York CHAMPION PLUS DNH024, CHAMPION PLUS DNH060, CHAMPION PLUS DNH048, CHAMPION PLUS DNH018, CHAMPION PLUS DNH030, CHAMPION PLUS DNH036, CHAMPION PLUS DNH042, DNH024, DNH030, DNH036, DNH042, DNH048, DNH060 Technical Manual
19 UNIT WEIGHTS AND CENTER OF GRAVITY. . . . . . 24
2Unitary Products Group
Page 3
036-21233-002-A-0903
DESCRIPTION
These packaged cooling/heating air conditioners are
designed for outdoor installation. Only utility and duct connections are required at the point of installation.
The gas-fired heaters have aluminized steel tubular heat
exchangers and hot surface to pilot ignition. They are available in natural gas with field conversion to propane.
STANDARD FEATURES/BENEFITS
OPERATING EFFICIENCY - All units provide high operating
efficiencies and have a m in imum AFUE o f 80 % an d SEER o f
up to 12.4. All efficiencies exceed legislated minimum levels.
ON SITE FLEXIBILITY - All model sizes share a common,
compact design cabin et in a single foot print. The insta ller has
the flexibility of setting one curb and placing the proper tonnage unit on that curb after the internal load has been determined. Field convertible duct connections from side shot to
down shot allows the installer to have greater flexibility with
less inventory.
LOWER INSTALLATION COST - Installation time and costs
are reduced by easy power and control wiring connections.
The small base dimension means less space is required on
the ground or roof, plus, the installer can fit this unit between
the wheel wells of full size pick-up truck. All models are well
under 500 pounds.
All units are completely wired, charged with R-22 and tested
prior to shipment. Unique test stations using a new state of
the art computerized proc ess s ystem are used to in sure pro duct quality. Refrige rant charge , and c ompon ent part n umbe rs
are verified via com puters at ass embly. Vital run test statistics
such as syste m pressure, motor currents, air velocity and
temperature, unit vibra tion , and gas sy stem safeties are monitored and recorded by the system to insure unit performance.
Equal size, side supply and return duct connections allows
easy hook-up of ducts to match low crawl spaces without
transition pieces.
UTILITY CONNECTIONS MADE EASY - Gas and electric
utility knockouts are provided through the bottom as well as
the side of the unit. Utility connections can be made quickly
and with a minimum amount of field labor. A field supplied
and field installed electrical disconnect switch must be
installed.
CONVERTIBLE AIRFLOW DESIGN - The bottom duct openings are covered when they leave the factory ready to be
used for a side supply / side return application. If a bottom
supply / bottom return application is desired, you simply
remove the two panels from the bottom of the unit and place
them in the side supply / s ide return duc t ope nin gs . N o pan el
cutting is required and no accessory panel is necessary.
Convertible airflo w design allows ma ximum field flexi bility and
minimum inventory.
CONDENSATE PAN - A non-corrosive, long-lasting, watertight pan is po sitioned below the evaporat or coil t o collec t and
drain all condensate. Less collection of stagnate condensate
will build-up. The condensate pan conforms to ASHRAE 6289 standards (Ventilation for Acceptable Indoor Air Quality).
CONDENSATE DRAIN - The heavy duty, 3/4 inch NPTI copper connection is more tolerable during installation and is
more durable over time. The con nection is rigidly mounted to
assure proper fit and leak tight seal.
DURABLE FINISH - With a heavy duty cab ine t ma de of pow der-painted, galvanized steel the neutral color blends into
surrounding areas. The powdered paint, provides a better
paint to steel bond, which resists corrosion and rust creep.
The special primer formulas and glossy finish insure less fading when exposed to sunlight and offers a more attra cti ve on
site appearance. This paint finish meets ASTM-B117 standards for 750 hours salt spray rating. The highest in the
industry.
FULL PERIMETER BASE RAILS - The easily removable
base rails provide a solid foundation for the entire unit and
protects the unit during shipment. The rails provide fork lift
access from all sides, and rigging holes are also provided so
that an overhead crane can be used to place the units on a
roof. On applications where the unit is placed on a pad, the
base will keep the unit off the pad to deter corrosion. On
applications where height is limited, the inch high base rails
may be removed on location.
MORE ATTRACTIVE APPEARANCE - A single piece Water
Shed top cover containing a top discharge condenser fan
arrangement requi res less square footag e on in stallation and
provides a wider variet y of install ations. The one piece design
adds greater water integri ty. Rounded c orners wit h water drip
edges add to the attractive appearance. The cabinet panels
have a non-fibrous insulation that will not release insulation
fibers into conditioned area.
