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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .58
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .59
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .61
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 MAGNUM™
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
MODELS: DJ180, 210, 240 & 300
66352-YIM-D-0904
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Table of Contents
Troubleshooting
Related Manuals for Unitary products group SUNLINE MAGNUM DJ180
Summary of Contents for Unitary products group SUNLINE MAGNUM DJ180
- Page 1 GENERAL ........4 MODELS: DJ180, 210, 240 & 300 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
UNIT FLASH CODES ......69 ECONOMIZER WITH SINGLE ENTHALPY SENSOR -. . 52 Unitary Products Group... - Page 3 27 GAS RATE - CUBIC FEET PER HOUR ....61 28 UNIT CONTROL BOARD FLASH CODES ... . 69 Unitary Products Group...
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Page 4: General
Wear safety glasses and work gloves, and follow all safety codes. Use a quenching cloth and have a fire • 035-19856-000 - Barometric Relief Damper extinguisher available for all brazing operations. Accessory Unitary Products Group... -
Page 5: Renewal Parts
For installation on combustible material. ings are given to alert installer that personal injury and/ or equipment damage may result if installation proce- • For use with natural gas or propane gas. dure is not handled properly. Unitary Products Group... -
Page 6: Product Nomenclature
66352-YIM-D-0904 PRODUCT NOMENCLATURE Unitary Products Group... - Page 7 CPC Controller, DFS, APS, Double Wall, & Technicoat Evap and Cond Coils CPC Controller, DFS, APS, Double Wall, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils CPC Controller, DFS, APS, Double Wall, SS Drain Pan, Phase Monitor, & Coil Guard Unitary Products Group...
- Page 8 HQ Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. & Cond Coils, Phase Monitor, & Coil Guard Honeywell Excel 10 Controller, DFS, APS, SS Drain Pan Unitary Products Group...
- Page 9 Noval ETC-3 Controller, DFS, APS, Double Wall, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils Technicoat Condenser Coil Technicoat Condenser Coil & Phase Monitor Technicoat Condenser Coil & Coil Guard Technicoat Condenser Coil & Dirty Filter Switch Technicoat Condenser Coil, Phase Monitor, & Coil Guard Unitary Products Group...
- Page 10 Simplicity Intelli-Comfort Controller, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils Simplicity Intelli-Comfort Controller, Double Wall Simplicity Intelli-Comfort Controller, Double Wall, Phase Monitor, & Coil Guard Simplicity Intelli-Comfort Controller, Double Wall, & Technicoat Cond Coils Simplicity Intelli-Comfort Controller, Double Wall, & Technicoat Evap Coil Unitary Products Group...
- Page 11 SS Drain Pan & Phase Monitor, Hinged Filter Door & Toolless Access Panels SS Drain Pan & Coil Guard, Hinged Filter Door & Toolless Access Panels BM SS Drain Pan & Dirty Filter Switch, Hinged Filter Door & Toolless Access Panels Unitary Products Group...
- Page 12 Johnson UNT Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard, Hinged Filter Door & Toolless Access Panels Johnson UNT Controller, DFS, APS, Technicoat Cond. Coil, Phase Monitor, & Coil Guard, Hinged Filter Door & Toolless Access Panels Unitary Products Group...
- Page 13 Honeywell Excel 10 Controller, DFS, APS, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils Honeywell Excel 10 Controller, DFS, APS, Double Wall Honeywell Excel 10 Controller, DFS, APS, Double Wall, Phase Monitor, & Coil Guard Unitary Products Group...
- Page 14 Technicoat Evaporator Coil & Phase Monitor, Hinged Filter Door & Toolless Access Panels Technicoat Evaporator Coil & Coil Guard, Hinged Filter Door & Toolless Access Panels UM Technicoat Evaporator Coil & Dirty Filter Switch, Hinged Filter Door & Toolless Access Panels Unitary Products Group...
- Page 15 Simplicity Intelli-Comfort Controller, Double Wall, SS Drain Pan, & Technicoat Cond Coils Hinged Filter Door & Toolless Access Panels Simplicity Intelli-Comfort Controller, Double Wall, SS Drain Pan, & Technicoat Evap Coil Hinged Filter Door & Toolless Access Panels Unitary Products Group...
- Page 16 Intelli-Comfort w/ModLINC Controller, Double Wall, SS Drain Pan, & Technicoat Evap and Cond Coils Hinged Filter Door & Toolless Access Panels Intelli-Comfort w/ModLINC Controller, Double Wall, SS Drain Pan, Phase Monitor, Coil Guard, & Technicoat Evap and Cond Coils Hinged Filter Door & Toolless Access Panels Unitary Products Group...
