York DM078 Series, DR090 Series, DF090 Series, DH078 Series, DM090 Series User's, Maintenance And Service Information Manual

CONTENTS

®

SAFETY INFORMATION . . . . . . . . . . . . . . . . 2

FOR YOUR SAFETY . . . . . . . . . . . . . . . . . . . . . 2

SYSTEM OPERATION. . . . . . . . . . . . . . . . . . 2

THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . 2

INTERMITTENT IGNITION DEVICE . . . . . . . . . . 2

INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

OPERATING INSTRUCTIONS. . . . . . . . . . . . . . .3

TO SHUT DOWN THE FURNACE: . . . . . . . . . . . 3

TO LIGHT THE FURNACE: . . . . . . . . . . . . . . . . 3

VENT SAFETY SYSTEM: . . . . . . . . . . . . . . . . . . 3

100% SHUT OFF: . . . . . . . . . . . . . . . . . . . . . . . . 3

EXPLAIN UNIT FUNCTION . . . . . . . . . . . . . 4

GENERAL MAINTENANCE . . . . . . . . . . . . . 4

HEATING SYSTEM INSPECTION . . . . . . . . . . . 4

BURNER CHECK . . . . . . . . . . . . . . . . . . . . . . . 4

CLEANING BURNERS . . . . . . . . . . . . . . . . . . . . 4

CLEANING FLUE PASSAGES AND

HEATING ELEMENTS . . . . . . . . . . . . . . . . . . . . . 4

AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 5

MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . 6

REGISTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

USER’S, MAINTENANCE

and

SERVICE INFORMA TION

MANUAL

SINGLE PACKAGE

AIR CONDITIONER

GAS/ELECTRIC

The manufacturer recommends that the “User” read all sections of this
manual and keep the manual for future reference.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . 6

BEFORE CALLING A SERVICE

TECHNICIAN: . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

REPLACEMENT PARTS . . . . . . . . . . . . . . . 7

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly
could result in serious injury, death, or
property damage.

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

- WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas sup­plier’s instructions.

• If you cannot reach your gas supplier, call

the fire department.

- Installation and service must be per
formed by a qualified installer, service
agency or the gas supplier.

035-19047-002-A-1103

035-19047-002-A-1103

SAFETY INFORMATION

FOR YOUR SAFETY

• Make sure that the furnace area is clear and free of
combustible materials, gasoline and other flamma­ble vapors and liquids.

• Be sure the furnace is clear and free of insulating
material. Examine the furnace area after installa­tion of the furnace or the installation of additional
insulation. Some types of insulation are combusti­ble.

• For proper operation of this furnace, air for com­bustion and ventilation is required. Make sure that
these openings are not obstructed.

• For lighting or shutting down this furnace, refer to
the lighting instructions provided adjacent to the
burners and also located in this manual.

• A blocked vent roll-out switch is provided in the
burner compartment. This switch is a manual reset.
If the furnace fails to operate, contact a qualified
service technician.

SYSTEM OPERATION

THERMOSTATS

Set your thermostat for either heating or cooling then
set it for the desired temperature. DO NOT ADJUST
THE THERMOSTAT RAPIDLY ON AND OFF, OR
BACK AND FORTH FROM HEAT TO COOL. THIS
COULD DAMAGE YOUR EQUIPMENT.

Always allow at least 5 minutes between changes. Find
the temperature that is most comfortable to you and
then LEAVE YOUR THERMOSTAT ALONE. (Excep­tion is for night or vacation “set back” to conserve
energy).

Manually moving the thermostat up or down will not
speed up temperature changes in your rooms. This
only causes the thermostat switch to function at your
command rather than responding to room temperature.

Heat generated by devices other than the furnace may
interfere with thermostat performance. Therefore,
lamps, radios, television sets, etc. should not be placed
near the thermostat.

• Should the gas supply fail to shut off or if overheat­ing occurs, shut off the gas valve to the furnace
before shutting off the electrical supply. Then call a
qualified service technician.

• Do not use this furnace if any part has been under
water. A flood-damaged furnace is extremely dan­gerous. Attempts to use the furnace can result in
fire or explosion. A qualified service technician
should be contacted to inspect the furnace and to
replace all gas controls, control system parts, elec­trical parts that have been wet or the furnace if
deemed necessary.

