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Installer’s Guide

IMPORTANT:  Read this entire manual before beginning installation procedures. 

 

Safety Considerations

WARNING: INDICATES A POTENTIALLY HAZ-

ARDOUS 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.

NOTICE

Warning and Cautions appear at appropriate locations 

throughout this guide. Read these carefully.

EXPLOSION HAZARD!

Propane gas is heavier than air and may collect in any low areas or con-

fined 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

!

CAUTION

!

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.

RECONNECT ALL GROUNDING DEVICES.

All parts of this product that are capable of conducting electrical cur-

rent 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.

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.

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 thor-

oughly.

• 

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

generate 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 

ceramic fibers are believed by the state of California to cause cancer 

through inhalation. Glasswool fibers may also cause respiratory, skin, or 

eye irritation.

CAUTION

!

Never use combustible cleaning fluids on any part of the furnace.

EXPLOSION HAZARD!

To prevent an explosion or possible injury, death, and equipment dam-

age, do not store combustible materials, gasoline, or other flammable 

vapors or liquids near the unit.

WARNING

!

WARNING

!

WARNING

!

WARNING

!

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.  

IMPORTANT:

 Reconnect all grounding devices. All parts of this product capable 

of conducting electrical current are grounded. If grounding wires, screws, straps, 
clips, nuts, or washers used to complete a path to ground are removed for service, 
they must be returned to their original position and properly fastened.

IMPORTANT:

 Wear appropriate gloves, arm sleeve protectors, and eye 

protection when servicing or maintaining this equipment.

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.

WARNING

!

IMPORTANT: 

Air filters and media wheels or plates shall meet the test require-

ments in UL 900.

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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