®
SUNLINE PLUS™
GAS / ELECTRIC
SINGLE PACKAGE AIR CONDITIONERS
035-14832-003-A-0204
Supersedes: 035-14832-002-A-0302
MODELS D2EG 048 & 060 and D3EG 036
(11 SEER)
INSTALLATION INSTRUCTION
FOR YOUR SAFETY
Do not store or use gasoline or
other flammable vapors or liquids
in the vicinity of this or any other
appliance.
If you smell gas:
1. Open windows
2. Don't touch electrical switches.
3. Extinguish any open flame.
4. Immediatelycallyourgassupplier.
GENERAL
• 530.18-N1.14V -Man. Outdoor Air Damper Accy 0-100%
• 530.18-N1.12V -Motorized Outdoor Air Damper Accy.
• 530.18-N1.8V -Coil Guard
YORK Model DEG units are single package air conditioners with
gasheat designedforoutdoorinstallationonarooftoporaslab.
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, gas piping and duct connections
at the point of installation.
The gas-fired heaters have aluminized steel tubular heat
exchangers and spark ignition with intermittent pilot.
This appliance is not to be used for temporary heating of
buildings or structures under construction.
• 530.18-N2.11V -Low NOx Accessory
• 530.18-N8.2V -High Altitude Accy. (Natural Gas)
• 530.18-N8.3V -High Altitude Accy. (Propane)
• 530.18-N8.4V -Gas Piping Accessory
• 530.18-N8.12V -Propane Conversion Accessory
• 690.15-N25V
-Low Ambient Accessory
Renewal Parts:
• Refer to Parts Manual for complete listing of replacement
parts on this equipment.
INSPECTION
All forms referenced in this instruction may be ordered from:
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. Aseparate
request for inspection by the carrier's agent should be made in
writing. Refer to Form 50.15-NM for additional information.
Standard Register
Toll Free Tel.: 877-318-9675
Fax: 877-379-7920
APPROVALS
REFERENCE
Design certified by CGA and UL listed as follows:
Additional information on the design, installation, operation
and service of this equipment is available in the following
reference forms:
1. For use as a forced air furnace with cooling unit.
2. For outdoor installation only.
3. Forinstallationdirectlyoncombustibleflooringor, intheU.S.A.,
on wood flooring or Class A, B, or C roof covering material.
4. For use with natural gas and/or propane (LP) gas.
• 55.70-N1
-General Installation
• 55.70-N2
-Pre-start & Post-start Check List
• 530.18-N1.2V -Economizer Accessory
Not suitable for use with conventional venting systems.
• 530.18-N1.13V -Man. Outdoor Air Damper Accy 0-35%
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.
CAUTION
THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUC-
TIONS 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, PROPERTY DAMAGE AND/OR DEATH.
WARNING
DE-ENERGIZE THE ELECTRICAL POWER AND TURN OFF THE GAS SUPPLY TO THE UNIT BEFORE ATTEMPTING TO
INSPECT, REPAIR OR PERFORM MAINTENANCE TO THE UNIT.
035-14832-003-A-0204
INSTALLATION
CAUTION: If a unit is to be installed on a roof curb or special
LIMITATIONS
frame other than a YORK roof curb, gasketing
must be applied to all surfaces that come in contact
with the unit underside.
These units must be installed in accordance with the current
edition of the following national and local safety codes:
In the U.S.A.:
5. Maintain level tolerance to 1/2" maximum across the entire
length or width of the unit.
6. Elevate the unit sufficiently to prevent any blockage of the
air entrances by snow in areas where there will be snow
accumulation. Check the local weather bureau for the
expected snow accumulation in your area.
1. National Electrical Code ANSI/NFPA No. 70.
2. National Fuel Gas Code Z223.1.
3. Gas-Fired Central Furnace Standard ANSI Z21.47-1993.
4. Local gas utility requirements.
In Canada:
RIGGING AND HANDLING
1. Canadian Electrical Code CSA C22.1
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 42".
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.
2. Current Gas Installation Codes CAN/CGA-2.3-M93.
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.
If components are to be added to a unit to meet local codes, they
aretobeinstalledat thedealer'sand/ orthecustomer'sexpense.
Size of unit for proposed installation should be based on heat
loss / heat gain calculation made according to the methods of
Air Conditioning Contractors of America (ACCA).
LOCATION
TABLE 1 - UNIT APPLICATION DATA
Model DEG
036
048
060
CAUTION: An adhesive backed label is provided over the out-
side of the combustion air inlet opening to prevent
moisture from entering the unit which could cause
damage to electrical components. Allow this clo-
sure label to remain in place until the combustion
air hood is to be installed (refer to Figure 6).
208/230V
460V
187 / 253
414 / 506
518 / 630
1600
Voltage Variation
Min. / Max.1
575V
Supply Air CFM, Nom.
1200
2000
Wet Bulb Temperature (°F) of
Air on Evaporator Coil,
Min. / Max.
Referto Table4 for unitweightsandto Figure1 for approximate
center of gravity.
57 / 72
57 / 72
57 / 72
Dry Bulb Temperature (°F) of
Air on Condenser Coil,
Min2 / Max.
Utilization range “A” in accordance with ARI Standard 110.
A low ambient accessory is available for operation down to 0°F.
CLEARANCES
CONDENSER
45 / 120
45 / 120
45 / 120
BACK
COIL END
APPROXIMATE
CENTER OF
GRAVITY
1
2
FRONT
Use the following guidelines to select a suitable location for
these units.
1. Unit is designed for outdoor installation only.
2. Condenser coils 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.
“
“
B
1A
DIM.
A
3-5 TON
19-3/4"
40-3/4"
B
FIG. 1 - CENTER OF GRAVITY
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 9 for the clearances required for combustible
construction, servicing, and proper unit operation.
WARNING:Excessive exposure of this furnace to contami-
nated combustion air may result equipment dam-
age 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, ce-
ments and glues, antistatic fabric softeners for
clothes dryers, masonry acid washing materials.
WARNING:Do not permit overhanging structures or shrubs to
obstruct condenser air discharge outlet, combus-
tion air inlet or vent outlet.
DUCTWORK
3. For ground level installation, a level pad or slab should be
used. The thickness and size of the pad or slab used should
meet local codes and unit weight. Do not tie the slab to the
building foundation.
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
madewithflexiblejointstominimizethetransmissionofnoise.
4. Roof structures 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.
Unitary Products Group
3
035-14832-003-A-0204
The supply and return air duct systems should be designed for the
CFM and static requirements of the job. They should NOT be
sizedtomatchthedimensionsof theduct connectionsontheunit.
ordinances. The unit must be electrically grounded in
accordance with the NEC (as specified above) and/or local
codes.
Voltage tolerances which must be maintained at the
compressor terminals during start-up 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 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 must be separate from all other circuits. Refer to Figure
9 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.
Electrical lines 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 protected.
