York Dj150 User Manual

INSTALLATION

MANUAL

MAGNUM

CONTENTS

SINGLE PACKAGE AIR CONDITIONERS AND

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . .4

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .5

APPROVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . .6

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

START-UP (COOLING). . . . . . . . . . . . . . . . . . . . . .39

START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . .39

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .43

SINGLE PACKAGE GAS/ELECTRIC UNITS

DJ150

12-1/2 TON

(10.8 EER)

See following pages 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 damage

may result if installation procedure is not handled properly.

Tested in accordance with:

CAUTION: READ ALL SAFETY GUIDES BEFORE YOU

BEGIN TO INSTALL YOUR UNIT.

SAVE THIS MANUAL

035-19046-002-B-0104

LIST OF FIGURES

Pg. # Fig. #

UNIT SHIPPING BRACKET . . . . . . . . . . . . . . . . . . . . . 8

Fig. #

Pg. #

16 ELECTRONIC THERMOSTAT FIELD WIRING . . . . . 18

17 FIELD WIRING 24 VOLT THERMOSTAT . . . . . . . . . 19

COMPRESSOR SECTION . . . . . . . . . . . . . . . . . . . . . . 9

PREDATOR“ MAGNUM COMPONENT LOCATION . 10

UNIT 4 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 11

UNIT 6 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 12

UNIT CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . 12

UNIT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 13

BOTTOM DUCT OPENINGS (FROM ABOVE). . . . . . 14

REAR DUCT DIMENSIONS . . . . . . . . . . . . . . . . . . . . 15

18 FIELD WIRING DISCONNECT - COOLING UNIT

WITH/WITHOUT ELECTRIC HEAT . . . . . . . . . . . . . . 19

19 FIELD WIRING DISCONNECT - COOLING UNIT

WITH GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

20 SIDE ENTRY GAS PIPING. . . . . . . . . . . . . . . . . . . . . 23

21 BOTTOM ENTRY GAS PIPING . . . . . . . . . . . . . . . . . 23

22 ENTHALPY SET POINT CHART . . . . . . . . . . . . . . . . 27

23 HONEYWELL ECONOMIZER CONTROL W7212. . . 27

24 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 28

25 DRY COIL DELTA P. . . . . . . . . . . . . . . . . . . . . . . . . . 32

26 TYPICAL FLAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

27 TYPICAL GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . 42

28 BASIC TROUBLESHOOTING FLOWCHART . . . . . . 44

29 POWER ON FLOW CHART . . . . . . . . . . . . . . . . . . . . 44

30 TRIP FAILURE FLOW CHART. . . . . . . . . . . . . . . . . . 45

10 PREDATOR“ MAGNUM ROOF CURB

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

11 SUNLINE™ TO PREDATOR“ MAGNUM

TRANSITION ROOF CURBS . . . . . . . . . . . . . . . . . . . 16

12 SIDE PANELS WITH HOLE PLUGS. . . . . . . . . . . . . . 16

13 RETURN DOWNFLOW PLENUM WITH PANEL . . . . 17

14 DISCHARGE PANEL IN PLACE. . . . . . . . . . . . . . . . . 17

15 CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . 17

LIST OF TABLES

Tbl. #

Pg. #

Tbl. #

Pg. #

UNIT VOLTAGE LIMITATIONS . . . . . . . . . . . . . . . . . . 11

UNIT TEMPERATURE LIMITATIONS 11

16 DJ150, 12-1/2 TON OPTIONAL MOTOR DOWN

SHOT BLOWER PERFORMANCE. . . . . . . . . . . . . . . 29

17 DJ150, 12-1/2 TON STANDARD MOTOR SIDE

SHOT BLOWER PERFORMANCE. . . . . . . . . . . . . . . 30

UNIT WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 POINT LOAD WEIGHT. . . . . . . . . . . . . . . . . . . . . . . 12

6 POINT LOAD WEIGHT. . . . . . . . . . . . . . . . . . . . . . . 12

UNIT CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . 17

18 DJ150, 12-1/2 TON OPTIONAL MOTOR SIDE

SHOT BLOWER PERFORMANCE. . . . . . . . . . . . . . . 30

19 INDOOR BLOWER SPECIFICATIONS. . . . . . . . . . . . 31

20 ADDITIONAL STATIC RESISTANCE . . . . . . . . . . . . . 33

21 MOTOR SHEAVE DATUM DIAMETERS . . . . . . . . . . 33

22 ELECTRIC HEAT LIMIT SETTING . . . . . . . . . . . . . . . 36

23 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . 36

24 GAS HEAT LIMIT CONTROL SETTINGS. . . . . . . . . . 38

25 GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . 39

26 GAS HEAT STAGES. . . . . . . . . . . . . . . . . . . . . . . . . . 40

27 GAS RATE CUBIC FEET PER HOUR . . . . . . . . . . . . 41

28 UNIT CONTROL BOARD FLASH CODES . . . . . . . . . 43

29 IGNITION CONTROL FLASH CODES . . . . . . . . . . . . 43

ELECTRICAL DATA DJ150 (12-1/2 TON) WITHOUT

POWERED CONVENIENCE OUTLET . . . . . . . . . . . . 21

ELECTRICAL DATA DJ150 (12-1/2 TON) WITH

POWERED CONVENIENCE OUTLET . . . . . . . . . . . . 21

10 PHYSICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

11 MINIMUM SUPPLY AIR CFM . . . . . . . . . . . . . . . . . . . 22

12 GAS HEAT APPLICATION DATA . . . . . . . . . . . . . . . . 23

13 GAS PIPE SIZING - CAPACITY OF PIPE. . . . . . . . . . 23

14 SUPPLY AIR LIMITATIONS . . . . . . . . . . . . . . . . . . . . 28

15 DJ150, 12-1/2 TON STANDARD MOTOR DOWN

SHOT BLOWER PERFORMANCE . . . . . . . . . . . . . . . 29

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GENERAL



YORK Predator Magnum units are single package air con-

ditioners 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.

If the information in this manual is not followed

exactly, a fire or explosion may result causing prop-

erty damage, personal injury or loss of life.

Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other

appliance.

These units are completely assembled on rigid, permanently

attached base rails. All piping, refrigerant charge, and electri-

cal wiring is factory installed and tested. The units require

electric power, gas supply (where applicable), and duct con-

nections. The electric heaters have nickel-chrome elements

and utilize single-point power connection.

WHAT TO DO IF YOU SMELL GAS:

a. Do not try to light any appliance.

b. Do not touch any electrical switch; do not use

any phone in your building.

SAFETY CONSIDERATIONS

c. Immediately call your gas supplier from a neigh-

bor’s phone. Follow the gas supplier’s instruc-

tions.

d. If you cannot reach your gas supplier, call the fire

department.

Should overheating occur, or the gas supply fail to

shut off, shut off the manual gas valve to the furnace

before shutting off the electrical supply.

Installation and service must be performed by a

qualified installer, service agency or the gas sup-

plier.

Do not use this furnace if any part has been under

water. Immediately call a qualified service technician

to inspect the furnace and to replace any part of the

control system and any gas control which has been

under water.

INSPECTION

As soon as a unit is received, it should be inspected for possi-

ble damage during transit. If damage is evident, the extent of

the damage should be noted on the carrier’s freight bill. A

separate request for inspection by the carrier’s agent should

be made in writing.

Due to system pressure, moving parts, and electrical compo-

nents, installation and servicing of air conditioning equipment

can be hazardous. Only qualified, trained service personnel

should install, repair, or service this equipment. Untrained

personnel can perform basic maintenance functions of clean-

ing coils and filters and replacing filters.

Observe all precautions in the literature, labels, and tags

accompanying the equipment whenever working on air condi-

tioning equipment. Be sure to follow all other applicable

safety precautions and codes including ANSI Z223.1 or CSA-

B149.1- latest edition.

This furnace is not to be used for temporary heating

of buildings or structures under construction.

Before performing service or maintenance opera-

tions on unit, turn off main power switch to unit. Elec-

trical shock could cause personal injury. Improper

installation, adjustment, alteration, service or main-

tenance can cause injury or property damage. Refer

to this manual. For assistance or additional informa-

tion consult a qualified installer, service agency or

the gas supplier.

Wear safety glasses and work gloves. Use quenching cloth

and have a fire extinguisher available during brazing opera-

tions.

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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 supple-

mental electric heat or a forced air furnace.

•

Technical Guide - DJ150, 036-21484-002

General Installation - DJ150, 035-19046-002

Pre-start & Post-start Check List - 035-18466-000

2. For outdoor installation only.

3. For installation on combustible material and may be

installed directly on combustible flooring or, in the U.S.,

on wood flooring or Class A, Class B or Class C roof cov-

ering materials.

Economizer Accessory -

Downflow Factory Installed, 035-18286-000

Downflow Field Installed, 035-18285-000

Horizontal Field Installed, 035-18287-000

4. For use with natural gas (convertible to LP with kit).

•

Motorized Outdoor Air Damper 035-18283-000

Manual Outdoor Air Damper (0-100%) 035-18282-000

Manual Outdoor Air Damper (0-35%) 035-18281-000

Gas Heat Propane Conversion Kit 035-17374-000

Gas Heat High Altitude Kit (Natural Gas) 035-17282-000

Gas Heat High Altitude Kit (Propane) 035-17281-000

–60°F Gas Heat Kit 035-18216-000

This product must be installed in strict compliance

with the enclosed installation instructions and any

applicable local, state, and national codes including,

but not limited to, building, electrical, and mechanical

codes.

Electric Heater Accessory 035-17291-001

Unit Renewal Parts List 035-19085-000

All forms referenced in this instruction may be ordered from:

Standard Register

Toll Free Fax: (877) 379-7920

Toll Free Phone: (877) 318-9675

Incorrect installation may create a condition where the

operation of the product could cause personal injury

or property damage.

RENEWAL PARTS

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 damage may

result if installation procedure is not handled properly.

Refer to York’s USER’S MAINTENANCE and SERVICE

INFORMATION MANUAL Part Number 035-19047-001.

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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

Additional Options

Installation Options

Product Identifier

Voltage

J = R-22 Ultra High Efficiency

2 = 208/230-3-60

4 = 460-3-60

5 = 575-3-60

A = No Options Installed

B = Option 1

C = Option 2

(See Next Page)

D = Options 1 & 2

E = Option 3

F = Option 4

Nominal Cooling Capacity - MBH

150 = 12-½ Ton

G = Options 1 & 3

H = Options 1 & 4

J = Options 1, 2 & 3

K = Options 1, 2 & 4

L = Options 1, 3 & 4

M = Options 1, 2, 3 & 4

N = Options 2 & 3

P = Options 2 & 4

Q = Options 2, 3 & 4

R = Options 3 & 4

S = Option 5

Heat Type & Nominal Heat Capacity

C00 = Cooling Only. Suitable for field installed electric heat

Gas Heat Options

N 15 = 150 MBH Output Aluminized Steel

N 20 = 200 MBH Output Aluminized Steel

T = Options 1 & 5

U = Options 1, 3 & 5

V = Options 1, 4 & 5

W = Options 1, 3, 4 & 5

X = Options 3 & 5

Y = Options 4 & 5

Z = Options 3, 4 & 5

S 15 = 150 MBH Output Stainless Steel

S 20 = 200 MBH Output Stainless Steel

Electric Heat Options

Options

E18 = 18 kW Electric Heat

E24 = 24 kW Electric Heat

E36 = 36 kW Electric Heat

E54 = 54 kW Electric Heat

1 = Disconnect

2 = Non-Pwr’d Conv Outlet

3 = Smoke Detector S. A.

4 = Smoke Detector R. A.

5 = Pwr’d Conv Outlet

Airflow

A = Standard Motor

B = Standard Motor/Economizer/Barometric Relief (Downflow only)

C = Standard Motor/Economizer/Power Exhaust (Downflow only)

D = Standard Motor/Motorized Damper (Downflow only)

E = Standard Motor/Horizontal Economizer (No Barometric Relief)

F = Standard Motor/Slab Economizer/Power Exhaust (Downflow only)

G = Standard Motor/Slab Economizer/Barometric Relief (Downflow only)

L = Standard Motor/BAS Ready Econ (NoBASController)/Barometric Relief w/2" Pleated Filters (Downflow only)

M = Standard Motor/BAS Ready Econ (NoBASController)/Power Exhaust w/2" Pleated Filters (Downflow only)

N = High Static Motor

P = High Static Motor/Economizer/Barometric Relief (Downflow only)

Q = High Static Motor/Economizer/Power Exhaust (Downflow only)

R = High Static Motor/Motorized Damper (Downflow only)

S = High Static Motor/Horizontal Economizer (No Barometric Relief)

T = High Static Motor/Slab Economizer/Power Exhaust (Downflow only)

U =High Static Motor/Slab Economizer/Barometric Relief (Downflow only)

Y = High Static Motor/BAS Ready Econ (NoBASController)/Barometric Relief w/2" Pleated Filters (Downflow only)

Z = High Static Motor/BAS Ready Econ (NoBASController)/Power Exhaust w/2" Pleated Filters (Downflow only)

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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. Coil, & Coil Guard

CN CPC Controller, DFS, APS & Technicoat Evap. & Cond Coils

CQ CPC Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

CV CPC Controller, DFS, APS, & 2” Pleated Filters

HA Honeywell Excel 10 Controller with Dirty Filter Switch & Air Proving Switch

HC Honeywell Excel 10 Controller, DFS, APS & Coil Guard

HE Honeywell Excel 10 Controller, DFS, APS & Technicoat Cond. Coil

HG Honeywell Excel 10 Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard

HJ Honeywell Excel 10 Controller, DFS, APS & Technicoat Evap. Coil

HL Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard

HN Honeywell Excel 10 Controller, DFS, APS & Technicoat Evap. & Cond Coils

HQ Honeywell Excel 10 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

JA Johnson UNT Controller with Dirty Filter Switch & Air Proving Switch

JC Johnson UNT Controller, DFS, APS & Coil Guard

JE Johnson UNT Controller, DFS, APS & Technicoat Cond. Coil

JG Johnson UNT Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard

Johnson UNT Controller, DFS, APS & Technicoat Evap. Coil

Johnson UNT Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard

JN Johnson UNT Controller, DFS, APS & Technicoat Evap. & Cond Coils

JQ Johnson UNT Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

NA Novar ETC-3 Controller with Dirty Filter Switch & Air Proving Switch

NC Novar ETC-3 Controller, DFS, APS & Coil Guard

NE Novar ETC-3 Controller, DFS, APS & Technicoat Cond. Coil

NG Novar ETC-3 Controller, DFS, APS, Technicoat Cond. Coil, & Coil Guard

NJ Novar ETC-3 Controller, DFS, APS & Technicoat Evap. Coil

NL Novar ETC-3 Controller, DFS, APS, Technicoat Evap. Coil, & Coil Guard

NN Novar ETC-3 Controller, DFS, APS & Technicoat Evap. & Cond Coils

NQ Novar ETC-3 Controller, DFS, APS, Technicoat Evap. & Cond Coils, & Coil Guard

TA Technicoat Condenser Coil

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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 & Condenser Coils & Dirty Filter Switch

TY Technicoat Evaporator & Condenser Coils, Coil Guard, & Dirty Filter Switch

INSTALLATION

INSTALLATION SAFETY INFORMATION

FIRE OR EXPLOSION HAZARD

Read these instructions before continuing this appliance

installation. This is an outdoor combination heating and cool-

ing unit. The installer must assure that these instructions are

made available to the consumer and with instructions to

retain them for future reference.

