4DCY4-IG-5
Installer's Guide
18-BG03D1-5
Single Packaged Dual Fuel 14 SEER
Convertible, 2 - 5 Ton, 64 - 120 KBTU
R-410A
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT — This Document is customer property. Please return this Installer's Guide to service information pack and give to the homeowner
upon completion of work.
4DCY4024A through 4DCY4060A
! WARNING
▲
SAFETY HAZARD!
This information is for use by individuals having adequate
backgrounds of electrical and mechanical experience. Any
attempt to repair a central air conditioning product may result
in personal injury and/or property damage. The manufacturer
or seller cannot be responsible for the interpretation of this
information, nor can it assume any liability in connection with
its use.
! WARNING
▲
HAZARDOUS GASSES!
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.
This product must be gas piped by a Licensed Plumber or Gas
Fitter in the Commonwealth of Massachusetts.
! WARNING
▲
HAZARDOUS VOLTAGE, MOVING PARTS, AND GAS!
Bodily injury can result from high voltage electrical components, fast moving fans, and combustible gas. For protection
from these inherent hazards during installation and service,
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 technician's responsibility to recognize these hazards and proceed safely.
! WARNING
▲
SAFETY HAZARD!
Do not operate the unit without the evaporator fan or coil
access panels in place. Reinstall the access panels after
performing maintenance proceedures on the fan. Operating
the unit without the access panels properly installed may
result in severe personal injury or death.
WARNING: HAZARDOUS VOLTAGE - DISCONNECT POWER and DISCHARGE
CAPACITORS BEFORE SERVICING
Installer’s Guide
Safety Considerations
IMPORTANT: Read this entire manual before beginning installation procedures.
NOTICE
Warning and Cautions appear at appropriate
locations throughout this guide. 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.
! WARNING
▲
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 area gently with soap and
warm water after handling.
! WARNING
▲
EXPLOSION HAZARD!
Propane gas is heavier than air and may collect in any low
areas or confined spaces. In addition, odorant fade may make
the gas undetectable except with a warning device. If the gas
furnace is installed in a basement, an excavated areas or a
confined space, it is strongly recommended to contact a gas
supplier to install a gas detecting warning device in case of
leak. The manufacturer of your furnace does not test any
detectors and makes no representations regarding any brand
or type of detector.
! WARNING
▲
EXPLOSION HAZARD!
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.
Page 2
! WARNING
▲
CONTAINS REFRIGERANT!
SYSTEM CONTAINS OIL AND REFRIGERANT UNDER HIGH
PRESSURE. RECOVER REFRIGERANT TO RELIEVE PRESSURE BEFORE OPENING SYSTEM. Failure to follow proper
procedures can result in personal illness or injury or severe
equipment damage.
! WARNING
▲
Unit contains R-410A Refrigerant!
R-410A operating pressure exceeds the limit of R-22. Proper
service equipment is required. Failure to use proper service
tools may result in equipment damage or personal injury.
SERVICE
Use only R-410A Refrigerant and approved POE compressor oil.
! WARNING
▲
Improper Unit Lift!
Test lift unit approximately 24 inches to verify proper
center of gravity lift point. To avoid dropping of unit,
reposition lifting point if unit is not level. Failure to properly
lift unit could result in death or serious injury or possible
equipment or property-only damage.
! CAUTION
▲
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.
! CAUTION
▲
Hot Surface!
Do Not touch top of compressor. May cause minor to severe
burning.
! CAUTION
▲
Never use combustible cleaning fluids on any part of the
furnace.
IMPORTANT: This product has been designed and manufactured to meet
ENERGY STAR criteria for energy efficiency. However, proper refrigerant
charge and proper air flow are critical to achieve rated capacity and
efficiency. Installation of this product should follow the manufacturer’s
refrigerant charging and air flow instructions. Failure to confirm proper
charge and airflow may reduce energy efficiency and shorten
equipment life.
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 (1/2 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 1/2 psi.
MPORTANT: 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 original position and
properly fastened.
IMPORTANT: Wear appropriate gloves, arm sleeve protectors, and eye
protection when servicing or maintaining this equipment.
Installer’s Guide
Introduction
Contents
Safety Considerations
Introduction
Step 1-Inspect Shipment
Step 2-Determine Unit Clearances
Step 3-Review Location and Recommendation
Information
Step 4-Unit Installation
Install Flue Hood
Ground Level Installation
Rooftop Installation -- Curb Mounting
Covert Horizontal Airflow to Down Airflow
Install Full Perimeter Roof Mounting Curb
Lifting and Rigging
Placing the Unit on the Mounting Curb
Rooftop Installation -- Frame Mounting
Rooftop Installation -- No Curb/Fram
Ductwork Installation
Attaching Downflow Ductwork to Roof Curb
Attaching Downflow Ductwork to Roof Frame
Attaching Horizontal Ductwork to Unit
Condensate Drain Piping
Gas Piping Installation
Pipe Delivery Schedule (natural gas only)
Gas Pressure Set-up Precautions
Gas Supply Line Pressure (all fuels)
Verify Manifold Pressure
Input Check and Adjustment
High Altitude Installation
Air Filter Installation
Electrical Wiring
Electrical Connections
Electrical Power
Disconnect Switch
Over current Protection
Power Wiring
Control Wiring (Class II)
Thermostat Operation
Field Wiring Diagram
Step 5-Unit Startup
Pre-start Quick Checklist
Starting the Unit in the Cooling Mode
Operating Pressures
Voltage Check
Cooling Shutdown
Starting the Unit in Heat Pump Heating Mode
Gas Furnace Heating Cycle
Starting the Unit in Gas Heating Mode
Heating Shut-down
Final Installation Checklist
Sequence of Operation
Maintenance
Owner Maintenance
Service Maintenance
Cooling Season
Heating Season
Flue Hood and Combustion Blower Cleaning
ECM Fan Motor Adjustments
Status LEDs
2
3
3
4
10
11
11
11
11
11
11
12
12
13
13
16
16
16
16
16
17
17
17
17
18
18
19
19
19
19
19
20
20
20
20
20
21
22
22
22
22
22
22
22
22
23
23
23
24
26
26
26
26
26
27
27
28
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. 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 LP Gas
conversion kit 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 Service
Maintenance section on page 26.
