TRANE Package Units(both Units Combined) Manual L0903060

User Manual: TRANE TRANE Package Units(both units combined) Manual TRANE Package Units(both units combined) Owner's Manual, TRANE Package Units(both units combined) installation guides

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STALLATI

OP RATIO

TCE

18-BG02D1-5

ALL phases of this installation must comply with

NATIONAL, STATE AND LOCAL CODES

Model: DCY024F1 Single Package Dual Fuel

DCY030FI Heat Pump Convertible

DCY036F1,3,4

DOY048F1,3,4 BAYLIFT002AA 2 - 5Ton 12 SEER

DCY060F1,3,4 LIFTING LUG KIT

IMPORTANT -- This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of work.

All phases of this installation must comply with

the NATIONAL, STATE &LOCAL CODES.

In the absence of local codes, the installation

must conform with National Electric Code --

ANSI/NFPA 70 or "LATEST REVISION':

OTlCE

Warnings and Cautions appear at appropriate locations throughout this manual.

Read these carefully.

_,WARNING: Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

,_CAUTION: Indicates a potentially hazardous situation which, if not avoided, may

result in minor or moderate injury. It may also be used to alert against unsafe practices

and where property-damage-only accidents could occur.

10/03

GENERAL INFORMATION

IMPORTANT: Read this entire manual before

beginning installation procedures.

kWARNING: BOD,LY,NJURYCANRESU'TFROM

HIGHVOLTAGE ELECTRICAL COMPONENTS, FAST MOVING FANS,

AND COMBUSTIBLE GAS. FOR PROTECTION FROM THESE

INHERENT HAZARDS DURING INSTALLATION AND SERVICING,

THE ELECTRICAL SUPPLY MUST BE DISCONNECTED AND THE

MAIN GAS VALVE MUST BE TURNED OFF. IF OPERATING CHECKS

MUST BE PERFORMED WITH THE UNIT OPERATING, IT IS THE

TECHNICIANS RESPONSIBILTY TO RECOGNIZE THESE HAZARDS

AND PROCEED SAFELY.

Read this manual carefully before attempting to install, operate,

or perform maintenance on this unit. Installation and mainte-

nance should be performed by qualified service technicians

only.

As shipped from the factory, this unit is for use with natural gas

only, and is listed by Underwriters Laboratory.

Model DCY-F heating/cooling 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-22 as

shipped.

INSPECTION

1. Checkfor damage after the unit is unloaded. Report promptly,

to the carrier, any damage found to the unit. Do not drop the

unit.

iMPORTANT: The use of "spreader bars" is required

when hoisting the unit (to prevent damage to sides and

top).

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.

The following warning complies with State of California law, Proposition 65.

kWARNING: This product contains

fiberglass wool insulation! Fiberglass dust and ceramic

fibers are believed by the State of California to cause

cancer through inhalation. Glasswool fibers may also

cause respiratory, skin, or eye irritation.

PRECAUTIONARY MEASURES

• Avoid breathing fiberglass dust.

• Use a NIOSH approved dust/mist respirator.

• Avoid contact with the skin or eyes. Wear long-

sleeved, loose-fitting clothing, gloves, and eye

protection.

3. Check to be sure the refrigerant charge has been retained

during shipment. Access to 1/4" flare pressure taps may be

gained by removing the furnace compartment access panel.

IMPORTANT: DO NOT CONNECT GAS PIPING TO THE UNIT

UNTIL A LINE PRESSURE TEST HAS BEEN COMPLETED.

DAMAGE TO THE GAS VALVE MAY RESULT IN AN UNSAFE

CONDITION. THIS UNIT SHOULD NEVER BE EXPOSED TO

GAS LINE PRESSURE IN EXCESS OF 13.8 INCHES WATER

COLUMN. (1/2 PSIG)

IMPORTANT: RECONNECT ALL GROUNDING DEVICES.

ALL PARTS OF THIS PRODUCT 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 ORIGI-

NAL POSITION AND PROPERLY FASTENED.

IMPORTANT: ALL POWER LEGS MAY NOT BE BROKEN BY

CONTACTORS. SEE WIRING DIAGRAM ON UNIT CONTROL

BOX COVER.

THIS UNIT, AS SHIPPED FROM THE FACTORY, IS DE-

SIGNED FOR NATURAL GAS ONLY.

BEFORE STARTING THE COMPRESSOR, THE CRANKCASE

HEATER SHOULD BE ENERGIZED FOR EIGHT HOURS

The following warning complies with State of California law, Proposition 65.

WARNING: HazardousGasses!

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.

• Wash clothes separately from other clothing: rinse

washer thoroughly.

Operations such as sawing, blowing, tear-out, and

spraying may generate fiber concentrations requiring

additional respiratory protection. Use the appropriate

NIOSH approved respirator in these situations.

FIRST AID MEASURES

Eye Contact Flush eyes with water to remove dust.

If symptoms persist, seek medical

attention.

Skin Contact Wash affected areas gently with soap

and warm water after handling.

Page 2Dwg. No. X664366 P01

TYPICAL ROOFTOP iNSTALLATiON WiTH FULL PERIMETER CURBS

• FIELD SUPPLIED

SUPPORTS

AT EACH END

OF CURB

SUPPLIED

CANT STRIP

FIELD SUPPLIED

RIGIDINSULATiON

SUPPLY AIR _ RETURN AIR

DUCT _ DUCT

ROOF MOUNTING

CURB

TYPICAL ROOFTOP iNSTALLATiON WiTH BAYCURB030/38A

SEE NOTE 1

SEE NOTE 2

•FIELD SUPPLIED

SUPPORTS

AT EACH END

OFCURB

FIELD SUPPLIED

RIGIDINSULATION

NOTES:

1. The DCY024-042F models extend out past this end of

the curb ONLY.

2. Only theDCY048F,060F models extend past both the

end and the side of the curb as illustrated•

SUPPLY AIR

DUCT

RETURN AIR

DUCT

FIELD SUPPLIED

CANT STRIP

ROOFMOUNTING

CURB

Dwg. No. X664366 P01 Page 3

®DiMENSiONAL DATA

DCY024=060F Outline ==Rear

(All dimensions are in inches)

131M

ItOR I ZONTAL _/

SUPPLY

OPEN I NO DOWNFLC

SUPP[Y

OPEN I NC

SUPPLY &

RE[URN

HOR I ZONTAI

RETURN OPENING

APPEARANCE SURFACE

OF SUPPLY _ REIURN

PANEL

SECT. X-X

TYPICAL CROSS SECTION

OF SUPPLY _ RETURN

PERIMETER FI ANGES

ECONOM}ZER/Fll TER

ACCESS

GRAVI/Y

EVAPOF<AfOR COIL &:

BLOWER PANEL

67 MM

59 MM

_48 MM [1_] DIA. ENTRY

29 MM FOR 15MM [1/2] N.P.I,

I_] GAS CONNECTION

_CONDENSATE DRA}N FOR

19 MM [5X4"] FEMALE NPT

DOWNF[OW RETURN

OPENING

L &:M

DI MENS}ONAL

SURFACE (SEE 19 MM

TABLE} [_4] ..........................}

9=MM

SECT Y-Y

]YPlCAL CROSS SEC] ION

OF DOWNI::LOW SUPPLY

REiURN PE{ MEIER FLANG S

MODEL CORNER WEIGHT (LBS) UNIT A B CD E F G H J KL M NP

W1 W2 W3 W4 WEIGHT

DCYO24F-L 93 77 99 120 389 20-5/16 29-1/2

DCYO3OF-M 105 82 102 131 420 64 36 29-3/16 18-9/16 11-1/16 6-9/16 11-1/8 17 19-5/16 28-1/2 17-1/2 10 3 8-3/4

DCYO36F-H 106 84 109 136 435 19-13/1E 28-1/2

DCYO48F-H 135 114 144 170 563 25 29-7/32

65-118 45 33-3/8 21-1116 15-1/16 4-15/16 9-1/8 21-15/1( 20 14 3-112 8-5/16

DCYO6OF-M 140 114 144 174 572 25 29-7/32

Page 4 Dwg. No. X664366 P01

DiMENSiONAL DATA

DCY024=060F Outline ==Front

(All dimensions are in inches)

CON ROI BOX

ACC SS PANE

152 MM

[6}

HOLE FOR

CONDUIT

WIRES)

15 MM [

{UNIT CONTROl _.

GAS

ACCESS

CLEARANCE TO

COMBUSTIBLE MATERIAL

BOTTOM 0.0"

BACK 1.0"

LEFT SIDE 6.0"

RIGHT SIDE 6.0"

FRONT SIDE 12.0"

TOP 36.0"

140 MM

_ FLUE

(FIEI) NSTA LED)

_COMBUSI}ON

BLOWER ACCESS

\<25 MM [1"1 DIA. KO.

FOR 13 MM [//2] N,P.T,

GAS CONNECTION

_CONDENSER CO!L

OUARD

RECOMMENDED SERVICE CLEARANCE

BACK * 6.0"

LEFT SIDE 30.0"

RIGHT SIDE 24.0"

FRONT SIDE 30.0"

• 18" WITH FRESHAIR ACCESSORY

• 30" WiTH ECONOMIZER

MODEL A B C D E

DCY024F-L

DCY030F-M 64 36 29-3/16 14-1/2 27-1/2

DCY036F-H

DCY048F-H 65-1/8 45 33-3/8 14-13/16 27-15/16

DCY060F-M

KNOCKOUTS FOR 3/4" AND 1-1/4" CONDUIT

KNOCKOUTS FOR 3/4" AND 1-1/2" CONDUIT

Dwg. No. X664366 P01 Page 5

REQUIRED CLEARANCE FOR UNIT iNSTALLATiON

AND ROOF PENETRATION HOLE SiZE REQUIRED

SERVICE CLEARANCE & PENETRATION DIMENSIONS

MODEL NO. A B C D E F

DCY024-036F 2'-6" 2'-6" *6" 2'-6" 44" 25"

DCY048-060F 3'-6" 2'-6" *6" 3'-0" 50" 25"

* I'-6" WITH FRESH AIR ACCESSORY

* 2'-6" WITH ECONOMIZER

SERVOE SERVOE

WOOD NAILER

E _

_ E

OLE IN ROOF I

E E

LOCATIONS AND RECOMMENDATIONS

HORIZONTAL AIRFLOW APPLICATIONS

1. These units are design certified for outdoor installations. These

units may be installed directly on wood flooring oron Class A, Class

B, or Class C roof covering material. The discharge air from the

condenser fans must be unrestricted for a minimum of 3 feet above

the unit.