TOP DISCHARGE - The top discharge condenser fan does
not disrupt neighboring areas or does this dry-out vegetation
surrounding the unit. The warm air from the top mounted fan
is blown up away from the structure and any landscaping.
This allows compact location on multi-unit applications.
CONDENSER COIL GR IL LE - A multi-piece totally enclosed,
rigidly mounted condenser coil grille provides protection from
objects after installation and provides protection during transit.
LOW OPERATING SOUND LEVEL - The upward air flow
carries the normal operating noise up and away from the living area. The rigid top panel effectively isolates any motor
sound. Isolator mounted compressor and the rippled fins of
the condenser coil muffle the normal fan motor and compressor operating sounds . The unique formed ba se pan also aids
in sound alterations with it’s Super-Structure design. This
design strategically places embossments in the pan for optimum strength and rigidity.
Unitary Products Group3
Page 4
036-21233-002-A-0903
FAN SYSTEM - All models operate over a wide range of
design conditions with a 3-speed direct-drive fan motor.
These units easily match all types of applications and provides greater on site flexibility to match comfort requirement.
Single phase models have the Comfort-Match system that
allows different speed taps for heating or cooling opera tions.
This allows maximum comfort conditions.
SIMPLE CONTROL CIRCUIT - A low voltage printed circuit
board contains a diagnostic indicator light and a low voltage
terminal strip. An additional set of pin connectors is also provided to simplify the field interface of external controls. Maten-lock plug connecto rs are us ed. Th e el ec tric al con trol box is
not located in the c ompress or com partm ent. The cont rols ar e
mounted on a Control-Tilt control panel to allow the access
cover to be removed for trouble shooting and maintenance
without affecting the normal system operating pressures. All
wiring internal to the unit is color/number coded.
PROTECTED COMPRESSOR - The compressor is i nternally
protected against high pressure and temperature. This is
accomplished by t he simultan eous opera tion of high p ressure
relief valve and a temperature sensor which protect the compressor if undesirable operating conditions occur.
EXCLUSIVE COIL DESIGN - Grooved copper tubes and
enhanced aluminum fin construction improves heat transfer
for maximum efficiency and durabi li ty.
HEAT EXCHANGERS - Are corrosion-resistant, aluminizedsteel tubular construction to provide long-life, trouble-free
operation. The uniq ue b low-through design also ass ure s th at
condensate does not collect in humid areas when in the cooling cycle. This adds to longer heat exchanger life and higher
long term efficiencies.
POST PURGE INDUCED DRAFT COMBUSTION - Exhausts
combustion products from the heat exchanger upon completion of the heating cycle to prolong the heat exchanger life.
SELF DIAGNOSTIC FAN CONTROL MODULE - Due to this
self diagnostic control, less on site time is required to trouble
shoot these units.
HOT SURFACE TO PILOT IGNITION - Provides faster heat
delivery. This ignition is highly reliable, durable and eliminates
nuisance lockouts. Also assures starts in damp conditions.
EASY SERVICE ACCESS - A large, single panel covers the
electrical and gas c ontro ls m ak es se rvi ci ng eas y . Th e b low e r
compartment has an additional large panel with a built-in
handle tab. Removing this panel will allow the blower assembly to slide-out for easy removal for mai ntenance and ease of
trouble shooting.
REPLACEMENT PARTS - The installer has no n eed to carry
an inventory of unique parts or needs special training to
replace any of the components parts for these units. All are
easily obtained from Source 1 or other part houses.
SYSTEM INTEGRATION - Each unit has the internal ability
to integrate an electronic air cleaner or humidifier to work in
conjunction with the base unit .
FIELD-INSTALLED ACCESSORIES
LOW NOx KIT - Kit includes all the necessary hardware and
instructions to field convert units to reduce emissions to less
than 40 nanogram per Joule. California requirem ent on single
phase models only.
PROPANE CONVERSION KIT - Kit includes burner orifices,
gas valve conversion and installation instructions necessary
to field convert unit from natural gas to propane.
HIGH ALTITUDE CONVERSION KIT (Natural Gas/Propane)
- Kit includes all necessary labels and instructions to field
alter units with natural gas/propane for installation above
2000 feet. Burner orifices must be obtained from Source 1
Parts. Propane Conversion Kit must be obtained separately.
