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INSTALLATION
MANUAL - 50Hz
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .42
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .43
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .45
See the following page for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes are intended to
clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to
alert installer that personal injury and/or equipment dam-
age may result if installation procedure is not handled
properly.
CAUTION:
READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
SUNLINE™ 2000
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
MODELS: DM180, 240 & 300
(Export)
ISO 9001
Certified Quality
Management System
356214-XIM-A-0108
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Table of Contents
Troubleshooting
Summary of Contents for Sunlife Enterprises SUNLINE DM180
- Page 1 INSTALLATION MANUAL - 50Hz CONTENTS GENERAL ........4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
GENERAL ........SAFETY CONSIDERATIONS . -
Page 3: List Of Figures
356214-XIM-A-0108 LIST OF FIGURES Fig. # 1 TYPICAL RIGGING ....... 9 2 CENTER OF GRAVITY . -
Page 4: General
GENERAL YORK Model DM units are either single package air conditions equipped with optional factory installed elec- tric heaters, or single package gas-fired central heating furnaces with cooling unit. Both are designed for out- door installation on a rooftop or slab. The units are completely assembled on rigid, perma- nently attached base rails. -
Page 5: Renewal Parts
356214-XIM-A-0108 RENEWAL PARTS ® Contact your local York Parts Distribution Center for authorized replacement parts. APPROVALS Design certified by CSA as follows: • For use as a cooling unit only with or without optional electric heat. • For use as a forced air furnace with cooling unit •... -
Page 6: Product Nomenclature
PRODUCT NOMENCLATURE 15-25 Ton Sunline & Magnum™ & MagnaDRY™ Model Number Nomenclature D M 180 N24 A 7 A AA 1 0 1 2 4 A Product Category D = A/C, Single Pkg., R-22 Product Identifier M = 8.5-9.0 EER A/C Nominal Cooling Capacity 180 = 15 Ton 240 = 20 Ton... -
Page 7: Installation
356214-XIM-A-0108 INSTALLATION INSTALLATION SAFETY INFORMATION: Read these instructions before continuing this appli- ance installation. This is an outdoor combination heat- ing and cooling unit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference. 1. -
Page 8: Location
TABLE 1: UNIT APPLICATION DATA UNIT MODEL NUMBER Voltage Variation, 380/415-3-50 Min. / Max. Supply Air CFM, Min. / Max. Wet Bulb Temperature (ºF) of Air on Evaporator Coil, Min. / Max. Dry Bulb Temperature (ºF) of Air on Condenser Coil, Min. / Max. Utilization range “A”... -
Page 9: Rigging And Handling
356214-XIM-A-0108 RIGGING AND HANDLING Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installa- tion. Rig the unit by attaching chain or cable slings to the round lifting holes provided in the base rails. Spreaders, whose length exceeds the largest dimen- sion across the unit, MUST BE USED. -
Page 10: Ductwork
Do not permit overhanging structures or shrubs to obstruct outdoor air discharge outlet, com- bustion air inlet or vent outlets. DUCTWORK Ductwork should be designed and sized according to the methods in Manual Q of the Air Conditioning Con- tractors of America (ACCA). A closed return duct system shall be used. -
Page 11: Condensate Drain
356214-XIM-A-0108 FIGURE 3 - FIXED OUTDOOR AIR DAMPER CONDENSATE DRAIN Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install a condensate drain line from the one-inch NPT female connection on the unit to an open drain. The condensate drain operates in a negative NOTE: pressure in the cabinet. -
