York DJ150 Installation manual

INSTALLATION

MANUAL

®

CONTENTS

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

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

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

REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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

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

NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . .6

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

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

START-UP (COOLING). . . . . . . . . . . . . . . . . . . . . .39

START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . .39

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .43

See following pages for a complete Table of Contents.

MAGNUM

SINGLE PACKAGE AIR CONDITIONERS AND

SINGLE PACKAGE GAS/ELECTRIC UNITS

DJ150

12-1/2 TON

(10.8 EER)

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.

Tested in accordance with:

CAUTION: READ ALL SAFETY GUIDES BEFORE YOU

BEGIN TO INSTALL YOUR UNIT.

SAVE THIS MANUAL

035-19046-002-B-0104

035-19046-002-B-0104

TABLE OF CONTENTS

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

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

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

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

INSTALLATION SAFETY INFORMATION . . . . . . . . . . . . . . . 8

PRECEDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 8

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . 11

CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DUCT COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

THERMOSTAT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . . . . 17

POWER WIRING DETAIL. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

OPTIONAL ELECTRIC HEAT. . . . . . . . . . . . . . . . . . . . . . . . 22

OPTIONAL GAS HEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

LP UNITS, TANKS AND PIPING . . . . . . . . . . . . . . . . . . . . . . . 24

VENT AND COMBUSTION AIR . . . . . . . . . . . . . . . . . . . . . . . . 25

FACTORY INSTALLED OPTIONS/

FIELD INSTALLED ACCESSORIES . . . . . . . . . . . . . . . . . . 25

ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

MOTORIZED OUTDOOR DAMPER . . . . . . . . . . . . . . . . . . . . 25

ECONOMIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

RAIN HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ECONOMIZER AND POWER EXHAUST SET POINT

ADJUSTMENTS AND INFORMATION. . . . . . . . . . . . . . . . . 26

MINIMUM POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . 26

ENTHALPY SET POINT ADJUSTMENT . . . . . . . . . . . . . . . . . 26

POWER EXHAUST DAMPER SET POINT (WITH OR

WITHOUT POWER EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . 26

INDOOR AIR QUALITY AQ . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

BLOWER ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

AIR BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CHECKING AIR QUANTITY . . . . . . . . . . . . . . . . . . . . . . . . . 31

METHOD ONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

METHOD TWO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SUPPLY AIR DRIVE ADJUSTMENT . . . . . . . . . . . . . . . . . . 32

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

SEQUENCE OF OPERATIONS OVERVIEW . . . . . . . . . . . . 33

COOLING SEQUENCE OF OPERATION . . . . . . . . . . . . . . 33

CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

INTERMITTENT BLOWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

NO OUTDOOR AIR OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . 34

ECONOMIZER WITH SINGLE ENTHALPY SENSOR -. . . . . . 34

ECONOMIZER WITH DUAL ENTHALPY SENSORS - . . . . . . 34

ECONOMIZER (SINGLE OR DUAL) WITH POWER

EXHAUST - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

MOTORIZED OUTDOOR AIR DAMPERS - . . . . . . . . . . . . . . .34

COOLING OPERATION ERRORS . . . . . . . . . . . . . . . . . . . . . .34

HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . .34

LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . .35

FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

SAFETY CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

COMPRESSOR PROTECTION . . . . . . . . . . . . . . . . . . . . . . 35

FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

ELECTRIC HEATING SEQUENCE OF OPERATIONS . . . . 36

ELECTRIC HEATING OPERATION ERRORS . . . . . . . . . . 36

TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

LIMIT SWITCH (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

ELECTRIC HEAT ANTICIPATOR SETPOINTS. . . . . . . . . . 36

GAS HEATING SEQUENCE OF OPERATIONS . . . . . . . . . 37

IGNITION CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . 37

FIRST STAGE OF HEATING . . . . . . . . . . . . . . . . . . . . . . . . . .37

SECOND STAGE OF HEATING. . . . . . . . . . . . . . . . . . . . . . . .37

RETRY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

RECYCLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

GAS HEATING OPERATION ERRORS. . . . . . . . . . . . . . . . 37

LOCK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

FLAME SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

SAFETY CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

LIMIT SWITCH (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

AUXILIARY LIMIT SWITCH (ALS) . . . . . . . . . . . . . . . . . . . . . .38

PRESSURE SWITCH (PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

ROLLOUT SWITCH (ROS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

INTERNAL MICROPROCESSOR FAILURE . . . . . . . . . . . . . .38

FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

RESETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . . . 39

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

PRESTART CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 39

OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . 39

POST START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . 39

START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . . . . 39

PRE-START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 39

OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . 39

LIGHTING THE MAIN BURNERS. . . . . . . . . . . . . . . . . . . . . . .39

POST START CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 40

SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

MANIFOLD GAS PRESSURE ADJUSTMENT. . . . . . . . . . . 40

CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . . . . 42

BURNERS/ORIFICES INSPECTION/SERVICING . . . . . . . 42

CHARGING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

PREDATOR“ MAGNUM FLASH CODES. . . . . . . . . . . . . . . 43

COOLING TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . 46

GAS HEAT TROUBLESHOOTING GUIDE . . . . . . . . . . . . . 49

2 Unitary Products Group

035-19046-002-B-0104

Fig. #

LIST OF FIGURES

Pg. #

1 UNIT SHIPPING BRACKET . . . . . . . . . . . . . . . . . . . . . 8

2 COMPRESSOR SECTION . . . . . . . . . . . . . . . . . . . . . . 9

3 PREDATOR“ MAGNUM COMPONENT LOCATION . 10

4 UNIT 4 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 11

5 UNIT 6 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 12

6 UNIT CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . 12

7 UNIT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8 BOTTOM DUCT OPENINGS (FROM ABOVE). . . . . . 14

9 REAR DUCT DIMENSIONS . . . . . . . . . . . . . . . . . . . . 15

10 PREDATOR“ MAGNUM ROOF CURB

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

11 SUNLINE™ TO PREDATOR“ MAGNUM

TRANSITION ROOF CURBS . . . . . . . . . . . . . . . . . . . 16

12 SIDE PANELS WITH HOLE PLUGS. . . . . . . . . . . . . . 16

13 RETURN DOWNFLOW PLENUM WITH PANEL . . . . 17

14 DISCHARGE PANEL IN PLACE . . . . . . . . . . . . . . . . . 17

15 CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . 17

Fig. # Pg. #

16 ELECTRONIC THERMOSTAT FIELD WIRING . . . . . 18

17 FIELD WIRING 24 VOLT THERMOSTAT . . . . . . . . . 19

18 FIELD WIRING DISCONNECT - COOLING UNIT

WITH/WITHOUT ELECTRIC HEAT . . . . . . . . . . . . . . 19

19 FIELD WIRING DISCONNECT - COOLING UNIT

WITH GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

20 SIDE ENTRY GAS PIPING. . . . . . . . . . . . . . . . . . . . . 23

21 BOTTOM ENTRY GAS PIPING . . . . . . . . . . . . . . . . . 23

22 ENTHALPY SET POINT CHART . . . . . . . . . . . . . . . . 27

23 HONEYWELL ECONOMIZER CONTROL W7212 . . . 27

24 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 28

25 DRY COIL DELTA P . . . . . . . . . . . . . . . . . . . . . . . . . . 32

26 TYPICAL FLAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

27 TYPICAL GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . 42

28 BASIC TROUBLESHOOTING FLOWCHART . . . . . . 44

29 POWER ON FLOW CHART . . . . . . . . . . . . . . . . . . . . 44

30 TRIP FAILURE FLOW CHART. . . . . . . . . . . . . . . . . . 45

LIST OF TABLES

Tbl. # Pg. #

1 UNIT VOLTAGE LIMITATIONS . . . . . . . . . . . . . . . . . . 11

2 UNIT TEMPERATURE LIMITATIONS 11

3 UNIT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 4 POINT LOAD WEIGHT . . . . . . . . . . . . . . . . . . . . . . . 12