CAUTION: When fastening ductwork to the side duct flanges on
the unit, insert the screws through the duct flanges
only. DO NOT insert thescrewsthroughthecasing.
Outdoorductworkmust beinsulatedandwaterproofed.
Refer to Figure 9 for information concerning side and bottom
supply and return air duct openings.
FILTERS
1" filters are supplied with each unit. 2" 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.
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
wheninstallingafield-supplieddisconnectswitch.
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"
PVC female connection on the unit to spill into an open drain.
NOTE: The condensate drain line MUST be trapped to pro-
vide proper drainage. See Figure 2.
Refer to Figure 3 for typical field wiring and to the appropriate unit
wiring diagram for control circuit and power wiring information.
BLOWER SPEED SELECTION
Three blower motor speeds are available on the direct-drive
units. The speed selection for the direct-drive units is
determined by the CFM and ESP requirements of the
applications. All units with belt-drive option have an adjustable
motor pulley to achieve the above conditions.
All direct-drive units with 208/230 voltage are shipped with the
wire labeled #116 connected to the “HIGH” speed tap on the
blowermotor. If a lowerblowermotor speedis desired, this wire
should be moved to the “MED” or “LOW” speed tap on the
motor for the speed desired.
All direct-drive units with 460 and 575 voltage are shipped with
the wire labeled #116 connected to the “HIGH” speed tap on
the blower motor. If the medium speed is required, connect
wire #116 to the “MED” speed tap and the blue motor lead to
the “HIGH” speedtap. If the lowspeedis required, connectwire
#116 to the “LOW” speed tap, the blue motor lead to the “HIGH”
speedtapandtheorangemotorleadtothe“MED”speedtap.
FIG. 2 - RECOMMENDED DRAIN PIPING
SERVICE ACCESS
Access to all serviceable components is provided by the
following removable panels:
• Compressor compartment
• Burner compartment
• Blower compartment
• Main control box
• Filter compartment
COMPRESSORS
On some units the compressor is mounted on springs which
have been tightened down for shipment only.
After this unit is installed, back out the compressor bolts until
the sleeve clears the top grommet.
• Motor access (on units with belt-drive option)
Refer to Figure 9 for location of these access panels.
CAUTION: Make sure that all screws are replaced on the unit
to maintain an air-tight seal.
THERMOSTAT
CAUTION: Do Not loosen compressor mounting bolts.
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. See Figure 3 for wiring details.
TABLE 2 - GAS HEAT APPLICATION DATA
Temp. Rise °F
Input
Output
Available
on
Gas Rate1
At Full Input 2
Capacity, Capacity,
(Ft.3/Hr.)
(Mbh)
50
(Mbh)
40
Models
Min.
15
Max.
45
55
3 Ton
4 Ton
47
70
75
60
25
100
125
79
99
3/5 Ton
4/5 Ton
93
116
40/25
45/35
70/55
75/65
NOTE: If the unit has an economizer, remove jumper J1 from
terminals 8 and 10 on the relay board to prevent si-
multaneous operation of the compressor and the
economizer. If you want to energize the compressor
for supplemental cooling during the economizer op-
eration, use a thermostat with two stages of cooling.
NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with
Kit Model No. 1NP0434. All furnaces meet the latest California seasonal efficiency
requirements.
3
1Based on 1075 Btu/Ft .
2The air flow must be adjusted to obtain a temperature rise within the range shown.
COMBUSTION DISCHARGE
POWER AND CONTROL WIRING
The products of combustion are discharged horizontally
through a screened opening on the gas heat access panel.
Field wiring to the unit must conform to provisions of the National
Electrical Code (NEC) ANSI/NFPA No. 70 and/or local
4
Unitary Products Group
035-14832-003-A-0204
COOLING / HEATING (24 VOLT THERMOSTAT)
CONTROL WIRING
COOLING / HEATING (ELECTRONIC THERMOSTAT)
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O
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R
A
T
I
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T
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E
O
M
P
R
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S
S
O
R
A
N
D
T
H
E
E
O
N
S
O
M
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Z
E
R
.
I
F
Y
O
U
W
A
N
T
T
O
C
O
N
T
R
O
L
T
T
H
E
C
O
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O
M
I
Z
E
R
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N
A
S
E
C
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D
T
A
G
E
O
F
C
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O
L
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G
,
U
S
E
T
H
E
R
M
O
S
T
A
2
E
T
0
4
7
0
0
2
2
4
.
POWER WIRING
REFER TO THE ELECTRICAL
REFER TO THE ELECTRICAL
DATA TO SIZE THE DISCONNECT
SWITCH, THE WIRING AND THE
OVERCURRENT PROTECTION
DATA TO SIZE THE DISCONNECT
SWITCH, THE WIRING AND THE
OVERCURRENT PROTECTION
FIG. 3 - TYPICAL FIELD WIRING
The heating value of the gas may differ with locality. The value
should be checked with the local gas utility.
DISCONNECT SWITCH BRACKET FOR UNITS
WITH OPTIONAL BELT-DRIVE BRACKET
NOTE: There may be a local gas utility requirement specifying
a minimum diameter for gas piping. All units require a
1/2 inch pipe connection at the entrance fitting.
A special bracket for mounting a field-supplied disconnect
switch is provided in each unit ordered with an optional belt-
drive supply air blower. The bracket is shipped inside the
blower compartment taped to the top of the blower housing.
Install the bracket on the left hand side of the unit as shown in
Figure 9. Several existing screws at the top of the unit and one
approximately midway down from the top will be used for
mounting the bracket. Screws should be loosened only - NOT
REMOVED. Mounting holes in the bracket have elongated
keyways allowing easy installation. Re-tighten screws after
bracket is in place to ensure panels will remain leak tight.
TABLE 3 - PIPE SIZING
Nominal Iron Pipe Size
Length in Feet
3/4 in.
1/2 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
520
350
285
245
215
195
180
170
160
150
1,050
730
590
500
440
400
370
350
320
305
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.
90
84
79
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).
Unitary Products Group
5
035-14832-003-A-0204
FIG. 5 - BOTTOM SUPPLY CONNECTION
FIG. 4 - EXTERNAL SUPPLY CONNECTION
EXTERNAL SHUT-OFF
EXTERNAL SHUT-OFF
The furnace must be isolated from the gas supply piping
system by closing its individual manual shut-off valve
during any pressure testing of the gas supply piping system
at test pressures equal to or less than 1/2 psig (3.48kPa).
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 9 to locate these access
openings. Typical supply piping arrangements are shown in
Figures 4 and 5. All shaded items are field-supplied.
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.
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.
L.P./PROPANE 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
1NP0434.
All L.P./propane gas equipment must conform to the safety
standards of the National Fire Protection Association.
Gas piping recommendations:
1. A drip leg and a ground joint union must be installed in the
gas piping.
For satisfactory operation, L.P./propane gas pressure must be
10.5inchW.Cattheunitunderfullload. Maintainingpropergas
pressure depends on three main factors:
2. When required by local codes, a manual shut-off valve may
have to be installed outside of the unit.
