York D2CG300, D2CE User Manual

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Page 1

SUNLINE 2000



ELECTRIC / ELECTRIC & GAS / ELECTRIC

SINGLE PA CKAGE AIR CONDITIONERS

(Constant Air Volume)

INSTALLATION INSTRUCTION

208/230/460

VOLT ONLY

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.

‘YORK Model DCE and DCG units are single package air conditioners d esig ned for outdoor inst alla tion on a roo ft op o r a slab and is manufactured under ISO 9002 Quality System Cert ification. The DCE models are coo ling only and can be equipped with factory installed electric heaters for cooling / heating applications. The DCG models are gas-fired central heating furnaces wit h co ol in g.

The units are co mplete ly asse mbl ed on rig id, permanen tly at tach ed base rails. All piping , refrigerant charge , and electrical wiring is factory installed and test ed. All units require electric po wer , duct connections and fixed outdoor air intake damper (units without economizer or motorized damper option only) at the point of installation.

The DCG units ad ditionally req uire gas connecti on, installat ion of the combustion air inlet hood and the flue gas outlet hoods at the point of installation . The gas-fired h eaters ha ve al uminized-st eel tub ular heat exchangers and spark ignition with proven pilot.

Supplemental electric heaters for DCE units have nickel-chrome elements and utilize single point power connections.

The following safety precautions apply to DCG units:

FOR Y OUR SAFETY

If you smell gas:

1. Open windows.

2. Don’t touch electrical switches; do not use any phones in the area of the gas leak.

3. Extinguish any open flame.

4. Immediatel y call y our gas supplier fr om another location. Follow your gas supplier’s instructions.

5. If you cannot reach y our gas supplier , call the fire department.

Supersedes: 530.18-N11Y (195)

MODELS D2CE & D2CG300

(8.5 EER)

DCG MODEL

SHOWN

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:

44-320-10 - Barometric Relief Damper Accessory

•

530.18-N6.1V - Propane Conversion Accessory

•

530.18-N6.2V - High Altitude Accessory (Nat. Gas)

•

530.18-N6.3V - High Altitude Accessory (Propane)

•

530.18-n13y - Coil Guard In st al la ti on

•

Renewal Parts:

Refer to the Renewal Par ts Manual for comple te listing of

•

replacement parts on this equi pm ent.

All forms referenced in this instruction may be ordered from:

Publications Distribution Center Unitary Products Group P.O. Box 1592, York, Pa. 17405

APPROVALS

Design certified by ETL & CGA as follows:

1. For use as a central cooling only unit with or without supplemental electric heat. (DCE models)

2. For use as a forced air furnace with cooling unit. (DCG models)

3. For use with natural gas or pro pa ne gas. (DCG mod el s)

4. For outdoor installat io n on ly.

5. For installation on combustible ma te ria l.

THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUCTIONS AND ANY APPLICABLE LOCAL, ST ATE, AND NATIONAL CODES INCLUDING, BUT NOT LIMITED TO , BUILDING, ELECTRICAL, AND MECHANICAL CODES.

CAUTION

530.18-N11Y (399)

035-16133

208/230/575

VOLT ONLY

Do not store o r use gasoline or ot her flammable vapors and liquids in the vicinity of this or any other appliance

Installer should pay particular attention to the words: NOTE, CAUTION and WARNING. Notes are inte nd ed t o clarify or m ake the installa tion ea sier . and/or equipment damage may result if installation pr ocedure is not handled properly.

FOR Y OUR SAFETY

INCORRECT INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY OR PROPERTY DAMAGE

Cautions are gi ven t o pre vent equipmen t damage . W arnings are giv en to ale rt installer that personal i njury

WARNING

Page 2

530.18-N11Y

TABLE OF CONTENTS

General................................................................................ 1

Inspection.............................................................................1

Reference............................................................................. 1

Approvals ............................................................................. 1

Nomenclature.......................................................................2

INSTALLATION

Limitations............................................................................ 3

Location ...............................................................................3

Rigging and Handling .......................................................... 3

Clearances........................................................................... 3

Ductwork .............................................................................. 3

Fixed Outdoor Air Intake Damper........................................ 4

Condensate Drain................................................................4

Compressors........................................................................4

Filters ................................................................................... 4

Service Access .................................................................... 4

Thermostat...........................................................................5

Power and Control Wiring.................................................... 5

Optional Electric Heaters (DCE Models)............................. 5

Combustion Disch arge (DCG Model s)................................5

Gas Piping (DCG Models)................................................... 6

Gas Connection (DCG Models)........................................... 6

L.P. Units, Tanks and Piping (DCG Models)......................... 6

Vent and Combustion Air Hoods (DCG Model s) ................. 7

Econ. / Mot. Damp er Rai n Hoo d Accy. (1EH0401)..............7

Econ. / Power Rain Hood Accy. (1EH0402)......................... 9

OPERA T ION

Cooling System.................................................................. 15

Preliminary Opera tion Cooling........................................... 15

Cooling Sequence of Operation........... ..............................15

Safety Controls (Cooling)................................................... 15

Electric Heating - Sequence of Operation ......................... 15

Heating Anticipat or Set poin ts....... .. .. .................. .. .............16

Gas Heating - Sequence of Op er at io n......... .. .. .. .. .............16

Safety Contro ls (Heat ing). .................. .. .. .................. .. .. ...... 16

Heat Antici pator Setpoints ................................................. 17

Pre-Start Check List........................................................... 17

START-UP

Operating Instructions........................................................ 17

Post-Start Check List.........................................................17

Manifold Ga s Pressure Adjustment...................... .............17

Pilot Checkout.................................................................... 18

Burner Instructions.............................................................18

Burner Air Shutter Adjustment...........................................18

Checking Supply Air CFM....... .. .................. .. .. .................. .18

Adjustment of Temperature Rise........................................ 19

Checking Gas Input ........................................................... 19

Secure Owner’s Approval .................................................. 19

MAINTENANCE & TROUBLESHOO TING

Normal Maintenance ......................................................... 20

Cleaning Flue Passages and Heating Elements...............20

Troubleshooting.................................................................. 2 1

Replacement Parts ..................................... .................. .. ... 23

TABLES

No. Description Page

1 Unit Application Data.................................. 3

2 Gas Heat Application Data ......................... 6

3 Pipe Sizing.................................................. 6

4 Physical Data.............................................. 10

5 Electrical Data - Basic Units...................... 10

6 Electrical Data - Units Wi th Ele c. Heat ...... 10

7 Four and Six Point Loads............................ 13

8 Supply Air Blower Performance .............. ... 13

9 Static Resistances ...................................... 14

10 Pow er Exh au st Performance....... .. .. .. ......... 14

11 Blower Motor and Drive Data...................... 14

12 Heat Anticipator Setpoint............................ 16

13 Limit Control Setting ................................... 17

14 Gas Rate - Cubic Feet Per Hour................. 19

FIGURES

No. Description Page

1 Typical Rigging....... ........................ ............. 3

2 Center of Gravi ty............................. .. .......... 3

3 Fixed Out door Air Dam pe r.............. .. .. .. ...... 4

4 Recommended Drain Piping....................... 4

5 Typical Field Wiring ..................................... 5

6 External Supply Connection ....................... 6

7 Bottom Supply Connection......................... 7

8 Vent and Combustion Air Hoods................. 8

9 Adjusting Enthalpy Setpoint.................... .. .. 9

10 Dimensions and Clearan ces...... .. ............... 11

Dimensions and Clearances (cont’d).......... 12

11 Four and Six Point Loads............................ 13

12 Gas V a lv e Pipin g................ .... .... .... .. .... .... ... 16

13 Gas Valve and Controls .............................. 17

14 Typical Gas Valve................... .... ...... ...... ..... 17

15 Proper Flame Adjustment................ .. ......... 18

16 Typical Flam e App ea ra nc e........ ................. 18

17 Belt Adjustment............................ .. .. ........... 18

18 Pressure Drop versus Supply Air CFM ...... 19

19 Typical Flue Baffle Installation .......... .......... 20

PRODUCT NOMENCLATURE

D 2 C G E C4N

PRODUCT CATEGORY

D = Single Package Air Conditioner (Air Cooled)

PRODUCT GENERATION

2 = 2nd Generation

PRODUCT IDENTIFIER

CG = Gas/Electric CE = Cooling only or Electric / Electric

NOMINAL COOLING

CAPACITY

300 = 25 Tons

2 Unitary Products Group

FACTORY INSTALLED

HEAT

A = No Heat N = Natural Gas E = Electric

2 003 0 2 5

NOMINAL HEATING OUTPUT CAPACITY

GAS 240 = 240 MBH 320 = 320 MBH

ELECTRIC 018 = 18 KW 036 = 36 KW 054 = 54 KW 072 = 72 KW

FACTORY INSTALLED

OPTION CODE

EC = Sing. Input Economiz er DK = Diff. Input Economiz er FD = Sing. Input Economizer w/Power Exhaust CF = Diff. Input Economizer w/Power Exhaust BG = Motorized Outdoor Air Damper

VOLTAGE CODE

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

Page 3

INSTALLATION

LIMITATIONS

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

In U.S.A.:

1. Nati on al Elec trica l Cod e ANSI/ NFPA No. 70.

2. National Fuel Gas Code Z223.1.

3. Gas-Fired Central Furnace Standard ANSI Z21.47a.

4. Local gas and electric utility requirements. In Canada:

1. Current Canadian Electrical Code C22.1.

2. Current Gas Installation Codes CAN/CGA-B149.1 and .2

3. Local plumbing and waste water codes.

4. Other applicable lo ca l co de s . Refer to the Unit Application Data T able and to the Gas Heat Application

Data T ab le. After installation, units with gas heat must be adjusted to obtain a

temperature rise within the range specified on the unit rating plate. 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 e xpense. Size of unit for prop os ed in st al la ti on sh ou ld be ba se d on hea t

loss/heat g ain calcul ation made a ccording to the method s of the Air Conditioning Contractors of America (ACCA).

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

TABLE 1

V oltage V ariation, Min. / Max.

Supply Air CFM, Min. / Max. 8,000 / 12,000 Wet Bulb Temperature (°F) of Air on

Evaporator Coil, Min. / Max. Dry Bulb T emperature (°F) of Air on

Condenser Coil, Min.

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

A low ambient accessory is available for applica tio ns down to 0°F.

LOCATION

Use the following guidelines to sele ct 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. For ground level installation, use a level concrete slab with

WARNING: Excessive exposure of this furnace to contami-

4. Roof structures must be able to support the weight of the

- UNIT APPLICATION DATA

208/230-3-60 187 / 253

Where a choice of location is possible, position the unit on either north or east side of bu il di ng.

a minimum thickness of 4 inches. The length and width should be at le ast 6 inc hes g rea ter t han the unit bas e ra ils . Do not tie slab to the building foundation.

nated combus tion air may res ult in equipment d amage or personal injury. Typical contaminates include: permanent wave solutions, chlorinated waxes and cleaners, chlorine based swimming pool chemicals, water soft ening chemica ls, carbon tetrachloride, Halogen type refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues, antistatic fabric softeners for clothes dryers, ma sonry acid washing materials.

unit and its opti ons and/or accessori es. Unit must be installed on a solid level roof curb or appropriate angle iron frame.