5 6 POINT LOAD WEIGHT . . . . . . . . . . . . . . . . . . . . . . . 12

6 UNIT CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7 CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . 17

8 ELECTRICAL DATA DJ150 (12-1/2 TON) WITHOUT

POWERED CONVENIENCE OUTLET . . . . . . . . . . . . 21

9 ELECTRICAL DATA DJ150 (12-1/2 TON) WITH

POWERED CONVENIENCE OUTLET . . . . . . . . . . . . 21

10 PHYSICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

11 MINIMUM SUPPLY AIR CFM . . . . . . . . . . . . . . . . . . . 22

12 GAS HEAT APPLICATION DATA . . . . . . . . . . . . . . . . 23

13 GAS PIPE SIZING - CAPACITY OF PIPE . . . . . . . . . . 23

14 SUPPLY AIR LIMITATIONS . . . . . . . . . . . . . . . . . . . . 28

15 DJ150, 12-1/2 TON STANDARD MOTOR DOWN

SHOT BLOWER PERFORMANCE . . . . . . . . . . . . . . . 29

Tbl. # Pg. #

16 DJ150, 12-1/2 TON OPTIONAL MOTOR DOWN


17 DJ150, 12-1/2 TON STANDARD MOTOR SIDE


18 DJ150, 12-1/2 TON OPTIONAL MOTOR SIDE


19 INDOOR BLOWER SPECIFICATIONS. . . . . . . . . . . . 31

20 ADDITIONAL STATIC RESISTANCE . . . . . . . . . . . . . 33

21 MOTOR SHEAVE DATUM DIAMETERS . . . . . . . . . . 33

22 ELECTRIC HEAT LIMIT SETTING . . . . . . . . . . . . . . . 36

23 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . 36

24 GAS HEAT LIMIT CONTROL SETTINGS. . . . . . . . . . 38

25 GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . 39

26 GAS HEAT STAGES. . . . . . . . . . . . . . . . . . . . . . . . . . 40

27 GAS RATE CUBIC FEET PER HOUR . . . . . . . . . . . . 41

28 UNIT CONTROL BOARD FLASH CODES . . . . . . . . . 43

29 IGNITION CONTROL FLASH CODES . . . . . . . . . . . . 43

Unitary Products Group 3

035-19046-002-B-0104

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.

SAFETY CONSIDERATIONS

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.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

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 CSA-

B149.1- latest edition.

Wear safety glasses and work gloves. Use quenching cloth and have a fire extinguisher available during brazing operations.

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.


035-19046-002-B-0104

REFERENCE

Additional information is available in the following reference forms:

• Technical Guide - DJ150, 036-21484-002

• General Installation - DJ150, 035-19046-002

• Pre-start & Post-start Check List - 035-18466-000

• Economizer Accessory -

Downflow Factory Installed, 035-18286-000

Downflow Field Installed, 035-18285-000

Horizontal Field Installed, 035-18287-000

• 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

• –60

°

F Gas Heat Kit 035-18216-000

• Electric Heater Accessory 035-17291-001

• Unit Renewal Parts List 035-19085-000

All forms referenced in this instruction may be ordered from:

Standard Register

Toll Free Fax: (877) 379-7920

Toll Free Phone: (877) 318-9675

RENEWAL PARTS

Refer to York’s USER’S MAINTENANCE and SERVICE

INFORMATION MANUAL Part Number 035-19047-001.

APPROVALS

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.

2.

For outdoor installation only.

3.

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).

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.

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.


6

035-19046-002-B-0104

NOMENCLATURE

12½ Ton Predator Model Number Nomenclature

D J 150 N15 A 2 A AA 3

Product Category

D = Air Cond., Single Package

Product Generation

3 = Third Generation

Product Identifier

J = R-22 Ultra High Efficiency

Voltage

2 = 208/230-3-60

4 = 460-3-60

5 = 575-3-60

Additional Options

(See Next Page)

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

E18 = 18 kW Electric Heat




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

Options

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)

Unitary Products Group

035-19046-002-B-0104

NOMENCLATURE, ADDITIONAL OPTIONS:

AA None

AC Coil Guard

AD Dirty Filter Switch

AG Coil Guard & Dirty Filter Switch

CA CPC Controller with Dirty Filter Switch & Air Proving Switch

CC CPC Controller, DFS, APS & Coil Guard

CE CPC Controller, DFS, APS & Technicoat Cond. Coil

CG CPC Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard

CJ CPC Controller, DFS, APS & Technicoat Evap. Coil

CL CPC Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard

CN CPC Controller, DFS, APS & Technicoat Evap. & Cond Coils

CQ CPC Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

CV CPC Controller, DFS, APS, & 2” Pleated Filters

HA Honeywell Excel 10 Controller with Dirty Filter Switch & Air Proving Switch

HC Honeywell Excel 10 Controller, DFS, APS & Coil Guard

HE Honeywell Excel 10 Controller, DFS, APS & Technicoat Cond. Coil

HG Honeywell Excel 10 Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard

HJ Honeywell Excel 10 Controller, DFS, APS & Technicoat Evap. Coil

HL Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard

HN Honeywell Excel 10 Controller, DFS, APS & Technicoat Evap. & Cond Coils

HQ Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

JA Johnson UNT Controller with Dirty Filter Switch & Air Proving Switch

JC Johnson UNT Controller, DFS, APS & Coil Guard

JE Johnson UNT Controller, DFS, APS & Technicoat Cond. Coil

JG Johnson UNT Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard

JJ Johnson UNT Controller, DFS, APS & Technicoat Evap. Coil

JL Johnson UNT Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard

JN Johnson UNT Controller, DFS, APS & Technicoat Evap. & Cond Coils

JQ Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

NA Novar ETC-3 Controller with Dirty Filter Switch & Air Proving Switch

NC Novar ETC-3 Controller, DFS, APS & Coil Guard

NE Novar ETC-3 Controller, DFS, APS & Technicoat Cond. Coil

NG Novar ETC-3 Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard

NJ Novar ETC-3 Controller, DFS, APS & Technicoat Evap. Coil

NL Novar ETC-3 Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard

NN Novar ETC-3 Controller, DFS, APS & Technicoat Evap. & Cond Coils

NQ Novar ETC-3 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

TA Technicoat Condenser Coil


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TC Technicoat Condenser Coil & Coil Guard

TD Technicoat Condenser Coil & Dirty Filter Switch

TG Technicoat Condenser Coil, Coil Guard, & Dirty Filter Switch

TJ Technicoat Evaporator Coil

TL Technicoat Evaporator Coil & Coil Guard

TM Technicoat Evaporator Coil & Dirty Filter Switch

TQ Technicoat Evaporator Coil, Coil Guard, & Dirty Filter Switch

TS Technicoat Evaporator & Condenser Coils

TU Technicoat Evaporator & Condenser Coils & Coil Guard

TV Technicoat Evaporator & Condenser Coils & Dirty Filter Switch

TY Technicoat Evaporator & Condenser Coils, Coil Guard, & Dirty Filter Switch

INSTALLATION

INSTALLATION SAFETY INFORMATION

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 11 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 8, 24, 25 and 40 of these instructions.

