SUNLINE 2000 GAS / ELECTRIC SINGLE PACKAGE AIR CONDITIONERS INSTALLATION INSTRUCTION Supersedes: 530.18N10Y (693) 530.18N10Y (995) MODELS D3CG090, 102, 120 (STYLE B) & D4CG150 (STYLE A) (8.59.0 EER) 03513092 208/230/460 VOLT MODELS ONLY GENERAL YORK Model DCG units are single package air conditioners with gas heat designed for outdoor installation on a rooftop or a slab. The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested. The units require only electric power and duct connections at the point of installation. The gasfired heaters have aluminized steel tubular heat exchangers and spark ignition with proven pilot. FOR YOUR SAFETY If you smell gas: 1. Open windows. 2. Don t touch electrical switches 3. Extinguish any open flame. 4. Immediately call your gas supplier. FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. INSPECTION As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier s freight bill. A separate request for inspection by the carrier s agent should be made in writing. Refer to Form 50.15NM for additional information. REFERENCE Additional information on the design, installation, operation and service of this equipment is available in the following reference forms: 208/230/575 VOLT MODELS ONLY 55.70N1 General Installation 55.70N2 Prestart & Poststart Check List 530.18N3.2V Economizer Accessory 530.18N3.4V Motorized Outdoor Air Damper Accy. 530.18N8.4V Gas Piping Accessory 530.18N10.1V Propane Conversion Accessory (USA) 530.18N10.2V High Altitude Accessory (Nat. Gas) 530.18N10.3V High Altitude Accessory (Propane) 530.18N10.4V Propane Conversion Accessory (CAN.) 690.15N25V 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. & CGA as follows: 1. For use as a forced air furnace with cooling unit. 2. For outdoor installation only. 3. For installation on combustible material. 4. For use with natural gas or propane gas. CAUTION THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE W ITH THE ENCLOSED INSTALLATION INSTRUCTIONS AND ANY APPLICABLE LOCAL, STATE, AND NATIONAL CODES INCLUDING, BUT NOT LIMITED TO, BUILDING, ELECTRICAL, AND MECHANICAL CODES. WARNING INCORRECT INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY OR PROPERTY DAMAGE. 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 injury and/or equipment damage may result if installation procedure is not handled properly.
530.18N10Y TABLE OF CONTENTS General... 1 Inspection... 1 Reference... 1 Approvals... 1 Nomenclature... 2 INSTALLATION Limitations... 3 Location... 3 Rigging and Handling... 3 Clearances... 3 Ductwork... 3 Barometric Relief / Fixed Outdoor Air Intake Damper Assembly... 4 Condensate Drain... 4 Compressors... 4 Filters... 4 Service Access... 4 Thermostat... 4 Power and Control Wiring... 4 Combustion Discharge... 5 Gas Piping... 5 Gas Connection... 5 L.P. Units, Tanks and Piping... 6 Vent and Combustion Air Hoods... 6 Optional Economizer / Mot. Damper Rain Hood... 6 OPERATION Cooling System... 12 Preliminary Operation Cooling... 12 Cooling Sequence of Operation... 12 Safety Controls (Cooling)... 12 Heating Sequence of Operation... 12 Safety Controls (Heating)... 13 Heat Anticipator Setpoints... 13 PreStart Check List... 13 STARTUP Operating Instructions... 14 PostStart 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... 8 5 Supply Air Blower Perf. 71/2 10 Ton... 10 6 Supply Air Blower Perf. 121/2 Ton... 11 7 Accessory Static Resistances... 11 8 Blower Motor and Drive Data... 11 9 Electrical Data... 12 10 Limit Control Setting... 13 11 Blower Motor Pulley Adjustment... 15 12 Gas Rate Cubic Feet Per Hour... 16 FIGURES No. Description Page 1 Center of Gravity... 3 2 Barometric Relief / Fixed Outdoor Air Intake Damper Assembly... 4 3 Recommended Drain Piping... 4 4 Typical Field Wiring... 5 5 External Supply Connection... 6 6 Bottom Supply Connection... 6 7 Vent and Combustion Air Hoods... 6 8 Econo. / Mot. Damper Hood Assembly... 7 9 Adjusting Enthalpy Setpoint... 8 10 Dimensions and Clearances... 9 11 Gas Valve Piping... 13 12 Typical Gas Valve... 14 13 Proper Flame Adjustment... 14 14 Typical Flame Appearance... 15 15 Pressure Drop versus Supply Air CFM... 15 PRODUCT NOMENCLATURE D 3 C G 0 9 0 N 1 3 0 2 5 PRODUCT CATEGORY D = Single Package Air Conditioner (Air Cooled) PRODUCT GENERATION VOLTAGE CODE 25 = 208/230360 46 = 460360 58 = 575360 3 = 3rd Generation 4 = 4th Generation PRODUCT IDENTIFIER CG = Gas/Electric NOMINAL COOLING CAPACITY 090 = 71/2 Ton 102 = 81/2 Ton 120 = 10 Ton 150 = 121/2 Ton FACTORY INSTALLED HEAT N = Gas Heat Installed NOMINAL GAS HEATING OUTPUT CAPACITY 130 = 130 MBH 165 = 163 MBH 200 = 198 MBH 2 Unitary Products Group
LIMITATIONS These units must be installed in accordance with the following national and local safety codes: In U.S.A.: 1. National Electrical Code ANSI/NFPA No. 70. 2. National Fuel Gas Code Z223.1. 3. GasFired Central Furnace Standard ANSI Z21.47a. 4. Local gas utility requirements. In Canada: 1. Current Canadian Electrical Code C22.1 2. Current Gas Installation Codes CAN/CGAB149.1 and.2. 3. Local plumbing and waste water codes. 4. Other applicable local codes Refer to Table 1 for Unit Application Data and to Table 2 for Gas Heat Application Data. After installation, the unit must be adjusted to obtain a temperature rise within the range specified on the unit rating plate. 