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Johnson Controls Unitary Products MagnaDRY DK-03 Installation Manual

Gas/electric single package air conditioners
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 51
START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . 51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 59
SEE THE FOLLOWING PAGES 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
MagnaDRY™
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
DK-03, -04, -05 & -A6
362253-BIM-A-0208

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Summary of Contents for Johnson Controls Unitary Products MagnaDRY DK-03

  • Page 1 INSTALLATION MagnaDRY™ MANUAL GAS/ELECTRIC SINGLE PACKAGE AIR CONDITIONERS CONTENTS DK-03, -04, -05 & -A6 GENERAL ....... . 4 SAFETY CONSIDERATIONS .

  • Page 2: Table Of Contents

    EXHAUST........46 Johnson Controls Unitary Products...
  • Page 3 BELT DRIVE) - SIDE DUCT APPLICATION ..37 IGNITION CONTROL BOARD FLASH CODES ..66 SUPPLY AIR BLOWER PERFORMANCE (DK-03 BELT DRIVE) - BOTTOM DUCT APPLICATION . . . 37 Johnson Controls Unitary Products...

  • Page 4: General

    If damage is evident, the extent of the damage should be noted on the car- 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

    • 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

    Never test for gas leaks with an open flame. use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. Johnson Controls Unitary Products...

  • Page 8: Unit Application Data (Dk)

    National Fuel Gas Code, ANSI Z223.1 (in U.S.A.) or antistatic fabric softeners for clothes dryers, Sections 7.2, 7.3 or 7.4 of Gas Installation Codes CSA- masonry acid washing materials. B149.1 (in Canada) and/or applicable provisions of the Johnson Controls Unitary Products...

  • Page 9: Ductwork

    WIRE TIE (CUT AND REMOVE) The cover should be attached in a manner FIGURE 2 - COMPRESSOR RESTRAINING BRACKET adequate to prevent leakage. Johnson Controls Unitary Products...

  • Page 10: Filters

    SERVICE ACCESS The following removable panels provide access to all Make sure that all screws and panel latches serviceable components: are replaced and properly positioned on the unit to maintain an airtight seal. • Compressor compartment Johnson Controls Unitary Products...

  • Page 11: Typical Power 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. DEHUMIDISTAT CLOSES ON RISE IN HUMIDITY. FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING Johnson Controls Unitary Products...

  • Page 12: Thermostat

    Some KW sizes require fuses and others do not. Refer Each unit must be wired with a separate branch circuit to Table 3 for minimum CFM limitations and to Tables fed directly from the meter panel and properly fused. 10 through 17 for electrical data. 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 or other material suitable for the purpose. NEVER supply piping and fittings must lie below the bottom gas USE A FLAME. manifold to avoid interference with the burner assem- bly. Johnson Controls Unitary Products...

  • Page 15: L.p. Units, Tanks And Piping

    Complete information regarding tank sizing for vapor- FIGURE 4 - EXTERNAL SUPPLY CONNECTION ization, recommended regulator settings, and pipe siz- EXTERNAL SHUT-OFF ing is available from most regulator manufacturers and L.P./propane gas suppliers. Johnson Controls Unitary Products...

  • Page 16: Vent And Combustion Air Hoods

    All of the components, including the dampers, hard- tally through this screened, hooded vent opening on ware, and mounting instructions are shipped in a single the gas heat access panel. 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: Center Of Gravity (All Models)

    DK 4 AND 6 POINT LOADS WEIGHT DISTRIBUTION 4-Point Loading (lb) 6-Point Loading (lb) UNIT TOTAL DK-03 Cooling/Electric DK-03N05 DK-03D07 DK-03N11 DK-03D13 DK-04 Cooling/Electric DK-04(D,N)07 DK-04(D,N)13 DK-05 Cooling/Electric DK-05D07 DK-05N11 DK-05(D,N)13 DK-A6 Cooling/Electric DK-A6D07 DK-A6N11 DK-A6(D,N)13 Johnson Controls Unitary Products...