4.

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.

5.

This equipment is not to be used for temporary heating of buildings or structures under construction.

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.

PRECEDING INSTALLATION

1.

Remove the two screws holding the brackets in the front, rear and compressor side fork-lift slots.

Bracket

Screws

Turn down

FIGURE 1 UNIT SHIPPING BRACKET


035-19046-002-B-0104

2.

Turn each bracket toward the ground and the protective plywood covering will drop to the ground.

3.

Remove the condenser coil external protective covering prior to operation.

4.

Remove the toolless doorknobs and instruction packet prior to installation.

FIGURE 2 -

Toolless

Doorknobs

Installation

Instruction

Packet

COMPRESSOR SECTION

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.

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.

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.

LIMITATIONS

These units must be installed in accordance with the following:

In U.S.A.:

1.

National Electrical Code, ANSI/NFPA No. 70 - Latest

Edition

2.

National Fuel Gas Code, ANSI Z223.1 - Latest Edition

3.

Gas-Fired Central Furnace Standard, ANSI Z21.47a. -

Latest Edition

4.

Local building codes, and

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.

Refer to Tables 1 & 2 for unit application data.

After installation, gas fired units must be adjusted to obtain a temperature rise within the range specified on the unit rating plate.

If components are to be added to a unit to meet local codes, they are to be installed at the dealer’s and/or 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.


035-19046-002-B-0104

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)

Dual stage cooling for maximum comfort

Compressor #2 access (highefficiency compressor w/crankcase heater)

Base rails w/forklift slots (three sides) and lifting holes

Filter drier

(solid core)

Condenser

Section

Belt-drive blower motor

Slide out motor and blower assembly for easy adjustment and service

Power ventor motor

20-gauge aluminized steel tubular heat exchanger for long life (stainless steel option)

Roof curbs in eight and fourteen-inch heights.

Roof curbs for transitioning from York

Sunline™ footprint to the DM/DH/DJ/DR Series footprint are available

(field-installed accessory)

Slide-out drain pan with brass 3/4" FPT connection

Tool-less door latch

Side entry power and control wiring knockouts

Compressor #1 access

(high-efficiency compressor w/ crankcase heater)

FIGURE 3 PREDATOR



MAGNUM COMPONENT LOCATION

Two-stage gas heating to maintain warm, comfortable temperature

Intelligent control board for safe and efficient operation


035-19046-002-B-0104

TABLE 1: UNIT VOLTAGE LIMITATIONS

Power Rating

* Minimum Maximum

208/230-3-60

460-3-60

575-3-60

187

432

540

252

504

630

*.

Utilization range “A” in accordance with ARI Standard 110.

TABLE 2: UNIT TEMPERATURE LIMITATIONS

Temperature

Wet Bulb Temperature (

°

F) of Air on

Evaporator Coil

Dry Bulb Temperature (

°

F) of Air on

Condenser Coil

Min.

57

0

*

*.

A low ambient accessory is available for operation down to -20°F.

Max.

72

125

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.

RIGGING AND HANDLING

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.

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.

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.

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.


FRONT

LEFT

B

A

D

FIGURE 4 UNIT 4 POINT LOAD

C

11

035-19046-002-B-0104

TABLE 3: UNIT WEIGHTS

Model DJ150

Shipping

Weight (lb.)

Cooling Unit Only w/Economizer w/Power Exhaust w/Gas Heat

* w/Electric Heat †

1415

85

150

110

49

*.

†.

8 Tube Heat Exchanger

54 kW heater

TABLE 4: 4 POINT LOAD WEIGHT

Location (lbs.)

*

Model

A B C

DJ150 282 323 424

*.

Weights include largest gas heat option.

Operating

Weight (lb.)

1400

84

148

110

49

D

371

TABLE 5: 6 POINT LOAD WEIGHT

Location (lbs.)

*

Model

A B C D

DJ150 184 201 220 289

E

264

*.

Weights include largest gas heat option.

F

242

CLEARANCES

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 .

Do not permit overhanging structures or shrubs to obstruct condenser air discharge outlet, combustion air inlet or vent outlets.

FRONT

LEFT

C

B E

A

F

FIGURE 5 UNIT 6 POINT LOAD

25-½"

D

47-½"

FRONT

LEFT

FIGURE 6 UNIT CENTER OF GRAVITY

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.

• 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.

• 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


035-19046-002-B-0104

119-7/16

50-3/4

4-1/4

30-11/32

Power

Entry

2-1/2

Control

Entry 7/8

LEFT

59

17-3/16

30-3/16

24-3/16 6-3/16

See Detail A

Convenience

Outlet

11-1/2

Convenience

Outlet

Power

Entry

7/8

For Drain Dimensions

See Detail C

89

FRONT

27

For

Baserail

Dimensions

See

Detail B

FIGURE 7 UNIT DIMENSIONS

DETAIL A

G a s P i p e I n l e t

DETAIL B

2 - 3 / 8

3 - 3 / 4

5 - 1 / 4

1 7 - 1 3 / 1 6

B a s e

P a n

V i e w o f W a l l A c r o s s f r o m C o i l

TABLE 6: UNIT CLEARANCES

Top

*

72” Right

Front †

Rear

‡

36”

36”

Left

Bottom

**

*.

†.

‡.

**.

Units must be installed outdoors. Overhanging structure or shrubs should not obstruct condenser air discharge outlet.

The products of combustion must not be allowed to accumulate within a confined space and re-circulate.

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.

Units may be installed on combustible floors made from wood or class A, B or C roof covering materials.

12”

36”

0”

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.

DETAIL C

5 - 3 / 8

3 - 9 / 1 6

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.


035-19046-002-B-0104

.

6-13/16

LEFT

32-11/16

6-13/16

Return

Air

27-1/2

18

Supply

Air

6-13/16

24

21

21-3/16

19-3/16

17-3/16

7-1/8

14-

23/32

FRONT

16-3/8

18-1/16

19-5/8

Bottom

Condensate

Entry

63-1/2

FIGURE 8 BOTTOM DUCT OPENINGS (FROM ABOVE)

Bottom

Power, Control and

Convenience

Outlet Wiring

Entries

Bottom Gas

Supply Entry

12-15/16


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Dot Plugs 18-1/4

Return

Air

28-1/4

Supply

Air

18-1/4

18-1/16

2-31/32

5-5/32

28-1/4

31-11/16

FIGURE 9 REAR DUCT DIMENSIONS

DUCTWORK

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.

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.

DUCT COVERS

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.


8 0 - 5 / 8

2 0

R I G H T

I N 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 I O N

S U P P L Y

2 0

R E T U R N

2 T Y P .

5 0 - 1 / 2

3 0

I N 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 I O N

F R O N T

8 o r 1 4

FIGURE 10 - PREDATOR



MAGNUM ROOF CURB DIMENSIONS

2 T Y P

2 3

5 0 - 1 / 2

3 0 - 1 / 2

2 6

R E T U R N

S U P P L Y

8 0 - 5 / 8

1 0

7 6 - 5 / 8

F R O N T

9 4

5 9 - 1 / 4

6 4 - 1 / 4

R I G H T

035-19046-002-B-0104

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.

