Daikin Dcg series User manual

ATTENTION INSTALLING PERSONNEL:

Prior to installation, thoroughly familiarize yourself with

this Installation Manual. Observe all safety warnings. Dur-

ing installation or repair, caution is to be observed.

It is your responsibility to install the product safely and to

educate the customer on its safe use.

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

These installation instructions cover the outdoor installation of

single package heating and cooling units. See the Specification

Sheet applicable to your model for information regarding acces-

sories.

*NOTE: Please contact your distributor or our website for the

applicable Specification Sheet referred to in this manual.

This Forced Air Central Unit Design Complies With Requirements

Embodied In The American National Standard / National Stan-

dard of Canada Shown Below.

ANSI Z21.47•CSA-2.3 Central Furnaces

INSTALLATION INSTRUCTIONS

DCGSERIES

LIGHT COMMERCIAL PACKAGED GAS UNIT

3 to 6 TON

5151 San Felipe St., Suite 500, Houston, TX 77056

www.daikincomfort.com

Our continuing commitment to quality products may mean a change in specifications without notice.

IOD-1004E

8/2016

Index

REPLACEMENTPARTS........................................................................... 2

SAFETY INSTRUCTIONS ......................................................................... 2

GENERAL INFORMATION ...................................................................... 3

UNIT LOCATION .................................................................................... 4

CLEARANCES ......................................................................................... 5

ROOF CURB POST-INSTALLATION CHECKS ............................................ 6

ROOF TOP DUCT CONNECTIONS .......................................................... 6

RIGGING DETAILS .................................................................................. 6

ELECTRICAL WIRING ............................................................................. 7

GAS SUPPLY PIPING .............................................................................. 9

PROPANE GAS INSTALLATIONS ........................................................... 10

CIRCULATING AIR AND FILTERS........................................................... 11

VENTING ............................................................................................. 12

CONDENSATE DRAIN CONNECTION ................................................... 12

STARTUP, ADJUSTMENTS, AND CHECKS ............................................. 12

AIR FLOW ADJUSTMENTS ................................................................... 13

MOTOR SHEAVE ADJUSTMENTS ......................................................... 14

GAS SYSTEM CHECK............................................................................ 15

NORMAL SEQUENCE OF OPERATION ................................................. 17

MAINTENANCE ................................................................................... 20

TROUBLESHOOTING ........................................................................... 21

APPENDIX A BLOWER PERFORMANCE TABLES .................................. 23

DIRECT DRIVE................................................................................. 23

DCG036 DOWN SHOT AND HORIZONTAL................................. 23

DCG048 DOWN SHOT AND HORIZONTAL................................. 24

DCG060 DOWN SHOT ............................................................... 25

DCG060 HORIZONTAL ............................................................... 26

BELT DRIVE ..................................................................................... 27

HIGH STATIC DOWN SHOT ........................................................ 28

STANDARD HORIZONTAL........................................................... 29

HIGH STATIC HORIZONTAL ........................................................ 30

APPENDIX B ELECTRICAL DATA ........................................................... 31

APPENDIX C UNIT DIMENSIONS ......................................................... 32

APPENDIX D WIRING DIAGRAMS ....................................................... 33

START-UP CHECKLIST........................................................................... 57

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN

OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE

TURNING OFF THE ELECTRICAL SUPPLY.

WARNING

THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE

STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER

REPRODUCTIVE HARM.

WARNING

TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT USE

THIS UNIT IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A

QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND TO REPLACE

ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL HAVING BEEN

UNDER WATER.

HIS

UNIT

MUST

NOT

USED

CONSTRUCTION

HEATER

DURING

THE

FINISHING

PHASES

CONSTRUCTION

NEW

STRUCTURE

. T

HIS

TYPE

USE

MAY

RESULT

PREMATURE

FAILURE

THE

UNIT

DUE

EXTREMELY

LOW

RETURN

AIR

TEMPERATURE

AND

EXPOSURE

CORROSIVE

VERY

DIRTY

ATMOSPHERES

HIGH VOLTAGE!

ISCONNECT

ALL

POWER

BEFORE

SERVICING

INSTALLING

THIS

UNIT

. M

ULTIPLE

POWER

SOURCES

MAY

PRESENT

. F

AILURE

MAY

CAUSE

PROPERTY

DAMAGE

PERSONAL

INJURY

DEATH

WARNING

TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,

DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER

FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

NLY

PERSONNEL

THAT

HAVE

BEEN

TRAINED

INSTALL

ADJUST

SERVICE

REPAIR

(

HEREINAFTER

, “

SERVICE

”)

THE

EQUIPMENT

SPECIFIED

THIS

MANUAL

SHOULD

SERVICE

THE

EQUIPMENT

. T

MANUFACTURER

WILL

NOT

RESPONSIBLE

FOR

ANY

INJURY

PROPERTY

DAMAGE

ARISING

FROM

IMPROPER

SERVICE

PROCEDURES

. I

YOU

SERVICE

THIS

UNIT

YOU

ASSUME

RESPONSIBILITY

FOR

ANY

INJURY

PROPERTY

DAMAGE

WHICH

MAY

RESULT

. I

ADDITION

JURISDICTIONS

THAT

REQUIRE

ONE

LICENSES

SERVICE

THE

EQUIPMENT

SPECIFIED

THIS

MANUAL

ONLY

LICENSED

PERSONNEL

SHOULD

SERVICE

THE

EQUIPMENT

. I

MPROPER

INSTALLATION

ADJUSTMENT

SERVICING

REPAIR

THE

EQUIPMENT

SPECIFIED

THIS

MANUAL

ATTEMPTING

INSTALL

ADJUST

SERVICE

REPAIR

THE

EQUIPMENT

SPECIFIED

THIS

MANUAL

WITHOUT

PROPER

TRAINING

MAY

RESULT

PRODUCT

DAMAGE

PROPERTY

DAMAGE

PERSONAL

INJURY

DEATH

REPLACEMENTPARTS

ORDERING PARTS

When reporting shortages or damages, or ordering repair

parts, give the complete unit model and serial numbers as

stamped on the unit’s nameplate.

Replacement parts for this appliance are available through

your contractor or local distributor. For the location of your

nearest distributor, consult the white business pages, the

yellow page section of the local telephone book or contact:

HOMEOWNER SUPPORT

DAIKIN NORTH AMERICA LLC

19001 KERMIER ROAD, WALLER, TX 77484

855-770-5678

SAFETYINSTRUCTIONS

TOTHE INSTALLER

Before installing this unit, please read this manual to

familiarize yourself on the specific items which must be

adhered to, including maximum external static pressure to

unit, air temperature rise, minimum or maximum CFM and

motor speed connections.

Keep this literature in a safe place for future reference.

THE

INFORMATION

THESE

INSTRUCTIONS

NOT

FOLLOWED

EXACTLY

FIRE

EXPLOSION

MAY

RESULT

CAUSING

PROPERTY

DAMAGE

PERSONAL

INJURY

LOSS

LIFE

- D

NOT

STORE

USE

GASOLINE

OTHER

FLAMMABLE

VAPORS

AND

LIQUIDS

THE

VICINITY

THIS

ANY

OTHER

APPLIANCE

- WHAT TO DO IF YOU SMELL GAS:

* D

NOT

TRY

LIGHT

ANY

APPLIANCE

* D

NOT

TOUCH

ANY

ELECTRICAL

SWITCH

;

NOT

USE

ANY

PHONE

YOUR

BUILDING

* I

MMEDIATELY

CALL

YOUR

GAS

SUPPLIER

FROM

NEIGHBORS

PHONE

. F

OLLOW

THE

GAS

SUPPLIERS

INSTRUCTIONS

* I

YOU

CANNOT

REACH

YOUR

GAS

SUPPLIER

CALL

THE

FIRE

DEPARTMENT

- I

NSTALLATION

AND

SERVICE

MUST

PERFORMED

QUALIFIED

INSTALLER

SERVICE

AGENCY

THE

GAS

SUPPLIER

WARNING

NOT

CONNECT

USE

ANY

DEVICE

THAT

NOT

DESIGN

CERTIFIED

THE

MANUFACTURER

FOR

USE

WITH

THIS

UNIT

ERIOUS

PROPERTY

DAMAGE

PERSONAL

INJURY

REDUCED

UNIT

PERFORMANCE

AND

/OR

HAZARDOUS

CONDITIONS

MAY

RESULT

FROM

THE

USE

SUCH

NON

APPROVED

DEVICES

WARNING

HEET

METAL

PARTS

SCREWS

CLIPS

AND

SIMILAR

ITEMS

INHERENTLY

HAVE

SHARP

EDGES

AND

NECESSARY

THAT

THE

INSTALLER

AND

SERVICE

PERSONNEL

EXERCISE

CAUTION

GENERALINFORMATION

For complete information and installation instructions for models

with DDC controls, see manual DK-DDC-TGD-01A.

WARNING

TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DUE TO FIRE,

EXPLOSIONS, SMOKE, SOOT, CONDENSATION, ELECTRIC SHOCK OR CARBON

MONOXIDE, THIS UNIT MUST BE PROPERLY INSTALLED, REPAIRED, OPERATED,

AND MAINTAINED.

This unit is approved for outdoor installation ONLY. Ratedperfor-

manceisachievedafter72hoursofoperation.Ratedperformance

is delivered at the specified airflow. See product specification

sheet for light commercial models. Specification sheets can be

found at www.daikincomfort.com for Daikin brand products.

Within thewebsite,pleaseselectthecommercialproductsmenu

and then select the submenu for the type of product to be in-

stalled, such as air conditioners or heat pumps, to access a list of

product pages that each contain links to that model’s specifica-

tion sheet.

To assure that your unit operates safely and efficiently, it must be

installed, operated, and maintained in accordance with these in-

stallation and operating instructions, all local building codes and

ordinances, or in their absence, with the latest edition of the Na-

tional Fuel Gas Code NFPA54/ANSI Z223.1 and National Standard

of Canada CAN/CSA B149 Installation Codes.

EPA REGULATIONS

IMPORTANT: THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY (EPA)

HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION AND DISPOSAL

OF REFRIGERANTS IN THIS UNIT.FAILURE TO FOLLOW THESE REGULATIONS MAY HARM

THE ENVIRONMENT AND CAN LEAD TO THE IMPOSITION OF SUBSTANTIAL FINES.

BECAUSE REGULATIONS MAY VARY DUE TO PASSAGE OF NEW LAWS, WE SUGGEST A

CERTIFIED TECHNICIAN PERFORM ANY WORK DONE ON THIS UNIT. SHOULD YOU

HAVE ANY QUESTIONS PLEASE CONTACT THE LOCAL OFFICE OF THE EPA.