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). This furnace is not to be used for temporary heating of buildings or structures under construction. TABLE 1 UNIT APPLICATION DATA Voltage Variation Min. / Max. 1 208 / 230V 187 / 253 460V 414 / 506 575V 518 / 630 Wet Bulb Temperature ( F) of Air on Evaporator Coil, Min. / Max. Dry Bulb Temperature ( F) of Air on Condenser Coil, Min. 2 / Max. Min. Dry Bulb Temperature ( F) on gasfired Heat Exchanger 1 Utilization range A in accordance with ARI Standard 110. 2 A low ambient accessory is available for operation down to 0 F. 57 / 72 45 / 120 LOCATION Use the following guidelines to select a suitable location for these units. 1. Unit is designed for outdoor installation only. 2. Condenser must have an unlimited supply of air. Where a choice of location is possible, position the unit on either north or east side of building. WARNING: Excessive exposure of this furnace to contaminated combustion air may result 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 weight of the unit and its options and/or accessories. Unit must be installed on a solid level roof curb or appropriate angle iron frame. CAUTION: If a unit is to be installed on a roof curb or special frame other than a YORK roof curb, gasketing must be applied to all surfaces that come in contact with the unit underside. 25 INSTALLATION 530.18N10Y 5. Maintain level tolerance to 1/2" maximum across the entire length or width of the unit. 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 prevent moisture from entering the unit which could cause damage to electrical components. Allow this closure label to remain in place until the combustion air hood is to be installed (refer to Figure 7). Refer to Table 4 for unit weights and to Figure 1 for approximate center of gravity. Unit Size (Tons) Dim. 71/2 81/2 10 121/2 A 331/4" 32" 321/2" 321/2" B 471/2" 441/2" 463/4" 45" FIG. 1 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/CGAB149.1 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 should be designed and sized according to the methods in Manual Q of the Air Conditioning Contractors of America (ACCA). A closed return duct system shall be used. This shall not preclude use of economizers or outdoor fresh air intake. The supply and return air duct connections at the unit should be made with flexible joints to minimize noise. The supply and return air duct systems should be designed for the CFM and static requirements of the job. They should NOT be sized 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. Unitary Products Group 3
530.18N10Y Refer to Figure 10 for information concerning side and bottom supply and return air duct openings. It is recommended that, in Canada, the outlet duct be provided with a removable access panel. It is recommended that this opening be accessible when the unit is installed in service, and of a size such that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover should be attached in a manner adequate to prevent leakage. BAROMETRIC RELIEF / FIXED OUTDOOR AIR INTAKE DAMPER ASSEMBLY This damper assembly is shipped inside of the return air compartment. It serves as a barometric relief damper on units with economizer or as a fixed outdoor air intake damper on units less economizer. On units with bottom return, install the damper assembly over the opening in the side return air duct cover. (See Figure 2.) Remove the adhesive backed label covering this opening before installing the damper assembly. On units with side return, install the damper assembly in the return air ductwork as close to the unit as possible. Cut an opening 111/2" high by 171/2" wide in the ductwork to accommodate the damper device. Attach the damper assembly into position by drilling six (6) holes, 9/64" dia. (#26 drill), using the holes in the hood flanges as a template and secure with the screws provided. On units less economizer, adjust the damper to the desired air flow opening by moving the damper bracket (inside of the hood) to one of the 3 positions provided. Position 1 will allow approximately 25% recirculated air flow, position 2 approximately 15% and position 3 approximately 10%. A screw on each side of the hood secures this bracket in place. 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 installed ahead of the evaporator coil and must be kept clean or replaced with same size and type. Dirty filters will reduce the capacity of the unit and will result in frosted coils or safety shutdown. Minimum filter area and required sizes are shown in Table 4. 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 10 for location of these access panels. CAUTION: Make sure that all screws are replaced on the unit to maintain an airtight 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. Seven color coded insulated wires (#18 AWG) should be used to connect thermostat to unit. POWER AND CONTROL WIRING Field wiring to the unit must conform to provisions of the National Electrical Code, ANSI / NFPA No. 70 (in U.S.A.), current Canadian Electrical Code C22.1 (in Canada) and/or local ordinances. The unit must be electrically grounded in accordance with NEC and CEC (as specified above) and/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 wiring harness furnished with this unit is an integral part of a UL and C.G.A. design certified unit. Field alteration to comply with electrical codes should not be required. FIG. 2 BAROMETRIC RELIEF / FIXED OUTDOOR AIR DAMPER ASSEMBLY CONDENSATE DRAIN Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install a condensate drain line from the 3/4" female connection on the unit to spill into an open drain. NOTE: The condensate drain line MUST be trapped to provide proper drainage. See Figure 3. FIG. 3 RECOMMENDED DRAIN PIPING A fused disconnect switch should be field provided for the unit. The switch must be separate from all other circuits. Wire entry at knockout openings require conduit fittings to comply with NEC (in U.S.A.), CEC (in Canada) and/or local codes. Refer to Figure 10 for installation location. If any of the wire supplied with the unit must be replaced, replacement wire must be of the type shown on the wiring diagram. Refer to Table 9 for electrical data. Electrical line must be sized properly to carry the load. USE COPPER CONDUCTORS ONLY. Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused. CAUTION: When connecting electrical power and control wiring 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 fieldsupplied disconnect switch. Refer to Figure 4 for typical field wiring and to the appropriate unit wiring diagram for control circuit and power wiring information. 4 Unitary Products Group
530.18N10Y *24 Volt Thermostat 2TH04701024 or (2TH04701524 w/subbase 2TB04700224) FIG. 4 TYPICAL FIELD WIRING TABLE 2 GAS HEAT APPLICATION DATA Input Capacity, (Mbh) Output Capacity, (Mbh) Available on Models Gas Rate 1 (Ft. 3 /Hr.) Temp. Rise F At Full Input 2 Min. Max. 163 130 7 1 2 & 8 1 2Ton 152 30 60 204 163 7 1 2 12 1 2 Ton 190 30 60 245 198 10 & 12 1 2 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. 1 Based on 1075 Btu/Ft 3. 2 The air flow must be adjusted to obtain a temperature rise within the range shown. 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 (in U.S.A.) or the current Gas Installation Codes CAN/CGAB149.1 and.2 (in Canada) 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. 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 10 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 fieldsupplied. A gas piping kit (1GP0402) is available for bottom supply with external shutoff. Two grommets are shipped in the blower compartment (in parts bag taped to the blower housing) of every unit with gas heat and should be used in the knockouts when the gas piping penetrates the front of the unit. After the gas supply piping has been installed, the bottom opening should be sealed to 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 shutoff valve may have to be installed outside of the unit. TABLE 3 PIPE SIZING Length in Feet 10 20 30 40 50 60 70 80 90 100 Nominal Iron Pipe Size 1/2 in. 3/4 in. 1 in. 11/4 in. 132 278 520 1,050 92 190 350 730 73 152 285 590 63 130 245 500 56 115 215 440 50 105 195 400 46 96 180 370 43 90 170 350 40 84 160 320 38 79 150 305 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). 3. Use wrought iron or steel pipe for all gas lines. Pipe compound should be applied sparingly to male threads only. WARNING: Natural gas may contain some propane. Propane, being an excellent solvent, will quickly dissolve white lead or most standard commercial compounds. Therefore, a special pipe dope 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. All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out the loose dirt and scale. Before initial startup, 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 shutoff valve admitting normal gas pressure to the mains. Check all joints for leaks with soap solution or other material suitable for the purpose. NEVER USE A FLAME. 6. The furnace must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures in excess of 1/2 psig (3.48kPa). The furnace must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.48kPa). 7. A 1/8 inch NPT plugged tapping, accessible for test gage connection, must be installed immediately upstream of the gas supply connection to the furnace. Unitary Products Group 5
530.18N10Y FIG. 5 EXTERNAL SUPPLY CONNECTION EXTERNAL SHUTOFF 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. / propane gas with accessory kit model number 1NP0421 (U.S.A.) or 1NP0427 (CAN.). All L.P. / propane gas equipment must conform to the safety standards of the National Fire Protection Association. For satisfactory operation, L.P. / propane gas pressure must be 10.5 inch W.C at 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. (Twostage 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 of the pipe run and the total load of all appliances. Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and L.P. / propane gas suppliers. L.P. / propane gas is an excellent solvent and special pipe compound must be used when assembling piping for this gas as it will quickly dissolve white lead or most standard commercial compounds. Shellac base 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 A FLAME. VENT AND COMBUSTION AIR HOODS The vent and combustion air 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 access panel with the screws provided in the bag also attached to the blower housing. The screen for the combustion air intake hood is secured to the inside of the access panel opening with three fasteners and the screws used for mounting the hood to the panel. The top flange of this hood slips in under the top of the access panel opening when installing. Refer to Figure 7. The vent hood is installed by inserting the top flange of the 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. 6 BOTTOM SUPPLY CONNECTION EXTERNAL SHUTOFF OPTIONAL ECONOMIZER / MOTORIZED DAMPER RAIN HOOD The following procedure should be used when assembling an economizer rain hood onto a unit. The outdoor and return air dampers, the damper actuator, the damper linkage, the outdoor and return air divider baffles and all the control sensors are factory mounted as part of the economizer option All of the hood components, including the filters, the gasketing and the hardware for assembling are packaged and located within the unit filter section. (See Figure 8). 