Failure to follow the safety warning exactly could

result in serious injury, death or property damage.

Never test for gas leaks with an open flame. use a

commercially available soap solution made specifi-

cally for the detection of leaks to check all connec-

tions. A fire or explosion may result causing property

damage, personal injury or loss of life.

1. Refer to the furnace rating plate for the approved type of

gas for this furnace.

2. Install this furnace only in a location and position as

specified on Page 11 of these instructions.

PRECEDING INSTALLATION

1. Remove the two screws holding the brackets in the front,

rear and compressor side fork-lift slots.

3. Never test for gas leaks with an open flame. Use com-

mercially available soap solution made specifically for

the detection of leaks when checking all connections, as

specified on Pages 8, 24, 25 and 40 of these instruc-

tions.

4. Always install furnace to operate within the furnace's

intended temperature-rise range with the duct system

and within the allowable external static pressure range,

as specified on the unit name/rating plate, specified on

Page 42 of these instructions.

Bracket

Turn down

Screws

5. This equipment is not to be used for temporary heating

of buildings or structures under construction.

FIGURE 1 - UNIT SHIPPING BRACKET

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2. Turn each bracket toward the ground and the protective

plywood covering will drop to the ground.

LIMITATIONS

These units must be installed in accordance with the follow-

ing:

3. Remove the condenser coil external protective covering

prior to operation.

4. Remove the toolless doorknobs and instruction packet

prior to installation.

In U.S.A.:

1. National Electrical Code, ANSI/NFPA No. 70 - Latest

Edition

2. National Fuel Gas Code, ANSI Z223.1 - Latest Edition

3. Gas-Fired Central Furnace Standard, ANSI Z21.47a. -

Latest Edition

4. Local building codes, and

5. Local gas utility requirements

In Canada:

Toolless

Doorknobs

1. Canadian Electrical Code, CSA C22.1

2. Installation Codes, CSA - B149.1.

3. Local plumbing and waste water codes, and

4. Other applicable local codes.

Refer to Tables 1 & 2 for unit application data.

Installation

Instruction

Packet

FIGURE 2 - COMPRESSOR SECTION

After installation, gas fired units must be adjusted to obtain a

temperature rise within the range specified on the unit rating

plate.

If components are to be added to a unit to meet local codes,

they are to be installed at the dealer’s and/or customer’s

expense.

This product must be installed in strict compliance

with the enclosed installation instructions and any

applicable local, state and national codes including,

but not limited to, building, electrical, and mechani-

cal codes.

Size of unit for proposed installation should be based on heat

loss/heat gain calculation made according to the methods of

Air Conditioning Contractors of America (ACCA).

The furnace and its individual shut-off valve must be

disconnected from the gas supply piping system

during any pressure testing at pressures in excess

of 1/2 PSIG.

This furnace is not to be used for temporary heating of build-

ings or structures under construction.

Pressures greater than 1/2 PSIG will cause gas

valve damage resulting in a hazardous condition. If it

is subjected to a pressure greater than 1/2 PSIG, the

gas valve must be replaced.

The furnace must be isolated from the gas supply

piping system by closing its individual manual shut-

off valve during any pressure testing of the gas sup-

ply piping system at test pressures equal to or less

than 1/2 PSIG.

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"Simplicity™" Control

board w/screw

Disconnect

location

(optional disconnect switch)

Filter access

(2" throw-away)

Filter drier

(solid core)

connectors for T-stat

wiring and Network

connection

Second model

nameplate inside

hinged access panel

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 (high-

efficiency compressor

w/crankcase heater)

Power ventor

motor

20-gauge

aluminized steel tubular

heat exchanger for long

life (stainless steel option)

Base rails w/forklift

slots (three sides)

and lifting holes

Roof curbs in eight and

fourteen-inch heights.

Roof curbs for

Two-stage gas heating to

maintain warm,

comfortable temperature

Slide-out drain pan

with brass 3/4" FPT

connection

transitioning from York

Sunline™ footprint to

the DM/DH/DJ/DR Series

footprint are available

(field-installed accessory)

Compressor #1 access

(high-efficiency

compressor w/

Tool-less door

latch

Intelligent control

board for safe and

efficient operation

Side entry power

and control wiring

knockouts

crankcase heater)

FIGURE 3 - PREDATOR^MAGNUM COMPONENT LOCATION

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RIGGING AND HANDLING

TABLE 1: UNIT VOLTAGE LIMITATIONS

Power Rating^*

Exercise care when moving the unit. Do not remove any

packaging until the unit is near the place of installation. Rig

the unit by attaching chain or cable slings to the lifting holes

provided in the base rails. Spreader bars, whose length

exceeds the largest dimension across the unit, MUST be

used across the top of the unit.

Minimum

Maximum

208/230-3-60

460-3-60

187

432

540

252

504

630

575-3-60

Utilization range “A” in accordance with ARI Standard 110.

TABLE 2: UNIT TEMPERATURE LIMITATIONS

Temperature

Min.

Max.

If a unit is to be installed on a roof curb other than a

YORK roof curb, gasketing must be applied to all

surfaces that come in contact with the unit under-

side.

Wet Bulb Temperature (°F) of Air on

Evaporator Coil

Dry Bulb Temperature (°F) of Air on

0^*

125

Condenser Coil

A low ambient accessory is available for operation

down to -20°F.

LOCATION

Before lifting, make sure the unit weight is distrib-

uted equally on the rigging cables so it will lift evenly.

Use the following guidelines to select a suitable location for

these units:

1. Unit is designed for outdoor installation only.

Units may be moved or lifted with a forklift. Slotted openings

in the base rails are provided for this purpose.

2. Condenser coils must have an unlimited supply of air.

Where a choice of location is possible, position the unit

on either north or east side of building.

LENGTH OF FORKS MUST BE A MINIMUM OF 60

INCHES.

3. Suitable for mounting on roof curb.

4. For ground level installation, use a level concrete slab

with a minimum thickness of 4 inches. The length and

width should be at least 6 inches greater than the unit

base rails. Do not tie slab to the building foundation.

All panels must be secured in place when the unit is

lifted.

5. Roof structures must be able to support the weight of the

unit and its options/accessories. Unit must be installed

on a solid, level roof curb or appropriate angle iron

frame.

The condenser coils should be protected from rig-

ging cable damage with plywood or other suitable

material.

6. Maintain level tolerance to 1/2” across the entire width

and length of unit.

Excessive exposure of this furnace to contaminated

combustion air may result in equipment damage or

personal injury. Typical contaminates include: per-

manent wave solution, chlorinated waxes and clean-

ers, chlorine based swimming pool chemicals, water

softening chemicals, carbon tetrachloride, Halogen

type refrigerants, cleaning solvents (e.g. perchloro-

ethylene), printing inks, paint removers, varnishes,

hydrochloric acid, cements and glues, antistatic fab-

ric softeners for clothes dryers, masonry acid wash-

ing materials.

FRONT

LEFT

FIGURE 4 - UNIT 4 POINT LOAD

Unitary Products Group

035-19046-002-B-0104

CLEARANCES

TABLE 3: UNIT WEIGHTS

Operating

Weight (lb.)

1400

All units require particular clearances for proper operation

and service. Installer must make provisions for adequate

combustion and ventilation air in accordance with section 5.3

of Air for Combustion and Ventilation of the National Fuel Gas

Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections

7.2, 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in

Canada) - Latest Edition, and/or applicable provisions of the

local building codes. Refer to Table 6 for clearances required

for combustible construction, servicing, and proper unit oper-

ation.

Shipping

Weight (lb.)

Model DJ150

Cooling Unit Only

w/Economizer

1415

150

148

w/Power Exhaust

w/Gas Heat^*

110

w/Electric Heat^†

†.

8 Tube Heat Exchanger

54 kW heater

TABLE 4: 4 POINT LOAD WEIGHT

Location (lbs.)^*

Model

DJ150

282

323

424

371

Do not permit overhanging structures or shrubs to

obstruct condenser air discharge outlet, combustion

air inlet or vent outlets.

Weights include largest gas heat option.

TABLE 5: 6 POINT LOAD WEIGHT

Location (lbs.)^*

Model

DJ150

184

201

220

289

264

242

Excessive exposure to contaminated combustion air

will result in safety and performance related prob-

lems. To maintain combustion air quality, the recom-

mended source of combustion air is the outdoor air

supply. The outdoor air supplied for combustion

should be free from contaminants due to chemical

exposure that may be present from the following

sources.

Weights include largest gas heat option.

•

Commercial buildings

Indoor pools

Laundry rooms

Hobby or craft rooms

Chemical storage areas

FRONT

LEFT

The following substances should be avoided to

maintain outdoor combustion air quality.

•

Permanent wave solutions

Chlorinated waxes and cleaners

Chlorine based swimming pool cleaners

Water softening chemicals

De-icing salts or chemicals

Carbon tetrachloride

FIGURE 5 - UNIT 6 POINT LOAD

Halogen type refrigerants

Cleaning solvents (such as perchloroethylene)

Printing inks, paint removers, varnishes, etc.

Hydrochloric acid

Cements and glues

Anti-static fabric softeners for clothes dryers

Masonry acid washing materials

25-½"

47-½"

FRONT

LEFT

FIGURE 6 - UNIT CENTER OF GRAVITY

Unitary Products Group

035-19046-002-B-0104

119-7/16

30-11/32

See Detail A

Power

Entry

2-1/2

50-3/4

Con-

venience

Outlet

Control

Entry 7/8

4-1/4

11-1/2

Con-

venience

Outlet

Power

Entry

FRONT

7/8

For

Baserail

Dimensions

See

17-3/16

For Drain Dimensions

See Detail C

30-3/16

LEFT

24-3/16

6-3/16

Detail B

FIGURE 7 - UNIT DIMENSIONS

DETAIL A

DETAIL B

DETAIL C

TABLE 6: UNIT CLEARANCES

Top^*

Front^†

Rear^‡

72”

36”

12”

36”

0”

Right

Left

Bottom^**

Units must be installed outdoors. Overhanging struc-

ture or shrubs should not obstruct condenser air dis-

charge outlet.

NOTE: If the unit includes gas heating, locate the unit so

†.

‡.

The products of combustion must not be allowed to

accumulate within a confined space and re-circulate.

the flue exhaust is at least:

To remove the slide-out drain pan, a rear clearance of

sixty inches is required. If space is unavailable, the

drain pan can be removed through the front by separat-

ing the corner wall.

•

Three (3) feet above any forced air inlet located within 10

horizontal feet (excluding those integral to the unit).

**.

Four (4) feet below, four (4) horizontal feet from, or one

(1) foot above any door or gravity air inlet into the build-

ing.

Units may be installed on combustible floors made from

wood or class A, B or C roof covering materials.

NOTE: A one-inch clearance must be provided between

any combustible material and the supply ductwork

for a distance of 3 feet from the unit.

•

Four (4) feet from electric meters, gas meters, regula-

tors, and relief equipment.

Unitary Products Group

035-19046-002-B-0104

32-11/16

6-13/16

Supply

Air

6-13/16

Return

Air

27-1/2

LEFT

21-3/16

19-3/16

17-3/16

12-15/16

7-1/8

FRONT

14-

23/32

Bottom

Bottom Gas

Supply Entry

Bottom

Power, Control

and

Condensate

Entry

16-3/8

18-1/16

19-5/8

Convenience

Outlet Wiring

Entries

63-1/2

FIGURE 8 - BOTTOM DUCT OPENINGS (FROM ABOVE)

Unitary Products Group

035-19046-002-B-0104

18-1/4

Dot Plugs

28-1/4

Return

Air

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

Units are shipped with the side duct openings covered and a

covering over the bottom of the unit. For bottom duct applica-

tion, no duct cover changes are necessary. For side duct

application, remove the side duct covers and install over the

bottom duct openings. The panels removed from the side

duct connections are designed to be reused by securing each

panel to its respective downflow opening. But keep in mind

that the supply panel is installed with the painted surface UP,

facing the heat exchanger, while the return panel is installed

with the painted surface DOWN, facing the downflow duct

opening. The supply panel is secured with the bracket

(already in place from the factory) and two screws. It’s a snug

fit for the panel when sliding it between the heat exchanger

and unit bottom, but there is room. The return panel is

secured with four screws.

