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REVIEWED BLD2023-0361+Manufacturer_Specifications_and_Installation_Instructions+3.24.2023_10.28.09_AM+3441170BLD2023-0361 RECEIVED Mar 24 2023 CITY OF EDMONDS DEVELOPMENT SERV E Installer's Guide REVIEWED BY Single Packaged Gas/Electric 14 SEER Convertible, 2 — 5 Ton 4YCC4024A1060A 4YCC403OAl070A 4YCC4036A1070A 4YCC4036A1090A 4YCC4042A1060A 4YCC4042A1090A 4YCC4048A1070A 4YCC4048A1090A 4YCC406OAl090A 4YCC406OAl 1 15A Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment. September 2017 18-E B31 D 1-1 C-E N ARD'Ingersoll Rand SAFETY SECTION Important — This document contains a wiring diagram, a parts list, and service information. This is customer property and is to remain with this unit. Please return to service information pack upon completion of work. HAZARDOUS GASES! Exposure to fuel substances or by-products of incomplete fuel combustion is believed by the state of California to cause cancer, birth defects, or other reproductive harm. This warning complies with state of California law, Proposition 65. HAZARDOUS VOLTAGE! Failure to follow this Warning could result in property damage, severe personal injury, or death. Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. SAFETY AND ELECTRICAL HAZARD! Failure to follow this Warning could result in property damage, severe personal injury, or death. These servicing instructions are for use by qualified personnel only. To reduce the risk of electrical shock, do not perform any servicing other than that contained in these operating instructions unless you are qualified to do so. GROUNDING REQUIRED! Failure to inspect or use proper service tools may result in equipment damage or personal injury. Reconnect all grounding devices. All parts of this product that are capable of conducting electrical current are grounded. If grounding wires, screws, straps, clips, nuts, or washers used to complete a path to ground are removed for service, they must be returned to their original position and properly fastened. UNIT CONTAINS R-410A REFRIGERANT! Failure to use proper service tools may result in equipment damage or personal injury. R-410A operating pressure exceeds the limit of R- 22. Proper service equipment is required. Service using only R-410A Refrigerant and approved POE compressor oil. SAFETY HAZARD! Operating the unit without the access panels properly installed may result in severe personal injury or death. Do not operate the unit without the evaporator fan access panel or evaporator coil access panel in place. Important. Wear appropriate gloves, arm sleeve protectors and eye protection when servicing or maintaining this equipment. Important_ Air filters and media wheels or plates shall meet the test requirements in UL 900. ©2014Ingersoll Rand 18-EB31 D1-1 C-EN Table of Contents Introduction ................................ 4 Step 2 — Determine Unit Clearances ....... 5 Step 3 — Review Location and Recommendation Information ............. 11 Step 4 — Unit Installation .................. 13 Electrical Wiring ........................... 23 Field Wiring Diagram .................... 25 Step 5 — Unit Startup ..................... 26 Sequence of Operation .................... 28 Service Maintenance ..................... 28 18-EB31 D1-1 C-EN Introduction Read this manual carefully before attempting to install, operate, or perform maintenance on this unit. Installation and maintenance should be performed by qualified service technicians only. This unit is listed by Underwriters Laboratory. DO NOT use this furnace for temporary heating of buildings under construction. As shipped from the factory, this unit is for use with natural gas only. It is listed by Underwriters Laboratory. An LPG conversion kit is available. A high altitude installation kit of additional orifice sizes is available. Extreme mounting kits for slab and curbs are also available. Packaged units are designed for outdoor mounting with a vertical condenser discharge. They can be located either at ground level or on a roof in accordance with local codes or National Fuel Gas Code (ANSI-Z223.1A) Latest Revision. Since these units are designed exclusively for outdoor operation, additional flue venting systems are not required. Each unit contains an operating charge of Refrigerant as shipped. Extreme mounting kits are available for slab (BAYEXMK003A), utility curb (BAYEXMK002B), or curb (BAYEXMK001A) mountings. The indoor fan motor speed adjustment is provided in the Maintenance section. This guide is organized as follows: • Step 1 — Inspect Shipment • Step 2 — Determine Unit Clearances • Step 3 — Review Location & Recommendation Information • Step 4 — Unit Installation • Step 5 — Unit Startup • Sequence of Operation • Maintenance Step 1 — Inspect Shipment 1. Check for damage after the unit is unloaded. Report promptly to the carrier any damage found to the unit. Do not drop the unit. Important To prevent damage to the sides and top of the unit when hoisting, use "spreader bars ". 2. Check the unit's nameplate to determine if the unit is correct for the intended application. The power supply must be adequate for both the unit and all accessories. 3. Check to be sure the refrigerant charge has been retained during shipment. Remove the Compressor access panel to access the 1/4" flare pressure taps. 4. The Flue Hood is included with the unit's literature pack. 5. If this unit is being installed on a curb, verify that the correct curb is provided with the unit. • 4YCC4024-4036 use model BAYCUR13050A. • 4YCC4042-4060 use model BAYCUR13051A. 6. If the unit is being hoisted, accessory kit BAYLIFT002B is recommended. It includes a kit of four (4) lifting lugs and instructions. Note: If practical, install any internal accessories to the unit at the shop. Note: The packaged units have been evaluated in accordance with the Code of Federal Regulations, Chapter XX, Part 3280 or the equivalent. "SUITABLE FOR MOBILE HOME USE". 18-EB31 D1-1 C-EN Step 2 — Determine Unit Clearances 18.03Li 18.29 [23/32] d.22 [9/l6] SECTION Y-Y TYPICAL (8) SIDES OF DOWNFLOW DUCT OPENINGS a .L:MIM LEFT SIDE I (DUCT F 10, [41 Figure 1. 4YCC4024-4036 Note: The view labeled "Bottom side" represents the base as viewed looking up from underneath the unit. 4 OUTLET FRONT SIDE BOTTOM SIDE M UE OD 18-EB31 D1-1 C-EN 5 Step 2 - Determine Unit Clearances 79.50 - [3-I/8] 398.22 115-11/161 (OUTSIDE) Figure 2. 4YCC4024-4036 296.62 [11-II/16] (OUTSIDE) f RETURN [2-9/32] 177.55 SUPPLY [7] 398.22 [15-II/16] (OUTSIDE) 176.01 [6-15/16] BACK DUCT OPENINGS 17. 18 [II/16] SECTION TYPICAL (8) SIDES OF SIDEFLOW DUCT OPENINGS BACK SIDE Height mm/in Flu Hood w/brkt mm in Approx. Corner Weight - kg / Ibs Shipping Weight kg/Ibs Total Unit Weight kg/Ibs Center of Gravity mm/in A D W1 W2 W3 W4 B C 4YCC4024 (060) 898.53 [35-3/8] 157.16 [6-3/16] 58.3 [129] 36.8 [811 26.1 [58] 41.0 [90] 196.1 [432] 162.4 [358] 479.8 [18.9] 527.8 [20.8] 4YCC4030 (070) 898.53 [35-3/8] 157.16 [6-3/16] 61.3 [135] 38.7 [85] 27.5 [61] 43.1 [95] 204.8 [451] 171.1 [377] 406.5 [16.0] 594.1 [23.4] 4YCC4036 (070) 949.33 [37-3/8] 157.16 [6-3/16] 61.1 [134] 38.3 [841 27.1 [601 43.2 [95] 203.4 [438] 169.7 [374] 414.3 [16.3] 697.6 [27.5] 4YCC4036 (090) 949.53 [37-3/8] 157.16 [6-3/16] 61.7 [136] 38.9 [861 27.7 [611 43.7 [96] 205.7 [453] 172.0 [379] 414.3 [16.3] 697.6 [27.5] 6 18-EB31D1-1C-EN Step 2 — Determine Unit Clearances Figure 3. 4YCC4024-4036 RECOMMENDED SERVICE CLEARANCE MM/IN. WITH ECONOMIZER BACK SIDE 304.8 1121 762.0 1301 LEFT SIDE 762.0 [301 914.4 [361 RIGHT SIDE 914.4 [361 - FRONT SIDE 1066.8 [421 - CLEARANCE TO COMBUSTIBLE MATERIAL MMIIN. 