• Determine the integrity of the installation regarding
the flue gas vent, the return and supply air duct.
Confirm the equipment is well supported and there
are no signs of deterioration. The manufacturer
recommends that main burner, ignition device and
controls are inspected by a qualified service techni­cian before each heating season.

FIGURE 1- TYPICAL THERMOSTAT
INTERMITTENT IGNITION DEVICE

This furnace is equipped with an intermittent auto­matic ignition system.

Do Not attempt to manually

relight the burners. Personal injury could result.

When the thermostat calls for heat, gas is supplied and
at the same time, sparking occurs to light the burner.
With the burner lit, the flame sensor rod closes a circuit
to the ignitor control which allows the burner to con­tinue to fire.

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When the room thermostat is satisfied, the electrical
circuit to the gas valve is opened, clos ing main burner
gas. If the bu rner shoul d f ail to lig ht, conta ct you r heat­ing contractor or gas utility for service to insure that
proper operating conditions are restored.

035-19047-002-A-1103

)

INPUT

The correct heat capacity of the furnace is regulated by
the burner orifices and the gas pressure. The proper
orifices are furnished but the gas pressure regulator
must be adjusted by the installer or gas utility service
technician.

OPERA TING INSTRUCTIONS

TO SHUT DOWN THE FURNACE:

1. Close the main gas shutoff valve(s).

2. Turn off the electric power supply.
TO LIGHT THE FURNACE:

1. Do not attempt to light manually.

2. Open the main gas shutoff valve(s).

3. Adjust the set point of the room thermostat above
the temperature in the space.

4. Turn on the electric power supply.

5. The draft fan will operate. After an adequate purge
time, the electric spark igniter will light the burners.

6. The burners will extinguish and relight automati­cally upon the demand of the room thermostat.

VENT SAFETY SYSTE M:

C. Opening and closing the unit's main disconnect

switch.

M a i n G a s
S h u t - o f f V a l v e
F i e l d I n s t a l l e d

( M o u n t e d E x t e r n a l l y

FIGURE 2- T YPI CAL INSTALLATION

If the furnace continues to lock out, a quali fied service
technician should be called to determine t he cause of
the problem.

This gas furnace is e quipped with a manu al reset h igh
temperature sensor or rollout switch which in the
unlikely event of a sustained main burner flame rollout
will shut off the flow of gas by closing the main gas
valve. The ignition modules wi ll also be disabled, pre­venting the flow of gas to the valve. The switch is
located inside the gas heat access panel above the
burner inlet. Flame rol lout can be c aused by blockage
of the power vent system, improper gas pressure or
adjustment. If this event occurs the furnace will not
operate properly. The gas supply to the furnace should
be shut off and no attempt should be made to place the
furnace in operation. The system should be inspected
by a qualified service technician. Refer to Figure 2 for a
typical installation.

100% SHUT OFF:
The ignition modules are designed for 100% shu t-off. If

the furnace fails to ignite after three ignition attempts,
the flow of gas w ill be sh ut off an d the ignit ion mod ule
will lock out. The module can be reset by:

A. Turning the system switch on the room thermostat

to the “OFF” position and back to the “HEAT” posi­tion.

B. Decreasing the set point of the room thermostat

below the temperature in the conditioned space
and returning it to its original setting.

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result
in dangerous operation, seriou s injury, death or prop­erty damage.

Improper servicing could result in dangerous opera­tion, serious injury, death or property damage.

• Before servicing, disconnect all electrical power
to furnace.

• When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

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

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EXPLAIN UNIT FUNCTION

When the system is functioning properly, show the
owner the location of all disconnect switches and the
thermostat. Explain how to start and stop the unit and
how to adjust temperature settings within the limitations
of the system. Adv ise that the flue exhaust hood su r­face and the immediate area will experienc e high tem­peratures during the heating cycle, and that all
unauthorized personnel and debris mu st be kept away
from this area.

G A S
S U P P L Y

B U R N E R

P I P E

B U R N E R B R A C K E T

I G N I T O R

035-19047-002-A-1103

H E A T E X C H A N G E R T U B E

B U R N E R F L A M E

( B L U E O N L Y )

GENERAL MAINTENANCE

In order to insure long and trouble free service from
your system, we recommend periodic inspection,
cleaning, lubrication and adjustment by your installing
Dealer/Contractor. Be sure to ask about this service.
For those who prefer to do-it-yourself, please follow the
instructions listed below to care for your system.