16

FIGURE 12 - SIDE PANELS WITH HOLE PLUGS

Note orientation. Panel is “insulation” side up.


035-19046-002-B-0104

COMPRESSORS

The compressors are mounted on elastomer insulators. The mounting bolts have been fully tightened for shipping.

Do not loosen the compressor mounting bolts.

FIGURE 13 - RETURN DOWNFLOW PLENUM WITH

PANEL

FILTERS

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.

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.

3 " M i n i m u m

O P T I O N A L C O I L

G U A R D

Make sure that panel latches are properly positioned on the unit to maintain an airtight seal.

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

Wire Size Maximum Length

*

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.

FIGURE 15 - CONDENSATE DRAIN


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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.

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.

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.

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.

Avoid damage to internal components if drilling holes for disconnect mounting.

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.

POWER WIRING DETAIL

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.

T H E R M O S T A T

T E R M I N A L S

R C

R H

Y 1

Y 2

W 1

W 2

U N I T T E R M I N A L S

S T R I P T B 1

Y 1

Y 2

W 1

W 2

2 4 V o l t

T r a n s f o r m e r

X 4

A 1

A 2

X 1

X 3 O C C

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 I F U S E D

E l e c t r o n i c p r o g r a m m a b l e T h e r m o s t a t 2 E T 0 7 7 0 0 1 0 0 2 4 ( i n c l u d e s s u b b a s e ) .

T e r m i n a l s A 1 a n d A 2 p r o v i d e a r e l a y o u t p u t t o c l o s e t h e o u t d o o r

e c o n o m i z e r d a m p e r s w h e n t h e t h e r m o s t a t s w i t c h e s t o t h e s e t - b a c k p o s i t i o n .

FIGURE 16 - ELECTRONIC THERMOSTAT FIELD WIRING


035-19046-002-B-0104

Y 2

R H

R C

T - S T A T

W 1

W 2

Y 1

W 1

W 2

Y 1

O C C

U N I T C O N T R O L

B O A R D

Y 2

S D

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


CONTACTOR 1M

T1 T2 T3

L1 L2 L3

FACTORY OR FIELD

SUPPLIED DISCONNECT

GROUND

LUG

FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT

THREE

PHASE

POWER

SUPPLY

035-19046-002-B-0104


035-19046-002-B-0104

TABLE 8: ELECTRICAL DATA DJ150 (12-1/2 TON) WITHOUT POWERED CONVENIENCE OUTLET

Voltage

208

230

460

575

*

Compressors

RLA ea.

LRA ea.

20.0

146.0

20.0

8.4

6.7

146.0

73.0

60.0

OD Fan

Motors

FLA ea.

1.5

1.5

0.8

0.6

Supply

Blower

Motor FLA

3

HP

5

HP

10.9 16.1

10.9 16.1

5.3

4.1

8.1

6.0

Pwr

Exh

Motor

FLA

5.5

5.5

2.2

1.8

Pwr

Conv

Outlet

FLA

0.0

0.0

0.0

0.0

Electric Heater

Model No.

Maximum HACR breaker of the same AMP size is applicable.

Actual

KW

Heater

Amps

Min. Circuit

Ampacity

3

(Amps)

HP

5

HP

MCA w/Power

Exhaust

(Amps)

3

HP

5

Max

Fuse

Size

*

(Amps)

3 5

HP HP HP

Max Fuse* Size w/Power

Exhaust

3

(Amps)

5

HP

None

2TP04521825

2TP04522425

2TP04523625

None

--

13.5

18.0

25.5

--

18.0

--

37.5

61.9

67.1

67.4 72.6

80 80

61.9

67.1

67.4 73.8

80 80

80

80

50.0

76.1

82.6

83.0 89.5

80 90 90

70.8

102.1 108.6 109.0 115.5 110 110 110

2TP04525425 40.6

112.7 154.5 161.0 161.4 167.9 175 175 175

2TP04521825

2TP04522425

2TP04523625

24.0

34.0

--

43.3

57.7

81.8

61.9

67.1

67.4 72.6

80 80

67.8

85.8

74.3

92.3

74.6 81.1

92.7 99.2

80 80

90 100

115.9 122.4 122.7 129.2 125 125

80

80

100

125

2TP04525425 54.0

129.9 143.5 150.0 150.4 156.9 175 175 175

None

2TP04521846

2TP04522446

2TP04523646

2TP04525446

None

2TP04521858

2TP04522458

2TP04523658

2TP04525458

--

18

24

34

54

--

18

24

34

54

--

67.8

--

27.4 30.2 29.6 32.4 35 35 35

22.6

33.7 37.2 36.4 39.9 35 40 40

30.1

42.7 46.2 45.5 49 45 50 50

42.7

57.7 61.2 60.5 64 60 70 70

71.6 75.1 74.3 77.8 80 90 80

21.6 23.5 23.4 25.3 25 30 30

18.1

26.8 29.2

29 31.4 30 30 30

24.1

34.1

54.2

34 36.4 36.2 38.6 35 40 40

46 48.4 48.3 50.6 50 50 50

57.1

59.5 59.3 61.7 70 70 70

HP

150

175

40

40

50

70

90

30

90

90

90

125

175

90

90

100

35

40

60

70

TABLE 9: ELECTRICAL DATA DJ150 (12-1/2 TON) WITH POWERED CONVENIENCE OUTLET

Voltage

208

230

460

575

*

Compressors

OD Fan

Motors

Supply

Blower

Motor FLA

Pwr

Exh

Motor

Pwr

Conv

Outlet

Electric Heater

Model No.

Actual

KW

Heater

Amps

Min. Circuit

Ampacity

(Amps)

MCA w/Power

Exhaust

(Amps)

Max

Fuse

Size

*

(Amps)

Max Fuse* Size w/Power

Exhaust

(Amps)

RLA LRA

20.0

146.0

20.0

146.0

FLA 3 5

FLA FLA

3 5 3 5 3 5 3 ea.

8.4

6.7

ea.

73.0

60.0

ea.

1.5

1.5

0.8

0.6

HP

10.9 16.1

10.9 16.1

5.3

4.1

HP

8.1

6.0

5.5

5.5

2.2

1.8

10.0

10.0

5.0

4.0

HP HP HP HP HP HP HP

None

2TP04521825

2TP04522425

2TP04523625

None

--

13.5

18.0

25.5

--

18.0

--

37.5

71.9

77.1

77.4

82.6

90 90

73.0

79.5

79.8

86.3

90 90

90

90

50.0

88.6

95.1

95.5 102.0 90 100 100

70.8

114.6 121.1 121.5 128.0 125 125 125

2TP04525425 40.6

112.7 167.0 173.5 173.9 180.4 175 175 175

2TP04521825

2TP04522425

2TP04523625

24.0

34.0

--

43.3

57.7

81.8

71.9

77.1

77.4

82.6

90 90

80.3

98.3

86.8

87.1

93.6

90 90

104.8 105.2 111.7 100 110

128.4 134.9 135.2 141.7 150 150

90

90

110

150

2TP04525425 54.0

129.9 156.0 162.5 162.9 169.4 175 175 175

None

2TP04521846

2TP04522446

2TP04523646

2TP04525446

None

2TP04521858

2TP04522458

2TP04523658

2TP04525458

--

18

24

34

54

--

18

24

34

54

--

22.6

39.9 43.4 42.7 46.2 40 45 45

30.1

42.7

--

32.4 35.2 34.6 37.4 40 40 40

49 52.5 51.7 55.2 50 60 60

64 67.5 66.7 70.2 70 70 70

67.8

77.8 81.3 80.6 84.1 90 90 90

25.6 27.5 27.4 29.3 30 30 30

18.1

31.8 34.2

34 36.4 35 35 35

24.1

34.1

54.2

39 41.4 41.2 43.6 40 45 45

51 53.4 53.3 55.6 60 60 60

62.1

64.5 64.3 66.7 70 70 70

Maximum HACR breaker of the same AMP size is applicable.