NATIONAL CODES

This product is designed and manufactured to permit installation

inaccordance with NationalCodes.Itis the installer’s responsibil-

ity to install the product in accordance with National Codes and/

or prevailing local codes and regulations.

The heating and cooling capacities of the unit should be greater

than or equal to the design heating and cooling loads of the area

to be conditioned. The loads should be calculated by an approved

method or in accordance with ASHRAE Guide or Manual J - Load

Calculations published by the Air Conditioning Contractors of

America.

Obtain from:

American National Standards Institute

25 West 43rd Street, 4th Floor

New York, NY 10036

System design and installation should also, where applicable, fol-

lowinformationpresentedinacceptedindustryguidessuchasthe

ASHRAE Handbooks. The manufacturer assumes no responsibility

forequipmentinstalledin violationof anycode or regulation.The

mechanical installation of the packaged roof top units consists of

making final connections between the unit and building services;

supply and return duct connections; and drain connections (if re-

quired). The internal systems of the unit are completely factory-

installed and tested prior to shipment.

Units are generally installed on a steel roof mounting curb assem-

bly which has been shipped to the job site for installation on the

roof structure prior to the arrival of the unit. The model number

shownontheunit’sidentificationplateidentifiesthevariouscom-

ponents of the unit such as refrigeration tonnage, heating input

and voltage.

Carefully inspect the unit for damage including damage to the

cabinetry. Anyboltsorscrewswhichmayhaveloosenedintransit

mustbere-tightened. Intheeventofdamage,thereceivershould:

1. Make notation on delivery receipt of any visible damage

to shipment or container.

2. Notify carrier promptly and request an inspection.

3. Incaseofconcealeddamage,carriershouldbenotifiedas

soon as possible-preferably within 5 days.

4. File the claim with the following supporting documents:

a. OriginalBill of Lading,certifiedcopy, or indemnitybond.

b. Original paid freight bill or indemnity in lieu thereof.

c. Original invoice or certified copy thereof, showing trade

and other discounts or reductions.

d. Copy of the inspection report issued by carrier

representative at the time damage is reported to the

carrier. The carrier is responsible for making prompt

inspection of damage and for a thorough investigation

of each claim. The distributor or manufacturer will not

accept claims from dealers for transportation damage.

NOTE: When inspecting the unit for transportation damage, re-

moveallpackagingmaterials.Recycleordispose ofthe packaging

material according to local codes.

PRE-INSTALLATION CHECKS

Carefullyreadall instructionsforthe installationpriortoinstalling

unit.Ensureeachsteporprocedureisunderstoodandanyspecial

considerations are taken into account before starting installation.

Assemblealltools,hardwareandsuppliesneededtocompletethe

installation. Some items may need to be purchased locally.

UNITLOCATION

WARNING

TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED

WHEN INSTALLING THE UNIT.

IMPORTANT NOTE: Remove wood shipping rails prior to installa-

tion of the unit.

ALL INSTALLATIONS:

IMPORTANT NOTE: Unit should be energized 24 hours prior to

compressor start up to ensure crankcase heater has suffi-

ciently warmed the compressors. Compressor damage may

occur if this step is not followed.

NOTE: Appliance is shipped from factory for vertical duct

application.

Proper installation of the unit ensures trouble-free operation. Im-

proper installation can result in problems ranging from noisy

operation to property or equipment damages, dangerous condi-

tions that could result in injury or personal property damage and

thatarenotcoveredbythe warranty.Givethisbooklettothe user

and explain it’s provisions. The user should retain these instruc-

tions for future reference.

•For proper flame pattern within the heat exchanger and

proper condensate drainage, the unit must be mounted

level.

•Theflueoutletmustbeatleast12inchesfromanyopening

through which flue gases could enter a building, and at

least three feet above any forced air inlet located within

ten feet. The economizer/manual fresh air intake/

motorized fresh air intake and combustion air inlet

mounted on the unit are not affected by this restriction.

•To avoid possible corrosion of the heat exchanger, do not

locate the unit in an area where the outdoor air (i.e.

combustion air for the unit) will be frequently

contaminated by compounds containing chlorine or

fluorine. Common sources of such compounds include

swimming pool chemicals and chlorine bleaches, paint

stripper,adhesives,paints,varnishes,sealers,waxes(which

are not yet dried) and solvents used during construction

and remodeling. Various commercial and industrial

processes may also be sources of chlorine/fluorine

compounds.

•Toavoidpossibleillnessordeathofthebuildingoccupants,

do NOT locate outside air intake device (economizer,

manual fresh air intake, motorized fresh air intake) too

close to an exhaust outlet, gas vent termination, or

plumbing vent outlet. For specific distances required,

consult local codes.

•Allow minimum clearances from the enclosure for fire

protection,properoperation,andserviceaccess(seeunit

clearances). These clearances must be permanently

maintained.

•The combustion air inlet and flue outlet on the unit must

neverbeobstructed.Ifused,donotallowtheeconomizer/

manual fresh air damper/ motorized fresh air damper to

become blocked by snow or debris. In some climates or

locations,itmaybe necessaryto elevatethe unit toavoid

these problems.

•When the unit is heating, the temperature of the return

air entering the unit must be a minimum of 55° F.

GROUND LEVEL INSTALLATIONS ONLY:

•When the unit is installed on the ground adjacent to the

building,alevelconcrete(orequal)baseisrecommended.

Prepare a base that is 3” larger than the package unit

footprint and a minimum of 3” thick.

•Thebaseshouldalso belocatedwherenorunoff ofwater

from higher ground can collect in the unit.

ROOF TOP INSTALLATIONS ONLY:

•Toavoidpossible propertydamage orpersonalinjury,the

roof must have sufficient structural strength to carry the

weight of the unit(s) and snow or water loads as required

bylocalcodes. Consultastructuralengineertodetermine

the weight capabilities of the roof.

•The unit may be installed directly on wood floors or on

Class A, Class B, or Class C roof covering material.

•To avoid possible personal injury, a safe, flat surface for

service personnel should be provided.

•As indicated on the unit data plate, a minimum clearance

of 36” to any combustible material is required on the

furnaceaccess sideof the unit. All combustible materials

must be kept out of this area.

•This 36” clearance must also be maintained to insure

propercombustionairandflue gasflow. Thecombustion

airintake and furnacefluedischarge mustnot be blocked

for any reason, including blockage by snow.

•Adequate clearances from the furnace flue discharge to

anyadjacentpublicwalkways,adjacentbuildings,building

openings or openable windows must be maintained in

accordancewiththelatesteditionoftheNationalFuelGas

Code (ANSI Z223.1)

•Minimum horizontal clearance of 48” from the furnace

fluedischargetoanyelectricmeters,gasmeters,regulators

and relief equipment is required.

UNIT PRECAUTIONS

• Do not stand or walk on the unit.

• Donotdrillholesanywhereinpanelsorinthebaseframe

of the unit except where indicated. Unit access panels

provide structural support.

• Do not remove any access panels until unit has been

installed on roof curb or field supplied structure.

• Donotrollunitacrossfinishedroofwithoutpriorapproval

of owner or architect.

• Do not skid or slide on any surface as this may damage

unitbase. Theunitmustbestoredonaflat,levelsurface.

Protect the condenser coil because it is easily damaged.

ROOF CURB INSTALLATIONS ONLY:

Curbinstallationsmustcomplywithlocalcodesandshouldbedone

inaccordancewiththeestablishedguidelinesoftheNationalRoof-

ing Contractors Association.

Proper unit installation requires that the roof curb be firmly and

permanently attached to the roof structure. Check for adequate

fastening method prior to setting the unit on the curb.

Full perimeter roof curbs are available from the factory and are

shipped unassembled. Field assembly, squaring, leveling and

mounting on the roof structure are the responsibility of the in-

stalling contractor. All required hardware necessary for the as-

sembly of the sheet metal curb is included in the curb accessory.

WARNING

TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED

WHEN INSTALLING THE UNIT.

•Sufficient structural support must be determined prior to

locating and mounting the curb and package unit.

•Ductwork must be constructed using industry guidelines.

The duct work must be placed into the roof curb before

mounting the package unit. Our full perimeter curbs

includeduct connection framestobeassembled withthe

curb. Cantilevered type curbs are not available from the

factory.

•Curb insulation, cant strips, flashing and general roofing

material are furnished by the contractor.

The curbs must be supported on parallel sides by roof members.

The roof members must not penetrate supply and return duct

opening areas as damage to the unit might occur.

NOTE:Theunitandcurbaccessoriesaredesignedtoallowvertical

ductinstallationbeforeunitplacement. Ductinstallationafterunit

placement is not recommended.

CURBS

LOOK

SIMILAR

. T

AVOID

INCORRECT

CURB

POSITIONING

CHECK

JOB

PLANS

CAREFULLY

AND

VERIFY

MARKINGS

CURB

ASSEMBLY

. I

NSTRUCTIONS

MAY

VARY

CURB

STYLES

AND

SUPERSEDES

INFORMATION

SHOWN

CAUTION

See the manual shipped with the roof curb for assembly and in-

stallation instructions.

CLEARANCES

24”

Min.* 24”

Min.*

36” Min.

Unit Clearances

*Insituationsthathavemultipleunits,a48”minimumclearanceis

required between the condenser coils.

Adequateclearancearoundtheunitshouldbekeptforsafety,ser-

vice, maintenance, and proper unit operation. A total clearance

of 75” on the main control panel side of the unit is recommended

to facilitate possible fan shaft, coil, electric heat and gas furnace

removal. A clearanceof 48” is recommended onall other sidesof

the unit to facilitate possible compressor removal, to allow ser-

vice access and to insure proper ventilation and condenser air-

flow. Theunitmustnotbeinstalledbeneathanyobstruction. The

unit should be installed remote from all building exhausts to in-

hibit ingestion of exhaust air into the unit fresh air intake.

NOTE: If the 48” minimum is used on the control panel side of a

DCG unit, a flue extension (MF# 220-GX-01) needs be to installed

to prevent flue gas recirculation.

INSULATED

PANELS

Roof Curb Installation

ROOFCURBPOST-INSTALLATIONCHECKS

Afterinstallation,checkthetopofthecurb,ductconnectionframe

and duct flanges to make sure gasket has been applied properly.

Gasket should be firmly applied to the top of the curb perimeter,

duct flanges and any exposed duct connection frame. If gasket is

loose, re-apply using strong weather resistant adhesive.

PROTRUSION

Inspect curb to ensure that none of the utility services (electric)

routed through the curb protrude above the curb.

PROTRUSIONS

EXIST

ATTEMPT

SET

UNIT

CURB

CAUTION

ROOFTOP DUCT CONNECTIONS

Install all duct connections on the unit before placing the unit on

rooftop.