304.E 1121 (INSIDE 75.41 12-31/3; 24V ENTRY 359.80 1 If [14-5/321 294.02 111-9/161 178.66 1 17-1/321 84.96 13-II/321 127.84 15-1/321 D /321 406.40 1161 )(INSIDE) 3] »'1'6..,, ( I INS IDE ) BOTTOM DUCT OPENINGS POWER ENTRY 34.13 DIA. HOLE 1 1 -3/321 GAS LINE ENTRY FOR 12.70 11121 N.P.T. 98.66 GAS CONNECTION RIGHT SIDE 18-EB31D1-1C-EN 7 304.E 1121 (INSIDE 75.41 12-31/3; 24V ENTRY 359.80 1 If [14-5/321 294.02 111-9/161 178.66 1 17-1/321 84.96 13-II/321 127.84 15-1/321 D /321 406.40 1161 )(INSIDE) 3] »'1'6..,, ( I INS IDE ) BOTTOM DUCT OPENINGS POWER ENTRY 34.13 DIA. HOLE 1 1 -3/321 GAS LINE ENTRY FOR 12.70 11121 N.P.T. 98.66 GAS CONNECTION RIGHT SIDE 18-EB31D1-1C-EN 7 Step 2 — Determine Unit Clearances Figure 4. 4YCC4042-4060 7. 78 II/I61 N TYPICAL (8) SIDES OF SIDEFLOW DUCT OPENINGS J- 18.03 18.29 12382 ] [ 23' 321 1IA.22 9/161 SECTION Y-Y TYPICAL (8) SIDES OF DOWNFLOW DUCT OPENINGS a RECOMMENDED SERVICE CLEARANCE MM/IN. WITH O.A. DAMPERIECON. OUTLET Note: the view labeled "Bottom Side" represents the base as viewed looking up from underneath the unit. BOTTOM SIDE 18-EB31D1-1C-EN Step 2 - Determine Unit Clearances Figure 5. 4YCC4042-4060 if RETURN SUPPLY 79.50 449 02 116.01 [17-11/16] (OUTSIDE) BACK DUCT OPENINGS 1402.34 [55-7/32] (SURFACE AREA) BACK SIDE 372.82 [14-II/I6] (OUTSIDE) L 58.19 [2-9/32] 322.84 [12-23/32] 449.02 [17-II/16] (OUTSIDE) 530.60 [20-7/8] Model Height mm/in Approx. Corner Weight - kg / Ibs Shipping Weight kg/Ibs Total Unit Weight kg/Ibs Center of Gravity mm/in A W1 W2 W3 W4 B C 4YCC4042 (060) 898.53 [35-3/8] 71.2 [157] 46.6 [103] 34.6 [76] 53.1 [117] 252.2 [555] 202.0 [452] 470.0 [18.5] 731.0 [28.8] 4YCC4042 (090) 898.53 [35-3/8] 71.8 [158] 47.2 [104] 35.2 [78] 53.6 11181 254.5 [561] 207.3 [457] 470.0 [18.5] 731.0 [28.8] 4YCC4048 (070) 1000.13 [39-3/8] 71.4 [157] 44.6 [98] 33.2 [73] 53.9 [119] 250.3 [552] 202.1 [448] 433.0 [17.0] 743.3 [29.3] 4YCC4048 (090) 1000.13 [39-3/8] 72.0 [159] 45.0 [99] 33.8 [75] 54.4 [120] 252.6 [557] 205.4 [453] 433.0 [17.0] 743.3 [29.3] 4YCC4060 (090) 1000.13 [39-3/8] 77.1 [170] 45.8 [101] 34.4 [76] 58.3 [128] 263.1 [580] 215.9 [476] 433.0 [17.0] 743.3 [29.3] 4YCC4060 (115) 1000.13 [39-3/8] 78.0 [172] 46.3 [102] 34.9 [77] 59.0 [130] 265.8 [5861 218.6 [482] 414.0 [16.3] 635.0 18-EB31D1-1C-EN 9 Step 2 — Determine Unit Clearances Figure 6. 4YCC4042-4060 457.20 1181 (INSIDE) 75.41 [2-31/32 [15JVV (INSIDE) BOTTOM DUCT OPENINGS 24V ENTRY 359.80 294.02 [14-5/321 111-9/161 178.66 1 1 [7-1/321 4 GAS L I NE ENTRY 84. 96 96 32] FOR 12.70 [1121 N.P.T. GAS CONNECTION 98.66 [3-7/81 POWER ENTRY 27.78 DIA. HOLE [1-3/321 127.84 RIGHT SIDE [5-11321 381.00 [151 (INSIDE) 75 9/161 20 iIDE) 09 /81 10 18-EB31D1-1C-EN Step 3 — Review Location and Recommendation Information Note: The unit is shipped for horizontal installation. Note: During heating operation, avoid supply air below 80 degrees F or return air below 50 degrees F to prevent flue gas condensation. Horizontal Airflow Units 1. Location of the unit must allow service clearance around it to ensure adequate serviceability, maximum capacity, and peak operating efficiency. 2. These units are designed for outdoor installation. They may be installed directly on a slab, wood flooring, or on Class A, B, or C roof covering material. The discharge air from the condenser fans must be unrestricted for a minimum of 3 feet above the unit. 3. The louvers above and below the flue hood in the side panel must have adequate clearance around the air opening into the combustion area. 4. Examine all flue product -carrying areas of the furnace, its vent system, and the main burner for safe operation. Important: A minimum clearance of 0.0" to combustible material shall be maintained on air outlet duct. 5. Exhaust vents or other sources of contaminated air must not be near the unit's air inlet if outside air is to be introduced as make-up air or a ventilation feature is to be used. Contamination from exhaust vents or chimneys may also foul the condenser causing degraded performance. 6. Check the handling facilities to ensure the safety of personnel and the unit's). 7. The unit must be mounted level for proper drainage of water through the drain holes in the base pan. 8. The unit should not be exposed to direct roof water runoff. 9. Flexible duct connectors must be of a flame retardant material. All duct work outside of the structure must be insulated and weatherproofed in accordance with local codes. 10. Holes through exterior walls or roof must be sealed in accordance with local codes. 11. All fabricated outdoor ducts should be as short as possible. Clearances 1. The recommended clearances for single -unit installations are illustrated in Figures 1 to 6. 2. Any reduction of the unit clearances indicated in these figures may result in condenser coil starvation or the recirculation of warm condenser air. Actual clearances, which appear to be inadequate should be reviewed with a local engineer. 3. See the unit's nameplate for the absolute minimum clearance between the unit and any combustible surfaces. Down Airflow Units 1. Location of the unit must allow service clearance around it to ensure adequate serviceability, maximum capacity, and peak operating efficiency. 2. Refer to the Installation section for instruction on converting the supply and return airflow covers to down airflow. 3. The field assembled Roof Mounting Curb (BAYCURB050A or BAYCURB051A) or a field fabricated curb should be in place before the unit is hoisted to the roof top. The Roof Mounting Curb (frame) must be installed on a flat, level section of the roof (maximum of 1/4" per foot pitch) and provide a level mounting surface for the unit. Also, be sure to provide sufficient height above the roof to prevent water from entering the unit. 4. Be sure the mounting curb spans structural members (trusses) of the roof, thereby providing sufficient support for the weight of the unit, the curb, the duct(s), and any factory or field installed accessories. 5. The unit must be mounted level for proper drainage of water through the drain holes in the base pan. 6. Be sure the hole in the structure for the ducts is large enough to accommodate the fabricated ducts and the insulation surrounding them. Flexible duct connectors must be of a flame retardant material. All duct work outside of the structure must be insulated and weatherproofed in accordance with local codes. 7. Holes through exterior walls or roof must be sealed in accordance with local codes. 8. These units are design certified for outdoor installation. They may be installed directly on a slab, wood flooring, or on Class A, B, or C roof covering material. The discharge air from the condenser fans must be unrestricted for a minimum of 3 feet above the unit. 9. The louvers above and below the flue hood in the side panel must have adequate clearance around the air opening into the combustion area. 10. Examine all flue product -carrying areas of the furnace, its vent system, and the main burner for safe operation. 18-EB31 D1-1 C-EN 11 Step 3 — Review Location and Recommendation Information Important_ A minimum clearance of 0.0" to combustible material shall be maintained on air outlet duct. 11. Exhaust vents or other sources of contaminated air should not be near the unit's air inlet if outside air is to be introduced as make-up air or a ventilation feature is to be used. Contamination from exhaust vents or chimneys may also foul the condenser causing degraded performance. 12. Check the handling facilities to ensure the safety of personnel and the unit(s). CiparanrPs 1. The recommended clearances for single -unit installations are illustrated in Figures 1 to 6. 2. Any reduction of the unit clearances indicated in these figures may result in condenser coil starvation or the recirculation of warm condenser air. Actual clearances, which appear to be inadequate should be reviewed with a local engineer. 