5

HP

150

175

45

50

60

80

90

35

100

100

110

150

200

100

100

125

40

45

60

70


035-19046-002-B-0104

TABLE 10: PHYSICAL DATA

Evaporator

Blower

Evaporator

Coil

Condenser

Fan

(4 per Unit)

Condenser

Coil

(2 per unit)

Refrigerant

Charge

Compressors

Air Filters

Component

Blower, Centrifugal (Dia. X Wd. in.)

Motor, Standard (HP)

Motor, Optional (HP)

Rows

Fins per Inch

Height (in.)

Face Area (ft.

2

each)

Propeller Dia. (in., each)

Motor (HP, each)

CFM, Nominal (each)

Rows (each)

Fins per Inch

Height (in. each)

Face Area (ft.

2

each)

System 1 (lb./oz.)

System 2 (lb./oz.)

Quantity

Type

Size (Wd. x Ht. x Thickness in.)

Number Per Unit

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.

These CSA approved heaters are located within the central compartment of the unit with the heater elements extending into the supply air chamber.

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.

TABLE 11: MINIMUM SUPPLY AIR CFM

Heater kW

Unit Model Size, Nominal Tons

12.5

Voltage

Minimum Supply Air CFM

18

24

36

54

18

24

36

54

18

24

36

54

208/230

480

600

3750

3750

3750

Model

DJ150

15 x 15

3

5

4

15

40

13.2

24

1/3

3000

2

20

44

14.5

11/0

11/8

2

Scroll

25x20x2

4


035-19046-002-B-0104

OPTIONAL GAS HEAT

These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition.

TABLE 12: GAS HEAT APPLICATION DATA

Unit

Size Opt.

Input (MBH) Output (MBH)

Temp Rise

(

°

F)

15 180 144 10-40

150

20 240 192 20-50

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.

O P T I O N A L

C O I L

G U A R D

S H O W N

FIGURE 20 - SIDE ENTRY GAS PIPING

OPTIONAL

COIL

GUARD

SHOWN

FIGURE 21 - BOTTOM ENTRY GAS PIPING

TABLE 13: GAS PIPE SIZING - CAPACITY OF PIPE

Length of

Pipe (ft.)

3/4 in.

Nominal Iron Pipe Size

1 in.

1-1/4 in.

50

60

70

80

10

20

30

40

90

100

278

190

152

130

115

105

96

90

84

79

520

350

285

245

215

195

180

170

160

150

1050

730

590

500

440

400

370

350

320

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.


035-19046-002-B-0104

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.

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.




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.

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.

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.

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.

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).


035-19046-002-B-0104

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.

Check all connections for leaks when piping is completed using a soap solution. NEVER USE A FLAME.




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.

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.

POWER EXHAUST

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.


035-19046-002-B-0104

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.

Extreme care must be exercised in turning all set point, maximum and minimum damper positioning adjustment screws to prevent twisting them off.

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.

POWER EXHAUST DAMPER SET POINT (WITH OR WITH-

OUT POWER EXHAUST)

• 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.

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 CO

2

Space Sensor Kit Part # 2AQ04700324

• Optional CO

2

Sensor Kit Part # 2AQ04700424

Replace the top rear access panel on the unit.


035-19046-002-B-0104

CONTROL

CURVE

CONTROL POINT

APPROX.

0 F ( 0 C)

AT 50% RH

A

B

C

D

73 (23)

70 (21)

67 (19)

63 (17)

35

(2)

55

(13)

60

(16)

A

65

(18)

40

(4)

45

(7)

50

(10)

D

C

B

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

100

(38)

105

(41)

110

(43)

D

C B

A

35

(2)

40

(4)

45

(7)

50

(10)

55

(13)

60

(16)

65

(18)

70

(21)

75

(24)

80

(27)

85

(29)

90

(32)

95

(35)

100

(38)

105

(41)

110

(43)

APPROXIMATE DRY BULB TEMPERATURE 0 F ( 0 C)

FIGURE 22 - ENTHALPY SET POINT CHART

Exhaust Air

Adjustment

Screw

Exhaust Air LED

Damper Min.

Position

Screw

N1 N

EXH

Set

P1 P EXH

Min

Pos Indoor Air Quality

Max. Adjustment

Screw

T1 T

Indoor Air Quality

LED

IAQ

Max

IAQ

AQ1 AQ

Indoor Air Quality

Min. Adjustment

Screw

Free Cooling LED

SO+ SO

SR+ SR

B

A

IAQ

Min

Free

Cool

C

D

Economizer Enthalpy

Set Point Adjustment

Screw

FIGURE 23 - HONEYWELL ECONOMIZER CONTROL W7212

TR

24

Vac

HOT

TR1

24

Vac

COM

+

1 2

3

EF

5

4

EF1


035-19046-002-B-0104

PHASING

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

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.

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’).

SPAN LENGTH

DEFL. FORCE

TABLE 14: SUPPLY AIR LIMITATIONS

Unit Minimum Maximum

DJ150 3750 6250

BELT TENSION

The tension on the belt should be adjusted as shown in Figure 24.

FIGURE 24 - BELT ADJUSTMENT

Procedure for adjusting belt tension:

1. Loosen six nuts (top and bottom) A.

2. Adjust by turning (B).

3. Never loosen nuts (C).

4. 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).


035-19046-002-B-0104

TABLE 15: DJ150, 12-1/2 TON STANDARD MOTOR DOWN SHOT BLOWER PERFORMANCE

* †

TURNS OPEN

**

ESP

‡ 0 1 2 3 4

CFM W

†† BHP CFM W




††

5

BHP CFM W

†† 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

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

*.

Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.

†.

Blower performance includes two-inch throwaway filters.

‡.

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.

**.

“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.

††.

W = Watts

TABLE 16: DJ150, 12-1/2 TON OPTIONAL MOTOR DOWN SHOT BLOWER PERFORMANCE

* †

TURNS OPEN

**

ESP

‡ 0 1 2 3 4

CFM W





††

5

BHP CFM W

†† 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

1.6

2.0

5233

4771

4255

4609

4174

3728

4.94

4.48

4.00

4771

4370

3966

3687

3395

3137

3.95

3.64

3.36

2.2

3976 3505 3.76

3763 3020 3.24

4604

4074

-

-

3426

3040

-

-

3.67

3.26

1.8

4520 3951 4.24

4169 3262 3.50

3786 2850 3.06

-

-

4335

3802

-

-

-

2933

2590

-

-

-

3.15

2.78

-

-

-

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

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

*.


†.


‡.


**.


††.