NOTE: The unit is shipped for horizontal installation. 1

The Air Inlet Hood in the combustion blower access panel must

have adequate clearance around the air opening into the combus-

tion area. See Outline Drawing, Figure 4.

Examine all flue product-carrying areas of the furnace, its vent

system, and the main burner for safe operation. A periodic inspec-

tion of the furnace should be made by a qualified service agency at

the start of each heating season.

Replacement parts list for this Dual Fuel Heat Pump, may be

obtained by contacting your local manufacturer representative.

NOTE: If any internal accessories are to be added to the unit,

install them at the shop if at all practical. J

2. Location of the unit must allow service clearance around it.

Clearance of the unit must be given careful consideration. See

Figures 3,4 and 5.

Page 6

IMPORTANT: Air outlet duct must have 1" clearance to corn=

bustible material downstream from the unit.

3. Check the handling facilities to ensure the safety of personnel

and the unit(s).

4. CAUTION MUST BE TAKE AT ALL TIMES TO AVOID PER-

SONAL INJURIES AND/OR DAMAGE TO EQUIPMENT

5. The unit must be mounted level for proper drainage of water

through the holes in the base pan.

6. The unit must not be exposed to direct roof water runoff.

7. 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.

8. Holes through exterior walls must be sealed in accordance with

local codes.

9. All fabricated outdoor ducts should be as short as possible

10. In locations where deep snows are encountered, raise the unit

a minimum of 12" off the roof, deck, or slab. This will reduce

the chance of the coil being blocked with snow. The water that

Dwg. No. X664366 P01

LOCATIONS AND RECOMMENDATIONS

occurs during the heat pump defrost cycle wilt have a better

chance of flowing from the vicinity of the unit.

11. Avoid locating the unit where snow tends to drift. This will

reduce the times when it is necessary for the customer to remove

the snow from around the unit.

12. A snow drift barrier may be installed around the unit to prevent

a buildup of snow on the sides of the unit. The barrier should be

sufficient distance from the unit to prevent restriction of airflow to

and from the unit.

13. Locate the unit so that water vapor that discharges upward

during defrost does not condense on windows and fog them or

cause icicles to form on overhangs.

CLEARANCES

1. The recommended clearances for single-unit installations are

illustrated in Figure 4. These minimum requirements are not only

an important consideration when determining unit placement, but

they are also essential to ensure adequate serviceability, maximum

capacity, and peak operating efficiency.

2. Any reduction of the unit clearances indicated in these illustra-

tions may result in condenser coil starvation or the recirculation of

warm condenser air. Actual clearances which appear to be inad-

equate should be reviewed with a local engineer.

3. See the unit's nameplate for the absolute minimum clearance

between the unit and any combustible surface(s).

IMPORTANT:

1. Remove the Flue and Air Inlet Hood with gasket from the return

air section of the unit.

The screws that attach the flue and air inlet hood will be installed in

their proper location at the factory. Therefore, they must be

removed and then used to attach the flue and the air inlet hood.

2. Remove the packaging material from the components and

secure the Flue and Air Inlet Hood with the gasket to the unit with

sheet metal screws as illustrated in Figure 6. See "Firing Rate

Selection" section for additional information.

NOTE: Outdoor air or other requirements during heating opera-

tion that result in supply air temperatures below 80 degrees F or

return air temperatures below 50 degrees F may cause flue gas

condensate to form and is to be avoided.

DOWNFLOW APPLICATION -=CURB MOUNTING

1. The Roof Mounting Curb, (field assembled

BAYCURB033,033,034A), or a field fabricated curb must be in

place before the unit it hoisted to the roof top.

2. 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. In addition, be sure to provide

sufficient height above the roof to prevent water from entering the

unit.

NOTE: This unit was shipped for horizontal installation. Convert

to downflow per these instructions:

Remove covers from the downflow supply and return air open-

ings and place them over the horizontal supply return air open-

ings (painted side out) and secure with sheet metal screws. See

Figure 6.

3. 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 acces-

sories. See Figures 1, 7, 8, 9, 10, and 11.

4. Be sure the hole in the structure for the ducts is large enough to

accommodate the fabricated ducts and the insulation surrounding

them. See Figure 4.

NOTE: If any internal accessories are to be added to the unit,

install them at the shop if at all practical.

5. These units are design certified for outdoor installation. These

units may be installed directly on wood flooring or on Class A, Class

B, or Class C roof covering material. The discharge air from the

condenser fans must be unrestricted for a minimum of 3 feet above

the unit.

The air inlet hood in the combustion blower access panel must

have adequate clearance around air openings into the combus-

tion area. See Outline Drawing, Figure 4.

Examine all flue product-carrying areas of the furnace, its vent

system, and the main burner for safe operation. A periodic

inspection of the furnace should be made at the start of each

heating season.

Replacement parts list for this Dual Fuel Heat Pump may be

obtained by contacting your local manufacturer representative.

6. Location dthe unit must allow for service clearance around it.

Clearance of the unit must be given careful consideration. See

Figures 4 and 5.

7. IMPORTANT: The air outlet duct must have one (1) inch

clearance to combustible material downstream from the unit.

8. 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.

9. Check the handling facilities to ensure the safety of personnel

and the unit(s).

10. Caution must be taken at all times to avoid personal injuries

and/or damage to the equipment.

11. The unit must be mounted level for proper drainage of water

through the holes in the base pan.

12. The unit must not be exposed to direct roof water runoff.

13. 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.

Dwg. No. X664366 P01 Page 7

LOCATIONS AND RECOMMENDATIONS

14. Roof flashing must be installed to seal the roof curb cavity and

must conform to local building codes.

15. Access and service clearances for the unit must be given careful

consideration when locating the duct entrance openings. Figures

4 and 5 provides unit dimensions.

16. All fabricated outdoor ducts should be as short as possible.

17. In locations where deep snows are encountered, raise the unit

aminimum of 12" off the roof, deck, or slab. This will reduce

the change of the coil being blocked with snow. The water that

occurs during the heat pump defrost cycle will have a better

chance dflowing from the vicinity of the unit. The roof mounting

curb used with the DCY-F models is approximately 14" high. This

is normally sufficient height to prevent snow blockage and addi-

tional clearance is not necessary.

18. Avoid locating the unit where snow tends to drift. The wilt

reduce the times when it is necessary for the customer to remove

the snow from around the unit. Make certain the customer

knows that snow accumulations should be removed from

the sides of the unit for best efficiency.

19. A snow drift barrier may be installed around the unit to prevent

a build up to snow on the sides of the unit. The barrier should be

sufficient distance from the unit to prevent restriction of airflow to

and from the unit.

20. Locate the unit so that water vapor that discharges upward

during defrost does not condense on windows and fog them

or cause icicles to form in inappropriate places.

CLEARANCES

1, The recommended clearances for single-unit installations are

illustrated in Figures 4 and 5. These minimum requirements are

not only an important consideration when determining unit place-

ment, but they are also essential to ensure adequate serviceabil-

ity, maximum capacity, and peak operating efficiency.

2, Any reduction of the unit clearances indicated in these illustra-

tions 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 sales engineer.

IMPORTANT:

1. Remove the Flue and Air Inlet Hood with the gasket from the

return air section of the unit.

The screws that attach the flue and air inlet hood will be

installed in their proper location at the factory. Therefore,

they must be removed and then used to attach the flue and

air inlet hood.

2. Remove the packaging material from the components and

secure the Flue and Air Inlet Hood with the gasket to the unit with

sheet metal screws as illustrated in Figure 6.

NOTE: Outdoor air or other requirements during heating opera-

tion that result in supply air temperatures below 80 degrees F or

return air temperatures below 50 degrees F may cause flue gas

condensate to form and is to be avoided.

INSTALLATION

UNIT SUPPORT

If the unit is to be roof mounted, check the appropriate building

codes for weight distribution requirements. Refer to the applicable

roof curb mounting instruction. Check the unit's nameplate for

supply voltage required. Determine if adequate electrical power is

available. The furnace may be installed on Class A, B, or C roofing

material.

LOCATION AND CLEARANCES

Installation dthe unit should conform to local building codes or, in

the absence of local codes, to the National Fuel Gas Code,

ANSlZ223.1, Latest Revision, and the National Electrical Code.

Canadian installations must conform to CSA and local codes.

Select a location that will permit adequate combustion and ventila-

tion air in accordance with Section 5.3, Air For Combustion and

Ventilation, of the National Fuel Gas Code, ANSlZ223.1, Latest

Revision, or applicable provisions of the local building code.

PLACING AND RIGGING

1. Before preparing the unit for lifting, check the outline drawing for

center of gravity for lifting safety. Because of placement of

internal components, the unit's weight may be unevenly distrib-

uted. Approximate unit weights are given in Figure 3, page 4.

NOTE. Accessory BAYLIFTOO2AA, a k# of four (4) firing lugs, i_

required for rigging the unit for hoisting. See Figure 8, insert B. J

2, Insert the four lifting tugs in the openings provided in the drip lip

on the perimeter of the unit. See Figure 8, insert B. A tap or jerk

to the tug will overcome the interference that arises due to the

nipple on the lug.