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 recog-

nized authority such as ASHRAE or SMACNA.

A closed return duct system should be used. This will not

preclude use of economizers or outdoor fresh air intake. The

supply and return air duct connections at the unit should be

made with flexible joints to minimize noise.

The supply and return air duct systems should be designed

for the CFM and static pressure requirements of the job. They

should NOT be sized to match the dimensions of the duct

connections on the unit.

Refer to Figure 8 for bottom air duct openings. Refer to Fig-

ure 9 for rear air duct openings.

Unitary Products Group

035-19046-002-B-0104

FIGURE 10 - PREDATOR^MAGNUM ROOF CURB DIMENSIONS

FIGURE 11 - SUNLINE™ TO PREDATOR^MAGNUM TRANSITION ROOF CURBS

When fastening ductwork to side duct flanges on

unit, insert screws through duct flanges only. DO

NOT insert screws through casing. Outdoor duct-

work must be insulated and water-proofed.

FIGURE 12 - SIDE PANELS WITH HOLE PLUGS

Note orientation. Panel is “insulation” side up.

Unitary Products Group

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

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. Dirty fil-

ters reduce the capacity of the unit and result in frosted coils

or safety shutdown. All units use four (4) 20”x25”x2” filters.

The unit should not be operated without filters properly

installed.

FIGURE 13 - RETURN DOWNFLOW PLENUM WITH

PANEL

Make sure that panel latches are properly positioned

on the unit to maintain an airtight seal.

THERMOSTAT WIRING

FIGURE 14 - DISCHARGE PANEL IN PLACE

CONDENSATE DRAIN

The thermostat should be located on an inside wall approxi-

mately 56 inch above the floor where it will not be subject to

drafts, sun exposure or heat from electrical fixtures or appli-

ances. Follow the manufacturer's instructions enclosed with

thermostat for general installation procedure. Seven (7) color-

coded, insulated wires should be used to connect the thermo-

stat to the unit. Refer to Table 7 for control wire sizing and

maximum length.

The side condensate drain is reversible and maybe re-ori-

ented to the rear of the cabinet to facilitate condensate pip-

ing. A condensate drain connection is available through the

base pan for piping inside the roof curb. Trap the connection

per Figure 15. The trap and drain lines should be protected

from freezing.

TABLE 7: CONTROL WIRE SIZES

Plumbing must conform to local codes. Use a sealing com-

pound on male pipe threads. Install condensate drain line

from the 3/4 inch NPT female connection on the unit to an

open drain.

Maximum Length^*

Wire Size

18 AWG

150 Feet

From the unit to the thermostat and back to the unit.

POWER AND CONTROL WIRING

Field wiring to the unit, fuses, and disconnects must conform

to provisions of National Electrical Code (NEC), ANSI/NFPA

No. 70 – Latest Edition (in U.S.A.), current Canadian Electri-

cal Code C221, and/or local ordinances. The unit must be

electrically grounded in accordance with NEC and CEC as

specified above and/or local codes.

Voltage tolerances which must be maintained at the com-

pressor terminals during starting and running conditions are

indicated on the unit Rating Plate and Table 1.

FIGURE 15 - CONDENSATE DRAIN

Unitary Products Group

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.

Refer to Figures 16, 17 and 18 for typical field wiring and to

the appropriate unit wiring diagram mounted inside control

doors for control circuit and power wiring information.

A disconnect must be utilized for these units. Factory

installed disconnects are available. If installing a disconnect

When connecting electrical power and control wiring

to the unit, water-proof connectors must be used so

that water or moisture cannot be drawn into the unit

during normal operation. The above water-proofing

conditions will also apply when installing a field sup-

plied disconnect switch.



(field supplied or York International supplied accessory),

refer to Figure 3 for the recommended mounting location.

Avoid damage to internal components if drilling

holes for disconnect mounting.

POWER WIRING DETAIL

Units are factory wired for the voltage shown on the unit

nameplate. Refer to Electrical Data Tables 8 and 9 to size

power wiring, fuses, and disconnect switch.

NOTE: Since not all local codes allow the mounting of a dis-

connect on the unit, please confirm compliance with

local code before mounting a disconnect on the unit.

Power wiring is brought into the unit through the side of the

unit or the basepan inside the curb.

Electrical line must be sized properly to carry the load. USE

COPPER CONDUCTORS ONLY. Each unit must be wired

with a separate branch circuit fed directly from the meter

panel and properly fused.

(

)

FIGURE 16 - ELECTRONIC THERMOSTAT FIELD WIRING

Unitary Products Group

035-19046-002-B-0104

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

035-19046-002-B-0104

CONTACTOR 1M

FACTORY OR FIELD

SUPPLIED DISCONNECT

GROUND

LUG

THREE

PHASE

POWER

SUPPLY

FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT

Unitary Products Group

035-19046-002-B-0104

TABLE 8: ELECTRICAL DATA DJ150 (12-1/2 TON) WITHOUT POWERED CONVENIENCE OUTLET

MCA

Max

Fuse*

Size

Max Fuse* Size

w/Power

Supply

Blower

Pwr

Min. Circuit

Ampacity

(Amps)

OD Fan

Motors

w/Power

Exhaust

(Amps)

Compressors

Exh Conv

Electric Heater Actual Heater

Exhaust

Voltage

Motor FLA Motor Outlet

Model No.

Amps

(Amps)

RLA

ea.

LRA

ea.

FLA

ea.

FLA

HP HP

None

13.5

18.0

25.5

40.6

61.9

76.1

67.1 67.4 72.6 80 80

67.1 67.4 73.8 80 80

82.6 83.0 89.5 80 90

2TP04521825

2TP04522425

2TP04523625

2TP04525425

None

37.5

50.0

208

230

460

20.0 146.0

1.5

0.8

0.6

10.9 16.1

5.5

0.0

70.8 102.1 108.6 109.0 115.5 110 110

112.7 154.5 161.0 161.4 167.9 175 175

110

175

125

175

61.9

67.8

85.8

67.1 67.4 72.6 80 80

74.3 74.6 81.1 80 80

92.3 92.7 99.2 90 100

2TP04521825

2TP04522425

2TP04523625

2TP04525425

None

18.0

24.0

34.0

54.0

43.3

57.7

20.0 146.0

10.9 16.1

5.5

2.2

1.8

0.0

100

125

175

100

150

175

81.8 115.9 122.4 122.7 129.2 125 125

129.9 143.5 150.0 150.4 156.9 175 175

27.4

33.7

42.7

57.7

71.6

21.6

26.8

30.2 29.6 32.4 35 35

37.2 36.4 39.9 35 40

2TP04521846

2TP04522446

2TP04523646

2TP04525446

None

22.6

30.1

42.7

67.8

8.4

6.7

73.0

60.0

5.3

4.1

8.1

6.0

46.2 45.5

61.2 60.5

45 50

60 70

75.1 74.3 77.8 80 90

23.5 23.4 25.3 25 30

2TP04521858

2TP04522458

2TP04523658

2TP04525458

18.1

24.1

34.1

54.2

29.2

31.4 30 30

575

36.4 36.2 38.6 35 40

48.4 48.3 50.6 50 50

59.5 59.3 61.7 70 70

57.1

Maximum HACR breaker of the same AMP size is applicable.

TABLE 9: ELECTRICAL DATA DJ150 (12-1/2 TON) WITH POWERED CONVENIENCE OUTLET

MCA

Max

Fuse*

Size

Max Fuse* Size

w/Power

Supply

Blower

Pwr

Min. Circuit

Ampacity

(Amps)

OD Fan

Motors

w/Power

Exhaust

(Amps)

Compressors

Exh Conv

Electric Heater Actual Heater

Exhaust

Voltage

Motor FLA Motor Outlet

Model No.

Amps

(Amps)

RLA

ea.

LRA

ea.

FLA

ea.

FLA

HP HP

100

110

150

200

100

125

150

175

None

13.5

18.0

25.5

40.6

71.9

73.0

88.6

77.1 77.4 82.6 90 90

79.5 79.8 86.3 90 90

95.1 95.5 102.0 90 100

2TP04521825

2TP04522425

2TP04523625

2TP04525425

None

37.5

50.0

208

230

460

20.0 146.0

1.5

0.8

0.6

10.9 16.1

5.5

10.0

100

125

175

70.8 114.6 121.1 121.5 128.0 125 125

112.7 167.0 173.5 173.9 180.4 175 175

71.9

80.3

77.1 77.4 82.6 90 90

86.8 87.1 93.6 90 90

2TP04521825

2TP04522425

2TP04523625

2TP04525425

None

18.0

24.0

34.0

54.0

43.3

57.7

20.0 146.0

10.9 16.1

5.5

2.2

1.8

10.0

5.0

98.3 104.8 105.2 111.7 100 110

110

150

175

81.8 128.4 134.9 135.2 141.7 150 150

129.9 156.0 162.5 162.9 169.4 175 175

32.4

39.9

35.2 34.6 37.4 40 40

43.4 42.7 46.2 40 45

52.5 51.7 55.2 50 60

67.5 66.7 70.2 70 70

81.3 80.6 84.1 90 90

27.5 27.4 29.3 30 30

2TP04521846

2TP04522446

2TP04523646

2TP04525446

None

22.6

30.1

42.7

67.8

8.4

6.7

73.0

60.0

5.3

4.1

8.1

6.0

77.8

25.6

31.8

2TP04521858

2TP04522458

2TP04523658

2TP04525458

18.1

24.1

34.1

54.2

34.2

36.4 35 35

575

4.0

41.4 41.2 43.6 40 45

53.4 53.3 55.6 60 60

64.5 64.3 66.7 70 70

62.1

Maximum HACR breaker of the same AMP size is applicable.

Unitary Products Group

035-19046-002-B-0104

TABLE 10: PHYSICAL DATA

Model

DJ150

Component

Blower, Centrifugal (Dia. X Wd. in.)

15 x 15

Evaporator

Blower

Motor, Standard (HP)

Motor, Optional (HP)

Rows

Fins per Inch

Height (in.)

Evaporator

Coil

13.2

Face Area (ft. each)

Propeller Dia. (in., each)

Motor (HP, each)

CFM, Nominal (each)

Rows (each)

1/3

3000

Condenser

Fan

(4 per Unit)

Condenser

Coil

(2 per unit)

Fins per Inch

Height (in. each)

14.5

Face Area (ft. each)

System 1 (lb./oz.)

System 2 (lb./oz.)

Quantity

11/0

11/8

Refrigerant

Charge

Compressors

Air Filters

Type

Scroll

25x20x2

Size (Wd. x Ht. x Thickness in.)

Number Per Unit

OPTIONAL ELECTRIC HEAT

TABLE 11: MINIMUM SUPPLY AIR CFM

Heater

Unit Model Size, Nominal Tons

The factory-installed heaters are wired for single point power

supply. Power supply need only be brought into the single

point terminal block.

12.5

Voltage

Minimum Supply Air CFM

These CSA approved heaters are located within the central

compartment of the unit with the heater elements extending

into the supply air chamber.

208/230

3750

Fuses are supplied, where required, by the factory. Some kW

sizes require fuses and other do not. Refer to Table 11 for

minimum CFM limitations and to Tables 8 through 9 for elec-

trical data.

480

600

Unitary Products Group

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

Temp Rise

Input (MBH) Output (MBH)

(°F)

Size

150

Opt.

180

240

144

192

10-40

20-50

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" Z223.1 (in U.S.A.) or

the current Gas Installation Codes CSA-B149.1 (in Canada)

should be followed in all cases unless superseded by local

codes or gas utility requirements. Refer to the Pipe Sizing

Table 13. The heating value of the gas may differ with locality.

The value should be checked with the local gas utility.

NOTE: There may be a local gas utility requirement specify-

ing a minimum diameter for gas piping. All units

require a one-inch pipe connection at the entrance

fitting.

FIGURE 21 - BOTTOM ENTRY GAS PIPING

TABLE 13: GAS PIPE SIZING - CAPACITY OF PIPE

Nominal Iron Pipe Size

Length of

Pipe (ft.)

3/4 in.

278

190

152

130

115

105

1 in.

520

350

285

245

215

195

180

170

160

150

1-1/4 in.

1050

730

100

590

500

440

400

370

350

320

305

NOTE: Maximum capacity of pipe in cubic feet of gas per

hour based upon a pressure drop of 0.3 inch W.C.

and 0.6 specific gravity gas.

FIGURE 20 - SIDE ENTRY GAS PIPING

NOTE: There may be a local gas utility requirement specify-

ing a minimum diameter for gas piping. All units

require a 3/4 inch pipe connection at the entrance

fitting. Line should not be sized smaller than the

entrance fitting size.

Unitary Products Group

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 arrange-

ments are shown in Figures 20 and 21. All pipe nipples, fit-

tings, 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.

Never test for gas leaks with an open flame. use a

commercially available soap solution made specifi-

cally for the detection of leaks to check all connec-

tions. A fire or explosion may result causing property

damage, personal injury or loss of life.

Gas piping recommendations:

1. A drip leg and a ground joint union must be installed in

the gas piping.

2. Where required by local codes, a manual shut-off valve

must be installed outside of the unit.

3. Use wrought iron or steel pipe for all gas lines. Pipe dope

should be applied sparingly to male threads only.

The furnace and its individual shut-off valve must be

disconnected from the gas supply piping system

during any pressure testing at pressures in excess

of 1/2 PSIG.

Natural gas may contain some propane. Propane is

an excellent solvent and will quickly dissolve white

lead and most standard commercial compounds. A

special pipe dope must be used when assembling

wrought iron or steel pipe. Shellac based com-

pounds such as Gaskolac or Stalastic, and com-

pounds such as Rectorseal #5, Clydes’s or John

Crane may be used.

