Reznor YDHA Operation, Maintenance & Service Manual
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Reznor YDHA Operation, Maintenance & Service Manual

Reznor YDHA Operation, Maintenance & Service Manual

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CQS
CQS
R-410A
Refrigerant
This unit contains R-410A high pressure refrigerant. Hazards exist that
could result in personal injury or death. Installation, maintenance, and
refrigerant and using proper tools and equipment. Due to much higher
pressure of R-410A refrigerant, DO NOT USE service equipment or tools
designed for R22 refrigerant.
IMPORTANT: Do not release refrigerant to the atmosphere! If required
service procedures include the adding or removing of refrigerant, the service
technician must comply with all federal, state and local laws. The procedures
technician.
Operation / Maintenance / Service
Applies to:
Models YDHA, YDMA, and YDSA
DANGER
Obsoletes Form O-Y (11-15)
Packaged Rooftop Equipment
Model YDHA -
High Outside
Air (Conditioned
Ventilation)
Model YDMA -
Conditioned
Makeup Air
Model YDSA -
Space
Conditioning
Form O-Y P/N 273647R5, Page 1
Form O-Y (4-16)

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Summary of Contents for Reznor YDHA

  • Page 1 Form O-Y (4-16) Obsoletes Form O-Y (11-15) Operation / Maintenance / Service Applies to: Models YDHA, YDMA, and YDSA Packaged Rooftop Equipment Model YDHA - High Outside Air (Conditioned Ventilation) Model YDMA - Conditioned Makeup Air R-410A Refrigerant Model YDSA -...

  • Page 2: Table Of Contents

    This booklet includes operation, maintenance, and service information for Model 1.0 General YDHA, Model YDMA, and Model YDSA. Before beginning any procedure, carefully review the information, paying particular attention to the warnings. Handling of refrig- the requirements of R-410A refrigerant and in compliance with all codes and require- ments of authorities having jurisdiction.

  • Page 3: Maintenance Schedule

    IMPORTANT: Do not release refrigerant to the atmosphere! If required service procedures include the adding or removing of refrigerant, the service technician must comply with all federal, state and local laws. The procedures discussed in technician familiar with R-410A refrigerant. WARNING Lock power OFF before performing any maintenance procedure (except where power is required such as...
  • Page 4 2.0 Maintenance Requirements (cont'd) 2.2 Control Locations FIGURE 1 - Access Doors and High and Low Voltage Inlet Air Control Hood Locations Supply Access Electrical / Control Condenser Compartments Section (See below.) Optional Gas or Electric Heat Section High Voltage Bus Bar - Compressor &...
  • Page 5 2.3 Cabinet Size 1 or 2 by Model & Size Cross-Referenced to Heat Section Size & Type Model YDHA YDMA YDSA Size 60 90 120 150 180 210 240 300 360 60 90 120 150 180 210 240 300 360 120 150 180 210 Nominal Cooling 7.5 10 12.5 15 17.5 20...

  • Page 6: Maintenance And Service Procedures - Unit & Cooling Components

    Replacement Filters by Model Size and Cabinet Size MERV 8 MERV 13 Pleated Cabinet Size Model(s) Model Sizes Size 16 x 25 211128 256666 YDHA & YDMA 090, 120, 150 20 x 24 222480 260828 YDHA & YDMA 180, 210, 240 16 x 25 211128 256666 YDSA...
  • Page 7 3) Clean and dry filters. 4) Return filters to hood and replace cover. Cabinet Size YSDA Models 120, 150 180, 210 YDHA, YDMA 060, 090, 120, 150 180, 210, 240 300, 360 Models Filter No / Size / 101607 101610...
  • Page 8 3.0 Maintenance and Service Procedures - Unit & Cooling Components (cont'd) Fan motors are permanently lubricated; lubrication is not required, During 3.2 Supply Fan maintenance, remove any accumulation of dirt and grease and Variable checked and balanced at startup. To recheck, follow the instructions in the installation Frequency Drive manual, Form I-Y, Paragraph 10.3.