3, Before hoisting the unit, be sure that the proper method of rigging

is used, with straps or 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.

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 a 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.

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.

Page 8 Dwg. No. X664366 P01

FLUE AND HOOD iLLUSTRATiON

OUILE] FLUE

F!UE DUCT

GASKET F UE DUCT

TOP ACCESS PANEL-

NOTES:

1.THE OUTLET FLUE RESTRICTOR IS REQUIRED

WHEN THE FURNACE IS OPERATED ON LOW INPUT

(AN OUTLET FLUE RESTRICTOR MAY BE REQUIRED

ON HIGH INPUT).

TO INSTALL THE OUTLET FLUE RESTRICTOR,

REMOVE THE TOP ACCESS PANEL AND FIT THE

OUTLET FLUE RESTRICTOR OVER THE OUTLET OF

THE FLUE DUCT. REASSEMBLE THE TOP ACCESS

PANEL ONTO UNIT.

FLUE_

INLET HOOD .......

GASKET

CONVERTING HORIZONTAL TO DOWNFLOW

C665474 REV. 1

From Dwg. 21C663474 Rev. 1

HEATER EXCHANGER

TUBES

NOTE

SUPPLY OPENING

1. REMOVE THE SCREW NEAREST TO

THE OPENING AND PULL THE PANEL

FIRMLY TOWARD THE OUTSIDE OF

THE UNIT TO DISENGAGE THE BACK

ATTACHMENT

RETURN OPENING

2. REMOVE RIGHT HAND SCREW AND

MOVE PANEL TO THE RIGHT OR RE-

MOVE BOTH SCREWS

HORIZONTAL SUPPLY

AIR COVER

SHEET METAL

SCREWS HORIZONTAL RETURN

AIR COVER

Dwg. No. X664366 P01 Page 9

iNSTALLATiON

SPREADER BARS

OUTDOOR COIL

END OFUNIT

)_ BAYLIFT002_

DIMPLE LIFTING LUGS

GASKET SEAL

NOTE:

THE INNER PERIMETER OF THE DRIP LIP ON ALL UNITS SHOULD

BE FLUSH WITH THE OUTER PERIMETER OF THE CURB ON THE

TWO SIDES SHOWN HERE UNITS WILL OVERHANG WHEN IN-

STALLED ON BAYCURB030 AND 038

BASE OF UNIT DRIP LIP ON

REST ON TOP OF PERIMETER OF UNIT

CURB RAILS

/ 1 / , UNIT CORNER

CURB CORNER

IIII_.j!_!

EXISTING

SHEET METAL

ISCREW

HOLD-DOWN

BRACKET WITH

CURB

FLANGE OF

CURB

Page 10 Dwg. No. X664366 P01

iNSTALLATiON

IMPORTANT: "Spreader Bars" must be used when hoisting |

the unit. 1

6. IMPORTANT: The unit must be lowered into position. The

P.V.C. rubber tape on the curb flange permits the unit to be

reposJtioned ifrequired without destroying the P.V.C. rubber

seals affixed to the mounting curb.

PLACING THE UNIT ON AMOUNTING CURB

1 The unit is designed with a perimeter drip lip that is Sowerthat the

unit base bar, see Figure 8, inset A.

2. Position the unit drip tip down over and in contact with the outside

corner of the curb, as illustrated in Figure 9, insert A. 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 dthe curb. The unit

should now rest on top of the curb.

3. Take the two (2) hold-down brackets shipped with the curb and

secure the unit to the curb with hold-down brackets as illustrated

in Figure 9, insert A.

ROOFTOP UNITS

For roof top applications using a field fabricated frame and ducts,

use the following procedure:

1. The frame must be located and secured by bolting or welding to

the roof. Flashing is required.

2. The hole in the roof must be prepared in advance of installing the

unit.

3. Secure the ducts to the roof.

4. Place the unit on the frame or roof curb. Refer to Figures 9 or 10.

5. Secure the unit to the frame or roof curb.

6. 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.

7. Complete the installation according to the instructions in the

following sections of this manual.

WEATHER-PROOF

DUCT

ROOF FLASHING

TYPICAL ROOFTOP APPLICATIONS WITH FRAME

(DCY024=060F)

RETURN AIR SUPPLY AIR

FLUE

-\\ .

INLET HOOD

ANGLE IRON

4/ FRAME

Dwg. No. X664366 P01 Page 1

iNSTALLATiON

®TYPICAL ROOFTOP APPLiCATiON WiTH FRAME

(DCY024=060F MODELS)

\FLUE

__ INLET HOOD

WEATHER-PROOF

DUCT

ROOF FLASHING

RETURN AIR

ROOF FLASHING

SUPPLY AIR

FRAME

®TYPICAL GROUND LEVEL APPLiCATiON

(DCY024=060F MODELS)

SUPPLY AIR

RETURN AIR DUCT

DUCT

SIDING I"_"'I!_

OUTDOOR AIR

DISCHARGE

EXTERIOR

WALL

INSULATE

WEATHERPROOF

OR RAIN SHIELD

FLEXIBLEDUCT

CONNECTORS

ISOLATORS

(1PERCORNER

AND1 UNDER

UNITCONTROLBOX)

OUTDOOR AIR

INTAKE

HOOD

SUPPORT PAD

FOUNDATION

Page 12 Dwg. No. X664366 P01

iNSTALLATiON

GROUND LEVEL =- HORIZONTAL UNITS

For ground level installations, the unit should be positioned on a pad

the size of the unit or larger. The unit must be level on the pad. The

pad must not come in contact with the structure (See Figure 12.) Be

sure the outdoor portion of the supply and return air ducts are as

short as possible.

Proceed with the installation as follows:

1. Place the unit on the pad and the five (5) rubber isolators

provided.

2. Attach the supply and return air ducts to the unit.

3. Insulate any ductwork outside of the structure with at least 2

inches of insulation and weatherproof. There must be a weath-

erproof seal where the duct enters the structure.

4. Complete the installation according to the instructions in the

following sections of this manual.

DUCTWORK

ATTACHING DOWNFLOW DUCTWORKTO 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.

Follow these guidelines for ductwork construction:

Connections to the unit should be made with three-inch canvas

connectors to minimize noise and vibration transmission.

Elbows with turning vanes or splitters are recommended to mini-

mize air noise and resistance.

The first elbow in the ductwork leaving the unit should be no closer

than two feet from the unit, to minimize noise and resistance.

AIR PROOF \

THIS SEAM

T BASE

FIELDDUCT1 XU_

FLANGE

_1_ /AIR PROOF

UN,TFLANGEDUCT_ ......7"if_BASE

FIELD DUCT

/AIR PROOF

THIS SEAM

FIELDDucT_._ _T BASE

L[ UNiT DUCT FLANGE

NIT BASE

UNIT DUCT ' !r_.

FLANGE /II \WATERPROOFSEAM

/II WITH BUTYL OR

,#.npn _ SILICONE

NOT RECOMMENDED FIELD DUCT

DOWNFLOW

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.

i NOTE: Do not draw the canvas taut between the solid ducts, i

_UNIT EXTERIOR

/II WEATHERPROOF

F,ELOjC?SEAM

T EXTERIOR

II \ UN,TDUCTFLANOE

tk WEATHERPROOF

lJ _ TH_SSEAM

"FIELD DUCT

HORIZONTAL

Dwg. No. X664366 P01 Page 13

CONDENSATE DRAIN PiPiNG

A 3/4-inch female NPT condensate drain connection is provided on

the evaporator access panel end of the unit. See Figure 2. 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 Figure 13.

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 not be connected to closed drain system.

®TYPICAL CONDENSATE PiPiNG

3/4"PVC OR COPPER

TUBING AND

1-1/2" MIN.

FILTER INSTALLATION

AiR FILTERS

Filters are to be used with the DCY024=060F heating/cooling units.

The basic unit does not have filters in it. However, a filter frame

accessory is offered that will allow filters to be installed within the

unit.

Otherwise a filter rack must be installed by the installer in the duct

work.

Affix the filter label supplied with the unit adjacent to the filter area.

UNIT NOMINAL FILTER* FILTER

CFM (Sq Ft) SIZE RESISTANCE

DCY024F 800 2.67 0.05

DCY030F 1000 3.33 0.05

DCY036F 1200 4.00 0.05

DCY048F 1600 5.33 0.05

DCY060F 2000 6.67 0.05

*Filters must be installed in the return air s, stem. 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.

FIRING RATE

All units are capable of firing at a tow or high rate. Check the unit

name-plate, to verify the firing rate of the unit as shipped from the

factory.

If the other input rate is desired, the conversion is made as follows:

1. Be sure the unit disconnect is open.

2. Be sure the gas valve is closed.

3. Remove furnace access panel.

4. Remove the presently installed gas orifices and replace with the

new gas orifices from the tow fire kit. The orifices should extend

1/4 inch out of the manifold for burner support.

5. For low fire operation an OUTLET FLUE RESTRICTOR (packed

in the towfire kit) must be installed (see Figure 6 on page 9). For

high fire operation on a few models a different OUTLET FLUE

RESTRICTOR may have been required.

SELECTION

6. Reinstall the furnace access panel.

7. Open the gas valve.

8. Close the unit disconnect.

9. Follow the heating cycle instructions to test unit's function.

10.Mark an "X" below the new input column on unit nameplate.

Attach conversion label to the unit below the nameplate.

NOTE: Do not convert to high fire when the units are applied above

2000 feet above sea level.

Page 14 Dwg. No. X664366 P01

GAS PiPiNG iNSTALLATiON

CAUTION: Before making the gas pipe connection give

serious consideration to providing the required clearance

necessary to remove the access panels on the unit (e.g.,

economizer and filter access panels).