460-3-60 414 / 506 575-3-60 518 / 630

57 / 72

/ Max.

25 / 120

530.18-N11Y

CAUTION: If a unit is t o b e i ns tall ed on a ro of cu rb o r spec ia l

frame, gasketing mu st be applied to all surfaces that come in contact with the unit underside.

5. Maintain lev el tole rance t o 1/2 " maximu m across the ent ire

length or width of the unit.

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 round lifting holes provided in t he base rails. Spreaders, wh ose length exceed s the largest di mension ac ross the uni t,

be used acros s

MUST

the top of the unit. Units may also be moved or lifted with a forklift, from the front

or rear only, providing that an accessory skid is used. LENGTH OF FORKS MUST BE A MINIMUM OF 90".

CAUTION: On gas heating units, an adhesive backed label is

provided over the outside of the combustion air inlet opening to prevent moisture from entering the unit which could cause damage to electrical components. Allow this closure label to remain in place until the combustion air hood is to be installed.

FIG. 1

- TYPICAL RIGGING

FIG. 2

- CENTER OF GRAVITY

136-1/4"

CLEARANCES

All units require certain clearances for proper operation and service. Installer must make provisions for adequate combustion and ventilation air in accordance with Combustion and V entilation of the National Fuel Gas Code , ANSI Z223.1 (in U.S.A.) or Sections 7.2, 7.3 or 7.4 of Gas Installation Codes CAN/CGA-B149.1 and .2 (in Canada) and/or applicable provisions of the local building codes. Refer to Dimensions and Clearances table for the clearances required for combustible construction, servicing, and proper unit operation.

WARNING:Do not permit o verhanging struct ure s or sh rubs to

obstruct ou tdoor air discharge ou tlet, combustion air inlet or vent outlets.

Section 5.3, Air for

Unitary Products Group 3

Page 4

530.18-N11Y

DUCTWORK

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

A closed return duct system shall be used. This shall not preclude u se of ec onomizers or outd oor fres h air inta ke. The supply and r eturn air duct connections at t he 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 be sized to matc h the dime nsions of the duct connect ions on the unit.

CAUTION: 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 the Dimensions and Clearances figure for information concerning side and bottom supply and return air duct openings.

It is recommended that, in Canada, the outlet duct on gas heating units be provided with a removable access panel. It is recommended that this opening be accessible when the unit is installed in service, and of a size such that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover should be attached in a ma nn er ad eq uate to preven t le ak ag e .

NOT

FIXED OUTDOOR AIR INTAKE DAMPER

FIG. 3

- FIXED OUTDOOR AIR DAMPER

CONDENSATE DRAIN

Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install a condensate drain line from the 1" NPT f emale connection on the unit to an op en drain.

This damper is shipped inside the return air compartment on units that are not provided with an economizer or a motorized damper option. It is completely assembled and ready for installation. A damper baffle inside of the hood is adjustable to provide v ariable amounts of outdoor air intake.

Gasketing and mounting screws are provided in a parts bag attached to the hood assembly. Apply gasketing to the three flange surfaces on the hood prior to installing the hood. Extend gasketing 1/4" beyond the top and bottom of the two side flanges to insure adequate sealing.

Adjusting the damper to the desired air flow may be done before mounting the hood into position or (after installation) by removing the front hood panel or the screen on the bottom of the hood. Damper baffle in po siti on 1 will allow appr oximatel y 10% recirculated air f low , posit ion 2 appro ximatel y 15% and, to allow approximately 25%, remove the damper baffle.

On units with assembly o v er the o peni ng in the side retu rn air a ccess pane l. Remove and discard the opening cover and the covering over the hood moun ti ng h ol es (u se d for ship pi ng ) be fore inst al li ng . Secure with the screws provided.

On units with side r eturn air appl ications, install th e damper assembly on th e return air duc twork as close to the unit as possible. Cut an opening 16" high by 18" wide in the ductwork to accommodate the damper. Using the holes in the hood flanges as a template, drill 9/64" dia. (#26 drill) holes into the ductwork and secu re with the screws provide d.

CAUTION: If outdoor air intake will not be required on units

bottom return air appl icat ions , i nstall the d ampe r

with bottom return air applications, the damper assembly s hould still be moun ted on the side return air access panel, per the instructions above, to insure mois ture is not drawn into the unit du ring operation. The covering over the mounting holes only need be removed. Do not remove the opening cover.

FIG. 4 -

NOTE: The condensate drain line MUST be trapped to provide

RECOMMENDED DRAIN PIPING

proper drainage.

COMPRESSORS

Units are ship ped with comp ressor mounting s facto ry-adjusted and ready for operation.

CAUTION: Do

Not loosen compressor moun ting bolts.

FILTERS

2" filters are su pplied with each uni t. Filt ers must alwa ys be installed ahead of the evaporator coil and must be kept clean or replaced with same size an d type. Dirty filters will redu ce the cap acity of t he unit and will result in frosted coils or safety shutdown. Minimum filter area and required si zes a re sho wn in t he Ph ysic al Dat a Table.

SERVICE ACCESS

Access to all serviceable components is provided by the follo w in g rem o vable panels:

Compressor compartment

•

Electri c Heat compartment - DCE models

•

Gas Heat compartment (Two panels) - DCG models

•

Side Supply & Return Air compartments (Two panels)

•

Blower compartment (Three panels)

•

Main control box

•

Filter compartment

•

Outdoor Air compartment (Two panels)

•

Refer to th e Di mensio ns an d Cl eara nces fi gure for location of t hese access panel s.

CAUTION: Make sure that all screws and panel latches are

replaced and properly positioned on the unit to maintain an air-ti gh t se al.

4 Unitary Products Group

Page 5

530.18-N11Y

CONTROL WIRE SIZES

Wire Size1 AWG. Gauge

22 20 19 18 16

25 40 50 65 100

Maximum Wire Length2 Feet

Notes:

1. Solid, Class II copper wire

FIG. 5

- TYPICAL FIELD WIRING

Unitary Products Group 5

Page 6

530.18-N11Y

THERMOSTA T

The room thermostat should be located on an inside wall approximately 56" above the floor where it will not be subject to drafts, sun exposure or heat from electrical fixtures or appliances. Follow manufacturer’s instructions enclosed with thermostat for general installation procedure. Seven color coded insulate d wires should be used to conn ect thermostat to unit.

POWER AND CONTR OL WIRING

Field wiring to the unit must conform to provisions of the National Electrical Code, ANSI / NFPA No. 70 (in U.S.A.), current Cana dian Electrical Cod e 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 in dicated on the unit Ratin g Pla t e.

The internal wiring harness furnished with this unit is an integral part of a ETL and CGA design certified unit. Field alteratio n 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 Cana da) an d/or loc al co des. If any of the wire suppl ied with the unit must be replaced, repla cement wire must be of th e type shown on the wiring diagram and the same minimum gauge as the replaced wire.

Electri cal line must be sized proper ly to carr y the load . Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused.

CAUTION: 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 operat ion. The above waterproofing conditions will also apply when installing a field-supplied disconnect switch.

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

OPTIONAL ELECTRIC HEATERS (DCE Models)

The factory installed heaters are wired for single point power supply. Po wer supply need only be brought in to the singl e point terminal block and thermostat w iring to the lo w volta ge terminal block located in the upper portion of the unit control box.

These ETL an d CGA a pp roved he ater s ar e lo ca te d w ithi n th e central compartment of the unit with the heater elements extending into the supply air chamber. Refer to the Dimension and Clearances figure for access panel location.

Fuses are supp li ed , whe r e req ui red , by the factory. Some KW sizes require fuses and others do not. Refer to the Unit Applicatio n Data Table 1 for minmum CFM limi tations an d to Electrical Data T able.

TABLE 2

2,000 Feet

Sea Leve l

Max. Min. Max. Min. Max. Max. Min. Max.

300 150 270 135 240 213 279 20 50 400 200 360 180 320 281 372 30 60

NOTE: Heaters are shipped available for natural gas , but can be converted to L.P. / Propane with Kit Model No. 1NP0418.

MBH rating should be red uce d at the ra te of 4 pe rce nt f o r ea ch 1, 000 feet above 4,500 feet.

Based on maximum input and 1075 Btu/Ft3.

The air flow must be adjusted to obtain a temperature rise within the range shown.

- GAS HEAT APPLICATION DATA

Input Capacity (Mbh) Output Capacity (Mbh)

0 T o

Above

2,000 To

4,500 Feet

Above

Sea Leve l

2,000 Feet

Sea Level

0 T o

Above

2,000 To

4,500 Feet

Above

Sea Leve l

Gas

Rate

(Ft.3/Hr.)

Temp.

Rise °F

Full Input

COMBUSTION DISCHARGE (DCG Models)

The products of combustion are discharged horizontally through two screened (hooded) openings on the upper gas heat access panel.

FIG. 6

- EXTERNAL SUPPLY CONNECTION EXTERNAL SHUT-OFF

GAS PIPING (DCG Models)

Proper sizing of gas piping depends on the cubi c f eet pe r hour of gas flow requir ed , sp ec ific gravity of th e ga s an d th e lengt h of run. “National Fuel Gas Code” Z223.1 (in U.S.A.) or the current Gas Installation Codes CAN/ CGA-B149.1 and .2 (in Canada) should be followed in all cases unless superseded by local codes or gas ut il ity requirements. See Pipe Sizin g t able.

The heating value of the gas may differ with locality. The value should be chec ked with the local ga s ut ility.

NOTE : There may be a loca l gas utility requi rement specif ying

a minimum diameter for gas piping. All units re quire a 1 inch pipe connec ti on at th e entrance fitting.

TABLE 3

Maximum capacity of pipe in cubic feet of gas per hour. (Based upon a pressure drop of 0.3 inch water column and 0.6 specific gravity gas).

- PIPE SIZING

Length in Feet

10 20 30 40 50 60 70 80 90

100

Nominal Iron Pipe Size

1 in. 1-1/4 in.

520 350 285 245 215 195 180 170 160 150

1,050

730 590 500 440 400 370 350 320 305

GAS CONNECTION (DCG Models)

The gas supply line can be routed through the knockouts located on the front of the unit or through the opening provided in the unit’s base. Typical supply piping arrangements are shown in the Supp ly C onn ecti on fi gures. All pipe, fitt ings, e tc. are field-supplied.

T wo grommets are shipped in the blower compartment (in parts bag taped to the blower housing) of every unit with gas heat and should be used in the knockouts when the gas piping enters through the front of the unit.

After the gas supply piping has been installed, the bottom opening in t he unit should be sealed to prevent water fro m leaking into the building.

