York SUNLINE DCG Series User Manual Download

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INSTALLATION
MANUAL

CAUTION:

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

SAVE THIS MANUAL

SUNLINE™

GAS/ELECTRIC SINGLE PACKAGE

AIR CONDITIONERS

D(CE, CG) 036, 048, 060 & 072

D(HE, HG) 036, 048 & 060

290699-YIM-B-0607

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 5

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 6

APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 45

START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . 45

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 48

SEE THE FOLLOWING PAGES 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 damage may
result if installation procedure is not handled properly.

Summary of Contents for SUNLINE DCG Series

Page 1: ...NOMENCLATURE 6 INSTALLATION 8 OPERATION 39 START UP COOLING 45 START UP GAS HEAT 45 TROUBLESHOOTING 48 SEE THE FOLLOWING PAGES FOR A COMPLETE TABLE OF CONTENTS NOTES CAUTIONS AND WARNINGS The installe...

Page 2: ...ER EXHAUST 40 MOTORIZED OUTDOOR AIR DAMPERS 40 COOLING OPERATION ERRORS 40 HIGH PRESSURE LIMIT SWITCH 41 LOW PRESSURE LIMIT SWITCH 41 FREEZESTAT 41 LOW AMBIENT COOLING 41 SAFETY CONTROLS 41 COMPRESSOR...

Page 3: ...EYWELL ECONOMIZER CONTROL W7212 19 9 FOUR AND SIX POINT LOADING 20 10 UNIT DIMENSIONS 3 6 TON COOLING ONLY ELECTRIC HEAT FRONT VIEW 29 Fig Pg 11 UNIT DIMENSIONS 3 6 TON COOLING GAS HEAT FRONT VIEW 30...

Page 4: ...RIC HEAT CORRECTION FACTORS 29 17 VOLTAGE LIMITATIONS 29 Tbl Pg 18 UTILITIES ENTRY 32 19 MINIMUM CLEARANCES 32 20 SUPPLY AIR BLOWER PERFORMANCE 3 TON BELT DRIVE SIDE DUCT APPLICATION 33 21 SUPPLY AIR...

Page 5: ...d trained service personnel should 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 co...

Page 6: ...to clarify or make the installation easier Cau tions are given to prevent equipment damage Warn ings are given to alert installer that personal injury and or equipment damage may result if installatio...

Page 7: ...e Package Air Conditioner Air Cooled PRODUCT GENERATION 2 Second Generation 3 Third Generation PRODUCT IDENTIFIER HE Cooling VOLTAGE CODE 036 3 Ton 048 4 Ton 060 5 Ton 25 208 230 3 60 46 460 3 60 58 5...

Page 8: ...res under construction LIMITATIONS These units must be installed in accordance with the following national and local safety codes In U S A National Electrical Code ANSI NFPA No 70 National Fuel Gas Co...

Page 9: ...for this pur pose Fork lengths must be a minimum of 42 inches Remove the nesting brackets from the four corners on the top of the unit All screws that are removed when removing the brackets must be r...

Page 10: ...at this opening be accessible when the unit is installed in service and of a size such that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exc...

Page 11: ...rea and required sizes are shown in Physical Data Tables 9 and 11 SERVICE ACCESS The following removable panels provide access to all serviceable components Compressor compartment Electric Heat compar...

Page 12: ...W1 W2 G LED 1 LED 2 COM A1 A2 T T B R Y1 Y2 G C X OCC W2 W1 THERMOSTAT1 TERMINALS UNIT TERMINAL STRIP TB1 24 VOLT TRANSFORMER TO REMOTE SENSOR 2TH040702224 IF USED NOT USED ADD JUMPER ADD JUMPER 4 4...

Page 13: ...d or local codes If any of the wire supplied with the unit must be replaced replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire Use copper...

Page 14: ...he range shown TABLE 3 ELECTRIC HEATER CFM LIMITATIONS UNITMODEL SIZE NOMINAL TONS VOLTAGE MINIMUM SUPPLY AIR CFM HEATER SIZE NOMINAL KW 5 7 10 15 20 30 3 208 230 3 60 1100 1100 1200 1200 1300 460 3 6...

Page 15: ...the unit should be sealed to prevent water from leaking into the building Gas piping recommendations 1 A drip leg and a ground joint union must be installed in the gas piping 2 When required by local...

Page 16: ...ovided at the unit manifold under full load Maintaining proper gas pressure depends on three main factors 1 The vaporization rate depends on a the tempera ture of the liquid and b the wetted surface a...

Page 17: ...penings on the gas heat access panel ECONOMIZER MOTORIZED DAMPER AND RAIN HOOD The instruction for the optional economizer motorized damper and rain hood can be found in form 035 07364 000 Use these i...

Page 18: ...STMENT The enthalpy set point may now be set by selecting the desired setpoint shown in the Enthalpy Setpoint Adjust ment Figure 7 Adjust as follows For a single enthalpy operation carefully turn the...