Pressures greater than 1/2 PSIG will cause gas

valve damage resulting in a hazardous condition. If it

is subjected to a pressure greater than 1/2 PSIG, the

gas valve must be replaced.

The furnace must be isolated from the gas supply

piping system by closing its individual manual shut-

off valve during any pressure testing of the gas sup-

ply piping system at test pressures equal to or less

than 1/2 PSIG.

4. All piping should be cleaned of dirt and scale by ham-

mering on the outside of the pipe and blowing out loose

particles. Before initial start-up, be sure that all gas lines

external to the unit have been purged of air.

LP UNITS, TANKS AND PIPING

All gas heat units are shipped from the factory equipped for

natural gas use only. The unit may be converted in the field

for use with LP gas with accessory kit model number

1NP0441.

5. The gas supply should be a separate line and installed in

accordance with all safety codes as prescribed under

“Limitations”.

All LP gas equipment must conform to the safety standards of

the National Fire Protection Association.

6. A 1/8-inch NPT plugged tapping, accessible for test gage

connection, must be installed immediately upstream of

the gas supply connection to the unit.

For satisfactory operation, LP gas pressure must be 10.5

inch W.C. at the unit under full load. Maintaining proper gas

pressure depends on three main factors:

7. After the gas connections have been completed, open

the main shut-off valve admitting normal gas pressure to

the mains. Check all joints for leaks with soap solution or

other material suitable for the purpose. NEVER USE A

FLAME.

1. The vaporization rate which depends on the temperature

of the liquid and the “wetted surface” area of the con-

tainer(s).

Unitary Products Group

035-19046-002-B-0104

2. The proper pressure regulation. (Two-stage regulation is

recommended).

MOTORIZED OUTDOOR DAMPER

The Motorized Outdoor Damper can be a factory installed

option or a field installed accessory. If factory installed, refer

to the instructions included with the outdoor air hood to com-

plete the assembly. Field installed Motorized Outdoor Damp-

ers accessories include complete instructions for installation.

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.

ECONOMIZER

The Economizer can be a factory installed option or a field

installed accessory. If factory installed, refer to the instruc-

tions included with the outdoor air hood to complete the

assembly. Field installed Economizer accessories include

complete instructions for installation.

LP gas is an excellent solvent and will quickly dissolve white

lead and most standard commercial compounds. A special

pipe dope must be used when assembling wrought iron or

steel pipe for LP. Shellac base compounds such as Gaskolac

or Stalastic, and compounds such as Rectorseal #5, Clyde’s,

or John Crane may be used.

There are two Economizer options:

1. Down Flow application with barometric relief hood stan-

dard.

Check all connections for leaks when piping is completed

using a soap solution. NEVER USE A FLAME.

2. Horizontal Flow application that requires the purchase of

a barometric relief hood.

POWER EXHAUST

The Power Exhaust can be a factory installed option or a field

installed accessory. If factory installed, refer to the instruc-

tions included with the outdoor air hood to complete the

assembly. Field installed Power Exhaust accessories include

complete instructions for installation.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could

result in serious injury, death or property damage.

Never test for gas leaks with an open flame. use a

commercially available soap solution made specifi-

cally for the detection of leaks to check all connec-

tions. A fire or explosion may result causing property

damage, personal injury or loss of life.

The Power Exhaust factory installed option is for Down Flow

application only.

There are two field installed Power Exhaust accessories:

1. Down Flow application.

VENT AND COMBUSTION AIR

2. Horizontal Flow application that requires the purchase of

a barometric relief hood.

Venting slots in the heating compartment access panel

remove the need for a combustion air hood. The gas heat

flue exhaust is routed through factory installed exhaust piping

with screen. If necessary, a flue exhaust extension may be

installed at the point of installation.

RAIN HOOD

The following procedure should be used when assembling a

rain hood onto a unit.

FACTORY INSTALLED OPTIONS/

FIELD INSTALLED ACCESSORIES

All of the hood components, including the filters, the gasket-

ing and the hardware for assembling, are packaged and

located between the condenser coil section and the main unit

cabinet, if the unit has factory installed options. If field

installed accessories are being installed all parts necessary

for the installation comes in the accessory.

ELECTRIC HEAT

Electric heaters are available as field installed accessories.

Refer to electric heat instructions for installation. These heat-

ers mount in the heat compartment with the heating elements

extending into the supply air chamber. All electric heaters are

fused and intended for use with single point power supply.

1. Remove the hood components, filters, gasketing and the

hardware from the box.

2. Follow the instructions included with the hood to com-

plete the installation.

Unitary Products Group

035-19046-002-B-0104

•

For a dual enthalpy operation, carefully turn the set point

adjusting screw fully clockwise past the "D" setting.

ECONOMIZER AND POWER EXHAUST SET POINT

ADJUSTMENTS AND INFORMATION

POWER EXHAUST DAMPER SET POINT (WITH OR WITH-

OUT POWER EXHAUST)

Remove the top rear access panel from the unit. Locate the

economizer control module, where the following adjustments

will be made.

•

With no power exhaust option, adjust the Exhaust Air

Adjustment Screw fully clockwise. This will allow 2nd

stage cooling to operate.

•

With power exhaust option, each building pressurization

requirement will be different. The point at which the

power exhaust comes on is determined by the econo-

mizer damper position (Percent Open). The Exhaust Air

Adjustment Screw should be set at the Percent Open of

the economizer damper at which the power exhaust is

needed. It can be set from 0 to 100% damper open.

Extreme care must be exercised in turning all set

point, maximum and minimum damper positioning

adjustment screws to prevent twisting them off.

MINIMUM POSITION ADJUSTMENT

•

Check that the damper blades move smoothly with bind-

ing; carefully turn the Minimum Position Adjust screw

(found on the damper control module) fully clockwise

and then set the thermostat indoor fan switch to the ON

position and then OFF or energize and de-energize ter-

minals “R” to “G”.

INDOOR AIR QUALITY AQ

Indoor Air Quality (indoor sensor input): Terminal AQ accepts

a +2 to +10 Vdc signal with respect to the (AQ1) terminal.

When the signal is below it's set point, the actuator is allowed

to modulate normally in accordance with the enthalpy and

mixed air sensor inputs. When the AQ signal exceeds it's set

point setting and there is no call for free cooling, the actuator

is proportionately modulated from the 2 to 10 Vdc signal, with

2 Vdc corresponding to full closed and 10 Vdc corresponding

to full open. When there is no call for free cooling, the damper

position is limited by the IAQ Max damper position setting.

When the signal exceeds it's set point (Demand Control Ven-

tilation Set Point) setting and there is a call for free cooling,

the actuator modulates from the minimum position to the full

open position based on the highest call from either the mixed

air sensor input or the AQ voltage input.

•

With the thermostat set to the indoor fan ON position or

terminals “R” to “G” energized, turn the Minimum Posi-

tion Adjusting screw (located on the damper control

module) counterclockwise until the desired minimum

damper position has been attained.

ENTHALPY SET POINT ADJUSTMENT

The enthalpy set point may now be set by selecting the

desired set point shown in the Enthalpy Set Point Adjustment

Figure 22. Adjust as follows:

•

For a single enthalpy operation carefully turn the set

point adjusting screw (found on the damper control mod-

ule) to the "A", "B", "C" or "D" setting corresponding to

the lettered curve of the Enthalpy Set Point Adjustment

Figure 22.

•

Optional CO Space Sensor Kit Part # 2AQ04700324

Optional CO Sensor Kit Part # 2AQ04700424

Replace the top rear access panel on the unit.

Unitary Products Group

035-19046-002-B-0104

CONTROL POINT

APPROX. ⁰F (⁰C)

AT 50% RH

CONTROL

CURVE

85 90 95 100 105 110

(29) (32) (35) (38) (41) (43)

73 (23)

70 (21)

67 (19)

63 (17)

(27)

(24)

(21)

(18)

(16)

(13)

(10)

(7)

(4)

(2)

40 45

(4) (7)

65 70 75 80

(24) (27)

105 110

(41) (43)

(2)

50 55 60

(10) (13) (16)

85 90

(29) (32)

100

(38)

(21)

(35)

(18)

APPROXIMATE DRY BULB TEMPERATURE - ⁰F (⁰C)

FIGURE 22 - ENTHALPY SET POINT CHART

Exhaust Air

Adjustment

Screw

EXH

Set

TR1

Exhaust Air LED

Damper Min.

Position

Screw

Vac

HOT

Vac

COM

EXH

Min

Pos

Indoor Air Quality

Max. Adjustment

Screw

IAQ

Max

Indoor Air Quality

LED

IAQ

AQ1

SO+

Indoor Air Quality

Min. Adjustment

Screw

IAQ

Min

Free

Cool

Free Cooling LED

SR+

EF1

Economizer Enthalpy

Set Point Adjustment

Screw

FIGURE 23 - HONEYWELL ECONOMIZER CONTROL W7212

Unitary Products Group

035-19046-002-B-0104

PHASING



Predator Magnum DJ units are properly phased and pro-

tected by a Phase Monitor from the factory. If the unit does

not start up, the electrical connection to the unit may be mis-

phased. 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 oper-

ate in only one direction. If the scroll is drawing low amper-

age, has similar suction and discharge pressures, or

producing a high noise level, the scroll is misphased.)

* NEVER LOOSEN

Scroll compressors require proper rotation to oper-

ate correctly. Units are properly phased at the fac-

tory. Do not change the internal wiring to make the

blower condenser fans, or compressor rotate cor-

rectly.

SPAN LENGTH

DEFL. FORCE

BLOWER ROTATION

Check for proper supply air blower rotation. If the blower is

rotating backwards, the line voltage at the unit point of power

connection is misphased (See ‘PHASING’).

TABLE 14: SUPPLY AIR LIMITATIONS

FIGURE 24 - BELT ADJUSTMENT

Unit

Minimum

Maximum

DJ150

3750

6250

BELT TENSION

Procedure for adjusting belt tension:

The tension on the belt should be adjusted as shown in Fig-

ure 24.

1. Loosen six nuts (top and bottom) A.

2. Adjust by turning (B).

3. Never loosen nuts (C).

4. Use belt tension checker to apply a perpendicular

force to one belt at the midpoint of the span as

shown. Deflection distance of 4mm (5/32”) is

obtained.

To determine the deflection distance from normal

position, use a straight edge from sheave to sheave

as reference line. The recommended deflection

force is as follows:

Tension new belts at the max. deflection force rec-

ommended for the belt section. Check the belt ten-

sion at least two times during the first 24 hours of

operation. Any retensioning should fall between the

min. and max. deflection force values.

5. After adjusting retighten nuts (A).

Unitary Products Group

035-19046-002-B-0104

* †

TABLE 15: DJ150, 12-1/2 TON STANDARD MOTOR DOWN SHOT BLOWER PERFORMANCE

TURNS OPEN^**

ESP^‡

W^††

CFM

BHP CFM

BHP

0.4

0.6

0.8

1.0

1.2

1.4

5078 3630 3.89 4809 3103 3.33 4594 3053 3.27 4360 2478 2.66 4090 2093 2.24 3812 1798 1.93

4865 3456 3.71 4584 2961 3.17 4349 2912 3.12 4106 2318 2.49 3814 1964 2.11

4642 3284 3.52 4356 2828 3.03 4089 2776 2.98 3840 2137 2.29

4408 3114 3.34 4124 2705 2.90 3815 2647 2.84

4164 2947 3.16 3889 2592 2.78

3910 2787 2.99

Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.

Blower performance includes two-inch throwaway filters.

†.

‡.

ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been

deducted from the total static pressure of the blower.

**.

“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.

W = Watts

††.

* †

TABLE 16: DJ150, 12-1/2 TON OPTIONAL MOTOR DOWN SHOT BLOWER PERFORMANCE

TURNS OPEN^**

ESP^‡

W^††

CFM

BHP CFM

BHP

5994 5400 5.79 5565 4369 4.69 5488 4169 4.47 5264 3599 3.86 4990 3085 3.31 4738 2812 3.02

5824 5216 5.59 5368 4186 4.49 5289 3991 4.28 5049 3437 3.69 4763 2937 3.15 4491 2655 2.85

5641 5022 5.39 5170 4012 4.30 5076 3807 4.08 4822 3272 3.51 4528 2790 2.99 4235 2497 2.68

5444 4819 5.17 4971 3846 4.12 4847 3618 3.88 4584 3103 3.33 4286 2644 2.83 3969 2340 2.51

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

5233 4609 4.94 4771 3687 3.95 4604 3426 3.67 4335 2933 3.15 4035 2499 2.68

5009 4394 4.71 4571 3537 3.79 4346 3233 3.47 4074 2762 2.96 3777 2356 2.53

4771 4174 4.48 4370 3395 3.64 4074 3040 3.26 3802 2590 2.78

4520 3951 4.24 4169 3262 3.50 3786 2850 3.06

4255 3728 4.00 3966 3137 3.36

3976 3505 3.76 3763 3020 3.24

Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.

Blower performance includes two-inch throwaway filters.

†.

‡.

ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been

deducted from the total static pressure of the blower.

**.

“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.

W = Watts

††.

Unitary Products Group

035-19046-002-B-0104

* †

TABLE 17: DJ150, 12-1/2 TON STANDARD MOTOR SIDE SHOT BLOWER PERFORMANCE

TURNS OPEN^**

ESP^‡

W^††

CFM

BHP CFM

BHP

5201 3162 3.39 4966 2796 3.00 4681 2405 2.58 4355 2054 2.20

0.4

0.6

0.8

1.0

1.2

1.4

5220 3395 3.64 4942 2980 3.20 4657 2608 2.80 4358 2230 2.39 4007 1890 2.03

4944 3194 3.43 4661 2806 3.01 4378 2572 2.76 4016 2057 2.21

5003 3490 3.74 4647 2988 3.20 4380 2636 2.83 4030 2257 2.42

4724 3290 3.53 4363 2875 3.08 4012 2505 2.69

4428 3040 3.26

Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.