1. The vaporization rate which depends on (a) the
temperature of the liquid and (b) the “wetted surface” area
of the container or containers.
3. Use wrought iron or steel pipe for all gas lines. Pipe
compound should be applied sparingly to male threads
only.
2. The proper pressure regulation. (Two-stage regulation is
recommended from the standpoint of both cost and
efficiency.)
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.
3. The pressure drop in the lines between regulators and
between the second stage regualtor 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 compunds 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.
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 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
soap solution or other material suitable for the purpose.
NEVER USE A FLAME.
LOW NOx APPLICATION
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).
For natural gas heat installations in locations which require low
Nitros Oxide emmissions, accessory model 1LN0404 must be
installed.
6
Unitary Products Group
035-14832-003-A-0204
1. With filter section access panel removed, take out hood
components, filters and sensor described above. Remove
and discard outdoor air opening cover on back unit (Upper
right hand corner).
VENT AND COMBUSTION AIR HOODS
The vent and combustion air hoods are shipped attached to the
blower housing in the blower compartment. These hoods must
be installed on the outside of the gas heat panel to ensure
proper unit function. The necessary mounting screws are
provided in a bag that is 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 6. Remove the protective label
covering the opening just prior to installing this hood.
The vent hood (including its screen) is installed by inserting the
top flange of the hood into the slotted opening in the access
panel. The top screw secures the hood to the access panel.
The remaining two side screws must be installed after the
access panel is installed on the unit. These screws engage the
bottom flue box flange.
2. Remove the 1/2" knockout (A) in the units rear panel
(located to the right side of the outdoor air opening). Insert
the two loose wires from inside the unit, into the 1/2"
bushing provided. Insert wires and bushing into knockout.
Snap bushing into place.
3. Mount the outdoor air sensor to the rear panel, just below
the knockout described in Step 2. Secure with two self-
drilling screws at dimples (B) provided in the panel.
NOTE: Sensor must be positioned so that the sensing ports
are at the top (louvers pointing downward) and termi-
nal connections to the right.
4. Connect the two wires, indicated in Step 2, to the sensor as
follows:
CAUTION: All three screws in the vent hood must be properly
installed before furnace operation to insure all
combustionproductsareexhaustedfromtheunit.
• Wire #73 to terminal (+)
• Wire #74 to terminal (S)
5. Assemble the LH and RH side plates to the top cover (2
screws each side) to form the hood. Apply gasketing to the
flange surface on each side plate. Extend gasketing 1/4"
beyond top and bottom of each flange to insure adequate
corner sealing. Secure this assembly to the unit back panel
(upper right hand corner). First, remove screw (C) on unit
top cover. Then slip flange of hood cover in under flange of
unit top cover, replace screw (C), engaging hole (E) in hood
flange and tighten. Attach the two side plates to the unit
panel by using two self-drilling screws for each side plate at
dimples (D) provided in the panel.
FIG. 6 - VENT AND COMBUSTION AIR HOODS
OPTIONAL ECONOMIZER RAIN HOOD
6. Position fillpiece at bottom of hood, between the two side
plates but do not secure at this time. (Slotted openings
MUSTbe downward for drainage). After fillpiece is properly
positioned, note where contact is made with the unit panel.
Remove fillpiece and apply gasket material to this area to
provide a seal. Reposition fillpiece and secure with 2
screws.
The following procedure should be used when assembling an
economizer rain hood onto a unit. Refer to Figure 7. The
outdoor and return air dampers, damper actuator, the linkage
and all the controls 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 located above the top
filter racks within the filter section. The outdoor air sensor is in
thebagofpartslocatedatthebottomofthereturnairsection.
7. Install the two filters into the hood assembly, sliding down
along retainers on side plates, into fillpiece at bottom of
hood.
OUTDOOR AIR
C
OPENING COVER
HOOD
COVER
FILTER
COVER
OUTDOOR AIR
SENSOR
D
E
D
A
GASKETED
FLANGE
D
GASKET
B
D
L. H. SIDE
PLATE
FILTER SECTION
ACCESS PANEL
GASKETED
FLANGE
FILTERS
R. H.
SIDE
SIDE DUCT
APPLICATION SHOWN
PLATE
FILLPIECE
FIG. 7 - ECONOMIZER RAIN HOOD ASSEMBLY (OPTION)
Unitary Products Group
7
035-14832-003-A-0204
NOTE: Install filters so that “Air Flow” arrows point toward the
unit.
8. Install filter cover over the end of the hood with one screw
(center of hood), securing filters into position.
CAUTION: When proceeding with Steps 9 and 10, extreme
care must be exercised while turning both the set
point and minimum position adjusting screws to
prevent twisting them off.
9. The enthalpy set point for the dampers may now be set by
selecting the desired set point from graph in Figure 8. For a
single enthalpy economizer, carefully turn the set point ad-
justing screw to the “A”, “B”, “C” or “D” setting correspond-
ing to the lettered curve. For a dual enthalpy economizer,
carefully turn the set point adjusting screw fully clockwise
past the “D” setting.
10. To check that the damper blades move smoothly without
binding, carefully turn the minimum position adjusting
screw fully clockwise and then energize and de-energize
terminals “R” to “G”. With terminals “R” to “G” energized,
turn the minimum position screw counterclockwise until the
desired minimum position has been attained.
11. Replace the filter section access panel.
FIG. 8 - ENTHALPY SET POINT ADJUSTMENT
TABLE 4 - PHYSICAL DATA
DEG
048
12 x 10
WEIGHTS (LBS)
3 Ton
MODELS
036
060
615
655
680
Basic Unit
CENTRIFUGAL BLOWER (Dia. x Wd. in.)
FAN MOTOR HP (Direct-Drive)
FAN MOTOR HP (Belt-Drive)
12 x 10
12 x 10
1
1.5
3
13
5.1
4 Ton
5 Ton
EVAP.
BLOWER
(Nom. Max.)
1.5
1.5
OPTIONS / ACCESSORIES
Economizer
Motorized Outdoor
Air Damper
Barometric Relief/Fixed
Outdoor Air Intake Damper
ROWS DEEP
FINS PER INCH
FACE AREA (Sq. Ft.)
3
13
3.6
3
13
4.3
50
26
EVAP.
COIL
PROPELLER DIA. (in.)
FAN MOTOR HP
NOM. CFM TOTAL
22
22
22
COND.
FAN
10
4,500
4,200
4,500
Roof Mounting Curb
Belt-Drive Blower
92
5
ROWS DEEP
FINS PER INCH
FACE AREA (Sq. Ft.)
2
2
2
COND.
COIL
18
18
18
17.1
17.1
17.1
AIR
FILTERS
(SEE NOTE)
QUANTITY PER UNIT (14" x 20" x 1")
QUANTITY PER UNIT (14" X 25" X 1")
TOTAL FACE AREA (sq. ft.)
