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Sunlife Enterprises SUNLINE DM180 User's Manual

1. EVAPORATOR CENTRIFUGAL BLOWER Dia x Wd 15x15 18x15 18x15 BLOWER FAN MOTOR HP 5 0 7 5 10 ROWS DEEP 3 3 4 EVAPORATOR COIL FINS PER INCH 13 5 FACE AREA Sq Ft 15 5 20 5 25 CONDEHSEBEAN PROPELLER DIA In Each 30 Two Per Unit FAN MOTOR HP Each 1 NOM CFM TOTAL Each 6 000 8 000 7 200 ROWS DEEP 2 2 3 FINS PER INCH 13 20 15 FACE AREA Sq Ft 36 43 3 43 3 5 TON HERMETIC RECIP 1 COMPRESSOR 10 TON TANDEM RECIP 1 Qty Per Unit 10 TON SCROLL 2 12 5 TON 2 QUANTITY PER UNIT 12 X 24 X 2 or 4 12 QUANTITY PER UNIT 16 X 20 X 2 or 4 4 FILTERS QUANTITY PER UNIT 16 X 25 X 2 or 4 4 QUANTITY PER UNIT 18 X 24 X 2 or 4 5 TOTAL FACE AREA Sq Ft 15 20 24 CHARGE REFRIGERANT SYSTEM No 1 16 19 0 25 8 22 Lb Oz SYSTEM No 2 7 8 16 4 24 8 COOLING ONLY 1900 2100 2709 BASIC UNIT 2100 2300 2909 GAS ELECTRIC 2140 2340 2971 ECONOMIZER 160 ECONOMIZER WITH m E POWER EXHAUST 5 MOTORIZED DAMPER 150 25 OPERATING 5 30 WEIGHTS ELECTRIC HEATER LBS 35 40 ROOF CURB 175 185 185 n BAROMETRIC DAMPER 45 ECONOMIZER MOTORIZED m DAMPER RAIN HOOD ECONOMIZER POWER Q EXHAUST RAIN HOOD WOOD SKID 200 220 220 20 NOTE This compressor will be energized first Johnson Controls Unitary Products 356214 XIM A 0108 TABLE 8 DM ELECTRICA
2. 42 oe spore siasa dar sins eA cai be 16 OPERATING INSTRUCTIONS eee 42 OPTIONAL POWER EXHAUST BAROMETRIC RELIEF POST START 8 42 DAMPER RAIN 17 SHUT DOWN 43 OPTIONAL ECONOMIZER AND POWER EXHAUST START UP GAS 43 DAMPER SET POINT ADJUSTMENTS AND PRE START 43 17 SPERATINGINGIBUCTIONS o e sols Ms MINIMUM POSITION ADJUSTMENT 17 TOLICHT PILOT AND MAN BURNERS ccc da ENTHALESCSET POINT ADJUSTMENT seves TO SHUT DOWN 4 7 43 POWER EXHAUST DAMPER SETPOINT pa 17 POST START CHECK LIST GAS 43 2 7 17 MANIFOLD GAS PRESSURE ADJUSTMENT 44 2 ME T PILOT 44 BURNER INSTRUCTIONS eee 44 GEM STATIC PRESSURE AND TOWERS BURNER AIR SHUTTER ADJUSTMENT 44 ALTITUDE AND TEMPERATURE CORRECTIONS 2 5 34 CHECKING GAS INPUT 45 CHECKING AIR SUPPLY 34 NATURAL GAS pea dais 44 ADJUSTMENT OF TEMPERATURE RISE 45 0 2 BELT DRIVE 45 COOLING SEQUENCE OF OPERA
3. EIL E POWERED 21 cur EE d due sun ts RE IIR Geko 195 EP MED Pew TOIT Ta t 9 DMELECTRICAL DATA WITH POWERED VENTAND COMBUSTION AIR HOOD 18 CONVENIENCE OUTLET 22 S ENTH SETPOINT ADJUSTMENT e papia gg 18 10 UTILITIES ENTRY DATA 23 10 HONE WELE EC ONOMIZER CONTROL iig ts 18 11 ALTITUDE CORRECTION FACTORS 26 11 FOUR AND SIX POINT LOADS 19 12 SUPPLY AIR BLOWER PERFORMANCE 15 TON 12 CENTER 19 COOLING ONLY 180 MBH BOTTOM DUCT 13 FRONT VIEW DIMENSIONS 15 20 amp 25 TON 23 CONNECTIONS 28 13 SUPPLY AIR BLOWER PERFORMANCE 20 TON 14 REAR VIEW 24 COOLING ONLY 240 MBH BOTTOM DUCT 15 UNIT CLEARANCES AND RAIN HOOD DIMENSIONS CONNECTIONS 29 15 20 amp 25 25 14 SUPPLY AIR BLOWER PERFORMANCE 15 TON 16 ALTITUDE TEMPERATURE CONVERSION FACTOR 27 GAS HEAT 180 MBH BOTTOM DUCT 17 BELTADJUSTMENT 34 CONNEC TIONS exi Cie a0 18 PRESSURE DROP ACROSS A DRY INDOOR COIL VS 13 0022222 PEPPER FOR ALBUN OARS gaunt 83 CONNECTIONS 31 19 GAS VALVE PIPING 40 16 SUPPLY AIR B
4. 30 Johnson Controls Unitary Products 356214 XIM A 0108 TABLE 14 SUPPLY AIR BLOWER PERFORMANCE 20 TON GAS HEAT 240 MBH BOTTOM DUCT CONNECTIONS AIRFLOW MOTOR SED PULLEY 2 80 m s 3 30 m3 s 3 80 m3 s 4 10 m3 s 4 40 m3 s TURNS RPM open ESP Output Input ESP Output Input ESP Output Input ESP Output Input ESP Output Input Pa kW kW Pa kW kW Pa kW kW Pa kW kW Pa kW kW HIGH STATIC DRIVE m s 895 6 0 361 2 8 3 2 249 3 5 4 0 114 4 3 4 9 22 4 7 5 4 925 5 0 400 2 9 3 4 290 3 7 4 2 157 4 5 5 1 66 5 0 5 7 955 4 0 439 3 1 3 6 332 3 9 4 4 201 4 7 5 4 112 5 2 6 0 15 5 8 6 6 990 3 0 486 3 3 3 8 381 4 1 4 7 254 5 0 5 7 166 5 5 6 3 70 6 1 7 0 1020 2 0 527 3 5 4 0 425 4 3 5 0 299 5 2 6 0 213 5 8 6 7 119 6 4 7 3 1050 1 0 569 3 7 4 2 469 4 6 5 2 346 5 5 6 3 261 6 1 7 0 1080 0 0 612 3 9 4 4 514 4 8 5 5 393 5 8 6 6 310 6 4 7 3 MOTOR AIRFLOW BLOWER PULLEY 5930 CFM 6990 CFM 8050 CFM 8685 CFM 9320 CFM gt TURNS RPM Open ESP Output Input ESP Output Input ESP Output Input ESP Output Input ESP Output Input wg bhp KW bhp KW bhp KW bhp KW wg bhp kW HIGH STATIC DRIVE CFM 895 6 0 1 5 3 7 3 2 1 0 4 7 4 0 0 5
5. a 15 Check Alarm History Reset All ASCDs for One Cycle Non Alarm Condition Green LED Flashing Current Alarm Flashed Red LED AT GAT START 1 Ev AER i MINE 0 MEAT n bans x as 4 022 he 6 5 FRE CQOUNC a 1 de EH H LFAD LAG M li E FIGURE 24 UNIT CONTROL BOARD Johnson Controls Unitary Products 356214 XIM A 0108 UNIT CONTROL BOARD OPTION SETUP OPTION BYTE 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 Delay is turned off The 8 4 2 and 1 LEDs will then show the status of the 4 labeled options 8 Fan Off at Heat Start 4 Low Ambient Lockout 2 Free Cooling Lockout and 1 Lead Lag Press the UP or Down button to change the LED status to correspond to the desired Option Setup To save the current displayed value push the OPTION SETUP STORE button and hold it for at least 2 seconds When the value is saved the green LED will flash a few times and then normal display will resume NOTE While in either Setup mode if no buttons are pushed for 60 seconds 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
6. NOTE If M1 is not pulled in check for 24 volts at the M1 coil If 24 volts is present and M1 is not pulled in replace the contactor Failing the above if voltage is supplied at M1 M1 is pulled in and the compressor still does not oper ate replace the compressor If 24 volts is not present at M1 check for 24 volts at the UCB terminal C1 If 24 volts is present check for loose wiring between C1 and the compressor contactor If 24 volts is not present at the C1 terminal check for 24 volts from the room thermostat at the UCB Y1 terminal If 24 volts are not present at the UCB Y1 terminal the UCB may have faulted Check for 24 volts at the Y1 ECON terminal If 24 volts is not present at Y1 ECON the UCB has faulted The UCB should de energize all compressors on a loss of call for the first stage of cooling i e a loss if 24 volts at the Y1 terminal 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 of the UCB If a switch has opened there should be a voltage potential between the UCB ter minals e g if LPS1 has opened there will be a 24 volt potential between the LPS1 terminals If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flash
7. 37 345 44 286 42 50 z 1155 3 0 502 28 448 40 387 39 47 2 s 1200 2 0 548 30 36 495 36 43 435 42 50 2 1240 1 0 590 32 38 538 38 46 5 AIRFLOW REED PULLEY 4450 CFM 5190 CFM 5930 CFM 6565 CFM 7200 CFM RPM RENE ESP Output Input ESP output Input ESP Output Input ESP Output Input ESP Output Input bhp KW bhp kW wg bhp KW bhp kW iwg bhp kW HIGH STATIC DRIVE CFM 1030 6 0 15 31 27 13 36 32 10 43 38 08 49 44 o5 56 50 1070 5 0 17 33 29 14 88 84 12 45 41 10 52 47 1115 4 0 19 35 31 16 41 37 14 49 44 12 56 50 1155 3 0 20 37 33 18 44 40 16 52 47 2 i 1200 2 0 22 40 36 20 48 43 17 56 50 1240 10 24 4 22 51 46 2 5 NOTES 1 Blower performance includes a gas fired heat exchanger fixed outdoor air two inch T A filters and a dry evaporator coil 2 Refer to the additional Static Resistances table ESP External Static Pressure available for the supply and return air duct system All internal unit resistances have been deducted from the total static pressure of the blower Do NOT close the pulley below 1 turn open Factory setting
8. a proper operation of the room thermostat contact 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 thermostat to the UCB If 24 volts is present at the room thermostat but not at the UCB check for proper wiring between the thermostat and the UCB i e that the thermostat G terminal is connected to the G terminal of the UCB and for loose wiring If the thermostat and UCB are properly wired replace the UCB On calls for cooling the supply air blower motor is operating but compressor 1 is not the room thermo stat fan switch is in the AUTO position 1 46 If installed check the position of the economizer blades If the blades are open the economizer is providing free cooling and the compressors will not immediately operate If both stages of cooling are requested simultaneously and the economizer pro vides free cooling following a short delay compres sor 1 will be energized unless it is locked out If compressor 1 is locked out compressor 2 is energized Compressor 2 is always energized in place of compressor 1 when compressor 1 is requested but locked out If no economizer is installed or the economizer is not opening to provide free cooling and compres sor 1 does not energize on a call for cooling check for line voltage at the compressor contactor M1
9. off position 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 leaks in the unit piping as well as the supply piping A WARNING FIRE OR EXPLOSION HAZARD FAILURE TO FOLLOW THE SAFETY WARN ING EXACTLY COULD RESULT IN SERIOUS INJURY DEATH OR PROPERTY DAMAGE NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME USE A COMMERICALLY AVAILABLE SOAP SOLUTION MADE SPE CIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS A FIRE OR EXPLOSION MAY RESULT CAUS ING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE 2 Check for correct manifold gas pressures See Checking Gas Input page 44 3 Check the supply gas pressure It must be within the limits shown on rating nameplate Supply pres sure should be checked with all gas appliances in the building at full fire At no time should the standby gas line pressure exceed 13 nor the operating pressure drop below 5 0 for natural gas units If gas pressure is outside these limits con tact the local gas utility for corrective action gt FIGURE 21 TYPICAL GAS VALVES Johnson Controls Unitary Products 43 356214 XIM A 0108 MANIFOLD GAS PRESSURE ADJUSTMENT Small adjustments to the high fire gas flow may be made by turning the pressure regulator adjusting screw o
10. 278 42 50 1155 3 0 514 29 468 34 40 40 39 47 2 s 1200 2 0 57 31 37 529 36 43 4 amp 1 41 50 2 1240 1 0 39 587 38 45 5 5 z AIRFLOW REED PULLEY 4450 CFM 5190 CFM 5930 CFM 6565 CFM 7200 CFM RPM RENE ESP Output Input ESP Output Input ESP Output Input ESP Output Input ESP Output Input bhp KW bhp kW wg bhp KW bhp kW iwg bhp kW HIGH STATIC DRIVE CFM 1030 6 0 14 32 28 13 38 34 10 44 39 07 50 45 04 56 50 1070 5 0 16 34 30 15 40 36 12 47 42 o9 53 47 1115 40 19 36 32 17 43 88 14 50 44 11 56 50 1155 3 0 21 19 45 40 16 52 47 P 1200 2 0 23 41 37 21 48 18 55 50 1240 1 0 26 44 39 24 51 45 5 5 NOTES 1 Blower performance includes fixed outdoor air 2 T A filters dry evaporator coil and no electric heat 2 Refer to Table 16 for additional static resistances ESP External Static Pressure available for the supply and return air duct system All internal unit resistances have been deducted from the total static pressure of the blower Do NOT close the pulley below 1 turn open Factory setting 28 Johnson Controls Unitar
11. FREEZESTAT During cooling operation if a freezestat opens the UCB will de energize the associated compressor initi ate the ASCD and if the other compressor is idle stop the condenser fans If the call for cooling is still present at the conclusion of the ASCD the UCB will re ener gize the halted compressor Johnson Controls Unitary Products 37 356214 XIM A 0108 Should a freezestat open three times within two hours of operation the UCB will lock out the associated com pressor and flash a code Table 24 If the other com pressor is inactive the condenser fans will be de energized 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 30 F When the low ambi ent switch is closed and the thermostat is calling for cooling the UCB will operate in the low ambient mode Low ambient mode operates the compressors in this manner 10 minutes on 5 minutes off The indoor blower is operated throughout the cycle The 5 minute off period 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 fre
12. The examples below will assist in determining the airflow per formance of the product at altitude Example 1 What are the corrected CFM static pressure and BHP at an elevation of 5 000 ft if the blower performance data is 6 000 CFM 1 5 IWC and 4 0 BHP Solution At an elevation of 5 000 ft the indoor blower will still deliver 6 000 CFM if the rpm is unchanged However Table 10 must be used to determine the static 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 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 26 blower tables to select the blower speed and the BHP requirement Solution As in the example above no temperature informa tion is given so 70 F is assumed The 1 5 static pressure given is at an elevation of 5 000 ft The first step is to convert this static pressure to equivalent sea level conditions Sea level static pressure 1 5 832 1 80 Enter the blower table at 6000 sCFM and static pressure of 1 8 The rpm listed will be the same rpm needed at 5 000 ft Suppose that the corresponding BHP listed in the table is 3 2 This value must be corrected for elevation BHP at 5 000 ft 3 2 x 832 2 66 Johnson Controls Unitary Products
13. 356214 XIM A 0108 Altitude Temperature Conversion Factor 1 100 1 000 0 900 SEA LEVEL 305 meter 610 0 800 914 1219 1524 CORRECTION FACTOR 0 700 1829 2134 2438 0 600 44 10 15 5 21 26 6 TEMPERATURE C 32 2743 3048 Altitude Temperature Conversion Factor 1 100 38 1 000 0 900 SEA LEVEL 1000 ft 2000 0 800 3000 4000 5000 CORRECTION FACTOR 0 700 6000 7000 8000 0 600 40 50 60 70 TEMPERATURE F FIGURE 16 ALTITUDE TEMPERATURE CONVERSION FACTOR 80 90 9000 10 000 100 Johnson Controls Unitary Products 27 356214 XIM A 0108 TABLE 11 SUPPLY AIR BLOWER PERFORMANCE 15 TON COOLING ONLY 180 MBH BOTTOM DUCT CONNECTIONS AIRFLOW SPEED PULLEY 2 10 m3 s 2 45 m s 2 80 m s 3 10 m s 3 40 m s RPM RENI ESP Output Input ESP Output Input ESP Output Input ESP Output Input ESP Output Input Pa kW kW Pa KW kW Pa kW kW Pa kW kW Pa kW kW HIGH STATIC DRIVE m s 1030 6 0 357 24 28 316 28 34 253 33 39 188 37 45 97 42 50 1070 5 0 405 25 362 208 35 42 226 39 47 5 1115 4 0 461 27 32 416 32 351 44
14. 5 213T 87 1vP75 140 165 354 3 8 BK100 239 94 30 1 3 164 BX81 2103 828 1 Static mans 5 5 6 5 i High 1LVP58 157 188 2 B gig 9501130 7510 254T ByoA 6274 Bushing 1B5V94 241 9 5 Bushing 5VX840 213484 1 they are located in the moving air upstream of any heating device 4 Do NOT close this pulley below 1 turn open Requires bushing included in kit All 50 Hz DM180 300 models come standard with factory filtered High Static Drive All motors have a nominal speed of 1450 RPM a 1 15 service factor and a solid base They can operate to the limit of their service factor because Johnson Controls Unitary Products 33 356214 XIM A 0108 PHASING YORK MODEL DM units are properly phased at the factory Check for proper compressor rotation If the blower or compressors rotate in the wrong direction at start up the electrical connection to the unit is mis phased Change the incoming line connection phasing to obtain proper rotation Scroll compressors operate in only one direction If the scroll is drawing low amper age has similar suction and discharge pressures or producing a high noise level the scroll is misphased A CAUTION Scroll compressors require proper rotation to operate correctly Units are properly phased at the factory Do not change the internal wiring to make the blower condenser fans o