Blower performance includes two-inch throwaway filters.

†.

‡.

ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been

deducted from the total static pressure of the blower.

**.

“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.

W = Watts

††.

* †

TABLE 18: DJ150, 12-1/2 TON OPTIONAL MOTOR SIDE SHOT BLOWER PERFORMANCE

TURNS OPEN^**

ESP^‡

W^††

CFM

BHP CFM

BHP

CFM

BHP CFM

BHP

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

2.6

6447 5315 5.70 6207 4760 5.1046 5966 4205 4.51 5717 3716 3.98 5470 3307 3.55

6110 4917 5.27 5965 4464

5772 4519 4.85 5741 4274

4.79

4.58

4.34

4.13

3.94

3.71

3.47

3.07

5740 4023 4.31 5430 3501 3.75 5126 3054 3.28

5503 3821 4.10 5162 3294 3.53 4849 2870 3.08

5244 3611 3.87 4882 3101 3.33 4530 2667 2.86

4941 3387 3.63 4589 2906 3.12 4225 2502 2.68

4651 3178 3.41 4284 2716 2.91 3858 2280 2.45

4365 2983 3.20 3951 2516 2.70 3491 2058 2.21

6235 5521 5.92 5628 4407 4.73 5474 4048

5881 5137 5.51 5384 4205 4.51 5248 3854

5695 4950 5.31 5123 3996 4.29 5014 3670

5471 4728 5.07 4919 3828 4.11 4732 3460

5242 4514 4.84 4656 3611 3.87 4438 3240

4954 4231 4.54 4339 3380 3.62 3905 2861

3998 2740 2.94 3618 2316 2.48

3631 2497 2.68

4585 3934 4.22 4022 3149 3.38

4217 3637 3.90

3848 3340 3.58

Blower performance for gas heat includes maximum number of heat tubes available for each tonnage.

Blower performance includes two-inch throwaway filters.

†.

‡.

ESP (External Static Pressure) given is that available for the supply and return air duct system. All internal resistances have been

deducted from the total static pressure of the blower.

**.

“Turns Open” refers to the setting of the variable pitch motor sheave, where “0 Turns Open” is fully closed.

W = Watts

††.

NOTES FOR TABLE 15 THROUGH TABLE 18:

•

Blower performance includes dry coil and two-inch

filters.

Blower performance for gas heat includes the maximum

number of heat tubes available for each tonnage.

•

ESP (External Static Pressure) given is that available for

the supply and return air duct system. All internal resis-

tances have been deducted from the total static pressure

of the blower.

Unitary Products Group

035-19046-002-B-0104

TABLE 19: INDOOR BLOWER SPECIFICATIONS

MOTOR

MOTOR SHEAVE

BLOWER SHEAVE

MODEL

BELT

RPM Eff.

SF Frame Datum Dia. (in.) Bore (in.) Model Datum Dia. (in.) Bore (in.) Model

1725 80% 1.15

1725 87% 1.15

3.4 - 4.4

4.3 - 5.3

7/8

1VM50

1VP56

7.0

6.7

AK74

BK77

A54

DJ150

184T

1 1/8

BX55

AIR BALANCE

Start the supply air blower motor. Adjust the resistances in both the supply and the return air duct systems to balance the air

distribution throughout the conditioned space. The job specifications may require that this balancing be done by someone other

than the equipment installer.

CHECKING AIR QUANTITY

METHOD ONE

METHOD TWO

1. Remove the dot plugs from the duct panel (for location of

the dot plugs see Figure 9).

1. Drill two 5/16 inch holes, one in the return air duct as

close to the inlet of the unit as possible, and another in

the supply air duct as close to the outlet of the unit as

possible.

2. Insert eight-inches of 1/4 inch metal tubing into the air-

flow on both sides of the indoor coil.

2. Insert eight inches of 1/4 inch metal tubing into the air-

flow of both return and supply air ducts of the unit.

NOTE: The tubes must be inserted and held in a position

perpendicular to the air flow so that velocity pres-

sure will not affect the static pressure readings.

NOTE: The tubes must be inserted and held in position per-

pendicular to the airflow so that velocity pressure

will not affect the static pressure readings.

3. Use an Inclined Manometer or Magnehelic to determine

the pressure drop across a dry evaporator coil. Since the

moisture on an evaporator coil can vary greatly, measur-

ing the pressure drop across a wet coil under field condi-

tions could be inaccurate. To assure a dry coil, the

compressors should be de-activated while the test is

being run.

3. Use an Inclined Manometer or Magnehelic to determine

the pressure drop across the unit. This is the External

Static Pressure (ESP).

4. Select the indoor blower specifications for the unit from

Table 19, 3 or 5 H.P. Motor.

5. Determine the number of turns the variable pitch motor

sheave is open.

NOTE: De-energize the compressors before taking any test

measurements to assure a dry evaporator coil.

6. Select the correct blower performance table for the unit

from Tables 15 - 18.

4. The CFM through the unit with clean 2 inch filters can be

determined from the pressure drop indicated by the

manometer by referring to Figure 25.

7. Determine the unit Measured CFM from the Blower Per-

formance Table, External Static Pressure and number of

turns the variable pitch motor sheave is open.

5. To adjust Measured CFM to Required CFM, see ’SUP-

PLY AIR DRIVE ADJUSTMENT’.

8. To adjust Measured CFM to Required CFM, see ’SUP-

PLY AIR DRIVE ADJUSTMENT’.

6. After adjustments have been completed, remove the

tubes and replace the dot plugs.

9. After adjustments have been completed, remove the

tubes and seal holes.

NOTE: With the addition of field installed accessories

repeat this procedure.

Failure to properly adjust the total system air quan-

tity can result in extensive blower damage.

Failure to properly adjust the total system air quan-

tity can result in extensive blower damage.

Unitary Products Group

035-19046-002-B-0104

Predator DJ 150 Units

Indoor Coil Pressure Drop vs. Airflow

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

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.

Use the equation to determine the required DD for the new

motor sheave,

Before making any blower speed changes review

the installation for any installation errors, leaks or

undesirable systems effects that can result in loss of

airflow.

4,000 CFM

• 4.0 in. = 4.21 in.

)

(

3,800 CFM

Even small changes in blower speed can result in

substantial changes in static pressure and BHP.

BHP and AMP draw of the blower motor will

increase by the cube of the blower speed. Static

pressure will increase by the square of the blower

speed. Only qualified personnel should make blower

speed changes, strictly adhering to the fan laws.

Use Table 21 to locate the DD nearest to 4.21 in. Close the

sheave to 1 turn open.

New BHP

= (Speed increase)³• BHP at 3,800 CFM

At unit start-up, the measured CFM may be higher or lower

than the required CFM. To achieve the required CFM, the

speed of the drive may have adjusted by changing the datum

diameter (DD) of the variable pitch motor sheave as

described below:

= (Speed increase)³• Original BHP

= New BHP

Required CFM

Measured CFM

• Existing DD = New DD

)

(

New motor Amps

= (Speed increase)³• Amps at 3,800 CFM

Use the following tables and the DD calculated per the above

equation to adjust the motor variable pitch sheave.

= (Speed increase)³• Original Amps

= New Amps

Unitary Products Group

035-19046-002-B-0104

TABLE 20: ADDITIONAL STATIC RESISTANCE

Electric Heat KW^†

† ‡

CFM

Cooling Only

Economizer

3700

3900

4100

4300

4500

4700

4900

5100

5300

5500

5700

5900

6100

6300

0.20

0.23

0.25

0.28

0.30

0.33

0.36

0.39

0.42

0.45

0.48

0.52

0.56

0.60

0.04

0.05

0.06

0.07

0.18

0.20

0.22

0.24

0.26

0.29

0.31

0.34

0.37

0.40

0.43

0.46

0.49

0.53

0.21

0.23

0.25

0.28

0.30

0.33

0.35

0.38

0.41

0.44

0.47

0.50

0.53

0.56

0.22

0.24

0.26

0.29

0.31

0.34

0.37

0.40

0.43

0.46

0.49

0.53

0.56

0.59

0.26

0.28

0.31

0.34

0.37

0.40

0.43

0.46

0.49

0.53

0.56

0.59

0.62

0.65

Add these resistance values to the available static resistance in the respective Blower Performance Tables.

†.

‡.

Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.

The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return

air duct system is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation.

For gas heating, the UCB monitors the "W1" call but does not

TABLE 21: MOTOR SHEAVE DATUM DIAMETERS

handle the operation of the gas furnace. An ignition control

board controls the gas heater operation. For electric heat

units, the UCB passes the call to the electric heater. In both

cases, when the "W1" call is sensed, the indoor air blower is

energized following a specified heating delay.

1VM50x7/8

(3 HP Motor)

1VP56x1-1/8

(5 HP Motor)

Datum

Diameter

Datum

Diameter

Turns Open

1/2

4.4

1-1/2

5.3

If at any time a call for both heating and cooling are present,

the heating operation will be performed. If operating, the cool-

ing system is halted as with a completion of a call for cooling.

Heating always takes priority.

4.3

5.2

4.2

5.1

1-1/2

4.1

2-1/2

5.0

4.0

4.9

COOLING SEQUENCE OF OPERATION

CONTINUOUS BLOWER

2-1/2

3.9

3-1/2

4.8

3.8

4.7

3-1/2

3.7

4-1/2

4.6

By setting the room thermostat fan switch to "ON," the supply

air blower will operate continuously.

3.6

4.5

4-1/2

3.5

5-1/2

4.4

INTERMITTENT BLOWER

3.4

4.3

With the room thermostat fan switch set to "AUTO" and the

system switch set to either the "AUTO" or "HEAT" settings,

the blower is energized whenever a cooling or heating opera-

tion is requested. The blower is energized after any specified

delay associated with the operation.

OPERATION

SEQUENCE OF OPERATIONS OVERVIEW



For the Predator Magnum series of units, the thermostat

makes a circuit between "R" and "Y1" for the first stage of

cooling.

When energized, the indoor blower has a minimum run time

of 30 seconds. Additionally, the indoor blower has a delay of

10 seconds between operations.

The call is passed to the unit control board (UCB), which then

determines whether the requested operation is available and,

if so, which components to energize.

Unitary Products Group

035-19046-002-B-0104

NO OUTDOOR AIR OPTIONS

gize compressor #1. If the outdoor air is above the set point,

"Y2" will energize compressor #2.

When the thermostat calls for the first stage of cooling, the

low-voltage control circuit from “R” to “Y1” and “G” is com-

pleted. 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. After completing the specified fan on delay

for cooling, the UCB will energize the blower motor.

Once the thermostat has been satisfied, it will de-energize Y1

and Y2. If the compressors have satisfied their minimum run

times, the compressors and condenser fans are de-ener-

gized. Otherwise, the unit operates each cooling system until

the minimum run times for the compressors have been com-

pleted. Upon the final compressor de-energizing, the blower

is stopped following the elapse of the fan off delay for cooling,

and the economizer damper goes to the closed position. If

the unit is in continues fan operation the economizer damper

goes to the min. position.

When the thermostat calls for the second stage of cooling,

the low-voltage control circuit from “R” to “Y2” is completed.

The control board energizes the first available compressor. If

free cooling is being used for the first stage of cooling, com-

pressor #1 is energized. If compressor #1 is active for first

stage cooling or the first compressor is locked-out, compres-

sor #2 is energized. In free-cooling mode, if the call for the

second stage of cooling continues for 20 minutes, compres-

sor #2 is energized, provided it has not been locked-out.

ECONOMIZER WITH DUAL ENTHALPY SENSORS -

The operation with the dual enthalpy sensors is identical to

the single sensor except that a second enthalpy sensor is

mounted in the return air. This return air sensor allows the

economizer to choose between outdoor air and return air,

whichever has the lowest enthalpy value, to provide maxi-

mum operating efficiency.

If there is an initial call for both stages of cooling, the UCB will

delay energizing compressor #2 by 30 seconds in order to

avoid a power rush.

ECONOMIZER (SINGLE OR DUAL) WITH POWER

EXHAUST -

Once the thermostat has been satisfied, the it will de-ener-

gize Y1 and Y2. If the compressors have satisfied their mini-

mum run times, the compressors and condenser fans are de-

energized. Otherwise, the unit operates each cooling system

until the minimum run times for the compressors have been

completed. Upon the final compressor de-energizing, the

blower is stopped following the elapse of the fan off delay for

cooling.

This system operates as specified above with one addition.

The power exhaust motor is energized 45 seconds after the

actuator position exceeds the exhaust fan set point on the

economizer control. When the power exhaust is operating,

the second stage of mechanical cooling will not operate. As

always, the "R" to "G" connection provides minimum position

but does not provide power exhaust operation.

MOTORIZED OUTDOOR AIR DAMPERS -

* To be available, a compressor must not be locked-out due

to a high or low-pressure switch or freezestat trip and the

anti-short cycle delay (ASCD) must have elapsed.

This system operation is the same as the units with no out-

door air options with one exception. When the "R" to "G" cir-

cuit is complete, the motorized damper drives open to a

position set by the thumbwheel on the damper motor. When

the "R" to "G" circuit is opened, the damper spring returns

fully closed.

ECONOMIZER WITH SINGLE ENTHALPY SENSOR -

When the room thermostat calls for "first-stage" cooling, the

low voltage control circuit from "R" to "G" and "Y1" is com-

pleted. The UCB energizes the blower motor (if the fan switch

on the room thermostat is set in the "AUTO" position) and

drives the economizer dampers from fully closed to their min-

imum position. If the enthalpy of the outdoor air is below the

set point of the enthalpy controller (previously determined),

"Y1" energizes the economizer. The dampers will modulate to

maintain a constant supply air temperature as monitored by

the discharge air sensor. If the outdoor air enthalpy is above

the set point, "Y1" energizes compressor #1, condenser fan

motor #1, and condenser fan motor #2 (if the ambient tem-

perature is above 60°F).