1. With filter section access panel removed, take out the hood components, filters, gasketing and hardware described above. Remove and discard the outdoor air opening cover on back of the unit. 2. Assemble the rain hood per the following procedures: a) Apply gasketing to all hood components as follows: To the top outside surface and to the flange (toward unit) of each side plate. Extend gasketing 1/4" beyond the top and bottom of the flange to insure adequate sealing. To the edge and flanges (in one continuous length) on each side of the center filter support. To the top flange of the bottom filter support (on the side facing the unit). To the hood cover flange (only on unit sizes 10 tons and over). (No gasketing required on this flange for unit sizes under 10 tons.) FIG. 7 VENT AND COMBUSTION AIR HOODS 6 Unitary Products Group
b) Attach two filter guide angles to the inside of each side plate using 3 screws for each angle. Note the hole locations on the angles for proper positioning when attaching them on the side plates. Tighten screws. c) Attach the two side plates to the center filter support using 4 screws on each side. Do not tighten screws. d) Attach the bottom filter support between the side plates using 2 screws on each side. Do not tighten screws. e) Attach the hood cover to the side plates using 3 screws on each side. Do not tighten screws. f) Set hood assembly on a flat surface to insure all components are plumb and now tighten all screws. 3. Attach the hood assembly over the outdoor air opening on the unit duct panel as follows: On unit sizes under 10 tons, the flange of the hood cover must be inserted in under the unit top cover flange. One screw in the unit cover flange must be removed and one screw (at the right hand corner of the unit cover flange) needs only to be loosened to allow the notched flange of the hood cover to slide into place. Replace and tighten the 2 screws. On unit sizes 10 ton and over, secure the hood flange to the duct panel with 3 screws. Use holes in the hood cover flange as a template and drill 3 holes, 9/64" dia. (#26 drill) into the duct panel. On all units, attach the hood side plate flanges to the duct panel by drilling 6 holes, 9/64" dia. (#26 drill) for each side plate at the dimples provided in the duct panel. Secure hood into position using 6 gasketed screws in each side plate. 4. Secure the flange on the hood cover to the duct panel with 3 screws. Use holes in the cover flange as a template and drill 3 holes, 9/64" dia. (#26 drill) into the duct panel. 530.18N10Y 5. Insert two (2) 1" filters into the center of the hood, coming to rest in the center filter support at the back of the hood. Press filters up against the filter guide angles on the side plates and use 1 screw (B) on each side of hood to hold into position. Insert two (2) 1" filters into the bottom filter support per the same procedures as the center filters. NOTE: Install filters so that Air Flow arrows point upward, toward the unit. ENTHALPY SETPOINT ADJUSTMENT CAUTION: Extreme care must be exercised in turning both the setpoint and minimum position adjusting screws to prevent twisting them off. 6. The enthalpy set point for the dampers may now be set by selecting the desired setpoint shown in Figure 9. Adjust as follows: For a single enthalpy (Model 2EE04700324), carefully turn the set point adjusting screw to the A, B, C or D setting corresponding to the lettered curve. For a dual enthalpy (Model 2EE04700424), carefully turn the set point adjusting screw fully clockwise past the D setting. 7. To check that the damper blades move smoothly without binding, carefully turn the minimum position adjusting screw fully clockwise and then energize and deenergize terminals R to G. With terminals R to G energized, turn the minimum position screw counterclockwise until the desired minimum position has been attained. 8. Replace the filter section access panel. FIG. 8 ECONOMIZER / MOTORIZED DAMPER RAIN HOOD ASSEMBLY (OPTION) Unitary Products Group 7
530.18N10Y FIG. 9 ENTHALPY SETPOINT ADJUSTMENT TABLE 4 PHYSICAL DATA EVAPORATOR EVAPORATOR COIL OUTDOOR FAN (Two Per Unit) CONDENSER COIL AIR FILTERS (SEE NOTE) CHARGE MODEL DCG 090 102 120 150 CENTRIFUGAL (Dia. x Wd. in.) 12 x 12 12 x 12 15 X 12 15 x 12 FAN MOTOR HP (STANDARD) 2 2 2 3 FAN MOTOR HP (ALTERNATE) 3 3 5 ROWS DEEP 4 4 4 4 FINS PER INCH 15 15 15 15 FACE AREA (Sq. Ft.) 7.8 9.1 10.9 13.4 PROPELLER DIA. (in.) 24 ea. 24 ea. 24 ea. 24 ea. FAN MOTOR HP 1/2 ea. 1/2 ea. 1/2 ea. 3/4 ea. NOM. CFM TOTAL 2900 ea. 3200 ea. 3600 ea. 4400 ea. ROWS DEEP 2 2 2 2 FINS PER INCH 13 13 13 13 FACE AREA (Sq. Ft.) 16.7 20.0 24.0 29.3 QUANTITY PER UNIT (12" X 24" X 2") 2 2 QUANTITY PER UNIT (16" X 24" X 2") 2 2 2 3 QUANTITY PER UNIT (18" X 24" X 2") 2 2 TOTAL FACE AREA (sq. ft.) 9.3 9.3 11.3 14.0 REFRIGERANT 22 SYSTEM NO. 1 6/8 7/4 8/0 10/4 (lbs./oz.) SYSTEM NO. 2 6/8 7/11 8/12 10/8 NOTE: Filter racks are adapted for 1" or 2" thick filters. WEIGHTS (LBS) 71/2 Ton 1100 81/2 Ton 1125 BASIC UNIT 10 Ton 1220 121/2 Ton 1470 ACCESSORIES Economizer 77 Motorized Outdoor Air 75 Damper Roof Mounting Curb 155 8 Unitary Products Group
