York D2CG 072, D7CG 036, D7CG 048, D7CG 060 User Manual

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SUNLINE 2000

GAS / ELECTRIC

SINGLE PACKAGE AIR CONDITIONERS

INSTALLATION INSTRUCTION

CAUTION

SCROLL COMPRESSORS OPERATE IN ONLY ONE DIRECTION.

If the compressor is experiencing:

- low amperage draw

- similar discharge and suction pressure

- increased noise level It is operating in reverse.

Switch two line voltage connections to correct.

GENERAL

YORK Model DCG units are single package air conditioners with gas heat desig ned fo r outd oor in st alla tion on a roof top or a slab.

The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory-installed and tested. The units require only electric power, gas piping and duct connections at the point of installation.

The gas-fired heaters have aluminized steel tubular heat exchangers and spark ignition with intermittent pilot.

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

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 car rier’s freig ht bill. A sepa rate request for inspec tion by the carr ier’s agent sho uld 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 eq uipment is availa ble in the followi ng reference form s:

55.70-N1 -General Installation

•

55.70-N2 -Pre-start & Post-start Check List

•

530.18-N1.2 V -Economizer Ac ce ss or y

•

530.18-N1.13V -M an. Out door Air Damp er Acc y 0-3 5%

•

530.18-N1.14V -Man. Outdoor Air Damper Accy 0-100%

•

Supersedes: 530. 18 -N 8 Y (2 95)

MODELS D7CG 036, 048 & 060 (10 SEER)

MODEL D2CG 072 (9 EER)

(STYLE A & Belt Drive Option)

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance

If you smell gas:

1. Open windows

2. Don’t touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

530.18-N1.12V - Mot oriz ed O utdo or Air Damp er Acc y.

•

530.18-N1.8V -Coil Guard

•

530.18-N2.11V -Low NOx Accessory

•

530.18-N8.2V -High Altitude Accy. (Natural Gas)

•

530.18-N8.3V -High Altit ud e Ac cy. (Propane)

•

530.18-N8.4V -Gas Piping Accessory

•

530.18-N8.12V -Propane Conver sion Accessor

•

690.15-N25V -Low Ambien t Access or y

•

Renewal Parts:

Refer to Part s Manual for comple te listing of repla cement

•

parts on this equipment.

All forms referenced in this instruction may be ordered from:

Publications Distribution Center Unitary Products Grou p P.O. Box 1592, York, P A 17405

APPROVALS

Design certified by CGA and UL listed as follows:

1. For use as a forc ed air furnace w ith cooling unit .

2. For outdoor installation only.

3. For installation directly on combustible flooring or, in the U.S.A., on wood flooring or Class A, B, or C roof covering material.

4. For use with natural gas and/or propane (LP) gas . Not suitable for use with conventional venting systems.

530.18-N8Y (1096)

035-14838

FOR YOUR SAFETY

Installer should pay particular attention to the words: the instal lation ea sier . Cautio ns are giv en to prev ent equip ment dam age. W arnings are given to alert installer that personal injury and/or equipment damage may result if installation procedure is not handled properly.

NOTE, CAUTION

and

WARNING

. Notes are inte nd ed to cl arif y o r make

CAUTION

THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUCTIONS AND ANY APPLICABLE LOCAL, STA TE, AND NA TIONAL CODES INCLUDING, BUT NOT LIMITED TO, BUILDING, ELECTRICAL, AND MECHANICAL CODES

WARNING

INCORRECT INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY, PROPER T Y DAM AGE AND/ OR DEATH.

WARNING

DE-ENERGIZE THE ELECTRICAL POWER AND TURN OFF THE GAS SUPPLY TO THE UNIT BEFORE ATTEMPTING TO INSPECT, REPAIR OR PERFORM MAINT ENANCE TO THE UNIT.

530.18-N8Y

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

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

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

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

Thermostat.................. ........ ........ ........ ........ ........ ........ ........ .4

Power and Control Wiring.................................................... 4

Blower Speed Selection....................................................... 4

Scroll Compressors....................................................... ....... 4

Combustion Discharge........... .. .. .. .......................... .. ...........4

Disconnect Switch Bracket For Optional Belt-Drive ............ 5

Gas Piping .......................................... .. .............. .............. ... 5

Gas Connection.................. .. .. .. .. .............. .............. .............6

L.P. Units, Tanks and Piping ................................................ 6

Low NOx Application......... ...... ...... ...... ...... ...... ...... ...... .... .....6

Ven t and Comb usti on Air Hood s............. .... .... .... .... .... .... .... .7

Optional Economizer Rain Hood...................................7 & 8

OPERATION

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

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

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

Heating Sequence of Operation ........................................15

Safety Controls (Heating) ..................................................15

Heat Anticipator Setpoints ................................................. 16

Pre-Start Check List...........................................................16

START-UP

Operating Instructions........................................................ 16

Post-Start Check List (Gas)............................................... 16

Manifold Gas Pre ssur e Adju st ment.................... .... .... .... .. .16

Pilot Checkout.................................................................... 17

Burner Instructions.............................................................17

Burner Air Shutt er Adju stment............ .... ...... ...... ...... ...... ...17

Supply Air Blower and Temperat ure Rise Adjus tment.......17

Checking Gas Input ........................................................... 18

Secure Owner’s Approval.................................................. 18

MAINTENANCE & TROUBLE SHOOTING

Normal Maintenance....... .. .. .. .............. .............. .............. ... 19

Cleaning Flue Passages and Heating Elements............... 19

Troubleshooting .........................................................19 & 20

TABLES

No. Description Page

1 Unit Applicatio n Da ta............ .... .... .... .... .... .. 3

2 Gas Heat Application Data.......................... 4

3 Pipe Sizing .... .................... .................. ....... 5

4 Static Resistances ...................................... 8

5 Physical Data.............................................. 9

6 Supply Air Blower Perf

. 3 - 6 Ton Direct-Drive

7 Motor & Drive Data-Belt-Drive Blower........ 9

8 Supply Air Blower Perf. 3 & 4 Ton Belt-Drive 10

9 Supply Air Blower Perf. 5 & 6 T on Belt-Drive 11

10 Electrical Data Direct- D ri ve.. .. ..................... 12

11 Electrical Data Belt-Drive............................ 12

12 Superheat, 036 ........................................... 12

13 Superheat, 048 ........................................... 13

14 Superheat, 060 ........................................... 13

15 Superheat, 072 ........................................... 13

16 Limit Control Setting ................................... 16

17 Belt Drive Supply Air Mot or Pulle y Adj........ 17

18 Gas Rate - Cubic Feet Per Hour ................ 18

FIGURES

No. Description Page

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

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

3 External Supply Connecti on ....................... 6

4 Bottom Supply Connection......................... 6

5 Ven t and Comb usti on Air Hood s......... .... .... 7

6 Economizer Rain Hoo d Assem bly.............. 7

7 Enthalpy Setpoint Adjustment..................... 8

8 Center of Gravity......................................... 9

9 Dimensions and Clearances....................... 14

10 Gas Valve Piping........................... .............. 15

11 Gas Valves.................... .......................... .. .. 16

12 Proper Flame Adjustm ent.................. ...... ... 17

13 Typ ical F lam e Ap pear ance...................... ... 17

14 Belt Adjustment.................... .......... .......... ... 17

15 Press. Drop versus Supply Air CFM........... 18

PRODUCT NOMENCLAT URE

D 7 C G 4N

PRODUCT CATEGORY

D = Single Package Air Conditioner (Air Cooled)

PRODUCT GENERAT ION

2 = 2nd Generation

7 = 7th Generation

PRODUCT IDENTIFIER

CG = Gas/El ectric

2 Unitary Products Group

NOMINAL COOLING

CAPACITY

036 = 3 Ton 048 = 4 Ton 060 = 5 Ton 072 = 6 Ton

0 030 6 2 5

FACTORY INSTALLED

HEAT

N = Gas Heat Installed

VOLTAGE CODE

06 = 208/230-1-60 25 = 208/230-3-60 46 = 460-3-60 58 = 575-3-60

NOMINAL GAS HEATING

OUTPUT CAP ACITY

040 = 40 MBH 060 = 60 MBH 079 = 79 MBH 099 = 99 MBH

INSTALLATION

LIMITATIONS

These units mu st be installe d in accorda nce with the cu rrent editions of the following national and local safety codes: In the U.S.A.:

1. National Electrical Co de AN SI /N F PA No . 70 .

2. National Fuel Gas Code Z223.1.

3. Gas-Fired Central Furnace Standard ANSI Z21.47-1993.

4. Local gas utility re quirements. In Canada:

1. Canadian Electrical Code CSA C22.1

2. Current Gas Installation Codes CAN/CGA-2.3-M93.

3. Local plumbing and was t e water codes.

4. Other applicable local codes. Refer to Table 1 for Unit Application Data and to T able 2 for Gas

Heat Application Data. If components are to be added to a unit to meet local codes, they

are to be installed at the dealer’s and / or the customer’s expense. Size of unit fo r pr op os ed ins tall at io n sh ou ld be base d on hea t

loss / heat gain calculation made according to the methods of Air Conditioning Contractors of America (ACCA).

TABLE 1

Voltage Variation Min. / Max.

Supply Air CFM, Nom. 1200 1600 2000 2400 Wet Bulb Temperature (°F) of

Air on Evaporator Coil, Min. / Max.

Dry Bulb Temperature (°F) of Air on Condenser Coil, Min.

Utilization range “A” in accordance with ARI St anda rd 110.

A low ambient accessory is available for operation down to 0°F.

LOCATION

Use the follow ing guidelines to selec t a suitable location for these units.

1. Unit i s designed for outdo or installation only.

2. Condenser coils must have an unlimited supply of air.

WARNING:Excessive exposure of this furnace to contami-

3. For ground level installation, a level pad or slab should be

- UNIT APPLICATION DATA

UNIT SIZE 036 048 060 072

208/230V 187 / 253

460V 414 / 504

575V 518/630

57 / 72 57 / 72 57 / 72 57 / 72

/ Max.

Where a choice of location is possible, p os ition the unit on either north or east side of building.

nated combustion air may result equipment damage or personal injury. Typical contaminates include: permanent wave solutions, chlorinated waxes and cleaners, chlorine based swimming pool chemicals, water softening chemicals, carbon tetrachloride, Halogen type refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues, antistatic fabric softeners for clothes dryers, masonry acid washing materials.

used. The thic kness and size of the pad or sl ab used should meet local codes and unit weight. Do not tie the slab to the building foundation.

