INSTALLATION MANUAL ® MAGNUM CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SINGLE PACKAGE AIR CONDITIONERS AND SINGLE PACKAGE GAS/ELECTRIC UNITS SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . .4 DJ150 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 12-1/2 TON REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 (10.8 EER) RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .5 APPROVALS. . . . .
035-19046-002-B-0104 TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 RENEWAL PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
035-19046-002-B-0104 LIST OF FIGURES Fig. # Pg. # Fig. # Pg. # 1 UNIT SHIPPING BRACKET . . . . . . . . . . . . . . . . . . . . . 8 16 ELECTRONIC THERMOSTAT FIELD WIRING . . . . . 18 2 COMPRESSOR SECTION . . . . . . . . . . . . . . . . . . . . . . 9 17 FIELD WIRING 24 VOLT THERMOSTAT . . . . . . . . . 19 3 PREDATOR“ MAGNUM COMPONENT LOCATION . 10 4 UNIT 4 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 11 18 FIELD WIRING DISCONNECT - COOLING UNIT WITH/WITHOUT ELECTRIC HEAT . . . .
035-19046-002-B-0104 GENERAL YORK Predator Magnum units are single package air conditioners with optional gas heating designed for outdoor installation on a rooftop or slab and for non-residential use. These units can be equipped with factory or field installed electric heaters for heating applications. These units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested.
035-19046-002-B-0104 REFERENCE APPROVALS Additional information is available in the following reference forms: Design certified by CSA as follows: 1. For use as a cooling only unit, cooling unit with supplemental electric heat or a forced air furnace. • General Installation - DJ150, 035-19046-002 2. For outdoor installation only. • Pre-start & Post-start Check List - 035-18466-000 3.
035-19046-002-B-0104 NOMENCLATURE 12½ Ton Predator Model Number Nomenclature D J 150 N15 A 2 A AA 3 Product Generation Product Category 3 = Third Generation D = Air Cond., Single Package Product Identifier J = R-22 Ultra High Efficiency Voltage 2 = 208/230-3-60 4 = 460-3-60 5 = 575-3-60 Nominal Cooling Capacity - MBH 150 = 12-½ Ton Heat Type & Nominal Heat Capacity C00 = Cooling Only.
035-19046-002-B-0104 NOMENCLATURE, ADDITIONAL OPTIONS: AA None AC Coil Guard AD Dirty Filter Switch AG Coil Guard & Dirty Filter Switch CA CPC Controller with Dirty Filter Switch & Air Proving Switch CC CPC Controller, DFS, APS & Coil Guard CE CPC Controller, DFS, APS & Technicoat Cond. Coil CG CPC Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard CJ CPC Controller, DFS, APS & Technicoat Evap. Coil CL CPC Controller, DFS, APS, Technicoat Evap.
035-19046-002-B-0104 TC Technicoat Condenser Coil & Coil Guard TD Technicoat Condenser Coil & Dirty Filter Switch TG Technicoat Condenser Coil, Coil Guard, & Dirty Filter Switch TJ Technicoat Evaporator Coil TL Technicoat Evaporator Coil & Coil Guard TM Technicoat Evaporator Coil & Dirty Filter Switch TQ Technicoat Evaporator Coil, Coil Guard, & Dirty Filter Switch TS Technicoat Evaporator & Condenser Coils TU Technicoat Evaporator & Condenser Coils & Coil Guard TV Technicoat Evaporator
035-19046-002-B-0104 2. Turn each bracket toward the ground and the protective plywood covering will drop to the ground. LIMITATIONS 3. Remove the condenser coil external protective covering prior to operation. These units must be installed in accordance with the following: 4. Remove the toolless doorknobs and instruction packet prior to installation. In U.S.A.: Toolless Doorknobs Installation Instruction Packet FIGURE 2 - COMPRESSOR SECTION 1. National Electrical Code, ANSI/NFPA No.
035-19046-002-B-0104 Second model nameplate inside hinged access panel "Simplicity™" Control board w/screw connectors for T-stat wiring and Network connection Disconnect location (optional disconnect switch) Filter access (2" throw-away) Filter drier (solid core) Condenser Section Belt-drive blower motor Dual stage cooling for maximum comfort Slide out motor and blower assembly for easy adjustment and service Compressor #2 access (highefficiency compressor w/crankcase heater) Power ventor motor 2
035-19046-002-B-0104 TABLE 1: RIGGING AND HANDLING UNIT VOLTAGE LIMITATIONS Power Rating* Minimum Maximum 208/230-3-60 187 252 460-3-60 432 504 575-3-60 540 630 *. Utilization range “A” in accordance with ARI Standard 110. TABLE 2: UNIT TEMPERATURE LIMITATIONS Temperature Min. Max. Wet Bulb Temperature (°F) of Air on Evaporator Coil 57 72 Dry Bulb Temperature (°F) of Air on Condenser Coil 0* 125 *. Exercise care when moving the unit.