HORIZONTAL DISCHARGE

RefertoIOD-7006includedintheliteraturepackforinstallinghori-

zontal duct covers.

Flexible duct connectors between the unit and ducts are recom-

mended. Insulate and weatherproof all external ductwork and

joints as required and in accordance with local codes.

SUPPLY

12”

17” 7 3/8”

11” 4 7/8””

25”

6 3/16”

REMOVE

COVERS

Horizontal Discharge Duct Connections

RIGGINGDETAILS

WARNING

TO PREVENT PROPERTY DAMAGE, THE UNIT SHOULD REMAIN IN AN UPRIGHT

POSITION DURING ALL RIGGING AND MOVING OPERATIONS. TO FACILITATE

LIFTING AND MOVING WHEN A CRANE IS USED, PLACE THE UNIT IN AN

ADEQUATECABLE SLING.

UNITS

ARE

LIFTED

TWO

TIME

THE

FORK

HOLES

THE

CONDENSER

END

THE

UNIT

MUST

NOT

USED

. M

INIMUM

FORK

LENGTH

42”

PREVENT

DAMAGE

THE

UNIT

;

HOWEVER

, 48”

RECOMMENDED

CAUTION

Provisionsforforkshavebeenincludedintheunitbaseframe. No

other fork locations are approved.

WARNING

TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED

WHEN INSTALLING THE UNIT.

• Unit must be lifted by the four lifting holes located at the

base frame corners.

• Liftingcablesshouldbeattachedtotheunitwithshackles.

• The distance between the crane hook and the top of the

unit must not be less than 60”.

• Two spreader bars must span over the unit to prevent

damage to the cabinet by the lift cables. Spreader bars

must be of sufficient length so that cables do not come in

contact with the unit during transport. Remove wood

struts mounted beneath unit base frame before setting

unit on roof curb. These struts are intended to protect

unit base frame from fork lift damage. Removal is

accomplishedbyextractingthesheet metalretainers and

pulling the struts through the base of the unit. Refer to

rigging label on the unit.

Important: If using bottom discharge with roof curb, ductwork

shouldbeattachedtothecurbpriortoinstallingtheunit.Ductwork

dimensions are shown in Roof Curb Installation Instructions.

Refer to the Roof Curb Installation Instructions for proper curb

installation. Curbing must be installed in compliance with the Na-

tional Roofing Contractors Association Manual.

Lower unit carefully onto roof mounting curb. While rigging unit,

centerofgravitywillcausecondenserendtobelowerthansupply

air end.

To assist in determining rigging requirements, unit weights are

shown as follows:

SUPPLY

RETURN

EVAPORATOR COIL

CONDENSER

COIL

COMPRESSOR

Corner & Center of Gravity Locations

ABCD

DCG036045* 37 30 550 525 100 165 100 165

DCG036090* 37 30 560 535 100 170 100 170

DCG048090* 37 30 600 575 110 180 110 180

DCG048115* 37 30 605 580 110 180 110 180

DCG060090* 37 30 635 610 113 187 118 192

DCG060140* 37 30 645 620 118 192 118 192

DCG072140* 37 30 700 675 127 210 127 211

Operating

Weight

(lbs)

Corner Weights ( lbs )

* Weights shown are belt drive with no accessories.

Model X

(in) Y

(in)

Shipping

Weight

(lbs)

PREVENT

SEVERE

DAMAGE

THE

BOTTOM

THE

UNIT

NOT

FORK

LIFT

UNIT

AFTER

WOOD

STRUTS

HAVE

BEEN

REMOVED

CAUTION

Bring condenser end of unit into alignment with the curb. With

condenserend ofthe unitrestingoncurbmember andusing curb

as a fulcrum, lower opposite end of the unit until entire unit is

seated on the curb. When a rectangular cantilever curb is used,

care should be taken to center the unit. Check for proper align-

ment and orientation of supply and return openings with duct.

RIGGING REMOVAL

PREVENT

DAMAGE

THE

UNIT

NOT

ALLOW

CRANE

HOOKS

AND

SPREADER

BARS

REST

THE

ROOF

THE

UNIT

CAUTION

Removespreaderbars,liftingcablesandotherriggingequipment.

ELECTRICAL WIRING

HIGH VOLTAGE!

ISCONNECT

ALL

POWER

BEFORE

SERVICING

INSTALLING

THIS

UNIT

. M

ULTIPLE

POWER

SOURCES

MAY

PRESENT

. F

AILURE

MAY

CAUSE

PROPERTY

DAMAGE

PERSONAL

INJURY

DEATH

WARNING

HIGH VOLTAGE!

AVOID

PERSONAL

INJURY

DEATH

DUE

ELECTRICAL

SHOCK

NOT

TAMPER

WITH

FACTORY

WIRING

. T

INTERNAL

POWER

AND

CONTROL

WIRING

THESE

UNITS

ARE

FACTORY

INSTALLED

AND

HAVE

BEEN

THOROUGHLY

TESTED

PRIOR

SHIPMENT

ONTACT

YOUR

LOCAL

REPRESENTATIVE

ASSISTANCE

REQUIRED

WARNING

PREVENT

DAMAGE

THE

WIRING

PROTECT

WIRING

FROM

SHARP

EDGES

. F

OLLOW

NATIONAL

ELECTRICAL

CODE

AND

ALL

LOCAL

CODES

AND

ORDINANCES

. D

NOT

ROUTE

WIRES

THROUGH

REMOVABLE

ACCESS

PANELS

CAUTION

ONDUIT

AND

FITTINGS

MUST

WEATHER

TIGHT

PREVENT

WATER

ENTRY

INTO

THE

BUILDING

CAUTION

For unit protection, use a fuse or HACR circuit breaker that is in

excess of the circuit ampacity, but less than or equal to the maxi-

mum overcurrent protection device. DO NOT EXCEED THE MAXI-

MUM OVERCURRENT DEVICE SIZE SHOWN ON UNIT DATA PLATE.

All line voltage connections must be made through weatherproof

fittings. All exterior power supply and ground wiring must be in

approved weatherproof conduit.

The main power supply wiring to the unit and low voltage wiring

to accessory controls must be done in accordance with these in-

structions,thelatesteditionoftheNationalElectricalCode(ANSI/

NFPA 70), and all local codes and ordinances. All field wiring shall

conform with the temperature limitations for Type T wire (63°F/

35°C rise).

The unit is factory wired for the voltage shown on the unit’s data

plate. Refer to model nomenclature in Appendix B for voltage re-

quirement for your unit.

NOTE: If supply voltage is 208V, lead on primary of transformer

must be moved from the 230V to the 208V tap. Refer to wiring

diagram on unit for details.

Mainpowerwiringshouldbesizedfortheminimumwireampacity

shown on the unit’s database. Size wires in accordance with the

ampacity tables in Article 310 of the National Electrical Code. If

long wires are required, it may be necessary to increase the wire

sizetopreventexcessivevoltagedrop. Wiresshouldbesizedfora

maximum of 3% voltage drop.

CAUTION

TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, USE

ONLY COPPER CONDUCTORS.

CAUTION

TO PREVENT IMPROPER AND DANGEROUS OPERATION DUE TO WIRING ERRORS,

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

VERIFY PROPER OPERATION AFTER SERVICING.

NOTE: A weather-tight disconnect switch, properly sized for the

unittotalload,mustbe fieldorfactoryinstalled. Anexternalfield

supplied disconnect may be mounted on the exterior panel.

Ensure the data plate is not covered by the field-supplied

disconnect switch.

• Some disconnect switches are not fused. Protect the

powerleadsatthepointofdistributioninaccordancewith

the unit data plate.

• Theunitmustbeelectricallygroundedinaccordancewith

localcodesor,intheabsenceoflocalcodes,withthelatest

edition of the National Electrical Code (ANSI-NFPA 70). A

ground lug is provided for this purpose. Size grounding

conductorinaccordancewithTable250-95oftheNational

ElectricalCode. Donot usethe groundlugforconnecting

a neutral conductor.

• Connectpowerwiringtothecompressorcontactorclosest

to the entrance located within the main control box or to

electrical power block, if equipped.

LOW VOLTAGE

BLOCK

MAIN POWER

LOW VOLTAGE

ENTRANCE POWER THRU

THE CURB

Power and Low Voltage Block Connections

AILURE

UNIT

DUE

OPERATION

IMPROPER

LINE

VOLTAGE

WITH

EXCESSIVE

PHASE

UNBALANCE

CONSTITUTES

PRODUCT

ABUSE

NOT

COVERED

THE

WARRANTY

AND

MAY

CAUSE

SEVERE

DAMAGE

THE

UNIT

ELECTRICAL

COMPONENTS

WARNING

Areas Without Convenience Outlet

It is recommended that an independent 115V power source be

brought to the vicinity of the roof top unit for portable lights and

tools used by the service mechanic.

NOTE: Refer to local codes for requirements. These outlets can

also be factory installed.

UNITS INSTALLED ON ROOF TOPS

Main power and low voltage wiring may enter the unit through

thecondenserendofunitorthroughtheroofcurb.Installconduit

connectors at the desired entrance locations. External connec-

tors must be weatherproof. All holes in the unit base must be

sealed(includingthosearoundconduitnuts)topreventwaterleak-

age into building. All required conduit and fittings are to be field

supplied.

Supplyvoltagetorooftopunitmustnotvaryby morethan10%of

the value indicated on the unit data plate. Phase voltage unbal-

ance must not exceed 2%. Contact your local power company for

correction of improper voltage or phase unbalance.

HIGH VOLTAGE ENTRANCE

LOW VOLTAGE ENTRANCE

1:4

30 1/4”*

12 3/8”

(REMOVE PLUG)

* (6 Ton - 34 1/4”)

41/2”

47 1/2” 7 1/2”

POWER THRU

THE CURB

3.5 DIA.

Electrical Entrance and Thru Curb

Unitis equippedwith aLow Voltage Terminal Block andhasSingle

Point wiring to the contactor or power block, if equipped.

LOW VOLTAGE CONTROL WIRING

1. A 24V thermostat must be installed for unit operation. It

may be purchased with the unit or field -supplied.

Thermostatsmaybeprogrammableorelectromechanical

as required.

2. Locate thermostat or remote sensor in the conditioned

space where it will sense average temperature. Do not

locate the device where it may be directly exposed to

supply air, sunlight or other sources of heat. Follow

installation instructions packaged with the thermostat.

3. Use #18 AWG wire for 24V control wiring runs not

exceeding75feet.Use#16AWGwirefor24Vcontrolwiring

runs not exceeding 125 feet. Use #14 AWG wire for 24V

control wiring runs not exceeding 200 feet. Low voltage

wiringmaybeNationalElectricalCode(NEC)Class2where

permitted by local codes.