2
1
6.3
2
1
6.3
2
1
6.3
CHARGE
REFRIGERANT 22 (lbs./oz.)
9/12
9/8
9/8
COMPRESSOR QUANTITY PER UNIT (HERMETIC TYPE) 1 / RECPT 1 /RECPT 1 / SCROLL
NOTE: Filter racks are adapted for 1" or 2" thick filters.
TABLE 5 - SUPPLY AIR PERFORMANCE
- 3, 4, & 5 TON w/Direct-Drive Blower
Side Duct Connections
GAS HEAT VALUES SHOWN @ 230/460/575 VOLTS -
Available External Static Pressure - IWG*
0.50 0.60 0.70
CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts CFM Watts
MODEL MOTOR
0.20
0.30
0.40
0.80
0.90
1.00
DEG
SPEED
HI
MED
LOW
-
-
-
-
1699 825 1650 785 1570 755 1430 725 1360 700 1280 680 1180 655
036
1684 800 1631 780 1582 750 1524 720 1410 690 1324 650 1260 630 1185 610 1100 590
1487 710 1464 690 1421 670 1367 650 1315 620 1246 605 1185 590 1110 570 1020 545
HI
1996 960 1933 936 1868 910 1795 880 1722 845 1635 820 1544 790 1419 765 1300 740
1804 838 1765 810 1714 785 1650 765 1589 735 1508 705 1407 675 1306 645 1195 625
1681 760 1640 738 1604 715 1541 695 1490 670 1416 645 1337 620 1230 595 1120 575
2400 1155 2338 1125 2274 1095 2167 1045 2096 1010 1990 980 1887 945 1771 905 1629 855
2290 1105 2214 1065 2145 1030 2071 990 1990 950 1911 920 1828 885 1724 835 1604 798
2150 1020 2100 990 2029 950 1965 910 1905 880 1816 838 1724 800 1644 770 1531 710
048
060
MED
LOW
HI
MED
LOW
NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.
*INCLUDES ALLOWANCES FOR A WET EVAPORATOR COIL, 1" FILTERS, AND THE GAS-FIRED HEAT EXCHANGERS. REFER TO TABLE 8 FOR RESISTANCE VALUES
ON APPLICATIONS OTHER THAN GAS/ELECTRIC UNITS WITH SIDE DUCT AIRFLOWS.
8
Unitary Products Group
035-14832-003-A-0204
TABLE 6 - SUPPLY AIR PERFORMANCE - 3 & 4 Tonw/Belt-Drive Blower
3TON - SIDE DUCT CONNECTIONS @ 230/460/575 Volts
Available External Static Pressure - IWG*
0.40 0.50 0.60
RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts
MODEL AIR FLOW
0.20
0.30
0.70
0.80
DEG
CFM
2000
1900
1800
1700
1600
1500
1400
1300
1200
843
817
790
-
-
-
-
-
-
860
775
700
-
-
-
-
-
-
880
854
828
802
-
-
-
-
-
925
850
760
670
-
-
-
-
-
919
893
867
840
818
-
-
-
-
1005
920
840
745
665
-
-
-
-
956
930
906
881
858
842
833
-
1065
995
905
815
740
695
650
-
993
970
944
920
898
882
867
858
847
1145
1065
980
900
820
755
705
665
640
1030
1008
985
961
940
922
904
893
880
1195
1125
1040
970
890
835
765
725
680
1067
1046
1025
1001
980
962
942
932
916
1235
1170
1100
1030
950
895
820
785
730
036
-
-
Available External Static Pressure - IWG*
1.10 1.20 1.30
RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts
MODEL AIR FLOW
0.90
1.00
1.40
1.50
DEG
CFM
2000
1900
1800
1700
1600
1500
1400
1300
1200
1103
1085
1064
1040
1020
1003
982
1270
1210
1145
1075
1005
945
880
835
780
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1102
1081
1060
1044
1024
1010
992
1180
1115
1050
995
920
870
815
1121
1100
1086
1067
1053
1034
1140
1085
1035
965
920
855
036
-
1107
1099
1080
1000
960
905
970
953
4 TON - SIDE DUCT CONNECTIONS @ 230/460/575 Volts
Available External Static Pressure - IWG*
0.40 0.50 0.60
RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts
MODEL AIR FLOW
0.20
0.30
0.70
0.80
DEG
CFM
2000
1900
1800
1700
1600
1500
1400
1300
1200
843
817
790
-
-
-
-
-
-
860
775
700
-
-
-
-
-
-
880
854
828
802
-
-
-
-
-
925
850
760
670
-
-
-
-
-
919
893
867
840
818
-
-
-
-
1005
920
840
745
665
-
-
-
-
956
930
906
881
858
842
833
-
1065
995
905
815
740
695
650
-
993
970
944
920
898
882
867
858
847
1145
1065
980
900
820
755
705
665
640
1030
1008
985
961
940
922
904
893
880
1195
1125
1040
970
890
835
765
725
680
1067
1046
1025
1001
980
962
942
932
916
1235
1170
1100
1030
950
895
820
785
730
048
-
-
Available External Static Pressure - IWG*
1.10 1.20 1.30
RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts
MODEL AIR FLOW
0.90
1.00
1.40
1.50
DEG
CFM
2000
1900
1800
1700
1600
1500
1400
1300
1200
1103
1085
1064
1040
1020
1003
982
1270
1210
1145
1075
1005
945
880
835
780
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1102
1081
1060
1044
1024
1010
992
1180
1115
1050
995
920
870
815
1121
1100
1086
1067
1053
1034
1140
1085
1035
965
920
855
048
-
1107
1099
1080
1000
960
905
970
953
NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.
*INCLUDES ALLOWANCES FOR A WET EVAPORATOR COIL, 1" FILTERS, AND THE GAS-FIRED HEAT EXCHANGERS. REFER TO TABLE 8 FOR RESISTANCE VALUES
ON APPLICATIONS OTHER THAN GAS / ELECTRIC UNITS WITH SIDE DUCT AIRFLOWS.
