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Installer’s Guide

*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 first stage gas 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 first stage gas 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 4DCZ6 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 4DCZ6 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.

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 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.

Summary of Contents for 4DCZ6036

Page 1: ...erent 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 t...

Page 2: ...ingpressureexceedsthelimitofR 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 appr...

Page 3: ...arefully before attempting to install oper ate or perform maintenance on this unit Installation and maintenance should be performed by qualified service techni cians only This unit is listed by Underw...

Page 4: ...Guide Step 2 Determine Unit Clearances Figure 1 4DCZ6036 1 of 3 Figures 1 through 6 show the unit critical dimensions NOTE The view labeled Bottom Side represents the Base as viewed looking up from u...

Page 5: ...Page 5 Installer s Guide Figure 2 4DCZ6036 2 of 3...

Page 6: ...Page 6 Installer s Guide Figure 3 4DCZ6036 3 of 3...

Page 7: ...Page 7 Installer s Guide Figure 4 4DCZ6048 through 4DCZ6060 1 of 3...

Page 8: ...Page 8 Installer s Guide Figure 5 4DCZ6048 through 4DCZ6060 2 of 3...

Page 9: ...Page 9 Installer s Guide Figure 6 4DCZ6048 through 4DCZ6060 3 of 3...

Page 10: ...fer 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 fabric...

Page 11: ...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 airflo...

Page 12: ...he 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 preparin...

Page 13: ...r roof top applications using field fabricated ducts and sleeper rails rather than a curb or frame use the following procedure 1 Locate and secure the sleeper rails to the roof Three 3 sleeper rails a...

Page 14: ...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 Gasket Seal Spreader Bars B...

Page 15: ...rizontal Airflow Application with Frame Supply Air Return Air Roof Flashing Channel Iron Center Support Center Sup port required on all Frame Applications Angle Iron Frame Roof Flashing Return Air Ang...

Page 16: ...ise and vibration transmission Elbows with turning vanes or splitters are recommended to minimize air noise and resistance The first elbow in the ductwork leaving the unit should be no closer than two...

Page 17: ...making the gas pipe connection give serious consideration to providing the clearance necessary to remove the accesspanelsontheunit e g economizerandfilteraccesspanels NOTE In the absence of local cod...

Page 18: ...chonthegasvalveinletboss 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...

Page 19: ...Models that require 49 orifices for altitudes from 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...

Page 20: ...ed 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 out...

Page 21: ...ns 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 ac...

Page 22: ...Page 22 Installer s Guide Figure 22 4DCZ6 Field Wiring Diagram 4DCZ6 FIELD WIRING DIAGRAM Y2 YL RD 2NDSTAGECOMPRESSOR 1STSTAGECOMPRESSOR CONSTANTCIRCULATION...

Page 23: ...h 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 Step 5 Unit Startup le...

Page 24: ...ot 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 T...

Page 25: ...e 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 c...

Page 26: ...fter 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 t...

Page 27: ...he 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 c...

Page 28: ...fast flashes is 3 seconds Status LED Liteport LED IGN Diagnostic Indicators Flash Codes Figure 23 ECM Fan Control ECM Fan Motor Adjustments If the airflow needs to be increased or decreased see the A...

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