UL BADF090 User manual

SAFETY CONSIDERATIONS
Due to system pressure, moving parts and electrical components,
installationandservicingofairconditioningequipmentcanbehazardous.
Only qualified, trained, service personnel should install, repair, maintain
or service this equipment.
Observe all precautions in the literature, on labels and tags
accompanying the equipment whenever working on air conditioning
equipment. Be sure to follow all other safety precautions that apply.
Wear safety glasses and work gloves, and follow all safety
codes. Use a quenching cloth and have a fire extinguisher
available for all brazing operations.
GENERAL
ModelBDFDualFuelHeatPumpsaresinglepackageunitswithgas
heat designed for outdoor installation on a rooftop or a slab.
The units are completely assembled on rigid, permanently
attachedbaserails.Allpiping,refrigerantcharge,andelectrical
wiring is factory installed and tested. The units require only
electric power and duct connections at the point of installation.
The gas-fired heaters have aluminized steel tubular heat
exchangers and spark ignition with proven pilot.
INSPECTION
Assoonasaunitisreceived,itshouldbeinspectedforpossible
damage during transit. If damage is evident, the extent of the
damage should be noted on the carrier’s freight bill. Aseparate
request for inspection by the carrier’s agent should be made in
writing. Refer to Form 50.15-NM for additional information.
REFERENCE
Additional information on the design, installation, operation and
serviceofthisequipmentisavailableinthefollowingreferenceforms:
•530.18-N3.2V - Economizer Accessory
•530.18-N3.8V - Motorized Outdoor Air Damper Accy.
•530.18-N3.9V - Manual Outdoor Air Damper 0-35%
•530.18-N3.10V - Manual Outdoor Air Damper 0-100%
•530.18-N8.4V - Gas Piping Accessory
•530.18-N10.5V - Propane Conversion Accessory (USA)
•530.18-N10.6V - High Altitude Accessory (Nat. Gas)
•530.18-N10.7V - High Altitude Accessory (Propane)
•690.15-N28V - Low Ambient Accessory
Renewal Parts:
•Refer to the Renewal Parts Manual for complete listing of
replacement parts on this equipment.
All forms referenced in this instruction may be ordered from:
Publications Distribution Center
Unitary Products Group
P.O. Box 1592, York, Pa. 17405
APPROVALS
Design certified by U.L. as follows:
1. For use as a heat pump only unit or a heat pump unit with
a forced air furnace.
2. For outdoor installation only.
3. For installation on combustible material.
4. For use with natural gas or propane gas.
Not suitable for use with conventional venting systems.
LIMITATIONS
INSTALLATION
INSTRUCTION
SINGLE PACKAGE
CONVERTIBLE SERIES
DUAL FUEL HEAT PUMPS
Supersedes: 511.17-N2W (293) 511.17-N2W (398)
MODELS BADF090 & 120
(9.0 EER)
035-15683
208/230/575 VOLT
MODELS ONLY
Installer should pay particular attention to the words:
NOTE, CAUTION
and
WARNING
. Notes are intended to clarify or make
the installation easier. Cautions are given to prevent equipment damage. Warnings are given to alert installer that personal in-
jury and/or equipment damage may result if installation procedure is not handled properly.
208/230/460 VOLT
MODELS ONLY
CAUTION
THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE
WITHTHEENCLOSEDINSTALLATIONINSTRUCTIONSANDANY
APPLICABLE LOCAL, STATE, AND NATIONAL CODES
INCLUDING, BUT NOT LIMITED TO, BUILDING, ELECTRICAL,
AND MECHANICAL CODES.
WARNING
INCORRECT INSTALLATION MAY CREATE A CONDITION
WHERE THE OPERATION OF THE PRODUCT COULD CAUSE
PERSONAL INJURY OR PROPERTY DAMAGE
FOR YOUR SAFETY
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don’t touch electrical switches; do not use
any phones in the area of the gas leak.
3. Extinguish any open flame.
4. Immediately call yourgas supplierfromanother
location.Follow your gas supplier’s instructions.
5. If you cannot reach your gas supplier, call the fire
department.

Safety Considerations.......................................................... 1
General ................................................................................ 1
Inspection............................................................................. 1
Reference ............................................................................ 1
Approvals............................................................................. 1
Nomenclature....................................................................... 2
INSTALLATION
Limitations............................................................................ 3
Location ............................................................................... 3
Condensate Drainage Precaution .......................................3
Rigging and Handling .......................................................... 3
Clearances........................................................................... 3
Ductwork.............................................................................. 3
Condensate Drain................................................................ 4
Compressors........................................................................ 4
Filters ................................................................................... 4
Service Access..................................................................... 4
Thermostat........................................................................... 4
Power and Control Wiring.................................................... 4
Combustion Discharge ........................................................ 4
Gas Piping ........................................................................... 4
Gas Connection................................................................... 5
L.P. Units, Tanks and Piping ................................................ 6
Vent and Combustion Air Hoods..........................................6
OPERATION
Cooling System.................................................................. 10
Heating System (Heat Pump)............................................10
Defrost Sequence of Operation..........................................11
Heating System (Gas Heat)............................................... 12
Safety Controls .................................................................. 12
Heat Anticipator Setpoints ................................................. 12
Pre-Start Check List........................................................... 12
START-UP
Operating Instructions........................................................ 14
Post-Start Check List......................................................... 14
Manifold Gas Pressure Adjustment ................................... 14
Pilot Checkout.................................................................... 14
Burner Instructions............................................................. 14
Burner Air Shutter Adjustment ........................................... 15
Checking Supply Air CFM.................................................. 15
Adjustment of Temperature Rise .......................................16
Checking Gas Input ........................................................... 16
Secure Owner’s Approval .................................................. 16
MAINTENANCE & TROUBLESHOOTING
Normal Maintenance.......................................................... 17
Cleaning Flue Passages and Heating Elements............... 17
Troubleshooting ................................................................. 18
Replacement Parts ............................................................ 19
TABLES
No. Description Page
1 Unit Application Data .................................. 3
2 Gas Heat Application Data.......................... 5
3 Pipe Sizing.................................................. 5
4 Physical Data.............................................. 9
5 Supply Air Blower Performance.................. 9
6 Accessory Static Resistances .................... 10
7 Blower Motor and Drive Data...................... 10
8 Electrical Data............................................. 10
9 Limit Control Setting ................................... 13
10 Blower Motor Pulley Adjustment................. 15
11 Gas Rate - Cubic Feet Per Hour ................ 16
FIGURES
No. Description Page
1 Center of Gravity......................................... 3
2 Recommended Drain Piping....................... 4
3 Typical Field Wiring..................................... 5
4 External Supply Connection ....................... 6
5 Bottom Supply Connection......................... 6
6 Vent and Combustion Air Hoods................. 6
7 Dimensions and Clearances....................... 7
8 Defrost Initiation Times............................... 12
9 Ambient Modified Time/Temp. Control........ 12
10 Gas Valve Piping......................................... 13
11 Typical Gas Valve ....................................... 14
12 Proper Flame Adjustment........................... 14
13 Typical Flame Appearance ......................... 15
14 Pressure Drop versus Supply Air CFM....... 15
TABLE OF CONTENTS
B A D F - F 09 0N
PRODUCT NOMENCLATURE
PRODUCT GENERATION
A = 1st Generation
PRODUCT CATEGORY
B = Single Package Heat Pump
(Air-Cooled)
PRODUCT IDENTIFIER
DF = Dual Fuel Heat Pump
VOLTAGE CODE
-T = 208/230-3-60
-W = 460-3-60
-X = 575-3-60
NOMINAL COOLING
CAPACITY
090 = 7-1/2 Ton
120 = 10 Ton
FACTORY
INSTALLED HEAT
N = Natural Gas
0 50
NOMINAL HEATING
INPUT CAPACITY
165 = 163 MBH
205 = 204 MBH
245 = 245 MBH
GAS
511.17-N2W
2Unitary Products Group

