York D3EG 036, D2EG 060, D2EG 048 User Manual

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SUNLINE PLUS™

GAS / ELECTRIC

SINGLE PACKAGE AIR CONDITIONERS

INSTALLATION INSTRUCTION

MODELS D2EG 048 & 060 and D3EG 036

GENERAL

YORK Model DEG units are single package air conditioners with gas heat designed for outdoor installation on a rooftop 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 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:

•

55.70-N1 -General Installation

•

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

•

530.18-N1.2V -Economizer Accessory

•

530.18-N1.13V -Man. Outdoor Air Damper Accy 0-35%

Supersedes: 035-14832-002-A-0302

(11 SEER)

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

•

530.18-N1.12V -Motorized Outdoor Air Damper Accy.

•

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 Altitude Accy. (Propane)

•

530.18-N8.4V -Gas Piping Accessory

•

530.18-N8.12V -Propane Conversion Accessory

•

690.15-N25V -Low Ambient Accessory

•

Renewal Parts:

•

Refer to Parts Manual for complete listing of replacement parts on this equipment.

All forms referenced in this instruction may be ordered from:

Standard Register Toll Free Tel.: 877-318-9675 Fax: 877-379-7920

APPROVALS

Design certified by CGA and UL listed as follows:

1. For use as a forced air furnace with cooling unit.

2. For outdoor installation only.

3. Forinstallationdirectlyoncombustibleflooringor,in theU.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.

035-14832-003-A-0204

FOR YOUR SAFETY

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.

Installer should pay particular attention to the words: NOTE, CAUTION and WARNING. Notes are intended to clarify or make the installation easier. Cautions jury and/or equipment damage may result if installation procedure is not handled properly.

are given to prevent equipment damage. Warnings are given to alert installer that personal in

CAUTION

THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUC TIONS AND ANY APPLICABLE LOCAL, STATE, AND NATIONAL 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, PROPERTY DAMAGE 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 MAINTENANCE TO THE UNIT.

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TABLE OF CONTENTS

General Inspection Reference Approvals Nomenclature

Limitations Location Rigging and Handling Clearances Ductwork Filters Condensate Drain Service Access Thermostat Power and Control Wiring Blower Speed Selection Compressors Combustion Discharge Disconnect Switch Bracket For Optional Belt-Drive Gas Piping Gas Connection L.P. Units, Tanks and Piping Low NOx Application Vent and Combustion Air Hoods Optional Economizer Rain Hood

Cooling System .................................................................13

Preliminary Operation Cooling ..........................................13

Cooling Sequence of Operation ........................................13

Safety Controls (Cooling) ..................................................13

Heating Sequence of Operation ........................................13

Safety Controls (Heating) ................................................. 14

Heat Anticipator Setpoints.................................................14

Pre-Start Check List ..........................................................14

Operating Instructions Post-Start Check List (Gas) Manifold Gas Pressure Adjustment Pilot Checkout Burner Instructions Burner Air Shutter Adjustment Supply Air Blower and Temperature Rise Adj. Supply Air Blower and Temperature Rise Adj. Checking Gas Input Secure Owner's Approval

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INSTALLATION

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OPERATION

START-UP

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15&16

14 14 14 15 15 15 15

16 16

1 1 1 1 2

MAINTENANCE & TROUBLESHOOTING

Normal Maintenance Cleaning Flue Passages and Heating Elements Troubleshooting

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TABLES

3 3 3 3 3 4 4 4 4 4 4 4 4 5 5 6 6 6 7 7

No. Description Page

1 Unit Application Data 2 Gas Heat Application Data 3 Pipe Sizing 4 Physical Data

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5 Supply Air Perf. Direct-Drive Units 6 Supply Air Perf.3 & 4Ton Belt-Drive Units 7 Supply Air Perf.5 Ton Belt-Drive Units 8 Static Resistances 9 Motor & Drive Data

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10 Electrical Data (Direct-Drive Units) 11 Electrical Data (Belt-Drive Units) 12 Limit Control Setting 13 Belt-Drive Supply Air Motor Pulley Adj. 14 Gas Rate - Cubic Feet Per Hour

FIGURES

No. Description Page

1 Center of Gravity ........................................ 3

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

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

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

5 Bottom Supply Connection......................... 6

6 Vent and Combustion Air Hoods................ 7

7 Economizer Rain Hood Assembly.............. 7

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

9 Dimensions and Clearances ...................... 12

10 Gas Valve Piping 11 Typical Gas Valve 12 Proper Flame Adjustment 13 Typical Flame Appearance 14 Belt Adjustment 15 Press. Drop versus Supply Air CFM

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035-14832-003-A-0204

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18 & 19

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17 17

3 4 5 8 8 9

10 11 11 11 11 14

13 14 15 15 15 16

PRODUCT NOMENCLATURE

D 2 E G 4N

PRODUCT CATEGORY

D = Single Package Air Conditioner

(Air Cooled)

PRODUCT GENERATION

2 = 2nd Generation

3 = 3rd Generation

PRODUCT IDENTIFIER

EG = High Efficiency Gas/Electric

2 Unitary Products Group

NOMINAL COOLING

CAPACITY

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

0 030 6 2 5

FACTORY INSTALLED HEAT

N = Natural Gas

VOLTAGE CODE

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

NOMINAL GAS HEATING

OUTPUT CAPACITY

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

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035-14832-003-A-0204

INSTALLATION

LIMITATIONS

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

In the U.S.A.:

1. National Electrical Code ANSI/NFPA No. 70.

2. National Fuel Gas Code Z223.1.

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

4. Local gas utility requirements. In Canada:

1. Canadian Electrical Code CSA C22.1

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

3. Local plumbing and waste water codes.

4. Other applicable local codes. Refer to Table 1 for UnitApplication Dataand toTable 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'sand /or the customer's expense. Size of unit for proposed installation should be based on heat

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

LOCATION TABLE 1 - UNIT APPLICATION DATA

Model DEG 036 048 060

Voltage Variation

Min. / Max.

