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INSTALLATION
MANUAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .48
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .49
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .51
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 ULTRA™
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
MODELS: DH180 & 240
66369-YIM-D-1004
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Troubleshooting
Related Manuals for Unitary products group SUNLINE ULTRA DH180
Summary of Contents for Unitary products group SUNLINE ULTRA DH180
- Page 1 INSTALLATION SUNLINE ULTRA™ MANUAL GAS/ELECTRIC SINGLE PACKAGE AIR CONDITIONERS CONTENTS MODELS: DH180 & 240 GENERAL ........4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
OPERATION........42 MANIFOLD GAS PRESSURE ADJUSTMENT..49 SEQUENCE OF OPERATIONS OVERVIEW ..42 Unitary Products Group... - Page 3 21 TYPICAL FLAME APPEARANCE....50 25 GAS RATE - CUBIC FEET PER HOUR ... 51 26 UNIT CONTROL BOARD FLASH CODES..58 Unitary Products Group...
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Page 4: General
Wear safety glasses and work gloves, and follow all safety codes. Use a quenching cloth and have a fire • 035-19856-000 - Barometric Relief Damper extinguisher available for all brazing operations. Accessory Unitary Products Group... -
Page 5: Renewal Parts
• For installation on combustible material. or equipment damage may result if installation proce- dure is not handled properly. • For use with natural gas or propane gas. Unitary Products Group... -
Page 6: Product Nomenclature
66369-YIM-D-1004 PRODUCT NOMENCLATURE Unitary Products Group... - Page 7 Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Phase Monitor Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard Johnson UNT Controller, DFS, APS, SS Drain Pan Unitary Products Group...
- Page 8 Novar ETC-3 Controller, DFS, APS, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils Technicoat Condenser Coil Technicoat Condenser Coil & Phase Monitor Technicoat Condenser Coil & Coil Guard Technicoat Condenser Coil & Dirty Filter Switch Technicoat Condenser Coil, Phase Monitor, & Coil Guard Unitary Products Group...
- Page 9 WG Intelli-Comfort w/ModLINC Controller, Technicoat Cond. Coil, & Coil Guard WH Intelli-Comfort w/ModLINC Controller, Technicoat Cond. Coil, Phase Monitor, & Coil Guard Intelli-Comfort w/ModLINC Controller, & Technicoat Evap. Coil WK Intelli-Comfort w/ModLINC Controller, Technicoat Evap. Coil, & Phase Monitor Unitary Products Group...
- Page 10 Johnson UNT Controller, DFS, APS & Phase Monitor, Hinged Filter Door & Toolless Access Panels Johnson UNT Controller, DFS, APS & Coil Guard, Hinged Filter Door & Toolless Access Panels Johnson UNT Controller, DFS, APS, Phase Monitor, & Coil Guard, Hinged Filter Door & Toolless Access Panels Unitary Products Group...
- Page 11 Novar ETC-3 Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard, Hinged Filter Door & Toolless Access Panels Novar ETC-3 Controller, DFS, APS, Technicoat Cond. Coil, Phase Monitor, & Coil Guard, Hinged Filter Door & Toolless Access Panels Novar ETC-3 Controller, DFS, APS & Technicoat Evap. Coil, Hinged Filter Door & Toolless Access Panels Unitary Products Group...
- Page 12 Simplicity Intelli-Comfort Controller, Technicoat Evap. Coil, & Coil Guard, Hinged Filter Door & Toolless Access Panels QM Simplicity Intelli-Comfort Controller, Technicoat Evap. Coil, Phase Monitor, & Coil Guard, Hinged Filter Door & Toolless Access QN Simplicity Intelli-Comfort Controller, & Technicoat Evap. & Cond Coils, Hinged Filter Door & Toolless Access Panels Unitary Products Group...
- Page 13 XW Intelli-Comfort w/ModLINC Controller, SS Drain Pan, & Technicoat Evap and Cond Coils Hinged Filter Door & Toolless Access Panels Intelli-Comfort w/ModLINC Controller, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils Hinged Filter Door & Toolless Access Panels Unitary Products Group...