This guide is organized as follows:
n
n
n
n
n
n
n
Step 1- Inspect Shipment
Step 2- Determine Unit Clearances
Step 3- Review Location and 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, retain the top shipping skid on the
unit or use “spreader bars” as shown on page 13.
2. Check the unit’s nameplate to determine if the unit is correct
for the intended application. The power supply must be
adequate for 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 for the unit.
• 4DCY4024-036 use model BAYCURB050A.
• 4DCY4042-060 use model BAYCURB051A.
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.
Page 3
Installer’s Guide
Step 2—Determine Unit Clearances
Figures 1 through 6 show the unit critical dimensions.
NOTE: The view labed
"Bottom Side" represents
the base as viewed
looking up from underneath the unit.
Figure 1. 4DCY4024A through 4DCY4036A (1 of 3)
Page 4
Installer’s Guide
Figure 2. 4DCY4024A through 4DCY4036A (2 of 3)
Page 5
Installer’s Guide
Figure 3. 4DCY4024A through 4DCY4036A (3 of 3)
Page 6
Installer’s Guide
NOTE: The view labed
"Bottom Side" represents
the base as viewed
looking up from underneath the unit.
Figure 4. 4DCY4042A through 4DCY4060A (1 of 3)
Page 7
Installer’s Guide
Figure 5. 4DCY4042A through 4DCY4060A (2 of 3)
Page 8
Installer’s Guide
Figure 6. 4DCY4042A through 4DCY4060A (3 of 3)
Page 9
Installer’s Guide
Step 3—Review Location and Recommendation Information
NOTE: The unit is shipped for horizontal installation.
Down Airflow Units
NOTE: During heating operation, avoid supply air below 80
degrees F or return air below 50 degrees F to prevent flue gas
condensation.
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.
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. See Figure 2 on page 5 or Figure 4 on page 7.
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.
IMPORTANT: Air outlet duct must have 1" clearance to
combustible material downstream from the unit.
5.
The unit must be mounted level for proper drainage of water
through the drain holes in the base pan.
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 makeup air or a ventilation feature is to be used. Contamination from
exhaust vents or chimneys may also foul the condenser causing
degraded performance.
6.
6.
Check the handling facilities to ensure the safety of personnel
and the unit(s).
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.
The unit must be mounted level for proper drainage of water
through the drain holes in the base pan.
Holes through exterior walls or roof must be sealed in accordance with local codes.
8.
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.
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.
4.
7.
Examine all flue product-carrying areas of the furnace, its vent
system, and the main burner for safe operation.
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, pages 4-9.
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.
10. Examine all flue product-carrying areas of the furnace, its vent
system, and the main burner for safe operation.
IMPORTANT: Air outlet duct must have 1" clearance to
combustible material downstream from the unit.
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).
Clearances
1. The recommended clearances for single-unit installations are
illustrated in Figures 1 to 6, pages 4-9.
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.
Page 10
Installer’s Guide
Step 4—Unit Installation
NOTE: The factory ships this unit for horizontal installation.
Install Flue Hood
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.
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 2. See Figure 2 on page 5 or Figure 5 on page 8 for correct
orientation of the Flue Hood.
7. Seal all holes through exterior walls in accordance with local
codes.
8. Continue with the following installation sections to complete
the installation: Ductwork on page 16, Gas Piping on page 17,
Filter on page 19, and Electrical Wiring on page 19.
Ground Level Installation
Rooftop Installation -- Curb Mounting
To install the unit at ground level:
Convert Horizontal Airflow to Down Airflow
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 securely attach the unit to the slab, use
extreme mounting kit, BAYEXMK003A.
The factory ships the unit for horizontal airflow. Perform this
procedure to convert the unit to down airflow:
The pad must not come in contact with the structure (see Figure
7.) Be sure the outdoor portion of the supply and return air
ducts are as short as possible.
Unit requires vibration support as indicated in Figure 7 below
and in Figure 9 on page 13.
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, pages 4-9.
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.
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.
See Figure 8, page 12.
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:
• 4DCY4024 through 4DCY4036 use model BAYCURB050A.
• 4DCY4042 through 4DCY4060 use model BAYCURB051A.
2. Assemble and install the curb following the instructions in the
Installer's Guide included with the curb.
IMPORTANT: The air outlet duct must have 1" clearance to
combustible material downstream from the unit.
4. Attach the supply and return air ducts to the unit as explained
in the following Ductwork Installation section on page 16.
SIDING
RETURN
AIR
DUCT
SUPPLY
AIR
DUCT
OUTDOOR AIR
DISCHARGE
Note: Use the extreme
mounting kit, BAYEXMK003A,
to secure the unit to the slab.
EXTERIOR
WALL
SUPPORT PAD
FOUNDATION
INSULATE
WEATHERPROOF
OR RAIN SHIELD
FLEXIBLE DUCT
CONNECTORS
3/4" VIBRATION ISOLATORS, USE 7 ISOLATORS AS
SHOWN IN FIGURE 9, PAGE 13.