4. Route thermostat wires from sub-base terminals to the

unit. Control wiring should enter through the condenser

panel opening or through curb indicated in “Electrical

Entrance” figure. Connect thermostat and any accessory

wiringtolowvoltageterminalblockTB1inthemaincontrol

box.

NOTE: Field-suppliedconduitmayneedtobeinstalleddepending

on unit/curb configuration. Use #18 AWG solid conductor wire

whenever connecting thermostat wires toterminals on sub-base.

DO NOT use larger than #18 AWG wire. A transition to #18 AWG

wire may be required before entering thermostat sub-base.

NOTE: Refer to unit wiring diagrams for thermostat hookups.

GAS SUPPLY PIPING

PREVENT

PERSONAL

INJURY

DEATH

DUE

IMPROPER

INSTALLATION

ADJUSTMENT

ALTERATION

SERVICE

MAINTENANCE

REFER

THIS

MANUAL

. F

ADDITIONAL

ASSISTANCE

INFORMATION

CONSULT

QUALIFIED

INSTALLER

SERVICE

AGENCY

THE

GAS

SUPPLIER

WARNING

IMPORTANT NOTE: This unit is factory set to operate on natural

gas at the altitudes shown on the rating plate.

AVOID

PROPERTY

DAMAGE

PERSONAL

INJURY

DEATH

WHEN

EITHER

USING

PROPANE

GAS

ALONE

HIGHER

ALTITUDES

OBTAIN

AND

INSTALL

THE

PROPER

CONVERSION

KIT

(

). F

AILURE

CAN

RESULT

UNSATISFACTORY

OPERATION

AND

EQUIPMENT

DAMAGE

. H

IGH

ALTITUDE

KITS

ARE

FOR

U.S.

NSTALLATIONS

ONLY

AND

ARE

NOT

APPROVED

FOR

USE

ANADA

WARNING

The rating plate is stamped with the model number, type of gas

andgasinputrating.Makesuretheunitisequippedtooperateon

thetypeofgasavailable.Conversiontopropane(LP)gasispermit-

ted with the use of the factory authorized conversion kit (see the

unit Technical Manual for the appropriate kit). For High Altitude

derates, refer to the latest edition of the National Fuel Gas Code

NFPA 54/ANSI Z223.1.

NATURAL Min. 5.0"W.C.,Max.10.0"W.C.

PROPANE Min.11.0" W.C., Max. 14.0"W.C.

INLET GAS PRESSURE

Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in Table Above.

Theminimumsupply pressureshouldnot varyfromthatshownin

the table above because this could prevent the unit from having

dependable ignition. In addition, gas input to the burners must

not exceed the rated input shown on the rating plate. Overfiring

of the unit could result in premature heat exchanger failure.

PIPING

IMPORTANT NOTE: To avoid possible unsatisfactory operation or

equipment damage due to under firing of equipment, do not un-

dersizethenatural/propanegaspipingfromthemeter/tanktothe

unit. When sizing a trunk line, include all appliances on that line

that could be operated simultaneously.

The rating plate is stamped with the model number, type of gas

andgasinputrating.Makesuretheunit isequippedtooperateon

the type of gas available. The gas line installation must comply

with local codes, or in the absence of local codes, with the latest

edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1.

Natural Gas Connection

1/2 3/4 1 1 1/4 1 1 /2

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 980

40 63 130 245 500 760

50 56 115 215 440 670

60 50 105 195 400 610

70 46 96 180 370 560

80 43 90 170 350 530

90 40 84 160 320 490

100 38 79 150 305 460

Pressure= .50PSIG or less and Pressure Drop of 0.3" W.C.

(Based on 0.60 Specific Gravity Gas)

Natural Gas Capacity of Pipe

in Cubic Feet of Gas Per Hour (CFH)

Nominal Black Pipe Size (inches)

Length of

Pipe in Feet

Heating Value of Gas (BTU/Cubic Foot

CFH= BTUHFurnaceInput

Refer to the Proper Piping Practice drawing for the general layout

at the unit. The following rules apply:

1. Use black ironpipe and fittingsforthesupply piping. The

use of a flex connector and/or copper piping is permitted

as long as it is in agreement with local codes.

2. Use pipe joint compound on male threads only. Pipe joint

compoundmustberesistanttotheactionofthefuelused.

3. Use ground joint unions.

4. Install a drip leg to trap dirt and moisture before it can

enter the gas valve. The drip leg must be a minimum of

three inches long.

5. Use two pipe wrenches when making connection to the

gas valve to keep it from turning.

6. Install a manual shut-off valve in a convenient location

(within six feet of unit) between the meter and the unit.

7. Tighten all joints securely.

8. Theunitmustbe connectedto thebuilding pipingbyone

of the following methods:

• Rigid metallic pipe and fittings

• Semirigid metallic tubing and metallic fittings (Aluminum

alloy tubing must not be used in exterior locations)

• Listedgasappliance connectorsusedinaccordance with

thetermsof theirlistingthat arecompletelyin thesame

room as the equipment

• In the prior two methods above the connector or tubing

must be protected from physical and thermal damage.

Aluminum alloy tubing and connectors must be coated

toprotectagainstexternalcorrosionwhenincontactwith

masonry, plasteror insulationor aresubject torepeated

wettingsbyliquids (water -notrain water,detergentsor

sewage).

BURNER

DOOR

DRIP

LEG

MANUAL

SHUT-OFFGROUND JOINT

UNION

TBD

Proper Piping Practice

NOTE: The unit gas supply entrance is factory sealed with plugs.

Keep plugs in place until gas supply is ready to be installed. Once

ready, replace the plugs with the supplied grommets and install

gas supply line.

GAS PIPING CHECKS

CAUTION

TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DUE TO FIRE, THE

FOLLOWING INSTRUCTIONS MUST BE PERFORMED REGARDING GAS

CONNECTIONS AND PRESSURE TESTING:

• THE UNIT AND ITS GAS CONNECTIONS MUST BE LEAK TESTED BEFORE

PLACING IN OPERATION. BECAUSE OF THE DANGER OF EXPLOSION OR

FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. NEVER

EXCEED SPECIFIED PRESSURES FOR TESTING. HIGHER PRESSURE MAY

DAMAGE GAS VALVE AND CAUSE OVERFIRING WHICH MAY RESULT IN

PREMATURE HEAT EXCHANGE FAILURE.

• THIS UNIT AND ITS SHUT-OFF VALVE MUST BE DISCONNECTED FROM

THE GAS SUPPLY DURING ANY PRESSURE TESTING OF THAT SYSTEM AT

TEST PRESSURES IN EXCESS OF 1/2 PSIG(3.48 KPA).

• THIS UNIT MUST BE ISOLATED FROM THE GAS SUPPLY SYSTEM BY

CLOSING ITS 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 (3.48 KPA).

WARNING

TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, BE SURE THERE IS

NO OPEN FLAME IN THE VICINITY DURING AIR BLEEDING.

There will be air in the gas supply line after testing for leaks on a

new installation. Therefore, the air must be bled from the line by

looseningthegroundjointunionuntilpuregasisexpelled.Tighten

unionand wait forfiveminutes until all gashas been dissipatedin

the air. Be certain there is no open flame in the vicinity during air

bleeding procedure. The unit is placed in operation by closing the

main electrical disconnect switch for the unit.

PROPANEGASINSTALLATIONS

WARNING

TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE

OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS

DETECTING WARNING DEVICE. SINCE RUST CAN REDUCE THE LEVEL

OF ODORANT IN PROPANE GAS, A GAS DETECTING WARNING DEVICE

IS THE ONLY RELIABLE WAY TO DETECT A PROPANE GAS LEAK.

CONTACT A LOCAL PROPANE GAS SUPPLIER ABOUT INSTALLING A

GAS DETECTING WARNING DEVICE.

IMPORTANT NOTE: Propane gas conversion kits must be installed

to convert units to propane gas. NOx screens must be removed

before converting to LP. Remove burner assembly and pull NOx

screens from each burner tube. When all the screens are out,

reassemble the burner assembly without the screens.

All propane gas equipment must conform to the safety standards

oftheNationalBoardofFireUnderwriters(SeeNBFUManual58).

For satisfactory operation, propane gas supply pressure must be

within 9.7 - 10.3 inches W.C. at the manifold with all gas appli-

ances in operation. Maintaining proper gas pressure depends on

three main factors:

1. Vaporization rate, which depends on (a) temperature of

theliquid,and(b) wettedsurfaceareaofthecontaineror

containers.

2. Proper pressure regulation.

3. Pressure drop in lines between regulators, and between

second stage regulator and the appliance. Pipe size

required will depend on length of pipe run and total load

of all appliances.

TANKS AND PIPING

Complete information regarding tank sizing for vaporization,

recommended regulator settings and pipe sizing is available

frommostregulatormanufacturersandpropanegassuppliers.

Since propane gas will quickly dissolve white lead or most

standardcommercialcompounds,special pipedope mustbe

used. Shellac base compounds resistant to the actions of

liquefiedpetroleumgasessuchasGasolac®,Stalactic®,Clyde’s®

or John Crane®are satisfactory.

See the following figure for typical propane gas piping.

200 PSIG

Maximum

5 to 15 PSIG

(20 PSIG Max.) Continuous

11" W.C.

Second Stage

Regulator

First Stage

Regulator

Typical Propane Gas Piping

ROOF TOP LOCATION AND INSTALLATION

The gas supply piping location and installation for roof top units

mustbeinaccordancewithlocalcodesor, intheabsence oflocals

codes, with ordinances of the latest edition of the National Fuel

Gas Code (ANSI Z223.1).

A manual gas shut off valve must be field installed external to the

roof top unit. In addition, a drip leg must be installed near the

inlet connection. A ground joint union connection is required be-

tween the external shut off valve and the unit connection to the

gas valve to permit removal of the burner assembly for servicing.

1. Route gas piping to unit so that it does not interfere with

the removal of access panels. Support and align piping to

preventstrainsormisalignmentofthemanifoldassembly.

2. All units are furnished with standard female NPT pipe

connections. Connection pipe sizes for DCG036 through

072unitsis1/2"NPT on045to140mBH units. Thesizeof

the gas supply piping to the unit must be based on length

ofrun,numberofunitsonthesystem,gascharacteristics,

BTUrequirementandavailablesupplypressure.Allpiping

must be done in accordance with local codes or, in the

absence of local codes, with the latest edition of the

National Fuel Gas Code (ANSI Z223.1).

NOTE: The gas connection size at the unit does NOT

establish the size of the supply line.

3. These units are designed for either natural or propane

(LP) gas and are specifically constructed at the factory for

onlyoneofthesefuels.ThefuelsareNOTinterchangeable.