Unitary Products Group
9
035-14832-003-A-0204
TABLE 7 - SUPPLY AIR PERFORMANCE - 5 Ton w/Belt-Drive Blower
5 TON - SIDE DUCT CONNECTIONS @230/460/575 Volts
Available External Static Pressure - IWG*
0.40 0.50 0.60
RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts
MODEL AIR FLOW
0.20
0.30
0.70
0.80
DEG
CFM
2500
2400
2300
2200
2100
2000
1900
1800
1700
1600
1500
1059
1032
1005
980
930
877
-
-
-
-
-
1560
1405
1260
1160
1060
950
-
-
-
-
-
1077
1054
1024
1002
957
908
-
-
-
-
-
1590
1470
1275
1170
1070
975
-
-
-
-
-
1095
1074
1049
1022
983
941
894
855
-
1630
1525
1370
1190
1080
1000
885
815
-
1114
1094
1069
1044
1010
976
940
903
884
864
-
1650
1560
1440
1250
1100
1020
940
860
815
770
-
1134
1116
1090
1066
1039
1009
980
950
925
908
882
1660
1595
1475
1350
1160
1050
980
905
850
805
740
1158
1140
1116
1090
1064
1040
1014
988
1685
1620
1505
1410
1260
1100
1020
940
1181
1167
1142
1117
1092
1070
1047
1022
1001
987
1720
1640
1535
1440
1340
1225
1095
970
060
964
948
926
880
835
780
910
870
830
-
-
-
-
965
Available External Static Pressure - IWG*
1.10 1.20 1.30
RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts RPM Watts
MODEL AIR FLOW
0.90
1.00
1.40
1.50
DEG
CFM
2500
2400
2300
2200
2100
2000
1900
1800
1700
1600
1500
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1193
1170
1148
1121
1100
1079
1058
1035
1020
1004
1665
1580
1480
1385
1285
1180
1060
960
1202
1180
1155
1133
1110
1090
1071
1056
1038
1620
1530
1425
1340
1240
1135
1030
965
1190
1169
1143
1122
1103
1088
1070
1475
1385
1280
1190
1100
1035
925
060
1205
1178
1158
1134
1118
1101
1445
1330
1240
1140
1065
980
-
-
1222
1196
1164
1145
1130
1375
1295
1175
1105
1045
1197
1170
1158
1205
1130
1075
-
900
860
1198
1184
1150
1110
880
NOTE: FOR 208 VOLTS, MULTIPLY VALUES BY 0.95.
*INCLUDES ALLOWANCES FOR A WET EVAPORATOR COIL, 1" FILTERS, AND THE GAS-FIRED HEAT EXCHANGERS. REFER TO TABLE 8 FOR RESISTANCE VALUES
ON APPLICATIONS OTHER THAN GAS / ELECTRIC UNITS WITH SIDE DUCT AIRFLOWS.
10
Unitary Products Group
035-14832-003-A-0204
TABLE 8 - STATIC RESISTANCES
EXTERNAL STATIC PRESSURE DROP
RESISTANCE, IWG
DESCRIPTION
Economizer1, 2
CFM
1800
0.13
0.10
1000
0.07
0.06
1200
0.08
0.07
1400
0.09
0.08
1600
0.11
0.09
2000
0.15
0.11
2200
0.17
0.12
2400
0.20
0.14
2600
0.23
0.16
Bottom Duct Connections1
1
Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.
2
The pressure thru the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct system is less than 0.25 IWG, the unit will deliver less CFM
during full economizer operation.
TABLE 9 - MOTOR AND DRIVE DATA - Belt-Drive Blower
ADJUSTABLE
FIXED
MOTOR*
BLOWER
BELT
PITCH
MOTOR PULLEY
BLOWER PULLEY
MODEL
RANGE
(RPM)
PITCH
BORE
DIA.
PITCH
BORE
DIA.
FRAME SERVICE
DESIG-
NATION
HP
RPM
LENGTH
(in.)
SIZE
FACTOR
(in.)
(in.)
(in.)
(in.)
DEG 036
DEG 048
DEG 060
790 - 1120 1-1/2
790 - 1120 1-1/2
850 - 1220 1-1/2
1725
1725
1725
56
56
56
1.15
1.15
1.15
2.4 - 3.4
2.4 - 3.4
2.4 - 3.4
7/8
7/8
7/8
3.7
5.7
5.2
1
1
1
37.3
37.3
37.3
A36
A36
A36
*All motors 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 10 - ELECTRICAL DATA - w/Direct-DriveBlower Motor
VOLTAGE
SUPPLY
AIR
BLOWER
MOTOR,
FLA
MAX.
FUSE
MAX.
HACR
COND.
FAN
MOTOR,
FLA
LIMITATIONS COMPRESSOR
(SEE NOTE 1)
MINIMUM
CIRCUIT
AMPACITY
MODEL
DEG
POWER
SUPPLY
SIZE,
BREAKER
SIZE,
(SEE NOTE 2)
AMPS
MIN. MAX.
RLA
LRA
AMPS
208/230-1-60 187
208/230-3-60 187
253
253
504
630
253
253
504
630
253
253
504
630
16.7
13.1
6.7
87
110
54
2.3
2.3
1.4
1.4
2.3
2.3
1.4
1.4
2.3
2.3
1.4
1.4
4.4
4.4
2.0
2.2
5.0
5.0
2.2
2.2
6.6
6.6
3.3
3.3
27.5
23.1
12.0
10.7
38.6
25.7
13.2
11.4
49.0
33.0
17.2
14.6
40
35
15
15
60
40
20
15
80
50
25
20
40
35
15
15
60
40
20
15
80
50
25
20
036
048
060
460-3-60
575-3-60
414
518
5.1
44
208/230-1-60 187
208/230-3-60 187
18.7
11.9
6.3
135
130
64
460-3-60
575-3-60
414
518
4.9
52.0
208/230-1-60 187
208/230-3-60 187
32.1
19.3
10.0
7.9
135
150
73
460-3-60
575-3-60
414
518
50
NOTES: 1. Utilization Range “A” in accordance with ARI Standard 110.
2. Dual element, time delay type.
TABLE 11 - ELECTRICAL DATA - w/Belt-DriveBlower Motor
VOLTAGE
SUPPLY
AIR
BLOWER
MOTOR,
FLA
MAX.
FUSE
MAX.
HACR
COND.
LIMITATIONS COMPRESSOR
MINIMUM
CIRCUIT
AMPACITY
MODEL
DEG
POWER
SUPPLY
FAN
MOTOR,
FLA
(SEE NOTE 1)
SIZE,
BREAKER
SIZE,
(SEE NOTE 2)
AMPS
MIN. MAX.
RLA
LRA
AMPS
208/230-1-60 187
208/230-3-60 187
253
253
504
630
253
253
504
630
253
253
504
630
16.7
13.1
6.7
87
110
54
2.3
2.3
1.4
1.4
2.3
2.3
1.4
1.4
2.3
2.3
1.4
1.4
7.6
5.3
2.6
2.0
8.6
5.2
2.6
2.0
8.6
6.0
3.0
2.4
30.7
23.9
12.4
9.8
42.6
26.3
14.3
11.4
51.0
32.4
16.9
13.7
45
35
20
15
60
40
20
15
80
50
25
20
45
35
20
15
60
40
20
15
80
50
25
20
036
048
060
460-3-60
575-3-60
414
518
5.1
44
208/230-1-60 187
208/230-3-60 187
18.7
11.9
6.3
135.0
130.0
64.8
460-3-60
575-3-60
414
518
4.9
52.0
208/230-1-60 187
208/230-3-60 187
32.1
19.3
10.0
7.9
169
123
62
460-3-60
575-3-60
414
518
50
NOTES: 1. Utilization Range “A” in accordance with ARI Standard 110.