  • Page 9: Optional Dampers And Damper Actuator

    3.0 Maintenance and Service Procedures - Unit & Cooling (cont'd) 3.2 Supply Fan and Variable Frequency Drive (cont'd) Function: Air Proving Switch controller that the supply fan is operating. If equipped with power exhaust or an P/N 234712 Set Point 0.10 I.W.C. fan is operating.
  • Page 10 3.0 Maintenance and Service Procedures - Unit & Cooling (cont'd) 3.4 Condenser Fans Depending on the model size, there are two or four condenser fans. Fan motors may only factory authorized replacement parts. FIGURE 7 - Condenser Fans Guard Housing Propeller Fan Fan Support Motor...
  • Page 11 Refrigerant Circuits - Standard Cooling without Optional Bypass Valve or Reheat FIGURE 8 - Cooling Circuit A-1&2 Circuit - Models Model JDHA 062 and 092 (Cabinet 0) YDHA and YDMA Sizes 060 and 090 Evaporator Coil with Single Circuit Circuit A-2...
  • Page 12 3.0 Maintenance and Service Procedures - Unit & Cooling (cont'd) 3.5 Coils and Related Components (cont'd) FIGURE 9 - Cooling Circuits - Models Circuit A YDHA and YDMA Circuit B Model JDHA 120 and 150 (Cabinet 1) Sizes 120 and 150 Circuit A...
  • Page 13 Circuit B Model JDHA 300 and 360 (Cabinet 3) Circuit A FIGURE 12 - Cooling Circuits - Models YDHA and YDMA Sizes 300 and 360 Valves Circuit B Circuit A Equilizer Tube Compressor Circuit B (Circuit B) Filter Drier Filter Drier...
  • Page 14 3.0 Maintenance and Service Procedures - Unit & Cooling (cont'd) 3.5 Coils and Related Components (cont'd) Optional Modulating Reheat (cont'd) FIGURE 14 - Optional DH Circuit (Option RPLE High Enthalpy Model JDHA 300 & 360 (Cabinet 3) Reheat Pump or Option RPHE Low Enthalpy Reheat Pump Circuit A &...
  • Page 15 FIGURE 16 - Cooling Circuit B with Optional Bypass Valve (Option AUC8) Hot Gas Bypass Check Valve at the Evaporator Coil Model JDHA 120 and 150 (Cabinet 1) with Option AUC8 Circuit B with Optional Hot Gas Bypass Model JDHA 180, 210, and 240 (Cabinet 2) with Option AUC8 Model JDHA 300 and 360 (Cabinet 3) with Option AUC8 Shutoff Shutoff...
  • Page 16 3.0 Maintenance and Service Procedures - Unit & Cooling (cont'd) 3.5 Coils and Related Components (cont'd) Low Ambient Control, Option BE8 (cont'd) Install sensor(s) to the top of the liquid line where the line exits the condenser coil Installation of Liquid as shown below in sketch.

  • Page 17: (Subcooling And Superheat)

    Temperature to Use Temperature to Resistance table shown below to verify proper sensor operation. Resistance Table Install sensor(s) to the top of the liquid line where the line exits the condenser coil Installation of Liquid as shown below in sketch. A liquid line sensor will be required for each independent Line Sensor(s) refrigerant circuit.
  • Page 18 3.0 Maintenance and Service Procedures - Unit & Cooling (cont'd) 3.6 Check Refrigerant Pressure and Temperatures (subcooling and superheat) (cont'd) Check SUBCOOLING Measure and record temperature and pressure of the liquid line at the condenser coil outlet. STEP 1) Record Measurements STEP 2) STEP 3) ______...
  • Page 19 Temperature/Pressure Conversion Chart R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature °F °F °F °F °F -48.3 49.5 -17.2 77.0 -7.2 112.2 218.2 23.9 -45.6 50.9 -16.7 78.7 -6.7 114.4 235.9...
  • Page 20 216400 235013 216400 261149 575/3/60 262806 216401 235018 216401 261153 208-240/3/60 262801 216394 262813 216394 259288 216394 262801 216394 261154 YDHA 480/3/60 262802 216396 262814 216396 259355 216396 262802 216396 261155 575/3/60 262803 216397 262815 216397 272635 216397 262803 216397...
  • Page 21 Modulating Cooling a digital controller. The digital controller in the electrical compartment (See FIGURE 1 on page 4, and FIGURE 15, page 14) is the electronic interface between the com- pressor and the system controller. The compressor controller is connected to the unit controller to provide protection and diagnostics for modulating compressor operation.
  • Page 22 3.0 Maintenance/Service Procedures - Unit & Cooling (cont'd) Use a high temperature torch to disconnect the suction line and the discharge line from 3.7 Compressor the compressor. Operation, d) Remove the mounting bolts and the compressor. Save the mounting hardware to Maintenance, attach the grommets and sleeves shipped with the replacement compressor.
  • Page 23 3.7 Compressor Operation, desiccant absorbs and holds moisture better when it is cool. Heat from a torch may Maintenance, Replacement Step 5. (cont'd) IF the oil measured in Step 2 or the test for acid in Step 2 did indicate compressor burnout, do the following: normally required for the circuit.
  • Page 24 3.0 Maintenance/Service Procedures - Unit & Cooling (cont'd) 3.7 Compressor CAUTION: Do not use the replacement compressor as an Operation, evacuation assist and never apply voltage to a compressor while Maintenance, it is in a vacuum. See Hazard Levels, page 2. Replacement Moisture and air are harmful to the system because they increase the condensing (cont'd)
  • Page 25 DH (Reheat) Model Size High Enthalpy Enthalpy YDHA YDMA YDSA Step 10. System Startup Assure voltage to compressor does not drop below minimum allowable voltage (e.g. 187 volts for 230/208-3-60, 415 volts for 460/3/60, 518 volts for 575/3/60) during the period the compressor is trying to start. If a low voltage or voltage imbalance condition exists, the electrical problem must be determined and corrected prior to operating the unit.
  • Page 26 3.0 Maintenance/Service Procedures - Unit & Cooling (cont'd) Record the ambient temperature. Adjust the system controller so that a call for 3.7 Compressor cooling exists. Operation, NOTE: Outdoor ambient lockouts may prevent mechanical cooling. Temporarily Maintenance, override lockouts by lowering the cooling setpoint. When testing is complete, reset the controller.