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

Air on Evaporator Coil,

Min. / Max.

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

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

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

Min

/ Max.

Use the following guidelines to select a suitable location for these units.

1. Unit is designed for outdoor installation only.

2. Condenser coils must have an unlimited supply of air. Where a choice of location is possible, position the unit on either north or east side of building.

WARNING:Excessive exposure of this furnace to contami

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

3. For ground level installation, a level pad or slab should be used. The thickness and size of the pad or slab used should meet local codes and unit weight. Do not tie the slab to the building foundation.

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.

208/230V 187 / 253

460V 414 / 506

575V 518 / 630

57 / 72 57 / 72 57 / 72

45 / 120 45 / 120 45 / 120

CAUTION: If a unit is to be installed on a roof curb or special

frame other than a YORK roof curb, gasketing must be applied to all surfaces thatcome in contact with 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 until the unit is near the place of installation. Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails. Spreaders, whose length exceeds the largest dimension across the unit, MUST be used across 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 out-

side 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 (refer to Figure 6).

Refer to Table 4 for unit weights and to Figure 1 for approximate center of gravity.

CLEARANCES

APPROXIMATE CENTER OF GRAVITY

30-1/2

“

15-1/8

BACK

FIG. 1 - CENTER OF GRAVITY

67-3/4

CONDENSER COIL END

FRONT



“

DIM. 3-5 TON

A 19-3/4" B 40-3/4"

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 operation.

WARNING:Do not permit overhanging structures or shrubs to

obstruct condenser air discharge outlet, combus tion air inlet or vent outlet.

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 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

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The supply and return air duct systems should be designed for the CFM and static requirements of the job. They should NOT

sized tomatch thedimensions ofthe ductconnections onthe 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 ductworkmust beinsulated andwaterproofed.

Refer to Figure 9 for information concerning side and bottom supply and return air duct openings.

FILTERS

1" filters are supplied with each unit. 2" replacement filters may be used with no modification to the filter racks. Filters must always be installed ahead of the evaporator coil and must be kept clean or replaced with same size and type. Dirty filters will reduce the capacity of the unit and will result in frosted coils or safety shutdown. Minimum filter area and required sizes are shown in Table 4.

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 trapped to pro

vide proper drainage. See Figure 2.

FIG. 2 - RECOMMENDED DRAIN PIPING SERVICE ACCESS

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

•

Compressor compartment

•

Burner compartment

•

Blower compartment

•

Main control box

•

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 screws are replaced on the unit

to maintain an air-tight seal.

THERMOSTAT

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. Color coded insulated wires (#18 AWG) should be used to connect thermostat to unit. See Figure 3 for wiring details.

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

terminals 8 and 10 on the relay board to prevent si multaneous operation of the compressor and the economizer. If you want to energize the compressor for supplemental cooling during the economizer op eration, use athermostat with two stages of cooling.

POWER AND CONTROL WIRING

Field wiring to the unit must conform to provisions of the National Electrical Code (NEC) ANSI/NFPA No. 70 and/or local

035-14832-003-A-0204

ordinances. The unit must be electrically grounded in accordance with the NEC (as specified above) and/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 and Table 1.

The internal wiring harness furnished with this unit is an integral part of a UL design certified unit. Field alteration to comply with electrical codes should not be required.

A disconnect switch should be field provided for the unit. The switch must be separate from all other circuits. Refer to Figure 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 wiring diagram.

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, waterproof type connectors MUST BE USED so that water or moisture cannot be drawn into the unit during normal operation. The above waterproofing conditions will also apply

when installing a field-supplied disconnect switch.

Refer to Figure 3 for typical field wiring and to the appropriate unit wiring diagram for control circuit and power wiring information.

BLOWER SPEED SELECTION

Three blower motor speeds are available 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-drive option have an adjustable 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 “HIGH” speed tap on the blower motor. If a lower blower motor speed is desired, this wire should be moved 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 tap. If the low speed is required, connect wire #116to the “LOW” speed tap, theblue motor lead to the“HIGH” speed tap and the orange motor lead to the “MED” speed tap.

COMPRESSORS

On some units the compressor is mounted on springs which have been tightened down for shipment only.

After this unit is installed, back out the compressor bolts until the sleeve clears the top grommet.

CAUTION: Do Not

loosen compressor mounting bolts.

TABLE 2 - GAS HEAT APPLICATION DATA

Input

Capacity,

(Mbh)

50 40 3 Ton 47 15 45 75 60 4 Ton 70 25 55

100 79 3/5 Ton 93 40/25 70/55

125 99 4/5 Ton 116 45/35 75/65

NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with

1Based on 1075 Btu/Ft

2The air flow must be adjusted to obtain a temperature rise within the range shown.

Output

Capacity,

(Mbh)

Kit Model No. 1NP0434. All furnaces meet the latest California seasonal efficiency requirements.

Available

Models

Gas Rate

(Ft.3/Hr.)

Temp. Rise °F

At Full Input

Min. Max.

COMBUSTION DISCHARGE

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

4 Unitary Products Group

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035-14832-003-A-0204

COOLING / HEATING (24 VOLT THERMOSTAT)

C O O L I N G / H E A T I N G ( 2 4 V O L T T H E R M O S T A T )

T H E R M O S T A T

T E R M I N A L S

A D D

J U M P E R

R H

R C

2 4 V O L T T H E R M O S T A T 2 T H 0 7 7 0 1 0 2 4 . I F T H E U N I T H A S A N E C O N O M I Z E R , R E M O V E J U M P E R J 1 F R O M T E R M I N A L S 8 A N D 1 0 O N T H E R E L A Y B O A R D T O P R E V E N T S I M U L T A N E O U S O P E R A T I O N O F T H E C O M P R E S S O R A N D T H E E C O N O M I Z E R . I F Y O U W S E C O N D S T A G E O F C O O L I N G O R H A V E A N D E L E C T R I C H E A T A C C E S S O R Y W I T H T W

O S T A G E S O F H E A T , U S E T H E R M O S T A T 2 T H 0 4 7 1 0 2 4

C O O L I N G / H E A T I N G ( E L E C T R O N I C T H E R M O S T A T )

T H E R M O S T A T

T E R M I N A L S

A D D

E L E C T R O N I C P R O G R A M M A B L E T H E R M O S T A T 2 E T 0 7 7 0 1 0 2 4 ( I N C L U D E S S U B B A S E ) .

