York SUNLINE MAGNUM DJ 180 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

284809-YIM-B-0707

CONTENTS

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

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

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

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

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

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

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .53

START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .53

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .56

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 DJ 180

Page 1: ...CLATURE 6 INSTALLATION 7 OPERATION 45 START UP COOLING 53 START UP GAS HEAT 53 TROUBLESHOOTING 56 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 ale...

Page 2: ...OPTIONAL HOT GAS BYPASS HGBP 21 CFM STATIC PRESSURE AND POWER ALTITUDE AND TEMPERATURE CORRECTIONS 32 PHASING 44 CHECKING SUPPLY AIR CFM 44 AIR BALANCE 44 OPERATION 45 SEQUENCE OF OPERATIONS OVERVIEW 45 COOLING SEQUENCE OF OPERATION 45 CONTINUOUS BLOWER 45 INTERMITTENT BLOWER 45 OPTIONAL VAV BLOWER OPERATION 45 NO OUTDOOR AIR OPTIONS 46 ECONOMIZER WITH SINGLE ENTHALPY SENSOR 46 ECONOMIZER WITH DUA...

Page 3: ...PPLY AIR CFM FOR ALL UNIT TONNAGES 45 23 GAS VALVE PIPING 51 24 GAS VALVE AND CONTROLS 52 Fig Pg 25 TYPICAL GAS VALVES 54 26 PROPER FLAME ADJUSTMENT 54 27 TYPICAL FLAME APPEARANCE 55 28 UNIT CONTROL BOARD 65 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 PHYS...

Page 4: ...ld 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 follow all other safety precautions that apply Wear safety glasses and work gloves and follow all safety codes Use a quenching cloth and have a fire extinguisher available for all brazing operations I...

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 that personal injury and or equipment damage may result if installation proce dure is not handled properly THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUC TIO...

Page 6: ...s BF Phase Monitor Dirty Filter Switch Hinged Filter 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 15 25 Ton Magnum Model Number Nomenclature ZZ If desired option combination is not listed above ZZ will be assigned and configuration options will be ...

Page 7: ...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 gas utility requirements In Canada Current Canadian Electrical Code C22 1 Current Gas Installation Codes CSA B149 1 Local plumbing and waste water codes Other applicable local codes Refer to the Unit A...

Page 8: ...oof 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 1 208 230 3 60 460 3 60 575 3 60 DJ180 UNIT MODEL NUMBER 187 253 414 506 518 630 DJ300 Supply Air CFM Min Max 4 500 7 000 7 500 12 500 DJ240 6 000 9 400 DJ210 6 000 8 750 Wet bulb Temperature 0 F of Air o...

Page 9: ...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 Gas Installation Codes CSA B149 1 in Canada and or applicable provisions of the local building codes Refer to Figures 13 14 and 15 for the dimensions and clearances required for com bustible constructio...

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 may be done before mounting the hood into position or after installation by removing the front hood panel or the screen on the bottom of the hood Damper baffle in position 1 will allow approximately 10...

Page 11: ...tor coil and 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 shown in Physical Data Table 7 SERVICE ACCESS The following removable panels provide access to all serviceable components Compressor compartment Electric Heat compartment Gas Heat compar...

Page 12: ... o s ta t 2 E T 0 7 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 r m o s ta t s w i tc h e s to th e s e t b a c k p o s i ti o n 2 4 V o l t T r a n s fo r m e r 2 T O R E M O T E S E N S O R 2 E T 0 4 7 0 1 3 2 4 IF U S E D OCC W1 W2 Y1 G Y2 X...

Page 13: ...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 the Dimensions Figure 13 for installation location If any of the wire sup plied 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 Electrical line must be sized properly to ...

Page 14: ...nits 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 gravity gas TABLE 3 ELECTRIC HEAT APPLICATION DATA NOMINAL HEATER SIZE KW VOLTAGE 3 PHASE 60 HZ MINIMUM CFM UNIT SIZE 15 TON 17 5 TON 20 TON 25 TON 18 208 230 460 575 4500 6000 6000 7500 36 208 230 460 575 4500 5...