530.18N10Y RETURN AIR SUPPLY AIR CONDENSER AIR OUTDOOR AIR (Economizer) All dimensions are in inches. They are subject to change without notice. Certified dimensions will be provided upon request. UTILITIES ENTRY DATA OPENING HOLE SIZE USED FOR (DIA.) A 3/4" KO Control Side 7/8" KO Wiring Bottom* B 2" KO Power Wiring (Side or Bottom)* C 2" KO Gas Piping (Front) D 111/16" KO Gas Piping (Bottom)* *Openings in the bottom of the unit can be located by the slice in the insulation. 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. 10 DIMENSIONS & CLEARANCES 71/2 121/2 TON CLEARANCES Front 24" Back 12" (Less Economizer) 36" (With Economizer) Left Side (Filter Access) 24" (Less Economizer) 54" (With Economizer) Right Side (Cond. Coil) 24" Below Unit 1 20" 72" with 36" maximum Above Unit 2 Horizontal Overhang (For Condenser 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. 2 Units (applicable in U.S.A. only) may be installed on combustible floors made from wood or class A, B or C roof covering material. 3 Units must be installed outdoors. Overhanging structures or shrubs should not obstruct the condenser 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. Unitary Products Group 9
530.18N10Y TABLE 5 SUPPLY AIR PERFORMANCE (71/2, 81/2 & 10 TON) MODEL DCG090 (SIDE DUCT APPLICATIONS) 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 DCG090 (BOTTOM DUCT APPLICATIONS) SPEED, RPM CFM 2250 2550 3000 3400 3750 ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW 975 0.76 1.16 1.08 0.57 1.27 1.18 0.24 1.45 1.35 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 DCG102 (SIDE DUCT APPLICATIONS) SPEED, RPM CFM 2550 3000 3400 3750 ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW 975 0.66 1.27 1.18 0.37 1.45 1.35 0.08 1.65 1.54 1025 0.82 1.34 1.25 0.52 1.54 1.44 0.21 1.75 1.63 1070 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 1.16 1.57 1.46 0.86 1.83 1.71 0.56 2.04 1.90 0.16 2.22 2.06 1175 1.36 1.67 1.56 1.07 1.92 1.79 0.75 2.18 2.03 0.31 2.34 2.16 1220 1.53 1.81 1.69 1.23 2.10 1.96 0.86 2.37 2.15 0.48 2.78 2.56 MODEL DCG102 (BOTTOM DUCT APPLICATIONS) SPEED, RPM CFM 2550 3000 3400 3750 ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW 975 0.57 1.27 1.18 0.24 1.45 1.35 1025 0.73 1.34 1.25 0.39 1.54 1.44 0.04 1.75 1.63 1070 0.86 1.46 1.36 0.54 1.68 1.57 0.20 1.89 1.76 0.04 2.11 1.97 1130 1.07 1.57 1.46 0.73 1.83 1.71 0.39 2.04 1.90 0.13 2.22 2.06 1175 1.27 1.67 1.56 0.94 1.92 1.79 0.58 2.18 2.03 0.28 2.34 2.16 1220 1.44 1.81 1.69 1.10 2.10 1.96 0.66 2.37 2.15 0.36 2.78 2.56 MODEL DCG120 (SIDE DUCT APPLICATIONS) 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 DCG120 (BOTTOM DUCT APPLICATIONS) 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 evaporator coil, 2" filters and the maximum number of heat exchangers. Refer to Table 7 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. = Larger Horsepower Alternate Motor Required. 10 Unitary Products Group
TABLE 6 SUPPLY AIR PERFORMANCE (121/2 TON) 530.18N10Y MODEL DCG150 (SIDE DUCT APPLICATIONS) CFM SPEED, 4000 4500 5000 5500 6000 RPM ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW 960 1.00 2.14 2.00 0.70 2.43 2.27 0.40 2.72 2.54 0.11 3.03 2.83 1000 1.20 2.33 2.17 0.93 2.62 2.45 0.65 2.91 2.72 0.35 3.24 3.03 0.16 4.20 3.91 1050 1.42 2.55 2.37 1.14 2.86 2.67 0.85 3.17 2.96 0.62 4.06 3.79 0.39 4.53 4.22 1090 1.63 2.72 2.54 1.34 3.06 2.86 1.10 3.78 3.53 0.78 4.28 3.99 0.58 4.79 4.46 1105 1.74 3.08 2.87 1.47 3.45 3.22 1.18 3.88 3.62 0.85 4.35 4.06 0.66 4.89 4.56 1140 1.91 3.25 3.03 1.63 3.66 3.41 1.35 4.11 3.83 1.02 4.53 4.22 0.85 5.12 4.77 MODEL DCG150 (BOTTOM DUCT APPLICATIONS) CFM SPEED, 4000 4500 5000 5500 6000 RPM ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW 960 0.77 2.14 2.00 0.40 2.43 2.27 0.04 2.72 2.54 1000 0.97 2.33 2.17 0.63 2.62 2.45 0.29 2.91 2.72 1050 1.19 2.55 2.37 0.84 2.86 2.67 0.49 3.17 2.96 0.26 4.06 3.79 1090 1.40 2.72 2.54 1.04 3.06 2.86 0.74 3.78 3.53 0.42 4.28 3.99 0.18 4.79 4.46 1105 1.51 3.08 2.87 1.17 3.45 3.22 0.82 3.88 3.62 0.49 4.35 4.06 0.26 4.89 4.56 1140 1.68 3.25 3.03 1.33 3.66 3.41 0.99 4.11 3.83 0.66 4.53 4.22 0.45 5.12 4.77 NOTES: Blower performance includes a wet evaporator coil, 2" filters and the maximum number of heat exchangers. Refer to Table 7 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. = Larger Horsepower Alternate Motor Required. TABLE 7 ACCESSORY STATIC RESISTANCES* EXTERNAL STATIC PRESSURE DROP RESISTANCE, IWG DESCRIPTION CFM 2250 3000 4000 5000 6000 Economizer/Motorized Damper 0.02 0.02 0.03 0.05 0.07 *Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table. TABLE 8 MOTOR AND DRIVE DATA MODELS RANGE (RPM) HP SERVICE FACTOR MOTOR* FRAME SIZE EFFICIENCY (%) ADJUSTABLE MOTOR PULLEY PITCH BORE DIA. (IN.) (IN.) FIXED PULLEY PITCH BORE DIA. (IN.) (IN.) PITCH LENGTH (IN.) BELTS DESIG NATION DCG090 2 1.20 56 82.0 3.4 4.4 7/8 6.2 1 50.3 A49 1 DCG102 9751220 2 3 1.20 56 82.0 3.4 4.4 7/8 6.2 1 50.3 A49 1 DCG120 8601090 2 3 1.20 56 82.0 3.4 4.4 7/8 7.0 1 57.3 A56 1 8601090 3 1.20 56 82.0 3.4 4.4 7/8 7.0 1 57.3 A56 1 DCG150 BX61 9601140 5 1.15 184 82.0 4.9 5.9 11/8 8.9 1 62.8 (Notched) 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. QTY Unitary Products Group 11
