Table of Contents
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INSTALLATION
MANUAL 50 Hz
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 . . . . . . . . . . . . . . . . . . . . . 39
See the following page for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
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™
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
DM 036, 048, 060 & 076
(50 Hz. EXPORT)
362248-XIM-C-0809
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Table of Contents
Troubleshooting
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Related Manuals for Johnson Controls SUNLINE DM 036
Summary of Contents for Johnson Controls SUNLINE DM 036
- Page 1 INSTALLATION SUNLINE™ MANUAL 50 Hz GAS/ELECTRIC SINGLE PACKAGE AIR CONDITIONERS CONTENTS DM 036, 048, 060 & 076 (50 Hz. EXPORT) GENERAL ....... . 4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
COOLING OPERATION ERRORS ....32 FAN ON AND OFF DELAYS ....46 Johnson Controls Unitary Products... - Page 3 VOLTAGE LIMITATIONS ....22 IGNITION CONTROL BOARD FLASH CODES . 47 UTILITIES ENTRY ......25 Johnson Controls Unitary Products...
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Page 4: General
Be sure to follow all the extent of the damage should be noted on the car- other safety precautions that apply. rier's freight bill. A separate request for inspection by the carrier's agent should be made in writing. Johnson Controls Unitary Products... -
Page 5: Reference
Warnings are given to alert installer that personal injury and/or equip- ® Contact your local York parts distribution center for ment damage may result if installation procedure is not authorized replacement parts. handled properly. 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
(computer rooms, switchgear, etc.), please reference applications bulletin AE-011-07 or call the applications department for Unitary Products @ 1-877-UPG-SERV for guidance. Additional accessories may be needed for stable operation at temperatures below 30° Johnson Controls Unitary Products... -
Page 8: Location
6. Maintain level tolerance to 13 mm (1/2”) maximum across the entire length or width of the unit. Johnson Controls Unitary Products... -
Page 9: Rigging And Handling
The condensate drain CSA-B149.1 (in Canada) and/or applicable provisions line MUST be trapped to provide proper drain- of the local building codes. Refer to Dimensions and age. See Figure 1. Clearances shown in Figures 10 through 14 and Johnson Controls Unitary Products... -
Page 10: Compressors
MOUNTING BRACKET TOP (REMOVE) WIRE TIE (CUT AND REMOVE) Make sure that all screws and panel latches are replaced and properly positioned on the FIGURE 2 - COMPRESSOR RESTRAINING unit to maintain an airtight seal. BRACKET Johnson Controls Unitary Products... -
Page 11: Typical Field Power & Control Wiring
Jumper is required for any combination of R, RC, or RH. OCC is an output from the thermostat to indicate the Occupied condition. X is an input to the thermostat to display Error Status conditions. FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING Johnson Controls Unitary Products... -
Page 12: Thermostat
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. Johnson Controls Unitary Products... -
Page 13: Optional Gas Heat
All units require a 1/2” pipe connection at the B149.1 (in Canada) should be followed in all cases entrance fitting. unless superseded by local codes or gas utility require- ments. Refer to the Pipe Sizing Table 5. Johnson Controls Unitary Products... -
Page 14: Gas Connection
A fire or explosion may result causing property damage, personal 2. When required by local codes, a manual shut-off injury or loss of life. valve may have to be installed outside of the unit. Johnson Controls Unitary Products... -
Page 15: L.p. Units, Tanks And Piping
NEVER USE A FLAME. For satisfactory operation, adequate L.P./propane gas pressure must be provided at the unit manifold under full load. Maintaining proper gas pressure depends on three main factors: Johnson Controls Unitary Products... -
Page 16: Vent And Combustion Air Hoods
(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- FIGURE 6 - VENT AND COMBUSTION AIR HOOD energize terminals “R” to “G”. Johnson Controls Unitary Products... -
Page 17: Minimum Position Adjustment