These units must be installed in accordance with the following
national and local safety codes:
1. National Electrical Code ANSI/NFPA No. 70.
2. National Fuel Gas Code Z223.1.
3. Gas-Fired Central Furnace Standard ANSI Z21.47a.
4. Local gas utility requirements.
5. Canadian Electrical Code C22.1
6. Canadian Installation Codes CAN1-B149.
Refer to Table 1 for Unit Application Data and to Table 2 for Gas
Heat Application Data.
If components are to be added to a unit to meet local codes,
they are to be installed at the dealer’s and/or the customer’s
expense.
Size of unit for proposed installation should be based on heat
loss/heat gain calculation made according to the methods of
the Air Conditioning Contractors of America (ACCA).
Thisfurnaceisnottobeusedfortemporaryheatingofbuildings
or structures under construction.
LOCATION
Use the following guidelines to select a suitable location for
these units.
1. Unit is designed for outdoor installation only.
2. Outdoor coil must have an unlimited supply of air. Elevate
the unit sufficiently to prevent any blockage of the air
entrances in areas where snow accumulations are
expected.
WARNING:Excessive exposure of this furnace to
contaminated combustion air may result in
equipment damage or personal injury. Typical
contaminates include: permanent wave solutions,
chlorinated waxes and cleaners, chlorine based
swimming pool chemicals, water softening
chemicals, carbon tetrachloride, Halogen type
refrigerants, cleaning solvents (e.g.
perchloroethylene), printing inks, paint removers,
varnishes, hydrochloric acid, cements and glues,
antistatic fabric softeners for clothes dryers,
masonry acid washing materials.
3. For ground level installation, use a level concrete slab with
a minimum thickness of 4 inches. The length and width
should be at least 6 inches greater than the unit base rails.
Do not tie slab to the building foundation.
4. Roof structure must be able to support the weightoftheunit
and its accessories. Unit must be installed on a solid level
roof curb or appropriate angle iron frame.
CAUTION: If a unit is to be installed on a roof curb or
special frame , gasketing mustbeappliedto all
surfaces that come in contact with the unit
underside.
5. Maintain level tolerance to 1/2" maximum across the entire
length or width of the unit.
OUTDOOR COIL CONDENSATE DRAINAGE
PRECAUTION
Condensate will drain from the outdoor coil during the heating
and defrost cycles. Normally this condensate may be allowed
to drain directly onto the ground/roof. A gravel bed is
recommended to prevent mud splashing.
WARNING:The unit should not be installed in an area where
mud or ice could cause personal injury. Remember
that condensate will drip from the outdoor coil
during heat and defrost cycles and that this
condensatewillfreezewhenthetemperatureofthe
outdoor air is below 32
° F.
RIGGING AND HANDLING
Exercise care when moving the unit. Do not remove any
packaging until the unit is near the place of installation. Rig the
unit by attaching chain or cable slings to the lifting holes
provided in the base rails. Spreaders, whose length exceeds
the largest dimension across the unit, MUST be used across
the top of the unit.
BEFORE LIFTING A UNIT, MAKE SURE THAT ITS WEIGHT
IS DISTRIBUTED EQUALLY ON THE CABLES SO THAT IT
WILL LIFT EVENLY.
Units may also be moved or lifted with a forklift. Slotted
openings in the base rails are provided for this purpose.
LENGTH OF FORKS MUST BE A MINIMUM OF 54".
Remove the nesting brackets from the four corners on top of
the unit. All screws that are removed when taking these
brackets off must be replaced on the unit.
CAUTION: An adhesive backed label is provided over the
outside of the combustion air inlet opening to
preventmoisturefromenteringtheunitwhichcould
cause damage to electrical components. Allow this
closure label to remain in place until the
combustion air hood is to be installed (refer to
Figure 7).
RefertoTable 4forunitweightsandtoFigure1 forapproximate
center of gravity.
CLEARANCES
All units require certain clearances for
proper operation and service. Installer must make provisions
for adequate combustion and ventilation air in accordance with
Section 5.3, Air for Combustion and Ventilation of the National
Fuel Gas Code, ANSI Z223.1 (in U.S.A.) or Sections 7.2, 7.3
or 7.4 of Gas Installation Codes CAN/CGA-B149.1 and .2 (in
Canada) and/or applicable provisions of the local building
codes. Refer to Figure 10 for the clearances required for
combustible construction, servicing, and proper unit operation.
WARNING:Do not permit overhanging structures or shrubs to
obstruct outdoor air discharge outlet, combustion
air inlet or vent outlet.
DUCTWORK
Ductwork shouldbe designed and sizedaccording to themethods
inManualQoftheAirConditioningContractorsofAmerica(ACCA).
Aclosed return duct system shall be used. This shall not preclude
use of economizers or outdoor fresh air intake. The supply and
INSTALLATION
Model 090 MBH 120 MBH
Voltage
Variation
Min. / Max.*
208 / 230V 187 / 253
460V 414 / 506
575V 518 / 630
Wet Bulb Temperature (°F)
of Air on Indoor Coil,
Min. / Max. 57 / 72 57 / 72
Dry Bulb Temperature (°F)
of Air on Outdoor Coil,
Min. / Max. 45 / 120 45 / 120
*Utilization range “A” in accordance with ARI Standard 110.
TABLE 1 - UNIT APPLICATION DATA
FIG. 1 - CENTER OF GRAVITY DIM. 7-1/2 Ton 10 Ton
A 32" 32-1/2"
B 44-3/4" 44"
511.17-N2W
Unitary Products Group 3

return air duct connections at the unit should be made with
flexible joints to minimize noise.
Thesupplyandreturnairductsystemsshouldbedesignedforthe
CFMandstaticrequirementsofthejob.TheyshouldNOTbesized
to match the dimensions of the duct connections on the unit.
CAUTION: When fastening ductwork to side duct flanges on
unit, insert screws through duct flanges only. DO
NOT insert screws through casing.
Outdoor ductwork must be insulated and
waterproofed.
Refer to Figure 8 for information concerning side and bottom
supply and return air duct openings.
CONDENSATE DRAIN
Plumbing must conform to local codes. Use a sealing compound
on male pipe threads. Install a condensate drainline from the 3/4"
female connection on the unit to spill into an open drain.
NOTE: ThecondensatedrainlineMUSTbetrappedtoprovide
proper drainage. See Figure 3.
COMPRESSORS
The compressors are mounted on springs which have been
tightened down for shipment only. After the unit is installed, back
out the compressor bolts until the sleeve clears the top grommet.
FILTERS
2" filters are supplied with each unit. 1" replacement filters may be
used with no modification to the filter racks. Filters must always be
installedaheadoftheindoorcoilandmustbekeptcleanorreplaced
with same size and type. Dirtyfilters will reduce the capacity of the
unitandwillresultinfrostedcoilsorsafetyshutdown.Minimumfilter
area and required sizes are shown in Table 4.
SERVICE ACCESS
Access to all serviceable components is provided by the
following removable panels:
•Compressor compartment
•Burner compartment (Two panels)
•Blower compartment
•Main control box
•Filter compartment
Refer to Figure 8 for location of these access panels.
CAUTION: Make sure that all screws are replaced on the unit
to maintain an air-tight seal.
THERMOSTAT
The room thermostat should be located on an inside wall
approximately 56" above the floor where it will not be subject
to drafts, sun exposure or heat from electrical fixtures or
appliances. Follow manufacturer’s instructions enclosed with
thermostat for general installation procedure. Color coded
insulated wires (#18 AWG) should be used to connect
thermostat to unit. Eight conductors are required.
POWER AND CONTROL WIRING
Field wiring to the unit must conform to provisions of the
National Electrical Code, ANSI / NFPA (latest edition) and/or
local ordinances. The unit must be electrically grounded in
accordance with N.E.C. ANSI / NFPA (latest edition) or local
codes. Voltage tolerances which must be maintained at the
compressor terminals during starting and running conditions
are indicated on the unit Rating Plate and Table 1.
The internal wiringharnessfurnishedwith this unitisanintegral
part of a UL and C.G.A. design certified unit. Field alteration to
comply with electrical codes should not be required.
A disconnect switch should be field provided for the unit. The switch
mustbeseparatefromallothercircuits.RefertoFigure8forinstallation
location. If any of the wire supplied with the unit must be replaced,
replacement wire must be of the type shown on the wiring diagram.
Electricallinemustbesizedproperlytocarrytheload.USECOPPER
CONDUCTORS ONLY. Each unit must be wired with a separate
branch circuit fed directly from the meter panel and properly fused.
CAUTION: When connecting electrical power and control wir-
ing to the unit, waterproof type connectors MUST
BE USED so that water or moisture cannot be
drawn into the unit during normal operation. The
above waterproofing conditions will also apply
when installing a field-supplied disconnect switch.
Refer to Figure 4 for typical field wiring and to the appropriate
unit wiring diagram for control circuit and power wiring
information. Refer to Table 8 for electrical data.
COMBUSTION DISCHARGE
The products of combustion are discharged horizontally
through a screened (hooded) opening on the upper gas heat
access panel.
GAS PIPING
Proper sizing of gas piping depends on the cubic feet per hour
of gas flow required, specific gravity of the gas and the length
of run. “National Fuel Gas Code” Z223.1 should be followed in
all cases unless superseded by local codes or gas company
requirements. Refer to Table 3.
The heating value of the gas may differ with locality. The value
should be checked with the local gas utility.
FIG. 2 - RECOMMENDED DRAIN PIPING
511.17-N2W
4Unitary Products Group