45 / 120 45 / 120 45 / 120 45 / 120

530.18-N8Y

4. Roof structures must be able to support the weight of the unit and its options and / or accessories. Unit must be installed on a solid level roof curb or appropriate angle iron frame.

CAUTION: If a unit i s to be in st al le d o n a roof cu rb or sp ec ia l

frame other than a YORK roof curb, gasketing must be applied to all su rfaces that come in con tact w ith the unit underside.

5. Maintain level tolerance to 1/2" maximum across the entire length or width of the unit.

6. Elevate the unit sufficiently to prevent any blockage of the air entrances by snow in areas where there will be snow accumulation. Check the local weather bureau for the expected snow accumulation in your area.

RIGGING AND HANDLING

Exercise care when moving the unit. Do not remove any packaging unti l the unit is ne ar the place of installa tion. Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails. Spreaders, whose length exceeds the largest d imension a cross the un it, MUST be used acr oss the top of the unit.

BEFORE LIFTING A UNIT, MAKE SURE THAT ITS WEIGHT IS DISTRIBUTED EQUALLY ON THE CABLES SO THAT IT WILL LIFT EVENLY.

Units may also be moved or lifted with a forklift. Slotted openings in the base rails are provided for this purpose.

LENGTH OF FORKS MUST BE A MINIMUM OF 42". Remove the nesting brackets from the four corners on top of

the unit. All screws that are removed when taking these brackets off must be replaced on the unit.

CAUTION: An adhesive backed label is provided over the

outside of the co mbu st ion ai r in le t op en in g to prevent moisture from entering the unit whic h could cause damage to electrical components. Allow this closure label to remain in place until the combustion air hood i s to be installed (r efer to Figure 5).

Refer to Table 5 for unit weights and to Figure 8 for approximate center of gravity.

CLEARANCES

All units require certain clearances for proper operation and service. Installer must make provisions for adequate combustion and ventilation air in accordance with Section 5.3, Air for Combustion and Ventilation 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 Figure 9 for the clearances required for combustible construction, servicing, and proper unit op er ation.

WARNING: Do not permit overhanging structures or shrubs to

obstruct condenser air discharge outlet, combustion air inlet or vent outlet.

DUCTWORK

Ductwork should be designed and sized ac cording to the metho ds in Manual Q of th e Air Conditioning Contrac tors of America (ACCA).

A closed return duct system shall be used. This shall not preclude use of economizers or outdoor fresh air intake. The supply and return air duct connections at the unit should be made with flexible joints to minimize the transmission of noise.

Unitary Products Group 3

530.18-N8Y

The supply and return air duct systems should be designed for the CFM and static requirements of the job. They should NO T be sized to match the dimensions of the duct connections on the unit.

CAUTION: When fastening ductwork to the side duct flanges on

the unit, insert the screws through the duct flanges only . DO NOT insert the screws through the casing.

Outdoor ductwork must be insulated and waterproofed.

Refer to Fig ure 9 for i nformatio n concerni ng side and bo ttom supply and return air duct openings.

FILTERS

1" filters ar e supp lied with each un it. 2" r eplace ment filt ers m ay be used wi th no modification to th e filter racks. Filters must always be installed ahead of the evaporator coil and must be kept clean or re placed wit h same size and t ype. Dir ty filt ers will reduce the cap acit y of t he un it an d wi ll re sult in fros ted coil s or safety shutdown. Minimum filter area and required sizes are shown in Table 5.

CONDENSATE DRAIN

Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install a condensate drain line from the 3/4" PVC female connection on the unit to spill into an open drain.

NOTE: The condensate drain line MUST be tr apped to provi de

proper drainage. See Figure 1.

POWER AND CONTROL WIRING

Field wiring to the unit must conform to provisions of the National Electrical Code (NEC), ANSI / NFPA 70-1987 (in U.S.A.) current Canadian Electric Code (CEC) C22.1 (in Canada), and / or local ordinances. The unit must be electrically grounded in accordance with the N.E.C. ANSI / NFP A 70 or local codes.

Voltage tolerances which must be maintained at the compressor terminals during start-up and running conditions are indicated on the unit Rating Plate an d Table 1.

The internal wiring harness furnished with this unit is an integral part of a UL and CGA design certif ied unit. Fi eld altera tion to comply with electrical codes should not be required.

A disconnect switch shou ld b e fi eld provid ed f or the u nit. The switch must be separat e from al l other ci rcuits . Refer to Fi gure 9 for installation location. If any of the wire supplied with the unit must be replaced, replacement wire must be of the type shown on the wirin g di ag ra m .

Electrical lines must be sized properly to carry the load. USE COPPER CONDUCTORS ONLY. Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly protected.

CAUTION: When connecting electrical power and control wir-

ing to the unit, w aterproo f type connecto rs MUST BE USED so that water or moisture cannot be drawn into t he unit during nor mal operation. The above waterproofing conditions will also apply when installing a field-supplied disconnect switch.

Refer to Figure 2 for typical field wiring and to the appropriate unit wiring diagram for control circuit and power wiring information.

FIG. 1

- RECOMMENDED DRAIN PIPING

SERVICE ACCESS

Access to all serviceable components is provided by the following removable panels:

•

Scroll compressor compartment

•

Burner compartment

•

Blower compartment

•

Main control bo x

•

Filter compartment

•

Motor access (on units with belt-drive option)

Refer to Figure 9 for location of these access panels.

CAUTION: Make sure that all scre ws a re re pl ac ed on the unit

to maintain an air-tight seal.

THERMOSTAT

The room thermostat should be located on an inside wall approximatel y 5 6" ab ove the flo or wh ere it will not be subj ect to drafts, sun exposure, or heat from electrical fixtures or appliances. Follow manufacturer’s instructions enclosed with thermostat for general installation procedure. Color coded insulated wires (#18 AWG) should be used to connect thermostat to unit. See Figure 2 for wiring details.

NOTE : If the unit has an economizer, remove jumper J1 from

terminals 8 and 10 on the relay board to prevent simultaneous operation of the scroll compressor and the economizer. If you want to energize the scroll compressor for supplemental cooling during the economizer operation, use a thermostat with two stages of cooling.

BLOWER SPEED SELECTION

Three blowe r motor spee ds are ava ilable on the direct- drive units. The speed selection for the direct-drive units is determined by the CFM and ESP requirements of the applications . All units with belt- driv e option have an adjust able motor pulley to achieve the above conditions.

All direct-drive units with 208/230 voltage are shipped with the wire labeled # 116 connected to the "HIG H" speed tap on the blower motor. If a lower blower motor speed is desired, this wire should be move d to the "MED" or "LOW " speed tap on the motor for the speed desired.

All direct-drive units with 460 and 575 voltage are shipped with the wire labeled #116 connected to the "HIGH" speed tap on the blower motor. If the medium speed is required, connect wire #116 to the "MED" speed tap and the blue motor lead to the "HIGH" speed ta p. If the low speed is required, conn ect wire #1 16 to the "LOW" sp eed tap, the blue mot or lead to the "H IGH" speed tap and t he orange motor lead to the " M ED" speed tap.

SCROLL COMPRESSOR

These units are shipped with the scroll compressor mountings factory-adjusted and ready for operation.

CAUTION: Do Not loosen the scroll compressor mounting bolts.

COMBUSTION DISCHARGE

The products of combustion are discharged horizontally through a screened opening on the gas heat access panel.

TABLE 2

Capacity,

(Mbh)

NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P . with Kit Model No. 1NP0434. All furnaces meet the latest California seasonal efficiency requirements.

Based on 1075 Btu/Ft3.

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

- GAS HEA T APPLICA T ION DATA

Input

50 40 3 Ton 47 15 45

75 60 4 Ton 70 25 55 100 79 3/5/6 Ton 93 40/25/25 70/55/55 125 99 4/5/6 Ton 116 45/35/35 75/65/65

Output

Capacity,

(Mbh)

Available

Models

Gas Rate

(Ft.3/Hr.)

Temp. Rise °F

At Full Input

Min. Max.

4 Unitary Products Group

COOLING / HEATING (24 VOLT THERMOSTAT )

THERMOSTAT

TERMINALS

UNIT TERMINAL

STRIP TB1

ADD JUMPER

24 VOLT

TRANSFORMER

TYPICAL CONTROL WIRING

COOLING / HEATING (24 VOL T ELECTRONIC THERMOSTAT)

THERMOSTAT

TERMINALS

ADD JUMPER

NOT USED

UNIT TERMINAL

STRIP TB1

530.18-N8Y

24 VOLT

TRANSFORMER

24 VOLT THERMOSTAT 2TH07701024. IF THE UNIT HAS AN ECONOMIZER, REMOVE JUMPER J1 FROM TERMINALS 8 AND 10 ON THE RELAY BOARD TO PREVENT SIMULTANEOUS OPERATION OF THE SCROLL CO MPRESSOR AND THE ECONOMIZER. IF YOU WANT TO CONTROL THE ECONOMIZER ON A SECOND STAGE OF COOLING OR HAVE AN ELECTRIC HEAT ACCESSORY WITH TWO STAGES OF HEAT, USE THERMOSTAT 2TH04701024.

COOLING / HEATING (24 VOL T ELECTRONIC THERMOSTAT)

THERMOSTAT

TERMINALS

UNIT TERMINAL

STRIP TB1

ADD JUMPER

24 VOLT

TRANSFORMER

TYPICAL POWER WIRING

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

TO REMOTE SENSOR

ELECTRONIC PROGRAMMABLE THERMOSTAT 2ET04700224 (INCLUDES SUBBASE) TO CONTROL ECONOMIZER ON SECOND STAGE OF COOLING, REMOVE JUMPER J1 FROM TERMINALS 8 AND 10 ON THE RELAY BOARD.

SECOND STAGE COOLING IS NOT REQUIRED ON UNITS LESS ECONOMIZER.

SECOND STAGE HEATING IS ONLY REQUIRED ON UNITS WITH A TWO STAGE ELECTRIC HEATER.