However, the furnace can be converted in the field from

natural gas to LP gas with the appropriate factory kit (see

unit Technical Manual for the appropriate kit). Only a

qualifiedcontractor,experiencedwithnaturalandpropane

gas systems, should attempt conversion. Kit instructions

must be followed closely to assure safe and reliable unit

operation.

4. With all units on a common line operating under full fire,

natural gas main supply pressure should be adjusted to

approximately7.0"w.c.,measuredatthe unitgasvalve.If

the gas pressure at the unit is greater than 10.5" w.c., the

contractor must furnish and install an external type

positive shut off service pressure regulator. The unit will

notfunctionsatisfactorilyifsupplygaspressureislessthan

5.5" w.c. or greater than 10.5" w.c..

NOTE: A minimum horizontal distance of 48" between

the regulator and the furnace flue discharge is required.

5. With all units on a common line operating under full LP

gasmainsupplypressureshouldbeatleast11.0"w.c.and

must be no greater than 13.0" w.c., measured at the unit

gas valve. Unit will not function satisfactorily if supply gas

pressureis lessthan 11.0"w.c.orgreaterthan 13.0" w.c..

6. All pipe connections should be sealed with a pipe thread

compound, which is resistant to the fuel used with the

furnace. A soapy water solution should be used to check

all joints for leaks. A tap is located on the entering side of

thegasvalvefortestgaugeconnectiontomeasuresupply

(main) gas pressure. Another tap is provided on the

manifold side of the gas valve for checking manifold

pressure.

HIS

UNIT

AND

ITS

INDIVIDUAL

SHUTOFF

VALVE

MUST

DISCONNECTED

FROM

THE

GAS

SUPPLY

SYSTEM

DURING

ANY

PRESSURE

TESTING

THAT

SYSTEM

TEST

PRESSURES

EXCESS

1/2 PSIG (13.8”

.).

WARNING

HIS

UNIT

MUST

ISOLATED

FROM

THE

GAS

SUPPLY

PIPING

SYSTEM

CLOSING

ITS

INDIVIDUAL

MANUAL

SHUTOFF

VALVE

DURING

ANY

PRESSURE

TESTING

EQUAL

LESS

THAN

1/2

PSIG.

CAUTION

7. There must be no obstruction to prevent the flow of

combustionandventilatingair.Aventstackisnotrequired

and must never be used. The power venter will supply an

adequate amount of combustion air as long as the air

passageways are kept free of any obstructions and the

recommended external unit clearances are maintained.

CIRCULATINGAIR ANDFILTERS

DUCTWORK

Thesupplyductfromtheunitthroughawallmaybeinstalledwith-

out clearance. However, minimum unit clearances must be main-

tained(see “Clearances”section). Thesupply ductshouldbe pro-

vided with an access panel large enough to inspect the air cham-

ber downstream of the heat exchanger. A cover should be tightly

attached to prevent air leaks.

Ductwork dimensions are shown in the roof curb installation

manual.

If desired, supply and return duct connections to the unit may be

made with flexible connections to reduce possible unit operating

sound transmission.

VENTING

NOTE: Venting is self-contained.

Theindoor motoronDCGunitsaredual voltagemotors. Theyare

factory wired for 230 volts. If field supply power is 208V, the

installer must swap the connections to the black and red loads

(located in the blower compartment) to ensure correct inductor

motor operation.

CONDENSATE DRAINCONNECTION

CONDENSATE DRAIN CONNECTION

A 3/4” female NPT drain connection is supplied on the end of the

unitandbottomofthe drainpanforcondensatepiping. Anexter-

nal trap must be installed for proper condensate drainage.

DRAIN

CONNECTION

UNIT 2" MINIMUM

FLEXIBLE

TUBING-HOSE

OR PIPE 3" MINIMUM

A POSITIVE LIQUID

SEAL IS REQUIRED

Drain Connection

Install condensate drain trap as shown. Use 3/4" drain line and

fittings or larger. Do not operate without trap.

HORIZONTAL DRAIN

Drainageofcondensatedirectly ontotheroof maybe acceptable;

refer to local code. It is recommended that a small drip pad of

either stone, mortar, wood or metal be provided to prevent any

possible damage to the roof.

CLEANING

Due to the fact that drain pans in any air conditioning unit will

have some moisture in them, algae and fungus will grow due to

airborne bacteria and spores. Periodic cleaning is necessary to

prevent this build-up from plugging the drain.

STARTUP, ADJUSTMENTS, AND CHECKS

HIGH VOLTAGE!

OND

THE

FRAME

THIS

UNIT

THE

BUILDING

ELECTRICAL

GROUND

USE

THE

GROUNDING

TERMINAL

PROVIDED

OTHER

ACCEPTABLE

MEANS

. D

ISCONNECT

ALL

POWER

BEFORE

SERVICING

INSTALLING

THIS

UNIT

AVOID

PERSONAL

INJURY

DEATH

DUE

ELECTRICAL

SHOCK

WARNING

PRE-STARTUP INSTRUCTIONS - GENERAL

PREVENT

PROPERTY

DAMAGE

PERSONAL

INJURY

, D

NOT

START

THE

UNIT

UNTIL

ALL

NECESSARY

PRE

CHECKS

AND

TESTS

HAVE

BEEN

PERFORMED

CAUTION

Priortothe beginningofStartup,Adjustments,and Checksproce-

dures, the following steps should be completed in the building.

MOVING MACHINERY HAZARD!

PREVENT

POSSIBLE

PERSONAL

INJURY

DEATH

DISCONNECT

POWER

THE

UNIT

AND

PADLOCK

THE

“OFF”

POSITION

BEFORE

SERVICNG

FANS

WARNING

This unit is equipped with an electronic ignition device to auto-

matically light the main burners. It also has a power vent blower

to exhaust combustion products.

On new installations, or if a major component has been replaced,

the operation of the unit must be checked.

Check unit operation as outlined in the following instructions. If

any sparking, odors, or unusual sounds are encountered, shut off

electrical power and recheck for wiring errors, or obstructions in

or near the blower motors. Duct covers must be removed before

operating unit.

The Startup, Adjustments, and Checks procedure provides a step-

by-stepsequencewhich,iffollowed,willassuretheproperstartup

of the equipment in the minimum amount of time. Air balancing

of duct system is not considered part of this procedure. However,

itisanimportantphaseofanyairconditioningsystemstartupand

shouldbeperformeduponcompletionoftheStartup,Adjustments,

andChecksprocedure.TheStartup,Adjustments,andCheckspro-

cedureatoutsideambientsbelow55°Fshouldbelimitedtoareadi-

nesscheckoftherefrigerationsystemwiththerequiredfinalcheck

and calibration left to be completed when the outside ambient

rises above 55°F.

TEMPORARY HEATING ORCOOLING

Iftheunitistobeusedfortemporaryheatingorcooling,a“Startup,

Adjustments, and Checks” must first be performed in accordance

withthis manual.Damage orrepairsdue tofailureto complywith

theserequirementsarenotcoveredunderthewarranty.Afterthe

machines are used for temporary heating or cooling, inspect the

coils,fans,andmotorsforunacceptablelevelsofconstructiondust

and dirt and install new filters.

CONTRACTOR RESPONSIBILITY

The installing contractor must be certain that:

• All supply and return air ductwork is in place, properly

sealed, and corresponds with installation instructions.

• All thermostats are mounted and wired in accordance

with installation instructions.

• All electric power, all gas, hot water or steam line

connections, and the condensate drain installation have

been made to each unit on the job. These main supply

linesmustbefunctionalandcapableofoperatingallunits

simultaneously.

• Requirements are met for venting and combustion air.

• Air filters are in place.

• Input rate and temperature rise are adjusted per rating

plate.

ROOF CURB INSTALLATION CHECK

Inspect the roof curb for correct installation. The unit and curb

assembly should be level. Inspect the flashing of the roof mount-

ing curb to the roof, especially at the corners, for good workman-

ship. Also check for leaks around gaskets. Note any deficiencies in

a separate report and forward to the contractor.

OBSTRUCTIONS, FAN CLEARANCE AND WIRING

Remove any extraneous construction and shipping materials that

may be found during this procedure. Rotate all fans manually to

check for proper clearances and that they rotate freely. Check for

bolts and screws that may have jarred loose during shipment to

the job site. Retighten if necessary. Re-tighten all electrical con-

nections.

FIELD DUCT CONNECTIONS

Verify that all duct connections are tight and that there is no air

bypass between supply and return.

FILTER SECTION CHECK

Removefiltersectionaccesspanelsandcheckthatfiltersareprop-

erly installed. Note airflow arrows on filter frames.

PRE-STARTUP PRECAUTIONS

It is important to your safety that the unit has been properly

groundedduringinstallation.Check groundlugconnectioninmain

control box for tightness prior to closing circuit breaker or discon-

nect switch. Verify that supply voltage on line side of disconnect

agrees with voltage on unit identification plate and is within the

utilizationvoltagerangeasindicatedinAppendixBElectricalData.

System Voltage - That nominal voltage value assigned to a circuit

or system for the purpose of designating its voltage class.

Nameplate Voltage - That voltage assigned to a piece of equip-

ment for the purpose of designating its voltage class and for the

purposeofdefining the minimumand maximum voltageat which

the equipment will operate.

UtilizationVoltage-Thevoltageofthelineterminalsoftheequip-

ment at which the equipment must give fully satisfactory perfor-

mance. Once it is established that supply voltage will be main-

tained within the utilization range under all system conditions,

check and calculate if an unbalanced condition exists between

phases. Calculate percent voltage unbalance as follows.

Three Phase Models Only

3) PERCENT VOLTAGE

UNBALANCE

2) MAXIMUM VOLTAGE DEVIATIONS

FROM AVERAGE VOLTAGE

1) AVERAGE VOLTAGE

HOW TO USE THE FORMULA:

EXAMPLE: With voltage of 220, 216, and 213

1) Average Voltage = 220+216+213=649 / 3 = 216

2) Maximum Voltage Deviations from Average Voltage = 220 - 216 = 4

3) Percent Voltage Unbalance = 100 x = = 1.8%

Percent voltage unbalance MUST NOT exceed 2%.

216 400

216

= 100 X

AIR FLOW ADJUSTMENTS

NOTE: For2 speedmodels,airflow adjustments mustbe made on

high speed, i.e., 2nd stage cooling or in heat mode.

Whenthefinaladjustmentsarecomplete,thecurrentdrawofthe

motor should be checked and compared to the full load current

rating of the motor. The amperage must not exceed the service

factor stamped on the motor nameplate. The total airflow must

notbelessthan thatrequiredforoperationofthe electricheaters

or the furnace.

Ifaneconomizerisinstalled,checktheunitoperatingbalancewith

the economizer at full outside air and at minimum outside air.

NOTE:NeverrunCFMbelow350CFMperton,evaporatorfreezing

or poor unit performance is possible.

