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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .53
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .53
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .56
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, 210, 240 & 300
284808-YIM-D-1008
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Related Manuals for Johnson Controls SUNLINE ULTRA DH180
Summary of Contents for Johnson Controls SUNLINE ULTRA DH180
- Page 1 INSTALLATION SUNLINE ULTRA™ MANUAL GAS/ELECTRIC SINGLE PACKAGE AIR CONDITIONERS CONTENTS MODELS: DH180, 210, 240 & 300 GENERAL ........4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
ADJUSTMENT OF TEMPERATURE RISE ..55 CONTINUOUS BLOWER ......45 Johnson Controls Unitary Products... - Page 3 GAS HEAT APPLICATION DATA ....14 34 VAV CONTROL BOARD FLASH CODES ..66 Johnson Controls Unitary Products...
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Page 4: General
Wear safety glasses and work gloves, and follow all • Technical Guide - 262260 safety codes. Use a quenching cloth and have a fire • General Installation - 284808 extinguisher available for all brazing operations. Johnson Controls Unitary Products... -
Page 5: Renewal Parts
Cau- tions are given to prevent equipment damage. Warn- ings are given to alert installer that personal injury and/ or equipment damage may result if installation proce- dure is not handled properly. Johnson Controls Unitary Products... -
Page 6: Product Nomenclature
M = Options 1, 2, 3, & 4 Z = Options 3, 4 & 5 Options 1 = Disconnect 4 = Smoke Detector R.A. 2 = Non-Pwr'd Conv. Outlet 5 = Pwr'd Conv. Outlet 3 = Smoke Detector S.A. Johnson Controls Unitary Products... -
Page 7: Installation
Unitary Products @ 1-877-UPG- SERV for guidance. Additional accessories may These units must be installed in accordance with the be needed for stable operation at temperatures following national and local safety codes: below 30°F. Johnson Controls Unitary Products... -
Page 8: 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. Johnson Controls Unitary Products... -
Page 9: Rigging And Handling
L I F T I N G T H A T I T W I L L L I F T H O L E S E V E N L Y FIGURE 1 - TYPICAL RIGGING Johnson Controls Unitary Products... -
Page 10: 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. Johnson Controls Unitary Products... -
Page 11: Condensate Drain
Refer to Figures 13 and 14 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 Johnson Controls Unitary Products... -
Page 12: Typical Field Wiring
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 Johnson Controls Unitary Products... -
Page 13: Thermostat
A fused disconnect switch should be field provided for to Table 3 for minimum CFM limitations and to Tables the unit. The switch must be separate from all other cir- 10 and 13 for electrical data. cuits. Wire entry at knockout openings require conduit Johnson Controls Unitary Products... -
Page 14: Optional Gas Heat
All units require a one-inch pipe connection at Maximum capacity of pipe in cubic feet of gas per hour. (Based upon the entrance fitting. a pressure drop of 0.3 inch water column and 0.6 specific gravity gas). Johnson Controls Unitary Products... -
Page 15: Gas Connection
Shellac base compounds nace. such as Gaskolac or Stalastic, and compounds such as Rectorseal #5, Clyde's or John Crane may be used. Johnson Controls Unitary Products... -
Page 16: L.p. Units, Tanks And Piping
The top flange of this hood slips in ture of the liquid and (b) the "wetted surface" area under the top of the access panel opening when install- of the container or containers. ing. Refer to Vent and Combustion Air Hood Figure 8. Johnson Controls Unitary Products... -
Page 17: Optional Economizer/Motorized Damper Rain Hood
With power exhaust option, each building pressuriza- tion requirement will be different. The point at which the power exhaust comes on is determined by the econo- mizer damper position (Percent Open). The Exhaust Air Adjustment Screw should be set at the Percent Johnson Controls Unitary Products... -