REMOVE JUMPER J2 FROM TERMINALS 4 AND 9 ON JUMPER PLUG CONNECTOR P6 ON UNITS WITH ECONOMIZER. TERMINALS A1 AND A2 PROVIDE A RELAY OUT-PUT TO CLOSE THE OUTDOOR ECONOMIZER DAMPERS WHEN THE THERMOSTA T SWITCHES TO THE SET-BACK POSITION.

ELECTRONIC PROGRAMMABLE THERMOSTAT 2ET07701024 (INCLUDES SUBBASE). IF THIS UNIT HAS AN ECONOMIZER, REMOVE JUMPER J1 FROM TERMINALS 8 AND 10 ON THE RELAY BOARD TO PREVENT SIMUL TANEOUS OPERATION OF THE SCROLL COMPRESSOR AND THE ECONOMIZER. IF YOU WANT TO CONTROL THE ECONOMIZER ON A SECOND STAG E OF COOLING, USE THERMOSTAT 2ET04700224.

2TH04702224 IF USED

CAUTION: Label all wires prior t o disconnection when servic-

ing controls. Wiring errors can cause improper and dangerous op eration. Verify pro pe r operation af te r servicing.

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

FIG. 2

- TYPICAL FIELD WIRING

DISCONNECT SWITCH BRACKET FOR UNITS WITH OPTIONAL BELT-DRIVE BLOWER

the current Gas Installatio n Codes CAN/CGA-B149.1 and .2 ( in Canada) should be followed in all cases unless superseded by

local codes or gas com p an y re qu irements. Refer to Table 3. A special bracket for mounting a field-supplied disconnect switch is provided in each unit ordered with an optional belt-drive supply air blower. The bracket is shipped inside the blower compartment taped to the top of the blower housing. Install the bracket on the le ft hand side of the unit as sho w n in Figure 9. Several existing screws at the top of the unit and one screw approximately midway down from the top will be used for mounting t he brack et. Sc rews shou ld be lo osened on ly NOT REMOVED. Matching holes in the bracket have elongated keyways allowing easy installation. Re-tighten screws after bracket is in place to ensure panels will remain leak tight.

GAS PIPING

Proper sizing of gas p ipin g de pend s on the cub ic fee t pe r ho ur of gas flow required, specific gravity of the gas and the length of run. “National Fuel Gas Code” Z223-1992 (in the U.S.A.), or

Unitary Products Group 5

TABLE 3

Length in Feet

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 spe ci fic gr avit y gas) .

- PIPE SIZING

10 20 30 40 50 60 70 80 90

100

Nominal Iron Pipe Size

1/2 in. 3/4 in. 1 in. 1-1/4 in.

132

92 73 63 56 50 46 43 40 38

278 190 152 130 115 105

96 90 84 79

520 350 285 245 215 195 180 170 160 150

1,050

730 590 500 440 400 370 350 320 305

530.18-N8Y

FIG. 3

- EXTERNAL SUPPLY CONNECTION EXTERNAL SHUT-OFF

FIG. 4

- BOTTOM SUPPLY CONNECTION EXTERNAL SHUT-OFF

The heating value of the gas may differ with locality. The value should be checke d w it h th e lo ca l gas utility.

NOTE: There may be a local gas utility requirement specifying

a minimum diameter for gas piping. All units require a 1/2 inch pipe connection at the entrance fitting.

GAS CONNECTION

The gas supply line can be routed through the knockouts located on the front of the unit or through th e opening pr ovided in the unit’s base. Refer to Figure 9 to locate these access openings. Typical supp ly piping arrangements a re shown in Figures 3 and 4. All shaded items are field-supplied.

Two 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 penetrates the f ro nt of th e un it .

After the gas supply piping has been installed, the bottom opening shou ld be sealed to prevent water f rom leaking into the building.

Gas piping recommendations:

1. A drip leg and a ground joint union must be installed in the gas piping.

2. When required by local codes, a manual shut-off valve may have to be installed outside of the unit.

3. Use wrought iron or steel pipe for all gas lines. Pipe compound should be applied sparingly to male threads only.

WARNING:Natural gas may cont ain some pr op an e. Propane,

4. All piping should b e cleaned of dirt and scale by hamm ering on the outside of the pipe and blowing out the loose dirt and scale. Before initial start-up, be sure that all of the gas lines external to the unit 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, o pen the main shut -off val ve ad mitting

gas pressu re

soap solution or other material su itable for the purpose. NEVER USE A FLAME.

being an excellent solvent, will quickly dissolve white lead or most standard commercial compounds. Therefore, a special pipe compound must be applied when wrought iron or steel pipe is used. Shellac base compounds such as Gaskolac or Stalastic, and compounds such as Rectorseal #5, Cyde’s or John Crane may be used.

normal

to the mains. Che ck all joint s for leaks wit h

6. The furnace and its individual manual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3. 48kPa).

The furnace mu st be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure t esting of th e gas supply piping syst em at te st pressures equa l to or le ss tha n 1/ 2 ps ig (3.48kPa).

7. A 1/8 inch NPT plug ged tappin g, acces sible for te st gage connection, must be installed immediately upstream of the gas supply connection to the furnace.

L.P./PROP ANE UNITS, TANKS AND PIPING

All gas heat units are shipped from the factory equipped for natural gas use only. The unit may be converted in the field for use with L.P./propane gas with accessory kit model number 1NP0440.

All L.P./propane gas equipment must conform to the safety standards of t he National Fi re Protection Asso ci ation.

For satisfactory operation, L.P ./propane gas pressure must be

10.5 inch W.C at the unit under full load. Maintaining proper gas

pressure depe nds on three main facto rs:

1. The vaporization rate which depends on (a) the temperature of t he liquid and (b) the “wetted surface” area of the container or containers.

2. The pr oper pressure regulat ion. (Two-stage regulation is recommended 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 requi red wi ll depe nd on th e lengt h of th e pipe run and the total load of all appliances.

Complete information 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 u se d whe n as se mbl ing pi pi ng for thi s 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 soluti on . NEVER USE A FLAME.

LOW NOx APPLICA TION

For natural gas heat installations in locations which require low Nitros Oxide emiss ions, accessory model 1LN0 404 must be installed.

6 Unitary Products Group

VENT AND COMBUSTION AIR HOODS

The vent and combustion air hoods are shipped attached to the blower housing in the blower compartm ent. T hese hoods m ust be installed on the outside of the gas heat access panel to ensure proper unit func tion. The necessary mo unting sc rews are provided in a bag also attached to the blower housing.

The screen for the comb ustion air intake ho od is secu red to the inside of the a ccess panel open ing with thre e fasteners an d the screws used for mo unting the hood t o the panel. The top flange of this hood s li ps i n under the top of the ac ce ss pa nel opening when installing. Refer to Figure 5. Remove the protective label covering the opening just prior to installing this hood.

The vent hood (including its screen) is installed by inserting the top flange of the hood into the slotted opening in the access panel. The top screw secures the hood to the access panel. The remaining two side screws must be installed after the access panel is insta lled on the unit . These screws en gage the bottom flue box flange.

CAUTION: All three screws in th e ven t hoo d mu st be pr oper ly

installed bef ore furnace oper ation to insure a ll combustion products are exhausted from the unit.

FIG. 5

- VENT AND COMBUSTION AIR HOODS

OPTIONAL ECONOMIZER RAIN HOOD

The following procedure should be used when assembling an economizer rain hood onto a unit. Refer to Figure 6. The outdoor and return air dampers, damper actuator, the linkage and all the controls are factory mounted as part of the economizer option.

All of the hood com pon ents , in clud ing the filt er s, t he g aske ting and the hardware for assembling are located ab ove the top filter racks with in the fil ter se ctio n. The outd oor a ir sens or is in th e bag of parts locat ed at the bottom of t he return air sectio n.

HOOD COVER

FILTER COVER

GASKETED FLANGE

1. With filter section access panel removed, take out hood components, filters and sensor described above. Remove and discard outdoor air opening cover on back unit (Upper right hand corner).

2. Remove the 1/2" knockout (A) in the units rear panel (located to the right side of th e o ut do or air opening). Insert the two loose wires from inside the unit, into the 1/2" bushing provided. Insert wires and bushing into knockout. Snap bushing into place.

3. Mount t he ou tdoo r air se nsor to the rear panel , just bel ow the knockout described in Step 2. Secure with two self-drilling screws at dimples (B) provided in the panel.

NOTE: Sensor must be positioned so that the sensing ports

are at the top (louvers pointing downward) and terminal connections to the right.

4. Connect the two wires, indicated in Step 2, to the sensor as follows:

•

Wire #73 to terminal (+)

•

Wire #74 to terminal (S)

5. Assemble the LH and RH side plates to the top cover (2 screws each side) to form the hood. Apply gasketing to the flange surface on each side plate. Extend gasketing 1/4" beyond top and bottom of each flange to insure adequate corner sealing. Secure this assembly to the unit back panel (upper right hand corner). First, remove screw (C) on unit top cover . Then sl ip flan ge of ho od co ver in u nder f lange of unit top cover , replace screw (C), engagi ng hole (E) in ho od flange and tighten. Attach the two side p lates to the uni t panel by us ing two s elf-dr illing screws f or each side pl ate at dimples (D) provided in the panel.

6. P osition fillpiece at bottom of hood, between the two side plates but do not secure at this time. (Slotted openings MUST be downward for drainage). After fillpiece is properly positioned, note where contact is made with the unit panel. Remove fillpiece and apply gasket material to this area to provide a seal. Reposition fillpiece and secure with 2 screws.

7. Install the two filters into the hood assembly, sliding down along retainers on side plates, into fillpiece at bottom of hood.

OUTDOOR AIR OPENING COVER

OUTDOOR AIR

SENSOR

GASKET

530.18-N8Y

L. H. SIDE PLATE

GASKETED FLANGE

FILTERS

FILLPIECE

FIG. 6

- ECONOMIZER RAIN HOOD ASSEMBLY (OPTION)

Unitary Products Group 7

R. H. SIDE PLATE

SIDE DUCT

APPLICATION SHOWN

FILTER SECTION ACCESS PANEL

530.18-N8Y

NOTE: Install filters so that “Air Flow” arrows point toward the

unit.

8. Install filter cover over the end of the hood with one screw (center of hood), securing filters into posit ion.

CAUTION: When procee ding with Steps 9 a nd 10, extreme

care must be ex ercise d wh ile tur ning both the se t point and minimum position adjusting screws to prevent twistin g th em of f.