Figure 7. Typical Ground Level Applications
Page 11
Installer’s Guide
Figure 8. Converting Horizontal to Down Airflow
Lifting and Rigging
! WARNING
▲
Improper Unit Lift!
Test lift unit approximately 24 inches to verify proper
center of gravity lift point. To avoid dropping of unit,
reposition lifting point if unit is not level. Failure to properly
lift unit could result in death or serious injury or possible
equipment or property-only damage.
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,
page 4-9). 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: When unit rigging and hoisting it is recommended that
accessory kit BAYLIFT002B be used. It includes a kit of four (4)
lifting lugs. See Figure 10 inset B, on page 14.
2. Insert the four lifting lugs in the openings provided in the drip
lip on each end of the unit. See Figure 10 inset B on page 14.
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 either the unit's top shipping skid 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.
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 12
IMPORTANT: To prevent damage to the sides and top of the
unit when hoisting, retain the top shipping skid on the unit or use
“spreader bars” as shown on page 14.
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.
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, see Figure 10, inset A, on page 14.
2. Position the unit drip lip down over and in contact with the
outside corner of the curb, as illustrated in Figure 10, inset A,
on page 14. 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.
Installer’s Guide
Small Cabinet
Medium Cabinet
*****018-036
*****042-060
NOTE: These views represent the base as viewed looking up from underneath the unit.
IMPORTANT: Unit requires vibration isolator supports 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.
Figure 9. Vibration Isolators/Snow Feet Locations
Rooftop Installation -- Frame Mounting
Rooftop Installation -- Flat Roof - No Curb/Frame
For roof top applications using field fabricated frame and ducts, use
the following procedure:
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 frame to the roof by bolting or welding.
Frame must provide adequate center support via a cross
member centrally located channel rail. See Figures 12 and 13
on page 15. Vibration isolators should be installed as indicated
in Figure 9, 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.
1. Locate and secure the sleeper rails to the roof. Three (3)
sleeper rails are 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 as indicated on Figure 9, 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 on page 11, if conversion is needed.
4. All fabricated outdoor ducts should be as short as possible.
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 on page 11, if conversion is needed.
5. Place the unit on the frame. Refer to Figures 12 or 13 on page
14.
4. All fabricated outdoor ducts should be as short as possible.
6. The unit must be mounted level for proper drainage of water
through the holes in the base pan.
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.
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.
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.
9. The unit should not be exposed to direct roof water runoff.
5. Place the unit on the rails.
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.
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, on pages 4-9, provide unit dimensions.
11. Access and service clearances for the unit must be given
careful consideration when locating the duct entrance openings. Figures 1 to 6, on pages 4-9, provide unit dimensions.
12. Continue with the following installation sections to complete
the installation: Ductwork on page 16, Gas Piping on page 17,
Filter on page 19, and Electrical Wiring on page 19.
12. Continue with the following installation sections to complete
the installation: Ductwork on page 16, Gas Piping on page 17,
Filter on page 19, and Electrical Wiring on page 19.
Page 13
Installer’s Guide
Base of unit
rest on top of
curb rails
Drip lip on
perimeter of
unit
IMPORTANT: To prevent damage
to the sides and top of the unit when
hoisting, retain the top shipping skid
on the unit or use “spreader bars” as
shown in these illustrations.
Spreader Bars
Top shipping skid attached to unit
Gasket Seal
Drip Lip
Dimple
BAYLIFT002A
Lifting Lugs
Figure 10. Lifting and Rigging
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.
Figure 11. Curb Dimensions
Page 14
Installer’s Guide
Supply Air
Return Air
Roof Flashing
Channel Iron Center
Support (Center
Support required on
all Frame Applications.)
Angle Iron Frame
Figure 12. Typical Rooftop Horizontal Airflow Application with Frame
Supply Air
Return Air
Roof Flashing
Roof Flashing
Channel Iron Center Support
(Center Support required on all
Frame Applications.)
Angle Iron Frame
Figure 13. Typical Rooftop Down Airflow Application with Frame
Page 15
Installer’s Guide
Ductwork Installation
Attaching Downflow Ductwork to Roof Curb
UNIT EXTERIOR
Supply and return air flanges are provided on the BAYCURB050
and BAYCURB051 model roof curbs for easy duct installation. All
ductwork must be run and attached to the curb before the unit is set
into place.
WEATHERPROOF
THIS SEAM
FIELD DUCT
Attaching Downflow Ductwork to Roof Frame
Follow these guidelines for ductwork construction:
UNIT EXTERIOR
Connections to the unit should be made with three (3) inch canvas
connectors to minimize noise and vibration transmission.
WEATHERPROOF
THIS SEAM
FIELD DUCT
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 14.
AIR PROOF
THIS SEAM
UNIT BASE
Figure 15. Horizontal Airflow Ductwork
Condensate Drain Piping
A 3/4-inch female NPT condensate drain connection is provided on
the filter 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 Figure 16.
FIELD DUCT
NOTE: Do not use reducing fittings in the drain lines.
UNIT DUCT
FLANGE
AIR PROOF
THIS SEAM
UNIT DUCT
FLANGE
UNIT BASE
FIELD DUCT
AIR PROOF
THIS SEAM
The condensate drain must be:
●
Made of 3/4" pipe.
●
Pitched 1/4" per foot to provide free drainage to convenient drain
system.
●
Trapped.
●
Must not be connected to a closed drain system unless the trap
is properly vented.
UNIT BASE
FIELD
DUCT
UNIT DUCT FLANGE
3/4"
PVC OR COPPER
TUBING AND FITTINGS
UNIT BASE
UNIT DUCT
FLANGE
NOT RECOMMENDED
1-1/2" MIN.
