Unitary products group YMB Series, HC3A Series, HL3A Series Installation Manual

INSTALLATION MANUAL
R-22 OUTDOOR SPLIT-SYSTEM HEAT PUMP
MODELS: 13 SEER - YMB / HC3A / HL3A SERIES
1.5 TO 5 TONS
TABLE OF CONTENTS
GENERAL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
INSTALLATIONS REQUIRING TXV . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
LIST OF FIGURES
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tubing Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Typical Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
CFM Selection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Heat Pump Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
LIST OF TABLES
R-22 Saturated Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TEST Input Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Operational Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Status Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
X/L Output Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Operational Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Sensor or Switch Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Wiring Related Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Defrost Initiate Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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Certified Quality
Management System
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Certification applies only
when the complete
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EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Demand Defrost Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Defrost Operation Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Hot Heat Pump Indoor Airflow Control . . . . . . . . . . . . . . . . . . . . . . . .14
Jumper Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Air Handler Auxiliary Heat Functionality . . . . . . . . . . . . . . . . . . . . . . 16
Fossil Fuel Furnace Auxiliary Heat Functionality . . . . . . . . . . . . . . . 16
1-1/2 Ton Subcooling Charging Chart . . . . . . . . . . . . . . . . . . . . . . . 18
2 Ton Subcooling Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-1/2 Ton Subcooling Charging Chart . . . . . . . . . . . . . . . . . . . . . . . 18
3 Ton Subcooling Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-1/2 Ton Subcooling Charging Chart . . . . . . . . . . . . . . . . . . . . . . . 19
4 Ton Subcooling Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Ton Subcooling Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION I: GENERAL
The outdoor units are designed to be connected to a matching indoor coil with sweat connect lines. Sweat connect units are factory charged with refrigerant for a matching indoor coil plus 15 feet of field supplied lines.
Matching indoor coils are available with a thermal expansion valve or an orifice liquid feed sized for the most common usage. The orifice size and/or refrigerant charge may need to be changed for some indoor-out­door unit combinations, elevation differences, or total line lengths. Refer to Application Data covering “General Piping Recommendations and Refrigerant Line Length” (Part Number 036-61920-001).
SECTION II: SAFETY
This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.
Understand and pay particular attention to the signal words DANGER,
WARNING , or CAUTION. DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury
WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury
.
CAUTION indicates a potentially hazardous situation, which, if not avoided may result in minor or moderate injury
. It is also used to alert against unsafe practices and hazards involving only property dam­age
Improper installation may create a condition where the operation of the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service, or mainte­nance can cause injury or property damage. Refer to this manual for assistance or for additional information, consult a qualified con­tractor, installer, or service agency.
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.
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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 delivery receipt. A separate request for inspection by the carrier’s agent should be made in writing. See Local Distributor for more information.
LIMITATIONS
The unit should be installed in accordance with all National, State, and Local Safety Codes and the limitations listed below:
1. Limitations for the indoor unit, coil, and appropriate accessories must also be observed.
2. The outdoor unit must not be installed with any duct work in the air stream. The outdoor fan is the propeller type and is not designed to operate against any additional external static pressure.
3. The maximum and minimum conditions for operation must be observed to assure a system that will give maximum performance with minimum service.
AIR TEMPERATURE AT
OUTDOOR COIL, °F
Min. Max. Min. Max.
DB
Cool
DB
HeatDBCool
DB
Heat
50 -10 115 75 57
1. Operation below this temperature is permissible for a short period of time, during morning warm-up.
4. The maximum allowable line length for this product is 75 feet.
AIR TEMPERATURE AT
INDOOR COIL, °F
WB
Cool
DB
Heat
50
1
WB
Cool
72 80
DB
Heat
SECTION III: UNIT INSTALLATION
LOCATION
Before starting the installation, select and check the suitability of the location for both the indoor and outdoor unit. Observe all limitations and clearance requirements.
The outdoor unit must have sufficient clearance for air entrance to the condenser coil, for air discharge, and for service access. See Figure 1.
NOTE: For multiple unit installations, units must be spaced a minimum
of 18 inches apart. (Coil face to coil face.)