Gas piping recommendations:

1. A drip leg and a ground joint union must b e installed in t he gas piping.

2. When required by local co des, a man ual shut-of f val ve ma y have to be in st al led outside of the unit.

3. U se w rough t ir on or st eel pipe for all ga s lines. Pipe compound should be ap plied sparingly to male thre ad s on ly.

6 Unitary Products Group

Page 7

FIG. 7

- BOTTOM SUPPLY CONNECTION EXTERNAL SHUT-OFF

WARNING:Natural gas may contain some propane. Propane,

being an excellent solvent, will quickly dissolve white lead or most standard commercial compounds. Therefore, a special pipe com pound must be applied when wrought iron or steel pipe is used. Shellac base compounds such as Gask olac or Stalastic, and compounds such as Rectorseal #5, Cyde’s or John Crane ma y be us ed.

4. All piping should be clea ned of dirt and scale b y hammering on the outside of th e pipe and bl owing out the loose dirt and scale. Before i nitial start-up , be sure t hat al l of t he ga s lin es external to the un it have been purged of air.

5. The gas supply should be a separate line and installed in accordance with all safety codes as prescribed under “Limitations”. After the gas connections have been completed, open the main shut-off valve admitting normal gas pressure to the mains. Check all joints for leaks with soap solution or other material suitable for the purpose. NEVER USE A FLAME.

6. T he fur nac e and its indiv idual m anual sh ut-off valve must be disconnect ed fro m t he ga s sup ply p ipin g syst em d uring any pressure testing of that system at test pressures in excess of 1/2 psig (3.48kPa).

The furnace must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.48kPa).

7. A 1/8 inch NPT plugged tapping, accessible for test gage connection, m ust be in st alle d imme dia tely upst ream o f t he gas supply connection to the furnace.

530.18-N11Y

L.P. UNITS, TANKS AND PIPING (DCG Models)

All gas heat units are shipped from the factor y equipped for natural gas use only. The unit may be converted in the field for use with L.P./ propane gas with access ory kit model nu mber 1NP0418.

All L. P./propane gas equipment must conform to the safety standards of the Nat io nal Fire Protection Association.

For satis factory operat ion, L.P ./propane gas pressure must be

8.8 inch W.C at the unit under full load. Maintainin g proper gas pressure depends on three main factors:

1. The vaporization rate which depends on (a) the temperature of the li quid and (b) the “wetted sur face” area of the container or containers.

2. The proper pressure regulation. (Two-stage regulation is recommende d from the standpoint of both cost and efficiency.)

3. The pressure drop in the lines between regulators and between the second stage regulator and the appliance. Pipe size required will depend on the length of the pipe run and the total load of al l ap pl iances.

Complete infor mation regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and L.P./propane gas suppliers.

L.P./propane gas is an excellent solvent and special pipe compound must be us ed w he n a ss em bling pi pi ng for this ga s as it will quickly dissolve white lead or most standard commercial compounds. Shellac base compounds such as Rectorseal #5 are satisfactory for this type of gas.

Check all connections for leaks when piping is completed, using a soap solution. NEVER USE A FLAME.

Unitary Products Group 7

Page 8

530.18-N11Y

VENT AND COMBUSTION AIR HOODS (DCG Models)

Two vent hoods and a combustion air hood (with screens) are shipped attached to the blower housing in the blower compartment. Thes e hoods must be ins talled to as sure pro per unit function. All hoods must be fastened to the outside of the gas heat access panel with the screws provided in the bag also attached to the blower housing.

The screen f or the comb ustion air i ntake hood is secured to the inside of the access panel op en in g w it h four fa st eners and the screws used f or moun ting the hood t o the pane l. The top flange of this hood s li ps i n under the top o f t he access panel o pe ning when installing. Refer to the V ent and Combustion Hood figure.

OPTIONAL ECONOMIZER/MOTORIZED DAMPER RAIN HOOD

The instru ction for the optional economizer/motorized damper rain hood can be found in form 44-320-2. Use these instructions when field a ssembling an econom izer rain hood ont o a unit. The outdoor and return air damp ers, 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 "Fac to ry install ed " ec on om izer option.

ENTHALPY SET POINT ADJUSTMENT Remove the economizer access panel from the unit to check

the following adjustments. Loosen but do not remove the two panel latches .

Each vent hood is installed by inserting the top flange of the hood into the s lotted op ening i n the acce ss panel and sec uring in place.

SLOTTED

VENT AIR OUTLET HOODS

COMBUSTION AIR INTAKE HOOD

OPENINGS IN ACCESS PANEL

GAS HEAT ACCESS PANELS

CAUTI ON: Extreme care must be ex ercise d in turning both the

setpoint and m inimum p osition adjustin g scre ws to prevent twisting them off.

1. T he enthalpy set point may now be set by selecting the desired se tpoint shown in the Ent halpy figure. Adjust a s follows:

For a single en thalpy operation, carefully turn the set

•

point adjusting screw to the “A”, “B”, “C” or “D” setting corresponding t o th e le tt ere d cu rve.

For a dual enthalpy operation, carefully turn the set point

•

adjusting screw fully clockwise past the “D” setting.

2. To check that the damper blades m ove smoothly without binding, carefully turn the minimum position adjusting screw fully cl ockwise and then energize and de -energize terminals “R” to “G”. With terminals “R” to “G” energized, turn the minimum position screw counterclockwise until the desired mini mum position has been attained.

3. Replace the economizer access panel. Reposition the two latches horizontally and retighten the screws.

POWER EXHAUST/BAROMETRIC RE LIEF DAMPER AND RAIN HOOD OPTION

The instructions for the power exhaust/barometric relief damper and ra in hood can be found in form 44-320-10. The exhaust fan, all supporting brackets, angles, and the wiring are factory installed as part of the power exhaust option.

All of the components, including the dampers, hardware, and mounting inst ructions are shipp ed in a single p ackag e e xternal

FIG. 8

- VENT AND COMBUSTION AIR HOODS

from the unit. The hood must be field a ssemble d and installe d. Power exhaust is not available as a field installed option.

8 Unitary Products Group

Page 9

530.18-N11Y

FIG. 9

- ENTHALPY SETPOINT ADJUSTMENT

Unitary Products Group 9

Page 10

(1)

(

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(

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(

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(

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(

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(

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(

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(

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530.18-N11Y

TABLE 4

- PHYSICAL DATA

MODELS

EV APORATOR

BLOWER

EV APORATOR

COIL

CONDENSER

FAN

(Two Per Unit) CONDENSER

COIL

COMPRESSOR

(Qty. Per Unit)

CENTRIFUGAL BLOWER (Dia. x Wd. in.) 18 x 15 F AN MOTOR HP 15 ROWS DEEP 4 FINS PER INCH 13.5 FACE AREA (Sq. Ft.) 25.0 PROPELLER DIA. (in.) (Each) 30 FA N MOTOR HP (Each) 1 NOM. CFM TOTAL (Each) 7200 ROWS DEEP 3 FINS PER INCH 15 FACE AREA (Sq. Ft.) 43.3

12.5-TON TANDEM 2 QUANTITY PER UNIT (16" X 20" X 2") 2

AIR

FIL TERS

QUANTITY PER UNIT (16" X 25" X 2") 4 QUANTITY PER UNIT (14" X 20" X 2") 3 TO TAL FACE AREA (sq. ft.) 21.4

CHARGE

This compressor will be energized first.

TABLE 5

REFRIGERANT

22 (lbs./oz.)

- ELECTRICAL DATA - BASIC UNITS

MODEL NO.

D2CE300 208/230-3-60 41.4 312 1 4.2 15 38.6 139.5 175

& D2CG300 460-3-60 20.0 140 1 2.1 15 19.3 68.3 80

DCE/DCG

300

OPERATING WEIGHTS (LBS.) 25 T ON

DCE (Cooling only) 2730

Basic Unit

DCG (Gas / Electric)

N240 2930 N320 2970

Economizer 160 Economizer with

Power Exhaust

Options

Motorized Damper 150 Electric

Heater (DCE only)

18 KW 25 36 KW 30 54 KW 35

72 KW 40 Roof Curb 185 Barometric Damper 45 Economizer/Motorized

Accessories

Damper Rain Hood Economizer/P o wer E xhaust

Rain Hood

SYSTEM NO. 1 20/8

Wood Skid 220

SYSTEM NO. 2 20/0

POWER

SUPP LY

COMPRESSORS

QTY. 2

COND. FAN

#1 & #2

RLA LRA HP FLA AMPACITY DEVICE

ea.

SUPPLY AIR MINIMUM MAXIM UM BLOWER MOTOR

ea.

HP RLA

CIRCUIT OV ERCURRENT

AMPS

575-3-60 16.4 108 1 2.0 15 15.4 56.1 70

245

55 90

TABLE 6

- ELECTRICAL DATA - UNITS w/ELECTRIC HEAT

MODEL POWER CIRCUIT OVERCURRENT

D2CE SUPPL Y AMPA CITY DEVIC E ( 1)

300A25 208-3-60 E018 13.5 1 37.5 139.5 175 300A25 208-3-60 E036 27.0 2 75.1 142.1 175 300A25 208-3-60 E054 40.6 2 112.6 189.0 200 300A25 208-3-60 E072 54.1 2 150.1 198.4 225 300A25 230-3-60 E018 18.0 1 43.3 139.5 175 300A25 230-3-60 E036 36.0 2 86.6 156.5 175 300A25 230-3-60 E054 54.0 2 129.9 178.2 200 300A25 230-3-60 E072 72.0 2 173.2 221.5 250 300A46 460-3-60 E018 18.0 1 21.7 68.3 80 300A46 460-3-60 E036 36.0 2 43.3 78.3 80 300A46 460-3-60 E054 54.0 2 65.0 89.1 100 300A46 460-3-60 E072 72.0 2 86.6 110.7 125 300A58 575-3-60 E018 18.0 1 17.3 56.1 70 300A58 575-3-60 E036 36.0 2 34.6 62.6 70 300A58 575-3-60 E054 54.0 2 52.0 71.2 80 300A58 575-3-60 E072 72.0 2 69.3 88.5 100

ELEC TRIC HEAT ER OPTION

MODEL kW(1) STAGES AMPS

MINIMUM MAXIMUM

(AMPS) (AMPS)

VOLT AGE

LIMITATIONS**

Utilization Range “A” in accordance with ARI Standard 110.

NOMINAL VOLT A GE VOL TAGE KW CAP . MULTIPLIER

POWER SUPPLY

208/230-3-60 187 253

460-3-60 414 506 575-3-60 518 630

208 208 1.00 240 230 0.92 480 460 0.92 600 575 0.92

MIN. MAX.

VOLT AGE

10 Unitary Products Group

Page 11

BLOW ER

BLOW ER MOTOR ACCESS

BLOW ER CO M PARTM ENT ACCESS (A u x ilia r y )

DOT PLUG (F o r p re s s ure Drop Reading)

ACCESS

FR O NT VIEW

UNIT BASE W ITH RAILS Show n separately to illustrate Bottom D uct openings and P ow er C onnection locations

NOTE: For curb m ounted units, refer to the curb hanger dim ensions of the curb for the proper size of the s u p p ly a n d re tu r n a ir d u c t c o n n e c tio n s .