  • Page 20: Physical Data

    6 TON DK (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 Belt-Drive Blower Johnson Controls Unitary Products...

  • Page 21: Electrical Data - Dk-03, -04, -05 & -A6 Direct Drive W/O Powered Convenience Outlet

    24.3 11.1 24.3 15.5 28.9 208-3-60 11.5 84.0 18.0 22.2 37.3 11.9 33.0 50.8 15.9 44.1 64.7 None 24.3 13.3 25.4 18.8 32.1 230-3-60 11.5 84.0 18.0 10.6 26.6 41.4 15.9 39.9 57.3 21.2 53.2 73.2 Johnson Controls Unitary Products...
  • Page 22 33.2 13.3 33.2 18.8 33.2 230-3-60 18.6 156.0 29.0 10.6 26.6 41.4 15.9 39.9 57.3 21.2 53.2 73.2 29.6 74.3 98.5 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 23: Electrical Data - Dk-03, -04, -05 & -A6 Belt Drive W/O Powered Convenience Outlet

    26.6 38.4 15.9 39.9 54.3 21.2 53.2 70.2 None 11.1 13.5 460-3-60 5.8 42.0 10.1 12.7 18.4 13.6 17.1 23.7 19.5 24.5 32.6 None 10.6 10.6 15.2 575-3-60 5.1 34.0 15.9 16.0 21.6 21.2 21.3 28.0 Johnson Controls Unitary Products...
  • Page 24 28.8 36.1 46.6 None 12.3 10.6 10.6 15.2 575-3-60 7.4 54.0 11.5 15.9 16.0 21.6 21.2 21.3 28.0 30.4 30.5 39.1 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 25: Electrical Data - Dk-03, -04, -05 & -A6 Belt Drive High Static W/O Powered Convenience Outlet

    26.6 38.4 15.9 39.9 54.3 21.2 53.2 70.2 None 11.1 13.5 460-3-60 5.8 42.0 10.1 12.7 18.4 13.6 17.1 23.7 19.5 24.5 32.6 None 10.6 10.6 15.2 575-3-60 5.1 34.0 15.9 16.0 21.6 21.2 21.3 28.0 Johnson Controls Unitary Products...
  • Page 26 28.8 36.1 49.9 None 14.4 10.6 10.6 17.9 575-3-60 7.4 54.0 11.5 15.9 16.0 24.2 21.2 21.3 30.6 30.4 30.5 41.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 27: Electrical Data - Dk-03, -04, -05 & -A6 Direct Drive W/Powered Convenience Outlet

    35.9 15.5 41.4 208-3-60 11.5 84.0 18.0 10.0 22.2 49.8 11.9 33.0 63.3 15.9 44.1 77.2 None 34.3 13.3 37.9 18.8 44.6 230-3-60 11.5 84.0 18.0 10.0 10.6 26.6 53.9 15.9 39.9 69.8 21.2 53.2 85.7 Johnson Controls Unitary Products...
  • Page 28 13.3 43.2 18.8 44.6 230-3-60 18.6 156.0 29.0 10.0 10.6 26.6 53.9 15.9 39.9 69.8 21.2 53.2 85.7 29.6 74.3 111.0 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 29: Electrical Data - Dk-03, -04, -05 & -A6 Belt Drive W/Powered Convenience Outlet

    50.9 15.9 39.9 66.8 21.2 53.2 82.7 None 16.1 19.7 460-3-60 5.8 42.0 10.1 12.7 24.7 13.6 17.1 29.9 19.5 24.5 38.8 None 13.4 10.6 10.6 20.2 575-3-60 5.1 34.0 15.9 16.0 26.6 21.2 21.3 33.0 Johnson Controls Unitary Products...
  • Page 30 28.8 36.1 52.8 None 16.3 10.6 10.6 20.2 575-3-60 7.4 54.0 11.5 15.9 16.0 26.6 21.2 21.3 33.0 30.4 30.5 44.1 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 31: Electrical Data - Dk-03, -04, -05 & -A6 Belt Drive High Static W/Powered Convenience Outlet

    50.9 15.9 39.9 66.8 21.2 53.2 82.7 None 16.1 19.7 460-3-60 5.8 42.0 10.1 12.7 24.7 13.6 17.1 29.9 19.5 24.5 38.8 None 13.4 10.6 10.6 20.2 575-3-60 5.1 34.0 15.9 16.0 26.6 21.2 21.3 33.0 Johnson Controls Unitary Products...
  • Page 32 28.8 36.1 56.2 None 18.4 10.6 10.6 22.9 575-3-60 7.4 54.0 11.5 15.9 16.0 29.2 21.2 21.3 35.6 30.4 30.5 46.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 33: Electric Heat Correction Factors

    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 - 6 TON COOLING ONLY/ELECTRIC HEAT) FRONT VIEW Johnson Controls Unitary Products...

