Unitary products group Sunline 2000 DM180 Installation Manual Download Page 3

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284806-YIM-B-0707

Unitary Products Group

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING TROUBLESHOOTING GUIDE . . . . . . . . . . . 53
GAS HEAT TROUBLESHOOTING GUIDE . . . . . . . . . . 58
UNIT CONTROL BOARD FLASH CODES . . . . . . . . . . 60

UNIT CONTROL BOARD OPTION SETUP

. . . . . . . . . . .

OPTION BYTE SETUP  . . . . . . . . . . . . . . . . . . . . . . . . . 62
HEAT DELAY SETUP  . . . . . . . . . . . . . . . . . . . . . . . . . . 62
OPTIONAL VAV CONTROL BOARD FLASH CODES  . 63

LIST OF FIGURES

Fig. #

Pg. #

TYPICAL RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . . 9

FIXED OUTDOOR AIR DAMPER . . . . . . . . . . . . . . . . 11

RECOMMENDED DRAIN PIPING . . . . . . . . . . . . . . . 11

TYPICAL FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . 12

EXTERNAL SUPPLY CONNECTION EXTERNAL
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

BOTTOM SUPPLY CONNECTION EXTERNAL
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

VENT AND COMBUSTION AIR HOOD . . . . . . . . . . . 17

ENTHALPY SETPOINT ADJUSTMENT . . . . . . . . . . . 22

10 HONEYWELL ECONOMIZER CONTROL W7212 . . . 23

11 FOUR AND SIX POINT LOADS . . . . . . . . . . . . . . . . . 23

12 CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . 24

13 FRONT VIEW DIMENSIONS (15, 20 & 25 TON) . . . . 30

14 REAR VIEW DIMENSIONS . . . . . . . . . . . . . . . . . . . . 31

15 UNIT CLEARANCE AND RAIN HOOD DIMENSIONS

(15, 20 & 25 TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16 ALTITUDE/TEMPERATURE CONVERSION

FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

17 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 41

18 PRESSURE DROP ACROSS A DRY INDOOR COIL

VS SUPPLY AIR CFM FOR ALL UNIT
TONNAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

19 GAS VALVE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . 49

20 GAS VALVE AND CONTROLS . . . . . . . . . . . . . . . . . 50

21 TYPICAL GAS VALVES . . . . . . . . . . . . . . . . . . . . . . . 52

22 PROPER FLAME ADJUSTMENT . . . . . . . . . . . . . . . . 52

23 TYPICAL FLAME APPEARANCE . . . . . . . . . . . . . . . . 52

24 UNIT CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . 61

LIST OF TABLES

Tbl. #

Pg. #

1 UNIT APPLICATION DATA . . . . . . . . . . . . . . . . . . . . . 8

2 CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . 13

3 ELECTRIC HEAT APPLICATION DATA . . . . . . . . . . 14

4 GAS HEAT APPLICATION DATA . . . . . . . . . . . . . . . 14

5 PIPE SIZING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 FOUR AND SIX POINT LOADS . . . . . . . . . . . . . . . . . 23

7 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8 SUPPLY FAN VFD WEIGHTS, IN LBS. . . . . . . . . . . . 25

9 DM 180, 240 ELECTRICAL DATA WITHOUT

POWERED CONVENIENCE OUTLET . . . . . . . . . . . . 26

10 DM 300 ELECTRICAL DATA STANDARD MOTOR

WITHOUT POWERED CONVENIENCE OUTLET . . . 27

11 DM 300 ELECTRICAL DATA HIGH STATIC MOTOR

WITHOUT POWERED CONVENIENCE OUTLET . . . 27

12 DM 180, 240 ELECTRICAL DATA WITH POWERED

CONVENIENCE OUTLET . . . . . . . . . . . . . . . . . . . . . 28

13 DM 300 ELECTRICAL DATA STANDARD MOTOR

WITH POWERED CONVENIENCE OUTLET . . . . . . 29

14 DM 300 ELECTRICAL DATA HIGH STATIC MOTOR

WITH POWERED CONVENIENCE OUTLET . . . . . . 29

15 ALTITUDE CORRECTION FACTORS . . . . . . . . . . . . 33

16 SUPPLY AIR BLOWER PERFORMANCE (15 TON) -

COOLING ONLY 180 MBH - BOTTOM DUCT
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

