York Predator MagnaDRY DR090 Series Installation Manual
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York Predator MagnaDRY DR090 Series Installation Manual

Single package air conditioners and single package gas/electric units
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INSTALLATION
MANUAL - 50 Hz
CONTENTS
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . 44
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . 45
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 49
See the following pages for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes are intended to
clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to alert
installer that personal injury and/or equipment damage
may result if installation procedure is not handled properly.
CAUTION:
READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
MagnaDRY™
SINGLE PACKAGE AIR CONDITIONERS AND
SINGLE PACKAGE GAS/ELECTRIC UNITS
DR090
7-1/2 TON
(50 Hz)
264276-XIM-B-1208

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Summary of Contents for York Predator MagnaDRY DR090 Series

  • Page 1 INSTALLATION MANUAL - 50 Hz MagnaDRY™ SINGLE PACKAGE AIR CONDITIONERS AND SINGLE PACKAGE GAS/ELECTRIC UNITS CONTENTS GENERAL........5 DR090 SAFETY CONSIDERATIONS.

  • Page 2: Table Of Contents

    264276-XIM-B-1208 TABLE OF CONTENTS ........LOW-PRESSURE LIMIT SWITCH .
  • Page 3 264276-XIM-B-1208 LIST OF FIGURES Fig. # Pg. # Fig. # Pg. # UNIT SHIPPING BRACKET ..... 8 18 FIELD WIRING DISCONNECT - COOLING UNIT WITH OR WITHOUT ELECTRIC HEAT .
  • Page 4 264276-XIM-B-1208 LIST OF TABLES Tbl. # Pg. # Tbl. # Pg. # UNIT VOLTAGE LIMITATIONS ....10 20 BLOWER PERFORMANCE 7-1/2 TON STANDARD MOTOR - DOWNSHOT (IMPERIAL) .

  • Page 5: General

    264276-XIM-B-1208 GENERAL ® ® YORK Predator MagnaDRY™ units are single package air conditioners with optional gas heating designed for outdoor If the information in this manual is not followed installation on a rooftop or slab and for non-residential use. exactly, a fire or explosion may result causing prop- These units can be equipped with factory or field installed erty damage, personal injury or loss of life.

  • Page 6: Reference

    • –60°F Gas Heat Kit codes. • Electric Heater Accessory RENEWAL PARTS ® Contact your local York parts distribution center for autho- Incorrect installation may create a condition where the rized replacement parts. operation of the product could cause personal injury or property damage.

  • Page 7: Nomenclature

    264276-XIM-B-1208 NOMENCLATURE ® 7.5 Ton York Model Number Nomenclature D R 090 N10 A 7 A AA 3 0 1 2 4 A Product Category Product Style D = A/C, Single Pkg., R-22 A = Style A B = Style B...

  • Page 8: Installation

    264276-XIM-B-1208 INSTALLATION INSTALLATION SAFETY INFORMATION Read these instructions before continuing this appliance Bracket Turn down Screws installation. This is an outdoor combination heating and cool- ing unit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference.

  • Page 9: Limitations

    264276-XIM-B-1208 LIMITATIONS These units must be installed in accordance with the follow- ing: This product must be installed in strict compliance with the enclosed installation instructions and any Local building codes, and applicable local, state and national codes including, but not limited to, building, electrical, and mechani- Local gas utility requirements cal codes.

  • Page 10: Location

    Roof efficient operation curbs for transitioning from Compressor #1 access Side entry power York Sunline™ footprint to Toolless (high-efficiency compressor and control wiring the ZH Series footprints are door latch w/crankcase heater)

  • Page 11: Rigging And Handling

    If a unit is to be installed on a roof curb other than a TABLE 5: 6 POINT LOAD WEIGHT YORK roof curb, gasketing must be applied to all sur- Locations (lbs. (kg.)) faces that come in contact with the unit underside.

  • Page 12: Clearances

    264276-XIM-B-1208 CLEARANCES All units require particular clearances for proper operation and service. Installer must make provisions for adequate combus- tion and ventilation air in accordance with section 5.3 of Air for Excessive exposure to contaminated combustion air Combustion and Ventilation of the National Fuel Gas Code, will result in safety and performance related prob- ANSI Z223.1 –...