NOTE: There may be a local gas utility requirement specifying
a minimum diameter for gas piping. All units require a
1/2 or 3/4 inch pipe connection at the gas valve.
GAS CONNECTION
The gas supply line can be routed through the knockouts
located on the front of the unit or through the opening provided
in the unit’s base. Refer to Figure 8 to locate these access
openings. Typical supply piping arrangements are shown in
Figures 5 and 6. All pipe nipples, fittings and the gas cock are
field-supplied. A gas piping kit (1GP0402) is available for
bottom supply with external shutoff.
Twogrommetsareshippedintheblower compartment (inparts
bag taped to the blower housing) of every unit and should be
used in the knockouts when the gaspiping penetratesthe front
of the unit.
After the gas supply piping has been installed, the bottom
opening should be sealed to prevent water from leaking into
the building.
Gas piping recommendations:
1. A drip leg and a ground joint union must be installed in the
gas piping.
2. When required by local codes, a manual shut-off valve may
have to be installed outside of the unit.
3. Usewroughtironorsteelpipeforallgaslines.Pipecompound
should be applied sparingly to male threads only.
WARNING:Natural gas may contain some propane. Propane,
being an excellent solvent, will quickly dissolve
white lead or most standard commercial com-
pounds. Therefore, a special pipe compound must
be applied when wrought iron or steel pipe is used.
Shellac base compounds such as Gaskolac or
Stalastic, and compounds such as Rectorseal #5,
Cyde’s or John Crane may be used.
4. Allpipingshouldbecleanedofdirtandscalebyhammering
on the outside of the pipe and blowing out the loose dirt and
scale. Before initial start-up, be sure that all of the gas lines
external to the unit have been purged of air.
5. The gas supply should be a separate line and installed in
accordance with all safety codes as prescribed under
“Limitations”. After the gas connections have been
completed, open the main shut-off valve admitting
normal
gas pressure
to the mains. Check all joints for leaks with
FIG. 3 - TYPICAL FIELD WIRING
Input
Capacity,
(Mbh)
Output
Capacity,
(Mbh)
Available on
Models Gas Rate1 (Ft.3/Hr.)
Temp. Rise °F
At Full Input 2
Min. Max.
163 130 71⁄2Ton 152 30 60
204 163 71⁄2& 10 Ton 190 30 60
245 198 10 Ton 228 30 60
NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with
Kit Model No. 1NP0421 (USA) or 1NP0427 (CAN.). All furnaces meet the latest
California seasonal efficiency requirements.
1Based on 1075 Btu/Ft3.
2The air flow must be adjusted to obtain a temperature rise within the range shown.
TABLE 2 - GAS HEAT APPLICATION DATA
Length in Feet Nominal Iron Pipe Size
1/2 in. 3/4 in. 1 in. 1-1/4 in.
10
20
30
40
50
60
70
80
90
100
132
92
73
63
56
50
46
43
40
38
278
190
152
130
115
105
96
90
84
79
520
350
285
245
215
195
180
170
160
150
1,050
730
590
500
440
400
370
350
320
305
Maximum capacity of pipe in cubic feet of gas per hour. (Based upon a pressure drop of 0.3
inch water column and 0.6 specific gravity gas).
TABLE 3 - PIPE SIZING CHART
511.17-N2W
Unitary Products Group 5

soap solution or other material suitable for the purpose.
NEVER USE AFLAME.
6. The furnace and its individual manual shut-off valve must
be disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
excess of 1/2 psig (3.48kPa).
The furnace must be isolated from the gas supply piping
systembyclosingitsindividualmanualshut-offvalveduring
any pressure testing of the gas supply piping system attest
pressures equal to or less than 1/2 psig (3.48kPa).
7. A 1/8 inch NPT plugged tapping, accessible for test gage
connection, must be installed immediately upstream of the
gas supply connection to the furnace.
L.P. UNITS, TANKS AND PIPING
All gas heat units are shipped from the factory equipped for
natural gas use only. The unit may be converted in the field for
use with L.P. gas with accessory kit model number 1NP0437 .
All L.P. gas equipment must conform to the safety standards
of the National Fire Protection Association.
For satisfactory operation, L.P. gas pressure must be 10.5 inch
W.C at the unit under full load. Maintaining proper gas pressure
depends on three main factors:
1. The vaporization rate which depends on (a) the
temperature of the liquid and (b) the “wetted surface” area
of the container or containers.
2. The proper pressure regulation. (Two-stage regulation is
recommended from the standpoint of both cost and
efficiency.)
3. The pressure drop in the lines between regulators and
between the second stage regulator and the appliance.
Pipe size required will depend on the length ofthe pipe run
and the total load of all appliances.
Complete information regarding tank sizing for vaporization,
recommended regulator settings, and pipe sizing is available
from most regulator manufacturers and L.P. gas suppliers.
L.P. gas is an excellent solvent and special pipe compound
must be used when assembling piping for this gas as it will
quickly dissolve white lead or most standard commercial
compounds. Shellac base compounds such as Rectorseal #5
are satisfactory for this type of gas.
Check all connections for leaks when piping is completed,
using a soap solution. NEVER USE AFLAME.
VENT AND COMBUSTION AIR HOODS
The ventand combustionair hoods(with screens)are shipped
attached to the blower housing in the blower compartment.
These hoods must be installed to assure proper unit function.
Both hoods must be fastened to the outside of the gas heat
accesspanelwith thescrewsprovidedin thebagalsoattached
to the blower housing.
The screen for the combustion airintake hood is secured to the
insideoftheaccess panelopening withthreefastenersandthe
screws usedformounting thehoodtothepanel.Thetopflange
of this hood slips in under the top of the access panel opening
when installing. Refer to Figure 7.
Theventhoodisinstalledbyinsertingthetopflangeofthe hood
into the slotted opening in the access panel, positioning the
vent screen between the hood flanges and the access panel,
and securing in place.
FIG. 4 - EXTERNAL SUPPLY CONNECTION
EXTERNAL SHUT-OFF FIG. 5 - BOTTOM SUPPLY CONNECTION
EXTERNAL SHUT-OFF
FIG. 6 - VENT AND COMBUSTION AIR HOODS
511.17-N2W
6Unitary Products Group

DUCT COVERS - Units are shipped with
all air duct openings covered.
For side duct applications;
1. Remove and discard the supply and return
air duct covers.
2. Connect ductwork to duct flanges on the rear
of the unit.
For bottom duct applications;
1. Remove the side supply and return air duct
covers to gain access to the bottom supply
and return air duct covers.
2. Remove and discard the bottom duct covers.
3. Replace the side duct covers.
FIG. 7 - DIMENSIONS & CLEARANCES - 7-1/2 & 10 TON
HOLE OPENING SIZE
(DIA.) USED FOR
A3/4" KO Control
Wiring Side
7/8" KO Bottom*
B2"KO
Power Wiring
(Side or Bottom)*
C 2" KO Gas Piping (Front)
D 1-11/16" KO Gas Piping (Bottom)*
*Openings in the bottom of the unit can be located by the slice in the
insulation.
UTILITIES ENTRY DATA
RETURN AIR
OUTDOOR AIR
(Economizer)
SUPPLY AIR
OUTDOOR AIR
NOTE:
For curb mounted units,refer to the duct
hanger dimensions of the curb for the
proper size of the supply and return air
duct connections
UNIT BASE WITH RAILS
Shown separately to illustrate
bottom duct openings, power and
gas piping connectionlocations
(A)
CONTROL WIRING
ENTRY
(B)
POWER WIRING
ENTRY
9-3/4"
7-1/4" 52-1/2"
13-1/8"
7-1/4"
(D)
GAS SUPPLY
ENTRY
FRONT
VIEW
5-1/4"
2"
6-3/8"
26-3/4"
24" 22"
17"
7-3/4"
7-1/4"
100-3/4"
52-1/2"
1-1/4"
9-5/8"
71"
3-3/4"
GAS/ELEC
UNITS
CONTROL BOX
ACCESS
(C)
GAS SUPPLY
ENTRY
GAS HEAT
ACCESS
COMBUSTION
AIR
INLET HOOD
CONDENSER
COIL
COMPRESSOR
ACCESS
(See Detail "X")
VENT AIR
OUTLET HOOD
BLOWER
ACCESS
(A)
CONTROL WIRING
ENTRY
FIELD-SUPPLIED
DISCONNECT SWITCH
LOCATION
33-7/8"
(090)
39-7/8"
(120)
47-7/8"
(150)
FILTER ACCESS
3/4" PVC FEMALE
COND. DRAIN CONN.
(See Detail "Y" for location)
BOTTOM SUPPLY
AND RETURN AIR
OPENINGS
(SEE NOTE)
(B)
POWER WIRING
ENTRY
DETAIL "X" (SIDE SUPPLY AND RETURN AIR DUCTOPENINGS) All dimensions are in inches. They are subject to change
without notice. Certified dimensions will be provided upon
request.
NOTE:
For curb mounted units,refer to the duct
hanger dimensions of the curb for the
proper size of the supply and return air
duct connections
UNIT BASE WITH RAILS
Shown separately to illustrate
bottom duct openings, power and
gas piping connectionlocations
(A)
CONTROL WIRING
ENTRY
(B)
POWER WIRING
ENTRY
9-3/4"
7-1/4" 52-1/2"
13-1/8"
7-1/4"
(D)
GAS SUPPLY
ENTRY
FRONT
VIEW
5-1/4"
2"
6-3/8"
26-3/4"
24" 22"
17"
7-3/4"
7-1/4"
100-3/4"
52-1/2"
1-1/4"
9-5/8"
71"
3-3/4"
GAS/ELEC
UNITS
CONTROL BOX
ACCESS
(C)
GAS SUPPLY
ENTRY
GAS HEAT
ACCESS
COMBUSTION
AIR
INLET HOOD
CONDENSER
COIL
COMPRESSOR
ACCESS
(See Detail "X")
VENT
AIR
OUTLET HOOD
BLOWER
ACCESS
(A)
CONTROL WIRING
ENTRY
FIELD-SUPPLIED
DISCONNECT SWITCH
LOCATION
33-7/8"
(090)
39-7/8"
(120)
47-7/8"
(150)
FILTER ACCESS
3/4" PVC FEMALE
COND. DRAIN CONN.
(See Detail "Y" for location)
BOTTOM SUPPLY
AND RETURN AIR
OPENINGS
(SEE NOTE)
(B)
POWER WIRING
ENTRY
DOT PLUG FOR PRESSURE
CHECK
DOT PLUG FOR PRESSURE CHECK
511.17-N2W
Unitary Products Group 7