530.18N10Y TABLE 9 ELECTRICAL DATA MODEL D3CG090 D3CG102 D3CG120 D4CG150 NOTES: POWER SUPPLY 208/230360 460360 575360 208/230360 460360 575360 208/230360 460360 575360 208/230360 460360 575360 COOLING SYSTEM COMPRESSOR (#1 and #2) RLA EACH 14.1 7.1 5.8 16.0 8.3 7.1 16.7 9.6 8.3 21.8 9.6 9.0 LRA EACH 130 64 52 137 69 58 150 73 62 158 79 65 The cooling section is a complete factory package utilizing an aircooled condenser. The system is factorycharged with Refrigerant22. The compressors are hermetically sealed, internally sprung and basemounted with rubberinsulated holddown bolts. 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 warmup, the compressors should be given three false starts (energized just long enough to make a few revolutions) with 57 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 OUTDOOR FAN MOTOR, (#1 & #2) FLA EACH 2.3 1.3 1.3 2.3 1.3 1.3 2.3 1.3 1.3 3.5 2.5 2.5 When the thermostat calls for firststage cooling, the low voltage control circuit from R to G and Y1" (wiring schematic) is completed to energize compressor #1, condenser fan motor #1 and blower motor simultaneously. When the thermostat calls for 2ndstage cooling, the low voltage control circuit from R to Y2" is completed to energize compressor #2 and condenser fan motor #2. After the thermostat is satisfied and opens, all components likewise stop simultaneously. CONTINUOUS Continuous blower operation is possible by closing the R to G circuit on the thermostat. SUPPLY AIR MOTOR, FLA OPERATION TOTAL UNIT AMPACITY, AMPS MAX. FUSE SIZE 1 AMPS MAX. HACR BREAKER SIZE, AMPS SAFETY CONTROLS Each refrigerant system is equipped with the following safety controls: 1. A Suction Line Freezestat to protect against low evaporator temperatures due to a low air flow or a low return air temperature. (Opens at 26 F + 5 F and resets at 38 F + 5 F). 2. A High Pressure Cutout Switch to protect against excessive discharge pressures due to a blocked condenser coil or a condenser motor failure. (Opens at 380 psig + 10 and resets at 300 psig +10). 3. A Low Pressure Switch/Loss Of Charge to protect against loss of refrigerant charge. (Opens at 7 psig + 3 and resets at 22 psig + 5). If either one of the above safety controls opens, that individual refrigerant system will bo locked out. The other refrigerant system will continue in operation unless it too is effected by the same fault. The lock out of either system can be reset by opening the 24V circuit either at the room thermostat or at the unit disconnect. HEATING SEQUENCE OF OPERATION MIN. WIRE SIZE, 2 AWG 2HP 3HP 5HP 2HP 3HP 5HP 2HP 3HP 5HP 7.5 3.4 2.7 7.5 3.4 2.7 7.5 3.4 2.7 10.6 4.8 3.9 10.6 4.8 3.9 10.6 4.8 3.9 15.1 7.5 5.9 1. Dual element, time delay type. Amps shown as 80/90" indicates rating for 3 HP / 5 HP, respectively. 2. Based on 75 C copper conductors. 43.8 21.9 18.3 48.2 24.8 21.2 49.6 27.6 24.1 51.3 26.2 22.4 52.7 29.0 25.3 66.6 31.4 29.1 71.1 34.1 31.1 50 25 20 60 30 25 60 35 30 80/90 40 35/40 50 25 60 30 60 35 90/100 50 8 12 14 8 12 12 8 10 12 6 10 12 6 10 10 4 8 8 4 8 8 The following sequence describes the operation of the gas heat section. CONTINUOUS : With the room thermostat switch set to ON, the supply air blower will operate continuously. The normally closed contact K51" provides 24 volt power to the 3M relay. The 3M1 and 3M2" power contacts close and the blower motor operates. INTERMITTENT : 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. 12 Unitary Products Group
The TH1" closes, the draft motor relay DMR" is energized. The DMR 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 to allow a flow of gas to only the carryover tube. See Figure 11. Only after the pilot flame has been ignited and the presence of pilot flame detected at the IC by a signal sent back through the flame sensor is sparking terminated and the main gas valve opened. 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 to ignite the pilot tube. If the pilot flame 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 DMR, a parallel circuit activates TDR which closes TDR after approximately 16 seconds and energizes K5" which closes K52" and starts the blower by energizing 3M. When TH2" closes calling for second stage heating, it energizes W2" on the gas valve GV directly. When the heating cycle is complete, TH1" opens deenergizing the DMR" and IC, thus closing the redundant and main gas valves. The blower motor continues to run REDUNDANT VALVE GAS MAIN GAS VALVE TO PILOT BURNER FIG. 11 GAS VALVE PIPING (approximately 15 seconds after the furnace is shut down) until TDR opens deenergizing the K5" and 3M" relays. SAFETY CONTROLS MAIN VALVE TO MAIN BURNER 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 10. It resets automatically. The limit switch operates when a high temperature condition, caused by inadequate supply air flow occurs, 530.18N10Y thus shutting down the ignition control and closing the main 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. If the flame sensor fails to detect the pilot flame during operation of the main burners, a signal is sent to the ignition control to close the main gas valve. TABLE 10 LIMIT CONTROL SETTING Units (Tons) 71/2, 81/2 71/2, 81/2 10, 121/2 10, 121/2 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. 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 Gas Valve Honeywell VR8520 WhiteRodgers 36C76 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 temperture within the conditioned space. PRESTART CHECK LIST Capacity, MBH Input Output 163 130 204 163 204 163 245 198 Limit Control Opens, F 180 170 170 170 Anticipator Setpoint 1st Stage 2nd Stage 0.50 amp 0.24 amp 0.60 amp 0.10 amp Complete the following checks before starting the unit. Unitary Products Group 13
