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INSTALLATION
MANUAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 4
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 36
START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . 37
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 40
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 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
SUNLINE MAGNUM™
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
DY 036, 048 & 060
362254-YIM-D-0109
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Table of Contents
Troubleshooting
Related Manuals for Johnson Controls SUNLINE MAGNUM DY 036
Summary of Contents for Johnson Controls SUNLINE MAGNUM DY 036
- Page 1 INSTALLATION SUNLINE MAGNUM™ MANUAL GAS/ELECTRIC SINGLE PACKAGE AIR CONDITIONERS CONTENTS DY 036, 048 & 060 GENERAL ....... . 4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
FAN ON AND OFF DELAYS ..... 49 FREEZESTAT ....... . . 32 Johnson Controls Unitary Products... - Page 3 CHARGING TABLE ......42 UNIT CONTROL BOARD FLASH CODES ..50 IGNITION CONTROL BOARD FLASH CODES ..50 Johnson Controls Unitary Products...
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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 extinguisher available for all brazing operations. Johnson Controls Unitary Products... -
Page 5: Reference
• For outdoor installation only. or equipment damage may result if installation proce- dure is not handled properly. • For installation on combustible material. • For use with natural gas or propane gas. Johnson Controls Unitary Products... -
Page 6: Product Nomenclature
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 Johnson Controls Unitary Products... -
Page 7: Installation
Unitary Products @ 1- 877-UPG-SERV guidance. Additional LIMITATIONS accessories may be needed for stable opera- tion at temperatures below 30° F. These units must be installed in accordance with the following national and local safety codes: Johnson Controls Unitary Products... -
Page 8: Location
B149.1 (in Canada) and/or applicable provisions of the masonry acid washing materials. local building codes. Refer to Dimensions and Clear- ances shown in Figures 10 through 13 and Tables 14 Johnson Controls Unitary Products... -
Page 9: Ductwork
The condensate drain operates in a negative NOTE: down. Minimum filter area and required sizes are pressure in the cabinet. The condensate drain shown in Physical Data Table 8. Johnson Controls Unitary Products... -
Page 10: Service Access
Electric Heat compartment Make sure that all screws and panel latches • Gas Heat compartment are replaced and properly positioned on the • Blower compartment unit to maintain an airtight seal. • Main control box • Filter compartment Johnson Controls Unitary Products... -
Page 11: Typical Field Power & Control Wiring
P6 ON UNITS WITH ECONOMIZER. TERMINALS A1 AND A2 PROVIDE A RELAY OUT-PUT TO CLOSE THE OUTDOOR ECONOMIZER DAMPERS WHEN THE THERMOSTAT SWITCHES TO THE SET-BACK POSITION. FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING Johnson Controls Unitary Products... -
Page 12: Thermostat
If any of the wire supplied with to Table 3 for minimum CFM limitations. 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. Johnson Controls Unitary Products... -
Page 13: Gas Heat
NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with Kit Model No. 1NP0440 or 1NP0485 (2 Stage). All furnaces meet the latest California seasonal efficiency requirements. 1. Based on 1075 Btu/Ft 2. The air flow must be adjusted to obtain a temperature rise within the range shown. Johnson Controls Unitary Products... -
Page 14: Gas Piping
The sup- or other material suitable for the purpose. NEVER ply piping and fittings must lie below the bottom gas USE A FLAME. manifold to avoid interference with the burner assembly. Johnson Controls Unitary Products... -
Page 15: L.p. Units, Tanks And Piping
FIGURE 4 - EXTERNAL SUPPLY CONNECTION L.P./propane gas suppliers. EXTERNAL SHUT-OFF L.P./propane gas is an excellent solvent and special pipe compound must be used when assembling piping Johnson Controls Unitary Products... -
Page 16: Vent And Combustion Air Hoods
All of the components, including the dampers, hard- ware, and mounting instructions are shipped in a single package external from the unit and must be field assembled and installed. Johnson Controls Unitary Products... -
Page 17: Economizer And Power Exhaust Damper Set Point Adjustments And Information
(found on the 2AQ04700424 damper control module) to the “A”, “B”, “C” or “D” setting corresponding to the lettered curve of the Enthalpy Setpoint Adjustment Figure 7. Replace the economizer access panel. Johnson Controls Unitary Products... -
Page 18: Enthalpy Setpoint Adjustment