If the unit is to be installed on a hot sun exposed roof or a black-topped ground area, the unit should be raised sufficiently above the roof or ground to avoid taking the accumulated layer of hot air into the outdoor unit.
Provide an adequate structural support.
ADD-ON REPLACEMENT/RETROFIT
The following steps should be performed in order to insure proper sys­tem operation and performance.
1. Change-out of the indoor coil to an approved R-22 coil/ condens­ing unit combination with the appropriate metering device.
2. If the outdoor unit is being replaced due to a compressor burnout, then installation of a 100% activated alumina suction-line filter drier is required, in addition to the factory installed liquid-line drier. Operate the system for 10 hours. Monitor the suction drier pres­sure drop. If the pressure drop exceeds 3 psig, replace both the suction-line and liquid-line driers. After a total of 10 hours run time where the suction-line pressure drop has not exceeded 3 psig, replace the liquid line drier, and remove the suction-line drier. Never leave a suction-line drier in the system longer than 50 hours of run time.
THERMOSTAT
NEC CLASS 1
WIRING
TO INDOOR BLOWER
TO COIL
SEAL OPENINGS WITH PERMAGUM OR EQUIVALENT
NOTE: ALL OUTDOOR WIRING MUST BE WEATHERPROOF
NEC CLASS 2 WIRING
18” FRONT
& SIDES
FIGURE 1: Typical Installation
GROUND INSTALLATION
The unit may be installed at ground level on a solid base that will not shift or settle, causing strain on the refrigerant lines and possible leaks. Maintain the clearances shown in Figure 1 and install the unit in a level position.
Normal operating sound levels may be objectionable if the unit is placed directly under windows of certain rooms (bedrooms, study, etc.).
Condensate will drain from beneath the coil of the outdoor unit during the defrost cycle. Normally this condensate may be allowed to drain directly on the ground.
WEATHERPROOF
DISCONNECT SWITCH
48” OVERHEAD CLEARANCE
24” SERVICE ACCESS CLEARANCE
The outdoor unit should not be installed in an area where mud or ice could cause personal injury. Remember that condensate will drip from the unit coil during heat and defrost cycles and that this condensate will freeze when the temperature of the outdoor air is below 32°F.
Elevate the unit sufficiently to prevent any blockage of the air entrances by snow in areas where there will be snow accumulation. Check the local weather bureau for the expected snow accumulation in your area.
Isolate the unit from rain gutters to avoid any possible wash out of the foundation.
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170761-UIM-B-0406
ROOF INSTALLATION
When installing units on a roof, the structure must be capable of sup­porting the total weight of the unit, including a pad, lintels, rails, etc., which should be used to minimize the transmission of sound or vibra­tion into the conditioned space.
UNIT PLACEMENT
1. Provide a base in the pre-determined location.
2. Remove the shipping carton and inspect for possible damage.
3. Compressor tie-down bolts should remain tightened.
4. Position the unit on the base provided. NOTE: Heat pumps will defrost periodically resulting in water drainage.
The unit should not be located where water drainage may freeze and create a hazardous condition - such as sidewalks and steps.
LIQUID LINE FILTER-DRIER
The heat pumps have a solid core bi-flow filter/drier located on the liquid line.
NOTE: Replacements for the liquid line drier must be exactly the same
as marked on the original factory drier. See Source 1 for O.E.M.
replacement driers.
Failure to do so or using a substitute drier or a granular type may result in damage to the equipment.
Filter-Drier
Source 1 Part No.
Apply with Models
YMB / HC3A / HL3A
026 - 25512 - 000 All Sizes
PIPING CONNECTIONS
The outdoor unit must be connected to the indoor coil using field sup­plied refrigerant grade copper tubing that is internally clean and dry. Units should be installed only with the tubing sizes for approved system combinations as specified in Tabular Data Sheet. The charge given is applicable for total tubing lengths up to 15 feet. See Application Data Part Number 036-61920-001 for installing tubing of longer lengths and elevation differences.