Page 15: ...xternal to 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 completed open the main shut off valve admitting normal gas pressure to the mains Check all joints for leaks with soap solution or other material suitable for the purpose NEVER USE A FLAME 6 The...

Page 16: ...ckly dissolve white lead or most standard commercial compounds Shellac base compounds such as Rectorseal 5 are satisfactory for this type of gas Check all connections for leaks when piping is com pleted using a soap solution NEVER USE A FLAME VENT AND COMBUSTION AIR HOODS Two vent hoods and a combustion air hood with screens are shipped attached to the blower housing in the blower compartment For ...

Page 17: ...nd then off or energize and de energize terminals R to G MINIMUM POSITION ADJUSTMENT With thermostat set to indoor fan on position or termi nals R to G energized turn the Minimum Position Adjusting screw located on the damper control mod ule counterclockwise until the desired minimum damper position has been attained ENTHALPY SET POINT ADJUSTMENT The enthalpy set point may now be set by selecting ...

Page 18: ...ntrol box compartment is used to sense static gauge pres sure in the supply air duct and convert this pressure measurement to a proportional 0 5 VDC electrical out put Pressure transmitting plastic tubing 1 4 diameter must be field supplied and installed from the transducer to both the ductwork and to the atmosphere Connect the tubing from the HIGH pressure tap of the trans ducer to a static press...

Page 19: ... ductwork in the event of either a drive or damper failure The high limit set point is adjustable between 0 WC and 5 WC with the factory default setting of 4 5 WC If the duct static pressure reaches the high limit set point then the supply fan motor will be shutdown NOTE Either of the set points described above can be changed through the unit control board UCB with the use of a USB to RS485 conver...

Page 20: ... clearances to allow for adequate internal cooling of the drive during operation The unit comes with a mounting bracket installed in the Blower Access compartment which may accommodate other vendor s drives depending on their size In order to utilize the unit s mounting bracket the maximum rec ommended drive dimensions are as follows For 5 hp motor applications 13 H x 6 W x 7 D For 7 5 thru 15 hp ...

Page 21: ...ressure modulating bypass control valve installed on the system 1 discharge line is used to divert high tem perature high pressure refrigerant around the TXV in order to maintain a desired minimum evaporator pres sure The opening pressure of the bypass valve is fully adjustable between 0 and 80 psig with a factory setting of 60 psig HGBP is standard on all units with VAV and optional with CV units...

Page 22: ...Q 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 Indoor Air Quality Min Adjustment Screw Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 11 FOUR AND SIX POINT LOADS A D C E B F A D B C ...

Page 23: ...ec 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 280 292 419 546 523 401 210 Elec 2728 317 317 455 592 592 455 240 Elec 2760 321 321 460 599 599 460 300 Elec 2846 331 331 474 618 618 474 Unit Size Total Shipping Weight 4 Point Loads lbs A B C D 6 Point Loads lbs ...

Page 24: ...RIGERANT 22 Lb Oz SYSTEM No 1 23 0 24 0 23 8 23 8 SYSTEM No 2 23 8 24 0 23 8 23 8 OPERATING WEIGHTS LBS BASIC UNIT COOLING ONLY 2260 2540 2560 2660 GAS ELECTRIC N24 2460 2740 2760 2860 N32 2500 2780 2800 2900 OPTIONS DOUBLE WALL 260 ECONOMIZER 160 ECONOMIZER WITH POWER EXHAUST 245 MOTORIZED DAMPER 150 ELECTRIC HEATER 18 KW 25 36 KW 30 54 KW 35 72 KW 40 HOT GAS BYPASS 10 SUPPLY FAN VFD See Table 8 ...

Page 25: ...1 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 34 6 50 7 60 E54 54 0 2 52 0 59 3 70 E72 72 0 2 69 3 76 7 90 210 17 1 2 208 25 6 190 2 1 20 0 0 0 None 0 0 86 0 110 E18 13 5 1 37 5 86 0 110 E36 27 0 2 75 1 118 7 125 E54 40 6 2 112 6 165 9 175 E72 5...

