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Sunlife Enterprises SUNLINE DM180 manual

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Table of contents for the manual

  • Page 1

    INST ALLA TION MANUAL - 50Hz CAUTION: READ ALL SAFETY GUIDES BEFORE YOU BEGIN TO INST ALL YOUR UNIT . SAVE THIS MANUAL ISO 9001 Certified Quality Management System SUNLINE™ 2000 GAS/ELECTRIC SINGLE P ACKAGE AIR CONDITIONERS MODELS: DM180, 240 & 300 (Export) 356214-XIM-A-0 108 CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 2

    356214-XIM-A-0108 2 Unitary Products Group T ABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REFERENCE . . . . . . . . . . . . [...]

  • Page 3

    356214-XIM-A-0108 Johnson Controls Unitary Products 3 LIST OF FIGURES Fig. # Pg. # 1 TYPICAL RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2 CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3 FIXED OUTDOOR AIR DA MPER . . . . . . . . . . . . . . . . . . . 11 4 RECOMMENDED DRAIN PIPING . . . . . .[...]

  • Page 4

    356214-XIM-A-0108 4 Johnson Controls Unitary Products GENERAL YORK Model DM u nits are either sing le package air conditions equipped with optional fa ctory installed ele c- tric heaters, or single pa ckage gas-fired central hea ting furnaces with cooling unit. Both are designed for out- door installation on a rooftop or sla b. The units are comple[...]

  • Page 5

    356214-XIM-A-0108 Johnson Controls Unitary Products 5 RENEW AL P ARTS Contact your local York ® Parts Distribution Center for authorized replacement parts. APPROV ALS Design certified by CSA as follows: • For use as a cooling unit only with or without optional electric heat. • For use as a forced air furnace with cooling unit • For outdoor i[...]

  • Page 6

    356214-XIM-A-0108 6 Johnson Controls Unitary Products PRODUCT NOMENCLA TURE D M 180 N24 A 7 A AA 1 0 1 2 4 A D = A/C, Single Pkg., R-22 Product Category A = Std. Drive Airflow B = Std. Drive/Single Input Econo. C = Std. Drive/Single Input Econo./Power Exhaust (Downflow Only) D = Std. Drive/Motorized Damper N = Hi Static Drive* P = Hi Static Drive/S[...]

  • Page 7

    356214-XIM-A-0108 Johnson Controls Unitary Products 7 INST ALLA TION INST ALLA TION SAFETY INFORMA TION: Read these instructions befo re continuing this a ppli- ance installation. This is an outdoor combination hea t- ing and cooling unit. The in staller must assure that these instructions are ma de available to the cons umer and with instructions [...]

  • Page 8

    356214-XIM-A-0108 8 Johnson Controls Unitary Products LOCA TION Use the following guidelines to select a suitable loca- tion for these units. 1. Unit is designed for ou tdoor installation only . 2. Condenser coils must have an unlimited supply of air . 3. Where a choice of location is p ossible, position the unit on either north or east side of bui[...]

  • Page 9

    356214-XIM-A-0108 Johnson Controls Unitary Products 9 RIGGING AND HANDLING Exercise care when mo ving the unit. Do not r emove any packaging until the unit is near th e place of installa- tion. Rig the unit by attaching chain or cable slings to the round lifting holes pr ovided in the base rails. Spreaders, whose leng th exceeds the larg est dimen-[...]

  • Page 10

    356214-XIM-A-0108 10 Johnson Controls Unitary Products DUCTWORK Ductwork shou ld be designed and sized accord ing to the methods in Manual Q of th e Air Conditioning Con- tractors of Am erica (ACCA). A closed return duct system shall be used. This shall not preclude use of econo mizers or outdoor fresh air intake. The supply and retur n air duct co[...]

  • Page 11

    356214-XIM-A-0108 Johnson Controls Unitary Products 11 CONDENSA TE DRA IN Plumbing must conform to local codes. Use a sealin g compound on male pipe thread s. Install a condensate drain line from the one-inch NPT female connection o n the unit to an open drain. NOTE: The condensate drain oper ates in a negative pressure in the ca binet. The condens[...]

  • Page 12

    356214-XIM-A-0108 12 Johnson Controls Unitary Products FIGURE 5 - FIELD WIRING - DM ELECTRIC/ELECTRIC AND GAS/ ELECTRIC UNITS W1 W2 Y1 G OCC P P1 Y2 X R SD C C SD SD R OCC C RC G Y2 Y1 W2 W1 Jumper Smoke Detector 24 VAC Class 2 X R THERMOSTAT TERMINALS CONTROL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 3 1 2 4 3 1 2 4 Second stage [...]