Page 12: Field Wiring - Dm Electric/Electric And Gas/ Electric Units
THERMOSTAT TERMINALS TERMINALS ON A LIMITED NUMBER OF THERMOSTATS Second stage heating not required on single stage heating units. Second stage cooling not required on single stage cooling units. Jumper is required if there is no Smoke Detector circuit. Jumper is required for any combination of R, RC, or RH. OCC is an output from the thermostat to indicate the Occupied condition. -
Page 13: Thermostat
356214-XIM-A-0108 THERMOSTAT The room thermostat should be located on an inside wall approximately 56 inches above the floor where it will not be subject to drafts, sun exposure or heat from electrical fixtures or appliances. Follow manufacturer's instructions enclosed with thermostat for general instal- lation procedure. -
Page 14: Optional Gas Heat
OPTIONAL GAS HEAT These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition with proven pilot. TABLE 4: GAS HEAT APPLICATION DATA 0 To 2,000 To 2,000 Feet 4,500 Feet Above Above Sea Level Sea Level Max. -
Page 15: L.p. Units, Tanks And Piping
356214-XIM-A-0108 Natural gas may contain some propane. Pro- pane, being an excellent solvent, will quickly dissolve white lead or most standard commer- cial compounds. Therefore, a special pipe compound must be applied when wrought iron or steel pipe is used. Shellac base compounds such as Gaskolac or Stalastic, and compounds such as Rectorseal #5, Clyde's or John Crane may be used. -
Page 16: Vent And Combustion Air Hoods
For satisfactory operation, L.P./propane gas pressure must be 10.0 I.W.C. at the unit manifold under full load. Maintaining proper gas pressure depends on three main factors: 1. The vaporization rate depends on (a) the tempera- ture of the liquid and (b) the "wetted surface" area of the container or containers. -
Page 17: Optional Power Exhaust/Barometric Relief Damper Rain Hood
356214-XIM-A-0108 OPTIONAL POWER EXHAUST/BAROMETRIC RELIEF DAMPER RAIN HOOD The instructions for the power exhaust/barometric relief damper rain hood can be found in the kit. The exhaust fan, all supporting brackets, angles, and the wiring are factory installed as part of the power exhaust option. OPTIONAL ECONOMIZER AND POWER EXHAUST DAMPER SET POINT ADJUSTMENTS AND INFORMA- TION... -
Page 18: Enthalpy Setpoint Adjustment
FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT Exhaust Air Adjustment Screw Exhaust Air LED Damper Min. Position Screw Indoor Air Quality Max. Adjustment Screw Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 10 - HONEYWELL ECONOMIZER CONTROL W7212 Free... -
Page 19: Four And Six Point Loads
356214-XIM-A-0108 FIGURE 11 - FOUR AND SIX POINT LOADS TABLE 6: FOUR AND SIX POINT LOADS Total Unit Size Shipping Weight 180 Gas 2300 240 Gas 2500 300 Gas 3130 180 Elec 2100 240 Elec 2300 300 Elec 2890 Total Unit Size Shipping Weight... -
Page 20: Physical Data
TABLE 7: PHYSICAL DATA MODELS CENTRIFUGAL BLOWER (Dia. x Wd.) EVAPORATOR BLOWER FAN MOTOR HP ROWS DEEP EVAPORATOR COIL FINS PER INCH FACE AREA (Sq. Ft.) PROPELLER DIA. (In.) CONDENSER FAN FAN MOTOR HP (Two Per Unit) NOM. CFM TOTAL ROWS DEEP CONDENSER FINS PER INCH... -
Page 21: Dm Electrical Data -Without Powered Convenience Outlet
356214-XIM-A-0108 TABLE 8: DM ELECTRICAL DATA -WITHOUT POWERED CONVENIENCE OUTLET COMPRESSORS MODEL VOLTAGE TONNAGE EACH EACH 20.7 20.7 22.9 22.9 Note 1: HACR Type per NEC. Johnson Controls Unitary Products OD FAN CONV BLOWER MOTORS OUTLET MOTOR MODEL FLA EACH AMPS None None... -
Page 22: Dm Electrical Data -With Powered Convenience Outlet