Page 26: ... 5 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 90 300 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 27 0 2 75 1 159 4 200 E54 40 6 2 112 6 189 1 200 E72 54 1 2 150 1 198 4 225 230 47 1 245 3 7 38 6 0 0 None 0 0 159 4 200 E18 18 0 1 43 3 159 4 200 E36 36 0 2 86 6 159 4 200 E54 54 0 2 129 9 178 ...

Page 27: ...1 1 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 34 6 55 7 60 E54 54 0 2 52 0 64 3 70 E72 72 0 2 69 3 81 7 90 210 17 1 2 208 25 6 190 2 1 20 0 10 0 None 0 0 96 0 110 E18 13 5 1 37 5 96 0 110 E36 27 0 2 75 1 131 2 150 E54 40 6 2 112 6 178 4 200 E72...

Page 28: ...5 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 90 300 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 27 0 2 75 1 169 4 200 E54 40 6 2 112 6 201 6 225 E72 54 1 2 150 1 210 9 225 230 47 1 245 3 7 38 6 10 0 None 0 0 169 4 200 E18 18 0 1 43 3 169 4 200 E36 36 0 2 86 6 169 4 200 E54 54 0 2 129 9 190...

Page 29: ... 4 21 00 6 3 8 7 1 8 35 5 7 8 136 1 4 GAS OR ELECTRIC HEAT ACCESS DOT PLUG For pressure drop reading BLOWER COMPARTMENT ACCESS Auxiliary C GAS SUPPLY ENTRY CONTROL BOX ACCESS VENT AIR OUTLET HOODS BLOWER MOTOR ACCESS Location of Optional VFD Bypass BLOWER ACCESS Location of Optional VFD 52 5 8 180 19 32 COMPRESSOR ACCESS DISCONNECT SWITCH LOCATION ECONOMIZER MOTORIZED DAMPER FIXED OUTDOOR INTAKE A...

Page 30: ...exhaust option 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 compartments with the side duct flange accessory kit panels 2 Connect ductwork to the flanges on those panels SUPPLY AIR RETURN AIR OUTDOOR AIR 5 1 8 18 5 8 27 3 4 39 5 8 40 1 2 OUTDOOR ...

Page 31: ...CATION 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 on combustible floors made from wood or class A B or C roof covering material 0 Above Unit2 2 Units must be installed outdoors Overhanging structures or shrubs should not obstruct condenser air discharge ou...

Page 32: ...static pressure and BHP Since no temperature data is given we will assume an air temperature of 70 F Table 11 shows the correction factor to be 0 832 Corrected static pressure 1 5 x 0 832 1 248 IWC Corrected BHP 4 0 x 0 832 3 328 Example 2 A system located at 5 000 feet of elevation is to deliver 6 000 CFM at a static pressure of 1 5 Use the unit blower tables to select the blower speed and the BH...

Page 33: ...284809 YIM B 0707 Unitary Products Group 33 FIGURE 16 ALTITUDE TEMPERATURE CONVERSION FACTOR ...

Page 34: ...9 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 3 2 2 9 1 3 3 9 3 5 1 1 4 5 4 0 0 8 5 1 4 6 0 7 5 6 5 0 1065 3 5 1 6 3 4 3 0 1 4 4 0 3 6 1 2 4 7 4 2 1 0 5 5 4 9 1095 3 0 1 7 3 5 3 1 1 5 4 2 3 8 1 3 4 9 4 4 1 2 5 7 5 1 1130 2 0 1 9 3 7 3 3 1 7 4 5...

Page 35: ... 9 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 6 8 5 7 1 7 7 4 6 2 1 2 8 1 6 8 1050 2 5 2 1 6 4 5 4 2 0 7 0 5 9 1 8 7 6 6 4 1 3 8 3 7 0 1075 2 0 2 3 6 6 5 5 2 1 7 2 6 0 1 9 7 8 6 6 1 5 8 6 7 2 1100 1 0 2 4 6 7 5 6 2 2 7 3 6 1 2 1 7 9 6 7 230 460...