BLOW ER ACCESS

FIELD-SUPPLIED BLOW ER MOTOR ACCESS

BLOW ER CO M PARTM ENT ACCESS (A u x ilia ry )

DOT PLUG (F o r p re s su re Drop Reading)

GAS HEAT ACCESS

VENT AIR OUTLET HOODS

COM BUSTION AIR INLET HOOD

(C ) GAS SUPPLY ENTRY

DISCONNECT SW ITCH

LO C A TIO N

136-1/4

CONTROL BOX ACCESS

FR O N T VIEW

UNIT BASE W ITH RA ILS Show n separately to illustrate Bottom D uct openings, P ow er and G as P iping C onnection lo c a tio n s

NOTE: For curb m ounted units, refer to the curb hanger dim ensions of the curb for the proper size of the s u p p ly a n d r e tu rn a ir d u c t c o n n e c tio n s .

(D ) GAS SUPPLY ENTRY

FIELD-SUPPLIED DISCONNECT SW ITCH LO C A TIO N

136-1/4"

ELECTRIC HE AT ACCESS

CONTROL BOX ACCESS

6-3/8"

35"

35-1/4

33"

11-1/8"

46-5/8"

35"

35-1/4"

33"

21"

7-1/8"

9-3/4"

5-7/8"

46-5/8"

RETURN

AIR

2-3/4" 21-1/2"

12-1/2"

E C O N O M IZ E R / M O T O R IZ E D D A M P E R , FIXED O UTDO O R IN TAKE AIR AND POW ER EXH AUST RAIN HO O DS (See detail "Y")

21"

9-3/4"

5-7/8"

11-1/2"

RETURN

AIR

SUPPLY

2-3/4" 21-1/2"

9-1/4"

AIR

9-1/4"

12-1/2"

E C O N O M IZ E R / M O T O R IZ E D D A M P E R , FIXED O UTDO O R INTAKE AIR AND POW ER EXH AUST RAIN HO O DS (See detail "Y ")

92"

11-1/2"

BOTTOM SUPPLY

AND RETURN

AIR OPENING S

(See Note)

SUPPLY

AIR

8-1/8"

9-3/4"

92"

BOTTOM SUPPLY

AND RETURN

AIR O PEN ING S

(See N ote)

8-1/8"

9-3/4"

COM PRESSOR ACCESS (See detail "X ")

52-5/8

(A ) CONTROL W IRING ENTRY

(B ) POW ER W IRING ENTRY

3-3/4"

(B ) POW ER W IRING ENTRY

(A ) CONTROL W IRING ENTRY

COM PRESSOR ACCESS (See detail "X")

52-5/8"

CONDENSER COILS

(A ) CONTROL W IRING ENTRY

(B ) POW ER W IRING ENTRY

3-3/4"

(B ) POW ER W IRING ENTRY

(A ) CONTROL W IRING ENTRY

OPTIONAL COIL GUARD

CONDENSER COILS

All dimensions are in inches. They are subject to change without notice. Cert ified dimensions will be provided upon request.

OPTIONAL COIL GUARD

RETURN AIR

SUPPLY AIR

CONDENSER AIR

OUTDOOR AIR (Economizer)

UTILITIES ENTRY DATA

HOLE

B C 2-3/8" KO Gas Piping (Front)

D 1-11/16" Hol e Gas Piping (Bottom)*

Opening in the bottom of the unit can be located by the slice

in the insulation.

OPENING

SIZE

USED FOR

(DIA.)

1-1/8" KO

3/4" NPS (Fem.) B ottom

3-5/8" KO

3" NPS (Fem.) Bottom

Control Wiring

Power Wiring

CLEARANCES

Front 36" Back

Left Side (Filter Access) Right Side (Cond. Coil) 36"

Below Unit

Above Unit

Units (applicable in U.S .A. only) may be installed on combustible floo rs

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

Units must be installed oudo ors. Overhanging structu re s or shrubs sho uld

not obstruct condenser air discharge outlet.

If economizer is factory installed, the assembled hood kit must be removed

prior to final installation. This hood is 54" long. NOTE:

DCE Models: Units and ductwork are appro v ed f o r ze ro cle arance to combustible materials when equipped with electric heaters.

DCG Models: A 1" clearance must be provided between any combustible material an d the supply air ductwork for a distance of 3 feet from the un it.

The products of comb ust ion mu st no t be al lo we d to accum u lat e wi th in a confined space and re ci rcu lat e .

Locate unit so that the vent air outlet hood is at least:

Three (3) feet above any forced a ir inlet loca ted within 10 horizontal feet

•

(excluding those integral to the unit). Four (4) feet below, 4 horizontal feet from, or 1 foot above any door or gravity

•

air inlet into the building. Four (4) feet from electric meters, gas meters, regulators and relief equip-

•

ment.

24" (Less Economizer) 49" (With Economizer)

24" (Less Economizer)

36"

(With Economizer)

20"

72" With 36" Maximum Horizontal Overhang (For Condenser Air Discharge)

530.18-N11Y

Front

Cont’d.

FIG. 10

Unitary Products Group 11

- DIMENSIONS & CLEARANCES - DCE & DCG

Page 12

530.18-N11Y

GAUGE LINE ACCESS

40-3/8"

COMPRESSOR ACCESS

SUPPLY AIR ACCESS

5-1/2"

CONDENSER SECTION

RETURN AIR ACCESS

REAR VIEW

SUPPLY AIR

18-5/8"

5-1/8"

RETURN AIR

27-3/4"

EVAPORATOR SECTION

DUCT COVERS - Units are shipped with the bottom duct openings covered. An accessory flange kit is avail-

DOT PLUG (For pressure drop reading)

able for connecting side ducts. For

1. Remove the side panels from the supply and return air compartments to gain access to the bottom

FILTER ACCESS

supply and return air duct covers.

2. Remove and discard the bottom duct covers. (Duct openings are closed with sheet metal covers except when the unit includes a power exhaust option. T he covering consists of a heavy black paper composition.)

OUTDOOR AIR

40-1/2"

3. Replace the side supply and return air compartment panels. For

1. Replace the side panels on the supply and return air compartments with the accessory flange kit panels.

2. Connect ductwork to the duct flanges on the rear of the unit.

29-5/8" (15 TON)

39-5/8

39-5/8" (20 TON)

OUTDOOR AIR COMPARTMENT ACCESS

1" NPT FEMALE COND. DRAIN CONNECTION

DETAIL “X”

ACCESSORY SIDE SUPPLY AND RETURN AIR OPENINGS

bottom duct applications:

side duct applications;

FIG. 10

ECONOMIZER

SUPPLY AIR COMPARTMENT

POWER

EXHAUST

RAIN

HOOD

Return Air Compartment)

(on

MOTORIZED DAMPER RAIN HOOD (on Outdoor Air Compartment)

36"

66-1/2"

34-1/4"

ECONOMIZER AND

REAR VIEW

DETAIL "Y"

UNIT WITH RAIN HOODS

DET AIL “Y”

UNIT WITH RAIN HOODS

- DIMENSIONS & CLEARANCES (Cont’d.)- DCE & DCG

MOTORIZED DAMPER

POWER EXHAUST RAIN HOODS

FIXED OUTDOOR

HOOD

INTAKE (located on Return Air Compartment)

16-1/8"

36-1/4"

AIR

92"

LH VIEW

1" CONDENSTATE DRAIN (Must be trapped)

12 Unitary Products Group

Page 13

(

)

(kW)

(iwg)

(

)

(kW)

(iwg)

(

)

(kW)

(iwg)

(

)

(kW)

(iwg)

(

)

(kW)

530.18-N11Y

FIG. 11

FRONT

4 POINT LOADS

- FOUR AND SIX POINT LOADS

TABLE 7

- FOUR AND SIX POINT LOADS

UNIT

TOTAL A B C D

4 - POINT LOADS (LBS)

300 3,130 615 671 962 882

NOTE: These weights are with economizer, high heat, and the largest blower motor available.

UNIT

TOTAL A B C D E F

300 3,130 418 438 533 628 603 510

6 - POINT LOADS (LBS)

NOTE: These weights are with economizer, high heat, and the largest blower motor available.

FRONT

6 POINT LOADS

TABLE 8

BLOWER PULLEY

SPEED TURNS ESP OUTPUT INPUT ESP OUTPUT INPUT ESP OUTPUT INPUT ESP OUTPUT INPUT ESP OUTPUT INPUT

NOTES:

- SUPPLY AIR BLOWER PERFORMANCE

7500 CFM 8750 CFM 10000 CFM 11250 CFM rpm)OPEN:(iw 975 6.0* 1.4 5.9 4.9 1.0 7.3 6.0 0.5 8.8 7.2 - - - - - -

1005 5.0 1.6 6.2 5.1 1.2 7.7 6.3 0.7 9.2 7.6 0.1 10.9 8.9 - - 1040 4.0 1.8 6.6 5.4 1.4 8.1 6.7 0.9 9.7 8.0 0.3 11.4 9.4 - - 1070 3.0 2.0 6.9 5.7 1.6 8.5 7.0 1.1 10.2 8.3 0.6 11.9 9.8 - - 1100 2.0 2.1 7.3 6.0 1.8 8.9 7.3 1.3 10.6 8.7 0.8 12.4 10.2 0.2 14.3 11.7 1135 1.0 2.4 7.7 6.3 2.0 9.3 7.6 1.6 11.1 9.1 1.0 13.0 10.6 0.4 14.9 12.2 1165 0.0 2.6 8.0 6.6 2.2 9.7 8.0 1.8 11.6 9.5 1.3 13.5 11.0 0.7 15.5 12.7

1140 6.0 2.4 7.7 6.3 2.1 9.4 7.7 1.6 11.2 9.2 1.1 13.1 10.7 0.5 15.0 12.3 1180 5.0 2.7 8.2 6.7 2.3 9.9 8.1 1.9 11.8 9.7 1.4 13.7 11.2 0.8 15.8 12.9 1215 4.0 2.9 8.6 7.0 2.6 10.4 8.5 2.2 12.3 10.1 1.7 14.3 11.7 1.1 16.4 13.5 1255 3.0 3.2 9.1 7.4 2.9 11.0 9.0 2.5 12.9 10.6 2.0 15.0 12.3 1.4 17.2 14.1 1290 2.0 3.4 9.5 7.8 3.1 11.5 9.4 2.7 13.5 11.1 2.2 15.6 12.8 - - 1330 1.0 3.7 10.0 8.2 3.4 12.0 9.9 3.0 14.1 11.6 2.6 16.4 13.4 - - 1365 0.0 3.9 10.5 8.6 3.7 12.6 10.3 3.3 14.7 12.1 2.9 17.0 13.9 - - -

Blower performance is based on co ol i ng only unit, with fixed outdoor air, 2" T/A filters and a dry evaporator coil. Refer to pa ESP - External Static Pressure available for the suppl blower. * FACTORY SETTING

e 14 for additional static resistances.