  • Page 13: Unit Dimensions

    264276-XIM-B-1208 30-11/32 See Detail (770) Control Power Entry Entry Ø 7/8 Ø 2-1/2 (22) (65) 4-1/4 Power (110) Entry Ø 2-1/2 11-1/2 (65) (290) Convenience Power Outlet For Baserail Entry Dimensions Ø 7/8 FRONT 17-3/16 30-3/16 (22) See Detail C For Drain (435) (765)

  • Page 14: Bottom Duct Openings (From Above)

    264276-XIM-B-1208 3 2 - 1 1 / 1 6 ( 8 3 0 ) N O T E : ( X X X ) I N D I C A T E S D I M E N S I O N S I N 6 - 1 3 / 1 6 6 - 1 3 / 1 6 M I L L I M E T E R S...

  • Page 15: Ductwork

    264276-XIM-B-1208 DUCTWORK DUCT COVERS Units are shipped with the side duct openings covered and a Ductwork should be designed and sized according to the covering over the bottom of the unit. For bottom duct applica- methods in Manual D of the Air Conditioning Contractors of tion, no duct cover changes are necessary.
  • Page 16 264276-XIM-B-1208 2 T Y P ( 5 0 ) 3 0 - 1 / 2 ( 5 8 5 ) 5 0 - 1 / 2 ( 7 7 5 ) ( 1 2 8 5 ) ( 1 0 0 ) 8 0 - 5 / 8 R E T U R N ( 6 6 0 )

  • Page 17: Condensate Drain

    264276-XIM-B-1208 CONDENSATE DRAIN THERMOSTAT WIRING The side condensate drain is reversible and maybe re-ori- The thermostat should be located on an inside wall approxi- ented to the rear of the cabinet to facilitate condensate pip- mately 56 inches (1422 mm) above the floor where it will not ing.

  • Page 18: Power Wiring Detail

    264276-XIM-B-1208 NOTE: Since not all local codes allow the mounting of a dis- connect on the unit, please confirm compliance with local code before mounting a disconnect on the unit. When connecting electrical power and control wiring Electrical line must be sized properly to carry the load. USE to the unit, water-proof connectors must be used so COPPER CONDUCTORS ONLY.

  • Page 19: Field Wiring Disconnect - Cooling Unit With Or Without Electric Heat

    264276-XIM-B-1208 TERMINAL BLOCK TB1 FIELD SUPPLIED DISCONNECT GROUND THREE PHASE POWER SUPPLY FIGURE 18 -FIELD WIRING DISCONNECT - COOLING UNIT WITH OR WITHOUT ELECTRIC HEAT CONTACTOR 1M FIELD SUPPLIED DISCONNECT GROUND THREE PHASE POWER SUPPLY FIGURE 19 -FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT Johnson Controls Unitary Products...
  • Page 20 264276-XIM-B-1208 TABLE 10: ELECTRICAL DATA 7-1/2 TON Max Fuse Size Min. Circuit † Supply Blower Pwr Exh w/Power w/Power Max Fuse Compressors Ampacity Electric Motor FLA Motor Exhaust Exhaust Size (Amps) Actual Heater Motors (Amps) Heater (Amps) (Amps) Voltage Amps Model No.

  • Page 21: Physical Data

    264276-XIM-B-1208 TABLE 11: PHYSICAL DATA Models Component Blower, Centrifugal 15 x 15 Dia. X Wd. in. (381 x 381) Evaporator (Dia. X Wd. mm.) Blower Motor, Standard - HP (kW) 1-1/2 (1.1) Motor, Optional - HP (kW) 2 (1.5) Rows Fins per 2.54 cm (1 in.) Evaporator Coil...

  • Page 22: Optional Electric Heat

    264276-XIM-B-1208 OPTIONAL ELECTRIC HEAT GAS PIPING Proper sizing of gas piping depends on the cubic feet per The factory-installed heaters are wired for single point power hour of gas flow required, specific gravity of the gas and the supply. Power supply need only be brought into the single length of run.

  • Page 23: Gas Connection

    264276-XIM-B-1208 All piping should be cleaned of dirt and scale by ham- TABLE 14: GAS PIPE SIZING - CAPACITY OF PIPE mering on the outside of the pipe and blowing out loose Nominal Iron Pipe Size Length of particles. Before initial start-up, be sure that all gas lines Pipe ft.