NOTE: Using a larger than specified line size could result in oil return
problems. Using too small a line will result in loss of capacity and other problems caused by insufficient refrigerant flow. Slope horizontal vapor lines at least 1" every 20 feet toward the out­door unit to facilitate proper oil return.
OIL TRAPPING
When the outdoor unit is above the indoor coil oil trapping is necessary. An oil trap should be provided for every 20 ft. of rise. See Figure 2.
PRECAUTIONS DURING LINE INSTALLATION
1. Install the lines with as few bends as possible. Care must be taken
not to damage the couplings or kink the tubing. Use clean hard drawn copper tubing where no appreciable amount of bending around obstruction is necessary. If soft copper must be used, care must be taken to avoid sharp bends which may cause a restriction.
2. The lines should be installed so that they will not obstruct service
access to the coil, air handling system, or filter.
3. Care must also be taken to isolate the refrigerant lines to minimize
noise transmission from the equipment to the structure.
4. The vapor line must be insulated with a minimum of 1/2" foam rub-
ber insulation (Armaflex or equivalent). Liquid lines that will be exposed to direct sunlight and/or high temperatures must also be insulated.
Tape and suspend the refrigerant lines as shown. DO NOT allow tube metal-to-metal contact. See Figure 3.
5. Use PVC piping as a conduit for all underground installations as
shown in Figure 4. Buried lines should be kept as short as possible to minimize the build up of liquid refrigerant in the vapor line during long periods of shutdown
6. Pack fiberglass insulation and a sealing material such as perma-
gum around refrigerant lines where they penetrate a wall to reduce vibration and to retain some flexibility.
7. See Form 690.01-AD1V for additional piping information.
Sheet Metal Hanger
Liquid Line
Incorrect
Correct
FIGURE 3: Tubing Hanger
TO INDOOR COIL
LIQUID LINE
PVC
CONDUIT
INSULATED
VAPOR LINE
FIGURE 4: Underground Installation
Insulated Vapor Line
Tape
TO O UTDO OR UNI T
CAP
OUTDOOR COIL
20 Ft.
INDOOR
COIL
20 Ft.
FIGURE 2: Oil Trap
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10 In.
6 In.
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PRECAUTIONS DURING BRAZING OF LINES
All outdoor unit and evaporator coil connections are copper-to-copper and should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. DO NOT use soft solder. The outdoor units have reusable service valves on both the liquid and vapor connections. The total system refrigerant charge is retained within the outdoor unit during shipping and installation. The reusable service valves are pro­vided to evacuate and charge per this instruction.
Serious service problems can be avoided by taking adequate precau­tions to assure an internally clean and dry system.
Dry nitrogen should always be supplied through the tubing while it is being brazed, because the temperature is high enough to cause oxidation of the copper unless an inert atmosphere is provided. The flow of dry nitrogen should continue until the joint has cooled. Always use a pressure regulator and safety valve to insure that only low pressure dry nitrogen is introduced into the tubing. Only a small flow is necessary to displace air and prevent oxidation.
PRECAUTIONS DURING BRAZING SERVICE VALVE
Precautions should be taken to prevent heat damage to service valve by wrapping a wet rag around it as shown in Figure 5. Also, protect all painted surfaces, insulation, and plastic base during brazing. After braz­ing cool joint with wet rag.
This is not a backseating valve. The service access port has a valve core. Opening or closing valve does not close service access port.
If the valve stem is backed out past the chamfered retaining wall, the O-ring can be damaged causing leakage or system pressure could force the valve stem out of the valve body possibly causing personal injury.
Valve can be opened by removing the plunger cap and fully inserting a hex wrench into the stem and backing out counter-clockwise until valve stem just touches the chamfered retaining wall.
Connect the refrigerant lines using the following procedure:
1. Remove the cap and Schrader core from both the liquid and vapor service valve service ports at the outdoor unit. Connect low pres­sure nitrogen to the liquid line service port.
2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure to wrap the valve body with a wet rag. Allow the nitrogen to con­tinue flowing. Refer to the Tabular Data Sheet for proper liquid line sizing.
3. Carefully remove the rubber plugs from the evaporator liquid and vapor connections at the indoor coil.
FIGURE 5: Heat Protection
The evaporator is pressurized.
