York DJ150 manual

INST ALLA TION MANUAL CAUTION: READ ALL SAF ETY GUIDES BEFORE YOU BEGIN T O INST ALL YOUR UNI T . SA VE THIS MANUAL MAGNUM SINGLE P ACKAGE AIR CONDITIONERS AND SINGLE P ACKAGE GAS/ELECT RIC UNITS DJ15 0 12-1/ 2 TON (10.8 E ER) 035-1904 6-002-B -0104 CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SAFETY CO N SIDE[...]

035-19046 -002-B- 0104 2 Unitar y Prod ucts Group T ABLE OF CONTENTS G EN ER AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SA FE TY C ON SID ERA TI O NS . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RE FE REN CE . . . . . . . . [...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 3 LIST O F FI GURE S Fig. # Pg. # 1 UN IT SH IPP ING B RA CK ET . . . . . . . . . . . . . . . . . . . . . 8 2 COMPRESSOR SECTION . . . . . . . . . . . . . . . . . . . . . . 9 3 PREDATOR“ MAGNUM COMPONENT LOCATION . 10 4 UN IT 4 P OIN T LO AD . . . . . . . . . . . . . . . . . . . . . . . . . 11 5 UN[...]

035-19046 -002-B- 0104 4 Unitar y Prod ucts Group GENERAL YORK  Pr edator  Magnum unit s are singl e pac kage air con- ditioner s with o ptional ga s heating des igned f or o utdoor inst allati on on a roof top o r slab and for no n-resident ial use. These unit s can be equipped wi th factor y or field i nstall ed electr ic heat ers for heati[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 5 REFEREN CE Addit ional i nformati on is a vailable in the f ollowing referenc e form s: • T echnical G uid e - DJ150, 036- 21484-002 • Gene ral Ins tal la tion - DJ150, 035- 1904 6-002 • Pre-s tar t & Post-st art Check Li st - 035-18466-00 0 • Ec onomizer Acc essory - Downfl ow Fact or [...]

035-19046 -002-B- 0104 6 Unitar y Prod ucts Group NOMENC LA T URE 12½ Ton Predator Model Number Nomenclature Product Category D = Air Cond., S ingle Package Product Identifier J = R-22 Ultra High Efficiency Airflo w Installation Options Additional Options (See Next Page) Product Genera tion 3 = Third Generation Voltage 2 = 208/2 30-3-60 4 = 460-3-[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 7 NOMENCLA TURE, ADDI TIONAL OPTIONS: AA None AC Coil Gu ard AD Dirty F ilter Sw itch AG Coil Gu ard & Dirty F ilter Switch CA CPC Controller with Dirty Fi lter Switch & Air Pr oving Switch CC CPC Controller , DFS, APS & Coil Guard CE CPC Controller , DFS, APS & T echnico at Cond. Coi[...]

035-19046 -002-B- 0104 8 Unitar y Prod ucts Group INST AL LA TIO N INS T ALL A TI ON SA FE TY IN F ORM A TI ON Read these ins tructi ons before conti nuing this appl iance inst allati on. This is an outdoo r combi natio n heating and co ol- ing uni t. The ins taller must ass ure that t hese ins tructio ns are made av ai lab le to the con sumer and [...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 9 2. T urn ea ch brac ket t oward the ground and t he pr otective ply w ood co v e rin g will d ro p to the gr o und. 3. Remov e the con dense r coil external prot ective coveri ng pri or to op era tion. 4. Remov e the t oolless doorknobs and i nstruct ion p acket pri or to inst allati on. LI MIT AT [...]

035-19046 -002-B- 0104 10 Unitar y Prod ucts Group FIGURE 3 - PREDAT OR  MAGNUM COMPONENT LOCATION " Simplicity ™" Control board w/screw connectors for T -stat wiring and Network connection Second model nameplate inside hinged access panel Dual stage cooling for maximum comfort Compressor #2 access (high- efficiency compressor w/cran[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 11 LO CA TI ON Use the f ollowing gui delines t o select a sui table lo cation for these unit s: 1. Unit is desi gned f or ou tdoor i nst allation only . 2. Condense r coi ls mus t have an unli mited supply of air . Wher e a choi ce of locati on is possi ble, posit i on the uni t on ei ther north o r[...]

035-19046 -002-B- 0104 12 Unitar y Prod ucts Group CLEARANCES All u nits req uire par ticular clear ances for pr oper operati on and se r vice . Inst aller must make prov isio ns for adequate combu stion and ven tilati on air in accordanc e with se ction 5.3 of Ai r for Combusti on and V entilat ion o f the Nati onal F uel Gas Code, ANSI Z223.1 –[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 13 NOTE: A one-i nch clea r anc e must be provi ded betwee n any combu stible mater ial and the supply duct work for a dis tance of 3 f eet fr om the unit. NOTE: If the unit i nclud es gas heati ng, lo cate the uni t so the flue exhaust is at lea st : • Three ( 3) feet ab ove any f orced a ir i nle[...]

035-19046 -002-B- 0104 14 Unitar y Prod ucts Group . FIGURE 8 - BOTT O M DUCT OPENINGS (FROM ABOVE) 14- 23/32 16-3/8 18-1/16 19-5/8 63-1/2 7-1/ 8 17-3/16 19-3/16 21-3/16 6-13 /16 32-11/16 6-13 /16 6-13/16 27-1/2 18 21 24 Return Air Supply Air Bottom Condensate Entr y FRONT Bottom Power, Control and Convenience Outlet Wi ring Entri es Bottom Gas Sup[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 15 DUCTWORK Ductwor k should be designed and si zed according to th e methods in M anual D of the Air Cond itioni ng Contractors of Americ a (ACCA) or as recomm ended by an y other re cog- nize d authori ty such as ASHRAE o r SMACNA. A cl ose d re tur n du ct sy ste m s ho uld b e u sed. T his will n[...]

035-19046 -002-B- 0104 16 Unitar y Prod ucts Group Note ori ent ation. Panel is “ins ulation” sid e up. FIGURE 1 0 - PRE DA TOR  MAGNUM ROOF CURB DI ME NSIONS FIGURE 1 1 - SUNL INE™ TO PREDA TOR  MAGNUM TRANSITION RO O F CURBS 8 o r 1 4 5 0 - 1 / 2 3 0 2 0 2 0 8 0 - 5 / 8 6 2 T Y P . I N S U L A T E D D E C K U N D E R C O M P R E S S O[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 17 CONDENSA TE DRAIN The sid e conden sate drai n is revers ible and maybe re- ori- ented to t he rear o f the cabine t to facil itat e condensat e pip- ing. A co ndensate drain c onnection is a vailable thro ugh the base p an for piping i n side the r oof cur b. T rap the conn ectio n per Fi gure 15[...]

035-19046 -002-B- 0104 18 Unitar y Prod ucts Group The inter nal wiring harn esses fur nished with thi s unit are an integr al part of t he design cert ified uni t . Fi eld alter ation to comply wi th elec trical codes should not be required. If an y of the wir e supp lied with the unit must be replaced , repl acem ent wire must be of the type show[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 19 FIGURE 17 - FIELD WIRI NG 24 VOL T THERMOST A T O C C W 1 W 2 Y 1 G Y 2 X R S D C R E M O T E M I N P O S W 1 W 2 Y 1 G Y 2 C U N I T C O N T R O L B O A R D T - S T A T R H R C FIGURE 18 - FIELD WIRI NG DISCONNECT - COO L ING UNIT WITH/ W ITHOUT ELECTRIC HEA T TERMINAL BLOCK TB1 FACTORY OR FIELD [...]

035-19046 -002-B- 0104 20 Unitar y Prod ucts Group FIGURE 1 9 - FIELD W IRING DISCONNECT - CO OLING UNIT WITH GAS HEA T L1 T1 L2 T2 T3 L3 FACTORY OR FIELD SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY GROUND LUG CONTACTOR 1M[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 21 T ABLE 8: E LECTRICAL DATA DJ150 (12 -1/2 TON) W ITHOUT POWERED CO NVENIENCE O UTLET RL A LR A FL A 35 3 5 3 5 3 5 3 5 ea. ea. ea. HP HP HP HP HP HP HP HP HP HP None -- -- 61.9 67.1 67.4 72.6 80 80 80 90 2TP04521825 13.5 37.5 61.9 67.1 67.4 73.8 80 80 80 90 2TP04522425 18.0 50.0 76.1 82.6 83.0 89.[...]

035-19046 -002-B- 0104 22 Unitar y Prod ucts Group OPTIONAL ELECT RIC HEA T The factor y-inst alled heater s ar e wired for single poi nt power supply . Power supply need onl y be bro ught into the singl e point t ermi nal block. These CSA approved hea ters are loca ted within the cent ral comp artment of t he unit with t he heater elements e xtend[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 23 OPTI ONA L GA S HEA T These gas -fired heat ers have alumi nized-st eel or optio nal st ainle ss st eel, tubul ar heat exchanger s with sp ark igni tion. GAS PIPING Proper sizing of gas pi ping depe nds on the cub ic feet per hour of gas flow re quired, speci fic gravity of the gas and th e lengt [...]

035-19046 -002-B- 0104 24 Unitar y Prod ucts Group GAS CONNECTI ON The gas supply line can be rout ed within the sp ace and roof curb, e xiting t hrough t he uni t’s ba sepan. Refer to Fi gure 8 for the gas pipin g inlet location . T ypical su pply pipi ng arrange- ments ar e shown in Fi gures 20 and 21. All pipe nippl es, fit- tings, and the gas[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 25 2. The pr oper pr essure reg ulation. (T wo- s t age reg ulation i s recomm ended). 3. The pr essure drop in the line s betwe en regu l ators and between the second st age regulat or and the appli ance. Pipe si ze re quired will depen d o n the l engt h o f th e pipe run and th e tot al load of al[...]

035-19046 -002-B- 0104 26 Unitar y Prod ucts Group ECONOMIZER AND POW ER EXHAUST SET POINT ADJUS TMENT S AND INFORMATION Remove the top rear acces s panel fro m the uni t. Locate t he economizer contr ol module, whe re the fol lowing adju stment s will be made. MINIMUM POSI TION ADJUSTMENT • Check that the damper blad es move smoot hly wit h bind[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 27 FIGURE 22 - ENTHALPY SET POINT CHART 40 (4) 70 (21) 50 (10) 55 (13) 60 (16) 65 (18) 35 (2) 45 (7) 75 (24) 80 (27) 35 (2) 40 (4) 45 (7) 50 (10) 55 (13) 60 (16) 65 (18) 70 (21) 75 (24) 80 (27) 85 (29) 85 (29) 90 (32) 90 (32) 105 (41) 110 (43) 100 (38) 95 (35) 95 (35) 100 (38) 105 (41) 110 (43) APPRO[...]

035-19046 -002-B- 0104 28 Unitar y Prod ucts Group PHASING Predator  M agnum DJ unit s are p roperly p hased and pro- tected by a Phase M onit or fr om the facto ry . I f t he unit does not st art up, the e lectric al con nection t o the unit may be mis- phased. Check t he Phase Monit or for a Red LED, i nd icating a misphase. Change the pha sin[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 29 T ABLE 15: DJ150, 12-1/ 2 T ON ST ANDARD MOTO R DOWN SHOT BL OWER PERF ORM ANCE * † ESP ‡ TURNS OPEN ** 012345 CFM W †† BHP CFM W †† BHP CFM W †† BHP CFM W †† BHP CFM W †† BHP CFM W †† BH P 0.4 5078 363 0 3 .89 480 9 3 103 3 .3 3 4 59 4 30 53 3.27 4 360 24 78 2. 66 40 9[...]

035-19046 -002-B- 0104 30 Unitar y Prod ucts Group NOTES FOR T AB LE 15 THROUGH T ABLE 18: • Blower per for mance incl udes dry coi l and two-in ch filt e rs. • Blower per for mance for gas heat i ncl udes the maxi mu m number of heat tubes availab le for each t onnage. • ESP (Ext ernal S ta tic Press ure) gi ve n is t hat availabl e for the [...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 31 AIR BALANCE S tart the sup ply air blower mot or . Adju st the resi stanc es in both the sup ply and th e ret urn air duct syst ems to bala nce the ai r dist ributi on t hrougho ut the con ditioned sp ace. The j ob s pecif ications may requi r e that t his balanc ing be done by s omeone othe r tha[...]

035-19046 -002-B- 0104 32 Unitar y Prod ucts Group SUPPL Y AI R DRIVE ADJUSTM ENT At unit start-up, the measur ed CFM may be higher or lower than the req ui red CFM . T o achieve the re quired CFM, the speed of the drive m ay hav e adjusted by ch anging the datum diameter (DD) of t he variabl e pitch motor sh eave as descri bed below: Req uired CFM[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 33 OPER A TION SE QUE N CE O F OP E R A TIO NS OV E RV I E W For t he Predator  Magnum ser ies of units, the ther m o stat make s a circui t betwe en "R" and " Y1" for t he first st age of cool ing. The cal l is pas sed to t he uni t cont r ol board (UCB) , which the n deter mi[...]

035-19046 -002-B- 0104 34 Unitar y Prod ucts Group NO OUTDOOR AIR OPTI ONS When the ther mostat calls for the firs t stage of c ooling, t he low-vol tage con trol circuit f rom “R” to “Y1” an d “G” i s com- pleted . The UCB en ergizes t he economi zer (if insta lled and free co oling is availabl e) or the fir st avail able compr essor *[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 35 Should a high -press ure switch open thr ee times within t wo hours of oper ation, t he UCB wil l l ock- out the associ ated com- press or and flash a code (see T able 28). If the other com- press or is inactive , the condens er fans will be de-en ergize d. LOW -PRESSURE LIMIT SWITCH The low- pres[...]

035-19046 -002-B- 0104 36 Unitar y Prod ucts Group RESET Remove the call for cool ing, by rais i ng ther m ost at setti ng higher than the co nditione d spac e temperat ure. This rese ts any pressur e or freezest at flash codes. ELECTRIC HEA T I NG SEQUENCE OF OPERA TIONS The followi ng sequence desc ribes t he operat i on of the elec- tric heat se[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 37 GAS H EA TING SEQUENC E OF OPER A TIONS When the thermos tat calls for the fir st stage of heating, the low- voltage contr ol cir cuit fr om “R” to “W 1” is c ompleted . A call for heat passes through th e UCB to the i g nition co ntrol board (ICB). The UCB m o nitors the “ W1” call a [...]

035-19046 -002-B- 0104 38 Unitar y Prod ucts Group If th e ICB senses vo lta ge at the G V when not r e quested, the ICB will energ iz e the dr af t motor . The ICB will not opera te the furnace until vol tage i s no lo nger sensed at t he GV . The draft motor is stoppe d when volt age is not sensed at t he GV . Any time the UCB sens es volta ge at[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 39 GAS HEA T A NTICIP A TOR S ET POINTS It i s importa nt that the ant icipat or setpoi nt be correct . T o o high of a sett i ng will res ult in longe r heat cycles an d a great er temper ature swing in the condi tioned sp ace. Reduci ng the valu e below the cor rect se tpoint will give short er “[...]

035-19046 -002-B- 0104 40 Unitar y Prod ucts Group POST ST ART CHECKLIST After the entir e cont rol circuit has been ener gi z ed and the heatin g sect i on i s operat ing, make th e foll owing check s: 1. Check f or gas leaks in th e unit piping as wel l as t he sup - ply pi ping. 2. Check for cor rect manifold gas pressur es. (See ’ CHECK- ING [...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 41 3. Meas ure the time needed f or one revolut ion o f th e hand on t he sm allest dial on the meter . A t ypica l gas meter has a 1/2 or a 1 cubic fo ot test dial . 4. Using the number of seco nds it takes for one r evoluti on of the dial , cal cu late th e cubi c feet of gas consumed per hour . (S[...]

035-19046 -002-B- 0104 42 Unitar y Prod ucts Group EXAMPLE: By actual measurement , it t akes 19 se conds for the hand on a 1 cubic f oot dial t o make a revo l uti on with a 192, 000 Btuh furnace runni ng. T o de termin e rotati ons per minute, d ivide 60 by 19 = 3. 16. T o cal culate rot ations per hour , mult iply 3. 16 • 60 = 189. 6. Mul tipl[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 43 CHARGING THE UNIT The DJ150 ( 12-1/ 2 T on) Hi gh Effi ciency Un it, uses a TXV meter ing de vice. Char ge uni t to 1 0º sub- cooli ng at t he TXV . TROUBLESHOOTING PRE DA TOR  MAGNUM F LASH CODES V ario us flash c odes are utiliz ed by the uni t cont rol boar d (UCB) t o aid tr oublesh ooting[...]

035-19046 -002-B- 0104 44 Unitar y Prod ucts Group FIGURE 2 8 - B ASIC T ROUBL ESHOOTING FLOWCHART Monit o r Mon itore d Systems Proble m ? Ca ll for Cooling? Call for Heat i ng? Call for Heat Yes No No No Ca ll fo r 1st Sta g e Cooling Fi rs t St ag e ? Ca ll for 2nd Sta g e Cooling Yes Ye s Loss of Ca ll for Heating? Loss of Call for Cooling ? He[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 45 FIGURE 30 - T RIP FAILURE F L OW CHART T r i p / F a i l u r e L o s s o f L S I n p u t E n e r g i z e b l o w e r : i n c r e a s e i n c i d e n t v a l u e b y 1 L S i n p u t r e g a i n e d ? I n c i d e n t v a l u e > = 3 ? L o c k o n b l o w e r ; f l a g a l a r m L o a d F o f f D [...]

035-19046 -002-B- 0104 46 Unitar y Prod ucts Group C OOLING T ROUBL ESH OOT ING G UIDE On call s for coolin g, if t he compr essors are o per a ting but the supply ai r blower moto r does not energ ize afte r a short del ay (the roo m thermos tat fan swi tch is in the “AUT O” positi on). 1. Tur n the thermos t at fa n swi tch t o the ON pos iti[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 47 lock ed out the compr esso r for repeat t ri ps. The UCB shoul d be fl ashing an alar m cod e. If not , press and rel ease t he ALARMS button on the UCB. The UCB will fl ash the las t five ala rms on t he LED. I f the compr ess or is lock ed out , cancel an y c all for coo ling. This wil l reset a[...]

035-19046 -002-B- 0104 48 Unitar y Prod ucts Group locked out the compr essor f or re peat tri p s. The UCB should be fl ash ing a code. If not , press and rele ase th e ALARMS button on the UCB. The UCB wi ll flash the las t five alarms on the LED. If the compres sor is lo cked out, remove any cal l for cooli ng at the the rmosta t or by dis- conn[...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 49 For uni ts with econo m ize rs :If 24 vol t s is present at the Y1 “O U T ” te rm i na l , ch e ck fo r 2 4 vo l ts at th e Y1 “EC O N ” ter minal. If 24 volts i s not pres ent , check for loo se wiri ng fro m t he Y1 “O UT” termi nal to the Mat e-N-Lock p lug, a poor connect ion b etw[...]

035-19046 -002-B- 0104 50 Unitar y Prod ucts Group 1. Check for 24 vol t s at the sp ar k igni tor from the igni t ion control boar d (ICB). Check th e 24-v olt wiring fr om the ICB to the sp ark igni to r . Check fo r 24 vol t s at the ICB spark igni t or terminal . 2. Check the ground wi r ing for t he ICB an d the ga s val ve i s int act an d m [...]

035-19 046-002- B-0104 Unit ary Produc ts Gro up 51[...]

Subject to c hang e without no tice. P rinted in U.S.A. 035-190 46-002- B-010 4 Copyright © 2004 by Unitary Pr oducts G roup. Al l rights reserv ed. Super sedes : 035-190 46-002-A- 0803 Unit ary 5005 Norm an Product s Y ork OK Group Drive 73 069[...]