3. See the unit's nameplate for the absolute minimum clearance between the unit and any combustible surfaces. 12 18-EB31 D1-1 C-EN Step 4 — Unit Installation Note_ The factory ships this unit for horizontal installation. Install Flue Hood 1. Locate the Flue Hood in the literature package. 2. Remove the two Flue Hood mounting screws from the unit. They are located to the right of the Power Entry connection panel. 3. Attach the Flue Hood to the unit with the two screws removed in step two. To Install the unit at ground level: 1. Place the unit on a pad the size of the unit or larger. The unit must be mounted level for proper drainage of water through the holes in the base pan. To attach the unit securely to the slab, use extreme mounting kit, BAYEXMK003A. The pad must not come in contact with the structure. Be sure the outdoor portion of the supply and return air ducts are as short as possible. The unit requires vibration support as indicated in the Ground Level Application Figure. 2. The louvers above and below the Flue Hood in the side panel must have adequate clearance around the air opening into the combustion area. 3. Location of the unit must allow service clearance around it. Clearance of the unit must be given careful consideration. See Figures 1 to 6 Note: Any reduction of the unit clearances indicated in these illustrations may result in condenser coil starvation or the recirculation of warm condenser air. Actual clearances, which appear to be inadequate should be reviewed with a local engineer. Important: A minimum clearance of 0.0" to combustible material shall be maintained on air outlet duct. 4. Attach the supply and return air ducts to the unit as explained in the Ductwork Installation section. 5. Flexible duct connectors must be of a flame retardant material. Insulate any ductwork outside of the structure with at least two (2) inches of insulation and weatherproof. There must be a weatherproof seal where the duct enters the structure. 6. Do not expose the unit to direct roof water runoff. 7. Seal all holes through exterior walls in accordance with local codes. 8. Continue with the following installation sections to complete the installation: Ductwork, Gas Piping, Filter and Electrical Wiring. Rooftop Installation — Curb Mounting Convert Horizontal Airflow to Down Airflow The factory ships the unit for horizontal airflow. Perform this procedure to convert it to down airflow: 1. Remove the three (3) sheet metal screws securing the supply air cover and the four (4) sheet metal screws securing the return air cover from the base of the unit. Remove the covers from the base. 2. Place the covers over the horizontal supply and return openings (painted side out). Align the screw holes, and secure using the same screws removed in step 1. Install Full Perimeter Roof Mounting Curb 1. Verify that the roof mounting curb is correct for the unit. There are two curbs depending on the unit cabinet sizes: • 4YCC4024 through 4YCC4036 use model BAYCURB050A • 4YCC4042 through 4YCC4060 use model BAYCURB051A 2. Assemble and install the curb following the instructions in the Installer's Guide included with the appropriate curb. 18-EB31 D1-1 C-EN 13 Step 4 — Unit Installation OUTDOOR AIR DISCHARGE SUPPORT PAD FOUNDATION 3/4" VIBRATION ISOLATORS, USE 7 ISOLATORS Figure 8. Converting Horizontal to Down Airflow Figure 7. Typical Ground Level Application Note: Use the extreme mounting kit BAYEXMK003AA, to secure the unit to the slab. SIDING --- r RETURN SUPPLY - AIR DUCT AIR DUCT I ^ C EXTERIOR WALL INSULATE WEATHERPROOF OR RAIN SHIELD FLEXIBLE DUCT CONNECTORS HORIZONTAL SUPPLY AIR COVER Lifting and Rigging Important: Do not lift the unit without test lifting for balance and rigging. Do not lift the unit in windy conditions or above personnel. Do not lift the unit by attaching clevis, hooks, pins, or bolts to the unit casing, casing hardware, corner lugs, angles, tabs, or flanges. Failure to observe these warnings may result in equipment damage. 1. Before preparing the unit for lifting, check the unit dimension drawings for center of gravity for lifting safety (Figures 1 to 6). Because of placement of internal components, the unit's weight may be unevenly distributed. Approximate unit weights are also provided in the unit drawings Note: Unit rigging and hoisting requires accessory kit BAYLIFT002A. It includes a kit of four (4) lifting lugs. 2. Insert the four lifting lugs in the openings provided in the drip lip on each end of the unit. A tap or jerk to the lug will overcome the interference that arises due to the dimple on the lug. 3. When hoisting the unit, be sure that a proper method of rigging is used. Use slings and spreader bars for protection during lifting. Always test -lift the unit to determine the exact unit balance and stability before hoisting it to the installation location. 14 18-EB31 D1-1 C-EN Step 4 — Unit Installation 4. When the curb and air ducts have been properly installed, the unit is ready to be hoisted to the roof and set in position. Important_ To prevent damage to the sides and top of the unit when hoisting use "spreader bars ". Important: The unit must be lowered into position. The P.V.C. rubber tape on the curb flange permits the unit to be repositioned if required without destroying the P.V.C. rubber seal affixed to the mounting curb. Table 1. Vibration Isolators/Snow Feet Locations Note: These views represent the base as viewed looking up from underneath the unit. Important: Unit requires vibration isolator support in the general areas shown. Locate 3/4"thick vibration isolators on the bottom of the basepan as illustrated by black dots for ground level pad applications. Modify vibration isolator location as necessary for frame and rail applications. Small Cabinet ****4024 - 4036 Rooftop Installation — Frame Mounting For rooftop applications using field fabricated frame and ducts use the following procedure: 1. Locate and secure the frame to the roof by bolting or welding. Frame must provide adequate center support via a cross member centrally located channel rail. See Table 4, p. 17 and Table 5, p. 18. Vibration isolators should be installed as indicated in Table 1, p. 15, adjust as necessary for your frame. The isolators must be placed on base pan, not drip lip. Add flashing as required. Flashing must conform to local building codes. 2. Prepare the hole in the roof in advance of installing the unit. 3. Secure the horizontal or down airflow ducts to the roof. Refer to the previous Convert from Horizontal Airflow to Down Airflow section if conversion is needed. 4. All fabricated outdoor ducts should be as short as possible. 5. Place the unit on the frame. Placing the Unit on the Mounting Curb 1. The unit is designed with a perimeter drip lip that is lower than the unit base pan. 2. Position the unit drip lip down over and in contact with the outside corner of the curb.. Continue to lower the unit on top of the curb, with the unit drip lip astraddle, and in contact with, both the end and side rail of the curb. The unit should now rest on top of the curb. Use the extreme mounting kit, BAYEXMK001A, to add additional hold down strength to the mounting. Note: The ductwork is installed as part of the curb installation. Do not attach ductwork to the unit and lower the unit with ductwork onto the curb. Medium Cabinet ****4042 - 4060 6. The unit must be mounted level for proper drainage of water through the holes in the base pan. 7. Secure the unit to the frame. 8. Insulate any ductwork outside of the structure with at least two (2) inches of insulation and then weatherproof. There must be a weatherproof seal where the duct enters the structure. 