WATERPROOF SEAM
WITH BUTYL OR
SILICONE
FIELD DUCT
1-1/2" MIN.
Figure 14. Down Airflow Ductwork
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.
Page 16
Figure 16. Typical Condensate Drain Piping
Gas Piping Installation
! WARNING
▲
FIRE OR EXPLOSION HAZARD!
Failure to follow the safety warning exactly could result in
serious injury, death, or property damage. Never test for gas
leaks with an open flame. Use a commercially available soap
solution made specifically for the detection of leaks to check
all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
Installer’s Guide
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.
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 (1/2 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 1/2 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).
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 Table 1 below and insert in the following formula:
CFH =
Furnace Input in BTUH
Gas Heat Contne in BTU/Cu. Ft. X Multiplier
5. Using Table 2, select the pipe length nearest to calculated size.
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 1. Specific Gravity Multiplier
MULTIPIERS TO BE USED
WHEN THE SPECIFIC
GRAVITY OF THE GAS IS
OTHER THAN 0.60
SPECIFIC
GRAVITY
.50
.55
.60
.65
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 operating.
NOTE: Gas pressure in excess of 14 inches water column
(1/2 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 Figure 17.
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.
MULTIPIER
1/8" N.P.T.PLUGGED
ACCESS FOR TEST
GAUGE CONNECTION
1.10
1.04
1.00
.962
DEALER INSTALLED
GROUND UNION
FROM
GAS SUPPLY
6"
MIN
NOTE: If this is an LP Gas application, consult your LP Gas
supplier for pipe sizes and deliveries.
TABLE OF CUBIC FEET PER HOUR OF GAS
FOR VARIOUS PIPE SIZES AND LENGTHS
PIPE
SIZE
(inch)
20
30
40
50
DRIP LEG
(6" MIN)
Figure 17. Gas Pipe
LENGTH OF PIPE (feet)
10
UNIT
FIELD SUPPLIED MAIN
GAS VALVE, MUST BE
INSTALLED BY DEALER
OUTSIDE OF UNIT.
Table 2. Natural Gas Only
TO MAIN
CONTROL
VALVE
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
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.
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 17. This drip leg is required to collect any
sediment that may be deposited in the line.
Page 17
Installer’s Guide
4. 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 14 inches water column.
a. Attach a manifold pressure gauge.
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.
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.
b. Remove the slot screw on top of the gas valve for 1st
stage manifold pressure adjustment. Remove slot screw
on outlet side for 2nd stage adjustment (See Figure 18).
6. After installation of the gas pipe in the unit, the pipe opening
should be closed with the filler/barrier plug provided.
Manifold Pressure
Table 3. Gas Flow in Cubic Feet Per Hour
2 Cubic Foot Dial
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
NOTE: For manifold pressures and orifice sizes for gas with other
BTU ratings, contact the local gas utility. Manifold
pressure should be 1.8 (low) to 3.5 (high) inches water column
(+0.1). Input for natural gas must not exceed the value shown on
the unit nameplate.
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.
Outlet Pressure Boss
Sec.
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Flow
900
800
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
267
257
2nd Stage (HI)
Manifold Pressure
Adjustment
Regulator
Vent
1st Stage
(LO)
Manifold
Pressure
Adjustment
Inlet
Pressure
Boss
Coaxial Coil
Terminal (M)
Gas Valve
ON/OFF
Toggle
Switch
High Fire Coil
Terminal (H)
Common
Terminal (C)
Figure 18. Burner and Valve
Page 18
Sec.
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Flow
248
240
232
225
218
212
206
200
195
189
185
180
176
172
167
164
160
157
153
150
147
Sec.
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
Flow
144
141
138
136
133
131
129
126
124
122
120
116
112
109
106
103
100
97
95
92
90
Sec.
82
84
86
88
90
92
94
96
98
100
104
108
112
116
120
124
128
132
136
140
144
Flow
88
86
84
82
80
78
76
75
73
72
69
67
64
62
60
58
56
54
53
51
50
Installer’s Guide
High Altitude Installation
Unit nameplate ratings are based on equipment operation from sea
level to 2000 feet elevation above sea level. No orifice changes
required for high altitude installation, please refer to below chart
for rating information.
Table 4. High Altitude Derate Chart
HIGH ALTITUDE DERATE CHART NAT.
Altitude (In Feet)
Unit Input
120k
2001
3000
4000 5000 6000 7000 8000
High stage 117000 108700 100400 92000 90700 89400 88800
Low stage
87700 81500 75300 69000 68000 67000 66600
96k
High stage
93600 87000 80300 73600 72600 71500 71000
Low stage
70200 65200 60200 55200 54400 53600 53300
75k
High stage
73100 67900 62700 57500 56700 55900 55500
Low stage
54800 51000 47100 43100 42500 41900 41600
64k
High stage
62400 58000 53500 49100 48400 47700 47300
Low stage
46800 43500 40200 36800 36300 35700 35500
Inputs shown are with factory orifices @ 3.5"WC (High Fire)
1.8"WC (Low Fire)
Natural Gas heating value of 950 btu/cuft.
For LP installations. Models that require #49 orifices, for
altitudes from 7000 - 8000' orifices must be changed to #50.
NOTE: This unit is factory wired for 230V. See wiring diagram
in SERVICE FACTS 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.
NOTE: For branch circuit wiring (main power supply to unit
disconnect), determine wire size for the length of run 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.
Run power supply
Lines through
weather-tight
conduit and
secure to unit with
strain relief
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. Refer to Table 5 to determine filter sizes for field supplied
filter racks.