2. Dual element, time delay type.
Unitary Products Group
11
035-14832-003-A-0204
(DirectDriveUnits)
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 air duct cover to gain
access to the bottom supply air knockout panel.
2. Remove and discard the bottom knockout panel.
3. Replace the side duct cover.
4. With filter section access panel removed from the
unit, remove and discard the bottom return air
knockout panel.
5. Replace the filter access panel.
All dimensions are in inches. They are
subject to change without notice. Certi-
fied dimensions will be provided upon
CLEARANCES
Front
32"
12" (Less Economizer)
UTILITIES ENTRY DATA
Back
36" (With Economizer or Fixed
Air/motorized Air Damper)
11
3
KNOCKOUT
SIZE
HOLE
USED FOR
24" (Less Economizer)
36" (With Economizer)
24"
Left Side (Filter Access)
(DIA.)
11
Control Wiring
(Side or Bot-
tom)**
Power Wiring
(Side or Bot-
tom)
Right Side (Cond. Coil)
Below Unit1
A
B
7/8" *
2" *
20"
4
Above Unit2
72" (For Condenser Air Discharge)
1 Units may be installed on combustible floors made from wood or class A, B or C
roof covering material.
2 Units must be installed oudoors. Overhanging structures or shrubs should not
obstruct the outdoor coil nor the fan 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.
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.
17
7
Gas Piping
(Front)
Gas Piping
(Bottom)
6
C
D
1-5/8"
1-1/2"
17
*Knockouts in the bottom of the unit can be located by
the slice in the insulation.
**Do not remove the 2" knockout ring.
REAR VIEW
SIDE SUPPLY AND RETURN
AIR OPENINGS
• Four (4) feet from electric meters, gas meters, regulators and relief equipment.
AIR FLOW LEGEND
RETURN AIR
SUPPLY AIR
OUTDOOR AIR
“ CONDENSATE
DRAIN
(must be trapped)
B
OUTDOOR AIR
(Economizer)
A
DIMENSION “A”
FIXED
OUTDOOR
12
“A”
AIR DAMPER
DETAIL “B”
UNIT WITH FIXED OUTDOOR
AIR/MOTORIZED DAMPER RAIN HOOD
DETAIL “A”
UNIT WITH ECONOMIZER RAIN HOOD
MOTORIZED
DAMPER
FIG. 9 - DIMENSIONS AND CLEARANCES (3, 4 & 5 TON)
12
Unitary Products Group
035-14832-003-A-0204
OPERATION
CONTINUOUS BLOWER: With the room thermostat switch
COOLING SYSTEM
set to “ON”, the supply air blower will operate continuously. The
normally closed blower interlock relay contact “K3-1" provides
24 volt power to the blower relay ”BR". The “BR” power
contacts close and the blower motor operates.
The cooling section is a complete factory package utilizing an
air-cooled condenser. The system is factory-charged with
Refrigerant-22.
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 air in the gas heat
compartment has achieved a pre-set temeprature.
The compressor is hermetically sealed and internally sprung.
The compressors have inherent (internal) protection. If there is
an abnormal temperature rise in the compressor, the protector
will open to shut down the compressor.
When “TH1" on the thermostat closes, the draft motor relay
”DMR" or “DMC” is energized. The “DMR” or “DMC” power
contacts close which energizes the line voltage draft motor. As
the speed of the draft motor reaches approximately 2500 RPM,
the centrifugal switch contact “CS” 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 locted inside the main gas valve
“GV” to allow a flow of gas to only the carryover tube. See
Figure 10. 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.
PRELIMINARY OPERATION COOLING
After the installation has been completed, energize the
crankcase heater (3 ton only) for at least 4 hours before
operating the unit. After this initial warm-up, the compressor
should be given three false starts (energized just long enough
to make a few revolutions) with a 5 minute delay between each
start before being put into full time service.
NOTE: Prior to each cooling season, the crankcase heater (3
ton only) must be energized at least 10 hours before
the system is put into operation.
REDUNDANT
VALVE
MAIN VALVE
COOLING SEQUENCE OF OPERATION
Single-Stage Cooling: When the thermostat calls for “cooling”,
“R” is closed to “G” and “Y1" (wiring schematic) which
completes the low voltage control circuit, immediately
energizing the compressor, condenser fan motor and blower
motor simultaneously.
GAS MAIN
GAS
TO MAIN
BURNER
VALVE
TO PILOT BURNER
Two-Stage Cooling: A two-stage cooling thermostat may be
used if the unit has an economizer. First-stage cooling is
provided by the economizer - if the outdoor air enthalpy is
acceptable, and second-stage cooling is provided by the
compressor. Jumper wire J1 must be removed. Refer to the
unit wiring diagram.
FIG. 10 - GAS VALVE PIPING
Gas flows into each of the main burners and is ignited from the
carryover tube flame.
The “IC” will try for 85 seconds to ignite the pilot carryover tube.
If the “IC” fails to detect a pilot flame during the 85 seconds, it
will close the redundant valve. After a 5 minute purge period,
the “IC” will again try to light the pilot carryover tube. This will
continue continuously until the “IC” detects a pilot flame.
After the thermostat is satisfied and opens, the blower will
continuetorunforashorttime. Allothercomponentswillstop.
CONTINUOUS BLOWER - Continuous blower operation is
possible by closing the R to G circuit on the thermostat.
If, after detecting a pilot flame and opening the main gas valve,
the “IC” looses pilot flame indication, it will close both the main
and redundant gas valves. The “IC” will start the above
sequence over until a pilot flame is detected and it will open the
main gas valve again.
SAFETY CONTROLS (Cooling)
The refrigerant system is equipped wth the following safety
controls:
The “IC” will only allow 16 pilot flameouts and a single rollout
switch opening per thermostat cycle. After 16 pilot flameouts or
a single rollout switch opening, the “IC” closes both the main
and redundant gas valves. The “IC” requires resetting the
thermostat or removal of it's power lead coming from the draft
motor to reset the “IC” and return it to the above sequence of
operation.
1. A Suction Line Freezestat to protect against low evapora-
tor temperature due to low air flow or a low return air tem-
perature.
2. AHigh Pressure Cutout Switch to protect against excessive
discharge pressures due to a blocked condenser coil or a
condenser motor failure.
At the same time power was supplied to the “DMR” or “DMC”, a
parallel circuit activates the time delay relay “BT” or “ETD”. The
“BT” or “ETD” closes in approximetly 35 seconds and starts the
circulating air blower by energizing the blower interlock relay
“K3", thus closing the ”K3-2" contact and energizing the blower
relay “BR”.
3. ALow Pressure Switch to protect against loss of refrigerant
charge.
If neither one of the above safety controls opens, the refrigerant
system will be locked out. The lock out of the system can be
reset by opening the 24V circuit either at the room thermostat
or at the unit disconnect.