4. Braze the liquid line to the evaporator liquid connection. Nitrogen should be flowing through the evaporator coil.
5. Slide the grommet away from the vapor connection at the indoor coil. Braze the vapor line to the evaporator vapor connection. After the connection has cooled, slide the grommet back into original position. Refer to the Tabular Data Sheet for proper vapor line siz­ing.
6. Protect the vapor valve with a wet rag and braze the vapor line connection to the outdoor unit. The nitrogen flow should be exiting the system from the vapor service port connection. After this con­nection has cooled, remove the nitrogen source from the liquid fit­ting service port.
7. Replace the Schrader core in the liquid and vapor valves.
8. Go to “SECTION IV” for TXV installation.
9. Leak test all refrigerant piping connections including the service port flare caps to be sure they are leak tight. DO NOT OVER­TIGHTEN (between 40 and 60 inch - lbs. maximum).
10. Evacuate the vapor line, evaporator, and the liquid line to 500 microns or less.
NOTE: Line set and indoor coil can be pressurized to 250 psig with dry
nitrogen and leak tested with a bubble type leak detector. Then release the nitrogen charge.
NOTE: Do not use the system refrigerant in the outdoor unit to purge or
leak test.
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11. Replace cap on service ports. Do not remove the flare caps from the service ports except when necessary for servicing the system.
Do not connect manifold gauges unless trouble is suspected. Approximately 3/4 ounce of refrigerant will be lost each time a stan­dard manifold gauge is connected.
12. Release the refrigerant charge into the system. Open both the liq­uid and vapor valves by removing the plunger cap and with an allen wrench back out counter-clockwise until valve stem just touches the chamfered retaining wall. See Page 4 "PRECAU­TIONS DURING BRAZING SERVICE VALVE".
13. Replace plunger cap finger tight, then tighten an additional 1/12 turn (1/2 hex flat). Cap must be replaced to prevent leaks.
Never attempt to repair any brazed connections while the system is under pressure. Personal injury could result.
See "System Charge” section for checking and recording system charge.
SECTION IV: INST ALLA TIONS REQUIRING TXV
For installations requiring a TXV, the following are the basic steps for installation. For detailed instructions, refer to the Installation Instructions accompanying the TXV kit.
Install TXV kit as follows:
1. First, relieve the holding charge by depressing the Schrader valve located in the end of the liquid line.
2. After holding charge is completely discharged, loosen and remove the liquid line fitting from the orifice distributor assembly. Note that the fitting has right
3. Remove the orifice from the distributor body using a small diame­ter wire or paper clip. Orifice is not used when the TXV assembly is installed.
4. After orifice is removed, install the thermal expansion valve to the orifice distributor assembly with supplied fittings. Hand tighten and turn an additional 1/8 turn to seal. Do not overtighten fittings
5. Reinstall the liquid line to the top of the thermal expansion valve. Hand modify the liquid line to align with casing opening.
6. Install the TXV equalizer line into the vapor line as follows: a. Select a location on the vapor line for insertion of the equal-
izer line which will not interfere with TXV bulb placement.
b. Use an awl to punch through the suction tube and insert the
awl to a depth to achieve a 1/8” diameter hole.
7. Install TXV equalizer line in 1/8” hole previously made in vapor line. Equalizer line should not be bottomed out in vapor line. Insert equalizer line at least 1/4” in the vapor line. Braze equalizer line making sure that tube opening is not brazed closed.
hand threads.
.
170761-UIM-B-0406
Dry nitrogen should always be supplied through the tubing while it is being brazed, because the temperature is high enough to cause oxidation of the copper unless an inert atmosphere is provided. The flow of dry nitrogen should continue until the joint has cooled. Always use a pressure regulator and safety valve to insure that only low pressure dry nitrogen is introduced into the tubing. Only a small flow is necessary to displace air and prevent oxidation.
All connections to be brazed are copper-to-copper and should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. DO NOT use soft solder.