TABLE 9: DM ELECTRICAL DATA -WITH POWERED CONVENIENCE OUTLET COMPRESSORS MODEL VOLTAGE TONNAGE EACH EACH 20.7 20.7 22.9 22.9 Note 1: HACR Type per NEC. OD FAN CONV BLOWER MOTORS OUTLET MOTOR MODEL FLA EACH AMPS None None None 11.7 None 11.5 None... -
Page 23: Front View Dimensions (15, 20 & 25 Ton)
356214-XIM-A-0108 BLOWER ACCESS BLOWER MOTOR ACCESS BLOWER COMPARTMENT ACCESS (Auxiliary) DOT PLUG (For pressure Drop Reading) ELECTRIC/ GAS HEAT ACCESS VENT AIR OUTLET HOODS COMBUSTION AIR INLET HOOD GAS SUPPLY ENTRY CONTROL BOX ACCESS UNIT BASE WITH RAILS Shown separately to illustrate GAS SUPPLY Bottom Duct openings, Power ENTRY... -
Page 24: Rear View Dimensions
Dimensions listed are for side duct flange openings; see Field Accessories for Side Duct Flange Kit. FIGURE 14 - REAR VIEW DIMENSIONS Units are shipped with the bottom duct open- NOTE: ings covered. An accessory flange kit is avail- able for connecting side ducts. For bottom duct applications: Remove the side panels from the supply and return air compartments to gain access to the bottom supply and... -
Page 25: Unit Clearances And Rain Hood Dimensions (15, 20 & 25 Ton)
356214-XIM-A-0108 CLEARANCES LOCATION Front 610 / 24” (Less Economizer) Rear 1245 / 49” (With Economizer) 610 / 24” (Less Economizer) Left Side (Filter Access) 1372 / 54” (With Economizer) Right Side (Cond. Coil) Below Unit 1829 / 72” With 914 / 36” Maximum Horizontal Overhang Above Unit (For Condenser Air Discharge) -
Page 26: Cfm, Static Pressure, And Power - Altitude And Temperature Corrections
CFM, STATIC PRESSURE, AND POWER - ALTITUDE AND TEMPERATURE CORRECTIONS The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 feet above sea level. The air flow rates listed in the standard blower performance tables are based on standard air at sea level. -
Page 27: Altitude/Temperature Conversion Factor
356214-XIM-A-0108 ltitude/Temperature Conversion Factor ltitude/Temperature Conversion Factor FIGURE 16 - ALTITUDE/TEMPERATURE CONVERSION FACTOR Johnson Controls Unitary Products 15.5 26.6 TEMPER TURE (°C) TEMPER TURE (°F) SEA LEVEL 3 5 meter 1219 1524 1829 2134 2438 2743 3 48 SEA LEVEL... -
Page 28: Supply Air Blower Performance (15 Ton) - Cooling Only 180 Mbh - Bottom Duct
TABLE 11: SUPPLY AIR BLOWER PERFORMANCE (15 TON) - COOLING ONLY 180 MBH - BOTTOM DUCT CONNECTIONS MOTOR BLOWER PULLEY 2.10 m SPEED, (TURNS (RPM) OPEN)* Output Input (Pa) (kW) (kW) HIGH STATIC DRIVE (m 1030 1070 1115 1155 1200 1240 MOTOR BLOWER... -
Page 29: Supply Air Blower Performance (20 Ton) - Cooling Only 240 Mbh - Bottom Duct
356214-XIM-A-0108 TABLE 12: SUPPLY AIR BLOWER PERFORMANCE (20 TON) - COOLING ONLY 240 MBH - BOTTOM DUCT CONNECTIONS MOTOR BLOWER PULLEY 2.80 m SPEED, (TURNS (RPM) OPEN)* Output Input (Pa) (kW) (kW) HIGH STATIC DRIVE (m 1005 1045 1080 MOTOR BLOWER PULLEY 5930 CFM... -
Page 30: Supply Air Blower Performance (15 Ton) - Gas Heat 180 Mbh - Bottom Duct
TABLE 13: SUPPLY AIR BLOWER PERFORMANCE (15 TON) - GAS HEAT 180 MBH - BOTTOM DUCT CONNECTIONS MOTOR BLOWER PULLEY 2.10 m SPEED, (TURNS (RPM) OPEN)* Output Input (Pa) (kW) (kW) HIGH STATIC DRIVE (m 1030 1070 1115 1155 1200 1240 MOTOR BLOWER... -
Page 31: Supply Air Blower Performance (20 Ton) - Gas Heat 240 Mbh - Bottom Duct
356214-XIM-A-0108 TABLE 14: SUPPLY AIR BLOWER PERFORMANCE (20 TON) - GAS HEAT 240 MBH - BOTTOM DUCT CONNECTIONS MOTOR BLOWER PULLEY 2.80 m SPEED, (TURNS (RPM) Output Input OPEN)* (Pa) (kW) (kW) HIGH STATIC DRIVE (m 1020 1050 1080 MOTOR BLOWER PULLEY 5930 CFM... -
Page 32: Supply Air Blower Performance (25 Ton) - Cooling Applications 300 Mbh - Bottom Duct
TABLE 15: SUPPLY AIR BLOWER PERFORMANCE (25 TON) - COOLING APPLICATIONS 300 MBH - BOTTOM DUCT CONNECTIONS DM300 UNIT - DOWNFLOW DUCT CONNECTIONS (CFM) BLOWER PULLEY SPEED (rpm) TURNS OPEN ESP (iwg) OUTPUT (bhp) 1005 1040 1070 1100 1130 DM300 UNIT - DOWNFLOW DUCT CONNECTIONS (m BLOWER PULLEY SPEED (rpm) -
