Unitary products group SUNLINE MAGNUM DJ180 Installation Manual Download Page 1

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INSTALLATION
MANUAL

CAUTION:

READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.

SAVE THIS MANUAL

SUNLINE MAGNUM™

GAS/ELECTRIC SINGLE PACKAGE

AIR CONDITIONERS

MODELS: DJ180, 210, 240 & 300

66352-YIM-D-0904

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .58

START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .59

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .61

See the following page for a complete Table of Contents.

NOTES, CAUTIONS AND WARNINGS

The installer should pay particular attention to the words:

NOTE

CAUTION

, and

WARNING

. Notes are intended to

clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to
alert installer that personal injury and/or equipment dam-
age may result if installation procedure is not handled
properly.

Summary of Contents for SUNLINE MAGNUM DJ180

Page 1: ...ATURE 6 INSTALLATION 17 OPERATION 51 START UP COOLING 58 START UP GAS HEAT 59 TROUBLESHOOTING 61 See the following page for a complete Table of Contents NOTES CAUTIONS AND WARNINGS The installer shoul...

Page 2: ...2 CONTINUOUS BLOWER 52 INTERMITTENT BLOWER 52 NO OUTDOOR AIR OPTIONS 52 ECONOMIZER WITH SINGLE ENTHALPY SENSOR 52 ECONOMIZER WITH DUAL ENTHALPY SENSORS 52 ECONOMIZER SINGLE OR DUAL WITH POWER EXHAUST...

Page 3: ...IPE SIZING 24 6 FOUR AND SIX POINT LOADS 30 7 PHYSICAL DATA 31 8 DJ ELECTRICAL DATA WITHOUT POWERED CONVENIENCE OUTLET 32 9 DJ ELECTRICAL DATA WITHOUT POWERED CONVENIENCE OUTLET CONTINUED 33 10 DJ ELE...

Page 4: ...in 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 follow all other safety p...

Page 5: ...mbustible material For use with natural gas or propane gas The installer should pay particular attention to the words NOTE CAUTION and WARNING Notes are intended to clarify or make the installation ea...

Page 6: ...Drive 4 Filters Single Input Econ R Options 3 4 Gas Heat Options H Std Mtr Drive 4 Filters Single Input Econ Power Exhaust S Option 5 N24 240 MBH Output Aluminized Steel L Std Mtr Drive BAS Ready Econ...

Page 7: ...S Technicoat Cond Coil Coil Guard CH CPC Controller DFS APS Technicoat Cond Coil Phase Monitor Coil Guard CJ CPC Controller DFS APS Technicoat Evap Coil CK CPC Controller DFS APS Technicoat Evap Coil...

Page 8: ...ouble Wall JZ Johnson UNT Controller DFS APS Double Wall Phase Monitor Coil Guard J1 Johnson UNT Controller DFS APS Double Wall Technicoat Cond Coils J2 Johnson UNT Controller DFS APS Double Wall Tech...

Page 9: ...Novar ETC 3 Controller DFS APS Technicoat Evap Coil NK Novar ETC 3 Controller DFS APS Technicoat Evap Coil Phase Monitor NL Novar ETC 3 Controller DFS APS Technicoat Evap Coil Coil Guard NM Novar ETC...

Page 10: ...ch LA Simplicity Intelli Comfort Controller LB Simplicity Intelli Comfort Controller Phase Monitor LC Simplicity Intelli Comfort Controller Coil Guard LD Simplicity Intelli Comfort Controller Phase Mo...

Page 11: ...w ModLINC Controller SS Drain Pan Technicoat Cond Coils WV Intelli Comfort w ModLINC Controller SS Drain Pan Technicoat Evap Coil WW Intelli Comfort w ModLINC Controller SS Drain Pan Technicoat Evap...

Page 12: ...Pan Technicoat Cond Coils Hinged Filter Door Toolless Access Panels DV CPC Controller DFS APS SS Drain Pan Technicoat Evap Coil Hinged Filter Door Toolless Access Panels DW CPC Controller DFS APS SS D...

Page 13: ...Hinged Filter Door Toolless Access Panels E8 Johnson UNT Controller DFS APS Double Wall SS Drain Pan Technicoat Evap and Cond Coils Hinged Filter Door Toolless Access Panels E9 Johnson UNT Controller...

Page 14: ...ard Hinged Filter Door Toolless Access Panels PR Novar ETC 3 Controller DFS APS Technicoat Evap Cond Coils Phase Monitor Coil Guard Hinged Filter Door Toolless Access Panels PS Novar ETC 3 Controller...

Page 15: ...icity Intelli Comfort Controller Technicoat Cond Coil Coil Guard Hinged Filter Door Toolless Access Panels QH Simplicity Intelli Comfort Controller Technicoat Cond Coil Phase Monitor Coil Guard Hinged...

Page 16: ...Phase Monitor Coil Guard Hinged Filter Door Toolless XS Intelli Comfort w ModLINC Controller SS Drain Pan Hinged Filter Door Toolless Access Panels XT Intelli Comfort w ModLINC Controller SS Drain Pa...

Page 17: ...in 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 g...