When the heating cycle is complete, “TH-1" opens de-
energizing the “IC”, thus closing the redundant and main gas
valves. The blower motor and the draft motor continue to run
for a short period after the furnace is shut down until the “BT” or
“ETD” opens (in approximately 25 seconds) de-energizing the
“K3", ”BR" and “DMR” or “DMC” relays.
HEATING SEQUENCE OF OPERATION
The following sequence describes the operation of the gas
heat section.
Unitary Products Group
13
035-14832-003-A-0204
SAFETY CONTROLS (Heating)
The control circuit includes the following safety controls:
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.
1. Limit Control (LS). This control is located inside the heat
exchanger compartment and is set to open at the
temperature indicated in Table 12. 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 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.
TABLE 12 - LIMIT CONTROL SETTING
6. Auxiliary Limit Switch. This control is located inside the
heat exchanger compartment and is set to open at 180°F. It
is a manual reset switch. If the auxiliary limit switch trips,
then the primary limit switch has not functioned properly.
Replace the primary limit switch.
HEAT ANTICIPATOR SETPOINTS
The anticipator must be set at 0.1 amps. Too high of a setting
will result in longer heat cycles and a greater temperature
swing in the conditioned space.
Capacity, MBH
Limit Control
Opens, °F
Units
(Tons)
Input
Output
3
4
3
4
5
5
50
75
100
125
100
125
40
60
79
99
79
99
165
165
165
165
165
165
2. Centrifugal Switch (CS-36). 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.
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.
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
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.
START-UP
OPERATING INSTRUCTIONS
MANIFOLD GAS PRESSURE ADJUSTMENT
Small adjustments to the high-fire gas flow may be made by
turning the pressure regulator adjusting screw on the automatic
gas valve. Refer to Figure 11.
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.
(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).
“ON”-"OFF"
PILOT ADJ.
(UNDER
CONTROL
SCREW)
HIGH FIRE ADJ.
(UNDER SCREW)
Honeywell
VR8204M
“ON”-"OFF" CONTROL
TO SHUT DOWN:
1. Turn “off” electric power to unit.
2. Depress knob of gas valve while turning to “off” position.
PILOT ADJ.
(UNDER
SCREW)
White-Rodgers
POST-START CHECK LIST (GAS)
36E36
PRESSURE REGULATOR
After the entire control circuit has been energized and the
heating section is operating, make the following checks:
1/2-14 NPT (OUTLET)
MANIFOLD ADJUST. SCREW
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 4.5" for natural gas
units. If gas pressure is outside these limits, contact the local
gas utility for corrective action.
FIG. 11 - GAS VALVES
Adjust as follows:
1. Remove the cap on the regulator. (High Fire adjusting screw
on valve).
2. To decrease the gas pressure, turn the adjusting screw
counterclockwise.
3. To increase the gas pressure, turn the adjusting screw
clockwise.
NOTE: Check the unit dataplate for the proper manifold pres-
sure and orifice size of the furnace.
14
Unitary Products Group
035-14832-003-A-0204
Knowing the required blower RPM and the blower motor HP,
the speed setting for the supply air motor can be determined.
PILOT CHECKOUT
The setting (turns open) for the optional belt-drive supply air
motor pulley can be determined from Table 13.
The pilot flame should envelope 3/8 inches of the end of the
flame sensor. Refer to Figure 12. To adjust pilot flame, (1)
remove pilot adjustment cover screw, (2) adjust the screw for
the proper pilot flame, (3) be sure to replace cover screw after
adjustment to prevent possible gas leakage.
TABLE 13 - BELT-DRIVE SUPPLY AIR
MOTOR PULLEY ADJUSTMENT
BLOWER DRIVE RANGE (RPM)
TURNS
OPEN*
3 TON
4 TON
5 TON
5
4
3
2
1
0
780
842
790
856
850
924
904
922
998
966
1028
1090
988
1054
1120
1072
1246
1220
*Pulley can be adjusted in half-turn increments.
OPTIONAL BELT-DRIVE BLOWER
FIG. 12 - PROPER FLAME ADJUSTMENT
All units with belt-drive blowers have single speed motors. The
variable pitch pulley on the blower motor can be adjusted to
obtain the desired supply air CFM. Refer to Table 9 for blower
motor and drive data. The tension on the belts should be
adjusted as shown in Figure 14.
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 SHUT-OFF 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
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
Adjust burner shutters so that a distinct, sharp, blue flame is
obtained. Refer to Figure 13.
FIG. 14 - BELT ADJUSTMENT
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:
FIG. 13 - TYPICAL FLAME APPEARANCE
SUPPLY AIR AIR BLOWER AND TEMPERATURE
RISE ADJUSTMENTS
1. Remove the (two) " dot plugs from the holes located on
the filter access panel side of the unit.
The speed 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 speed for the supply air blower can be determined from the
blower performance and accessory static resistance data in
Table 5 through 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 coil.
Unitary Products Group
15
035-14832-003-A-0204
NOTE: The tubes must be inserted and held in a position per-
pendicular to the air flow so that velocity pressure will
not affect the static pressure readings.
CHECKING GAS INPUT
NATURAL GAS
3. Using an inclined manometer, determine the pressure drop
across a dry evaporator coil. Since the moisture on an
evaporator coil may vary greatly, measuring the pressure
drop across a wet coil under field conditions would be inac-
curate. To assure a dry coil, the compressors should be de-
energized while the test is being run.
1. Turn off all other gas appliances connected to the gas me-
ter.
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.
0.7
3. Using the number of seconds for each revolution and the
size of the test dial increment, find the cubic feet of gas con-
sumed per hour from Table 14.
0.6
060
048
0.5
0.4
0.3
0.2
0.1
036
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
your particular locality (contact your gas company for this
information - it varies widely from city to city.)
0
TABLE 14 - GAS RATE - CUBIC FEET PER HOUR
750
1250
1750
2250
2750
3250
3750
Seconds
for One
Rev.
Size of Test Dial
1/2 cu. ft.
NOMINAL CFM
1 cu. ft.
FIG. 15 - PRESSURE DROP ACROSS A DRY
10
12
14
16
18
180
150
129
113
100
360
300
257
225
200
EVAPORATOR COIL VS SUPPLY AIR CFM,
WITHOUT AIR FILTERS
4. Knowing the pressure drop across a dry coil, the actual
CFM through the unit can be determined from the curve in
Figure 15.
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
90
82
75
69
64
60
56
53
50
47
45
43
41
39
37
36
35
34
32
31
30
180
164
150
138
129
120
113
106
100
95
90
86
82
78
75
72
69
67
64
62
60
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 UL rating plate and the data in Table 2.
=
If the CFM is above or below the specified value, the supply air
motor speed may have to be changed by moving the motor
speed tap to another terminal.
WARNING:Failure to properly adjust the total system air quan-
tity can result in poor system performance.
5. After readings have been obtained, remove the tubes and
sealtheholeswiththe5/16"dotplugsremovedinStep1.