9. The unit should not be exposed to direct roof water runoff. 10. Flexible duct connectors must be of a flame retardant material. All duct work outside of the structure must be insulated and weatherproofed in accordance with local codes. 11. Access and service clearances for the unit must be given careful consideration when locating the duct entrance openings. Figures 1 to 6 provide unit dimensions. 12. Continue with the following installation sections to complete the installation: Ductwork, Filter, and Electrical Wiring. 18-EB31 D1-1 C-EN 15 Step 4 — Unit Installation Rooftop Installation — Flat Roof -No Curb/Frame For roof top applications using field fabricated ducts and sleeper rails rather than a curb or frame, use the following procedure: 1. Locate and secure the sleeper rails to the roof by bolting (three (3) rails required). One on each end to support the edges of the unit and one across the center of the unit. The center rail must run inside both drip lips. Vibration isolators should be installed, adjust as necessary for your sleeper rails. The isolators must be placed on base pan, not drip lip. Add flashing as required. Flashing must conform to local building codes. 2. Prepare the hole in the roof in advance of installing the unit. 3. Secure the horizontal or down airflow ducts to the roof. Refer to the previous Convert from Horizontal Airflow to Down Airflow section if conversion is needed. 4. All fabricated outdoor ducts should be as short as possible. Table 2. Lifting and Rigging 5. Place the unit on the rails. 6. The unit must be mounted level for proper drainage of water through the holes in the base pan. 7. Secure the unit to the rails. 8. Insulate any ductwork outside of the structure with at least two (2) inches of insulation and then weatherproof. There must be a weatherproof seal where the duct enters the structure. 9. No exposure to direct roof water runoff. 10. Flexible duct connectors must be of a flame retardant material. All duct work outside of the structure must be insulated and weatherproofed in accordance with local codes. 11. Access and service clearances for the unit must be given careful consideration when locating the duct entrance openings. Figures 1 to 6 provide unit dimensions. 12. Continue with the following installation sections: Ductwork, Filter and Electrical Wiring. Base of unit i Drip lip on rest on top of perimeter of curb rails unit E 1 Spreader Bars Top shipping skid attached to unit Gasket Seal „B„ ��\I\\�l Drip Lip AYLIFr002A Dimple Liftin Lu s 16 18-EB31 D1-1 C-EN Step 4 — Unit Installation Table 3. Curb Dimensions A J E H L I'--- ------------ i 2-7/8- II II � II UNIT DOWNFLOW _ F RETURN OPENING K UNIT DOWNFLG B C_ MAX. SUPPLY OPENING CURB WIDTH II � II II 2-7/8- l-1— 1- (RECOMMENDED PERIMETER CURB RECESS) II II 1' X 1- RECOMMENDED FIELD CURB I MITER (TO TOP CURB FLANGE)-4 PLACES — IELD CURB NIT BASE PAN 1.5/8 X 1.5/8 UNIT "D" MAX. CURB LENGTH MITER (4 CORKERS) PAN FRWM FROM D674162 REFERENCE ILLUSTRATION FOR A CUSTOMER SUPPLIED ROOF CURB MODEL I A I B I C D E F G I H J K L 4 TC-,YC-,WC-,DC•OI8,024,030,036 48-3/8 40-7/8 38-7/8 46-3/8 16 1 12 6-5/8 1 6-7/8 1 12 16 4 TC•,YC*,WCi,DCe042,048,060 1 58 143-7/8141-7/81 56 1 18 1 15 1 IS 1 9-5/8 12-1/2 15 This drawing was prepared by the manufacturer in order to provide detail regarding job layout only. This drawing is not intended to be used as a basis to construct, build or modify the item depicted in the drawing. The manufacturer is not responsible for the unauthorized use of this drawing and expressly disclaims any liability for damages resulting from such unauthorized use. Table 4. Typical Rooftop Horizontal Airflow Application with Frame Supply Air Return Air ` Roof Flashing \ ' Channel Iron Center ` Support (Center Support Angle Iron Frame required on all frame applications). Z� 18-EB31D1-1C-EN 17 Step 4 — Unit Installation Table 5. Typical Rooftop Down Airflow Application with Frame 41% + az r Return Air § � g Supply Air Roof Flashing /� �� N % Roof \y c Flashing Channel Iron Center Support (center support required on all frame applications). Angle Iron Frame Ductwork Installation Attaching Downflow Ductwork to Roof Curb Supply and return air flanges are provided on the roof curb for easy duct installation. All ductwork must be run and attached to the curb before the unit is set into place. Attaching Downflow Ductwork to Roof Frame Follow these guidelines for ductwork construction: Connections to the unit should be made with three (3) inch canvas connectors to minimize noise and vibration transmission. Elbows with turning vanes or splitters are recommended to minimize air noise and resistance. The first elbow in the ductwork leaving the unit should be no closer than two (2) feet from the unit, to minimize noise and resistance. To prevent leaking, do not attach the ductwork to the bottom of the unit base. Refer to the bottom example in Figure 9, p. 18 Figure 9. Attaching Down Airflow Ductwork AIR PROOF THIS SEAM UNIT BASE FIELD DUCT UNIT DUCT FLANGE AIR PROOF THIS SEAM UNIT DUCT FLANGE UNIT BASE FIELD DUCT AIR PROOF THIS SEAM UNIT BASE FIELD DUCT - \ UNIT DUCT FLANGE UNIT BASE UNIT DUCT f FLANGE / WATERPROOF SEAM WITH BUTYL OR SILICONE NOT RECOMMENDED FIELD DUCT 18 18-EB31 D1-1 C-EN Step 4 — Unit Installation Attaching Horizontal Ductwork to Unit All conditioned air ductwork should be insulated to minimize heating and cooling duct losses. Use a minimum of two (2) inches of insulation with a vapor barrier. The outside ductwork must be weatherproofed between the unit and the building. When attaching ductwork to a horizontal unit, provide a flexible watertight connection to prevent noise transmission from the unit to the ducts. The flexible connection must be indoors and made out of heavy canvas. Note_ Do not draw the canvas taut between the solid ducts. Figure 10. Attaching Horizontal Airflow Ductwork 7 UNIT EXTERIOR WEATHERPROOF THIS SEAM FIELD DUCT UNIT EXTERIOR WEATHERPROOF THIS SEAM FIELD DUCT Condensate Drain Piping A 3/4-inch female NPT condensate drain connection is provided on the evaporator access panel end of the unit. Provide a trap and fill it with water before starting the unit to avoid air from being drawn through. Follow local codes and standard piping practices when running the drain line. Pitch the line downward away from the unit. Avoid long horizontal runs. See . Note: Do not use reducing fittings in the drain lines. The condensate drain must be: • Made of 3/4" pipe size • Pitched 1/4" per foot to provide free drainage to convenient drain system • Trapped • Must be connected to a closed drain system unless the trap is properly vented Figure l 1. Typical Condensate Drain Piping 3/4" PVC OR COPPER TUBING AND FITTINGS 1-1/2" MIN. 1-1/2" MIN. 41 Gas Piping Installation FIRE OR EXPLOSION HAZARD! Failure to follow the safety warning exactly could result in serious injury, death, or property damage. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. Important: Before making the gas pipe connection, give serious consideration to providing the clearance necessary to remove the access panels on the unit (e.g., economizer and filter access panels). Note: In the absence of local codes, the installation must conform with American National Standard— Z223.1—National Fuel Gas Code, Latest Revision. The available gas supply must agree with the required gas supply marked on the unit nameplate. Minimum permissible gas supply pressure for purpose of input adjustment must be at least 7.0 in. w. c. (inches water column) for natural gas and 11 in. w. c. for LP Gas. Pipe Delivery Schedule Note: The following procedure and tables apply to Natural Gas only. 1. Obtain from the gas company the heating value and specific gravity of the gas delivered. 