Page 18: Indoor Air Quality Aq
Replace the economizer access panel. This modulating speed reference signal is generated using an internal algorithm which continuously calcu- lates an output value. Johnson Controls Unitary Products... -
Page 19: Factory-Installed Vfd
2nd-stage gas heat operation or receives an FACTORY-INSTALLED VFD error signal from the variable frequency drive. The factory-installed VFD is mounted in the Blower Access Compartment above the blower assembly. The drive comes wired from the factory to include both 3- Johnson Controls Unitary Products... -
Page 20: Manual Bypass
LINE (BYPASS) position and there are VAV boxes present in the duct sys- tem, then boxes must be driven to the full-open position using a customer-supplied power source to prevent over-pressurizing and possi- ble damage to the ductwork. Johnson Controls Unitary Products... -
Page 21: Vfd-Ready' For Customer-Installation
0 and 80 psig with a factory-setting nected after the drive is installed. of 60 psig. HGBP is standard on all units with VAV and optional with CV units. Johnson Controls Unitary Products... -
Page 22: Enthalpy Setpoint Adjustment
284808-YIM-D-1008 FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT Johnson Controls Unitary Products... -
Page 23: Honeywell Economizer Control W7212
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 Johnson Controls Unitary Products... -
Page 24: Center Of Gravity
(lb) DH180C00 1900 DH180N24 2100 DH180N32 2140 DH210C00 1950 DH210N24 2150 DH210N32 2190 DH240C00 2100 DH240N24 2300 DH240N32 2340 DH300C00 2345 DH300N24 2545 DH300N32 2585 (17.5, 20 & 25 Ton) FIGURE 12 - CENTER OF GRAVITY Johnson Controls Unitary Products... -
Page 25: Physical Data
Wood Skid TABLE 9: SUPPLY FAN VFD WEIGHTS, IN LBS. SUPPLY FAN MOTOR 230V 460V 575V W/O MANUAL BYPASS 5.0 hp 7.5 hp 10.0 hp 15.0 hp W/MANUAL BYPASS 5.0 hp 7.5 hp 10.0 hp 15.0 hp Johnson Controls Unitary Products... -
Page 26: Dh 180, 210 & 240 Electrical Data Without Powered Convenience Outlet
21.7 46.6 460-3-60 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 39.9 575-3-60 12.9 36.0 34.6 52.7 54.0 52.0 61.3 72.0 69.3 78.7 NOTE 1: HACR Type per NEC. Johnson Controls Unitary Products... -
Page 27: Dh 300 Electrical Data Standard Motor Without Powered Convenience
18.0 21.7 62.9 17.2 19.3 36.0 43.3 78.3 54.0 65.0 89.1 72.0 86.6 110.7 None 47.5 18.0 17.3 47.5 12.4 15.4 36.0 34.6 62.6 54.0 52.0 71.2 72.0 69.3 88.5 NOTE 1: HACR Type per NEC. Johnson Controls Unitary Products... -
Page 28: Dh 180, 210 & 240 Electrical Data With Powered Convenience Outlet
21.7 51.6 460-3-60 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 43.9 575-3-60 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. Johnson Controls Unitary Products... -
Page 29: Dh 300 Electrical Data Standard Motor With Powered Convenience
18.0 21.7 67.9 17.2 19.3 36.0 43.3 84.5 54.0 65.0 95.3 72.0 86.6 117.0 None 51.5 18.0 17.3 51.5 12.4 15.4 36.0 34.6 67.6 54.0 52.0 76.2 72.0 69.3 93.5 NOTE 1: HACR Type per NEC. Johnson Controls Unitary Products... -
Page 30: Front View Dimensions
Opening in the bottom of the unit can be located by the slice in the insulation. NOTE: All entry holes should be field sealed to prevent rain water entry into the building. FIGURE 13 - FRONT VIEW DIMENSIONS Johnson Controls Unitary Products... -
Page 31: Rear View Dimensions
Connect ductwork to the flanges on those panels. openings are closed with sheet metal covers except when the unit includes a power exhaust option. The covering consists of a heavy black paper composition. Replace the side supply and return air compartment panels. Johnson Controls Unitary Products... -
Page 32: Dimensions
INTAKE HOOD (located on Return Air Compartment) 36-5/8” 1“ CONDENSATE DRAIN 16-1/8” (Must be trapped) 5” 28-3/16” 92” REAR VIEW LH VIEW DETAIL “Y” UNIT WITH RAIN HOODS FIGURE 15 - UNIT CLEARANCES AND RAIN HOOD DIMENSIONS Johnson Controls Unitary Products... -