Page 36: ...2 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 7 1 7 7 4 6 2 1 2 8 1 6 8 0 7 8 6 7 3 1050 2 5 2 1 6 4 5 4 2 0 7 0 5 9 1 8 7 6 6 4 1 3 8 3 7 0 1075 2 0 2 3 6 6 5 5 2 1 7 2 6 0 1 9 7 8 6 6 1 5 8 6 7 2 1100 1 0 2 4 6 7 5 6 2 2 7 3 6 1 2 1 7 9 6 7 ...

Page 37: ... 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 6 1025 4 5 1 4 3 1 2 8 1 2 3 6 3 2 0 9 4 1 3 7 0 7 4 8 4 3 0 4 5 5 4 9 1065 3 5 1 6 3 4 3 0 1 4 3 9 3 5 1 1 4 5 4 0 0 9 5 1 4 6 1125 2 0 1 9 3 6 3 2 1 7 4 4 3 9 1 4 5 0 4 5 1 2 5 8 5 2 1170 1 0 2 1 ...

Page 38: ... 0 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 2 0 6 1 5 1 1 4 7 1 6 0 0 9 8 4 7 0 1065 2 0 2 6 5 3 4 4 2 1 6 3 5 3 1 5 7 3 6 2 1 0 8 6 7 2 1100 1 0 2 9 5 6 4 7 2 3 6 8 5 7 1 8 7 9 6 6 230 460 575 VOLT AND STANDARD DRIVE 870 6 0 1 3 3 6 3 0 0 7...

Page 39: ...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 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 5 1 4 3 2 0 6 1 5 1 1 4 7 1 6 0 0 9 8 4 7 0 1065 2 0 2 6 5 3 4 4 2 1 6 3 5 3 1 5 7 3 6 2 1 0 8 6 7 2 1100 1 0 2 9 5 6 4 7 2 3 6 8 5 7 1 8 7 9 6 6 230 460 575 VOLT AND STANDARD DRIVE 870 6 0 1 3 3 6 ...

Page 40: ...0 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 1330 1 0 3 5 10 0 8 2 3 0 12 0 9 9 2 3 14 1 11 6 1 5 16 4 13 4 1365 0 0 3 7 10 5 8 6 3 2 12 6 10 3 2 6 14 7 12 1 1 8 17 0 13 9 230 460 575 VOLT AND STANDARD DRIVE 975 6 0 1 4 5 9 4 9 1 0 7 3 6 0 0 5 8...

Page 41: ...erformance table TABLE 20 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 0 93 3000 0 99 MEDIUM 4900 0 77 3900 0 79 3500 0 82 2900 0 85 LOW 4400 0 72 3700 0 74 3000 0 78 TABLE 21 BLOWER MOTOR AND DRIVE DATA MODEL SIZE DRIVE BLOWER RANGE RPM MOTOR1 ADJUSTABLE MOTOR PULLEY FI...

Page 42: ...left to the factory setting If the TXV s have been adjusted in the field The charging chart may no longer apply º FIGURE 18 CHARGING CHART 17 5 TON 17 5 Ton Charging Chart 100 150 200 250 300 350 400 60 65 70 75 80 85 90 95 100 Suction Pressure psi Discharge Pressure psi 115º 105º 95º 85º 75º Outdoor Temp 0 F 1 Make sure that both condenser fans are running when charging One fan may switch off at ...

Page 43: ... 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 20 CHARGING CHART 25 TON 25 Ton Charging Chart 100 150 200 250 300 350 400 60 65 70 75 80 85 90 95 100 Suction Pressure psi Discharge Pressure psi 115º 105º 95º 85º 75º 65º Outdoor Temp ºF 1 Make sure that both condenser fans are running when charging One fan may switch...

Page 44: ... and 20 ton units and Model 1LD0435 for 25 ton units Refer to the Blower Motor and Drive Data Table 21 Note the following 1 The supply air CFM must be within the limitations shown in the Unit Application Data Table 1 2 Pulleys can be adjusted in half turn increments 3 The tension on the belt should be adjusted as shown in the Belt Adjustment Figure 21 AIR BALANCE Start the supply air blower motor ...