15. 5 7 4 9 0 1 6 3 5 4 925 5 0 1 6 3 9 3 4 1 2 4 9 4 2 0 6 6 0 5 1 0 3 6 7 5 7 955 4 0 1 8 4 2 3 6 1 3 5 2 4 4 0 8 6 3 5 4 0 4 7 0 6 0 0 1 7 8 6 6 990 3 0 2 0 4 4 3 8 1 5 5 5 4 7 1 0 6 7 5 7 0 7 7 4 6 3 0 3 8 2 7 0 1020 2 0 2 1 4 7 4 0 1 7 5 8 5 0 1 2 7 0 6 0 0 9 7 8 6 7 0 5 8 6 7 8 1050 1 0 2 3 4 9 4 2 1 9 6 1 5 2 1 4 7 4 6 3 1 0 8 2 7 0 1080 0 0 2 5 5 2 4 4 2 1 6 4 5 5 1 6 7 7 6 6 1 2 8 5 7 3 NOTES 1 Blower performance includes a gas fired heat exchanger fixed outdoor air two inch T A filters and a dry evaporator coil 2 Refer to the additional Static Resistances table ESP External Static Pressure available for the supply and return air duct system All internal unit resistances have been deducted from the total static pressure of the blower Do NOT close the pulley below 1 turn open Factory setting Johnson Controls Unitary Products 31 TABLE 15 SUPPLY AIR BLOWER PERFORMANCE 25 TON COOLING APPLICATIONS 300 MBH BOTTOM DUCT CONNECTIONS DM300 UNIT DOWNFLOW DUCT CONNECTIONS CFM a 7500 CFM 8750 CFM 10000 CFM SPEED rpm TURNS OPEN Esp OUTPUT bhp INPUT kW ESP iwg OUTPUT bhp E ESP iwg OUTPUT bhp 945 6 0 12 5 6 4 6 0 8 70 57 0 3 84 69 975 5 0 14 59 49 10 73 6 0 0 5 8 8 72 1005 4 0 1 6 6 2 5 1 12 77 6 3 0 7 92 76 1040
16. 7 2 6 2 970 4 0 1 7 5 3 4 5 1 5 5 7 4 9 1 2 6 4 5 5 1 0 7 0 6 0 0 8 7 8 6 6 1005 3 0 1 9 5 6 4 8 1 7 6 0 5 1 1 4 6 8 5 8 1 2 7 4 6 4 1 0 8 2 7 0 1045 2 0 2 1 5 9 5 0 2 0 6 4 5 5 1 7 7 3 6 2 1 5 7 9 6 8 1080 1 0 2 4 6 2 5 3 2 2 6 8 5 8 1 9 6 5 1 7 8 4 7 1 NOTES 1 Blower performance includes fixed outdoor air 2 T A filters a dry evaporator coil and no electric heat 2 Refer to Table 16 for additional static resistances ESP External Static Pressure available for the supply and return air duct system All internal unit resistances have been deducted from the total static pressure of the blower Do NOT close the pulley below 1 turn open Factory setting Johnson Controls Unitary Products 29 356214 XIM A 0108 TABLE 13 SUPPLY AIR BLOWER PERFORMANCE 15 TON GAS HEAT 180 MBH BOTTOM DUCT CONNECTIONS AIRFLOW SPEED PULLEY 2 10 m3 s 2 45 m s 2 80 m s 3 10 m3 s 3 40 m s RPM OPEN ESP Output Input ESP Output Input ESP Output Input ESP Output Input ESP Output Input Pa kW kW Pa kW kW Pa kW kW Pa kW kW Pa kW kW HIGH STATIC DRIVE m s 1030 6 0 378 23 27 321 27 32 258 a2 38 199 36 44 134 42 50 1070 5 0 47 24 29 29 299 34 41 240 39 47 1115 4 0 461 26 31 47
17. A MINIMUM OF 90 Refer to the Physical Data Table 7 for unit weights and to the Figures 2 or 12 for approximate center of gravity APPROXIMATE CENTER OF A GRAVITY CONDENSER END FRONT a 136 25 20 25 TON N 125 25 15 TON FIGURE 2 CENTER OF GRAVITY A CAUTION A CAUTION Before lifting a unit make sure that all panels are in place and that its weight is distributed equally on all cables so it will lift evenly QUE s LIFTING SOB HOLES N FIGURE 1 TYPICAL RIGGING An adhesive backed label is provided over the outside of the combustion air inlet opening to prevent moisture from entering the unit which could cause damage to electrical components Allow this closure label to remain in place until the combustion air hood is to be installed refer to Vent and Combustion Hood Figure 8 CLEARANCES All units require certain clearances for proper operation and service Installer must make provisions 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 Dimensions and Clearances Figure 13 for the clearances required for combustible construction servicing and proper unit operation Johns
18. Caution should be used at all times as the sup ply air blower may energize regardless of the room thermostat fan switch position On calls for heating the draft motor operates 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 50 Place the thermostat fan switch in the ON posi tion If the supply air blower motor energizes go to Step 10 If the supply air blower motor does not energize when the fan switch is set to ON check that line voltage is being supplied to the contacts of the M3 contactor and that the contactor is pulled in Check for loose wiring between the contactor and the sup ply air blower motor If M3 is pulled in and voltage is supplied at M3 lightly touch the supply air blower motor housing If it is hot the motor may be off on inherent protec tion Cancel any thermostat calls and set the fan switch to AUTO wait for the internal overload to reset Test again when cool If M3 is not pulled in check for 24 volts at the M3 coil If 24 volts is present at M3 but M3 is not pulled in replace the contactor 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 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 24 volts
19. Off On On 0 30 Off Off On Off 0 10 Off Off Off On Non std Non std Off Off Off Off 54 Johnson Controls Unitary Products 356214 XIM A 0108 Johnson Controls Unitary Products 55 Subject to change without notice Printed in U S A 356214 XIM A 0108 Copyright 2008 by Johnson Controls Inc All rights reserved Supersedes 175240 XIM B 0707 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069
20. Options 1 2 amp 4 L Options 1 3 amp 4 M Options 1 2 3 amp 4 N Options 2 amp 3 P Options 2 amp 4 Q Options 2 3 amp 4 R Options 3 amp 4 S Option 5 T Options 1 amp 5 U Options 1 3 amp 5 V Options 1 4 amp 5 W Options 1 3 4 amp 5 X Options 3 amp 5 Y Options 4 amp 5 Z Options 3 4 amp 5 1 Disconnect 2 Non Pwr d Conv 3 Smoke Detector S A 4 Smoke Detector R A 5 Pwr d Conv Outlet tlet Johnson Controls Unitary Products 356214 XIM A 0108 INSTALLATION INSTALLATION SAFETY INFORMATION Read these instructions before continuing this appli ance installation This is an outdoor combination heat ing and cooling unit The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference 1 Refer the unit rating plate for the approved type of gas for this unit 2 Install this unit only in a location and position as specified on Page 10 of these instructions 3 Never test for gas leaks with an open flame Use commercially available soap solution made specifi cally for the detection of leaks when checking all connections as specified on Pages 8 16 17 and 40 of these instructions 4 Always install unit to operate within the furnace s intended temperature rise range with the duct sys tem and within the allowable external static pres sure r
21. PER HOUR Seconds Size of Test Dial for One Rev 1 2 cu ft 1 cu ft 4 450 900 6 300 600 8 228 450 10 180 360 12 150 300 14 129 257 16 113 225 18 100 200 20 90 180 22 82 164 24 75 150 26 69 138 28 64 129 Example By actual measurement it takes 13 seconds for the hand on the 1 cubic foot dial to make a revolution with just a 300 000 Btuh furnace running Read across to the column in the table above headed 1 Cubic Foot where you will see that 278 cubic feet of gas per hour are consumed by the furnace at that rate Multiply 278 x 1050 the Btu rating of the gas obtained from the local gas company The result is 292 425 Btuh which is close to the 300 000 Btuh rating of the furnace ADJUSTMENT OF TEMPERATURE 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 Application Table 4 CFM Btuh Input x 0 8 108 x F Temp Rise After the temperature rise has been determined the cfm can be calculated as follows After about 20 minutes of operation determine the fur nace temperature rise 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 ature rise decrease the blower cfm to increase the rise Refer to the Blower Motor
22. XIM A 0108 on delay for heating the UCB will energize the blower motor If the second stage of heat is required heater con tactor 7M will be energized Note that on the 54 KW 240V heater heater contactors 7M amp 8M will be energized and on the 72 KW 240V heater heater contactors 8M amp 9M will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space NOTE All 50 Hz heaters are provided with manual reset backup protection limits These will de energize the 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 one hour it will lock on the indoor blower motor and a flash code is initiated See Table 24 SAFETY CONTROLS The unit control board monitors the temperature limit switch of electric heat units 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 temperatu
23. and Drive Data Table 18 BELT DRIVE BLOWER All units have belt drive single speed blower motors The variable pitch pulley on the blower motor can be adjusted to obtain the desired supply air CFM TROUBLESHOOTING COOLING TROUBLESHOOTING GUIDE A WARNING Troubleshooting of components may require opening the electrical control box with the power connected to the unit Use extreme care when working with live circuits Check the unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any connections with line termi nals When not necessary shut off all electric power to the unit prior to any of the following mainte nance procedures so as to prevent personal injury A CAUTION Label all wires prior to disconnection when ser vicing controls Wiring errors can cause improper and dangerous operation which could cause injury to person and or damage unit components Verify proper operation after servicing On calls for cooling if the compressors are operating but the supply air blower motor does not energize after a short delay the room thermostat fan switch is in the AUTO position 1 Turn the thermostat fan switch to the ON position If the supply air blower motor does not energize go to Step 3 2 f the blower motor runs with the fan switch in the ON position but will not run after the first compres sor has energized
24. and that the contactor is pulled in Check for loose wiring between the contactor and the com pressor 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 the inter nal overload to reset Test again when cool If M1 is not pulled in check for 24 volts at the M1 coil If 24 volts are present and M1 is not pulled in replace the contactor Failing the above if voltage is supplied at M1 M1 is pulled in and the compressor still does not oper ate replace the compressor If 24 volts is not present at M1 check for 24 volts at the UCB terminal C1 If 24 volts is present check for loose wiring between C1 and the compressor contactor If 24 volts is not present at the C1 terminal check for 24 volts from the room thermostat at the UCB Y1 terminal If 24 volts is not present from the room thermostat check for the following a 24 volts at the thermostat Y1 terminal b Proper wiring between the room thermostat and the UGB i e Y1 to Y1 Y2 to Y2 c Loose wiring from the room thermostat to the UCB If 24 volts is 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 of the UCB If a switch has opened there should be a voltage potential between the UCB te
25. of the power exhaust option OPTIONAL ECONOMIZER AND POWER EXHAUST DAMPER SET POINT ADJUSTMENTS AND INFORMA TION Remove the economizer access panel from the unit Loosen but do not remove the two panel latches Locate the economizer control module where the fol lowing adjustments will be made A CAUTION EXTREME CARE MUST BE EXCERCISED IN TURNING ALL SETPOINT MAXIMIUM AND MINIMUM DAMPER POSITIONING ADJUST MENT SCREWS TO PREVENT TWISTING THEM OFF Check that the damper blades move smoothly without binding carefully turn the Minimum Position Adjusting screw found on the damper control module fully clockwise and then set the thermostat indoor fan switch to the on position and 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 the desired setpoint shown in the Enthalpy Setpoint Adjust ment Figure 9 Adjust as follows For a single enthalpy operation carefully turn the set point adjusting screw found on the damper control module to the A B C or D setting corresponding to the lettered curve of the Enthalpy Setpoint Adjustme
26. 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 If none of the above corrected the error test the integrity of the UCB Disconnect the C1 terminal wire and jumper it to the Y1 terminal DO NOT jump the Y1 to C1 terminals If the compressor engages the UCB has faulted If none of the above correct the error replace the UCB On calls for the second stage of cooling the supply air blower motor and compressor 1 are operating but compressor 2 is not the room thermostat fan switch is in the AUTO position 1 If installed check the position of the economizer blades If the blades are open the economizer is providing free cooling If the second stage of cooling is requested following a short delay compressor 1 will be energized unless it is locked out Typically compressor 2 is energized only during free cooling if the call for the second stage of cooling persists for 20 minutes Compressor 2 will not energize simultaneously with compressor 1 if a call for both stages of cool ing is received The UCB delays compressor 2 by 30 seconds to prevent a power surge If after the delay compressor 2 does not energize on a sec ond stage call for cooling check for line voltage at the compressor contact
27. propane Pro pane being an excellent solvent will quickly dissolve white lead or most standard commer cial compounds Therefore a special pipe compound must be applied when wrought iron or steel pipe is used Shellac base compounds such as Gaskolac or Stalastic and compounds such as Rectorseal 5 Clyde s or John Crane may be used 4 All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out the loose dirt and scale Before initial start up be sure that all of the gas lines external 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 PUES prescribed under Limitations After the gas con nections have been completed open the main FIGURE 6 EXTERNAL SUPPLY CONNECTION shut off valve admitting normal gas pressure to the EXTERNAL SHUT OFF mains Check all joints for leaks with soap solution or other material suitable for the purpose NEVER USE A FLAME A WARNING FIRE OR EXPLOSION HAZARD FAILURE TO FOLLOW THE SAFETY WARN ING EXACTLY COULD RESULT IN SERIOUS INJURY DEATH OR PROPERTY DAMAGE NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME USE COMMERICALLY AVAILABLE SOAP SOLUTION MADE SPE CIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS A FIRE OR EXPLOSION MAY RESULT CAUS FIGURE 7 BOTTOM SUPPLY CONNECTION ING PROPERTY DAMAGE PERSONAL EXTERNAL S