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 Johnson Controls Unitary Products... -
Page 34: Factor
284808-YIM-D-1008 ltitude/Temperature Conversion Factor SEA LEVEL TEMPER TURE (°F) FIGURE 16 - ALTITUDE/TEMPERATURE CONVERSION FACTOR Johnson Controls Unitary Products... -
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. Johnson Controls Unitary Products... -
Page 36: Supply Air Blower Performance (17.5 Ton) - Cooling Only 210 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. Johnson Controls Unitary Products... -
Page 37: 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. Johnson Controls Unitary Products... -
Page 38: 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. Johnson Controls Unitary Products... -
Page 39: Supply Air Blower Performance (17.5 Ton) - Gas Heat 210 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. Johnson Controls Unitary Products... -
Page 40: 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. Johnson Controls Unitary Products... -
Page 41: Supply Air Blower Performance (25 Ton) - Gas Heat 300 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. 15 HP Motor is required. Johnson Controls Unitary Products... -
Page 42: 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. Johnson Controls Unitary Products... -
Page 43: Phasing
10-12 hrs. run time is recommended. High speed drive accessories (containing a smaller blower pulley and a shorter belt) are available for appli- cations requiring the supply air blower to produce FIGURE 17 - BELT ADJUSTMENT Johnson Controls Unitary Products... -
Page 44: Air Balance
MENTS TO ASSURE A DRY INDOOR COIL. SUPPLY AIR 0.65 210, 240MBH 180MBH 300MBH 0.55 0.45 0.35 0.25 NOMINAL CFM (THOUSANDS) SUPPLY AIR FIGURE 18 - PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM FOR ALL UNIT TONNAGES Johnson Controls Unitary Products... -
Page 45: Operation
"R" to "G" and tain when operating the unit in VAV mode. If the duct "Y1" is completed. The UCB energizes the blower Johnson Controls Unitary Products... -
Page 46: Economizer With Dual Enthalpy Sensors
When free-cooling is available, then a Y1 call will also initiate the power exhaust is operating, the second stage of 1st-stage mechanical cooling. mechanical cooling will not operate. As always, the "R" Johnson Controls Unitary Products... -
Page 47: Economizer With Optional Vav Blower With Power Exhaust
When the "R" to "G" circuit is opened, be de-energized. the damper spring returns fully closed. Johnson Controls Unitary Products... -
Page 48: Freezestat
(opens at 26 ± 5 °F and The following sequence describes the operation of the resets at 38 ± 5°F). electric heat section. Johnson Controls Unitary Products... -
Page 49: Heating Operation Errors
15, 17.5, 20 & 25 HEATING OPERATION ERRORS 15, 17.5, 20 & 25 TEMPERATURE LIMIT If the UCB senses zero volts from the high temperature limit, the indoor blower motor is immediately energized. Johnson Controls Unitary Products... -
Page 50: Flash Codes
The following sequence describes the operation of the first stage furnace operation for five minutes or until gas heat section. 24V power is removed from the module either at the unit or by resetting the room thermostat. Johnson Controls Unitary Products... -
Page 51: Gas Heating Operation Errors
“W1”, the UCB will initiate the fan when a high temperature condition, caused by on delay for heating, energizing the indoor blower after inadequate supply air flow occurs, thus shutting the specified delay has elapsed. Johnson Controls Unitary Products... -
Page 52: Flash Codes
190°F. It is a will give shorter "ON" cycles and may result in the low- manual reset switch. If AUX trips, then the primary ering of the temperature within the conditioned space. Johnson Controls Unitary Products... -
Page 53: Start-Up (Cooling)
2. Depress knob of gas valve while turning to “off” 1. Verify proper system pressures for both circuits. position, or turn gas valve switch to “off” position. 2. Measure the temperature drop across the evapora- tor coil. Johnson Controls Unitary Products... -