COOLING OPERATION ERRORS

Each cooling system is monitored for operation outside of the

intended parameters. Errors are handled as described below.

All system errors override minimum run times for compres-

sors.

HIGH-PRESSURE LIMIT SWITCH

During cooling operation, if a high-pressure limit switch

opens, the UCB will de-energize the associated compressor,

initiate the ASCD (Anti-short cycle delay), and, if the other

compressor is idle, stop the condenser fans. If the call for

cooling is still present at the conclusion of the ASCD, the

UCB will re-energize the halted compressor.

When the thermostat calls for "second-stage" cooling, the low

voltage control circuit from "R" to "Y2" is completed. The UCB

energizes the first available compressor If the enthalpy of the

outdoor air is below the set point of the enthalpy controller

(i.e. first stage has energized the economizer), "Y2" will ener-

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Should a high-pressure switch open three times within two

hours of operation, the UCB will lock-out the associated com-

pressor and flash a code (see Table 28). If the other com-

pressor is inactive, the condenser fans will be de-energized.

of compressor operation. The defrost cycle will begin immedi-

ately following the elapse of the minimum run time.

When operating in low ambient mode, the UCB will not lock-

out the compressors due to a freezestat trip. However, a

freezestat trip will de-energize the associated compressor. If

the call for cooling is still present at the end of the ASCD and

the freezestat has closed, the unit will resume operation.

LOW-PRESSURE LIMIT SWITCH

The low-pressure limit switch is not monitored during the ini-

tial 30 seconds of a cooling system's operation. For the fol-

lowing 30 seconds, the UCB will monitor the low-pressure

switch to ensure it closes. If the low-pressure switch fails to

close after the 30-second monitoring phase, the UCB will de-

energize the associated compressor, initiate the ASCD, and,

if the other compressor is idle, stop the condenser fans.

SAFETY CONTROLS

The unit control board monitors the following inputs for each

cooling system:

1. A suction line freezestat to protect against low evapora-

tor temperatures due to a low airflow or a low return air

temperature, (opens at 26 ± 5 °F and resets at 38 ± 5°F).

Once the low-pressure switch has been proven (closed dur-

ing the 30-second monitor period described above), the UCB

will monitor the low-pressure limit switch for any openings. If

the low-pressure switch opens for greater than 5 seconds,

the UCB will de-energize the associated compressor, initiate

the ASCD, and, if the other compressor is idle, stop the con-

denser fans.

2. A high-pressure switch to protect against excessive dis-

charge pressures due to a blocked condenser coil or a

condenser motor failure, (opens at 380 ± 10 psig and

resets at 300 ± 10 psig).

3. A low-pressure switch to protect against loss of refriger-

ant charge, (opens at 7 ± 3 psig and resets at 22 ± 5

psig).

If the call for cooling is still present at the conclusion of the

ASCD, the UCB will re-energize the halted compressor.

Should a low-pressure switch open three times within one

hour of operation, the UCB will lock-out the associated com-

pressor and flash a code (Table 28). If the other compressor

is inactive, the condenser fans will be de-energized.

The above pressure switches are hard-soldered to the unit.

The refrigeration systems are independently monitored and

controlled. On any fault, only the associated system will be

affected by any safety/preventive action. The other refrigerant

system will continue in operation unless it is affected by the

fault as well.

FREEZESTAT

During cooling operation, if a freezestat opens, the UCB will

de-energize the associated compressor, initiate the ASCD,

and, if the other compressor is idle, stop the condenser fans.

If the call for cooling is still present at the conclusion of the

ASCD, the UCB will re-energize the halted compressor.

The unit control board monitors the temperature limit switch

of electric heat units and the temperature limit switch and the

gas valve of gas furnace units.

COMPRESSOR PROTECTION

Should a freezestat open three times within two hours of

operation, the UCB will lock-out the associated compressor

and flash a code (Table 28). If the other compressor is inac-

tive, the condenser fans will be de-energized.

The compressors also have inherent (internal) protection. If

there is an abnormal temperature rise in a compressor, the

protector will open to shut down the compressor. The UCB

incorporates features to minimize compressor wear and dam-

age. An anti-short cycle delay (ASCD) is utilized to prevent

operation of a compressor too soon after its previous run.

Additionally, a minimum run time is imposed any time a com-

pressor is energized.

LOW AMBIENT COOLING

To determine when to operate in low ambient mode, the UCB

has a pair of terminals connected to a temperature-activated

switch set at 45ºF. When the low ambient switch is closed

and the thermostat is calling for cooling, the UCB will operate

in the low ambient mode.

The ASCD is initiated on unit start-up and on any compressor

reset or lock-out.

FLASH CODES

Low ambient mode operates the compressors in this manner:

10 minutes on, 5 minutes off. The indoor blower is operated

throughout the cycle. The 5-minute off period is necessary to

defrost the indoor coil.

The UCB will initiate a flash code associated with errors

within the system. Refer to UNIT CONTROL BOARD FLASH

CODES Table 28.

Low ambient mode always begins with compressor opera-

tion. Compressor minimum run time may extend the minutes

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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.

LIMIT

SWITCH

OPENS °F

HEATER

UNIT (TONS)

VOLTAGE

12.5

150

ELECTRIC HEATING SEQUENCE OF OPERATIONS

208/230

The following sequence describes the operation of the elec-

tric heat section.

Two-stage heating:

480

600

a. Upon a call for first stage heat by the thermostat, the

heater relay (RA) will be energized. After completing

the specified fan on delay for heating, the UCB will

energize the blower motor. If the second stage of

heat is required, heater relay (RB) will be energized.

After completing the specified fan on delay for heat-

ing, the UCB will energize the blower motor.

b. The thermostat will cycle the electric heat to satisfy

the heating requirements of the conditioned space.

FLASH CODES

The UCB will initiate a flash code associated with errors

within the system. Refer to UNIT CONTROL BOARD FLASH

CODES Table 28.

ELECTRIC HEATING OPERATION ERRORS

TEMPERATURE LIMIT

RESET

If the UCB senses zero volts from the high temperature limit,

the indoor blower motor is immediately energized.

Remove the call for heating by lowering the thermostat set-

ting lower than the conditioned space temperature.This

resets any flash codes.

This limit is monitored regardless of unit operation status, i.e.

the limit is monitored at all times.

ELECTRIC HEAT ANTICIPATOR SETPOINTS

If the temperature limit opens three times within one hour, it

will lock-on the indoor blower motor and a flash code is initi-

ated (See Table 28).

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 23 for the required electric

heat anticipator setting.

SAFETY CONTROLS

The UCB monitors the temperature limit switch of electric

heat units.

The control circuit includes the following safety controls:

TABLE 23: ELECTRIC HEAT ANTICIPATOR

SETPOINTS

LIMIT SWITCH (LS)

This control is located inside the heater compartment and is

set to open at the temperature indicated in the Electric Heat

Limit Setting Table 22. It resets automatically. The limit switch

operates when a high temperature condition, caused by inad-

equate supply air flow occurs, thus shutting down the heater

and energizing the blower.

SETTING, AMPS

0.13

0.1

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If the unit fails after three ignition attempts, the furnace is

locked-out for one hour. The furnace is monitored during this

one-hour period for unsafe conditions.

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 volt-

age has been sensed at the GV, the UCB will initiate the fan

on delay for heating, energizing the indoor blower the speci-

fied delay has elapsed.

RECYCLE OPERATION

When a flame is lost after the flame stabilization period, a

recycle operation occurs. If the unit fails after five recycle

attempts, the furnace is locked-out for one hour.

GAS HEATING OPERATION ERRORS

LOCK-OUT

When the thermostat has been satisfied, heating calls are

ceased. The GV is immediately closed. The blower is de-

energized after the fan off delay for heating has elapsed. The

draft motor performs a 30-second post purge.

A one-hour lockout occurs following three retries or five recy-

cles. During the one-hour lockout, flame detection, limit con-

ditions, and main valves are tested. Any improper results will

cause the appropriate action to occur. Recycling the low volt-

age power cancels the lock-out.

IGNITION CONTROL BOARD

FIRST STAGE OF HEATING

TEMPERATURE LIMIT

When the ICB receives a call for first stage of heating, “W1,”

the draft motor is energized. Once the draft motor has been

proven, a 30-second purge is initiated. At the end of the

purge, both main valves of the GV are opened, and the spark

ignitor is energized for 10 seconds. The ICB then checks for

the presence of flame. If flame is detected, the ICB enters a

flame stabilization period. If flame was not detected, both

main valves close, and a retry operation begins.

If the UCB senses zero volts from the high temperature limit,

the indoor blower motor is immediately energized. When the

UCB again senses 24 volts from the temperature limit, the

draft motor will perform a 15-second post-purge and the

indoor blower will be de-energized following the elapse of the

fan off delay for heating.

This limit is monitored regardless of unit operation status, i.e.

this limit is monitored at all time.

During the flame stabilization period, a loss of the flame for 2

seconds will cause the main valves to close and the retry

operation to begin. After the flame stabilization period, a loss

of flame for 3/4 second will cause the main valves to close

and the retry operation to begin.

If the temperature limit opens three times within one hour, it

will lock-on the indoor blower motor and flash code is initiated

(See Table 28).

FLAME SENSE

At the conclusion of the flame stabilization period, the ICB will

operate the gas heat in high fire (both valves open) for an

additional 100 seconds (for a total for 120 seconds of high fire

operation). After this 100 seconds, the ICB will then use the

call for the second stage of heat to control the second main

valve of the GV.

Flame sensing occurs at all times. If “W1” is not present and

a flame is sensed for 2 seconds, the draft motor is energized

and the main valve is kept off. The ICB halts any operation

until a flame is not detected. Once the flame detection is lost,

the ICB performs a post-purge. Normal operation is allowed

concurrently with the purge (i.e. this purge can be considered

the purge associated with a call for “W1”).

When “W1” is satisfied, both valves are closed.

SECOND STAGE OF HEATING

If “W1” is present, a flame is sensed, but the main valve is not

energized, the draft motor is energized until the flame detec-

tion is lost. Normal operation is now allowed.

When the ICB receives a call for the second stage of heating,

“W2,” the ICB conducts a complete first stage ignition

sequence. If this sequence is satisfied, the second main

valve of the GV is opened.

The flame detection circuitry continually tests itself. If the ICB

finds the flame detection circuitry to be faulty, the ICB will not

permit an ignition sequence. Also, the draft motor is ener-

gized. If this failure should occur during an ignition cycle the

failure is counted as a recycle.

When “W2” is satisfied, the second main valve is closed.

RETRY OPERATION

When a flame is lost or is not detected during an attempt to

achieve ignition, a retry operation occurs. A 30-second purge

is performed between ignition attempts.

GAS VALVE

The UCB and ICB continuously monitor the GV.

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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.

The auxiliary limit switch is wired in series with the limit

switch. As such, the UCB cannot distinguish the auxiliary limit

and the gas heat limit switch operation except the auxiliary is

manual reset. Consequently, the control will respond in the

same manner as outlined above under “Limit Switch”.

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).

When voltage is no longer sensed at the GV, the UCB will de-

energize the indoor blower following the elapse of the fan off

delay for heating.

TABLE 24: GAS HEAT LIMIT CONTROL SETTINGS

# of HX Tubes

Main Limit Setting

195°F

160°F

If voltage has been sensed at the GV for at least 15 seconds

during the fan on delay for heating and GV voltage or “W1” is

lost, the indoor blower is forced on for the length of the fan off

delay for heating.

Rollout = 300°F, Auxiliary Limit = 200°F

The ICB monitors the Pressure and Rollout switches of gas

heat units.

During a call for heat, if the UCB does not sense voltage at

the GV for a continuous five-minute period the UCB will ini-

tiate a flash code (Table 28). The indoor blower motor will not

be locked-on while there is no GV voltage.

The control circuit includes the following safety controls:

PRESSURE SWITCH (PS)

However, if during a normal ignition sequence, the NPC has

been tested to be open, IDM energized, NPC closes and then

the first stage main valve (MV1) is detected as being on, the

ignition sequence stops and the IDM is de-energized. (Since

the NPC is wired serially with the main valve relays, de-ener-

gizing the IDM will open the NPC). This failure is counted as

a recycle and will result in an eventual recycle lockout. If the

main valve continues to be energized after the IDM is de-

energized the IDM is re-energized. The second stage (MV2)

main valve is not monitored for closure after energization.

Once the draft motor has reached full speed and closes the

pressure switch during a normal ignition sequence, if the

pressure sw opens for 2 seconds, the GV will be de-ener-

gized, the ignition cycle is aborted, and the ICB flashes the

appropriate code. See Table 29 Ignition Control Flash Codes.

The draft motor is energized until the pressure switch closes

or “W1” is lost.

ROLLOUT SWITCH (ROS)

The rollout switch is wired in series with the pressure switch.

As such, the ICB cannot distinguish the rollout switch opera-

tion from that of the pressure switch.

SAFETY CONTROLS

The UCB monitors the temperature limit switch of gas heat

units.

Consequently, the control will only respond in the same man-

ner as outlined above under “Pressure Switch”. An open roll-

out will inhibit the gas valve from actuating.

The control circuit includes the following safety controls:

INTERNAL MICROPROCESSOR FAILURE

LIMIT SWITCH (LS)

If the ICB detects an internal failure, it will turn cease all out-

puts, ignore inputs, and display the proper flash code for con-

trol replacement. The ICB remains in this condition until

replaced.

This control is located inside the gas heat compartment and

is set to open at the temperature indicated in the Gas Heat

Limit Control Settings Table 24. It resets automatically. The

limit switch operates when a high temperature condition,

caused by inadequate supply air flow occurs, thus shutting

down the heater and energizing the blower.

