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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .49
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .50
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .52
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
SUNLINE™ 2000
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
MODELS: DM180, 240 & 300
284806-YIM-B-0707
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Related Manuals for Unitary products group Sunline 2000 DM180
Summary of Contents for Unitary products group Sunline 2000 DM180
- Page 1 SUNLINE™ 2000 INSTALLATION GAS/ELECTRIC SINGLE PACKAGE MANUAL AIR CONDITIONERS MODELS: DM180, 240 & 300 CONTENTS GENERAL ........4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
COOLING SEQUENCE OF OPERATION ... 43 BELT DRIVE BLOWER ......53 Unitary Products Group... - Page 3 30 HEAT DELAY ....... 62 31 VAV CONTROL BOARD FLASH CODES ..63 Unitary Products Group...
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Page 4: General
• Technical Guide - 262259 Wear safety glasses and work gloves, and follow all safety codes. Use a quenching cloth and have a fire • General Installation - 284806 extinguisher available for all brazing operations. Unitary Products Group... -
Page 5: Renewal Parts
For use with natural gas or propane gas. THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH ENCLOSED INSTALLATION INSTRUC- TIONS AND ANY APPLICABLE LOCAL, STATE, AND NATIONAL CODES INCLUD- ING, BUT NOT LIMITED TO, BUILDING, ELECTRICAL, AND MECHANICAL CODES. Unitary Products Group... -
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. Unitary Products Group... -
Page 7: 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 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. Unitary Products Group... -
Page 9: Rigging And Handling
CSA-B149.1 (in Canada) and/or applicable provisions of the local building codes. Refer to Figures 13, 14 and 15 for the dimensions and clearances required for com- bustible construction, servicing, and proper unit opera- tion. FIGURE 1 - TYPICAL RIGGING Unitary Products Group... -
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. Unitary Products Group... -
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 Unitary Products Group... -
Page 12: Typical Field Wiring
O C C 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 Unitary Products Group... -
Page 13: Thermostat
If any of the wire supplied with the unit Some KW sizes require fuses and others do not. Refer must be replaced, replacement wire must be of the to Table 3 for minimum CFM limitations and to Tables 9 and 12 for electrical data. Unitary Products Group... -
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). Unitary Products Group... -
Page 15: Gas Connection
Shellac base compounds gage connection, must be installed immediately such as Gaskolac or Stalastic, and compounds upstream of the gas supply connection to the fur- such as Rectorseal #5, Clyde's or John Crane nace. may be used. Unitary Products Group... -
Page 16: L.p. Units, Tanks And Piping
(b) the "wetted surface" area access panel with the screws provided in the bag also of the container or containers. attached to the blower housing. Unitary Products Group... -
Page 17: Optional Economizer/Motorized Damper Rain Hood
The enthalpy set point may now be set by selecting the sors are factory mounted as part of the "Factory desired setpoint shown in the Enthalpy Setpoint Adjust- installed" economizer option. ment Figure 9. Adjust as follows: Unitary Products Group... -
Page 18: Power Exhaust Damper Setpoint
Loosen, but do not remove the two panel latches. openings are sealed to prevent air and water Locate the economizer actuator, where the following leakage. adjustment can be made. Unitary Products Group... -
Page 19: Vav Control Board
• PUR - a 24 VAC binary input for building purge calls from an external source. Unitary Products Group... -
Page 20: Factory-Installed Vfd
Unitary Products Group... -
Page 21: Optional Hot Gas Bypass (Hgbp)
0 and 80 psig with a factory-setting of 60 psig. HGBP is standard on all units with VAV and optional with CV units. Do not connect AC power to the T1, T2, T3 drive terminals to prevent damage to the VFD. Unitary Products Group... -
Page 22: 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 10 - HONEYWELL ECONOMIZER CONTROL W7212 Unitary Products Group... -
Page 23: Four And Six Point Loads
2300 300 Elec 2331 Total 6 Point Loads (lbs) Unit Size Shipping Weight 180 Gas 2300 240 Gas 2500 300 Gas 2531 180 Elec 2100 240 Elec 2300 300 Elec 2331 FIGURE 12 - CENTER OF GRAVITY Unitary Products Group... -
Page 24: Physical Data
This compressor will be energized first. TABLE 8: 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 Unitary Products Group... -
Page 25: Dm 180, 240 Electrical Data Without Powered Convenience Outlet
173.2 197.7 (20) None 55.1 18.0 21.7 55.1 36.0 43.3 66.4 54.0 65.0 77.2 72.0 86.6 98.6 None 44.5 18.0 17.3 44.5 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 26: Dm 300 Electrical Data Standard Motor Without Powered Convenience Outlet
69.8 18.0 21.7 69.8 20.5 19.3 36.0 43.3 78.3 54.0 65.0 89.1 72.0 86.6 110.7 None 57.7 18.0 17.3 57.7 17.3 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. Unitary Products Group... -
Page 27: Dm 180, 240 Electrical Data With Powered Convenience Outlet
173.2 210.2 (20) None 60.1 18.0 21.7 60.1 36.0 43.3 72.6 54.0 65.0 83.5 72.0 86.6 105.1 None 48.5 18.0 17.3 48.5 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 28: Dm 300 Electrical Data Standard Motor With Powered Convenience Outlet
74.8 18.0 21.7 74.8 20.5 19.3 36.0 43.3 84.5 54.0 65.0 95.3 72.0 86.6 117.0 None 61.7 18.0 17.3 61.7 17.3 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. Unitary Products Group... -
Page 29: Front View
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 (15, 20 & 25 TON) Unitary Products Group... -
Page 30: 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. Unitary Products Group... -
Page 31: Unit Clearance And Rain Hood Dimensions
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 CLEARANCE AND RAIN HOOD DIMENSIONS (15, 20 & 25 TON) Unitary Products Group... -
Page 32: 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 33 284806-YIM-B-0707 ltitude/Temperature Conversion Factor SEA LEVEL TEMPER TURE (°F) FIGURE 16 - ALTITUDE/TEMPERATURE CONVERSION FACTOR Unitary Products Group...
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Page 34: 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 35: 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 36: Supply Air Blower Performance (15 Ton) - Gas Heat 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 37: Supply Air Blower Performance (20 Ton) - Gas Heat 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 38: Supply Air Blower Performance (25 Ton) - Gas Heat 300 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. 15 HP Motor is required. Unitary Products Group... -
Page 39: Factor
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 40: Phasing
CFM's and/or higher static pressures. Use Model 1LD0416 for 15 ton units, Model 1LD0417 for 20 FIGURE 17 - BELT ADJUSTMENT ton units, and Model 1LD0435 for 25 ton units. Refer to the Blower Motor and Drive Data Table 23. Unitary Products Group... -
Page 41: Air Balance
MENTS TO ASSURE A DRY INDOOR COIL. 0.65 240 MBH 300 MBH 180 MBH 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 Unitary Products Group... -
Page 42: Operation
(if the fan switch on the room thermostat is set in static pressure reaches or exceeds the high-limit set- the "AUTO" position) and drives the economizer damp- point, then the supply fan motor will be shutdown. ers from fully closed to their minimum position. If the Unitary Products Group... -
Page 43: Economizer With Dual Enthalpy Sensors
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" to "G" connection provides minimum position but does not provide power exhaust operation. Unitary Products Group... -
Page 44: Economizer With Optional Vav Blower With Power Exhaust
If the call for cooling is still present at the conclusion of the ASCD, the UCB will re- Each cooling system is monitored for operation outside energize the halted compressor. of the intended parameters. Errors are handled as Unitary Products Group... -
Page 45: Low Ambient Cooling
(6M) will be energized. After completing The other refrigerant system will continue in operation the specified fan on delay for heating, the UCB will unless it is affected by the fault as well. energize the blower motor. Unitary Products Group... -
Page 46: Heating Operation Errors
Reducing the value below the correct setpoint automatically. The limit switch operates when a will give shorter "ON" cycles and may result in the low- high temperature condition, caused by inadequate ering of the temperature within the conditioned space. Unitary Products Group... -
Page 47: Gas Heating Sequence Of Operations
The UCB will de-energize the Ignition module "IC1" will immediately start the first blower motor. stage igniter sparking and will open the redundant valve located inside the first stage main gas valve Unitary Products Group... -
Page 48: Gas Heating Operation Errors
(Table 29). When voltage is no longer sensed at the power is removed from the module either at the GV, the UCB will de-energize the indoor blower follow- unit or by resetting the room thermostat. ing the elapse of the fan off delay for heating. Unitary Products Group... -
Page 49: Flash Codes
B U R N E R C O M P A R T M E N T 8. Set the room thermostat fan switch to off. FIGURE 20 - GAS VALVE AND CONTROLS 9. Turn unit electrical power off. Unitary Products Group... -
Page 50: Operating Instructions
5.0" for natural gas 1. Turn “off” electric power to unit. units. If gas pressure is outside these limits, con- tact the local gas utility for corrective action. 2. Turn room thermostat to lowest setting. Unitary Products Group... -
Page 51: Manifold Gas Pressure Adjustment
(3) be sure to replace est dial on the meter. A typical gas meter usually cover screw after adjustment to prevent possible gas has a 1/2 or a 1 cubic foot test dial. leakage. Unitary Products Group... -
Page 52: Adjustment Of Temperature Rise
F Temp Rise could cause injury to person and/or damage unit components. Verify proper operation after After the temperature rise has been determined, the servicing. cfm can be calculated as follows: Unitary Products Group... - Page 53 UCB terminal, C1. If 24 volts is present, check 8. If 24 volts is not present at the “FAN” terminal, for loose wiring between C1 and the compressor check for 24 volts from the room thermostat. If 24 contactor. Unitary Products Group...
- Page 54 Y1 “OUT” terminal compressor #1 will be energized unless it is locked to the Mate-N-Lock plug, the jumper in the Mate-N- out. Typically, compressor #2 is energized only Unitary Products Group...
- Page 55 ALARMS button on the loose wiring between the contactor and the com- UCB. The UCB will flash the last five alarms on the pressor. LED. If the compressor is locked out, remove any Unitary Products Group...
- Page 56 UCB allows compressor operation all the time. This programming can be 10. If 24 volts is present at the UCB Y1 terminal and checked or changed by the local distributor. none of the switches are open and the compressor Unitary Products Group...
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Page 57: Gas Heat Troubleshooting Guide
(refer to the drive user manual for full descriptions, if necessary). Clear any fault by pressing 'RESET' on the drive's keypad and take any corrective action as needed. If the motor still does not operate, replace the motor. Unitary Products Group... - Page 58 If all connections are cor- rect, replace the relay board. Unitary Products Group...
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Page 59: Unit Control Board Flash Codes
If intact, check for 24 Flash codes that do and do not represent alarms are volts across terminals “MV” and “COMMON” termi- listed in Table 29. nals. If no voltage detected, replace ignitor control. If voltage is present, replace gas valve. Unitary Products Group... -
Page 60: Unit Control Board
14 Flashes 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 Unitary Products Group... -
Page 61: Unit Control Board Option Setup Option Byte Setup
Enter the Option Setup mode by pushing the 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. Unitary Products Group... -
Page 62: 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 Unitary Products Group... - Page 63 284806-YIM-B-0707 Unitary Products Group...
- Page 64 Subject to change without notice. Printed in U.S.A. 284806-YIM-B-0707 Copyright © 2007 by Unitary Products Group. All rights reserved. Supersedes: 284806-YIM-A-0107 Unitary 5005 Norman Products York Group Drive 73069...
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