York BCH 036, 048 & 060 User Manual

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Page 1

INSTALLATION

SUNLINE 2000™

MANUAL

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . 4

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 4

APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . 5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 31

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 32

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SINGLE PACKAGE HEAT PUMP

BCH 036, 048 & 060

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 clarify or make the installation easier. Cautions to prevent equipment damage. Warnings 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.

are intended to

are given

are given to

SAVE THIS MANUAL

177820-YIM-A-0506

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TABLE OF CONTENTS

177820-YIM-A-0506

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 4

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 4

APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . 5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION SAFETY INFORMATION: . . . . . . . . 5

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . 6

CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . 7

COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SUPPLY AIR BLOWERS . . . . . . . . . . . . . . . . . . . . . 26

CHECKING SUPPLY AIR CFM . . . . . . . . . . . . . . . . 26

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SEQUENCE OF OPERATIONS OVERVIEW . . . . . . 27

COOLING SEQUENCE OF OPERATION . . . . . . . . 27

CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . 27

INTERMITTENT BLOWER . . . . . . . . . . . . . . . . . . . . 28

NO OUTDOOR AIR OPTIONS . . . . . . . . . . . . . . . . . 28

ECONOMIZER WITH SINGLE ENTHALPY

SENSOR - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ECONOMIZER WITH DUAL ENTHALPY

SENSORS - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ECONOMIZER (SINGLE OR DUAL) WITH POWER

EXHAUST - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

MOTORIZED OUTDOOR AIR DAMPERS - . . . . . . . 28

COOLING OPERATION ERRORS . . . . . . . . . . . . . 28

HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . 28

LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . 29

FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . 29

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 29

COMPRESSOR PROTECTION . . . . . . . . . . . . . . . 29

FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

HEATING SEQUENCE OF OPERATIONS . . . . . . . 30

WITH OR WITHOUT ELECTRIC HEAT . . . . . . . . . . . 30

DEFROST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FORCED DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . 30

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 30

HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . 31

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . 31

PRESTART CHECK LIST . . . . . . . . . . . . . . . . . . . . 31

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . 32

POST START CHECK LIST . . . . . . . . . . . . . . . . . . 32

SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 32

COOLING TROUBLESHOOTING GUIDE . . . . . . . . 32

UNIT FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . 34

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

NORMAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 34

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

OUTDOOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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LIST OF FIGURES

Fig. # Pg. #

1 RECOMMENDED DRAIN PIPING . . . . . . . . . . . . . . . . 7

2 COMPRESSOR RESTRAINING BRACKET . . . . . . . . 7

3 TYPICAL FIELD POWER & CONTROL WIRING . . . . 9

4 ENTHALPY SETPOINT ADJUSTMENT . . . . . . . . . . 12

5 HONEYWELL ECONOMIZER CONTROL

W7212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6 FOUR AND SIX POINT LOADING . . . . . . . . . . . . . . . 13

7 UNIT DIMENSIONS (3 - 5 TON HEAT PUMP) FRONT

VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8 UNIT WITH ECONOMIZER RAINHOOD . . . . . . . . . . 20

9 UNIT WITH FIXED OUTDOOR AIR/MOTORIZED

DAMPER RAINHOOD . . . . . . . . . . . . . . . . . . . . . . . . 20

10 UNIT DIMENSIONS (REAR VIEW) . . . . . . . . . . . . . . 21

11 DISCONNECT/BLOWER ACCESS LOCATION . . . . 21

12 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 26

13 PRESSURE DROP ACROSS COIL . . . . . . . . . . . . . . 27

LIST OF TABLES

Tbl. # Pg. #

1 UNIT APPLICATION DATA (BCH) . . . . . . . . . . . . . . . 6

2 CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . 10

3 ELECTRIC HEATER CFM LIMITATIONS . . . . . . . . . 11

4 CENTER OF GRAVITY (ALL MODELS) . . . . . . . . . . 13

5 BCH 4 POINT LOADS WEIGHT DISTRIBUTION . . . 13 6 BCH 6 POINT LOADS WEIGHT DISTRIBUTION . . . 13

7 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8 OPERATING WEIGHTS (LBS.) . . . . . . . . . . . . . . . . . 14

9 ELECTRICAL DATA - BCH036 - 060 DIRECT

DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

10 ELECTRICAL DATA - BCH036 - 060 BELT DRIVE . . 17

11 ELECTRIC HEAT CORRECTION FACTORS . . . . . . 19

12 VOLTAGE LIMITATIONS . . . . . . . . . . . . . . . . . . . . . 19

13 UTILITIES ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

14 MINIMUM CLEARANCES . . . . . . . . . . . . . . . . . . . . . 21

15 SUPPLY AIR BLOWER PERFORMANCE (3 TON BELT

DRIVE) - SIDE DUCT APPLICATION . . . . . . . . . . . . 22

16 SUPPLY AIR BLOWER PERFORMANCE (4 TON BELT

DRIVE) - SIDE DUCT APPLICATION . . . . . . . . . . . . 23

17 SUPPLY AIR BLOWER PERFORMANCE (5 TON BELT

DRIVE) - SIDE DUCT APPLICATION . . . . . . . . . . . . 24

18 SUPPLY AIR BLOWER PERFORMANCE (3 - 5 TON

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

19 BELT DRIVE BLOWER MOTOR AND DRIVE DATA. 25

20 STATIC RESISTANCES . . . . . . . . . . . . . . . . . . . . . . 26

21 ELECTRIC HEAT LIMIT CONTROL SETTING . . . . . 31

22 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . 31

23 UNIT CONTROL BOARD FLASH CODES . . . . . . . . 34

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GENERAL

YORK Model BCH units are single package heat pumps. These are designed fo r 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, duct connections, installation of fixed outdoor air intake damper (units without economizer or motorized damper option only) at the point of installation.

The supplemental field installed 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.

• 177820 -General Installation

• 255036 - Technical Guide

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.

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:

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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B 7 C H A

PRODUCT GENERATION

4 = Fourth Generation 5 = Fifth Generation 6 = Sixth Generation 7 = Seventh Generation

PRODUCT CATEGORY

B = Single Package Heat Pump

(Air Cooled)

PRODUCT IDENTIFIER

CH = Heat Pump

VOLTAGE CODE

25 = 208/230-3-60 46 = 460-3-60 58 = 575-3-60

036 = 3 Ton 048 = 4 Ton 060 = 5 Ton

30 6 2 5

FACTORY INSTALLED HEAT

A = No Supplemental Heat

NOMINAL COOLING CAPACITY

PRODUCT NOMENCLATURE

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.

Unitary Products Group 5

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.

Page 6

TABLE 1: UNIT APPLICATION DATA (BCH)

UNIT MODEL NUMBER 036 048 060

Voltage Variation,

Min. / Max.

Supply Air CFM, Nom. 1200 1600 2000

208/230 187 / 253

460 414 / 506 575 518 / 630

177820-YIM-A-0506

Wet Bulb Temper ature (ºF) of Air on

Evaporator Coil, Min. / Max

Dry Bulb Temperature (ºF) of Air on

Condenser Coil, Min. / Max.

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.

57 / 72

0 / 120

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 fr om 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 14 for the clearances required for combustible construction, servicing, and proper unit operation.

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.

6 Unitary Products Group

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

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177820-YIM-A-0506

DUCTWORK

Ductwork should be designed and sized according to the methods in Manual Q of the A ir 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 one-inch 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

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)

FIGURE 2 - COMPRESSOR RESTRAINING

BRACKET

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• Compressor compartment

• Electric Heat compartment

177820-YIM-A-0506

Do not loosen compressor mounting bolts.

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 replace d with same size and type. Dirty filters will reduce the capacity of the unit and will result in frosted c oils or safety sh utdown. 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:

• Blower compartment

• Main control box

• Filter compartment Refer to the Dimensions and Clearances shown in Fig-

ures 7 and 11 for location of these access panels.

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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ADD

JUMPER

THERMOSTAT

TERMINALS

UNIT TERMINAL

STRIP TB1

24 VOLT

TRANSFORMER

ELECTRONIC PROGRAMMABLE THERMOSTAT 2ET07701024 (INCLUDES SUBBASE). TO CONTROL THE ECONOMIZER ON SECOND STAGE COOLING, USE THERMOSTAT 2TH04700224.