Page 33: Static Resistances
356214-XIM-A-0108 TABLE 16: STATIC RESISTANCES DESCRIPTION 2.1/4500 WET COIL 24.8/0.1 GAS HEAT 24.8/0.1 18 KW 24.8/0.1 36 KW 24.8/0.1 ELECTRIC HEAT OPTIONS 54 KW 50.0/0.2 72 KW 50.0/0.2 ECONOMIZER OPTION 24.8/0.1 HORIZONTAL DUCT CONNECTIONS 50.0/0.2 Deduct these resistance values from the available external static pressures shown in the respective Blower Performance Table except for Horizontal Duct Connections. -
Page 34: Phasing
PHASING YORK MODEL DM, units are properly phased at the factory. Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is mis- phased. Change the incoming line connection phasing to obtain proper rotation. -
Page 35: Pressure Drop Across A Dry Indoor Coil Vs Supply Air Cfm For All Unit Tonnages
356214-XIM-A-0108 Start the supply air blower motor. Adjust the resis- tances in both the supply and the return air duct sys- tems to balance the air distribution throughout the conditioned space. The job specifications may require that this balancing be done by someone other than the equipment installer. -
Page 36: Operation
OPERATION SEQUENCE OF OPERATIONS OVERVIEW For these 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 opera- tion is available and, if so, which components to ener- gize. -
Page 37: Xim-A
356214-XIM-A-0108 has energized the economizer), "Y2" will energize compressor #1. If the outdoor air is above the setpoint, "Y2" will energize compressor #2. Once the thermostat has been satisfied, it will de-ener- gize Y1 and Y2. If the compressors have satisfied their minimum run times, the compressors and condenser fans are de-energized. -
Page 38: Low Ambient Cooling
Should a freezestat open three times within two hours of operation, the UCB will lock-out the associated com- pressor and flash a code (Table 24). If the other com- pressor is inactive, the condenser fans will be de- energized. LOW AMBIENT COOLING To determine when to operate in low ambient mode, the UCB has a pair of terminals connected to a temper- ature-activated switch set at 30ºF. -
Page 39: Heating Operation Errors
356214-XIM-A-0108 on delay for heating, the UCB will energize the blower motor. If the second stage of heat is required, heater con- tactor (7M) will be energized. Note that on the 54 KW, 240V heater, heater contactors (7M & 8M) will be energized and on the 72 KW, 240V heater, heater contactors (8M &... -
Page 40: Gas Heating Operation Errors
When the thermostat calls for the first stage of heating, the low-voltage control circuit from "R" to "W1" and "G" is completed, thru the UCB. The heat relay "RW1" is energized. The "RW1-2" contacts close energizing the draft motor control. The draft motor control contacts close and start the draft motor. -
Page 41: Gas Valve
356214-XIM-A-0108 If the temperature limit opens three times within one hour, it will lock-on the indoor blower motor and a flash code is initiated (See Table 24). GAS VALVE The UCB continuously monitors the GV. Any time the UCB senses voltage at the GV without a call for heat for a continuous five-minute period, the UCB will lock- on the indoor blower and a flash code is initiated (Table 24). -
Page 42: Flash Codes
FIGURE 20 - GAS VALVE AND CONTROLS FLASH CODES The UCB will initiate a flash code associated with errors within the system. Refer to UNIT CONTROL BOARD FLASH CODES Table 24. RESETS Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature. -
Page 43: Shut Down