17 SUPPLY AIR BLOWER PERFORMANCE (20 TON) -

COOLING ONLY 240 MBH - BOTTOM DUCT
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

18 SUPPLY AIR BLOWER PERFORMANCE (15 TON) -

GAS HEAT 180 MBH - BOTTOM DUCT
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

19 SUPPLY AIR BLOWER PERFORMANCE (20 TON) -

GAS HEAT 240 MBH - BOTTOM DUCT
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

20 SUPPLY AIR BLOWER PERFORMANCE (25 TON) -

GAS HEAT 300 MBH - BOTTOM DUCT
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

21 STATIC RESISTANCES . . . . . . . . . . . . . . . . . . . . . . . 40

22 POWER EXHAUST PERFORMANCE . . . . . . . . . . . . 40

23 BLOWER MOTOR AND DRIVE DATA . . . . . . . . . . . . 40

24 LIMIT CONTROL SETTING . . . . . . . . . . . . . . . . . . . . 47

25 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . 48

26 LIMIT CONTROL SETTING . . . . . . . . . . . . . . . . . . . . 50

27 GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . 50

28 GAS RATE - CUBIC FEET PER HOUR . . . . . . . . . . . 53

29 UNIT CONTROL BOARD FLASH CODES . . . . . . . . . 61

30 HEAT DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

31 VAV CONTROL BOARD FLASH CODES . . . . . . . . . 63

Summary of Contents for Sunline 2000 DM180

Page 1: ...URE 6 INSTALLATION 7 OPERATION 42 START UP COOLING 49 START UP GAS HEAT 50 TROUBLESHOOTING 52 See the following pages for a complete Table of Contents NOTES CAUTIONS AND WARNINGS The installer should...

Page 2: ...OPERATION 43 SEQUENCE OF OPERATIONS OVERVIEW 43 COOLING SEQUENCE OF OPERATION 43 CONTINUOUS BLOWER 43 INTERMITTENT BLOWER 43 OPTIONAL VAV BLOWER OPERATION 43 NO OUTDOOR AIR OPTIONS 43 ECONOMIZER WITH...

Page 3: ...HEAT APPLICATION DATA 14 4 GAS HEAT APPLICATION DATA 14 5 PIPE SIZING 14 6 FOUR AND SIX POINT LOADS 23 7 PHYSICAL DATA 25 8 SUPPLY FAN VFD WEIGHTS IN LBS 25 9 DM 180 240 ELECTRICAL DATA WITHOUT POWER...

Page 4: ...d install repair main tain or service this equipment Observe all precautions in the literature on labels and tags accompanying the equipment whenever working on air conditioning equipment Be sure to f...

Page 5: ...r attention to the words NOTE CAUTION and WARNING Notes are intended to clarify or make the installation easier Cau tions are given to prevent equipment damage Warn ings are given to alert installer t...

Page 6: ...r Door Tool Free Access Panels BG Coil Guard Dirty Filter Switch Hinged Filter Door Tool Free Access Panels BH Phase Monitor Coil Guard Dirty Filter Switch Hinged Filter Door Tool Free Access Panels 1...

Page 7: ...n accordance with the following national and local safety codes In U S A National Electrical Code ANSI NFPA No 70 National Fuel Gas Code Z223 1 Gas Fired Central Furnace Standard ANSI Z21 47a Local ga...

Page 8: ...ed on a roof curb or special frame other than a YORK roof curb gasketing must be applied to all surfaces that come in contact with the unit underside TABLE 1 UNIT APPLICATION DATA UNIT MODEL NUMBER DM...

Page 9: ...ions for ade quate combustion and ventilation air in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 in U S A or Sections 7 2 7 3 or 7 4 of Gas...

Page 10: ...surfaces on the hood prior to installing the hood Extend gasketing 1 4 inch beyond the top and bottom of the two side flanges to insure adequate sealing Adjusting the damper to the desired air flow ma...

Page 11: ...kept clean or replaced with same size and type Dirty filters will reduce the capacity of the unit and will result in frosted coils or safety shut down Minimum filter area and required sizes are shown...

Page 12: ...7 0 0 1 0 0 2 4 i n c l u d e s s u b b a s e 2 T e r m i n a l s A 1 a n d A 2 p r o v i d e a r e l a y o u tp u t to c l o s e th e o u td o o r e c o n o m i z e r d a m p e r s w h e n th e th e...