Install the TXV bulb to the vapor line near the equalizer line, using the two bulb clamps furnished with the TXV assembly. Ensure the bulb is making maximum contact. Refer to TXV installation instruction for view of bulb location.
In all cases, mount the TXV bulb after vapor line is brazed and has had sufficient time to cool.
a. Bulb should be installed on a horizontal run of the vapor line if
possible. On lines under 7/8" OD the bulb may be installed on top of the line. With 7/8" OD and over, the bulb should be installed at the position of about 2 or 10 o'clock.
b. If bulb installation is made on a vertical run, the bulb should
be located at least 16 inches from any bend, and on the tub­ing sides opposite the plane of the bend. The bulb should be positioned with the bulb tail at the top, so that the bulb acts as a reservoir.
c. Bulb should be insulated using thermal insulation pro vided to
protect it from the effect of the surrounding ambient tempera­ture.
SECTION V: ELECTRICAL CONNECTIONS
GENERAL INFORMATION & GROUNDING
Check the electrical supply to be sure that it meets the values specified on the unit nameplate and wiring label.
Power wiring, control (low voltage) wiring, disconnect switches, and over current protection must be supplied by the installer. Wire size should be sized per NEC requirements.
All field wiring must USE COPPER CONDUCTORS ONLY and be in accordance with Local, National Fire, Safety & Electrical Codes. This unit must be grounded with a separate ground wire in accordance with the above codes.
The complete connection diagram and schematic wiring label is located on the inside surface of the unit service access panel and in Figure 14 of this instruction.
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FIELD CONNECTIONS POWER WIRING
1. Install the proper size weatherproof disconnect switch outdoors and within sight of the unit.
2. Remove the screws at the bottom of the corner cover. Slide corner cover down and remove from unit. See Figure 6.
3. Run power wiring from the disconnect switch to the unit.
4. Remove the service access panel to gain access to the unit wiring. Route wires from disconnect through power wiring opening pro­vided and into the unit control box as shown in Figure 6.
5. Install the proper size time-delay fuses or circuit breaker, and make the power supply connections.
6. Energize the crankcase heater if equipped to save time by pre­heating the compressor oil while the remaining installation is com­pleted.
SERVICE ACCESS PANEL
CONTROL WIRING
POWER WIRING
FIGURE 6: Typical Field Wiring
CORNER COVER
FIELD CONNECTIONS CONTROL WIRING
1. Route low voltage wiring into bottom of control box as shown in Figure 5.
2. Replace the corner cover and service access panel that were removed in Steps 2 and 4 of the “Field Connections Power Wiring” section.
3. All field wiring to be in accordance with national electrical codes (NEC) and/or local-city codes.
NOTE: A Start Assist Kit is available and recommended for long line set
applications or in areas of known low voltage problems.
4. Mount the thermostat about 5 ft. above the floor, where it will be exposed to normal room air circulation. Do not place it on an out­side wall or where it is exposed to the radiant effect from exposed glass or appliances, drafts from outside doors or supply air grilles.
5. Route the 24-volt control wiring (NEC Class 2) from the outdoor unit to the indoor unit and thermostat.
NOTE: To eliminate erratic operation, seal the hole in the wall at the
thermostat with permagum or equivalent to prevent air drafts affecting the operation of in the thermostat.
DEHUMIDIFICATION CONTROL
A dehumidification control accessory 2HU06700124 may be used with variable speed air handlers or furnaces in high humidity areas. This control works with the variable speed indoor unit to provide cooling at a reduced air flow, lowering evaporator temperature and increasing latent capacity . The humidist at in this control opens the humidist at contact s on humidity rise. Prior to the installation of the dehumidification control, the jumper across the HUMIDISTAT terminals on the indoor variable speed air handler or furnace CFM selection board must be removed.
During cooling, if the relative humidity in the space is higher than the desired set point of the dehumidification control, the variable speed blower motor will operate at lower speed until the dehumidification con­trol is satisfied. A 40-60% relative humidity level is recommended to achieve optimum comfort.
If a dehumidification control is installed, it is recommended that a mini­mum air flow of 325 cfm/ton be supplied at all times.
For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com in the Product Catalog Section.
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