CORNER WEIGHTS
A
D
C
B
FRO N T
4 POINT LOADS
BDF
UNIT 4 - POINT LOADS (LBS)
TOTAL A B C D
090 1,237 247 310 378 302
120 1,612 322 416 492 382
BDF
UNIT 6 - POINT LOADS (LBS)
TOTAL A B C D E F
090 1,237 155 186 217 264 226 189
120 1,612 199 246 293 347 291 236
NOTE: These weights are with economizer and 24kW electric heat.
A
E
D
B
C
F
FRO N T
6 POINT LOADS
BAROM ETRIC RELIEF RAIN HOOD
REAR VIEW L.H.END VIEW
23-3/8" 2" 3-3/4" A
27"
3/4"CONDENSATE
DRAIN
(M UST BE TRAPPED)
7"
(B)POW ER W IRING
E N T R Y
29-5/8"
3-1/2"
4-1/2"
71"
E C O N O M IZ E R R A IN H O O D
DIM
"A "
28
31
31
24
ECONOMIZER
MOTORIZED DAMPER
M ANUAL DAM PER 0-100%
M ANUAL DAM PER 0-35%
DETAIL "Y" (UNIT WITH ECONOMIZER RAIN HOOD)
CLEARANCES
Front 24"
Back 12" (Less Economizer) 36" (With Economizer/
Fresh Air Damper)
Left Side (Filter Access) 24" (Less Economizer)
54" (With Economizer)
Right Side (Cond. Coil) 24"
Below Unit120"
Above Unit272" with 36" maximum
Horizontal Overhang
(For Outdoor Air Discharge)
1 Locate unit so that the vent air outlet hood is at least:
•Three (3) feet above any forced air inlet located within 10
horizontal feet (excluding those integral to the unit).
•Four (4) feet below, 4 horizontal feet from, or 1 foot above any
door or gravity air inlet into the building.
•Four (4) feet from electric meters, gas meters, regulators and
relief equipment.
2Units may be installed on combustible floors made from wood
or class A, B or roof covering material.
3Units must be installed outdoors. Overhanging structures or
shrubs should not obstruct outdoor air discharge outlet.
NOTE: A 1" clearance must be provided between any
combustible material and the supply air ductwork for a distance
of 3 feet from the unit.
The products of combustion must not be allowed to
accumulate within a confined space and recirculate.
511.17-N2W
8Unitary Products Group

WEIGHTS (LBS)
BASIC
UNIT
7-1/2
Ton 130 Mbh 1140
165 Mbh 1160
10
Ton 165 Mbh 1515
200 Mbh 1535
ACCESSORIES
Economizer 77
Motorized Outdoor Air Damper 97
Roof Mounting Curb 155
MODEL BDF
090 120
SUPPLYAIR
BLOWER CENTRIFUGAL BLOWER (Dia. x Wd. in.) 12 x 12 15 X 12
FAN MOTOR HP (STANDARD) 2 3
INDOOR
COIL
ROWS DEEP 3 3
FINS PER INCH 15 13
FACE AREA (Sq. Ft.) 7.8 13.4
OUTDOOR
FAN
(Two Per Unit)
PROPELLER DIA. (in.) 24 ea. 24 ea.
FAN MOTOR HP 1/2 ea. 3/4 ea.
NOM. CFM TOTAL 2900 ea. 4400 ea.
OUTDOOR
COIL
ROWS DEEP 2 2
FINS PER INCH 13 15
FACE AREA (Sq. Ft.) 20.0 29.3
AIR
FILTERS
(SEE NOTE)
QUANTITY PER UNIT (12" X 24" X 2") 2 -
QUANTITY PER UNIT (16" X 24" X 2") 2 3
QUANTITY PER UNIT (18" X 24" X 2") - 2
TOTAL FACE AREA (sq. ft.) 9.3 14.0
CHARGE REFRIGERANT 22
(lbs./oz.) SYSTEM NO. 1 9/0 11/8
SYSTEM NO. 2 9/0 13/8
NOTE: Filter racks are adapted for 1" or 2" thick filters.
TABLE 4 - PHYSICAL DATA
TABLE 5 - SUPPLY AIR BLOWER PERFORMANCE (7-1/2 & 10 TON)
BLOWER
SPEED,
RPM
CFM
2250 2550 3000 3400 3750
ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW
975 0.83 1.16 1.08 0.66 1.27 1.18 0.37 1.45 1.35 0.08 1.65 1.54 - - -
1025 0.98 1.21 1.13 0.82 1.34 1.25 0.52 1.54 1.44 0.21 1.75 1.63 - - -
1070 1.12 1.32 1.23 0.95 1.46 1.36 0.67 1.68 1.57 0.37 1.89 1.76 0.07 2.11 1.97
1130 1.31 1.43 1.33 1.16 1.57 1.46 0.86 1.83 1.71 0.56 2.04 1.90 - - -
1175 1.51 1.51 1.41 1.36 1.67 1.56 1.07 1.92 1.79 0.75 2.18 2.03 - - -
1220 1.68 1.66 1.55 1.53 1.81 1.69 1.23 2.10 1.96 - - - - - -
MODEL BDF090 - (SIDE DUCT APPLICATIONS)
BLOWER
SPEED,
RPM
CFM
2250 2550 3000 3400 3750
ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW
975 0.761.161.080.571.271.180.241.451.35------
1025 0.91 1.21 1.13 0.73 1.34 1.25 0.39 1.54 1.44 0.04 1.75 1.63 - - -
1070 1.05 1.32 1.23 0.86 1.46 1.36 0.54 1.68 1.57 0.20 1.89 1.76 - - -
1130 1.24 1.43 1.33 1.07 1.57 1.46 0.73 1.83 1.71 0.39 2.04 1.90 - - -
1175 1.44 1.51 1.41 1.27 1.67 1.56 0.94 1.92 1.79 0.58 2.18 2.03 - - -
1220 1.61 1.66 1.55 1.44 1.81 1.69 1.10 2.10 1.96 ------
MODEL BDF090 - (BOTTOM DUCT APPLICATIONS)
BLOWER
SPEED,
RPM
CFM
3000 3500 4000 4500 5000
ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW
860 1.05 1.40 1.31 0.85 1.58 1.48 0.62 1.80 1.68 0.32 2.05 1.91 - - -
915 1.23 1.55 1.45 1.05 1.76 1.64 0.80 1.98 1.85 0.51 2.23 2.08 0.22 2.48 2.31
950 1.42 1.68 1.57 1.24 1.91 1.78 1.00 2.14 2.00 0.70 2.43 2.27 0.40 2.72 2.54
1000 1.60 1.83 1.71 1.44 2.07 1.93 1.20 2.33 2.17 0.93 2.62 2.45 0.65 2.91 2.72
1050 1.80 1.98 1.84 1.65 2.25 2.10 1.42 2.55 2.37 1.14 2.86 2.67 0.85 3.17 2.96
1090 1.99 2.12 1.97 1.84 2.41 2.24 1.63 2.72 2.54 1.34 3.06 2.86 - - -
MODEL BDF120 - (SIDE DUCT APPLICATIONS)
BLOWER
SPEED,
RPM
CFM
3000 3500 4000 4500 5000
ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW
860 0.92 1.40 1.31 0.67 1.58 1.48 0.39 1.80 1.68 0.02 2.05 1.91 - - -
915 1.10 1.55 1.45 0.87 1.76 1.64 0.57 1.98 1.85 0.21 2.23 2.08 - - -
950 1.29 1.68 1.57 1.06 1.91 1.78 0.77 2.14 2.00 0.40 2.43 2.27 0.04 2.72 2.54
1000 1.47 1.83 1.71 1.26 2.07 1.93 0.97 2.33 2.17 0.63 2.62 2.45 0.29 2.91 2.72
1050 1.67 1.98 1.84 1.47 2.25 2.10 1.19 2.55 2.37 0.84 2.86 2.67 0.49 3.17 2.96
1090 1.86 2.12 1.97 1.66 2.41 2.24 1.40 2.72 2.54 1.04 3.06 2.86 - - -
NOTES: Blower performance includes a wet indoor coil, 2" filters and the maximum number of heat exchangers.
Refer to Table 6 for the resistance of the unit accessories.
ESP= External Static Pressure available for the supply and return air duct sytem. All internal unit resistances have been deducted from the total static pressure of the blower.
MODEL BDF120 - (BOTTOM DUCT APPLICATIONS)
511.17-N2W
Unitary Products Group 9

