Sunline 2000TM packaged air conditioners with gas heating models D3IG 180, 240 and 300 (Euro 50 Hz) Ref: Y-R24976 1001M ER-028/1/91 ISO 14001 ISO 9001 Operating Instructions CGM-97/013 GB 1
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GB Index General description - Nomenclature General information Environmental protection Warning signs Inspection Standards Installation - - - Limits Table 1 - Unit application data Location Installation and use Clearance Ducts Fixed outdoor air intake damper (optional accessory) Condensed water drain Compressors Air filters Combustion discharge Table 2 - Application data with gas heating Gas pipes Gas connection Ventilation and combustion air hoods GLP/propane gas units, tanks and pipes Power and cont
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General description Nomenclature Product category: D = Packaged air conditioner (air-cooled) Product generation: 3 = 3rd generation Product identification: IG = International cooling with gas heating Nominal cooling capacity: 180 = 52.7 kW (180 MBH) 240 = 70.3 kW (240 MBH) 300 = 87.8 kW (300 MBH) Heating installed and type of refrigerant: N = Natural gas equipment and R-22 refrigerant G = Natural gas equipment and R-407C refrigerant Nominal heating capacity with gas: 320 = 93.
3. To be installed on combustible materials without any danger. 4. To be used with natural or propane gas. These units are not to be used with conventional ventilating systems. This symbol indicates an electrical danger or risk. CAUTION This product should be installed by strictly following the enclosed instructions and all local, state and national regulations including, but not limited to, standards on buildings, electricity and mechanics.
Typical sling CAUTION If this equipment is to be installed on a mounting base or a special angle frame that is not the standard mounting base, gaskets should be placed on all surfaces in contact with the lower part of the unit.
See Fig. 11 for details concerning the side and bottom openings for the impulse and return air ducts. NOTE The condensed water drain pipe must have a siphon so as to facilitate correct drainage. See Fig. 4. Fixed outdoor air intake damper (optional accessory) 75 mm Piping recommended for drain UNIT CONDENSED WATER DRAIN CONNECTION BASE TRAY BASE BEAMS 51 mm See the instructions included in the accessory.
Gas pipes Ventilation and combustion air hoods The correct sizing of the gas pipes depends upon the flow required, density of the gas and the length of the pipes. The regulations of the local gas company must be complied with when determining the diameter of the pipes. The heating value of the gas may vary from city to city. This value should be check with the local gas (supplier) company. Two gas outlet and combustion air intake hoods are supplied fastened to the fan casing inside this compartment.
GLP/propane gas units, tanks and pipes All units with gas heating are supplied factory equipped for operation with natural gas only. The unit can be transformed for operation with GLP/propane gas by means of a conversion kit installed on job site. All units operating with GLP/propane gas must comply with local or city safety regulations. For satisfactory operation, the pressure of the GLP/propane gas should be 37 mbar with the unit at full load.
Thermostat The ambient thermostat should be located on an inner wall, at about 1420 mm. above floor level, where it will not be exposed to air flows, direct sunlight or heat from other electric devices. For general installation, follow the instructions supplied by the manufacturers. To connect the thermostat to the unit, eight colour-coded 1 mm² wires should be used. Unit control wiring The following notes and indications pertain to the unit wiring diagram shown in Fig. 9. NOTES: 1.
(01) 104 103 GB 108 107 106 - Fig. 9 133 122 121 113 112 111 110 109 330 N X3/... 165 BLACK 114 M6 M7 OUTDOOR FAN 1 OUTDOOR FAN 2 P4 S4 7 166 X1/... N M 1~ E16 2 3 GV1 1 Y2 7 IC1 Y1 5 334 M5 INDOOR FAN MOTOR E8 M8 2 X3/...
(01) 104 103 108 107 106 GB 134 133 125 124 123 122 121 113 112 111 110 109 E8 P4 S4 7 166 X1/... N 330 165 WHITE 126 114 X3/... N M 1~ 1 2 3 E16 GV1 Y2 7 IC1 Y1 5 334 M6 M7 OUTDOOR FAN 1 OUTDOOR FAN 2 E7 M8 2 X3/... PS 1 3 3 PS 2 S5 P5 P3 S3 3 1 5 X3 S4 13 4 3 S4 ST 3 3 d b c X3/... a 14 I-2079-2a (2 of 4) D3IG240N32050 ST 5 306 177 N X1/...
c BF 3 318 326 327 352 - Fig. 9 - GB X2/...