PSC MOTOR

Adjust the CFM for the unit by changing the speed tap of the in-

door blower motor at the heat or cool tap on the control board

connectionwiththeoneofthespeedtapson“M1”or“M2”(Black-

High Speed, Blue-Medium Speed, Red-Low Speed).

EEM Motor

Adjust the CFM for the unit by changing the position of the low

voltage leads on the motor terminal block. Green is for Fan Only.

Yellow is for Cooling and Heat Pump Heating. Refer to Appendix A

for blower performance at each speed tap. NOTE: If more than

one lead is energized simultaneously, the motor will run at the

higher speed.

SET EVAPORATOR FAN RPM

ActualRPM’smustbesetandverifiedwithatachometerorstrobe

light. Refer to Appendices A and B for basic unit fan RPM. Refer

also to “Airflow” section of this manual. With disconnect switch

open, disconnect thermostat wires from terminals Y and W. This

willpreventheatingandmechanicalcoolingfromcomingon.Place

ajumperwireacrossterminalsRandGatTB1terminalblock.Close

disconnect switch; evaporator fan motor will operate so RPM can

be checked.

For gas heat units, the airflow must be adjusted so that the air

temperaturerise fallswithin therangesgivenstatedon Data Plate

(see Appendix A - Blower Performance).

EVAPORATOR FAN ROTATION CHECK (THREE PHASE MODELS ONLY)

Checkthat fan rotates clockwise whenviewedfrom the driveside

of unit and in accordance with rotation arrow shown on blower

housing. If it does not, reverse any two incoming power cables at

Single Point Power Block. In this case, repeat bearing check.

Donot attempttochange loadside wiring.Internalwiringassures

all motors and compressors will rotate in correct direction once

evaporator fan motor rotation check has been made.

ELECTRICAL INPUT CHECK

Makepreliminarycheckofevaporatorfanamperedrawandverify

that motor nameplate amps are not exceeded. A final check of

amp draw should be made upon completion of air balancing of

the duct system (see Appendix C).

BELT DRIVE MODELS ONLY

The drive on the supply fan is typically set in the middle of the

RPM range. The drive motor sheave pitch diameter is field adjust-

ablefortherequiredairflow.Referto“MotorSheaveAdjustments”

section.

Upon completion of the air flow balancing, we recommend re-

placing the variable pitched motor sheave with a properly-sized

fixedsheave.A matching fixedsheave will providelongerbelt and

bearinglifeand vibration freeoperation. Initially,it is best tohave

avariablepitchedmotorsheaveforthepurposeofairflowbalanc-

ing, but once the balance has been achieved, fixed sheaves main-

tain alignment and minimize vibration more effectively. For direct

drive units, move fan speed wire.

BEARING CHECK

Priortoenergizinganyfans,checkandmakesurethatallsetscrews

are tight so that bearings are properly secured to shafts.

TENSION AND ALIGNMENT ADJUSTMENT

Correct belt tension is very important to the life of your belt. Too

loose a belt will shorten its life; too tight, premature motor and

bearing failure will occur. Check you belt drive for adequate “run-

in” belt tension by measuring the force required to deflect the

belt at the midpoint of the span length. Belt tension force can be

measured using a belt tension gauge, available through most belt

drive manufacturers.

SPANLENGTHt

*DEFLECTION

FORCE

*Apply force to the center of the span.

Belt Tension Adjustment

t = Span length, inches

C = Center distance, inches

D = Larger sheave diameter, inches

d = Smaller sheave diameter, inches

h = Deflection height, inches

BELT DRIVE USED NEW

AX Standard 3.0 to 4.0 4.2 ± 0.5 5.5 ± 0.5 0.313

DEFLECTION

FORCE (lbs)

TYPE DEFLECTION

(in)

SMALL

SHEAVE

DIAMETER

(in)

Recommended Pounds of Force Per Belt

New V-belts will drop rapidly during the first few hours of use.

Check tension frequently during the first 24 hours of operation.

Tensionshouldfallbetweentheminimumandmaximumforce.To

determine the deflection distance from a normal position, mea-

sure the distance from sheave to sheave using a straightedge or a

cord. This is your reference line. On multiple belt drives, an adja-

cent undeflected belt can be used as a reference.

MOTORSHEAVEADJUSTMENTS

VL, VM, & 2VP VARIABLE PITCH KEY TYPE MOTOR SHEAVES

Thedrivinganddriven motorsheavesshouldbe inalignmentwith

each other and the shafts parallel.

VL& VMSHEAVES ADJUSTMENT

1. Loosen set screw “B” using a 5/32" Allen key.

2. Making half or full turns from closed position, adjust

sheave pitch diameter for desired speed. DO NOT OPEN

MORE THAN FIVE FULL TURNS.

3. Tighten set screw “B” securely over flat.

4. Carefully put on belts and adjust belt tension. DO NOT

FORCE BELTS OVER GROOVES.

5. Ensureallkeysareinplaceandthesetscrewstightbefore

starting drive. Recheck set screws and belt tension after

24 hours service.

NOTE: Future adjustments should be made by loosening the belt

tension and increasing or decreasing the pitch diameter of the

sheavebyhalforfullturnsasrequired.Readjustbelttensionbefore

starting drive.

VL & VM

NOTE: Do NOT operate sheave with flange projecting beyond

the hub end.

GAS SYSTEM CHECK

Pre-Operation Checks

1. Close the manual gas valve external to the unit.

2. Turn off the electrical power supply to the unit.

3. Set the room thermostat to its lowest possible setting.

4. Remove the heat exchanger door on the side of the unit

by removing screws.

5. This unit is equipped with an ignition device which

automatically lights the main burner. DO NOT try to light

burner by any other method.

6. Movethe gas control valveswitch tothe OFF position.Do

not force.

7. Wait five minutes to clear out any gas.

8. Smellforgas,includingneartheground.Thisisimportant

becausesometypesofgasareheavierthanair.Ifyouhave

waited five minutes and you do smell gas, immediately

follow the warnings on page 3 of this manual. If having

waited for five minutes and no gas smell is noted, move

the gas control valve switch to the ON position.

9. Replace the heat exchanger door on the side of the unit.

10. Open the manual gas valve external to the unit.

11. Turn on the electrical power supply to the unit.

12. Set the thermostat to desired setting.

GAS SUPPLY PRESSURES & REGULATOR ADJUSTMENTS

HOULD

OVERHEATING

OCCUR

THE

GAS

SUPPLY

FAIL

SHUT

OFF

TURN

OFF

THE

MANUAL

GAS

SHUTOFF

VALVE

EXTERNAL

THE

UNIT

BEFORE

TURNING

OFF

THE

ELECTRICAL

SUPPLY

WARNING

AVOID

PROPERTY

DAMAGE

PERSONAL

INJURY

DEATH

NOT

FIRE

GAS

UNIT

WITH

FLUE

BOX

COVER

REMOVED

WARNING

NOTE: Exceptduringbriefperiodswhengaspressuresare being

measuredbyqualifiedservicepersonnel,thefurnaceaccesspanel

mustalwaysbesecuredinplace whenthe furnaceisin operation.

An inspection port in the access panel is provided to monitor the

flame.

The first step in checking out the gas-fired furnace is to test the

gassupplypipingtothe unitfortightnessand purgethesystemof

air using methods outlined in the latest edition of the National

FuelGasCodeANSI Z223.1. Verifythatthe disconnectswitchis in

the“OFF”position. Asoapywatersolutionshouldbeusedtocheck

for gas leaks. Since the unit is subject to considerable jarring dur-

ing shipment, it is extremely important that all gas connections

and joints be tested for tightness. Gas piping downstream from

the unit inlet should be checked for leaks during the subsequent

sequence check.

Thesupply gaspressureshould beadjustedto7.0" w.c. onnatural

gas and 11.0" on LP gas with the gas burners operating. If there is

more than one unit on a common gas line, the pressures should

be checked with all units under full fire. A supply pressure tap is

provided on the upstream side of the gas valve. A manifold pres-

sure tap is provided on the gas valve. The normal manifold pres-

sure for full input is 3.5" w.c. on natural gas and 9.5" w.c. for pro-

panegas.Lowfire naturalgas2.0”w.c.,6.0” lowfirepropanegas.

Minimumgassupply pressureis5.5"w.c.fornaturalgasand11.0"

forpropanegas.Inordertoobtainrating,gassupplypressuremust

be 11.0" w.c. for propane gas.

The pressure regulator on LP gas models is adjusted for 9.5" w.c.

manifold pressure and is intended to prevent over-firing only. Do

not attempt adjustment of the built-in pressure regulator unless

thesupplypressureisatleast7.0"w.c.on naturalgasor13.0"w.c.

on propane gas. Check the location of the ignition electrode and

the flame sensor for correct gap setting.

FLAME

SENSOR

Flame Sensor and Ignition Electrode Location

NATURAL

(Dia) PROPANE (LP)

(Dia)

45,000 2 23,000 #43 #55

115,000 5 23,000 #43 #55

140,000 6 23,000 #43 #55

90,000 4 23,000 #43 #55

GASORIFICES

MAXIMUM

INPUT

(BTUH)

NUMBER

BURNERS

MAXIMUM

BTUH/BURNER

Heat Exchanger and Burner Orifice Specifications

NOTE:Gasapplianceslocatedmorethan2000feetabovesealevel

must be derated 4% per 1000 feet of total elevation and that

variance in gas heating value and specific gravity require change

inmanifoldpressuretoobtainrating,itismandatorythattheinput

beadjustedattheinstallationsite.Allinstallationsshouldbemade

asoutlinedinthelatesteditionoftheNationalFuelGasCodeANSI

Z223.1,section “Procedures To Be Followed To Place An Appliance

in Operation”. Refer also to the “User’s Information Manual”

suppliedwiththeunitforadditionalinformationonthegasfurnace.

Gas Supply And Manifold Check

Gassupplypressureandmanifoldpressurewiththeburnersoper-

ating must be as specified on the rating plate.

Gas Inlet Pressure Check

Gasinletpressuremustbecheckedandadjustedin accordanceto

the type of fuel being consumed.

With Power And Gas Off:

1. Connect a water manometer or adequate gauge to the

inlet pressure tap of the gas valve.

Inlet gas pressure can also be measured by removing the

cap from the dripleg and installing a predrilled cap with a

hose fitting.

With Power And Gas On:

2. Put unit into heating cycle and turn on all other gas

consuming appliances.

NATURAL Min. 5.0"W.C.,Max.10.0"W.C.

PROPANE Min.11.0" W.C., Max. 14.0"W.C.

INLET GAS PRESSURE

NOTE: Inlet Gas Pressure Must Not Exceed the Maximum Value

Shown.

Ifoperatingpressuresdifferfromabove,makenecessarypressure

regulatoradjustments,check pipingsize,etc.,and/orconsultwith

local utility.