TABLE 6 - ACCESSORY STATIC RESISTANCES*
DESCRIPTION
EXTERNAL STATIC PRESSURE DROP -
RESISTANCE, IWG
CFM
2250 3000 4000 5000
Economizer 0.02 0.02 0.03 0.05
*Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.
MODELS BLOWER RANGE
(RPM)
MOTOR* ADJUSTABLE
MOTOR PULLEY FIXED BLOWER PULLEY BELTS
HP SERVICE
FACTOR FRAME SIZE EFFICIENCY (%) PITCH
DIA.
(IN.) BORE
(IN.) PITCH
DIA.
(IN.) BORE
(IN.) PITCH
LENGTH
(IN.) DESIG-
NATION QTY
BDF090 975-1220 2 1.20 56 82.0 3.4 - 4.4 7/8 6.2 1 50.3 A49 1
BDF120 860-1090 3 1.20 56 82.0 3.4 - 4.4 7/8 7.0 1 57.3 A56 1
* All motors are 1750 RPM, have solid bases and are inherently protected. These motors can be selected to operate into their service factor because they are located in the moving air,
upstream of any heating device.
TABLE 7 - BLOWER MOTOR AND DRIVE DATA
MODEL POWER
SUPPLY
COMPRESSOR
(#1 and #2)1
OUTDOOR
FAN
MOTOR,
(#1 & #2)
FLA
EACH
SUPPLY
AIR
BLOWER
MOTOR,
FLA
TOTAL
UNIT
AMPACITY,
AMPS
MAX.
FUSE
SIZE2
AMPS
MAX.
HACR
BREAKER
SIZE,
AMPS
MIN.
WIRE
SIZE,3
AWG
RLA
EACH LRA EACH 2HP 3HP 2HP 3HP 2HP 3HP
BDF090 208/230-3-60 460-3-60
575-3-60
14.1
7.1
5.8
130
64
52
2.3
1.3
1.3*
7.5
3.4
2.7
-
-
-
43.8
22.0
18.4
-
-
-
50
25
20
50
25
-
6/8
10/10
12/12
-
-
-
BDF120 208/230-3-60 460-3-60
575-3-60
17.3/16.7
9.6
8.3
150
73
59
3.5
2.5
2.5*
-
-
-
10.6
4.8
3.9
-
-
-
55.9
31.4
27.6
70
40
35
70
40
-
-
-
-
4/6
8/8
10/8
NOTES: 1. Dual numbers shown as “17.3/16.7" amps indicates compressor #1 / #2 respectively.
2. Dual element, time delay type.
3. Dual wire sizes are based on conductors at 60°C/75°C respectively,
*Motor voltage (460-1-60). Unit includes 575/460V transformer.
TABLE 8 - ELECTRICAL DATA
511.17-N2W
10 Unitary Products Group

COOLING SYSTEM
The cooling section is a complete factory package utilizing an
air-cooled condenser. The system is factory-charged with
Refrigerant-22. The compressors are hermetically sealed and
internally sprung.
The compressors also have inherent (internal) protection. If
there is an abnormal temperature rise in a compressor, the
protector will open to shut down the compressor.
PRELIMINARY OPERATION COOLING: After installation has
been completed, energize the crankcase heaters for at least
four hours before operating unit. After this initial warm-up, the
compressors should be given three false starts (energized just
long enough to make a few revolutions) with 5-7 minutes delay
between each start before being put into full time service.
NOTE: Prior to each cooling season, the crankcase heaters
must be energized at least 10 hours before system is
put into operation.
COOLING SEQUENCE OF OPERATION:When the
thermostat calls for “first-stage” cooling, the low voltage control
circuit from “R” to “G” and “Y1" (wiring schematic) is completed
to energize compressor #1, outdoor fan motor #1 and blower
motor simultaneously.
When the thermostat calls for “2nd-stage” cooling, the low
voltage control circuit from “R” to “Y2" is completed to energize
compressor #2 and outdoor fan motor #2.
After the thermostat is satisfied and opens, all components
likewise stop simultaneously.
The reversing valve is energized thru the "Y1" circuit when the
subbase is in the cooling mode.
The suction line freezestat will cut the compressor out when
the suction line temperature drops below 26°F. This is an
automatic reset device.
GENERAL: With the proper thermostat, continuous blower
operation is possible by closing the R to G circuit. This, of
course, alters the sequences for this component operation.
HEATING SYSTEM (HEAT PUMP)
COOLING MODE: Normal heat pump cooling operation. The
reversing valves, compressors, and outdoor fan motors are
energized through the Y1 and Y2 terminals. The indoor blower
motor is energized by terminal G. Two stages of mechanical
cooling are provided.
HEATING MODE - AMBIENT TEMPERATURE ABOVE
BALANCE POINT: The unit will operate in the mechanical
heating mode with both compressors energized through the
heat relay for stage 1 heating (W1). Terminal W2 will have no
affect on the unit in this situation. The indoor blower motor will
be energized by the blower interlock relay K5 on the relay
board. Gas heat will not beenergized unless thereis a lockout
condition or until the ambient temperature falls below the
balance point setting. One stage of mechanical heating is
provided.
HEATING MODE - DEFROST: When the unit is operating in
the mechanical heating mode and one compressor goes into a
defrost cycle, the gas heat will not be energized. The gas heat
will be energized only when both systems are in the defrost
mode simultaneously. When one of the defrost cycles
terminates, the gas heat will be shut off.
HEATING MODE - AMBIENT TEMPERATURE BELOW
BALANCE POINT: When the ambient temperature drops
below the balance point setting, the controls will disable the
mechanical heat and enable the gas heat. The gas heat will
cycle on first stage (W1) demand with second stage gas heat
available through terminal (W2). After a time delay, the indoor
blower motor will be energized through the blower interlock
relay K5 on the relay board. Two stages of gas heat are
available.
HEATING MODE - EMERGENCY HEAT AT THE ROOM
THERMOSTAT: If the indoor thermostat is set to Emergency
Heat, the unit controls will disable the mechanical heat and
energize the gas heat anytime there is a call for first stage
heating (W1) independent of the ambient temperature and the
balance point. This Emergency Heat mode is enabled by
energizing terminal E. Second stage gas heat will be energized
by terminal W2.
COMPRESSOR LOCKOUT: Anytime a safety switch opens,
the controls will send a signal through the X terminal on TB1 to
theindoorthermostattoindicateaproblem.Onlythelocked-out
compressor will be disabled in cooling, but both compressors
will be disabled in heating. The gas heat will not be energized
by first stage heat (W1) independent of the ambient
temperature and the balance point. Lockout must be reset by
interrupting power at the disconnect switch.
GENERAL: During the installation process, the installer must
set the balance point thermostat which is located behind the
blower access panel in the blower compartment. The balance
point thermostat should be set 5 degrees higher than the
calculated balance point. When the unit leaves the factory, the
balance point thermostat will be set to 50°F (the highest
setting).
OPERATION 511.17-N2W
Unitary Products Group 11

DEFROST SEQUENCE OF OPERATION
These heat pumps have a unique “ambient modified”
time-temperature defrost control that automatically adjusts to
changes in the outdoor temperature. The defrost control will
shorten the defrost initiation time periods above 35°F and will
extend the defrost initiation time periods below 35°F. The
control is factory set to defrost at 110 minutes (T3), but it can
be field adjusted to defrost at 80 minutes (T2) or 50 minutes
(T1) in areas with high humidity.
The curve in Figure 9 shows how defrost initiation times are
automatically compensated for changes in outdoor temperature.
EXAMPLE: If the timer is factory set on pin T-3 (110 minutes at
35°F outdoor) and the outdoor temperature climbs to 45°, the
time initiation cycle will decrease to every 100 minutes.
Iftheoutdoortemperature dropsto10°Fwhereiceislesslikely
to form, the 110 minute interval will extend to every 150
minutes.
Two requirements must be met before a defrost cycle can be
initiated.
1. The defrost time cycle must be complete.
2. The liquid line temperature must be less than 28°F.
Defrost will terminate when the liquid line sensor reaches 55°F
or after 10 minutes.
The defrost time cycle will restart 10 minutes after the start of
the defrost cycle even though the liquid sensor terminated
defrost after 3 minutes.
During troubleshooting, the defrost time can be reduced to 20
seconds by shorting out the SW1 test pegs on the module. The
pegs are 1/2" long, 3/16" apart and are mounted on a white
base. See Figure 10.
LOCKOUT CONTROL: Any one of four conditions will put the
system into a lock-out condition during the heating or cooling
mode:
1. The discharge line temperature reaches 255°F (215°F
reset) or,
2. The discharge pressure reaches 398 PSIG (310 PSIG
reset) or,
3. The suction line freezestat equals 26°F (38°F reset) or,
4. The low-pressure cut-out equals 7 PSIG (22 PSIG reset).
A lock-out will energize the emergency heat light on the
thermostat and the red LED light on the unit relay board. The
lockout circuit can only be reset by opening the main power
disconnect switch. Turning the thermostat switch to“OFF” then
back to “ON”s will not reset the system.
NOTICE TO OWNER:
If a lockout occurs, check for the following problems before
calling a serviceman:
1. Dirty filters.
2. Snow accumulation.
3. Leaf or debris blockage.
After eliminating the problem, attempt to restart the system as
follows:
•
turnthesystemswitchonthethermostattoits“OFF”position
for 10 seconds.
•
turn it back to its original position.
If the unit doesn’t start, call a serviceman.
NOTE: Models with an anti-recycle accessory will have a
5-minute delay before starting.
FIG. 8 - DEFROST INITIATION TIMES
FIG. 9 - AMBIENT MODIFIED TIME/TEMPERATURE CONTROL
T1 - 50 MINUTE SETTING
T2 - 80 MINUTE SETTING
T3 - 110 MINUTE SETTING
(Factory Set Point)
SHORTING PEGS TO
OVERRIDE TIMER
FOR SERVICE
MOVABLE JUMPER
WIRE TO CHANGE
DEFROST TIMER
511.17-N2W
12 Unitary Products Group