  • Page 27: Maintenance/Service Procedures - Power Exhaust And Energy Recovery

    drier. See Hazard Levels, page 2. Step 11). e) When the system is operating properly, remove the gauges. Or, IF the oil measured in Step 2 shown in the table on page 20 or the acid test in Step 2 did not indi- cate a compressor burnout, continue to the review in Step 13.

  • Page 28: Energy Recovery Wheel, Option Ew

    4.0 Maintenance/Service Procedures - Power Exhaust & Energy Recovery (cont'd) 4.2 Energy The energy recovery wheel including power exhaust is an integral part of the system. Recovery FIGURE 20 - Energy Wheel, Recovery Wheel Option EW Optional Preheat Elements Outside Sensor Power Exhaust...
  • Page 29 4.2 Energy Recovery Wheel, Option EW (cont'd) Clean the Wheel Segments WARNING Gently brush off any loose dirt and dust. Weight of the installed segments will cause the To wash the segments, use a non-acid based wheel to accelerate in rotation. Failure to maintain (evaporator) coil cleaner or alkaline detergent control of the wheel rotation while re-installing solution.
  • Page 30 4.0 Maintenance/Service Procedures - Power Exhaust & Energy Recovery (cont'd) 4.2 Energy Recovery Wheel, Option EW (cont'd) FIGURE 21 - Checking the Seals (cont'd) Wheel Rotation Folded Paper Feeler Gauge Slide seal (shown in gray) toward wheel Adjusting Screws until a slight friction on the feeler gauge (When adjusting is detected when gauge is moved along seal, loosen only;...
  • Page 31 Optional Preheat If equipped with optional preheat, one or two 10kw electric heat modules are located in the inlet air stream. Preheat operation is controlled by the system controller and is (frost Control) commanded ON when the supply air discharge sensor signals a temperature reading Optional Frost Control Electric Element Part Number Voltage...