I F T H I S U N I T H A S A N D E C O N O M I Z E R , R 1 0 O N T H E R E L A Y B O A R D T O P R E V E N T S I M U L T A N E O U S O P E R A T I O N O F T H E

O M P R E S S O R A N D T H E E C O N O M I Z E R . I F Y O U W A N T T O C O N T R O L T H E

C E C O N O M I Z E R O N A S E C O N D S T A G E O F C O O L I N G , U S

R H

R C

U N I T T E R M I N A L

S T R I P T B 1

Y 1

Y 2

W 1

W 2

A N T T O C O N T R O L T H E R E C O N O M I Z E R O N A

2 4 V O L T

T R A N S F O R M E R

S I N G L E S T A G E

U N I T T E R M I N A L

S T R I P T B 1

Y 1

W 1

2 4 V O L T

T R A N S F O R M E R

E M O V E J U M P E R J 1 F R O M T E R M I N A L S 8 A N D

E T H E R M O S T A T 2 E T 0 4 7 0 0 2 2 4 .

CONTROL WIRING

POWER WIRING

COOLING / HEATING (ELECTRONIC THERMOSTAT)

L E D 1

L E D 2

C O M

U N I T T E R M I N A L

R C

R H

Y 1

Y 2

W 1

W 2

N O T U S E D

A 1

A 2

S T R I P T B 1

Y 1

Y 2

W 1

W 2

T O R E M O T E S E N S O R 2 T H 0 4 0 7 0 2 2 2 4 I F U S E D

N A L S A 1 A N D A 2 P R O V I D E A R E L A Y

2 4 V O L T

T R A N S F O R M E R

T H E R M O S T A T

T E R M I N A L S

A D D

J U M P E R

A D D

J U M P E R

E L E C T R O N I C P R O G R A M M A B L E T H E R M O S T A T 2 E T 0 4 7 0 0 2 2 4 ( I N C L U D E S S U B B A S E )

S E C O N D S T A G E C O O L I N G I S N O T R E Q U I R E D O N U N I T S L E S S E C O N O M I Z E R .

S E C O N D S T A G E H E A T I N G I S O N L Y R E Q U I R E D O N U N I T S W I T H A T W O S T A G E

E L E C T R I C H E A T E R .

R E M O V E J U M B E R J 2 F R O M T E R M I N A L S 4 A N D 9 O N J U M P E R P L U G C O N N E C T O R P 6 O N U N I T S W I T H E C O N M I Z E R . T E R M I O U T - P U T T O C L O S E T H E O U T D O O R E C O N O M I Z E R D A M P E R S W H E N T H E T H E R M O S T A T S W I T C H E S T O T H E S E T - B A C K P O S I T I O N .

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

FIG. 3 - TYPICAL FIELD WIRING

DISCONNECT SWITCH BRACKET FOR UNITS WITH OPTIONAL BELT-DRIVE BRACKET

A special bracket for mounting a field-supplied disconnect switch is provided in each unit ordered with an optional beltdrive supply air blower. The bracket is shipped inside the blower compartment taped to the top of the blower housing. Install the bracket on the left hand side of the unit as shown in Figure 9. Several existing screws at the top of the unit and one approximately midway down from the top will be used for mounting the bracket. Screws should be loosened only - NOT REMOVED. Mounting 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 piping depends on the cubic feet per hour of gas flow required, specific gravity ofthe gas and the lengthof run. “National Fuel Gas Code” Z223.1 should be followed in all cases unless superseded by local codes or gas company requirements. Refer to Table 3.

Unitary Products Group 5

The heating value of the gas may differ with locality. The value should be checked with the local gas utility.

NOTE: There may be a local gasutility requirement specifying

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

TABLE 3 - PIPE SIZING

Length in Feet

10 20 30 40 50 60 70 80 90

100

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).

1/2 in.

132

92 73 63 56 50 46 43 40 38

Nominal Iron Pipe Size

3/4 in.

278 190 152 130 115 105

96 90 84 79

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

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035-14832-003-A-0204

FIG. 4 - EXTERNAL SUPPLY CONNECTION

EXTERNAL SHUT-OFF

GAS CONNECTION

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. Refer to Figure 9 to locate these access openings. Typical supply piping arrangements are shown in Figures 4 and 5. All shaded items are field-supplied.

Twogrommets 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 front of the unit.

After the gas supply piping has been installed, the bottom opening should be sealed to preventwater from 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 contain some propane. Propane,

being an excellent solvent, will quickly dissolve white lead or most standard commercial com pounds. 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.

4. Allpiping should becleaned of dirtand scale by hammering 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, 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. 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).

FIG. 5 - BOTTOM SUPPLY CONNECTION

EXTERNAL SHUT-OFF

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, must be installed immediately upstream of the gas supply connection to the furnace.

L.P./PROPANE 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 1NP0434.

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

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

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

pressure depends on three main factors:

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

2. The proper pressure regulation. (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 regualtor and the appliance. Pipe size required will depend on the length of the 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 used when assembling piping for this gas as it will quickly dissolve white lead or most standard commercial compounds. Shellac base compunds 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.

LOW NOx APPLICATION

For natural gas heat installations in locations which require low Nitros Oxide emmissions, accessory model 1LN0404 must be installed.

6 Unitary Products Group

Page 7

035-14832-003-A-0204

VENT AND COMBUSTION AIR HOODS

The vent and combustion air hoodsare shipped attached tothe blower housing in the blower compartment. These hoods must be installed on the outside of the gas heat panel to ensure proper unit function. The necessary mounting screws are provided in a bag that is also attached to the blower housing.