Page 13: ...r cir cuits Wire entry at knockout openings require conduit fittings to comply with NEC in U S A CEC in Can ada and or local codes Refer to Figure 13 for installa tion location If any of the wire supp...

Page 14: ...iping All units require a one inch pipe connection at the entrance fitting Maximum capacity of pipe in cubic feet of gas per hour Based upon a pressure drop of 0 3 inch water column and 0 6 specific g...

Page 15: ...o the unit have been purged of air 5 The gas supply should be a separate line and installed in accordance with all safety codes as prescribed under Limitations After the gas con nections have been com...

Page 16: ...d L P propane gas suppliers L P propane gas is an excellent solvent and special pipe compound must be used when assembling piping for this gas as it will quickly dissolve white lead or most standard c...

Page 17: ...n be found in the kit The exhaust fan all supporting brackets angles and the wiring are factory installed as part of the power exhaust option OPTIONAL ECONOMIZER AND POWER EXHAUST DAMPER SET POINT ADJ...

Page 18: ...the economizer access panel from the unit Loosen but do not remove the two panel latches Locate the economizer actuator where the following adjustment can be made With power exhaust option each build...

Page 19: ...its installed with economizer option APS a 24 VAC binary input provided by a field installed air proving switch which monitors the pressure difference across the indoor blower PUR a 24 VAC binary inpu...

Page 20: ...ailable with BAS ready models Terminal blocks are provided in the con trol box in place of the VAV control board for field wir ing of a customer installed BAS to receive 24 VAC power and to connect to...

Page 21: ...d after the drive is installed A terminal block located in the control box is provided for field connection of the VFD speed reference signal 2 10 VDC and to the normally open run permit auxil iary co...

Page 22: ...C C B B A A CONTROL CURVE CONTROL POINT APPROX 0 F 0 C AT 50 RH A D C B 63 17 73 23 70 21 67 19 FIGURE 10 HONEYWELL ECONOMIZER CONTROL W7212 N1 N P1 P EXH Set EXH Min Pos IAQ Max IAQ IAQ Min Free Coo...

Page 23: ...563 715 684 300 Gas 2531 593 645 674 619 180 Elec 2100 492 514 558 536 240 Elec 2300 295 517 658 630 300 Elec 2331 546 594 621 570 Unit Size Total Shipping Weight 6 Point Loads lbs A B C D E F 180 Ga...

Page 24: ...r 4 4 4 QUANTITY PER UNIT 18 X 24 X 2 or 4 5 TOTAL FACE AREA Sq Ft 15 20 24 CHARGE REFRIGERANT 22 Lb Oz SYSTEM No 1 17 8 18 0 18 0 SYSTEM No 2 8 8 18 0 18 0 OPERATING WEIGHTS LBS BASIC UNIT COOLING ON...

Page 25: ...6 62 2 2 7 0 0 0 None 0 0 42 6 50 E18 18 0 1 21 7 42 6 50 E36 36 0 2 43 3 62 9 70 E54 54 0 2 65 0 73 7 90 E72 72 0 2 86 6 95 4 110 575 7 7 50 1 7 5 3 0 0 None 0 0 33 7 40 E18 18 0 1 17 3 33 7 40 E36 3...

Page 26: ...102 9 110 575 17 3 102 1 7 10 0 0 0 None 52 3 60 E18 18 0 1 17 3 52 3 60 E36 36 0 2 34 6 55 8 60 E54 54 0 2 52 0 64 5 70 E72 72 0 2 69 3 81 8 90 TABLE 11 DM 300 ELECTRICAL DATA HIGH STATIC MOTOR WITHO...

Page 27: ...62 2 2 7 0 5 0 None 0 0 47 6 50 E18 18 0 1 21 7 47 6 50 E36 36 0 2 43 3 69 1 70 E54 54 0 2 65 0 80 0 90 E72 72 0 2 86 6 101 6 110 575 7 7 50 1 7 5 3 4 0 None 0 0 37 7 45 E18 18 0 1 17 3 37 7 45 E36 36...

Page 28: ...109 1 110 575 17 3 102 1 7 10 0 4 0 None 56 3 70 E18 18 0 1 17 3 56 3 70 E36 36 0 2 34 6 60 8 70 E54 54 0 2 52 0 69 5 70 E72 72 0 2 69 3 86 8 90 TABLE 14 DM 300 ELECTRICAL DATA HIGH STATIC MOTOR WITH...