  • Page 24: Lp Units, Tanks And Piping

    264276-XIM-B-1208 LP UNITS, TANKS AND PIPING with screen. If necessary, a flue exhaust extension may be installed at the point of installation. All gas heat units are shipped from the factory equipped for natural gas use only. The unit may be converted in the field OPTIONS/ACCESSORIES for use with LP gas with accessory kit model number 1NP0441.

  • Page 25: Economizer And Power Exhaust Set Point Adjustments And Information

    264276-XIM-B-1208 located between the condenser coil section and the main unit module) to the "A", "B", "C" or "D" setting corresponding cabinet, if the unit has factory installed options. If field to the lettered curve of the Enthalpy Set Point Adjust- installed accessories are being installed all parts necessary ment Figure 22.

  • Page 26: Enthalpy Set Point Chart

    264276-XIM-B-1208 CONTROL POINT CONTROL APPROX. CURVE (29) (32) (35) (38) (41) (43) AT 50% RH 73 (23) 70 (21) (27) 67 (19) 63 (17) (24) (21) (18) (16) (13) (10) (10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43)

  • Page 27: Phasing

    264276-XIM-B-1208 PHASING ® Predator units are properly phased at the factory. Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connec- tion to the unit is misphased. Change the phasing of the Field Line Connection at the factory or field supplied discon- nect to obtain proper rotation.

  • Page 28: Blower Performance 7-1/2 Ton Standard Motor - Side Duct (Imperial)

    264276-XIM-B-1208 TABLE 16: BLOWER PERFORMANCE 7-1/2 TON STANDARD MOTOR - SIDE DUCT (IMPERIAL) Turns Open (iwg) Watts Watts Watts Watts Watts Watts 3580 1340 1.44 3351 1203 1.29 3436 1368 1.47 3158 1213 1.30 2929 1076 1.15 3310 1402 1.50 2983 1229 1.32...

  • Page 29: Blower Performance 7-1/2 Ton Optional Motor - Side Duct (Metric)

    264276-XIM-B-1208 TABLE 19: BLOWER PERFORMANCE 7-1/2 TON OPTIONAL MOTOR - SIDE DUCT (METRIC) Turns Open (Pa) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1.86 1.67 1.33 1.85 1.76 1.41 1.69 1.52 1.22 1.84 1.87 1.49 1.66 1.61 1.29...

  • Page 30: Blower Performance 7-1/2 Ton Optional Motor - Downshot (Imperial)

    264276-XIM-B-1208 TABLE 22: BLOWER PERFORMANCE 7-1/2 TON OPTIONAL MOTOR - DOWNSHOT (IMPERIAL) Turns Open (iwg) Watts Watts Watts Watts Watts Watts 3786 1702 1.83 3476 1489 1.60 3727 1791 1.92 3409 1570 1.68 3099 1357 1.46 3994 2117 2.27 3661 1881 2.02 3335...

  • Page 31: Air Balance

    264276-XIM-B-1208 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.

  • Page 32: Checking Air Quantity

    264276-XIM-B-1208 CHECKING AIR QUANTITY METHOD ONE METHOD TWO Remove the dot plugs from the duct panel (for location of Drill two 5/16 inch holes, one in the return air duct as the dot plugs see Figure 10). 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 Insert eight-inches of 1/4 inch metal tubing into the air- possible.

  • Page 33: Supply Air Drive Adjustment

    264276-XIM-B-1208 0.65 0.55 0.45 0.35 0.25 2700 3200 2200 3700 4200 4700 5200 Volumetric Flow Rate (cfm) 100% Return Economizer No Economizer FIGURE 25 - DRY COIL DELTA P CABINET SUPPLY AIR DRIVE ADJUSTMENT Use the equation to determine the required DD for the new motor sheave.

  • Page 34: Additional Static Resistance (Imperial)

    264276-XIM-B-1208 TABLE 25: ADDITIONAL STATIC RESISTANCE (IMPERIAL) † Electric Heat KW † ‡ Cooling Only Economizer 1900 0.06 0.02 0.05 0.06 0.07 0.08 0.10 2100 0.07 0.02 0.06 0.07 0.08 0.09 0.11 2300 0.08 0.02 0.07 0.08 0.09 0.10 0.13 2500 0.09 0.02...