The screen for the combustion air intake hood is secured to the inside of the access panel opening with three fasteners and the screws used formounting the hood to the panel. The top flange of this hood slips in under the top of the access panel opening when installing. Refer to Figure 6. 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 installed on the unit. These screws engage the bottom flue box flange.

CAUTION: All three screws in the vent hood must be properly

installed before furnace operation to insure all combustion products are exhausted from the unit.

FIG. 6 - 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 7. 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 components, including the filters, the gasketing and the hardware for assembling are located above the top filter racks within the filter section. The outdoor air sensor is in the bag of parts located at the bottom of the return air section.

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 the outdoor 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 the outdoor air sensor to the rear panel, just below the knockout described in Step 2. Secure with two selfdrilling 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 termi nal 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 slip flange of hood cover in under flange of unit top cover, replace screw (C), engaginghole (E) in hood flange and tighten. Attach the two side plates to the unit panel by using twoself-drilling screwsfor eachside plateat dimples (D) provided in the panel.

6. Position 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 fillpieceis 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.

GASKETED FLANGE

L. H. SIDE PLATE

FILTERS

FILTER COVER

HOOD COVER

FILLPIECE

OUTDOOR AIR OPENING COVER

GASKETED FLANGE

R. H. SIDE PLATE

SIDE DUCT APPLICATION SHOWN

OUTDOOR AIR SENSOR

GASKET

FILTER SECTION ACCESS PANEL

FIG. 7 - ECONOMIZER RAIN HOOD ASSEMBLY (OPTION)

Unitary Products Group 7

Page 8

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 position.

035-14832-003-A-0204

CAUTION: When proceeding with Steps 9 and 10, extreme

care must be exercised while turning both the set point and minimum position adjusting screws to prevent twisting them off.

9. The enthalpy set point for the dampers may now be set by selecting the desired set point from graph in Figure 8. For a single enthalpy justing screw to the “A”, “B”, “C” or “D” setting correspond ing to the lettered curve. For a dual enthalpy

economizer, carefully turn the set point ad

economizer,

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 then energize and de-energize terminals “R” to “G”. With terminals “R” to “G” energized, turn the minimum position screw counterclockwise until the desired minimum position has been attained.

11. Replace the filter section access panel.

FIG. 8 - ENTHALPY SET POINT ADJUSTMENT

TABLE 4 - PHYSICAL DATA

DEG

12 x 10

1.5 3

4.3



4,200

17.1 2

6.3

12 x 10

1.5 3

5.1



4,500

17.1 2

6.3

EVAP.

BLOWER

EVAP.

COIL

COND.

FAN

COND.

COIL

AIR

FILTERS

(SEE NOTE)

MODELS

CENTRIFUGAL BLOWER (Dia. x Wd. in.) FAN MOTOR HP (Direct-Drive) FAN MOTOR HP (Belt-Drive)

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

PROPELLER DIA. (in.) FAN MOTOR HP NOM. CFM TOTAL

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

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

036 048 060

12 x 10



1.5 3

3.6



4,500

17.1 2

6.3

CHARGE REFRIGERANT 22 (lbs./oz.) 9/12 9/8 9/8

COMPRESSOR QUANTITY PER UNIT (HERMETIC TYPE) 1 / RECPT 1 /RECPT 1 / SCROLL

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

WEIGHTS (LBS)

Basic Unit (Nom. Max.)

3 Ton 615 4 Ton 655 5 Ton 680

OPTIONS / ACCESSORIES Economizer 50 Motorized Outdoor

Air Damper Barometric Relief/Fixed

Outdoor Air Intake Damper

Roof Mounting Curb 92 Belt-Drive Blower 5

TABLE 5 - SUPPLY AIR PERFORMANCE

GAS HEAT VALUES SHOWN @ 230/460/575 VOLTS -

MODEL

DEG

036

048

060

NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.

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

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

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

1684 1487

1996 1804 1681

2400 2290 2150

800 710

960 838 760

1155 1105

1020

1631 1464

1933 1765 1640

2338 2214 2100

780 690

936 810 738

1125 1065

990

- 3, 4, & 5 TON w/Direct-Drive Blower Side Duct Connections

Available External Static Pressure - IWG*

1570

785

1650

825

1699

1524

750

1582 1421

1868 1714 1604

2274 2145 2029

670 910

785 715

1095 1030

950

1367 1795

1650 1541

2167 2071 1965

720 650

880 765 695

1045

990 910

1410 1315

1722 1589 1490

2096 1990 1905

755 690 620

845 735 670

1010

950 880

1430 1324 1246

1635 1508 1416

1990 1911 1816

725 650 605

820 705 645

980 920 838

1360 1260 1185

1544 1407 1337

1887 1828 1724

700 630 590

790 675 620

945 885 800

1280 1185

1110

1419 1306 1230

1771 1724 1644

680 610 570

765 645 595

905 835 770

1180 1100 1020

1300 1195 1120

1629 1604 1531

655 590 545

740 625 575

855 798 710

8 Unitary Products Group

Page 9

035-14832-003-A-0204

TABLE 6 - SUPPLY AIR PERFORMANCE - 3 & 4 Ton

w/Belt-Drive Blower

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

MODEL

DEG

036

MODEL

DEG

036

AIR FLOW

CFM

2000 843 860 880 925 919 1005 956 1065 993 1145 1030 1195 1067 1235 1900 817 775 854 850 893 920 930 995 970 1065 1008 1125 1046 1170 1800 790 700 828 760 867 840 906 905 944 980 985 1040 1025 1100 1700 - - 802 670 840 745 881 815 920 900 961 970 1001 1030 1600 ----818665858740898820940890980950 1500 ------842695882755922835962895 1400 ------833650867705904765942820 1300 --------858665893725932785 1200 --------847640880680916730

AIR FLOW

CFM

2000 1103 1270 -----------1900 1085 1210 -----------1800 1064 1145 1102 1180 ---------1700 1040 1075 1081 1115 1121 1140 -------1600 1020 1005 1060 1050 1100 1085 -------1500 1003 945 1044 995 1086 1035 -------1400 982 880 1024 920 1067 965 1107 1000 -----1300 970 835 1010 870 1053 920 1099 960 -----1200 953 780 992 815 1034 855 1080 905 ------

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

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*

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

MODEL

DEG

MODEL

DEG

NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.

