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
© 2013 - 2016
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

2
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.
T HIS UNIT MUST NOT BE USED AS A " CONSTRUCTION HEATER "
DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW
STRUCTURE . T HIS TYPE OF USE MAY RESULT IN PREMATURE
FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR
TEMPERATURE AND EXPOSURE TO CORROSIVE OR VERY
DIRTY
ATMOSPHERES .
HIGH VOLTAGE!
D
ISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT . M ULTIPLE POWER SOURCES MAY
BE PRESENT . F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE , PERSONAL INJURY OR DEATH .
WARNING
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.
O NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL , ADJUST , SERVICE OR
REPAIR ( HEREINAFTER , “ SERVICE ”) THE EQUIPMENT SPECIFIED IN THIS
MANUAL SHOULD SERVICE THE EQUIPMENT . T HE MANUFACTURER WILL NOT
BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM
IMPROPER SERVICE OR SERVICE PROCEDURES . I F YOU SERVICE THIS UNIT , YOU
ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY
RESULT . I N ADDITION , IN JURISDICTIONS THAT REQUIRE ONE OR MORE
LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL , ONLY
LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT . I MPROPER
INSTALLATION , ADJUSTMENT , SERVICING OR REPAIR OF THE EQUIPMENT
SPECIFIED IN THIS MANUAL , OR ATTEMPTING TO INSTALL , ADJUST , SERVICE OR
REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER
TRAINING MAY RESULT IN PRODUCT DAMAGE , PROPERTY DAMAGE , PERSONAL
INJURY OR 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.
I F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED
EXACTLY , A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE , PERSONAL INJURY OR LOSS OF LIFE .
- D
O 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:
* D
O NOT TRY TO LIGHT ANY APPLIANCE .
* D
O NOT TOUCH ANY ELECTRICAL SWITCH ; DO NOT USE
ANY PHONE IN YOUR BUILDING .
* I
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A
NEIGHBORS PHONE . F OLLOW THE GAS SUPPLIERS
INSTRUCTIONS .
* I
F YOU CANNOT REACH YOUR GAS SUPPLIER , CALL THE
FIRE DEPARTMENT .
- I
NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED
INSTALLER , SERVICE AGENCY OR THE GAS SUPPLIER
WARNING
D O NOT CONNECT TO OR USE ANY DEVICE THAT IS NOT DESIGN
CERTIFIED BY THE MANUFACTURER FOR USE WITH THIS UNIT .
S
ERIOUS PROPERTY DAMAGE , PERSONAL INJURY , REDUCED UNIT
PERFORMANCE AND /OR HAZARDOUS CONDITIONS MAY RESULT
FROM THE USE OF SUCH NON - APPROVED DEVICES .
WARNING
S HEET METAL PARTS , SCREWS , CLIPS AND SIMILAR ITEMS INHERENTLY
HAVE SHARP EDGES , AND IT IS NECESSARY THAT THE INSTALLER AND
SERVICE PERSONNEL EXERCISE CAUTION .
CAUTION

3
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.

4
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.

5
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.
A LL CURBS LOOK SIMILAR . T O AVOID INCORRECT CURB
POSITIONING , CHECK JOB PLANS CAREFULLY AND VERIFY MARKINGS
ON CURB ASSEMBLY . I NSTRUCTIONS MAY VARY IN 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

6
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.
I F PROTRUSIONS EXIST , DO NO ATTEMPT TO SET UNIT ON 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.
I F UNITS ARE LIFTED TWO AT A TIME , THE FORK HOLES ON THE
CONDENSER END OF THE UNIT MUST NOT BE USED . M INIMUM FORK
LENGTH IS 42” TO PREVENT DAMAGE TO THE UNIT ; HOWEVER , 48”
IS 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.

7
To assist in determining rigging requirements, unit weights are
shown as follows:
A
B
C
D
CG
SUPPLY
RETURN
EVAPORATOR COIL
CONDENSER
COIL
COMPRESSOR
Y
X
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)
T O PREVENT SEVERE DAMAGE TO THE BOTTOM OF THE UNIT , DO 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
T O PREVENT DAMAGE TO THE UNIT , DO NOT ALLOW CRANE HOOKS
AND SPREADER BARS TO REST ON THE ROOF OF THE UNIT .
CAUTION
Removespreaderbars,liftingcablesandotherriggingequipment.
ELECTRICAL WIRING
HIGH VOLTAGE!
D
ISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT . M ULTIPLE POWER SOURCES MAY
BE PRESENT . F AILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE , PERSONAL INJURY OR DEATH .
WARNING
HIGH VOLTAGE!
T
O AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK , DO NOT TAMPER WITH FACTORY
WIRING . T HE INTERNAL POWER AND CONTROL WIRING
OF THESE UNITS ARE FACTORY - INSTALLED AND HAVE
BEEN THOROUGHLY TESTED PRIOR TO SHIPMENT .
C
ONTACT YOUR LOCAL REPRESENTATIVE IF
ASSISTANCE IS REQUIRED .
WARNING
T O PREVENT DAMAGE TO THE WIRING , PROTECT WIRING FROM
SHARP EDGES . F OLLOW NATIONAL ELECTRICAL CODE AND ALL
LOCAL CODES AND ORDINANCES . D O NOT ROUTE WIRES THROUGH
REMOVABLE ACCESS PANELS .
CAUTION
C ONDUIT AND FITTINGS MUST BE WEATHER - TIGHT TO 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.

8
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
F AILURE OF UNIT DUE TO OPERATION ON IMPROPER LINE VOLTAGE
OR WITH EXCESSIVE PHASE UNBALANCE CONSTITUTES PRODUCT
ABUSE IS NOT COVERED BY THE WARRANTY AND MAY CAUSE
SEVERE DAMAGE TO 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.

9
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
T O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
INSTALLATION , ADJUSTMENT , ALTERATION , SERVICE OR
MAINTENANCE , REFER TO THIS MANUAL . F OR ADDITIONAL
ASSISTANCE OR INFORMATION , CONSULT A QUALIFIED INSTALLER ,
SERVICE AGENCY OR THE GAS SUPPLIER .
WARNING
IMPORTANT NOTE: This unit is factory set to operate on natural
gas at the altitudes shown on the rating plate.
T O AVOID PROPERTY DAMAGE , PERSONAL INJURY OR DEATH WHEN
EITHER USING PROPANE GAS ALONE OR AT HIGHER ALTITUDES ,
OBTAIN AND INSTALL THE PROPER CONVERSION KIT ( S ). F AILURE TO
DO SO CAN RESULT IN UNSATISFACTORY OPERATION AND / OR
EQUIPMENT DAMAGE . H IGH ALTITUDE KITS ARE FOR U.S.
I
NSTALLATIONS ONLY AND ARE NOT APPROVED FOR USE IN C 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

10
• 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.