Unitary products group CHAMPION PLUS Series, CHAMPION PLUS DNP 036, CHAMPION PLUS DNP 048 Installation Manual
INSTALLATION
CHAMPION®PLUS
SINGLE PACKAGED GAS/ELECTRIC
MANUAL
CONTENTS
INSTALLATION SAFETY INFORMATION . . . . . . . . 3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND RENEWAL PARTS . . . . . . . . 3
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . 14
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AIR COOLED AIR CONDITIONERS
3 AND 4 NOMINAL TON
DNP: 036
048
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . 18
TYPICAL WIRING DIAGRAM NOTES . . . . . . . . . . 22
Complete Table of Contents on following pages.
NOTES, CAUTIONS AND WARNINGS
Installer should pay particular attention to the words: NOTE,
CAUTION, and WARNING. Notes
make the installation easier. Cautions
equipment damage. Warnings
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.
are intended to clarify or
are given to prevent
are given to alert installer
SAVE THIS MANUAL
This product was manufactured
in a plant whose quality system
is certified/registered as being
in conformity with ISO 9001.
035-18579-001-B-0103
TABLE OF CONTENTS
035-18579-001-B-0103
INSTALLATION SAFETY INFORMATION . . . . . . . . 3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND RENEWAL PARTS . . . . . . . . 3
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RIGGING OR HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . 5
DUCT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ROOF CURB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . . 6
COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FLUE VENT HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . 14
HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CIRCULATING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . . 16
NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . 18
TYPICAL WIRING DIAGRAM NOTES . . . . . . . . . 22
LIST OF FIGURES
Fig. # Pg. #
1 PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . 4
2 UNIT CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . 5
3 FIELD WIRING DIAGRAM CONTROL WIRING . . . . . 7
4 POWER WIRING FIELD DIAGRAM . . . . . . . . . . . . . . 7
5 EXT SUPPLY CONN EXT SHUT-OFF . . . . . . . . . . . . 9
6 FLUE VENT OUTLET AIR HOOD . . . . . . . . . . . . . . . 10
7 UNIT DIMENSIONS - FRONT . . . . . . . . . . . . . . . . . . 12
8 UNIT DIMENSIONS - FRONT & BOTTOM . . . . . . . . 13
9 UNIT DIMENSIONS - BACK & BOTTOM . . . . . . . . . 13
10 GAS VALVE - FRONT . . . . . . . . . . . . . . . . . . . . . . . . 15
11 GAS VALVE - REAR . . . . . . . . . . . . . . . . . . . . . . . . . 15
12 PROPER FLAME ADJUSTMENT . . . . . . . . . . . . . . . 15
13 IGNITOR AND FLAME SENSOR ASSEMBLY . . . . . 16
14 TYP WIRING DIA (208/230-1-60 PS) . . . . . . . . . . . . 19
15 TYP WIRING DIA (208/230-3-60 PS) . . . . . . . . . . . . 20
16 TYP WIRING DIA (460-3-60 PS) . . . . . . . . . . . . . . . . 21
17 TYPICAL WIRING DIAGRAM LEGEND . . . . . . . . . . 22
LIST OF TABLES
Tbl. # Pg. #
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRE-START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 14
TO TURN OFF GAS TO UNIT . . . . . . . . . . . . . . . . . . . . 15
POST-START CHECK LIST (GAS) . . . . . . . . . . . . . . . .15
MANIFOLD GAS PRESSURE ADJUSTMENT . . . . . . . . 15
BURNER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . 15
HOT SURFACE PILOT INSTRUCTIONS . . . . . . . . . . . . 15
ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . 16
DIRECT DRIVE BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2 Unitary Products Group
1 UNIT APPLICATION DATA . . . . . . . . . . . . . . . . . . . . . . 4
2 UNIT WEIGHTS AND CENTER OF GRAVITY . . . . . . . 5
3 NATURAL GAS APPLICATION DATA . . . . . . . . . . . . . 8
4 PROPANE (LP) GAS APPLICATION DATA . . . . . . . . . 8
5 NATURAL GAS PIPE SIZING CHART . . . . . . . . . . . . . 9
6 PROPANE (LP) GAS PIPE SIZING CHART . . . . . . . . . 9
7 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 UNIT DIMENSIONS FRONT . . . . . . . . . . . . . . . . . . . . 12
10 UNIT MINIMUM CLEARANCES . . . . . . . . . . . . . . . . . 12
11 GASE RATE - CUBIC FEET PER HOUR . . . . . . . . . . 17
035-18579-001-B-0103
INSTALLATION SAFETY INFORMATION
Read these instructions before continuing this appliance
installation. This is an outdoor combination heating and cooling equipment. The installer must assure that these instructions are made available to the consumer and with
instructions to retain them for future reference.