INOTE: 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 dinput adjustment must be

at least 5.0" W. C.(inches Water Column) for natural gas and

11" W. C. for propane.

PiPE DELIVERY SCHEDULE (NATURAL GAS ONLY'

IOTE: The following procedure and tables below 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 Table 1 below and insert in the following formula:

TABLE 1

MULTIPIER

MULTIPIERS TO BE USED

WHEN THE SPECIFIC

GRAVITY OF THE GAS IS

OTHER THAN 0.60

SPECIFIC

GRAVITY

.50

.55

.60

.65

1.10

1.04

1.00

.962

Furnace Input in BTUH

CFH =Gas Heat Content in BTU/Cu. Ft. X Multiplier

This witl give the factor for columns 2 through 6 in Table 2.

TABLE 2

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE LENGTH OF PIPE (feet)

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 tS BASED QN PRESSURE DROP QF 0.3 INCH W.C. AND 0.6 SP.GR. GAS

5. Using Table 2, select the pipe length nearest to yours.

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

diameter.

INOTE: If this is a propane application, consult your propane]

supplier for pipe sizes and deliveries. J

®BURNER & VALVE ILLUSTRATION

(TWO BURNERS SHOWN)

,-, ,,_r, _ _u_ / _ _,

NY: OI\ j/ " "

-I :*\C _'

T _ o S ! N ,

AFOR ..J

DETAIL "A"

GAS PRESSURE SET-UP PRECAUTIONS

WARNING: NEVERUSEANOPENFLAME

TO TEST FOR GAS LEAKS: AN EXPLOSION COULD

OCCUR, CAUSING INJURY OR DEATH.

IMPORTANT: The furnace and its individual shut-off valve

must be disconnected from the gas supply piping system

duff ng any pressure testing of that system at test pressures

exceeding 1/2 psig (3.48 kPa).

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 (ALL FUELS)

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 13.8 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 maximum pressure of 13.8" W.C. to

the gas valve for natural gas with a minimum supply pressure of 5.0"

W.C. Maximum supply pressure of 13.8" W.C. to the gas valve for

propane with a minimum pressure of 11.0" W.C.

NOTE: Maximum pressure to the gas valve for natural gas

is 13.8" W.C. Minimum pressure is 5.0" W.C. Maximum

pressure to the gas valve for propane is 13.8"W. C. Minimum

pressure to the gas valve is 11.0" W.C.

Dwg. No. X664366 P01 Page 15

GAS PiPiNG INSTALLATION

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 Figure 15.

1. Install a tapped, Style A (1/8-inch NPT tap) shut-off gas cock at

the end of the gas supply line near the unit. Be sure the tapped gas

cock is downstream of the pressure regulator, if used.

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.

2. Install a ground union joint downstream of the shut-off cock. This

joint must also be installed outside of the unit.

3. Install a drip leg at least six (6) inches in depth next to the union

as shown in Figure 15. This drip leg is required to collect any

sediment that may be deposited in the line.

4. Before connecting the piping circuit to the unit, bleed the air from

the supply line. Then cap or plug the line and test the pressure

at the tapped shut-off cock. The pressure reading should not

exceed 14 inches water column.

5. 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.

6. After installation of the gas pipe in the unit, the pipe chase

opening should be closed with the filler/barrier plug provided.

MANIFOLD PRESSURE

Check the manifold pressure at the unit gas valve. Do not exceed

the recommended pressure shown on the unit nameplate.

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 3 with the

time clocked.

4. Read the "Flow" column opposite the number of seconds clocked.

5. Use the following factors if necessary.

For 1 Cu. Ft. Dial Gas Flow CFH = Chart Flow Reading /2

For 1/2 Cu Ft. Dial Gas Flow CFH = Chart Flow Reading /4

For 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.

b. Remove the slot screw on top of the gas valve for 1st stage

manifold pressure adjustment.

c. Turn the adjustment nut IN to increase the gas flow rate, and

OUT to decrease the gas flow rate using a 3/32" hex wrench.

Page 16

(_) DIAGRAM OF GAS PiPiNG TO UNiT

DEALERINSTALLED

GROUND UNION

1/8"N.P.T.PLUGGED I

ACCESSFOR TEST I /

GAUGECONNECTION I

FROM _ /

GAL_PPLY _

FIELD SUPP_R_ LEG_ UNIT_

GAS VALVE, MUST BE

INSTALLEDBY DEALER

OUTSIDE UNIT.

TO MAIN

_" CONTROL

VALVE

TABLE 3

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

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

HIGH ALTITUDE INSTALLATION

Unit nameplate ratings are based on equipment operation from sea

level to 2000 feet elevation above sea level. If the unit installation

isfrom 2000 - 4500 feet elevation, itwill be necessary to change the

burner orifices to the noted sizes, (ref. National Fuel Gas Code, sec

8.1.2, Appendix F, Table F4).

GAS

TYPE

NATURAL

( high input )

NATURAL

( low input )

PROPANE

MANIFOLD

PRESSURE

(in. W.C. )

3.3

ORIFICE SIZE

0 - 2000 ft

42*

3.3 44

10.0 54

ORIFICE SIZE

2000 - 4500 ft

* FACTORY SHIPPED

Dwg. No. X664366 P01

ELECTRICAL WIRING

_OUNL_PO_,R

5 PI

PO_',E R

NOTE 2

WIRE _._ (._

NO; ,2

DCY-F FIELD WIRING DIAGRAM

NON-RESTRICTED MODE

NOTE 7

Ii,

PICA. EAT PJ_P

IHERMOS AI

o1:

[

_1"'1'DJ_I°ITIRI

/YP CAL I_AF P MP

I _ERMOS AT

NOTE 5

..... A(yL) Y (r RM NAi [A} ND

bOA(YL_ YX COV RFSSOR

Z__ ....... 56_ __L ) COMMON

Z_ 47At_K_ S FAN

Z_ 43A_SR) X2 E_ROLNCY HEAT _OASI

Z__ _OA_OR_ 0 SWl ICHOV_R VALVE

_:_-----55A_RD_ R 24V01 FS

RESTRICTED MODE

NOTE 8

LWl {ON IR( /}X

Z__ ......... _A Y[ (Oh R SO_

1_ ........ OA_YL, YX i: ERMINA LEAD END}

/_- ...... _.6B{St B couvou

.... £:3: 3_i::....................

40A{OR 0 S¢, TC O./ER VA ',

4 _{tR) )[I ROS ON iROL S (PAL

Z_---_ 5A { _,} I< 2£VOL /S

NOTES:

1. FUSED DISCONNECT SIZE, POWER WIRING AND

GROUNDING OF EQUIPMENT MUST COMPLY WITH

CODES.

2. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT

NAMEPLATE.

3. LOW VOLTAGE WIRING TO BE 18 AWG MINIMUM

CONDUCTOR.

4. SEE UNIT DIAGRAM FOR ELECTRICAL CONNECTION

DETAILS.

5. WHEN THE BAYECON054B OR --055B OR 073A

ECONOMIZER IS INSTALLED, THE BAYRLAY004 RELAY

ACCESSORY KIT IS REQUIRED TO INTERFACE THE

ECONOMIZER TO THE HEAT PUMP FOR PROPER

SYSTEM OPERATION.

6. THE OUTDOOR THERMOSTAT (ODT) SHOULD BE

LOCATED IN AN AREA WHICH WILL PROVIDE A

REPRESENTATIVE OUTDOOR TMPERATURE.

7. THE UNIT IS SHIPPED FROM THE FACTORY WITH THE

UNIT RELAY BOARD (RLB) IN THE NON-RESTRICTIVE

MODE. IN THE NON-RESTRICTIVE MODE ON A CALL

FOR FIRST STAGE HEAT (Y SIGNAL) THE UNIT WILL

OPERATE IN THE HEAT PUMP MODE. ON A CALL FOR

SECOND STAGE OF HEAT (W SIGNAL) THE HEAT PUMP

IS LOCKED OUT AND GAS FURNACE OPERATES TO

SATISFY BOTH STAGES OF HEATING.

8. THE SELECTOR PIN ON THE UNIT RELAY BOARD (RLB)

MUST BE MOVED TO THE "RESTR" POSTION

(RESTRICTED MODE). IN THE RESTRICTED MODE, THE

UNIT OPERATES IN THE HEAT PUMP MODE UNTIL THE

ODT SWITCHES, BASED ON THE OUTDOOR AMBIENT,

TO OPERATE THE GAS FURNACE FOR HEATING, THIS

HEATING MODE IS CONTROLLED BY THE ROOM

THERMOSTAT'S FIRST STAGE OF HEAT (Y SIGNAL)

ONLY.

[ ] E _ COl,,pO[ [ [ _ NO W RE O0 OR DE t5 ;IS[_/:_T 01i

ABBR COtOR ABBR CCXOR

() [

;[:R_¢CS _r ....... I N E ',, } ,'7 R i N(

IELD S _,LL Z/ I![ B[ E _1} I il}

_,t _ __ NE S GR GREEN Y YE IIO,/i

0 R _ Ii 13L:

TYmCA_ 2 ST_G_

ECONOMI ZER ACCESSORY

IO ZCO_ON'!ZR CONNECT _ONS

FAC OAY PROy I []E:[

RESTRICTED MODE

:NLII II L_ _ 5R{ L_

II I L .... _ _L_1_

II I

',_ F_ _-...........

I ", ..........

L........... _2_

----_SA_Sm

_II_ 7'_.... -..........

Dwg. No. X664366 P01 Page 17

ELECTRICAL WIRING

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.

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

ELECTRICAL POWER

It is important that proper electrical power be available for the unit.

Voltage variation should remain within the limits stamped on the unit

nameplate.