  • Page 34: Unit Dimensions

    362253-BIM-A-0208 FIGURE 11 - UNIT DIMENSIONS (3 - 6 TON COOLING/GAS HEAT) FRONT VIEW DETAIL “A” FIGURE 12 - UNIT WITH ECONOMIZER RAINHOOD Johnson Controls Unitary Products...

  • Page 35: Unit With Fixed Outdoor Air/Motorized Damper Rainhood

    362253-BIM-A-0208 DETAIL “B” FIGURE 13 - UNIT WITH FIXED OUTDOOR AIR/MOTORIZED DAMPER RAINHOOD FIGURE 14 - UNIT DIMENSIONS (REAR VIEW) Johnson Controls Unitary Products...

  • Page 36: Utilities Entry

    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 37: Supply Air Blower Performance (Dk-03 Belt Drive) - Side Duct Application

    1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. Johnson Controls Unitary Products...

  • Page 38: Supply Air Blower Performance (Dk-05 Belt Drive) - Side Duct Application

    1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. Johnson Controls Unitary Products...

  • Page 39: 03, -04, -05 & -A6 (3-6 Ton) Direct Drive Blower Performance Side Duct

    MED/LOW 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 40: Belt Drive Rpm Selection

    3. The pressure through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct system is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation. Johnson Controls Unitary Products...
  • Page 41 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Open Closed 34.50 1VL51 BK99 1000 1025 1045 1060 1110 1150 46.00 1VL63 BK67 1125 1175 1250 1325 1400 1475 Johnson Controls Unitary Products...
  • Page 42 1.100 1.050 1.000 Sea Level 0.950 1000 ft 0.900 2000 ft 3000 ft 0.850 4000 ft 0.800 5000 ft 6000 ft 0.750 7000 ft 8000 ft 0.700 9000 ft 10000 ft 0.650 0.600 Air Temperature (ºF) Johnson Controls Unitary Products...

  • Page 43: Phasing

    (direct drive) or the motor pulley number of turns 3. The tension on the belt should be adjusted as open (belt drive) can be determined from the Blower shown in the Belt Adjustment Figure 16. Performance Data Tables. Johnson Controls Unitary Products...

  • Page 44: Operation

    COOLING SEQUENCE OF OPERATION De-energize the compressors before taking NOTE: CONTINUOUS BLOWER any test measurements to assure a dry indoor coil. By setting the room thermostat fan switch to “ON,” the supply air blower will operate continuously. Johnson Controls Unitary Products...

  • Page 45: Intermittent Blower

    During reheat mode, the Y1 signal will bring on the efficiency. compressor and will send the 24V signal through the humidistat, through the normally closed contacts of the hot gas relay (RHG) and will energize both the liquid Johnson Controls Unitary Products...

  • Page 46: Economizer (Single Or Dual) With Power Exhaust

    The unit control board monitors the following inputs for Once the low-pressure switch has been proven (closed the cooling system: during the 30-second monitor period described above), the UCB will monitor the low-pressure limit switch for Johnson Controls Unitary Products...

  • Page 47: Compressor Protection

    Remove the call for cooling, by raising thermostat set- high temperature condition, caused by inadequate ting higher than the conditioned space temperature. supply air flow occurs, thus shutting down the This resets any pressure or freezestat flash codes. heater and energizing the blower. Johnson Controls Unitary Products...

  • Page 48: Reset

    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 49: Two Stage Furnace Only

    The primary limit is located such that the temperature valves. sensitive switch can sense the temperature of the heat exchanger tubes. On single stage models the limit is mounted to the condenser partition panel. On two Johnson Controls Unitary Products...

  • Page 50: Centrifugal Switch

    White-Rodgers 36E36 0.54 amp ICB will lock out furnace operation for 5 minutes. TABLE 35: SINGLE STAGE GAS HEAT LIMIT CONTROL SETTING Capacity, MBH Limit Control Opens, °F Unit (Tons) Input Output Direct Drive Belt Drive Johnson Controls Unitary Products...