356214-XIM-A-0108 3. Measure the system Amperage draw across all legs of 3 phase power wires. 4. Measure the condenser fan amp draw. SHUT DOWN 1. Set the thermostat to highest temperature setting. 2. Turn off the electrical power to the unit. START-UP (GAS HEAT) PRE-START CHECK LIST Complete the following checks before starting the unit. -
Page 44: Manifold Gas Pressure Adjustment
MANIFOLD GAS PRESSURE ADJUSTMENT Small adjustments to the high-fire gas flow may be made by turning the pressure regulator adjusting screw on the automatic gas valve. Adjust as follows: 1. Remove the cap on the regulator. It's located next to the push-on electrical terminals. 2. -
Page 45: Xim-A
356214-XIM-A-0108 of the regulator setting), replace the orifice spuds with spuds of the proper size. To find the Btu input, multiply the number of NOTE: cubic feet of gas consumed per hour by the Btu content of the gas in your particular locality (contact your gas company for this information - it varies widely from city to city.) TABLE 23: GAS RATE - CUBIC FEET PER HOUR... - Page 46 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 sup- ply air blower motor.
- Page 47 356214-XIM-A-0108 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 an alarm code. If not, press and release the ALARMS button on the UCB.
- Page 48 3. If M2 is pulled in and voltage is supplied at M2, lightly touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls for cooling and wait for the inter- nal overload to reset. Test again when cool. 4.
- Page 49 356214-XIM-A-0108 4. If M1 is not pulled in, check for 24 volts at the M1 coil. If 24 volts is present and M1 is not pulled in, replace the contactor. 5. Failing the above, if voltage is supplied at M1, M1 is pulled in, and the compressor still does not oper- ate, replace the compressor.
-
Page 50: Properly
15. If none of the above correct the error, replace the UCB. GAS HEAT TROUBLESHOOTING GUIDE Troubleshooting of components may require opening the electrical control box with the power connected to the unit. Use extreme care when working with live circuits! Check the unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any connections with line termi-... - Page 51 356214-XIM-A-0108 10. If the blower motor runs with the fan switch in the “ON” position but does not run shortly after the fur- nace has ignited when the fan switch is in the “AUTO” position, check the room thermostat for contact between R and G during “W1”...
-
Page 52: Shutter Adjustment
4. If 24 volts is present, remove the pilot burner and remove the pilot orifice from the pilot burner. The orifice is removed in the direction opposite the flow of gas. Inspect the orifice for obstruction. If it is clear, replace the main gas valve. The ignitor sparks at the pilot burner but the pilot does not ignite and a gas odor is detected at the draft motor outlet. -
Page 53: Unit Control Board
356214-XIM-A-0108 TABLE 24: UNIT CONTROL BOARD FLASH CODES FLASH CODE On Steady This is a Control Failure 1 Flash Not Applicable 2 Flashes Control waiting ASCD 3 Flashes HPS1 Compressor Lockout 4 Flashes HPS2 Compressor Lockout 5 Flashes LPS1 Compressor Lockout 6 Flashes LPS2 Compressor Lockout 7 Flashes... -
Page 54: Unit Control Board Option Setup
UNIT CONTROL BOARD OPTION SETUP OPTION BYTE SETUP • Enter the Option Setup mode by pushing the OPTION SETUP / STORE button, and holding it for at least 2 seconds. • The green status LED (Option Byte) will be turned on and the red status LED (Heat Delay) is turned off. - Page 55 356214-XIM-A-0108 Johnson Controls Unitary Products...
- Page 56 Subject to change without notice. Printed in U.S.A. 356214-XIM-A-0108 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 175240-XIM-B-0707 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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