FLASH CODES

The UCB will initiate a flash code associated with errors

within the system. Refer to UNIT CONTROL BOARD FLASH

CODES Table 28.

AUXILIARY LIMIT SWITCH (ALS)

This control is located inside the supply air compartment and

is set to open at the temperature indicated in the Gas Heat

Limit Control Settings Table 24. It resets manually. The limit

switch operates when a high temperature condition, caused

by inadequate supply air flow occurs, thus shutting down the

heater and energizing the blower.

RESETS

Remove the call for heating by lowering the thermostat set-

ting lower than the conditioned space temperature. This

resets any flash codes.

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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. Turn unit electrical power on.

NOTE: Prior to each cooling season, the crankcase heaters

must be energized at least 10 hours before the sys-

tem is put into operation.

2. Set the room thermostat setting to lower than the room

temperature.

3. First stage compressors will energize after the built-in

time delay (five minutes).

TABLE 25: GAS HEAT ANTICIPATOR SETPOINTS

SETTING, AMPS

4. The second stage of the thermostat will energize second

stage compressor if needed.

0.65

0.1

POST START CHECK LIST

1. Verify proper system pressures for both circuits.

2. Measure the temperature drop across the evaporator

coil.

START-UP (GAS HEAT)

PRE-START CHECK LIST

ꢀ

(

)

Complete the following checks before starting the unit.

1. Check the type of gas being supplied. Be sure that it is

the same as listed on the unit nameplate.

FIGURE 26 - TYPICAL FLAME

START-UP (COOLING)

PRESTART CHECK LIST

2. Make sure that the vent outlet and combustion air inlet

are free of any debris or obstruction.

OPERATING INSTRUCTIONS

After installation has been completed:

1. Check the electrical supply voltage being supplied. Be

sure that it is the same as listed on the unit nameplate.

2. Set the room thermostat to the off position.

3. Turn unit electrical power on.

This furnace is equipped with an intermittent pilot and

automatic re-ignition system. DO NOT attempt to

manually light the pilot.

4. Set the room thermostat fan switch to on.

5. Check indoor blower rotation.

LIGHTING THE MAIN BURNERS

1. Turn “OFF” electric power to unit.

2. Turn room thermostat to lowest setting.

•

If blower rotation is in the wrong direction. Refer to

Phasing Section in general information section.

3. Turn gas valve counter-clockwise to “ON” position (see

Figure 27).

•

Check blower drive belt tension.

6. Check the unit supply air (CFM).

4. Turn “ON” electric power to unit.

7. Measure evaporator fan motor's amp draw.

8. Set the room thermostat fan switch to off.

9. Turn unit electrical power off.

5. If thermostat set temperature is above room tempera-

ture, the main burners will ignite. If a second stage of

heat is called for, the main burners for second stage heat

will ignite for the second stage heat.

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2. Using the outlet pressure port on the gas valve, connect

a manometer to monitor the manifold pressure.

POST START CHECKLIST

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 adjust-

ment screws.

1. Check for gas leaks in the unit piping as well as the sup-

ply piping.

4. Turn on power to the unit.

5. Set thermostat to call for second stage heat and start fur-

nace.

6. If necessary, using a screwdriver, turn the second stage

adjustment screw (adjacent to the “HI” marking on the

valve) clockwise to increase manifold pressure or coun-

terclockwise to decrease manifold pressure. Be sure not

to over-fire the unit on second stage.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could

result in serious injury, death or property damage.

7. After the high manifold pressure has been checked,

adjust the thermostat to call for first stage heat.

Never test for gas leaks with an open flame. use a

commercially available soap solution made specifi-

cally for the detection of leaks to check all connec-

tions. A fire or explosion may result causing property

damage, personal injury or loss of life.

8. If necessary, using a screwdriver, turn the first stage

adjustment screw (adjacent to the “LO” marking on the

valve) clockwise to increase manifold pressure or

counterclockwise to decrease manifold pressure. Be

sure not to under-fire the unit on first stage.

2. Check for correct manifold gas pressures. (See ’CHECK-

ING GAS INPUT’.)

9. Once pressure has been checked, replace the plastic

cap covering the HI and LO pressure adjustment screws.

3. Check the supply gas pressure. It must be within the lim-

its shown on the rating nameplate. Supply pressure

should be checked with all gas appliances in the building

at full fire. At no time should the standby gas pressure

exceed 13 in. or the operating pressure drop below 5.0 in

for natural gas units. If gas pressure is outside these

limits, contact the local gas utility or propane supplier for

corrective action.

NOTE: When using natural gas, the manifold pressure for

second stage (100% input) should be 3.5 IWG ±

0.3. The manifold pressure for first stage (60%

input) when using natural gas should be 1.5 IWG ±

0.3.

CHECKING GAS INPUT

NATURAL GAS

SHUT DOWN

1. Set the thermostat to the lowest temperature setting.

2. Turn “OFF” all electric power to unit.

3. Open gas heat access panel.

This unit has two stages of gas heat. The first stage is 60% of

the full fire input and is considered the minimum input for the

furnace. The intended input for each furnace is shown in the

table below. The following Table applies to units operating on

60 Hz power only.

4. Turn gas valve clockwise to “OFF” position (See Figure

27).

TABLE 26: GAS HEAT STAGES

MANIFOLD GAS PRESSURE ADJUSTMENT

2nd Stage

Input (100%

Btuh)

1st Stage

Input (60%

Btuh)

# of Burner Tubes

This gas furnace has two heat stages. Therefore, the gas

valve has two adjustment screws located under a plastic pro-

tective cover. The second stage (100% input) adjustment

screw is adjacent to the “HI” marking on the valve and the

first stage (60% input) adjustment screw is located adjacent

to the “LO” marking on the valve (See Figure 27).

180,000

240,000

108,000

144,000

To determine the rate of gas flow (second Stage).

1. Turn of all other gas appliances connected to the gas

meter.

Manifold pressure adjustment procedure.

Adjust second stage (100% input) pressure first, then adjust

first stage (60% input) pressure.

2. Turn on the furnace and make sure the thermostat is

calling for Second stage (100% input) heat.

1. Turn off all power to the unit.

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3. 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.

TABLE 27: GAS RATE CUBIC FEET PER HOUR

Seconds

for One

Rev.

Size of Test Dial

1/2 cu. ft.

1 cu. ft.

4. 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).

180

150

129

113

100

360

300

257

225

200

180

164

150

138

129

120

113

106

100

5. If necessary, adjust the high pressure regulator as dis-

cussed in the section “Manifold Gas Pressure Adjust-

ment”. Be sure not to over-fire the furnace on Second

stage. If in doubt, it is better to leave the Second stage of

the furnace slightly under-fired. Repeat Steps 1-5.

To determine the rate of gas flow (First Stage)

1. Turn of all other gas appliances connected to the gas

meter.

2. Turn on the furnace and make sure the thermostat is

calling for first stage (60% input) heat.

3. Even when the thermostat is calling for first stage heat,

the unit will light on second stage and will run on Second

stage for 1 minute. Allow this one-minute time period to

expire and be certain the unit is running on first stage.

4. 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.

5. 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).

6. If necessary, adjust the low pressure regulator as dis-

cussed in the section “Manifold Gas Pressure Adjust-

ment”. Be sure not to under-fire the furnace on first

stage. If in doubt, it is better to leave the first stage of the

furnace slightly over-fired (greater than 60% input).

Repeat Steps 1-6.

NOTE: To find the Btu input, multiply the number of cubic

feet of gas consumed per hour by the Btu content of

the gas in your particular locality (contact your gas

company for this information as it varies widely from

area to area).

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EXAMPLE:

3. Disconnect wiring to the gas valves and spark igniter(s).

Remove the manifold & gas valve assembly. Orifices can

now be inspected and/or replaced.

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

To service burners, complete step 4.

4. Remove the heat shield on top of the manifold supports.

Burners are now accessible for inspection and/or

replacement.

NOTE: Reverse the above procedure to replace the assem-

Btu/ft.³. The result of 199,000 Btuh is within 5% of the

192,000 Btuh rating of the furnace.

blies.

Make sure that burners are level and seat at the rear of the

gas orifice.

ADJUSTMENT OF TEMPERATURE RISE

The temperature rise (the difference of temperature between

the return air and the heated air from the furnace) must lie

within the range shown on the CSA rating plate and the data

in Table 25.

After the temperature rise has been determined, the CFM can

be calculated as follows:

0.8

(1.08 ⋅ ∆°F)

-----------------------------

CFM = Btu Input •

ꢀ

After about 20 minutes of operation, determine the furnace

temperature rise. Take readings of both the return air and the

heated air in the ducts (about 6 feet from the furnace) where

they will not be affected by radiant heat. Increase the blower

CFM to decrease the temperature rise; decrease the blower

CFM to increase the rise (See ’SUPPLY AIR DRIVE

ADJUSTMENT’).

NOTE: Each gas heat exchanger size has a minimum

allowable CFM. Below this CFM, the limit will open

below this rating.

BURNERS/ORIFICES INSPECTION/SERVICING

Before checking or changing burners, pilot or orifices,

CLOSE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF

ALL POWER TO THE UNIT.

1. Open the union fitting just upstream of the unit gas valve

and downstream from the main manual shut-off valve in

the gas supply line.

FIGURE 27 - TYPICAL GAS VALVE

2. Remove the screws holding each end of the manifold to

the manifold supports.

Unitary Products Group

035-19046-002-B-0104

CHARGING THE UNIT

TABLE 28: UNIT CONTROL BOARD FLASH CODES

Flash Code

On Steady

Heart Beat

1 Flash

Description

Control Failure - Replace Control

Normal Operation

The DJ150 (12-1/2 Ton) High Efficiency Unit, uses a TXV

metering device. Charge unit to 10º sub-cooling at the TXV.

Not Applicable

TROUBLESHOOTING

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

7 Flashes

8 Flashes

Control waiting ASCD

HPS1 - Compressor Lock out

HPS2 - Compressor Lock out

LPS1 - Compressor Lock out

LPS2 - Compressor Lock out

FS1 - Compressor Lock out

FS2 - Compressor Lock out

Troubleshooting of components may require open-

ing the electrical control box with the power con-

nected to the unit. Use extreme care when

working with live circuits! Check the unit name-

plate for the correct line voltage and set the voltme-

ter to the correct range before making any

connections with line terminals.

Ignition Control Locked Out/

Ignition Control Failure / Limit Switch Trip / No

Jumper Plug in Heat Section

9 Flashes

Compressors Locked Out On Low

10 Flashes

11 Flashes

12 Flashes

Outdoor Air Temperature

When not necessary, shut off all electric power to the

unit prior to any of the following maintenance proce-

dures so as to prevent personal injury.

Compressors Locked Out Because The

Economizer Is Using Free Cooling

Fan Overload Switch Trip - Not Applicable On This

Unit

13 Flashes

14 Flashes

OFF

Compressor Held Off Due To Low Voltage*

EEPROM Storage Failure (Control Failure)

No Power or Control Failure

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dan-

gerous operation which could cause injury to person

and/or damage unit components. Verify proper oper-

ation after servicing.

These flash codes do not represent alarms.

TABLE 29: IGNITION CONTROL FLASH CODES

FLASHES

STEADY ON

HEARTBEAT

FAULT CONDITIONS

CHECK

PREDATOR^MAGNUM FLASH CODES

Control Failure

Control

Normal Operation

Not Applicable

Various flash codes are utilized by the unit control board

(UCB) to aid troubleshooting. Flash codes are distinguished

by the short on and off cycle used (approximately 200ms on

and 200ms off). To show normal operation, the control board

flashes a 1 second on, 1 second off “heartbeat” during normal

operation. This is to verify that the UCB is functioning cor-

rectly. Do not confuse this with an error flash code. To prevent

confusion, a 1-flash, flash code is not used.

Pressure Switch

Stuck Closed

Pressure Switch

Pressure Switch Failed

To Close

Venter Pressure Switch

Vent Blocked

Main Limit

AUX Limit

Limit Switch Open

Current alarms are flashed on the UCB LED. The alarm his-

tory can be checked by pressing and releasing the ALARMS

button on the UCB. The UCB will cycle through the last five

(5) alarms, most recent to oldest, separating each alarm flash

code by approximately 2 seconds.

Flame Present With Gas

Off First Stage Gas Valve

Energized With W1 Off

Second Stage Gas Valve

Energized With First

Stage

Gas Valve

Gas Valve Off

In some cases, it may be necessary to “zero” the ASCD for

the compressors in order to perform troubleshooting. To reset

all ASCDs for one cycle, press and release the UCB TEST

button once.

Gas Flow

Gas Pressure

Gas Valve

Ignition Lockout

Flame Sensor

No Power Or Control

Failure

24VAC or Control

STEADY OFF

Unitary Products Group

035-19046-002-B-0104

Loss of

Call for

Heating?

Monitored

Systems

Problem?

Yes

Call for

Heating?

Programming?

Yes

Heat Off

Yes

Program

Unit

Control

Board

Call for 2nd

Stage

Cooling

Call for

Heat

Trip/Failure

Yes

Energize ID

Call for

First

Monitor

Blower Motor

Cooling?

Stage?

Yes

Call for 1st

Stage

Cooling

Yes

Turn off ID

Blower Motor

Fan on

>30 secs?

Fan off

>10 secs?

Yes

Lossof Call

for ID Blower?

Call for

ID Blower?

Loss of Call

for Cooling?

Cool Off

FIGURE 28 - BASIC TROUBLESHOOTING FLOWCHART

Yes

Voltage @

Gas Valve?

Call for

heat?

Power to

Unit

Energize ID

Blower

Initialize ASCD

Montior

FIGURE 29 - POWER ON FLOW CHART

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035-19046-002-B-0104

ꢀ

;

ꢀ

;

ꢀ

FIGURE 30 - TRIP FAILURE FLOW CHART

Unitary Products Group

035-19046-002-B-0104

On calls for cooling, the supply air blower motor is operating

but compressor #1 is not (the room thermostat fan switch is in

the “AUTO” position).