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Page 14: Installation
This furnace is not to be used for temporary heating of CIFICALLY DETECTION buildings or structures under construction. LEAKS TO CHECK ALL CONNECTIONS. A FIRE OR EXPLOSION MAY RESULT CAUS- PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. Unitary Products Group... -
Page 15: Location
York roof curb, gasketing must be applied to all surfaces that come in contact with the unit 6. Maintain level tolerance to 1/2 inch maximum underside. across the entire length or width of the unit. Unitary Products Group... -
Page 16: Rigging And Handling
T H A T I T W I L L L I F T H O L E S Clearances Figure 13 for the clearances required for E V E N L Y combustible construction, servicing, and proper unit operation. FIGURE 1 - TYPICAL RIGGING Unitary Products Group... -
Page 17: Ductwork
The cov- The cover should be attached in a manner ering over the mounting holes only need be adequate to prevent leakage. removed. Do not remove the opening cover. Unitary Products Group... -
Page 18: Condensate Drain
Refer to the Dimensions and Clearances Figure 13 for location of these access panels. Make sure that all screws and panel latches are replaced and properly positioned on the unit to maintain an airtight seal. FIGURE 4 - RECOMMENDED DRAIN PIPING Unitary Products Group... -
Page 19: Typical Field Wiring
O C C U N I T C O N T R O L B O A R D ERMINAL BLOCK B1 FAC ORY OR FIELD GROUND SUPPLIED DISCONNEC HREE PHASE POWER SUPPLY FIGURE 5 - TYPICAL FIELD WIRING Unitary Products Group... -
Page 20: Thermostat
Use copper conductors only. Each unit must be wired TABLE 3: ELECTRIC HEAT APPLICATION DATA NOMINAL VOLTAGE MINIMUM CFM UNIT SIZE HEATER SIZE 3-PHASE, 15 TON 20 TON (KW) 60 HZ 208/230,460,575 4500 208/230,460,575 4500 208/230 5000 6000 460,575 4500 208/230 5000 460,575 4500 Unitary Products Group... -
Page 21: Optional Gas Heat
3. Use wrought iron or steel pipe for all gas lines. Pipe Maximum capacity of pipe in cubic feet of gas per hour. (Based upon a pressure drop of 0.3 inch water column and 0.6 specific gravity compound should be applied sparingly to male gas). threads only. Unitary Products Group... -
Page 22: L.p. Units, Tanks And Piping
All L.P./propane gas equipment must conform to the The furnace must be isolated from the gas supply safety standards of the National Fire Protection Associ- piping system by closing its individual manual shut- ation. off valve during any pressure testing of the gas Unitary Products Group... -
Page 23: Vent And Combustion Air Hoods
Two vent hoods and a combustion air hood (with the "Factory installed" economizer option. screens) are shipped attached to the blower housing in Unitary Products Group... -
Page 24: Optional Power Exhaust/Barometric Relief Damper And Rain Hood
Adjusting screw (located on the damper control mod- ule) counterclockwise until the desired minimum • Optional CO Space Sensor Kit Part # damper position has been attained. 2AQ04700324 • Optional CO Unit Sensor Kit Part # 2AQ04700424 Replace the economizer access panel. Unitary Products Group... -
Page 25: Enthalpy Setpoint Adjustment
66369-YIM-D-1004 FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT Unitary Products Group... -
Page 26: Honeywell Economizer Control W7212 . 26 11 Four And Six Point Loads
Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cool Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 10 - HONEYWELL ECONOMIZER CONTROL W7212 FRONT FRONT FIGURE 11 - FOUR AND SIX POINT LOADS Unitary Products Group... -
Page 27: Center Of Gravity
6 Point Loads (lbs) Unit Total DH180 Gas 2060 DH240 Gas 2206 DH180 Elec 2300 DH240 Elec 2500 NOTE: These weights are with economizer and high option heat (gas or electric). FIGURE 12 - CENTER OF GRAVITY Unitary Products Group... -
Page 28: Physical Data
20 TON DH (Cooling Only) 1900 2100 BASIC 240Mbh 2100 2300 UNIT (Gas/Electric) 320Mbh 2140 2340 Economizer Economizer with Power Exhaust Motorized Damper OPTIONS 18kW 36kW Electric Heater 54kW 72kW Roof Curb ACCY. Barometric Damper Wood Skid Unitary Products Group... -