Page 45: ...electric heat units the UCB passes the call to the electric heater In both cases when the W1 call is sensed the indoor air blower is energized following a specified heating delay If at any time a call for both heating and cooling are present the heating operation will be performed If oper ating the cooling system is halted as with a completion of a call for cooling Heating always takes priority CO...

Page 46: ...ve 60 F When the thermostat calls for second stage cooling the low voltage control circuit from R to Y2 is com pleted The UCB energizes the first available compres sor If the enthalpy of the outdoor air is below the setpoint of the enthalpy controller i e first stage has energized the economizer Y2 will energize com pressor 1 If the outdoor air is above the setpoint Y2 will energize compressor 2 O...

Page 47: ...Upon de energizing the final compressor the blower will continue to run with the economizer damper in its minimum position if in the Occupied mode otherwise the blower will stop following the elapse of the fan off delay for cooling and the economizer outdoor damper will close ECONOMIZER WITH OPTIONAL VAV BLOWER WITH POWER EXHAUST The power exhaust motor is energized via the control ler s EXH termi...

Page 48: ... is necessary to defrost the indoor coil Low ambient mode always begins with compressor operation Compressor minimum run time may extend the minutes of compressor operation The defrost cycle will begin immediately following the elapse of the mini mum run time When operating in low ambient mode the UCB will not lockout the compressors due to a freezestat trip How ever a freezestat trip will de ener...

Page 49: ... heaters should the primary limit fail to open or the contactors fail to open in a failure mode HEATING OPERATION ERRORS TEMPERATURE LIMIT If the UCB senses zero volts from the high temperature limit the indoor blower motor is immediately energized This limit is monitored regardless of unit operation sta tus i e the limit is monitored at all times If the temperature limit opens three times within ...

Page 50: ... has been ignited and the presence of pilot flame detected at the IC1 by a signal sent back through the flame sensor is sparking terminated and the first stage main gas valve opened Gas flows into each of the main burners and is ignited from the carryover tube flame After completing the specified fan on delay for heating the UCB will energize the blower motor If IC1 fails to detect a pilot flame i...

Page 51: ... are ceased The GV is immediately de energized The blower is de energized after the fan off delay for heat ing has elapsed The draft motor performs a 25 second post purge GAS HEATING OPERATION ERRORS TEMPERATURE LIMIT If the UCB senses zero volts from the high temperature limit the indoor blower motor is immediately energized When the UCB again senses 24 volts from the temper ature limit the draft...

Page 52: ...and locks out both ignition controls closing both gas valves The ignition controls lock out furnace operation until 24V power is removed from the controls either at the unit or by resetting the room thermostat NOTE The auto reset rollout switch must reset before allowing furnace operation 6 Auxiliary limit switch AUX This control is located inside the heat exchanger compartment and is set to open ...

Page 53: ...s for both circuits 2 Measure the temperature drop across the evapora tor coil 3 Measure the system Amperage draw across all legs of 3 phase power wires 4 Measure the condenser fan amp draw SHUT DOWN 1 Set the thermostat to highest temperature setting 2 Turn off the electrical power to the unit START UP GAS HEAT PRE START CHECK LIST Complete the following checks before starting the unit 1 Check th...

Page 54: ...SURE ADJUSTMENT Small adjustments to the high fire gas flow may be made by turning the pressure regulator adjusting screw on the automatic gas valve Adjust as follows 1 Remove the cap on the regulator It s located next to the push on electrical terminals 2 To decrease the gas pressure turn the adjusting screw counterclockwise 3 To increase the gas pressure turn the adjusting screw clockwise NOTE T...

Page 55: ...gas meter 2 With the furnace turned on measure the time needed for one revolution of the hand on the small est dial on the meter A typical gas meter usually has a 1 2 or a 1 cubic foot test dial 3 Using the number of seconds for each revolution and the size of the test dial increment find the cubic feet of gas consumed per hour from the Gas Rate Cubic Feet Per Hour Table 26 If the actual input is ...