Manifold Pressure Check

The gas valve has a tapped opening to facilitate measurement of

themanifoldpressure.A“U”Tubemanometerhavingascalerange

from 0 to 12 inches of water should be used for this measure-

ment. The manifold pressure must be measured with the burners

operating.

1. With disconnect switch open, remove field connected

thermostat wire from terminal R, W1 and W2 on TB1.

Placejumper wirebetweenR,W1and W2toengagehigh

stage heat. (note on 045 kbtu/hr units W2 is not used,

only jumper R to W1).

2. SeeFigureininputratingsectionforgasvalveadjustment.

To adjust the pressure regulator, remove the adjustment screw or

cover on the gas valve. Turn out (counterclockwise) to decrease

pressure,turnin(clockwise)toincreasepressure.Onlysmallvaria-

tionsingasflowshouldbemadebymeansof thepressureregula-

toradjustment.Inno case shouldthe final manifoldpressure vary

more than plus or minus 0.3 inches water column from the speci-

fiednominalpressure.Anymajorchangesin flowshouldbe made

by changing the size of the burner orifices. The measured input

rate to the furnace must not exceed the rating specified on the

unit rating plate.

Fornaturalgas,thehighstagemanifoldpressuremustbebetween

3.2 and 3.8 inches water column (3.5 nominal). Low stage mani-

fold pressure must be between 1.7 to 2.3 inches water column

(2.0 nominal).

3. To set low fire rate on 090, 115 and 140 kbtu/hr: Open

disconnect switch, and remove jumper from R to W2. To

set low fire manifold pressure, repeat steps above. Refer

to Figure in input rating section for location of high and

low stage adjustment.

For propane gas, the manifold pressure must be between 9.7 and

10.3incheswatercolumn(10.0nominal).Lowstagemanifoldmust

be between 5.7 and 6.3 inches water column (6.0 nominal).

Gas Input (Natural Gas Only) Check

It is the responsibility of the contractor to adjust the gas input to

the unit.

To measure the gas input use a gas meter and proceed as

follows:

1. Turnoffgassupplytoallotherappliancesexcepttheunit.

2. With the unit operating, time the smallest dial on the

meterforonecomplete revolution. Ifthis isa2 cubicfoot

dial,divide the secondsby 2; if itis a 1 cubicfootdial, use

the seconds as is. This gives the seconds per cubic foot of

gas being delivered to the unit.

3. INPUT=GAS HTG VALUE x 3600 / SEC. PER CUBIC FOOT

Example: Natural gas with a heating value of 1000 BTU per cubic

footand34 secondsper cubicfootas determinedby Step2, then:

Input = 1000 x 3600 / 34 = 106,000 BTU per Hour. NOTE:

BTU content of the gas should be obtained from the gas

supplier. This measured input must not be greater than

shown on the unit rating plate.

Adjust input rate by varying the adjustment of the gas pressure

regulator on the gas valve. All adjustments must be made with

furnace operating at high fire and at normal operating tempera-

ture. A manometer should be connected to the gas valve to verify

pressure is within the specified range (see following figures for

manometerconnections). Clockwiserotationofthepressureregu-

latorscrewincreasespressureandgasflow rate.Turnscrewcoun-

terclockwise to decrease pressure and gas flow rate. After adjust-

mentthefurnacetemperaturerisemustbewithintherangespeci-

fied on the unit data plate. NOTE: Thermal efficiency of the fur-

nace is a product efficiency rating determined under continuous

operating conditions independent of any installed system.

Pressure Regulator

Adjustment

(Under Cap Screw)

Gas Valve

On/Off

Selector

Switch

INLET OUTLET

Inlet Pressure

Tap

Outlet Pressure

Tap

White-Rodgers 36G22 - Single Stage

Inlet

Pressure Boss

Low Fire

Regulator Adjust

Manometer

Hose

High Fire Regulator

Adjust Regulator

Vent

Outlet

Pressure Boss

Open t

Atmosphere

White-Rodgers 36G54 (2-Stage) Connected to Manometer

Pressure Adjustments

To connect manometer to gas valve:

1. Backoutletpressuretestscrew(inlet/outletpressureboss)

outone turn(counterclockwise,notmorethan oneturn).

2. Attachahoseand manometertotheoutletpressureboss

of the valve.

To remove manometer from gas valve:

1. Remove manometer hose from outlet pressure boss.

2. Turn outlet pressure test screw in to seal pressure port

(clockwise, 7 in-lb. minimum).

3. Turn on electrical power and gas supply to the system.

4. Turn on system power and energize valve.

5. Usingaleakdetectionsolutionorsoapsuds,checkforleaks

at pressure boss screw. Bubbles forming indicate a leak.

SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY.

PREVENT

UNRELIABLE

OPERATION

EQUIPMENT

DAMAGE

THE

GAS

MANIFOLD

PRESSURE

MUST

SPECIFIED

THE

UNIT

RATING

PLATE

. O

NLY

MINOR

ADJUSTMENTS

SHOULD

MADE

ADJUSTING

THE

GAS

VALVE

PRESSURE

REGULATOR

CAUTION

4. Relight all other appliances turned off in step 1. Be sure all

pilot burners are operating.

Main Burner Flame Check

Flames should be stable, soft and blue (dust may cause orange

tips but they must not be yellow) and extending directly outward

from the burner without curling, floating or lifting off.

NOx Screen Check

Verify that the alignment of the NOx screens is at 6 o' clock. In

jurisdictions that do not require low NOx emissions, NOx screens

may be removed.

Temperature Rise Check

Checkthetemperaturerisethroughtheunit byplacing thermom-

eters in supply and return air registers as close to the unit as pos-

sible. Thermometers must not be able to sample temperature di-

rectly from the unit heat exchangers, or false readings could be

obtained.

1. All registers must be open; all duct dampers must be in

their final (fully or partially open) position and the unit

operated for 15 minutes before taking readings.

2. The temperature rise must be within the range specified

on the rating plate.

NOTE:Airtemperatureriseisthetemperaturedifferencebetween

supply and return air.

With a properlydesigned system,theproperamountof tempera-

ture rise will normally be obtained when the unit is operated at

rated input with the recommended blower speed.

If the correct amount of temperature rise is not obtained, it may

be necessary to change the blower speed. A higher blower speed

will lower the temperature rise. A slower blower speed will in-

crease the temperature rise.

NOTE: Blower speed MUST be set to give the correct air

temperature rise through the unit as marked on the rating plate.

NORMALSEQUENCEOFOPERATION

HEATING

This unit has one (RS) Manual Reset Limit Control Switch. Check

the limit to make sure it has not tripped. The limit may arrive at

the job site tripped as a result of shipping shock.

If the venter motor comes on, but the unit does not attempt igni-

tion,checkiftheALS(AuxiliaryHighLimitControlSwitch)requires

resetting.

1. With electricity and gas turned on, the system switch in

the “HEAT” or “AUTO” position and the fan switch in the

“AUTO” position, the thermostat will close the circuit

between unit terminals R and W (R-W) when the

temperature falls below the thermostat setting.

2. D1 on IIC energizes relay IDMR.

3. Relay IDMR energizes the venter motor IDM.

4. Operation of the venter motor closes the pressure switch

PS located in the burner compartment. Unless excessive

temperatures or shipping shock have opened high limit

controlALS,powerisfedtotheintegratedignitioncontrol,

which then initiates a 15-second pre-purge time delay.

During this period, the venter motor will clear the

combustion chamber of any residual gas.

5. After the pre-purge period, the ignition control energizes

the Wl-C gas valve and simultaneously initiates a “three

(3)-try” spark ignition sequence.

6. When the burners are ignited, a minimum one (1) micro-

amp DC current will flow through the flame between the

sensor electrode and the grounded burner.

7. When the controller proves that the flame has been

established, it will keep the gas valve energized and

discontinue the ignition spark. High stage manifold

pressure will be approximately 3.5" w.c. for natural gas

and10.0"w.c.forpropane(LP).Lowfirenaturalgasis2.0”

w.c.; low fire propane 6.0” w.c.

8. Ifthecontrolisunabletoignitethe burnersafteritsinitial

attempt,itwillinitiateanotherpurgeandsparksequence.

A third purge and spark sequence will be initiated if the

second attempt is unsuccessful. If the third attempt is

unsuccessful, the controller will close the gas valve and

lockitselfout.Itmayberesetbymomentarilyinterrupting

power. This may be accomplished by briefly lowering the

room thermostat set-point below room temperature, or

by shutting off the main power to the unit. (See TP-105

for more details.)

9. Integrated ignition control will close its normally open

contacts after a delay of approximately 30 seconds. This

action energizes contactor BC and starts the supply fan

motor. Operation of the supply fan circulates air across

the heat exchanger and delivers heated air to the

conditioned space.

10. When the space temperature rises, the thermostat will

open R-W. Opening R-W will cause the gas valve to close,

and the furnace to shut down.

11. The furnace has three high temperature limit controls,

which can shut down the burner. They do not shut down

the venter motor.

Unit Shutdown

1. Set the thermostat to lowest setting.

2. Turn off the electrical power supply to the unit.

3. Remove the heat exchanger door on the side of the unit

by removing screws.

4. Movethe gascontrolvalveswitchtotheOFF position. Do

not force.

5. Close manual gas shut off valve external to the unit.

6. Replace the heat exchanger door on the unit.

7. If cooling and/or air circulation will be desired, turn ON

the electrical power.

AUTOMATIC RESET HIGH LIMIT CONTROL (LS)

Locatedintheburnercompartmentontheheatexchanger,itssens-

ing element projects through the blower section bulkhead and

sensesthe temperature atthe rear ofthe furnace. Itwillcyclethe

furnace off if the temperature exceeds 100°F plus maximum rise.

AUXILIARY HIGH LIMIT CONTROL (ALS)

Located in the blower compartment on the blower housing, it

senses air temperature within the blower compartment and pro-

tects the filters from excessive temperature. It will shut down the

furnace if it senses excessive temperatures.

Elevated temperatures at the control are normally caused by

blower failure. The reason for the opening should be determined

and repaired prior to resetting.

MANUAL RESET FLAME ROLLOUT CONTROL (RS)

Located in the burner compartment at the top of the burner as-

sembly, it senses high temperature that could occur if the heat

exchanger tubes were plugged and the flame was rolling out in-

steadofenteringthetubes.Ithasamanualpush-buttonresetthat

cannot be actuated until the limit control has cooled.

The reason for elevated temperatures at the control should be

determined and repaired prior to resetting this manual reset con-

trol.

WARNING

TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE

OR EXPLOSION, A QUALIFIED SERVICER MUST INVESTIGATE THE REASON FOR

THE ROLLOUT PROTECTION DEVICE TO OPEN BEFORE MANUALLY RESETTING

THE ROLLOUT PROTECTION DEVICE.