Page 18: ...of 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 Voltage Varation Min Max 1 208...

Page 19: ...sions 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 Ga...

Page 20: ...ge 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...

Page 21: ...must be 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 shutdown Minimum filter area and required sizes are...

Page 22: ...NTROL BOARD 1 Electronic programmable Thermostat 2ET0770010024 includes subbase 2 Terminals A1 and A2 provide a relay output to close the outdoor economizer dampers when the thermostat switches to the...

Page 23: ...the type shown on the wir ing diagram and the same minimum gauge as the replaced wire Electrical line must be sized properly to carry the load Use copper conductors only Each unit must be wired with...

Page 24: ...piping arrangements are shown in the figures on page 25 All shaded items are field supplied If gas supply line is routed through the unit s base ensure that the burner assembly can be removed for mai...

Page 25: ...accessible for test gage connection must be installed immediately upstream of the gas supply connection to the fur nace L P UNITS TANKS AND PIPING All gas heat units are shipped from the factory equip...

Page 26: ...the outside of the gas heat access panel with the screws provided in the bag also attached to the blower housing The screen for the combustion air intake hood is secured to the inside of the access pa...

Page 27: ...ng to the lettered curve of the Enthalpy Setpoint Adjustment Figure 9 For a dual enthalpy operation carefully turn the set point adjusting screw fully clockwise past the D setting POWER EXHAUST DAMPER...

Page 28: ...66352 YIM D 0904 28 Unitary Products Group FIGURE 9 ENTHALPY SETPOINT ADJUSTMENT...

Page 29: ...SO SO SR SR A B C D TR TR1 24 Vac HOT 24 Vac COM EF EF1 2 3 4 5 1 Exhaust Air Adjustment Screw Exhaust Air LED Damper Min Position Screw Indoor Air Quality Max Adjustment Screw Indoor Air Quality LED...

Page 30: ...2846 496 927 927 496 180 Gas 2660 302 316 453 590 565 434 210 Gas 2928 340 340 488 636 636 488 240 Gas 2960 344 344 493 643 643 493 300 Gas 3046 354 354 508 661 661 508 180 Elec 2460 280 292 419 546...

Page 31: ...t CONDENSER COIL COMPRESSOR Qty Per Unit SCROLL QUANTITY PER UNIT 12 X 24 X 2 TOTAL FACE AREA Sq Ft REFRIGANT 22 Lb Oz SYSTEM No 1 SYSTEM No 2 BASIC UNIT OPTIONS ACCESSORIES COOLING ONLY GAS ELECTRIC...

Page 32: ...1 7 2 0 0 None 0 0 36 1 45 E18 18 0 1 21 7 36 1 45 E36 36 0 2 43 3 63 1 70 E54 54 0 2 65 0 74 0 90 E72 72 0 2 86 6 95 6 110 575 8 3 78 0 9 5 9 0 0 None 0 0 28 2 35 E18 18 0 1 17 3 29 0 35 E36 36 0 2 3...

Page 33: ...8 2 0 0 None 0 0 44 6 50 E18 18 0 1 17 3 44 6 50 E36 36 0 2 34 6 53 6 60 E54 54 0 2 52 0 62 2 70 E72 72 0 2 69 3 79 5 90 25 208 47 1 245 3 7 38 6 0 0 None 0 0 159 4 200 E18 13 5 1 37 5 159 4 200 E36...

Page 34: ...7 2 5 0 None 0 0 41 1 50 E18 18 0 1 21 7 42 3 50 E36 36 0 2 43 3 69 4 70 E54 54 0 2 65 0 80 2 90 E72 72 0 2 86 6 101 9 110 575 8 3 78 0 9 5 9 4 0 None 0 0 32 2 40 E18 18 0 1 17 3 34 0 40 E36 36 0 2 3...

Page 35: ...8 2 4 0 None 0 0 48 6 60 E18 18 0 1 17 3 48 6 60 E36 36 0 2 34 6 58 6 60 E54 54 0 2 52 0 67 2 70 E72 72 0 2 69 3 84 5 90 25 208 47 1 245 3 7 38 6 10 0 None 0 0 169 4 200 E18 13 5 1 37 5 169 4 200 E36...

Page 36: ...he assembled hood kit must be removed prior to final installation This hood is 54 long NOTE A 1 clearance must be provided between any combustible material and the supply air ductwork for a distance o...

Page 37: ...he side supply and return air compartment pan els For side duct application 1 Replace the side panels on the supply and return air com partments with the accessory flange kit panels 2 Connect ductwork...

Page 38: ...tatic pressure and BHP Since no temperature data is given we will assume an air temperature of 70 F Table 10 shows the correction factor to be 0 832 Corrected static pressure 1 5 x 0 832 1 248 IWC Cor...

Page 39: ...66352 YIM D 0904 Unitary Products Group 39 FIGURE 14 ALTITUDE TEMPERATURE CONVERSION FACTOR...

Page 40: ...5 2 4 7 0 7 5 7 5 1 208 VOLT AND HIGH SPEED 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 41: ...5 0 980 5 0 1 6 5 3 4 5 1 4 5 8 4 9 1 2 6 3 5 3 0 7 6 9 5 8 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 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 1035 3 0 2 0 6 2 5 2 1 9...