Snow or debris should not be allowed to accumulate in
or around the unit. Do not permit overhanging struc­tures or shrubs to obstruct outdoor air discharge, com­bustion air inlets or vent outlets on your unit. These
provide air for combustion and ventilation. Adequate air
is important to the safe and proper operation of the
unit.

HEATING SYSTEM INSPECTION

It is the owner's responsibility to insure that an annual
inspection of the entire heating portion of the unit is
made by a qualified service technician. This should
include inspection of the burner, heating element and
flue for any corrosion or soot accumulation which may
require cleaning and al so c heck ing o f burner and con­trols for proper operation.

In addition, at least once during the heating season,
the owner shall make a visual inspection of the flue out­let for evidence of black soot or blockage of flue outlet
by leaves or other debris. If any soot is found, it is rec­ommended a qualified service technician be called
immediately. If any blockage is found, it must be
cleared immediately.

Check for obvious signs of deterioration of the unit.
Check that the return and supply du cts attached to the
unit are sound and air tight. Check that the unit's physi­cal support, concrete slab or roof curb, is sound and
not in need of repair. Make sure there are no gaps
between the roof curb and the unit where rain could
leak into the building.

Start the furnace. The vent motor should start, the
igniter will start to spark and ignite the burner. If it does
not, contact a qualified service technician for assis­tance. Check the appearance of the main burner flame.
The flame should have a blue appearance. (See Fig­ure 3.)

FIGURE 3- TYPICAL FLAME

BURNER CHECK

Periodically (at least annually at the beginning of each
heating season) make a visual check of the main
burner flame to determine if the burners need cleaning.

CLEANING BURNERS

Remove them from the furnace as explained the in
BURNER/ORIFICE INSTRUCTIONS section in the
Unit Installation Instructions. Clean burners with wire
brush and vacuum as needed.

CLEANING FLUE PASSAGES & HEATING ELEMENTS

With proper combustion adjustment, the heat
exchanger tubes of a gas-fired furnace will seldom
need cleaning. If the tubes should become sooted,
they can be cleaned as follows:

1. Remove the burner assembly as outlined in
“BURNER/ORIFICES INSTRUCTIONS” of the unit
Install at i on Instructions.

2. Remove the screws holding the flue collector box.
Carefully remove the flue collector box.

3. Remove the flue baffles from the tube interiors.

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

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

6. Run the wire brush into the flue exhaust tube from
the flue collector end. Do not damage the flue
exhaust screen, remove if necessary.

7. If soot build-up is particularly bad, remove the draft
motor and clean the wheel and housing.

8. After brushing is complete, blow away all brushed
areas with air or nitrogen. Vacuum as needed.

9. Replace parts in the reverse order that they were
removed in Steps 1 through 3.

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

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035-19047-002-A-1103

AIR FILTERS

All units contain four (4) 20” x 25” x 2" filters. The filter
racks on these units will receive either 1" or 2" filters.
Filters can also be installed in t he bu ilding at a sui table
return air location if an economizer or outside air
accessory is not used. Filters must always be used.
They should be inspected once a month and thor­oughly cleaned or replaced if it appears they are begin­ning to accumulate excessive dirt.

To install the filters, remove the filter access panel as
shown in Figure 4.

F I L T E R S

I N D O O R C O I L

NOTE: Filters must be installed with “Air Flow” arrows

pointing inward -- toward the indoor coil. In the
event the spacers in the filter section are
removed, they must be reinstalled in their origi­nal position.

Slide filters all the way into the filter racks provided.
When more than one filter in a filter rack is required,
they must butt each other when sliding into position.
Replace the filter access panel.

F I L T E R A C C E S S

P U L L S

FIGURE 4- FILTER ACCESS

BLOWER ASSEMBLY

Even with good filters properly in place, blower wheels
and motors will become dus t laden after many months
of operation. The entire blower assembly should be
inspected annually. If the motor and wheel are heavily
coated with dust, they can be brushed and cleaned
with a vacuum cleaner.