Page 19: ...D 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 8 HONEYWELL ECONOMIZER CONTROL W7212 N1 N P1 P EXH Set EXH Min Pos IAQ Max IAQ IAQ Min Free Coo...

Page 20: ...4 102 100 99 126 128 129 DCE060 Cooling Electric 640 142 140 178 181 95 94 93 118 119 121 DCG060N079 700 155 153 194 198 104 103 101 129 131 132 DCG060N099 710 158 155 197 201 105 104 103 131 132 134...

Page 21: ...eep 1 1 1 2 Fins Per Inch 16 16 22 16 Face Area Sq Ft 17 1 17 1 17 1 16 7 COMPRESSOR Qty Per Unit Quantity Type 1 Recip 1 Scroll 1 Scroll 1 Scroll AIR FILTERS Quantity Per Unit 15 X 20 X 1 or 2 2 2 2...

Page 22: ...2 2 2 Fins Per Inch 18 18 18 Face Area Sq Ft 17 1 17 1 17 1 COMPRESSOR Qty Per Unit Recip Type 1 1 1 AIR FILTERS Quantity Per Unit 15 X 20 X 1 or 2 2 2 2 Quantity Per Unit 14 X 25 X 1 or 2 1 1 1 Tota...

Page 23: ...5107462 6 8 8 2 13 0 15 2CE045110462 10 1 12 1 17 9 20 2CE045115462 13 6 16 4 23 2 25 2CE045120462 19 5 23 5 32 1 35 575 3 60 3 9 36 0 0 8 2 2 None 7 3 15 2CE04511058 10 6 10 2 14 9 15 2CE04511558 15...

Page 24: ...15 3 22 4 25 2CE04512058 21 2 20 4 28 8 30 2CE04513058 30 4 29 3 39 9 40 D CE CG 072 6 0 208 3 60 18 9 146 0 1 3 6 8 None 31 7 40 2CE045105252 4 11 1 31 7 40 2CE045107252 5 6 15 5 31 7 40 2CE04511025...

Page 25: ...7462 6 8 8 2 13 5 15 2CE045110462 10 1 12 1 18 4 20 2CE045115462 13 6 16 4 23 7 25 2CE045120462 19 5 23 5 32 6 35 575 3 60 3 9 36 0 0 8 2 0 None 7 5 15 2CE04511058 10 6 10 2 15 2 20 2CE04511558 15 9 1...

Page 26: ...8 15 9 15 3 21 6 25 2CE04512058 21 2 20 4 28 30 2CE04513058 30 4 29 3 39 1 40 D CE CG 072 6 0 208 3 60 18 9 146 0 1 3 5 0 None 29 9 40 2CE045105252 4 11 1 29 9 40 2CE045107252 5 6 15 5 29 9 40 2CE0451...

Page 27: ...1 2 51 0 70 2 80 460 3 60 6 7 54 0 1 3 2 6 None 12 3 15 2CE045107462 6 8 8 2 13 5 15 2CE045110462 10 1 12 1 18 4 20 2CE045115462 13 6 16 4 23 7 25 2CE045120462 19 5 23 5 32 6 35 D HE HG 048 4 0 208 3...

Page 28: ...29 1 40 2CE04511025 10 6 25 5 38 4 40 2CE04511525 15 9 38 2 54 3 60 2CE04512025 21 2 51 0 70 2 80 2CE04513025 29 6 71 2 95 5 100 460 3 60 8 3 69 0 1 3 2 6 None 14 3 20 2CE045107462 6 8 8 2 14 3 20 2C...

Page 29: ...CAP MULTIPLIER 208 208 0 75 240 230 0 92 480 460 0 92 600 575 0 92 TABLE 17 VOLTAGE LIMITATIONS1 1 Utilization Range A in accordance with ARI Standard 110 POWER SUPPLY VOLTAGE MIN MAX 208 230 3 60 18...

Page 30: ...290699 YIM B 0607 30 Unitary Products Group FIGURE 11 UNIT DIMENSIONS 3 6 TON COOLING GAS HEAT FRONT VIEW FIGURE 12 UNIT WITH ECONOMIZER RAINHOOD DETAIL A...

Page 31: ...290699 YIM B 0607 Unitary Products Group 31 FIGURE 13 UNIT WITH FIXED OUTDOOR AIR MOTORIZED DAMPER RAINHOOD DETAIL B FIGURE 14 UNIT DIMENSIONS REAR VIEW...

Page 32: ...located by the side in the insulation Control Wiring2 2 Do not remove the 2 knockout ring Side Bottom B 2 KO1 Power Wiring Side Bottom C 1 5 8 KO Gas Piping Front D 1 1 2 KO Gas Piping Bottom TABLE 19...

Page 33: ...90 580 RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS 1700 1600 1500 1400 1055 875 1300 1036 780 1066 850 1200 1011 735 1047 765 1075 800 1100 987 690 1028 720 1060 750 1084 775...

Page 34: ...WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS 2000 1103 1270 1900 1085 1210 1800 1064 1145 1102 1180 1700 1040 1075 1081 1115 1121 1140 1600 1020 1005 1060 1050 1100 1085 1500 100...