1. Refer to the furnace rating plate for the approved type of
gas for this furnace.
2. Install this furnace only in a location and position as
specified on pages 4 and 5 of these instructions.
3. Never test for gas leaks with an open flame. Use commercially available soap solution made specifically for
the detection of leaks when checking all connections, as
specified on pages 3 and 10 of these instructions.
4. Always install furnace to operate within the furnace’s
intended temperature-rise range with the duct system
and within the allowable external static pressure range,
as specified on the unit name/rating plate, specified on
pages 8 and 16 of these instructions.
5. This equipment is not to be used for temporary heating
of buildings or structures under construction.
ler that personal injury and/or equipment damage may result
if installation procedure is not handled properly.
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.
MAINTENANCE AND RENEWAL PARTS
Refer to User’s, Maintenance and Service Information Manual, Part No. 035-15509-001.
APPROVALS
Design certified by CGA and AGA listed as follows:
1. For use as a forced air furnace with cooling unit.
2. For outdoor installation only.
3. For installation directly on combustible flooring or, in
U.S., on wood flooring or Class A; B; C roof covering
material.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing
property damage, personal injury or loss of life.
GENERAL
YORK Model D1NP units are cooling/heating air conditioners
designed for outdoor installation. Only gas piping, electric
power and duct connections are required at the point of
installation.
The gas-fired heaters have hot surface to pilot ignition. The
tubular heat exchangers are aluminized steel.
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 the instal-
4. For installation on combustible material.
5. For use with natural gas and/or propane (LP) gas.
Not suitable for use with conventional venting systems.
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.
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035-18579-001-B-0103
INSTALLATION
LIMITATIONS
These units must be installed in accordance with the following national and local safety codes.
1. National Electrical Code ANSI/NFPS No. 70 or Canadian
Electrical Code Part 1, C22.1 (latest editions).
2. National Fuel Gas Code Z223.1 or CSA B149.1 Installation Code.
3. Local gas utility requirements.
4. Local plumbing and waste water codes and other applicable local codes.
Refer to Table 1 for unit application data and to Tables 3 and
4 for gas heat application data.
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 calculations made in accordance with industry
recognized procedures identified by the Air Conditioning
Contractors of America.
FIGURE 1: PRODUCT NOMENCLATURE
TABLE 1: UNIT APPLICATION DATA
Voltage Variation
Min. / Max.
Wet Bulb Temperature (°F) of Air on
Dry Bulb Temperature (°F) of Air on
1.
2.
3.
1
Evaporator Coil, Min. / Max.
Condenser Coil, Min.
Rated in accordance with ARI Standard 110, utilization
range “A”.
“T1” transformer primary tap must be moved from the
230 volt connection to the 208 volt connection for low
voltage applications of 208 volt and below
A low ambient accessory is available for operation
down to 0 °F.
208/230V
3
2
460V 414 / 504
/ Max.
187 / 253
57 / 72
45 / 120
LOCATION
Use the following guidelines to select a suitable location for
these units.
2. Condenser must have an unlimited supply of air. Where
a choice of location is possible, position unit on either
north or east side of building.
Excessive exposure of this furnace to contaminated combustion air may result in equipment
damage or personal injury. Typical contaminates
include: permanent wave solution, chlorinated
washes and cleaners, chlorine based swimming
pool chemicals, water softening chemicals, carbon
tetrachloride, halogen type refrigerants, cleaning
solvents (e.g. perchloroethylene), printing inks,
paint removers, varnishes, hydrochloric acid,
cements and glues, antistatic fabric softeners for
clothes dryers, masonry acid washing materials.
1. Unit is designed for outdoor installation only.
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035-18579-001-B-0103
3. For ground level installation, a level pad or slab should
be used. The thickness and size of the pad or slab used
should meet local codes and unit weight. Do not tie the
slab to the building foundation.