28. setpoint be correct Too high of a setting will result in longer heat cycles and a greater temperature 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 TABLE 22 GAS HEAT ANTICIPATOR SETPOINTS Anticipator Setpoint 2nd Stage Gas Valve 1st Stage Honeywell VR8440 White Rodgers 36C68 42 START UP COOLING PRESTART CHECK LIST After installation has been completed 1 Check the electrical supply voltage being supplied Be sure that it is the same as listed on the unit nameplate 2 Setthe room thermostat to the off position 3 Turn unit electrical power on 4 Setthe room thermostat fan switch to on 5 Check indoor blower rotation If blower rotation is in the wrong direction Refer to Phasing Section in general information section Check blower drive belt tension 6 Check the unit supply air CFM See CHECKING SUPPLY AIR CFM on page 34 7 Measure evaporator fan motor s amp draw 8 Setthe room thermostat fan switch to off 9 Turn unit electrical power off OPERATING INSTRUCTIONS 1 Turn unit electrical power on 2 Set the room thermostat setting to lower than the room temperature 3 First stage compressors will energize after the built in time delay five minutes 4 The second stage of the thermostat will energize second stage compress
29. to locate these access openings Typical supply piping arrangements are shown in the figures on page 15 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 maintenance without disturbing the supply line The supply piping and fittings must lie below the bottom gas manifold to avoid interference with the burner assem bly Two grommets are shipped in the blower compartment in parts bag taped to the blower housing of every unit with gas heat and should be used in the knockouts when the gas piping penetrates the front of the unit After the gas supply piping has been installed the bot tom opening in 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 codes a manual shut off valve may have to be installed outside of the unit 3 Use wrought iron or steel pipe for all gas lines Pipe compound should be applied sparingly to male threads only Johnson Controls Unitary Products 356214 XIM A 0108 supply piping system at test pressures equal to or AWARNING less than 1 2 psig 3 48kPa 7 A 1 8 inch NPT plugged tap accessible for test gage connection must be installed immediately upstream of the gas supply connection to the fur nace Natural gas may contain some
30. will re energize the halted compressor Should a high pressure switch open three times within two hours of operation the UCB will lock out the asso ciated compressor and flash a code see Table 24 If the other compressor is inactive the condenser fans will be de energized LOW PRESSURE LIMIT SWITCH The low pressure limit switch is not monitored during the initial 30 seconds of a cooling system s operation For the following 30 seconds the UCB will monitor the low pressure switch to ensure it closes If the low pres sure switch fails to close after the 30 second monitor ing phase the UCB will de energize the associated compressor initiate the ASCD and if the other com pressor is idle stop the condenser fans Once the low pressure switch has been proven closed during the 30 second monitor period described 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 the ASCD and if the other compressor is idle stop the condenser fans If the call for cooling is still present at the conclusion of the ASCD the UCB will re energize the halted com pressor Should a low pressure switch open three times within one hour of operation the UCB will lock out the associ ated compressor and flash a code Table 24 If the other compressor is inactive the condenser fans will be de energized
31. with four fasteners and the screws used for mounting the hood to the panel The top flange of this hood slips in under the top of the access panel opening when install ing Refer to Vent and Combustion Air Hood Figure 8 Each vent hood is installed by inserting the top flange of the hood into the slotted opening in the access panel and securing in place The products of combustion are discharged horizon tally through these two screened hooded vent open ings on the upper gas heat access panel COMBUSTION AIR INTAKE 72 GAS HEAT ACCESS lt J PANELS RP d SLOTTED OPENINGS IN VENT AIR ACCESS PANEL OUTLET 65595 FIGURE 8 VENT AND COMBUSTION AIR HOOD OPTIONAL ECONOMIZER MOTORIZED DAMPER RAIN HOOD The instruction for the optional economizer motorized damper rain hood can be found in the kit Use these instructions when field assembling an economizer rain hood onto a unit The outdoor and return air dampers the damper actuator the damper linkage the outdoor and return air divider baffles and all the control sen sors are factory mounted as part of the Factory installed economizer option Johnson Controls Unitary Products 356214 XIM A 0108 OPTIONAL POWER EXHAUST BAROMETRIC RELIEF DAMPER RAIN HOOD The instructions for the power exhaust barometric relief damper rain hood can be found in the kit The exhaust fan all supporting brackets angles and the wiring are factory installed as part
32. 3 0 1 8 6 6 5 4 14 8 1 6 7 0 9 97 8 0 1070 20 20 6 9 57 16 8 5 7 0 11 10 2 83 1100 1 0 21 73 6 0 1 8 8 9 73 13 10 6 87 1130 0 0 23 7 6 6 2 2 0 93 7 6 15 11 0 9 0 DM300 UNIT DOWNFLOW DUCT CONNECTIONS m3 s 3 53 m3 Sec 4 13 m3 Sec 4 72 m Sec BLOWER PULLEY SPEED rpm TURNS Esp Pa OUTPUT bhp INPUT kW ESP Pa OUTPUT bhp pu ESP Pa OUTPUT bhp puo 945 6 0 303 5 6 16 198 70 57 71 84 69 975 5 0 347 59 49 244 73 6 0 120 8 8 72 1005 4 0 391 62 5 1 291 77 6 3 169 9 2 7 6 1040 8 0 443 6 6 54 347 8 1 67 228 97 8 0 1070 2 0 489 6 9 57 396 8 5 7 0 280 10 2 83 1100 1 0 536 73 6 0 445 8 9 73 332 10 6 8 7 1130 0 0 583 7 6 6 2 495 9 3 7 6 385 11 0 9 0 DM300 UNIT DOWNFLOW DUCT CONNECTIONS GAS HEAT MODELS CFM 7500 CFM 8750 CFM 10000 CFM BLOWER PULLEY SPEED rpm TURNS ESP iwg OUTPUT bhp INPUT kW ESP iwg OUTPUT bhp p ESP iwg OUTPUT bhp 945 6 0 TO 56 4 6 03 70 57 975 5 0 12 59 4 9 0 5 73 6 0 1005 4 0 14 6 2 5 1 07 77 6 3 z 5 s 1040 3 0 1 6 6 6 54 0 9 8 1 6 7 02 97 8 0 1070 2 0 1 8 6 9 57 14 8 5 7 0 0 4 10 2 83 1100 1 0 2 0 73 6 0 13 8 9 73 0 6 10 6 87 1130 0 0 22 7 6 6 2 15 93 76 0 8 11 0 9 0 DM300 UNIT DOWNFLOW DUCT CONNECTIONS GAS HEAT MODELS ms3 s 3 53 m sec 4 13 m sec 4 72 m sec BLOWER PULLEY SPEED rpm TURNS OPEN Esp pay QUTPUT bhp INPUT kw ESP Pa OUTPUT bhp perd ESP Pa OUTPUT bhp pond 945 6 0 258 5 6 4 6 87 7 0 57 a 975 5 0 301 5 9
33. 49 133 7 3 6 0 1005 4 0 345 6 2 5 1 180 77 6 3 5 1040 3 0 398 6 6 54 236 8 1 6 7 43 97 8 0 1070 2 0 444 6 9 57 285 8 5 7 0 94 10 2 83 1100 10 490 73 6 0 334 8 9 73 146 10 6 87 1130 0 0 537 7 6 62 384 93 76 199 11 0 9 0 NOTES 1 Blower performance includes a gas fired heat exchanger fixed outdoor air two inch T A filters and a dry evaporator coil 2 Refer to the additional Static Resistances table ESP External Static Pressure available for the supply and return air duct system All internal unit resistances have been deducted from the total static pressure of the blower Do NOT close the pulley below 1 turn open Factory setting CD 2 Johnson Controls Unitary Products 356214 XIM A 0108 TABLE 16 STATIC RESISTANCES RESISTANCE Pa IWG 3 DESCRIPTION MODEL 180 MODEL 240 MODEL 300 2 1 4500 2 8 6000 3 4 7200 2 8 6000 3 8 8000 4 4 9400 3 78 8000 4 25 9000 4 7210000 WET COIL 228 01 248 01 242801 22801 24601 24601 25 01 25707 25707 248 01 24 8701 24 8701 24 8701 248 01 248 03 25 04 25 0 1 25 0 1 18 KW 24 8 03 24 8 0 1 248 01 248 01 248 01 24801 25701 25 0 1 25 0 1 36KW 248 01 500 02 744 03 24 8701 50002 744 03 25701 50 0 2 75 0 3 ELECTRIC HEAT OPTIONS 54 KW 500 02 744 03 992 04 50 002 744 03 99 2 0 4 50 02 75 0 3 100 0 4 72KW 500 02
34. 99 2 0 4 149 0 0 6 50 002 99 2 0 4 149 0 0 6 50 02 100 0 4 150 0 6 ECONOMIZER OPTION 248 01 24 8701 248 01 24801 248 03 248 03 25 01 257011 25 01 HORIZONTAL DUCT CONNECTIONS 50 002 744 03 124 005 50002 74403 124005 50 02 75 0 3 125 0 5 1 Duct Connections Add these values due to less airflow resistance TABLE 17 POWER EXHAUST PERFORMANCE Deduct these resistance values from the available external static pressures shown in the respective Blower Performance Table except for Horizontal STATIC RESISTANCE OF RETURN DUCTWORK IWG MOTOR SPEED 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 Factory Setting Power Exhaust motor is a 3 4 HP PSC type with sleeve bearings a 48 frame and inherent protection TABLE 18 BLOWER MOTOR AND DRIVE DATA MOTOR ADJUSTABLE MOTOR PULLEY FIXED BLOWER PULLEY BLOWER NOTCHED DRIVE RANGE PITCH PITCH PITCH s RPM kwHP FRAME EFF DESIG DIA BORE DESIG BORE DESIG LENGTH NATION mmN mm iNJ NATION nmi mm IN NATION Gorin 180 High 4030 1240 3 7 5 0 1847 1VPe2 109 135 297 18 BK75 175 69 25 1 BX68 1773 69 8 1 Static 8 4 3 5 3 i 240 High 895 1080 5 6 7
35. BH Output Stainless Steel Electric Heat Options E18 18 KW E36 36 KW E54 54 KW E72 72 KW A Std Drive B Std Drive Single Input Econo C Std Drive Single Input Econo Power Exhaust Downflow Only D Std Drive Motorized Damper E Std Drive Motorized Damper Barometric Relief J Std Drive Single Input Econo Barometric Relief N Hi Static Drive P Hi Static Drive Single Input Econo Q Hi Static Drive Single Input Econo Power Exhaust Downflow Only R Hi Static Drive Motorized Damper K Hi Static Drive Motorized Damper Barometric Relief S Hi Static Drive Single Input Econo Barometric Relief Note 50 Hz DM180 300 Models come standard with high static drive package Voltage 7 380 415 3 50 Product Style A Style A Configuration Options not required for all units These four digits will not be assigned until a quote is requested or an order placed SS Drain Pan CPC Controller DFS APS Johnson Controller DFS APS Honeywell Controller DFS APS Novar Controller DFS APS Simplicity IntelliComfort Controller Simplicity IntelliComfort Controller w ModLinc 2 Pleated filters 4 Pleated filters BAS Ready Economizer 2 10 V D C Actuator Without a Controller Double Wall Construction Any Combination of Additional Options that Don t Have an Option Code Pre assigned Product Generation First Generation Second Generation Additional Options Standard Cab
36. CB 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 If none of the above corrected the error test the integrity of the UGB Disconnect the C2 terminal wire and jumper it to the Y2 terminal DO NOT jump the Y2 to C2 terminals If the compressor engages the UCB has faulted If none of the above correct the error replace the UCB On a call for cooling the supply air blower motor and compressor 2 are operating but compressor 1 is not the room thermostat fan switch is in the AUTO posi tion 1 Compressor 2 is energized in place of compres sor 1 when compressor 1 is unavailable for cool ing calls Check the UCB for alarms indicating that compressor 1 is locked out Press and release the ALARMS button if the LED is not flashing an alarm 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 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 the inter nal overload to reset Test again when cool Johnson Controls Unitary Products 356214 XIM A 0108
37. CLEARANCE Front 914 36 Rear 610 24 Less Economizer 1245 49 With Economizer Left Side Filter Access 610 24 Less Economizer 1372 54 With Economizer Right Side Cond Coil 914 36 Below Unit 0 0 1829 72 With 914 36 Above Unit Maximum Horizontal Overhang For Condenser Air Discharge 1 Units may be installed on combustible floors made from wood or class A B or C roof covering material Units must be installed outdoors Overhanging structures or shrubs should not obstruct condenser air discharge outlet 3 If economizer is factory installed the unassembled rain hood must be removed from its ride along position in front of evapo rator coil or in the outdoor air compartment prior to final instal lation POWER EXHAUST RAIN HOOD SUPPLY AIR COMPARTMENT on Return Air Compartment REAR VIEW ECONOMIZER MOTORIZED DAMPER RAIN HOOD on Outdoor Air Compartment 127 5 716 28 3 16 DETAIL Y ELEC ELEC Models Units and ductwork are approved for zero clearance to combustible material when equipped with electric heaters GAS ELEC Models A 25mm 1 clearance must be provided between any combustible material and the supply air ductwork for a distance of 9 meter 3 feet from the unit The products of combustion must not be allowed to accumulate within a confined space and recirculate Locate unit so that the ven
38. G OPERATION 39 DUCTWORK 10 TEMPERATURE 39 FIXED OUTDOOR AIR INTAKE DAMPER a 10 SAFETY CONTROLS UK QU ee LURA amp amp RECETA 39 CONDENSATE DRAIN l un PREMIERE 11 FLASH CODES Wo SUS a MUS WO Ew o A 39 COMPRESSORS SEE S 1 1 RESET 39 FIITERS 11 HEAT ANTICIPATOR 39 SERVICE 11 GAS HEATING SEQUENCE OF OPERATIONS 39 THERMOSTAT 13 GAS HEATING OPERATION ERRORS 40 POWER AND CONTROL WIRING CR 13 TEMPERATURE LIMIT Pop re e dC Ge ee W ae Be 40 OPTIONAL ELECTRIC HEAT REPRE 13 GAS VALVE race EEcE ur 41 OPTIONALGAS HEAT a SAFETY 18 41 GAS 1 14 FLASH 8 42 GAS CONNECTION 14 RESETS a ee a aa ee ee 4 4 ae 42 LP UNITS TANKS AND PIPING HEAT ANTICIPATOR SETPOINTS 42 VENT AND COMBUSTION AIR HOODS 16 START UP COOLING 42 OPTIONAL ECONOMIZER MOTORIZED DAMPER RAIN PRESTART CHECKLIST
39. 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 Delay is turned off Press the COMM SETUP SELECT button to toggle into the Heat Delay Setup the green LED will turn off and the red LED for Heat Delay will turn on The 8 4 2 and 1 LEDs will then show the status of the Heat Delay See Table 25 Press the UP or Down button to change the LED status to correspond to the desired Heat Delay Value To save the current displayed value push the OPTION SETUP STORE button and hold it for at least 2 seconds When the value is saved the red LED will flash a few times and then normal display will resume NOTE While in either Setup mode if no buttons are pushed for 60 seconds 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 TABLE 25 HEAT DELAY Heat Heat Red Red Red Red FanOn FanOff LED4 1 2 LED1 Delay Delay 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