  • Page 35: Additional Static Resistance (Metric)

    264276-XIM-B-1208 TABLE 26: ADDITIONAL STATIC RESISTANCE (METRIC) † Electric Heat kW † ‡ Cooling Only Economizer 0.89 14.9 12.4 14.9 17.4 19.9 24.8 0.99 17.4 14.9 17.4 19.9 22.4 27.3 1.08 19.9 17.4 19.9 22.4 24.8 32.3 1.18 22.4 19.9 22.4 24.8 27.3...

  • Page 36: Operation

    264276-XIM-B-1208 TABLE 27: MOTOR SHEAVE DATUM 1VM50x7/8 1VP56x1-1/8 (1-1/2, 2 & 3 HP Motor) (5 HP Motor) Datum Dia. Datum Dia. Turns Open Turns Open in.(mm.) in.(mm.) 4.4 (111.7) 5.3 (134.6) 4.3 (109.2) 1-1/2 5.2 (132) 4.2 (106.6) 5.1 (129.5) 1-1/2 4.1 (104.1) 2-1/2...

  • Page 37: Economizer With Single Enthalpy Sensor

    264276-XIM-B-1208 pleted. Upon the final compressor de-energizing, the blower MOTORIZED OUTDOOR AIR DAMPERS - is stopped following the elapse of the fan off delay for cooling. This system operation is the same as the units with no out- door air options with one exception. When the "R" to "G" cir- * To be available, a compressor must not be locked-out due cuit is complete, the motorized damper drives open to a to a high or low-pressure switch or freezestat trip and the...

  • Page 38: Low Ambient Cooling

    264276-XIM-B-1208 Should a freezestat open three times within two hours of COMPRESSOR PROTECTION operation, the UCB will lock-out the associated compressor In addition to the external pressure switches, the compressors and flash a code (Table 34). If the other compressor is inac- also have inherent (internal) protection.

  • Page 39: Alternate" Mode

    264276-XIM-B-1208 Anytime there is a call for 2 stages of cooling, the unit will not When the room thermostat calls for first stage cooling while operate in the reheat mode, even if there is a call for dehu- there is still a call for dehumidification, no operational change midification at "HUM".

  • Page 40: Reheat Control Board

    264276-XIM-B-1208 HGRR DEHUMIDISTAT MODE HARNESS SELECTION CONNECTION JUMPER FIGURE 26: REHEAT CONTROL BOARD Johnson Controls Unitary Products...
  • Page 41 264276-XIM-B-1208 eheat Solenoid 1 eheat Solenoid 3 eheat Solenoid 2 Unit Control Board eheat Terminal Block eheat Control eheat Board elay Dehumidistat Terminal FIGURE 27: DR090 REHEAT CONTROLS Johnson Controls Unitary Products...

  • Page 42: Electric Heating Sequence Of Operations

    264276-XIM-B-1208 ELECTRIC HEATING SEQUENCE OF OPERATIONS FLASH CODES The UCB will initiate a flash code associated with errors The following sequence describes the operation of the elec- within the system. Refer to UNIT CONTROL BOARD FLASH tric heat section. CODES Table 34. Two-stage heating: RESET Upon a call for first stage heat by the thermostat, the...

  • Page 43: Second Stage Of Heating

    264276-XIM-B-1208 During the flame stabilization period, a loss of the flame for 2 If the temperature limit opens three times within one hour, it seconds will cause the GV to close and the retry operation to will lock-on the indoor blower motor and flash code is initiated begin.

  • Page 44: Auxiliary Limit Switch (Als)

    264276-XIM-B-1208 equate supply air flow occurs, thus shutting down the heater RESETS and energizing the blower. Remove the call for heating by lowering the thermostat set- AUXILIARY LIMIT SWITCH (ALS) ting lower than the conditioned space temperature. This resets any flash codes. This control is located inside the supply air compartment and is set to open at the temperature indicated in the Gas Heat GAS HEAT ANTICIPATOR SETPOINTS...

  • Page 45: Operating Instructions

    264276-XIM-B-1208 OPERATING INSTRUCTIONS POST START CHECKLIST After the entire control circuit has been energized and the Turn unit electrical power on. heating section is operating, make the following checks: NOTE: Prior to each cooling season, the crankcase heaters Check for gas leaks in the unit piping as well as the sup- must be energized at least 10 hours before the sys- ply piping.

