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Page 11

Installer’s Guide

Figure 7. Typical Ground Level Applications

Note:

 Use the extreme mounting kit, 

BAYEXMK003A, to secure the unit 

to the slab.

Step 4—Unit Installation

NOTE:

 The factory ships this unit for horizontal installation.

Install Flue Hood

1.  Locate the Flue Hood in the literature package.

2.  Remove the two Flue Hood mounting screws from the unit. 

They are located to the right of the Power Entry connection 
panel.  

3.  Attach the Flue Hood to the unit with the two screws removed 

in step 2. See Figure 2 on page 5 or Figure 5 on page 8 for 
correct orientation of the Flue Hood.

Ground Level Installation

To install the unit at ground level:
1.  Place the unit on a pad the size of the unit or larger.  The unit must 
   be mounted level for proper drainage of water through the holes  
  in the base pan. To securely attach the unit to the slab, use 
 

extreme mounting kit, BAYEXMK003A.

 

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.

   IMPORTANT: 

A minimum 0” clearance to combustible mate-

rial shall be maintained on air outlet duct.

Rooftop Installation -- Curb Mounting

Convert Horizontal Airflow to Down Airflow

The factory ships the unit  for horizontal airflow.  Perform  this 
procedure to convert the unit to down airflow:

1.  Remove the three (3) sheet metal screws securing the supply 
air cover and the four (4) sheet metal screws securing the return 
air  cover from the base of the unit. Remove the covers from the 
base. See Figure 8, page 12.

2.  Place the covers over the horizontal supply and return open-
ings (painted side out). Align the screw holes, and secure using 
the same screws removed in step 1.

4.   Attach the supply and return air ducts to the unit as explained 

in the following Ductwork Installation section on page 16.

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 
weather proof seal where the duct enters the structure.

6.   Do not expose the unit to direct roof water runoff.
7.   Seal all holes through exterior walls in accordance with local 

codes.

8.   Continue with the following installation sections to complete 

the installation: Ductwork on page 16, Gas Piping on page 17, 
Filter on page 19, and Electrical Wiring on page 19.

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: 

    • 

4DCL4024 through 4DCL4036 use model BAYCURB050A.

    • 

4DCL4042 through 4DCL4060 use model BAYCURB051A.

2. Assemble and install the curb following the instructions in the 
     Installer's Guide included with the curb.  

SIDING

RETURN 

AIR 

DUCT

SUP-

PLY AIR 

DUCT

EXTERIOR 

WALL

INSULATE WEATH-

ERPROOF OR RAIN 

SHIELD

FLEXIBLE DUCT 

CONNECTORS

3/4" VIBRATION ISOLATORS, USE 7 ISOLATORS AS 

SHOWN IN FIGURE 9, PAGE 13.

SUPPORT PAD FOUNDATION

OUTDOOR AIR DIS-

CHARGE

RELEASED 10/Aug/2020 16:34:00 GMT

Summary of Contents for 4DCL4024

Page 1: ...ards 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 pan els in place Reinstall the access panels...

Page 2: ...erate fiber concentrations requiring additional respiratory pro tection 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 This product contains fiberglass wool insulation Fiberglass dust and cer...

Page 3: ...ctory this unit is for use with natural gas only It is listed by Underwriters Laboratory An LP Gas conver sion 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 L...

Page 4: ...Unit Clearances Figure 1 4DCL4024 through 4DCL4036 1 of 3 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 RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 5: ...Page 5 Installer s Guide Figure 2 4DCL4024 through 4DCL4036 2 of 3 RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 6: ...Page 6 Installer s Guide Figure 3 4DCL4024 through 4DCL4036 3 of 3 4DCL4024 060 4DCL4030 070 4DCL4036 4DCL6036 070 RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 7: ...Page 7 Installer s Guide Figure 4 4DCL4042 through 4DCL 4060 1 of 3 NOTE The view labed Bottom Side represents the base as viewed looking up from underneath the unit RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 8: ...Page 8 Installer s Guide Figure 5 4DCL4042 through 4DCL4060 2 of 3 RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 9: ...Page 9 Installer s Guide Figure 6 4DCL4042 through 4DCL4060 3 of 3 4DCL4042 090 4DCL4048 090 4DCL4060 115 RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 10: ...tion section for instruction on converting the supply and return airflow covers to down airflow 3 The field assembled Roof Mounting Curb BAYCURB050A or BAYCURB051A or a field fabricated curb should be in place before the unit is hoisted to the roof top The Roof Mounting Curb frame must be installed on a flat level section of the roof maximum of 1 4 per foot pitch and provide a level mounting surfa...

