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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 40
START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 43
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
DJ 036, 048 & 060
175615-YIM-A-0306
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Table of Contents
Troubleshooting
Related Manuals for Unitary products group DJ 036
Summary of Contents for Unitary products group DJ 036
- Page 1 CONTENTS DJ 036, 048 & 060 GENERAL ....... . 4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
UNIT FLASH CODES......52 HIGH-PRESSURE LIMIT SWITCH ....35 Unitary Products Group... - Page 3 INSTALLED BLOWER SHEAVE - SIDE FLOW ..28 IGNITION CONTROL BOARD FLASH CODES ..53 DJ036 BLOWER PERFORMANCE - DOWN FLOW . 29 DJ036 BLOWER PERFORMANCE W/FIELD INSTALLED BLOWER SHEAVE - DOWN FLOW . . . 29 Unitary Products Group...
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Page 4: General
Refer to other safety precautions that apply. Form 50.15-NM for additional information. Wear safety glasses and work gloves, and follow all safety codes. Use a quenching cloth and have a fire extinguisher available for all brazing operations. Unitary Products Group... -
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. Unitary Products Group... -
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 Unitary Products Group... -
Page 7: Installation
Wet Bulb Temperature (ºF) of Air on Evaporator Coil, 57 / 72 Min. / Max Dry Bulb Temperature (ºF) of Air on Condenser Coil, 0 / 125 Min. / Max. 1. Utilization range “A” in accordance with ARI Standard 110. Unitary Products Group... -
Page 8: Location
They should NOT be sized to match the dimen- the lifting holes provided in the base rails. Spreader sions of the duct connections on the unit. bars, whose length exceeds the largest dimension across the unit, MUST BE USED. Unitary Products Group... -
Page 9: Condensate Drain
Units with scroll compressors have a shipping bracket which must be removed after the unit is set in place. Make sure that all screws and panel latches See Figure 2. are replaced and properly positioned on the unit to maintain an airtight seal. Unitary Products Group... -
Page 10: Typical Field Power & Control Wiring
REMOVE JUMPER J2 FROM TERMINALS 4 AND 9 ON JUMPER PLUG CONNECTOR 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. FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING Unitary Products Group... -
Page 11: 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 and 11 for electrical data. Unitary Products Group... -
Page 12: 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. Unitary Products Group... -
Page 13: Gas Piping
The sup- or other material suitable for the purpose. NEVER ply piping and fittings must lie below the bottom gas manifold to avoid interference with the burner assembly. USE A FLAME. Unitary Products Group... -
Page 14: L.p. Units, Tanks And Piping
FIGURE 4 - EXTERNAL SUPPLY CONNECTION ing is available from most regulator manufacturers and EXTERNAL SHUT-OFF L.P./propane gas suppliers. L.P./propane gas is an excellent solvent and special pipe compound must be used when assembling piping Unitary Products Group... -
Page 15: Vent And Combustion Air Hoods
All of the components, including the dampers, hard- ware, and mounting instructions are shipped in a single package external from the unit and must be field assembled and installed. Unitary Products Group... -
Page 16: 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. Unitary Products Group... -
Page 17: 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 Unitary Products Group... -
Page 18: Center Of Gravity (All Models)
FRONT OF UNIT FRONT OF UNIT FIGURE 9 - FOUR AND SIX POINT LOADING TABLE 6: CENTER OF GRAVITY (ALL MODELS) DIMENSION DJ 036-060 TABLE 7: DJ 4 AND 6 POINT LOADS WEIGHT DISTRIBUTION 4-Point Loading (lb) 6-Point Loading (lb) UNIT... -
Page 19: Dj Physical Data
4 TON 5 TON DJ (Cooling Only) BASIC UNIT (Gas/Electric) Economizer Motorized Damper 5 - 7 kW OPTIONS Electric Heater 10 - 15 kW 20 - 30 kW Roof Curb ACCY. Barometric Relief / Fixed Air Damper Unitary Products Group... -
Page 20: Electrical Data - Dj036, 048 & 060 Belt Drive W/O Powered Outlet
2CE04512025 21.2 51.0 70.2 None 11.1 2CE04510746 13.5 460-3-60 42.0 2CE04511046 10.1 12.1 18.4 2CE04511546 13.6 16.4 23.7 2CE04512046 19.5 23.5 32.6 None 2CE04511058 10.6 10.2 15.2 575-3-60 34.0 2CE04511558 15.9 15.3 21.6 2CE04512058 21.2 20.4 28.0 Unitary Products Group... - Page 21 1. HACR Type per NEC. 2. These electric heaters do not include a fuse box. If a fuse box is required to meet a local code (i.e. Chicago), the fuse block accessories 2FB04700825 and 2FB04700846 are available for field installation. Unitary Products Group...