2. Determine the exact length of pipe needed. 3. Read BTUH input nameplate on the furnace. 4. Use the multiplier opposite the specific gravity of the gas given in Multiplier Table and insert in the following formula: 5. Use the Natural Gas Only table and select the pipe length nearest to calculated size. CFH = Furnace Input in BTUH Gas Heat Contne in BTU/Cu. Ft. X Multiplier 6. Follow this line vertically down to the exact CFH found in Step 4 above or the next highest value. 7. Read horizontally to the left of this column for the required pipe size diameter. Table 6. Specific Gravity Multiplier SPECIFIC MULTIPLIER GRAVITY .50 1.10 MULTIPLIERS TO BE USED WHEN THE SPECIFIC GRAVITY •55 1.04 .60 1.00 OFTHE GAS IS OTHERTHAN 0.060 .65 .962 Note: If this is an LP Gas application, consult your LP Gas supplier for pipe sizes and deliveries. 18-EB31 D1-1 C-EN 19 Step 4 — Unit Installation Table 7. Natural Gas Only TABLE OF CUBIC FEET PER HOUR OF GAS FOR VARIOUS PIPE SIZES AND LENGTHS PIPE SIZE (inch) 10 20 30 40 50 60 70 1/2 132 92 73 63 56 50 46 3/4 278 190 152 130 115 105 96 1 520 350 285 245 215 195 180 1-1/4 1050 730 590 520 440 400 370 THIS TABLE IS BASED ON PRESSURE DROP OF 0.3 INCH W.C. AND 0.6 SP.GR. GAS Gas Pressure Set-up Precautions Important_ Do not connect gas piping to the unit until a line pressure test has been completed. This unit should never be exposed to gas line pressure in excess of 14 inches water column (112 PSIG). The furnace and its equipment shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 112 psi. 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 less than or equal to 1/2 psig (3.48 kPa). Gas Supply Line Pressure Before connecting the unit to the gas supply line, be sure to determine the gas pressure in the line. If the gas supply pressure is excessive (above 14 inches water column or 1/2 psig), install a pressure regulator either at the supply source or in the branch circuit serving the unit. Once the regulator is installed, set it to provide a pressure of 7 inches water column with the unit operating and no greater than 14 inches water column with the unit not firing. Note_ Gas pressure in excess of 14 inches water column (112 psig) may damage the regulator, while improper regulation may result at pressures lower than 5.5 inches water column at the unit inlet. If the supply line pressure is below the minimum supply pressure indicated on the unit nameplate, contact the gas supply company. Follow these steps to complete the installation of the unit gas piping. See Table 8, p. 20 Note_ The shut-off gas cock must be installed outside of the unit and should meet the specifications of all applicable national and local codes. Table 8. Gas Pipe DEALERINSTALLED GROUND UNION 1/8" N.P.T.PLUGGED ACCESS FOR TEST GAUGE CONNECTION FROM {�6" GAS SUPPLY MIN TO MAIN I CONTROL VALVE UNIT FIELD SUPPLIED MAIN GAS VALVE, MUST BE DRIP LEG INSTALLED BY DEALER (6" MIN) OUTSIDE OF UNIT. Note: The shut-off gas cock must be installed outside of the unit and should meet the specifications of all applicable national and local code. 1. Install a ground union joint downstream of the shut-off cock. This joint must also be installed outside of the unit. 2. Install a drip leg at least six (6) inches in depth next to the union as shown in . This drip leg is required to collect any sediment that may be deposited in the line. 3. Before connecting the piping circuit to the unit, bleed the air from the supply line and then cap or plug the line and test the pressure at the tapped shut-off cock. The pressure reading should not exceed 13.8 inches water column. 4. Using an appropriate backup wrench on the gas valve inlet boss, connect the gas piping to the unit. Check the completed piping for leaks using a soap and water solution or the equivalent. 5. After installation of the gas pipe in the unit, the pipe opening should be closed with the filler/barrier plug provided. Verify Manifold Pressure Check the manifold pressure at the unit gas valve. Do not exceed the recommended pressure shown on the unit nameplate. See for connections. Refer to Manifold Pressure Check and Adjust in the following Step 5-Unit Startup section if adjustment is needed. Input Check and Adjustment 1. Make sure all gas appliances are off except the furnace. 2. Clock the gas meter with the furnace operating (determine the dial rating of the meter) for one revolution. 3. Match the "Sec" column in the Gas Flow (in cfh) Table 9, p. 21 with the time clocked. 4. Read the "Flow" column opposite the number of seconds clocked. 5. Table 9, p. 21 lists values for a 2 cubic foot dial. For 1, 1/2, or 5 Cu. Ft. dials use the following conversions: 20 18-EB31 D1-1 C-EN Step 4 — Unit Installation • 1 Cu. Ft. Dial Gas Flow CFH = Chart Flow Reading / 2 • 1/2 Cu Ft. Dial Gas Flow CFH = Chart Flow Reading / 4 • 5 Cu. Ft. Dial Gas Flow CFH = 10X Chart Flow Reading / 4 6. Multiply the final figure by the heating value of the gas obtained from the utility company and compare to the nameplate rating. This must not exceed the nameplate rating. 7. Changes can be made by adjusting the manifold pressure. a. Attach a manifold pressure gauge to the Outlet Pressure Tap. Inlet Manual Pressu On -Off Tap Sw$ch Regu]ator Cover Screw (Adj. screw beneath this screw) Vent Post b. Remove the cover screw on top of the gas valve to access the manifold pressure adjustment screw. c. Turn the adjustment screw in to increase the gas flow rate, and out to decrease the gas flow rate using a 3/32" hex wrench or flat -head screwdriver. Note: For manifold pressures and orifice sizes for gas with other BTU ratings, contact the local gas utility. Manifold pressure should be 3.5 inches water column (+ 0.1). Input for natural gas must not exceed the value shown on the rating plate. Figure 12. Burner and Valve Mani: Outlets REF. VIEW Pressure ap (GAS VALVE) Table 9. Sec. Flow Sec. Flow Sec. Flow Sec. Flow 8 900 29 248 50 144 82 88 9 800 30 240 51 141 84 86 10 720 31 232 52 138 86 84 11 655 32 225 53 136 88 82 12 600 33 218 54 133 90 80 13 555 34 212 55 131 92 78 14 514 35 206 56 129 94 76 15 480 36 200 57 126 96 75 16 450 37 195 58 124 98 73 17 424 38 189 59 122 100 72 18 400 39 185 60 120 104 69 19 379 40 180 62 116 108 67 20 360 41 176 64 112 112 64 \i Table 9. (continued) Sec. Flow Sec. Flow Sec. Flow Sec. Flow 21 343 42 172 66 109 116 62 22 327 43 167 68 106 120 60 23 313 44 164 70 103 124 58 24 300 45 160 72 100 128 56 25 288 46 157 74 97 132 54 26 277 47 153 76 95 136 53 27 267 48 150 78 92 140 51 28 257 49 147 80 90 144 50 18-EB31 D1-1 C-EN 21 Step 4 — Unit Installation High Altitude Installation Input ratings (BTUH) of these furnaces are based on sea level operation and should not be changed at elevations up to 2000 ft. If the unit installation is from 2000 to 8000 feet elevation, then change the burner orifices to the size listed in Table 4. Refer to Table 5 for orifice part numbers. Orifice Twist Altitude Above Sea Level and Orifice Change Required for that Elevation Drill Size if Installed at Sea Level 2000 3000 4000 5000 6000 7000 8000 32 33 34 35 35 36 36 37 33 35 35 36 36 37 38 38 37 38 39 39 40 41 42 42 49 50 50 50 51 51 51 52 52 52 53 53 53 53 53 54 From National Fuel Gas Code —Table F-4 Table 10. Orifice Part Numbers Drill Size Part Number Drill Size Part Number 32 ORF01307 41 ORF01413 33 ORF0134 42 ORF01410 34 ORF01335 49 ORF01333 35 ORF01407 50 ORF01332 36 ORF01408 51 ORF01336 37 ORF01406 52 ORF01331 38 ORF01306 53 ORF01411 39 ORF01409 54 ORF01412 40 ORF01336 Air Filter Installation The packaged unit requires an air filter. The unit does not come with a factory installed filter rack in it, however, two filter frame accessories are offered that will allow the installation