W1 24VAC RS2 RS+V GB Y1 G SR +R S + K2-2 R K2-2 N 1 3 2 4 DEFROST SENSOR 24V LLEVAR A POSICION MINIMA 0V LLEVAR TOTALMENTE CERRADO K1-1 +0 + K1-2 S0 S ECONOMISER SECTION (OPTIONAL) LD2 Y2 TR1 RELE K1, K2 REFRIGERACION MECANICA: CONTACTOS POSICION NORMAL "FREE COOLING": CONTACTOS POSICION ACTIVO TR 24V DAMPER MODULATOR 0V MINIMUM POSITION RETURN AIR ENTHALPY SENSOR (OPTIONAL) OUTDOOR AIR ENTHALPY SENSOR RS1 REMOTE SENSOR W2 AMBIENT THERMOSTAT DSL-700 BROWN BROWN OR OR T
(01) 104 103 108 107 106 GB 4 4 134 133 100 99 97 96 125 124 122 121 113 112 111 110 109 101 126 114 E2 E3 E4 E5 E23 E24 E6 M1 M2 M3 M4 M9 M10 M5 COMPRESSOR 1 COMPRESSOR 2 COMPRESSOR 3 COMPRESSOR 4 COMPRESSOR 5 COMPRESSOR 6 CENTRIFUGAL FAN M 3~ 6 135 2 (34) M6 OUTDOOR FAN 1 M 3~ 6 5 4 3 2 1 145 M 3~ (33) KM4 146 M 3~ 6 98 2 5 147 M 3~ (37) 3 E7 (35) KM5 M7 OUTDOOR FAN 2 M 3~ 6 5 4 3 2 1 148 M 3~ 4 1 F5 6A 149 M 3~ 6 123 2 KM3 6 5
166 305 GB 349 BLACK FLAME SENSOR 1 350 E16 S4 ST 3 3 BF 3 3 1 4 2 7 RPS 8 354 (17) 15 ST 5 IN 1 IN 2 IE 10 IC2 PS 2 PS 1 Y1 5 Y2 7 E15 2 3 GV2 1 329 334 WHITE 330 6 5 S4 ST 3 3 RPS 5 (14a) 18 X3 19 372 X3/... 332 165 331 N ST 5 352 2 3 GV1 1 X3 377 S4 310 532 M 1~ 317 PS 2 357 2 X3/...
168 GB 3 1 4 2 700 171 280 (15) 263 287 247 701 754 755 753 5 1 3 5 13 757 2 4 (03) 6 14 234 3 1 4 2 1 3 5 13 229 756 2 4 (01) 6 14 S11 6 P11 8 K6 7 207 167 E10 6 (37) 5 (36) 3 (05) 1 4 2 3 1 4 2 7 RY3 8 6 5 (30) (34) 7 RY2 8 3 1 4 2 6 5 759 2 4 6 14 3 1 4 2 760 2 1 4 (09) 3 6 5 14 13 761 1 2 4 (08) 3 5 6 13 14 758 2 1 4 (07) 3 6 5 14 13 7 RY1 8 716 A2 KM6 A1 14 5 721 A2 KM5 A1 Y3 751 750 1 3 5 13 1 Y3 Y2 41 42 Y2 720 40 722 Y1 207 60
W1 24VAC RS2 RS+V GB RETURN AIR S ENTHALPY SENSOR + (OPTIONAL) S OUTDOOR AIR ENTHALPY SENSOR + DEFROST SENSOR RS1 LD2 Y2 Y1 G S1 +R SR +0 SO S2 K2-2 K1-2 R1-2 R1-1 R1 A A S12 5 6 4 2 3 TR TR1 7 9 1 ERC OR OR OR ECR 2 B B 8 R P12 GV2 IC2 IC1 RPS 3 1 B3 B2 B1 A T1 T2 ECONOMISER SECTION (OPTIONAL) REMOTE SENSOR W2 AMBIENT THERMOSTAT DSL-700 UNIT WIRED FOR 66% OF CAPACITY IN 1st STAGE AND 33% EIN 2 nd STAGE OF COOLING FOR33% EIN THE1ª Est STAGE AND 66
Optional economiser rain-hood/motor-driven 1. At this point, the damper enthalpy set point can be adjusted by selecting the desired position, as shown in Fig. damper 10. Proceed as follows: For operation in single enthalpy, carefully turn the set point adjustment screw to settings “A”, “B”, “C” or “D” that correspond to the curve with letters. - For operation in dual enthalpy, carefully turn the set point adjustment screw all the way to the right, past position “D”. 2.