Page 29: Dh Electrical Data Without Powered Convenience Outlet
None 46.6 18.0 21.7 46.6 14.3 10.0 36.0 43.3 66.6 54.0 65.0 77.5 72.0 86.6 99.1 None 39.9 18.0 17.3 39.9 12.9 36.0 34.6 52.7 54.0 52.0 61.3 72.0 69.3 78.8 NOTE 1: HACR Type per NEC. Unitary Products Group... -
Page 30: Dh Electrical Data With Powered Convenience Outlet
None 51.6 18.0 21.7 51.6 14.3 10.0 36.0 43.3 72.9 54.0 65.0 83.7 72.0 86.6 105.4 None 43.9 18.0 17.3 43.9 12.9 36.0 34.6 57.7 54.0 52.0 66.3 72.0 69.3 83.7 NOTE 1: HACR Type per NEC. Unitary Products Group... -
Page 31: Unit Dimensions & Clearances 15 & 20 Ton
3 feet from the unit. and relief equipment. NOTE: The products of combustion must not be allowed to NOTE: All entry holes should be field sealed to prevent rain accumulate within a confined space and recirculate. water entry into building. Unitary Products Group... - Page 32 D E T A I L " Y " U N I T W I T H R A I N H O O D S FIGURE 13 - DIMENSIONS & CLEARANCES 15 & 20 TON (CONTINUED) Unitary Products Group...
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Page 33: Cfm, Static Pressure, And Power - Altitude And Temperature Corrections
This value must be corrected for elevation. Example 2: A system, located at 5,000 feet of elevation, is to BHP at 5,000 ft = 3.2 x .832 = 2.66 deliver 6,000 CFM at a static pressure of 1.5". Use the unit Unitary Products Group... -
Page 34: Altitude/Temperature Conversion Factor
66369-YIM-D-1004 ltitude/Temperature Conversion Factor SEA LEVEL TEMPER TURE (°F) FIGURE 14 - ALTITUDE/TEMPERATURE CONVERSION FACTOR Unitary Products Group... -
Page 35: Supply Air Blower Performance (15 Ton) - Cooling Only 180 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Unitary Products Group... -
Page 36: Supply Air Blower Performance (20 Ton) - Cooling Only 240 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Unitary Products Group... -
Page 37: Supply Air Blower Performance (15 Ton) - Gas Heat 180 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Unitary Products Group... -
Page 38: Supply Air Blower Performance (20 Ton) - Gas Heat 240 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Unitary Products Group... -
Page 39: Static Resistances
All motors have a nominal speed of 1800 RPM, a 1.15 service factor and a solid base. They can operate to the limit of their service factor because they are located in the moving air, upstream of any heating device. Do NOT close this pulley below 1 turn open. Unitary Products Group... -
Page 40: Phasing
CFM's and/or higher static pressures. Use Model 1LD0416 for 15 ton units and Model 1LD0417 FIGURE 15 - BELT ADJUSTMENT for 20 ton units. Refer to the Blower Motor and Drive Data Table 20. Unitary Products Group... -
Page 41: Air Balance
3. Using an inclined manometer, determine the pres- sure drop across a dry evaporator coil. Since the moisture on an evaporator coil may vary greatly, FIGURE 16 - PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM FOR ALL UNIT TONNAGES Unitary Products Group... -
Page 42: Operation
For first stage cooling, compressor #1, the setpoint of the enthalpy controller (i.e. first stage condenser fan motor #1 and condenser fan motor #2, has energized the economizer), "Y2" will energize Unitary Products Group... -
Page 43: Economizer With Dual Enthalpy Sensors
ASCD, the UCB will re- run times for compressors. energize the halted compressor. HIGH-PRESSURE LIMIT SWITCH Should a freezestat open three times within two hours of operation, the UCB will lock-out the associated com- Unitary Products Group... -
Page 44: Low Ambient Cooling
On any fault, only the associated system will be affected by any safety/preventive action. Upon a call for first-stage heat by the thermostat, the heater contactor (6M) (6M & 7M on 72 KW, 240V) Unitary Products Group... -
Page 45: Heating Operation Errors