Example: By actual measurement, it takes 38 seconds for the hand on the 1-
cubic foot dial to make a revolution with just a 100,000 Btuh furnace running.
Using this information, locate 38 seconds in the first column in the table above.
Read across to the column headed “1 Cubic Foot”, where you will see that 95
cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 95
x 1050 (the Btu rating of the gas obtained from the local gas company). The re-
sult is 99,750 Btuh, which is close to the 100,000 Btuh rating of the furnace.
NOTE: DE-ENERGIZE THE COMPRESSOR BEFORE TAK-
ING ANY TEST MEASUREMENTS TO ASSURE A
DRY INDOOR COIL.
SECURE OWNER'S APPROVAL: When the system is functioning properly, secure the owner's approval. Show him the loca-
tion 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
035-14832-003-A-0204
MAINTENANCE
NORMAL MAINTENANCE
CLEANING FLUE PASSAGES AND HEATING
ELEMENTS
CAUTION: Prior to any of the following maintenance proce-
dures, shut off all power to the unit to prevent per-
sonal injury.
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:
Periodic maintenance normally consists of changing or cleaning
filters and (under some conditions) cleaning the main burners.
1. Remove the burner assembly as outlined in “BURNER IN-
STRUCTIONS”.
FILTERS - Inspect once a month. Replace disposable or clean
permanent type as necessary. DO NOT replace permanent
type with disposable.
2. Remove the roof over the gas heat section.
3. At the top front of the heat section, remove the screws hold-
ing the top of the flue collector box. Carefully remove the
top of the flue collector box without ripping the adjacent in-
sulation.
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.
4. Lift out the flue diverter baffle.
5. On the inside of the flue collector box, remove the screws
holding the flue baffle. Remove the flue baffle.
6. Using a wire brush on a flexible wand, brush out the inside
of each heat exchanger from the burner inlet and flue outlet
ends.
NOTE: Exercise care when cleaning the coil so that the coil
fins are not damaged.
7. Brush out the inside of the flue collector box and the flue
baffles.
Do not permit the outdoor air discharge to be ob-
structed by overhanging structures of shrubs.
8. Run the wire brush down the vent tube from the flue collec-
tor end.
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.
9. If soot build-up 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.
10. After brushing is complete, blow all brushed areas with air
or nitrogen. Vacuum as needed.
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.
11. ReplacepartsintheordertheywereremovedinSteps1to5.
12. When replacing the top of the flue collector box, be careful
so as not to tear the adjoining insulation.
13. 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.
The manufacture recommends that the furnace system be
inspected once a year by a qualified service person.
Unitary Products Group
17
035-14832-003-A-0204
TROUBLESHOOTING
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.
e. If the “DMR” or “DMC” relay is not pulled in, check for 24
volts at the “DMR” or 24 volts at “TMC-G” terminal coil. If
24 volts is present, replace the “DMR” or “DMC” relay. If
24 volts is not present, check for a loose 24 volt connec-
tion back to the relay board and check the connections
from the room thermostat to the relay board. If all connec-
tions are correct, replace the relay board.
CAUTION: The wire number or color and terminal designa-
tions referred to may vary. Check the wiring label
inside the control box access panel for the correct
wiring.
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-
tions to the “BT" and “DMC” or “ETD” located in the con-
trol box.
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”.
b. If the furnace is hot, it may be out on an over tempera-
ture condition, wait for limit reset.
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 sup-
plied to the contacts of the blower relay, “BR”, and if the
blower relay is pulled in. Check for loose wiring.
c. With the draft motor running, check for 24 volts at termi-
nal 24V 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 re-
place the draft motor. If line voltage is low call the power
company.
b. If “BR” is pulled in, touch the supply air blower motor
housing. If it is hot the motor may be off on inherent pro-
tection. Disconnect power to the unit and check the
blower motor capacitor. If it is defective, replace it with
one of equal capacitance and voltage.
d. If 24 volts is present at the ignitor control, check all con-
trol 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 re-
place the ignition control “IC”.
c. If “BR” is pulled in and the blower motor still does not
run, replace the blower motor.
d. If “BR” is not pulled in check for 24 volts at the “BR” coil.
If 24 volts is present, replace the “BR” relay.
e. If 24 volts is not present at the “BR” coil, check for loose
24 volt wiring back to the relay board. Check control wir-
ing to the room thermostat. If all is fine, replace the relay
board.
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.
f. If the blower motor runs with the fan switch in the “ON”
position but does not run soon after the furnace has ig-
nited 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 par-
tition between the evaporator and gas heat sections
and the time delay relay “BT” or “ETD”.
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
someflowofgasasdescribedin“PILOTCHECKOUT”.
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”.
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.
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 shut-down.
d. If 24 volts is present, remove the pilot burner and re-
move the pilot orifice from the pilot burner. The orifice is
removed in the direction opposite the flow of gas. In-
spect the orifice for obstruction. If it is clear, replace the
main gas valve.
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
ishot tothetouch, wait fortheinternaloverloadtoreset.
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.
b. If the motor shell is cold with the room thermostat calling
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.
a. Adjust the pilot adjust screw on the gas valve as de-
scribed in “PILOT CHECKOUT”.
b. Check the supply pressure as described in “POST
START CHECK LIST”. Make adjustments as neces-
sary.
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.
c. Check the pilot orifice for obstruction as described in
Item 4. Clean as needed but the problem should not be
the gas valve.
d. If the “DMR” or “DMC” relay is pulled in, check for a
loose line voltage connection.
Cont'd
18
Unitary Products Group
035-14832-003-A-0204
TROUBLESHOOTING - Continued.
6. The pilot burner ignites but the sparker continues to spark
and the main burners do not ignite.
8. Furnace lights with roll out or one burner has delayed igni-
tion.
a. Make the same checks and adjustments as described
in Item 5.
a. Make sure that the pilot burner is aligned properly with
the carryover as described in “PILOT CHECKOUT”.
b.Makesurethatthepilotburnerisnotbentordamaged.
b. Make sure that the carryovers on adjoining burners are
screwedfast andarelevelwithrespecttooneanother.
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.
9. Mainburnerslightbutexhibiterraticflamecharacteristics.
a. Adjust air shutters as described in “BURNER AIR
SHUTTER ADJUSTMENT”.
7. The pilot burner lights and the spark stops but the main
burners do not light.
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.
a. Check electrical connections between the ignitor con-
trol and the gas valve. If intact, check for 24 volts across
terminals “MV” and “COMMON” terminals. If no voltage
is detected, replace the ignitor control. If voltage is pres-
ent, replace the gas valve.
Unitary Products Group
19
Unitary Products Group
5005 York Drive, Norman Oklahoma 73069
Subject to change without notice. Printed in U.S.A.
Copyright © by York International Corporation 2004. All Rights Reserved.
035-14832-003-A-0204
Supersedes: 035-14832-002-A-0302
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