530.18N10Y OPERATING INSTRUCTIONS CAUTION: This furnace is equipped with an intermittent pilot and automatic reignition system. DO NOT attempt to manually light the pilot. TO LIGHT PILOT AND MAIN BURNERS: 1. Turn off electric power to unit. 2. Turn room thermostat to lowest setting. 3. Turn gas valve knob to on position. 4. Turn on electric power to unit. 5. Set room thermostat to desired temperature. (If thermostat set temperature is above room temperature, pilot burner ignition will occur and, after an interval to prove pilot flame, main burners will ignite). TO SHUT DOWN: 1. Turn off electric power to unit. 2. Depress knob of gas valve while turning to off position. POSTSTART CHECK LIST (GAS) After the entire control circuit has been energized and the heating section is operating, make the following checks: 1. Check for gas leaks in the unit piping as well as the supply piping. 2. Check for correct manifold gas pressures. See Checking Gas Input. 3. Check the supply gas pressure. It must be within the limits shown on rating nameplate. Supply pressure should be checked with all gas appliances in the building at full fire. At no time should the standby gas line pressure exceed 13", nor the operating pressure drop below 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 highfire gas flow may be made by turning the pressure regulator adjusting screw on the automatic gas valve. Refer to Figure 12. ONOFF CONTROL HIGH FIRE ADJ. (UNDER SCREW) STARTUP Adjust as follows: 1. Remove the cap on the regulator. It s located next to the pushon 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 4.1 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. FIG. 13 PROPER FLAME ADJUSTMENT Put the system into operation and observe through complete cycle to be sure all controls function properly. BURNER INSTRUCTIONS To check or change burners, pilot or orifices, CLOSE MAIN MANUAL SHUTOFF VALVE AND SHUT OFF ALL POWER TO THE UNIT. 1. Remove the two screws holding either end of the manifold to the burner supports. 2. Open the union fitting in the gas supply line just upstream of the unit gas valve and downstream from the main manual shutoff valve. 3. Remove the gas piping patch plate. 4. Disconnect wiring to the gas valve and spark ignitor. Remove the manifoldburner gas valve assembly by lifting up and pulling back. PILOT ADJ. (UNDER SCREW) FIG. 12 TYPICAL GAS VALVE 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. 14 Unitary Products Group
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 530.18N10Y 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 holes in the filter access and blower access panels as shown in Figure 10. 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. FIG. 14 TYPICAL FLAME APPEARANCE been properly installed. BURNER AIR SHUTTER ADJUSTMENT Adjust burner shutters so no yellow flame is observed in the heat exchanger tubes. Refer to Figure 14. CHECKING SUPPLY AIR CFM The RPM of the supply air blower will depend on the required CFM, the unit accessories and the static resistances of both the supply and the return air duct systems. With this information, the RPM for the supply air blower can be determined from the blower performance data in Tables 5 and 6. NOTE: The tubes must be inserted and held in a position perpendicular to the air flow so that velocity pressure will not affect the static pressure readings. 3. Using an inclined manometer, determine the pressure drop across a dry 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 quantity can result in extensive blower damage. 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 11. BELT DRIVE TABLE 11 SUPPLY AIR MOTOR PULLEY ADJUSTMENT TURNS DRIVE RANGE (RPM) OPEN* DCG090, 102 DCG120, 150 5 975 860 4 1024 906 3 1073 952 2 1122 998 1 1171 1044 0 1220 1090 *Pulleys can be adjusted in halfturn increments. All units have belt drive singlespeed blower motors. The variable pitch pulley on the blower motor can be adjusted to obtain the desired supply air CFM. Tighten belts enough to prevent slipping. but do not over tighten. Belt deflection should be between 1/4" and 1/2" per foot. Refer to Table 8 for blower motor and drive data. FIG. 15 PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM Unitary Products Group 15
530.18N10Y After readings have been obtained, remove the tubes and seal up the drilled holes in the side panels. 5/16" dot plugs (P/N 02913880) are available through normal parts ordering procedures. NOTE: DEENERGIZE THE COMPRESSORS BEFORE TAKING ANY TEST MEASUREMENTS TO ASSURE A DRY INDOOR COIL. 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 CGA rating 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 cfm to decrease the temperature rise; decrease the blower cfm to increase the rise. Refer to Table 8 for blower motor and drive data. CHECKING GAS INPUT Btuh Input x 0.8 CFM = 1.08 x o F Temp. Rise 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 one revolution of the hand on the smallest dial on the meter. A typical gas meter usually has a 1/2 or a 1 cubic foot test dial. 3. Using the number of seconds for each revolution and the size of the test dial increment, find the cubic feet of gas consumed per hour from Table 12. TABLE 12 GAS RATE CUBIC FEET PER HOUR Seconds for One Rev. 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 Size of Test Dial 1/2 cu. ft. 1 cu. ft. 180 150 129 113 100 90 82 75 69 64 60 56 53 50 47 45 43 41 39 37 36 35 34 32 31 30 360 300 257 225 200 180 164 150 138 129 120 113 106 100 95 90 86 82 78 75 72 69 67 64 62 60 Example: By actual measurement, it takes 19 seconds for the hand on the 1cubic 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. 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. 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 temperature settings within the limitations of the system. 16 Unitary Products Group