"ON" cycles and may result in the low- heater and energizing the blower. ering of the temperature within the conditioned space. Refer to Table 22 for the required heat anticipator set- 2. Temperature Limit Switch (TLS 3, 4, 5 and 6). ting. Unitary Products Group... -
Page 46: Gas Heating Sequence Of Operations
“W1”, the UCB will initiate the fan 24V power is removed from the module either at the on delay for heating, energizing the indoor blower after unit or by resetting the room thermostat. the specified delay has elapsed. Unitary Products Group... -
Page 47: Gas Heating Operation Errors
The limit switch operates manual reset switch. If AUX trips, then the primary when a high temperature condition, caused by limit has not functioned correctly. Replace the pri- inadequate supply air flow occurs, thus shutting mary limit. Unitary Products Group... -
Page 48: Flash Codes
3. Measure the system Amperage draw across all Anticipator Setpoint legs of 3 phase power wires. Gas Valve 1st Stage 2nd Stage 4. Measure the condenser fan amp draw. Honeywell VR8440 0.30 amp 0.11 amp White-Rodgers 36C68 Unitary Products Group... -
Page 49: Shut Down
Small adjustments to the high-fire gas flow may be made by turning the pressure regulator adjusting screw After the entire control circuit has been energized and on the automatic gas valve. the heating section is operating, make the following checks: Unitary Products Group... -
Page 50: Pilot Checkout
2. Open the union fitting in the gas supply line just (contact your gas company for this information upstream of the unit gas valve and downstream - it varies widely from city to city.) from the main manual shut-off valve. 3. Remove the gas piping closure panel. Unitary Products Group... -
Page 51: Adjustment Of Temperature Rise
CFM. 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. Unitary Products Group... - Page 52 Compressor #2 is always energized in lock outs. place of compressor #1 when compressor #1 is requested but locked out. While the above step will reset any lockouts, NOTE: compressor #1 may be held off for the ASCD. See the next step. Unitary Products Group...
- Page 53 Y1 terminal. DO NOT UCB, i.e. Y1 to Y1, Y2 to Y2. jump the Y1 to C1 terminals. If the compressor engages, the UCB has faulted. Loose wiring from the room thermostat to the UCB. Unitary Products Group...
- Page 54 LED. If the compressor is locked out, remove any sor #1 when compressor #1 is unavailable for cool- call for cooling. This will reset any compressor lock ing calls. Check the UCB for alarms indicating that outs. Unitary Products Group...
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Page 55: Gas Heat Troubleshooting Guide
These options are not enabled by 1. Place the thermostat fan switch in the “ON” posi- default. They can be checked by local distributors. tion. If the supply air blower motor energizes, go to Step 9. Unitary Products Group... - Page 56 If lock-out con- tinues to occur, locate the source of the problem 7. If 24 volts is present at the room thermostat but not and correct. at the UCB, check for proper wiring between the Unitary Products Group...
- Page 57 “MV” and “COMMON” termi- described in “PILOT CHECKOUT” Page 50. nals. If no voltage detected, replace ignitor control. If voltage is present, replace gas valve. Unitary Products Group...
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Page 58: Unit Flash Codes
14 Flashes EEPROM Storage Failure (Control Failure) Current alarms are flashed on the UCB LED. Pressing No Power or Control Failure and releasing the ALARMS button on the UCB can These flash codes do not represent alarms. Unitary Products Group... - Page 59 66369-YIM-D-1004 Unitary Products Group...
- Page 60 Subject to change without notice. Printed in U.S.A. 66369-YIM-D-1004 Copyright © 2004 by Unitary Products Group. All rights reserved. Supersedes: 66369-YIM-C-0504/035-18937-002-C-0504 Unitary 5005 Norman Products York Group Drive 73069...
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