W = Watts


035-19046-002-B-0104

TABLE 17: DJ150, 12-1/2 TON STANDARD MOTOR SIDE SHOT BLOWER PERFORMANCE

* †

TURNS OPEN

**

ESP

‡ 0 1 2 3 4

0.4

CFM W

††

-

BHP CFM W

††

-

5

BHP

-

CFM W




†† BHP

5201 3162 3.39

4966 2796 3.00

4681 2405 2.58

4355 2054 2.20

0.6

0.8

-

-

-

-

-

-

1.4

4428 3040 3.26

5220

4944

-

3395

3194

-

3.64

3.43

-

4942

4661

-

2980

2806

-

3.20

3.01

-

4657

4378

-

2608

2572

-

2.80

2.76

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

-

-

4358

4016

-

-

-

2230

2057

-

-

-

2.39

2.21

-

-

-

4007

-

-

-

-

1890

-

-

-

-

2.03

-

-

-

-

*.


†.


‡.


**.


††.

W = Watts

1.4

1.6

1.8

2.0

0.6

0.8

1.0

1.2

2.2

2.4

2.6

TABLE 18: DJ150, 12-1/2 TON OPTIONAL MOTOR SIDE SHOT BLOWER PERFORMANCE

* †

TURNS OPEN **

ESP

‡ 0

CFM W

††

1

BHP CFM W

††

2

BHP CFM W

††

3

BHP CFM W

††

4

BHP CFM W

††

5

BHP CFM W

††

0.4

-

BHP

6447 5315 5.70

6207 4760 5.1046

5966 4205 4.51

5717 3716 3.98

5470 3307 3.55

6110 4917 5.27

5965 4464 4.79

5740 4023 4.31

5430 3501 3.75

5126 3054 3.28

5772 4519 4.85

5741 4274 4.58

5503 3821 4.10

5162 3294 3.53

4849 2870 3.08

6235 5521 5.92

5628 4407 4.73

5474 4048 4.34

5244 3611 3.87

4882 3101 3.33

4530 2667 2.86

5881 5137 5.51

5384 4205 4.51

5248 3854 4.13

4941 3387 3.63

4589 2906 3.12

4225 2502 2.68

5695 4950 5.31

5123 3996 4.29

5014 3670 3.94

4651 3178 3.41

4284 2716 2.91

3858 2280 2.45

5471 4728 5.07

4919 3828 4.11

4732 3460 3.71

4365 2983 3.20

3951 2516 2.70

3491 2058 2.21

5242 4514 4.84

4656 3611 3.87

4438 3240 3.47

3998 2740 2.94

3618 2316 2.48

-

4954 4231 4.54

4339 3380 3.62

3905 2861 3.07

3631 2497 2.68

4585 3934 4.22

4022 3149 3.38

-

4217 3637 3.90

3848 3340 3.58

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

*.


†.


‡.


**.


††.

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.

• 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.


035-19046-002-B-0104

TABLE 19: INDOOR BLOWER SPECIFICATIONS

MOTOR

MODEL

MOTOR SHEAVE BLOWER SHEAVE

HP RPM Eff.

SF Frame Datum Dia. (in.) Bore (in.) Model Datum Dia. (in.) Bore (in.) Model

3 1725 80% 1.15

56 3.4 - 4.4

7/8 1VM50 7.0

1 AK74

DJ150

5 1725 87% 1.15

184T 4.3 - 5.3

1 1/8 1VP56 6.7

1 BK77

BELT

A54

BX55

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

1.

Remove the dot plugs from the duct panel (for location of the dot plugs see Figure 9).

2.

Insert eight-inches of 1/4 inch metal tubing into the airflow on both sides of the indoor coil.

METHOD TWO

1.

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.

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 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.

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.

5.

Determine the number of turns the variable pitch motor sheave is open.

NOTE: De-energize the compressors before taking any test measurements to assure a dry evaporator coil.

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.

5.

To adjust Measured CFM to Required CFM, see ’SUP-

PLY AIR DRIVE ADJUSTMENT’.

6.

Select the correct blower performance table for the unit from Tables 15 - 18.

7.

Determine the unit Measured CFM from the Blower Performance Table, External Static Pressure and number of turns the variable pitch motor sheave is open.

8.

To adjust Measured CFM to Required CFM, see ’SUP-

PLY AIR DRIVE ADJUSTMENT’.

6.

After adjustments have been completed, remove the tubes and replace the dot plugs.

9.

After adjustments have been completed, remove the tubes and seal holes.

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.

Failure to properly adjust the total system air quantity can result in extensive blower damage.


035-19046-002-B-0104

Predator DJ 150 Units

Indoor Coil Pressure Drop vs. Airflow

0.7

0.6

0.5

0.4

0.3

1

0.9

0.8

0.2

0.1

0

3500 4000 4500 5500 6000 6500 5000

Airflow (CFM)

FIGURE 25 - DRY COIL DELTA P

SUPPLY AIR DRIVE ADJUSTMENT

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

Measured CFM

)

• Existing DD = New DD

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.

Use the equation to determine the required DD for the new motor sheave,

( 4,000 CFM

3,800 CFM

)

• 4.0 in. = 4.21 in.

Use Table 21 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

Use the following tables and the DD calculated per the above equation to adjust the motor variable pitch sheave.

New motor Amps

3

= (Speed increase) • Amps at 3,800 CFM

3

= (Speed increase) • Original Amps

= New Amps


035-19046-002-B-0104

TABLE 20: ADDITIONAL STATIC RESISTANCE

CFM

5300

5500

5700

5900

6100

6300

3700

3900

4100

4300

4500

4700

4900

5100

Cooling Only

*

0.42

0.45

0.48

0.52

0.56

0.60

0.20

0.23

0.25

0.28

0.30

0.33

0.36

0.39

Economizer

† ‡

0.06

0.06

0.06

0.07

0.07

0.07

0.04

0.04

0.04

0.05

0.05

0.05

0.05

0.06

18

0.37

0.40

0.43

0.46

0.49

0.53

0.18

0.20

0.22

0.24

0.26

0.29

0.31

0.34

Electric Heat KW †

24

0.41

0.44

0.47

0.50

0.53

0.56

0.21

0.23

0.25

0.28

0.30

0.33

0.35

0.38

36

0.43

0.46

0.49

0.53

0.56

0.59

0.22

0.24

0.26

0.29

0.31

0.34

0.37

0.40

*.

†.

‡.

Add these resistance values to the available static resistance in the respective Blower Performance Tables.

Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.

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.

54

0.49

0.53

0.56

0.59

0.62

0.65

0.26

0.28

0.31

0.34

0.37

0.40

0.43

0.46

TABLE 21: MOTOR SHEAVE DATUM DIAMETERS

1VM50x7/8

(3 HP Motor)

1VP56x1-1/8

(5 HP Motor)

Turns Open

Datum

Diameter

Turns Open

Datum

Diameter

0

1/2

1

1-1/2

2

2-1/2

3

3-1/2

4

4-1/2

5

4.0

3.9

3.8

3.7

4.4

4.3

4.2

4.1

3.6

3.5

3.4

1

1-1/2

2

2-1/2

3

3-1/2

4

4-1/2

5

5-1/2

6

4.9

4.8

4.7

4.6

5.3

5.2

5.1

5.0

4.5

4.4

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.

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.


035-19046-002-B-0104

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 deenergized. 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.

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.


035-19046-002-B-0104

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 28). If the other compressor is inactive, the condenser fans will be de-energized.

LOW-PRESSURE LIMIT SWITCH

The low-pressure limit switch is not monitored during the initial 30 seconds of a cooling system's operation. For the following 30 seconds, the UCB will monitor the low-pressure switch to ensure it closes. If the low-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.

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 28). If the other compressor is inactive, the condenser fans will be de-energized.

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 28). 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.