ECONOMIZER DOWN DISCHARGE / SUPPLY KIT - Modulating integrated economiz er prov ides simultaneous operation between the mechanical cooling and economizer
operation. Independent blade design insures proper control
and less than 1% leak rate. Includes hood and mesh bird
screen filter integrated into the hood, dry bulb sensor and
relief damper. Separate field accessories of single enthalpy
and dual enthalpy are also available. A built-in barometric
relief of 25% is provided.
SINGLE ENTHALPY SENSOR - Sensor replaces dry bulb
sensor standard in ec on omi ze r ki t. Pro vi des improved economizer operation by sensing the dry bulb temperature from
outdoors plus the enthalpy content of the outdoor air.
MULTI PORT IN-SHOT BURNERS - No field adjustment is
required to mix the air and gas. These burners are constructed of high-grade corrosion-resistant, aluminized-steel.
LOW MAINTENANCE - Long life, permanently lubricated
condenser and evaporator fan motor bearings need no
annual maintenance adding greater reliability to the unit.
Blower assembly can be easily cleaned by the unique SlipTrack slide-out blower assembly.
SECURED SERVICE ACCESS PORTS - Protected, externally mounted, re-usable service access ports are provided
on both the high and low lines for ease of evacuating and
charging the system. No final field mounting required.
4Unitary Products Group
DUAL ENTHALPY SENSOR - Additional sensor to single
enthalpy sensor. Sensor senses both the return air temperature dry bulb and humidity in conjunction with the single
enthalpy to determine the most economical mix. Single
Enthalpy sensor also required.
PRESSURE SWITCH UPGRADE KIT - Contains screw in
type High pressure, Low Pressure/Loss of Charge switch,
freeze protection switch and lockout relay. Switches are
placed onto existing scharder ports located in the unit by furnished adapters. When abnormal conditions are sensed
through the pressure switches, the unit will lock out preventing any further operation until reset or problem is corrected.
Package agency approved.
Page 5
036-21233-002-A-0903
HAIL GUARD KIT - Kit contains protective grilles made of
expanded aluminum with full perimeter frame. Sloped hoods
are also included to assure maximum protection.
ANTI SHORT CYCLE TIMER - Automatically prevents the
compressor from restarting for 5 minutes after cycled off.Not
required if Thermostat 2ET07700224 and 2ET04700224 are
used.
FILTER / FRAME KIT (Single Phase only) - Kit contains the
necessary hardware to field install return air filters into the
base unit. Pre-cut filter racks and appropriate cleanable standard size filters are shipped in one kit. The filter rack is suitable for either 1" or 2" filters. (1" filter is supplied) This kit is
available for single phase horizontal or vertical duct application only. Standard in all 3 Phase models.
MOTORIZED FRESH AIR DAMPER - Designed for duct
mounted side supply/return and unit mounted down supply/
return applicatio ns . Da mp er c ap abl e of providing 0% thro ugh
50% of outdoor air (field supplied). Closes on power loss,
includes hood and screen asse mb ly .
RECTANGLE TO ROUND ADAPTERS - Kit includes one
supply and one return air rectangle to round duct adapter.
Adapters are preformed and designed to fit over current duct
openings on the base unit. Transitio n is from side squa re duct
opening to 14" round duct opening.
ROOF CURBS - NRCA approved curbs provide proper fit to
base unit for rooftop installations. Curbs are designed to be
assembled through hinge pins in each corner. Kit also provides seal strip to assure a water tight seal. 8 and 14 inch
high roof curbs are available.
MANUAL OUTDOOR DAMPER - Provides 0% through 50%
outdoor air capability (field adjustable). Designed for duct
mounted side supply/return applications. Includes hood and
screen assembly.
WALL THERMOSTAT - The units are designed to operate
with 24-volt electronic and electro-mechanical thermostats.
All units can oper ate with si ngle stag e heat / si ngle stag e cool
thermostats - with or without the economizer.
LOW AMBIENT KIT - Kit provides necessary hardware to
convert unit to operate in coolin g cycle down to 0 F. Stand ard
unit operation 45 F.
TRANSFORMER KIT - Kit provides necessary hardware to provide single phase models from factory furnished 40 VA transformer capability to 75 VA transformer capability. (Required on
installations with economizer or motorized damper.)