Damper Min. Position Screw Indoor Air Quality Max. Adjustment Screw Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cool Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 8 - HONEYWELL ECONOMIZER CONTROL W7212 Johnson Controls Unitary Products... -
Page 19: Four And Six Point Loading
TABLE 7: DY 4 AND 6 POINT LOADS WEIGHT DISTRIBUTION 4-Point Loading (lb) 6-Point Loading (lb) UNIT TOTAL DY036 Cooling/ Electric DY036N04 DY036D06 DY036N08 DY036D10 DY048 Cooling/ Electric DY048(D,N)06 DY048(D,N)10 DY060 Cooling/ Electric DY060D06 DY060N08 DY060(D,N)10 Johnson Controls Unitary Products... -
Page 20: Dy Physical Data
4 TON 5 TON DY (Cooling Only) BASIC UNIT (Gas/Electric) Economizer Motorized Damper OPTIONS 5 - 7 kW Electric Heater 10 - 15 kW 20 - 30 kW Roof Curb ACCY. Barometric Relief / Fixed Air Damper Johnson Controls Unitary Products... -
Page 21: Electrical Data - Dy036, 048 & 060 Direct Drive W/O Powered Convenience Outlet
26.6 39.4 15.9 39.9 55.3 21.2 53.2 71.2 None 10.7 14.0 460-3-60 5.1 34.0 10.1 12.7 18.9 13.6 17.1 24.2 19.5 24.5 33.1 None 10.6 10.6 15.7 575-3-60 3.2 26.0 15.9 16.0 22.1 21.2 21.3 28.5 Johnson Controls Unitary Products... - Page 22 28.8 36.1 48.1 None 13.3 10.6 10.6 16.5 575-3-60 7.4 53.0 11.5 15.9 16.0 22.9 21.2 21.3 29.3 30.4 30.5 40.4 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
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Page 23: Electrical Data - Dy036, 048 & 060 Direct Drive W/ Powered Convenience Outlet
51.9 15.9 39.9 67.8 21.2 53.2 83.7 None 15.7 20.2 460-3-60 5.1 34.0 10.1 12.7 25.2 13.6 17.1 30.4 19.5 24.5 39.3 None 11.6 10.6 10.6 20.7 575-3-60 3.2 26.0 15.9 16.0 27.1 21.2 21.3 33.5 Johnson Controls Unitary Products... - Page 24 28.8 36.1 54.3 None 17.3 10.6 10.6 21.5 575-3-60 7.4 53.0 11.5 15.9 16.0 27.9 21.2 21.3 34.3 30.4 30.5 45.4 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
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Page 25: Unit Dimensions
POWER SUPPLY 1.00 MIN. MAX. 0.92 208/230-1-60 0.92 208/230-3-60 0.92 460-3-60 575-3-60 1. Utilization Range “A” in accordance with ARI Standard 110. FIGURE 10 - UNIT DIMENSIONS (3 - 5 TON COOLING ONLY/ELECTRIC HEAT) FRONT VIEW Johnson Controls Unitary Products... -
Page 26: Unit Dimensions
362254-YIM-D-0109 FIGURE 11 - UNIT DIMENSIONS (3 - 5 TON COOLING/GAS HEAT) FRONT VIEW DETAIL “A” FIGURE 12 - UNIT WITH ECONOMIZER RAINHOOD Johnson Controls Unitary Products... -
Page 27: Unit With Fixed Outdoor Air/Motorized
362254-YIM-D-0109 DETAIL “B” FIGURE 13 - UNIT WITH FIXED OUTDOOR AIR/MOTORIZED DAMPER RAINHOOD FIGURE 14 - UNIT DIMENSIONS (REAR VIEW) Johnson Controls Unitary Products... -
Page 28: Disconnect/Blower Access Location
1. Units may be installed on combustible floors made from wood or class A, B, or C roof covering material. 2. Units must be installed outdoors. Overhanging struc- tures or shrubs should not obstruct condenser air dis- charge outlet. Johnson Controls Unitary Products... -
Page 29: Supply Air Blower Performance (Dy036, 048, & 060 Direct Drive) Side Duct
1448 1. Factory set on medium speed tap. 2. Includes allowances for a wet evaporator coil, 1” filters, and the heat exchangers. Refer to STATIC RESISTANCES Table for resistance values. 3. Bottom Duct application (230 Volts) Johnson Controls Unitary Products... -
Page 30: Phasing
De-energize the compressors before taking any that this balancing be done by someone other than the NOTE: test measurements to assure a dry indoor coil. equipment installer. To check the supply air CFM after the initial balancing has been completed: Johnson Controls Unitary Products... -
Page 31: Operation
By setting the room thermostat fan switch to “ON,” the delay for cooling, and the economizer damper goes to supply air blower will operate continuously. the closed position. If the unit is in continues fan opera- tion the economizer damper goes to the min. position. Johnson Controls Unitary Products... -
Page 32: Economizer With Dual Enthalpy Sensors
UCB will de-energize the compressor, 1. A suction line freezestat to protect against low initiate the ASCD, and stop the condenser fan. evaporator temperatures due to a low airflow or a Johnson Controls Unitary Products... -
Page 33: Compressor Protection
Heat Limit Control Setting Table 19. It resets auto- This resets any pressure or freezestat flash codes. matically. The limit switch operates when a high temperature condition, caused by inadequate sup- ply air flow occurs, thus shutting down the heater and energizing the blower. Johnson Controls Unitary Products... -
Page 34: Reset
Table 20 for the required heat anticipator setting. the operation of the draft motor. The UCB continues the operation of the indoor blower for a configurable amount of time after the call for heat is satisfied. Johnson Controls Unitary Products... -