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

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

048

AIR FLOW

CFM

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

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*

Unitary Products Group 9

Page 10

TABLE 7 - SUPPLY AIR PERFORMANCE - 5 Ton w/Belt-Drive Blower 5 TON - SIDE DUCT CONNECTIONS @230/460/575 Volts

MODEL

DEG

060

AIR FLOW

CFM

2500 1059 1560 1077 1590 1095 1630 1114 1650 1134 1660 1158 1685 1181 1720 2400 1032 1405 1054 1470 1074 1525 1094 1560 1116 1595 1140 1620 1167 1640 2300 1005 1260 1024 1275 1049 1370 1069 1440 1090 1475 1116 1505 1142 1535 2200 980 1160 1002 1170 1022 1190 1044 1250 1066 1350 1090 1410 1117 1440 2100 930 1060 957 1070 983 1080 1010 1100 1039 1160 1064 1260 1092 1340 2000 877 950 908 975 941 1000 976 1020 1009 1050 1040 1100 1070 1225 1900 ----8948859409409809801014 1020 1047 1095 1800 ----8558159038609509059889401022 970 1700 ------8848159258509648801001 910 1600 ------864770908805948835987870 1500 --------882740926780965830

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

Available External Static Pressure - IWG*

035-14832-003-A-0204

MODEL

DEG

NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.

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

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

060

AIR FLOW

CFM

2500 -------------2400 1193 1665 -----------2300 1170 1580 1202 1620 ---------2200 1148 1480 1180 1530 ---------2100 1121 1385 1155 1425 1190 1475 -------2000 1100 1285 1133 1340 1169 1385 1205 1445 -----1900 1079 1180 1110 1240 1143 1280 1178 1330 1222 1375 ---1800 1058 1060 1090 1135 1122 1190 1158 1240 1196 1295 ---1700 1035 960 1071 1030 1103 1100 1134 1140 1164 1175 1197 1205 - 1600 1020 900 1056 965 1088 1035 1118 1065 1145 1105 1170 1130 1198 1150 1500 1004 860 1038 880 1070 925 1101 980 1130 1045 1158 1075 1184 1110

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*

10 Unitary Products Group

Page 11

035-14832-003-A-0204

TABLE 8 - STATIC RESISTANCES

EXTERNAL STATIC PRESSURE DROP

RESISTANCE, IWG

DESCRIPTION

Economizer Bottom Duct Connections

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

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 during full economizer operation.

1, 2

1000 1200 1400 1600 1800 2000 2200 2400 2600

0.07 0.08 0.09 0.11 0.13 0.15 0.17 0.20 0.23

0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.14 0.16

CFM

TABLE 9 - MOTOR AND DRIVE DATA - Belt-Drive Blower

ADJUSTABLE

MOTOR PULLEY

PITCH

DIA.

(in.)

BORE

(in.)

MODEL

BLOWER

RANGE

(RPM)

HP RPM

MOTOR*

FRAME

SIZE

SERVICE

FACTOR

DEG 036 790 - 1120 1-1/2 1725 56 1.15 2.4 - 3.4 7/8 3.7 1 37.3 A36 DEG 048 790 - 1120 1-1/2 1725 56 1.15 2.4 - 3.4 7/8 5.7 1 37.3 A36 DEG 060 850 - 1220 1-1/2 1725 56 1.15 2.4 - 3.4 7/8 5.2 1 37.3 A36

*All motors have 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

heating device.

FIXED

BLOWER PULLEY

PITCH

DIA.

(in.)

BORE

(in.)

PITCH

LENGTH

(in.)

BELT

DESIG-

NATION

TABLE 10 - ELECTRICAL DATA - w/Direct-Drive

VOLTAGE

MODEL

DEG

POWER

SUPPLY

LIMITATIONS

(SEE NOTE 1)

COMPRESSOR

MIN. MAX. RLA LRA

16.7

253

208/230-1-60

036

208/230-3-60

460-3-60 575-3-60

208/230-1-60

048

208/230-3-60

460-3-60 575-3-60

208/230-1-60

060

208/230-3-60

460-3-60 575-3-60

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

187 187 414 518

253 504 630

253 253 504 630

13.1

6.7

5.1

18.7

11.9

6.3

4.9

32.1

19.3

10.0

7.9

TABLE 11 - ELECTRICAL DATA - w/Belt-Drive

VOLTAGE

MODEL

DEG

POWER SUPPLY

LIMITATIONS

(SEE NOTE 1)

MIN. MAX. RLA LRA

208/230-1-60

036

208/230-3-60 460-3-60 575-3-60

208/230-1-60

048

208/230-3-60 460-3-60 575-3-60

208/230-1-60

060

208/230-3-60 460-3-60 575-3-60

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

187 187 414 518

COMPRESSOR

253 253 504 630

16.7

13.1

6.7

5.1

18.7

11.9

6.3

4.9

32.1

19.3

10.0

7.9

Blower Motor

MOTOR,

110

54 44

135 130

52.0 135

150

73 50

Blower Motor

MOTOR,

110

54 44

135.0

130.0

64.8

52.0

169 123

62 50

COND.

FAN

FLA

2.3

1.4

2.3

1.4

2.3

1.4

COND.