  • Page 32: Maintenance/Service Procedures - Gas Heat Section

    5.0 Maintenance/Service Procedures - Gas Heat Section This gas heat section will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a heater that is operated under normal conditions should be inspected and cleaned at the start of each heating season. If the heater is operating in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent maintenance is recommended.
  • Page 33 5.1 Gas Heat Controls (cont'd) FIGURE 24 - Furnaces with Staged Control Option AG71 Flue Venter Collection Assembly (2-stage control, single heat section) and Option AG72 Optional (4-stage control, dual heat High Gas Pressure Optional sections) Switch Low Gas Pressure Switch Single Heat Section NOTE: Heat sections...
  • Page 34 5.0 Maintenance/Service Procedures - Gas Heat Section (cont'd) 5.1 Gas Heat Controls (cont'd) FIGURE 25 - Furnaces with Single Heat Modulating Control Option Section Manifold Assembly with AG73 (5:1 control, single Electronic Venter heat section) and Option Modulation Assembly Option AG73 AG74 (10:1 control, dual heat sections) Optional...
  • Page 35 The vent temperature limit switch is located on the discharge of the combustion air blower (venter) and its purpose is to prevent the vent gas temperature from exceed- switch is activated, the cause must be determined and corrected before the heater is placed back into operation.
  • Page 36 5.0 Maintenance/Service Procedures - Gas Heat Section (cont'd) 5.1 Gas Heat Controls (cont'd) Depending on the heat section and gas control selected, all gas trains have one or Operating Gas Valve - two single-stage and/or two-stage combination gas valves. These gas valves must be checked annually the instructions below.
  • Page 37 Optional Gas Location: switch is at the burner end. See FIGURE 24, page 33 or 25, page 34. Pressure Switches Function: Monitors gas pressure and shuts down the heat section if gas pressure becomes too low or too high. The low pressure switch is an auto reset type and is set Service: There are no replaceable parts and the settings are non-adjustable.
  • Page 38 5.0 Maintenance/Service Procedures - Gas Heat Section (cont'd) 5.2 Combustion Air and Venting (cont'd) Combustion Air Switches for Sea Level to 6000 ft. (1830 m) High Pressure Switch Low Pressure Switch (AG73 & AG74 Only) 230, 460, 208V Heat Heat 575V Startup Equilibrium...
  • Page 39 Combustion Air Switches for Above 6000 ft. (1830 m) - (cont’d) High Pressure Switch High Pressure Switch Heat Heat Heat Heat Setpoint Label Switch Setpoint Label Switch Section Size(s) Section Size(s) Color Color Option (Btuh) Option (Btuh) Negative Pressure (iwc) Negative Pressure (iwc) 75,000 1.35...
  • Page 40 5.0 Maintenance/Service Procedures - Gas Heat Section (cont'd) Vent Maintenance 5.3 Vent Maintenance Remove dirt and grease from the venter motor housing. The venter motor is perma- and Operation cautious not to bend the wheel. optional vertical vent extension, inspection should include all joints, seams, and the terminal.

  • Page 41: Burner And Heat Exchanger

    5.4 Burner and Heat Inspect the gas heat section annually to determine if cleaning is necessary. If there is an accumulation of dirt, dust, and/or lint, clean the compartment. Exchanger CAUTION: Use of eye protection is recommended. (Requires a wire brush, cleaning cloth, Inspect and Clean the Burner an automotive type...

  • Page 42: Maintenance/Service Procedures - Electric Heat Section

    6.0 Maintenance/Service Procedures - Electric Heat Section Electric Heating A call for mechanical heat will occur when the discharge air temperature is Operation, Elements and Controls tem will remain in this state for 30 seconds. After the initial timer has expired, the unit will stage as shown in the staging chart and the PID loop will activate.

  • Page 43: Troubleshooting

    7.0 Troubleshooting 7.1 Troubleshooting - Refrigeration IMPORTANT: Do not release refrigerant to the atmosphere! If required service procedures include the adding or removing of refrigerant, the service technician must comply with all federal, state and local laws. The procedures discussed in this manual NOTE: Unit is equipped with a phase loss/phase reversal control.
  • Page 44 7.0 Troubleshooting (cont'd) 7.1 Troubleshooting - Refrigeration (cont'd) General Refrigeration Circuit (cont'd) SYMPTOM POSSIBLE CAUSE REMEDY F. Noisy unit 1. Blower rotational noise. bearings, loose parts, and/or blower out of balance. operation. 2. Air noise. check contact points. 4. Tubing rattle. 4.
  • Page 45 7.2 Troubleshooting Compressor Digital Controller General - The digital controller is located in the electrical compartment and acts as the interface between the digital pressor (contactor and unloader valve) being de-energized. Compressor Digital Controller LED’s LED State Indicates Additional Information Color CODE Green...

  • Page 46: Troubleshooting The Heat Section

    7.0 Troubleshooting (cont'd) 7.2 Troubleshooting Compressor Digital Controller (cont'd) LED State Indicates Additional Information Color CODE Solid Digital compressor The installed digital compressor controller can be tested controller failure Flashing operation Input Tests - 1) Thermistor Input - Disconnect thermistor 2) Demand Input present.
  • Page 47 7.3.2 General Troubleshooting - Gas Heat Section - (Option G__ or H__) PROBLEM PROBABLE CAUSE REMEDY 1. No power to unit. will not start 2. No 24 volt power to ignition system circuit board. 3. Integrated circuit board fuse blown. 4.

  • Page 48: Index

    INDEX Air Proving Switch 9 Spark Gap 39 Filter Driers 22 Recommended subcooling 18 See also Filters 6 Subcooling 18, 24, 26 Belt (Wheel) 30 Recommended superheat 18 Braze 23 Superheat 26 Burner Removal Instructions 41 System Startup 25 Gas Pressure Safety Switches 37 Heat Exchanger 32, 33, 34, 36, 38, 40, 41 Heat Exchanger Maintenance 41...

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