035-19046-002-B-0104 CLEARANCES TABLE 3: UNIT WEIGHTS Operating Model DJ150 Shipping Weight (lb.) Weight (lb.) Cooling Unit Only 1415 1400 w/Economizer 85 84 w/Power Exhaust 150 148 w/Gas Heat * 110 110 w/Electric Heat† 49 49 *. 8 Tube Heat Exchanger †. 54 kW heater All units require particular clearances for proper operation and service. Installer must make provisions for adequate combustion and ventilation air in accordance with section 5.
035-19046-002-B-0104 119-7/16 30-11/32 See Detail A Power Entry 2-1/2 50-3/4 Convenience Outlet Control Entry 7/8 4-1/4 11-1/2 Convenience Outlet Power Entry 7/8 17-3/16 30-3/16 24-3/16 59 FRONT For Baserail Dimensions See Detail B For Drain Dimensions See Detail C 6-3/16 89 LEFT 27 FIGURE 7 - UNIT DIMENSIONS DETAIL A DETAIL B G a s P ip e In le t 3 -3 /4 5 -1 /4 B a s e P a n 1 7 -1 3 /1 6 V ie w o f W a ll A c r o s s fr o m TABLE 6: 3 -9 /1 6 C o il DETAIL C UNIT CLEARANCE
035-19046-002-B-0104 .
035-19046-002-B-0104 18-1/4 Dot Plugs Return Air 28-1/4 Supply Air 18-1/4 18-1/16 2-31/32 5-5/32 28-1/4 31-11/16 FIGURE 9 - REAR DUCT DIMENSIONS DUCTWORK DUCT COVERS Ductwork should be designed and sized according to the methods in Manual D of the Air Conditioning Contractors of America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA. Units are shipped with the side duct openings covered and a covering over the bottom of the unit.
035-19046-002-B-0104 R IG H T 8 0 -5 /8 IN S U L A T E D D E C K U N D E R C O N D E N S E R S E C T IO N 2 0 2 0 S U P P L Y 6 R E T U R N 2 T Y P .
035-19046-002-B-0104 COMPRESSORS The compressors are mounted on elastomer insulators. The mounting bolts have been fully tightened for shipping. Do not loosen the compressor mounting bolts. FILTERS FIGURE 13 - RETURN DOWNFLOW PLENUM WITH PANEL Two-inch filters are supplied with each unit. One-inch filters may be used with no modification to the filter racks. Filters must always be installed ahead of evaporator coil and must be kept clean or replaced with same size and type.
035-19046-002-B-0104 The internal wiring harnesses furnished with this unit are an integral part of the design certified unit. Field alteration to comply with electrical codes should not be required. If any of the wire supplied with the unit must be replaced, replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire.
035-19046-002-B-0104 T -S T A T W 1 W 1 W 2 W 2 Y 1 Y 1 G G Y 2 O C C R H R C R E M O T E M IN P O S C U N IT C O N T R O L B O A R D Y 2 X R S D C FIGURE 17 - FIELD WIRING 24 VOLT THERMOSTAT TERMINAL BLOCK TB1 FACTORY OR FIELD SUPPLIED DISCONNECT GROUND LUG THREE PHASE POWER SUPPLY FIGURE 18 - FIELD WIRING DISCONNECT - COOLING UNIT WITH/WITHOUT ELECTRIC HEAT Unitary Products Group 19
035-19046-002-B-0104 CONTACTOR 1M GROUND LUG T1 T2 T3 L1 L2 L3 FACTORY OR FIELD SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT 20 Unitary Products Group
035-19046-002-B-0104 TABLE 8: ELECTRICAL DATA DJ150 (12-1/2 TON) WITHOUT POWERED CONVENIENCE OUTLET Supply Pwr Pwr Blower Exh Conv Electric Heater Actual Heater Voltage Motor FLA Motor Outlet KW Amps Model No. RLA LRA FLA 3 5 FLA FLA ea. ea. ea. HP HP None --2TP04521825 13.5 37.5 20.0 146.0 1.5 10.9 16.1 5.5 0.0 208 2TP04522425 18.0 50.0 2TP04523625 25.5 70.8 2TP04525425 40.6 112.7 None --2TP04521825 18.0 43.3 20.0 146.0 1.5 10.9 16.1 5.5 0.0 230 2TP04522425 24.0 57.7 2TP04523625 34.0 81.