DISCONNECT SWITCH

Provide an approved weatherproof disconnect either on the side of

the unit or within close proximity and within sight of the unit.

OVER CURRENT PROTECTION

The branch circuit feeding the unit must be protected as shown on

the unit rating plate.

POWER WIRING

The power supply lines must be run in weathertight conduit to the

disconnect and into the bottom 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.

Ensure all connections are made tight. See Figure 16.

NOTES: For branch circuit wiring (main power supply to unit

disconnect), wire size for the length of run should be determined

using the circuit ampacity found on the unit nameplate and the

N.E.C.

For more than 3 conductors in a raceway or cable, see the N.E. C.

for derating the ampacity of each conductor.

GROUNDING: THE UNIT MUST BE ELECTRICALLY GROUNDED

IN ACCORDANCE WITH LOCAL CODES OR THE NATIONAL

ELECTRIC CODE.

NOTE: Unit must be grounded for igniter to operate prop- j

erly. Gas pipe to unit is not an adequate ground. Ground the Junit internally as provided. See wiring diagram for location.

CONTROL WIRING (CLASS ll)

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 gromment on the unit. See Figure 3 for the control entry

location. Make connections as shown on the unit wiring diagram

and in Figure 16.

Do not short thermostat wires since this wilt damage the control

transformer.

Recommended wire sizes and lengths for installing the unit thermo-

stat are provided in Table 3. The total resistance of these low

Page 18

TABLE 3

THERMOSTAT WIRE SIZE AND MAXIMUM LENGTH

WIRE SIZE MAXIMUM LENTGH (Ft)

18 75

16 125

14 200

THERMOSTAT HEAT ANTICIPATOR

The thermostat heat anticipators should be set to equal the amper-

age draw of the Wl thermostat circuit. Set to approximately 0.7

amps.

The control system is designed to allow the unit to be operated in two

different modes: restricted and non-restricted. A brief explanation

deach mode follows:

RESTRICTED: In the restricted mode of operation an outdoor

thermostat is used to cause the unit to operate in the heat pump

mode above a selected outdoor temperature and to operate in the

gas heating mode below the selected setpoint. The gas heat wilt

operate with the heat pump when the unit requires a defrost

operation. The gas heat is used to offset the effect of the unit going

into the cooling mode during defrost.

NON=RESTRICTED: This mode of operation allows the unit to

operate in the heat pump mode during the first call, or stage, of heat

by the indoor thermostat. If the thermostat can be satisfied by the

heat pump operation, the gas heat will not be required. If the

thermostat is not satisfied, the thermostat will bring on a call for the

second stage of heat. At that point, the gas heat will begin to operate

and the heat pump will be locked out. Both stages of the thermostat

will be satisfied by the gas heat. The heat pump will not operate until

the next call for first stage heat by the room thermostat. As in the

restricted mode, the gas heat will act as supplementary heat during

the unit's defrost cycle. The DCY-F units will be shipped from the

factory in the non=restricted mode. See the Field Wiring Dia-

gram, Figure 16.

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 doors before leaving the unit or turning

on the power to the unit.

After all electrical wiring is complete, set the thermostat system

switch in the OFF position so that the compressor will not run

and then apply power by closing the system main disconnect switch.

This will activate the compressor sump heat. Do not change the

Thermostat System Switch until power has been applied long

enough to evaporate any liquid R-22 in the compressor. It is

recommended that the sump heater be energized for eight (8) hours

prior to starting.

Dwg. No. X664366 P01

START-UP

PRE-START QUICK CHECKLIST

•Is the unit properly located and level with the proper clearance?

See Figures 4 and 5.

• Is the duct work correctly sized, run, taped, insulated, and

weatherproofed with proper unit arrangement. See Ductwork

Installation section.

• Is the gas piping correctly sized, run, trapped, and purged of air?

See Gas Piping section.

• Is the condensate line properly sized, run, trapped, and pitched?

• Is the filter of the correct size and number? Is it clean and in

place?

• 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 recom-

mended fuse size? See Wiring Data.

• Is the thermostat level, correctly wired, welt located, and set for

the proper heat anticipation?

• 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? See the Unit Wiring Diagram.

• 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 THE COOLING MODE

CAUTION: Before starting the system on the cooling cycle, turn the

thermostat switch to OFF and close the unit disconnect switch. This

procedure energizes the compressor crankcase heater, vaporizing

any liquid refrigerant in the crankcase. This is a precaution against

foaming at start-up which could damage the compressor bearings.

Allow the heater to operate a minimum of eight (8) hours.

NOTE: See the section on "Sequence of Operation" for a descrip-

tion 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 (outdoor) fan

motor compressor and evaporator (indoor) fan motor wilt operate

automatically.

VOLTAG E

With the compressor operating, check the line voltage at the unit.

The voltage should be within the range shown on the unit name-

plate. 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.

OPERATING PRESSURES

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. Check the suction and discharge pressures

and compare them to the normal operating pressures provided in

the unit's SERWCE FACTS.

NOTE: Do not use the pressures 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, use superheat charging or weigh the charge.

COOLING SHUT DOWN

Place the system selector in the OFF position or reset thermostat at

a setting above room temperature.

Do not de-energize the main power disconnect except when unit it

to be serviced. Power is required to keep the heat pump compres-

sor warm and boil off refrigerant in the compressor.

GAS FURNACE HEATING CYCLE

NOTE: See Sequence of Heating Operation.

These units are equipped with a solid-state ignition control that

lights the burners each time the thermostat calls for heat. The

burners are extinguished during the OFF cycle.

The gas heating section of the unit can be started using the following

procedure:

Be sure the thermostat is at its lowest setting and the power to

the unit is off.

a. Turn the main shut-off valve on the gas supply line ON.

b. Turn the manual valve on the combination gas valve ON

position.

Be sure the burner compartment access panel is in place.

a. Turn on the electrical power to the unit.

b. Turn the thermostat to the highest setting in the heating

cycle. (Note: The second stage heating must be ener=

gized to bring on the gas furnace in the non=restricted

mode.)

c. Turn the thermostat switch to emergency heat (x2).

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.

With the burners operating, check the manifold pressure with a

manometer. Do not exceed recommended pressures.

Adjust the unit to obtain an air temperature rise with that

specified on the unit nameplate.

NOTE: For manifold pressures and orifice sizes for gas with

other BTU ratings, contact the local gas utility. Manifold pres-

sure should be 3.3 inches water column (+0.1). Input must not

exceed the value shown on the rating plate.

Set the heat anticipator of the thermostat to equal the amperage

draw of the gas valve, approximately 0.7

Set the thermostat at the desired temperature setting and the

unit will function automatically.

Dwg. No. X664366 P01 Page 19

START-UP

STARTING THE UNIT IN THE GAS HEATING MODE

1. Check to make sure all grilles and registers are open and all unit

access doors are closed before start-up.

2. Purge the gas supply line of air by opening the union ahead of

the unit. When the odor of gas is detected, retighten the union

and wait five (5) minutes before proceeding.

3. Set the wall thermostat to its lowest position and place the fan

switch in the AUTO or ON position.

3. Check the temperature rise during furnace operation to insure

that it falls within the range specified on the unit nameplate.

4. If the temperature rise noted is outside of the specified limits,

adjust the indoor air flow to cause the temperature rise of the

heat exchanger to fall within the required range.

Set the thermostat to the desired setpoint. The unit will automati-

cally function in the heating mode.

4. Open the main gas valve(s) and turn on the unit power supply.

5, Reset the heating temperature lever on the room thermostat at

the highest value above room temperature. The combustion

blower motor should energize. The main burners should light

within 20-25 seconds. Initial start may be delayed somewhat if

the unit has not been purged and air is trapped in the gas line.

NOTE: Blue smoke produced by the heat exchanger during the

initial burner firing is caused by a thin film of off on the surface

of the heat exchanger. This off will bum off quickly.

6. Cycle the thermostat OFF and ON a few times at a rate of not

more than once every thirty (30) seconds. Check both the

control operation and the burner operating conditions.

STARTING THE UNIT IN

THE HEAT PUMP HEATING MODE

NOTE. See the section on "Sequence of Operation" for a

description of the heat pump heating operating sequence.

Check to make sure all grilles and registers are open an all unit

access doors are closed before start-up.

Slowly set the thermostat above room temperature until achieving

a first stage call for heat and place the fan switch in the AUTO or ON

position.

MANIFOLD PRESSURE

1. Connect a manometer to the pressure tap at the outlet side of

the unit's gas valve. Read the manifold pressure with the main

burners firing.

HEATING SHUT-DOWN

Place the system selector switch at OFF or place the heating

selector lever at a setting below room temperature.

2, If the manifold pressure reading does not match the value

indicated on the unit nameplate, the unit pressure regulator

must be adjusted as follows:

a. Remove the cover screw on the gas regulator located on the

front side of the unit's gas valve.

b. Turn the adjusting screw clockwise to increase manifold

pressure or counterclockwise to decrease manifold pres-

sure.

,&WARNING" DONOTOPERATETHEUNIT

WITHOUT THE EVAPORATOR FAN ACCESS PANEL IN

PLACE. REINSTALL THE ACCESS PANEL AFTER

PERFORMING ANY MAINTENANCE PROCEDURES ON THE

FAN. OPERATING THE UNIT WITHOUT THE ACCESS

PANEL PROPERLY INSTALLED MAY RESULT IN SEVERE

PERSONAL INJURY OR DEATH.

GENERAL

SEQUENCE OF OPERATION

Operation of the unit heating and cooling cycles is automatic

for HEAT and COOL functions. (The optional automatic

changeover thermostat, when in the AUTO position, auto-

matically changes to heat or cool with an appropriate indoor

temperature change.) The fan switch can be placed in either

the ON position, causing continuous evaporator (indoor) fan

operation, or the AUTO position causing fan operation to

coincide with the heating or cooling run cycles

COOLING CYCLE

(NOTE: TSH & TSC are contacts internal to the indoor

thermostat.)