COOLING / HEATING (ELECTRONIC THERMOSTAT)

SINGLE STAGE

TYPICAL POWER WIRING

REFER TO THE ELECTRICAL DATA TABLES TO SIZE THE DISCONNECT SWITCH, OVERCURRENT PROTECTION AND WIRING.

TYPICAL CONTROL WIRING

COOLING / HEATING (24 VOLT THERMOSTAT)

UNIT TERMINAL

STRIP TB1

ADD

JUMPER

THERMOSTAT

TERMINALS

COOLING / HEATING (ELECTRONIC THERMOSTAT)

MULTI STAGE

LED 1

LED 2

COM

UNIT TERMINAL

STRIP TB1

NOT USED

TO REMOTE SENSOR 2TH040702224 IF USED

THERMOSTAT

TERMINALS

ADD

JUMPER

ADD

JUMPER

ELECTRONIC PROGRAMMABLE THERMOSTAT 2ET04700224 (INCLUDES SUBBASE).

FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING

SECOND STAGE COOLING IS NOT REQUIRED ON UNITS LESS ECONOMIZER.

SECOND STAGE HEATING IS ONLY REQUIRED ON UNITS WITH A TWO STAGE

ELECTRIC HEATER.

REMOVE JUMPER J2 FROM TERMINALS 4 AND 9 ON JUMPER PLUG CONNECTOR P6 ON UNITS WITH ECONOMIZER. TERMINALS A1 ANDA2 PROVIDE A RELAY OUT-PUT TO CLOSE THE OUTDOOR ECONOMIZER DAMPERS WHEN THE THERMOSTAT SWITCHES TO THE SET-BACK POSITION.

Unitary Products Group 9

24 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.

24 VOLT

TRANSFORMER

OCC

24 VOLT

TRANSFORMER

Page 10

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.

177820-YIM-A-0506

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

18 AWG 150 Feet

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

Maximum Length

OPTIONS/ACCESSORIES

ELECTRIC HEAT

The 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 and 10 for electrical data.

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TABLE 3: ELECTRIC HEATER CFM LIMITATIONS

UNITMODEL SIZE NOMINAL

TONS

VOLTAGE

208/230-3-60 1100 1100 1200 1200 1300 -

460-3-60 - 1100 1200 1200 1300 575-3-60 - - 1200 1200 1300 -

208/230-3-60 1300 1300 1300 1300 1300 -

460-3-60 - 1300 1300 1300 1300 575-3-60 - - 1300 1300 1400 -

208/230-3-60 1600 1600 1600 1600 1600 1600

460-3-60 1600 1600 1600 1600 1600 1600 575-3-60 - 1600 1600 1600 1600 1800

MINIMUM SUPPLY AIR CFM

HEATER SIZE NOMINAL KW

5 7 10 15 20 30

ECONOMIZER/MOTORIZED DAMPER AND RAIN HOOD

The instruction for the optional economizer/motorized damper and rain hood can be found in form 03507364-000. 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”.

Unitary Products Group 11

Page 12

MINIMUM POSITION ADJUSTMENT

40 (4)

(21)

(10)

(13)

(16)

(18)

35 (2)

45 (7)

(24)

(27)

35 (2)

(4)45(7)

(10)55(13)

(16)

(18)

(21)

(24)80(27)

(29)

(32)

105 (41)

110 (43)

100 (38)95(35)

(35)

100 (38)

105 (41)

110 (43)

APPROXIMATE DRY BULB TEMPERATURE - 0F (0C)

CONTROL

CURVE

CONTROL POINT

APPROX.

F (0C)

AT 50% RH

63 (17)

73 (23)

70 (21) 67 (19)

EXH

Set

EXH

Min

Pos

IAQ

Max

IAQ

IAQ Min

Free Cool

AQ1 AQ

SO+ SO

SR+

TR TR1

Vac

HOT

Vac

COM

EF EF1

Exhaust Air Adjustment

Screw

Exhaust Air LED

Damper Min.

Position

Screw

Indoor Air Quality

Max. Adjustment

Screw

Indoor Air Quality

LED

Indoor Air Quality

Min. Adjustment

Screw

Free Cooling LED

Economizer Enthalpy Set Point Adjustment

Screw

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.

177820-YIM-A-0506

FIGURE 4 - ENTHALPY SETPOINT ADJUSTMENT

POWER EXHAUST DAMPER SETPOINT (WITH OR WITHOUT POWER EXHAUST)

• With no power exhaust option, adjust the Exha u st

• With power exhaust option, each building pressur-

12 Unitary Products Group

Air Adjustment Screw fully clockwise.

ization 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.

FIGURE 5 - HONEYWELL ECONOMIZER CONTROL

W7212

Page 13

177820-YIM-A-0506

447/

BACK OF UNIT

821/

APPROXIMATE CENTER OF GRAVITY

FRONT OF UNIT

CONDENSER COIL

END OF UNIT

FIGURE 6 - FOUR AND SIX POINT LOADING

TABLE 4: CENTER OF GRAVITY (ALL MODELS)

DIMENSION 3 - 5 TON

X 40-¾” Y 19-¾”

TABLE 5: BCH 4 POINT LOADS WEIGHT DISTRIBUTION

UNIT TOTALABCD BCH036 BCH048

BCH060

628 139 137 174 177 668 148 146 185 189

693 154 151 192 196

447/

APPROXIMATE CENTER OF GRAVITY

FRONT OF UNIT

BACK OF UNIT

821/

CONDENSER COIL

END OF UNIT

TABLE 6: BCH 6 POINT LOADS WEIGHT DISTRIBUTION

UNIT TOTAL A B C D E F BCH036 BCH048

BCH060

628939291116117119 668 99 98 97 123 125 126

693 103 102 100 128 129 131

Unitary Products Group 13

Page 14

TABLE 7: PHYSICAL DATA

EVAPORATOR

BLOWER

EVAPORATOR

COIL

CONDENSER

FANS

CONDENSER

COILS

COMPRESSOR

(Qty. Per Unit)

AIR

FILTERS

CHARGE

177820-YIM-A-0506

MODELS

Centrifugal Blower (Dia. x Wd. in.) 12 X 10 12 X 10 12 X 10

Fan Motor HP (Direct Drive) 1/2 3/4 1

Fan Motor HP (Belt Drive) 1 1/2 1 1/2 1 1/2

Rows Deep 4 3 3

Fins Per Inch 16 15 15

Face Area (Sq. Ft.) 4.3 5.1 5.1

Propeller Dia. (in.) 22 22 24

Fan Motor Hp 1/3 1/2 1/2

Nom. CFM 4300 4200 4500

Rows Deep 1 1 1

Fins Per Inch 20 20 20

Face Area (Sq. Ft.) 17.1 17.1 17.1 Reciprocating Type 1 1 1

Quantity Per Unit (15” X 20” X 1” or 2“) 2 2 2 Quantity Per Unit (14” X 25” X 1” or 2“) 1 1 1

Total Face Area (sq. ft.) 6.6 6.6 6.6

Refrigerant 22

(lbs./oz.)

036 048 060

7/12 9/2 8/4

BCH

TABLE 8: OPERATING WEIGHTS (LBS.)

MODEL SIZE 3 TON 4 TON 5 TON

BASIC UNIT

OPTIONS

ACCY.

Electric Heater

Barometric Relief / Fixed Air Damper 10

BCH 628 668 693

Economizer 50

Motorized Damper 26

5 - 7 kW 18 10 - 15 kW 23 20 - 30 kW 28

Roof Curb 92

Belt-Drive Blower 5

14 Unitary Products Group

Page 15

177820-YIM-A-0506

TABLE 9: ELECTRICAL DATA - BCH036 - 060 DIRECT DRIVE

MODEL VOLTAGE

208-3-60 11.9 85.0 1.7 4.4

230-3-60 11.9 85.0 1.7 4.4

BCH036

460-3-60 5.9 42.0 1.0 2.2

575-3-60 4.8 34.0 1.0 2.2

208-3-60 14.7 130.0 2.3 5.0

230-3-60 14.7 130 2.3 5.0

BCH048

460-3-60 7.7 64.0 1.3 2.2

575-3-60 6.4 52.0 1.3 2.2

COMPRESSORS

RLA

EACH

LRA

EACH

OD FAN MOTOR

FLA

BLOWER

MOTOR

FLA

ELECTRIC HEATER

MODEL NO.