of a filter within the unit, BAYFLTR101 & BAYFLTR201. Otherwise a field supplied filter rack must be installed by the installer in the return duct work. Affix the filter label supplied with the unit adjacent to the filter area. Refer to Table 6 to determine filter size. Table 11. Determine Filter Size Unit Nominal CFM Filter(a)Size (Sq Ft) Filter(a) Resistance (W.C.) YC-4024A 800 2.67 0.08 YC-4030A 1000 3.33 0.08 YC-4036A 1200 4 0.08 YC-4042A 1400 4.67 0.08 YC-4048A 1600 5.33 0.08 YC-4060A 2000 6.67 0.08 (a) Filters must be installed in the return air system. The above square footages are based on 300 F.P.M. face velocity. If permanent filters are used, size per mfg. Recommendation with clear resistance of 0.05" WC. Important: Air filters and media wheels or plates shall meet the test requirements in UL 900 22 18-EB31 D1-1 C-EN Electrical Wiring INSTALLATION WARNING - HIGH VOLTAGE MOVING PARTS! Failure to follow this Warning could result in property damage, severe personal injury, or death. Bodily injury can result from high voltage electrical components, fast moving fans, and combustible gas. For protection from these inherent hazards during installation and servicing, the main gas valve must be turned off and the electrical supply must be disconnected. If operating checks must be performed with the unit operating, it is the technician's responsibility to recognize these hazards and proceed safely. Note: This unit is factory wired for 230V. See wiring diagram for 208V conversion. Electrical Connections Electrical wiring and grounding must be installed in accordance with local codes or, in the absence of local codes, with the National Electrical Code ANSI/NFPA 70, Latest Revision. Disconnect Switch Provide an approved weatherproof disconnect within close proximity and within sight of the unit.lf disconnect must be mounted to the cabinet, the location shown in Figure 15, p. 24should be the only one considered. Over Current Protection The branch circuit feeding the unit must be protected as shown on the unit's rating plate. Power Wiring The power supply lines must be run in weather -tight conduit to the disconnect and into the side of the unit control box. Provide strain relief for all conduit with suitable connectors. Provide flexible conduit supports whenever vibration transmission may cause a noise problem within the building structure. 1. Remove the Control/Heat access panel. Pass the power wires through the Power Entry hole in the end of the unit. Figure 13, p. 23 2. Connect the high voltage wires to the appropriate contactor terminals. Single phase units use a two (2) pole contactor and three phase units use three (3) pole contactor. Connect the ground to the ground lug on the chassis. See Figure 14, p. 23. Be sure all connections are tight. GROUNDING: THE UNIT MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR THE NATIONAL ELECTRIC CODE. Note: Unit must be grounded for ignitor to operate properly. Gas pipe to unit is not an adequate ground. Ground the unit internally as provided. See wiring diagram for location in. Figure 13. Power Wiring Run power supply lines through weather -tight conduit and secure to unit with strain relief. Figure 14. Power Connections Contactor Ground 18-EB31 D1-1 C-EN 23 Electrical Wiring Figure 15. Mounted Disconnect Location Control Wiring (Class II) Low voltage control wiring should not be run in conduit with power wiring unless Class 1 wire of proper voltage rating is used. Route the thermostat cable or equivalent single leads of No. 18 AWG colored wire from the thermostat subbase terminals through the rubber grommet on the unit. See Unit Clearance Graphics for the control entry (24V Entry) location. Make connections as shown on the unit wiring diagram. Do not short thermostat wires since this will damage the control transformer. Refer to Table 12, p. 24 for recommended wire sizes and lengths for installing the unit thermostat. The total resistance of these low voltage wires must not exceed one (1) ohm. Any resistance in excess of 1 ohm may cause the control to malfunction because of the excessive voltage drop. Table 12. Thermostat Wire Size and Max. Length Wire Size Maximum Length 18 75 16 125 14 200 Thermostat Heat Anticipator Set the heat anticipator of the thermostat to equal the amperage draw of the gas valve Important: Upon completion of wiring, check all electrical connections, including factory wiring within the unit. Make sure all connections are tight. Replace and secure all electrical box covers and access panels before leaving the unit or turning on the power to the unit. 24 18-EB31 D1-1 C-EN Electrical Wiring Field Wiring Diagram Figure 16. 4YCC4 —Field Wiring Diagram PACKAGEI GAS —ELECTRIC UNIT UNIT CONTROL BOX TWO STAGE HEAT !THERMOSTAT CONNECTIONS WIRE F_ I I — -- I I � B COMMON I I I G FAN (GR) — — — — — — — — — — Y COMPRESSOR W11 HEAT FIRST STAGE (WH) W21 HEAT SECOND STAGE (WIT) R 24V -- ----- UNIT LOW VOLTAGE AREA -- -- --� - 1PH E c vwlwzR POWER TYPICAL 2 STAGE HEAT THERMOSTAT 3 PH POWER UNIT NOTE 1 SINGLE STAGE ECONOMIZER ACCESSORY FT. THERMOSTAT CONNECTIONS CONNECTIONS ECONOMIZER FACTORY PROVIDED FIEWIrRE^S ST�ALLEO / 1 I I I I I I I TYPICAL 1 STAGE HEAT THERMOSTAT NOTE 6 L__ _— I L36E(BL1�------------ — — — L__ B I G FAN(GR) 4aE(Yu ----- Y COMPRESSOR -----W1IHEAT FIRST STAGE (WH) I L — — — — 4]E(BKI ----------------G (GR) -----W2HEAT SECOND STAGE (WH ) L------- 44D(PRI --------------- Y -.— R 24V I I 'OLTAGE AREA ---------W1 (WH) -- UNIT Low -------W2(WH) I I VOLTAGE AREA R I ✓/ I .! JUMPER I I I I I NOTES: 1. FUSED DISCONNECT SIZE, POWER WIRING AND GROUNDING OF EQUIPMENT MUST COMPLY WITH CODES. 2. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT AND HEATER NAMEPLATE. 3. LOW VOLTAGE WIRING TO BE 18 AWG MINIMUM CONDUCTOR. 4. SEE UNIT DIAGRAM FOR ELECTRICAL CONNECTION DETAILS. 5. THE THERMOSTAT ON THE GAS/ELECTRIC UNIT MUST PROVIDE A 'G' SIGNAL IN THE COOLING MODE ONLY. DURING THE HEATING MODE THE FAN WILL BE ENERGIZED BY THE SYSTEM. 6. FOR SINGLE STAGE THERMOSTATS JUMPER W1 AND W2 TOGETHER SECOND STAGE HEAT WILL BEGIN 10 MINUTES AFTER FIRST STAGE, C 7571902 TYPICAL 2-STAGE THERMOSTAT INTER —COMPONENT WIRING 24V. FACTORY ------- LINE V. WIRING 24V. FIELD LINE V. WRING WIRE COLOR DESIGNATION ABBR COLOR ABBR COLOR BK BLACK PR PURPLE BL BLUE RD RED BR BROWN WH WHITE GR GREEN YL YELLOW OR ORANGE 18-EB31 D1-1 C-EN 25 Step 5 — Unit Startup Pre -Start Quick Checklist ❑ Is the unit properly located and level with the proper clearances? See Figures 1-6. ❑ Is the duct work correctly sized, run, taped, insulated, and weatherproofed with proper unit arrangement as shown in the ductwork installation section? ❑ Is the condensate line properly sized, run, trapped, and pitched and shown in the Condensate Drain Piping section? ❑ Is the gas piping correctly sized, run, trapped, and purged of air? See Gas Piping Installation section. ❑ Is the filter of the correct size and quantity? Is it clean and in place? See Air Filter Installation section. ❑ Is the wiring properly sized and run according to the unit wiring diagram? ❑ Are all the wiring connections, including those in the unit tight? ❑ Has the unit been properly grounded and fused with the recommended fuse size? ❑ Is the thermostat well located, level, and correctly wired? See Electrical Wiring section ❑ Have the air conditioning systems been checked at the service ports for charge and leak tested if necessary? ❑ Do the condenser fan and indoor blower turn free without rubbing and are they tight on the shafts? ❑ Has the indoor blower speed been determined and the proper speed been set? To adjust the fan, see the Indoor Fan Motor Speed Tap Setting section. ❑ Has all work been done in accordance with applicable local