  • Page 46: Checking Gas Input

    264276-XIM-B-1208 Turn off all power to the unit. To determine the rate of gas flow (Second Stage). Using the outlet pressure port on the gas valve, connect Turn off all other gas appliances connected to the gas a manometer to monitor the manifold pressure. meter.

  • Page 47: Adjustment Of Temperature Rise

    264276-XIM-B-1208 ADJUSTMENT OF TEMPERATURE RISE TABLE 33: GAS RATE CUBIC FEET PER HOUR Seconds Size of Test Dial The temperature rise (the difference of temperature between for One 1/2 cu. ft. 1 cu. ft. Rev. 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 31.

  • Page 48: Charging The Unit

    264276-XIM-B-1208 H I G H & L O W G A S A D J U S T M E N T I N L E T O F F P R E S S U R E T A P O U T L E T P R E S S U R E T A P...

  • Page 49: Troubleshooting

    264276-XIM-B-1208 TROUBLESHOOTING ® PREDATOR FLASH CODES Various flash codes are utilized by the unit control board (UCB) to aid in troubleshooting. Flash codes are distinguished by the short on and off cycle used (approximately 200ms on and 200ms off). To show normal Troubleshooting of components may require open- operation, the control board flashes a 1 second on, 1 second ing the electrical control box with the power con-...

  • Page 50: Unit Control Board Option Setup

    264276-XIM-B-1208 Check Alarm History Reset All ASCDs for One Cycle Non Alarm Condition Green LED Flashing Current Alarm Flashed Red LED FIGURE 30: UNIT CONTROL BOARD UNIT CONTROL BOARD OPTION SETUP HEAT DELAY SETUP • Enter the Option Setup mode by pushing the OPTION OPTION BYTE SETUP SETUP / STORE button, and holding it for at least 2 sec- onds.

  • Page 51: Heat Delay

    264276-XIM-B-1208 TABLE 35: HEAT DELAY TABLE 37: REHEAT CONTROL BOARD FLASH CODES Heat Heat Fan On Fan Off FLASH CODES DESCRIPTION LED 8 LED 4 LED 2 LED 1 Delay Delay On Steady This is a Control Failure 1 Flash Not Applicable Hot Gas Reheat is on with Y1 Output 2 Flashes...
  • Page 52 264276-XIM-B-1208 Monitored Loss of Call for Programming? Heat Off Systems Call for Heating? Problem? Heating? Program Call for 2nd Unit Call for Trip/Failure Stage Control Heat Cooling Board Energize ID Call for First Monitor Stage? Blower Motor Cooling? Call for 1st Turn off ID Fan on Fan off...
  • Page 53 264276-XIM-B-1208 L o s s o f F r e e z e s t a t T r i p / F a i l u r e S w i t c h S w i t c h O p e n L S I n p u t O p e n ? O p e n...

  • Page 54: Cooling Troubleshooting Guide

    264276-XIM-B-1208 COOLING TROUBLESHOOTING GUIDE 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): On calls for cooling, if the compressors are operating but the supply air blower motor does not energize after a short delay If installed, check the position of the economizer blades.
  • Page 55 264276-XIM-B-1208 If 24 volts is present at the UCB Y1 terminal and none of For units without factory installed or with field installed the protection switches have opened, the UCB may have economizers, the UCB allows compressor operation all locked out the compressor for repeat trips. The UCB the time.
  • Page 56 264276-XIM-B-1208 low-pressure switch, or freezestat. Check for 24 volts at Check for line voltage at the compressor contactor, M1, the HPS2, LPS2, and FS2 terminals of the UCB. If a and that the contactor is pulled in. Check for loose wiring switch has opened, there should be a voltage potential between the contactor and the compressor.

  • Page 57: Gas Heat Troubleshooting Guide

    264276-XIM-B-1208 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 The furnace may shut down on a high temperature at the Y1 “OUT”...
  • Page 58 264276-XIM-B-1208 If the blower motor runs with the fan switch in the “ON” switch. If present, go to step 4. If 24 volts is not present, position but does not run shortly after the furnace has the either pressure or rollout switch is not closed. Or the ignited when the fan switch is in the “AUTO”...
  • Page 59 264276-XIM-B-1208 Johnson Controls Unitary Products...
  • Page 60 Subject to change without notice. Printed in U.S.A. 264276-XIM-B-1208 Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 264276-YIM-A-0806 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...

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