Table of Contents
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INSTALLATION
MANUAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . .6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
START-UP (COOLING). . . . . . . . . . . . . . . . . . . . . .39
START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . .39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .43
See 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
MAGNUM
SINGLE PACKAGE AIR CONDITIONERS AND
SINGLE PACKAGE GAS/ELECTRIC UNITS
12-1/2 TON
(10.8 EER)
Tested in accordance with:
®
DJ150
035-19046-002-B-0104
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Table of Contents
Troubleshooting
Related Manuals for Predator PREDATOR MAGNUM DJ150
Summary of Contents for Predator PREDATOR MAGNUM DJ150
- Page 1 INSTALLATION ® MANUAL MAGNUM CONTENTS SINGLE PACKAGE AIR CONDITIONERS AND GENERAL ....... . .4 SINGLE PACKAGE GAS/ELECTRIC UNITS SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
ECONOMIZER WITH SINGLE ENTHALPY SENSOR -..34 GAS HEAT TROUBLESHOOTING GUIDE ... . . 49 ECONOMIZER WITH DUAL ENTHALPY SENSORS - ..34 Unitary Products Group... - Page 3 29 IGNITION CONTROL FLASH CODES ... . 43 15 DJ150, 12-1/2 TON STANDARD MOTOR DOWN SHOT BLOWER PERFORMANCE ....29 Unitary Products Group...
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Page 4: General
Refer tions. to this manual. For assistance or additional informa- tion consult a qualified installer, service agency or the gas supplier. Unitary Products Group... -
Page 5: Reference
INFORMATION MANUAL Part Number 035-19047-001. 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. Unitary Products Group... -
Page 6: Nomenclature
12½ Ton Predator Model Number Nomenclature AA 3 Product Generation Product Category Additional Options Product Identifier Voltage Installation Options Nominal Cooling Capacity - MBH Heat Type & Nominal Heat Capacity Gas Heat Options Electric Heat Options Options Airflow Unitary Products Group... - Page 7 Novar ETC-3 Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard Novar ETC-3 Controller, DFS, APS & Technicoat Evap. & Cond Coils Novar ETC-3 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard Technicoat Condenser Coil Unitary Products Group...
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Page 8: Installation
Screws as specified on the unit name/rating plate, specified on Page 42 of these instructions. This equipment is not to be used for temporary heating FIGURE 1 - UNIT SHIPPING BRACKET of buildings or structures under construction. Unitary Products Group... -
Page 9: Limitations
The furnace must be isolated from the gas supply piping system by closing its individual manual shut- off valve during any pressure testing of the gas sup- ply piping system at test pressures equal to or less than 1/2 PSIG. Unitary Products Group... -
Page 10: Predator" Magnum Component Location
035-19046-002-B-0104 Simplicity FIGURE 3 - PREDATOR MAGNUM COMPONENT LOCATION Unitary Products Group... -
Page 11: Location
Halogen type refrigerants, cleaning solvents (e.g. perchloro- ethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues, antistatic fab- ric softeners for clothes dryers, masonry acid wash- ing materials. FIGURE 4 - UNIT 4 POINT LOAD Unitary Products Group... -
Page 12: Clearances
• Cleaning solvents (such as perchloroethylene) • Printing inks, paint removers, varnishes, etc. • Hydrochloric acid • Cements and glues • Anti-static fabric softeners for clothes dryers • Masonry acid washing materials FIGURE 6 - UNIT CENTER OF GRAVITY Unitary Products Group... -
Page 13: Unit Dimensions
NOTE: A one-inch clearance must be provided between • Four (4) feet from electric meters, gas meters, regula- any combustible material and the supply ductwork tors, and relief equipment. for a distance of 3 feet from the unit. Unitary Products Group... -
Page 14: Bottom Duct Openings (From Above)
035-19046-002-B-0104 FIGURE 8 - BOTTOM DUCT OPENINGS (FROM ABOVE) Unitary Products Group... -
Page 15: Ductwork
The return panel is Refer to Figure 8 for bottom air duct openings. Refer to Fig- secured with four screws. ure 9 for rear air duct openings. Unitary Products Group... -
Page 16: Dimensions
When fastening ductwork to side duct flanges on unit, insert screws through duct flanges only. DO NOT insert screws through casing. Outdoor duct- work must be insulated and water-proofed. FIGURE 12 - SIDE PANELS WITH HOLE PLUGS Note orientation. Panel is “insulation” side up. Unitary Products Group... -
Page 17: Condensate Drain
NEC and CEC as specified above and/or local codes. Voltage tolerances which must be maintained at the com- pressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 1. FIGURE 15 - CONDENSATE DRAIN Unitary Products Group... -