HEATING SYSTEM (GAS HEAT)
Thefollowingsequencedescribestheoperationofthegasheat
section.
CONTINUOUSBLOWER:Withtheroomthermostatswitch set
to “ON”, the supply air blower will operate continuously. The
normally closed contact “K5-1" provides 24 volt power to the
"M3" relay. The “M3-1” and "M3-2" power contacts close and
the blower motor operates.
INTERMITTENT BLOWER: With the room thermostat system
switch set to the “AUTO” or “HEAT” position and the fan switch
set to “AUTO”, the supply air blower will operate after the room
thermostat calls for heat and the time delay relay closes.
The “TH1" closes, the draft motor control ”DMC" or "ETD"" is
energized. The power contact closes which energizes the line
voltage draft motor. As the speed of the draft motor reaches
approximately 2500 RPM, the centrifugal switch contact
located on the end of the draft motor shaft closes to power the
ignition control “IC”.
After 15 seconds, the "IC" will start the ignitor sparking and will
open the redundant valve located inside the main gas valve
“GV”toallowaflowofgastoonlythecarryovertube.SeeFigure
11. Only after the pilot flame has been ignited and the presence
of pilot flame detected atthe “IC”by a signal sent back through
the flame sensor is sparking terminated and the main gas valve
opened.
Gas flows into each of the main burners and is ignited from the
carryover tube flame.
If “IC” fails to detect a pilot flame, it will continue to try for a
maximum of 85 seconds toignitethepilot tube.Ifthepilotflame
is not detected, then "IC" will soft lock out for 5 minutes. If the
pilot flame is not detected after 16 retries , then "IC" will hard
lock out the first stage furnace operation until 24V power is
removed from the module either at the unit or by resetting the
room thermostat.
At the same time power was supplied to the “DMC”, a parallel
circuit activates "BT" which closes "BT-1" after approximately
35 seconds and energizes "K5" which closes "K5-2" and starts
the blower by energizing "M3".
When "TH2" closes calling for second stage heating, it
energizes "W2" on the gas valve "GV" directly.
When the heating cycle is complete, “TH-1" opens
de-energizing the ”DMR" and “IC”, thus closing the redundant
and main gas valves. The blower motor continues to run
(approximately 15 seconds after the furnace is shut down) until
“TDR” opens de-energizing the “K5" and ”M3" relays.
SAFETY CONTROLS
The control circuit includes the following safety controls:
1. Limit Control (LS). This control is located inside the heat
exchanger compartment and is set to open at the
temperature indicated in Table 9. It resets automatically.
The limit switch operates when a high temperature
condition, caused by inadequate supply air flow occurs,
thus shutting down the ignition control and closing themain
gas valve and energizing the blower.
2. Centrifugal Switch (CS). If the draft motor should fail, the
centrifugal switch attached to the shaft of the motor
prevents the ignition control and gas valve from being
energized.
3. Redundant Gas Valve. This valve is an integral part of the
main gas valve and is located up stream of the main gas
valve. Should the main gas valve fail in the open position
the redundant valve serves as a back up and shuts off the
flow of gas.
4. Flame Sensor Rod. This sensor rod is located on the far
side of the carryover tube. If the ignition control does not
receive a signal from the flame sensor indicating that the
pilot flame has ignited properly, the main gas valve will not
open.Iftheflamesensorfailstodetectthepilotflameduring
operationofthemainburners, asignalissenttotheignition
control to close the main gas valve.
5. Rollout Switch. This switch is located in the burner
vestibule. In the event of a sustained main burner flame
rollout, it shuts off the ignition control and closes the main
gas valve.
6. This control is located inside the heat exchanger
compartment and is set to open at 180°F. It is a manual
reset switch. If Aux limit trips, then the primary limit has not
functioned correctly. Replace the primary limit.
HEAT ANTICIPATOR SETPOINTS
It is important that the anticipator setpoint be correct. Too high
of a setting will result in longer heat cycles and a greater
temperature swing in the conditioned space. Reducing the
value below the correct setpoint will give shorter “ON” cycles
and may result in the lowering of the temperature within the
conditioned space.
PRE-START CHECK LIST
Complete the following checks before starting the unit.
1. Check the type of gas being supplied. Be sure that it is the
same as listed on the unit nameplate.
2. Make sure that the vent and combustion air hoods have
been properly installed.
Units
(Tons) Capacity, MBH Limit Control
Opens, °F
Input Output
7-1/2
7-1/2
10
10
163
204
204
245
130
163
163
198
180
170
170
170
TABLE 9 - LIMIT CONTROL SETTING
Gas Valve Anticipator Setpoint
1st Stage 2nd Stage
Honeywell
VR8520 0.50 amp 0.24 amp
White-Rodgers
36C76 0.60 amp 0.10 amp
GAS
VALVE
GAS MAIN
MAIN VALVE
TO MAIN
BURNER
REDUNDANT
VALVE
TO PILOT BURNER
TO PILOT BURNER
FIG. 10 - GAS VALVE PIPING
511.17-N2W
Unitary Products Group 13

OPERATING INSTRUCTIONS
CAUTION: This furnace is equipped with an intermittent pilot
and automatic re-ignition system. DO NOT attempt
to manually light the pilot.
TO LIGHT PILOT AND MAIN BURNERS:
1. Turn “off” electric power to unit.
2. Turn room thermostat to lowest setting.
3. Turn gas valve knob to “on” position.
4. Turn “on” electric power to unit.
5. Set room thermostat to desired temperature.
(Ifthermostat“set”temperatureisaboveroomtemperature,
pilot burner ignition will occur and, after an interval to prove
pilot flame, main burners will ignite).
TO SHUT DOWN:
1. Turn “off” electric power to unit.
2. Depress knob of gas valve while turning to “off” position.
POST-START CHECK LIST (GAS)
After the entire control circuit has been energized and the
heating section is operating, make the following checks:
1. Check for gas leaks in the unit piping as well as the supply
piping.
2. Check for correct manifold gas pressures. See “Checking
Gas Input”.
3. Check the supply gas pressure. It must be within the limits
shown on rating nameplate. Supply pressure should be
checked with all gas appliances in the building at full fire.
Atnotimeshouldthestandbygaslinepressureexceed13",
nor the operating pressure drop below 5.3" for natural gas
units. If gas pressure is outside these limits, contact the
local gas utility for corrective action.
MANIFOLD GAS PRESSURE ADJUSTMENT
Small adjustments to the high-fire gas flow may be made by
turningthepressureregulatoradjustingscrewontheautomatic
gas valve. Refer to Figure 12.
Adjust as follows:
1. Remove the cap on the regulator. It’s located next to the
push-on electrical terminals.
2. To decrease the gas pressure, turn the adjusting screw
counterclockwise.
3. To increase the gas pressure, turn the adjusting screw
clockwise
.
NOTE: The correct manifold pressure for these furnaces is 3.5
IWG
± 0.3.
PILOT CHECKOUT
The pilot flame should envelope the end of the flame sensor.
Refer to Figure 13. To adjust pilot flame, (1) remove pilot
adjustment cover screw, (2) increase or decrease the
clearance for air to the desired level, (3) be sure to replace
cover screw after adjustment to prevent possible gas leakage.
Put the system into operation and observe through complete
cycle to be sure all controls function properly.
BURNER INSTRUCTIONS
To check or change burners, pilot or orifices, CLOSE MAIN
MANUALSHUT-OFFVALVEANDSHUTOFFALLPOWERTO
THE UNIT.
1. Remove the two screws holding either end of the manifold
to the burner supports.
2. Open the union fitting in the gas supply line just upstream
oftheunitgasvalve anddownstream fromthemainmanual
shut-off valve.
3. Remove the gas piping patch plate.
4. Disconnect wiring to the gas valve and spark ignitor.
Remove the manifold-burner gas valve assembly by lifting
up and pulling back.
Burners are now accessible for service.
Reverse the above procedure to replace the assembly. Make
sure that burners are level and seat at the rear of the heat
exchanger.
BURNER AIR SHUTTER ADJUSTMENT
ON-OFF CONTROL
HIGH FIRE ADJ.
(UNDER SCREW)
PILOTADJ.
(UNDER SCREW)
FIG. 11 - TYPICALGAS VALVE
1/8" GAP BETWEEN CARRY-OVER
TUBE AND FLAME SENSOR BULB
CARRY-OVER TUBE
FLAME SENSOR BULB
BURNER ASSEMBLY BRACKET
FIG. 12 - PROPER FLAME ADJUSTMENT
START-UP
511.17-N2W
14 Unitary Products Group