SAFETY CONTROLS

The unit control board monitors the following inputs for each cooling system:

1.

A suction line freezestat to protect against low evaporator temperatures due to a low airflow or a low return air temperature, (opens at 26 ± 5 °F and resets at 38 ± 5°F).

2.

A high-pressure switch to protect against 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.

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 28.


035-19046-002-B-0104

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 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.

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 28).

SAFETY CONTROLS

The UCB monitors the temperature limit switch of electric heat units.

The control circuit includes the following safety controls:

LIMIT SWITCH (LS)

This control is located inside the heater compartment and is set to open at the temperature indicated in the Electric Heat

Limit Setting Table 22. 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 22: ELECTRIC HEAT LIMIT SETTING

UNIT (TONS)

12.5

12.5

12.5

12.5

12.5

12.5

12.5

12.5

12.5

12.5

12.5

12.5

VOLTAGE

208/230

480

600

HEATER kW

54

18

24

34

18

24

34

54

18

24

34

54

LIMIT

SWITCH

OPENS °F

150

150

150

150

150

150

150

150

150

150

150

150

FLASH CODES


CODES Table 28.

RESET

Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature.This

resets any flash codes.

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 23 for the required electric heat anticipator setting.

TABLE 23: ELECTRIC HEAT ANTICIPATOR

SETPOINTS

SETTING, AMPS

W1

0.13

W2

0.1


035-19046-002-B-0104

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.

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.

When “W2” is satisfied, the second main valve is closed.

RETRY OPERATION

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.

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.

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 28).

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.

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.

GAS VALVE

The UCB and ICB continuously monitor the GV.


035-19046-002-B-0104

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 28).

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 28). 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.

SAFETY CONTROLS

The UCB monitors the temperature limit switch of gas heat units.


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 24. 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.

AUXILIARY LIMIT SWITCH (ALS)

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 24. 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 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”.

TABLE 24: GAS HEAT LIMIT CONTROL SETTINGS

*

# of HX Tubes

6

Main Limit Setting

195°F

8 160°F

*.

Rollout = 300°F, Auxiliary Limit = 200°F

The ICB monitors the Pressure and Rollout switches of gas heat units.


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 29 Ignition Control Flash Codes.

The draft motor is energized until the pressure switch closes or “W1” is lost.

ROLLOUT SWITCH (ROS)

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.

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.

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.

FLASH CODES


CODES Table 28.

RESETS

Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature. This resets any flash codes.


035-19046-002-B-0104

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 25 for the required gas heat anticipator setting.

TABLE 25: GAS HEAT ANTICIPATOR SETPOINTS

SETTING, AMPS

W1

0.65

W2

0.1

START-UP (COOLING)

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

P I P E B U R N E R

B U R N E R B R A C K E T

I G N I T O R

B U R N E R F L A M E

( B L U E O N L Y )

FIGURE 26 - TYPICAL FLAME

PRESTART CHECK LIST

After installation has been completed:

1.

Check the electrical supply voltage being supplied. Be sure that it is the same as listed on the unit nameplate.

2.

Set the room thermostat to the off position.

3.

Turn unit electrical power on.

4.

Set the room thermostat fan switch to on.

5.

Check indoor blower rotation.

• If blower rotation is in the wrong direction. Refer to

Phasing Section in general information section.

• Check blower drive belt tension.

6.

Check the unit supply air (CFM).

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.

The second stage of the thermostat will energize second stage compressor if needed.

POST START CHECK LIST

1.

Verify proper system pressures for both circuits.

2.

Measure the temperature drop across the evaporator coil.

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.

OPERATING INSTRUCTIONS

This furnace is equipped with an intermittent pilot and automatic re-ignition system. DO NOT attempt to manually light the pilot.

LIGHTING THE MAIN BURNERS

1.

Turn “OFF” electric power to unit.

2.

Turn room thermostat to lowest setting.

3.

Turn gas valve counter-clockwise to “ON” position (see

Figure 27).

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.


035-19046-002-B-0104

POST START CHECKLIST

After the entire control circuit has been energized and the heating section is operating, make the following checks:

1.

Check for gas leaks in the unit piping as well as the supply piping.




2.

Check for correct manifold gas pressures. (See ’CHECK-

ING 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.

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).

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).

Manifold pressure adjustment procedure.

Adjust second stage (100% input) pressure first, then adjust first stage (60% input) pressure.

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.

After the high manifold pressure has been checked, adjust the thermostat to call for first stage heat.

8.

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.

9.

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

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 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 26: GAS HEAT STAGES

# of Burner Tubes

2nd Stage

Input (100%

Btuh)

6 180,000

8 240,000

1st Stage

Input (60%

Btuh)

108,000

144,000

To determine the rate of gas flow (second 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 Second stage (100% input) heat.


035-19046-002-B-0104

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.

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.

TABLE 27: GAS RATE CUBIC FEET PER HOUR

Seconds for One

Rev.

10

1/2 cu. ft.

180

Size of Test Dial

1 cu. ft.

360

150

129

300

257

36

38

40

42

28

30

32

34

20

22

24

26

12

14

16

18

52

54

56

58

60

44

46

48

50

113

100

90

82

75

69

64

60

56

53

50

47

45

37

36

35

34

32

31

43

41

39

30

225

200

180

164

150

138

129

120

113

106

100

95

90

67

64

62

86

82

78

75

72

69

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).


035-19046-002-B-0104

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

•

60 = 189.6. Multiply 189.6

•

1 (0.5 if using a 1/2 cubic foot dial) = 189.6. Multiply 189.6

•

(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.

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 25.

After the temperature rise has been determined, the CFM can be calculated as follows:

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 I G H & L O W G A S A D J U S T M E N T

L O

H I

CFM = Btu Input

•

(

1.08

⋅ ∆°F )

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.

I N L E T

P R E S S U R E

T A P

M V

H I

O F F

M A T E - N - L O C K

C O N N E C T O R S

O N

FIGURE 27 - TYPICAL GAS VALVE

O U T L E T

P R E S S U R E

T A P


035-19046-002-B-0104

CHARGING THE UNIT

The DJ150 (12-1/2 Ton) High Efficiency Unit, uses a TXV metering device. Charge unit to 10º sub-cooling at the TXV.

TROUBLESHOOTING

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.

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.

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 28: UNIT CONTROL BOARD FLASH CODES

Flash Code

On Steady

Description

Control Failure - Replace Control

Heart Beat

1 Flash

Normal Operation

Not Applicable

Control waiting ASCD

* 2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

7 Flashes

8 Flashes

HPS1 - Compressor Lock out

HPS2 - Compressor Lock out

LPS1 - Compressor Lock out

LPS2 - Compressor Lock out

FS1 - Compressor Lock out

FS2 - Compressor Lock out

9 Flashes

10 Flashes

11 Flashes

12 Flashes

Ignition Control Locked Out/

Ignition Control Failure / Limit Switch Trip / No

Jumper Plug in Heat Section

Compressors Locked Out On Low

Outdoor Air Temperature

*

Compressors Locked Out Because The

Economizer Is Using Free Cooling

*

Fan Overload Switch Trip - Not Applicable On This

Unit

Compressor Held Off Due To Low Voltage* 13 Flashes

14 Flashes

OFF

EEPROM Storage Failure (Control Failure)

No Power or Control Failure

*.

These flash codes do not represent alarms.