9. The enthalpy set po in t for the dampers may now b e set by selecting the desired set point from graph in Figure 7. For a s ingle enth alpy econom izer, carefully turn th e set point

adjusting screw to the “A”, “B”, “C” or “D” setting corresponding to the lettered curve. For a dual ent ha lp y ec on omizer, carefully turn the set point adjusting screw fully clockwise past the “D” setting.

10.To check that the damper blades move smoothly without binding, carefully turn the minimum position adjusting screw fully clockwise and th en energize and de -energize terminals “ R” to “G”. Wi th terminal s “R” to “G” en ergized, turn the mi nimum po sition s crew c ountercl ockwise until the desired minimum position has been attained.

1 1. Replace the filter section access panel.

FIG. 7

- ENTHALPY SET POINT ADJUSTMENT

TABLE 4

Economizer Bottom Duct Connections

Deduct these resistance values from the available external static pressure shown in the respective Blower Performance T able.

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

8 Unitary Products Group

- STATIC RESISTANCES

DESCRIPTION

1, 2

EXTERNAL STATIC PRESSURE DROP

RESISTANCE, IWG

CFM

1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

0.07 0.08 0.09 0.11 0.13 0.15 0.17 0.20 0.23 0.26 0.30

0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.14 0.16 0.19 0.22

TABLE 5

- PHYSICAL DATA

MODELS

CENTRIFUGAL BLOWER (Dia. x Wd. in.)

EVAP.

BLOWER

FAN MOTOR HP (Direct-Drive) FAN MOTOR HP (Belt-Drive)

EVAP.

COIL

COMPR.

TYPE

COND.

FAN

COND.

COIL

ROWS DEEP FINS PER INCH FACE AREA (Sq. Ft.)

HERMETICALLY SEALED SCROLL TYPE PROPELLER DIA. (in.)

FAN MOTOR HP NOM. CFM TOTAL

ROWS DEEP FINS PER INCH FACE AREA (Sq. Ft.)

QUANTITY PER UNIT

AIR

FILTERS

(SEE NOTE)

(15" x 20" x 1") QUANTITY PER UNIT (14" X 25" X 1") TOTAL FACE AREA (sq. ft.)

CHARGE

NOTE: Filter racks are adapted for 1" or 2" thick filters.

CORNER D

REFRIGERANT 22 (lbs./oz.)

APPROXIMATE CENTER OF GRAVITY

BACK

CORNER C

UNIT SIZE

036 048 060 072

12 x 10

⁄

3.6

⁄

3,400

17.1 2

6.3

4.3

3,400

17.1

6.3

⁄

5.1

⁄

3,400

17.1

6.3

5/8 6/8 6/8 10/0

CONDENSER COIL END

CORNER B

FRONT

12 x 11

⁄

5.1

⁄

3,300

16.7 2

6.3

530.18-N8Y

WEIGHTS

UNIT SIZE

(heat)

UNIT

WEIGHT*

(lbs.)

CORNER WEIGHTS*

(location, lbs., see figure 8)

"A" "B" "C" "D" 036 (40 Mbh) 625 180 172 133 140 036 (79 Mbh) 635 180 177 138 140 048 (60 Mbh) 675 193 185 145 152 048 (99 Mbh) 685 193 190 150 152 060 (79 Mbh) 700 200 192 150 158 060 (99 Mbh) 710 200 197 155 158 072 (79 Mbh) 775 186 209 201 179 072 (99 Mbh) 785 186 214 206 179

OPTIONS / ACCESSORI ES WEIGHTS (lbs.) Economizer 50 Motorized Outdoor

Air Damper Barometric Relief/Fixed

Outdoor Air Intake Damper

Roof Mounting Curb 92 Belt-Drive Blower 5

* Weight = Unit + Economizer

48-11/32

⁄

“

32-1/8

⁄

“

15-1/4

FIG 8

- CENTER OF GRAVITY

TABLE 6

- SUPPLY AIR PERFORMANCE

GAS HEAT VALUES SHOWN @ 230/460/575 Volts

UNIT

SIZE

036

048

060

072 HI 2461 1480 2402 1440 2361 1395 2260 1350 2178 1305 2101 1260 2000 1205 1914 1155 1830 1 110 NOTE: For 208 volts,multiply values by 0.95. *Includes allowances for a wet evaporator coil, 1" filters and gas fired heat exchangers. Refer to Table 8 for static resistance values on applications other than side duct airflows.

TABLE 7

MOTOR

SPEED

HI MED LOW

0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00

CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts

- 800 710

960 838 760

1155 1105 1020

- 1631 1464

1933 1765 1640

2338 2214 2100

1684 1487

1996 1804 1681

2400 2290 2150

- MOTOR AND DRIVE DA TA - Belt-Drive Blower

UNIT

SIZE

BLOWER

RANGE

(RPM)

HP RPM

CORNER A

DIM. 3-5 TON 6 TON

Y 19-3/4" 22" X 40-3/4" 44"

- 3 Thru 6 Ton w/Direct-Drive Blower

1699 1582 1421

1868 1714 1604

2274 2145 2029

FRAME

SIZE

825 750 670

910 785 715

1095 1030

950

780 690

936 810 738

1125 1065

990

MOTOR*

- Side Duct Connections

Available External Static Pressure - IWG*

1650

785

1570

755

1430 1524 1367

1795 1650 1541

2167

1045 2071 1965

SERVICE

FACTOR

720

1410

650

1315

880

1722

765

1589

695

1490 2096

990

1990

910

1905

ADJUSTABLE

MOTOR PULLEY

PITCH

DIA.

(in.)

690 620

845 735 670

1010

950 880

BORE

(in.)

725

1324

650

1246

605

1635

820

1508

705

1416

645

1990

980

1911

920

1816

838

BLOWER PULLEY

PITCH

DIA.

(in.)

1360 1260 1185

1544 1407 1337

1887 1828 1724

FIXED

700 630 590

790 675 620

945 885 800

BORE

(in.)

1280 1185 1110

1419 1306 1230

1771 1724 1644

PITCH

LENGTH

(in.)

680 610 570

765 645 595

905 835 770

1180 1100 1020

1300 1195 1120

1629 1604 1531

BELT

036 780 - 1090 1-1/2 1725 56 1.15 2.4 - 3.4 7/8 5.7 1 37.3 A36 048 790 - 1120 1-1/2 1725 56 1.15 2.4 - 3.4 7/8 5.7 1 37.3 A36 060 850 - 1220 1-1/2 1725 56 1.15 2.4 - 3.4 7/8 5.2 1 37.3 A36 072 900 - 1250 1-1/2 1725 56 1.15 2.8 - 3.8 7/8 5.2 1 37.3 A36

All motors hav e solid bases and are inherently protected. These motors can be selected to operate into their service factor because they are located in the moving air, upstream of any

655 590 545

740 625 575

855 798 710

DESIG-

NATION

Unitary Products Group 9

530.18-N8Y

TABLE 8

- SUPPLY AIR PERFORMANCE - 3 & 4 Ton w/Belt-Drive Blower

3 TON - SIDE DUCT CONNECTIONS @ 230/460/575 VOLTS

UNIT SIZE

036

AIR FLOW

CFM

0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts 2000 843 860 880 925 919 1005 956 1065 993 1145 1030 1195 1067 1235 1900 817 775 854 850 893 920 930 995 970 1065 1008 1 125 1046 1170 1800 790 700 828 760 867 840 906 905 944 980 985 1040 1025 1100 1700 - - 802 670 840 745 881 815 920 900 961 970 1001 1030 1600 - - - - 818 665 858 740 898 820 940 890 980 950 1500 - - - - - - 842 695 882 755 922 835 962 895 1400 - - - - - - 833 650 867 705 904 765 942 820 1300 - - - - - - - - 858 665 893 725 932 785 1200 - - - - - - - - 847 640 880 680 916 730

Available External Static Pressure - IWG*

UNIT SIZE

AIR FLOW

CFM

0.90 1.00 1.10 1.20 1.30 1.40 1.50

RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts

Available External Static Pressure - IWG*

2000 1103 1270 - - - - - - - - - - - 1900 1085 1210 - - - - - - - - - - - 1800 1064 1 145 1102 1180 - - - - - - - - - 1700 1040 1075 1081 1115 1121 1140 - - - - - - - -

036

1600 1020 1005 1060 1050 1100 1085 - - - - - - - 1500 1003 945 1044 995 1086 1035 - - - - - - - 1400 982 880 1024 920 1067 965 1107 1000 - - - - - 1300 970 835 1010 870 1053 920 1099 960 - - - - - 1200 953 780 992 815 1034 855 1080 905 - - - - - -

NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.

INCLUDES ALLOWANCES FOR A WET EVAPORATOR COIL, 1" FILTERS, AND THE HEAT EXCHANGERS. REFER TO THE STATIC RESISTANCES TABLE FOR RESISTANCE VALUES

ON APPLICATIONS OTHER THAN GAS / ELECTRIC UNITS WITH SIDE DUCT AIRFLOWS.

4 TON - SIDE DUCT CONNECTIONS @ 230/460/575 Volts

UNIT SIZE

048

AIR FLOW

CFM

0.20 0.30 0.40 0.50 0.60 0.70 0.80

Available External Static Pressure - IWG*

UNIT SIZE

AIR FLOW

CFM

0.90 1.00 1.10 1.20 1.30 1.40 1.50

RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts

Available External Static Pressure - IWG*

2000 1103 1270 - - - - - - - - - - - 1900 1085 1210 - - - - - - - - - - - 1800 1064 1 145 1102 1180 - - - - - - - - - 1700 1040 1075 1081 1115 1121 1140 - - - - - - - -

048

NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.

INCLUDES ALLOWANCES FOR A WET EVAPORATOR COIL, 1" FILTERS, AND GAS-FIRED HEAT EXCHANGERS. REFER TO TABLE 8 FOR RESISTANCE VALUES ON CONNECTIONS

OTHER THAN SIDE DUCT AIRFLOWS.