None -- -- 21.0 30 2CE04510525 2CE04510725

2CE04511025 8.0 22.2 48.7 50 2CE04511525 11.9 33.0 62.3 70 2CE04512025 15.9 44.1 76.1 80

None -- -- 21.0 30 2CE04510525 2CE04510725

2CE04511025 10.6 25.5 52.8 60 2CE04511525 15.9 38.2 68.8 70 2CE04512025 21.2 51.0 84.7 90

None -- -- 10.6 15 2CE04510746 2CE04511046 2CE04511546 2CE04512046

None -- -- 8.6 15

2CE04511058 10.6 10.2 21.3 25 2CE04511558 15.9 15.3 27.7 30 2CE04512058 21.2 20.4 34.1 35

None -- -- 25.7 35 2CE04510525 2CE04510725

2CE04511025 8.0 22.2 53.4 60 2CE04511525 11.9 33.0 67.0 70 2CE04512025 15.9 44.1 80.8 90

None -- -- 25.7 35 2CE04510525 2CE04510725

2CE04511025 10.6 25.5 57.5 60 2CE04511525 15.9 38.2 73.5 80 2CE04512025 21.2 51.0 89.4 90

None -- -- 13.1 20 2CE04510746 2CE04511046 2CE04511546 2CE04512046

None -- -- 10.8 15

2CE04511058 10.6 10.2 23.5 25 2CE04511558 15.9 15.3 29.9 30 2CE04512058 21.2 20.4 36.3 40

HEATERKWHEATER

2 2

2 2 2 2

2 2

2 2 2 2

AMPS

MIN.

CIRCUIT

AMPACITY

(AMPS)

MAX. FUSE/

BRKR

SIZE

(AMPS)

4.0 11.1 34.9 40

5.6 15.5 40.4 45

5.3 12.7 36.9 45

7.5 18.0 43.5 50

6.8 8.2 20.8 25

10.1 12.1 25.8 30

13.6 16.4 31.0 35

19.5 23.5 39.9 40

4.0 11.1 39.6 50

5.6 15.5 45.1 50

5.3 12.7 41.6 50

7.5 18.0 48.2 50

6.8 8.2 23.3 25

10.1 12.1 28.3 30

13.6 16.4 33.6 35

19.5 23.5 42.4 45

Unitary Products Group 15

Page 16

TABLE 9: ELECTRICAL DATA - BCH036 - 060 DIRECT DRIVE (CONT.)

MODEL VOLTAGE

COMPRESSORS

RLA

EACH

LRA

EACH

OD FAN MOTOR

FLA

208-3-60 19.3 137.0 2.3 6.6

230-3-60 19.3 137.0 2.3 6.6

BCH060

460-3-60 10.0 62.0 1.3 3.3

575-3-60 7.9 50.0 1.3 3.3

HACR Type per NEC.

These electric heaters do not include a fuse box. If a fuse box is required to meet a local code (i.e. Chicago), the fuse block accessories 2FB04700825 and 2FB04700846 are available for field installation.

BLOWER

MOTOR

FLA

ELECTRIC HEATER

MODEL NO.

None -- -- 33.0 45 2CE04510525 2CE04510725

2 2

2CE04511025 8.0 22.2 60.8 70 2CE04511525 11.9 33.0 74.3 80 2CE04512025 15.9 44.1 88.2 90 2CE04513025 22.2 61.6 110.1 125

None -- -- 33.0 45 2CE04510525 2CE04510725

2 2

2CE04511025 10.6 25.5 64.9 70 2CE04511525 15.9 38.2 80.8 90 2CE04512025 21.2 51.0 96.8 100 2CE04513025 29.6 71.2 122.0 125

None -- -- 17.1 25 2CE04510746 2CE04511046 2CE04511546 2CE04512046 2CE04513046

2 2 2 2 2

None -- -- 13.5 20

2CE04511058 10.6 10.2 26.2 30 2CE04511558 15.9 15.3 32.6 35 2CE04512058 21.2 20.4 39.0 40 2CE04513058 30.4 29.3 50.1 60

177820-YIM-A-0506

HEATERKWHEATER

AMPS

MIN.

CIRCUIT

AMPACITY

(AMPS)

4.0 11.1 46.9 60

5.6 15.5 52.5 60

5.3 12.7 49.0 60

7.5 18.0 55.6 70

6.8 8.2 27.3 35

10.1 12.1 32.3 35

13.6 16.4 37.5 40

19.5 23.5 46.4 50

28.8 34.6 60.4 70

MAX. FUSE/

BRKR

SIZE

(AMPS)

16 Unitary Products Group

Page 17

177820-YIM-A-0506

TABLE 10: ELECTRICAL DATA - BCH036 - 060 BELT DRIVE

MODEL VOLTAGE

208-3-60 11.9 85.0 1.7 5.2

230-3-60 11.9 85.0 1.7 5.2

BCH036

460-3-60 5.9 42.0 1.0 2.6

575-3-60 4.8 34.0 1.0 2.0

208-3-60 14.7 130.0 2.3 5.2

230-3-60 14.7 130 2.3 5.2

BCH048

460-3-60 7.7 64.0 1.3 2.6

575-3-60 6.4 52.0 1.3 2.0

COMPRESSORS

RLA

EACH

LRA

EACH

OD FAN MOTOR

FLA

BLOWER

MOTOR

FLA

ELECTRIC HEATER

MODEL NO.

None -- -- 21.8 30 2CE04510525 2CE04510725

2CE04511025 8.0 22.2 49.5 50 2CE04511525 11.9 33.0 63.1 70 2CE04512025 15.9 44.1 76.9 80

None -- -- 21.8 30 2CE04510525 2CE04510725

2CE04511025 10.6 25.5 53.6 60 2CE04511525 15.9 38.2 69.6 70 2CE04512025 21.2 51.0 85.5 90

None -- -- 11.0 15 2CE04510746 2CE04511046 2CE04511546 2CE04512046

None -- -- 8.8 15

2CE04511058 10.6 10.2 21.5 25 2CE04511558 15.9 15.3 27.9 30 2CE04512058 21.2 20.4 34.3 35

None -- -- 25.9 35 2CE04510525 2CE04510725

2CE04511025 8.0 22.2 53.6 60 2CE04511525 11.9 33.0 67.2 70 2CE04512025 15.9 44.1 81.0 90

None -- -- 25.9 35 2CE04510525 2CE04510725

2CE04511025 10.6 25.5 57.7 60 2CE04511525 15.9 38.2 73.7 80 2CE04512025 21.2 51.0 89.6 90

None -- -- 13.5 20 2CE04510746 2CE04511046 2CE04511546 2CE04512046

None -- -- 11.0 15

2CE04511058 10.6 10.2 23.8 25 2CE04511558 15.9 15.3 30.2 35 2CE04512058 21.2 20.4 36.5 40

HEATERKWHEATER

2 2

2 2 2 2

2 2

2 2 2 2

AMPS

MIN.

CIRCUIT

AMPACITY

(AMPS)

MAX. FUSE/

BRKR

SIZE

(AMPS)

4.0 11.1 35.7 40

5.6 15.5 41.2 45

5.3 12.7 37.7 45

7.5 18.0 44.3 50

6.8 8.2 21.2 25

10.1 12.1 26.2 30

13.6 16.4 31.4 35

19.5 23.5 40.3 45

4.0 11.1 39.8 50

5.6 15.5 45.3 50

5.3 12.7 41.8 50

7.5 18.0 48.4 50

6.8 8.2 23.7 25

10.1 12.1 28.7 30

13.6 16.4 34.0 35

19.5 23.5 42.8 45

Unitary Products Group 17

Page 18

TABLE 10: ELECTRICAL DATA - BCH036 - 060 BELT DRIVE (CONT.)

MODEL VOLTAGE

COMPRESSORS

RLA

EACH

LRA

EACH

OD FAN MOTOR

FLA

208-3-60 19.3 137.0 2.3 5.2

230-3-60 19.3 137.0 2.3 5.2

BCH060

460-3-60 10.0 62.0 1.3 2.6

575-3-60 7.9 50.0 1.3 2.0

HACR Type per NEC.