bhp

and return air duct system. All internal unit resistances have been deducted from the total static pressure of the

DCE300

STANDARD DRIVE:

ACCESSORY DRIVE:

- BOT TOM DUCT CO NNECTIONS

bhp

(

COOLI NG APPLICATIONS)

12500 CFM

bhp

Unitary Products Group 13

Page 14

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(kW)

(iwg)

(

)

(kW)

(iwg)

(

)

(kW)

(iwg)

(

)

(kW)

(iwg)

(

)

(kW)

530.18-N11Y

TABLE 9

- SUPPLY AIR BLOWER PERFORMANCE

BLOWER PULLEY

SPEED TURNS ESP OUTPUT INPUT ESP OUTPUT INPUT ESP OUTPUT INPUT ESP OUTPUT INPUT ESP OUTPUT INPUT

rpm)OPEN:(iw

975 6.0 1.2 5.9 4.9 0.5 7.3 6.0 - - - - - - - - 1005 5.0 1.4 6.2 5.1 0.7 7.7 6.3 - - - - - - - - 1040 4.0 1.6 6.6 5.4 0.9 8.1 6.7 0.2 9.7 8.0 - - - - - 1070 3.0 1.8 6.9 5.7 1.1 8.5 7.0 0.4 10.2 8.3 - - - - - 1100 2.0 2.0 7.3 6.0 1.3 8.9 7.3 0.6 10.6 8.7 - - - - - 1135 1.0 2.2 7.7 6.3 1.6 9.3 7.6 0.8 11.1 9.1 - - - - - 1165 0.0 2.4 8.0 6.6 1.8 9.7 8.0 1.0 11.6 9.5 0.2 13.5 11.0 - - -

1140 6.0 2.2 7.7 6.3 1.6 9.4 7.7 0.9 11.2 9.2 - - - - - 1180 5.0 2.5 8.2 6.7 1.9 9.9 8.1 1.2 11.8 9.7 0.3 13.7 11.2 - - 1215 4.0 2.7 8.6 7.0 2.1 10.4 8.5 1.4 12.3 10.1 0.6 14.3 11.7 - - 1255 3.0 3.0 9.1 7.4 2.4 11.0 9.0 1.7 12.9 10.6 0.9 15.0 12.3 - - 1290 2.0 3.2 9.5 7.8 2.7 11.5 9.4 2.0 13.5 11.1 1.2 15.6 12.8 - - 1330 1.0 3.5 10.0 8.2 3.0 12.0 9.9 2.3 14.1 11.6 1.5 16.4 13.4 - - 1365 0.0 3.7 10.5 8.6 3.2 12.6 10.3 2.6 14.7 12.1 1.8 17.0 13.9 - - -

NOTES:

Blower performance is based on cooling only unit, with fixed outdoor air, 2" T/A filters and a dry evaporator coil. Refer to pa ESP - External Static Pressure available for the suppl blower. * FACTORY SETTING

7500 CFM 8750 CFM 10000 CFM 11250 CFM 1 2500 CFM

bhp

e 14 for additional static resistances.

and return air duct system. All internal unit resistances have been deducted from the total static pressure of the

DCG300

bhp

-BOTTOM DUCT CONNECTIONS(COOLING APPLICATIONS)

STANDARD DRIVE:

ACCESSORY DRIVE:

bhp

TABLE 10

- STATIC RESISTANCES*

DESCRIPTION

7500 8750 10000 11250 12500

ESP ESP ESP ESP ESP

IWG

AIRFLOW

IWG

CFM

IWG

DEDUCTIO NS: ( SUBTRACT VALUES BELOW FROM UNIT'S AVAILABLE ESP)

ALLOWANCE FOR WET COIL: 0.10 0.10 0.10 0.10 0.10 ECONOMIZER

RETURN DUCT): 0.06 0.09 0.11 0.14 0.18 18kW ELECTRIC HEAT: 0.31 0.43 0.56 0.71 0.87 36kW ELECTRIC HEAT: 0.38 0.52 0.68 0.87 1.07 54kW ELECTRIC HEAT: 0.62 0.84 1.10 1.39 1.72 72kW ELECTRIC HEAT: 0.68 0.93 1.21 1.54 1.90

ADDI T I ONS: (ADD VALUES BELOW TO UNIT'S A V AILA BL E ESP)

HORIZONT AL HORIZONT AL

TABLE 11

MOTOR SPEED

SIDE) SUPPLY DUCT: 0.31 0.26 0.27 0.31 0.41 SIDE) RETURN DUCT: 0.05 0.05 0.05 0.05 0.05

- POWER EXHAUST PERFORMANCE

STATIC RESISTANCE OF RETURN DUCTWORK, IWG

0.20.30.40.50.6

CFM KW CFM KW CFM KW CFM KW CFM KW

HIGH* 5250 0.83 4500 0.85 4200 0.88 3750 0.93 3000 0.99

MEDIUM 4900 0.77 3900 0.79 3500 0.82 2900 0.85 - -

LOW 44000.7237000.7430000.78 - - - -

Factory Setting

Power Exhaust motor is a 3/4 HP, PSC type with sleeve bearings, a 48 frame and inherent protection.

TABLE 12

MODEL

SIZE

25 TON

All motors have a nominal speed of 1800 RPM, a 1.15 service factor and a solid base. They can operate to the limit of their service factor because they are located in the mov ing air, upstream

of any heating device.

- BLOWER MOTOR AND DRIVE DATA

BLOWER

MOTOR

DRIVE

Stan-

Speed

dard

High

RANGE

(RPM)

975/1165

HP FRAME

15 254T 91 1LVP58B70A 7.5

EFF.

(%)

1140/1365 1B5V94 9.7 9.5 1-7/16 5VX840 84.0 1

Access

ADJUSTABLE MOTOR PULLEY FIXED BLOWER PULLEY

DESIG-

NATION

OUTSIDE

DIA. (IN.)

PITCH

DIA. (IN.)

BORE

(IN.)

DESIG-

NATION

OUTSIDE

DIA. (IN.)

PITCH

DIA. (IN.)

1B5V110 11. 3 11.1 1-7/16 5VX860 86.0 1

6.2-

1-5/8

7.4

BORE

(IN.)

DESIGNATION

14 Unitary Products Group

BELT

(NOTCHED)

PITCH

LENGTH

(IN.)

QTY.

Page 15

OPERATION

COOLING SYSTEM

The cooling section is a complete factory package utilizing an air-cooled condenser. The system is factory-charged with Refrigerant-22.

The compresso rs are hermetically sealed, internally sp rung and base-mounted with rubber-insulated hold-down bolts.

Compressors have inherent (internal) protection. If there is an abnormal temperature rise in a compressor, the protector will open to shut down the compressor.

PRELIMINARY OP ERATION COOLING

After the ini tial installa tion, the compres sors should be gi ven three false starts (energized just long enough to make a few revolutions) with 5-7 minutes delay between each start, before being put into ful l ti me service .

COOLING SEQUENCE OF OPERATION

NO OUTDOOR AIR OPTIONS - When the room ther mostat calls f or “first-stage” cooling, the low voltage control circuit from “R” to “G” and “Y1" is completed to energiz e compressors #1/2 (50% capacity), condenser fan motor #1, and the supply air blower motor (if the fan switch on the room thermostat is set in the ”A U TO" position).

When the thermostat calls for “second-stage” cooling, the low voltage con trol circui t from “R” to “Y2" is completed to energize compressor #3/4.

After the thermostat is satisfied and opens, all components will stop simultaneously. The blower motor will continue to operate if the fan switch on the room thermostat is set in the “ON” position.

ECONOMIZER WITH SINGLE ENTHALPY SENSOR - When the room thermostat calls for “first-stage” cooling, the low voltage control circuit from “R” to “G” and “Y1" is completed. The ”R" to “G” circuit 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 positi on. If the enthalp y of the ou tdoor air is be low 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" energiz es compressors #1/2, and co ndenser f an motor #1.

When the thermostat calls for “second-stage” cooling, the low voltage control circuit from “R” to “Y2" is completed. If the enthalp y of the outdoor ai r is below t he setpoi nt of the e nthalp y controller ( i .e. first stage ha s e ne r gi zed the ec on om izer ) , ”Y2" will energize compressors #1/2. If the outdoor air is above the setpoint, “Y2" will energize compressor #3/4.

ECONOMIZER WITH DUAL ENTHALPY SENSORS - The operation with the dual enthalpy sensors is identical to the single sensor e xcept that a second ent halpy se nsor is mounted in the retur n air. This return air sens or 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 - Thi s system op erates as specifie d abov e with o ne

530.18-N11Y

addition. The power exhaust motor is energized whenever the economizer is chosen by the enthalpy sensor for first stage cooling, “Y1". As always, the ”R" to “G” connection pr ovides minimum position but does not provide power exhaust operation.

MOTORIZED OUTDOOR AIR DAMPERS - This system operation i s th e sa me a s th e un it s wi th no ou tdoo r ai r op ti on s with one exception. When the “R” to “G” circuit is comp lete , the motorized damp er driv es open to a po siti on s et b y the d ampe r motor adjustment. When the “R” to “G” circuit i s opened, the damper spring ret urns fu ll y cl os ed .

CONTINUOUS BLOWER - Continuous blower operation is possible by closing the R to G circuit on the thermostat.

SAFETY CONTROLS

Each refrigerant system is equipped with the following safety controls:

1. A Suction Line Freezestat to protect against low evaporator temperatures due to a low air flow or a low return air temperature. (Opens at 26°F + 5°F and resets at 38°F + 5°F)

2. A High Pressure Cutout Switc h to protect against excessiv e discharge p ressu res due to a blocked conden ser c oil or a condenser moto r failure. (Opens at 380 psig + 10 and rese ts at 300 psig +10)

3. A Low Pressure Switch/Loss Of Charge to protect against loss of refrigerant charge. (Opens at 7 psig + 3 and resets at 22 psig + 5)

If either one of th e abo v e sa f et y cont rol s open s, that indi vidu al refrigerant system will be locked out. The other refrigerant system will con tinue in operat ion un less it too is e ff ected b y the same fault. The lock out of either system can be reset by opening the 24V circui t ei th er a t t he roo m t he rmostat or at the unit disconnect.

ELECTRIC HEATING - SEQUENCE OF OPERATION

WITH POWER TO UNIT AND THERMOSTAT IN THE HEATING MODE

Single-stage heating: (applies only to 18 KW heater, all other heaters MUST use a two-s ta ge t he rmostat :)

a) If the fan switch is in the “ON” position, the evaporator

blower motor contactor (3M) will be energized through terminal G to provide continuous blower operation. If the fan switch is in the “AUTO” position, the blower will operate only when there is a call for heating by the thermostat.

NOTE: All 240 & 480V heaters are provided with manual

reset backup protection limits. These will de-energize the heaters should the primary limit fail to open or the contactors fail to open in a failure mode.

b) Upon a call f or h eat by the thermostat , the heater co ntactor

(6M) will be energized.

c) The thermostat will cycle the electric heat to satisfy the

heating requirem en ts of th e co nd it ioned space.