Page 35: Two Stage Furnace Only
The primary limit is located such that the temperature valves. sensitive switch can sense the temperature of the heat Johnson Controls Unitary Products... -
Page 36: Centrifugal Switch
4. Set the room thermostat fan switch to on. 5. Check the unit supply air (CFM). See “CHECKING SUPPLY AIR CFM” on page 30. 6. Measure evaporator fan motor's amp draw. 7. Set the room thermostat fan switch to off. Johnson Controls Unitary Products... -
Page 37: Operating Instructions
TO LIGHT PILOT AND MAIN BURNERS: pressure drop below 5.0" for natural gas units. If gas pressure is outside these limits, contact the local 1. Turn “off” electric power to unit. gas utility for corrective action. Johnson Controls Unitary Products... -
Page 38: Manifold Gas Pressure Adjustment
3. To increase the gas pressure, turn the adjusting screw clockwise. 4. Replace adjustment screw caps. The factory set high-fire manifold pressure for NOTE: these furnaces is 3.50 IWG. The actual mani- FIGURE 21 - TYPICAL FLAME APPEARANCE Johnson Controls Unitary Products... -
Page 39: Burner Air Shutter Adjustment
(contact your gas company for this information gas obtained from the local gas company). The result is - it varies widely from city to city.). 99,750 Btuh, which is close to the 100,000 Btuh rating of the furnace. Johnson Controls Unitary Products... -
Page 40: Adjustment Of Temperature Rise
AUTO position during operation calls). could cause injury to person and/or damage Proper wiring between the room thermostat and the unit components. Verify proper operation after UCB. servicing. Loose wiring from the room thermostat to the UCB. Johnson Controls Unitary Products... - Page 41 Mate-N-Lock plug, the jumper in the Mate-N- Y1 terminal. If 24 volts is not present from the room Lock plug, and in the wiring from the Mate-N-Lock thermostat, check for the following: plug to the Y1 “ECON” terminal. Johnson Controls Unitary Products...
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Page 42: Charging The Unit
17.3 19.9 22.6 25.1 27.6 28.8 30.1 11.4 14.2 17.1 21.0 24.9 26.9 28.9 11.4 13.5 16.6 19.6 21.2 22.7 12.1 14.3 15.4 16.5 10.3 The DY060 uses a TXV. Charge the unit to 12°F subcooling. Johnson Controls Unitary Products... -
Page 43: Normal Operating Pressures
85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 22 - DY036 OPERATING PRESSURES 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 23 - DY048 OPERATING PRESSURES Johnson Controls Unitary Products... -
Page 44: Gas Heat Troubleshooting Guide
Verify proper operation after code troubleshooting section. Refer to Table 37 for flash servicing. code identification and component causing fault. Johnson Controls Unitary Products... -
Page 45: Flash Code Troubleshooting
9 pin connector from the ICB and and verify proper operation of the furnace. measure the continuity of the centrifugal switch with a battery powered test light or an ohm meter between terminals 3 and 8 of the harness connec- Johnson Controls Unitary Products... -
Page 46: Pilot Flame Lockout
Verify both conditions are within the The temperature limits limit the temperature in the fur- published ranges. nace to a safe level. If a temperature higher than the Johnson Controls Unitary Products... -
Page 47: Unexpected Flame Presence
Proper wiring between the room thermostat and the UCB. If the control detects an internal hardware failure in the flame sense circuit, it shuts off all outputs and enters a Loose wiring from the room thermostat to the UCB. Johnson Controls Unitary Products... - Page 48 On 575 volt models, if voltage is present at the terminal, then check the draft motor relay 1. Check electrical connections between the ignition (DMR on single stage gas heat and DMR-2 on two control and the gas valve. If intact, check for 24 Johnson Controls Unitary Products...
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Page 49: Unit Flash Codes
The first time the button is pressed within five seconds, it scans the bus, then assigns itself the first available address {starts at 2}. It then flashes that address one time. FIGURE 25 - UNIT CONTROL BOARD Johnson Controls Unitary Products... -
Page 50: Unit Control Board
11 Flashes Economizer Is Using Free Cooling 13 Flashes Compressor Held Off Due To Low Voltage 14 Flashes EEPROM Storage Failure (Control Failure) No Power or Control Failure 1. These flash codes do not represent alarms. Johnson Controls Unitary Products... - Page 51 362254-YIM-D-0109 Johnson Controls Unitary Products...
- Page 52 Subject to change without notice. Printed in U.S.A. 362254-YIM-D-0109 Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 362254-YIM-C-0708 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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