AQ voltage input. Exhaust Air Adjustment Screw fully clockwise. • Optional CO Space Sensor Kit Part # 2AQ04700324 • Optional CO Unit Sensor Kit Part # 2AQ04700424 Replace the economizer access panel. Johnson Controls Unitary Products... -
Page 18: Enthalpy Setpoint Adjustment
362248-XIM-C-0809 FIGURE 7 - ENTHALPY SETPOINT ADJUSTMENT Johnson Controls Unitary Products... -
Page 19: Honeywell Economizer Control
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 20: Four And Six Point Loading
57 / 126 52 / 115 TABLE 8: CENTER OF GRAVITY (ALL MODELS) 3 - 5 TON 6 TON DIMENSION (mm / in) (mm / in) 1035 / 40-¾ 1118 / 44 502 / 19-¾ 559 / 22 Johnson Controls Unitary Products... -
Page 21: Physical Data
Electric Heater 10 - 15 kW 10 / 23 20 - 30 kW 13 / 28 Roof Curb 42 / 92 ACCY. Barometric Relief / Fixed Air Damper 5 / 10 Belt-Drive Blower 2.3 / 5 Johnson Controls Unitary Products... -
Page 22: Electrical Data: 3 - 6.3 Ton
Note 3: Heaters are suitable for operation on 380/415V-3-50Hz power supply. TABLE 12: ELECTRIC HEAT CORRECTION TABLE 13: VOLTAGE LIMITATIONS FACTORS VOLTAGE POWER SUPPLY kW CAP. MULTI- MIN. MAX. NOMINAL VOLTAGE VOLTAGE PLIER 380/415-3-50 0.627 0.75 Johnson Controls Unitary Products... -
Page 23: Unit Dimensions
FIGURE 10 - UNIT DIMENSIONS (3 - 6 TON COOLING ONLY/ELECTRIC HEAT) FRONT VIEW 111 [4 178 [7] mm[inch] 2089 1140 445 [17 165 [6 445 [17 171 [6 819 [32 FIGURE 11 - UNIT DIMENSIONS (3 - 6 TON COOLING/GAS HEAT) FRONT VIEW Johnson Controls Unitary Products... -
Page 24: Unit With Economizer Rainhood
362248-XIM-C-0809 1140 mm[inch] DETAIL “A” FIGURE 12 - UNIT WITH ECONOMIZER RAINHOOD 1140 305 [12] DETAIL “B” mm[inch] 419 [16 FIGURE 13 - UNIT WITH FIXED OUTDOOR AIR/MOTORIZED DAMPER RAINHOOD Johnson Controls Unitary Products... -
Page 25: Utilities Entry
41 / 1.63 KO Gas Piping (Front) 38 / 1.5 KO Gas Piping (Bottom) Opening in the bottom to the unit can be located by the side in the insulation. Do not remove the 2” knockout ring. Johnson Controls Unitary Products... -
Page 26: Supply Air Blower Performance (3 & 4 Ton Direct Drive) - Side Duct
1. Side Duct application (380/415 Volts) * . Includes allowances for a wet evaporator coil, 25mm [1 in] filters, and the heat exchangers. Refer to STATIC RESISTANCES Table for resistance values on applications other than gas/electric units with side duct airflows. Johnson Controls Unitary Products... -
Page 27: Supply Air Blower Performance (5 Ton Belt Drive) - Side Duct Application
* . Includes allowances for a wet evaporator coil, 25mm [1in] filters, and the heat exchangers. Refer to STATIC RESISTANCE Table for resistance values on applications other than gas / electric units with side duct airflows. Johnson Controls Unitary Products... -
Page 28: Supply Air Blower Performance (6.3 Ton Belt Drive) - Side Duct Application
* . Includes allowances for a wet evaporator coil, 25mm [1in] filters, and the heat exchangers. Refer to STATIC RESISTANCE Table for resistance values on applications other than gas / electric units with side duct airflows. Johnson Controls Unitary Products... -
Page 29: Phasing
If the scroll is drawing low amper- make the blower, condenser fans, or compres- age, has similar suction and discharge pressures, or sor rotate correctly. producing a high noise level, the scroll is misphased). Johnson Controls Unitary Products... -
Page 30: Supply Air Blowers
4. Knowing the pressure drop across a dry coil, the actual volumetric flow rate through the unit can be determined from the curve in Pressure Drop vs. Supply Air flow rate (Figure 17). FIGURE 16 - BELT ADJUSTMENT Johnson Controls Unitary Products... -
Page 31: Operation
To be available, a compressor must not be locked-out due to a high or low-pressure switch or freezestat trip For electric heat units, the UCB passes the call to the and the anti-short cycle delay (ASCD) must have electric heater. elapsed. Johnson Controls Unitary Products... -
Page 32: Economizer With Single Enthalpy Sensor
When the “R” to UCB will de-energize the compressor, initiate the “G” circuit is complete, the motorized damper drives ASCD, and stop the condenser fan. If the call for cool- Johnson Controls Unitary Products... -
Page 33: Low Ambient Cooling