10 Unitary Products Group

TABLE 9

- SUPPLY AIR PERFORMANCE - 5 & 6 Ton w/Belt-Drive Blower

5 TON - SIDE DUCT CONNECTIONS @ 230/460/575 Volts

UNIT

SIZE

060

AIR FLOW

CFM

0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts 2500 1059 1560 1077 1590 1095 1630 1114 1650 1134 1660 1158 1685 1181 1720 2400 1032 1405 1054 1470 1074 1525 1094 1560 1116 1595 1140 1620 1167 1640 2300 1005 1260 1024 1275 1049 1370 1069 1440 1090 1475 1116 1505 1 142 1535 2200 980 1160 1002 1170 1022 1190 1044 1250 1066 1350 1090 1410 1117 1440 2100 930 1060 957 1070 983 1080 1010 1100 1039 1160 1064 1260 1092 1340 2000 877 950 908 975 941 1000 976 1020 1009 1050 1040 1100 1070 1225 1900 ----8948859409409809801014 1020 1047 1095 1800 ----8558159038609509059889401022 970 1700 ------8848159258509648801001 910 1600 ------864770908805948835987870 1500 --------882740926780965830

Available External Static Pressure - IWG*

530.18-N8Y

UNIT

SIZE

AIR FLOW

CFM

0.90 1.00 1.10 1.20 1.30 1.40 1.50

RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts

Available External Static Pressure - IWG*

2500 -------------2400 1193 1665 -----------2300 1170 1580 1202 1620 ---------2200 1148 1480 1180 1530 ---------2100 1121 1385 1155 1425 1190 1475 --------

060

2000 1100 1285 1133 1340 1169 1385 1205 1445 -----1900 1079 1 180 1 110 1240 1143 1280 1178 1330 1222 1375 ---1800 1058 1060 1090 1135 1122 1190 1158 1240 1196 1295 ---1700 1035 960 1071 1030 1103 1100 1134 1140 1164 1175 1197 1205 - 1600 1020 900 1056 965 1088 1035 1118 1065 1145 1105 1170 1130 1198 1150 1500 1004 860 1038 880 1070 925 1101 980 1130 1045 1158 1075 1184 1110

NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.

INCLUDES ALLOWANCES FOR A WET EVAPORATOR COIL, 1" FIL TERS, AND G AS-FIRED HEAT EXCHANGERS. REFER TO TABLE 8 FOR RESIST ANCE VALUES ON CONNECTIONS

OTHER THAN SIDE DUCT AIRFLOWS.

6 TON - SIDE DUCT CONNECTIONS @ 230/460/575 Volts

UNIT

SIZE

072

AIR FLOW

CFM

0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM W atts 3200 1150 2325 1182 2425 1212 2525 - - - - - - - 3000 1100 2010 1129 2090 1157 2150 1185 2225 1215 2290 1242 2360 - 2800 1045 1700 1074 1780 1102 1850 1131 1940 1160 2025 1190 2075 1217 2130 2600 985 1425 1015 1475 1045 1540 1075 1630 1103 1715 1135 1760 1163 1825 2400 930 1240 958 1300 990 1350 1020 1400 1051 1430 1081 1490 11 11 1600 2200 - - 905 1070 933 1160 965 1210 997 1250 1028 1285 1060 1325 2000 - - - - - - 919 1025 950 1100 982 1130 1014 1160 1800 - - - - - - - - 909 925 939 1005 968 1030

Available External Static Pressure - IWG*

UNIT

SIZE

AIR FLOW

CFM

0.90 1.00 1.10 1.20 1.30 1.40 1.50

RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts

Available External Static Pressure - IWG*

3200 - - - - - - - - - - - - - 3000 - - - - - - - - - - - - - 2800 1245 2190 - - - - - - - - - - - -

072

2600 1193 1920 1222 1990 1250 2060 - - - - - - - 2400 1142 1675 1173 1730 1205 1800 1234 1885 - - - - - 2200 1090 1380 1124 1450 1 155 1550 1186 1640 1217 1710 1249 1775 - 2000 1045 1 175 1077 1200 1109 1275 1140 1360 1170 1460 1205 1545 1235 1600 1800 998 1050 1028 1060 1058 1060 1087 1075 1 118 1150 1148 1250 1176 1360

NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.

INCLUDES ALLOWANCES FOR A WET EVAPORATOR COI L, 1" FILTERS, AND GAS-FIRED HEAT EXCHANGERS. REFER TO TABLE 8 FOR RESISTANCE VALUES ON CONNECTIONS

OTHER THAN SIDE DUCT AIRFLOWS.

Unitary Products Group 11

530.18-N8Y

TABLE 10

- ELECTRICAL DATA (BASIC UNIT)

w/Direct-Drive Blower Motor

VOLTAGE

UNIT SIZE

036

048

060

072

NOTES: 1. Utilization Range “A” in accordance with ARI Standard 110. 2. Dual element, time delay type.

TABLE 11

UNIT SIZE

036

048

060

072

NOTES: 1. Utilization Range “A” in accordance with ARI Standard 110. 2. Dual element, time delay type.

POWER SUPPLY

208/230-1-60 208/230-3-60

460-3-60 575-3-60

208/230-1-60 208/230-3-60

460-3-60 575-3-60

208/230-1-60 208/230-3-60

460-3-60 575-3-60

208/230-3-60

460-3-60 575-3-60

- ELECTRICAL DATA (BASIC UNIT)

POWER SUPPLY

208/230-1-60 208/230-3-60

460-3-60 575-3-60

208/230-1-60 208/230-3-60

460-3-60 575-3-60

208/230-1-60 208/230-3-60

460-3-60 575-3-60

208/230-3-60

460-3-60 575-3-60

LIMITATIONS

(SEE NOTE 1)

MIN. MAX. RLA LRA

187 187 414 518

187 414 518

LIMITATIONS

(SEE NOTE 1)

MIN. MAX. RLA LRA

187 187 414 518

187 414 518

253 253 504 630

253 504 630

VOLTAGE

253 253 504 630

253 504 630

SCROLL

COMPRESSOR

18.0

11.4

6.2

5.0

24.4

14.1

7.1

5.6

28.9

16.0

8.0

6.4

20.3

10.2

8.2

105.0

90.0

45.0

36.0

140.0

105.0

55.0

44.0

165.0

125.0

67.0

50.0

146.0

73.0

58.4

MOTOR,

w/Belt-Drive Blower Motor

SCROLL

COMPRESSOR

18.0

11.4

6.2

5.0

24.4

14.1

7.1

5.6

28.9

16.0

8.0

6.4

20.3

10.2

8.2

105.0

90.0

45.0

36.0

140.0

105.0

55.0

44.0

165.0

125.0

67.0

50.0

146.0

73.0

58.4

MOTOR,

COND.

FAN FLA

1.3

0.8

1.3

0.8

1.3

0.8

1.3

0.8

COND.

FAN FLA

1.3

0.8

1.3

0.8

1.3

0.8

1.3

0.8

SUPPLY

AIR

BLOWER

MOTOR,

FLA

4.4

2.2

5.0

2.2

6.6

3.3

6.8

3.6

SUPPLY

AIR

BLOWER

MOTOR,

FLA

5.3

3.1

8.6

5.2

2.6

2.0

8.6

6.0

3.0

2.4

7.3

3.7

2.8

MINIMUM

CIRCUIT

AMPACITY

28.2

20.0

10.8

9.3

36.8

23.9

11.9

10.1

44.0

27.9

14.1

12.1

33.5

17.2

14.7

MINIMUM

CIRCUIT

AMPACITY

29.1

20.9

11.7

10.2

40.4

24.1

12.3

9.9

46.0

27.3

13.8

11.2

34.0

17.3

13.9

MAX.

FUSE

SIZE,

(SEE NOTE 2)

AMPS

45 30 15 15

60 35 15 15

70 40 20 15

50 25 20

MAX. FUSE SIZE,

(SEE NOTE 2)

AMPS

45 30 15 15

60 35 15 15

70 40 20 15

50 25 20

MAX.

HACR

BREAKER

SIZE,

AMPS

45 30 15

60 35 15

70 40 20

50 25

MAX.

HACR

BREAKER

SIZE,

AMPS

45 30 15

60 35 15

70 40 20

50 25

TABLE 12

TEMPERATURE,

12 Unitary Products Group

- SUPERHEAT CHARGING TABLE FOR MODEL 036

OUTDOOR

65 25.6 26.8 28 29.2 30.4 31.6 32.8 33.3 33.9 34.4 34.9 70 20.1 21.7 23.3 24.9 26.5 28.1 29.6 30.6 31.5 32.4 33.4 75 14.6 16.6 18.5 20.5 22.5 24.5 26.5 27.8 29.1 30.5 31.8 80 9.0 11.4 13.8 16.2 18.5 20.9 23.3 25.0 26.8 28.5 30.3 85 - 6.3 9.0 11.8 14.6 17.4 20.1 22.3 24.4 26.6 28.7 90 - - 6.7 9.1 11.4 13.8 16.2 18.9 21.7 24.4 27.1

95 - - - 6.3 8.3 10.3 12.3 15.6 18.9 22.2 25.6 100 - - - 5.3 6.8 8.4 10.0 13.4 16.8 20.2 23.6 105 ----5.46.57.711.214.718.221.7

110 ------5.49.012.616.219.8 115 -------6.810.514.117.8

55 57 59 61 63 65 67 69 71 73 75

SUPERHEAT AT SCROLL COMPRESSOR SUCTION, °F, AIRFLOW = 400 CFM/TON

INDOOR WB TEMPERATURE, °F

TABLE 13

530.18-N8Y

- SUPERHEAT CHARGING TABLE FOR MODEL 048

OUTDOOR

TEMPERATURE,

65 18.1 20.1 22.2 24.3 26.3 28.4 30.5 31.7 32.9 34.2 35.4 70 14.5 16.6 18.7 20.8 22.9 25 27.1 28.7 30.2 31.8 33.4 75 11.0 13.1 15.2 17.4 19.5 21.6 23.7 25.6 27.5 29.5 31.4 80 7.5 9.6 11.7 13.9 16.0 18.2 20.3 22.6 24.8 27.1 29.3 85 - 6.1 8.3 10.4 12.6 14.8 16.9 19.5 22.1 24.7 27.3 90 - - 6.6 8.2 9.8 11.4 13.0 16.1 19.1 22.2 25.2

95 - - - 5.9 7.0 8.0 9.1 12.6 16.1 19.6 23.1 100 - - - 5.3 6.2 7.0 7.9 11.1 14.2 17.4 20.5 105 ----5.46.06.79.512.315.218.0 110 -----5.05.58.010.513.015.4 115 -------6.48.610.712.9