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Page 22: Electrical Data - Dj036, 048 & 060 Belt Drive With Powered Convenience Outlet
21.2 51.0 82.7 None 16.1 2CE04510746 19.7 460-3-60 42.0 2CE04511046 10.1 12.1 24.7 2CE04511546 13.6 16.4 29.9 2CE04512046 19.5 23.5 38.8 None 13.4 2CE04511058 10.6 10.2 20.2 575-3-60 34.0 2CE04511558 15.9 15.3 26.6 2CE04512058 21.2 20.4 33.0 Unitary Products Group... - Page 23 1. HACR Type per NEC. 2. These electric heaters do not include a fuse box. If a fuse box is required to meet a local code (i.e. Chicago), the fuse block accessories 2FB04700825 and 2FB04700846 are available for field installation. Unitary Products Group...
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Page 24: Unit Dimensions (3 - 5 Ton Cooling Only/Electric Heat) Front View
CAP. MULTIPLIER MIN. MAX. 1.00 208/230-1-60 0.92 208/230-3-60 0.92 0.92 460-3-60 575-3-60 1. Utilization Range “A” in accordance with ARI Standard 110. FIGURE 10 - UNIT DIMENSIONS (3 - 5 TON COOLING ONLY/ELECTRIC HEAT) FRONT VIEW Unitary Products Group... -
Page 25: Unit Dimensions
175615-YIM-A-0306 FIGURE 11 - UNIT DIMENSIONS (3 - 5 TON COOLING/GAS HEAT) FRONT VIEW DETAIL “A” FIGURE 12 - UNIT WITH ECONOMIZER RAINHOOD Unitary Products Group... -
Page 26: Unit With Fixed Outdoor Air/Motorized Damper Rainhood
175615-YIM-A-0306 DETAIL “B” FIGURE 13 - UNIT WITH FIXED OUTDOOR AIR/MOTORIZED DAMPER RAINHOOD FIGURE 14 - UNIT DIMENSIONS (REAR VIEW) Unitary Products Group... -
Page 27: 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. Unitary Products Group... -
Page 28: Dj036 Blower Performance - Side Flow
2. TURNS OPEN = Setting of the variable pitch motor sheave where "0 Turns Open" is fully closed. DJ036 Belt Drive Assembly With Field Installed AK61 Blower Sheave And A36 Belt (Side Flow) 0 Turns 1 Turn 5 Turns 4 Turns 3 Turns 2 Turns 1000 1200 1400 1600 1800 2000 2200 2400 2600 Unitary Products Group... -
Page 29: Dj036 Blower Performance - Down Flow
2. TURNS OPEN = Setting of the variable pitch motor sheave where "0 Turns Open" is fully closed. DJ036 Belt Drive Assembly With Field Installed AK61 Blower Sheave And A36 Belt (Down Flow) 1 Turn 0 Turns 5 Turns 4 Turns 3 Turns 2 Turns 1000 1200 1400 1600 1800 2000 2200 2400 2600 Unitary Products Group... -
Page 30: Dj048 Blower Performance - Side Flow
DJ048 Belt Drive Assembly With Field Installed AK56 Blower Sheave And A36 Belt (Side Flow) 0 Turns 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 Unitary Products Group... -
Page 31: Dj048 Blower Performance - Down Flow
DJ048 Belt Drive Assembly With Field Installed AK56 Blower Sheave And A36 Belt (Down Flow) 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn 0 Turns 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 Unitary Products Group... -
Page 32: Dj060 Blower Performance - Side Flow
DJ060 Belt Drive Assembly With Factory Installed AK56 Blower Sheave And A36 Belt (Down Flow) 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn 0 Turns 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 Unitary Products Group... -
Page 33: Phasing
1. The supply air CFM must be within the limitations static resistances of both the supply and the return air shown in the Unit Application Data Table 1. duct systems. With this information, the motor pulley 2. Pulleys can be adjusted in half turn increments. Unitary Products Group... -
Page 34: Operation
5/16” dot plugs that were removed present, the heating operation will be performed. If oper- in Step 1. ating, the cooling system is halted as with a completion of a call for cooling. Heating always takes priority. Unitary Products Group... -
Page 35: Cooling Sequence Of Operation
“Y1”. If the compressor has satisfied its minimum The low-pressure limit switch is not monitored during run time, the compressor and condenser fan are de- the initial 30 seconds of a cooling system's operation. energized. Otherwise, the unit operates the cooling sys- Unitary Products Group... -
Page 36: Freezestat
If the call for cooling is still present at the end of the ting higher than the conditioned space temperature. ASCD and the freezestat has closed, the unit will This resets any pressure or freezestat flash codes. resume operation. Unitary Products Group... -
Page 37: Electric Heating Sequence Of Operations
“ON” cycles and may result in the lowering of matically. The limit switch operates when a high the temperature within the conditioned space. Refer to temperature condition, caused by inadequate sup- Table 29 for the required heat anticipator setting. Unitary Products Group... -
Page 38: Gas Heating Sequence Of Operation
On single stage models the limit is mounted to the condenser partition panel. On two stage models the limit is mounted just above the inlet of Unitary Products Group... -
Page 39: Gas Valve
The gas valve is of the redundant type. If for any rea- son the main gas valve fails in the open position, then the redundant valve ahead of the main gas valve will shut off the flow of gas to both the pilot and main gas valves. Unitary Products Group... -
Page 40: Flash Codes
2. Set the room thermostat to the off position. 2. Make sure that the vent and combustion air hoods 3. Turn unit electrical power on. have been properly installed. 4. Set the room thermostat fan switch to on. 5. Check indoor blower rotation. Unitary Products Group... -
Page 41: Operating Instructions
A fire or explosion may result causing property damage, personal injury or loss of life. FIGURE 20 - TYPICAL 2 STAGE GAS VALVES Unitary Products Group... -
Page 42: Manifold Gas Pressure Adjustment
If the actual input is not within 5% of the furnace rating MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF (with allowance being made for the permissible range ALL ELECTRIC POWER TO THE UNIT. of the regulator setting), replace the orifice spuds with spuds of the proper size. Unitary Products Group... -
Page 43: Adjustment Of Temperature Rise
(the room thermostat fan switch is in the between the return air and the heated air from the fur- “AUTO” position). nace) must lie within the range shown on the rating plate and the data in the Gas Heat Application Table 4. Unitary Products Group... -
Page 44: Properly
UCB, check for proper wiring between the thermostat and the UCB, i.e. that the thermostat G Loose wiring from the room thermostat to the UCB. terminal is connected to the G terminal of the UCB, and for loose wiring. Unitary Products Group... -
Page 45: Properly
Y1 “OUT” terminal, the UCB must be replaced. 15. If none of the above correct the error, replace the UCB. 12. For units without economizers: If 24 volts is present at the Y1 OUT terminal, check for 24 volts Unitary Products Group... -
Page 46: Charging The Unit
14.7 17.3 19.9 22.6 25.1 27.6 28.8 30.1 11.4 14.2 17.1 21.0 24.9 26.9 28.9 11.4 13.5 16.6 19.6 21.2 22.7 12.1 14.3 15.4 16.5 10.3 The DJ060 uses a TXV. Charge the unit to 12°F subcooling. Unitary Products Group... -
Page 47: Normal Operating Pressures
95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 23 - DJ036 OPERATING PRESSURES 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 24 - DJ048 OPERATING PRESSURES Unitary Products Group... -
Page 48: Gas Heat Troubleshooting Guide
If the ICB has a flash code unit components. Verify proper operation after other than the heartbeat, then determine the flash code servicing. and locate its troubleshooting procedures in the flash Unitary Products Group... -
Page 49: Flash Code Troubleshooting
ICB, then replace the ICB between terminals 3 and 8 of the harness connec- and verify proper operation of the furnace. tor. If a closed circuit is indicated, then check the Unitary Products Group... -
Page 50: Pilot Flame Lockout
The temperature limits limit the temperature in the fur- mended rate. Verify both conditions are within the nace to a safe level. If a temperature higher than the published ranges. Unitary Products Group... -
Page 51: Unexpected Flame Presence
2. If the motor shell is cold with the room thermostat calling for heat, check if 24 volts is present at the Unitary Products Group... -
Page 52: Unit Flash Codes
(approximately 200ms described in “PILOT CHECKOUT” on page 42. on and 200ms off). To show normal operation, the con- trol boards flashes a 1 second on, 1 second off “heart- Unitary Products Group... -
Page 53: Ignition Control Board Flash Codes
Pressure / Centrifugal Switch Closed with Inducer Off 3 Flashes Not Applicable 4 Flashes Lock Out From Too Many Flame Losses 5 Flashes High Temperature Switch Open (Primary or Aux.) 6 Flashes Rollout Switch Open 7 Flashes Flame Present With Gas OFF 8 Flashes Unitary Products Group... - Page 54 175615-YIM-A-0306 Unitary Products Group...
- Page 55 175615-YIM-A-0306 Unitary Products Group...
- Page 56 Subject to change without notice. Printed in U.S.A. 175615-YIM-A-0306 Copyright © 2006 by Unitary Products Group. All rights reserved. Supersedes: 170652-YIM-A-1105 Unitary 5005 Norman Products York Group Drive 73069...
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