Page 54: Post-Start Check List (Gas)
MANIFOLD GAS PRESSURE ADJUSTMENT from the main manual shut-off valve. Small adjustments to the high-fire gas flow may be 3. Remove the gas piping closure panel. made by turning the pressure regulator adjusting screw on the automatic gas valve. Johnson Controls Unitary Products... -
Page 55: Burner Air Shutter Adjustment
F Temp Rise If the actual input is not within 5% of the furnace rating After the temperature rise has been determined, the (with allowance being made for the permissible range cfm can be calculated as follows: Johnson Controls Unitary Products... -
Page 56: Belt Drive Blower
8. If 24 volts is not present at the “FAN” terminal, On calls for cooling, if the compressors are operating check for 24 volts from the room thermostat. If 24 but the supply air blower motor does not energize after Johnson Controls Unitary Products... - Page 57 Y1 “ECON” terminal. If 24 volts is not present, 6. If 24 volts is not present at M1, check for 24 volts at check for loose wiring from the Y1 “OUT” terminal the UCB terminal, C1. If 24 volts is present, check Johnson Controls Unitary Products...
- Page 58 If the blades are open, the economizer is none of the protection switches have opened, the providing free cooling. If the second stage of UCB may have locked out the compressor for cooling is requested, following a short delay, Johnson Controls Unitary Products...
- Page 59 While the above step will reset any lock outs, NOTE: compressor #1 is locked out. Press and release compressor #2 will be held off for the ASCD, the ALARMS button if the LED is not flashing an alarm. Johnson Controls Unitary Products...
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Page 60: Gas Heat Troubleshooting Guide
UCB is programmed to lock out compressor opera- Btu content of the gas in your particular locality tion when the LAS set point is reached. (contact your gas company for this information - it varies widely from city to city.). Johnson Controls Unitary Products... - Page 61 (RW1) contacts in the main con- descriptions, if necessary). Clear any fault by trol box and check to see if the (RW1) is pulled in. pressing 'RESET' on the drive's keypad and take Johnson Controls Unitary Products...
- Page 62 Clean as needed but the prob- and RW2) relay coils. If these relays are pulled in, lem should not be the gas valve. then check for a loose connection at terminal 2 and Johnson Controls Unitary Products...
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Page 63: Unit Control Board Flash Codes
To reset all ASCDs for one cycle, press and Main burners light but exhibit erratic flame characteris- release the UCB TEST/ RESET button once. tics. Flash codes that do and do not represent alarms are listed in Table 32. Johnson Controls Unitary Products... -
Page 64: Unit Control Board
EEPROM Storage Failure No Power or Control Failure Non-alarm condition. Check Alarm History Reset All ASCDs for One Cycle Non Alarm Condition Green LED Flashing Current Alarm Flashed Red LED FIGURE 24 - UNIT CONTROL BOARD Johnson Controls Unitary Products... -
Page 65: Unit Control Board Option Setup
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 Non-std Non-std off. Johnson Controls Unitary Products... -
Page 66: Optional Vav Control Board Flash Codes
IAQ Sensor Failure 10 Flashes OAQ Sensor Failure 11 Flashes APS Switch Failure 12 Flashes Limit 2 Switch Open 13 Flashes Purge 14 Flashes VFD Input Failure 15 Flashes Dirty Filter Switch No Power or Control Failure Johnson Controls Unitary Products... - Page 67 284808-YIM-D-1008 Johnson Controls Unitary Products...
- Page 68 Subject to change without notice. Printed in U.S.A. 284808-YIM-D-1008 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 284808-YIM-C-0708 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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