REFRIGERATION SYSTEM CHECKS

This unit is equipped with a piston type metering device or non-

adjustable TXV.

Ensurethehold-downboltsonthecompressoraresecureandhave

notvibratedlooseduringshipment. Checkthatthevibrationgrom-

mets have been installed and visually check all piping for damage

andleaksand repairif necessary. The entiresystem hasbeen fac-

tory charged and tested, making it unnecessary to field charge.

Factory refrigerant charge is shown on the unit’s nameplate.

Toconfirmchargelevelsor,ifaleakoccursand chargeneedstobe

added to the system, it is recommended to evacuate the system

and recharge refrigerant to the unit’s nameplate specifications.

This unit has been rated in the cooling mode at the AHRI rated

conditions of: indoor (80°F db/67°F wb) and outdoor (95°F db).

Whileoperatingatthiscondition,thesuperheatshouldrangefrom

9°F to 11°F for each refrigeration circuit measured at the suction

service port located near the compressor.

START-UPPROCEDURE AND CHECKLIST

Begin with power turned off at all disconnects.

1. Turn thermostat system switch to “Cool,” and fan switch

to “Auto” and turn temperature setting as high as it will

go.

2. Inspect all registers and set them to the normal open

position.

3. Turn on the electrical supply at the disconnect.

4. Turn the fan switch to the “ON” position. The blower

should operate after a 7 second delay.

5. Turn the fanswitchto“Auto”position. The blowershould

stop after a 65 second delay.

6. Slowlylowerthecoolingtemperatureuntiltheunitstarts.

Thecompressor,blowerandfanshouldnowbeoperating.

Allow the unit to run 10 minutes, make sure cool air is

being supplied by the unit.

On2stagemodels(modelswitha“V”inthe11thposition)

the unit is now operating on low speed. After the 10

minute run, continue lowering cooling temperature until

blowerspeedincreasesindicating2ndstagecooling. Make

sure cool air is still being supplied by unit and proceed to

step 7.

7. Turn the temperature setting to the highest position,

stopping the unit. The indoor blower will continue to run

for 65 seconds.

8. Turn the thermostat system switch to “OFF” and

disconnect all power when servicing the unit.

REFRIGERATION SEQUENCE CHECK

Withthedisconnectswitchopen,removethefieldconnectedther-

mostatwirefromterminalRonTB1terminalblock.Placeajumper

acrossterminalsRandG,andacrossRandYonTB1terminalblock.

Close the disconnect switch. The following operational sequence

should be observed.

1. Current through primary winding of transformer TRANS1

energizes the 24-volt control circuit.

2. To simulate a mechanical call for cooling from the wall

thermostat, place a jumper across terminals R and Y of

terminal block TB1. The cooling is energized when the

room temperature is above the thermostat set-point for

cooling. The thermostat makes R to Y.

3. UNITWITHECONOMIZEROPTION:Thecompressorcircuit

isinterlockedthroughterminals1and4oftheeconomizer

module. If the outdoor air enthalpy (temperature and

humidity) is not suitable for cooling, the economizer

terminals will be closed permitting compressor to be

energized.

4. The belt drive blower contactor closes its contacts L1, L2

andL3toT1,T2andT3toprovidepowertothesupplyfan

motor.

PSC Motor

Adjust the CFM for the unit by changing the speed tap of

the indoor blower motor at the EBTDR “com” connection

with one of the speed taps on “M1” or “M2”. (Black-High

Speed, Blue-Medium Speed, Red-Low Speed.)

EEM Motor

Adjust the CFM for the unit by changing the position of

the low voltage leads on the motor terminal block. White

is for fan only and gas heat, Yellow is for cooling. Refer to

Appendix A for blower performance at each speed tap.

NOTE: If more than one lead is energized simultaneously,

the motor will run at the higher speed.

5. Check supply fan rotation. If the supply fan is rotating in

the wrong direction, disconnect and lock off Single Point

Power Block. Do not attempt to change load side wiring.

Internalwiringissetatthefactorytoassurethatthesupply

fan and compressors all rotate in the proper direction.

Verificationof correctsupply fanrotationatinitialstartup

will also indicate correct compressor rotation. Reconnect

power and check for proper operation.

6. Compressor contactor closes its contacts L1, L2 and L3 to

T1, T2 and T3 to provide power to the compressor motor

COMP. 1. In addition, contactor C1 closes its contact L3 to

T3 , energizing the condenser fan motor.

BURN HAZARD!

DO NOT TOUCH! DISCHARGE LINE MAY BE HOT!

WARNING

7. Checkthatthecompressorisoperatingcorrectly.Thescroll

compressors in these units MUST operate in the proper

rotation. To ensure the compressors are operating in the

correct direction, check the compressor discharge line

pressure or temperature after the compressor is started.

The discharge pressure and discharge line temperature

shouldincrease. Ifthisdoesnotoccurandthecompressor

isproducingan exceptionalamountof noise,performthe

following checks.

• Ensure all compressors and the supply fan motor are

operating in the proper direction. If a single motor is

operating backwards, check the power wiring for that

motorandcorrectanyleadsthathavebeeninterchanged

at the contactor or at the motor.

• Ifallofthemotorsareoperatingbackward,disconnect

the unit power supply and lock it in the “OFF” position.

Switch two leads of the power supply at the unit Single

Point Power Block. Reconnect power and check for

compressor and supply fan motor operation.

8. With all safety devices closed, the system will continue

cooling operation until the thermostat is satisfied.

9. Disconnecting the jumper wire between R and Y and

between R and G on TB1 terminal block will simulate a

satisfied thermostat. The compressor will cycle off and

IIC(pin12)willinitiateitstimedelaycycle.Thecompressor

and the supply fan will cycle off.

10. After a time delay of approximately 3 minutes, the

compressor control circuits will be ready to respond to a

subsequent call for cooling from the wall thermostat.

11. Open disconnect switch. Reconnect the field thermostat

wire at terminal R on terminal block TB1.

REFRIGERATION PERFORMANCE CHECK

Check that compressor RLA corresponds to values shown in Ap-

pendix B. RLA draw can be much lower than values listed at low

load conditions and low ambient condensing temperatures. Val-

ues in Appendix B can slightly exceed at high load conditions and

high ambient condensing temperatures.

FINAL SYSTEM CHECKS

1. Checktoseeifallsupplyandreturnairgrillesareadjusted

and the air distribution system is balanced for the best

compromise between heating and cooling.

2. Check for air leaks in the ductwork. See Sections on Air

Flow Adjustments.

3. Make sure the unit is free of “rattles”, and the tubing in

the unit is free from excessive vibration. Also make sure

tubesor linesarenot rubbing againsteachotheror sheet

metal surfaces or edges. If so, correct the trouble.

4. Set the thermostat at the appropriate setting for cooling

and heating or automatic changeover for normal use.

5. BesuretheOwnerisinstructedontheunitoperation,filter,

servicing, correct thermostat operation, etc.

MAINTENANCE

HIGH VOLTAGE!

ISCONNECT

ALL

POWER

BEFORE

SERVICING

INSTALLING

THIS

UNIT

. M

ULTIPLE

POWER

SOURCES

MAY

PRESENT

. F

AILURE

MAY

CAUSE

PROPERTY

DAMAGE

PERSONAL

INJURY

DEATH

WARNING

PREVENT

PERSONAL

INJURY

DEATH

DUE

IMPROPER

INSTALLATION

ADJUSTMENT

ALTERATION

SERVICE

MAINTENANCE

REFER

THIS

MANUAL

. F

ADDITIONAL

ASSISTANCE

INFORMATION

CONSULT

QUALIFIED

INSTALLER

SERVICE

AGENCY

THE

GAS

SUPPLIER

WARNING

HEET

METAL

PARTS

SCREWS

CLIPS

AND

SIMILAR

ITEMS

INHERENTLY

HAVE

SHARP

EDGES

AND

NECESSARY

THAT

THE

INSTALLER

AND

SERVICE

PERSONNEL

EXERCISE

CAUTION

Preventive maintenance is the best way to avoid unnecessary ex-

pense and inconvenience. Have this system inspected at regular

intervalsbyqualified servicepersonnel,at leasttwice ayear. Rou-

tine maintenance should cover the following items:

1. Tighten all belts, set screws, and wire connections.

2. Cleanevaporatorandcondensercoilsmechanicallyorwith

coldwater,if necessary.Usuallyanyfoulingisonlymatted

ontheenteringair faceofthecoil andcanberemovedby

brushing.

3. Lubricate motor bearings.

4. Align or replace belts as needed.

5. Replace filters as needed (see below).

6. Check for blockage of condensate drain.

7. Check power and control voltages.

8. Check running amperage.

9. Check operating temperatures and pressures.

10. Check and adjust temperature and pressure controls.

11. Check and adjust damper linkages.

12. Check operation of all safety controls.

13. Examine gas furnaces (see below and the User’s

Information Manual).

14. Check condenser fans and tighten set screws.

FILTERS

CAUTION

TO PREVENT PROPERTY DAMAGE DUE TO FIRE AND LOSS OF

EQUIPMENT EFFICIENCY OR EQUIPMENT DAMAGE DUE TODUST AND LINT

BUILD UP ON INTERNAL PARTS, NEVER OPERATE UNIT WITHOUT AN AIR

FILTER INSTALLED IN THE RETURN AIR SYSTEM.

Every application may require a different frequency of replace-

ment of dirty filters. Filters must be replaced at least every three

(3) months during operating seasons.

Dirty filters are the most common cause of inadequate heating or

cooling performance. Filter inspection should be made at least

everytwomonths;moreoftenifnecessarybecauseoflocalcondi-

tions and usage.

Dirty throwaway filters should be discarded and replaced with a

new, clean filter.

Disposable return air filters are supplied with this unit. See the

unit Specification Sheet or Technical Manual for the correct size

and part number. To remove the filters, remove the filter access

panel on return side of the unit.

CABINET FINISH MAINTENANCE

Usea finegradeautomotivewaxon thecabinetfinish tomaintain

the finish’s original high luster. This is especially important in in-

stallations with extended periods of direct sunlight.

CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)

The coil with the outside air flowing over it should be inspected

annuallyandcleanedasfrequentlyasnecessarytokeepthefinned

areas free of lint, hair and debris.

CONDENSER AND INDUCED DRAFT MOTORS

Bearings on the condenser fan motors and the combustion fan

motorarepermanentlylubricated.Noadditionaloilingisrequired.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

A drop in the flame current can be caused by a nearly invisible

coating on the flame sensor. This coating, created by the fuel or

combustion air supply, can be removed by carefully cleaning the

flame sensor with steel wool.

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