and national codes? ❑ Are all covers and access panels in place to prevent air loss and safety hazards? Starting the Unit in Cooling Mode Note: See the section on Sequence of Operation for a description of the cooling operating sequence. To start the unit in the cooling mode, set the thermostat system switch to COOL and move the thermostat COOL indicator to a setting below room temperature. The condenser fan motor, compressor and evaporator fan motor will operate automatically. Operating Pressure Checks After the unit has operated in the cooling mode for a short period of time, install pressure gauges on the gauge ports of the discharge and suction line valves (behind the Compressor access panel). Check the suction and discharge pressures and compare them to the normal operating pressures provided in the unit's SERVICE FACTS. Note: Do not use the PRESSURE CURVES from the unit's SERVICE FACTS to determine the unit refrigerant charge. The correct charge is shown on the unit nameplate. To charge the system accurately, weigh in the charge according to the unit nameplate and check subcooling against the Subcooling Charging Table in the SERVICE FACTS. Voltage Check With the compressor operating, check the line voltage at the unit (contactor is located behind the Control/Heat access panel). The voltage should be within the range shown on the unit nameplate. If low voltage is encountered, check the size and length of the supply line from the main disconnect to the unit. The line may be undersized for the length of the run. Cooling Shut Down At the thermostat, place the system selector to the OFF position or reset the thermostat to a setting above room temperature. Important: De -energize the main power disconnect ONLY when servicing the unit. Power may be required to keep the heat pump compressor warm and to boil off refrigerant in the compressor. Starting the Unit in Heating Mode Note: See the section on Sequence of Operation for a description of the heat pump heating operating sequence. These units are equipped with a solid-state ignition control that lights the burners each time the thermostat calls for heat. The burners are extinquished during the OFF cycle. To start the gas heating section of the unit: 1. Check that all grills and registers are open and all unit access panels are closed before start-up. 2. Purge the gas supply line of air by opening the union ahead (upstream) of the unit. When the odor of gas is detected, retighten the union and wait five (5) minutes before proceeding. 3. Be sure the thermostat is at its lowest setting and the power to the unit is off. a. Turn the main shut-ff valve on the gas supply line to ON. b. Turn the thermostat to the highest setting in the heating cycle. 4. Be sure the burner compartment access panel is in place. 26 18-EB31 D1-1 C-EN Step 5 — Unit Startup a. Turn on the electrical power to the unit. b. Turn the thermostat to the highest setting in the heating cycle. 5. As the thermostat calls for heat, the system cycles as follows: a. The combustion blower is energized. b. The pressure switch is closed. c. The gas valve opens and the ignitor lights the burner. d. Cycle the thermostat on and off a few times to check out the control system and burner operation characteristics. Note: For manifold pressures and orifice sizes for gas with other BTU ratings, contact the local gas utility. Manifold pressure should be 3.5 inches w.c. (+0.1). Input must not exceed the value shown on the rating plate. e. With the burner operating, check the manifold pressure with a manometer. 6. Do not exceed recommended pressures. If the manifold pressure needs adjustment, refer to Manifold Pressure Check and Adjust in the Maintenance section. With the burners operating, check the manifold pressure with a manometer. 7. If necessary, adjust the unit to obtain an air temperature rise with that specified on the unit nameplate. To adjust, refer to the Indoor Fan Motor Speed Adjustment in the Maintenance section. Note: Blue smoke produced by the heat exchanger during the initial burner firing is caused by a thin film of oil on the surface of the heat exchanger. This oil will burn off quickly. 8. Set the thermostat at the desired temperature setting and the unit will function automatically. Final Installation Checklist ❑ Does the unit run and operate as described in the section on "Sequence of Operation" in response to the room thermostat? ❑ Are the condenser fan and indoor blower operating correctly with proper rotation and without undue noise? ❑ Is the compressor operating correctly and has the system been checked with a charging chart? ❑ Has the voltage and running current been checked to deter mine if it is within limits? ❑ Has the thermostat been checked for calibration and the air discharge grilles adjusted to balance the system? ❑ Has the ductwork been checked for air leaks and condensation? ❑ Has the furnace manifold pressure been checked and adjusted if necessary? ❑ Has the heating air temperature rise been checked? ❑ Has the unit been checked for tubing and sheet metal rattles? Are there any other unusual noises to be checked? ❑ Are all covers and panels in place and properly fastened? ❑ Has the owner been instructed on the proper operation and maintenance of the unit? Be sure to leave this manual with the owner. 18-EB31 D1-1 C-EN 27 Sequence of Operation General Operation of the system cooling (and optional heating) cycles is controlled by the setting of the system switch on the room thermostat. Once the system switch is placed either in the "HEAT" or "COOL" position, unit operation is automatic. A fan switch on the thermostat also provides for continuous operation of the evaporator fan when desired. The fan switch "ON" position provides continuous operation while the "AUTO" position provides operation during the heating or cooling cycles. Heating Cycle Thermostat call for heat (R) and (W) thermostat contacts close signaling the control module (IGN) to run its self -check routine. After the control has verified that the pressure switch (PS) contacts are open, the limit switch (TCO) contacts are closed, and the flame rollout (RO) switch is closed, the induced draft blower (CFM) will be energized. After the induced draft blower (CFM) has come up to speed, the control will verify that the pressure switch (PS) contacts are closed and run the induced draft blower for a 20 second pre -purge. The gas valve (GV) is energized to permit gas flow and the spark ignitor (IP) is energized. The flame detector (FD) confirms that ignition has been achieved within the 7 second trial period. As the flame detector confirms that ignition has been achieved the delay to indoor fan on period begins timing and after approximately 45 seconds, the indoor blower motor (IDM) will be energized and will continue to run during the heating cycle Thermostat satisfied: (R) and (W) contacts open signaling the control module to close the gas valve and de -energize the induced draft blower after approximately 5 seconds post -purge. The indoor blower motor will continue to operate at the current speed for 60 or 90 seconds (field selectable) after the flames are extinguished. Cooling Cycle With the room thermostat system switch in the "COOLING" position and the fan switch in the "AUTO" position, the compressor contactor (CC) and the indoor fan motor (IDM) are energized. The energized compressor contactor (CC) completes the circuit to the compressor (CPR) and a secondary circuit to the outdoor fan motor (ODM). If the compressor safety controls are closed, the compressor (CPR) will operate with the outdoor fan motor (ODM). The indoor fan motor (IDM) will operate. The thermostat will continue to cycle the compressor and fans to maintain