Page 42: ...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 5...

Page 43: ...1 0 4 4 3 9 0 8 5 0 4 5 0 6 5 6 5 0 208 VOLT AND HIGH SPEED 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 44: ...2 6 9 5 8 980 5 0 1 9 4 5 3 8 1 5 5 4 4 5 1 0 6 3 5 3 0 4 7 2 6 1 995 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 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 5 1 4 3...

Page 45: ...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 46: ...3 13 7 11 2 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 1...

Page 47: ...erformance table TABLE 19 POWER EXHAUST PERFORMANCE MOTOR SPEED STATIC RESISTANCE 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...

Page 48: ...left to the factory setting If the TXV s have been adjusted in the field The charging chart may no longer apply FIGURE 16 CHARGING CHART 17 5 TON 17 5 Ton Charging Chart 100 150 200 250 300 350 400 60...

Page 49: ...the TXV s left to the factory setting If the TXV s have been adjusted in the field the charging chart may no longer apply FIGURE 18 CHARGING CHART 25 TON 25 Ton Charging Chart 100 150 200 250 300 350...

Page 50: ...upply 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 shorter bel...

Page 51: ...Pressure Drop vs Supply Air CFM Figure 20 After readings have been obtained remove the tubes and reinstall the two 5 16 dot plugs that were removed in Step 1 NOTE DE ENERGIZE THE COMPRESSORS BEFORE TA...

Page 52: ...PY SENSOR When the room thermostat calls for first stage cool ing the low voltage control circuit from R to G and Y1 is completed The UCB energizes the blower motor if the fan switch on the room therm...

Page 53: ...cribed above the UCB will monitor the low pressure limit switch for any openings If the low pressure switch opens for greater than 5 seconds the UCB will de energize the associated compressor initiate...

Page 54: ...om pressor reset or lock out FLASH CODES The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 26 RESET Remove the call for cooling...

Page 55: ...e temperature This resets any flash codes HEAT ANTICIPATOR SETPOINTS It is important that the anticipator setpoint be correct Too high of a setting will result in longer heat cycles and a greater temp...

Page 56: ...ails to detect a pilot flame it will continue to try for a maximum of 85 seconds to ignite the pilot tube If the pilot flame is not detected then IC2 will lock out first stage furnace operation for fi...

Page 57: ...rnace Each valve contains a main and a redundant valve The redundant valves are located upstream of the main gas valves Should either or both of the main gas valves fail in the open position the redun...

Page 58: ...switch to on 5 Check indoor blower rotation If blower rotation is in the wrong direction Refer to Phasing Section in general informa tion section Check blower drive belt tension 6 Check the unit suppl...

Page 59: ...on or turn gas valve switch to off position POST START CHECK LIST GAS After the entire control circuit has been energized and the heating section is operating make the following checks 1 Check for gas...

Page 60: ...controls function properly BURNER INSTRUCTIONS To check or change burners pilot or orifices CLOSE MAIN MANUAL SHUT OFF VALVE AND SHUT OFF ALL ELECTRIC POWER TO THE UNIT 1 Remove the screws holding eit...

Page 61: ...RE RISE The temperature rise or temperature difference between the return air and the heated air from the fur nace must lie within the range shown on the rating plate and the data in the Gas Heat Appl...

Page 62: ...t between R and G with the fan switch in the ON posi tion and in the AUTO position during operation calls b proper wiring between the room thermostat and the UCB and c loose wiring from the room therm...

Page 63: ...s 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 indication of an ASCD cycle The...

Page 64: ...and the compressor still does not oper ate replace the compressor 6 If 24 volts is not present at M2 check for 24 volts at the UCB terminal C2 If 24 volts are present check for loose wiring between C...

Page 65: ...If 24 volts are present at the UCB Y1 terminal the compressor may be out due to an open high pres sure switch low pressure switch or freezestat Check for 24 volts at the HPS1 LPS1 and FS1 terminals o...

Page 66: ...ates and the furnace lights but the supply air blower motor does not energize after a short delay the room thermostat fan switch is in AUTO position 1 Place the thermostat fan switch in the ON posi ti...

Page 67: ...een R and G during W1 calls On calls for heating the supply air blower operates but the draft motor does not the room thermostat fan switch is in the AUTO position 1 The draft motor has inherent prote...

Page 68: ...ring is intact check for 24 volts across ter minals PV and COMMON on the ignitor control If 24 volts is not present replace the ignitor control 4 If 24 volts is present remove the pilot burner and rem...

Page 69: ...alarms most recent to oldest separating each alarm flash code by approximately 2 seconds In some cases it may be necessary to zero the ASCD for the compressors in order to perform trouble shooting To...

Page 70: ...66352 YIM D 0904 70 Unitary Products Group...

Page 71: ...66352 YIM D 0904 Unitary Products Group 71...

Page 72: ...e without notice Printed in U S A 66352 YIM D 0904 Copyright 2004 by Unitary Products Group All rights reserved Supersedes 66352 YIM C 0504 035 18567 002 C 0504 Unitary 5005 Norman Products York OK Gr...

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