Table 5. Filter Sizes (field supplied filter rack)
UNIT
NOMINAL
CFM
FILTER*
SIZE (Sq Ft)
FILTER
RESISTANCE
("W.C.)
4DCY4024A
4DCY4036A
4DCY4048A
4DCY4060A
800
1200
1600
2000
2.67
4.00
5.33
6.67
0.08
0.08
0.08
0.08
*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" W.C.
Electrical Wiring
! WARNING
▲
HAZARDOUS VOLTAGE, MOVING PARTS, AND GAS
Bodily injury can result from high voltage electrical components, fast moving fans, and combustible gas. For protection
from these inherent hazards during installation and service,
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 technician's responsibility to recognize these hazards and proceed safely.
Figure 19. Power Wiring
Electrical Power
It is important that proper electrical power be available for the unit.
Voltage variation should remain within the limits found on the unit
nameplate.
Disconnect Switch
Provide an approved weatherproof disconnect within close proximity and within sight of the unit. If disconnect must be mounted
to the cabinet, the location shown in Figure 21 should be the only
one considered.
Over Current Protection
The branch circuit feeding the unit must be protected as shown on
the unit nameplate.
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.
See Figure 19.
2. Connect the high voltage wires to the appropriate contactor
lug terminals. Single phase units use a two (2) pole contactor
and three phase units use two (2) pole contactor and a Blue
lead wire. Connect the ground to the ground lug on the
chassis. See Figure 20. 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.
Page 19
Installer’s Guide
Thermostat Operation
Contactor
Unit Ground Lug
Figure 20. Power Connections
Operation of the unit heating or cooling cycles is controlled by the
comfort control. Once the system mode is set to either HEAT or
COOL, unit operation is automatic. The fan ON setting provides
continuous indoor blower operation. The AUTO setting provides
indoor blower operation during the compressor heating and cooling cycles. CONTINUOUS fan mode during COOLING operation
may not be appropriate in humid climates. If the indoor air exceeds
60% relative humidity or simply feels uncomfortably humid, it is
recommended that the fan only be used in the AUTO mode.
NOTE: The 4DCY4 units require either a *CONT402,
*CONT802 or *CONT803 Comfort Control. Do not install any
other model of thermostat with this 4DCY4 unit. Otherwise,
mis-operation could result due to the dual fuel nature of this
unit. Note: A BAYSEN02ATEMPA outdoor temperature sensor
must be purchased separately and installed in order to use the
*CONT802 and *CONT803 Comfort Controls with this unit. A
BAYSEN01ATEMPA outdoor sensor is shipped with the
*CONT402.
NOTE: A field installed jumper wire (18 AWG minimum
conductor) is required between the W1 and W2/X2 low voltage
wires at the 4DCY4 unit when using the *CONT802 or
*CONT803 Comfort Controls since these two controls produce
only a W1 output for auxiliary heat. This will result in low fire
gas heating for 10 minutes or for as long as W1 is present if
less than 10 minutes. Then, if the W1 signal is still present from
the Comfort Control, the 4DCY4 unit will transition
automatically to high fire and operate on high fire for the
remaining duration of the call for auxiliary heat.
NOTE: The JP1 Dual Fuel jumper wire on the printed circuit
board of the *CONT402 must be cut for proper and reliable
operation of this dual fuel 4DCY4 unit. There is no jumper to
cut on the *CONT802 and *CONT803 Comfort Controls
Figure 21. 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 Figures 2 or 5 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 6 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 6. Thermostat Wire Size and Maximum Length
Wire Size
18
16
14
Page 20
Maximum Length
75
125
200
TWO MODES OF OPERATION:
The unit can be installed and configured to operate in one of
two different heating modes: restricted and non-restricted. A brief
explanation of each mode follows.
RESTRICTED: In the restricted mode of operation an outdoor
temperature sensor 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 outdoor
temperature. The gas heat will operate with the heat pump when
the unit requires a defrost cycle. The gas heat is used to offset
the effect of the unit going into the cooling mode during defrost.
For the *CONT402, the unit will be commanded to transition to
gas heat even when the outdoor temperature is above the
selected outdoor temperature changeover point if the heat
pump capacity is not enough to maintain the indoor temperature
at the desired heating setpoint.
NON-RESTRICTED: This mode of operati on allows the unit to
operate in the heat pump mode during the first call, or stage, of
heat commanded by the indoor thermostat. If the heat pump
capacity is sufficient, gas heat will not be required. If the heat
pump capacity is not enough to maintain the indoor temperature
at the desired heating setpoint, the thermostat will 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. As in the
restricted mode, the gas heat will act as supplementary heat
during the unit’s defrost cycle.
See the Field Wiring Diagram, page 21, for field wiring
instructions.
Installer’s Guide
Figure 22. 4DCY4 Field Wiring Diagram
Page 21
Installer’s Guide
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.
NOTE: The outdoor sensor should be located in an area
which will provide a representative outdoor ambient
temperature reading.
Step 5—Unit Startup
Pre-Start Quick Checklist
●
Is the unit properly located and level with the proper
clearance? See Figures 1-6, pages 4-9.
●
Is the duct work correctly sized, run, taped, insulated, and
weatherproofed with proper unit arrangement?
See
Ductwork Installation section on page 16.
●
Is the gas piping correctly sized, run, trapped, and purged of
air? See Gas Piping section on page 17.
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 SERVICE 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, weigh in the charge according to the unit
nameplate.
Voltage
With the compressor operating, check the line voltage at the
unit. 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
●
Is the condensate line properly sized, run, trapped, and
pitched? See Condensate drain section on page 16.