40. HUT OFF INJURY OR LOSS OF LIFE L P UNITS TANKS AND PIPING 6 The furnace and its individual manual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 48kPa All gas heat units are shipped from the factory equipped for natural gas use only The unit may be converted in the field for use with L P propane gas with accessory kit model number 1NP0418 All L P propane gas equipment must conform to the safety standards of the National Fire Protection Associ ation The furnace must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas Johnson Controls Unitary Products 15 356214 XIM A 0108 For satisfactory operation L P propane gas pressure must be 10 0 I W C 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 area of the container or containers 2 The proper pressure regulation Two stage regula tion is recommended from the standpoint of both cost and efficiency 3 The pressure drop in the lines between regulators and between the second stage regulator and the appliance Pipe size required will depend on the length of the pipe run and the total load of all appli ances Comple
41. JUSTMENT Exhaust Air Adjustment Screw Exhaust Air LED TR gp Damper Min 24 24 Vac Vac 0 Position Screw HOT COM 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 10 HONEYWELL ECONOMIZER CONTROL W7212 18 Johnson Controls Unitary Products 356214 XIM A 0108 1 B 50 SS f SS 5 LA C 3 A A ORAS OQ FRONT D FIGURE 11 FOUR AND SIX POINT LOADS TABLE 6 FOUR AND SIX POINT LOADS u gt O Total 4 Point Loads Ibs Unit Size Shipping Weight A B c D 180 Gas 2300 539 563 612 586 240 Gas 2500 538 563 715 684 300 Gas 3130 615 671 962 882 180 Elec 2100 492 514 558 536 240 Elec 2300 295 517 658 630 300 Elec 2890 487 619 646 508 Total 6 Point Loads Ibs Unit Size Shipping Weight A B C D E F 180 Gas 2300 351 367 392 416 399 375 240 Gas 2500 334 350 426 502 481 407 300 Gas 3130 418 438 533 628 603 510 180 Elec 2100 320 335 358 380 364 343 240 Elec 2300 307 322 392 462 442 375 300 Elec 2890 415 471 528 551 492 433 APPROXIMATE CENTER OF BACK GRAVITY CONDENSER END 60 92 45 FRONT NR S 125 25 15 TON 136 25 20 25 TON FIGURE 12 CENTER OF GRAVITY Johnson Controls Unitary Products 356214 XIM A 0108 TABLE 7 PHYSICAL DATA
42. L DATA WITHOUT POWERED CONVENIENCE OUTLET COMPRESSORS Hm ID HEATER OPTION MIN U E MODEL BLOWER CIRCUIT 1 TONNAGE VOLTAGE SER ppt Moton MS MODEL KW STAGES AMPS gee AMPS None 0 0 46 0 50 E18 11 3 1 17 1 46 0 50 380 9 6 62 2 1 8 3 0 0 E36 22 6 2 34 3 53 3 60 E54 33 8 2 51 4 74 6 80 E72 45 1 2 68 6 96 0 100 13 None 0 0 46 0 50 18 13 5 1 18 7 46 0 50 415 9 6 62 2 1 8 3 0 0 E36 26 9 2 37 4 57 2 60 E54 40 4 2 56 2 80 6 90 E72 53 8 2 74 9 85 2 100 None 0 0 62 5 80 E18 11 3 1 17 1 62 5 80 380 20 7 130 2 1 11 7 0 0 E36 22 6 2 34 3 62 5 80 E54 33 8 2 51 4 80 6 90 E72 45 1 2 68 6 100 3 110 ii None 0 0 62 5 80 18 13 5 1 18 7 62 5 80 415 20 7 130 2 1 11 5 0 0 6 26 9 2 37 4 62 3 80 E54 40 4 2 56 2 84 6 90 E72 53 8 2 74 9 89 2 100 None 0 0 74 7 90 E18 11 3 1 17 1 76 0 90 22 9 145 2 1 19 0 0 E36 22 6 2 34 3 76 0 90 E54 33 8 2 51 4 87 9 90 E72 45 1 2 68 6 109 4 110 e None 0 0 74 7 90 E18 13 5 1 18 7 76 0 90 415 22 9 145 2 1 19 0 0 E36 26 9 2 37 4 76 0 90 E54 40 4 2 56 2 94 0 100 E72 53 8 2 74 9 98 6 110 Note 1 HACR Type per NEC Johnson Controls Unitary Products 21 356214 XIM A 0108 TABLE 9 DM ELECTRICAL DATA WITH POWERED CONVENIENCE OUTLET COMPRESSORS comu T com HEATER O
43. LOWER PERFORMANCE 25 TON 20 GAS VALVE AND CONTROLS 42 COOLING APPLICATIONS 300 MBH BOTTOM DUCT NNEGTIONS isse ha boas 2 21 TYPICAL GAS VALVES 43 eo evens 3 17 STATICRESISTANCES 33 22 PROPER FLAME 44 18 POWER EXHAUST PERFORMANCE 23 TYPICAL FLAME 44 us M 19 BLOWER MOTOR AND DRIVE 33 24 UNIT CONTROL BOARD eee 53 20 LIMIT CONTROL SETTING 39 21 ELECTRIC HEAT ANTICIPATOR SETPOINTS 39 22 LIMIT CONTROL SETTING 41 23 GAS HEAT ANTICIPATOR SETPOINTS 42 24 GAS RATE CUBIC FEET PERHOUR 45 25 UNIT CONTROL BOARD FLASH CODES 53 26 HEAT DELAY sais ses ins em e gem m RR sa 54 Johnson Controls Unitary Products 3 356214 XIM A 0108 GENERAL YORK Model DM units are either single package air conditions equipped with optional factory installed elec tric heaters or single package gas fired central heating furnaces with cooling unit Both are designed for out door installation on a rooftop or slab The units are completely assembled on rigid perma nently attached base rails All piping refrigerant charge and electrical wiring is factory installed and tested The units require electric power gas connec tion duct connections in
44. Limit Control Setting Table 21 It resets automatically The limit switch operates when a high temperature condition caused by inadequate supply air flow occurs thus shutting down the ignition control and closing the main gas valves and energizing the blower 2 Centrifugal Switch CS If the draft motor should fail the centrifugal switch attached to the shaft of the motor prevents the igni tion controls and gas valves from being energized 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 redundant valves serve as back ups and shut off the flow of gas 4 Flame Sensor Rod 100 Ignition Control Lock Out The flame rods and controls are located per Proper Flame Adjustment Figure 22 If an ignition control fails to detect a signal from the flame sensor indi cating the pilot flame is properly ignited then the main gas valve will not open It will continue to try and ignite the pilot for a maximum of 85 seconds then if the pilot flame is not detected the ignition control will lock out furnace operation until 24V power is removed from the module either at the unit or by resetting the room thermostat 5 Rollout Switch This switch is located above the main burners in the control compartment which in the event of a sustained main burner rollout shuts off and locks out both ignition controls closing both gas valves The ignition contro
45. PTION ww MAX MODEL BLOWER CIRCUIT TONNAGE VOLTAGE ES apod xd MODEL KW STAGES AMPS ur prs AMPS None 0 0 52 3 50 Ete 423 1 171 823 60 380 96 62 2 1 8 3 E36 226 2 612 70 E54 338 2 si4 624 90 E72 451 2 686 1039 110 s None 00 52 3 50 E18 135 1 187 523 60 415 96 62 21 8 3 E36 269 2 374 650 70 E54 404 2 562 885 90 E72 538 2 749 934 100 None 0 0 68 8 80 Ete nsl 1 171 688 80 380 20 7 130 21 17 63 Ese 226 2 688 80 E54 338 2 514 867 90 E72 451 2 686 1082 110 25 0 0 68 8 80 E18 135 1 187 688 80 45 207 130 21 15 63 E36 269 2 374 690 80 E54 404 2 562 925 100 E72 5388 2 749 971 100 None 00 823 100 Ete 13 1 171 823 100 380 229 145 21 19 63 E86 226 2 823 100 E54 338 2 si4 958 100 E72 451 2 686 173 125 a None 00 82 3 100 Ete 135 1 187 823 100 415 229 145 21 19 63 E36 269 2 374 823 100 E54 404 2 562 1019 110 E72 538 2 749 1065 110 Note 1 HACR Type per NEC 22 Johnson Controls Unitary Products 356214 XIM A 0108 ECONOMIZER MOTORIZED DAMPER dimensions of the curb for the proper size of the supply and return air duct connections BLOWER FIXED OUTDOOR INTAKE AIR AND CCERS FIELD SUPPCIED POWER E
46. SUNLINE 2000 GAS ELECTRIC SINGLE PACKAGE AIR CONDITIONERS MODELS DM180 240 amp 300 Export ISO 9001 Certified Quality Management System AD 9 000 REGISTR 356214 XIM A 0108 356214 XIM A 0108 TABLE OF CONTENTS GENERAL 4 ECONOMIZER SINGLE OR DUAL ENTHALPY WITH SAFETY CONSIDERATIONS 4 POWER 08 37 INSPECTION 4 MOTORIZED OUTDOOR AIR DAMPERS 37 COOLING OPERATION ERRORS 37 REFERENCE ooo a 4 HIGHEBRESSURELIMITSWITGH L 37 RENEWAL PARTS 5 LOW PRESSURE LIMIT SWITCH ooo ouaaa 37 APPROVALS 5 FREEZESTAT 37 PRODUCT NOMENCLATURE 6 LOW AMBIENT COOLING 38 INSTALLATION 7 SAFETY 58 nne 38 INSTALLATION SAFETY 7 COMPRESSOR 38 LIMITATIONS 7 FLASH 38 LOCATION ae VM 8 RESET ee ee ee ee ee eee ee ee ee eee ee eee ee 38 RIGGING AND HANDLING 9 ELECTRIC HEATING SEQUENCE OF OPERATIONS 38 CLEARANCES 9 HEATIN
47. TION ag TROUBLESHOOTING 45 CONTINUOUS 36 COOLING TROUBLESHOOTING GUIDE 45 INTERMITTENT BLOWER 36 GAS HEAT TROUBLESHOOTING GUIDE ii pridie 50 NOXGUTBGORENROPTIONS U 25 UNIT FLASH 52 ECONOMIZE WITH SINGLE ENTHACPY SENSOR 58 UNIT CONTROL BOARD OPTION SETUP 54 ECONONIZER WITH DUAL ENTHAUPY SENSORS 37 OPTION BYTE SETUP 54 HEAT DELAY SETUP 54 Unitary Products Group 356214 XIM A 0108 LIST OF FIGURES LIST OF TABLES Fig Pg Pg 1 TYPICAL RIGGING 9 1 UNIT APPLICATION DATA 8 2 CENTER OF 9 2 CONTROL WIRE 6 2 13 3 FIXED OUTDOOR AIR DAMPER 11 3 ELECTRIC HEAT APPLICATION DATA 13 4 RECOMMENDED DRAIN PIPING 11 4 GAS HEAT APPLICATION 14 5 FIELD WIRING DM ELECTRIC ELECTRIC AND 5 14 GAS ELECTRIC UNITS 12 6 FOUR AND SIXPOINTLOADS 19 6 EXTERNAL SUPPLY CONNECTION EXTERNAL SHUT OFF 3 15 7 PHYSICAL DATA ui 283 58 racea wri peer ege 20 7 BOTTOM SUPPLY CONNECTION EXTERNAL i
48. XHAUST RAIN HOODS BLOWER MOTOR DISCONNECT SWITCH See detail Y ACCESS LOCATION oo oe BLOWER COMPARTMENT ACCESS COIL Auxiliary GUARD DOT PLUG For pressure 48 5 8 15 TON Drop Reading 52 5 8 20 25 TON ELECTRIC GAS HEAT ACCESS VENT AIR CONDENSER OUTLET COILS HOODS COMBUSTION AIR INLET HOOD C A GAS SURREY CONTROL WIRING ENTRY CONTROL BO 1 11 1 2 B 35 SS POWER WIRING BOTTOM SUPPLY ENTRY AND RETURN FRONT AIR OPENINGS See Note VIEW 3 3 4 0 dimensions inches They subject to change without notice Certified UNIT BASE WITH RAILS X dimensions will be provided upon request Shown separately to illustrate D POWER WIRING Bottom Duct openings Power GAS SUPPLY Z ENTRY and Gas Piping Connection ENTRY y locations lt X A RSS CONTROL WIRING 8 1 8 NOTE WY OS ENTRY For curb mounted units refer to the curb hanger 46 5 8 i 9 3 4 Control Wirin 1973 4 NPS Fem Bottom 92 3 5 8 KO Sid B Power Wiring 76 3 NPS Fem Bottom C 60 2 3 8 KO Gas Piping Front D 43 1 11 16 Hole Gas Piping Bottom 1 One inch gas piping NPT required 2 Opening in the bottom of the unit can be located by the slice in the insulation NOTE All entry holes should be field sealed to prevent rain water entry into the building FIGURE 13 FRONT VIEW DIMENSIONS 15 20 amp 25 TON Johnson Controls Unitary Produ
49. a Level Above Above on Models FtJHr Full Input Sea Level Sea Level Max Min Max Min Max Max Min Max 300 150 2 0 135 240 213 15 20 amp 25 Ton 2 9 20 50 350 175 320 160 280 241 25 Ton 326 30 60 GAS PIPING GAS CONNECTION Proper sizing of gas piping depends on the cubic feet per hour of gas flow required specific gravity of the gas and the length of run National Fuel Gas Code Z223 1 in U S A or the current Gas Installation Codes CSA B149 1 in Canada should be followed in all cases unless superseded by local codes or gas utility require ments Refer to the Pipe Sizing Table 5 The heating value of the gas may differ with locality The value should be checked with the local gas utility NOTE There may be a local gas utility requirement specifying a minimum diameter for gas piping All units require a one inch pipe connection at the entrance fitting TABLE 5 PIPE SIZING Nominal Iron Pipe Size Length in Feet 1 1 1 4 10 520 1 050 20 350 730 30 285 590 40 245 500 50 215 440 60 195 400 70 180 370 80 170 350 90 160 320 100 150 305 Maximum capacity of pipe cubic feet of gas per hour Based upon a pressure drop of 0 3 inch water column and 0 6 specific gravity gas The gas supply line can be routed through the knock outs located on the front of the unit or through the opening provided in the unit s base Refer to the Dimensions and Clearances Figure 13
50. ange as specified on the unit name rating plate specified on Page 42 of these instructions 5 This equipment is not to be used for temporary heating of buildings or structures under construc tion A WARNING FIRE OR EXPLOSION HAZARD FAILURE TO FOLLOW THE SAFETY WARN ING EXACTLY COULD RESULT IN SERIOUS INJURY DEATH OR PROPERTY DAMAGE NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME USE COMMERICALLY AVAILABLE SOAP SOLUTION MADE SPE CIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS A FIRE OR EXPLOSION MAY RESULT CAUS ING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE 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 Code 2223 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 e Other applicable local codes Refer to the Unit Application Data table and to the Gas Heat Application Data table After installation the unit must be adjusted to obtain a temperature rise within the range specified on the unit rating plate If components are to be added to a unit to meet local codes they are to be installed at the dealer s and or the customer s expense Size o
51. cts 23 356214 XIM A 0108 40 3 8 SUPPLY AIR COMPRESSOR ACCESS SUPPLY AIR ACCESS Dimensions listed are for side duct flange openings see RETURN AIR ACCESS REAR VIEW Field Accessories for Side Duct Flange Kit FIGURE 14 REAR VIEW DIMENSIONS NOTE Units are shipped with the bottom duct open ings covered An accessory flange kit is avail able for connecting side ducts For bottom duct applications 1 24 Remove the side panels from the supply and return air compartments to gain access to the bottom supply and return air duct covers Remove and discard the bottom duct covers Duct openings are closed with sheet metal covers except when the unit includes a power exhaust option The covering consists of a heavy black paper composition Replace the side supply and return air compartment panels 28 5 8 15 TON 39 5 8 20 25 TON EVAPORATOR SECTION DOT PLUG For pressure drop reading FILTER ACCESS OUTDOOR AIR 1 NPT FEMALE COND DRAIN CONNECTION END OUTDOOR AIR COMPARTMENT ACCESS N For side duct applications 1 Replace the side panels on the supply and return air compartments with the side duct flange accessory kit panels Connect ductwork to the flanges on those panels Johnson Controls Unitary Products 356214 XIM A 0108 CLEARANCES NOTE LOCATION
52. d liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions f you cannot reach the gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier INSPECTION As soon as a unit is received it should be inspected for possible damage during transit If damage is evident the extent of the damage should be noted on the car rier s freight bill A separate request for inspection by the carrier s agent should be made in writing REFERENCE Additional information on the design installation oper ation and service of this equipment is available in the following reference forms Technical Guide 262257 General Installation 175240 Johnson Controls Unitary Products 356214 XIM A 0108 RENEWAL PARTS Contact your local York Parts Distribution Center for authorized replacement parts APPROVALS Design certified by CSA as follows For use as a cooling unit only with or without optional electric heat For use as a forced air furnace with cooling unit For outdoor installation only For installation on combustible mater