the desired temperature. With the thermostat fan switch in the "ON" position, the indoor fan motor (IDM) will continue to run regardless of compressor and condenser fan operation. Safety Sequences This product is equipped with safety devices to protect against abnormal conditions. The temperature limit switch (TCO) is located on the blower barrier, and can be accessed through the blower compartment. This automatic reset device protects against excessive leaving air temperature. If this device opens, the gas valve is immediately closed and will not permit operation until the limit switch closes. The rollout switch (RO) is located in the gas compartment near the inlet of the burners. This is a manual reset device designed to protect against any form of flame rollout. If this device is opened the gas valve is immediately de -energized and the control (IGN) will lockout the system. The rollout switch (RO) must be reset before operation is allowed to continue. The pressure switch (PS) is located in the upper right side of the gas compartment. This automatic device assures adequate combustion air pressure. If pressure against the induced draft blower outlet becomes excessive, the pressure switch will react and shut off the gas valve, until acceptable combustion pressure is again available. If the control (IGN) does not sense flame within the first trial for ignition period, the gas valve will be de - energized. The control (IGN) will initiate a 60 seconds interpurge. Following the interpurge, the control will perform a second ignition attempt. If the second try is not successful, the control will start another 60 second interpurge. After the interpurge, a third attempt will be tried. If the third try is not successful, the control will lock out. If loss of flame occurs during a heating cycle, the control (IGN) will close the gas valve and cycle through the ignition trial as stated above. If control lock out occurs, the control (IGN) will retry a complete ignition sequence in 1 hour. The control (IGN) can be reset by removing power to the unit or by turning the thermostat from "on" to "off" for approximately three seconds, then back "on". Service Maintenance Service maintenance should be performed by qualified service personnel. Cooling Season To keep the unit operating safely and efficiently, the manufacturer recommends that a qualified service technician check the entire system at least once each 28 18-EB31 D1-1 C-EN Sequence of Operation year or more often if needed. The service technician should examine these areas of the unit: • filters (for cleaning or replacement) • motors and drive system components • economizer gaskets (for possible replacement) • safety controls (for mechanical cleaning) • electrical components and wiring (for possible replacement and connection tightness) • condensate drain (for proper sealing and cleaning) • unit duct connections (to see that they are physically sound and sealed to the unit casing) • unit mounting support (for structural integrity) • the unit (for obvious unit deterioration) Heating Season Complete the following unit inspections and service routines described at the beginning of each heating season. • Visually inspect the unit to ensure that the airflow required for combustion and condenser coil is not obstructed from the unit. • Inspect the control panel wiring to verify that all electrical connections are tight and that the wire insulation is intact. • Check the operation of the gas ignition system as follows: Turn off the gas supply with the unit operating to verify that the gas valve closes and that a re -ignition cycle is initiated by the unit. • Visually inspect the inside of the burners and the burner ports for deposit buildup and corrosion. Wipe and brush the inside of the burner and the burner ports and then clean with a dry cloth. If the deposit buildup or corrosion is excessive, replace the burners. Flue Hood and Combustion Blower Cleaning Never use combustible cleaning fluids on any part of the furnace. Before each heating season, the flue should be inspected for signs of flaking rust and soot deposits. Dirty flues should be cleaned by qualified service personnel ONLY using the following procedure: 1. Turn the comfort control to OFF. Turn the main power disconnect OFF. Turn the manual gas valve OFF. 3. Remove the combustion blower assembly from the flue box. Remove the flue box and the flue restrictors. 4. Remove all wires from the gas valve while carefully noting their locations. 5. Disconnect the gas supply line from the valve. 6. Remove the manifold retaining screws and pull the burner -manifold assembly from the heat exchanger. 7. Remove the inlet turbulators being careful not to break or damage them. 8. Wipe the flue box and flue baffles clean with a clean, dry cloth. 9. Replace all gaskets with new ones. 10. Replace all damaged or broken turbulators with new ones. 11. Reassemble the unit by reversing Steps 2 through 7 above. Take care that all gaskets seat properly. 12. Check all wires for correct installation by referring to the unit's electrical wiring diagram in the SERVICE FACTS. 13. Leak test all gas line connections with a soap and water solution or the equivalent. 14. Re -install the CONTROL/HEAT access panels and the flue hood. 15. Visually inspect the unit to ensure that the airflow opening for combustion is not obstructed. 16. Follow "Step 5 — Unit Startup," p. 26to place the unit back in service. Indoor Fan Motor (IDM) Speed Tap Setting The 208/230 units are factory set to medium speed. 208/230 Volt Motor Tap Settings () High speed setting: On the IGN board: 1. Connect the "RD" wire to the "PARK" terminal. 2. Connect the (IDM) PR wire to the "BLOWER LOAD" terminal. Low speed setting: On the IGN board: 1. Connect the "RD" wire to the "BLOWER LOAD" terminal. 2. Remove the flue hood and the CONTROL/HEAT 2. Connect the (IDM) PR wire to the "PARK" terminal. access panel. 18-EB31 D1-1 C-EN 29 Sequence of Operation YL (CC1) RE ( CC, ) RE (IDM) PR Figure 17. 208/230 Volt Speed Taps RD LOAD JINDUCER PARK IGN ORANGE IN E IN IGN GNDt GR LITE PORT STATUS C a C A LED LED k6o- COOLHEAT (IDM) PR� YL INDUCER PARK (CC1) R IN ( CC1) R IN IGN BLLOADR RD LITE PORT STATUS (::�p C511 LED LED HEAT 064"- COOL Table 13. IGN LED Diagnostic Indicators G W Y R B TH GN E GND G W Y R B TH TR GR WH YL RD EL OR BL ORANGE GR GR WH YL RD EL OR 3L Status LED Liteport LED Steady OFF Check Power or Failed Board 2 Flashes System Lockout: Failed to detect or sustain flame Slow Flash Rate Normal, No Call for Heat 3 Flashes Pressure switch problem detected Fast Flash Rate Not used 4 Flashes High Limit switch protection device open Steady ON Normal, No Call for Heat 5 Flashes Flame sensed and gas valve not energized or "W" flame sensed and no signal. 6 Flashes Flame Rollout Switch open 7 Flashes Thermostat miswired; W! & W2 Fast Flash Rate: The LED will flash on for 1/4 second and off for 1/4 second. Slow Flash Rate: The LED will flash on for 3/4 second, then offfor 1/4 second. The pause between groups of fast flashes is 3 seconds. 30 18-EB31D1-1C-EN Notes 18-EB31 D1-1 C-EN 4B)Ingersoll Rand® Ingersoll Rand (NYSE: IR) advances the quality of life by creating comfortable, sustainable and efficient environments. Our people and our family of brands — including Club Caro, Ingersoll Rand@, Thermo King@ and Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency. We are a global business committed to a world of sustainable progress and enduring results. APIngersoll Rand T, THERMO KING 0 TXWE® ingersollrand.com c ETA us Intertek Ingersoll Rand has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices. 18-EB31D1-1C-EN 15Sep2017 Supersedes18-EB31D1-1B-EN (August2015) ©2014Ingersoll Rand