Table 3 - Physical data Unit model Description of components Impulser air fan Indoor coil Outdoor fans (two per unit) 180 240 300 Dia. x Width (mm) 381 x 381 457 x 381 457 x 381 kW 4 5.5 7.5 Tubing depth 3 3 4 Fins per inch 13.5 13.5 13 Centrifugal fan Fan motor Front surface m2 1.45 1.92 2.14 Dia. propeller mm (per unit) 762 762 762 Fan motor kW (per unit) 1.5 1.5 1.5 m3 / s (per unit) 2.83 3.78 3.
Dimensions and clearances - D*IG180, 240 and 300 LOCATION OF SWITCH ACCESS TO FAN ECONOMISER RAIN-HOOD/MOTOR-DRIVEN DAMPER AND FIXED OUTDOOR AIR INTAKE (See detail "Y") ACCESS TO FAN MOTOR SIDE DUCT ACCESSORY OPENING (See detail "X") ACCESS TO FAN COMPARTMENT (Auxiliary) 1235 (180) 1337 (240, 300) CAP (For pressure drop readings) COMBUSTION AIR INTAKE HOOD 180 COMBUSTION AIR OUTLET HOOD 533 ACCESS TO GAS HEATING FRONT VIEW 127 COIL PROTECTION OUTDOOR COILS 248 34 318 60 0 ( (24 18 0, 0) 30
Dimensions and clearances - D*IG180, 240 and 300 (Cont.) 1027 OUTDOOR SECTION INDOOR SECTION IMPULSE AIR 140 CAP (For pressure drop readings) RETURN AIE OUTDOOR AIR ACCESS TO COMPRESSOR 47 5 ACCESS TO OUTDOOR AIR COMPART RETURN AIR ACCESS 30 10 70 7 127 10 727 06 ( (24 180 0, ) 30 0) REAR VIEW DUCT COVERS - The units are supplied with all air duct openings covered. An accessory kit with flanges is available for connecting the side ducts. In applications with bottom discharge: 1.
Table 5 - Impulse air fan performances (Mod. D*GI180) - with application of downward discharge ducts Standard operation (m³/s) Flow Fan speed RPM 3 3 2.80 m3/s 2.45 m /s 2.10 m /s E.S.P. E.S.P. 3.40 m3/s 3.10 m3/s E.S.P. E.S.P. E.S.P. (Pa) (kW) (Pa) (kW) (Pa) (kW) (Pa) (kW) (Pa) (kW) 845 173 2.2 138 2.6 83 3.1 18 3.5 - - 885 208 2.3 172 2.8 115 3.3 49 3.7 - - 925 245 2.4 208 2.9 149 3.4 82 3.9 - - 960 281 2.6 242 3.1 182 3.6 114 4.1 30 4.
Table 7 - Impulse air fan performances (Mod. D*IG300) - with application of downward discharge Standard operation (m³/s) Flow 3.78 m3/s Fan speed RPM 4.72 m3/s 4.25 m3/s E.S.P. E.S.P. 5.19 m3/s 5.66 m3/s E.S.P. E.S.P. E.S.P. (Pa) (Pa) (kW) (Pa) (kW) (Pa) (kW) 1 010 375 6.4 225 7.5 102 8.7 1 064 448 6.9 325 8 203 9.3 1 118 548 7.4 423 8.6 305 10 224 1 172 648 7.9 523 9.2 410 10.6 249 (kW) (Pa) (kW) - - - - 50 10.6 - - 11.4 25 12.9 12.2 105 13.
Operation Cooling system The cooling system is a complete factory-mounted assembly that uses an air-cooled condenser. The system is delivered loaded with R-22 refrigerant. The compressors are sealed airtight, have internal shock absorbency and are mounted onto their base by means of isolated fixing screws. The compressors also have intrinsic (internal) protection. Should there be an unusual temperature increase in the compressor, the safety device will turn the compressor off.