MAINTENANCE 530.18N10Y NORMAL MAINTENANCE CAUTION: Prior to any of the following maintenance procedures, 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 obstructed by overhanging structures of shrubs. BURNER & PILOT Periodically (at least annually at the beginning of each heating season) make a visual check of the pilot and main burner flame. If necessary, adjust main burner primary air shutters so that no yellow flame is observed as explained under BURNER AIR SHUTTER ADJUSTMENT. If it is not possible to adjust for the proper flame, the burners may need cleaning. TO CLEAN BURNERS Remove them from the furnace as explained in Burner Instructions. Clean burners with hot water applied along top of the burner. COMBUSTION AIR DISCHARGE Visually inspect discharge outlet periodically to make sure that the buildup of soot and dirt is not excessive. If necessary, clean to maintain adequate combustion air discharge. 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 of the flue collector box without ripping the adjacent insulation. 4. On the inside of the flue collector box, remove the flue baffle 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 buildup is particularly bad, remove the vent motor and clean the wheel and housing. Run the wire brush down the flue extentions at the outlet of the vent housing. 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. Unitary Products Group 17
530.18N10Y WARNING:Troubleshooting of components necessarily requires 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 procedures, shut off all electric power to the unit to prevent personal injury. CAUTION: Label all wires prior to disconnection when servicing 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 your particular locality (contact your gas company for this 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 of the contactor (3M), and if the contactor is pulled in. Check for loose wiring. b. If (3M) 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 (3M) is pulled in and the blower motor still does not run, replace the blower motor. d. If (3M) is not pulled in, check for 24 volts at the (3M) coil. If 24 volts is present, replace the (3M) contactor. e. If 24 volts is not present at the (3M) 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 MateNLok connector in the partition between the evaporator and gas heat sections and the time delay relay (TDR). 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 (TDR) relay. NOTE: The furnace may shut itself down on a high temperature condition during the procedure, but this will not effect the test if it is done within 5 minutes of furnace shutdown. 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. TROUBLESHOOTING b. If the motor shell is cold with the room thermostat calling for heat, check for line voltage at the motor s MateN 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) contacts in the main control box and check to see if the (DMR) is pulled in. d. If the (DMR) relay is pulled in, check for a loose line voltage connection. e. If the (DMR) relay is not pulled in, check for 24 volts at the (DMR) coil. If 24 volts is present, replace the (DMR) 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 connections to the (TDR) located in the control box. b. If the furnace is hot, it may be out on an over temperature condition, wait for limit reset. c. If the furnace is cold, check for 24 volts at wire 64 attached to the time delay relay (TDR) located in the main control box. If 24 volts is not found, replace the TDR relay. d. If 24 volts is found at wire 64, remove the wires attached to the (TDR) and with a VOM, check for continuity across contacts 1 and 2. If none is found, the (TDR) is open and must be replaced. If there is continuity, reattach the wires. 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 voltage is low call the power company. e. 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 proper limits as described in the POST START CHECK LIST and that the pilot adjust screw is allowing some flow of gas as described in PILOT CHECKOUT. 18 Unitary Products Group
b. Check all wiring between the ignitor control and the gas valve. Check to make sure the ground connections are intact. c. If the wiring is intact, check for 24 volts across terminals PV and COMMON on the ignitor control. If 24 volts is not present, replace the ignitor control. d. If 24 volts is present, remove the pilot burner and remove the pilot orifice from the pilot burner. 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 START CHECK LIST. Make adjustments as necessary. 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. 530.18N10Y 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 control and the gas valve. If intact, check for 24 volts across 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 SHUTTER ADJUSTMENT. b. Check the main burner orifices for obstruction and alignment. Removal procedure is described in BURNER INSTRUCTIONS. Clean or replace burner orifices and burners as needed. 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 REPLACEMENT PARTS 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: IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE. CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR YOUR LOCAL GAS SUPPLIER FOR INFORMATION OR ASSISTANCE. Unitary Products Group 19
Unitary Products Group P.O. Box 1592, York, Pennsylvania USA 174051592 Subject to change without notice. Printed in U.S.A Copyright by York International Corporation 1995. All Rights Reserved. SHU 10M 995 1.10 Code: SBY 530.18N10Y