035-19046-002-B-0104 TABLE 10: PHYSICAL DATA Model DJ150 Component Blower, Centrifugal (Dia. X Wd. in.) 15 x 15 Motor, Standard (HP) 3 Motor, Optional (HP) 5 Rows 4 Fins per Inch 15 Height (in.) 40 Face Area (ft.2 each) 13.2 Propeller Dia. (in., each) 24 Motor (HP, each) 1/3 CFM, Nominal (each) 3000 Rows (each) 2 Fins per Inch 20 Height (in. each) 44 Face Area (ft.2 each) 14.5 System 1 (lb./oz.) 11/0 System 2 (lb./oz.) 11/8 Quantity 2 Type Scroll Size (Wd. x Ht.
035-19046-002-B-0104 OPTIONAL GAS HEAT These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition. OPTIONAL COIL GUARD SHOWN TABLE 12: GAS HEAT APPLICATION DATA Unit Input (MBH) Output (MBH) Size Opt. Temp Rise (°F) 15 180 144 10-40 20 240 192 20-50 150 GAS PIPING Proper sizing of gas piping depends on the cubic feet per hour of gas flow required, specific gravity of the gas and the length of run. "National Fuel Gas Code" Z223.
035-19046-002-B-0104 GAS CONNECTION The gas supply line can be routed within the space and roof curb, exiting through the unit’s basepan. Refer to Figure 8 for the gas piping inlet location. Typical supply piping arrangements are shown in Figures 20 and 21. All pipe nipples, fittings, and the gas cock are field supplied or may be purchased in UPG accessory kit #1GP0404. FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury, death or property damage.
035-19046-002-B-0104 2. The proper pressure regulation. (Two-stage regulation is recommended). 3. The pressure drop in the lines between regulators and between the second stage regulator and the appliance. Pipe size required will depend on the length of the pipe run and the total load of all appliances. Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and LP gas suppliers.
035-19046-002-B-0104 ECONOMIZER AND POWER EXHAUST SET POINT ADJUSTMENTS AND INFORMATION • Remove the top rear access panel from the unit. Locate the economizer control module, where the following adjustments will be made. POWER EXHAUST DAMPER SET POINT (WITH OR WITHOUT POWER EXHAUST) Extreme care must be exercised in turning all set point, maximum and minimum damper positioning adjustment screws to prevent twisting them off.
035-19046-002-B-0104 CONTROL CURVE CONTROL POINT APPROX.
035-19046-002-B-0104 PHASING A Predator Magnum DJ units are properly phased and protected by a Phase Monitor from the factory. If the unit does not start up, the electrical connection to the unit may be misphased. Check the Phase Monitor for a Red LED, indicating a misphase. Change the phasing of the Field line connection at the Factory or Field Supplied Disconnect to obtain a Green LED on the Phase Monitor. (Scroll compressors operate in only one direction.
035-19046-002-B-0104 TABLE 15: DJ150, 12-1/2 TON STANDARD MOTOR DOWN SHOT BLOWER PERFORMANCE* † TURNS OPEN ** ESP‡ 0 1 2 3 4 5 CFM W†† BHP CFM W†† BHP CFM W†† BHP CFM W†† BHP CFM W†† BHP CFM W†† BHP 0.4 5078 3630 3.89 4809 3103 3.33 4594 3053 3.27 4360 2478 2.66 4090 2093 2.24 3812 1798 1.93 0.6 4865 3456 3.71 4584 2961 3.17 4349 2912 3.12 4106 2318 2.49 3814 1964 2.11 - - - 0.8 4642 3284 3.52 4356 2828 3.03 4089 2776 2.
035-19046-002-B-0104 TABLE 17: DJ150, 12-1/2 TON STANDARD MOTOR SIDE SHOT BLOWER PERFORMANCE* † TURNS OPEN ** ESP‡ 0 1 2 3 4 5 CFM W†† BHP CFM W†† BHP CFM W†† BHP CFM W†† BHP CFM W†† BHP CFM W†† BHP 0.4 - - - - - - 5201 3162 3.39 4966 2796 3.00 4681 2405 2.58 4355 2054 2.20 0.6 - - - 5220 3395 3.64 4942 2980 3.20 4657 2608 2.80 4358 2230 2.39 4007 1890 2.03 3194 3.43 4661 2806 3.01 4378 2572 2.76 4016 2057 2.21 0.