TABLE 14

TEMPERATURE,

- SUPERHEAT CHARGING TABLE FOR MODEL 060

OUTDOOR

65 20.1 22.0 24.0 25.9 27.8 29.8 31.7 32.5 33.3 34.1 35.0

70 16.9 18.9 21.0 23.1 25.2 27.2 29.3 30.3 31.3 32.3 33.4

75 13.7 15.9 18.1 20.3 22.5 24.7 26.9 28.1 29.3 30.5 31.8

80 10.4 12.8 15.1 17.4 19.8 22.1 24.5 25.9 27.3 28.7 30.2

85 7.2 9.7 12.2 14.6 17.1 19.6 22.0 23.7 25.3 27.0 28.6

90 - 6.6 8.9 11.3 13.6 16.0 18.3 20.6 22.8 25.0 27.3

95 - - 5.7 7.9 10.1 12.4 14.6 17.4 20.3 23.1 25.9 100 - - - 6.5 8.2 9.9 11.6 14.6 17.6 20.6 23.6 105 - - - 5.1 6.3 7.4 8.6 11.8 15.0 18.1 21.3 110 ------5.69.012.315.719.0 115 -------6.19.713.216.7

55 57 59 61 63 65 67 69 71 73 75

SUPERHEAT AT SCROLL COMPRESSOR SUCTION, °F, AIRFLOW = 400 CFM/TON

INDOOR WB TEMPERATURE, °F

SUPERHEAT AT SCROLL COMPRESSOR SUCTION, °F, AIRFLOW = 400 CFM/TON

INDOOR WB TEMPERATURE, °F

TABLE 15

TEMPERATURE,

Unitary Products Group 13

- SUPERHEAT CHARGING TABLE FOR MODEL 072

OUTDOOR

65 15.2 18.0 20.9 23.7 26.5 29.3 32.1 33.4 34.7 36.0 37.3

70 11.9 14.9 17.8 20.8 23.7 26.7 29.6 31.0 32.4 33.8 35.3

75 8.6 11.7 14.8 17.9 21.0 24.1 27.2 28.7 30.2 31.7 33.2

80 5.2 8.5 11.7 15.0 18.2 21.4 24.7 26.3 27.9 29.6 31.2

85 - 5.3 8.7 12.0 15.4 18.8 22.2 23.9 25.7 27.4 29.2

90 - 5.1 7.7 10.4 13.0 15.7 18.4 20.7 23.1 25.4 27.8

95 - - 6.8 8.7 10.6 12.6 14.5 17.5 20.4 23.4 26.3 100 - - 6.2 7.7 9.2 10.7 12.3 15.4 18.5 21.7 24.8 105 - - 5.6 6.7 7.8 8.9 10.0 13.4 16.7 20.0 23.3 110 - - - 5.6 6.4 7.1 7.8 11.3 14.8 18.3 21.8 115 -----5.25.59.212.916.620.4

55 57 59 61 63 65 67 69 71 73 75

SUPERHEAT AT SCROLL COMPRESSOR SUCTION, °F, AIRFLOW = 400 CFM/TON

INDOOR WB TEMPERATURE, °F

530.18-N8Y

⁄

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

REAR VIEW

SIDE SUPPLY AND RETURN

DUCT COVERS - Units are shipped with all air duct openings covered. For

side duct applications;

1. Remove and discard the supply and return air duct covers.

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

bottom duct applications;

1. Remove the side supply air duct cover to gain access to the bottom supply air knockout panel.

2. Remove and discard the bottom knockout panel.

3. Replace the side duct cover.

4. With filter section access panel removed from the unit, remove and discard the bottom return air knockout panel.

5. Replace the filter access panel.

CLEARANCES

Front 32" Back

Left Side (Filter Access) Right Side (Cond. Coil) 24"

Below Unit Above Unit

Units may be installed on combustible floo rs made fro m woo d or cla ss A, B o r C

roof covering material (Applicable in the U.S.A. only).

Units must be i nstalled outd oors. Overhanging structures or shrubs should not obstruct the outdoor coil nor the fan outlet. NOTE: A 1" clea ra nce must be pr ovid ed be tw e en an y com bu stib le m at er ial a nd th e supply air ductwork for a distance of 3 feet from the unit. The products of combustion must not be allowed to accumulate within a confined space and recirculate. Locate unit so that the vent air outlet hood is at least:

•

Three (3) feet above any forced air inlet located 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 equipment.

FIG. 9 -

DIMENSIONS AND CLEARANCE (3, 4, 5 & 6 TON)

12" (Less Economizer) 36" (With Economizer or Fixed Air/Motorized Air Damper)

24" (Less Economizer) 36" (With Economizer)

20"

72" (For Condenser Air Discharge)

(Direct-Drive Units)

AIR FLOW LEGEND

RETURN AIR

SUPPLY AIR

OUTDOOR AIR

OUTDOOR AIR (Economizer)

DIMENSION "A"

FIXED

OUTDOOR

AIR DAMPER MOTORIZED

DAMPER

SCROLL COMPR. ACCESS

UTILITIES ENTRY DATA

HOLE

Knockouts in the bottom of th e un it can be loca te d by th e slice

in the insulation.

Do not remove the 2" knockout ring.

⁄

UNIT WITH ECONOMIZER RAIN HOOD

⁄

"A"

KNOCKOUT

SIZE

USED FOR

(DIA.)

A7/8" * B2" *

Control Wiring (Side or Bottom)**

Power Wiring

(Side or Bottom) C 1-5/8" Gas Piping (Front) D 1-1/2" Gas Piping (Bottom)

⁄

“ CONDENSATE

DRAIN (must be trapped)

⁄

DETAIL “A”

⁄

DETAIL “B”

UNIT WITH FIXED OUTDOOR

AIR/MOTORIZED DAMPER RAIN HOOD

⁄

14 Unitary Products Group

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 scroll compressor is hermetically sealed and internally sprung. The scroll compressors have inherent (internal) protection. I f there is an a bnormal temper ature rise in the scro ll compressor, the protector will open to shut down the scroll compressor.

COOLING SEQUENCE OF OPERATION

Single-Stage Cooling: When the thermostat calls for “cooling”, “R” is closed to “G” and “Y1" (wiring schematic) which completes the low voltage control circuit, immediately energizing the scroll compressor, condenser fan motor and blower motor simultaneously.

Two-Stage Cooling: A two-stage c ooling thermostat may be used if the unit has an economizer. First-stage cooling is provided by the economizer - if the outdoor air enthalpy is acceptable, a nd seco nd-sta ge coo ling i s prov ided b y the scroll compressor. Jumper wire J1 must be removed. Refer to the unit wiring diagram.

After the thermostat is satisfied and opens, all components will stop simultaneously.

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

SAFETY CONTROLS (Cooling)

The refriger ant system is equipp ed 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.

2. A High Pressure Cutout Swit ch to protect agai nst excessive discharge pr essu res due to a bloc ked co nden ser coil or a condenser motor failure.

3. A Low Pressure Switch to protect against loss of refrigerant charge.

If either one of th e abo ve safety contro ls open s, th e refri gera nt system will be locked out. The lock out of the system can be reset by opening the 24V circuit either at the roo m thermostat or at the unit disconnect.

HEATING SEQUENCE OF OPERATION

The following seq uence describes the op eration of the gas heat section.

CONTINUOUS BLOWER: With the room thermostat switch set to “ON”, the supply air blower will operate continuously. The normally closed blo w er interlock relay contact “K3-1" provides 24 volt power to the blower relay ”B R". The “BR” power co ntacts close and the blowe r 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 ai r blower will op erate afte r the room thermostat calls for heat and the air in the gas heat compartmen t ha s ac hi ev ed a pr e -s et temperatur e.

530.18-N8Y

When “TH1" on the thermostat closes, the draft motor relay ”DMR" or "DMC" is energized. The “DMR” or "DMC" power contacts close w hich e nergiz es the line voltag e dr aft m otor. As the speed of the draft motor reaches approximately 2500 RPM, the centrifugal switch contact “CS” located on the end of the draft motor shaft closes to power the ignition control “IC”.

After 15 seconds, the "I C" will star t the igni tor sparki ng and will open the re dundant valve lo cated inside the main gas valve “GV” to allow a flow of gas to only the carryover tube. See Figure

10. Only after the pi lot flame has been ignite d and the presence of pilot flame de tected at the “IC” by a signa l sent bac k through the flame sensor is sparking terminated and the main gas valve opened.

REDUNDANT VALVE

GAS MAIN

GAS VALVE

FIG. 10 -

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

The "IC" will try for 8 5 seconds to ignite the pilot carr yover tube. If the "IC" fails to detect a pilot flame during the 85 seconds, it will close the redundant valve. After a 5 minute purge period, the "IC" wi ll a ga in t ry t o li gh t th e pi lot ca rr yo ve r tu be . Th is wil l continue continuously until the "IC" detects a pilot flame.

If, after de tecting a pilot fla me and op ening th e main gas valv e, the "IC" looses pil ot flam e indica tion, it will clo se both th e main and redundant gas valves. The "IC" will start the above sequence over until a pilo t flame i s detected and it wil l open the main gas valve ag ai n.

The "IC" wi ll o nly allow 16 p ilot fl ameou ts an d a si ngle roll out switch opening pe r thermostat cy cle. After 16 pil ot flameouts or a single rollout switch opening, the "IC" closes both the main and redundant gas valves. The "IC" requires resetting the thermostat or removal of it’s power lead coming from the draft motor to reset the "IC" and return it to the above sequence of operation.

At the same time pow er wa s su pp li ed to the “DMR” or "DMC", a parallel ci rc ui t a ct iv ates the time delay ( "B T" o r " ETD " ). Th e "BT" or "ETD" closes in approximately 35 seconds and starts the circulating air blower by energizing the blower interlock relay “K3", thus closing the ”K3-2" contact and energizing the blower relay “BR”.

When the heating cycle is complete, “TH-1" opens de-energizi ng the “IC”, thus c losing the redundan t and main gas valves. The blower motor and the draft motor continue to run for a short perio d after the furn ace is shut do wn until the "BT" or "ETD"” opens (in approximately 25 seconds) de-energizing th e “K3 ", ”BR" and "DMR" or "DMC " rel ay s.