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Page 17: Installation
This furnace is not to be used for temporary heating of CIFICALLY DETECTION buildings or structures under construction. LEAKS TO CHECK ALL CONNECTIONS. A FIRE OR EXPLOSION MAY RESULT CAUS- PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. Unitary Products Group... -
Page 18: 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. Unitary Products Group... -
Page 19: Rigging And Handling
Sections 7.2, 7.3 or 7.4 of Gas Installation Codes CSA-B149.1 (in Canada) and/or applicable provisions of the local building codes. Refer to Dimensions and Clearances Figure 13 for the clearances required for combustible construction, servicing, and proper unit FIGURE 1 - TYPICAL RIGGING operation. Unitary Products Group... -
Page 20: 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. Unitary Products Group... -
Page 21: Condensate Drain
Refer to the Dimensions and Clearances Figure 13 for location of these access panels. Make sure that all screws and panel latches are replaced and properly positioned on the FIGURE 4 - RECOMMENDED DRAIN PIPING unit to maintain an airtight seal. Unitary Products Group... -
Page 22: Typical Field Wiring
Terminals A1 and A2 provide a relay output to close the outdoor economizer dampers when the thermostat switches to the set-back position. T-STAT UNIT CONTROL BOARD ERMINAL BLOCK B1 FAC ORY OR FIELD GROUND SUPPLIED DISCONNEC HREE PHASE POWER SUPPLY FIGURE 5 - TYPICAL FIELD WIRING Unitary Products Group... -
Page 23: Thermostat
TABLE 3: ELECTRIC HEAT APPLICATION DATA NOMINAL VOLTAGE MINIMUM CFM UNIT SIZE HEATER SIZE 3-PHASE, 15 TON 17.5 TON 20 TON 25 TON (KW) 60 HZ 208/230,460,575 4500 208/230,460,575 4500 208/230 5000 6000 6000 7500 460,575 4500 208/230 5000 460,575 4500 Unitary Products Group... -
Page 24: Optional Gas Heat
3. Use wrought iron or steel pipe for all gas lines. Pipe Maximum capacity of pipe in cubic feet of gas per hour. (Based upon a pressure drop of 0.3 inch water column and 0.6 specific gravity compound should be applied sparingly to male gas). threads only. Unitary Products Group... -
Page 25: L.p. Units, Tanks And Piping
All L.P./propane gas equipment must conform to the The furnace must be isolated from the gas supply safety standards of the National Fire Protection Associ- piping system by closing its individual manual shut- ation. off valve during any pressure testing of the gas Unitary Products Group... -
Page 26: Vent And Combustion Air Hoods
Two vent hoods and a combustion air hood (with the "Factory installed" economizer option. screens) are shipped attached to the blower housing in Unitary Products Group... -
Page 27: Optional Power Exhaust/Barometric Relief Damper And Rain Hood
Adjusting screw (located on the damper control mod- ule) counterclockwise until the desired minimum • Optional CO Space Sensor Kit Part # damper position has been attained. 2AQ04700224 • Optional CO Sensor Kit Part # 2AQ04700124 Replace the economizer access panel. Unitary Products Group... -
Page 28: Enthalpy Setpoint Adjustment
66352-YIM-D-0904 FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT Unitary Products Group... -
Page 29: Four And Six Point Loads
Max. Adjustment Screw 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 FIGURE 11 - FOUR AND SIX POINT LOADS Unitary Products Group... -
Page 30: Center Of Gravity
240 Gas 2960 300 Gas 3046 180 Elec 2460 210 Elec 2728 240 Elec 2760 300 Elec 2846 NOTE: These weights are with economizer, and high option heat (gas or electric) FIGURE 12 - CENTER OF GRAVITY Unitary Products Group... -
Page 31: Physical Data
ECONOMIZER WITH POWER EXHAUST MOTORIZED DAMPER 18 KW OPERATING ELECTRIC 36 KW WEIGHTS HEATER 54 KW ( LBS.) 72 KW ROOF CURB BAROMETRIC DAMPER ECONOMIZER / MOTORIZED DAMPER RAIN HOOD ECONOMIZER / POWER EXHAUST RAIN HOOD WOOD SKID Unitary Products Group... -
Page 32: Dj Electrical Data Without Powered Convenience Outlet
None 43.2 18.0 21.7 43.2 12.8 10.0 36.0 43.3 66.6 54.0 65.0 77.5 72.0 86.6 99.1 None 35.0 18.0 17.3 35.0 10.3 36.0 34.6 53.6 54.0 52.0 62.2 72.0 69.3 79.5 NOTE 1: HACR Type per NEC. Unitary Products Group... -
Page 33: Dj Electrical Data Without Powered Convenience Outlet (Continued)
