code C22.1 (in Canada) and/or local ordinances. The unit must be electrically grounded in accordance with NEC and CEC (as specified above) and/or local codes. Voltage tolerances, which must be maintained at the compressor terminals, during starting and running conditions, are indicated on the unit Rating Plate and the Unit Application Data table.

The internal wiring harness furnished with this unit is an integral part of a CSA design certified unit. Field alteration to comply with electrical codes should not be required.

A fused disconnect switch should be field provided for the unit. The switch must be separate from all other circuits. Wire entry at knockout openings require conduit fittings to comply with NEC (in U.S.A.), CEC (in Canada) and/or local codes. If any of the wire supplied with the unit must be replaced, replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire.

Use copper conductors properly sized to carry the load. Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused.

When connecting electrical power and control wiring to the unit, waterproof type connectors MUST BE USED so that water or moisture cannot be drawn into the unit during normal operation. The above waterproofing conditions will also apply when installing a field-supplied disconnect switch.

Refer to the Typical Field Wiring Figure 3 and to the appropriate unit wiring diagram for control circuit and power wiring information.

TABLE 2: CONTROL WIRE SIZES

Wire Size	Maximum Length1
18 AWG	150 Feet

1. From the unit to the thermostat and back to the unit.

OPTIONS/ACCESSORIES

ELECTRIC HEAT

The factoryor field-installed heaters are wired for single point power supply. Power supply need only be brought into the single point terminal block and thermostat wiring to the low voltage terminal strip located in the upper portion of the unit control box.

These CSA approved heaters are located within the central compartment of the unit with the heater elements extending into the supply air chamber. Refer to Figure 7 for access panel location.

Fuses are supplied, where required, by the factory. Some KW sizes require fuses and others do not. Refer to Table 3 for minimum CFM limitations and to Tables 9 through 14 for electrical data.

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TABLE 3: ELECTRIC HEATER CFM LIMITATIONS

UNIT MODEL SIZE				MINIMUM SUPPLY AIR CFM
	VOLTAGE			HEATER SIZE NOMINAL KW
NOMINAL TONS
		5	7		10	15		20	30
	208/230-1-60	900	900		900	900		900	-
036	208/230-3-60	900	900		900	900		900	-
(3)	460-3-60	-	900		900	900		900	-
	600-3-60	-	-		900	900		900	-
	208/230-1-60	1200	1200		1200	1200		1200	-
048	208/230-3-60	1200	1200		1200	1200		1200	-
(4)	460-3-60	-	1200		1200	1200		1200	-
	600-3-60	-	-		1200	1200		1200	-
	208/230-1-60	1500	1500		1500	1500		1500	1500
060	208/230-3-60	1500	1500		1500	1500		1500	1500
(5)	460-3-60	-	1500		1500	1500		1500	1500
	600-3-60	-	-		1500	1500		1500	1500

ECONOMIZER/MOTORIZED DAMPER AND RAIN HOOD

The instruction for the optional economizer/motorized damper and rain hood can be found in form 035- 07364-000. Use these instructions when field assembling an economizer rain hood onto a unit. The outdoor and return air dampers, the damper actuator, the damper linkage, the outdoor and return air divider baffles, and all the control sensors are factory mounted as part of the “Factory installed” economizer/motorized damper options.

POWER EXHAUST/BAROMETRIC RELIEF DAMPER AND RAIN HOOD

The instructions for the power exhaust/barometric relief damper and rain hood can be found in form 530.18N1.10V.

All of the components, including the dampers, hardware, and mounting instructions are shipped in a single package external from the unit and must be field assembled and installed.

Power exhaust is only available as a field installed accessory.

ECONOMIZER AND POWER EXHAUST DAMPER SET POINT ADJUSTMENTS AND INFORMATION

Remove the economizer access panel from the unit. Loosen but do not remove the two panel latches. Locate the economizer control module, where the following adjustments will be made.

Extreme care must be exercised in turning all setpoint, maximum, and minimum damper positioning adjustment screws to prevent twisting them off.

Check that the damper blades move smoothly without binding; carefully turn the Minimum Position Adjusting screw (found on the damper control module) fully clockwise and then set the thermostat indoor fan switch to the on position and then off, or energize and deenergize terminals “R” to “G”.

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MINIMUM POSITION ADJUSTMENT

With thermostat set to indoor fan on position, or terminals “R” to “G” energized, turn the Minimum Position Adjusting screw (located on the damper control module) counterclockwise until the desired minimum damper position has been attained.

ENTHALPY SET POINT ADJUSTMENT

The enthalpy setpoint may now be set by selecting the desired setpoint shown in the Enthalpy Setpoint Adjustment Figure 4. Adjust as follows:

•For a single enthalpy operation carefully turn the setpoint adjusting screw (found on the damper control module) to the “A”, “B”, “C” or “D” setting corresponding to the lettered curve of the Enthalpy Setpoint Adjustment Figure 4.

•For a dual enthalpy operation, carefully turn the setpoint adjusting screw fully clockwise past the “D” setting.

POWER EXHAUST DAMPER SETPOINT (WITH OR WITHOUT POWER EXHAUST)

•With no power exhaust option, adjust the Exhaust Air Adjustment Screw fully clockwise.

•With power exhaust option, each building pressurization requirement will be different. The point at which the power exhaust comes on is determined by the economizer damper position (Percent Open). The Exhaust Air Adjustment Screw should be set at the Percent Open of the economizer damper at which the power exhaust is needed. It can be set from 0 to 100% damper open.

INDOOR AIR QUALITY

Indoor air quality (indoor sensor input): Terminal AQ accepts a +2 to +10 Vdc signal with respect to the (AQ1) terminal. When the signal is below it's setpoint, the actuator is allowed to modulate normally in accordance with the enthalpy and mixed air sensor inputs. When the AQ signal exceeds it's setpoint setting and there is no call for free cooling, the actuator is proportionately modulated from the 2 to 10 Vdc signal, with 2 Vdc corresponding to full closed and 10 Vdc corresponding to full open. When there is no call for free cooling, the damper position is limited by the IAQ Max damper position setting. When the signal exceeds it's setpoint (Demand Control Ventilation Setpoint) setting and there is a call for free cooling, the actuator modulates from the minimum position to the full open position based on the highest call from either the mixed air sensor input or the AQ voltage input.

•Optional CO2 Space Sensor Kit Part # 2AQ04700324

•Optional CO2 Unit Sensor Kit Part # 2AQ04700424

Replace the economizer access panel.

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