BLOWER

MOTOR

FLA

ELECTRIC HEATER

MODEL NO.

None -- -- 31.6 40 2CE04510525 2CE04510725

2 2

2CE04511025 8.0 22.2 59.4 70 2CE04511525 11.9 33.0 72.9 80 2CE04512025 15.9 44.1 86.8 90 2CE04513025 22.2 61.6 108.7 110

None -- -- 31.6 40 2CE04510525 2CE04510725

2 2

2CE04511025 10.6 25.5 63.5 70 2CE04511525 15.9 38.2 79.4 80 2CE04512025 21.2 51.0 95.4 100 2CE04513025 29.6 71.2 120.6 125

None -- -- 16.4 25 2CE04510746 2CE04511046 2CE04511546 2CE04512046 2CE04513046

2 2 2 2 2

None -- -- 12.9 20

2CE04511058 10.6 10.2 25.6 30 2CE04511558 15.9 15.3 32.0 35 2CE04512058 21.2 20.4 38.4 40 2CE04513058 30.4 29.3 49.4 50

177820-YIM-A-0506

HEATERKWHEATER

AMPS

MIN.

CIRCUIT

AMPACITY

(AMPS)

4.0 11.1 45.5 60

5.6 15.5 51.1 60

5.3 12.7 47.6 60

7.5 18.0 54.2 60

6.8 8.2 26.6 30

10.1 12.1 31.6 35

13.6 16.4 36.8 40

19.5 23.5 45.7 50

28.8 34.6 59.7 60

MAX. FUSE/

BRKR

SIZE

(AMPS)

18 Unitary Products Group

Page 19

177820-YIM-A-0506

TABLE 11: ELECTRIC HEAT CORRECTION

FACTORS

NOMINAL VOLTAGE VOLTAGE kW CAP. MULTIPLIER

208 240 480 600

208 0.75 230 0.92 460 0.92 575 0.92

TABLE 12: VOLTAGE LIMITATIONS

POWER SUPPLY

208/230-3-60

460-3-60 575-3-60

Utilization Range “A” in accordance with ARI Standard

110.

MIN. MAX.

187 253 414 506

518 630

VOLTAGE

FIGURE 7: UNIT DIMENSIONS (3 - 5 TON HEAT PUMP) FRONT VIEW

Unitary Products Group 19

Page 20

FIGURE 8 - UNIT WITH ECONOMIZER RAINHOOD

177820-YIM-A-0506

DETAIL “A”

DETAIL “B”

FIGURE 9 - UNIT WITH FIXED OUTDOOR AIR/MOTORIZED DAMPER RAINHOOD

20 Unitary Products Group

Page 21

177820-YIM-A-0506

FIGURE 10 - UNIT DIMENSIONS (REAR VIEW)

FILTER ACCESS

BLOWER MOTOR ACCESS

DOT PLUGS

FIELD-SUPPLIED DISCONNECT SWITCH LOCATION

MOUNTING BRACKET FOR DICONNECT SWITCH (Shipped attached to the

blower housing inside the blower compartment)

DISCONNECT SWITCH LOCATION

AND MOTOR ACCESS PANEL FOR

UNIT WITH “BELT-DRIVE” OPTION

A,B WIRING ENTRY (See Detail “B”)

CONTROL BOX ACCESS

FIGURE 11 - DISCONNECT/BLOWER ACCESS

LOCATION

TABLE 14: MINIMUM CLEARANCES

LOCATION

Front

Rear

Left Side (Filter Access)

Right Side (Cond. Coil)

Below Unit Above Unit

Units may be installed on combustible floors made

from wood or class A, B, or C roof covering material.

Units must be installed outdoors. Overhanging structures or shrubs should not obstruct condenser air discharge outlet.

CLEARANCE

24” (Cooling/Electric Heat)

32” (Gas Heat)

12” (Less Economizer)

36” (With Economizer or Fixed

Air/Motorized Damper) 24” (Less Economizer)

36” (With Economizer)

Condenser Air Discharge)

24”

0”

72” (For

TABLE 13: UTILITIES ENTRY

HOLE OPENING SIZE (DIA.) USED FOR

B C

Opening in the bottom to the unit can be located by the

7/8” KO

2” KO

Control Wiring

Power Wiring

1-5/8” KO Gas Piping (Front) 1-1/2” KO

Gas Piping (Bottom)

side in the insulation.

Do not remove the 2” knockout ring.

Unitary Products Group 21

Side

Bottom

Side

Bottom

Page 22

177820-YIM-A-0506

TABLE 15: SUPPLY AIR BLOWER PERFORMANCE (3 TON BELT DRIVE) - SIDE DUCT APPLICATION

UNIT

TONNAGE

1, 2

UNIT

TONNAGE

1, 2

AIR

FLOW

CFM

2000 843 860 880 925 919 1005 956 1065 993 1145 1030 1195 1067 1235

1900 817 775 854 850 893 920 930 995 970 1065 1008 1125 1046 1170

1800 790 700 828 760 867 840 906 905 944 980 985 1040 1025 1100

1700 - - 802 670 840 745 881 815 920 900 961 970 1001 1030

1600 ----818665858740898820940890980950

1500 ------842695882755922835962895

1400 ------833650867705904765942820

1300 --------858665893725932785

1200 --------847640880680916730

AIR

FLOW

CFM

2000 1103 1270 ------------

1900 1085 1210 ------------

1800 1064 1145 1102 1180 ----------

1700 1040 1075 1081 1115 1121 1140 --------

1600 1020 1005 1060 1050 1100 1085 --------

1500 1003 945 1044 995 1086 1035 --------

1400 982 880 1024 920 1067 965 1107 1000 ------

1300 970 835 1010 870 1053 920 1099 960 ------

1200 953 780 992 815 1034 855 1080 905 ------

1. 230/460/575 Volts

2. For 208 Volts multiply values by 0.95.

3. Includes allowances for a wet evaporator coil and 1” filters. Refer to STATIC RESISTANCE Table for resistance values on applications other than side duct airflows.

0.20 0.30 0.40 0.50

RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS

0.90 1.00 1.10 1.20 1.30 1.40 1.50

RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS

AVAILABLE EXTERNAL STATIC PRESSURE-IWG

0.60 0.70 0.80

22 Unitary Products Group

Page 23

177820-YIM-A-0506

RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS

2000 843 860 880 925 919 1005 956 1065 993 1145 1030 1195 1067 1235

1900 817 775 854 850 893 920 930 995 970 1065 1008 1125 1046 1170

1800 790 700 828 760 867 840 906 905 944 980 985 1040 1025 1100

1700 - - 802 670 840 745 881 815 920 900 961 970 1001 1030

1600 ----818665858740898820940890980950

1500 ------842695882755922835962895

1400 ------833650867705904765942820

1300 --------858665893725932785

1200 --------847640880680916730

RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS

2000 1103 1270 ------------

1900 1085 1210 ------------

1800 1064 1145 1102 1180 ----------

1700 1040 1075 1081 1115 1121 1140 --------

1600 1020 1005 1060 1050 1100 1085 --------

1500 1003 945 1044 995 1086 1035 --------

1400 982 880 1024 920 1067 965 1107 1000 ------

1300 970 835 1010 870 1053 920 1099 960 ------

1200 953 780 992 815 1034 855 1080 905 ------

1, 2

AVAILABLE EXTERNAL STATIC PRESSURE-IWG

0.90 1.00 1.10 1.20 1.30 1.40 1.50

UNIT

TONNAGE

AIR

FLOW

CFM

1, 2

UNIT

TONNAGE

AIR

FLOW

CFM

0.60 0.70 0.80

AVAILABLE EXTERNAL STATIC PRESSURE-IWG

0.20 0.30 0.40 0.50

1. 230/460/575 Volts

2. For 208 Volts multiply values by 0.95.

3. Includes allowances for a wet evaporator coil and 1” filters. Refer to STATIC RESISTANCE Table for resistance values on applications other than side duct airflows.