TABLE 29: IGNITION CONTROL FLASH CODES

FLASHES FAULT CONDITIONS CHECK

STEADY ON Control Failure

HEARTBEAT Normal Operation

1

2

Not Applicable

Pressure Switch

Stuck Closed

3

4

5

6

STEADY OFF

No Power Or Control

Failure

Control

Pressure Switch

Pressure Switch Failed

To Close

Limit Switch Open

Venter Pressure Switch

Vent Blocked

Main Limit

AUX Limit

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

Ignition Lockout

Gas Flow

Gas Pressure

Gas Valve

Flame Sensor

24VAC or Control


035-19046-002-B-0104

Monitor

Monitored

Systems

Problem?

Yes

No

Trip/Failure

Programming?

No

Yes

Program

Unit

Control

Board

Turn off ID

Blower Motor

Yes

No

Fan on

>30 secs?

Yes

No

Lossof Call for ID Blower?

Call for

Heating?

Yes

No

Call for

Heat

Loss of

Call for

Heating?

No

Yes

Call for

Cooling?

No

Yes

Heat Off

Energize ID

Blower Motor

Yes

No

Fan off

>10 secs?

No

Yes

Call for

ID Blower?

No

Loss of Call for Cooling?

Yes

Cool Off

Call for 2nd

Stage

Cooling

No

First

Stage?

Yes

Call for 1st

Stage

Cooling

FIGURE 28 - BASIC TROUBLESHOOTING FLOWCHART

Power to

Unit

Call for heat?

No

Yes

Voltage @

Gas Valve?

No

Yes

Initialize ASCD

Energize ID

Blower

FIGURE 29 - POWER ON FLOW CHART

44

Montior


035-19046-002-B-0104

T r i p / F a i l u r e

I n c i d e n t v a l u e > = 3 ?

Y e s

L o c k o n b l o w e r ; f l a g a l a r m

L o s s o f

L S I n p u t

N o

Y e s

E n e r g i z e b l o w e r : i n c r e a s e i n c i d e n t v a l u e b y 1

N o

L S i n p u t r e g a i n e d ?

Y e s

N o

L o a d F o f f D

Y e s

H P

S w i t c h

O p e n

T u r n o f f c o m p r e s s o r ; i n i t i a t e A S C D ; i n c r e a s e i n c i d e n t v a l v e b y 1

N o

I n c i d e n t

v a l u e > = 3

Y e s

L o c k - o u t c o m p r e s s o r , f l a g a l a r m

N o

S w i t c h O p e n

> 5 S e c s

Y e s

L P

T u r n o f f

C o m p r e s s o r , i n i t i a t e A S C D ; i n c r e a s e i n c i d e n t v a l u e b y 1

N o

I n c i d e n t

v a l u e > = 3

Y e s

L o c k - o u t c o m p r e s s o r , f l a g a l a r m

N o

F r e e z e s t a t

Y e s

O p e n ?

T u r n o f f c o m p r e s s o r , i n i t i a t e A S C D ; i n c r e a s e i n c i d e n t v a l u e b y 1

N o I n c i d e n t

v a l u e > = 3

Y e s

L o c k - o u t c o m p r e s s o r , t u r n o f f I D b l o w e r , t u r n o f f c o n d e n s e r f a n s , f l a g a l a r m

N o

M o n i t o r

L o s s o f

F O S i n p u t

> 5 S e c s ?

Y e s

T u r n o f f f a n c o m p r e s s o r & c o n d e n s e r f a n s ; i n i t i a t e A S C D

N o

I n c i d e n t v a l u e > = 3

Y e s

L o c k - o u t c o m p r e s s o r s , t u r n o f f I D b l o w e r , t u r n o f f c o n d e n s e r f a n s , f l a g a l a r m

N o

C a l l f o r

H e a t w / o u t G V v o l t a g e ?

Y e s

N o v o l t a g e > 5 m i n ?

Y e s

F O S i n p u t r e g a i n e d ?

Y e s

N o

N o

I n c r e a s e i n c i d e n t v a l u e b y 1

N o

F l a g A l a r m

N o

F O S i n p u t > 1 5 m i n u t e s ?

Y e s

F l a g a l a r m , t u r n o n

X l i n e

G V

v o l t a g e

w / o u t c a l l f o r h e a t ?

N o

G V v o l t a g e

> 5 m i n ?

Y e s

F l a g a l a r m , l o c k o n I D b l o w e r

N o

Y e s

L o s s o f G V

V o l t a g e ?

N o

E n e r g i z e I D b l o w e r , l o a d ' F a n

O f f D e l a y ' f o r h e a t i n g

M o n i t o r

1 T h e c o n t r o l b o a r d o n l y m o n i t o r s t h e i n p u t w h e n t h e c o m p r e s s o r r e a l l y i s e n e r g i z e d .

2 T h e l o w - p r e s s u r e s w i t c h i s n o t m o n i t o r e d f o r t h e f i r s t 3 0 s e c o n d s o f c o m p r e s s o r a c t i v i t y . T h e c o n t r o l b o a r d t h e n m o n i t o r s t h e s w i t c h t o e n s u r e i t c l o s e s . I f t h e s w i t c h r e m a i n s o p e n

a n d a d d i t i o n a l 3 0 s e c o n d s , t h e c o n t r o l b o a r d t u r n s o f f t h e a s s o c i a t e d c o m p r e s s o r a n d i n i t i a t e s t h e A S C D . O n c e i t h a s c l o s e d d u r i n g t h e s t a r t u p p e r i o d , t h e c o n t r o l b o a r d n o

l o n g e r h a n d l e s t h e l o w - p r e s s u r e s w i t c h d i f f e r e n t l y t h a n o t h e r i n p u t s .

FIGURE 30 - TRIP FAILURE FLOW CHART


035-19046-002-B-0104

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.

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.

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.

6.

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.

7.

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.

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.

Proper operation of the room thermostat (contact between R and G with the fan switch in the ON position and in the AUTO position during operation calls).

b.

Proper wiring between the room thermostat and the

UCB.

c.

Loose wiring from the room thermostat to the UCB.

9.

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.

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).

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 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.


24 volts are 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.

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: a.

24 volts at the thermostat Y1 terminal b.


UCB, i.e. Y1 to Y1, Y2 to Y2 c.


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


035-19046-002-B-0104 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.

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.

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.

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.



4.


24 volts is present and M2 is not pulled in, replace the contactor.

5.


6.


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: a.

24 volts at the thermostat Y2 terminal b.


UCB, i.e. Y1 to Y1, Y2 to Y2 c.


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


035-19046-002-B-0104 locked out the compressor for repeat trips. The UCB should be flashing a code. If not, press and release the

ALARMS button on the UCB. The UCB will flash the last five alarms on the LED. If the compressor is locked out, remove any call for cooling at the thermostat or by 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.




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.



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.



4.


24 volts is present and M1 is not pulled in, replace the contactor.

5.


6.


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.

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.




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.


035-19046-002-B-0104

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.

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.



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.

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.

4.


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: a.

Proper operation of the room thermostat (contact between R and G with the fan switch in the “ON” position and in the “AUTO” position during operation calls).

b.


UCB.

c.


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.


035-19046-002-B-0104

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.

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.


035-19046-002-B-0104


Subject to change without notice. Printed in U.S.A.

Copyright © 2004 by Unitary Products Group. All rights reserved.

Unitary

Products

Group

035-19046-002-B-0104

Supersedes: 035-19046-002-A-0803

5005 Norman

York OK

Drive 73069

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