FAN

FLA

2.3

1.4

2.3

1.4

2.3

1.4

SUPPLY

BLOWER

MOTOR,

SUPPLY

BLOWER

MOTOR,

AIR

FLA

4.4

2.0

2.2

5.0

2.2

6.6

3.3

AIR

FLA

7.6

5.3

2.6

2.0

8.6

5.2

2.6

2.0

8.6

6.0

3.0

2.4

MINIMUM

CIRCUIT

AMPACITY

27.5

23.1

12.0

10.7

38.6

25.7

13.2

11.4

49.0

33.0

17.2

14.6

MINIMUM

CIRCUIT

AMPACITY

30.7

23.9

12.4

9.8

42.6

26.3

14.3

11.4

51.0

32.4

16.9

13.7

MAX.

FUSE

SIZE,

(SEE NOTE 2)

AMPS

40 35 15 15

60 40 20 15

80 50 25 20

MAX. FUSE SIZE,

(SEE NOTE 2)

AMPS

45 35 20 15

60 40 20 15

80 50 25 20

MAX.

HACR

BREAKER

SIZE,

AMPS

40 35 15 15

60 40 20 15

80 50 25 20

MAX.

HACR

BREAKER

SIZE,

AMPS

45 35 20 15

60 40 20 15

80 50 25 20

Unitary Products Group 11

Page 12

(Direct Drive Units)

035-14832-003-A-0204

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

1 Units may be installed on combustible floors made from wood or class A, B or C

roof covering material.

2 Units must be installed oudoors. Overhanging structures or shrubs should not

obstruct the outdoor coil nor the fan outlet.

NOTE: A 1" clearance must be provided between any combustible material and the

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.



UNIT WITH ECONOMIZER RAIN HOOD

12" (Less Economizer) 36" (With Economizer or Fixed

Air/motorized Air Damper)

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

20"

72" (For Condenser Air Discharge)

“ CONDENSATE

DRAIN (must be trapped)

DETAIL “A”

AIR FLOW LEGEND

OUTDOOR

AIR DAMPER

MOTORIZED

RETURN AIR

SUPPLY AIR

OUTDOOR AIR

OUTDOOR AIR (Economizer)

DIMENSION “A”

FIXED

DAMPER



REAR VIEW

SIDE SUPPLY AND RETURN

AIR OPENINGS





$

“A”

All dimensions are in inches. They are subject tochange without notice. Certified dimensions will be provided upon

UTILITIES ENTRY DATA



HOLE



*Knockouts in the bottom of the unit can be located by

the slice in the insulation.

**Do not remove the 2" knockout ring.

DETAIL “B”

UNIT WITH FIXED OUTDOOR

AIR/MOTORIZED DAMPER RAIN HOOD

KNOCKOUT

SIZE

(DIA.)

A 7/8" *

B 2" *

C 1-5/8"

D 1-1/2"

USED FOR

Control Wiring (Side or Bottom)**

Power Wiring (Side or Bot tom)

Gas Piping (Front)

Gas Piping (Bottom)



FIG. 9 - DIMENSIONS AND CLEARANCES (3, 4 & 5 TON)

12 Unitary Products Group

Page 13

035-14832-003-A-0204

GAS VALVE

GAS MAIN

MAIN VALVE

TO MAIN BURNER

REDUNDANT VALVE

TO PILOT BURNER

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 compressor is hermetically sealed and internally sprung. The compressors have inherent (internal) protection. If there is an abnormal temperature rise in the compressor, the protector will open to shut down the compressor.

PRELIMINARY OPERATION COOLING

After the installation has been completed, energize the crankcase heater (3 ton only) for at least 4 hours before operating the unit. After this initial warm-up, the compressor should be given three false starts (energized just long enough to make a few revolutions) with a 5 minute delay between each start before being put into full time service.

NOTE: Prior to each cooling season, the crankcase heater (3

ton only) must be energized at least 10 hours before the system is put into operation.

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 compressor, condenser fan motor and blower motor simultaneously.

CONTINUOUS BLOWER: With the room thermostat switch set to “ON”, the supply air blower will operate continuously. The normally closed blower interlock relay contact “K3-1" provides 24 volt power to the blower relay ”BR". The “BR” power contacts close and 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 air in the gas heat compartment has achieved a pre-set temeprature.

When “TH1" on the thermostat closes, the draft motor relay ”DMR" or “DMC” is energized. The “DMR” or “DMC” power contacts close which energizes the line voltage draft motor. 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 “IC” will start the ignitor sparking and will open the redundant valve locted inside the main gas valve “GV” to allow a flow of gas to only the carryover tube. See Figure 10. Only after the pilot flame has been ignited and the presence of pilot flame detected at the “IC” by a signal sent back through the flame sensor is sparking terminated and the main gas valve opened.

Two-Stage Cooling used if the unit has an economizer. First-stage cooling is provided by the economizer - if the outdoor air enthalpy is acceptable, and second-stage cooling is provided by the compressor. Jumper wire J1 must be removed. Refer to the unit wiring diagram.

After the thermostat is satisfied and opens, the blower will continue to run for a short time. All other components will stop.

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

SAFETY CONTROLS (Cooling)

The refrigerant system is equipped wth the following safety controls:

1. A Suction Line Freezestat tor temperature due to low air flow or a low return air tem perature.

2. AHigh PressureCutout Switch discharge pressures due to a blocked condenser coil or a condenser motor failure.

3. ALow Pressure Switch charge.

If neither one of the abovesafety controls opens, the refrigerant system will be locked out. The lock out of the system can be reset by opening the 24V circuit either at the room thermostat or at the unit disconnect.

HEATING SEQUENCE OF OPERATION

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

Unitary Products Group 13

: A two-stage cooling thermostat may be

to protect against low evapora

to protect against excessive

to protect against loss of refrigerant

FIG. 10 - GAS VALVE PIPING

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

The “IC” will try for 85 seconds to ignite the pilot carryover 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” will again try to light the pilot carryover tube. This will continue continuously until the “IC” detects a pilot flame.