Adjust burner shutters so no yellow flame is observed in the
heat exchanger tubes. Refer to Figure 14.
CHECKING SUPPLY AIR CFM
TheRPMofthesupplyairblowerwilldependontherequiredCFM,
the unit accessories and the static resistances of both the supply
andthereturn airductsystems.Withthisinformation,theRPMfor
the supply air blower can be determined from the blower
performance data in Table 5 .
Knowing the required blower RPM and the blower motor HP,
the setting (turns open) for the supply air motor pulley can be
determined from Table 10.
Start the supply air blower motor. Adjust the resistances in both
the supply and the return air duct systems to balance the air
distribution throughout the conditioned space. The job
specifications may require that this balancing be done by
someone other than the equipment installer.
To check the supply air CFM after the initial balancing has been
completed:
1. Remove the dot plugs from the filter access and blower
access panels as shown in Figure 8.
2. Insert at least 8" of 1/4 inch tubing into each of these holes
for sufficient penetration into the air flow on both sides of
the evaporator (or indoor) coil.
NOTE: The tubes must be inserted and held in a position
perpendicular to the air flow so that velocity pres-
sure will not affect the static pressure readings.
3. Using an inclined manometer, determine the pressure drop
across a dry indoor coil. Since the moisture on an indoor
coil may vary greatly, measuring the pressure drop across
a wet coil under field conditions would be inaccurate. To
assure a dry coil, the compressors should be deactivated
while the test is being run.
4. Knowing the pressure drop across a dry coil, the actual
CFM through the unit can be determined from the curve in
Figure 16.
WARNING:Failure to properly adjust the total system air quan-
tity can result in extensive blower damage.
After readings have been obtained, remove the tubes and seal
up the drilled holes in the side panels. 5/16" dot plugs (P/N
029-13880) are available through normal parts ordering
procedures.
FIG. 13 - TYPICAL FLAME APPEARANCE
TURNS
OPEN* BLOWER DRIVE RANGE (RPM)
7-1/2 TON 10 TON
5 975 860
4 1024 906
3 1073 952
2 1122 998
1 1171 1044
0 1220 1090
*Pulleys can be adjusted in half-turn increments.
ADJUSTMENT
TABLE 10 - SUPPLY AIR BLOWER MOTOR PULLEY
FIG. 14 - PRESSURE DROP ACROSS ADRY INDOOR
COIL VS SUPPLY AIR CFM
511.17-N2W
Unitary Products Group 15

ADJUSTMENT OF TEMPERATURE RISE
The temperature rise (or temperature difference between the
return air and the heated air from the furnace) must lie within
the range shown on the U.L. or CGArating plate and the data
in Table 2.
After the temperature rise has been determined, the cfm can
be calculated as follows:
After about 20 minutes of operation, determine the furnace
temperature rise. Take readings of both the return air and the
heated air in the ducts (about six feet from the furnace) where
they will not be affected by radiant heat. Increase the blower
cfmto decrease the temperature rise; decrease the blowercfm
toincrease the rise. Refer to Table 8 for blower motor and drive
data.
BELT DRIVE BLOWER
All units have belt drive single-speed blower motors. The
variable pitch pulley on the blower motor can be adjusted to
obtain the desired supply air CFM.
CHECKING GAS INPUT
NATURAL GAS
1. Turn off all other gas appliances connected to the gas meter.
2. With the furnace turned on, measure the time needed for
onerevolutionofthehandonthesmallestdialonthemeter.
A typical gas meter usually has a 1/2 or a 1 cubic foot test
dial.
3. Using the number of seconds for each revolution and the
size of the test dial increment, find the cubic feet of gas
consumed per hour from Table 11.
If the actual input is not within 5% of the furnace rating (with
allowance being made for the permissible range of the
regulator setting), replace the orifice spuds with spuds of the
proper size.
NOTE To find the Btu input, multiply the number of cubic feet of
gas consumed per hour by the Btu content of the gas in
yourparticularlocality(contact your gascompanyforthis
information - it varies widely from city to city.)
CFM =Btuh Input x 0.8
1.08 x oF Temp. Rise
Seconds
for One
Rev.
Size of Test Dial
1/2 cu. ft. 1 cu. ft.
10
12
14
16
18
180
150
129
113
100
360
300
257
225
200
20
22
24
26
28
90
82
75
69
64
180
164
150
138
129
30
32
34
36
38
60
56
53
50
47
120
113
106
100
95
40
42
44
46
48
45
43
41
39
37
90
86
82
78
75
50
52
54
56
58
60
36
35
34
32
31
30
72
69
67
64
62
60
Example:
By actual measurement, it takes19 seconds for thehand on the1-cubic
foot dial to make a revolution with just a 100,000 Btuh furnace running. Using this
information, interpolate for 19 seconds in the first column in the table above. Read
across to the column headed “1 Cubic Foot”, where you will see that 190 cubic
feet of gas per hour are consumed by the furnace at that rate. Multiply 190 x 1050
(the Btu rating of the gas obtained from the local gas company). The result is
199,500 Btuh, which is close to the 204,000 Btuh rating of the furnace.
TABLE 11 - GAS RATE - CUBIC FEET PER HOUR
SECURE OWNER’S APPROVAL:
When the system is functioning properly, secure the owner’s approval. Show him
the location of all disconnect switches and the thermostat. Teach him how to start and stop the unit and how to adjust tem-
perature settings witnin the limitations of the system.
511.17-N2W
16 Unitary Products Group

NORMAL MAINTENANCE
CAUTION: Prior to any of the following maintenance proce-
dures, shut off all power to the unit to prevent
personal injury.
Periodic maintenance normally consists of changing or
cleaning filters and (under some conditions) cleaning the main
burners.
FILTERS - Inspect once a month. Replace disposable or clean
permanent type as necessary. DO NOT replace permanent
type with disposable.
MOTORS - Indoor fan and outdoor fan motors are permanently
lubricated and require no maintenance. Ventor motor is factory
lubricated for an estimated 10 year life.
OUTDOOR COIL - Dirt should not be allowed to accumulate
on the outdoor coil surface or other parts in the air circuit.
Cleaning should be as often as necessary to keep coil clean.
Use a brush, vacuum cleaner attachment, or other suitable
means. If water is used to clean coil, be sure power to the unit
is shut off prior to cleaning.
NOTE: Exercise care when cleaning the coil so that the coil
fins are not damaged.
Do not permit the outdoor air discharge to be ob-
structed by overhanging structures of shrubs.
BURNER & PILOT - Periodically (at least annually at the
beginning of each heating season) make a visual check of the
pilot and main burner flame. If necessary, adjust main burner
primary air shutters so that no yellow flame is observed as
explained under “BURNER AIR SHUTTER ADJUSTMENT”. If
it is not possible to adjust for the proper flame, the burners may
need cleaning.
TO CLEAN BURNERS - Remove them from the furnace as
explainedin“BurnerInstructions”.Cleanburnerswithhotwater
applied along top of the burner.
COMBUSTION AIR DISCHARGE - Visually inspect discharge
outlet periodically to make sure that the buildup of soot and dirt
is not excessive. If necessary, clean to maintain adequate
combustion air discharge.
CLEANING FLUE PASSAGES AND HEATING
ELEMENTS
With proper combustion adjustment the heating element of a
gas fired furnace will seldom need cleaning. If the element
should become sooted, it can be cleaned as follows:
1. Remove the burner assembly as outlined in “BURNER
INSTRUCTIONS”.
2. Remove the roof over the gas heat section.
3. At the top front of the heat section, remove the screws
holding the top of the flue collector box. Carefully remove
the top ofthe flue collector box without ripping the adjacent
insulation.
4. Ontheinsideofthefluecollectorbox,removethefluebaffle
from the tube interiors.
5. Using a wire brush on a flexible wand, brush out the inside
of each heat exchanger from the burner inlet and flue outlet
ends.
6. Brush out the inside of the flue collector box and the flue
baffles.
7. Run the wire brush down the vent tube from the flue
collector end.
8. If soot build-up is particularly bad, remove the vent motor
and clean the wheel and housing. Run the wire brush down
the flue extensions at the outlet of the vent housing.
9. After brushing is complete, blow all brushed areas with air
or nitrogen. Vacuum as needed.
10. Replace parts in the order they were removed in Steps
1 through 4.
11. When replacing the top of the flue collector box, be careful
so as not to tear the adjoining insulation.
12.Assure that all seams on the vent side of the combustion
system are air tight. Apply a high temperature (+500°F)
sealing compound where needed.
MAINTENANCE 511.17-N2W
Unitary Products Group 17