53. ector circuit Jumper is required for any combination of R or RH o OCC is an output from the thermostat to indicate the Occupied condition X is an input to the thermostat to display Error Status conditions FIGURE 5 FIELD WIRING DM ELECTRIC ELECTRIC AND GAS ELECTRIC UNITS 12 Johnson Controls Unitary Products 356214 XIM A 0108 THERMOSTAT The room thermostat should be located on an inside wall approximately 56 inches above the floor where it will not be subject to drafts sun exposure or heat from electrical fixtures or appliances Follow manufacturer s instructions enclosed with thermostat for general instal lation procedure A minimum of seven color coded insulated wires 18 AWG should be used to connect thermostat to unit POWER AND CONTROL WIRING Field wiring to the unit must conform to provisions of the National Electrical Code ANSI NFPA No 70 in U S A current Canadian Electrical Code C22 1 in Canada and or local ordinances The unit must be electrically grounded in accordance with NEC and CEC as specified above and or local codes Voltage toler ances which must be maintained at the compressor terminals during starting and running conditions are indicated on the unit Rating Plate and the Unit Applica tion Data table The internal wiring harness furnished with this unit is an integral part of a CSA design certified unit Field alteration to com
54. ents 3 The tension on the belt should be adjusted as shown in the Belt Adjustment Figure 17 Johnson Controls Unitary Products 356214 XIM A 0108 Start the supply air blower motor Adjust the resis tances in both the supply and the return air duct sys tems to balance the air distribution throughout the conditioned space The job specifications may require that this balancing be done by someone other than the equipment installer To check the supply air CFM after the initial balancing has been completed 1 Remove the two 5 16 dot plugs from the blower motor and the filter access panels shown in the Dimensions and Clearances Figure 13 2 Insert at least 8 of 1 4 inch tubing into each of these holes for sufficient penetration into the air flow on both sides of the indoor coil NOTE The tubes must be inserted and held in a posi tion perpendicular to the air flow so that veloc ity pressure will not affect the static pressure readings 3 Using an inclined manometer determine the pres sure drop across a dry evaporator coil Since the moisture on an 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 being run 4 Knowing the pressure drop across a dry coil the actual CFM through the unit can be determined from the curve in Pressure Drop vs Supply Air CFM Figu
55. es or until 40 24V power is removed from the module either at the unit or by resetting the room thermostat NOTE That the second stage furnace can operate even if first stage has locked out When the thermostat satisfies de energizing the RW2 and RW1 thus opening all gas valves blower motor will continue to run after the furnace is shut down until the specified fan off delay for heating has been satisfied The UCB will de energize the blower motor REDUNDANT VALVE u Ee Py GAS MAIN NEN GS 1 TOMAIN VALVE TO PILOT BURNER BURNER MAIN VALVE Ay X Yi VA AU FIGURE 19 GAS VALVE PIPING When the thermostat calls for the first stage of heating the low voltage control circuit from R to W1 is com pleted A call for heat passes through the UCB to the ignition control board ICB The UCB monitors the W1 call and acts upon any call for heat Once voltage has been sensed at W1 the UCB will initiate the fan on delay for heating energizing the indoor blower after the specified delay has elapsed When the thermostat has been satisfied heating calls 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 immed
56. eset all ASCDs for one cycle press and release the UCB TEST RESET button once Flash codes that do and do not represent alarms are listed in Table 24 Johnson Controls Unitary Products 356214 XIM A 0108 TABLE 24 UNIT CONTROL BOARD FLASH CODES GREEN RED RED RED RED FLASH CODE DESCRIPTION LED LED LED LED LED 16 8 4 2 1 On Steady This is a Control Failure 1 Flash Not Applicable 2 Flashes Control waiting ASCD1 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 Off On Off Off On 10 Flashes Compressors Locked Out on Low Outdoor Air Temperature Flashing On Off On Off 11 Flashes D locked out because the Economizer is using free Flashing On Off Cooling 12 Flashes Unit Locked Out due to Fan Overload Switch Failure Off On On Off Off 13 Flashes Compressor Held Off due to Low Voltage Flashing On On Off On 14 Flashes EEPROM Storage Failure Off On On On Off OFF No Power or Control Failure Off Off Off Off Off 1 Non alarm condition COMM LAST IEST OPTION SETUP ERROR R SS RESET i
57. etween outdoor air and return air whichever has the lowest enthalpy value to provide maximum operating efficiency ECONOMIZER SINGLE OR DUAL ENTHALPY WITH POWER EXHAUST This system operates as specified above with one addition The power exhaust motor is energized 45 seconds after the actuator position exceeds the exhaust fan setpoint 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 power exhaust operation MOTORIZED OUTDOOR AIR DAMPERS This system operation is the same as the units with no outdoor air options with one exception When the R to G circuit is complete the motorized damper drives open to a position set by the thumbwheel on the damper motor When the R to G circuit is opened the damper spring returns fully closed COOLING OPERATION ERRORS Each 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 SWITCH During cooling operation if a high pressure limit switch opens the UCB will de energize the associated com pressor initiate the ASCD Anti short cycle delay and if the other compressor is idle stop the condenser fans If the call for cooling is still present at the conclu sion of the ASCD the UCB
58. ezestat trip will de energize the associated compressor If the call for cooling is still present at the end of the ASCD and the freezestat has closed the unit will resume operation SAFETY CONTROLS The unit control board monitors the following inputs for each cooling system 1 A suction line freezestat to protect against low evaporator temperatures due to a low airflow or a low return air temperature opens at 26 5 F and resets at 38 5 F 2 A high pressure switch to protect against exces sive discharge pressures due to a blocked con denser coil or a condenser motor failure opens at 380 10 psig and resets at 300 10 psig 3 A low pressure switch to protect against loss of refrigerant charge opens at 22 5 psig and resets at 45 5 psig The above pressure 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 action 38 The other refrigerant system will continue in operation unless it is affected by the fault as well The unit control board monitors the temperature limit switch of electric heat units and the temperature limit switch and the gas valve of gas furnace units COMPRESSOR PROTECTION The compressors also have inherent internal protec tion If there is an abnormal temperature rise in a com pressor the protector will open to shut down the compresso
59. f unit for proposed installation should be based on heat loss heat gain calculation made according to the methods of the Air Conditioning Contractors of America ACCA This equipment is not to be used for temporary heating of buildings or structures under construction International Local Government Agency Regulations Johnson Controls Unitary Products 356214 XIM A 0108 TABLE 1 UNIT APPLICATION DATA UNIT MODEL NUMBER Voltage Variation Min 380 415 3 50 342 456 Supply Air CFM Min Max 4 500 7 200 6 000 9 400 7 500 12 500 Wet Bulb Temperature F of Air on 57 72 Evaporator Coil Min Max Dry Bulb Temperature F of Air on 0 125 Condenser Coil Min Max 1 Utilization range A in accordance with ARI Standard 110 LOCATION Use the following guidelines to select a suitable loca tion for these units 1 Unit is designed for outdoor installation only 2 Condenser coils must have an unlimited supply of air 3 Where a choice of location is possible position the unit on either north or east side of building 4 For ground level installation use a level concrete slab with a minimum thickness of 4 inches The length and width should be at least 6 inches greater than the unit base rails Do not tie slab to the building foundation 5 Roof structures must be able to support the weight of the unit and its options and or accessories Un
60. for single point power supply Power supply need only be brought into the single point terminal block and thermostat wiring to the low voltage terminal strip located in the upper por tion of the unit control box These CSA approved heaters are located within the central compartment of the unit with the heater ele ments extending into the supply air chamber Refer to Figure 13 for access panel location Fuses are supplied where required by the factory Some KW sizes require fuses and others do not Refer to Table 3 for minimum CFM limitations and to Tables 8 and 9 for electrical data MINIMUM CFM UNIT SIZE NOMINAL VOLTAGE HEATER SIZE 3 PHASE KW 50 HZ 18 380 415 36 380 415 54 380 415 72 380 415 15 TON 20 TON 25 TON 4500 6000 7500 4500 6000 7500 5000 6000 7500 5000 6000 7500 Johnson Controls Unitary Products 356214 XIM A 0108 OPTIONAL GAS HEAT These gas fired heaters have aluminized steel or optional stainless steel tubular heat exchangers with spark ignition with proven pilot All gas heaters are shipped from the factory equipped for natural gas use but can be field converted to L P Propane with Kit Model 1NP0418 See Gas Heat Application Data Table TABLE 4 GAS HEAT APPLICATION DATA Output Capacity Mbh 0 To 2 000 To Temp 2 000 Feet 4 500 Feet 0 To 2 000 To Rise F 2 000 Feet 4 500 Feet Available Above Above Rate At Sea Level Se
61. he Y1 to C1 terminals If the compressor engages the UCB has faulted Johnson Controls Unitary Products 49 356214 XIM A 0108 15 If none of the above correct the error replace the UCB GAS HEAT TROUBLESHOOTING GUIDE AWARNING Troubleshooting of components may require opening the electrical control box with the power connected to the unit Use extreme care when working with live circuits Check the unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any connections with line termi nals When not necessary shut off all electric power to the unit prior to any of the following mainte nance procedures so as to prevent personal injury A CAUTION Label all wires prior to disconnection when ser vicing controls Wiring errors can cause improper and dangerous operation which could cause injury to person and or damage unit components Verify proper operation after servicing NOTE To find the Btu input multiply the number of cubic feet of gas consumed per hour by the Btu content of the gas in your particular locality contact your gas company for this information it varies widely from city to city AWARNING The furnace may shut down on a high temper ature condition during the procedure If this occurs the UCB energize the supply air blower motor until the high temperature limit has reset
62. he manifold burner gas valve assembly by lifting up and pulling back HEAT EXCHANGER BURNER FLAME Blue only FIGURE 23 TYPICAL FLAME APPEARANCE Burners are now accessible for service Reverse the above procedure to replace the assem blies Make sure that burners are level and seat at the rear of the heat exchanger BURNER AIR SHUTTER ADJUSTMENT Adjust burner shutters so no yellow flame is observed in the heat exchanger tubes CHECKING GAS INPUT NATURAL GAS 1 Turn off all other gas appliances connected to the 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 23 If the actual input is not within 596 of the furnace rating with allowance being made for the permissible range Johnson Controls Unitary Products 356214 XIM A 0108 of the regulator setting replace the orifice spuds with spuds of the proper size NOTE To find the Btu input multiply the number of cubic feet of gas consumed per hour by the Btu content of the gas in your particular locality contact your gas company for this information it varies widely from city to city TABLE 23 GAS RATE CUBIC FEET
63. hell is cold with the room thermostat calling for heat check for line voltage at the motor s Mate N Lok connector attached to the evaporator partition If line voltage is present replace the draft motor If line voltage is not present check for line voltage at the heat relay RW1 contacts in the main con trol box and check to see if the RW1 is pulled in If the RW1 relay is pulled in check for a loose line voltage connection If the RW1 relay is not pulled in check for 24 volts at the RW1 coil If 24 volts is present replace the RW1 relay If 24 volts is not present check for a loose 24 volt connection back to the relay board and check the connections from the room thermo 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 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 occur locate the source of the problem and correct Check all 24 volt connections from the relay board to and in the gas heat section Check low voltage connections to the ETD located in the control box If the fu
64. hin the conditioned space Refer to Table 20 for the required heat anticipator set ting TABLE 20 ELECTRIC HEAT ANTICIPATOR SETPOINTS HEATER SETTING AMPS VOLTAGE KW SENS TH1 TH2 18 0 29 36 0 29 0 29 380 415 3 50 54 0 29 0 29 72 0 29 0 29 GAS HEATING SEQUENCE OF OPERATIONS The following sequence describes the operation of the gas heat section Johnson Controls Unitary Products 39 356214 XIM A 0108 When the thermostat calls for the first stage of heating the low voltage control circuit from R to W1 and G is completed thru the UCB The heat relay RW1 is energized The RW1 2 contacts close energizing the draft motor control The draft motor control contacts close and start the draft motor As the speed of the draft motor reaches approximately 2500 RPM the cen trifugal switch contact located on the end of the draft motor shaft closes to power the first stage ignition module IC1 thru the RW1 1 contacts Ignition module IC1 will immediately start the first stage igniter sparking and will open the redundant valve located inside the first stage main gas valve GV1 to allow a flow of gas to only the first stage carry over tube Only after the pilot flame 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
65. ial For use with natural gas or propane gas A CAUTION THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUC TIONS AND ANY APPLICABLE LOCAL STATE AND NATIONAL CODES INCLUD ING BUT NOT LIMITED TO BUILDING ELECTRICAL AND MECHANICAL CODES AWARNING IMPROPER INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY OR PROPERTY DAMAGE The installer should pay particular 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 Johnson Controls Unitary Products 356214 XIM A 0108 PRODUCT NOMENCLATURE 15 25 Ton Sunline amp Magnum amp MagnaDRY Model Number Nomenclature D MJ 180 N24 A 7 A AA 10 1 2 4 A MEER Product Category D Single Pkg R 22 Product Identifier M 8 5 9 0 EER A C Nominal Cooling Capacity 180 15 Ton 240 20 Ton 300 25 Ton Heat Type and Nominal Heat Capacity C00 Cooling Only No field installed electric heat Gas Heat Options N24 240 MBH Output Aluminized Steel N32 320 MBH Output Aluminized Steel 524 240 MBH Output Stainless Steel 32 320 M