(SOV) and places it in the cooling position. (The switchover

valve is in the heating position when not energized.)

When the indoor temperature rises 1-1/2 degrees, the TSC-

2 contacts close thereby supplying power to the "Y" terminal

on the indoor thermostat and to the compressor contactor

(CC). This starts the outdoor fan motor and compressor. The

TSC-2 contacts also energizes the "G"-(IGN) on the control

module and starts the indoor fan motor.

HEATING MODE

TWO MODES OF OPERATION:

With the disconnect switch in the ON position, current is

supplied to the compressor crankcase heater and control

transformer. The cooling cycle is enabled through the low

voltage side of the control transformer to the "R" terminal on

the indoor thermostat. With the system switch in the AUTO

position and TSC-lcontacts closed, power is supplied to the

"O" terminal on the indoor thermostat to the switchover valve

The control system is designed to allow the unit to be

operated in two different modes: restricted and non-re-

stricted. A brief explanation of each mode follows.

NON-RESTRICTED HEAT PUMP OPERATION:

Any time ( regardless of outdoor temperature ) that second

stage of heat is called for, the heat pump is cut offand the gas

Page 20 Dwg. No. X664366 P01

SEQUENCE OF OPERATION

furnace operates until both stages are satisfied. This provides

for a normal off cycle the thermostat. As in the restricted

mode, the gas heat will act as supplementary heat during the

unit's defrost cycle. The DCY=F units will be shipped from

the factory in the non=restricted mode.

RESTRICTED HEAT PUMP OPERATION:

This mode of operation allows the heat pump to operate only

at outdoor temperatures above the setting of an outdoor

thermostat. At the lower outdoor temperatures, only the gas

furnace can operate. The gas heat will act as supplementary

heat during the unit's defrost cycle.

NOTE: The outdoor thermostat should be located in an area

which will provide a representative outdoor ambient tempera-

ture reading.

SEQUENCE OFHEATING OPERATION

NON-RESTRICTED MODE

With the disconnect switch in the ON position, current is

supplied to the compressor crankcase heater and control

transformers. Starting at the "R" terminal on the indoor

thermostat, current goes through the system switch (which is

in the AUTO position) to the TSH-1 contacts. When closed,

these contacts supply power to the "Y" terminal on the indoor

thermostat as well astothe heating anticipator. The switchover

valve will not energize because of the high resistance of the

heating anticipator in the thermostat. Power is provided from

"Y" to the compressor contactor (CC) which starts the out-

door fan motor and compressor. The indoor thermostat

contact TSH=I also provides power to the "G" terminal on the

indoor thermostat thereby energizing the "G"=(IGN) and

starting the indoor fan motor.

The gas heat is brought on when the indoor temperature

drops 1-1/2 degrees F below the thermostat setting. The

second stage heat TSH=2 contacts close and provide power

to the "W" terminal on the indoor thermostat and tothe W=IGN

on the control module.

On a "W" call for heat by the room thermostat, the control

module (IGN) runs 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

(FL) switch is closed, the induced draft blower (CBM) will be

energized.

As the induced draft blower (CBM) comes up to speed, the

pressure switch (PS) contacts will close. After approximately

20 seconds, for the induced draft blower (CBM) prepurge, the

gas valve (GV) is energized permitting gas flow to the burners.

concurrently, the spark ignitor (IP) is energized. The flame

detector (FD) confirms that ignition has been achieved within

the seven second trial period.

Upon opening of the gas valve (GV), the delay to the indoor

fan on period begins timing and after approximately 45 sec-

onds, the indoor blower motor (IDM)will be energized and will

continue to run during the heating cycle.

When the thermostat is satisfied, the gas valve (GV) will close

and the flame will extinguish. The induced draft blower (CBM)

will continue to run for a postpurge period of approximately 5

seconds than will be deenergized. The indoor blower motor

(IDM) will continue to run for fan off period (field selectable for

60 or 90 seconds), than will be de-energized by the control

module.

NOTE: On the indoor thermostat call for second stage heat,

the "G" signal to the IGN control module is disallowed by a

relay switch on the relay board (RLB). Fan is controlled by

normal sequence of gas furnace operation.

NOTE: On the indoor thermostat call for second stage heat,

the compressor circuit "Y" signal locks in the gas heat mode.

This allows the gas heat to satisfy both stages of call for heat

through the TSH=I and TSH=2 contacts.

Moving the indoor thermostat to the emergency heat position

energizes the "X2" terminal through the TSH-1 switch. The

"X2" terminal supplies power to W-IGN on the con trol module,

which starts the gas heating operation. The emergency heat

position converts the system to gas heating operation regard-

less of outdoor temperatures. The indoor temperature is

regulated by the indoor thermostat TSH=I switch.

RESTRICTED MODE

With the disconnect switch in the ON position, current is

supplied to the compressor crankcase heater and control

transformers. Starting at the "R" terminal on the indoor

thermostat, current goes through the system switch (which is

in the AUTO position) to the TSH-1 contacts. When closed,

these contacts supply power to the "Y" terminal on the indoor

thermostat aswell astothe heating anticipator. The switchover

valve will not energize because of the high resistance of the

heating anticipator in the thermostat.

If the outdoor ambient is above the set point of the outdoor

thermostat (ODT), power is provided from "Y" through the

(ODT) to the compressor contactor (CC) which starts the

outdoor fan and compressor. The indoor thermostat also

provides power to the"G" terminal which energizes the G=IGN

on the control module and starts the indoor fan motor.

If the outdoor ambient is at or belowthe set=point of the (ODT),

power is provided from "Y" through the (ODT) through the

relay board (RLB) to W=IGN on the control module.

On a "W" call for heat by the room thermostat, the control

module (IGN) runs its self-check routine. After the control has

verified that the pressure switch (PS) contacts are open, the

limit switch (TOO) contacts are closed, and the flame rollout

(FL) switch is closed, the induced draft blower (CBM) will be

energized.

As the induced draft blower (CBM) comes up to speed, the

pressure switch (PS) contacts will close. After approximately

20 seconds, for the induced draft blower (CBM) prepurge, the

gas valve (GV) is energized permitting gas flow to the burn=

ers. concurrently, the spark ignitor (IP) is energized. The

flame detector (FD) confirms that ignition has been achieved

within the seven second trial period.

Upon opening of the gas valve (GV), the delay to the indoor

Dwg. No. X664366 P01 Page 21

SEQUENCE OF OPERATION

fan on period begins timing and after approximately 45

seconds, the indoor blower motor (IBM) will be energized and

will continue to run during the heating cycle.

control will lock out. It can be reset by removing power to the

unit by turning the thermostat from "on" to "off" for approxi-

mately three seconds, than back "on". If not reset, the control

module will automatically reset in one hour.

When the thermostat is satisfied, the gas valve (GV) will close

and the flame will extinguish. The induced draft blower

(CBM) will continue to run for a postpurge period of approxi-

mately 5 seconds than will be deenergized. The indoor

blower motor (IDM) will continue to run for fan offperiod (field

selectable for 60 or 90 seconds), than will be de-energized by

the control module.

NOTE: On the indoor thermostat call for second stage heat,

the "G" signal to the IGN control module is disallowed by a

relay switch on the relay board (RLB). Fan is controlled by

normal sequence of gas fumace operation.

NOTE: On the indoor thermostat call for second stage heat,

the compressor circuit "Y" signal locks in the gas heat mode.

This allows the gas heat to satisfy both stages of call for heat

through the TSH-1 and TSH-2 contacts.

SAFETY SEQUENCES AND LIMIT CONTROLS

During the main burner operation, if gas is interrupted or

discontinued, the gas valve (GV) is de-energized instantly.

The ignition control module (IGN)then enters the retry mode.

The retry mode allows the control (IGN) to purge for 60

seconds. Following this time period, the valve is energized

and the spark is started. If the flame is not sensed by the

flame detector (FD) within (7) seconds the valve is de-

energized and the spark is stopped.

A second retry is then attempted. If this attempt at ignition is

unsuccessful, a third retry will be attempted after a prepurge

period. If this third attempt at ignition is unsuccessful, the

The temperature limit switch (TCO) protect against overheat-

ing if the indoor motor (IDM) fails to operate. Also afusible link

(FS) protects against flame rollout due to flue blockage.

These switches will interrupt the operation of the unit by de-

energizing the ignition control module (IGN) if overheating

OCCU rs.

The temperature limit switch (TCO) is located in the gas

compartment. This automatic reset device protects against

excessive leaving air temperature.

The fusible link (FS) is located in the gas compartment near

the burners. This is a single use device and is designed to

protect against any form of flame rollout.

DEMAND DEFROST OPERATION

During the heating cycle, the outdoor coil may require a

defrost cycle which is determined by the demand defrost

control (DFC). This control continuously measures the

outdoor coil temperature (CBS) and the outdoor ambient

temperature (ODS-B) and calculates the difference or

delta-T measurement. When the calculated delta-T is met,

the demand defrost control (DFC) opens the circuit to the

outdoor fan motor (ODM) and energizes the switch-over

valve (SOV), placing the unit in the cooling mode to defrost

the outdoor coil. The outdoor coil temperature sensor

(CBS) terminates the defrost cycle, or times off after

twelve minutes in defrost, the (DFC) energizes the outdoor

fan motor (ODM) and fifteen seconds later de-energizes

the (SOV), which returns the unit to the heating mode.

Supplementary gas heat is brought on to control indoor

temperature during the defrost cycle.