NOTE 1: HACR Type per NEC. ELECTRIC HEAT CORRECTION FACTORS VOLTAGE LIMITATIONS VOLTAGE NOMINAL VOLTAGE VOLTAGE kW CAP. MULTIPLIER POWER SUPPLY MIN. MAX. 1.00 208/230-3-60 0.92 460-3-60 0.92 565-3-60 0.92 Utilization Range “A” in accordance with ARI Standard 110. Unitary Products Group... -
Page 34: Dj Electrical Data With Powered Convenience Outlet
None 48.2 18.0 21.7 48.2 12.8 10.0 36.0 43.3 72.9 54.0 65.0 83.7 72.0 86.6 105.4 None 39.0 18.0 17.3 39.0 10.3 36.0 34.6 58.6 54.0 52.0 67.2 72.0 69.3 84.5 NOTE 1: HACR Type per NEC. Unitary Products Group... -
Page 35: Dj Electrical Data With Powered Convenience Outlet (Continued)
NOTE 1: HACR Type per NEC. ELECTRIC HEAT CORRECTION FACTORS VOLTAGE LIMITATIONS VOLTAGE NOMINAL VOLTAGE VOLTAGE kW CAP. MULTIPLIER POWER SUPPLY MIN. MAX. 1.00 208/230-3-60 0.92 460-3-60 0.92 565-3-60 0.92 Utilization Range “A” in accordance with ARI Standard 110. Unitary Products Group... -
Page 36: Utilities Entry Data
*Opening in the bottom of the unit can be located by the slice Four (4) feet below, 4 horizontal feet from, or 1 foot above any door or gravity air inlet into the building. in the insulation. FIGURE 13 - DIMENSIONS & CLEARANCES 15, 17.5, 20 & 25 TON Unitary Products Group... -
Page 37: Unitary Products Group
D E T A I L " Y " U N I T W I T H R A I N H O O D S FIGURE 13 - DIMENSIONS & CLEARANCES 15, 17.5, 20 & 25 TON (CONTINUED) Unitary Products Group... -
Page 38: 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 Unitary Products Group... -
Page 39: Altitude/Temperature Conversion Factor
66352-YIM-D-0904 ltitude/Temperature Conversion Factor SEA LEVEL TEMPER TURE (°F) FIGURE 14 - ALTITUDE/TEMPERATURE CONVERSION FACTOR Unitary Products Group... -
Page 40: Supply Air Blower Performance (15 Ton) - Cooling Only 180 Mbh - Bottom Duct
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. Unitary Products Group... -
Page 41: Supply Air Blower Performance (17.5 Ton) - Cooling Only 210 Mbh - Bottom Duct
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. Unitary Products Group... -
Page 42: Supply Air Blower Performance (20 Ton) - Cooling Only 240 Mbh - Bottom Duct
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. Unitary Products Group... -
Page 43: 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. Unitary Products Group... -
Page 44: 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. Unitary Products Group... -
Page 45: 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. Unitary Products Group... -
Page 46: 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. Unitary Products Group... -
Page 47: Connections
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. Unitary Products Group... -
Page 48: Charging Chart - 15 Ton
2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply. FIGURE 16 - CHARGING CHART - 17.5 TON Unitary Products Group... -
Page 49: Charging Chart - 20 Ton
2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply. FIGURE 18 - CHARGING CHART - 25 TON Unitary Products Group... -
Page 50: Phasing
CFM's and/or higher static pressures. Use Model 1LD0460 for 15 ton units, Model 1LD0417 for FIGURE 19 - BELT ADJUSTMENT 17.5 and 20 ton units, and Model 1LD0435 for 25 ton units. Refer to the Blower Motor and Drive Data Table 20. Unitary Products Group... -
Page 51: Air Balance
9000 10000 11000 12000 pletion of a call for cooling. Heating always takes prior- NOMINAL AIR FLOW (CFM) ity. FIGURE 20 - PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM FOR ALL UNIT TONNAGES Unitary Products Group... -
Page 52: Cooling Sequence Of Operation
This system operates as specified above with one due to a high or low-pressure switch or freezestat trip addition. The power exhaust motor is energized 45 and the anti-short cycle delay (ASCD) must have seconds after the actuator position exceeds the elapsed. Unitary Products Group... -
Page 53: Motorized Outdoor Air Dampers
UCB will monitor the low-pressure limit switch for end of the ASCD and the freezestat has closed, the any openings. If the low-pressure switch opens for unit will resume operation. greater than 5 seconds, the UCB will de-energize the Unitary Products Group... -
Page 54: Safety Controls
The UCB will initiate a flash code associated with If the UCB senses zero volts from the high temperature errors within the system. Refer to UNIT CONTROL limit, the indoor blower motor is immediately energized. BOARD FLASH CODES Table 26. Unitary Products Group... -
Page 55: Safety Controls
The draft motor control contacts 15,17.5, close and start the draft motor. As the speed of the 20, 25 draft motor reaches approximately 2500 RPM, the cen- trifugal switch contact, located on the end of the draft Unitary Products Group... -
Page 56: Gas Heating Operation Errors
If the temperature limit opens three times within one hour, it will lock-on the indoor blower motor and a flash That the second stage furnace can operate NOTE: code is initiated (See Table 26). even if first stage has locked out. Unitary Products Group... -
Page 57: Gas Valve
There are two separate gas valves in the furnace. (Tons) Opens, ºF Input Output Each valve contains a main and a redundant valve. 15, 17.5, 20 & 25 The redundant valves are located upstream of the 15, 17.5, 20 & 25 Unitary Products Group... -
Page 58: Flash Codes
Anticipator Setpoint Gas Valve 1st Stage 2nd Stage POST START CHECK LIST Honeywell VR8440 0.30 amp 0.11 amp White-Rodgers 36C68 1. Verify proper system pressures for both circuits. 2. Measure the temperature drop across the evapora- tor coil. Unitary Products Group... -
Page 59: Shut Down
TO SHUT DOWN: 1. Turn “off” electric power to unit. FIGURE 23 - TYPICAL GAS VALVES 2. Depress knob of gas valve while turning to “off” position, or turn gas valve switch to “off” position. Unitary Products Group... -
Page 60: Manifold Gas Pressure Adjustment
(2) increase or decrease the clear- ance for air to the desired level, (3) be sure to replace Adjust burner shutters so no yellow flame is observed cover screw after adjustment to prevent possible gas in the heat exchanger tubes. leakage. Unitary Products Group... -
Page 61: Checking Gas Input
278 cubic feet of gas per hour are consumed by the furnace at injury. that rate. Multiply 278 x 1050 (the Btu rating of the gas obtained from the local gas company). The result is 292,425 Btuh, which is close to the 300,000 Btuh rating of the furnace. Unitary Products Group... - Page 62 4. If M1 is not pulled in, check for 24 volts at the M1 check for loose wiring between the UCB and M3. coil. If 24 volts are present and M1 is not pulled in, replace the contactor. Unitary Products Group...
- Page 63 Lock plug. If compressor #1 energizes, there is a fault in the economizer wiring or DME. 10. If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor Unitary Products Group...
- Page 64 5. Failing the above, if voltage is supplied at M2, M2 ent conditions. These options are not enabled by is pulled in, and the compressor still does not oper- default. Local distributors can test the UCB for this ate, replace the compressor. programming. Unitary Products Group...
- Page 65 24 “ECON” terminal. If 24 volts is not present, check volts at the Y1 terminal. for loose wiring from the Y1 “OUT” terminal to the Unitary Products Group...
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Page 66: Gas Heat Troubleshooting Guide
Check to the unit prior to any of the following mainte- for loose wiring between the contactor and the sup- nance procedures so as to prevent personal ply air blower motor. injury. Unitary Products Group... - Page 67 On calls for heating, the supply air blower operates but in the main control box. If 24 volts is not found, the draft motor does not (the room thermostat fan replace the ETD. switch is in the “AUTO” position). Unitary Products Group...
- Page 68 The another. orifice is removed in the direction opposite the flow Main burners light but exhibit erratic flame characteris- of gas. Inspect the orifice for obstruction. If it is tics. clear, replace the main gas valve. Unitary Products Group...
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Page 69: Unit Flash Codes
No Power or Control Failure ASCD for the compressors in order to perform trouble- These flash codes do not represent alarms. shooting. To reset all ASCDs for one cycle, press and release the UCB TEST button once. Unitary Products Group... - Page 70 66352-YIM-D-0904 Unitary Products Group...
- Page 71 66352-YIM-D-0904 Unitary Products Group...
- Page 72 Subject to change without notice. Printed in U.S.A. 66352-YIM-D-0904 Copyright © 2004 by Unitary Products Group. All rights reserved. Supersedes: 66352-YIM-C-0504/035-18567-002-C-0504 Unitary 5005 Norman Products York Group Drive 73069...
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