TABLE 16: SUPPLY AIR BLOWER PERFORMANCE (4 TON BELT DRIVE) - SIDE DUCT APPLICATION

Unitary Products Group 23

Page 24

177820-YIM-A-0506

TABLE 17: SUPPLY AIR BLOWER PERFORMANCE (5 TON BELT DRIVE) - SIDE DUCT APPLICATION

UNIT

TONNAGE

1, 2

UNIT

TONNAGE

1, 2

AIR

FLOW

CFM

2500 1059 1560 1077 1590 1095 1630 1114 1650 1134 1660 1158 1685 1181 1720

2400 1032 1405 1054 1470 1074 1525 1094 1560 1116 1595 1140 1620 1167 1640

2300 1005 1260 1024 1275 1049 1370 1069 1440 1090 1475 1116 1505 1142 1535

2200 980 1160 1002 1170 1022 1190 1044 1250 1066 1350 1090 1410 1117 1440

2100 930 1060 957 1070 983 1080 1010 1100 1039 1160 1064 1260 1092 1340

2000 877 950 908 975 941 1000 976 1020 1009 1050 1040 1100 1070 1225

1900 ----8948859409409809801014 1020 1047 1095

1800 ----8558159038609509059889401022 970

1700 ------8848159258509648801001 910

1600 ------864770908805948835987870

1500 --------882740926780965830

AIR

FLOW

CFM

2500 --------------

2400 1193 1665 ------------

2300 1170 1580 1202 1620 ----------

2200 1148 1480 1180 1530 ----------

2100 1121 1385 1155 1425 1190 1475 --------

2000 1100 1285 1133 1340 1169 1385 1205 1445 ------

1900 1079 1180 1110 1240 1143 1280 1178 1330 1222 1375 ----

1800 1058 1060 1090 1135 1122 1190 1158 1240 1196 1295 ----

1700 1035 960 1071 1030 1103 1100 1134 1140 1164 1175 1197 1205 - -

1600 1020 900 1056 965 1088 1035 1118 1065 1145 1105 1170 1130 1198 1150

1500 1004 860 1038 880 1070 925 1101 980 1130 1045 1158 1075 1184 1110

1. 230/460/575 Volts

2. For 208 Volts multiply values by 0.95.

3. Includes allowances for a wet evaporator coil and 1” filters. Refer to STATIC RESISTANCE Table for resistance values on applications other than side duct airflows.

0.20 0.30 0.40 0.50

RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS

0.90 1.00 1.10 1.20 1.30 1.40 1.50

RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS

AVAILABLE EXTERNAL STATIC PRESSURE-IWG

0.60 0.70 0.80

24 Unitary Products Group

Page 25

177820-YIM-A-0506

TABLE 18: SUPPLY AIR BLOWER PERFORMANCE (3 - 5 TON DIRECT DRIVE) - SIDE DUCT APPLICATION

UNIT

TONNAGE

MOTOR SPEED

MED

LOW

MED

LOW

MED

LOW

UNIT

TONNAGE

MOTOR SPEED

MED

LOW

MED

LOW

MED

LOW

1. Side Duct application (230/460/575 Volts)

2. Includes allowances for a wet evaporator coil

AVAILABLE EXTERNAL STATIC PRESSURE-IWG

0.600.20 0.30 0.40 0.50

CFM WATTS CFM WATTS CFM WATTS CFM WATTS CFM WATTS

------1720 825 1665 795

1660 850 1630 820 1590 780 1550 750 1500 720

1470 750 1440 725 1410 700 1370 675 1330 650

----2000 1010 1950 975 1905 945

1810 910 1780 880 1740 850 1700 825 1665 800

1635 810 1610 780 1580 760 1555 740 1540 730

----2500 1400 2420 1350 2340 1300

2390 1350 2350 1300 2300 1255 2245 1210 2190 1165

2270 1320 2230 1270 2190 1220 2145 1170 2090 1110

0.70

AVAILABLE EXTERNAL STATIC PRESSURE-IWG

0.900.80 1.00

CFM WATTS CFM WATTS CFM WATTS CFM WATTS

1600 765 1540 735 1490 700 1380 670

1450 690 1400 665 1360 650 1270 610

1290 625 1250 610 1220 600 1130 560

1840 910 1770 825 1660 825 1530 775

1620 775 1560 740 1480 700 1390 660

1510 715 1460 690 1400 660 1300 615

2260 1250 2160 1190 2060 1135 1925 1065

2130 1120 2065 1075 1990 1030 1900 970

2030 1070 1960 1020 1890 970 1810 920

and 1” filters. Refer to STATIC RESISTANCES Table for resistance values.

TABLE 19: BELT DRIVE BLOWER MOTOR AND DRIVE DATA

MODEL

3 TON 790/1120 1 1/2 56 1VL40 2.7-3.7 2.4-3.4 5/8 AK61 5.9 5.7 1 A36 37.3 1 4 TON 790/1120 1 1/2 56 1VL40 2.7-3.7 2.4-3.4 5/8 AK61 5.9 5.7 1 A36 37.3 1 5 TON 850/1220 1 1/2 56 1VL40 2.7-3.7 2.4-3.4 5/8 AK56 5.4 5.2 1 A36 37.3 1

BLOWER

SIZE

RANGE

(RPM)

All motors have solid bases and are inherently protected. these motor s ca n be selecte d to o perate int o their service facto r be cau se they ar e locat ed in the moving air, upstream of any heating device.

MOTOR

HP FRAME

ADJUSTABLE MOTOR PULLEY FIXED BLOWER PULLEY

DESIG-

NATION

OUTSIDE

DIA. (IN.)

PITCH

DIA. (IN.)

BORE

(IN.)

DESIG-

NATION

OUTSIDE

DIA. (IN.)

PITCH

DIA. (IN.)

BORE

(IN.)

DESIG-

NATION

BELT

(NOTCHED)

PITCH

LENGTH

(IN.)

QTY.

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TABLE 20: STATIC RESISTANCES

DESCRIPTION

ECONOMIZER

ELECTRIC

HEATERS

BOTTOM DUCT CONNECTIONS

1. Deduct these resistance values from the available external static pressure shown in SUPPLY AIR BLOWER PERFORMANCE Tables.

2. The pressure through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct system is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation.

1, 2

5-15KW 0.04 0.05 0.06 0.07 0.08 0.10 0.12 0.14 0.16

20-30KW 0.06 0.07 0.08 0.09 0.11 0.13 0.15 0.17 0.20

1000 1200 1400 1600 1800 2000 2200 2400 2600

0.07 0.08 0.09 0.11 0.13 0.15 0.17 0.20 0.23

0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.14 0.16

PHASING

Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the incoming line connection phasing to obtain proper rotation. (Scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar suction and discharge pressures, or producing a high noise level, the scroll is misphased).

177820-YIM-A-0506

RESISTANCE, IWG

CFM

PROCEDURE FOR ADJUSTING BELT TENSION:

Loosen nuts (A) (top and bottom).

1. Adjust the tension by turning bolt (B).

2. Never loosen nuts (C) from each other.

3. Use a belt tension checker to apply a perpendicular force to be one belt at th

4. midpoint of the span as shown. The deflection force should be applied until a specific deflection distance of 4mm (5/32") is obtained. To determine the deflection distance from normal position, use a straight edge from sheave to sheave as a reference line. The recommended deflection force is as follows:

SPAN LENGTH

DEFL FORCE

Scroll compressors require proper rotation to operate correctly. Do not change the internal wiring to make the blower, condenser fans, or compressor rotate correctly. Change the incoming power to the main terminal block to obtain proper rotation.

SUPPLY AIR BLOWERS

These blowers have either 3-speed d ire ct drive m otor s, or single speed motors equipped with a belt driv e. Be lt drive units have a variable pitch motor pulley that allows the blower speed to be adjusted.

CHECKING SUPPLY AIR CFM

The RPM of the supply air blower will depend on the required CFM, the unit accessories or options and the static resistances of both the supply and the return air duct systems. With this information, the motor speed tap (direct drive) or the motor pulley number of turns open (belt drive) can be determined from the Blower Performance Data Tables.

(B)

*Never Loosen

(A)

Tension new belts at the max. deflection force recommended for the belt section. Check the belt tension at least two times during the first 24 hours of operation. Any re-tensioning should fall between the min. and max. deflection force values.