FILTERFACE AREA (Sq. Ft.) Size (Nominal)2.6/20x202.6/20x202.6/20x202.6/20x20
FURNACE
SECTION
COMPRESSORHERMETIC TYPE, (Qty. = 1)
CENTRIFUGAL BLOWER (Dia. x W. in.)10 X 810 X 810 X 811 x 1011 x 1012 x 1112 x 11
FAN MOTOR HP (3 Speed)1/21/21/23/43/43/41
ROWS DEEP2233333
FINS PER INCH13151313131616
FACE AREA (Sq. Ft.)3.53.53.53.54.54.54.5
PROPELLER DIA. (in.)22222222222222
FAN MOTOR HP1/41/41/41/41/41/31/3
NOM. CFM TOTAL1,8002,2002,4002,4002,4003,0003,000
ROWS DEEP1112122
FINS PER INCH20202020202020
FACE AREA (Sq. Ft.)11.711.711.711.714.714.714.7
Deduct these resistance values from the available external static pressure shown in Table 10, 11, 12, and 13
2.
The pressure through the economizer is greater for 100% outdoor air then for 100% return air. If the resistance of the return air
duct system is less then 0.25 IWG, the unit will deliver less CFM during full economizer operation.
IN S U L A T IO N A N D R O O F IN G M A T E R IA L
ROOF DECT AND ROO FING M ATERIAL
Unitary Products Group25
Page 26
036-21233-002-A-0903
OPTIONALCCH
S/PCONFIGURATION
CCH
BLK
BLK
D/PCONFIGURATION
CCH
BLK
BLK
M1-2
T2
2
L
DETAIL"A"
L1
T1
L1
2
L
SEE
DETAIL
"A"
FIGURE 13 - TYPICAL WIRING DIAGRAM (208/230-1-60 POWER SUPPLY)
FIGURE 14 - TYPICAL WIRING DIAGRAM (208/230-3-60 POWER SUPPLY)
26Unitary Products Group
Page 27
036-21233-002-A-0903
FIGURE 15 - TYPICAL WIRING DIAGRAM (460-3-60 POWER SUPPLY)
FIGURE 16 - TYPICAL WIRING DIAGRAM (575-3-60)
Unitary Products Group27
Page 28
036-21233-002-A-0903
TYPICAL WIRING DIAGRAM NOTES
1.All field wiring to be accomplished following city, local
and/or national codes in effect at time of installation of
this unit.
2.Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and
dangerous operation if any of the wire as supplied with
this unit must be removed it must be replaced with type
105°C, 600V wire or equivalent clearly renumbered for
identification. Verify proper operation after servicing.
3.Motors are inherently protected.
4.See unit nameplate for maxi mum fuse size and minimum
circuit ampacity.
5.Unit factory wired for low or medium sp eed indoor blower
operation to change motor speed connect speed tap
wires from indoor blower motor per Detail B (Figure 18)
tape unused speed tap wires to prevent shorting and
secure near M2 contactor.
6.Select indoor blower speed to remain within the temperature rise range on the nameplate in heating and to
obtain approximately 400 CFM/Ton in cooling.
7.If both LR and ASCT are present, wire 801/BL and 805/
BL are connected to ASCT-3 if LR only is present wire
801/BL and 805/BL are connected to M1 coil. If ASCT
only is present wire 202/Y is connected to ASCT-3. If
neither LR or ASCT are present, Wire 202/Y is connect
to M1 coil.
8.Shunt contact also used with crankcase heater.
(Optional).
Open all disconnects before servicing this unit.
FIGURE 17 - TYPICAL WIRING DIAGRAM LEGEND
1. See Figures 13, 14, 15 and 16.
(ALTERNATE)
(ALTERNATE)
1
28Unitary Products Group
Page 29
036-21233-002-A-0903
FIGURE 18 - WIRING DIAGRAM DETAIL B (460 & 575-3-60 POWER SUPPLY)
1.
See Figures 15 and 16.
MECHANICAL SPECIFICA TIONS
GENERAL
Units shall be manufactured by York International Unitary
Products Group in an ISO 9001 certified facility. YORK’s
Champion® package units are designed to handle applications ranging from residential to light commercial and any in
between. The Champion® is a unit that gives you the flexibility and choices you need in today’s market. These packaged
cooling/heating air conditioners are designed for outdoor
installation. Only utility and duct connections are required at
the point of installation. The gas fired heaters have aluminized steel tubular heat exchangers and hot surface to pilot
ignition. They are available in natural gas with field conversion to propane.
DESCRIPTION
Units shall be factory-assembled, single packaged, Electric
Cooling/Gas Heating units, designed for outdoor mounted
installation. For SEER ratings, refer to technical literature.