TO PILOT BURNER

GAS VALVE PIPING

MAIN VALVE

TO MAIN BURNER

SAFETY CONTROLS (Heating)

The control circuit includes the following safety controls:

1. Limit Cont rol (LS). This control is located inside the hea t exchanger compartment and is set to open at the temperature in dicated in Table 16. It res ets automa tically.

Unitary Products Group 15

530.18-N8Y

The limit switch operates when a high temperature condition, caused by inadequate supply air flow, occurs shutting down t he igni tion co ntrol a nd clos ing the main g as valve.

TABLE 16

- LIMIT CONTROL SETTING

Units

(Tons)

3 4 3 4 5 5 6 6

Capacity, MBH

Input Output

75 100 125 100 125 100 125

40 60 79 99 79 99 79 99

Limit Control

Opens, °F

165 165 165 165 165 165 165 165

2. Centrifugal Switch (CS-36). If the draft motor should fail, the centrifugal switch attached to the shaft of the motor prevents the ignition control and gas valve from being energized.

3. Redundant Gas Valve. This valve is an integral part of the main gas valve and is loc ated up st ream of the mai n gas valve. Should the main gas valve fail in the open position the redundant va lv e se rv es as a ba ck up an d sh uts off the flow of gas.

4. Flame Sensor Rod. This sensor rod is located on the far side of the carryover tube. If the ignition control does not receive a sig nal from the flame sensor indicati ng that the pilot flame has ignited properly , the main gas valve will not open. If the flame sensor fails to detect the pilot flame during

operation of t he main bur ners, a signal is sent to the ignition control to close the main gas valve.

5. Rollout Switch. This switch is located in the burner vestibule. In the event of a sustained main burner flame rollout, it shuts off the igniti on control and closes the main gas valve.

6. Auxiliary Limit Switch. This control is located inside the heat exchanger comp ar tment an d is set to open at 18 0°F. It is a manual reset s witch . If t he auxi liar y limi t swit ch tr ips, the n the primary limit switch has not functioned properly. Replace the primary limit switch.

HEA T ANT ICIPA TOR SETPOINTS

The anticipator must be set c orrectly. Too high of a setting will result in long er heat cycle s and a grea ter te mpera ture swing in the conditioned space.

Gas Val ve Anticipator Setpoint

Honeywell VR8204M 0.60 amp

White-Rodgers 36E36 0.54 amp

Reducing the value below the correct setpoint will give shorter “ON” cycles and may result in the lowering of the temperat ure within the cond itioned space.

PRE-START CHECK LIST

Complete the following checks before starting the unit.

1. Check the type of gas being supplied. 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 installed.

START-UP

OPERATING INSTRUCTIONS

CAUTION: This furnace is equi pped wit h an int ermittent pilot

and automatic re-ignition system. DO NOT attempt to manually light the pilot.

TO LIGHT PILOT AND MAI N BURNERS:

1. Turn “off” electric power to unit.

2. Turn room thermostat to lowest setting.

3. Turn gas valve knob to “on” position.

4. Turn “on” electric power to unit.

5. Set room thermostat to desired temperature. (If thermostat “set” temperature is above room temperature, pilot burner ignition will occur and, after an interval to prove pilot flame, mai n bu rn er s w il l ig ni te ).

TO SHUT DOWN:

1. Turn “off” electric power to unit.

2. Depress knob of gas valv e while turning to “off” position.

POST-START CHECK LIST (GAS)

After the entire control circuit has been energized and the heating section is operating, make the following checks:

1. Check for gas leaks in the unit piping as well as the supply piping.

2. Chec k for correc t manifol d gas press ures. See “C heckin g Gas Input”.

3. Check the supply gas pressure. It must be within the limits shown on rating nameplate. Supply pressure should be checked with all gas appliances in the building at full fire. At no time should the standby gas line pr essure exceed 13", nor the operating pressure drop below 4.5" for natural gas units. If gas pressure is outside these limits, contact the local gas utility for corrective action.

16 Unitary Products Group

MANIFOLD GAS PRESSURE ADJUSTMENT

Small adjustments to the high-fire gas flow may be made by turning the pressure regulator adjusting screw on the automatic gas valve. Refer to Figure 11.

Adjust as follows:

PILOT AD J. (UNDER SCREW)

Honeywell VR8204M

PILOT AD J. (UNDER SCREW)

PRESSURE REGULATOR

MANIFOLD ADJUST. SCREW

FIG. 11 -

GAS VALVES

1. Remove the cap on the regulator. (High Fire adjusting screw on valve).

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

counterclockwise.

3. T o increase the gas pressure, turn the adjusting screw

NOTE: Check the unit data plate for the proper manifold pres-

sure and orfice size of the furnace.

“ON”-"OFF" CONTROL HIGH FIRE ADJ. (UNDER SCREW)

“ON”-"OFF" CONTROL

White-Rodgers 36E36

1/2-14 NPT (OUTLET)

clockwise

PILOT CHECKOUT

The pilot flame should envelope 3/8 inches of the end of the flame sensor. Refer to Figure 12. To adjust pilot flame, (1) remove pilot adjustment cover screw, (2) adjust the screw for the proper pilot flame, (3) be sure to replace cover screw after adjustment to prevent possible gas leakage.

FIG. 12 -

Put the sys tem into op eration and observe t hrough co mplete cycle to be sure all controls function properly.

PROPER FLAME ADJUSTMENT

530.18-N8Y

TABLE 17

- BELT-DR I VE S U PP LY AIR

MOTOR PULLEY ADJUSTMENT

TURNS

OPEN*

5 4 3 2 1 0

Pulley can be adjusted in half-turn increments.

BLOWER DRIVE RANGE (RPM)

3 TON 4 TON 5 TON 6 TON

780 842 904

966 1028 1090

790 856 922

988 1054 1120

850 924

998 1072 1246 1220

900 970

1040

1110 1180 1250

OPTIONAL BELT-DRIVE BLOWER All units with belt-drive blowers have single-speed motors. The

variable pi tch pulley on the blower motor can be adjusted t o obtain the desired supply air CFM. Refer to Table 7 for blower motor and drive data. The tension on the belts should be adjusted as shown in Figure 14.

BURNER INSTRUCTIONS

T o check or chang e burners, pilot or or ifices, CLOSE MAIN MANU AL SHUT-OFF VAL VE AND SHUT OFF ALL POW ER TO THE UNIT.

1. Remove the two scr ew s ho ld in g e ither end of the manifold to the burner supports.

2. Open the union fitting in the gas supply line just upstream of the unit gas valve and downstream from the main manual shut-off valve.

3. Remove the gas piping patch plate.

4. Disconnect wiring to the gas valve and spark ignitor. Remove the mani fo ld -burner gas valve as sembly by lifti ng up and pulling back.

Burners are now accessible for service. Reverse the above procedure to replace the assembly. Make sure

that burners are level and seat at the rear of the heat exchanger.

BURNER AIR SHUTTER ADJUSTMENT

Adjust burner shutters so that a distinc t, sharp, bl ue flame is obtained. Refer to Figure 13.

FIG. 13

- TYPICAL FLAME APPEARA N CE

SUPPLY AIR BLOWER AND TEMPERATURE RISE ADJUSTMENTS

The speed of the supply air blower will depend on the required CFM, the unit ac cessories and the static resi stances of both the supply and the return air duct systems. With this information, the speed for the supply air blower can be determined f rom the b lower p erfo rma nce and acce ssor y stat ic resistance dat a in Tables 4,6,8 and 9.

Knowing the required blower RPM and the blower motor HP, the speed setting for the supply air motor can be determined.

The setting (turns open) for the option al belt-drive supply air motor pulley ca n be det ermined from Table 17.

Procedure for adjusting belt tension:

1. Loosen nut (D) from the motor mount.

2. Never loosen nuts (C) from each other while loosening nut (D).

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

4. Do not loosen the four nuts (top and bottom) (A); unless additional tensioning distance is required; immediately re-tighten these bolts if loosened.

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

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

6. After adjusting, re-tighten nut (D) against the motor mount taking care not to loosen nuts (C).

FIG. 14

- BELT ADJUSTMENT

CAUTION

SPAN LENGTH

(A)

DEFL FORCE

(C)*

(B)

(D)

* NEVER LOOSEN

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

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

Remove the (two)

⁄

" dot plugs from the ho le s lo cated on the

filter acces s pane l side of th e unit .

2. Insert at least 8" of 1/4 inch tubing into each of these holes for sufficient p enetration into th e air fl ow on bo th sides o f the evaporator 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 pressure readings.

3. Using an inclined mano meter , det ermine the pr essure drop across a dry evaporator coil. Since the moisture on an

Unitary Products Group 17

530.18-N8Y

evaporator coil may vary greatly, measuring the pressure drop across a wet coil under field conditions would be inaccurate. To assure a dry coil, the scroll compressors should be de-energized while the test is being run.

4. Knowing the pressure drop across a dry coil, the actual CFM through the un it can be deter mined from the curve in Figure 1 5.

0.7

0.6

0.5

0.4

036

048

072

060

CHECKING GAS INPUT

NA T URAL GAS

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

2. With the furnace turned on, measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter usually has a 1/2 or a 1 cubic foot test dial.

3. Usin g the number of se conds for ea ch revolut ion and the size of the test dial inc rement, find the c ubic feet of gas consumed per hour from Table 18.

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.

0.3

0.2

PRESSURE DROP (IWG)

0.1

750 1250 1750 2250 2750 3250 3750

NOMINAL CFM

FIG. 15

PRESSURE DROP vs SUPPL Y AIR CFM

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 UL or CGA rating plate and the da ta in Table 2.

If the CFM is above or below the specified value, the supply air motor speed may have to be changed by movi ng the motor speed tap to another terminal.

CFM =

Btuh Input x 0.8

1.08 x

F Temp. Rise

WARNING:Failure to properly adjust the total system air quan-

tity can result i n poor system performance.

5. After readings have been obtained, remove the tubes and seal the holes w ith the

⁄

" dot plugs removed in Ste p 1.

NOTE: DE-ENERGIZE THE SCROLL COMPRESSORS BE-

FORE TAKING ANY TEST MEASUREMENTS TO ASSURE A DR Y INDOOR COIL.

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 .)

TABLE 18

Example:

foot dial to make a revolution with just a 100,000 Btuh furnace running. Using this information, locate 38 seconds in the first column in the table above. Read across to the column headed “1 Cubic Foot”, where you will see that 95 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 95 x 1050 (the Btu rating of the gas obtained from the local gas company). The result is 99,750 Btuh, which is close to the 100,000 Btuh rating of the furnace.