Page 56: ...ith VFD check that line voltage is being supplied to the M3 Auxiliary contacts Check for loose wiring between the contactor and the supply air blower motor 4 If M3 is pulled in and voltage is supplied to M3 lightly touch the supply air blower motor housing If it is hot the motor may be off on internal protec tion Cancel any thermostat calls and set the fan switch to AUTO Wait for the internal over...

Page 57: ...ompres sor 1 does not energize on a call for cooling check for line voltage at the compressor contactor M1 and that the contactor is pulled in Check for loose wiring between the contactor and the com pressor 3 If M1 is pulled in and voltage is supplied at M1 lightly touch the compressor housing If it is hot the compressor may be off on inherent protection Cancel any calls for cooling and wait for ...

Page 58: ...ult Local distributors can test the UCB for this programming For units with factory installed economizers the UCB is programmed to lock out compressor opera tion when the LAS set point is reached For units without factory installed or with field installed economizers the UCB allows compressor operation all the time This programming can be checked or changed by the local distributor 15 If none of t...

Page 59: ...ow ambi ent conditions These options are not enabled by default Local distributors can test the UCB for this programming For units with factory installed economizers the UCB is programmed to lock out compressor opera tion when the LAS set point is reached For units without factory installed or with field installed economizers the UCB allows compressor operation all the time This programming can be...

Page 60: ...UT terminal of the UCB If 24 volts is present trace the wiring from Y1 OUT for incorrect wiring If 24 volts is not present at the Y1 OUT terminal the UCB must be replaced 12 For units without economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the 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 jump...

Page 61: ...ault warning messages displayed on the drive s digital display refer to the drive user manual for full descriptions if necessary Clear any fault by pressing RESET on the drive s keypad and take any corrective action as needed If the motor still does not operate replace the motor 6 If 24 volts is not present at M3 check that 24 volts is present at the supply air blower motor terminal on the UCB If ...

Page 62: ...oes not light and the sparker does not spark 1 The ignition control IC1 IC2 may be locked out due to either a flame roll out or 100 shut off These safety features are described above If lock out has occurred 24V must be removed from the ignition controls This is done at the unit or by resetting the room thermostat After resetting 24V check for proper furnace operation If lock out con tinues to occ...

Page 63: ...ner gas valve and ignitor control are intact Check the high tension wire for good electrical con nection If all are intact replace the ignitor module The pilot burner lights and the spark stops but the main burners do not light 1 Check electrical connections between the ignitor control and the gas valve If intact check for 24 volts across terminals MV and COMMON termi nals If no voltage detected r...

Page 64: ... Flashing Off Off On Off 3 Flashes HPS1 Compressor Lockout Off Off Off On On 4 Flashes HPS2 Compressor Lockout Off Off On Off Off 5 Flashes LPS1 Compressor Lockout Off Off On Off On 6 Flashes LPS2 Compressor Lockout Off Off On On Off 7 Flashes 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 O...

Page 65: ... the display will revert to its normal display exiting the Option Setup mode When saving the control board only saves the parameters for the currently dis played mode Option Byte or Heat Delay HEAT DELAY SETUP Enter the Option Setup mode by pushing the OPTION SETUP STORE button and holding it for at least 2 seconds The green status LED Option Byte will be turned on and the red status LED Heat Dela...

Page 66: ...n a 1 flash flash code is not used TABLE 28 HEAT DELAY Heat Fan On Delay Heat Fan Off Delay Red LED 8 Red LED 4 Red LED 2 Red LED 1 60 180 On On On On 60 90 On On On Off 60 60 On On Off On 60 30 On On Off Off 45 180 On Off On On 45 90 On Off On Off 45 60 On Off Off On 45 30 On Off Off Off 30 180 Off On On On 30 90 Off On On Off 30 60 Off On Off On 30 30 Off On Off Off 0 60 Off Off On On 0 30 Off O...

Page 67: ...284809 YIM B 0707 Unitary Products Group 67 ...

Page 68: ...ct to change without notice Printed in U S A 284809 YIM B 0707 Copyright 2007 by Unitary Products Group All rights reserved Supersedes 284809 YIM A 0107 Unitary 5005 Norman Products York OK Group Drive 73069 ...

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Summary of Contents for SUNLINE MAGNUM DJ 180

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