They shall have bu ilt i n, eq ual si ze, f iel d co nv erti ble duc t co nnections for down discharge suppl y/return or horizontal discharge supply/return. The units shall be factory wired, piped,
charged with R-22 refrigerant and factory tested prior to shipment. All unit wiri ng sha ll be both n umbere d and color coded .
All units shall be manufactured in a facility certified to ISO
9001 standards, and the cooling performance shall be rated
in accordance with DOE and ARI test procedures. The heating performance s hal l be ra ted to D OE and GAMA test p roc edures. Units shall be CSA lis ted a nd c las s ified to ANSI 22.4 7.
CAN/CGA2.3 standards and UL 1995/CAN/CSA No. 236M90 conditions.
UNIT CABINET
Unit cabinet shall be constructed of G90 galvanized steel,
with exterior surfaces coated with a non-chalking, powdered
paint finish, certified at 750 hours salt spray test per ASTMB117 standards. The unit top shall be a single piece “Water
Shed” design, with drip edges and no-seam corners to pro-
vide optimum water integrity. Unit shall have a rigidly
mounted condenser coil guard to provide protection from
objects and personne l after installat ion. Indoor blower se ction
shall be insulated with up to 3/4” thick, aluminum, foil faced
insulation, fasten ed to prevent insulatio n from entering the air
stream. Cabinet panels shall be “large” size, easily removable for servicing and maintenance, with built-in lift handles.
Unit shall be built on a formed, “Super-Structure” design base
pan, with embossments at critica l poin ts to add stre ngth,
rigidity and aid in minimizing sound. Full perimeter base rails
shall be provided to assure reliable transit of equipment,
overhead rigging, for truck access and proper se aling on roof
curb applications. Base rails shall be removable, when
required, to lower unit height. Filters shall be furnished and
be accessible through a removable access door, sealed airtight. Units vertical discharge and return duct configuration
shall be designed to fit between standard 24” O.C. beams
without modificati on to buildi ng st ructure, duct work and b ase
unit. Condensate pan shall be internally sloped and conform
to ASHRAE 62-89 self-draining standards, with 3/4” NPTI
copper, ridged mount conne cti on.
INDOOR (EVAPORATOR) FAN ASSEMBLY
Fan shall be direct drive, multi-speed design. Job site
selected (BHP) brake horsepower shall not exceed the
motors nameplate horsepower rating. Fan wheel shall be
double-inlet type with forward-curved blades, dynamically
balanced to operate smoothly throughout the entire range of
operation. Airflow design shall be constant air volume. Bearings shall be sea led and permanently lubricate d for long er life
and no maintenance. Fan assembly shall be “Slip Track”
(slide-out) design for easy removal and cleaning.
OUTDOOR (CONDENSER) FAN ASSEMBLY
The outdoor fan shall be of the direct-driven propeller type,
discharge air vertically, hav e alu mi num blade s riv eted to corrosion resistant steel spider bracket and shall be statically
balanced for smooth operation. The outdoor fan motor shall
be totally enclosed with permanently lubricated bearings and
internally protected aga ins t over loa d cond iti ons .
1
Unitary Products Group29
Page 30
036-21233-002-A-0903
REFRIGERANT COMPONENTS
Compressors:
a.Shall be fully hermetic type, direct drive, internally
protected with internal high-pressure relief and over
temperature protection. The hermetic motor shall be
suction gas cooled and have a voltage range of + or
- 10% of the unit nameplate voltage.
b.Shall have internal isolation and sound muffling to
minimize vibration and noise, and be externally isolated on a dedicated, independent mounting.
Coils:
a.Evaporator and condenser coils shall have alumi-
num plate fins mechanically bonded to seamless
internally enhanced copper tubes with all joints
brazed.
b.Evaporator coil shall be of the direct expansion,
blow through design, while condenser coil shall be
draw through design.
Refrigerant Circuit and Refrigerant Safety Components:
a.Shall include independent fixed-orifice expansion
devices.
b.Shall include filter/strainer to eliminate any foreign
matter.
UNIT OPERATING CHARACTERISTICS
Unit shall be capable of starting and running at 125º F outdoor temperature, exceeding maximum load criteria ARI
Standard 210/240. The compressor, with standard controls,
shall be capable of operation down to 45 º F outdoor temperature. Accessory low ambient kit shall be available for operation to 0º F.
ELECTRICAL REQUIREMENTS
All unit power wiring shall enter un it cabinet at a singl e factory
provided location and be capable of side or bottom entry, to
minimize roof penetrations and avoid unit field modifications.
Separate side and bottom openings shall be provided for the
control wiring.