035-19046-002-B-0104 TABLE 19: INDOOR BLOWER SPECIFICATIONS MODEL DJ150 MOTOR MOTOR SHEAVE HP RPM Eff. SF Frame Datum Dia. (in.) 3 1725 80% 5 1725 87% 1.15 56 1.15 184T BLOWER SHEAVE BELT Bore (in.) Model Datum Dia. (in.) Bore (in.) Model 3.4 - 4.4 7/8 1VM50 7.0 1 AK74 A54 4.3 - 5.3 1 1/8 1VP56 6.7 1 BK77 BX55 AIR BALANCE Start the supply air blower motor.
035-19046-002-B-0104 Predator DJ 150 Units Indoor Coil Pressure Drop vs. Airflow 1 0.9 Dry Coil Delta P (IWG) 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 3500 4000 4500 5000 5500 6000 6500 Airflow (CFM) FIGURE 25 - DRY COIL DELTA P SUPPLY AIR DRIVE ADJUSTMENT EXAMPLE A 12.5 ton unit was selected to deliver 4,000 CFM with a 3 HP motor, but the unit is delivering 3,800 CFM. The variable pitch motor sheave is set at 2 turns open.
035-19046-002-B-0104 TABLE 20: ADDITIONAL STATIC RESISTANCE Cooling Only* Economizer† ‡ 3700 0.20 3900 0.23 4100 CFM Electric Heat KW† 18 24 36 54 0.04 0.18 0.21 0.22 0.26 0.04 0.20 0.23 0.24 0.28 0.25 0.04 0.22 0.25 0.26 0.31 4300 0.28 0.05 0.24 0.28 0.29 0.34 4500 0.30 0.05 0.26 0.30 0.31 0.37 4700 0.33 0.05 0.29 0.33 0.34 0.40 4900 0.36 0.05 0.31 0.35 0.37 0.43 5100 0.39 0.06 0.34 0.38 0.40 0.46 5300 0.42 0.06 0.37 0.41 0.43 0.
035-19046-002-B-0104 NO OUTDOOR AIR OPTIONS When the thermostat calls for the first stage of cooling, the low-voltage control circuit from “R” to “Y1” and “G” is completed. The UCB energizes the economizer (if installed and free cooling is available) or the first available compressor* and the condenser fans. For first stage cooling, compressor #1 is energized. If compressor #1 is unavailable, compressor #2 is energized.
035-19046-002-B-0104 Should a high-pressure switch open three times within two hours of operation, the UCB will lock-out the associated compressor and flash a code (see Table 28). If the other compressor is inactive, the condenser fans will be de-energized. LOW-PRESSURE LIMIT SWITCH The low-pressure limit switch is not monitored during the initial 30 seconds of a cooling system's operation. For the following 30 seconds, the UCB will monitor the low-pressure switch to ensure it closes.
035-19046-002-B-0104 RESET TABLE 22: ELECTRIC HEAT LIMIT SETTING Remove the call for cooling, by raising thermostat setting higher than the conditioned space temperature. This resets any pressure or freezestat flash codes. HEATER kW LIMIT SWITCH OPENS °F 12.5 18 150 12.5 24 150 34 150 UNIT (TONS) ELECTRIC HEATING SEQUENCE OF OPERATIONS VOLTAGE 208/230 The following sequence describes the operation of the electric heat section. 12.5 12.5 54 150 Two-stage heating: 12.
035-19046-002-B-0104 GAS HEATING SEQUENCE OF OPERATIONS When the thermostat calls for the first stage of heating, the low-voltage control circuit from “R” to “W1” is completed. A call for heat passes through the UCB to the ignition control board (ICB). The UCB monitors the “W1” call and acts upon any call for heat by monitoring the gas valve (GV). Once voltage has been sensed at the GV, the UCB will initiate the fan on delay for heating, energizing the indoor blower the specified delay has elapsed.
035-19046-002-B-0104 If the ICB senses voltage at the GV when not requested, the ICB will energize the draft motor. The ICB will not operate the furnace until voltage is no longer sensed at the GV. The draft motor is stopped when voltage is not sensed at the GV. Any time the UCB senses voltage at the GV without a call for heat for a continuous five-minute period, the UCB will lock-on the indoor blower and a flash code is initiated (Table 28).
035-19046-002-B-0104 GAS HEAT ANTICIPATOR SETPOINTS OPERATING INSTRUCTIONS It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space. Reducing the value below the correct setpoint will give shorter “ON cycles and may result in the lowering of the temperature within the conditioned space. Refer to Table 25 for the required gas heat anticipator setting. 1. 2.