66. iately energized When the UCB again senses 24 volts from the temper ature limit the draft motor will perform a 25 second post purge and the indoor blower will be de energized following the elapse of the fan off delay for heating This limit is monitored regardless of unit operation sta tus i e the limit is monitored at all times Johnson Controls Unitary Products 356214 XIM A 0108 If the temperature limit opens three times within one hour it will lock on the indoor blower motor and a flash code is initiated See Table 24 GAS VALVE The UCB continuously monitors the GV Any time the UCB senses voltage at the GV without a call for heat for a continuous five minute period the UCB will lock on the indoor blower and a flash code is initiated Table 24 When voltage is no longer sensed at the GV the UCB will de energize the indoor blower follow ing the elapse of the fan off delay for heating If voltage has been sensed at the GV for 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 board monitors the temperature limit switch and the gas valve of gas furnace units The control circuit includes the following safety con trols 1 Limit Control LS This control is located inside the heat exchanger compartment and is set to open at the temperature indicated in the
67. imum position to the full open posi tion based on the highest call from either the mixed air sensor input or the AQ voltage input Optional Space Sensor Kit Part 2AQ04700324 Optional Unit Sensor Kit Part 2AQ04700424 Replace the economizer access panel OPTIONAL BAS READY ECONOMIZER POWER EXHAUST DAMPER SET POINT ADJUSTMENT Remove 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 building pressuriza tion requirement will be different The point at which the power exhaust comes on is determined by the econo mizer s outdoor damper position The actuator s auxil iary switch adjustment screw should be set at the damper position at which the power exhaust is needed The adjustment screw can be set between 25 to 85 degrees open Replace the economizer access panel Johnson Controls Unitary Products 356214 XIM A 0108 90 95 100 105 110 129 51 32 35 138 140 5 43 5 CONTROL POINT CON Conor APPROX DEG AT 50 RH 8 7I 7o 67 19 j sum RELATIVE HUMIDITY A 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 1 a D 9p 55 18 5 2 24 126 5 29 5 32 351 38 40 5 DRY BULB TEMPERATURE APPROXIMATE FAHRENHEIT CELSIUS FIGURE 9 ENTHALPY SETPOINT AD
68. inch filters can be supplied with each unit Filters must always be installed ahead of the evaporator 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 shut down 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 compartment Two panels Side Supply amp Return Air compartments Two panels Blower compartment Three panels Main control box Filter compartment Outdoor Air compartment Two panels Refer to the Dimensions and Clearances Figure 13 for location of these access panels A CAUTION Make sure that all screws and panel latches are replaced and properly positioned on the unit to maintain an airtight seal Johnson Controls Unitary Products 356214 XIM A 0108 THERMOSTAT CONTROL TERMINALS TERMINAL BLOCK W2 Y1 Y2 p Smoke Detector E TERMINALS ON ALIMITED NUMBER OF THERMOSTATS Second stage heating not required on single stage heating units N Second stage cooling not required on single stage cooling units Jumper is required if there is no Smoke Det
69. inet Hinged Filter Door amp Tool Free Access Cabinet AA None BA Hinged Filter Door amp Tool Free Access Panels AB Phase Monitor BB Phase Monitor Hinged Filter Door amp Tool Free AC Coil Guard AD Dirty Filter Access Panels Switch BC Coil Guard Hinged Filter Door amp Tool Free AE Phase Monitor amp Coil Guard Access Panels AF Phase Monitor amp Dirty Filter Switch BD Dirty Filter Switch Hinged Filter Door amp AG Coil Guard amp Dirty Filter Switch Tool Free Access Panels AH Phase Monitor Coil Guard amp Dirty Filter Switch BE Phase Monitor amp Coil Guard Hinged Filter RC Coil Guard amp American Flag Door amp Tool Free Access Panels TA Technicoat TJ Technicoat TS Technicoat ZZ If desired o Condenser Coil BF Phase Monitor amp Dirty Filter Switch Hinged Evaporator Coil Filter Door amp Tool Free Access Panels Evaporator amp Condenser Coils BG Coil Guard amp Dirty Filter Switch Hinged Filter Door amp Tool Free Access Panels BH Phase Monitor Coil Guard amp Dirty Filter Switch Hinged Filter Door amp Tool Free Access Panels ption combination is not listed above ZZ will be assigned and configuration options will be located in digits 15 18 Installation Options A 7 No Options Installed B Option 1 C Option 2 D Options 1 amp 2 E Option 3 F Option 4 G Options 1 amp 3 H Options 1 amp 4 J Options 1 2 amp 3 K
70. ing a code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms on the LED If the compressor is locked out remove any call for cooling This will reset any compressor lock outs While the above step will reset any lock outs compressor 2 will be held off for the ASCD and compressor 1 may be held off for a por tion of the ASCD See the 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 indication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs 11 12 13 14 If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip repeat trip lock out or ASCD the econ omizer terminals of the UCB may be improperly wired Check for 24 volts at the Y1 OUT 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 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 jumper in the Mate N Lock plug and in the wiring from the Ma
71. is present at the UCB termi nal check for loose wiring between the UCB and M3 If 24 volts is not present at the UCB supply air blower motor terminal check for 24 volts from the room thermostat If 24 volts is not present from the room thermostat check for the following a Proper operation of the room thermostat contact between R and G with the fan switch in the ON position and in the AUTO position during operation calls b Proper wiring between the room thermostat and the UCB C Loose wiring from the room thermostat to the UCB If 24 volts is present at the room thermostat but not at the UCB check for proper wiring between the thermostat and the UCB i e that the thermostat G terminal is connected to the G terminal of the UCB and for loose wiring If the thermostat and UCB are properly wired replace the UCB Johnson Controls Unitary Products 356214 XIM A 0108 10 If the blower motor runs with the fan switch in the ON position but does not run shortly after the fur nace has ignited when the fan switch is in the AUTO position check the room thermostat for contact between 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 protection If the motor shell is hot to the touch wait for the internal overload to reset If the motor s
72. it must be installed on a solid level roof curb or appropriate angle iron frame 6 Maintain level tolerance to 1 2 inch maximum across the entire length or width of the unit A WARNING Excessive exposure of this furnace to contami nated combustion air may result in equipment damage or personal injury Typical contami nates include permanent wave solutions chlo rinated waxes and cleaners chlorine based swimming pool chemicals water softening chemicals carbon tetrachloride Halogen type refrigerants cleaning solvents e g perchloro ethylene printing inks paint removers var nishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers masonry acid washing materials If a unit is to be installed 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 Johnson Controls Unitary Products 356214 XIM A 0108 RIGGING AND HANDLING Exercise care when moving the unit Do not remove any packaging until the unit is near the place of installa tion Rig the unit by attaching chain or cable slings to the round lifting holes provided in the base rails Spreaders whose length exceeds the largest dimen sion across the unit MUST BE USED Refer to Figure 1 Units may also be moved or lifted with a forklift from the side only providing that an accessory skid is used LENGTH OF FORKS MUST BE
73. lay If at any time a call for both heating and cooling are present the heating operation will be performed If operating the cooling system is halted as with a com pletion of a call for cooling Heating always takes prior ity COOLING SEQUENCE OF OPERATION CONTINUOUS BLOWER By setting the room thermostat fan switch to ON the supply air blower will operate continuously INTERMITTENT BLOWER With the room thermostat fan switch set to AUTO and the system switch set to either the AUTO or HEAT settings the blower is energized whenever a cooling or heating operation is requested The blower is ener gized after any specified delay associated with the operation When energized the indoor blower has a minimum run time of 30 seconds Additionally the indoor blower has a delay of 10 seconds between operations 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 36 condenser fan motor 1 and condenser fan motor 2 for 15 and 20T only if the ambient temperature is above 60 F are energized After completing the spec ified fan on delay for cooling the UCB will energize the blower motor When the thermostat calls for the second stage of cool ing the low voltage control circuit from R to Y2 is completed Compressor 2 and condenser fan motor 2 25T only if the ambient
74. ls 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 at 190 It is a manual reset switch If AUX trips then the primary limit has not functioned correctly Replace the pri mary limit TABLE 21 LIMIT CONTROL SETTING Units Capacity MBH Limit Control 3 Redundant Gas Valve Tons Input Output Opens F 15 20 amp 25 300 240 195 There are two separate gas valves in the furnace Each valve contains a main and a redundant valve 15 20 amp 25 350 280 195 Johnson Controls Unitary Products 41 356214 XIM A 0108 a CONTROL 2 ROLLOUT SW IGN CONTROL 1 SENSOR 1 GV 1 VALVE GV2 GAS GNITOR 1 VALVE lt IGNITOR 2 SENSOR 2 L BURNER COMPARTMENT FIGURE 20 GAS VALVE AND CONTROLS FLASH CODES The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 24 RESETS Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature This resets any flash codes HEAT ANTICIPATOR SETPOINTS It is important that the anticipator
75. ls of the UCB If a switch has opened there should be a voltage potential between the UCB ter minals e g if LPS2 has opened there will be 24 volts of potential between the LPS2 terminals If 24 volts is present at the UCB Y2 terminal and none of the protection switches have 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 on the LED If the compressor is locked out remove any call for cooling at the thermostat or by disconnect ing the thermostat wiring at the Y2 UCB terminal This will reset any compressor lock outs While the above step will reset any lock outs compressor 1 will be held off for the ASCD and compressor 2 may be held off for a por tion of the ASCD See the next step 10 11 12 13 If 24 volts is present at the UCB Y2 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 ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs The UCB can be programmed to lock out compres sor operation during free cooling and in low 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 U
76. 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 it will continue to try for a maximum of 85 seconds to ignite the pilot tube If the pilot flame is not detected then IC1 will lock out first stage furnace operation for five minutes or until 24V power is removed from the module either at the unit or by resetting the room thermostat When the thermostat calls for the second stage of heating the low voltage control circuit from R to W2 is completed thru the UCB Heat relay RW is ener gized The RW2 1 contact is closed energizing the second stage ignition module IC2 IC2 will immedi ately start the second stage igniter sparking and will open the redundant valve located inside the second stage main gas valve GV2 to allow a flow of gas to the second stage carryover tube Only after the pilot flame has been ignited and the presence of pilot flame detected at IC2 by a signal sent back through the flame sensor is sparking terminated and the main gas valve opened Gas flows into each of the second stage main burners and is ignited from the carryover tube flame If IC2 fails 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 five minut
77. n 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 The correct manifold pressure for these fur naces is 3 65 IWG 0 3 BURNER ASSEMBLY BRACKET FLAME SENSOR BULB 1 8 GAP BETWEEN CARRY OVER TUBE AND FLAME SENSOR BULB CARRY OVER TUBE FIGURE 22 PROPER FLAME ADJUSTMENT PILOT CHECKOUT The pilot flame should envelope the end of the flame sensor To adjust pilot flame 1 remove pilot adjust ment cover screw 2 increase or decrease the clear ance for air to the desired level 3 be sure to replace cover screw after adjustment to prevent possible gas leakage Put the system into operation and observe through complete cycle to be sure all 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 44 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 the main manual shut off valve 3 Remove the gas piping closure panel 4 Disconnect wiring to the gas valves and spark ignit ors Remove t
78. nger The cover should be attached in a manner adequate to prevent leakage FIXED OUTDOOR AIR INTAKE DAMPER This damper is shipped inside the return air compart ment It is completely assembled and ready for installa tion A damper baffle inside of the hood is adjustable to provide variable amounts of outdoor air intake on units that are not provided with an economizer or a motor ized damper option Refer to the Fixed Outdoor Damper Figure 3 Gasketing and mounting screws are provided in a parts bag attached to the hood assembly Apply gasketing to the three flange 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 outdoor air flow position 2 approximately 15 and to allow approximately 25 remove the damper baffle On units with bottom return air application install the damper assembly over the opening in the side return air access panel Remove and discard the opening cover and the covering over the hood mounting holes used for shipping before installing Secure with the screws provided On units with side return air applications install the damper assembly on the return air d