Two-stage heating: (applies to all heaters except 18 KW): a) If the fan switch is in the “ON” position, the evaporator

blower motor contactor (3M) will be energized through terminal G to provide continuous blower operation. If the fan

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530.18-N11Y

switch is in the “AUTO” position, the blower will operate only when there is a call for heating by the thermostat.

b) Upon a call for first-stage heat by the thermostat, the heater

contactor (6M) (6M & 7M on 72 KW, 240V) will be energized.

If the second stage of heat is required, heater contactor (7M) will be energized. Note that on the 54 KW, 240V heater , heater contactors (7M & 8M) wi ll b e en erg ized and on the 72 KW, 240V heater, heater contactors (8M & 9M)

TABLE 9

- HEAT ANTICIPATOR SETTING

HEATER

18 36 0.29 0.29 54 0.29 0.58 72 0.58 0.58 18 36 0.29 0.29 54 0.29 0.29 72 0.29 0.29 18 36 0.29 0.29 54 0.29 0.29 72 0.29 0.29

VOLT AGE

208/230-3-60

460-3-60

575-3-60

SETTING, AMPS

TH1 TH2

0.29 -

will be energize d.

c) The thermostat will cycle the electric heat to satisfy the

heating requirem en ts of th e co nd it ioned space.

HEAT ANTICIPATOR SETPOINTS

It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater temperature swing in the co nditioned space. Reducing the value below th e correct setpoint will give shorter “ON” cy cles and ma y resul t in the lowering of the te mpertur e withi n the co ndit ioned s pace. Refer to the Heat Anticipator Setpoints table for the required .

GAS HEATING SEQUENCE OF OPERATION

The following sequence describes the operation of the gas heat section.

CONTINUOUS BLOWER With the room thermostat switch set to “ON”, the supply air

blower will operate cont inuousl y. The normally cl osed cont act “K5-1" provides 24 volt po wer to the “3M” cont actor . The “3M-1, 2 & 3" power contact s clos e an d the blower motor operates.

INTERMITTENT BLOWER With the room thermostat system switch set to the “AUTO” or “HEAT”

position and the fan switch set to “AUTO”, the supply air blower will operate after the room thermostat calls for heat and the time delay relay cl oses.

The “TH1" closes, the heat relay ”RW1" is energized. The “RW1-1” power contact cl oses energizin g the line voltage draft moto r. Th e “RW1-2" contact is also closed. As the speed of the draft motor reaches ap proximatel y 2500 RPM, the centrif ugal switch contact located on the end of the draft mot or shaft closes to power the first stage ignition module “IC1”.

After a brief pre-purge time, ignition module “IC1" will start the first stage ignitor sparking and will open the redundant valve located inside the first st age main g as va lve “GV1” to allow a flow of gas to only the first stage c arr yover tube. Only after the pilot flam e has been ignited a nd th e p r es en ce of pi lo t flame detected at th e “IC1” by a signal sent back through the flame sensor is sparking terminated and the first stage mai n gas v alv e open ed.

Gas flows into each of the main burners and is ignited from the carryover tube flame.

If “IC1” fails to detect a pilot flame, it will continue to try for a maximum of 85 seconds to ignite the pilot tube. If the pilot flame is not detected, then “IC1" will lock out furnace operation for 5 minutes, then retry ignition sequence.

At the same time power was supplied to the “RW1”, a parallel circuit activates “ETD” which closes the “ETD” contact after approximately 35 seconds and energizes “K5" which closes ”K5-2" and starts the blow er by energizing “3M”.

When “TH2" closes, heat relay ”RW2" is energized. The “RW2-1" contact is closed energizing the second stage ignition module ”IC2". “IC2" will immediately start the second stage ignitor sparking and will open the redundant valve located inside the second stage main gas valve ”GV2" to allow a flow of gas to the second sta ge carryo ver tube. Only after the pilot flame has been ig nited and the presence of pi lot flame dete cted at “IC2" by a signal sent back through the flame sensor is sparking terminated and the main gas valve opened.

Gas flows into each of th e se cond stage main burn ers and i s ignited from the carryo ver tube flame.

If “IC2" fails to detect a pilot fl ame, it will c ontinue to tr y for a maximum of 85 seconds to ignite the pilot tube. If the pilot flame is not detected, then ”IC2" will lock out furnace operation for 5 minutes, then retry ignition sequence. Note that the sec ond

stage furnace can operate even if first st age has locked out.

When the heating cycle is complete, “TH2" opens de-energizing the ”RW2" then “TH1" opens de-energizing ”RW1" and “ETD”,

FIG. 12

REDUNDANT VALVE

GAS MAIN

GAS VALVE

TO PILOT BURNER

- GAS VALVE PIPING

MAIN VALVE

TO MAIN BURNER

thus closing all gas valves. The blower motor will continue to run (approximately 45 seconds after the furnace is shut down) until “ETD” opens, de-energizing the “K5" relay and ”3M" contactor. The draft motor will continue to run for a brief post-purge cycle.

SAFETY CONTROLS

The control circuit includes the following safety controls:

1. Limit Control (LS). This control is located inside the heat exchanger compartment and is set to open at the temperature indicated in the Limit Control Setting Table. It resets automatically. The limit switch operates when a high temperature condition, caused by inadequate supply air flow occurs, thus shutting down the ignition control and closing the main gas valves and energizing the blower .

2. Centrifugal Switch (CS). If the draft motor should fail, the centrifugal switch attached to the shaft of the motor prevents the ignition controls and gas valves from being energized.

3. Redundant Gas Valve. There are two separate gas valves in the furnace. Eac h valv e cont ains a mai n and a red undant valve. The red undant valves are loca ted upstream of th e main gas valves. Should either or both of the main gas valves fail in the open position the redundant valves serve as back-ups and sh ut s off the flow of gas.

4. Flame Sensor Rod / 100% Ignition Control Lock-Out. If an ignition cont rol fai ls to detec t a signal from the flame sen sor indicating the pilot flame is properly ignited, then the main gas valve will not open. It will continue to try and ignite the pilot for a ma ximum of 85 secon ds, th en if the pilot f lame is not detected, the ignition control will lock out furnace operation until 24V power is removed from the module either at the unit or by resetting the room thermostat.

5. Rollout Switch. This switch is located above the main burners in the control compartment which in the event of a sustained ma in bur ner roll out sh uts of f and locks out both ignition controls closing both gas valves. The ignition controls lock out furnace op eration un til 24V pow er is remov ed from the controls either at the unit or by resetting the room thermostat. Note th e auto reset rollou t switch must reset

before allowing furnace operation.

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530.18-N11Y

FIG 13

IGN. CONTROL #2

IG N . C O N T R O L # 1

R O LLO U T S W .

SENSO R #1

GV2 GAS

VALVE

IG NITOR #2

BURNER COM PARTM ENT

-GAS VALVE AND CONTROLS

GV 1

GAS

VALVE

IG NITOR #1

SENSO R #2

TABLE 10

- LIMIT CONTROL SETTING

Capacity, MBH

Input Output

300 240 195 400 320 195

HEAT ANTICIPATOR SETPOINTS

It is important that th e an ti ci pa tor setpoint 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 correct setpoint will give shorter “ON” cycles a nd may result in the lowering of the temper ture within the conditioned space.

Gas Valve

Honeywell VR8440 White-Rodgers 36C68

Anticipator Setpoint

1st Stage 2nd Stage

0.30 amp 0.11 amp

PRE-START CHECK LIST

Complete the following checks before starting the unit.

1. C heck the type of gas being su pplied. Be sure that it is the same as listed on the unit nameplate.

2. Make sure that the vent and combustion air hoods have been properly instal le d.

START-UP

Limit Control

Opens, °F

6. Auxiliary Limit Switch (AUX) This control is located inside the heat exchanger compartment and is set to open at 190°F. It is a manual reset switch. If A UX limit trips, then the primary limit has not functioned correctly., Replace the primary limit

OPERATING INSTRUCTIONS

CAUTION: This fur na ce i s eq uipp ed w ith an i ntermittent pilo t

and automatic re-i gnition sys tem. DO NO T att empt to manually light the pilot.

TO LIGHT PILOT AND MAIN BURNERS:

1. Turn “off” electric power to unit.

2. Turn room thermostat to lowest sett ing.

3. Turn gas valve kn ob t o “on” position.

4. Turn “on” electric power to unit.

5. Set room thermostat to d esired temperature. (If thermostat “set” temperature is above room temperature, pilot burner ignition will occur and, after an interval to prove pilot flame, main burners will ignite).

TO SHUT DOWN:

1. Turn “off” electric power to unit.

2. Depress knob of gas valve while t urning to “off” position.

POST-START CHECK LIST (GAS)

After the entire control circuit has been energized and the heating section is operating, make the follo w in g ch ecks:

1. Check for gas le aks in the uni t pipi ng as wel l as t he supp ly piping.

2. Check for correct manifold gas pressures. See “Checking Gas Input”.

3. Check the supply gas pres sure. It m u st be w it hin the limits shown on rating nameplate. Supply pressure should be checked w ith all g as applia nces in the b uildi ng at f ull fire. At no time should the standby gas line pressure exceed 13", nor the operating pressur e drop below 5.0" for natural gas units. If gas pressure is outside these limits, contact the

ON-OFF CONTROL

HIGH FIRE ADJ. (UNDER SCREW)

PILOT ADJ. (UNDER SCREW)

FIG. 14

- TYPICAL GAS VALVE

local gas utility for correctiv e action.

MANIFOLD GAS PRESSURE ADJUSTMENT

Small adjustments to the high-fire gas flow may be made by turning the pressure regul ator adjusting scre w on the automatic gas valve. Refer to figure below.

Adjust as follows:

1. Remove the cap on the regulator. It’s located next to the push-on electrical terminals.

2. To decrease the gas pressure, turn the adjusting screw

counterclockwise.

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BURNER ASSEMBLY BRACKET

Reve rse the abo ve procedure t o replace the asse mblie s. M ake sure that burners are level and seat at the rear of the heat exchanger.

FLAME SENSOR BULB

1/8" GAP BETWEEN CARRY-OVER TUBE AND FLAME SENSOR BULB

CARRY-OVER TUBE

FIG. 15

- PROPER FLAME ADJUSTMENT

3. To increase the gas pressure, turn the adjusting screw

clockwise.

NOTE: The correc t manifold pressure for these furnaces is

3.65 IWG ±0.3.

PILOT CHECKOUT

The pilot flame should envelope the end of the flame sensor . Refer to Proper Flame Adjustment figure. To adjust pilot flame, (1) remove pilot adjustment cover scre w, (2) increase or decrease the clearance for air to the desired level, (3) be sure to replace cover screw after adjustment to prevent possib le gas leakage.

Put the system into oper ation and ob serve th rough compl ete cycle to be sure all co nt rol s fu nc ti on pr op erly.