WARNING:Troubleshooting of components necessarily re-
quires opening the electrical control box with the
power connected to the unit. Use extreme care
when working with live circuits! Check the unit
nameplate for the correct line voltage and set the
volt meter to the correct range before making any
connections with line terminals.
WARNING:Prior to any of the following maintenance proce-
dures, shut off all electric power to the unit to
prevent personal injury.
CAUTION: Label all wires prior to disconnection when servic-
ing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
NOTE To find the Btu input, multiply the number of cubic feet of
gas consumed per hour by the Btu content of the gas in
yourparticularlocality(contact your gascompanyforthis
information - it varies widely from city to city.)
1. Draft motor operates and furnace lights but supply air
blower does not start after a short time delay with room
thermostat fan switch set to “AUTO”.
a. Set fan switch to “ON”. If blower motor runs, go to Step f.
If it does not, check to see if line voltage is being
supplied to the contacts ofthe contactor(M3), and ifthe
contactor is pulled in. Check for loose wiring.
b. If (M3) is pulled in, touch the supply air blower motor
housing. If it is hot, the motor may be off on inherent
protection. Disconnect power to the unit and check the
blower motor capacitor. If it is defective, replace it with
one of equal capacitance and voltage.
c. If (M3) is pulled in and the blower motor still does not
run, replace the blower motor.
d. If (M3) is not pulled in, check for 24volts at the (M3) coil.
If 24 volts is present, replace the (M3) contactor.
e. If 24 volts is not present at the (M3) coil, check for loose
24 volt wiring back to the relay board. Check control
wiring to the room thermostat. If all is fine, replace the
relay board.
f. If the blower motor runs with the fan switch in the “ON”
position but does not run soon after the furnace has
ignited with the fan switch in the “AUTO” position, check
for loose 24 volt wiring between the relay board in the
main control box, the Mate-N-Lok connector in the
partition between the evaporator and gas heatsections
and the time delay (BT) or (ETD).
g. If all control wiring is fine, check for 24 volts at the relay
board. If 24 volts is present, replace the relay board. If
24 volts is not present, replace the (BT) or (ETD).
NOTE: The furnace may shut itself down on a high tempera-
ture condition during the procedure, but this will not
effect the test if it is done within 5 minutes of furnace
shut-down.
2. The supply air blower operates but the draft motor does not
when the room thermostat is set to call for heat and the fan
switch in the “ON” position.
a. The draft motor has inherent protection. If the motor shell
is hot to the touch, wait for the internal overload to reset.
b. If themotor shelliscoldwiththeroomthermostatcalling
for heat, check for line voltage at the motor’s Mate-N-
Lok connector attached to the evaporator partition. If
line voltage is present, replace the draft motor.
c. If line voltage is not present, check for line voltage at
the draft motor relay (DMR) or (DMC) contacts in the
main control box and check to see if the (DMR) or
(DMC) is pulled in.
d. If the (DMR) relay is pulled in, check for a loose line
voltage connection.
e. If the (DMR) or (DMC) relay is not pulled in, check for
24 volts at the (DMR) coil or 24 volts at the DMC-6
terminal. If 24 volts is present, replace the (DMR) or
(DMC) relay. If 24 volts is not present, check for a loose
24 volt connection back to the relay board and check
the connections from the room thermostat to the relay
board. If all connections are correct, replace the relay
board.
3. The draft motor runs but the furnace does not light and the
sparker does not spark.
a. Check all 24 volt connections from the relay board to
and in the gas heat section. Check low voltage connec-
tionstothe(BT)& (DMC)or(ETD)locatedinthecontrol
box.
b. If the furnace is hot, it may be out on an over tempera-
ture condition, wait for limit reset.
c. With the draft motor running, check for 24 volts at
terminal 25V on the ignitor control (IC) where the red
lead from the draft motor attaches. If 24 volts is not
present, the centrifugal switch (CS) has not closed or
has gone bad. Check the line voltage to the unit, if it is
correct replace the draft motor. If line voltageis lowcall
the power company.
d. If 24 volts is present at the ignitor control, check all
control wiring at the ignitor control and the high tension
wire to the ignitor. Check that the green ground wires
from the ignitor control, the gas valve and pilot burner
are all intact and making good electrical connection.
Check to make sure that the ceramic insulator on the
pilot ignitor or sensor is not broken or cracked, if all are
intact replace the ignition control “IC”.
4. The draft motor runs and the sparker sparks at the pilot
burner but the pilot does not ignite and a gas odor is not
detected at the draft motor outlet.
a. Check to make sure gas is being supplied to the unit.
Make sure that the gas pressure to the unit is within the
properlimitsasdescribedinthe“POSTSTARTCHECK
LIST” and that the pilot adjust screw is allowing some
flow of gas as described in “PILOTCHECKOUT”.
b. Check all wiring between the ignitor control and the gas
valve. Check to make sure the ground connections are
intact.
c. If the wiring is intact,checkfor 24 volts across terminals
“PV” and “COMMON” on the ignitor control. If 24 volts
is not present, replace the ignitor control.
TROUBLESHOOTING
511.17-N2W
18 Unitary Products Group

d. If 24 volts is present, remove the pilot burner and
remove the pilot orifice from the pilotburner. The orifice
is removed in the direction opposite the flow of gas.
Inspect the orifice for obstruction. If it is clear, replace
the main gas valve.
5. The sparker sparks at the pilot burner but the pilot does not
ignite and a gas odor is detected at the draft motor outlet.
a. Adjust the pilot adjust screw on the gas valve as
described in “PILOT CHECKOUT”.
b. Check the supply pressure as described in “POST
STARTCHECKLIST”.Makeadjustmentsasnecessary.
c. Check the pilot orifice for obstruction as described in
Item 4. Clean as needed but the problem should not be
the gas valve.
6. The pilot burner ignites but the sparker continues to spark
and the main burners do not ignite.
a. Make the same checks and adjustment as described in
Item 5.
b.Make sure that the pilot burner is not bent or damaged.
c. Make sure that the ground connections at the pilot
burner, gas valve and ignitor control are intact. Check
the high tension wire for good electrical connection. If
all are intact, replace the ignitor module.
7. The pilot burner lights and the spark stops but the main
burners do not light.
a. Check electrical connections between the ignitor con-
trolandthegasvalve.Ifintact,checkfor24voltsacross
terminals “MV” and “COMMON” terminals. If no voltage
detected, replace ignitor control. If voltage is present,
replace gas valve.
8. Furnace lights with roll out or one burner has delayed
ignition.
a. Make sure that the pilot burner is aligned properly with
the carryover as described in “PILOT CHECKOUT”.
b. Make sure that the carryovers on adjoining burners are
screwed fast and are level with respect to one another.
9. Main burners light but exhibit erratic flame characteristics.
a. Adjust air shutters as described in “BURNER AIR
SHUTTERADJUSTMENT”.
b. Check the main burner orifices for obstruction and
alignment. Removal procedure is described in
“BURNER INSTRUCTIONS”. Clean or replace burner
orifices and burners as needed.
REPLACEMENT PARTS
COMPRESSOR SECTION
•Hermetic compressor
•Compressor mounting
MOTOR SECTION
•Blower motor
•Fan motor
•Ventor motor
ELECTRICAL SECTION
•Ignition control
•Relay board
•Contactor
•Circuit breaker
•Temperature controls
•Capacitors
•Relays
•Transformers
•Connectors
GAS HEAT SECTION
•Heat exchanger
•Gas valve
•Pilot
•Flame sensor
•Spark ignitor
•Gas manifold
•Gas burner
AIR MOVING SECTION
•Blower wheel
•Blower wheel housing
REFRIGERANT SECTION
•Evaporator coil
•Evaporator coil header
•Expansion valve assembly
•Condenser coil
•Condenser coil header
FABRICATED PARTS SECTION
•Panels
•Posts
•Covers Drain pans
•Base rails
•Air hoods
MISCELLANEOUS SECTION
•Air inlet hood screen
•Fan guard
•Air filters
TO OBTAIN PARTS INFORMATION: Replacement parts and information from OUR current parts list for this unit are available to
your servicing contractor through our local distributor. The name and address of our nearest distributor may be obtained by
consulting the Yellow Pages of a local telephone directory.
IMPORTANT: In order to supply the correct part or information from the parts list, our distributor will need to be provided with the
complete model number listed on the rating plate located on your unit. See page 2 for Product Nomenclature.
WARNING:IMPROPERINSTALLATION,ADJUSTMENT, SERVICEORMAINTENANCECANCAUSEINJURYORPROPERTY
DAMAGE.CONSULTAQUALIFIEDINSTALLER,SERVICEAGENCYOR YOURLOCALGAS SUPPLIERFOR INFORMATION
OR ASSISTANCE.
511.17-N2W
Unitary Products Group 19

Subject to change without notice. Printed in U.S.A.
Copyright  by Unitary Products Group 19958 All rights reserved. 511.17-N2W
Code: EBL, F
Post Office
Box 1592 York Pennsylvania
17405-1592
Unitary
Products
Group