Page 18: Power Wiring Detail
Electrical line must be sized properly to carry the load. USE unit or the basepan inside the curb. COPPER CONDUCTORS ONLY. Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused. FIGURE 16 - ELECTRONIC THERMOSTAT FIELD WIRING Unitary Products Group... -
Page 19: Field Wiring 24 Volt Thermostat
035-19046-002-B-0104 FIGURE 17 - FIELD WIRING 24 VOLT THERMOSTAT FIGURE 18 - FIELD WIRING DISCONNECT - COOLING UNIT WITH/WITHOUT ELECTRIC HEAT Unitary Products Group... -
Page 20: Field Wiring Disconnect - Cooling Unit
035-19046-002-B-0104 FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT Unitary Products Group... -
Page 21: Electrical Data Dj150 (12-1/2 Ton) Without Powered Convenience Outlet
None 25.6 27.5 27.4 29.3 2TP04521858 18.1 31.8 34.2 36.4 60.0 2TP04522458 24.1 41.4 41.2 43.6 2TP04523658 34.1 53.4 53.3 55.6 2TP04525458 54.2 62.1 64.5 64.3 66.7 Maximum HACR breaker of the same AMP size is applicable. Unitary Products Group... -
Page 22: Optional Electric Heat
Fuses are supplied, where required, by the factory. Some kW 3750 sizes require fuses and other do not. Refer to Table 11 for minimum CFM limitations and to Tables 8 through 9 for elec- trical data. 3750 Unitary Products Group... -
Page 23: Optional Gas Heat
NOTE: There may be a local gas utility requirement specify- ing a minimum diameter for gas piping. All units require a 3/4 inch pipe connection at the entrance fitting. Line should not be sized smaller than the entrance fitting size. Unitary Products Group... -
Page 24: Gas Connection
The vaporization rate which depends on the temperature the mains. Check all joints for leaks with soap solution or of the liquid and the “wetted surface” area of the con- other material suitable for the purpose. NEVER USE A tainer(s). FLAME. Unitary Products Group... -
Page 25: Vent And Combustion Air
All electric heaters are fused and intended for use with single point power supply. Follow the instructions included with the hood to com- plete the installation. Unitary Products Group... -
Page 26: Economizer And Power Exhaust Set Point Adjustments And Information
"A", "B", "C" or "D" setting corresponding to the lettered curve of the Enthalpy Set Point Adjustment • Optional CO Sensor Kit Part # 2AQ04700424 Figure 22. Replace the top rear access panel on the unit. Unitary Products Group... -
Page 27: Enthalpy Set Point Chart
(21) (18) (16) (13) (10) (10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43) APPROXIMATE DRY BULB TEMPERATURE - FIGURE 22 - ENTHALPY SET POINT CHART FIGURE 23 - HONEYWELL ECONOMIZER CONTROL W7212 Unitary Products Group... -
Page 28: Phasing
Check the belt ten- sion at least two times during the first 24 hours of operation. Any retensioning should fall between the min. and max. deflection force values. 5. After adjusting retighten nuts (A). Unitary Products Group... -
Page 29: Dj150, 12-1/2 Ton Standard Motor Down Shot Blower Performance
ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been deducted from the total static pressure of the blower. “Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed. ††. W = Watts Unitary Products Group... -
Page 30: Dj150, 12-1/2 Ton Standard Motor Side Shot Blower Performance
All internal resis- • Blower performance for gas heat includes the maximum tances have been deducted from the total static pressure number of heat tubes available for each tonnage. of the blower. Unitary Products Group... -
Page 31: Air Balance
NOTE: With the addition of field installed accessories repeat this procedure. Failure to properly adjust the total system air quan- tity can result in extensive blower damage. Failure to properly adjust the total system air quan- tity can result in extensive blower damage. Unitary Products Group... -
Page 32: Supply Air Drive Adjustment
Measured CFM = (Speed increase) • Amps at 3,800 CFM Use the following tables and the DD calculated per the above = (Speed increase) • Original Amps equation to adjust the motor variable pitch sheave. = New Amps Unitary Products Group... -
Page 33: Operation
30 seconds. Additionally, the indoor blower has a delay of 10 seconds between operations. The call is passed to the unit control board (UCB), which then determines whether the requested operation is available and, if so, which components to energize. Unitary Products Group... -
Page 34: No Outdoor Air Options
If the enthalpy of the UCB will re-energize the halted compressor. outdoor air is below the set point of the enthalpy controller (i.e. first stage has energized the economizer), "Y2" will ener- Unitary Products Group... -
Page 35: Low-Pressure Limit Switch
The 5-minute off period is necessary to within the system. Refer to UNIT CONTROL BOARD FLASH defrost the indoor coil. CODES Table 28. Low ambient mode always begins with compressor opera- tion. Compressor minimum run time may extend the minutes Unitary Products Group... -
Page 36: Reset
Electric Heat Limit Setting Table 22. It resets automatically. The limit switch operates when a high temperature condition, caused by inad- 0.13 equate supply air flow occurs, thus shutting down the heater and energizing the blower. Unitary Products Group... -
Page 37: Gas Heating Sequence Of Operations
When a flame is lost or is not detected during an attempt to GAS VALVE achieve ignition, a retry operation occurs. A 30-second purge The UCB and ICB continuously monitor the GV. is performed between ignition attempts. Unitary Products Group... -
Page 38: Safety Controls
Remove the call for heating by lowering the thermostat set- by inadequate supply air flow occurs, thus shutting down the ting lower than the conditioned space temperature. This heater and energizing the blower. resets any flash codes. Unitary Products Group... -
Page 39: Gas Heat Anticipator Setpoints
If a second stage of Set the room thermostat fan switch to off. heat is called for, the main burners for second stage heat Turn unit electrical power off. will ignite for the second stage heat. Unitary Products Group... -
Page 40: Post Start Checklist
Adjust second stage (100% input) pressure first, then adjust Turn on the furnace and make sure the thermostat is first stage (60% input) pressure. calling for Second stage (100% input) heat. Turn off all power to the unit. Unitary Products Group... -
Page 41: Gas Rate Cubic Feet Per Hour
NOTE: To find the Btu input, multiply the number of cubic Repeat Steps 1-6. feet of gas consumed per hour by the Btu content of the gas in your particular locality (contact your gas company for this information as it varies widely from area to area). Unitary Products Group... -
Page 42: Adjustment Of Temperature Rise
Open the union fitting just upstream of the unit gas valve and downstream from the main manual shut-off valve in the gas supply line. Remove the screws holding each end of the manifold to the manifold supports. Unitary Products Group... -
Page 43: Charging The Unit
To reset Gas Flow all ASCDs for one cycle, press and release the UCB TEST Gas Pressure Ignition Lockout Gas Valve button once. Flame Sensor No Power Or Control STEADY OFF 24VAC or Control Failure Unitary Products Group... - Page 44 Cool Off for ID Blower? ID Blower? for Cooling? FIGURE 28 - BASIC TROUBLESHOOTING FLOWCHART Power to Call for Voltage @ Gas Valve? heat? Unit Energize ID Initialize ASCD Blower Montior FIGURE 29 - POWER ON FLOW CHART Unitary Products Group...
- Page 45 035-19046-002-B-0104 FIGURE 30 - TRIP FAILURE FLOW CHART Unitary Products Group...
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Page 46: Cooling Troubleshooting Guide
24-volt potential between the LPS1 termi- ing. nals. If 24 volts is present at the UCB Y1 terminal and none of 10. If the thermostat and UCB are properly wired, replace the protection switches have opened, the UCB may have the UCB. Unitary Products Group... - Page 47 If the compressor engages, the UCB has faulted. minals. 16. If none of the above correct the error, replace the UCB. If 24 volts is present at the UCB Y2 terminal and none of the protection switches have opened, the UCB may have Unitary Products Group...
- Page 48 Failing the above, if voltage is supplied at M1, M1 is Lock plug, the jumper in the Mate-N-Lock plug, and in pulled in, and the compressor still does not operate, the wiring from the Mate-N-Lock plug to the Y1 “ECON” replace the compressor. terminal. Unitary Products Group...
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Page 49: Gas Heat Troubleshooting Guide
The draft motor runs but the furnace does not light and the motor may be off on inherent protection. Cancel any spark ignitor does not spark. thermostat calls and set the fan switch to “AUTO”, wait for the internal overload to reset. Test again when cool. Unitary Products Group... - Page 50 If the furnace is hot, it may be out on a high temperature “BURNER/ORIFICE INSTRUCTIONS.” Clean or replace limit open; wait for limit reset. burner orifices and burners as needed. If all are intact replace the ICB. Unitary Products Group...
- Page 51 035-19046-002-B-0104 Unitary Products Group...
- Page 52 Subject to change without notice. Printed in U.S.A. 035-19046-002-B-0104 Copyright © 2004 by Unitary Products Group. All rights reserved. Supersedes: 035-19046-002-A-0803 Unitary 5005 Norman Products York Group Drive 73069...