5. After adjusting, re-tighten nuts (A).

(C)*

FIGURE 12 - BELT ADJUSTMENT

Note the following:

1. The supply air CFM must be within the limitations shown in the Unit Application Data Table 1.

2. Pulleys can be adjusted in half turn increments.

3. The tension on the belt should be adjusted as shown in the Belt Adjustment Figure 12.

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0.1

0.2

0.3

0.4

0.5

1000 1500 2000 2500 3000

036

048

060

NOMINAL CFM

PRESSURE DROP (IWG)

Start the supply air blower motor. Adjust the resistances in both the supply and the return air duct systems to balance the air distribution throughout the conditioned space. The job specifications may require that this balancing be done by someone other than the equipment installer.

To check the supply air CFM after the initial balancing has been completed:

1. Remove the two 5/16” dot plugs from the blower motor and the filter access panels shown in Figure

11.

2. Insert at least 8" of 1/4 inch tubing into each of these holes for sufficient penetration into the air flow on both sides of the indoor coil.

NOTE: The tubes must be inserted and held in a posi-

tion perpendicular to the air flow so that velocity pressure will not affect the static pressure readings.

3. Using an inclined m anometer, determine the pressure drop across a dry evaporator coil. Since the moisture on an evaporator coil may vary greatly, measuring the pressure drop across a wet coil under field conditions would be inaccurate. To assure a dry coil, the compressors should be deactivated while the test is being run.

4. Knowing the pressure drop across a dry coil, the actual CFM through the unit can be determined from the curve in Pressure Drop vs. Supply Air CFM (Figure 13).

Failure to properly adjust the total system air quantity and static pressure can result in extensive system damage.

FIGURE 13 - PRESSURE DROP ACROSS COIL

OPERATION

SEQUENCE OF OPERATIONS OVERVIEW

For these units, the thermostat makes a circuit between “R” and “Y1” for the cooling cycle.

The call is passed to the unit control board (UCB), which then determines whether the requested operation is available and, if so, which components to energize.

For heating, the thermostat makes a circuit between “R” and “W1”. The UCB energizes the compr essor and condenser fan allowing the unit to run in heating mode. A time / temperature control operates the defrost cycle.

If at any time a call for both heating and cooling are present, the heating operation will be performed. If operating, the cooling system is halted as with a completion of a call for cooling. Heating always takes priority.

After readings have been obtained, remove the tubes and reinstall the two 5/16” dot plugs that were removed in Step 1.

NOTE: De-energize the compressors before taking

any test measurements to assure a dry indoor coil.

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COOLING SEQUENCE OF OPERATION

CONTINUOUS BLOWER

By setting the room thermostat fan switch to “ON,” the supply air blower will operate continuously.

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INTERMITTENT BLOWER

With the room thermostat fan switch set to “AUTO” and the system switch set to either the “AUTO” or “HEAT” settings, the blower is energized whenever a cooling or heating operation is requested. The blower is energized after any specified delay associated with the operation.

When energized, the indoor blower has a minimum run time of 30 seconds. Additionally, the indoor blower has a delay of 10 seconds between operations.

NO OUTDOOR AIR OPTIONS

When the thermostat calls for cooling, the low-voltage control circuit from “R” to “Y1” and “G” is completed. The compressor and condenser fan motor are energized. After completing the specified f an on delay for cooling, the UCB will energize the blower motor.

Once the thermostat has been satisfied, it will de-energize Y1. If the compressor has satisfied its minimum run time, the compressor and condenser fan de-energize. Otherwise, the unit operates the cooling system until the minimum run time for the compressor has been completed. After the compressor de-energizes, the blower is stopped following the elapse of the fan off delay for cooling.

energized. Otherwise, the unit operates the cooling system until the minimum run times for the compressor has been completed. After the compressor de-energizes, the blower is stopped following the elapse of the fan off delay for cooling, and the economizer damper goes to the closed position. If the unit is in continues fan operation the economizer damper goes to the min. position.

ECONOMIZER WITH DUAL ENTHALPY SENSORS -

The operation with the dual enthalpy sensors is identical to the single sensor except that a second enthalpy sensor is mounted in the return air. This retu rn air sensor allows the economizer to choose between outdoor air and return air, whichever has the lowest enthalpy value, to provide maximum operating efficiency.

ECONOMIZER (SINGLE OR DUAL) WITH POWER EXHAUST -

This system operates as specified above with one addition. The power exhaust motor is energized 45 seconds after the actuator position exceeds the exhaust fan setpoint on the economizer control. When the power exhaust is operating, the second stage of mechanical cooling will not operate. As always, the “R” to “G” connection provides minimum position but does not provide power exhaust operation.

To be available, a compressor must not be locked-out due to a high or low-pressure switch or freezestat trip and the anti-short cycle delay (ASCD) must have elapsed.

ECONOMIZER WITH SINGLE ENTHALPY SENSOR -

When the room thermostat calls for cooling, the low voltage control circuit from “R” to “G” and “Y1” is completed. The UCB energizes the blower motor (if the fan switch on the room thermostat is set in the “AUTO” position) and drives the economizer dampers from fully closed to their minimum position. If the enthalpy of the outdoor air is below the setpoint of the enthalpy controller (previously determined), “Y1” energizes the economizer. The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor. If the outdoor air enthalpy is above the setpoint, “Y1” energizes the compressor and condenser fan motor only.

Once the thermostat has been satisfied, it will de-energize “Y1”. If the compressor has satisfied its minimum run time, the compressor and condenser fan are de-

MOTORIZED OUTDOOR AIR DAMPERS -

This system operation is the same as the units with no outdoor air options with one exception. When the “R” to “G” circuit is complete, the motorized damper drives open to a position set by the thumbwheel on the damper motor. When the “R” to “G” circuit is opened, the damper spring returns fully closed.

COOLING OPERATION ERRORS

Each cooling system is monitored for operation outside of the intended parameters. Errors are handled as described below. All system errors override minimum run times for compressors.

HIGH-PRESSURE LIMIT SWITCH

During cooling operation, if a high-pressure limit switch opens, the UCB will de-energize the compressor, initiate the ASCD (Anti-short cycle delay), and, stop the condenser fan. If the call for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the compressor.

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Should a high-pressure switch open thre e times within two hours of operation, the UCB will lock-out the compressor and flash a code (see Table 23).

LOW-PRESSURE LIMIT SWITCH

The low-pressure limit switch is not monitored during the initial 30 seconds of a cooling system's operation. For the following 30 seconds, the UCB will monitor the low-pressure switch to ensure it closes. If the low-pressure switch fails to close after the 30-second monitoring phase, the UCB will de-energize the compressor, initiate the ASCD, and stop the condenser fan.

Once the low-pressure switch has been proven (closed during the 30-second monitor period described above), the UCB will monitor the low-pressure limit switch for any openings. If the low-pressure switch opens for greater than 5 seconds, the U CB will de-energize the compressor, initiate the ASCD, and stop the condenser fan.

If the call for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the compressor.

Should a low-pressure switch open three times within one hour of operation, the UCB will lock-out the compressor and flash a code (see Table 23).

FREEZESTAT

During cooling operation, if a freezestat opens, the UCB will de-energize the compressor, initiate the ASCD, and stop the condenser fan. If the call for cooling is still present at the co nclusion of the ASCD, the UCB will re-energize the compressor.

Low ambient mode always begins with compressor operation. Compressor minimum run time may extend the minutes of compressor operation. The defrost cycle will begin immediately following the elapse of the minimum run time.

When operating in low ambient mode, the UCB will not lockout the compressor due to a freezestat trip. However, a freezestat trip will de-energize the compressor. If the call for cooling is still present at the end of the ASCD and the freezestat has closed, the unit will resume operation.

SAFETY CONTROLS

The unit control board monitors the following inputs for the cooling system:

1. A suction line freezestat to protect against low evaporator temperatures due to a low airflow or a low return air temperature, (opens at 26 ± 5 °F and resets at 38 ± 5°F).

2. A high-pressure switch to protect against excessive discharge pressures due to a blocked condenser coil or a condenser motor failure, (opens at 380 ± 10 psig and resets at 300 ± 10 psig).