Set the comfort control to OFF or adjust the cooling setpoint
above the room temperature.
●
Is the filter of the correct size and number? Is it clean and in
place? See Air Filter section on page 19.
Starting the Unit in the Heat Pump Heating Mode
●
Is the wiring properly sized and run according to the unit
wiring diagram?
NOTE: See the section on “Sequence of Operation”, page
23, for a description of the heat pump heating operating
sequence.
●
Are all the wiring connections, including those in the unit,
tight?
Check to make sure all grilles and registers are open and all
unit access doors are closed before start-up.
●
Has the unit been properly grounded and fused with the
recommended fuse size?
●
Is the thermostat correctly wired and well located?
●
Is the W1 to W2 jumper installed at the unit when using a
*CONT802 or *CONT803 Comfort Control?
●
Have the air conditioning systems been checked at the
service ports for charge and leak tested if necessary?
●
The comfort control may be temporarily operated in Manual
Test Mode for the *CONT402 or in Installer System Test mode
for the *CONT802 AND *CONT803.
These are modes
designed to be used to “bump” the system on the various
capacity stages. Since the test mode timeouts are 1 minute
and 5 minutes respectively (in the absence of installer key
presses), these modes are not designed to be used as the only
means of system checkout. Normal thermostat operation
should be used for operating the unit for extended periods of
time.
Does 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?
●
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
NOTE: See the section on “Sequence of Operation”, page
24, for a description of the cooling operating sequence.
To start the unit in the cooling mode, set the comfort control to
COOL and adjust the cooling setpoint below the room
temperature. Wait for the minimum compressor off time to
elapse. The condenser (outdoor) fan motor, compressor, and
evaporator (indoor) fan motor will operate automatically.
Page 22
To start the unit in the heat pump heating mode, set the comfort
control to HEAT and adjust the heating setpoint slightly above
the room temperature. Wait for the minimum compressor off
time to elapse.
The condenser (outdoor) fan motor,
compressor, and evaporator (indoor) fan motor will operate
automatically.
Heat Pump Heating Shut Down
Set the comfort control to OFF or adjust the heating setpoint
below the room temperature.
Gas Furnace Heating Cycle
In addition to the heat pump controls, 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.
NOTE: See the section on “Sequence of Operation”, page
24, for a description of the heating operating sequence.
Installer’s Guide
The gas heating section of the unit can be started using the
following procedure:
1. Be sure the comfort control is configured to power up in the
OFF mode, or be prepared to change the comfort control to
OFF just as soon as power is applied to the thermostat in
the steps below.
5. 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 oil on the
surface of the heat exchanger. This oil will burn off quickly.
a. Turn the main shutoff valve on the gas supply line ON.
b. Turn or switch the manual valve on the combination gas
valve to the ON position.
2. Be sure the burner compartment access panel is in
place.
a. Turn on the electrical power to the unit.
b. Change the thermostat mode to Emergency Heat and
adjust the heating setpoint slightly above the room
temperature.
2. When the comfort control calls for heat, the system
operates 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. Allow the comfort control to cycle on and off a few times
in Emergency Heat mode to check out the control
system and burner operation characteristics. For the
*CONT802 and *CONT803 Comfort Controls if the call
for heat lasts longer than 10 minutes, these controls will
transition to high fire automatically.
3. With the burners operating, check the manifold pressure
with a manometer.
Do not exceed recommended
pressures.
4. 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 pressure should be 1.8 (low) to 3.5 (high) inches
water column (+0.1). Input must not exceed the value
shown on the nameplate.
5. Set the comfort control the desired temperature setting and
the unit will function automatically.
6.
Allow the comfort control to cycle on and off 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.
7.
Increase the heating setpoint significantly so that the
comfort control will transition to high fire automatically.
For the *CONT802 and *CONT803 Comfort Controls,
there is a 10 minute delay before the transition occurs.
Make the following manifold pressure check on high fire.
MANIFOLD PRESSURE
1. Connect a manometer to the pressure boss at the outlet
side of the unit’s gas valve. Read the manifold pressure
with the main burners firing. See figure 18, page 18.
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
pressure.
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 airflow to cause the temperature
rise of the heat exchanger to fall within the required range.
HEATING SHUT-DOWN
Set the comfort control to OFF or adjust the heating set point to below
room temperature.
Final Installation Checklist
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. Open the main gas valve(s) and turn on the unit power
supply.
4. Set the comfort control to Emergency Heat and adjust the
heating setpoint slightly above the room temperature.
o Does the unit run and operate as described in the section on
Sequence of Operation, page 24, in response to the room
thermostat?
o Are the condenser fan and indoor blower operating correctly
with proper rotation and without undue noise?
o Is the compressor operating correctly and has the system been
checked with a charging chart?
o Has the voltage and running current been checked to determine if it is within limits?
o Has the thermostat been checked for calibration and the air
discharge grilles adjusted to balance the system?
o Has the ductwork been checked for air leaks and
condensation?
o Has the furnace manifold pressure been checked and
Page 23
Installer’s Guide
adjusted if necessary?
o Has the heating air temperature rise been checked?
o Has the unit been checked for tubing and sheet metal rattles?
Are there any other unusual noises to be checked?
o Are all covers and panels in place and properly fastened?
o Has the owner been instructed on the proper operation and
maintenance of the unit? Be sure to leave this manual with the
owner.
SEQUENCE OF OPERATION
The following description applies to the *CONT402. Some of
the operational differences of the *CONT802 and *CONT803
are described at the end of this section.
The following description applies to non-restricted mode.