These units are supplied with blower shaft bearings
that do not require maintenance but may be lubricated

if desired. Every three years, using a low pressure
grease gun, pump grease into th e bearing grease fit­ting until grease just begins to show at the seals. Do
not over lubricate. Use any lithium base grease rec om ­mended for ball bearing service.

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

MOTORS

Outdoor fan motors are permanently lubricated and
require no maintenance.

Ventor motor is factory lubricated for an estimated 10
year life.

Indoor Blower Motor and Drive - The indoor blower
motor features ball bearings that do not require peri­odic lubrication. However, if the motor has grease
fittings, periodic lubrication of the motor bearings can
extend the life of components but is optional.

If desired, every three years, using a low pressure
grease gun, pump grease into the bearing greas e fit­ting until grease just begins to show at the seals. Do
not over lubricate. Use any lithium base g rease recom­mended for ball bearing service.

035-19047-002-A-1103

CONDENSER COIL

An annual check and cleanin g, if necessary, of the out­door coil should be done. Cleaning should be as often
as necessary to keep the coil clean. Clean any debris
and dirt from the outside coil face with a brush being
careful not to damage the fins. If extremely dirty , a hose
can be used to wash the c oil from the inside out while
brushing a soapy solution on the outside.

Damage can occur if the bearings are overlubricated.
Use grease sparingly.

REGISTERS

Supply and return air registers must be open when the
unit is in operation. Obstructions m ust not be allowed
to block airflow in or out of the registers.

TROUBLESHOOTING

BEFORE CALLING A SERVICE TECHNICIAN:

A. Check thermostat setting and insure thermostat is

calling for heat or cooling.

B. Check thermostat for lint, etc.
C. Check fuses or circuit breakers.
D. Check filters for excessive dust accumulation.

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035-19047-002-A-1103

REPLACEMENT PARTS

SINGLE PACKAGE AIR CONDITIONER GAS ELECTRIC ( 6.5 TON)
REPLACEMENT PARTS FORM No.

035-19092-000 DF078***
035-17288-000 DH078***
035-17288-000 DM078***

SINGLE PACKAGE AIR CONDITIONER GAS ELECTRIC (8.5 TON)
REPLACEMENT PARTS FORM No.

035-19092-000 DF102***
035-17288-000 DH102***
035-17288-000 DM102***

SINGLE PACKAGE AIR CONDITIONER GAS ELECTRIC (12.5 TON)
REPLACEMENT PARTS FORM No.

035-17288-000 DH150***
035-19085-000 DJ150***
035-17288-000 DM150***
035-19796-000 DR150***

RESPECTIVE MODEL No.

RESPECTIVE MODEL No.

RESPECTIVE MODEL No.

SINGLE PACKAGE AIR CONDITIONER GAS ELECTRIC (7.5 TON)
REPLACEMENT PARTS FORM No.

035-19092-000 DF090***
035-17288-000 DH090***
035-17288-000 DM090***
035-19794-000 DR090***

SINGLE PACKAGE AIR CONDITIONER GAS ELECTRIC (10 TON)
REPLACEMENT PARTS FORM No.

035-19092-000 DF120***
035-17288-000 DH120***
035-17288-000 DM120***
035-19795-000 DR120***

RESPECTIVE MODEL No.

RESPECTIVE MODEL No.

All forms referenced in this manual may be ordered from:

Stan dard Register
T oll free Telephone: [phone]
T o ll free Fax: [phone]

OWNER please have your installer fill in the following information immediately after unit has been
installed and is properly operating.

Installed by __________________________________________________________________________ _______
Installer’s Address ____________________________________________________________________________
Installation Date _____________________________________________________________________________
Owner’s Name ______________________________________________________________________________
Owner’s Address _____________________________________________________________________________
Equipment inst alled at (address) _________________________________________________________________
Model Number ___________________________________ Serial Number_____________________________
Distributor from whom the equipment was purchased __ ______________________________________________

The owner should keep this information in a place where it can be found if needed for warranty purposes.

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Subject to change without notice. Printed in U.S.A. 035-19047-002-A-1103
Copyright © by Unitary Products Group 2003. All rights reserved. Supersedes: 035-19047-001-B-1102

Unitary 5005 Norman
Products York OK
Group Drive 73069