3. A low-pressure switch to protect against loss of refrigerant charge, (opens at 7 ± 3 psig and resets at 22 ± 5 psig).

The above pressure switches are hard-soldered to the unit. The refrigeration system is monitored and controlled. On any fault, the system will be affected by any safety/preventive action.

Should a freezestat open three times within two hours of operation, the UCB will lock-out the compressor and

The unit control board monitors the temperature limit switch of electric heat units.

flash a code (see Table 23).

COMPRESSOR PROTECTION

LOW AMBIENT COOLING

The compressor also has inherent (internal) protection.

To determine when to operate in low ambient mode, the UCB has a pair of terminals connected to a temperature-activated switch set at 45ºF. When the lo w ambient switch is closed and the thermostat is calling for cooling, the UCB will operate in the low ambient mode.

If there is an abnormal temper ature rise in a compressor, the protector will open to shut down the compressor. The UCB incorporates features to minimize compressor wear and damage. An anti-short cycle delay (ASCD) is utilized to prevent operation of a compressor too soon after its previous run. Additionally, a

Low ambient mode operates the compressors in this manner: 10 minutes on, 5 minutes off. The indoor

minimum run time is imposed any time a compressor is energized.

blower is operated throughout the cycle. The 5-minute off period is necessary to defrost the indoor coil.

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The ASCD is initiated on unit start-up and on any compressor reset or lock-out.

FLASH CODES The UCB will initiate a flash code associated with

errors within the system. Refer to UNIT CONTROL BOARD FLASH CODES Table 23.

RESET Remove the call for cooling, by raising thermostat set-

ting higher than the conditioned space temperature. This resets any pressure or freezestat flash codes.

HEATING SEQUENCE OF OPERATIONS WITH OR WITHOUT ELECTRIC HEAT When the thermostat calls for the first stage of heating,

the low voltage control circuit is completed between “R” and “W1”. The 24vac signal is passed through the UCB to the “Y” contact on the Defrost Control (DC) assuring the reversing valve cannot be energized, except during defrost. If the ASCD timer is satisfied the UCB will energize compressor contactor M1.

If the compressor alone cannot satisfy the heating requirements, a second stage call from the thermostat completes the circuit between “R” and “W2”. This 24vac signal is passed through the UCB to the electric heat section (if available). The total available kW of electric heat will be energized on a call for “W2”.

DEFROST MODE As mentioned earlier, the defrost control (DC) utilizes a

time/temperature defrost scheme. The following two conditions must be met before the DC will enter a defrost mode:

The defrost thermostat (SD ) must be closed. This normally open thermostat is mounted on the liquid line an d is set to close at 28 ± 4°F.

Once the defrost thermostat closes, the defrost con trol starts a run timer that must be satisfied before defrost can begin. This is accumulated compressor run time. The selection pin is factory set at 60 minutes, but is field adjustable to 30, 60 or 90 minutes.

When the DC enters the defrost mode, it’s on-board defrost relay is powered. This energizes the reversing valve, de-energizes the condenser fan motor and energizes the unit’s optional electric heater. The DC remains in defrost mode until either

of the following two

conditions is met:

1. The liquid line thermostat is open. It is set to open at 55 ± 4°F.

2. The maximum defrost run time of 10 minutes is met.

FORCED DEFROST

The processor on the defrost board is only energized when the defrost sensor (DS) is closed.

To create a forced defrost:

1. The DS must eit her be closed or a jump er must be placed across the DFS terminals on the board.

2. Place a jumper across the test pin terminals on the board.

Depending on the selected defrost minimum run time of 30, 60 or 90 minutes, the board will go into defrost in 7.5, 15 or 22.5 seconds.

The DC will remain in defrost until the jumpers across the DS and the test pin terminals are removed.

Once the jumpers are removed, the board then terminates defrost when the DS opens or a maximum of 10 minutes after the test pin jumper is removed, whichever comes first.

SAFETY CONTROLS

The control circuit includes the following safety controls:

1. Temperature Limit Switch (TLS) - This control is located inside the heater compartment and is set to open at the temperature indicated in the Electric Heat Limit Control Setting Table 21. It resets automatically. The limit switch operates when a high temperature condition, caused by inadequate supply air flow occurs, thus shu tting down the heater and energizing the blower.

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TABLE 21: ELECTRIC HEAT LIMIT CONTROL

SETTING

VOLTAGE kW TEMPERATURE LIMIT SWITCH

5 1 140

7 1,3 140

10 1,2,3 140

230-1-60

230-3-60

460-3-60

575-3-60

15 2,4,6 140

30 1,2,3,4,5,6 150

5 1,2,3 140

7 1,2,3 140

10 1,2,3 150

15 2,4,6 140

20 1,2,3,4,5,6 150

7 2,4,6 140

10 2,4,6 140

15 2,4,6 140

20 3 160

30 3 150

10 2,4,6 140

15 2,4,6 140

20 5 160

30 5 150

1,2,3,4,5 140

6 150

1,3,5 160

2,4,6 150

Open Temp

TABLE 22: ELECTRIC HEAT ANTICIPATOR

SETPOINTS

HEATER

7 0.024 0.35 10 0.024 0.35 15 0.024 0.35 20 0.024 0.35 30 0.024 0.35

7 10 0.024 0.35 15 0.024 0.35 20 0.024 0.37 30 0.024 0.37 10 15 0.024 0.35 20 0.024 0.37 30 0.024 0.37

VOLTAGE

230-3-60

460-3-60

575-3-60

SETTING, AMPS

TH1 TH2

0.024 0.35

START-UP (COOLING)

PRESTART CHECK LIST

After installation has been completed:

1. Check the electrical supply voltage being supplied. Be sure that it is the same as listed on the unit nameplate.

2. Set the room thermostat to the off position.

HEAT ANTICIPATOR SETPOINTS

It is important that the anticipator setpoin t be correct. Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space. Reducing the value below the co rrect setpoint will give shorter “ON” cycles and may result in the lowering of the temperature within the conditioned space. Refer to Table 22 for the required electric heat anticipator setting.

3. Turn unit electrical power on.

4. Set the room thermostat fan switch to on.

5. Check indoor blower rotation.

• If blower rotation is in the wrong direction.

Refer to Phasing Section in general information section.

• Check blower drive belt tension.

6. Check the unit supply air (CFM). See “CHECKING SUPPLY AIR CFM” on page 26.

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7. Measure evaporator fan motor's amp draw.

8. Set the room thermostat fan switch to off.

9. Turn unit electrical power off.

OPERATING INSTRUCTIONS

1. Turn unit electrical power on.

2. Set the room thermostat setting to lower than the room temperature.

3. First stage compressors will energize after the built-in time delay (five minutes).

4. The second stage of the thermostat will energize second stage compressor if needed.

POST START CHECK LIST

1. Verify proper system pressures for both circuits.

2. Measure the temperature drop across the evaporator coil.

3. Measure the system Amperage draw across all legs of 3 phase power wires.

4. Measure the condenser fan amp draw.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation, which could cause injury to person and/or damage unit components. Verify proper op eration after servicing.

On calls for cooling, if the compressors are opera ting but the supply air blower motor does not energize after a short delay (the room thermostat fan switch is in the “AUTO” position).

1. Turn the thermostat fan switch to the ON position. If the supply air blower motor does not energize, go to Step 3.

2. If the blower motor runs with the fan switch in the ON position but will not run after the compressor has energized when the fan switch is in the AUTO position, check the room thermostat for contact between R and G in the AUTO position during calls for cooling.

SHUT DOWN

1. Set the thermostat to highest temperature setting.

2. Turn off the electrical power to the unit.

TROUBLESHOOTING

COOLING TROUBLESHOOTING GUIDE

Troubleshooting of components may require opening the electrical control box with the power connected to the unit. Use extreme care when working with live circuits! Check the unit nameplate for the correc t line voltage and set the voltmeter to the correct range before making any connections with line terminals.

When not necessary, shut off all elect ric po wer to the unit prior to any of the following maintenance procedures so as to prevent personal injury.

3. If the supply air blower motor does not energize when the fan switch is set to ON, check that line voltage is being supplied to the contacts of the M2, contactor , and that the con t actor is pulled in. Check for loose wiring between the contacto r and the supply air blower motor.