IGN LED DIAGNOSTIC INDICATOR

FLASHING SLOW NORMAL CALL FOR HEAT

CONTINUOUS ON NORMAL

CONTINUOUS OFF CHECK POWER /INTERNAL FAILURE

2 FLASHES SYSTEM LOCKOUT ( NO FLAME )

3 FLASHES PRESSURE SWITCH PROBLEM

4 FLASHES HIGH LIMIT (TCO) OPEN

5 FLASHES FLAME SENSED WITH GAS VALVE OFF

6 FLASHES FLAME ROLLOUT SWITCH (FL) OPEN

7 FLASHES W1 & W2 SWAPPED

Page 22 Dwg. No. X664366 P01

DEMAND DEFROST SYSTEM

DEFROST CONTROL

The demand defrost control measures heat pump outdoor ambient

temperature with a sensor located outside the outdoor coil. A

second sensor located on the outdoor coil is used to measure the

coil temperature. The difference between the ambient and the

colder coil temperature is the difference or detta-T measurement.

This detta-T measurement is representative of the operating state

and relative capacity of the heat pump system. By measuring the

change in delta-T, we can determine the need for defrost. The coil

sensor also serves to sense outdoor coil temperature for termina-

tion of the defrost cycle.

FAULT DETECTION

A fault condition is indicated by the flashing light on the defrost

control inside the heat pump control box.

In normal operation, the defrost control light wilt flash once each

second. If the light is flashing more than once per second or not-at-

all, refer to the service manual for that unit.

PIN IDENTIFICATION (See Figure)

1. TEST_COMMON (Shorting any of the other pins to this pin

causes the function of the other pin to be executed. Leaving this

pin open results in the normal mode of operation.)

2. TST = Test (Shorting TEST_COMMON to this pin speeds up

all defrost board timings.)

PiN IDENTIFICATION

FRC DFT

[]

TEST COMMON

TST

DEFROST CONTROL CHECKOUT

Normal operation requires:

a. LED on board flashing 1 time/second.

b. 24V AC between R & B

c. 24V AC between Y & B with unit operating

d. Defrost initiation when FRC_DFT pin is shorted to

TEST_COMMON pin.

If a defrost control problem is suspected, proceed to DEMAND

DEFROST CONTROL CHECKOUT in this Service Facts.

3. FRC_DFT = Forced Defrost (Short TEST_COMMON to this pin

for two (2) seconds to initiate a forced defrost. Remove the short

after defrost initiates.)

AWARNING: DO NOT connect 24 VAC toTI

(ODS-A) terminal.ODS-A thermistorWILL BE BLOWN.

PROCEDURE FORTESTING SENSORS

Measure the temperature the subject sensor is exposed to. If the sensor is mounted on a

tube, place the lead on an Annie A-8 (or equiv.) temperature tester on the same tube near

the sensor and insulate the bulb.

Unplug the sensor and measure the resistance with a good quality ohmmeter (Simpson

260 or equiv.). Read the value as quickly as possible to prevent the meter current from

changing the resistance reading.

Using the chart on the right, locate (as close as possible) the actual sensor temperature.

The measured resistance should be relatively close to the resistance value shown in the

chart.

Example:

Sensor temp. = 19°F.

Measured Resistance = 46K ohms

This sensor is good since the measured value is relatively close to the

chart value.

FLASH RATE INDICATIONS:

TEMP °F RESISTANCE

86 7.85K

81 8.85K

75 10.24K

70 11.59K

65 13.14K

59 15.32K

55 16.93K

50 19.41K

45 22.20K

41 24.76K

36 28.45K

32 31.84K

25 37.50K

19 46.44K

14 53.94K

10 57.64K

5 67.06K

0 78.05K

I -- Flash/Second =

2 -- Flashes/Second =

3 -- Flashes/Second =

Normal operation.

Fault A (Low AT) i.e.: Inoperative compressor, toss of charge, open ambient sensor, shorted coil sensor.

Fault B (20 defrosts terminated on time)

Fault C (High AT) i.e.: SOV stuck in heating, shorted ambient sensor, open coil sensor, closed TXV,

OD motor failure, OD fan on in defrost, undercharged unit.

4--Flashes/Second = FaultA&CorA&B

For additional information consult Pub. No. 34-1001 Heat Pump Defrost Controls.

Dwg. No. X664366 P01 Page 23

DEMAND DEFROST CONTROL CHECKOUT

SYMPTOMS

1. LED off.

2. LED flashing very rapidly (greater

than 4 times/sec) or appears to be on

continuously.

3. Control does not initiate a normal

defrost.

4. Control does not initiate a forced

defrost.

CHECKS

1.24V R-B & Y-B at board, with unit running?

2.Short FRC_DFT pin to TEST_COMMON pin.

Is defrost cycle initiated?

TEST_COMMON pin shorted to TST pin?

OD Temp. below 49°R

OD Coil temp. below 35°R?

"Delta" T increasing?

1. LED flashing?

2. Check for 24V Y-B at board with unit running.

3. Check sensors for correct mounting

(connection) and resistance.

4. Short FRC_DFT pin to TEST_COMMON pin.

Is defrost cycle initiated?

24V R-B & Y-B at board with unit running?

5. Defrost initiates manually but terminates in less than 10 seconds.

6. Defrost initiates manually but

terminates on time.

7. Defrost initiates on approximately

15/25 minute intervals.

8. Defrost initiates on approximately

30/45 minute intervals.

9. OD fan runs during defrost.

10. No SOV delay on defrost

termination.

11. ODS-A burned out.

12. On SCROLL bearing units,

compressor does not operate.

13. On SCROLL bearing units, no 30

second off delay at defrost initiation.

1. Coil sensor circuit open or reading at a very

high resistance?

2. Does OD fan cycle off in defrost?

3. Windy weather preventing normal

termination?

Be sure OD coil is clean.

1. Coil sensor open or reading a very

high resistance?

2. Ambient sensor reading less than normal?

3. OD fan off in defrost?

1.TEST_COMMON pin shorted to TST pin?

2. Do both sensors check OK?

3. Verify correct system charge.

4. Verify a "forced defrost" terminates less than

15 minutes.

5. OD fan motor off in defrost.

6. Verify proper SOV operation.

Has J1 been cut?

1. B to T greater than 10 volts?

1.24V R-B at board & 24V Y-B at board?

2. Check protective devices in YO circuit. 24V

YO-B present after 30 seconds.

Check voltage between control terminals 2 and

7,force a defrost cycle. Is 24V present for 30

seconds and 0V thereafter?

YES/NO

ACTIONS

Repair low voltage wiring.

Complete Check #2.

Replace defrost control.

LED is bad but control will still function.

Remove short.

Replace defrost control.

Check refrigerant circuits for balanced

distribution of refrigerant if OD coil is

frosting and delta T is not increasing

Refer to SYMPTOM #1.

Complete Check #2.

Repair low voltage wiring.

Complete Check #3.

Remount or replace sensor if necessary.

Replace defrost control.

Y-B signal or control may be intermittent

Repair low voltage wiring.

Replace defrost control.

Replace coil sensor.

Replace defrost control.

Complete Check #2.

Replace coil sensor.

Complete Check #3.

Replace ambient sensor.

Replace defrost control.

Remove short.

Replace defective sensor (Clear coil and

reset Emergency heat light).

Complete SYMPTOM #3.

Adjust as needed.

Replace defrost control.

See SYMPTOM #9.

Replace if necessary.

Replace defrost control.

The soft-switch time is defeated when J1

is cut.

Replace defrost control.

Check low voltage wiring for miswire.

Check for short in low voltage wiring.

Repair low voltage wiring.

Y-B signal or control may be intermittent

Replace defrost control.

Page 24 Dwg. No. X664366 P01

CHECKOUT PROCEDURE

P TO CHECK

THERMOSTAT SETTINGS I

(INDOOR) N

T I.D.

Fan

Switch SystemSwitch R Air

U Supply

C Indoor Con& Comp. Comp. Switch Gas Comb.

Both Auto Manual T Blower Fan Sump Over Burner Blower

I Runs Runs Runs Heat Valve Flame Run

Auto On Off Auto Heat Off Cool N Warm Cool

COMPONENT OPERATION

Thermostat

1 X X X -- X

System Switch

2 Sump Heater X X X -- X

Thermostat Fan Switch Room

3 X X X -- X X

& ID Fan Operation Temp.

4 Cooling Operation X _ & -- X X X X X

5 Checking Performance X _ & A X X X X X

& Charge (if needed)

Heating Operation--1 Stage X _ _ -- X X X X

Non-Restricted Mode

Heating Operation--2 Stage X _ _ -- (_ (_) X X

Non-Restricted Mode

Heating Operation--1 Stage X _ _ B X X X X

Restricted Mode

Heating Operation--2Stage X _ _ C (_ (_) X X

Restricted Mode

Defrost Operation

7 Gas Heat During Defrost X "€' "€' D X X X (_ X _)

8 Emergency Heat (Gas) X "€' "€' E (_ (_ X X

9 Inform owner or representative on how to operate system and what to expect of it.

INSTRUCTIONS

• _ Move "HEAT" temperature selector above room temperature.

Move "COOL" temperature selector below room temperature.

A Use chart's contained in service facts.

B The outdoor ambient temperature must be greater than the

ODT (Outdoor Thermostat) set point.

C The outdoor ambient temperature must be equal to or less than the

ODT (Outdoor Thermostat) set point.

D Initiate Defrost,

E Move thermostat switch from "NORMAL" to "EMERGENCY HEAT" position.

NOTES

(_) Approx. 30 seconds after start of combustion blower,

the gas burner will light.

(_ The indoor blower motor starts approx. 30 seconds

after the gas burner lights.

(_) The gas burner provides supplementary heat

during defrost.