4. For roof top installation, be sure the structure will support
the weight of the unit plus any field installed components.
Unit must be installed on a level roof curb or appropriate
angle iron frame providing adequate support under the
compressor/condenser section.
5. Maintain level tolerance of unit to 1/8" maximum.
Do not permit overhanging structures or shrubs to
obstruct the condenser air discharge, combustion
air inlet or vent outlet.
CLEARANCES
All units require certain clearances for proper operation and
service. Refer to Table 10 for the clearances required for
combustion, construction, servicing and proper unit operation.
RIGGING OR HANDLING
Refer to Table 2 for unit weights and to Figure 2 for approximate center of gravity.
TABLE 2: UNIT WEIGHTS AND CENTER OF
GRAVITY
SHIPPING
UNIT
SIZE
036 400 395 100 96 98 101
048 475 470 133 130 102 104
WEIGHT
LBS.)
(
FRONT
OF
UNIT
"A"
49-1/8
OPERATING
WEIGHT
(LBS.)
"D"
25
"B"
CORNER WEIGHTS
LOCATION, LBS.)
(
“A” “B” “C” “D”
CENTER OF
GRAVITY
"C"
47-1/4
25
Care must be exercised when moving the unit. Do not
remove any packaging until the unit is near the place of
installation. Rig unit with slings placed under the unit.
Spreader bars of sufficient length should be used across the
top of the unit.
Before lifting a unit, make sure that its weight is
distributed equally on the cables so that it will lift
evenly.
Units may also be moved or lifted with a fork-lift. Slotted
openings in the skid are provided for this purpose. Forks
must pass completely through the base.
FIGURE 2: UNIT CENTER OF GRAVITY
DUCT WORK
These units are adaptable to downflow use as well as rear
supply and return air duct openings. To convert to downflow,
use the following steps:
1. Remove the duct covers found in the bottom return and
supply air duct openings. There are four (4) screws
securing each duct cover (save these screws to use
later).
2. Install the duct covers, removed in step one, to the rear
supply and return air duct openings. Secure with the four
(4) screws used in step one.
3. Seal duct covers with silicone caulk.
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035-18579-001-B-0103
Duct work should be designed and sized according to the
methods of the Air Conditioning Contractors of America
(ACCA), as set forth in their Manual D.
A closed return duct system shall be used. This shall not preclude use of economizers or ventilation air intake. Flexible
joints may be used in the supply and return duct work to minimize the transmission of noise.
When fastening duct work to the side duct flanges
on the unit, insert the screws through the duct
flanges only. Do not insert the screws through the
casing. Outdoor ductwork must be insulated and
waterproofed.
NOTE: Be sure to note supply and return openings.
Refer to Figure 8 and 9 for information concerning rear and
bottom supply and return air duct openings.
ROOF CURB
On applications when a roof curb is used, the unit must be
positioned on the curb so the front of the unit is tight against
the curb.
FILTERS
Single phase units are shipped without a filter or filter racks
and is the responsibility of the installer to secure a filter in the
return air ductwork or install a Filter/Frame Kit (1FF0110).
A filter rack and a high velocity filters are standard on three
phase units.
Filters must always be used and must be kept clean. When
filters become dirt laden, insufficient air will be delivered by
the blower, decreasing your units efficiency and increasing
operating costs and wear-and-tear on the unit and controls.
Filters should be checked monthly especially since this unit is
used for both heating and cooling.
CONDENSATE DRAIN
A condensate trap is recommended to be installed in the condensate drain. The plumbing must conform to local codes.
Use a sealing compound on male pipe threads. Install the
condensate drain line (NPTF) to spill into an open drain.
SERVICE ACCESS
Access to all serviceable components is provided by the following removable panels:
• Blower compartment
• Gas control/electrical service access
Refer to Figure 7 for location of these access panels and minimum clearances in Table 10.
THERMOSTAT
The room thermostat should be located on an inside wall
approximately 56" above the floor where it will not be subject
to drafts, sun exposure or heat from electrical fixtures or
appliances. Follow manufacturer's instructions enclosed with
the thermostat for general installation procedure. Four color
coded insulated wires (minimum #18 AWG) should be used
to connect thermostat to unit. See Figure 3.