Restricted operation will be identical except that transitions
from and to first stage (heat pump) heating to and from
second stage (gas) heating can occur, not necessarily as a
result of building load and equipment capacity, but as
determined by the outdoor temperature changeover point
selected by the installer at the indoor thermostat (see
Restricted Mode described on page 19).
Call for 1st stage heating (heat pump):
With the disconnect switch in the ON position, current is
supplied to the compressor crankcase heater, if supplied with
one, and to the control transformer. When the thermostat calls
for first stage heat, power from (R) is switched by the thermostat
to the (Y/Y1) terminal. This powers the compressor contactor
(CC) which starts the outdoor fan motor and compressor. The
thermostat also switches (R) power to (G) thereby starting the
indoor blower motor (IDM).
To maintain the indoor temperature at the desired setpoint, the
thermostat may operate the heat pump continuously or cycle
the heat pump off and on (cycling on 1st stage heat).
Cycling on 1st stage heat: When the thermostat cycles the
heat pump off, power is removed from (Y/Y1) and (G). If the
indoor blower delay is defeated in the unit, it is an installer
option for the thermostat to control the delay of the indoor
blower by using (G). If there is a thermostat controlled indoor
blower delay, the thermostat will turn (G) off after the delay time
set within the thermostat has elapsed.
Call for 2nd stage heating (gas) after 1st stage (heat pump):
If the heat pump capacity is not enough to handle the building
load, the heat pump is turned off and the gas heat is brought on
as the second stage of heat. The thermostat will call for second
stage heat by removing power from (Y/Y1) and by powering
(W1). (G) will remain energized for a minimum of 2 minutes so
that the transition to gas heat will not interrupt indoor airflow.
(W1) from the thermostat signals the control module (IGN) to
run its self-check routine. After the control module 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 on
high speed for approximately 5 seconds.
Page 24
After the induced draft blower (CFM) has come up to speed, the
control will verify that the pressure switch (PS) contacts are
closed and will switch the induced draft blower to low speed for
a 20 second prepurge. The gas valve (GV) is energized in the
first stage to permit gas flow and the spark igniter (IP) is
energized. The flame detector (FD) confirms that ignition has
been achieved within the 7 second trial period.
When the flame detector confirms that ignition has been
achieved, the delay to indoor blower ON period begins timing.
After approximately 45 seconds, the control module (IGN) will
take over control of the indoor blower motor (IDM). The control
module (IGN) will command the indoor blower to operate at low
speed throughout the heating cycle.
To maintain the indoor temperature at the desired setpoint, the
thermostat may operate the low fire gas heating continuously
or cycle low fire gas heating off and on (cycling on 2nd stage
heat).
Cycling on 2nd stage heat: When the thermostat cycles off
during second stage heating, power will be removed from
(W1), the gas valve (GV) will close, and the flame will
extinguish. The induced draft blower (CFM) will continue to run
for a postpurge period of approximately 5 seconds before
shutting off. The indoor blower motor (IDM) will continue to
operate as the heat exchanger cools down (the delay is field
selectable for 45 or 90 seconds) before being turned off by the
control module.
NOTE: During gas heating operation, the indoor blower is
controlled by the normal sequence of gas furnace operation,
and not by the thermostat.
Note that the *CONT402 may transition from second stage
heating (gas) to first stage (heat pump) and then back to
second stage heating (gas) instead of just cycling the gas
heat on and off if the building load is relatively low (see the
Transitioning from 2nd stage heating (gas) to 1st stage (heat
pump) section for a complete description).
Call for 3rd stage heating (gas) after 2nd stage (gas):
The thermostat adds (W2/X2) to (W1) signaling a call for
second stage heat. The induced draft motor (CFM) is energized
on high speed and the gas valve (GV) on second stage. After
approximately 30 seconds the control energizes the indoor
blower on high speed.
To maintain the indoor temperature at the desired setpoint, the
thermostat may operate the high fire gas heating continuously
or cycle between high fire gas heating and low fire gas heating
(cycling on 3rd stage heat).
Cycling on 3rd stage heat: When the thermostat cycles on
third stage heating, power will be removed from (W2/X2) and
(W1) will remain powered. The control module (IGN) will switch
the gas valve (GV) to first stage and the induced draft blower
(CFM) to low speed. After approximately 30 seconds the
indoor blower motor is reduced to low speed.
Installer’s Guide
NOTE: During gas heating operation, the indoor blower is
controlled by the normal sequence of gas furnace operation,
and not by the thermostat.
Transitioning from 3rd stage heating (gas) to 2nd stage
(gas):
Same sequence as cycling on 3rd stage heat (described
previously) except that the thermostat will make the transition
as described previously but will then begin to operate
continuously on second stage heating or will begin cycling on
second stage heating.
Transitioning from 2nd stage heating (gas) to 1st stage
(heat pump):
When the thermostat is cycling on second stage heat, the load
may decrease to the point where the thermostat determines
that the heat pump would have sufficient capacity to maintain
the indoor temperature at the desired setpoint. When this
occurs, power will be removed from (W1). This will cause the
gas valve (GV) to close and the control module to de-energize
the induced draft blower (CFM) after approximately 5 seconds
postpurge. The indoor blower motor (IDM) will continue to
operate (with no (G) signal) for the blower off period (45 or 90
seconds) while the heat exchanger cools down. At
approximately 45 seconds after power was removed from
(W1), the thermostat will apply power to (Y1). This powers the
compressor contactor (CC) which starts the outdoor fan motor
and compressor. The thermostat will also apply power to (G) at
this time so that the transition from gas heat to heat pump will
not interrupt indoor airflow. The purpose of the 45 second
delay is to give the indoor coil sufficient time to cool down
before resuming compressor operation.