4. If M2 is pulled in and voltage is supplied to M2, lightly touch the supply air blower motor housing. If it is hot, the motor may be off on internal protec tion. Cancel any thermostat calls and set the fan switch to AUTO. Wait for the internal overload to reset. Test again when cool.

5. If M2 is not pulled in, check for 24 volts at the M2 coil. If 24 volts are present at M2 but M2 is not pulled in, replace the contactor.

6. Failing the above, if there is line voltage supplied at M2, M2 is pulled in, and the supply air blower motor still does not operate, replace the motor.

7. If 24 volts is not present at M2, check that 24 volts is present at the UCB supply air blower motor terminal, “FAN”. If 24 volts is present at the FAN, check for loose wiring between the UCB and M2.

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8. If 24 volts is not present at the “FAN” terminal, check for 24 volts from the room thermostat. If 24 volts are not present from the room thermostat, check for the following:

a. Proper operation of the room thermostat (contact

between R and G with the fan switch in the ON position and in the AUTO position during operation calls).

b. Proper wiring between the room thermostat and the

UCB.

c. Loose wiring from the room thermostat to the UCB.

9. If 24 volts is present at the room thermostat but not at the UCB, check for proper wiring between the thermostat and the UCB, i.e. that the thermostat G terminal is connected to the G terminal of the UCB, and for loose wiring.

10. If the thermostat and UCB are properly wired, replace the UCB.

On a call for cooling, the supply air blower motor is operating but the compressor is not (the room thermostat fan switch is in the “AUTO” position).

1. If installed, check the position of the economizer blades. If the blades are open, the economizer is providing free cooling and the compressors will not immediately operate. If both stages of cooling are requested simultaneously and the economizer provides free cooling, following a short delay the compressor will be energized unless it is locked out, unless this option has been disabled through computer communications.

2. If no economizer is installed or the econ omizer is not opening to provide free cooling and the compressor does not energize on a call for cooling, check for line voltage at the compressor contactor, M1, and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor.

3. If M1 is pulled in and voltage is supplied at M1, lightly touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool.

4. If M1 is not pulled in, check for 24 volts at the M1 coil. If 24 volts are present and M1 is not pulled in, replace the contactor.

5. Failing the above, if voltage is supplied at M1, M1 is pulled in, and the compressor still does not operate, replace the compressor.

6. If 24 volts is not present at M1, check for 24 volts at the UCB terminal, C1. If 24 volts is present, check for loose wiring between C1 and the compressor contactor.

7. If 24 volts is not present at the C1 terminal, check for 24 volts from the room thermostat at the UCB Y1 terminal. If 24 volts is not present from the room thermostat, check for the following:

a. 24 volts at the thermostat Y1 terminal b. Proper wiring between the room thermostat and the

UCB, i.e. Y1 to Y1, Y2 to Y2

c. Loose wiring from the room thermostat to the UCB.

8. If 24 volts is present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure switch, low-pressure switch, or freezestat. Check for 24 volts at the HPS1, LPS1, and FS1 terminals of the UCB. If a switch has opened, there should be a voltage potential between the UCB terminals, e.g. if LPS1 has opened, there will be a 24volt potential between the LPS1 terminals.

9. If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened, the UCB may have locked out the compressor for repeat trips. The UCB should be flashing an alarm code. If not, press and release the ALARMS button on the UCB. The UCB will flash the last five alarms on the LED. If the compressor is locked out, cancel any call for cooling. This will reset any compressor lock outs.

NOTE: While the above step will reset any lockouts,

the compressor may be held off for the ASC D. See the next step.

10. If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out, the UCB may have the compressor in an ASCD. Check the LED for an indication of an ASCD cycle. The ASCD should time out within 5 minutes. Press and release the TEST button to reset all ASCDs.

11. If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip, repeat trip lock out, or ASCD, the economizer terminals of the UCB may be improperly wired. Check for 24 volts at the Y1 “OUT” terminal

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of the UCB. If 24 volts is present, trace the wiring from Y1 “OUT” for incorrect wiring. If 24 volts is not present at the Y1 “OUT” terminal, the UCB must be replaced.

12. For units without economizers: If 24 volts is present at the Y1 OUT terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, the jumper in the Mate-N Lock plug, and in the wiring from the Mate-N-Lock plug to the Y1 “ECON” terminal.

13. For units with economizers: If 24 volts is present at the Y1 “OUT” terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, a poor connection between the UCB and economizer Mate-N-Lock plugs, loose wiring from the Mate-N-Lock plug to the economizer, back to the Mate-N-Lock plug, and from the Mate-N-Lock plug to the Y1 “ECON” terminal. If nothing is found, the economizer actuator may have faulted and is failing to return the 24-volt “call” to the Y1 “ECON” terminal even th ou gh the economizer is not providing free cooling. To test, disconnect the Mate-N-Locks and jumper between the WHITE and YELLOW wires of the UCB’s Mate-NLock plug. If the compressor ener gizes, there is a fault in the economizer wiring or actuator.

14. The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions. These options are not enabled by default. Local distributors can test the UCB for this programming.

For units with factory installed economizers, the UCB is programmed to lock out compressor operation when the LAS set point is reached.

normal operation, the control board flashes a 1 second on, 1 second off “heartbeat” during normal operation. This is to verify that the UCB is functioning correctly. Do not confuse this with an error flash code. To prevent confusion, a 1-flash, flash code is not used.

Current alarms are flashed on the UCB L ED. Pressing and releasing the ALARMS button on the UCB can check the alarm history. The UCB will cycle through the last five (5) alarms, most recent to oldest, separating each alarm flash code by approximately 2 seconds.

In some cases, it may be necessary to “zero” the ASCD for the compressors in order to perform troubleshooting. To reset all ASCDs for one cycle, press and release the UCB TEST button once.

TABLE 23: UNIT CONTROL BOARD FLASH CODES

Flash Code Description

On Steady Heart Beat

1 Flash 2 Flashes 3 Flashes 5 Flashes 7 Flashes

9 Flashes

10 Flashes

11 Flashes 13 Flashes

14 Flashes

OFF

These flash codes do not represent alarms.

Control Failure - Replace Control Normal Operation Not Applicable

Control waiting ASCD HPS1 - Compressor Lock out LPS1 - Compressor Lock out FS1 - Compressor Lock out Ignition Control Locked Out/

Ignition Control Failure / Limit Switch Trip / No Jumper Plug in Heat Section

Compressors Locked Out On Low Outdoor Air Temperature Compressors Locked Out Because the Economizer Is Using Free Cooling

Compressor Held Off Due To Low Voltage EEPROM Storage Failure (Control Failure) No Power or Control Failure

MAINTENANCE

NORMAL MAINTENANCE

For units without factory installed or with field installed economizers, the UCB allows compressor operation all the time. This programming can be checked or changed by the local distributor.

15. If none of the above correct the error, replace the UCB.

UNIT FLASH CODES

Various flash codes are utilized by the unit control board (UCB) to aid in troubleshooting. Flash codes are distinguished by the short on and off cycle used

Prior to any of the following maintenance procedures, shut off all electric power to the unit to prevent personal injury.

FILTERS

Inspect once a month. Replace disposable or clean permanent type as necessary. DO NOT replace permanent type with disposable. The dimensional size of

(approximately 200ms on and 200ms off). To show

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the replacement filter must be the same as the replaced filter.

MOTORS

Outdoor fan motors

are permanently lubricated and

require no maintenance. Indoor Blower Motor and Drive

- The indoor blower motor features ball bearings that do not require periodic lubrication.

Perform all maintenance operations on the blower motor with electric power disconnected from the unit. Do not attempt to lubricate bearings with the unit in operation.

On an annual basis, check the motor for accumulations of dust, etc. that may block the cooling slots in the motor shell. Check for loose, damaged or misaligned drive components. Check that all mounting bolts are tight. Replace defective parts as required.

OUTDOOR COIL

Dirt should not be allowed to accumulate on the outdoor coil surface or other parts in the air circuit. Cleaning should be as often as necessary to keep coil clean. Use a brush, vacuum cleaner attachment, or other su itable means. If water is used to clean coil, be sure electric power to the unit is shut off prior to cleaning.

NOTE: Exercise care when cleaning the coil so that

the coil fins are not damaged.

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Unitary 5005 Norman Products York OK Group Drive 73069