Page 11: ... mate rial shall be maintained on air outlet duct Rooftop Installation Curb Mounting Convert Horizontal Airflow to Down Airflow The factory ships the unit for horizontal airflow Perform this procedure to convert the unit to down airflow 1 Remove the three 3 sheet metal screws securing the supply air cover and the four 4 sheet metal screws securing the return air cover from the base of the unit Rem...

Page 12: ... 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 draw ings 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 Approxi...

Page 13: ...cations using field fabricated ducts and sleeper rails rather than a curb or frame use the following procedure 1 Locate and secure the sleeper rails to the roof 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 adjus...

Page 14: ...facturer is not responsible for the unauthorized use of this drawing and expressly disclaims any liability for damages resulting from such unauthorized use Gasket Seal Spreader Bars 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 use spreader bars as shown in these illustrations Figure 11 Curb Dimension...

Page 15: ... Application with Frame Supply Air Return Air Roof Flashing Channel Iron Center Support Center Support required on all Frame Applications Angle Iron Frame Roof Flashing Return Air Angle Iron Frame Roof Flashing Supply Air Channel Iron Center Support Center Support required on all Frame Applica tions RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 16: ...ation transmission Elbows with turning vanes or splitters are recommended to minimize air noise and resistance The first elbow in the ductwork leaving the unit should be no closer than two 2 feet from the unit to minimize noise and resistance To prevent leaking do not attach the ductwork to the bottom of the unit base refer to the bottom example in Figure 14 A 3 4 inch female NPT condensate drain ...

Page 17: ... pipe connection give serious consideration to providing the clearance necessary to remove the accesspanelsontheunit e g economizerandfilteraccesspanels 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 pe...

Page 18: ...nletboss 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 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 a...

Page 19: ...om 7000 8000 orifices must be changed to 50 HIGH ALTITUDE DERATE CHART NAT Altitude In Feet Inputs shown are with factory orifices 3 5 WC High Fire 1 8 WC Low Fire Natural Gas heating value of 950 btu cuft 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...

Page 20: ...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 abobve the selected outdoor temperature changeover oint if the heat pump capacity is not enough to maintain the indoor te...

Page 21: ...Page 21 Installer s Guide Figure 22 4DCL4 Field Wiring Diagram CONSTANT CIRCULATION 4DCL4 FIELD WIRING DIAGRAM RELEASED 10 Aug 2020 16 34 00 GMT ...

Page 22: ... to the normal operating pressures provided in the unit s SERVICE FACTS NOTE Do not use the PRESSURE CURVES from the unit s SERVICE FACTS to determine the unit refrigerant charge The correct charge is shown on the unit nameplate To charge the system accurately weigh in the charge according to the unit nameplate and check subcooling against the Subcooling Charging Table in the SERIVCE FACTS Voltage...

Page 23: ... 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 contr...

Page 24: ...ratures above 40 degrees heating is provided by Heat Pump operation only For temperatures 40 and below heating may be provided by both gas or Heat Pump operation 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 outd...

Page 25: ...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 ...

Page 26: ...o OFF for approximately three seconds then back ON 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 setpoi...

Page 27: ...a general unit inspection on a regular basis Filters When the system is in constant operation inspect the filters at least once each month If you have disposable type filters replace them with new filters of the same type and size Donotattempttocleandisposablefilters Permanent type filters can be cleaned by washing them with a milddetergentandwater Makesurethatthefiltersarethoroughly dry before re...

Page 28: ... 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 Status LED Liteport LED IGN Diagnostic Indicators Flash Codes CFM SELECTION LIGHT DIP SWITCHES CFM FAN R W3 W2 W1 Y Y LO J 21C800796P01 CNT03600 Figure 23 E...

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