Low temperature operation: If the outdoor temperature is above 21º C (70º F), Low Temperature Thermostat TLA is closed, and Contact KM5 of the outdoor fan operates as described above. TLA opens below 16º C (60º F), avoiding operation of KM5 and the fan of condenser No. 2. The limited air flow on the front of the condensing coil allows cooling operation up to -4º C (25º F). Heating operation sequence REQUEST FOR HEATING, W1: Signal W1 from the thermostat activates Heat Relay RW1 and Timer Relay TDR.
control IC2 is locked out. guard F3 opens, interrupting the electric power supply to Indoor Fan Contact KM3. Controls and gas valves NOTE: Since IC2 is controlled by IC1, any limiting device or failure that may lock out IC1, also disactivates out IC2.
of the heat exchanger is 1 mbar (2.5" each). 9. Make sure all wiring connections of the gas chamber are correct. Start up Operating instructions CAUTION: This burner is equipped with automatic ignition systems. Do not attempt to ignite it manually. 2. Turn the Quick Partial Opening Regulation flywheel (B) one complete turn backwards. 3. With the gas valve in operation, loosen the Flow Regulating Flywheel of the second flame V2 (C) slightly, and set said flywheel to its maximum opening.
there is sufficient penetration in the air flow on both sides of the indoor coil. View of typical flame NOTE: The pipes should be inserted and kept in perpendicular to the air flow in such a way that the speed pressure does not affect the static pressure reading. 3. Using an inclined pressure gauge, determine the pressure drop in a dry indoor coil. Since humidity can vary considerably in an indoor coil, to measure a pressure drop in a wet coil under site conditions would not be precise.
After about 20 minutes of operation, determine the temperature increase in the boiler. Take a reading of both the return and hot air in the ducts (at about 1.8 m. from the boiler), where this reading is not affected by radiant heat. Increase the fan air flow so as to decrease the temperature; decrease the fan air flow so as to increase the temperature. See Table 8 for fan motor and data on operation of same. Pressure drop in dry indoor coil vs.
Maintenance Normal maintenance CAUTION: Before carrying out any of the following operations, disconnect all electric power supply to the unit. Not doing this could cause personal injuries. Normally, periodical maintenance comprises changing or cleaning filters and (in certain cases) cleaning the main burners. FILTERS: Check them once a month. Replace the non-reusable or clean the permanent filters, as required. DO NOT replace the permanent type with non-reusable types.
Trouble shooting ii. With economiser: a. Economiser logic module or wiring defective. b. Thermostat set to unoccupied mode. c. Defective occupied relay coil or contacts. General information Before trouble shooting in depth, first make sure the thermostat is calling for Cool or Heat, and that the power supply to the unit has not been interrupted by any automatic switch, etc. Make sure both the thermostat as well as the site wiring operate correctly.
2 activated, but contacts K5-2 of relay board are open. Replace the relay board. SEC. 5: No heating, presence of impulse air; ignition control locked out. Make sure there is 230 VAC tension between terminals ST-3 and ST-4, so as to determine lock-out of IC1 and IC2. A. No flame detected. Check the ignition electrode, the ignition transformer and the flame detector. Check grounding of unit, ignition control and ignition transformer. Make sure the fuel is being liberated by the gas valve. B.
out the following steps: a. Set the potentiometer of the enthalpy set point to position “A”. The LED should go on, indicating low enthalpy, and the damper motor should advance to its open position. b. Set the potentiometer of the enthalpy set point to position “D”. The LED should go off, indicating high enthalpy, and the damper motor should advance to its closed position. c. If the logic module does not surpass test a. or b., replace it.
DECLARATION OF COMPLIANCE ON MACHINERY MANUFACTURER: CLIMA ROCA YORK, S.L. ADDRESSE: Paseo Espronceda, 278, 08.204 SABADELL This machine complies with the basic demands of the EC Standards on machinery (Standard "EC" 89/392/CEE), including any modification of same. APPLICATION OF THE MACHINE: AIR CONDITIONER/COOLING 180, 240 & 300 TYPE: D3IG ..............................