  • Page 13

    356214-XIM-A-0108 Johnson Controls Unitary Products 13 THERMOST A T The room thermostat shou ld be located on an inside wall approximat ely 56 inches a bove the floor wh ere it will not be subject to drafts , sun exposure or heat from electrical fixtures or appliances. F ollow manufacturer's instructions enclosed with th ermostat for general i[...]

  • Page 14

    356214-XIM-A-0108 14 Johnson Controls Unitary Products OPTIONAL GAS HEA T These gas-fired heater s ha ve aluminized-steel or optional stainless steel, tu bular he at exchangers with spark ignition with proven pilot. All gas heaters are shipped from the factory equippe d for natural gas use, but can be field converted to L.P./ Propane with Kit Model[...]

  • Page 15

    356214-XIM-A-0108 Johnson Controls Unitary Products 15 4. All piping should be cleaned of dirt and sca le by hammering on the ou tside of the pip e and blowing out the loose dirt and scale . Before initial start-up, be sure that all of the g as lines external to the unit have been pur ged of ai r . 5. The gas supply should be a separate line an d i[...]

  • Page 16

    356214-XIM-A-0108 16 Johnson Controls Unitary Products For satisfactory operation, L .P./propane gas pressur e must be 10.0 I.W.C. at the unit manifold under full load. Maintaining prop er gas pressure de pends on three main factors: 1. The vaporization rate depe nds on (a) the tempera- ture of the liquid an d (b) the "wetted surf ace" ar[...]

  • Page 17

    356214-XIM-A-0108 Johnson Controls Unitary Products 17 OPTIONAL POWER EXHAUST/ BAROMETRIC RELIEF DAMPER RAIN HOOD The instructions for the po wer exhau st/barometric r elief damper ra in hood can b e found in the kit. The ex haust fan, all supporting br ackets, angles, and the wir ing are factory installed as part of the power exh aust option. OPTI[...]

  • Page 18

    356214-XIM-A-0108 18 Johnson Controls Unitary Products FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT FIGURE 10 - HONEYWELL EC ONOMIZER CONTROL W7212 N1 N P1 P EXH Set EXH Min Pos IAQ Max IAQ IAQ Min Free Cool T T1 AQ1 AQ SO+ SO SR+ SR A BC D TR TR1 24 Vac HOT 24 Vac COM EF EF1 2 3 4 5 1 + Exhaust Air Adjustment Screw Exhaust Air LED Damper Min. Position [...]

  • Page 19

    356214-XIM-A-0108 Johnson Controls Unitary Products 19 FIGURE 1 1 - FOUR AND SIX POINT LOADS A B C D FRONT A E D B F C FRONT T ABLE 6: FOUR AND SIX POINT LOADS Unit Size To t a l Shipping Wei gh t 4 Point Loads (lbs) AB C D 180 Gas 2300 539 563 612 586 240 Gas 2500 538 563 715 684 300 Gas 3130 615 671 962 882 180 Elec 2100 49 2 514 558 536 240 Elec[...]

  • Page 20

    356214-XIM-A-0108 20 Johnson Controls Unitary Products * NOTE: This compressor will be energized first. T ABLE 7: PHYSICAL DATA MODELS DM180 DM240 DM300 EV APORA TOR BLOWER CENTRIFUGAL BLOWER (Dia. x Wd.) 15x15 18x15 18x15 F AN MOTOR HP 5.0 7.5 10 EV APORA TOR COIL ROWS DEEP 3 3 4 FINS PER INCH 13.5 F ACE AREA (Sq. Ft.) 15.5 20.5 25 CONDENSER F AN [...]

  • Page 21

    356214-XIM-A-0108 Johnson Controls Unitary Products 21 Note 1: HACR T ype per NEC. T ABLE 8: DM ELECTRICAL DA T A -W ITHOUT POWERED CONVENIENCE OUTLET MODEL TONNAGE VOL T AGE COMPRESSORS OD F AN MOTORS FLA EACH ID BLOWER MOTOR FLA CONV OUTLET AMPS HEA T ER OPTION MIN. CIRCUIT AMP ACITY (AMPS) MAX. FUSE/ BRKR 1 SIZE (AMPS) RLA EACH LRA EACH MODEL KW[...]

  • Page 22

    356214-XIM-A-0108 22 Johnson Controls Unitary Products Note 1: HACR T y pe per NEC. T ABLE 9: DM ELECTRIC AL DA T A -WITH POWERED CONVENIENCE OUTLET MODEL TONNAGE VOL T AGE COMPRESSORS OD F AN MOTORS FLA EACH ID BLOWER MOTOR FLA CONV OUTLET AMPS HEA T ER OPTION MIN. CIRCUIT AMP ACITY (AMPS) MAX. FUSE/ BRKR 1 SIZE (AMPS) RLA EACH LRA EACH MODEL KW S[...]

  • Page 23

    356214-XIM-A-0108 Johnson Controls Unitary Products 23 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) UTILITIES ENTR Y DA T A HOLE OPENING SIZE (DIA.) USED FOR A 29 / 1-1/8” KO Control Wi ring Side 19 / 3/4” N PS (Fem.) Bottom B 92 / 3-5/8” KO[...]

  • Page 24

    356214-XIM-A-0108 24 Johnson Controls Unitary Products FIGURE 14 - REAR VIEW DIMENSIONS NOTE: Unit s are shipped with the b ottom duct open- ings covered. An accessory flange kit is avai l- able for connecting side duct s. For bottom duct applicatio ns: 1. Remove the side panels from the supply and return air compartments to gain access to the bott[...]

  • Page 25

    356214-XIM-A-0108 Johnson Controls Unitary Products 25 NOTE: ELEC / ELEC Models : Units and ductwork are approved for zero cle arance to combustible material when equipped wi th electric heaters. GAS / ELEC Models : A 25mm/1” clearance must be provided between any combustible material and the supply air ductwork for a distance of .9 meter/3 feet [...]

  • Page 26

    356214-XIM-A-0108 26 Johnson Controls Unitary Products CFM, ST A TIC PRESSURE, AND POWER - AL TITUDE A ND TEMPERA TURE CORRECTIONS The information below should b e used to assist i n applicatio n of product when being ap plied at altitudes at or exceeding 1000 feet above sea level. The air flow rates listed in the standard blower perfo rmance table[...]

  • Page 27

    356214-XIM-A-0108 Johnson Controls Unitary Products 27 FIGURE 16 - AL TITUDE/TEMPERA TUR E CONVERSION F ACTOR[...]

  • Page 28

    356214-XIM-A-0108 28 Johnson Controls Unitary Products NOTES: 1.Blower performance includes fixed out door air , 2” T/A filters, a dry evaporator coil and no el ectr ic heat. 2.Refer to T able 16 for additional stati c resistances. ESP = External S tatic Pressure available for the supply and re turn air duct system. All internal unit resist ances[...]

  • Page 29

    356214-XIM-A-0108 Johnson Controls Unitary Products 29 NOTES: 1.Blower performance includes fixed out door air , 2” T/ A filters, a dry evaporator coil and no electr ic heat. 2.Refer to T able 16 for additional stati c resistances. ESP = External S tatic Pressure available for t he supply and ret urn air duct system . All internal unit resist anc[...]

  • Page 30

    356214-XIM-A-0108 30 Johnson Controls Unitary Products NOTES: 1.Blower performance includes a gas-fired heat exchanger , fi xed outdoor air , two-inch T/A filters and a dry evaporator co il. 2.Refer to the additional S tatic Resistances t able. ESP = External S tatic Pressure available for the supply and re turn air duct system. All internal unit r[...]

  • Page 31

    356214-XIM-A-0108 Johnson Controls Unitary Products 31 NOTES: 1.Blower performance includes a gas-fire d heat exchanger , fi xed outdoor air , two-inch T/A filters and a dry evapo rator co il. 2.Refer to the additional S tatic Resistances t able. ESP = External S tatic Pressure available for t he supply and ret urn air duct system . All internal un[...]

  • Page 32

    356214-XIM-A-0108 32 Johnson Controls Unitary Products NOTES: 1.Blower performance includes a gas-fired heat exchanger , fi xed outdoor air , two-inch T/A filters and a dry evaporator co il. 2.Refer to the additional S tatic Resistances t able. ESP = External S tatic Pressure available for the supply and re turn air duct system. All internal unit r[...]

  • Page 33

    356214-XIM-A-0108 Johnson Controls Unitary Products 33 * Factory Sett ing Power Exhaust motor is a 3/4 HP , PSC type with slee ve bearings, a 48 frame and inheren t protection. T ABLE 16: STATIC RESIST ANCES 1 DESCRIPTION RESIST ANCE, Pa/ IWG m 3 /s/ CFM MODEL 180 MODEL 240 MODEL 300 2.1/4500 2.8 /6000 3.4/72 00 2.8/6000 3.8/8000 4.4/9400 3.78/8000[...]

  • Page 34

    356214-XIM-A-0108 34 Johnson Controls Unitary Products PHASING YORK MODEL DM, units are properly p hased at the factory. Chec k for proper compres sor rotation. If the blower or compressors ro tate in the wrong directio n at start-up, the electrica l connection to the unit is mis- phased. Change the incoming line connection phasin g to obtain prope[...]

  • Page 35

    356214-XIM-A-0108 Johnson Controls Unitary Products 35 Start the supply air b lower motor. Adjust the resis- tances in both the supply and the return air duct sys- tems to balance the air distri bution throughout the conditioned sp ace. The job specifications may require that this balancing be done by someone other th an the equipment installer. To[...]

  • Page 36

    356214-XIM-A-0108 36 Johnson Controls Unitary Products OPERA TION SEQUENCE OF OPERA TIONS OVERVIEW For these units, the ther mostat makes a circuit between "R" and "Y1" for th e first stage o f cooling. The call is passed to th e unit control board ( UCB), which then dete rmines whether the re quested opera - tion is available a[...]

  • Page 37

    356214-XIM-A-0108 Johnson Controls Unitary Products 37 has energized the econ omizer), "Y2" will ener gize compressor #1. If the outdoor air is above the setp oint, "Y2" will energize compressor #2. Once the thermostat has been satisfied, it will de-ener- gize Y1 and Y2. If the compressors have satisfied their minimum run times,[...]

  • Page 38

    356214-XIM-A-0108 38 Johnson Controls Unitary Products Should a freezestat op en three times within two hours of operation, the UCB will lo ck-out the associated com- pressor and flash a cod e (Table 24). If the other com- pressor is inact ive, the condenser fans will be de- energized. LOW AMBIENT COOLING To determine when to operate in low ambient[...]

  • Page 39

    356214-XIM-A-0108 Johnson Controls Unitary Products 39 on delay for heating , the UCB will energize the blower mo tor . If the second stage of heat is required, heater con - tactor (7M) will be energized. Note that on the 54 KW , 240V heater , h eater contactors (7M & 8M) will be energized and on the 72 KW , 240V heater , heater contactors (8M [...]

  • Page 40

    356214-XIM-A-0108 40 Johnson Controls Unitary Products When the thermostat calls fo r the first stage of heating, the low-voltage control cir cuit from "R" to "W1" and "G" is completed, th ru the UCB. The heat relay "RW1" is energized. The "RW1-2 " contacts close energizing the draft motor control. [...]

  • Page 41

    356214-XIM-A-0108 Johnson Controls Unitary Products 41 If the temperature limit opens three times within one hour, it will lock-on the indoor blower motor and a flash code is initiated (See Table 24). GAS V AL VE The UCB continuously monitors the GV. Any time the UCB senses voltage at the GV without a call for heat for a continuous five-min ute per[...]

  • Page 42

    356214-XIM-A-0108 42 Johnson Controls Unitary Products FLASH CODES The UCB will initiate a flash code associated with errors with in the system . Refer to UNIT CONTR OL BOARD FLASH CODES Table 24. RESETS Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature. This resets any flash co de s. HEA T [...]

  • Page 43

    356214-XIM-A-0108 Johnson Controls Unitary Products 43 3. Measure the system Ampera ge draw across all legs of 3 phase power wires. 4. Measure the condense r fan amp draw . SHUT DOWN 1. Set the thermosta t to hig hest tempe rature setting. 2. T urn off the electrical power to th e unit. ST ART -UP (GAS HEA T) PRE-ST ART CHECK LIST Complete the foll[...]

  • Page 44

    356214-XIM-A-0108 44 Johnson Controls Unitary Products MANIFOLD GAS PRESSURE ADJUSTMENT Small adjustments to the high-fire ga s flow may be made by turning the pr essure regula tor adjusting scr ew on the autom atic gas valve. Adjust as follows: 1. Remove the ca p on the regulator . It's located next to the push-on electrical terminals. 2. T o[...]

  • Page 45

    356214-XIM-A-0108 Johnson Controls Unitary Products 45 of the regulator setting), replace the orifice spu ds with spuds of the prop e r size . NOTE: T o find the Btu input, multiply the number of cubic feet of gas consumed per ho ur by the Btu cont ent of the gas in your particular localit y (contact your gas compan y for this information - it vari[...]

  • Page 46

    356214-XIM-A-0108 46 Johnson Controls Unitary Products 3. If the supply air blower motor do es not energize when the fan switch is set to ON, check that line voltage is b eing supplied to the cont acts of the M3, contactor , and that the contactor is p ulled in. Check for loose wiring between the cont actor an d the sup- ply air blower motor . 4. I[...]

  • Page 47

    356214-XIM-A-0108 Johnson Controls Unitary Products 47 9. If 24 volts is present a t the UCB Y1 terminal and none of the protection switches have ope ned, the UCB may have locked out the compressor for repeat tr ip s. The UCB sh ould be flashing an alarm code. If not, press and rele ase the ALARMS bu tton on the UCB. The UCB will flash the last fiv[...]

  • Page 48

    356214-XIM-A-0108 48 Johnson Controls Unitary Products 3. If M2 is pulled in and voltage is supplied at M2, lightly touch the compressor housing. If it is hot, the compressor may be of f on inherent protection. Cancel any calls for cooling an d wait for the inter- nal overload to reset. T est again when cool. 4. If M2 is not pulled in, check for 24[...]

  • Page 49

    356214-XIM-A-0108 Johnson Controls Unitary Products 49 4. If M1 is not pulled in, check for 24 volts at the M1 coil. If 24 volts is present and M1 is not pulled in, replace th e contactor . 5. Failing the above, if volt age is supplied at M1, M1 is pulled in, and the comp ressor still does not oper- ate, replace the compressor . 6. If 24 volts is n[...]

  • Page 50

    356214-XIM-A-0108 50 Johnson Controls Unitary Products 15. If none of the above correct the err or , replace the UCB. GAS HEA T TR OUBLESHOOTING GUI DE NOTE: T o find the Btu input, multiply the number of cubic feet of gas consumed per ho ur by the Btu cont ent of the gas in your particular localit y (contact your gas company for this information -[...]

  • Page 51

    356214-XIM-A-0108 Johnson Controls Unitary Products 51 10. If the blower motor runs with the fan switch in the “ON” position but does not run shortly af ter the fur- nace has ignited when the fan switch is in th e “AUTO” position, check the room thermost at for contact between R and G during “W1” calls. On calls for heating, the supply [...]

  • Page 52

    356214-XIM-A-0108 52 Johnson Controls Unitary Products 4. If 24 volts is present, re move the pilot burner and remove the pilot orifice from the pilot burner . The orifice is removed in the direction opposite the flow of gas. Inspect the orifice for obstr uction. If it is clear , re place the ma in gas valve. The ignitor sparks at the pilot burner [...]

  • Page 53

    356214-XIM-A-0108 Johnson Controls Unitary Products 53 FIGURE 24 - UNIT CONTROL BOARD T ABLE 24: UNIT CONTRO L BOARD FLA SH CODES FLASH CODE DESCRIPTION GREEN LED 16 RED LED 8 RED LED 4 RED LED 2 RED LED 1 On S t eady This is a C ontrol Failure - - - - - 1 Flash Not Applicable - - - - - 2 Flashes Control waiting ASCD 1 1. Non-alarm condition. Flash[...]

  • Page 54

    356214-XIM-A-0108 54 Johnson Controls Unitary Products UNIT CONTROL BOARD OPTION SETUP OPTION BYTE SETUP • Ente r the Opti on Setup mode by pushing the OPTION SETUP / STORE button, and holding it for at leas t 2 seconds. • The green status LED (Option Byte) will be turned o n and the red status LED (Heat Dela y) is turned o ff. • The 8, 4, 2 [...]

  • Page 55

    356214-XIM-A-0108 Johnson Controls Unitary Products 55[...]

  • Page 56

    Subject to change without notice. Print ed in U. S.A. 356214-XIM-A-0108 Copyright © 2008 by Johnson Controls, In c. All righ ts reserved. Supersedes: 175240-XIM-B -0707 Johnson Cont rols Unitary Pr oducts 5005 York Drive Norman, OK 73069[...]