Page 35: ...5 830 RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS 2500 2400 1193 1665 2300 1170 1580 1202 1620 2200 1148 1480 1180 1530 2100 1121 1385 1155 1425 1190 1475 2000 1100 1285 1133...

Page 36: ...PM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS RPM WATTS 3200 3000 2800 1245 2190 2600 1193 1920 1222 1990 1250 2060 2400 1142 1675 1173 1730 1205 1800 1234 1885 2200 1090 1380 1124 1450 1155 1550 1...

Page 37: ...24 800 1644 770 1531 710 6 1 HI 2101 1260 2000 1205 1914 1155 1830 1110 5 1 0 60 0 20 0 30 0 40 0 50 UNIT TONNAGE MOTOR SPEED UNIT TONNAGE MOTOR SPEED 3 1 4 1 5 1 AVAILABLE EXTERNAL STATIC PRESSURE IW...

Page 38: ...08 0 09 0 10 0 11 0 12 0 14 0 16 0 19 0 22 0 08 0 10 0 12 0 14 0 16 0 18 0 20 0 23 0 26 0 29 0 32 COOLING ONLY2 RESISTANCE IWG CFM DESCRIPTION ECONOMIZER1 3 BOTTOM DUCT CONNECTIONS1 ELECTRIC HEATERS1...

Page 39: ...nit can be determined from the curve in Pressure Drop vs Supply Air CFM Figure 17 After readings have been obtained remove the tubes and reinstall the two 5 16 dot plugs that were removed in Step 1 NO...

Page 40: ...zes the economizer The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor If the outdoor air enthalpy is above the setpoint Y1 energizes the c...

Page 41: ...h a code Table 32 LOW AMBIENT COOLING To determine when to operate in low ambient mode the UCB has a pair of terminals connected to a temper ature activated switch set at 45 F When the low ambi ent sw...

Page 42: ...st stage heat by the thermostat the heater sequencer 1S 15 20 30 kW 230 volt and contactor 2M 20 30 kW 460 and 575 volt will be energized After completing the specified fan on delay for heating the UC...

Page 43: ...ration the ICB monitors the flame sense circuit the centrifugal switch the primary limit switch and the roll out switch If a signal from any of the inputs moves to a fault state then the ICB immediate...

Page 44: ...heat the ICB checks the cen trifugal switch CS for open state before it energizes the draft motor If it is closed then the ICB will lock out the furnace and flash a code Table 33 If open then the ICB...

Page 45: ...neral infor mation section Check blower drive belt tension 6 Check the unit supply air CFM See CHECKING SUPPLY AIR CFM on page 38 7 Measure evaporator fan motor s amp draw 8 Set the room thermostat fa...

Page 46: ...iping 2 Check for correct manifold gas pressures See Checking Gas Input on page 47 3 Check the supply gas pressure It must be within the limits shown on rating nameplate Supply pressure should be chec...

Page 47: ...ust upstream of the unit gas valve and downstream from the main manual shut off valve 3 Remove the gas piping closure panel 4 Disconnect wiring to the gas valves and spark igni tors Remove the manifol...

Page 48: ...ergized when the fan switch is in the AUTO posi TABLE 31 GAS RATE CUBIC FEET PER HOUR1 1 By actual measurement it takes 38 seconds for the hand on the 1 cubic foot dial to make a revolution with a 100...

Page 49: ...ill not immediately operate If both stages of cooling are requested simultaneously and the economizer pro vides free cooling following a short delay the com pressor will be energized unless it is lock...

Page 50: ...s Mate N Lock plug If the compressor energizes there is a fault in the economizer wiring or actuator 14 The UCB can be programmed to lock out compres sor operation during free cooling and in low ambi...

Page 51: ...eat is steady then verify proper operation of the furnace If the ICB does not flash the heartbeat then gently move the wires in the harness connector while observing the ICB LED If you get any flashes...

Page 52: ...hen the temperature limits opens and the ICB closes the gas valve and flashes code 6 The primary limit is automatic reset type while the aux iliary limit is manual reset type If either one opens then...

Page 53: ...of 24VAC power the board may need to be replaced SYMPTOMATIC TROUBLESHOOTING On calls for heating the draft motor operates and the furnace lights but the supply air blower motor does not energize aft...

Page 54: ...aft motor relay If not present at terminal 7 of the draft motor relay then troubleshoot the transformer in blower section and its wiring If present at terminal 7 and not at termi nal 5 of the draft mo...

Page 55: ...t Applicable 2 Flashes Control waiting ASCD1 1 These flash codes do not represent alarms 3 Flashes HPS1 Compressor Lock out 5 Flashes LPS1 Compressor Lock out 7 Flashes FS1 Compressor Lock out 9 Flash...

Page 56: ...t to change without notice Printed in U S A 290699 YIM B 0607 Copyright 2007 by Unitary Products Group All rights reserved Supersedes 290699 YIM A 0207 Unitary 5005 Norman Products York OK Group Drive...

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