If, after detecting a pilot flame and opening the main gas valve, the “IC” looses pilot flame indication, it will close both the main and redundant gas valves. The “IC” will start the above sequence over untila pilot flame is detected and it will open the main gas valve again.

The “IC” will only allow 16 pilot flameouts and a single rollout switch opening per thermostat cycle. After16 pilot 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 power was supplied to the “DMR” or “DMC”, a parallel circuit activates thetime delayrelay “BT” or “ETD”. The “BT” or “ETD” closesin approximetly35 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 deenergizing the “IC”, thus closing the redundant and main gas valves. The blower motor and the draft motor continue to run for a shortperiod after the furnace is shut down until the “BT” or “ETD” opens (in approximately 25 seconds) de-energizing the “K3", ”BR" and “DMR” or “DMC” relays.

Page 14

SAFETY CONTROLS (Heating)

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 Table 12. 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 valve.

TABLE 12 - LIMIT CONTROL SETTING

Units

(Tons)

3 4 3 4 5 5

2. Centrifugal Switch (CS-36).

Capacity, MBH

Input Output

75 100 125 100 125

40 60 79 99 79 99

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 located up stream of the main gas valve. Should the main gas valve fail in the open position the redundant valve serves as a back up and shuts 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 signal from the flame sensor indicating that the

Limit Control

Opens, °F

165 165 165 165 165 165

035-14832-003-A-0204

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 the main burners, 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 ignition control and closes the main gas valve.

6. Auxiliary Limit Switch.

This control is located inside the heat exchanger compartmentand is set to open at 180°F. I t is a manual reset switch. If the auxiliary limit switch trips, then the primary limit switch has not functioned properly. Replace the primary limit switch.

HEAT ANTICIPATOR SETPOINTS

The anticipator must be set at 0.1 amps. 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 and may result in the lowering of the temperature within the conditioned 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 equipped with an intermittent pilot

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

TO LIGHT PILOT AND MAIN 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, main burners will ignite).

TO SHUT DOWN:

1. Turn “off” electric power to unit.

2. Depress knob of gas valve 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. Check for correct manifold gas pressures. See “Checking 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 pressure exceed 13", nor the operating pressure drop below 4.5" for natural gas units. If gas pressure is outside theselimits, contact the local gas utility for corrective action.

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.

PILOT ADJ. (UNDER SCREW)

Honeywell VR8204M

PILOT ADJ. (UNDER SCREW)

PRESSURE REGULATOR

MANIFOLD ADJUST. SCREW

“ON”-"OFF"

CONTROL HIGH FIRE ADJ. (UNDER SCREW)

“ON”-"OFF" CONTROL

White-Rodgers 36E36

1/2-14 NPT (OUTLET)

FIG. 11 - GAS VALVES

Adjust as follows:

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. To increase the gas pressure, turn the adjusting screw

clockwise.

NOTE: Check the unit dataplate for the proper manifold pres

sure and orifice size of the furnace.

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Page 15

035-14832-003-A-0204

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 - PROPER FLAME ADJUSTMENT

Put the system into operation and observe through complete cycle to be sure all controls function properly.

BURNER INSTRUCTIONS

To check or change burners, pilot or orifices, CLOSE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF ALL POWER TO THE UNIT.

1. Remove the two screws holding either end of the manifold to the burner supports.

2. Open the union fittingin the gas supplyline 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 manifold-burner gas valve assembly by lifting up and pulling back.

Burners are now accessible for service.

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 optional belt-drive supply air motor pulley can be determined from Table 13.

TABLE 13 - BELT-DRIVE SUPPLY AIR

MOTOR PULLEY ADJUSTMENT

TURNS

OPEN*

5 4 3 2 1 0

*Pulley can be adjusted in half-turn increments.

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

variable pitch pulley on the blower motor can be adjusted to obtain the desired supply air CFM. Refer to Table 9 for blower motor and drive data. The tension on the belts should be adjusted as shown in Figure 14.

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:

BLOWER DRIVE RANGE (RPM)

3 TON 4 TON 5 TON

780 842 904

966 1028 1090

CAUTION

SPAN LENGTH

DEFL FORCE

790 856 922

988 1054 1120

850 924

998 1072 1246 1220

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 distinct, sharp, blue flame is obtained. Refer to Figure 13.

FIG. 13 - TYPICAL FLAME APPEARANCE

SUPPLY AIR AIR BLOWER AND TEMPERATURE RISE ADJUSTMENTS

The speed of the supply air blower will depend on the required CFM, the unit accessories and the staticresistances of both the supply and the return air duct systems. With this information, the speed for the supply air blower can be determined from the blower performance and accessory static resistance data in Table 5 through 8.

(B)

(A)

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

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

(C)*

(D)

* NEVER LOOSEN

FIG. 14 - BELT ADJUSTMENT

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

To check thesupply air CFMafter the initial balancing has been completed:

1. Remove the (two) the filter access panel side of the unit.

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

" dot plugs from the holes located on

$

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Page 16

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

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

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

0.7

0.6

0.5

036

048

060

0.4

0.3

0.2

PRESSURE DROP (IWG)

0.1

750 1250 1750 2250 2750 3250 3750

NOMINAL CFM

FIG. 15 - PRESSURE DROP ACROSS A DRY

EVAPORATOR COIL VS SUPPLY AIR CFM, WITHOUT AIR FILTERS

4. Knowing the pressure drop across a dry coil, the actual CFM through the unit can be determined from the curve in Figure 15.

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 rating plate and the data in Table 2.

BtuhInput x 0.8

CFM

108..

xFTempRise

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

WARNING:Failure to properly adjust the total system air quan

5. After readings have been obtained, remove the tubes and seal the holes with the 5/16" dot plugs removed in Step 1.

NOTE: DE-ENERGIZE THE COMPRESSOR BEFORE TAK

tity can result in poor system performance.

ING ANY TEST MEASUREMENTS TO ASSURE A DRY INDOOR COIL.