From Dwg. 21 B660887 Rev. 0

MAINTENANCE

ROUTINE MAINTENANCE BY OWNER

You can do some of the periodic maintenance functions for your

DCY=F unit yourself; this includes replacing the disposable or

cleaning the permanent air fitters, cleaning the unit cabinet, clearing

the condenser coil, and conducting a general unit inspection on a

regular basis.

When the system is in constant operation. In new homes, check

the filters every week for the first four (4) weeks.

WARN ING: TO PREVENT INJURY OR DEATH

DUE TO ELECTRICAL SHOCK OR CONTACT WITH MOVING

PARTS, LOCK UNIT DISCONNECT SWITCH IN OPEN

POSITION BEFORE SERVICING UNIT.

If you have disposable-type filters, replace them with new filters of

the same type and size. Do not attempt to clean disposable

filters.

Permanent-type filters can be cleaned by washing them with a mild

detergent and water. Make sure that the filters are thoroughly dry

before re-installing them in the unit (or duct system).

,&WARNING: TO PREVENT AN EXPLOSION

OR POSSIBLE INJURY, DEATH AND EQUIPMENT DAMAGE,

DO NOT STORE COMBUSTIBLE MATERIALS, GASOLINE

OR OTHER FLAMMABLE VAPORS OR LIQUIDS NEAR THE

UNIT.

NOTE: It may be necessary to replace permanent filters annu-

ally if washing fails to clean the filter or if the filter shows signs of

deterioration. Be sure to use the same type and size as was

originally installed.

CONDENSER COIL

Unfiltered air circulates through the unit's condenser coil and can

cause the coil's surface to become clogged with dust, dirt, etc. To

clean the coil, vertically (i.e., with the fins) stroke the coil surface

with a soft-bristled brush.

Be sure to keep all vegetation away from the condenser coil area.

Dwg. No. X664366 P01 Page 25

MAINTENANCE

MAINTENANCE PERFORMED BY SERVICEMAN--

COOLING SEASON

To keep your unit operating safely and efficiently, the manufacturer recom-

mends that a qualified serviceman check the entire system at least once

each year and any other time that you feel one is needed. Your serviceman

should examine these areas of your DCY-F 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 connec-

tion tightness)

• condensate drain (for 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)

MAINTENANCE PERFORMED BY SERVICEMAN--

HEATING SEASON

Complete the unit inspections and service routines described below 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 CLEANING

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 room thermostat to the OFF position. Turn the main power

disconnect OFF. Turn the manual gas valve OFF.

2. Remove the flue cap, the lower access panel, and the upper access

panel.

3. Remove the combustion blower assembly from the fluebox. Remove

the flue box and the flue restdctors.

4. Remove all wires from the gas value while carefully noting their location.

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 notto break or damage them.

8. Wipe the flue box and flue baffles clean with a clean, dry cloth.

9. CAUTION: Never use combustible cleaning fluids on any part of the

furnace.

Page 26

10. Replace all gaskets with new ones.

11. Replace all damaged or broken turbulators with new ones.

12. Reassemble the unit by reversing Steps 2 through 7 above. Take care

that all gaskets seat properly.

13. Check all wires for correct installation by referring to the unit's electrical

wiring diagram.

14. Leak test all gas line connections with a soap and water solution or the

equivalent.

WARNING: NEVERUSEANOPENFLAME

TO TEST FOR GAS LEAKS: AN EXPLOSION COULD

OCCUR, CAUSING INJURY OR DEATH.

15. Re-install the top and bottom access panels and the flue stack.

16. Visually inspect the unit to ensure that the airflow opening for combus-

tion is not obstructed.

17. Follow the start-up procedure above to place the unit back in service.

The following warning complies with State of California law, Proposition 65.

AWARNING: This product contains

fiberglass wool insulation! Fiberglass dust and ceramic

fibers are believed by the State of California to cause

cancer through inhalation. Glasswool fibers may also

cause respiratory, skin, or eye irritation.

PRECAUTIONARY MEASURES

• Avoid breathing fiberglass dust.

• Use a NIOSH approved dust/mist respirator,

• Avoid contact with the skin or eyes, Wear long-

sleeved, loose-fitting clothing, gloves, and eye

protection,

• Wash clothes separately from other clothing: rinse

washer thoroughly,

Operations such as sawing, blowing, tear-out, and

spraying may generate fiber concentrations requiring

additional respiratory protection. Use the appropriate

NIOSH approved respirator in these situations.

FIRST AID MEASURES

Eye Contact Flush eyes with water to remove dust,

If symptoms persist, seek medical

attention,

Skin Contact Wash affected areas gently with soap

and warm water after handling.

Dwg. No. X664366 P01

LiMiTED WARRANTY

COMBiNATiON HEAT PUMP/GAS ELECTRIC

DCY

Models Less Than 20 Tons for Residential Use*

(Parts Only)

This limited warranty is extended by American Standard Inc., to the original purchaser and to any

succeeding owner of the real property to which the Combination Heat Pump/Gas Electric is originally

affixed, and applies to products purchased and retained for use within the U.S.A. and Canada.

If any part of your Combination Heat Pump/Gas Electric fails because of a manufacturing defect within

five years from the date of the original purchase, Warrantor will furnish without charge the required

replacement part. Any local transportation, related service labor, diagnosis calls, air filters, refrigerant

and related items are not included.

In addition, if the sealed motor-compressor(s) fail(s) or the outdoor coil* should become defective,

either or both events occurring because of a manufacturing defect within the sixth through tenth year

from the date of original purchase, Warrantor will furnish without charge the required replacement

compressor and/or outdoor coil. Any local transportation, related service labor, diagnosis calls,

refrigerant and related items are not included.

*NOTE: If your Combination Heat Pump/Gas Electric is installed within one mile of salt water, including

but not limited to seacoasts and inland waterways, your outdoor coil warranty as stated above is

limited to five years from the date of original purchase.

In addition, if the steel heat exchanger fails because of a manufacturing defect within the sixth through

twentieth yea r

from the date of original purchase, Warrantor will furnish without charge a replacement heat

exchanger. Any local transportation, related service labor and diagnosis calls are not included.

This limited warranty does not cover failure of your Heat Pump/Gas Electric if it is damaged while in

your possession, damage caused by unreasonable use of the Heat Pump/Gas Electric and/or damage

from failure to properly maintain the Heat Pump/Gas Electric as set forth in the Use and Care

manual (see Proper Maintenance section).

This limited warranty applies to product installed on or after 10/1/2001 where product is manufactured

after 1/1/2000.This limited warranty is not retroactive to any installations prior to 10/1/2001 or on

product produced prior to 2000.

THE LIMITED WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OFALL OTHER

WARRANTIES AND LIABILITIES, WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS

OR IMPLIED, IN LAW OR IN FACT, INCLUDING IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR PARTICULAR USE, AND IN NO EVENT SHALL

WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow limitations on how long an implied limited warranty lasts or do not allow the

exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion

may not apply to you.This limited warranty gives you specific legal rights, and you may also have

other rights which vary from state to state.

Parts will be provided by our factory organization through an authorized service organization in your

area listed in the yellow pages. If you wish further help or information concerning this limited

warranty, contact:

American Standard Inc.

Troup Highway

Tyler, TX 75711-9010

Attention: Manager, After Sales Support

GW-626-1802

*This limited warranty is for residential usage of this equipment and not applicable when this

equipment is used for a commercial application. A commercial use is any application where the end

purchaser uses the product for other than personal, family or household purposes.

Dwg. No. X664366 P01 Page 27

LiMiTED WARRANTY

COMBiNATiON HEAT PUMP/GAS ELECTRIC

DCY

Models Less Than 20 Tons for Commercial Use*

(Parts Only)

This warranty is extended by American Standard Inc., to the original purchaser and to any succeeding owner

of the real property to which the Combination Heat Pump/Gas Electric is originally affixed, and applies to

products purchased and retained for use within the U.S.A. and Canada. There is no warranty against

corrosion, erosion or deterioration.

If any part of your Combination Heat Pump/Gas Electric fails because of a manufacturing defect within one

year from the date of the original purchase, Warrantor will furnish without charge the required replacement

part.

In addition, if the sealed motor-compressor fails because of a manufacturing defect within the second through

fifth year from the date of original purchase, Warrantor will furnish without charge the required replacement

compressor. Warrantor's obligations and liabilities under this warranty are limited to furnishing F.O.B.

Warrantor factory or warehouse replacement parts for Warrantor's products covered under this warranty.

Warrantor shall not be obligated to pay for the cost of lost refrigerant. No liability shall attach to Warrantor until

products have been paid for and then liability shall be limited solely to the purchase price of the equipment

under warranty shown to be defective.

In addition, if the steel heat exchanger fails because of a manufacturing defect within the second through fifth

year from the date of original purchase, Warrantor will furnish without charge a replacement heat exchanger.

Any local transportation, related service labor and diagnosis calls are not included.

THE WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER

WARRANTIES AND LIABILITIES, WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS

OR IMPLIED, IN LAW OR IN FACT, INCLUDING IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR PARTICULAR USE, AND IN NO EVENT SHALL

WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow limitations on how long an implied warranty lasts or do not allow the exclusion or

limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to

state.

American Standard Inc.

Troup Highway

Tyler, TX 75711-9010

Attention: Manager, After Sales Support

GW-607-4.800

* This warranty is for commercial usage of said equipment and not applicable when the equipment is used for

a residential application. Commercial use is any application where the end purchaser uses the product for

other than personal, family or household purposes.

American Standard inc.

6200 Troup Highway

Tyler, TX 75703

Page28

0Q°sSince American-Standard has a policy of continuous product

and product data improvement, it reserves the right to change

the specifications and design without notice.

Technical Literature -Printed in U.S.A.

Dwg. No. X664366 P01

TRANE Package Units(both Units Combined) Manual L0903060

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