The above pressure switches are hard-soldered to the Upon a call for first-stage heat by the thermostat, the unit. The refrigeration system is monitored and con- heater sequencer (1S) and contactor (2M) (20, 30 kW 460 volt) will be energized. After completing the Johnson Controls Unitary Products... -
Page 34: Safety Controls
“ON” cycles and may result in the lowering of the GAS MAIN temperature within the conditioned space. Refer to Table 22 for the required heat anticipator setting. TO MAIN VALVE BURNER TO PILOT BURNER FIGURE 18 - GAS VALVE PIPING Johnson Controls Unitary Products... -
Page 35: Two Stage Furnace Only
ICB will start the sequence. If at any time during furnace operation the ignition sequence over and the UCB will de-energize centrifugal switch opens, then the ICB will de-energize Johnson Controls Unitary Products... -
Page 36: Rollout Switch
“ON” cycles and may result in the low- ering of the temperature within the conditioned space. 3. Measure the system Amperage draw across all legs of 3 phase power wires. 4. Measure the condenser fan amp draw. Johnson Controls Unitary Products... -
Page 37: Shut Down
Small adjustments to the high-fire gas flow may be made by turning the pressure regulator adjusting screw 1. Check for gas leaks in the unit piping as well as the on the automatic gas valve. supply piping. Johnson Controls Unitary Products... -
Page 38: Pilot Checkout
Btu content of the gas in your particular locality from the main manual shut-off valve. (contact your gas company for this information - it varies widely from city to city.) Johnson Controls Unitary Products... -
Page 39: Adjustment Of Temperature Rise
Take readings of both the return for loose wiring between the contactor and the sup- air and the heated air in the ducts (about six feet from ply air blower motor. the furnace) where they will not be affected by radiant Johnson Controls Unitary Products... - Page 40 UCB. The UCB will flash the last five alarms on the pressor will be energized unless it is locked out. LED. If the compressor is locked out, cancel any call for cooling. This will reset any compressor lock outs. Johnson Controls Unitary Products...
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Page 41: Gas Heat Troubleshooting Guide
(UCB) and the ignition control board (ICB). Fault codes default. Local distributors can test the UCB for this have a quick sequence of flashes indicating the flash programming. code number followed by a pause with the LED off. The Johnson Controls Unitary Products... -
Page 42: Flash Code Troubleshooting
3.2A circuit breaker to verify that the cir- switch wiring between the ICB and the draft cuit breaker has control voltage on both input and output motor. If ok, then disconnect power to the unit Johnson Controls Unitary Products... -
Page 43: Pilot Flame Lockout
If not clean, then clean, reinstall and adjust pilot per the The rollout switch is installed to protect the furnace start up procedures. from damage due to excessive heat in the burner area. Johnson Controls Unitary Products... -
Page 44: Unexpected Flame Presence
M2, M2 is pulled in, and the supply air blower gas valve, then replace the ICB. If voltage is not present motor still does not operate, replace the motor. at the gas valve, then replace the gas valve. Johnson Controls Unitary Products... - Page 45 2. Check the supply pressure as described in “POST mum of 120 volts to ground on 230 and 460 volt START CHECK LIST” on page 37. Make adjust- models or a minimum of 18 volts to ground on 575 ments as necessary. Johnson Controls Unitary Products...
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Page 46: Unit Flash Codes
When pressed and released twice within a five second span, the fault history is cleared. • - When this button is pressed and TEST RESET released one time within five seconds, any Johnson Controls Unitary Products... -
Page 47: Unit Control Board
Compressors Locked Out Because The 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 These flash codes do not represent alarms. Johnson Controls Unitary Products... - Page 48 Subject to change without notice. Printed in U.S.A. 362248-XIM-C-0809 Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 362248-XIM-B-0109 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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