Turning off from 1st stage:
Same sequence as cycling on 1st stage heat (described
previously) except that the thermostat will make the transition
to off as described previously and will keep the heat pump
turned off.
Cooling Cycle:
With the comfort control set to COOL and the fan set to AUTO,
the thermostat will energize (Y/Y1), (G), and (O). These signals
will energize the compressor contactor (CC), the indoor blower
motor (IDM), and the switchover valve (SOV), respectively.
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 blower motor (IDM) will operate as a
result of the (G) signal. The thermostat will continue to cycle the
compressor with the indoor blower to maintain the indoor
temperature at the desired setpoint.
With the thermostat fan switch in the ON position, the indoor
blower motor (IDM) will continue to run regardless of
compressor and condenser fan operation.
*CONT802 and *CONT803 Operational Differences from
the above sequence:
NOTE: Unlike the *CONT402, these two controls will not
call for the furnace to operate when the outdoor
temperature is above the selected outdoor temperature
changeover point even if the heat pump capacity is not
enough to maintain the indoor temperature at the desired
heating setpoint. If it is anticipated that the installer
selected outdoor temperature changeover point from heat
pump to furnace must be set to a temperature at or below
where this occurs, then the *CONT402 control must be
used instead of the *CONT802 and *CONT803 Comfort
Controls.
These two controls are not able to cycle on second stage heat
in the same way as the *CONT402. The *CONT402 can cycle
the gas heat on and off to maintain the indoor temperature at
the desired heating setpoint without transitioning to heat pump
operation each cycle if the building load is relatively high.
These two controls will cycle on second stage heat by
alternating between gas heat and heat pump operation. These
two controls may take up to 25 minutes to transition between
heat pump and gas operation.
These two controls require a field installed jumper wire
between the W1 and W2/X2 low voltage wires at the 4DCY4
unit since these two controls produce only a W1 output for
auxiliary heat. This jumper will result in low fire gas heating for
10 minutes or for as long as W1 is present if less than 10
minutes during auxiliary heating. Then, if the W1 signal is still
present from the Comfort Control, the 4DCY4 unit will transition
automatically to high fire and operate on high fire for the
remaining duration of the call for auxiliary heat. During
Emergency Heat mode operation these two controls will first
energize X2 on a call for heat and will potentially energize W1
as well. In contrast, the *CONT402 Comfort Control will first
energize W1 on a call for Auxiliary or Emergency Heat mode
and will potentially energize W2 as well as required by the
building load.
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.
An initiate delta-T is calculated based on the delta-T
measurements obtained after defrost terminates (when the
outdoor coil should be clear of frost). When the measured
delta-T during heating operation reaches the calculated initiate
delta-T, 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, fifteen, or
twenty 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.
Page 25
Installer’s Guide
Safety Sequences
This product is equipped with the following devices.
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 supply
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-second 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 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 reinstalling them.
NOTE: It may be necessary to replace permanent filters
annually 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
Be sure to keep all vegetation and debris away from the condenser
coil area.
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 year or more often if
needed. The service technician should examine these areas
of the packaged unit:
●
●
●
●
●
●
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.
●
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
Maintenance
Complete the following unit inspections and service routines
described at the beginning of each heating season.
Owner Maintenance
●
! WARNING
▲
EXPLOSION HAZARD!
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.
Some of the periodic maintenance functions of the packaged
unit can be performed by the owner; this includes replacing the
disposable or cleaning the permanent air filters, cleaning the
unit cabinet, and conducting a general unit inspection on a
regular basis.
Filters
When the system is in constant operation, inspect the filters
at least once each month.
Page 26
●
●
●
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.
Installer’s Guide
Flue Hood and Combustion Blower Cleaning
! CAUTION
▲
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.
2.
Remove the flue hood and the CONTROL/HEAT access
panel.
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.
ECM Fan Motor Adjustments
If the airflow needs to be increased or decreased, see the
Airflow Table in the SERVICE FACTS. Information on changing
the speed of the blower motor is in the Blower Performance
Table. Blower speed changes are made on the ECM Fan
Control mounted in the control box. The ECM Fan Control
controls the variable speed motor. There is a bank of 8 dip
switches, (See Figure 23 below) located on the board. The dip
switches work in pairs to match the cooling/heat airflow (CFM/
TON), Fan off-delay options and electric heat airflow adjustment. The switches appear as shown in the figure below.
CFM
SELECTION
LIGHT
DIP
SWITCHES
Figure 23. ECM Fan Control
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 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 the start-up procedure on page 22 to place the unit
back in service.
Page 27
Installer’s Guide
Status LEDs
IGN Board Diagnostic Codes
There are two LEDs on the IGN board that provide status and
diagnostic information. Refer to Table 7 for a description of the
LED codes.
Table 7. IGN LED Diagnostic Indicators
Steady OFF
IGN Diagnostic Indicators Flash Codes
Status LED
Liteport LED
System Lockout: Failed to detect or
Check Power or Failed Board 2 Flashes sustain flame
Slow Flash Rate Normal, No Call for Heat
Fast Flash Rate
Not used
Steady ON
Normal, No Call for Heat
3 Flashes Pressure switch problem detected
High Limit switch protection device
4 Flashes open
Flame sensed and gas valve not
energized or flame sensed and no "W"
5 Flashes signal
6 Flashes Flame Rollout Switch open
7 Flashes Thermostat miswired; W1 & 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 off for 1/4 second.
The pause between groups of fast flashes is 3 seconds.
Trane
6200 Troup Highway
Tyler, TX 75707
© 2008 Trane
Page 28
The manufacture has a policy of continuous product and product data improvement.
It reserves the right to change design and specification without notice.