BURNER AIR SHUTTER ADJUSTMENT

Adjust burn er shutters so no yellow fla me is obser ved in the heat exchanger tubes.

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 RPM for the supply air blower and the motor pulley adjustment (turns open) can be deter mined from the Blower Performance Data Table.

A high speed drive accessory 1LD0435 (containing a smaller blower pulley and shorter belts) is available for applications requiring the supply air blo wer to pro duce high er CFM’s and/or higher static pressures. Refer to the Blower M otor and Drive Data T able.

Note the following:

BURNER INSTRUCTIONS

To check or change burners, pilot or orifices, CLOSE MAIN MANUAL SHUT-OFF V ALVE AND SHUT OFF ALL ELECTRIC POWER T O THE UNIT.

1. R emove the screws holding ei ther end of the man ifold to the burner supports.

2. Op en the un io n f itti ng in the g as su pp ly li ne ju st up str ea m of the unit gas v alve an d downstream f rom the main manu al shut-off valve.

3. Remove the gas pipi ng clo su re pa ne l.

4. Disconnect wiring to the gas valves and spark ignitors. Remove the manifold-bur ner ga s valve assembly by lift in g up and pulling back.

Burners are now accessible for service.

FIG.17 -

BELT ADJUSTMENT

1. The supply air CFM mus t be w ithin the l imitat ions s hown in Unit Application DataTab le.

2. Pulleys can be adjusted in half turn increments.

3. The tension on the belts should be adjusted as shown in the belt adjustmen t fi gu re be low.

Start the supply air blower motor. Adjust the resistances in both the supply an d the retur n air du ct system s to balanc e the air distribution throughout the conditioned space. The job specifications may require that this balancing be done by someone other tha n the equipment installe r.

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

FIG. 16

- TYPICAL FLAME APPEARANCE

18 Unitary Products Group

1. Remove the two 5/16 " dot plugs fro m the blo wer motor a nd the filter access pan el s .

Page 19

2. Insert at least 8" of 1/4 inch tubing in to each of thes e holes for sufficient pene tration into the air flow on both side s of the indoor coil.

NOTE: The tubes must be inserted and held in a position

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

3. Using an inclined manometer, determine the pressure drop across a dry evaporator coil. Since the moisture on an evaporator coil may vary gr eatly, measuring the pressu re drop across a wet coil under field conditions would be

inaccurat e. To assure a dry coil, the co mpres sors should be deactivated while the test is being run.

4.Knowing the pressure drop across a dry coil, the actual CFM through the unit and clean 2" filters, can be determined from the curve in the Pressure Drop Verses Supply Air CFM figure.

WARNI NG:Failure to prope rly adjust th e total syst em air quan -

530.18-N11Y

NOTE:

DE-ENERGIZE THE COMPRESSORS BEF ORE TAKING ANY TEST MEASUREMENTS TO ASSURE A DRY INDOOR COIL.

ADJUSTMENT OF TEMPERATURE RISE

The temperature rise (or temperature difference between the return air and the heated air from the furnace) must lie within the range shown on the ETL rating plate.

After the te mperat ure r ise has been de ter mine d, the c fm can be calculated as follows:

After about 20 minutes of operation, determine the furnace temperature rise. Take readings of both the return air and the heated air in the ducts (about six feet from the furnace) where they will not be affected by radiant heat. Increase the blower cfm to decrease the temperature rise; decrease the blower cfm to increase the rise. Refer to the Blo wer Motor And Drive Data tab le.

BELT DRIVE BLOWER All units have belt drive single-speed blower motors. The

variable pitch pu lley on the blower motor can be adjust ed to obtain the desired supply air CFM. Tighten belts enough to prev en t s li pp in g. but do not over ti gh te n. Belt deflection should be between 1/4" and 1/2" per foot. Refer to the table for Blower Motor And Drive Data.

CHECKING GAS INPUT

NATURAL GAS

FIG. 18 -

PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUP PLY AIR CF M

tity can result in extensive blower damage.

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

CFM =

Btuh Input x 0.8

1.08 x

F Temp. Rise

1. Turn off all other gas appliances connected to the gas meter.

2. With the furnace turned on, measure the time needed for one rev olution of t he hand on the smallest dia l on the met er. A typical gas meter usually has a 1/2 or a 1 cubic foot test dial.

3. Using the number of seconds for each revolution and the size of the test dial increment, find the cubic feet of gas consumed per hour from th e Gas Ra te Table.

TABLE 11

Example: By actual measurement, it takes 13 seconds for the hand on the 1-cubic foot dial to make a revolution with just a 300,000 Btuh furnace running. Read across to the column in the table above , headed “1 Cubic F oot”, where y ou will see that 278 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 278 x 1050 (the Btu rating of the gas obtained from the local gas company). The result is 292,425 Btuh, which is close to the 300,000 Btuh rating of the furnace.

- GAS RATE - CUBIC FEET PER HOUR

Seconds

for One

Rev.

4 6 8

12 14 16 18 20

22 24 26 28

Size of Test Dial

1/2 cu. ft. 1 cu. ft.

450 300 228 180

150 129 113 100

90 82

75 69 64

900 600 450 360

300 257 225 200 180

164 150 138 129

SECURE OWNER’S APPRO VAL

: When the system is func ti oning properly, secure the owner’s ap proval. Show him the location of all disconnect switches and the thermostat. Teach him how to start and stop the unit and how to adjust temperature settings within the limitations of the system.

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530.18-N11Y

MAINTENANCE

If the actual input is not within 5% of the furnace rating (with allowance being made for the permissible range of the regulator setting), replace the orifice spuds with spuds of the proper size.

NOTE To find the Btu input, multiply the number of cubic feet of

gas consumed per hour by the Btu content of the gas in your particular locality (contact your gas company for this information - it varies widely from city to city.)

NORMAL MAINTENANCE

CAUTION: Prior to any of the following maintenance proce-

dures, shut off all electric power to the unit to prev en t pe rso na l in ju ry.

Periodic maintenance normally consists of changing or cleaning filt ers and (u nder some c onditi ons) cle aning t he main burners.

FILTERS - Inspect once a month. Replace disposable or clean permanent type as necessary. DO NOT replace permanent type with disposable. The dimensional size of the replacement filter must be the same as the replaced filter.

MOTORS Outdoor f an mo tors are p ermanently l ubricated and requ ire no

maintenance.

V entor motor is factory lubricated for an estimated 10 year life.

Indoor Blower Motor and Drive - The indoor blower motor features ball bea rin gs that do not req uire pe rio dic lubr ica tion. Periodic lubrication of the motor and bearings can extend the life of com po ne nt s but is optional.

CAUTION: Damage can occur if the bearings are overlubri-

cated. Use grease sparingly.

WARNING:P erform all maintenance op er at ions 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 def ectiv e parts as required.

If desired, every three years remove both pipe plugs at each end shell and clean out any hardened grease or foreign matter. Replace one plug on each end with a clean grease fitting. Using a low pressure grease gun, pump grease (Chevron SRI-2 or equivalent) into the bearing cavity until new grease shows at the open port. Do not over lubricate. Run the motor for ten minutes until excess grease is purged from the cavity. Replace the plugs.

Units are supplie d with blower sh aft bearings that do no t require maintenance but may be relubricated if desired. Every three years, using a low pressure grease gun, pump grease into the bearing grease fitting until grease j ust begins to s how at the seals. Do not over lubricate. Use any lithium base grease recommende d for ball bearing service.

OUTDOOR COIL - Dirt should not be allowed to accumulate on the outdoor coil surface or other par ts in the air circuit. Cleaning sh ould be as often a s nec es sar y to keep c oi l cle an. Use a brush, vacuum cleaner attachment, or other suitable 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 damage d.

GAS HEATING UNITS BURNER & PILOT - Periodically (at least annually at the

beginning of each heating season) make a visual check of the pilot and main burner flame. If necessary, adjust main burner primary air shutters to give a distinct, sharp blue flame as explained under “BURNER AIR SHUTTER ADJUSTMENT”. If it is not possibl e to adjust f or the proper fla me, the b urners may need cleaning.

TO CLEAN BURNERS - Remove them from the furnace as explained in “Burner Instructions”. Clean burners wi th hot water applied along to p of the burner.

COMBUSTION AIR DISCHARGE - Visually inspect discharge outlet periodical ly to make su re that the b uildup of soo t and dirt is not excessive. If necessary, clean to maintain adequate combustion air discharge.

CLEANING FLUE PASSAGES AND HEATING ELEMENTS With proper combustion adjustment the heating element of a

gas fired fur nace will seldom need cleaning. If the element should become so ot ed , it can be cleaned as fo llows:

1. Remove the burner assembly as outlined in “BURNER INSTRUCTIONS”.

2. Remove the roof over the gas heat section.

3. At the top plate from the top draft blower housing and the top draft blower wheel.

4. Remove the screws holding the top of the flue collector box. Carefully remove the top of the flue collecto r box without ripping the adjacent insulation. Then remove the center divider plate separating the upper and lower flu e boxes.

5. On the inside of the flue collector box, remove the flue baffles from the tube interiors. Note the last bend of the baffle fits tigh tly against the tube forci ng the end of the baffle to lock into t he tube collar. This collar is formed w hen the tube is expanded into the end sheet. To remove, move the end of the baffle toward the center of the tube releasing the end of the baffle from the tube co llar, then pull straight out of the tube.

6. Using a wire brush on a flexible wand, brush out the inside of each heat e xchang er from the b urner inlet and fl ue outlet ends.

7. Brush out the inside of the flue collector box and the flue baffles.

8. Run the wire brush down the vent hoods from the flue collector end.

9. I f soot buil d-up is par t icular ly b ad, remove the ven t motor and clean the wheel and housin gs. Run the wire brush down the flue extentions at the outlet of th e vent housings.

Do not per mit the hot co ndenser air dis charge to be obstructed by overhanging structures of shrubs.

20 Unitary Products Group

FIG. 19

- TYPICAL FLUE BAFFLE INSTALLATION

Page 21

TROUBLESHOOTING

530.18-N11Y

10.After brushing is complete, blow all brushed areas with air or nitrogen. Vacuum as need ed .

11.Replace parts in the order they were removed in Steps 1 thru 4.

12. When replacing the center and top of the flue collector box, be careful not to tear the adjoining insulation.

13.Ensure that all seams on the vent side of the combustion system are air tight. Apply a high temperature (+500°F) sealing compound where needed.

WARNING:Troubleshooting of components necessarily re-

quires open ing the electr ica l contro l box with th e power connected to the unit. Use extreme care when working with live circuits! Check the unit nameplate for the correct line voltage and set the volt meter to the corr ect ra nge before maki ng any connections with line terminals.

WARNING: Pr ior to any of the following maintenanc e proce-

dures, shut off all electric power to the unit to prev en t pe rso na l in ju ry.

CAUTION: Label all wires prior to disconnection when servic-

ing controls. Wiring errors can cause improper and dangerous oper at io n. Verify prop er operation afte r servicing.