79. nt Figure 9 Foradual enthalpy operation carefully turn the set point adjusting screw fully clockwise past the D setting POWER EXHAUST DAMPER SETPOINT With power exhaust option each building pressuriza tion requirement will be different The point at which the power exhaust comes on is determined by the econo mizer damper position Percent Open The Exhaust Air Adjustment Screw should be set at the Percent Open of the economizer damper at which the power exhaust is needed It can be set from 0 to 100 damper open dual enthalpy operation carefully turn the set point adjusting screw fully clockwise past the D setting INDOOR AIR QUALITY AQ Indoor Air quality indoor sensor input Terminal AQ accepts a 2 to 10 Vdc signal with respect to the AQ1 terminal When the signal is below it s setpoint the actuator is allowed to modulate normally in accor dance with the enthalpy and mixed air sensor inputs When the AQ signal exceeds it s setpoint setting and there is no call for free cooling the actuator is propor tionately modulated from the 2 to 10 Vdc signal with 2 Vdc corresponding to full closed and 10 Vdc corre sponding to full open When there is no call for free cooling the damper position is limited by the IAQ Max damper position setting When the signal exceeds it s setpoint Demand Control Ventilation Setpoint setting and there is a call for free cooling the actuator modu lates from the min
80. nthalpy is above the setpoint Y1 energizes com pressor 1 condenser fan motor 1 and condenser fan motor 2 15 and 20T only if the ambient tempera ture is above 60 F When the thermostat calls for second stage cooling the low voltage control circuit from R to Y2 is completed The UCB energizes the first available compressor If the enthalpy of the outdoor air is below the setpoint of the enthalpy controller i e first stage Johnson Controls Unitary Products 356214 XIM A 0108 has energized the economizer Y2 will energize compressor 1 If the outdoor air is above the setpoint Y2 will energize compressor 2 Once the thermostat has been satisfied it will de ener gize Y1 and Y2 If the compressors have satisfied their minimum run times the compressors and condenser fans are de energized Otherwise the unit operates each cooling system until the minimum run times for the compressors have been completed Upon the final compressor de energizing the blower is stopped fol lowing the elapse of the fan off delay for cooling and the economizer damper goes to the closed position If the unit is in continues fan operation the economizer damper goes to the min position ECONOMIZER WITH DUAL ENTHALPY SENSORS The operation with the dual enthalpy sensors is identi cal to the single sensor except that a second enthalpy sensor is mounted in the return air This return air sen sor allows the economizer to choose b
81. on Controls Unitary Products 356214 XIM A 0108 AWARNING Do not permit overhanging structures or shrubs to obstruct outdoor air discharge outlet com bustion air inlet or vent outlets DUCTWORK Ductwork should be designed and sized according to the methods in Manual Q of the Air Conditioning Con tractors of America ACCA A closed return duct system shall be used This shall not preclude use of economizers or outdoor fresh air intake The supply and return air duct connections at the unit should be made with flexible joints to minimize noise The supply and return air duct systems should be designed for the CFM and static requirements of the job They should NOT be sized to match the dimen sions of the duct connections on the unit A CAUTION When fastening ductwork to side duct flanges on unit insert screws through duct flanges only DO NOT insert screws through casing Outdoor ductwork must be insulated and waterproofed Refer to Dimensions and Clearances Figure 13 for information concerning side and bottom supply and return air duct openings NOTE It is recommended that in Canada the outlet duct be provided with a removable access panel It is recommended that 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 excha
82. onomizers lf 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 jumper in the Mate N Lock plug and in the wiring from the Mate N Lock plug to the Y1 ECON terminal For units with economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y 1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug a poor connection between the UCB and economizer dMate N Lock plugs loose wiring from the Mate N Lock plug to the econo mizer back to the Mate N Lock plug and from the Mate N Lock plug to the Y1 ECON terminal If nothing is found the economizer control may have faulted and is failing to return the 24 volt call to the Y1 ECON terminal even though the econo mizer is not providing free cooling To test discon 14 15 16 nect the Mate N Locks and jumper between the WHITE and YELLOW wires of the UCB s Mate NLock plug If compressor 1 energizes there is a fault in the economizer wiring or economizer con trol The UCB can be programmed to lock out compres sor operation during free cooling and in low 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
83. or M2 and that the contac tor is pulled in Check for loose wiring between the contactor and the compressor Johnson Controls Unitary Products 47 356214 XIM A 0108 NOTE 48 If M2 is pulled in and voltage is supplied at M2 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 the inter nal overload to reset Test again when cool If M2 is not pulled in check for 24 volts at the M2 coil If 24 volts is present and M2 is not pulled in replace the contactor Failing the above if voltage is supplied at M2 M2 is pulled in and the compressor still does not oper ate replace the compressor 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 C2 and the com pressor contactor If 24 volts is not present at the C2 terminal check for 24 volts from the room thermostat at the UCB Y2 terminal If 24 volts is not present from the room thermostat check for the following a 24 volts at the thermostat Y2 terminal b Proper wiring between the room thermostat and the UCB i e Y1 to Y1 Y2 to Y2 c Loose wiring from the room thermostat to the UCB If 24 volts is present at the UCB Y2 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 HPS2 LPS2 and FS2 termina
84. or if needed POST START CHECK LIST 1 Verify proper system pressures for both circuits 2 Measure the temperature drop across the evapora tor coil Johnson Controls Unitary Products 356214 XIM A 0108 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 the type of gas being supplied Be sure that itis the same as listed on the unit nameplate 2 Make sure that the vent and combustion air hoods have been properly installed OPERATING INSTRUCTIONS A CAUTION This furnace is equipped with an intermittent pilot and automatic re ignition system DO NOT attempt to manually light the pilot TO LIGHT PILOT AND MAIN BURNERS 1 Turn off electric power to unit 2 Turn room thermostat to lowest setting 3 Turn gas valve knob or switch to on position 4 Turn on electric power to unit 5 Setroom thermostat to desired temperature If thermostat set temperature is 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 while turning to
85. ply with electrical codes should not be required A fused disconnect switch should be field provided for the unit The switch must be separate from all other 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 the Dimensions and Clearances Figure 13 for installation location If any of the wire supplied with the unit must be replaced replacement wire must be of 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 TABLE 3 ELECTRIC HEAT APPLICATION DATA with a separate branch circuit fed directly from the meter panel and properly fused A CAUTION When connecting electrical power and control wiring to the unit waterproof type connectors MUST BE USED so that water or moisture cannot be drawn into the unit during normal operation The above waterproofing conditions will also apply when installing a field supplied disconnect switch Refer to the Typical Field Wiring Figure 5 and to the appropriate unit wiring diagram for control circuit and power wiring information TABLE 2 CONTROL WIRE SIZES Wire Size Maximum Length 18 AWG 150 Feet 1 From the unit to the thermostat and back to the unit OPTIONAL ELECTRIC HEAT The factory installed heaters are wired
86. r minals e g if LPS1 has opened there will be a 24 volt potential between the LPS1 terminals Johnson Controls Unitary Products 356214 XIM A 0108 NOTE 10 If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing an alarm code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms on the LED If the compressor is locked out cancel any call for cooling This will reset any compressor lock outs While the above step will reset any lockouts compressor 1 may be held off for the ASCD See the next step 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 indication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip repeat trip lock out or ASCD the econ omizer terminals of the UCB may be improperly wired Check for 24 volts at the Y1 OUT 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 For units without ec
87. r The UCB incorporates features to mini mize compressor wear and damage anti short cycle delay ASCD is utilized to prevent operation of a compressor too soon after its previous run Addition ally a minimum run time is imposed any time a com pressor is energized The ASCD is initiated on unit start up and on any com 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 24 RESET Remove the call for cooling by raising thermostat set ting higher than the conditioned space temperature This resets any pressure or freezestat flash codes ELECTRIC HEATING SEQUENCE OF OPERATIONS The following sequence describes the operation of the electric heat section Single stage heating applies only to 18 KW heater all other heaters MUST use a two stage thermostat a Upon a call for heat by the thermostat the heater contactor 6M will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space Two stage heating applies to all heaters except 18 KW a Upon a call for first stage heat by the thermostat the heater contactor 6M 6M amp 7M on 72 KW 240V will be energized After completing the specified fan Johnson Controls Unitary Products 356214
88. r compres sor rotate correctly CHECKING AIR SUPPLY CFM The RPM of the supply air blower will depend on the required CFM the unit accessories or options and the static resistances of both the supply and the return air duct systems With this information the RPM for the supply air blower and the motor pulley adjustment turns open can be determined from the Blower Per formance Data Tables 34 CAUTION Procedure for adjusting belt tension 1 Loosen four nuts top and bottom A 2 Adjust by turning B 3 Never loosen nuts C 4 Use a belt tension checker to apply a perpendicular force to one belt at the midpoint of the span as shown The deflection force should be applied until a specific delfection distance of Amm 5 32 is obtained To determina the deflection distance from normal position use a straight edge from sheave to sheave as a reference line The recommended deflection force is as follows gum per FoR 4 Tension new belts atthe max deflection force recommended for the belt section Check the belt tension at least two times during the first 24 hours of operation Anyre tensioning should fall between the min and max deflection force values 5 After adjusting re tighten nuts A FIGURE 17 BELT ADJUSTMENT 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 increm
89. rdless of the density of the air However since the air at high altitude is less dense less static pressure will be generated and less power will be required than a similar application at sea level Air density correction factors are shown in Table 10 and Figure 16 AIR TEMP ALTITUDE METER C 0 305 610 914 1219 1524 1829 2134 2438 2743 3048 4 4 1 060 1 022 0 986 0 950 0 916 0 882 0 849 0 818 0 788 0 758 0 729 10 1 039 1 002 0 966 0 931 0 898 0 864 0 832 0 802 0 772 0 743 0 715 15 5 1 019 0 982 0 948 0 913 0 880 0 848 0 816 0 787 0 757 0 729 0 701 21 1 000 0 964 0 930 0 896 0 864 0 832 0 801 0 772 0 743 0 715 0 688 26 6 0 982 0 947 0 913 0 880 0 848 0 817 0 787 0 758 0 730 0 702 0 676 32 0 964 0 929 0 897 0 864 0 833 0 802 0 772 0 744 0 716 0 689 0 663 38 0 946 0 912 0 880 0 848 0 817 0 787 0 758 0 730 0 703 0 676 0 651 AIR TEMP ALTITUDE FEET F 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 40 1 060 1 022 0 986 0 950 0 916 0 882 0 849 0 818 0 788 0 758 0 729 50 1 039 1 002 0 966 0 931 0 898 0 864 0 832 0 802 0 772 0 743 0 715 60 1 019 0 982 0 948 0 913 0 880 0 848 0 816 0 787 0 757 0 729 0 701 70 1 000 0 964 0 930 0 896 0 864 0 832 0 801 0 772 0 743 0 715 0 688 80 0 982 0 947 0 913 0 880 0 848 0 817 0 787 0 758 0 730 0 702 0 676 90 0 964 0 929 0 897 0 864 0 833 0 802 0 772 0 744 0 716 0 689 0 663 100 0 946 0 912 0 880 0 848 0 817 0 787 0 758 0 730 0 703 0 676 0 651
90. re 18 AWARNING Failure to properly adjust the total system air quantity can result in extensive blower dam age After readings have been obtained remove the tubes and reinstall the two 5 16 dot plugs that were removed in Step 1 DE ENERGIZE THE COMPRESSORS BEFORE TAKING ANY TEST MEASURE MENTS TO ASSURE A DRY INDOOR COIL NOTE 0 65 300 MBH PRESSURE DROP IWG o 4 5 6 7 NOMINAL THOUSANDS SUPPLY AIR 9 10 11 12 13 FIGURE 18 PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM FOR ALL UNIT TONNAGES Johnson Controls Unitary Products 35 356214 XIM A 0108 OPERATION SEQUENCE OF OPERATIONS OVERVIEW For these units the thermostat makes circuit between R and Y1 for the first stage of cooling The call is passed to the unit control board UCB which then determines whether the requested opera tion is available and if so which components to ener gize For gas heating the UCB monitors the W1 call but does not handle the operation of the gas furnace An ignition control board controls the gas heater operation For 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 de
91. re indi cated in the Limit Control Setting Table 19 It resets automatically The limit switch operates when a high temperature condition caused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower 2 Temperature Limit Switch TLS 3 4 5 and 6 This control is located inside the heater compart ment and is set to open at the temperature indi cated in the Limit Control Setting Table 19 It is a manual reset limit These limit switches will de energize the heaters should the primary limit fail to open or the contactors fail to open in a failure mode TABLE 19 LIMIT CONTROL SETTING TEMPERATURE LIMIT TEMPERATURE VOLTAGE EATER SWITCH 1 2 LIMIT SWITCH 3 4 5 OPENS F 6 OPENS F 18 120 170 36 120 170 1520 ais 54 120 170 72 120 170 FLASH CODES The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 24 RESET Remove the call for heating by lowering the thermostat setting lower than the conditioned space 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 temperature 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 wit
92. ribed in BURNER AIR SHUTTER ADJUSTMENT page 44 2 Check the main burner orifices for obstruction and alignment Removal procedure is described in BURNER INSTRUCTIONS page 44 Clean or replace burner orifices and burners as needed UNIT FLASH CODES Various flash codes are utilized by the unit control board UCB to aid in troubleshooting Flash codes are distinguished by the short on and off cycle used approximately 200ms on and 200ms off To show normal operation the control board flashes a 1 second on 1 second off heartbeat during normal operation This is to verify that the UCB is functioning correctly Do not confuse this with an error flash code To prevent confusion a 1 flash flash code is not used Alarm condition codes are flashed on the UCB lower left Red LED See Figure 24 While the alarm code is being flashed it will also be shown by the other LEDs lit continuously while the alarm is being flashed The total of the continuously lit LEDs equates to the number of flashes and is shown in the table Pressing and releasing the LAST ERROR button on the UCB can check the alarm history The UCB will cycle through the last five 5 alarms most recent to oldest separating each alarm flash code by approximately 2 seconds In all cases a flashing Green LED will be used to indicate non alarm condition In some cases it may be necessary to zero the ASCD for the compressors in order to perform trouble shooting To r
93. rnace is hot it may be out on an over tem perature condition wait for limit reset If the furnace is cold check for 24 volts at wire 241 attached to the electrical time delay ETD located in the main control box If 24 volts is not found replace the ETD 24 volts is found at wire 241 remove the wires attached to the TDR and with a VOM check for continuity across contacts 1 and 2 If none is found the TDR is open and must be replaced If there is continuity re attach the wires With the draft motor running check for 24 volts at terminal 4 of RW1 2 and RW2 1 If 24 volts is not present the centrifu gal switch CS has not closed or has gone bad Check the line voltage to the unit if it is correct replace the draft motor If line voltage is low call the power company Check for 24V at terminal 2 of RW1 2 and RW2 1 If 24V is not present check for 24V at RW1 and RW2 relay coils If these relays are pulled in then check for a loose connection at terminal 2 and terminal 4 of each relay If no problem is found then replace RW1 and or RW2 as required If 24 volts is present at the ignitor controls check all control wiring at the ignitor controls and the high tension wire to the ignitors Check that the ground wires from the ignitor controls the gas valves and pilot burners are all intact and making good electri cal connection Check to make sure that the ceramic insulator on the pilot ignitors or sensors is no
94. ssary 3 Check the pilot orifice for obstruction as described in paragraph above Clean as needed but the prob lem should not be the gas valve The pilot burner ignites but the ignitor continues to spark and the main burners do not ignite 1 Make the same checks and adjustment as described in PILOT CHECKOUT page 44 2 Check the supply pressure as described in POST START CHECK LIST page 43 Make adjustments as necessary 3 Make sure that the pilot burner is not bent or dam aged 4 Make sure that the ground connections at the pilot burner 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 replace ignitor control If voltage is present replace gas valve Furnace lights with roll out or one burner has delayed ignition 52 1 Make sure that the pilot burner is aligned properly with the carryover as described in PILOT CHECK OUT page 44 2 Make sure that the carryovers on adjoining burners are screwed fast and are level with respect to one another Main burners light but exhibit erratic flame characteris tics 1 Adjust air shutters as desc
95. stallation of combustion air inlet hood flue gas outlet hoods and fixed outdoor air intake damper units without economizer or motorized damper option only at the point of installation The supplemental electric heaters have nickel chrome elements and utilize single point power connection These gas fired heaters have aluminized steel or optional stainless steel tubular heat exchangers with spark ignition with proven pilot All gas heaters are shipped from the factory equipped for natural gas use but can be field converted to L P Propane with Kit Model 1NP0418 See Gas Heat Application Data Table SAFETY CONSIDERATIONS Due to system pressure moving parts and electrical components installation and servicing of air condition ing equipment can be hazardous Only qualified 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 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 AWARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property dam age Do not store or use gasoline or other flamma ble vapors an
96. t air outlet hood is at least 9 meters 3 feet above any force air inlet located within 3 0 meters 10 horizontal feet excluding those integral to the unit 1 2 meters 4 feet below four horizontal feet from or one foot above any door or gravity air inlet into the building 1 2 meters 4 feet from electric and gas meters regulators and relief equipment ECONOMIZER MOTORIZED DAMPER AND POWER EXHAUST RAIN HOODS FIXED OUTDOOR AIR INTAKE HOOD located on Return Air Compartment 25 1 CONDENSATE DRAIN Must be trapped 2337 92 LH VIEW UNIT WITH RAIN HOODS FIGURE 15 UNIT CLEARANCES AND RAIN HOOD DIMENSIONS 15 20 amp 25 TON Johnson Controls Unitary Products 25 356214 XIM A 0108 CFM STATIC PRESSURE AND POWER ALTITUDE AND TEMPERATURE CORRECTIONS The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 feet above sea level The air flow rates listed in the standard blower performance tables are based on standard air at sea level As the altitude or temperature increases the density of air decreases In TABLE 10 ALTITUDE CORRECTION FACTORS order to use the indoor blower tables for high altitude applica tions certain corrections are necessary A centrifugal fan is a constant volume device This means that if the rpm remains constant the CFM delivered is the same rega
97. t broken or cracked if all are intact replace the ignition control IC1 or IC2 The draft motor runs and the ignitor sparks at the pilot burner but the pilot does not ignite and a gas odor is not detected at the draft motor outlet 1 Check to make sure gas is being supplied to the unit Make sure that the gas pressure to the unit is within the proper limits as described in the POST START CHECK LIST page 43 and that the pilot adjust screw is allowing some flow of gas as described in PILOT CHECKOUT page 44 Check all wiring between the ignitor control and the gas valve Check to make sure the ground connec tions are intact If the wiring 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 Johnson Controls Unitary Products 51 356214 XIM A 0108 4 f 24 volts is present remove the pilot burner and remove the pilot orifice from the pilot burner The orifice is removed in the direction opposite the flow of gas Inspect the orifice for obstruction If it is clear replace the main gas valve The ignitor sparks at the pilot burner but the pilot does not ignite and a gas odor is detected at the draft motor outlet 1 Adjust the pilot adjust screw on the gas valve as described in PILOT CHECKOUT page 44 2 Check the supply pressure as described in POST START CHECK LIST page 43 Make adjustments as nece
98. te N Lock plug to the Y1 ECON terminal For units with economizers f 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y 1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug a poor connection between the UCB and economizer Mate N Lock plugs loose wiring from the Mate N Lock plug to the economizer back to the Mate N Lock plug and from the Mate N Lock plug to the Y1 ECON terminal The economizer control may have faulted and is not returning the 24 volts to the Y1 ECON terminal even though the economizer is not providing free cooling To test the economizer control disconnect the Mate N Locks and jumper between the WHITE and YELLOW wires of the UCB s Mate N Lock plug The UCB can be programmed to lock out compres sor operation during free cooling and in low ambi ent conditions These options are not enabled by default They can be checked by local distributors 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 If none of the above corrected the error test the integrity of the UCB Disconnect the C1 terminal wire and jumper it to the Y1 terminal DO NOT jump t
99. te information regarding tank sizing for vapor ization recommended regulator settings and pipe siz ing is available from most regulator manufacturers and 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 commercial compounds Shellac base com pounds 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 AWARNING FIRE OR EXPLOSION HAZARD FAILURE TO FOLLOW THE SAFETY WARN ING EXACTLY COULD RESULT IN SERIOUS INJURY DEATH OR PROPERTY DAMAGE NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME USE A COMMERICALLY AVAILABLE SOAP SOLUTION MADE SPE CIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS A FIRE OR EXPLOSION MAY RESULT CAUS ING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE 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 These hoods must be installed to assure proper unit function All hoods must be fastened to 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 panel opening
100. temperature is above 60 F is energized provided it has not been locked out If there is an initial call for both stages of cooling the UCB will delay energizing compressor 2 by 30 sec onds in order to avoid a power in rush Once the thermostat has been satisfied it will de ener gize Y1 and Y2 If the compressors have satisfied their minimum run times the compressors and condenser fans are de energized Otherwise the unit operates each cooling system until the minimum run times for the compressors have been completed Upon the final compressor de energizing the blower is stopped fol lowing the elapse of the fan off delay for cooling To be available a compressor must not be locked out due to a high or low pressure switch or freezestat trip and the anti short cycle delay ASCD must have elapsed ECONOMIZER WITH SINGLE ENTHALPY 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 thermostat is set in the AUTO position and drives the economizer damp ers from fully closed to their minimum position If the enthalpy of the outdoor air is below the setpoint of the enthalpy controller previously determined Y1 ener gizes the economizer The dampers will modulate to maintain a constant supply air temperature as moni tored by the discharge air sensor If the outdoor air e
101. uctwork as close to the unit as possible Cut an opening 16 inches high by 18 inches wide in the ductwork to accommodate the damper Using the holes in the hood flanges as a tem plate drill 9 64 inch dia 26 drill holes into the duct work and secure with the screws provided A CAUTION If outdoor air intake will not be required on units with bottom return air applications the damper assembly should still be mounted on the side return air access panel per the instructions above to insure moisture is not drawn into the unit during operation The cov ering over the mounting holes only need be removed Do not remove the opening cover Johnson Controls Unitary Products 356214 XIM A 0108 REAR VIEW FIGURE 3 FIXED OUTDOOR AIR DAMPER CONDENSATE DRAIN Plumbing must conform to local codes Use a sealing compound on male pipe threads Install a condensate drain line from the one inch NPT female connection on the unit to an open drain NOTE The condensate drain operates in a negative pressure in the cabinet The condensate drain line MUST be trapped to provide proper drain age See Figure 4 UNT CONDENSATE PAN CONNECTION DRAIN PLUG FIGURE 4 RECOMMENDED DRAIN PIPING COMPRESSORS Units are shipped with compressor mountings factory adjusted and ready for operation A CAUTION Do not loosen compressor mounting bolts FILTERS Two inch or four
102. when the fan switch is in the AUTO position check the room thermostat for con tact between R and G in the AUTO position during calls for cooling Johnson Controls Unitary Products 45 356214 XIM A 0108 10 If the supply air blower motor does not energize when the fan switch is set to ON check that line voltage is being supplied to the contacts of the M3 contactor and that the contactor is pulled in Check for loose wiring between the contactor and the sup ply air blower motor 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 overload to reset Test again when cool If M3 is not pulled in check for 24 volts at the M3 coil If 24 volts are present at M3 but is not pulled in replace the contactor 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 If 24 volts is not present at M3 check that 24 volts is present at the UCB supply air blower motor ter minal FAN If 24 volts is present at the FAN check for loose wiring between the UCB and M3 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
103. y Products 356214 X IM A 0108 TABLE 12 SUPPLY AIR BLOWER PERFORMANCE 20 TON COOLING ONLY 240 MBH BOTTOM DUCT CONNECTIONS AIRFLOW MOTOR BLOWER PULLEY 2 80 m3 s 3 30 m3 s 3 80 m3 s 4 10 m3 s 4 40 m3 s SEPI TURNS OPEN ESP Output Input ESP Output Input ESP Output Input ESP Output Input ESP Output Input Pa kW kW Pa kW kW Pa kW kW Pa kW kW Pa kW kW HIGH STATIC DRIVE m3 s 895 6 0 312 3 5 4 0 268 3 7 4 3 198 4 2 4 8 143 4 6 5 2 79 5 1 5 8 930 5 0 362 3 7 4 3 318 4 0 4 5 248 4 5 5 1 193 4 9 5 6 129 5 4 6 2 970 4 0 421 4 0 4 5 377 4 2 4 9 306 4 8 5 5 252 5 2 6 0 187 5 8 6 6 1005 3 0 473 4 2 4 8 429 4 5 5 1 359 5 1 5 8 304 5 6 6 4 240 6 1 7 0 1045 2 0 535 4 4 5 0 491 4 8 5 5 420 5 4 6 2 365 5 9 6 8 1080 1 0 590 4 6 5 3 546 5 0 5 8 475 5 7 6 5 420 6 2 7 1 AIRFLOW MOTOR SEED PULLEY 5930 CFM 6990 CFM 8050 CFM 8685 CFM 9320 CFM TURNS RPM Open ESP Output Input ESP Output Input ESP Output Input ESP Output Input ESP Output Input wg bhp KW bhp KW bhp KW bhp KW wg bhp kW HIGH STATIC DRIVE CFM 895 6 0 1 3 4 7 4 0 1 1 5 0 4 3 0 8 5 6 4 8 0 6 6 1 5 2 0 3 6 8 5 8 930 5 0 1 5 5 0 4 3 1 3 5 3 4 5 1 0 6 0 5 1 0 8 6 6 5 6 0 5

Sunlife Enterprises SUNLINE DM180 User's Manual

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