035-14832-003-A-0204

CHECKING GAS INPUT

NATURAL GAS

1. Turn off all other gas appliances connected to the gas me ter.

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. Using the number of seconds for each revolution and the size of the test dial increment, findthe cubic feet of gascon sumed per hour from Table 14.

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.)

TABLE 14 - 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

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

cubic 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 re sult is 99,750 Btuh, which is close to the 100,000 Btuh rating of the furnace.

52 54 56 58 60

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 APPROVAL: When the system is functioning properly, secure the owner's approval. Show him the loca

tion 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.

16 Unitary Products Group

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035-14832-003-A-0204

MAINTENANCE

NORMAL MAINTENANCE

CAUTION: Prior to any of the following maintenance proce

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

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

FILTERS - Inspect once a month. Replace disposable 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 year life.

CLEANING FLUE PASSAGES AND HEATING ELEMENTS

With proper combustion adjustment the heating element 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 IN STRUCTIONS”.

2. Remove the roof over the gas heat section.

3. At the top frontof the heat section, removethe screws hold ing the top of the flue collector box. Carefully remove the top of the flue collector box without ripping the adjacent in sulation.

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

NOTE: Exercise care when cleaning the coil so that the coil

fins are not damaged.

Do not permit the outdoor air discharge to be ob structed by overhanging structures of shrubs.

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 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 Instructions”. Clean burners with hot water applied along top of the burner.

COMBUSTION AIR DISCHARGE - Visually inspect discharge outlet periodically to make sure that the buildup of soot and dirt is not excessive. If necessary, clean to maintain adequate combustion air discharge.

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

4. Lift out the flue diverter 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 on a flexible wand, brush out the inside of each heat exchanger from the burner inlet and flue outlet ends.

7. Brush out the inside of the flue collector 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. Vacuum as needed.

11. Replace parts in the order they were removed in Steps1 to5.

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.

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Page 18

TROUBLESHOOTING

035-14832-003-A-0204

WARNING:Troubleshooting of components necessarily re

quires opening the electrical control box with the power connected to the unit. Use extreme care when working with live circuits! Check the unit nameplate for the correct line voltage and set the volt meter to the correct range before making any connections with line terminals.

CAUTION: The wire number or color and terminal designa

tions 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 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 sup plied to the contacts of the blower relay, “BR”, and if the blower relay 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 pro tection. Disconnect power to the unit and check the blower motor capacitor. If it is defective, replace it with one of equal capacitance and voltage.

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 wiring back to the relayboard. Check control wiring to the room thermostat.If all isfine, 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 fan switch in the “AUTO” position, check for loose 24 volt wiring between the relay board in the main control box, the Mate-N-Lok connector in the par tition between the evaporator and gas heat sections and the time delay relay “BT” or “ETD”.

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

board. If 24 volts is present, replace the relay board. If 24 volts is not present, replace the “BT” or “ETD”.

NOTE: The furnace may shut itself down on a high temperature

condition during the procedure but this will not effect the test if it is done within 5 minutes of furnace shut-down.

2. The supply air blower operates but the draft motor 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 forthe internaloverload to reset.

b. If themotor 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, replace the draft motor.

c. If line voltage isnot present, checkfor line voltage atthe

draft motor relay “DMR” or “DMC” contacts 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.

18 Unitary Products Group

e. If the “DMR” or “DMC” relay is not pulled in, check for 24

volts at the “DMR” or 24 volts at “TMC-G” terminal coil. If 24 volts is present, replace the “DMR” or “DMC” relay. If 24 volts is not present, check for a loose 24 volt connec tion back to the relay board and check the connections from the room thermostat to the relay board. If all connec tions are correct, replace the relay board.

3. The draft motor runs but the furnace does not light and the sparker does not spark.

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

and in the gas heat section. Check low voltage connec tions to the “BT" and “DMC” or“ETD” located in thecon trol 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 termi

nal 24V on the ignitor control (IC) where the red lead from the draft motor attaches. If 24 volts is not present, the centrifugal switch (CS) has not closed or has gone bad. Check the line voltage to the unit, if it is correct re place the draft motor. If line voltage is low call the power company.

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

trol wiring at the ignitor controland the hightension wire to the ignitor. Check that the green ground wires from the ignitor control, the gas valve and pilot burner are all intact and making good electrical connection. Check to make sure that the ceramic insulator on the pilot ignitor or sensor is not broken or cracked, if all are intact replace the ignition control “IC”.

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

a. Check to make sure gas is being supplied to the unit.

Make sure that the gas pressure to the unit is within the proper limits as described in the “POST START CHECK LIST” and that thepilot adjust screwis allowing some 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 intact, check for 24 volts across terminals

“PV” and “COMMON” on theignitor control. If 24volts is not present, replace the ignitor control.

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

move the pilot orifice from the pilot burner. The orifice is removed in the direction opposite the flow of gas. In spect the orifice for obstruction. If it is clear, replace the main gas valve.

5. The sparker sparks at the pilot burner but the pilot does not 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

START CHECK LIST”. Make adjustments as neces sary.

c. Check the pilot orifice for obstruction as described in

Item 4. Clean as needed but the problem should not be the gas valve.

Cont'd

Page 19

035-14832-003-A-0204

TROUBLESHOOTING - Continued.

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

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

a. Make the same checks and adjustments 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 ignitor control are intact. Check the high tension wire for good electrical connection. If all are intact, replace the ignitor module.

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

a. Check electrical connections between the ignitor con

trol and the gas valve. If intact, check for 24 volts across terminals “MV” and “COMMON” terminals. If no voltage is detected, replace the ignitor control. If voltage is pres ent, replace the gas valve.

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

the carryover as described in “PILOT CHECKOUT”.

b. Make sure that the carryovers on adjoining burners are

screwed fast and are level with respect to one another.

9. Main burnerslight 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.

Unitary Products Group 19

Page 20

Supersedes: 035-14832-002-A-0302

035-14832-003-A-0204

York D3EG 036, D2EG 060, D2EG 048 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual