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York SUNLINE MAGNUM DJ180 User Manual

York SUNLINE MAGNUM DJ180
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INSTALLATION
MANUAL
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
284809-YIM-B-0707
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .53
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .53
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . .56
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.

Table of Contents

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York SUNLINE MAGNUM DJ180 Specifications

General IconGeneral
BrandYork
ModelSUNLINE MAGNUM DJ180
CategoryAir Conditioner
LanguageEnglish

Summary

General Unit Overview

Safety Considerations for Installation

Fire and Explosion Hazard Warning

Warnings about flammable vapors and gas smell procedures.

Unit Inspection Upon Receipt

Related Technical References

Obtaining Replacement Parts

CSA Certifications and Approvals

Installation Compliance Warning

Emphasizes strict compliance with codes and instructions.

Installation Hazard Warning

Warns of injury or damage from incorrect installation.

Model Number Nomenclature Explained

Configuration Options

Lists various factory-installed options and configurations.

Installation Options

Details specific installation-related option codes.

Installation Procedures and Guidelines

Installation Safety Precautions

Essential safety guidelines before starting installation.

Gas Leak Testing Warning

Prohibits flame testing for gas leaks, emphasizing soap solution.

Installation Limitations and Codes

US Installation Codes

Lists applicable US national and local safety codes.

Canadian Installation Codes

Lists applicable Canadian national and local safety codes.

Selecting the Unit Location

Contaminant Exposure Warning

Warns of damage/injury from contaminants in combustion air.

Rigging and Handling Procedures

Lifting Unit Caution

Advises ensuring panels are in place for even lifting.

Required Installation Clearances

Combustion Air Inlet Label Caution

Advises leaving the combustion air inlet label until hood installation.

Ductwork Design and Installation

Ductwork Fastening Caution

Instructs on proper screw insertion for ductwork.

Fixed Outdoor Air Intake Damper Installation

Outdoor Air Intake Damper Caution

Advises mounting damper even if outdoor air is not required.

Compressor Mounting and Handling

Compressor Mounting Bolts Caution

Warns not to loosen compressor mounting bolts.

Access Panels for Service

Airtight Seal Caution

Emphasizes proper panel and latch replacement for airtight seal.

Typical Field Wiring Diagram

Thermostat Wiring Terminals

Details thermostat terminal connections to the unit.

Unit Control Board Wiring

Details unit control board wiring connections.

Power and Control Wiring Requirements

Waterproof Connectors Caution

Emphasizes using waterproof connectors for wiring.

Optional Gas Heat Information

Gas Piping Installation Guidelines

Gas Piping Local Requirements Note

Notes potential local gas utility requirements for piping.

Gas Supply Connection Procedures

Natural Gas Solvent Warning

Warns about propane dissolving common pipe compounds.

Gas Leak Test Safety Warning

Prohibits flame testing for gas leaks, emphasizing soap solution.

Propane Gas Unit, Tank, and Piping

Propane Gas Leak Test Warning

Prohibits flame testing for gas leaks, emphasizing soap solution.

Optional Economizer and Power Exhaust Damper Set Point Adjustments and Information

Damper Position Adjustment Caution

Warns against twisting damper screws when adjusting.

Minimum Damper Position Adjustment

Describes economizer minimum damper position adjustment.

VAV Control Board Overview

VAV Control Board Inputs

Lists analog and binary inputs for the VAV control board.

Plastic Tubing Installation Caution

Warns against running plastic tubing in ducts and sealing openings.

VAV Programmable Set Points

Duct Pressure Design Limit Caution

Advises customer awareness of duct pressure limits and sensor readings.

Factory-Installed Variable Frequency Drive (VFD)

BAS-Ready VFD Configuration

VFD Power Connection Caution

Warns against connecting AC power to VFD terminals.

Optional Hot Gas Bypass (HGBP)

FIGURE 10 - Honeywell Economizer Control W7212 Diagram

TABLE 6: FOUR AND SIX POINT LOADS

TABLE 7: PHYSICAL DATA

TABLE 9: DJ ELECTRICAL DATA WITHOUT POWERED CONVENIENCE OUTLET

TABLE 9: DJ ELECTRICAL DATA WITHOUT POWERED CONVENIENCE OUTLET (CONTINUED)

TABLE 10: DJ ELECTRICAL DATA WITH POWERED CONVENIENCE OUTLET

TABLE 10: DJ ELECTRICAL DATA WITH POWERED CONVENIENCE OUTLET (CONTINUED)

FIGURE 13 - FRONT VIEW DIMENSIONS 15, 17.5, 20 & 25 TON

Utilities Entry Data

Details opening sizes and uses for utilities entry.

FIGURE 14 - REAR VIEW DIMENSIONS

Bottom Duct Application Notes

Instructions for connecting to bottom duct openings.

Side Duct Application Notes

Instructions for connecting to side duct openings.

Unit Clearances and Rain Hoods

Electric Heat Model Clearances

Notes zero clearance for combustible material with electric heaters.

Gas/Electric Model Clearances

Notes 1" clearance for combustible material and supply air ductwork.

Altitude and Temperature Airflow Corrections

Altitude Correction Example 1

Demonstrates calculating corrected static pressure and BHP.

Altitude Correction Example 2

Demonstrates converting static pressure to sea level conditions.

TABLE 12: SUPPLY AIR BLOWER PERFORMANCE (15 TON) - COOLING ONLY

Blower Performance Table Notes

Explains conditions and deductions for blower performance data.

TABLE 19: STATIC RESISTANCES¹

Static Resistance Notes

Explains how to deduct/add resistance values for calculations.

FIGURE 17 - CHARGING CHART - 15 TON

Charging Chart Condenser Fan Operation Note

Notes condenser fan operation impact on chart accuracy.

Charging Chart TXV Setting Note

States chart applicability depends on factory TXV settings.

Unit Air Balance Procedures

VAV Unit Air Balance Caution

Advises VAV unit setup for maximum output and damper positions.

Unit Operation Overview

Sequence of Operations Overview

Outlines how thermostat calls interact with unit control.

Cooling Sequence of Operation

Describes the steps for cooling operation.

Continuous Blower Operation

Explains continuous blower operation via thermostat setting.

Intermittent Blower Operation

Explains intermittent blower operation via thermostat setting.

Optional VAV Blower Operation

Describes VAV blower control via duct static pressure.

Cooling Operation Error Conditions

High-Pressure Limit Switch Operation

Describes UCB action when high-pressure limit opens.

Unit Safety Controls

Compressor Protection Features

Details inherent compressor protection and UCB features.

Unit Control Board Flash Codes

Indicates UCB flashes codes for system errors.

Electric Heating Sequence of Operations

VFD/Electric Heat Airflow Caution

Advises ensuring airflow for heating elements with VFD units.

Heating Operation Error Conditions

Describes UCB action for high temperature limit faults.

Gas Heating Sequence of Operations

VFD/Gas Heat Airflow Caution

Advises ensuring airflow for heat exchanger tubes with VFD units.

Gas Heating Safety Controls

Describes LS location, setting, and operation.

Start-Up (Cooling)

Cooling Pre-Start Checklist

Lists checks before starting the cooling system.

Cooling Operating Instructions

Step-by-step guide for operating the cooling system.

Cooling Post-Start Checklist

Lists checks after the cooling system has started.

Cooling System Shut Down

Instructions for safely shutting down the cooling system.

Start-Up (Gas Heat)

Gas Heat Pre-Start Checklist

Lists checks before starting the gas heating system.

Gas Heat Operating Instructions

Step-by-step guide for operating the gas heating system.

Manual Pilot Lighting Caution

Warns against manually lighting the pilot burner.

Gas Heat Post-Start Checklist

Gas Leak Test Safety Warning

Prohibits flame testing for gas leaks, emphasizing soap solution.

Manifold Gas Pressure Adjustment

Describes how to adjust manifold gas pressure.

Checking Gas Input

Natural Gas Input Check

Details checking gas input using the meter and a table.

BTU Input Calculation Note

Instructs on calculating BTU input using gas rate and local gas content.

Troubleshooting

Cooling Troubleshooting Guide

Provides steps to troubleshoot cooling system issues.

Live Circuit Troubleshooting Warning

Warns of extreme care when working with live circuits.

Wiring Error Caution

Warns that wiring errors can cause dangerous operation.

VFD Troubleshooting Note

Advises disconnecting power before VFD troubleshooting.

Compressor #1 Not Operating During Cooling

Economizer Blade Position Check

Checks economizer blade position for free cooling.

Compressor #1 Contactor Check

Checks for line voltage at compressor #1 contactor.

Compressor #1 Overload Check

Checks if compressor #1 is hot, indicating overload.

Compressor #1 Coil Voltage Check

Checks for 24V at the compressor #1 contactor coil.

Compressor #1 Replacement

Recommends replacing compressor #1 if other checks fail.

Compressor #1 UCB Terminal Check

Checks for 24V at the UCB terminal C1 for compressor #1.

Compressor #1 Protection Switch Check

Checks protection switches (HPS1, LPS1, FS1) for compressor #1.

Compressor #1 Lockout Reset

Resets compressor #1 lockouts via UCB alarms.

UCB Integrity Test for Compressor #1

Tests UCB integrity by bypassing C1 to Y1.

Compressor #1 UCB Replacement

Recommends replacing the UCB if errors persist.

Compressor #2 Not Operating During Cooling

Compressor #2 Contactor Check

Checks for line voltage at compressor #2 contactor.

Compressor #2 Coil Voltage Check

Checks for 24V at the compressor #2 contactor coil.

Compressor #2 Replacement

Recommends replacing compressor #2 if other checks fail.

Compressor #2 Protection Switch Check

Checks protection switches (HPS2, LPS2, FS2) for compressor #2.

Compressor #2 Lockout Reset

Resets compressor #2 lockouts via UCB alarms.

UCB Integrity Test for Compressor #2

Tests UCB integrity by bypassing C2 to Y2.

Compressor #2 UCB Replacement

Recommends replacing the UCB if errors persist.

Gas Heat Troubleshooting Guide

Live Circuit Troubleshooting Warning

Warns of extreme care when working with live circuits.

Wiring Error Caution

Warns that wiring errors can cause dangerous operation.

BTU Input Calculation Note

Instructs on calculating BTU input using gas rate and local gas content.

High Temperature Shutdown Warning

Warns of potential furnace shutdown on high temperature.

Blower Motor Not Energizing During Gas Heat

Blower Motor Contactor Check

Checks voltage at blower motor contactor M3.

Blower Motor Overload Check

Checks if blower motor is hot, indicating overload.

Blower Motor Coil Voltage Check

Checks for 24V at the blower motor contactor coil M3.

VFD Blower Motor Troubleshooting

Guides troubleshooting VFD blower motor issues.

The draft motor runs but the furnace does not light and the sparker does not spark.

Ignition Control Lockout Check

Checks ignition control lockout due to flame rollout or shutoff.

Gas Heat Control Wiring Check

Checks 24V connections to gas heat section and ETD.

Over-Temperature Condition Check

Checks for over-temperature condition and waits for limit reset.

Electrical Time Delay (ETD) Check

Checks for 24V at the ETD for furnace operation.

Ignitor Control and Wiring Check

Checks ignitor controls, wiring, ground connections, and ceramic insulators.

The pilot burner runs but the furnace does not light and a gas odor is detected at the draft motor outlet.

Adjust Pilot Adjust Screw

Adjusts pilot flame using gas valve screw.

Check Supply Gas Pressure

Checks supply gas pressure for proper operation.

The pilot burner ignites but the ignitor continues to spark and the main burners do not ignite.

Pilot Checkout and Adjustment

Repeats pilot checkout and adjustment steps.

Gas Supply Pressure Check for Main Burners

Checks supply gas pressure for main burner ignition.

The pilot burner lights and the spark stops but the main burners do not light.

Ignitor Control Voltage and Gas Valve Check

Checks ignitor control voltage and gas valve.

Furnace lights with roll-out or one burner has delayed ignition.

Pilot Burner Alignment Check

Checks pilot burner alignment with carryover.

Main burners light but exhibit erratic flame characteristics.

Burner Air Shutter Adjustment

Adjusts burner shutters for proper flame appearance.

Main Burner Orifice Check

Checks main burner orifices for obstruction or alignment.

Unit Control Board Option Setup

Option Byte Setup Procedure

Details how to enter and set option bytes.

Control Board Setup Mode Note

Notes timeout for setup mode and saving parameters.

Heat Delay Setup Procedure

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