035-19046-002-B-0104 POST START CHECKLIST 2. Using the outlet pressure port on the gas valve, connect a manometer to monitor the manifold pressure. After the entire control circuit has been energized and the heating section is operating, make the following checks: 3. Remove plastic cap covering HI and LO pressure adjustment screws. 1. 4. Turn on power to the unit. 5. Set thermostat to call for second stage heat and start furnace. 6.
035-19046-002-B-0104 3. 4. 5. Measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter has a 1/2 or a 1 cubic foot test dial. Using the number of seconds it takes for one revolution of the dial, calculate the cubic feet of gas consumed per hour. (See example below). If necessary, adjust the high pressure regulator as discussed in the section “Manifold Gas Pressure Adjustment”. Be sure not to over-fire the furnace on Second stage.
035-19046-002-B-0104 EXAMPLE: By actual measurement, it takes 19 seconds for the hand on a 1 cubic foot dial to make a revolution with a 192,000 Btuh furnace running. To determine rotations per minute, divide 60 by 19 = 3.16. To calculate rotations per hour, multiply 3.16 • 60 = 189.6. Multiply 189.6 • 1 (0.5 if using a 1/2 cubic foot dial) = 189.6. Multiply 189.6 • (the Btu rating of the gas). For this example, assume the gas has a Btu rating of 1050 Btu/ft.3.
035-19046-002-B-0104 CHARGING THE UNIT TABLE 28: UNIT CONTROL BOARD FLASH CODES Flash Code The DJ150 (12-1/2 Ton) High Efficiency Unit, uses a TXV metering device. Charge unit to 10º sub-cooling at the TXV. TROUBLESHOOTING Troubleshooting of components may require opening the electrical control box with the power connected to the unit.
035-19046-002-B-0104 Monitored Systems Problem? No No Call for Heating? Programming? Yes Yes Program Unit Control Board Call for Heat Yes Trip/Failure Loss of Call for Heating? No Yes Heat Off No Call for 2nd Stage Cooling No Energize ID Blower Motor Monitor Call for Cooling? Yes First Stage? Yes No Yes No Turn off ID Blower Motor Yes No Fan on >30 secs? Yes Yes No Call for 1st Stage Cooling Fan off >10 secs? No Lossof Call for ID Blower? Call for ID Blower? No Loss o
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035-19046-002-B-0104 COOLING TROUBLESHOOTING GUIDE On calls for cooling, if the compressors are operating but the supply air blower motor does not energize after a short delay (the room thermostat fan switch is in the “AUTO” position). 1. If installed, check the position of the economizer blades. If the blades are open, the economizer is providing free cooling and the compressors will not immediately operate.
035-19046-002-B-0104 locked out the compressor for repeat trips. The UCB should be flashing an alarm code. If not, press and release the ALARMS button on the UCB. The UCB will flash the last five alarms on the LED. If the compressor is locked out, cancel any call for cooling. This will reset any compressor lock outs. On calls for the second stage of cooling, the supply air blower motor and compressor #1 are operating but compressor #2 is not (the room thermostat fan switch is in the “AUTO” position). 1.
035-19046-002-B-0104 locked out the compressor for repeat trips. The UCB should be flashing a code. If not, press and release the ALARMS button on the UCB. The UCB will flash the last five alarms on the LED. If the compressor is locked out, 6. If 24 volts is not present at M1, check for 24 volts at the UCB terminal, C1. If 24 volts is present, check for loose wiring between C1 and the compressor contactor. 7.
035-19046-002-B-0104 For units with economizers:If 24 volts is present at the Y1 “OUT” terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, a poor connection between the UCB and economizer Mate-N-Lock plugs, loose wiring from the Mate-N-Lock plug to the economizer, back to the Mate-N-Lock plug, and from the Mate-N-Lock plug to the Y1 “ECON” terminal.
035-19046-002-B-0104 1. Check for 24 volts at the spark ignitor from the ignition control board (ICB). Check the 24-volt wiring from the ICB to the spark ignitor. Check for 24 volts at the ICB spark ignitor terminal. 2. Check the ground wiring for the ICB and the gas valve is intact and making good electrical connection. Check the ceramic insulator on the spark ignitor for breaks or cracks. Replace the spark ignitor if damaged. 3.
035-19046-002-B-0104 Unitary Products Group 51
Subject to change without notice. Printed in U.S.A. Copyright © 2004 by Unitary Products Group. All rights reserved.