- GAS RATE - CUBIC FEET PER HOUR

Seconds

for One

Rev .

10 12 14 16 18

20 22 24 26 28

30 32 34 36 38

40 42 44 46 48

50 52 54 56 58 60

By actual measurement, it takes 38 seconds for the hand on the 1-cubic

Size of Test Dial

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

180 150 129 113 100

90 82 75 69 64

60 56 53 50 47

45 43 41 39 37

36 35 34 32 31 30

360 300 257 225 200

180 164 150 138 129

120 113 106 100

95 90

86 82 78 75

72 69 67 64 62 60

SECURE OWNER’S APPROV AL

When the system is functioning properly , secure the owner’s approval. Show him the location of all disconnect switches and the thermostat. Teach him how to start and stop the unit and how to adjus t temperature settings within the limitations of the system.

18 Unitary Products Group

MAINTENANCE

NORMAL MAINTENANCE

CAUTION: Prior to any of the following ma intenance proce-

dures, shut off all power to the unit to prevent personal injury.

Periodic maintenance normally consists of changing or cleaning filters and (under some conditions) cleaning the main burners.

FIL TERS - Insp ect once a mo nth. Replac e disposabl e or clean permanent type as necessary. DO NOT replace permanent type with disposable.

MOTORS - Indoor fan and outdoor fan motors are permanently lubricated and require no maintenance. Ventor motor is factory lubricated for an estimated 10 ye ar life.

OUTDOOR COIL - Dirt should not be allow ed to accumulate on the outdoor coil surface or other parts in the air circuit. Cleaning sho uld be as o ften as nece ssar y to kee p coi l cle an. Use a brush, vacuum cleaner attachme nt, or other suitable means. If wate r is used to cl ean coil, be s ure power to the unit is shut off pri or to cleaning.

NOTE: Exercise care when clea ning the coil so that the c oil

fins are not damag ed. Do not permit the outdoor air discharge to be ob-

structed by over ha nging structur es of shrubs.

BURNER & PILOT - Periodically (at least annually at the beginning of each heating season) make a visual check of the pilot and m ain burner flame. If necessary , adjust main burner primary air shutters so that no yellow flame is observed as explained under “BURNER AIR SHUTTER ADJUSTMENT”. If it is not possible to adjust for the proper flame, the burners may need cleaning.

TO CLEAN BURNERS - Remove them from the furnace as explained in “ Burner Instruc tions”. Clean b urners with ho t water applied along to p of the burner.

COMBUSTION AIR DISCHARGE - Visually inspect discharge outlet period ically to make sur e that the buildup of soot and di rt is not excessive. If necessary, clean to maintain adequate combustion air discharge.

530.18-N8Y

The manufacture recommends that the furnace system be inspected once a year by a qualified service person.

CLEANING FLUE PASSAGES AND HEATING ELEMENTS

With proper c ombustion adjustme nt the hea ting eleme nt of a gas fired furnace will seldom need cleaning. If the element should become sooted, it can be cleaned as follows:

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

2. Remove the roof over the gas heat section.

3. At the top front of the heat section, remove the screws holding th e top of th e flue co llec tor box. Ca refull y remove the top of the flue co llector b ox witho ut rippin g the adja cent insulation.

4. Lift out the flue dive rt er baffle.

5. On the inside of the flue collector box, remove the screws holding the flue baffle. Remove the flue baffle.

6. Using a wire brush o n a fl exib le w and, brus h out the in side of each heat exchanger from the burner inlet and flue outlet ends.

7. Brus h out th e insi de of th e flue c ollector box and the flue baffles.

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

9. If soot build-up is particularly bad, remove the vent motor and clean the wheel and housing. Run the wire brush down the flue extentions at the outlet of the vent housing.

10.After brushing is complete, blow all brushed areas with air or nitrogen. V acuum as needed.

11. Replace parts in the order they were removed in Steps 1 to 5.

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

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

TROUBLESHOOTING

WARNING:Troubleshooting of components necessarily re-

quires opening the electrical control box with the power conne cted to the unit. Use ex treme care when working with live circuits! Check the unit nameplate for the correct line voltag e and set th e volt meter to th e c orre ct ra nge b ef or e maki ng an y connections w it h line terminal s.

CAUTION: The wire number or color and terminal designations

referred to may vary . Check the wiring label inside the control box access panel for the correct wiring.

1. Draft motor operates and furnace lights but supply air blower does not start after a shor t 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 l ine voltage is being supplied to th e cont acts of th e blo wer rela y, “BR”, and if the blower re lay is pulled in. Check for loose wiring.

b. If “BR” is pulled in, touch the supply air blower motor

housing. If it is hot the motor may be off on inherent protection. D i sc on ne ct power to the unit and check t he blower motor capacitor. If it is defective, replace it with one of equal capa citance and voltage.

Unitary Products Group 19

c. If “BR” is pulled in and the blower motor still does not

run, replace the blower motor.

d. If “BR” is not pulled in check for 24 volts at the “BR” coil.

If 24 volts is present, replace the “BR” relay .

e. If 24 volts is not present at the “BR” coil, check for loose

24 volt wi ring back to the r elay board. Check control wiring to th e roo m ther mosta t. If al l is fi ne, re plac e th e 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 fan switch in the “AUTO” position, check for loose 24 volt wiring between the relay board in the main control bo x.

g. If all control wiring is fine, check for 24 volts at the relay

board. If 24 volts is pre se nt, re pl ac e th e re la y bo ard. If 24 volts is not present, replace the “BT” or "ETD".

NOTE: The furnace may s hut its elf do wn on a hig h tempe ra-

ture conditio n during the procedure b ut this will not effect the test if it is done withi n 5 min utes of fu rnac e shut-down.

2. The supply air blower operates bu t the draft m otor does not when the room thermostat is set to call for heat and the fan switch in the “ON” position.

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 motor shell is cold with the room thermostat calling

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

c. I f line vol tage is no t present, c heck for li ne voltage a t

the draft motor r elay "DMR" or "DMC" contac ts in the main control box and check to see if the “DMR” or "DMC" is pulled in.

d. If the “DMR” or "DMC" relay is pulled in, check for a

loose line voltage connection.

e. If the “DMR” or "DMC" relay is no t pulled in, check for

24 volts at the “DMR” or 24 volts at the "TMC-G" terminal coil . If 24 volts is presen t, replace the “DMR” or "DM" relay . If 24 vo lts is not presen t, check for a loo se 24 volt conne ction back t o the relay bo ard and check the connections from the room thermostat to the relay board. If all connecti ons are cor rect, repl ace the rela y board.

3. The draft motor runs b ut th e fur nace does not lig ht an d the sparker does not spa r k .

a. Check all 24 volt connection s from the relay board to

and in the gas heat section. Check low voltage connections to the “BT” and "DMC" or "ETD" located in the control box.

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

ture condition, wait for limit reset.

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

terminal 24V on the ignitor control (IC) wher e the red lead from the draft motor attaches. If 24 volts is not present, the ce ntrifugal s witch (CS) has no t closed or has gone bad. Check the line voltage to the unit, if it i s correct replac e the draf t motor. If line voltage is low ca ll the power company.

d. If 24 volts is present at the ignitor control, check all

control wiring at the i gnit or co ntro l and the high ten sion wire to the i gnitor. Check that the gr een ground wire s from the ignitor control, the gas valve and pilot burner are all intac t and making good electrical connec tion. Check to make sure tha t the ceramic insul ator on the pilot ignitor or sensor i s no t br oken or cr acke d, if all a re intact replace the ignition control “IC”.

4. The dr aft motor runs and the spar ker sparks at the pilot burner but the pilot do es not ignit e and a gas odor is not detected at the draft motor outlet.

a. Check to mak e sure gas is be ing suppli ed to the unit.

Make sure that the gas pressure to the unit is within the proper limi ts as described in the “POS T ST ART CHECK

LIST” and th at the pilot adj ust s crew is a llowing some flow of gas as descri bed i n “PIL OT C HECKO UT”.

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 intact , check for 24 volts a cross termi nals

“PV” and “COMMON” on the ignitor control. If 24 volts is not present, repl ac e th e ig ni to r control.

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

remove the pilot or ifice fro m the pil ot burner. The orifice is removed in the direction opposite the flow of gas. Inspect the orifice for obstruction. If it is clear, replace the main gas valv e.

5. The sparker spar ks at the p ilot burn er but the pilo t does n ot ignite and a gas odor is detected at the draft motor outlet.

a. Adjust the p ilot adjust scre w on the gas valve as de-

scribed in “PILOT CHECKOUT”.

b. Check the supply pressure as described in “POST

ST ART CHECK LIST”. Make adjustments as necessary.

c. C heck the pilo t orifice for o bstruction as described in

Item 4. Clean as neede d but the pr oblem shoul d not be the gas valve.

6. The pilot burner ignites but the sparker continues to spark and the main burn er s do not ignite.

a. Make the same checks and adjustment as described in Item 5. b. Make sure that the pilot burner is not bent or damaged. c. Make sure that the ground connections at the pilot

burner, gas valve and i gnitor control a re inta ct. Chec k the high tens ion wire for good elec trical c onnectio n. If all are intact, re pl ac e th e ig ni to r m od ul e.

7. The pi lot burner lights and the sp ark stops but the main burners do not lig ht.

a. Check el ectrical connecti ons betwee n the igni tor con-

trol and the gas valve. If i ntact, chec k for 24 vo lts across terminals “MV” an d “COMMON” terminal s. If no voltage detected, re place ignito r control. If voltag e is present, replace gas valve.

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

a. Make sure that the pilot burner is aligned properly with

the carryover as desc ribe d in “ PILO T CHEC KOUT ”.

b. Make sure that the carryovers on adjoining burners are

screwed fast and are level with respect to one another.

9. 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 replace burner orifices and burners as needed.

208/230-1-60 VOLT

MODELS ONLY

Unitary Products Group P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in U.S.A. Copyright  by York In te rnat ional Co rpor ation 19 98. All Rig ht s Reserve d.

208/230, 460 VOLT

MODELS ONLY

208/230, 575 VOLT

MODELS ONLY

530.18-N8Y

York D2CG 072, D7CG 036, D7CG 048, D7CG 060 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual