York PREDATORTM MAGNUM DJ 150 Installation manual

York PREDATORTM MAGNUM DJ 150 Installation manual
INSTALLATION
MANUAL
®
MAGNUM
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SINGLE PACKAGE AIR CONDITIONERS AND
SINGLE PACKAGE GAS/ELECTRIC UNITS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . .4
DJ150
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
12-1/2 TON
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
(11.35 EER)
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . .6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
START-UP (COOLING). . . . . . . . . . . . . . . . . . . . . .40
START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . .40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .43
See following pages for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes are intended to
clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to alert
installer that personal injury and/or equipment damage
may result if installation procedure is not handled properly.
CAUTION:
Tested in accordance with:
READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
035-19046-003-A-0804
035-19046-003-A-0804
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RENEWAL PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION SAFETY INFORMATION . . . . . . . . . . . 10
PRECEDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . 10
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . 12
CLEARANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DUCT COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COMPRESSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
THERMOSTAT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . 18
POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . 18
POWER WIRING DETAIL . . . . . . . . . . . . . . . . . . . . . . . . 19
OPTIONAL ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . 23
OPTIONAL GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LP UNITS, TANKS AND PIPING . . . . . . . . . . . . . . . . . . . .
VENT AND COMBUSTION AIR. . . . . . . . . . . . . . . . . . . . .
24
25
25
26
FACTORY INSTALLED OPTIONS/
FIELD INSTALLED ACCESSORIES . . . . . . . . . . . . . . . . 26
ELECTRIC HEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORIZED OUTDOOR DAMPER . . . . . . . . . . . . . . . . .
ECONOMIZER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAIN HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
26
26
26
ECONOMIZER AND POWER EXHAUST SET
POINT ADJUSTMENTS AND INFORMATION . . . . . . . . 27
MINIMUM POSITION ADJUSTMENT . . . . . . . . . . . . . . . .
ENTHALPY SET POINT ADJUSTMENT . . . . . . . . . . . . . .
POWER EXHAUST DAMPER SET POINT (WITH
OR WITHOUT POWER EXHAUST) . . . . . . . . . . . . . . . . .
INDOOR AIR QUALITY AQ . . . . . . . . . . . . . . . . . . . . . . . .
27
27
27
27
PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BLOWER ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
AIR BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CHECKING AIR QUANTITY . . . . . . . . . . . . . . . . . . . . . . 32
METHOD ONE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
METHOD TWO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SUPPLY AIR DRIVE ADJUSTMENT. . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SEQUENCE OF OPERATIONS OVERVIEW . . . . . . . . . 34
COOLING SEQUENCE OF OPERATION . . . . . . . . . . . . 34
CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMITTENT BLOWER . . . . . . . . . . . . . . . . . . . . . . . .
NO OUTDOOR AIR OPTIONS . . . . . . . . . . . . . . . . . . . . .
ECONOMIZER WITH SINGLE ENTHALPY SENSOR . . .
ECONOMIZER WITH DUAL ENTHALPY SENSORS . . . .
2
34
34
35
35
35
ECONOMIZER (SINGLE OR DUAL) WITH POWER
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORIZED OUTDOOR AIR DAMPERS . . . . . . . . . . . .
COOLING OPERATION ERRORS . . . . . . . . . . . . . . . . . .
HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . .
LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . .
FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . .
35
35
35
35
36
36
36
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
COMPRESSOR PROTECTION . . . . . . . . . . . . . . . . . . . 36
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
RESET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ELECTRIC HEATING SEQUENCE OF OPERATIONS . 36
ELECTRIC HEATING OPERATION ERRORS . . . . . . . . 37
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIMIT SWITCH (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
37
37
37
ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . . . 37
GAS HEATING SEQUENCE OF OPERATIONS . . . . . . 37
IGNITION CONTROL BOARD . . . . . . . . . . . . . . . . . . . . 37
FIRST STAGE OF HEATING . . . . . . . . . . . . . . . . . . . . . .
SECOND STAGE OF HEATING . . . . . . . . . . . . . . . . . . . .
RETRY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECYCLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .
37
38
38
38
GAS HEATING OPERATION ERRORS . . . . . . . . . . . . . 38
LOCK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLAME SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
38
38
38
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LIMIT SWITCH (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY LIMIT SWITCH (ALS) . . . . . . . . . . . . . . . . . .
PRESSURE SWITCH (PS) . . . . . . . . . . . . . . . . . . . . . . . .
ROLLOUT SWITCH (ROS) . . . . . . . . . . . . . . . . . . . . . . . .
INTERNAL MICROPROCESSOR FAILURE. . . . . . . . . . .
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
39
39
39
39
39
GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . 39
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESTART CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . .
POST START CHECK LIST . . . . . . . . . . . . . . . . . . . . . .
40
40
40
40
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PRE-START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 40
LIGHTING THE MAIN BURNERS . . . . . . . . . . . . . . . . . . . 40
POST START CHECKLIST . . . . . . . . . . . . . . . . . . . . . . .
SHUT DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD GAS PRESSURE ADJUSTMENT . . . . . . . .
CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . . .
40
41
41
41
NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . . 42
BURNERS/ORIFICES INSPECTION/SERVICING . . . . . 42
CHARGING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREDATOR“ MAGNUM FLASH CODES . . . . . . . . . . . .
COOLING TROUBLESHOOTING GUIDE. . . . . . . . . . . .
GAS HEAT TROUBLESHOOTING GUIDE . . . . . . . . . . .
43
44
47
50
Unitary Products Group
035-19046-003-A-0804
LIST OF FIGURES
Fig. #
Pg. #
Fig. #
Pg. #
1
UNIT SHIPPING BRACKET . . . . . . . . . . . . . . . . . . . . 10
17 FIELD WIRING 24 VOLT THERMOSTAT . . . . . . . . . 20
2
COMPRESSOR SECTION . . . . . . . . . . . . . . . . . . . . . 10
3
PREDATOR®
18 FIELD WIRING DISCONNECT - COOLING UNIT
WITH/WITHOUT ELECTRIC HEAT . . . . . . . . . . . . . . 20
4
UNIT 4 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 12
5
UNIT 6 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 13
6
UNIT CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . 13
7
UNIT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8
BOTTOM DUCT OPENINGS (FROM ABOVE). . . . . . 15
9
REAR DUCT DIMENSIONS . . . . . . . . . . . . . . . . . . . . 16
MAGNUM COMPONENT LOCATION . 11
10 PREDATOR® MAGNUM ROOF CURB DIMENSIONS17
11 SUNLINE™ TO PREDATOR® MAGNUM TRANSITION
ROOF CURBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12 SIDE PANELS WITH HOLE PLUGS. . . . . . . . . . . . . . 17
13 RETURN DOWNFLOW PLENUM WITH PANEL . . . . 18
14 DISCHARGE PANEL IN PLACE . . . . . . . . . . . . . . . . . 18
15 CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . 18
16 ELECTRONIC THERMOSTAT FIELD WIRING . . . . . 19
19 FIELD WIRING DISCONNECT - COOLING
UNIT WITH GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . 21
20 SIDE ENTRY GAS PIPING. . . . . . . . . . . . . . . . . . . . . 24
21 BOTTOM ENTRY GAS PIPING . . . . . . . . . . . . . . . . . 24
22 ENTHALPY SET POINT CHART . . . . . . . . . . . . . . . . 28
23 HONEYWELL ECONOMIZER CONTROL W7212 . . . 28
24 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 29
25 DRY COIL DELTA P . . . . . . . . . . . . . . . . . . . . . . . . . . 33
26 TYPICAL FLAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
27 TYPICAL GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . 42
28 CHARGING CHART . . . . . . . . . . . . . . . . . . . . . . . . . 43
29 BASIC TROUBLESHOOTING FLOWCHART . . . . . . 45
30 POWER ON FLOW CHART . . . . . . . . . . . . . . . . . . . . 45
31 TRIP FAILURE FLOW CHART. . . . . . . . . . . . . . . . . . 46
LIST OF TABLES
Tbl. #
Pg. #
Tbl. #
Pg. #
1
UNIT VOLTAGE LIMITATIONS . . . . . . . . . . . . . . . . . . 12
2
UNIT TEMPERATURE LIMITATIONS . . . . . . . . . . . . . 12
3
UNIT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4
4 POINT LOAD WEIGHT . . . . . . . . . . . . . . . . . . . . . . . 13
5
6 POINT LOAD WEIGHT . . . . . . . . . . . . . . . . . . . . . . . 13
18 DJ150, 12-1/2 TON OPTIONAL MOTOR
SIDE SHOT BLOWER PERFORMANCE . . . . . . . . . . 31
6
UNIT CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . 14
19 INDOOR BLOWER SPECIFICATIONS. . . . . . . . . . . . 32
7
CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . 18
20 POWER EXHAUST SPECIFICATIONS . . . . . . . . . . . 32
8
ELECTRICAL DATA DJ150 (12-1/2 TON) WITHOUT
POWERED CONVENIENCE OUTLET . . . . . . . . . . . . 22
21 ADDITIONAL STATIC RESISTANCE . . . . . . . . . . . . . 34
9
ELECTRICAL DATA DJ150 (12-1/2 TON) WITH
POWERED CONVENIENCE OUTLET . . . . . . . . . . . . 22
23 ELECTRIC HEAT LIMIT SETTING . . . . . . . . . . . . . . . 37
10 PHYSICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11 MINIMUM SUPPLY AIR CFM . . . . . . . . . . . . . . . . . . . 23
12 GAS HEAT APPLICATION DATA . . . . . . . . . . . . . . . . 24
13 GAS PIPE SIZING - CAPACITY OF PIPE . . . . . . . . . . 24
14 SUPPLY AIR LIMITATIONS . . . . . . . . . . . . . . . . . . . . 29
15 DJ150, 12-1/2 TON STANDARD MOTOR
DOWN SHOT BLOWER PERFORMANCE . . . . . . . . . 30
Unitary Products Group
16 DJ150, 12-1/2 TON OPTIONAL MOTOR
DOWN SHOT BLOWER PERFORMANCE. . . . . . . . . 30
17 DJ150, 12-1/2 TON STANDARD MOTOR
SIDE SHOT BLOWER PERFORMANCE . . . . . . . . . . 31
22 MOTOR SHEAVE DATUM DIAMETERS . . . . . . . . . . 34
24 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . 37
25 GAS HEAT LIMIT CONTROL SETTINGS. . . . . . . . . . 39
26 GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . 39
27 GAS HEAT STAGES. . . . . . . . . . . . . . . . . . . . . . . . . . 41
28 GAS RATE CUBIC FEET PER HOUR . . . . . . . . . . . . 42
29 UNIT CONTROL BOARD FLASH CODES . . . . . . . . . 44
30 IGNITION CONTROL FLASH CODES . . . . . . . . . . . . 44
3
035-19046-003-A-0804
GENERAL
YORK® Predator® Magnum units are single package air conditioners with optional gas heating designed for outdoor
installation on a rooftop or slab and for non-residential use.
These units can be equipped with factory or field installed
electric heaters for heating applications.
These units are completely assembled on rigid, permanently
attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested. The units require
electric power, gas supply (where applicable), and duct connections. The electric heaters have nickel-chrome elements
and utilize single-point power connection.
If the information in this manual is not followed
exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
WHAT TO DO IF YOU SMELL GAS:
a.
Do not try to light any appliance.
b.
Do not touch any electrical switch; do not use
any phone in your building.
c.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
d.
If you cannot reach your gas supplier, call the fire
department.
SAFETY CONSIDERATIONS
Should overheating occur, or the gas supply fail to
shut off, shut off the manual gas valve to the furnace
before shutting off the electrical supply.
Do not use this furnace if any part has been under
water. Immediately call a qualified service technician
to inspect the furnace and to replace any part of the
control system and any gas control which has been
under water.
Due to system pressure, moving parts, and electrical components, installation and servicing of air conditioning equipment
can be hazardous. Only qualified, trained service personnel
should install, repair, or service this equipment. Untrained
personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags
accompanying the equipment whenever working on air conditioning equipment. Be sure to follow all other applicable
safety precautions and codes including ANSI Z223.1 or CSAB149.1- latest edition.
Wear safety glasses and work gloves. Use quenching cloth
and have a fire extinguisher available during brazing operations.
4
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 carrier’s freight bill. A
separate request for inspection by the carrier’s agent should
be made in writing.
This furnace is not to be used for temporary heating
of buildings or structures under construction.
Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. Improper
installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer
to this manual. For assistance or additional information consult a qualified installer, service agency or
the gas supplier.
Unitary Products Group
035-19046-003-A-0804
REFERENCE
APPROVALS
Additional information is available in the following reference
forms:
Design certified by CSA as follows:
1.
For use as a cooling only unit, cooling unit with supplemental electric heat or a forced air furnace.
• General Installation - DJ150, 035-19046-003
2.
For outdoor installation only.
• Pre-start & Post-start Check List - 035-18466-000
3.
• Economizer Accessory Downflow Factory Installed, 035-18286-000
Downflow Field Installed, 035-18285-000
Horizontal Field Installed, 035-18287-000
For installation on combustible material and may be
installed directly on combustible flooring or, in the U.S.,
on wood flooring or Class A, Class B or Class C roof covering materials.
4.
For use with natural gas (convertible to LP with kit).
• Technical Guide - DJ150, 036-21484-003
• Motorized Outdoor Air Damper 035-18283-000
• Manual Outdoor Air Damper (0-100%) 035-18282-000
• Manual Outdoor Air Damper (0-35%) 035-18281-000
• Gas Heat Propane Conversion Kit 035-17374-000
• Gas Heat High Altitude Kit (Natural Gas) 035-17282-000
• Gas Heat High Altitude Kit (Propane) 035-17281-000
This product must be installed in strict compliance
with the enclosed installation instructions and any
applicable local, state, and national codes including,
but not limited to, building, electrical, and mechanical
codes.
• –60°F Gas Heat Kit 035-18216-000
• Electric Heater Accessory 035-17291-001
• Unit Renewal Parts List 035-19085-000
RENEWAL PARTS
Refer to York’s USER’S MAINTENANCE and SERVICE
INFORMATION MANUAL Part Number 035-19047-001.
Incorrect 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. CAUTIONS are given
to prevent equipment damage. WARNINGS are given to alert
installer that personal injury and/or equipment damage may
result if installation procedure is not handled properly.
Unitary Products Group
5
035-19046-003-A-0804
NOMENCLATURE
12½ Ton Predator Model Number Nomenclature
D J
150 N15 A 2 A AA 4
Product Generation
Product Category
4 = Fourth Generation
D = Air Cond., Single Package
Product Identifier
J = R-22 Ultra High Efficiency
Voltage
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
Nominal Cooling Capacity - MBH
150 = 12-½ Ton
Heat Type & Nominal Heat Capacity
C00 = Cooling Only. Suitable for field installed electric heat
Gas Heat Options
N 15 = 150 MBH Output Aluminized Steel
N 20 = 200 MBH Output Aluminized Steel
S 15 = 150 MBH Output Stainless Steel
S 20 = 200 MBH Output Stainless Steel
Electric Heat Options
Installation Options
A = No Options Installed
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2 & 4
L = Options 1, 3 & 4
M = Options 1, 2, 3 & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3 & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3 & 5
V = Options 1, 4 & 5
W = Options 1, 3, 4 & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
Additional Options
(See Next Page)
Options
E18 = 18 kW Electric Heat
E24 = 24 kW Electric Heat
E36 = 36 kW Electric Heat
E54 = 54 kW Electric Heat
1 = Disconnect
2 = Non-Pwr’d Conv Outlet
3 = Smoke Detector S. A.
4 = Smoke Detector R. A.
5 = Pwr’d Conv Outlet
Airflow
A = Standard Motor
B = Standard Motor/Economizer/Barometric Relief (Downflow only)
C = Standard Motor/Economizer/Power Exhaust (Downflow only)
D = Standard Motor/Motorized Damper (Downflow only)
E = Standard Motor/Horizontal Economizer (No Barometric Relief)
F = Standard Motor/Slab Economizer/Power Exhaust (Downflow only)
G = Standard Motor/Slab Economizer/Barometric Relief (Downflow only)
L = Standard Motor/BAS Ready Econ (NoBASController)/Barometric Relief w/2" Pleated Filters (Downflow only)
M = Standard Motor/BAS Ready Econ (NoBASController)/Power Exhaust w/2" Pleated Filters (Downflow only)
N = High Static Motor
P = High Static Motor/Economizer/Barometric Relief (Downflow only)
Q = High Static Motor/Economizer/Power Exhaust (Downflow only)
R = High Static Motor/Motorized Damper (Downflow only)
S = High Static Motor/Horizontal Economizer (No Barometric Relief)
T = High Static Motor/Slab Economizer/Power Exhaust (Downflow only)
U =High Static Motor/Slab Economizer/Barometric Relief (Downflow only)
Y = High Static Motor/BAS Ready Econ (NoBASController)/Barometric Relief w/2" Pleated Filters (Downflow only)
Z = High Static Motor/BAS Ready Econ (NoBASController)/Power Exhaust w/2" Pleated Filters (Downflow only)
6
Unitary Products Group
035-19046-003-A-0804
NOMENCLATURE, ADDITIONAL OPTIONS:
Additional Options
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
AN
CA
CB
CC
CD
CE
CF
CG
CH
CJ
CK
CL
CM
CN
CP
CQ
CR
CS
CT
CU
CV
CW
CX
JA
JB
JC
JD
JE
JF
JG
JH
JJ
JK
JL
JM
JN
JP
JQ
JR
JS
JT
JU
JV
JW
JX
None
Phase Monitor
Coil Guard
Dirty Filter Switch
Phase Monitor & Coil Guard
Phase Monitor & Dirty Filter Switch
Coil Guard & Dirty Filter Switch
Phase Monitor, Coil Guard, & Dirty Filter Switch
SS Drain Pan
SS Drain Pan & Phase Monitor
SS Drain Pan & Coil Guard
SS Drain Pan & Dirty Filter Switch
SS Drain Pan, Phase Monitor, Coil Guard & Dirty Filter Switch
CPC Controller with Dirty Filter Switch & Air Proving Switch
CPC Controller, DFS, APS & Phase Monitor
CPC Controller, DFS, APS & Coil Guard
CPC Controller, DFS, APS, Phase Monitor, & Coil Guard
CPC Controller, DFS, APS & Technicoat Cond. Coil
CPC Controller, DFS, APS, Technicoat Cond. Coil, & Phase Monitor
CPC Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard
CPC Controller, DFS, APS, Technicoat Cond. Coil, Phase Monitor, & Coil Guard
CPC Controller, DFS, APS & Technicoat Evap. Coil
CPC Controller, DFS, APS, Technicoat Evap. Coil, & Phase Monitor
CPC Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard
CPC Controller, DFS, APS, Technicoat Evap. Coil, Phase Monitor, & Coil Guard
CPC Controller, DFS, APS & Technicoat Evap. & Cond Coils
CPC Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Phase Monitor
CPC Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard
CPC Controller, DFS, APS, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard
CPC Controller, DFS, APS, SS Drain Pan
CPC Controller, DFS, APS, SS Drain Pan, Phase Monitor, & Coil Guard
CPC Controller, DFS, APS, SS Drain Pan, & Technicoat Cond Coils
CPC Controller, DFS, APS, SS Drain Pan, & Technicoat Evap Coil
CPC Controller, DFS, APS, SS Drain Pan, & Technicoat Evap and Cond Coils
CPC Controller, DFS, APS, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils
Johnson UNT Controller with Dirty Filter Switch & Air Proving Switch
Johnson UNT Controller, DFS, APS & Phase Monitor
Johnson UNT Controller, DFS, APS & Coil Guard
Johnson UNT Controller, DFS, APS, Phase Monitor, & Coil Guard
Johnson UNT Controller, DFS, APS & Technicoat Cond. Coil
Johnson UNT Controller, DFS, APS, Technicoat Cond. Coil, & Phase Monitor
Johnson UNT Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard
Johnson UNT Controller, DFS, APS, Technicoat Cond. Coil, Phase Monitor, & Coil Guard
Johnson UNT Controller, DFS, APS & Technicoat Evap. Coil
Johnson UNT Controller, DFS, APS, Technicoat Evap. Coil, & Phase Monitor
Johnson UNT Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard
Johnson UNT Controller, DFS, APS, Technicoat Evap. Coil, Phase Monitor, & Coil Guard
Johnson UNT Controller, DFS, APS & Technicoat Evap. & Cond Coils
Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Phase Monitor
Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard
Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard
Johnson UNT Controller, DFS, APS, SS Drain Pan
Johnson UNT Controller, DFS, APS, SS Drain Pan, Phase Monitor, & Coil Guard
Johnson UNT Controller, DFS, APS, SS Drain Pan, & Technicoat Cond Coils
Johnson UNT Controller, DFS, APS, SS Drain Pan, & Technicoat Evap Coil
Johnson UNT Controller, DFS, APS, SS Drain Pan, & Technicoat Evap and Cond Coils
Johnson UNT Controller, DFS, APS, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils
Unitary Products Group
7
035-19046-003-A-0804
Additional Options
HA
HB
HC
HD
HE
HF
HG
HH
HJ
HK
HL
HM
HN
HP
HQ
HR
HS
HT
HU
HV
HW
HX
WA
WB
WC
WD
WE
WF
WG
WH
WJ
WK
WL
WM
WN
WP
WQ
WR
WS
WT
WU
WV
WW
WX
NA
NB
NC
ND
NE
NF
NG
NH
NJ
NK
NL
NM
NN
NP
NQ
8
Honeywell Excel 10 Controller with Dirty Filter Switch & Air Proving Switch
Honeywell Excel 10 Controller, DFS, APS & Phase Monitor
Honeywell Excel 10 Controller, DFS, APS & Coil Guard
Honeywell Excel 10 Controller, DFS, APS, Phase Monitor, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS & Technicoat Cond. Coil
Honeywell Excel 10 Controller, DFS, APS, Technicoat Cond. Coil, & Phase Monitor
Honeywell Excel 10 Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS, Technicoat Cond. Coil, Phase Monitor, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS & Technicoat Evap. Coil
Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. Coil, & Phase Monitor
Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. Coil, Phase Monitor, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS & Technicoat Evap. & Cond Coils
Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Phase Monitor
Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS, SS Drain Pan
Honeywell Excel 10 Controller, DFS, APS, SS Drain Pan, Phase Monitor, & Coil Guard
Honeywell Excel 10 Controller, DFS, APS, SS Drain Pan, & Technicoat Cond Coils
Honeywell Excel 10 Controller,DFS, APS, SS Drain Pan, & Technicoat Evap Coil
Honeywell Excel 10 Controller,DFS, APS, SS Drain Pan, & Technicoat Evap and Cond Coils
Honeywell Excel 10 Controller,DFS, APS, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils
Intelli-Comfort w/ModLINC Controller
Intelli-Comfort w/ModLINC Controller, & Phase Monitor
Intelli-Comfort w/ModLINC Controller, & Coil Guard
Intelli-Comfort w/ModLINC Controller, Phase Monitor, & Coil Guard
Intelli-Comfort w/ModLINC Controller, & Technicoat Cond. Coil
Intelli-Comfort w/ModLINC Controller, Technicoat Cond. Coil, & Phase Monitor
Intelli-Comfort w/ModLINC Controller, Technicoat Cond. Coil, & Coil Guard
Intelli-Comfort w/ModLINC Controller, Technicoat Cond. Coil, Phase Monitor, & Coil Guard
Intelli-Comfort w/ModLINC Controller, & Technicoat Evap. Coil
Intelli-Comfort w/ModLINC Controller, Technicoat Evap. Coil, & Phase Monitor
Intelli-Comfort w/ModLINC Controller, Technicoat Evap. Coil, & Coil Guard
Intelli-Comfort w/ModLINC Controller, Technicoat Evap. Coil, Phase Monitor, & Coil Guard
Intelli-Comfort w/ModLINC Controller, & Technicoat Evap. & Cond Coils
Intelli-Comfort w/ModLINC Controller, Technicoat Evap. & Cond Coils, & Phase Monitor
Intelli-Comfort w/ModLINC Controller, Technicoat Evap. & Cond Coils, & Coil Guard
Intelli-Comfort w/ModLINC Controller, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard
Intelli-Comfort w/ModLINC Controller, SS Drain Pan
Intelli-Comfort w/ModLINC Controller, SS Drain Pan, Phase Monitor, & Coil Guard
Intelli-Comfort w/ModLINC Controller, SS Drain Pan, & Technicoat Cond Coils
Intelli-Comfort w/ModLINC Controller, SS Drain Pan, & Technicoat Evap Coil
Intelli-Comfort w/ModLINC Controller, SS Drain Pan, & Technicoat Evap and Cond Coils
Intelli-Comfort w/ModLINC Controller, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils
Novar ETC-3 Controller with Dirty Filter Switch & Air Proving Switch
Novar ETC-3 Controller, DFS, APS & Phase Monitor
Novar ETC-3 Controller, DFS, APS & Coil Guard
Novar ETC-3 Controller, DFS, APS, Phase Monitor, & Coil Guard
Novar ETC-3 Controller, DFS, APS & Technicoat Cond. Coil
Novar ETC-3 Controller, DFS, APS, Technicoat Cond. Coil, & Phase Monitor
Novar ETC-3 Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard
Novar ETC-3 Controller, DFS, APS, Technicoat Cond. Coil, Phase Monitor, & Coil Guard
Novar ETC-3 Controller, DFS, APS & Technicoat Evap. Coil
Novar ETC-3 Controller, DFS, APS, Technicoat Evap. Coil, & Phase Monitor
Novar ETC-3 Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard
Novar ETC-3 Controller, DFS, APS, Technicoat Evap. Coil, Phase Monitor, & Coil Guard
Novar ETC-3 Controller, DFS, APS & Technicoat Evap. & Cond Coils
Novar ETC-3 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Phase Monitor
Novar ETC-3 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard
Unitary Products Group
035-19046-003-A-0804
Additional Options
NR
NS
NT
NU
NV
NW
NX
LA
LB
LC
LD
LE
LF
LG
LH
LJ
LK
LL
LM
LN
LP
LQ
LR
LS
LT
LU
LV
LW
LX
TA
TB
TC
TD
TE
TF
TG
TH
TJ
TK
TL
TM
TN
TP
TQ
TR
TS
TT
TU
TV
TW
TX
TY
TZ
T1
T3
T4
T6
T7
T9
Novar ETC-3 Controller, DFS, APS, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard
Novar ETC-3 Controller, DFS, APS, SS Drain Pan
Novar ETC-3 Controller, DFS, APS, SS Drain Pan, Phase Monitor, & Coil Guard
Novar ETC-3 Controller, DFS, APS, SS Drain Pan, & Technicoat Cond Coils
Novar ETC-3 Controller, DFS, APS, SS Drain Pan, & Technicoat Evap Coil
Novar ETC-3, DFS, APS, SS Drain Pan, & Technicoat Evap and Cond Coils
Novar ETC-3 Controller, DFS, APS, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils
Simplicity Intelli-Comfort Controller
Simplicity Intelli-Comfort Controller, & Phase Monitor
Simplicity Intelli-Comfort Controller, & Coil Guard
Simplicity Intelli-Comfort Controller, Phase Monitor, & Coil Guard
Simplicity Intelli-Comfort Controller, & Technicoat Cond. Coil
Simplicity Intelli-Comfort Controller, Technicoat Cond. Coil, & Phase Monitor
Simplicity Intelli-Comfort Controller, Technicoat Cond. Coil, & Coil Guard
Simplicity Intelli-Comfort Controller, Technicoat Cond. Coil, Phase Monitor, & Coil Guard
Simplicity Intelli-Comfort Controller, & Technicoat Evap. Coil
Simplicity Intelli-Comfort Controller, Technicoat Evap. Coil, & Phase Monitor
Simplicity Intelli-Comfort Controller, Technicoat Evap. Coil, & Coil Guard
Simplicity Intelli-Comfort Controller, Technicoat Evap. Coil, Phase Monitor, & Coil Guard
Simplicity Intelli-Comfort Controller, & Technicoat Evap. & Cond Coils
Simplicity Intelli-Comfort Controller, Technicoat Evap. & Cond Coils, & Phase Monitor
Simplicity Intelli-Comfort Controller, Technicoat Evap. & Cond Coils, & Coil Guard
Simplicity Intelli-Comfort Controller, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard
Simplicity Intelli-Comfort Controller, SS Drain Pan
Simplicity Intelli-Comfort Controller, SS Drain Pan, Phase Monitor, & Coil Guard
Simplicity Intelli-Comfort Controller, SS Drain Pan, & Technicoat Cond Coils
Simplicity Intelli-Comfort Controller, SS Drain Pan, & Technicoat Evap Coil
Simplicity Intelli-Comfort Controller, SS Drain Pan, & Technicoat Evap and Cond Coils
Simplicity Intelli-Comfort Controller, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils
Technicoat Condenser Coil
Technicoat Condenser Coil & Phase Monitor
Technicoat Condenser Coil & Coil Guard
Technicoat Condenser Coil & Dirty Filter Switch
Technicoat Condenser Coil, Phase Monitor, & Coil Guard
Technicoat Condenser Coil, Phase Monitor, & Dirty Filter Switch
Technicoat Condenser Coil, Coil Guard, & Dirty Filter Switch
Technicoat Condenser Coil, Phase Monitor, Coil Guard, & Dirty Filter Switch
Technicoat Evaporator Coil
Technicoat Evaporator Coil & Phase Monitor
Technicoat Evaporator Coil & Coil Guard
Technicoat Evaporator Coil & Dirty Filter Switch
Technicoat Evaporator Coil, Phase Monitor, & Coil Guard
Technicoat Evaporator Coil, Phase Monitor, & Dirty Filter Switch
Technicoat Evaporator Coil, Coil Guard, & Dirty Filter Switch
Technicoat Evaporator Coil, Phase Monitor, Coil Guard, & Dirty Filter Switch
Technicoat Evaporator & Condenser Coils
Technicoat Evaporator & Condenser Coils & Phase Monitor
Technicoat Evaporator & Condenser Coils & Coil Guard
Technicoat Evaporator & Condenser Coils & Dirty Filter Switch
Technicoat Evaporator & Condenser Coils, Phase Monitor, & Coil Guard
Technicoat Evaporator & Condenser Coils, Phase Monitor, & Dirty Filter Switch
Technicoat Evaporator & Condenser Coils, Coil Guard, & Dirty Filter Switch
Technicoat Evaporator & Condenser Coils, Phase Monitor, Coil Guard, & Dirty Filter Switch
Technicoat Condenser & SS Drain Pan
Technicoat Condenser Coil, SS Drain Pan, Phase Monitor, Coil Guard, & Dirty Filter Switch
Technicoat Evaporator & SS Drain Pan
Technicoat Evaporator Coil, SS Drain Pan, Phase Monitor, Coil Guard, & Dirty Filter Switch
Technicoat Evaporator & Condenser Coils & SS Drain Pan
Technicoat Evaporator & Condenser Coils, SS Drain Pan, Phase Monitor, Coil Guard, & Dirty Filter Switch
Unitary Products Group
9
035-19046-003-A-0804
INSTALLATION
INSTALLATION SAFETY INFORMATION
3.
Remove the condenser coil external protective covering
prior to operation.
4.
Remove the toolless doorknobs and instruction packet
prior to installation.
Read these instructions before continuing this appliance
installation. This is an outdoor combination heating 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 to the furnace rating plate for the approved type of
gas for this furnace.
2.
Install this furnace only in a location and position as
specified on Page 12 of these instructions.
3.
Never test for gas leaks with an open flame. Use commercially available soap solution made specifically for the
detection of leaks when checking all connections, as specified on Pages 10, 25, 26 and 40 of these instructions.
4.
5.
Toolless
Doorknobs
Always install furnace to operate within the furnace's
intended temperature-rise range with the duct system
and within the allowable external static pressure range,
as specified on the unit name/rating plate, specified on
Page 42 of these instructions.
Installation
Instruction
Packet
This equipment is not to be used for temporary heating
of buildings or structures under construction.
FIGURE 2 -
COMPRESSOR SECTION
FIRE OR EXPLOSION HAZARD
This product must be installed in strict compliance
with the enclosed installation instructions and any
applicable local, state and national codes including,
but not limited to, building, electrical, and mechanical codes.
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system
during any pressure testing at pressures in excess
of 1/2 PSIG.
PRECEDING INSTALLATION
1.
Pressures greater than 1/2 PSIG will cause gas
valve damage resulting in a hazardous condition. If it
is subjected to a pressure greater than 1/2 PSIG, the
gas valve must be replaced.
Remove the two screws holding the brackets in the front,
rear and compressor side fork-lift slots.
Bracket
Screws
The furnace must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than 1/2 PSIG.
Turn down
LIMITATIONS
FIGURE 1 2.
10
UNIT SHIPPING BRACKET
Turn each bracket toward the ground and the protective
plywood covering will drop to the ground.
These units must be installed in accordance with the following:
In U.S.A.:
1.
National Electrical Code, ANSI/NFPA No. 70 - Latest
Edition
Unitary Products Group
035-19046-003-A-0804
2.
National Fuel Gas Code, ANSI Z223.1 - Latest Edition
Refer to Tables 1 & 2 for unit application data.
3.
Gas-Fired Central Furnace Standard, ANSI Z21.47a. Latest Edition
4.
Local building codes, and
After installation, gas fired units must be adjusted to obtain a
temperature rise within the range specified on the unit rating
plate.
5.
Local gas utility requirements
In Canada:
1.
Canadian Electrical Code, CSA C22.1
2.
Installation Codes, CSA - B149.1.
3.
Local plumbing and waste water codes, and
4.
Other applicable local codes.
If components are to be added to a unit to meet local codes,
they are to be installed at the dealer’s and/or customer’s
expense.
Size of unit for proposed installation should be based on heat
loss/heat gain calculation made according to the methods of
Air Conditioning Contractors of America (ACCA).
This furnace is not to be used for temporary heating of buildings or structures under construction
.
Second model
nameplate inside
hinged access panel
“Simplicity” Control
board w/screw
connectors for T-stat
wiring and Network
Connection
Disconnect
location (optional
disconnect switch)
Filter access
(2" throw-away)
Filter drier (solid core)
Condenser Section
Dual stage cooling
for maximum
comfort
Belt-drive blower
motor
Slide out motor
and blower
assembly for easy
adjustment and
service
Compressor #2
access
(high-efficiency
compressor w/
crankcase heater)
Power ventor
motor
20-gauge
aluminized steel
tubular heat
exchanger for
long life
(stainless steel
option)
Base rails w/
forklift slots
( three sides)
and lifting
holes
Roof curbs in eight-and
fourteen-inch heights.
Roof curbs for
transitioning from York Tool-less door
latch
Sunline TM footprint to
the DM/DH/DJ Series
Side entry power
footprint are available
and control wiring
(field-installed accessory)
knockouts
FIGURE 3 -
Slide-out drain pan
with brass ¾" FPT
connection
Compressor #1 access
(high-efficiency
compressor w/crankcase
heater)
Two-stage gas heating to
maintain warm,
comfortable temperature
Intelligent control
board for safe and
efficient operation
PREDATOR® MAGNUM COMPONENT LOCATION
Unitary Products Group
11
035-19046-003-A-0804
RIGGING AND HANDLING
TABLE 1: UNIT VOLTAGE LIMITATIONS
Power Rating1
Minimum
208/230-3-60
187
252
460-3-60
432
504
575-3-60
540
630
1.
Maximum
Utilization range “A” in accordance with ARI Standard 110.
Exercise care when moving the unit. Do not remove any
packaging until the unit is near the place of installation. Rig
the unit by attaching chain or cable slings to the lifting holes
provided in the base rails. Spreader bars, whose length
exceeds the largest dimension across the unit, MUST be
used across the top of the unit.
TABLE 2: UNIT TEMPERATURE LIMITATIONS
Temperature
Min.
Max.
Wet Bulb Temperature (°F) of Air on
Evaporator Coil
57
72
Dry Bulb Temperature (°F) of Air on
Condenser Coil
01
125
1.
If a unit is to be installed on a roof curb other than a
YORK roof curb, gasketing must be applied to all
surfaces that come in contact with the unit underside.
A low ambient accessory is available for operation
down to -20°F.
LOCATION
Use the following guidelines to select a suitable location for
these units:
1.
Unit is designed for outdoor installation only.
2.
Condenser coils must have an unlimited supply of air.
Where a choice of location is possible, position the unit
on either north or east side of building.
3.
Suitable for mounting on roof curb.
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/accessories. Unit must be installed
on a solid, level roof curb or appropriate angle iron
frame.
6.
Maintain level tolerance to 1/2” across the entire width
and length of unit.
Excessive exposure of this furnace to contaminated
combustion air may result in equipment damage or
personal injury. Typical contaminates include: permanent wave solution, chlorinated waxes and cleaners, chlorine based swimming pool chemicals, water
softening chemicals, carbon tetrachloride, Halogen
type refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes,
hydrochloric acid, cements and glues, antistatic fabric softeners for clothes dryers, masonry acid washing materials.
12
Before lifting, make sure the unit weight is distributed equally on the rigging cables so it will lift evenly.
Units may be moved or lifted with a forklift. Slotted openings
in the base rails are provided for this purpose.
LENGTH OF FORKS MUST BE A MINIMUM OF 60
INCHES.
All panels must be secured in place when the unit is
lifted.
The condenser coils should be protected from rigging cable damage with plywood or other suitable
material.
FRONT
C
LEFT
B
A
D
FIGURE 4 -
UNIT 4 POINT LOAD
Unitary Products Group
035-19046-003-A-0804
TABLE 3: UNIT WEIGHTS
Operating
Model DJ150
Shipping
Weight (lb.)
Weight (lb.)
Cooling Unit Only
1495
1480
w/Economizer
85
84
w/Power Exhaust
150
148
w/Gas Heat1
110
110
49
49
2
w/Electric Heat
1.
8 Tube Heat Exchanger
2.
54 kW heater
All units require particular clearances for proper operation
and service. Installer must make provisions for adequate
combustion and ventilation air in accordance with section 5.3
of Air for Combustion and Ventilation of the National Fuel Gas
Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections
7.2, 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in
Canada) - Latest Edition, and/or applicable provisions of the
local building codes. Refer to Table 6 for clearances required
for combustible construction, servicing, and proper unit operation.
TABLE 4: 4 POINT LOAD WEIGHT
Location (lbs.)1
Model
DJ150
1.
A
B
C
D
282
359
468
371
Do not permit overhanging structures or shrubs to
obstruct condenser air discharge outlet, combustion
air inlet or vent outlets.
Weights include largest gas heat option.
TABLE 5: 6 POINT LOAD WEIGHT
Location (lbs.)1
Model
DJ150
1.
A
B
C
D
E
F
184
210
246
323
275
242
Excessive exposure to contaminated combustion air
will result in safety and performance related problems. To maintain combustion air quality, the recommended source of combustion air is the outdoor air
supply. The outdoor air supplied for combustion
should be free from contaminants due to chemical
exposure that may be present from the following
sources.
Weights include largest gas heat option.
•
•
•
•
•
Commercial buildings
Indoor pools
Laundry rooms
Hobby or craft rooms
Chemical storage areas
The following substances should be avoided to
maintain outdoor combustion air quality.
FRONT
D
LEFT
C
A
E
B
F
FIGURE 5 -
UNIT 6 POINT LOAD
60"
LEFT
FIGURE 6 -
25-½"
FRONT
•
•
•
•
•
•
•
•
•
•
•
•
•
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine based swimming pool cleaners
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Anti-static fabric softeners for clothes dryers
Masonry acid washing materials
UNIT CENTER OF GRAVITY
CLEARANCES
Unitary Products Group
13
035-19046-003-A-0804
119-7/16
For Gas Pipe Entry
see DETAIL A
Convenience
Outlet
Power
Entry
2-1/2
30-11/32
4-1/4
Convenience
Outlet Power
Entry 7/8
Control
Entry
7/8
50-3/4
11-1/2
FRONT
For Baserail
Dimensions
see
DETAIL B
30-3/16
17-3/16
24-3/16
6-3/16
59
89
27
LEFT
For Drain Dimensions
see DETAIL C
FIGURE 7 -
UNIT DIMENSIONS
DETAIL A
DETAIL B
G a s P ip e In le t
3 -3 /4
5 -1 /4
B a s e
P a n
1 7 -1 3 /1 6
V ie w o f W a ll A c r o s s fr o m
3 -9 /1 6
C o il
DETAIL C
TABLE 6: UNIT CLEARANCES
Top1
72”
Right
12”
2
Front
36”
Left
36”
Rear3
36”
Bottom4
0”
1.
Units must be installed outdoors. Overhanging structure or shrubs should not obstruct condenser air discharge outlet.
2.
The products of combustion must not be allowed to
accumulate within a confined space and re-circulate.
3.
To remove the slide-out drain pan, a rear clearance of
sixty inches is required. If space is unavailable, the
drain pan can be removed through the front by separating the corner wall.
4.
Units may be installed on combustible floors made from
wood or class A, B or C roof covering materials.
NOTE: A one-inch clearance must be provided between
any combustible material and the supply ductwork
for a distance of 3 feet from the unit.
14
2 -3 /8
5 -3 /8
NOTE: If the unit includes gas heating, locate the unit so
the flue exhaust is at least:
•
Three (3) feet above any forced air inlet located within 10
horizontal feet (excluding those integral to the unit).
•
Four (4) feet below, four (4) horizontal feet from, or one
(1) foot above any door or gravity air inlet into the building.
•
Four (4) feet from electric meters, gas meters, regulators, and relief equipment.
Unitary Products Group
035-19046-003-A-0804
.
32-11/16
6-13/16
Supply
Air
6-13/16
6-13/16
Return
Air
24
LEFT
27-1/2
21
18
21-3/16
19-3/16
17-3/16
12-5/16
7-1/8
14-23/32
FRONT
16-3/8
18-1/16
19-5/8
Bottom
Condensate
Drain
Bottom
Power, Control and
Convenience Outlet
Wiring Entries
Bottom
Gas Supply Entry
63-1/2
FIGURE 8 -
BOTTOM DUCT OPENINGS (FROM ABOVE)
Unitary Products Group
15
035-19046-003-A-0804
Dot
Plugs
18-1/4
Return
Air
28-1/4
Supply
Air
18-1/4
18-1/16
2-31/32
28-1/4
31-11/16
5-5/32
FIGURE 9 -
REAR DUCT DIMENSIONS
DUCTWORK
DUCT COVERS
Ductwork should be designed and sized according to the
methods in Manual D of the Air Conditioning Contractors of
America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA.
Units are shipped with the side duct openings covered and a
covering over the bottom of the unit. For bottom duct application, no duct cover changes are necessary. For side duct
application, remove the side duct covers and install over the
bottom duct openings. The panels removed from the side
duct connections are designed to be reused by securing each
panel to its respective downflow opening. But keep in mind
that the supply panel is installed with the painted surface UP,
facing the heat exchanger, while the return panel is installed
with the painted surface DOWN, facing the downflow duct
opening. The supply panel is secured with the bracket
(already in place from the factory) and two screws. It’s a snug
fit for the panel when sliding it between the heat exchanger
and unit bottom, but there is room. The return panel is
secured with four screws.
A closed return duct system should be used. This will 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 pressure requirements of the job. They
should NOT be sized to match the dimensions of the duct
connections on the unit.
Refer to Figure 8 for bottom air duct openings. Refer to Figure 9 for rear air duct openings.
16
Unitary Products Group
035-19046-003-A-0804
R IG H T
8 0 -5 /8
IN S U L A T E D D E C K U N D E R
C O N D E N S E R S E C T IO N
2 0
2 0
S U P P L Y
6
R E T U R N
2 T Y P .
3 0
IN S U L A T E D D E C K U N D E R
C O M P R E S S O R S E C T IO N
5 0 -1 /2
F R O N T
8 o r 1 4
FIGURE 10 - PREDATOR® MAGNUM ROOF CURB DIMENSIONS
2 T Y P
5 0 -1 /2
3 0 -1 /2
2 3
4
8 0 -5 /8
2 6
R E T U R N
S U P P L Y
1 0
7 6 -5 /8
9 4
F R O N T
5 9 -1 /4
6 4 -1 /4
R IG H T
FIGURE 11 - SUNLINE™ TO PREDATOR® MAGNUM TRANSITION ROOF CURBS
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 water-proofed.
FIGURE 12 - SIDE PANELS WITH HOLE PLUGS
Note orientation. Panel is “insulation” side up.
Unitary Products Group
17
035-19046-003-A-0804
COMPRESSORS
The compressors are mounted on elastomer insulators. The
mounting bolts have been fully tightened for shipping.
Do not loosen the compressor mounting bolts.
FILTERS
FIGURE 13 - RETURN DOWNFLOW PLENUM WITH
PANEL
Two-inch filters are supplied with each unit. One-inch filters
may be used with no modification to the filter racks. Filters
must always be installed ahead of evaporator coil and must
be kept clean or replaced with same size and type. Dirty filters reduce the capacity of the unit and result in frosted coils
or safety shutdown. All units use four (4) 20”x25”x2” filters.
The unit should not be operated without filters properly
installed.
Make sure that panel latches are properly positioned
on the unit to maintain an airtight seal.
FIGURE 14 - DISCHARGE PANEL IN PLACE
CONDENSATE DRAIN
The side condensate drain is reversible and maybe re-oriented to the rear of the cabinet to facilitate condensate piping. A condensate drain connection is available through the
base pan for piping inside the roof curb. Trap the connection
per Figure 15. The trap and drain lines should be protected
from freezing.
Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install condensate drain line
from the 3/4 inch NPT female connection on the unit to an
open drain.
THERMOSTAT WIRING
The thermostat should be located on an inside wall approximately 56 inch above the floor where it will not be subject to
drafts, sun exposure or heat from electrical fixtures or appliances. Follow the manufacturer's instructions enclosed with
thermostat for general installation procedure. Seven (7) colorcoded, insulated wires should be used to connect the thermostat to the unit. Refer to Table 7 for control wire sizing and
maximum length.
TABLE 7: CONTROL WIRE SIZES
1.
O P T IO N A L C O IL
G U A R D
3 " M in im u m
FIGURE 15 - CONDENSATE DRAIN
18
Wire Size
Maximum Length1
18 AWG
150 Feet
From the unit to the thermostat and back to the unit.
POWER AND CONTROL WIRING
Field wiring to the unit, fuses, and disconnects must conform
to provisions of National Electrical Code (NEC), ANSI/NFPA
No. 70 – Latest Edition (in U.S.A.), current Canadian Electrical Code C221, and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC as
specified above and/or local codes.
Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are
indicated on the unit Rating Plate and Table 1.
Unitary Products Group
035-19046-003-A-0804
The internal wiring harnesses furnished with this unit are an
integral part of the design certified unit. Field alteration to
comply with electrical codes should not be required. If any of
the wire supplied with the unit must be replaced, replacement
wire must be of the type shown on the wiring diagram and the
same minimum gauge as the replaced wire.
Refer to Figures 16, 17 and 18 for typical field wiring and to
the appropriate unit wiring diagram mounted inside control
doors for control circuit and power wiring information.
A disconnect must be utilized for these units. Factory
installed disconnects are available. If installing a disconnect
(field supplied or York International® supplied accessory),
refer to Figure 3 for the recommended mounting location.
Avoid damage to internal components if drilling
holes for disconnect mounting.
POWER WIRING DETAIL
NOTE: Since not all local codes allow the mounting of a disconnect on the unit, please confirm compliance with
local code before mounting a disconnect on the unit.
Electrical line must be sized properly to carry the load. USE
COPPER CONDUCTORS ONLY. Each unit must be wired
with a separate branch circuit fed directly from the meter
panel and properly fused.
T H E R M
T E R M
O S T A T
IN A L S
When connecting electrical power and control wiring
to the unit, water-proof connectors must be used so
that water or moisture cannot be drawn into the unit
during normal operation. The above water-proofing
conditions will also apply when installing a field supplied disconnect switch.
Units are factory wired for the voltage shown on the unit
nameplate. Refer to Electrical Data Tables 8 and 9 to size
power wiring, fuses, and disconnect switch.
Power wiring is brought into the unit through the side of the
unit or the basepan inside the curb.
1
U N IT T E R M IN A L S
S T R IP T B 1
R C
R H
R
Y 1
Y 1
Y 2
Y 2
W
1
W
W
2
1
W
G
2
G
C
C
X 1
X 3
2 4
X
2
V o lt
T r a n s fo r m
e r
O C C
X 4
A 1
A 2
T
T
T O R E M O T E S E N S O R
2 E T 0 4 7 0 1 3 2 4 IF U S E D
1
2
E le c tr o n ic p r o g r a m m a b le T h e r m o s ta t 2 E T 0 7 7 0 0 1 0 0 2 4 ( in c lu d e s s u b b a s e ) .
T e r m in a ls A 1 a n d A 2 p r o v id e a r e la y o u tp u t to c lo s e th e o u td o o r
e c o n o m iz e r d a m p e r s w h e n th e th e r m o s ta t s w itc h e s to th e s e t- b a c k p o s itio n .
FIGURE 16 - ELECTRONIC THERMOSTAT FIELD WIRING
Unitary Products Group
19
035-19046-003-A-0804
T -S T A T
W 1
W 1
W 2
W 2
Y 1
Y 1
G
G
Y 2
O C C
R H
R C
R E M O T E
M IN P O S
C
U N IT C O N T R O L
B O A R D
Y 2
X
R
S D
C
FIGURE 17 - FIELD WIRING 24 VOLT THERMOSTAT
TERMINAL BLOCK TB1
FACTORY OR FIELD
SUPPLIED DISCONNECT
GROUND
LUG
THREE
PHASE
POWER
SUPPLY
FIGURE 18 - FIELD WIRING DISCONNECT - COOLING UNIT WITH/WITHOUT ELECTRIC HEAT
20
Unitary Products Group
035-19046-003-A-0804
CONTACTOR 1M
GROUND
LUG
T1
T2
T3
L1
L2
L3
FACTORY OR FIELD
SUPPLIED DISCONNECT
THREE
PHASE
POWER
SUPPLY
FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT
Unitary Products Group
21
035-19046-003-A-0804
TABLE 8: ELECTRICAL DATA DJ150 (12-1/2 TON) WITHOUT POWERED CONVENIENCE OUTLET
Supply
Pwr
Pwr
Blower
Exh Conv
Electric Heater Actual Heater
Voltage
Motor FLA Motor Outlet
KW
Amps
Model No.
RLA
LRA
FLA
3
5
FLA FLA
ea.
ea.
ea.
HP
HP
None
--2TP04521825
13.5
37.5
20.0 146.0
1.5
10.9 16.1
5.5
0.0
208
2TP04522425
18.0
50.0
2TP04523625
25.5
70.8
2TP04525425
40.6 112.7
None
--2TP04521825
18.0
43.3
20.0 146.0
1.5
10.9 16.1
5.5
0.0
230
2TP04522425
24.0
57.7
2TP04523625
34.0
81.8
2TP04525425
54.0 129.9
None
--2TP04521846
18
22.6
8.4
73.0
0.8
5.3
8.1
2.2
0.0
460
2TP04522446
24
30.1
2TP04523646
34
42.7
2TP04525446
54
67.8
None
--2TP04521858
18
18.1
6.7
60.0
0.6
4.1
6.0
1.8
0.0
575
2TP04522458
24
24.1
2TP04523658
34
34.1
2TP04525458
54
54.2
Maximum HACR breaker of the same AMP size is applicable.
1
Compressors
OD Fan
Motors
Min. Circuit
Ampacity
(Amps)
3
HP
61.9
61.9
76.1
102.1
154.5
61.9
67.8
85.8
115.9
143.5
27.4
33.7
42.7
57.7
71.6
21.6
26.8
34
46
57.1
5
HP
67.1
67.1
82.6
108.6
161.0
67.1
74.3
92.3
122.4
150.0
30.2
37.2
46.2
61.2
75.1
23.5
29.2
36.4
48.4
59.5
Max
Max Fuse1 Size
Fuse1
w/Power
Size
Exhaust
(Amps)
(Amps)
3
5
3
5
HP HP
HP
HP
80 80
80
90
80 80
80
90
80 90
90
90
110 110 110
125
175 175 175
175
80 80
80
90
80 80
80
90
90 100 100
100
125 125 125
150
175 175 175
175
35 35
35
40
35 40
40
40
45 50
50
50
60 70
70
70
80 90
80
90
25 30
30
30
30 30
30
35
35 40
40
40
50 50
50
60
70 70
70
70
MCA
w/Power
Exhaust
(Amps)
3
5
HP
HP
67.4 72.6
67.4 73.8
83.0 89.5
109.0 115.5
161.4 167.9
67.4 72.6
74.6 81.1
92.7 99.2
122.7 129.2
150.4 156.9
29.6 32.4
36.4 39.9
45.5
49
60.5
64
74.3 77.8
23.4 25.3
29
31.4
36.2 38.6
48.3 50.6
59.3 61.7
TABLE 9: ELECTRICAL DATA DJ150 (12-1/2 TON) WITH POWERED CONVENIENCE OUTLET
Supply
Pwr
Pwr
Blower
Exh Conv
Electric Heater Actual Heater
Voltage
Motor FLA Motor Outlet
KW
Model No.
Amps
RLA
LRA
FLA
3
5
FLA
FLA
ea.
ea.
ea.
HP
HP
None
--2TP04521825
13.5
37.5
1.5
10.9 16.1
5.5
10.0
20.0 146.0
208
2TP04522425
18.0
50.0
2TP04523625
25.5
70.8
2TP04525425
40.6 112.7
None
--2TP04521825
18.0
43.3
20.0 146.0
1.5
10.9 16.1
5.5
10.0
230
2TP04522425
24.0
57.7
2TP04523625
34.0
81.8
2TP04525425
54.0 129.9
None
--2TP04521846
18
22.6
73.0
0.8
5.3
8.1
8.4
2.2
5.0
460
2TP04522446
24
30.1
2TP04523646
34
42.7
2TP04525446
54
67.8
None
--2TP04521858
18
18.1
6.7
60.0
0.6
4.1
6.0
1.8
4.0
575
2TP04522458
24
24.1
2TP04523658
34
34.1
2TP04525458
54
54.2
Maximum HACR breaker of the same AMP size is applicable.
1
OD Fan
Compressors
Motors
22
Min. Circuit
Ampacity
(Amps)
3
HP
71.9
73.0
88.6
114.6
167.0
71.9
80.3
98.3
128.4
156.0
32.4
39.9
49
64
77.8
25.6
31.8
39
51
62.1
5
HP
77.1
79.5
95.1
121.1
173.5
77.1
86.8
104.8
134.9
162.5
35.2
43.4
52.5
67.5
81.3
27.5
34.2
41.4
53.4
64.5
MCA
w/Power
Exhaust
(Amps)
3
5
HP
HP
77.4 82.6
79.8 86.3
95.5 102.0
121.5 128.0
173.9 180.4
77.4 82.6
87.1 93.6
105.2 111.7
135.2 141.7
162.9 169.4
34.6 37.4
42.7 46.2
51.7 55.2
66.7 70.2
80.6 84.1
27.4 29.3
34
36.4
41.2 43.6
53.3 55.6
64.3 66.7
Max
Max Fuse1 Size
Fuse1
w/Power
Size
Exhaust
(Amps)
(Amps)
3
5
3
5
HP HP
HP
HP
90 90
90
100
90 90
90
100
90 100 100
110
125 125 125
150
175 175 175
200
90 90
90
100
90 90
90
100
100 110 110
125
150 150 150
150
175 175 175
175
40 40
40
45
40 45
45
50
50 60
60
60
70 70
70
80
90 90
90
90
30 30
30
35
35 35
35
40
40 45
45
45
60 60
60
60
70 70
70
70
Unitary Products Group
035-19046-003-A-0804
TABLE 10: PHYSICAL DATA
Model
DJ150
Component
Blower, Centrifugal (Dia. X Wd. in.)
15 x 15
Motor, Standard (HP)
3
Motor, Optional (HP)
5
Rows
4
Fins per Inch
15
Height (in.)
40
Face Area (ft.2 each)
13.2
Propeller Dia. (in., each)
24
Motor (HP, each)
1/3
CFM, Nominal (each)
3500
Rows (each)
2
Fins per Inch
15
Height (in. each)
36
Face Area (ft.2 each)
11.88
System 1 (lb./oz.)
21/0
System 2 (lb./oz.)
20/8
Quantity
2
Type
Scroll
Size (Wd. x Ht. x Thickness in.)
25x20x2
Number Per Unit
4
Evaporator
Blower
Evaporator
Coil
Condenser
Fan
(4 per Unit)
Condenser
Coil
(2 per unit)
Refrigerant
Charge
Compressors
Air Filters
OPTIONAL ELECTRIC HEAT
The factory-installed heaters are wired for single point power
supply. Power supply need only be brought into the single
point terminal block.
TABLE 11: MINIMUM SUPPLY AIR CFM
Heater
kW
Unit Model Size, Nominal Tons
Voltage
12.5
Minimum Supply Air CFM
18
These CSA approved heaters are located within the central
compartment of the unit with the heater elements extending
into the supply air chamber.
24
36
208/230
3750
480
3750
600
3750
54
18
Fuses are supplied, where required, by the factory. Some kW
sizes require fuses and other do not. Refer to Table 11 for
minimum CFM limitations and to Tables 8 through 9 for electrical data.
24
36
54
18
24
36
54
Unitary Products Group
23
035-19046-003-A-0804
OPTIONAL GAS HEAT
These gas-fired heaters have aluminized-steel or optional
stainless steel, tubular heat exchangers with spark ignition.
OPTIONAL
COIL
GUARD
SHOWN
TABLE 12: GAS HEAT APPLICATION DATA
Unit
Input (MBH) Output (MBH)
Size
Opt.
Temp Rise
(°F)
15
180
144
10-40
20
240
192
20-50
150
GAS PIPING
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 requirements. Refer to the Pipe Sizing
Table 13. 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.
FIGURE 21 - BOTTOM ENTRY GAS PIPING
TABLE 13: GAS PIPE SIZING - CAPACITY OF PIPE
O P
C O
G U
S H
FIGURE 20 - SIDE ENTRY GAS PIPING
T IO N A L
IL
A R D
O W N
Nominal Iron Pipe Size
Length of
Pipe (ft.)
3/4 in.
1 in.
1-1/4 in.
10
278
520
1050
20
190
350
730
30
152
285
590
40
130
245
500
50
115
215
440
60
105
195
400
70
96
180
370
80
90
170
350
90
84
160
320
100
79
150
305
NOTE: Maximum capacity of pipe in cubic feet of gas per
hour based upon a pressure drop of 0.3 inch W.C.
and 0.6 specific gravity gas.
NOTE: There may be a local gas utility requirement specifying a minimum diameter for gas piping. All units
require a 3/4 inch pipe connection at the entrance
fitting. Line should not be sized smaller than the
entrance fitting size.
24
Unitary Products Group
035-19046-003-A-0804
GAS CONNECTION
The gas supply line can be routed within the space and roof
curb, exiting through the unit’s basepan. Refer to Figure 8 for
the gas piping inlet location. Typical supply piping arrangements are shown in Figures 20 and 21. All pipe nipples, fittings, and the gas cock are field supplied or may be
purchased in UPG accessory kit #1GP0404.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
Gas piping recommendations:
1.
A drip leg and a ground joint union must be installed in
the gas piping.
2.
Where required by local codes, a manual shut-off valve
must be installed outside of the unit.
3.
Use wrought iron or steel pipe for all gas lines. Pipe dope
should be applied sparingly to male threads only.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system
during any pressure testing at pressures in excess
of 1/2 PSIG.
Natural gas may contain some propane. Propane is
an excellent solvent and will quickly dissolve white
lead and most standard commercial compounds. A
special pipe dope must be used when assembling
wrought iron or steel pipe. Shellac based compounds such as Gaskolac or Stalastic, and compounds such as Rectorseal #5, Clydes’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 loose
particles. Before initial start-up, be sure that all 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 prescribed under
“Limitations”.
6.
A 1/8-inch NPT plugged tapping, accessible for test gage
connection, must be installed immediately upstream of
the gas supply connection to the unit.
7.
After the gas connections have been completed, open
the main shut-off valve admitting normal gas pressure to
the mains. Check all joints for leaks with soap solution or
other material suitable for the purpose. NEVER USE A
FLAME.
Unitary Products Group
Pressures greater than 1/2 PSIG will cause gas
valve damage resulting in a hazardous condition. If it
is subjected to a pressure greater than 1/2 PSIG, the
gas valve must be replaced.
The furnace must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than 1/2 PSIG.
LP UNITS, TANKS AND PIPING
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 LP gas with accessory kit model number
1NP0441.
All LP gas equipment must conform to the safety standards of
the National Fire Protection Association.
For satisfactory operation, LP gas pressure must be 10.5
inch W.C. at the unit under full load. Maintaining proper gas
pressure depends on three main factors:
1.
The vaporization rate which depends on the temperature
of the liquid and the “wetted surface” area of the container(s).
25
035-19046-003-A-0804
2.
The proper pressure regulation. (Two-stage regulation is
recommended).
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 appliances.
Complete information regarding tank sizing for vaporization,
recommended regulator settings, and pipe sizing is available
from most regulator manufacturers and LP gas suppliers.
LP gas is an excellent solvent and will quickly dissolve white
lead and most standard commercial compounds. A special
pipe dope must be used when assembling wrought iron or
steel pipe for LP. Shellac base compounds such as Gaskolac
or Stalastic, and compounds such as Rectorseal #5, Clyde’s,
or John Crane may be used.
MOTORIZED OUTDOOR DAMPER
The Motorized Outdoor Damper can be a factory installed
option or a field installed accessory. If factory installed, refer
to the instructions included with the outdoor air hood to complete the assembly. Field installed Motorized Outdoor Dampers accessories include complete instructions for installation.
ECONOMIZER
The Economizer can be a factory installed option or a field
installed accessory. If factory installed, refer to the instructions included with the outdoor air hood to complete the
assembly. Field installed Economizer accessories include
complete instructions for installation.
There are two Economizer options:
1.
Down Flow application with barometric relief hood standard.
2.
Horizontal Flow application that requires the purchase of
a barometric relief hood.
Check all connections for leaks when piping is completed
using a soap solution. NEVER USE A FLAME.
POWER EXHAUST
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
VENT AND COMBUSTION AIR
Venting slots in the heating compartment access panel
remove the need for a combustion air hood. The gas heat
flue exhaust is routed through factory installed exhaust piping
with screen. If necessary, a flue exhaust extension may be
installed at the point of installation.
FACTORY INSTALLED OPTIONS/
FIELD INSTALLED ACCESSORIES
ELECTRIC HEAT
Electric heaters are available as field installed accessories.
Refer to electric heat instructions for installation. These heaters mount in the heat compartment with the heating elements
extending into the supply air chamber. All electric heaters are
fused and intended for use with single point power supply.
26
The Power Exhaust can be a factory installed option or a field
installed accessory. If factory installed, refer to the instructions included with the outdoor air hood to complete the
assembly. Field installed Power Exhaust accessories include
complete instructions for installation.
The Power Exhaust factory installed option is for Down Flow
application only.
There are two field installed Power Exhaust accessories:
1.
Down Flow application.
2.
Horizontal Flow application that requires the purchase of
a barometric relief hood.
RAIN HOOD
The following procedure should be used when assembling a
rain hood onto a unit.
All of the hood components, including the filters, the gasketing and the hardware for assembling, are packaged and
located between the condenser coil section and the main unit
cabinet, if the unit has factory installed options. If field
installed accessories are being installed all parts necessary
for the installation comes in the accessory.
1.
Remove the hood components, filters, gasketing and the
hardware from the box.
2.
Follow the instructions included with the hood to complete the installation.
Unitary Products Group
035-19046-003-A-0804
ECONOMIZER AND POWER EXHAUST SET POINT
ADJUSTMENTS AND INFORMATION
•
Remove the top rear access panel from the unit. Locate the
economizer control module, where the following adjustments
will be made.
POWER EXHAUST DAMPER SET POINT (WITH OR WITHOUT POWER EXHAUST)
Extreme care must be exercised in turning all set
point, maximum and minimum damper positioning
adjustment screws to prevent twisting them off.
•
With no power exhaust option, adjust the Exhaust Air
Adjustment Screw fully clockwise. This will allow 2nd
stage cooling to operate.
•
With power exhaust option, each building pressurization
requirement will be different. The point at which the
power exhaust comes on is determined by the economizer 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.
MINIMUM POSITION ADJUSTMENT
•
•
Check that the damper blades move smoothly with binding; carefully turn the Minimum Position Adjust 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”.
With the thermostat set to the indoor fan ON position or
terminals “R” to “G” energized, turn the Minimum Position Adjusting screw (located on the damper control
module) 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 set point shown in the Enthalpy Set Point Adjustment
Figure 22. 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 Set Point Adjustment
Figure 22.
For a 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 set point, the actuator is allowed
to modulate normally in accordance with the enthalpy and
mixed air sensor inputs. When the AQ signal exceeds it's set
point setting and there is no call for free cooling, the actuator
is proportionately modulated from the 2 to 10 Vdc signal, with
2 Vdc corresponding to full closed and 10 Vdc corresponding
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 set point (Demand Control Ventilation Set Point) setting and there is a call for free cooling,
the actuator modulates from the minimum position to the full
open position based on the highest call from either the mixed
air sensor input or the AQ voltage input.
•
Optional CO2 Space Sensor Kit Part # 2AQ04700324
•
Optional CO2 Sensor Kit Part # 2AQ04700424
Replace the top rear access panel on the unit.
Unitary Products Group
27
035-19046-003-A-0804
CONTROL
CURVE
CONTROL POINT
APPROX. 0F (0C)
AT 50% RH
A
73 (23)
B
C
70 (21)
67 (19)
D
63 (17)
85 90 95 100 105 110
(29) (32) (35) (38) (41) (43)
80
(27)
75
(24)
70
(21)
65
(18)
60
(16)
55
(13)
50
(10)
45
(7)
35
(2)
A
B
C
D
40
(4)
B A
D C
35
(2)
40 45 50 55 60 65 70 75 80 85 90 95 100 105 110
(4) (7) (10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43)
APPROXIMATE DRY BULB TEMPERATURE - 0F (0C)
FIGURE 22 - ENTHALPY SET POINT CHART
Exhaust Air
Adjustment
Screw
Exhaust Air LED
Damper Min.
Position
Screw
Indoor Air Quality
Max. Adjustment
Screw
N1
N
EXH
Set
TR
P1
P
EXH
24
Vac
HOT
T1
T
Min
Pos
IAQ
Max
Indoor Air Quality
LED
AQ1
AQ
IAQ
SO
IAQ
Min
TR1
24
Vac
COM
+
1
2
5
Indoor Air Quality
Min. Adjustment
Screw
Free Cooling LED
SO+
3
4
EF
EF1
Free
Cool
SR+
SR
B
A
C
D
Economizer Enthalpy
Set Point Adjustment
Screw
FIGURE 23 - HONEYWELL ECONOMIZER CONTROL W7212
28
Unitary Products Group
035-19046-003-A-0804
PHASING
A
Predator® Magnum DJ units are properly phased and protected by a Phase Monitor from the factory. If the unit does
not start up, the electrical connection to the unit may be misphased. Check the Phase Monitor for a Red LED, indicating a
misphase. Change the phasing of the Field line connection
at the Factory or Field Supplied Disconnect to obtain a
Green LED on the Phase Monitor. (Scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar suction and discharge pressures, or
producing a high noise level, the scroll is misphased.)
A
C*
* NEVER LOOSEN
A
B
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, or compressor rotate correctly.
SPAN LENGTH
DEFL. FORCE
BLOWER ROTATION
Check for proper supply air blower rotation. If the blower is
rotating backwards, the line voltage at the unit point of power
connection is misphased (See ‘PHASING’).
TABLE 14: SUPPLY AIR LIMITATIONS
Unit
Minimum
Maximum
DJ150
3750
6250
FIGURE 24 - BELT ADJUSTMENT
BELT TENSION
Procedure for adjusting belt tension:
The tension on the belt should be adjusted as shown in Figure 24.
1.
2.
3.
4.
Loosen six nuts (top and bottom) A.
Adjust by turning (B).
Never loosen nuts (C).
Use belt tension checker to apply a perpendicular
force to one belt at the midpoint of the span as
shown. Deflection distance of 4mm (5/32”) is
obtained.
To determine the deflection distance from normal
position, use a straight edge from sheave to sheave
as reference line. The recommended deflection
force is as follows:
Tension new belts at the max. deflection force recommended for the belt section. Check the belt tension at least two times during the first 24 hours of
operation. Any retensioning should fall between the
min. and max. deflection force values.
5. After adjusting retighten nuts (A).
Unitary Products Group
29
035-19046-003-A-0804
TABLE 15: DJ150, 12-1/2 TON STANDARD MOTOR DOWN SHOT BLOWER PERFORMANCE1 2
TURNS OPEN4
ESP3
0
1
2
3
4
5
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
0.4
5078
3630
3.89
4809
3103
3.33
4594
3053
3.27
4360
2478
2.66
4090
2093
2.24
3812
1798
1.93
0.6
4865
3456
3.71
4584
2961
3.17
4349
2912
3.12
4106
2318
2.49
3814
1964
2.11
-
-
-
0.8
4642
3284
3.52
4356
2828
3.03
4089
2776
2.98
3840
2137
2.29
-
-
-
-
-
-
1.0
4408
3114
3.34
4124
2705
2.90
3815
2647
2.84
-
-
-
-
-
-
-
-
-
1.2
4164
2947
3.16
3889
2592
2.78
-
-
-
-
-
-
-
-
-
-
-
-
1.4
3910
2787
2.99
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1.
Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.
2.
Blower performance includes two-inch throwaway filters.
3.
ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been
deducted from the total static pressure of the blower.
4.
“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.
5.
W = Watts
TABLE 16: DJ150, 12-1/2 TON OPTIONAL MOTOR DOWN SHOT BLOWER PERFORMANCE1 2
TURNS OPEN4
ESP3
0
1
2
3
4
5
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
0.4
5994
5400
5.79
5565
4369
4.69
5488
4169
4.47
5264
3599
3.86
4990
3085
3.31
4738
2812
3.02
0.6
5824
5216
5.59
5368
4186
4.49
5289
3991
4.28
5049
3437
3.69
4763
2937
3.15
4491
2655
2.85
0.8
5641
5022
5.39
5170
4012
4.30
5076
3807
4.08
4822
3272
3.51
4528
2790
2.99
4235
2497
2.68
1.0
5444
4819
5.17
4971
3846
4.12
4847
3618
3.88
4584
3103
3.33
4286
2644
2.83
3969
2340
2.51
1.2
5233
4609
4.94
4771
3687
3.95
4604
3426
3.67
4335
2933
3.15
4035
2499
2.68
-
-
-
1.4
5009
4394
4.71
4571
3537
3.79
4346
3233
3.47
4074
2762
2.96
3777
2356
2.53
-
-
-
1.6
4771
4174
4.48
4370
3395
3.64
4074
3040
3.26
3802
2590
2.78
-
-
-
-
-
-
1.8
4520
3951
4.24
4169
3262
3.50
3786
2850
3.06
-
-
-
-
-
-
-
-
-
2.0
4255
3728
4.00
3966
3137
3.36
-
-
-
-
-
-
-
-
-
-
-
-
2.2
3976
3505
3.76
3763
3020
3.24
-
-
-
-
-
-
-
-
-
-
-
-
30
1.
Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.
2.
Blower performance includes two-inch throwaway filters.
3.
ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been
deducted from the total static pressure of the blower.
4.
“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.
5.
W = Watts
Unitary Products Group
035-19046-003-A-0804
TABLE 17: DJ150, 12-1/2 TON STANDARD MOTOR SIDE SHOT BLOWER PERFORMANCE1 2
TURNS OPEN4
ESP3
0
1
2
3
4
5
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
CFM
W5
BHP
0.4
-
-
-
-
-
-
5201
3162
3.39
4966
2796
3.00
4681
2405
2.58
4355
2054
2.20
0.6
-
-
-
5220
3395
3.64
4942
2980
3.20
4657
2608
2.80
4358
2230
2.39
4007
1890
2.03
0.8
-
-
-
4944
3194
3.43
4661
2806
3.01
4378
2572
2.76
4016
2057
2.21
-
-
-
1.0
5003
3490
3.74
4647
2988
3.20
4380
2636
2.83
4030
2257
2.42
-
-
-
-
-
-
1.2
4724
3290
3.53
4363
2875
3.08
4012
2505
2.69
-
-
-
-
-
-
-
-
-
1.4
4428
3040
3.26
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1.
Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.
2.
Blower performance includes two-inch throwaway filters.
3.
ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been
deducted from the total static pressure of the blower.
4.
“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.
5.
W = Watts
TABLE 18: DJ150, 12-1/2 TON OPTIONAL MOTOR SIDE SHOT BLOWER PERFORMANCE1 2
TURNS OPEN4
ESP3
0
1
CFM
W5
BHP
CFM
W5
2
3
4
CFM
W5
BHP
CFM
W5
BHP
BHP
CFM
W5
BHP
0.4
-
-
-
6447
5315
5.1046
5966
4205
4.51
5717
3716
3.98
5470
3307
3.55
0.6
-
-
-
6110
0.8
-
-
-
5772
4464
4.79
5740
4023
4.31
5430
3501
3.75
5126
3054
3.28
4274
4.58
5503
3821
4.10
5162
3294
3.53
4849
2870
3.08
1.0
6235
5521
5.92
5474
4048
4.34
5244
3611
3.87
4882
3101
3.33
4530
2667
2.86
1.2
5881
5137
4.51
5248
3854
4.13
4941
3387
3.63
4589
2906
3.12
4225
2502
2.68
1.4
5695
1.6
5471
3996
4.29
5014
3670
3.94
4651
3178
3.41
4284
2716
2.91
3858
2280
2.45
3828
4.11
4732
3460
3.71
4365
2983
3.20
3951
2516
2.70
3491
2058
2.21
1.8
4656
3611
3.87
4438
3240
3.47
3998
2740
2.94
3618
2316
2.48
-
-
-
4.54
4339
3380
3.62
3905
2861
3.07
3631
2497
2.68
-
-
-
-
-
-
3934
4.22
4022
3149
3.38
-
-
-
-
-
-
-
-
-
-
-
-
3637
3.90
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3340
3.58
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
CFM
W5
BHP
5.70
6207
4760
4917
5.27
5965
4519
4.85
5741
5628
4407
4.73
5.51
5384
4205
4950
5.31
5123
4728
5.07
4919
5242
4514
4.84
2.0
4954
4231
2.2
4585
2.4
4217
2.6
3848
5
1.
Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.
2.
Blower performance includes two-inch throwaway filters.
3.
ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been
deducted from the total static pressure of the blower.
4.
“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.
5.
W = Watts
NOTES FOR TABLE 15 THROUGH TABLE 18:
•
•
Blower performance includes dry coil and two-inch
filters.
Blower performance for gas heat includes the maximum
number of heat tubes available for each tonnage.
Unitary Products Group
•
ESP (External Static Pressure) given is that available for
the supply and return air duct system. All internal resistances have been deducted from the total static pressure
of the blower.
31
035-19046-003-A-0804
TABLE 19: INDOOR BLOWER SPECIFICATIONS
MODEL
DJ150
HP
RPM
3
5
1725
1725
MOTOR
Eff.
SF
80%
87%
1.15
1.15
Frame
56
184T
MOTOR SHEAVE
Datum Dia. (in.) Bore (in.)
3.4 - 4.4
4.3 - 5.3
Model
7/8
1 1/8
BLOWER SHEAVE
Datum Dia. (in.) Bore (in.)
1VM50
1VP56
7.0
6.7
1
1
Model
AK74
BK77
BELT
A54
BX55
TABLE 20: POWER EXHAUST SPECIFICATIONS
POWER EXHAUST
MODEL
VOLT
PHASE
2PE0473125
2PE0473146
2PE0473158
208/230
460
575
1
1
1
1.
MOTOR
ELECTRICAL
RPM1
HP
QTY
1075
0.75
1
1050
LRA
FLA
MCA
FUSE
SIZE
[email protected]
0.1 ESP
24.9
5.0
2.2
1.5
6.3
2.8
1.9
10
5
4
3,800
N/A
Motors are multi-tapped and factory wired for high speed.
AIR BALANCE
Start the supply air blower motor. Adjust the resistances in both the supply and the return air duct systems 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.
CHECKING AIR QUANTITY
METHOD ONE
METHOD TWO
1.
Remove the dot plugs from the duct panel (for location of
the dot plugs see Figure 9).
1.
2.
Insert eight-inches of 1/4 inch metal tubing into the airflow on both sides of the indoor coil.
Drill two 5/16 inch holes, one in the return air duct as
close to the inlet of the unit as possible, and another in
the supply air duct as close to the outlet of the unit as
possible.
2.
Insert eight inches of 1/4 inch metal tubing into the airflow of both return and supply air ducts of the unit.
NOTE: The tubes must be inserted and held in a position
perpendicular to the air flow so that velocity pressure will not affect the static pressure readings.
3.
Use an Inclined Manometer or Magnehelic to determine
the pressure drop across a dry evaporator coil. Since the
moisture on an evaporator coil can vary greatly, measuring the pressure drop across a wet coil under field conditions could be inaccurate. To assure a dry coil, the
compressors should be de-activated while the test is
being run.
NOTE: The tubes must be inserted and held in position perpendicular to the airflow so that velocity pressure
will not affect the static pressure readings.
3.
Use an Inclined Manometer or Magnehelic to determine
the pressure drop across the unit. This is the External
Static Pressure (ESP).
4.
Select the indoor blower specifications for the unit from
Table 19, 3 or 5 H.P. Motor.
NOTE: De-energize the compressors before taking any test
measurements to assure a dry evaporator coil.
5.
Determine the number of turns the variable pitch motor
sheave is open.
4.
The CFM through the unit with clean 2 inch filters can be
determined from the pressure drop indicated by the
manometer by referring to Figure 25.
6.
Select the correct blower performance table for the unit
from Tables 15 - 18.
7.
5.
To adjust Measured CFM to Required CFM, see ’SUPPLY AIR DRIVE ADJUSTMENT’.
Determine the unit Measured CFM from the Blower Performance Table, External Static Pressure and number of
turns the variable pitch motor sheave is open.
6.
After adjustments have been completed, remove the
tubes and replace the dot plugs.
8.
To adjust Measured CFM to Required CFM, see ’SUPPLY AIR DRIVE ADJUSTMENT’.
9.
After adjustments have been completed, remove the
tubes and seal holes.
Failure to properly adjust the total system air quantity can result in extensive blower damage.
NOTE: With the addition of field installed accessories
repeat this procedure.
Failure to properly adjust the total system air quantity can result in extensive blower damage.
32
Unitary Products Group
035-19046-003-A-0804
Predator DJ 150 Units
Indoor Coil Pressure Drop vs. Airflow
1
0.9
Dry Coil Delta P (IWG)
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
3500
4000
4500
5000
5500
6000
6500
Airflow (CFM)
FIGURE 25 - DRY COIL DELTA P
SUPPLY AIR DRIVE ADJUSTMENT
EXAMPLE
A 12.5 ton unit was selected to deliver 4,000 CFM with a 3
HP motor, but the unit is delivering 3,800 CFM. The variable
pitch motor sheave is set at 2 turns open.
Before making any blower speed changes review
the installation for any installation errors, leaks or
undesirable systems effects that can result in loss of
airflow.
Even small changes in blower speed can result in
substantial changes in static pressure and BHP.
BHP and AMP draw of the blower motor will
increase by the cube of the blower speed. Static
pressure will increase by the square of the blower
speed. Only qualified personnel should make blower
speed changes, strictly adhering to the fan laws.
At unit start-up, the measured CFM may be higher or lower
than the required CFM. To achieve the required CFM, the
speed of the drive may have adjusted by changing the datum
diameter (DD) of the variable pitch motor sheave as
described below:
Required CFM
• Existing DD = New DD
( Measured
CFM )
Use the equation to determine the required DD for the new
motor sheave,
CFM • 4.0 in. = 4.21 in.
( 4,000
3,800 CFM )
Use Table 22 to locate the DD nearest to 4.21 in. Close the
sheave to 1 turn open.
New BHP
3
= (Speed increase) • BHP at 3,800 CFM
3
= (Speed increase) • Original BHP
= New BHP
New motor Amps
3
= (Speed increase) • Amps at 3,800 CFM
Use the following tables and the DD calculated per the above
equation to adjust the motor variable pitch sheave.
3
= (Speed increase) • Original Amps
= New Amps
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33
035-19046-003-A-0804
TABLE 21: ADDITIONAL STATIC RESISTANCE
Cooling Only1
Economizer2 3
18
24
36
54
3700
0.20
0.04
0.18
0.21
0.22
0.26
3900
0.23
0.04
0.20
0.23
0.24
0.28
4100
0.25
0.04
0.22
0.25
0.26
0.31
4300
0.28
0.05
0.24
0.28
0.29
0.34
4500
0.30
0.05
0.26
0.30
0.31
0.37
4700
0.33
0.05
0.29
0.33
0.34
0.40
4900
0.36
0.05
0.31
0.35
0.37
0.43
5100
0.39
0.06
0.34
0.38
0.40
0.46
5300
0.42
0.06
0.37
0.41
0.43
0.49
5500
0.45
0.06
0.40
0.44
0.46
0.53
5700
0.48
0.06
0.43
0.47
0.49
0.56
5900
0.52
0.07
0.46
0.50
0.53
0.59
6100
0.56
0.07
0.49
0.53
0.56
0.62
6300
0.60
0.07
0.53
0.56
0.59
0.65
1.
Add these resistance values to the available static resistance in the respective Blower Performance Tables.
2.
Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.
3.
The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return
air duct system is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation.
TABLE 22: MOTOR SHEAVE DATUM DIAMETERS
1VM50x7/8
(3 HP Motor)
1VP56x1-1/8
(5 HP Motor)
Turns Open
Datum
Diameter
Turns Open
Datum
Diameter
0
4.4
1
5.3
1/2
4.3
1-1/2
5.2
1
4.2
2
5.1
1-1/2
4.1
2-1/2
5.0
2
4.0
3
4.9
2-1/2
3.9
3-1/2
4.8
3
3.8
4
4.7
3-1/2
3.7
4-1/2
4.6
4
3.6
5
4.5
4-1/2
3.5
5-1/2
4.4
5
3.4
6
4.3
OPERATION
SEQUENCE OF OPERATIONS OVERVIEW
For the Predator® Magnum series of units, the thermostat
makes a 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 operation is available and,
if so, which components to energize.
34
Electric Heat KW2
CFM
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 delay.
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 completion of a call for cooling.
Heating always takes priority.
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 energized 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.
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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. The UCB energizes the economizer (if installed and
free cooling is available) or the first available compressor*
and the condenser fans. For first stage cooling, compressor
#1 is energized. If compressor #1 is unavailable, compressor
#2 is energized. After completing the specified fan on delay
for cooling, the UCB will energize the blower motor.
When the thermostat calls for the second stage of cooling,
the low-voltage control circuit from “R” to “Y2” is completed.
The control board energizes the first available compressor. If
free cooling is being used for the first stage of cooling, compressor #1 is energized. If compressor #1 is active for first
stage cooling or the first compressor is locked-out, compressor #2 is energized. In free-cooling mode, if the call for the
second stage of cooling continues for 20 minutes, compressor #2 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 seconds in order to
avoid a power rush.
Once the thermostat has been satisfied, the it will de-energize
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 following 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" cooling, 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 dampers from fully closed to their minimum position. If the enthalpy of the outdoor air is below the
set point of the enthalpy controller (previously determined),
"Y1" energizes the economizer. The dampers will modulate to
maintain a constant supply air temperature as monitored by
the discharge air sensor. If the outdoor air enthalpy is above
the set point, "Y1" energizes compressor #1, condenser fan
motor #1, and condenser fan motor #2 (if the ambient temperature 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 set point of the enthalpy controller
(i.e. first stage has energized the economizer), "Y2" will energize compressor #1. If the outdoor air is above the set point,
"Y2" will energize compressor #2.
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Once the thermostat has been satisfied, it will de-energize 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 following 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 identical to
the single sensor except that a second enthalpy sensor is
mounted in the return air. This return air sensor allows the
economizer to choose between outdoor air and return air,
whichever has the lowest enthalpy value, to provide maximum operating efficiency.
ECONOMIZER (SINGLE OR DUAL) 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 set point 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 compressor,
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 conclusion of the ASCD, the
UCB 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 associated compressor and flash a code (see Table 29). If the other compressor is inactive, the condenser fans will be de-energized.
35
035-19046-003-A-0804
LOW-PRESSURE LIMIT SWITCH
SAFETY CONTROLS
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-pressure switch fails to
close after the 30-second monitoring phase, the UCB will deenergize the associated compressor, initiate the ASCD, and,
if the other compressor is idle, stop the condenser fans.
The unit control board monitors the following inputs for each
cooling system:
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 compressor.
Should a low-pressure switch open three times within one
hour of operation, the UCB will lock-out the associated compressor and flash a code (Table 29). If the other compressor
is inactive, the condenser fans will be de-energized.
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 excessive discharge pressures due to a blocked condenser 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 7 ± 3 psig and resets at 22 ± 5 psig).
The above pressure switches are hard-soldered to the unit.
The refrigeration systems are independently monitored and
controlled. On any fault, only the associated system will be
affected by any safety/preventive action. 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.
FREEZESTAT
During cooling operation, if a freezestat opens, 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 compressor.
Should a freezestat open three times within two hours of
operation, the UCB will lock-out the associated compressor
and flash a code (Table 29). If the other compressor 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 temperature-activated
switch set at 45ºF. When the low ambient 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 minimum run time.
When operating in low ambient mode, the UCB will not lockout the compressors due to a freezestat trip. However, a
freezestat 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.
36
COMPRESSOR PROTECTION
The compressors also have inherent (internal) protection. If
there is an abnormal temperature rise in a compressor, the
protector will open to shut down the compressor. The UCB
incorporates features to minimize compressor wear and damage. An anti-short cycle delay (ASCD) is utilized to prevent
operation of a compressor too soon after its previous run.
Additionally, a minimum run time is imposed any time a compressor is energized.
The ASCD is initiated on unit start-up and on any compressor
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 29.
RESET
Remove the call for cooling, by raising thermostat setting
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.
Two-stage heating:
a.
Upon a call for first stage heat by the thermostat, the
heater relay (RA) will be energized. After completing
the specified fan on delay for heating, the UCB will
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035-19046-003-A-0804
energize the blower motor. If the second stage of
heat is required, heater relay (RB) 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.
FLASH CODES
The UCB will initiate a flash code associated with errors
within the system. Refer to UNIT CONTROL BOARD FLASH
CODES Table 29.
RESET
Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature.This
resets any flash codes.
ELECTRIC 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 status, 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 29).
SAFETY CONTROLS
The UCB monitors the temperature limit switch of electric
heat units.
ELECTRIC 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 lowering of the temperature within the
conditioned space. Refer to Table 24 for the required electric
heat anticipator setting.
TABLE 24: ELECTRIC HEAT ANTICIPATOR
SETPOINTS
SETTING (AMPS)
The control circuit includes the following safety controls:
W1
W2
LIMIT SWITCH (LS)
0.13
0.1
This control is located inside the heater compartment and is
set to open at the temperature indicated in the Electric Heat
Limit Setting Table 23. 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.
TABLE 23: ELECTRIC HEAT LIMIT SETTING
UNIT (TONS)
VOLTAGE
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
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208/230
480
600
HEATER
kW
LIMIT
SWITCH
OPENS °F
18
24
34
54
18
24
34
54
18
24
34
54
150
150
150
150
150
150
150
150
150
150
150
150
GAS HEATING SEQUENCE OF OPERATIONS
When the thermostat calls for the first stage of heating, the
low-voltage control circuit from “R” to “W1” is completed. 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 by monitoring the gas valve (GV). Once voltage has been sensed at the GV, the UCB will initiate the fan
on delay for heating, energizing the indoor blower the specified delay has elapsed.
When the thermostat has been satisfied, heating calls are
ceased. The GV is immediately closed. The blower is deenergized after the fan off delay for heating has elapsed. The
draft motor performs a 30-second post purge.
IGNITION CONTROL BOARD
FIRST STAGE OF HEATING
When the ICB receives a call for first stage of heating, “W1,”
the draft motor is energized. Once the draft motor has been
proven, a 30-second purge is initiated. At the end of the
purge, both main valves of the GV are opened, and the spark
ignitor is energized for 10 seconds. The ICB then checks for
the presence of flame. If flame is detected, the ICB enters a
flame stabilization period. If flame was not detected, both
main valves close, and a retry operation begins.
37
035-19046-003-A-0804
During the flame stabilization period, a loss of the flame for 2
seconds will cause the main valves to close and the retry
operation to begin. After the flame stabilization period, a loss
of flame for 3/4 second will cause the main valves to close
and the retry operation to begin.
At the conclusion of the flame stabilization period, the ICB will
operate the gas heat in high fire (both valves open) for an
additional 100 seconds (for a total for 120 seconds of high fire
operation). After this 100 seconds, the ICB will then use the
call for the second stage of heat to control the second main
valve of the GV.
When “W1” is satisfied, both valves are closed.
SECOND STAGE OF HEATING
When the ICB receives a call for the second stage of heating,
“W2,” the ICB conducts a complete first stage ignition
sequence. If this sequence is satisfied, the second main
valve of the GV is opened.
If the temperature limit opens three times within one hour, it
will lock-on the indoor blower motor and flash code is initiated
(See Table 29).
FLAME SENSE
Flame sensing occurs at all times. If “W1” is not present and
a flame is sensed for 2 seconds, the draft motor is energized
and the main valve is kept off. The ICB halts any operation
until a flame is not detected. Once the flame detection is lost,
the ICB performs a post-purge. Normal operation is allowed
concurrently with the purge (i.e. this purge can be considered
the purge associated with a call for “W1”).
If “W1” is present, a flame is sensed, but the main valve is not
energized, the draft motor is energized until the flame detection is lost. Normal operation is now allowed.
When “W2” is satisfied, the second main valve is closed.
The flame detection circuitry continually tests itself. If the ICB
finds the flame detection circuitry to be faulty, the ICB will not
permit an ignition sequence. Also, the draft motor is energized. If this failure should occur during an ignition cycle the
failure is counted as a recycle.
RETRY OPERATION
GAS VALVE
When a flame is lost or is not detected during an attempt to
achieve ignition, a retry operation occurs. A 30-second purge
is performed between ignition attempts.
The UCB and ICB continuously monitor the GV.
If the unit fails after three ignition attempts, the furnace is
locked-out for one hour. The furnace is monitored during this
one-hour period for unsafe conditions.
RECYCLE OPERATION
When a flame is lost after the flame stabilization period, a
recycle operation occurs. If the unit fails after five recycle
attempts, the furnace is locked-out for one hour.
GAS HEATING OPERATION ERRORS
LOCK-OUT
A one-hour lockout occurs following three retries or five recycles. During the one-hour lockout, flame detection, limit conditions, and main valves are tested. Any improper results will
cause the appropriate action to occur. Recycling the low voltage power cancels the lock-out.
TEMPERATURE LIMIT
If the UCB senses zero volts from the high temperature limit,
the indoor blower motor is immediately energized. When the
UCB again senses 24 volts from the temperature limit, the
draft motor will perform a 15-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 status, i.e.
this limit is monitored at all time.
38
If the ICB senses voltage at the GV when not requested, the
ICB will energize the draft motor. The ICB will not operate the
furnace until voltage is no longer sensed at the GV. The draft
motor is stopped when voltage is not sensed at 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 29).
When voltage is no longer sensed at the GV, the UCB will deenergize the indoor blower following 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.
During a call for heat, if the UCB does not sense voltage at
the GV for a continuous five-minute period the UCB will initiate a flash code (Table 29). The indoor blower motor will not
be locked-on while there is no GV voltage.
However, if during a normal ignition sequence, the NPC has
been tested to be open, IDM energized, NPC closes and then
the first stage main valve (MV1) is detected as being on, the
ignition sequence stops and the IDM is de-energized. (Since
the NPC is wired serially with the main valve relays, de-energizing the IDM will open the NPC). This failure is counted as
a recycle and will result in an eventual recycle lockout. If the
main valve continues to be energized after the IDM is deenergized the IDM is re-energized. The second stage (MV2)
main valve is not monitored for closure after energization.
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035-19046-003-A-0804
SAFETY CONTROLS
ROLLOUT SWITCH (ROS)
The UCB monitors the temperature limit switch of gas heat
units.
The rollout switch is wired in series with the pressure switch.
As such, the ICB cannot distinguish the rollout switch operation from that of the pressure switch.
The control circuit includes the following safety controls:
Consequently, the control will only respond in the same manner as outlined above under “Pressure Switch”. An open rollout will inhibit the gas valve from actuating.
LIMIT SWITCH (LS)
This control is located inside the gas heat compartment and
is set to open at the temperature indicated in the Gas Heat
Limit Control Settings Table 25. 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.
INTERNAL MICROPROCESSOR FAILURE
If the ICB detects an internal failure, it will turn cease all outputs, ignore inputs, and display the proper flash code for control replacement. The ICB remains in this condition until
replaced.
AUXILIARY LIMIT SWITCH (ALS)
FLASH CODES
This control is located inside the supply air compartment and
is set to open at the temperature indicated in the Gas Heat
Limit Control Settings Table 25. It resets manually. 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.
The UCB will initiate a flash code associated with errors
within the system. Refer to UNIT CONTROL BOARD FLASH
CODES Table 29.
The auxiliary limit switch is wired in series with the limit
switch. As such, the UCB cannot distinguish the auxiliary limit
and the gas heat limit switch operation except the auxiliary is
manual reset. Consequently, the control will respond in the
same manner as outlined above under “Limit Switch”.
1
TABLE 25: GAS HEAT LIMIT CONTROL SETTINGS
# of HX Tubes
Main Limit Setting
6
195°F
8
160°F
1.
Rollout = 300°F, Auxiliary Limit = 200°F
RESETS
Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature. This
resets any flash codes.
GAS 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 lowering of the temperature within the
conditioned space. Refer to Table 26 for the required gas
heat anticipator setting.
TABLE 26: GAS HEAT ANTICIPATOR SETPOINTS
SETTING (AMPS)
The ICB monitors the Pressure and Rollout switches of gas
heat units.
The control circuit includes the following safety controls:
W1
W2
0.65
0.1
PRESSURE SWITCH (PS)
Once the draft motor has reached full speed and closes the
pressure switch during a normal ignition sequence, if the
pressure sw opens for 2 seconds, the GV will be de-energized, the ignition cycle is aborted, and the ICB flashes the
appropriate code. See Table 30 Ignition Control Flash Codes.
The draft motor is energized until the pressure switch closes
or “W1” is lost.
H E A T E X C H A N G E R T U B E
G A S
S U P P L Y
B U R N E R
P IP E
B U R N E R B R A C K E T
B U R N E R F L A M E
(B L U E O N L Y )
IG N IT O R
FIGURE 26 - TYPICAL FLAME
Unitary Products Group
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035-19046-003-A-0804
START-UP (COOLING)
OPERATING INSTRUCTIONS
PRESTART CHECK LIST
After installation has been completed:
This furnace is equipped with an intermittent pilot and
automatic re-ignition system. DO NOT attempt to
manually light the pilot.
1.
Check the electrical supply voltage being supplied. Be
sure that it is the same as listed on the unit nameplate.
2.
Set the room thermostat to the off position.
3.
Turn unit electrical power on.
LIGHTING THE MAIN BURNERS
4.
Set the room thermostat fan switch to on.
1.
Turn “OFF” electric power to unit.
5.
Check indoor blower rotation.
2.
Turn room thermostat to lowest setting.
•
If blower rotation is in the wrong direction. Refer to
Phasing Section in general information section.
3.
Turn gas valve counter-clockwise to “ON” position (see
Figure 27).
•
Check blower drive belt tension.
4.
Turn “ON” electric power to unit.
5.
If thermostat set temperature is above room temperature, the main burners will ignite. If a second stage of
heat is called for, the main burners for second stage heat
will ignite for the second stage heat.
6.
Check the unit supply air (CFM).
7.
Measure evaporator fan motor's amp draw.
8.
Set the room thermostat fan switch to off.
9.
Turn unit electrical power off.
OPERATING INSTRUCTIONS
1.
Turn unit electrical power on.
NOTE: Prior to each cooling season, the crankcase heaters
must be energized at least 10 hours before the system is put into operation.
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.
POST START CHECKLIST
After the entire control circuit has been energized and the
heating section is operating, make the following checks:
1.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
The second stage of the thermostat will energize second
stage compressor if needed.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
POST START CHECK LIST
1.
Verify proper system pressures for both circuits.
2.
Measure the temperature drop across the evaporator
coil.
2.
Check for correct manifold gas pressures. (See ’CHECKING GAS INPUT’.)
3.
Check the supply gas pressure. It must be within the limits shown on the rating nameplate. Supply pressure
should be checked with all gas appliances in the building
at full fire. At no time should the standby gas pressure
exceed 13 in. or the operating pressure drop below 5.0 in
for natural gas units. If gas pressure is outside these
limits, contact the local gas utility or propane supplier for
corrective action.
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 it is
the same as listed on the unit nameplate.
2.
Make sure that the vent outlet and combustion air inlet
are free of any debris or obstruction.
40
Check for gas leaks in the unit piping as well as the supply piping.
Unitary Products Group
035-19046-003-A-0804
SHUT DOWN
1.
Set the thermostat to the lowest temperature setting.
2.
Turn “OFF” all electric power to unit.
3.
Open gas heat access panel.
4.
Turn gas valve clockwise to “OFF” position (See Figure 27).
furnace. The intended input for each furnace is shown in the
table below. The following Table applies to units operating on
60 Hz power only.
TABLE 27: GAS HEAT STAGES
MANIFOLD GAS PRESSURE ADJUSTMENT
This gas furnace has two heat stages. Therefore, the gas
valve has two adjustment screws located under a plastic protective cover. The second stage (100% input) adjustment
screw is adjacent to the “HI” marking on the valve and the
first stage (60% input) adjustment screw is located adjacent
to the “LO” marking on the valve (See Figure 27).
# of Burner Tubes
2nd Stage
Input (100%
Btuh)
1st Stage
Input (60%
Btuh)
6
180,000
108,000
8
240,000
144,000
To determine the rate of gas flow (second Stage).
1.
Turn of all other gas appliances connected to the gas
meter.
Manifold pressure adjustment procedure.
2.
Turn on the furnace and make sure the thermostat is
calling for Second stage (100% input) heat.
Adjust second stage (100% input) pressure first, then adjust
first stage (60% input) pressure.
3.
Measure the time needed for one revolution of the hand
on the smallest dial on the meter. A typical gas meter
has a 1/2 or a 1 cubic foot test dial.
4.
Using the number of seconds it takes for one revolution
of the dial, calculate the cubic feet of gas consumed per
hour. (See example below).
5.
If necessary, adjust the high pressure regulator as discussed in the section “Manifold Gas Pressure Adjustment”. Be sure not to over-fire the furnace on Second
stage. If in doubt, it is better to leave the Second stage of
the furnace slightly under-fired. Repeat Steps 1-5.
1.
Turn off all power to the unit.
2.
Using the outlet pressure port on the gas valve, connect
a manometer to monitor the manifold pressure.
3.
Remove plastic cap covering HI and LO pressure adjustment screws.
4.
Turn on power to the unit.
5.
Set thermostat to call for second stage heat and start furnace.
6.
If necessary, using a screwdriver, turn the second stage
adjustment screw (adjacent to the “HI” marking on the
valve) clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure. Be sure not
to over-fire the unit on second stage.
7.
8.
9.
After the high manifold pressure has been checked,
adjust the thermostat to call for first stage heat.
If necessary, using a screwdriver, turn the first stage
adjustment screw (adjacent to the “LO” marking on the
valve) clockwise to increase manifold pressure or
counterclockwise to decrease manifold pressure. Be
sure not to under-fire the unit on first stage.
Once pressure has been checked, replace the plastic
cap covering the HI and LO pressure adjustment screws.
NOTE: When using natural gas, the manifold pressure for
second stage (100% input) should be 3.5 IWG ± 0.3.
The manifold pressure for first stage (60% input)
when using natural gas should be 1.5 IWG ± 0.3.
CHECKING GAS INPUT
NATURAL GAS
To determine the rate of gas flow (First Stage)
1.
Turn of all other gas appliances connected to the gas
meter.
2.
Turn on the furnace and make sure the thermostat is
calling for first stage (60% input) heat.
3.
Even when the thermostat is calling for first stage heat,
the unit will light on second stage and will run on Second
stage for 1 minute. Allow this one-minute time period to
expire and be certain the unit is running on first stage.
4.
Measure the time needed for one revolution of the hand
on the smallest dial on the meter. A typical gas meter
has a 1/2 or a 1 cubic foot test dial.
5.
Using the number of seconds it takes for one revolution
of the dial, calculate the cubic feet of gas consumed per
hour (See example below).
6.
If necessary, adjust the low pressure regulator as discussed in the section “Manifold Gas Pressure Adjustment”. Be sure not to under-fire the furnace on first
stage. If in doubt, it is better to leave the first stage of the
furnace slightly over-fired (greater than 60% input).
Repeat Steps 1-6.
This unit has two stages of gas heat. The first stage is 60% of
the full fire input and is considered the minimum input for the
Unitary Products Group
41
035-19046-003-A-0804
TABLE 28: GAS RATE CUBIC FEET PER HOUR
Seconds
for One
Rev.
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
180
150
129
113
100
90
82
75
69
64
60
56
53
50
47
45
43
41
39
37
36
35
34
32
31
30
360
300
257
225
200
180
164
150
138
129
120
113
106
100
95
90
86
82
78
75
72
69
67
64
62
60
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 as it varies widely from
area to area).
After about 20 minutes of operation, determine the furnace
temperature rise. Take readings of both the return air and the
heated air in the ducts (about 6 feet from the furnace) where
they will not be affected by radiant heat. Increase the blower
CFM to decrease the temperature rise; decrease the blower
CFM to increase the rise (See ’SUPPLY AIR DRIVE
ADJUSTMENT’).
NOTE: Each gas heat exchanger size has a minimum
allowable CFM. Below this CFM, the limit will open
below this rating.
BURNERS/ORIFICES INSPECTION/SERVICING
Before checking or changing burners, pilot or orifices,
CLOSE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF
ALL POWER TO THE UNIT.
1.
Open the union fitting just upstream of the unit gas valve
and downstream from the main manual shut-off valve in
the gas supply line.
2.
Remove the screws holding each end of the manifold to
the manifold supports.
3.
Disconnect wiring to the gas valves and spark igniter(s).
Remove the manifold & gas valve assembly. Orifices can
now be inspected and/or replaced.
To service burners, complete step 4.
4.
Remove the heat shield on top of the manifold supports.
Burners are now accessible for inspection and/or
replacement.
NOTE: Reverse the above procedure to replace the assemblies.
Make sure that burners are level and seat at the rear of the
gas orifice.
H IG H & L O W
EXAMPLE:
By actual measurement, it takes 19 seconds for the hand on
a 1 cubic foot dial to make a revolution with a 192,000 Btuh
furnace running. To determine rotations per minute, divide
60 by 19 = 3.16. To calculate rotations per hour, multiply
3.16 x 60 = 189.6. Multiply 189.6 x 1 (0.5 if using a 1/2 cubic
foot dial) = 189.6. Multiply 189.6 x (the Btu rating of the
gas). For this example, assume the gas has a Btu rating of
1050 Btu/ft.3. The result of 199,000 Btuh is within 5% of the
192,000 Btuh rating of the furnace.
H I
G A S A D J U S T M E N T
L O
O N
IN L E T
P R E S S U R E
T A P
O F F
O U T L E T
P R E S S U R E
T A P
M A T E -N -L O C K
C O N N E C T O R S
ADJUSTMENT OF TEMPERATURE RISE
The temperature rise (the difference of temperature between
the return air and the heated air from the furnace) must lie
within the range shown on the CSA rating plate and the data
in Table 26.
M V
C
H I
After the temperature rise has been determined, the CFM can
be calculated as follows:
CFM = Btu Input x
42
0.8
(1.08 x ∆°F)
FIGURE 27 - TYPICAL GAS VALVE
Unitary Products Group
035-19046-003-A-0804
CHARGING THE UNIT
330
115 °F Outdoor
Discharge Pressure (psig)
310
290
105 °F Outdoor
270
250
95 °F Outdoor
230
85 °F Outdoor
210
190
75 °F Outdoor
170
65°F Outdoor
150
70
75
80
85
90
95
Suction Pressure (psig)
FIGURE 28: CHARGING CHART
TROUBLESHOOTING
Label all wires prior to disconnection when servicing
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.
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 terminals.
When not necessary, shut off all electric power to the
unit prior to any of the following maintenance procedures so as to prevent personal injury.
Unitary Products Group
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035-19046-003-A-0804
PREDATOR® MAGNUM FLASH CODES
Various flash codes are utilized by the unit control board
(UCB) to aid 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.
Current alarms are flashed on the UCB LED. The alarm history can be checked by pressing and releasing the ALARMS
button on the UCB. The UCB will cycle through the last five
(5) alarms, most recent to oldest, separating each alarm flash
code by approximately 2 seconds.
In some cases, it may be necessary to “zero” the ASCD for
the compressors in order to perform troubleshooting. To reset
all ASCDs for one cycle, press and release the UCB TEST
button once.
TABLE 29: UNIT CONTROL BOARD FLASH CODES
Flash Code
On Steady
Control Failure - Replace Control
Normal Operation
Control waiting ASCD1
3 Flashes
HPS1 - Compressor Lock out
4 Flashes
HPS2 - Compressor Lock out
5 Flashes
LPS1 - Compressor Lock out
6 Flashes
LPS2 - Compressor Lock out
7 Flashes
FS1 - Compressor Lock out
8 Flashes
FS2 - Compressor Lock out
9 Flashes
Ignition Control Locked Out/
Ignition Control Failure / Limit Switch Trip / No
Jumper Plug in Heat Section
11 Flashes
44
Control Failure
HEARTBEAT
Normal Operation
Control
1
Not Applicable
2
Pressure Switch
Stuck Closed
Pressure Switch
3
Pressure Switch Failed
To Close
Venter Pressure Switch
Vent Blocked
4
Limit Switch Open
Main Limit
AUX Limit
5
Flame Present With Gas
Off First Stage Gas Valve
Energized With W1 Off
Second Stage Gas Valve
Energized With First
Stage
Gas Valve Off
Gas Valve
6
Ignition Lockout
Gas Flow
Gas Pressure
Gas Valve
Flame Sensor
No Power Or Control
Failure
24VAC or Control
STEADY OFF
Outdoor Air Temperature1
Compressors Locked Out Because The
Economizer Is Using Free Cooling1
Fan Overload Switch Trip - Not Applicable On This
Unit
13 Flashes
Compressor Held Off Due To Low Voltage1
14 Flashes
EEPROM Storage Failure (Control Failure)
OFF
STEADY ON
CHECK
Compressors Locked Out On Low
12 Flashes
1.
FAULT CONDITIONS
Not Applicable
2 Flashes
10 Flashes
FLASHES
Description
Heart Beat
1 Flash
TABLE 30: IGNITION CONTROL FLASH CODES
No Power or Control Failure
These flash codes do not represent alarms.
Unitary Products Group
035-19046-003-A-0804
Monitored
Systems
Problem?
No
No
Call for
Heating?
Programming?
Yes
Yes
Program
Unit
Control
Board
Call for
Heat
Yes
Trip/Failure
Loss of
Call for
Heating?
No
Yes
Heat Off
No
Call for 2nd
Stage
Cooling
No
Energize ID
Blower Motor
Monitor
Call for
Cooling?
Yes
First
Stage?
Yes
No
Yes
No
Turn off ID
Blower Motor
Yes
No
Fan on
>30 secs?
Yes
Yes
No
Call for 1st
Stage
Cooling
Fan off
>10 secs?
No
Lossof Call
for ID Blower?
Call for
ID Blower?
No
Loss of Call
for Cooling?
Yes
Cool Off
FIGURE 29 - BASIC TROUBLESHOOTING FLOWCHART
Power to
Unit
Call for
heat?
No
Initialize ASCD
Yes
Voltage @
Gas Valve?
Yes
No
Energize ID
Blower
Montior
FIGURE 30 - POWER ON FLOW CHART
Unitary Products Group
45
035-19046-003-A-0804
H P
S w itc h
O p e n 1
N o
L o s s o f
L S In p u t
T r ip /F a ilu r e
L P
S w itc h O p e n
> 5 S e c s2
N o
Y e s
Y e s
T
c o m
in itia
in c r e a
v a
E n e r g iz e b lo w e r :
in c r e a s e in c id e n t
v a lu e b y 1
N o
Y e s
u rn
p r
te
s e
lv e
o ff
e s s o r;
A S C D ;
in c id e n t
b y 1
N o
F re e z e s ta t
O p e n ?1
Y e s
T u rn o ff
C o m p re s s o r,
in itia te A S C D ;
in c r e a s e in c id e n t
v a lu e b y 1
T u rn
c o m p r
in itia te
in c r e a s e
v a lu e
o ff
e s s o r,
A S C D ;
in c id e n t
b y 1
N o
In c id e n t
v a lu e > = 3 ?
N o
Y e s
N o
L S in p u t
r e g a in e d ?
Y e s
L o c k o n b lo w e r ;
fla g a la r m
N o
In c id e n t
v a lu e > = 3
Y e s
N o
In c id e n t
v a lu e > = 3
Y e s
L o c k -o u t
c o m p r e s s o r , fla g
a la r m
L o a d F o ffD
In c id e n t
v a lu e > = 3
Y e s
L o c k -o u t
c o m p r e s s o r , fla g
a la r m
L o c k
c o m p re s
o ff ID b lo
o ff c o n
fa n s , fla
-o u t
s o r,
w e r,
d e n s
g a la
tu rn
tu rn
e r
rm
M o n ito r
L o s s o f
F O S in p u t
> 5 S e c s ?
C a ll fo r
H e a t w /o u t G V
v o lta g e ?
N o
Y e s
Y e s
T u rn
c o m p r
c o n d e n
in itia te
N o
o ff fa n
e s s o r &
s e r fa n s ;
A S C D
G V
v o lta g e
w /o u t c a ll fo r
h e a t?
N o
G V v o lta g e
> 5 m in ?
Y e s
F la g A la r m
N o
v o lta g e > 5
m in ?
N o
Y e s
F la g a la r m , lo c k
o n ID b lo w e r
N o
In c id e n t
v a lu e > = 3
F O S in p u t
r e g a in e d ?
N o
Y e s
c o m
o ff
o
fa
L o c k -o
p re s s o
ID b lo w
ff c o n d e
n s , fla g
N o
F O S in p u t > 1 5
m in u te s ?
N o
Y e s
u t
rs ,
e r,
n s
a la
tu rn
tu rn
e r
rm
Y e s
In c r e a s e in c id e n t
v a lu e b y 1
F la g a la r m , tu r n o n
X lin e
Y e s
L o s s o f G V
V o lta g e ?
N o
E n e rg
b lo w e r ,
O ff D e
h e a
iz e ID
lo a d 'F a n
la y ' fo r
tin g
M o n ito r
1 T h e
2 T h e
a n d
lo n g
c o n
lo w
a d d
e r h
tro l b o a rd
-p re s s u re
itio n a l 3 0
a n d le s th
o n ly
s w itc
s e c o
e lo w
m
h
n d
-p
o n ito r s
is n o t m
s , th e c
re s s u re
th e in
o n ito
o n tro
s w itc
p u t
re d
l b o
h d
w h e n th e c o m p re s s o r re a
fo r th e fir s t 3 0 s e c o n d s o f
a r d tu r n s o ff th e a s s o c ia te
iffe r e n tly th a n o th e r in p u ts
lly is e n e r g iz e d .
c o m p r e s s o r a c tiv ity . T h e c o n tr o l b o a r d th e n m o n ito r s th e s w itc h to e n s u r e it c lo s e s . If th e s w itc h r e m a in s o p e n
d c o m p r e s s o r a n d in itia te s th e A S C D . O n c e it h a s c lo s e d d u r in g th e s ta r t u p p e r io d , th e c o n tr o l b o a r d n o
.
FIGURE 31 - TRIP FAILURE FLOW CHART
46
Unitary Products Group
035-19046-003-A-0804
COOLING TROUBLESHOOTING GUIDE
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.
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 provides free cooling,
following a short delay compressor #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.
2.
If no economizer is installed or the economizer is not
opening to provide free cooling and compressor #1 does
not energize on a call for cooling, check for line voltage
at the compressor contactor, M1, and that the contactor
is pulled in. Check for loose wiring between the contactor and the compressor.
3.
If M3 is not pulled in, check for 24 volts at the M3 coil. If
24 volts are present at M3 but M3 is not pulled in,
replace the contactor.
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 internal overload to reset.
Test again when cool.
4.
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 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.
5.
If 24 volts is not present at M3, check that 24 volts is
present at the UCB supply air blower motor terminal,
“FAN”. If 24 volts is present at the FAN, check for loose
wiring between the UCB and M3.
Failing the above, if voltage is supplied at M1, M1 is
pulled in, and the compressor still does not operate,
replace the compressor.
6.
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.
7.
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:
1.
Turn the thermostat fan switch to the ON position. If the
supply air blower motor does not energize, go to Step 3.
2.
If the blower motor runs with the fan switch in the ON
position but will not run after the first compressor has
energized when the fan switch is in the AUTO position,
check the room thermostat for contact between R and G
in the AUTO position during calls for cooling.
3.
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 supply air blower motor.
4.
If M3 is pulled in and voltage is supplied to M3, lightly
touch the supply air blower motor housing. If it is hot, the
motor may be off on internal protection. Cancel any
thermostat calls and set the fan switch to AUTO. Wait for
the internal overload to reset. Test again when cool.
5.
6.
7.
8.
If 24 volts is not present at the “FAN” terminal, check for
24 volts from the room thermostat. If 24 volts are not
present from the room thermostat, check for the following:
a.
9.
On calls for cooling, the supply air blower motor is operating
but compressor #1 is not (the room thermostat fan switch is in
the “AUTO” position).
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).
a.
24 volts at the thermostat Y1 terminal
b.
Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2
b.
Proper wiring between the room thermostat and the
UCB.
c.
Loose wiring from the room thermostat to the UCB.
c.
Loose wiring from the room thermostat to the UCB.
8.
If 24 volts is present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure 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 terminals, e.g. if LPS1 has opened,
there will be a 24-volt potential between the LPS1 terminals.
9.
If 24 volts is present at the UCB Y1 terminal and none of
the protection switches have opened, the UCB may have
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.
10. If the thermostat and UCB are properly wired, replace
the UCB.
Unitary Products Group
47
035-19046-003-A-0804
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.
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.
2.
Compressor #2 will not energize simultaneously with
compressor #1 if a call for both stages of cooling 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 second stage call for
cooling, check for line voltage at the compressor contactor, M2, and that the contactor is pulled in. Check for
loose wiring between the contactor and the compressor.
3.
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 internal overload to reset.
Test again when cool.
4.
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.
5.
Failing the above, if voltage is supplied at M2, M2 is
pulled in, and the compressor still does not operate,
replace the compressor.
6.
If 24 volts is not present at M2, check for 24 volts at the
UCB terminal, C2. If 24 volts are present, check for
loose wiring between C2 and the compressor contactor.
7.
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:
NOTE: While the above step will reset any lockouts, compressor #1 may be held off for 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 compressor 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. 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 economizer 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.
12. For units without economizers:If 24 volts is present at the
Y1 OUT terminal, check for 24 volts at the Y1 “ECON”
terminal. If 24 volts is not present, check for loose wiring
from the Y1 “OUT” terminal to the Mate-N-Lock plug, the
jumper in the Mate-N-Lock plug, and in the wiring from
the Mate-N-Lock plug to the Y1 “ECON” terminal.
13. For units with 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, 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. If nothing is found, the economizer DME may have
faulted and is failing to return the 24-volt “call” to the Y1
“ECON” terminal even though the economizer is not providing free cooling. To test, disconnect the Mate-N-Locks
and jumper between the WHITE and YELLOW wires of
the UCB’s Mate-N-Lock plug. If compressor #1 energizes, there is a fault in the economizer wiring or DME.
14. The UCB can be programmed to lock out compressor
operation during free cooling and in low ambient conditions. These options are not enabled by default. Local
York distributors can test the UCB for this programming.
48
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.
8.
If 24 volts is present at the UCB Y2 terminal, the compressor may be out due to an open high-pressure switch,
low-pressure switch, or freezestat. Check for 24 volts at
the HPS2, LPS2, and FS2 terminals of the UCB. If a
switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS2 has opened,
there will be 24 volts of potential between the LPS2 terminals.
9.
If 24 volts is present at the UCB Y2 terminal and none of
the protection switches have opened, the UCB may have
15. 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.
16. If none of the above correct the error, replace the UCB.
a.
Unitary Products Group
035-19046-003-A-0804
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,
6.
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.
7.
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.
8.
If 24 volts are present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure 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 terminals, e.g. if LPS1 has opened,
there will be a 24-volt potential between the LPS1 terminals.
9.
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 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.
remove any call for cooling at the thermostat or by disconnecting the thermostat wiring at the Y2 UCB terminal.
This will reset any compressor lock outs.
NOTE: 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 portion of the
ASCD. See the next step.
10. 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 compressor 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. The UCB can be programmed to lock out compressor
operation during free cooling and in low ambient conditions. These options are not enabled by default. Local
York distributors can test the UCB for this programming.
12. If none of the above corrected the error, test the integrity
of the UCB. 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.
13. 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” position).
1.
Compressor #2 is energized in place of compressor #1
when compressor #1 is unavailable for cooling 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.
2.
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 compressor.
3.
If M1 is pulled in and voltage is supplied at M1, lightly
touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls
for cooling and wait for the internal overload to reset.
Test again when cool.
4.
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.
5.
Failing the above, if voltage is supplied at M1, M1 is
pulled in, and the compressor still does not operate,
replace the compressor.
Unitary Products Group
NOTE: 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 portion 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 compressor 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. 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 economizer 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.
12. For units without economizers: If 24 volts is present at
the Y1 “OUT” terminal, check for 24 volts at the Y1
“ECON” terminal. If 24 volts is not present, check for
loose wiring from the Y1 “OUT” terminal to the Mate-NLock plug, the jumper in the Mate-N-Lock plug, and in
the wiring from the Mate-N-Lock plug to the Y1 “ECON”
terminal.
49
035-19046-003-A-0804
For units with 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, 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 board 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 board, disconnect the Mate-N-Locks
and jumper between the WHITE and YELLOW wires of
the UCB’s Mate-N-Lock plug.
4.
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.
5.
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.
6.
If 24 volts is not present at M3, check that 24 volts is
present at the supply air blower motor terminal on the
UCB. If 24 volts is present at the UCB terminal, check for
loose wiring between the UCB and M3.
7.
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:
13. The UCB can be programmed to lock out compressor
operation during free cooling and in low ambient conditions. These options are not enabled by default. They
can be checked by local York distributors.
a.
14. 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.
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.
15. If none of the above correct the error, replace the UCB.
c.
Loose wiring from the room thermostat to the UCB.
GAS HEAT TROUBLESHOOTING GUIDE
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).
The furnace may shut down on a high temperature
condition during the procedure. If this occurs, the
UCB energize the supply air blower motor until the
high temperature limit has reset. Caution should be
used at all times as the supply air blower may energize regardless of the room thermostat fan switch
position.
1.
Place the thermostat fan switch in the “ON” position. If
the supply air blower motor energizes, go to Step 10.
2.
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 supply air blower motor.
3.
50
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 protection. Cancel any
thermostat calls and set the fan switch to “AUTO”, wait
for the internal overload to reset. Test again when cool.
8.
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.
9.
If the thermostat and UCB are properly wired, replace
the UCB.
10. If the blower motor runs with the fan switch in the “ON”
position but does not run shortly after the furnace 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.
2.
If the motor shell is cold with the room thermostat calling
for heat, check for line voltage at the motor leads. If line
voltage is present, replace the draft motor.
3.
If line voltage is not present, check for line voltage on the
ignition control at the “inducer” terminal draft motor relay
(DMR or DMC) contacts in the main control box and
check to see if the (DMR or DMC) is pulled in.
The draft motor runs but the furnace does not light and the
spark ignitor does not spark.
Unitary Products Group
035-19046-003-A-0804
1.
Check for 24 volts at the spark ignitor from the ignition
control board (ICB). Check the 24-volt wiring from the
ICB to the spark ignitor. Check for 24 volts at the ICB
spark ignitor terminal.
2.
Check the ground wiring for the ICB and the gas valve is
intact and making good electrical connection. Check the
ceramic insulator on the spark ignitor for breaks or
cracks. Replace the spark ignitor if damaged.
3.
With the draft motor running, check for 24 volts at the
pressure switch terminal on the ICB. If not present,
check for 24 volts on the terminal from the pressure
switch. If present, go to step 4. If 24 volts is not present,
the either pressure or rollout switch is not closed. Or the
draft motor is not sufficiently evacuating the heat
exchanger tubes or the pressure switch has failed.
Check the operation of the pressure switch. Check the
line voltage to the unit; if line voltage is low, call the local
power company. If the problem persists, the draft motor
may need replacement.
4.
If the furnace is hot, it may be out on a high temperature
limit open; wait for limit reset.
5.
If all are intact replace the ICB.
Unitary Products Group
The draft motor runs and the spark ignitor sparks at the
burner, but the burner does not ignite and a gas odor is not
detected at the draft motor outlet.
1.
Check to ensure gas is being supplied to the unit. Confirm that the gas pressure to the unit is within the proper
limits as described in the “POST START CHECKLIST”.
2.
Check the voltage at the gas valve and at the gas valve
terminals on the ICB. Check all wiring between the ICB
and the gas valve. Check to make sure the ground connections are intact.
3.
If 24 volts is present, remove the pilot burner and the orifice. The removal procedure is described in
“BURNER/ORIFICE INSTRUCTIONS.” Inspect the orifice for obstruction. If it is clear, replace the gas valve.
Main burners light but exhibit erratic flame characteristics.
4.
Check the main burner orifices for obstruction and alignment. The removal procedure is described in
“BURNER/ORIFICE INSTRUCTIONS.” Clean or replace
burner orifices and burners as needed.
51
Subject to change without notice. Printed in U.S.A.
Copyright © 2004 by Unitary Products Group. All rights reserved.
Unitary
Products
Group
035-19046-003-A-0804
Supersedes: 035-19046-002-C-0504
5005
York
Drive
Norman
OK
73069
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