NOTE: To find the Btu input, multiply the n umber of cubic f eet of

gas consumed per hour by the Btu content of the gas in your particular locality (contact your gas company for this information - it varies widely from city to city.)

1. The indoor blower motor is a non-inherently protected three-phase motor. Protection is provided by an overload relay f or o v erc urrent a nd f uses for short circuit. I f th e mo tor fails to run, check the line voltage circuit and control voltage circuit per the following procedure:

a. If the Indoor Blower Motor does not operate, check

visually that contactor M3 is pulled in. If so, check for line voltage betwee n al l th ree pha se s at the lin e terminals of the Blower Overload Relay (BOR). If line voltage is found, check the l eads to th e blower mot or for open circuit. If line voltage is found at the motor leads (inside the conduit box on the motor shell), disconnect the motor and check f or open windin gs per the motor wiring diagram. If open windings are found, replace the motor. If line voltage is not found at th e BOR , trac e the lead s back to the field supp ly terminal block, check ing for an open circuit or blown fuses.

b. I f the contactor M3 is not pul led in, check for control

voltage (24V) at the M3 coil. If voltage is found, replace the contactor . If control v oltage is not f ound at M 3, check for voltage across terminals 95 & 96 of the BOR. If voltage exists, the BOR is open on overload. The BOR should be set to the auto reset position. The BOR must cool down in order to reset. If the BOR will not reset, replace the BOR. If the BOR resets and M3 pulls in, but the indoor blower moto r wi ll sti ll not r un, refer to para . (a) for troubleshooting the line voltage supply circuit. If control vol tage is not f ound at the BOR, trace the circuit back to the relay board and thermostat per the unit wiring diagram. Replace any defective components.

2. Draft motor operates and furnace lights but supply air blower does not start after a short time delay with room thermostat fan switch set to “AUTO”.

a. Set fan switch to “ON”. If blower motor runs, go to Step f.

If it does not, check to see if line voltage is being supplied to the contac ts of the contactor (M3), and if the contactor is pulled in. Check for loose wiring.

b. If contactor (M3) is pulled in, proceed with the trou-

bleshooting steps indicated in Step 1 above.

c. If (M3) is pulled in and the blower motor still does not

run, repl ace the blower motor.

d. If (M3) is not pulled in, check for 24 volts at the (M3) coil.

If 24 volts is pres en t, repl ac e th e (M3 ) contactor.

e. If 24 volts is not present at the (M3) coil, check for loose

24 volt wiring back to the relay board. Check control wiring to the room thermostat. If all is fine, replace the relay board .

f. If the blower motor runs with the fan switch in the “ON”

position but does not run soon after the furnace has ignited with the f an s witch in the “AUTO” position, check for loose 24 volt wirin g between th e relay board in the main control box, the Mate-N-Lok connector in the partition between th e e vap orator and gas hea t sectio ns and the time delay relay (ETD).

g. If all control wiring is fine , check fo r 24 vo lts at th e rela y

board. If 24 volts is present, replace the relay board. If 24 volts is not present, replace the (ETD) relay.

NOTE: The furna ce may sh ut itsel f down on a hig h temp era-

ture conditio n during the proc edure, but this will not effect the test if it is done within 5 minutes of furnace shut-down.

3. The supply air blower operates but the draft motor does not when the room the rmostat is set to c all f or he at an d the f an switch in the “ON” posi ti on .

a. The draft motor has inherent protection. If the motor shell

is hot to the touch, wait for the internal overload to reset.

b. If the moto r shell is cold wi th the room the rmostat calling

for heat, check for line voltage at the motor’s Mate-N- Lok conne ctor attached to the evaporator partition . If line voltage is present, replac e the draft motor.

c. If line voltage is not present, chec k for li ne voltag e at the

heat relay (RW1) contacts in th e main contro l box and check to see if the (RW1) is pulled in.

d. If the (RW1) relay is pulled in, check for a loose line

voltage co nn ec ti on.

e. If the (RW1) relay is no t pu ll ed in, c heck for 24 volts at

the (RW1) coil. If 24 volts is present, replace the (RW1) relay. If 24 volts is not present, check for a loose 24 volt connection back to the relay board and check the connections from t he room t hermostat to th e rela y board. If all connections are correct, replace the relay board.

Cont’d.

Unitary Products Group 21

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530.18-N11Y

TROUBLESHOOTING

4. The draft motor runs but the furnace does not light and the sparker does not sp ark.

a. The ignition control (IC1, IC2 ) may be loc ked ou t due to

either a fla me roll out or 100% s hut off. These safety features are described above. If lock-out has occurred, 24V must be remov ed from the igniti on cont rols. This is done at the unit or by resetting the room thermostat. After resetting 2 4V, check fo r proper f urnace oper atio n. If lock-out continues to occur, locate the source of the problem and co rrec t.

b. Check all 24 volt connections from the relay board to

and in the gas hea t sect ion. Check low vo ltage connec tions to the (ETD) located in the control box.

c. If the furnace is hot, it may be out on an over-tempera-

ture condition, wait for limit reset.

d. If the furnace is cold, check for 24 volts at wire 241

attached to the electronic time delay (ETD) located in the main control box. If 24 volts is not found, replace the ETD.

e. With the draft motor running, check for 24 volts at

terminal 4 of (RW1-2) and (RW2-1). If 24 volts is not present, the centrifugal switch (CS) has not closed or has gone bad. Check the li ne v olt age to t he unit - if it is correct, replace th e draft motor . If line voltage i s low , call the power compan y.

- Cont’d.

d. If 24 volts is present, remove the pilot burner and

remove the pi lot orifice fr om the pilot b urner . T he orifice is removed in the direction opposite the flow of gas. Inspect the o rific e for obstruc tion. If it is clear, replace the main gas valve.

6. The sparker sparks at the p ilot b urner but the pilo t does n ot ignite and a gas odor is detected at the draft motor outlet.

a. Adjust the pilot adjust screw on the gas valve as de-

scribed in “PILOT CHECKOUT”.

b. Check the supply pressure as described in “POST

ST ART CHECK L IST”. Mak e adjustment s as necessary .

c. Check the pilot orifice for obstruction as described in

para. 5d. Clean as needed but the problem should not be the gas valve.

7. The pilot burner ignites but the sparker continues to spark and the main bu rners do not ignite.

a. Make the same chec ks and ad justme nt as desc ribed in

para. 6.

b. Make sure that the pil ot b urner is not be nt or damage d. c. Make sure that the ground connections at the pilot

burner, gas valve and ignitor control are intact. Check the high tension wire for good electrical connection. If all are intact, replac e th e ig ni tor module.

f. Check for 24V at terminal 2 of (RW1-2 and RW2-1). If

24V is not present, check for 24V at (RW1 and RW2) relay coils. If these relays are pulled in, then check for a loose connec tion at terminal 2 an d terminal 4 of each relay. If no problem is found, then replace (RW1 and/or RW2) as require d.

g. I f 24 volts is presen t at the ignitor cont rols, check all

control wiring at the ignitor controls and the high tension wire to the ignitors. Check that the ground wires from the ignitor controls , the gas v alves and pilot b urners are all intact a nd mak ing go od ele ctrical conn ection . Check to make sure that the ceramic insulator on the pilot ignitors or sensors is not broken or cracked, if all are intact, replace the ignition control IC1 or IC2.

5. The draft motor runs and the sparker sparks at the pilot burner but the pilot does not ignite and a gas odor is detected at the dr aft motor outlet.

a. C heck to make sur e gas is be ing supplied to the unit.

Make sure that the gas pressure to the unit is within the proper limits as describe d in the “POST START CHECK LIST” and that the pilot adjust scr ew is allowing s ome flow of gas as described in “PILOT CHECKOUT”.

b. Check all wiring between the ignitor control and the gas

valve. Check to make sure the ground connections are intact.

c. If the wiring is in tact, chec k f or 24 vo lts across terminals

“PV” and “COMMON” on the ign itor c ontro l. If 24 volts is not present, replace the ignitor control.

not

8. The pilot burner lights and the spark stops but the main burners do not light.

a. C heck electr ical c onnectio ns betwee n the igni tor con-

trol and the gas v alve . If intact , check f or 24 v olts acro ss terminals “MV” and “COMMON” terminals. If no voltage detected, replace ignitor control. If voltage is present, replace gas valve.

9. Furnace lights with roll-out or one burner has delayed ignition.

a. Make sure that the pilot b u rner is al ig ne d p r op erly w i th

the carryover as described in “PILOT CHECKOUT”.

b. Make sure that the carryov ers on adj oining b urners are

screwed fast and are level with respect to one another.

10. Main burners light but exhibit erratic flame characteristics. a. Adjust air shutters as described in “BURNER AIR

SHUTTER ADJUSTMENT”.

b. Check the main burner orifices for obstruction and

alignment. Removal procedure is described in “BURNER INSTRUCTIONS”. Clean or re place bur ner orifices and burners as needed.

22 Unitary Products Group

Page 23

530.18-N11Y

REPLACEMENT PARTS

COMPRESSOR SECTION

Hermetic compressor

•

Compressor mounti ng

•

MOTOR SECTION

Blower motor

•

Fan motor

•

Ventor motor

•

ELECTRICAL SECTION

Ignition control

•

Relay board

•

Contactor

•

Circuit breaker

•

Temperature controls

•

Capacitors

•

Relays

•

Transformers

•

Connectors

•

TO OBTAIN PARTS INFORM ATION: Replacem ent pa rts and in form at io n fro m OU R c urr e nt parts lis t for this unit are available to your servicing contractor through our local distributor. The name and address of our nearest distributor may be obtained by consulting the Yellow Pages of a local tele phon e direc tory.

IMPORTANT:

complete model number listed on the rating plate located on your unit. See page 2 for Product Nomenclature.

WARNING: IMPROPER INSTALLA TION, ADJUSTMENT, SERVICE OR MAINTENANCE CAN CA USE INJUR Y OR PR OPERTY DAMA GE. CONSUL T A Q UAL IFIED INSTALLER, SERVICE A GENCY OR YOUR LOCAL GAS SUPPLIER FOR INFORMA TION OR ASSISTANCE.

In order to supply the correct part or information from the parts list, our distributor will need to be provided with the

GAS HEAT SECTION

Heat exchanger

•

Gas valve

•

Pilot

•

Flame sensor

•

Spark ignitor

•

Gas manifold

•

Gas burner

•

AIR MO VING SECTION

Blower wheel

•

Blower wheel housing

•

REFRIGERANT SECTION

Evaporat or co il

•

Evaporat or co il hea der

•

Expansion valve assembl y

•

Condenser coil

•

Condenser coil header

•

FABRICATED PARTS SECTION

Panels

•

Posts

•

Covers Drain pans

•

Base rails

•

Air hoods

•

MISCELLANEOUS SECTION

Air inlet hood screen

•

Fan gu ard

•

Air filters

•

Unitary Products Group 23

Page 24

Code: SBY

530.18-N11Y