Page 29: ...IT BASE WITH RAILS Shown separately to illustrate Bottom Duct openings Power and Gas Piping Connection locations 12 1 2 9 1 4 8 1 8 9 3 4 3 3 4 B POWER WIRING ENTRY A CONTROL WIRING ENTRY 92 CONDENSER...

Page 30: ...n The covering consists of a heavy black paper composition 3 Replace the side supply and return air compartment panels For side duct applications 1 Replace the side panels on the supply and return air...

Page 31: ...CE LOCATION CLEARANCE Front 36 Rear 24 Less Economizer 49 With Economizer Left Side Filter Access 24 Less Economizer 36 With Economizer 3 Right Side Cond Coil 36 Below Unit1 1 Units may be installed o...

Page 32: ...tatic pressure and BHP Since no temperature data is given we will assume an air temperature of 70 F Table 15 shows the correction factor to be 0 832 Corrected static pressure 1 5 x 0 832 1 248 IWC Cor...

Page 33: ...284806 YIM B 0707 Unitary Products Group 33 FIGURE 16 ALTITUDE TEMPERATURE CONVERSION FACTOR...

Page 34: ...5 2 4 7 0 7 5 7 5 1 208 VOLT AND HIGH STATIC DRIVE 965 6 0 1 2 2 9 2 6 1 0 3 6 3 2 0 8 4 0 3 6 0 5 4 7 4 2 0 4 5 0 4 4 980 5 5 1 3 3 0 2 7 1 1 3 7 3 3 0 9 4 1 3 7 0 6 4 8 4 3 0 5 5 1 4 6 1025 4 5 1 5...

Page 35: ...6 3 5 3 0 7 6 9 5 8 0 2 7 3 6 1 1010 4 0 1 8 5 8 4 9 1 7 6 3 5 3 1 5 6 9 5 8 1 0 7 5 6 3 0 5 7 9 6 7 1020 3 5 1 9 6 1 5 1 1 8 6 5 5 5 1 6 7 1 6 0 1 1 7 8 6 6 0 6 8 3 7 0 1035 3 0 2 0 6 2 5 2 1 9 6 8...

Page 36: ...1 0 4 4 3 9 0 8 5 0 4 5 0 6 5 6 5 0 208 VOLT AND HIGH STATIC DRIVE 965 6 0 1 2 2 7 2 5 0 9 3 2 2 9 0 6 3 7 3 3 0 4 4 4 3 9 0 2 5 0 4 5 980 5 5 1 3 2 9 2 6 1 0 3 4 3 0 0 7 3 8 3 4 0 5 4 5 4 0 0 3 5 1 4...

Page 37: ...0 1 9 4 5 3 8 1 5 5 4 4 5 1 0 6 3 5 3 0 4 7 2 6 1 0 1 8 5 7 1 995 4 5 2 1 4 5 3 9 1 6 5 5 4 7 1 1 6 4 5 4 0 5 7 5 6 3 0 2 8 6 7 3 1025 3 5 2 3 4 9 4 1 1 8 5 8 4 9 1 3 6 7 5 7 0 7 8 0 6 7 1050 2 5 2 5...

Page 38: ...1215 4 0 2 7 8 6 7 0 2 1 10 4 8 5 1 4 12 3 10 1 0 6 14 3 11 7 1255 3 0 3 0 9 1 7 4 2 4 11 0 9 0 1 7 12 9 10 6 0 9 15 0 12 3 1290 2 0 3 2 9 5 7 8 2 7 11 5 9 4 2 0 13 5 11 1 1 2 15 6 12 8 1330 1 0 3 5...

Page 39: ...ESISTANCE OF RETURN DUCTWORK IWG 0 2 0 3 0 4 0 5 0 6 CFM KW CFM KW CFM KW CFM KW CFM KW HIGH 5250 0 83 4500 0 85 4200 0 88 3750 0 93 3000 0 99 MEDIUM 4900 0 77 3900 0 79 3500 0 82 2900 0 85 LOW 4400 0...

Page 40: ...the supply air blower and the motor pulley adjustment turns open can be determined from the Blower Per formance Data Tables High speed drive accessories containing a smaller blower pulley and a shorte...