  • Page 51: Start-Up (Cooling)

    1. Turn “off” electric power to unit. tor coil. 2. Depress knob of gas valve while turning to “off” 3. Measure the system Amperage draw across all position or position the switch to the “off” position. legs of 3 phase power wires. Johnson Controls Unitary Products...

  • Page 52: Post-Start Check List (Gas)

    The factory set high-fire manifold pressure for NOTE: lator. these furnaces is 3.50 IWG. The actual mani- fold pressure depends on the local fuel heating 2. To decrease the gas pressure, turn the adjusting value. screw counterclockwise. Johnson Controls Unitary Products...

  • Page 53: Pilot Checkout

    4. Disconnect wiring to the gas valves and spark ignit- of the regulator setting), replace the orifice spuds with ors. Remove the manifold-burner gas valve spuds of the proper size. assembly by lifting up and pulling back. Johnson Controls Unitary Products...

  • Page 54: Adjustment Of Temperature Rise

    Multiply 95 X 1050 (the Btu rating of the gas obtained from the local gas company). The result is 99,750 Btuh, which is close to the 100,000 Btuh rating of the furnace. Johnson Controls Unitary Products...
  • Page 55 362253-BIM-A-0208 DK-03 Charging Chart 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 23 - DK-03 CHARGING CURVES Johnson Controls Unitary Products...
  • Page 56 362253-BIM-A-0208 DK-04 Charging Chart 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 24 - DK-04 CHARGING CURVES Johnson Controls Unitary Products...
  • Page 57 362253-BIM-A-0208 DK-05 Charging Chart 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 25 - DK-05 CHARGING CURVES Johnson Controls Unitary Products...

  • Page 58: A6 Charging Curves

    362253-BIM-A-0208 DK-A6 Charging Chart 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 26 - DK-A6 CHARGING CURVES Johnson Controls Unitary Products...

  • Page 59: Troubleshooting

    Johnson Controls Unitary Products...
  • Page 60 Lock plug. If the compressor energizes, there is a UCB may have locked out the compressor for fault in the economizer wiring or actuator. repeat trips. The UCB should be flashing an alarm code. If not, press and release the ALARMS button Johnson Controls Unitary Products...

  • Page 61: Gas Heat Troubleshooting Guide

    Label all wires prior to disconnection when ser- wiring diagram. Mis-wired units will give false flash vicing controls. Wiring errors can cause codes. improper and dangerous operation, which could cause injury to person and/or damage unit components. Verify proper operation after servicing. Johnson Controls Unitary Products...

  • Page 62: Ignition Control Board

    Restore power to the unit. If the ICB continues to flash a code 3, then replace the ICB. 1. If the flash code indicates the switch is open with the draft (inducer) motor on (flash code 2), then Johnson Controls Unitary Products...

  • Page 63: Pilot Flame Lockout

    UCB energizes the indoor blower until the primary limit flame with and without indoor blower operation. If automatically resets or the auxiliary limit is manually the flame changes when the blower is running Johnson Controls Unitary Products...

  • Page 64: Unexpected Flame Presence

    24VAC power to the control. If the UCB. problem persists after removal and reapplication of 24VAC power, the board may need to be replaced. c. Loose wiring from the room thermostat to the UCB. Johnson Controls Unitary Products...
  • Page 65 If voltage is present at the terminal on The pilot burner lights and the spark stops but the main 230 and 460 volt models, then the draft motor is at burners do not light. Johnson Controls Unitary Products...

  • Page 66: Unit Flash Codes

    Gas Valve Stuck Off or On ASCD for the compressors in order to perform trouble- 10 Flashes Flame Sense Circuit Failure shooting. To reset all ASCDs for one cycle, press and release the UCB TEST button once. Johnson Controls Unitary Products...
  • Page 67 362253-BIM-A-0208 Johnson Controls Unitary Products...
  • Page 68 Subject to change without notice. Printed in U.S.A. 362253-BIM-A-0208 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 335223-BIM-A-0807 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...

This manual is also suitable for:

Magnadry dk-04Magnadry dk-05Magnadry dk-a6

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