POWER AND CONTROL WIRING
Field wiring to the unit must conform to provisions of the current N.E.C. ANSI/NFPA No. 70 or C.E.C. and/or local ordinances. The unit must be electrically grounded in accordance
with local codes or, in their absence, with the N.E.C./C.E.C.
Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are
indicated on the unit Rating Plate and Table 8.
The wiring entering the cabinet must be provided with
mechanical strain relief.
A fused disconnect switch should be field provided for the
unit. If any of the wire supplied with the unit must be replaced,
replacement wire must be of the type shown on the wiring
diagram.
Electrical line must be sized properly to carry the load. Each
unit must be wired with a separate branch circuit fed directly
from the meter panel and properly fused.
Refer to Figure 4 for typical field wiring and to the appropriate
unit wiring diagram for control circuit and power wiring information.
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035-18579-001-B-0103
*
N O T E :
H E A T A N T I C I P A T O R
S H O U L D B E S E T A T 0 . 3 5
A M P S F O R A L L M O D E L S .
* = M i n i m u m w i r e s i z e o f 1 8 A W G
w i r e s h o u l d b e u s e d f o r a l l
f i e l d i n s t a l l e d 2 4 v o l t w i r e .
T H E R M O S T A T
R
G
W
C
U N I T T E R M I N A L S T R I P
* *
P R O G R A M A B L E
T H E R M O S T A T O N L Y
FIGURE 3: FIELD WIRING DIAGRAM CONTROL WIRING
C O N T A C T O R
F I E L D - S U P P L I E D
G R O U N D
L U G
D I S C O N N E C T
R E F E R T O E L E C T R I C A L
D A T A T A B L E S T O S I Z E
T H E D I S C O N N E C T
S I N G L E
P H A S E
P O W E R
S U P P L Y
G R O U N D
L U G
R
G
YY
W
C
C O N T A C T O R
R E F E R T O E L E C T R I C A L
D A T A T A B L E S T O S I Z E
T H E D I S C O N N E C T
2 4 V O L T
T R A N S F O R M E R
F I E L D - S U P P L I E D
D I S C O N N E C T
T H R E E
P H A S E
P O W E R
S U P P L Y
FIGURE 4: POWER WIRING FIELD DIAGRAM
COMPRESSORS
Units are shipped with compressor mountings factoryadjusted and ready for operation.
Unitary Products Group 7
Do not loosen compressor mounting bolts.
TABLE 3: NATURAL GAS APPLICATION DATA
035-18579-001-B-0103
TEMP. RISE ºF A FULL
AVAILABLE ON MODELS
INPUT CAPACITY
1
(MBH)
OUTPUT CAPACITY
(MBH)
G
AS RATE
FT.3/HR.
2
UMBER OF
N
BURNERS
MIN.MAX.
3 TON 45 36 42 2 25 55
3 TON 70 56 65 3 25 55
4 TON 80 64 74 3 25 55
3 TON 90 72 84 4 30 60
4 TON 108 87 43 4 30 60
4 TON 135 108 126 5 35 65
1.
Heating capacity valid for elevations up to 2000 feet above sea level. For elevations above 2,000 feet, rated capacity should be
reduced by 4% for each 1,000 feet above sea level.
2.
Based on 1075 BTU/Ft.3.
3.
The air flow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperature should not
be below 55°F.
TABLE 4: PROPANE1 (LP) GAS APPLICATION DATA
TEMP. RISE ºF A FULL
AVAILABLE ON
M
ODELS
INPUT CAPACITY
2
BH)
(M
OUTPUT CAPACITY
(M
BH)
AS RATE
G
FT.3/HR.
3
UMBER OF
N
B
URNERS
3
I
NPUT
4
INPUT
MIN.MAX.
3 TON 45 36 18 2 25 55
3 TON 70 56 28 3 25 55
4 TON 80 64 32 3 25 55
3 TON 90 72 36 4 30 60
4 TON 108 87 43 4 30 60
4 TON 135 108 54 5 35 65
1.
Propane applications are accomplished by field installation of a Propane Conversion Accessory, Model 1NP0805.
2.
Heating capacity valid for elevations up to 2,000 feet above sea level. For elevations above 2,000 feet, rated capacity should be
reduced by 4% for each 1,000 feet above sea level.
3.
Based on 2500 BTU/Ft.3.
4.
The air flow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperatures should not
be below 55°F.
8 Unitary Products Group
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