Page 41: ...evaporator coil may vary greatly measuring the pressure drop across a wet coil under field conditions would be inaccurate To assure a dry coil the compressors should be deac tivated while the test is...

Page 42: ...own NO OUTDOOR AIR OPTIONS When the thermostat calls for the first stage of cooling the low voltage control circuit from R to Y1 and G is completed For first stage cooling compressor 1 condenser fan m...

Page 43: ...t on the economizer control When the power exhaust is operating the second stage of mechanical cooling will not operate As always the R to G connection provides minimum position but does not provide p...

Page 44: ...cooling system is monitored for operation outside of the intended parameters Errors are handled as described below All system errors override minimum run times for compressors HIGH PRESSURE LIMIT SWIT...

Page 45: ...ssure switches are hard soldered to the unit The refrigeration systems are independently mon itored and controlled On any fault only the associated system will be affected by any safety preventive act...

Page 46: ...s The control circuit includes the following safety con trols 1 Temperature Limit Switch TLS 1 2 This control is located inside the heater compart ment and is set to open at the temperature indi cated...

Page 47: ...ontrol circuit from R to W2 is completed thru the UCB Heat relay RW2 is ener gized The RW2 1 contact is closed energizing the second stage ignition module IC2 IC2 will immedi ately start the second st...

Page 48: ...at least 15 seconds during the fan on delay for heating and GV voltage or W1 is lost the indoor blower is forced on for the length of the fan off delay for heating SAFETY CONTROLS The unit control bo...

Page 49: ...rature swing in the conditioned space Reducing the value below the correct setpoint will give shorter ON cycles and may result in the low ering of the temperature within the conditioned space START UP...

Page 50: ...above room tem perature pilot burner ignition will occur and after an interval to prove pilot flame main burners will ignite TO SHUT DOWN 1 Turn off electric power to unit 2 Depress knob of gas valve...

Page 51: ...ER TO THE UNIT 1 Remove the screws holding either end of the mani fold to the burner supports 2 Open the union fitting in the gas supply line just upstream of the unit gas valve and downstream from th...

Page 52: ...Take readings of both the return air and the heated air in the ducts about six feet from the furnace where they will not be affected by radiant heat Increase the blower cfm to decrease the temper atu...

Page 53: ...wiring between the UCB and M3 8 If 24 volts is not present at the FAN terminal check for 24 volts from the room thermostat If 24 volts are not present from the room thermostat check for the following...

Page 54: ...Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug the jumper in the Mate N Lock plug and in the wiring from the Mate N Lock plug to th...

Page 55: ...ave opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing a code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms o...

Page 56: ...next step 10 If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out the UCB may have the compres sor in an ASCD Check the LED for an indic...

Page 57: ...Failing the above if there is line voltage supplied at M3 M3 is pulled in and the supply air blower motor still does not operate replace the motor For units with VFD if there is line voltage supplied...

Page 58: ...rmo stat to the relay board If all connections are cor rect replace the relay board The draft motor runs but the furnace does not light and the sparker does not spark 1 The ignition control IC1 IC2 ma...

Page 59: ...ignitor control and the gas valve If intact check for 24 volts across terminals MV and COMMON termi nals If no voltage detected replace ignitor control If voltage is present replace gas valve Furnace...

Page 60: ...es FS1 Compressor Lockout Off Off On On On 8 Flashes FS2 Compressor Lockout Off On Off Off Off 9 Flashes Ignition Control Locked Out Ignition Control Failure Off On Off Off On 10 Flashes Compressors L...

Page 61: ...east 2 seconds The green status LED Option Byte will be turned on and the red status LED Heat Delay is turned off Press the COMM SETUP SELECT button to tog gle into the Heat Delay Setup the green LED...

Page 62: ...heartbeat with the error flash codes shown in the table below To prevent confusion a 1 flash flash code is not used TABLE 31 VAV CONTROL BOARD FLASH CODES FLASH CODE DESCRIPTION On Steady Control Fail...

Page 63: ...284806 YIM B 0707 Unitary Products Group 63...

Page 64: ...t to change without notice Printed in U S A 284806 YIM B 0707 Copyright 2007 by Unitary Products Group All rights reserved Supersedes 284806 YIM A 0107 Unitary 5005 Norman Products York OK Group Drive...

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