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 oper-

ate. If both stages of cooling are requested simulta-

neously and the economizer provides free cooling,

following a short delay compressor #1 will be energized

unless it is locked out. If compressor #1 is locked out,

compressor #2 is energized. Compressor #2 is always

energized in place of compressor #1 when compressor

#1 is requested but locked out.

1. Turn the thermostat fan switch to the ON position. If the

supply air blower motor does not energize, go to Step 3.

2. If the blower motor runs with the fan switch in the ON

position but will not run after the first compressor has

energized when the fan switch is in the AUTO position,

check the room thermostat for contact between R and G

in the AUTO position during calls for cooling.

3. If the supply air blower motor does not energize when

the fan switch is set to ON, check that line voltage is

being supplied to the contacts of the M3, contactor, and

that the contactor is pulled in. Check for loose wiring

between the contactor and the supply air blower motor.

2. If no economizer is installed or the economizer is not

opening to provide free cooling and compressor #1 does

not energize on a call for cooling, check for line voltage

at the compressor contactor, M1, and that the contactor

is pulled in. Check for loose wiring between the contac-

tor and the compressor.

4. If M3 is pulled in and voltage is supplied to M3, lightly

touch the supply air blower motor housing. If it is hot, the

motor may be off on internal protection. Cancel any

thermostat calls and set the fan switch to AUTO. Wait for

the internal overload to reset. Test again when cool.

3. If M1 is pulled in and voltage is supplied at M1, lightly

touch the compressor housing. If it is hot, the compres-

sor may be off on inherent protection. Cancel any calls

for cooling and wait for the internal overload to reset.

Test again when cool.

5. If M3 is not pulled in, check for 24 volts at the M3 coil. If

24 volts are present at M3 but M3 is not pulled in,

replace the contactor.

4. If M1 is not pulled in, check for 24 volts at the M1 coil. If

24 volts are present and M1 is not pulled in, replace the

contactor.

6. Failing the above, if there is line voltage supplied at M3,

M3 is pulled in, and the supply air blower motor still does

not operate, replace the motor.

5. Failing the above, if voltage is supplied at M1, M1 is

pulled in, and the compressor still does not operate,

replace the compressor.

7. If 24 volts is not present at M3, check that 24 volts is

present at the UCB supply air blower motor terminal,

“FAN”. If 24 volts is present at the FAN, check for loose

wiring between the UCB and M3.

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.

8. If 24 volts is not present at the “FAN” terminal, check for

24 volts from the room thermostat. If 24 volts are not

present from the room thermostat, check for the follow-

ing:

7. If 24 volts is not present at the C1 terminal, check for 24

volts from the room thermostat at the UCB Y1 terminal.

If 24 volts is not present from the room thermostat, check

for the following:

a. Proper operation of the room thermostat (contact

between R and G with the fan switch in the ON posi-

tion and in the AUTO position during operation

calls).

a. 24 volts at the thermostat Y1 terminal

b. Proper wiring between the room thermostat and the

UCB, i.e. Y1 to Y1, Y2 to Y2

c. Loose wiring from the room thermostat to the UCB.

b. Proper wiring between the room thermostat and the

UCB.

8. If 24 volts is present at the UCB Y1 terminal, the com-

pressor may be out due to an open high-pressure switch,

low-pressure switch, or freezestat. Check for 24 volts at

the HPS1, LPS1, and FS1 terminals of the UCB. If a

switch has opened, there should be a voltage potential

between the UCB terminals, e.g. if LPS1 has opened,

there will be a 24-volt potential between the LPS1 termi-

nals.

c. Loose wiring from the room thermostat to the UCB.

9. If 24 volts is present at the room thermostat but not at the

UCB, check for proper wiring between the thermostat

and the UCB, i.e. that the thermostat G terminal is con-

nected to the G terminal of the UCB, and for loose wir-

ing.

9. If 24 volts is present at the UCB Y1 terminal and none of

the protection switches have opened, the UCB may have

10. If the thermostat and UCB are properly wired, replace

the UCB.

Unitary Products Group

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” posi-

tion).

1. If installed, check the position of the economizer blades.

If the blades are open, the economizer is providing free

cooling. If the second stage of cooling is requested, fol-

lowing a short delay, compressor #1 will be energized

unless it is locked out. Typically, compressor #2 is ener-

gized only during free cooling if the call for the second

stage of cooling persists for 20 minutes.

NOTE: While the above step will reset any lockouts, com-

pressor #1 may be held off for the ASCD. See the

next step.

10. If 24 volts is present at the UCB Y1 terminal and none of

the switches are open and the compressor is not locked

out, the UCB may have the compressor in an ASCD.

Check the LED for an indication of an ASCD cycle. The

ASCD should time out within 5 minutes. Press and

release the TEST button to reset all ASCDs.

2. Compressor #2 will not energize simultaneously with

compressor #1 if a call for both stages of cooling is

received. The UCB delays compressor #2 by 30 sec-

onds to prevent a power surge. If after the delay com-

pressor #2 does not energize on a second stage call for

cooling, check for line voltage at the compressor contac-

tor, M2, and that the contactor is pulled in. Check for

loose wiring between the contactor and the compressor.

11. If 24 volts is present at the UCB Y1 terminal and the

compressor is not out due to a protective switch trip,

repeat trip lock out, or ASCD, the economizer terminals

of the UCB may be improperly wired. Check for 24 volts

at the Y1 “OUT” terminal of the UCB. If 24 volts is

present, trace the wiring from Y1 “OUT” for incorrect wir-

ing. If 24 volts is not present at the Y1 “OUT” terminal,

the UCB must be replaced.

3. If M2 is pulled in and voltage is supplied at M2, lightly

touch the compressor housing. If it is hot, the compres-

sor may be off on inherent protection. Cancel any calls

for cooling and wait for the internal overload to reset.

Test again when cool.

12. For units without 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, the

jumper in the Mate-N-Lock plug, and in the wiring from

the Mate-N-Lock plug to the Y1 “ECON” terminal.

4. If M2 is not pulled in, check for 24 volts at the M2 coil. If

24 volts is present and M2 is not pulled in, replace the

contactor.

5. Failing the above, if voltage is supplied at M2, M2 is

pulled in, and the compressor still does not operate,

replace the compressor.

13. 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” termi-

nal. If nothing is found, the economizer DME may have

faulted and is failing to return the 24-volt “call” to the Y1

“ECON” terminal even though the economizer is not pro-

viding free cooling. To test, disconnect the Mate-N-Locks

and jumper between the WHITE and YELLOW wires of

the UCB’s Mate-N-Lock plug. If compressor #1 ener-

gizes, there is a fault in the economizer wiring or DME.

6. If 24 volts is not present at M2, check for 24 volts at the

UCB terminal, C2. If 24 volts are present, check for

loose wiring between C2 and the compressor contactor.

7. If 24 volts is not present at the C2 terminal, check for 24

volts from the room thermostat at the UCB Y2 terminal. If

24 volts is not present from the room thermostat, check

for the following:

a. 24 volts at the thermostat Y2 terminal

b. Proper wiring between the room thermostat and the

UCB, i.e. Y1 to Y1, Y2 to Y2

c. Loose wiring from the room thermostat to the UCB.

14. The UCB can be programmed to lock out compressor

operation during free cooling and in low ambient condi-

tions. These options are not enabled by default. Local

York distributors can test the UCB for this programming.

8. If 24 volts is present at the UCB Y2 terminal, the com-

pressor may be out due to an open high-pressure switch,

low-pressure switch, or freezestat. Check for 24 volts at

the HPS2, LPS2, and FS2 terminals of the UCB. If a

switch has opened, there should be a voltage potential

between the UCB terminals, e.g. if LPS2 has opened,

there will be 24 volts of potential between the LPS2 ter-

minals.

15. If none of the above corrected the error, test the integrity

of the UCB. Disconnect the C1 terminal wire and jumper

it to the Y1 terminal. DO NOT jump the Y1 to C1 termi-

nals. If the compressor engages, the UCB has faulted.

16. If none of the above correct the error, replace the UCB.

9. If 24 volts is present at the UCB Y2 terminal and none of

the protection switches have opened, the UCB may have

Unitary Products Group

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. If 24 volts is not present at the C1 terminal, check for 24

volts from the room thermostat at the UCB Y1 terminal.

If 24 volts are not present at the UCB Y1 terminal, the

UCB may have faulted. Check for 24 volts at the Y1

ECON terminal. If 24 volts is not present at Y1 “ECON”,

the UCB has faulted. The UCB should de-energize all

compressors on a loss of call for the first stage of cool-

ing, i.e. a loss if 24 volts at the Y1 terminal.

remove any call for cooling at the thermostat or by dis-

connecting the thermostat wiring at the Y2 UCB terminal.

This will reset any compressor lock outs.

NOTE: While the above step will reset any lock outs, com-

pressor #1 will be held off for the ASCD, and com-

pressor #2 may be held off for a portion of the

ASCD. See the next step.

8. If 24 volts are present at the UCB Y1 terminal, the com-

pressor may be out due to an open high-pressure switch,

low-pressure switch, or freezestat. Check for 24 volts at

the HPS1, LPS1, and FS1 terminals of the UCB. If a

switch has opened, there should be a voltage potential

between the UCB terminals, e.g. if LPS1 has opened,

there will be a 24-volt potential between the LPS1 termi-

nals.

10. If 24 volts is present at the UCB Y2 terminal and none of

the switches are open and the compressor is not locked

out, the UCB may have the compressor in an ASCD.

Check the LED for an indication of an ASCD cycle. The

ASCD should time out within 5 minutes. Press and

release the TEST button to reset all ASCDs.

11. The UCB can be programmed to lock out compressor

operation during free cooling and in low ambient condi-

tions. These options are not enabled by default. Local

York distributors can test the UCB for this programming.

9. If 24 volts is present at the UCB Y1 terminal and none of

the protection switches have opened, the UCB may have

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,

remove any call for cooling. This will reset any compres-

sor lock outs.

12. If none of the above corrected the error, test the integrity

of the UCB. Disconnect the C2 terminal wire and jumper

it to the Y2 terminal. DO NOT jump the Y2 to C2 termi-

nals. If the compressor engages, the UCB has faulted.

13. If none of the above correct the error, replace the UCB.

NOTE: While the above step will reset any lock outs, com-

pressor #2 will be held off for the ASCD, and com-

pressor #1 may be held off for a portion of the

ASCD. See the next step.

On a call for cooling, the supply air blower motor and com-

pressor #2 are operating but compressor #1 is not (the room

thermostat fan switch is in the “AUTO” position).

10. If 24 volts is present at the UCB Y1 terminal and none of

the switches are open and the compressor is not locked

out, the UCB may have the compressor in an ASCD.

Check the LED for an indication of an ASCD cycle. The

ASCD should time out within 5 minutes. Press and

release the TEST button to reset all ASCDs.

1. Compressor #2 is energized in place of compressor #1

when compressor #1 is unavailable for cooling calls.

Check the UCB for alarms indicating that compressor #1

is locked out. Press and release the ALARMS button if

the LED is not flashing an alarm.

2. Check for line voltage at the compressor contactor, M1,

and that the contactor is pulled in. Check for loose wiring

between the contactor and the compressor.

11. If 24 volts is present at the UCB Y1 terminal and the

compressor is not out due to a protective switch trip,

repeat trip lock out, or ASCD, the economizer terminals

of the UCB may be improperly wired. Check for 24 volts

at the Y1 “OUT” terminal of the UCB. If 24 volts is

present, trace the wiring from Y1 “OUT” for incorrect wir-

ing. If 24 volts is not present at the Y1 “OUT” terminal,

the UCB must be replaced.

3. If M1 is pulled in and voltage is supplied at M1, lightly

touch the compressor housing. If it is hot, the compres-

sor may be off on inherent protection. Cancel any calls

for cooling and wait for the internal overload to reset.

Test again when cool.

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 the

contactor.

12. For units without 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, the jumper in the Mate-N-Lock plug, and in

the wiring from the Mate-N-Lock plug to the Y1 “ECON”

terminal.

5. Failing the above, if voltage is supplied at M1, M1 is

pulled in, and the compressor still does not operate,

replace the compressor.

Unitary Products Group

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” termi-

nal. The economizer board may have faulted and is not

returning the 24 volts to the Y1 “ECON” terminal even

though the economizer is not providing free cooling. To

test the economizer board, disconnect the Mate-N-Locks

and jumper between the WHITE and YELLOW wires of

the UCB’s Mate-N-Lock plug.

4. If M3 is not pulled in, check for 24 volts at the M3 coil. If

24 volts is present at M3 but M3 is not pulled in, replace

the contactor.

5. Failing the above, if there is line voltage supplied at M3,

M3 is pulled in, and the supply air blower motor still does

not operate, replace the motor.

6. If 24 volts is not present at M3, check that 24 volts is

present at the supply air blower motor terminal on the

UCB. If 24 volts is present at the UCB terminal, check for

loose wiring between the UCB and M3.

7. If 24 volts is not present at the UCB supply air blower

motor terminal, check for 24 volts from the room thermo-

stat. If 24 volts is not present from the room thermostat,

check for the following:

13. The UCB can be programmed to lock out compressor

operation during free cooling and in low ambient condi-

tions. These options are not enabled by default. They

can be checked by local York distributors.

a. Proper operation of the room thermostat (contact

between R and G with the fan switch in the “ON”

position and in the “AUTO” position during operation

calls).

14. If none of the above corrected the error, test the integrity

of the UCB. Disconnect the C1 terminal wire and jumper

it to the Y1 terminal. DO NOT jump the Y1 to C1 termi-

nals. If the compressor engages, the UCB has faulted.

b. Proper wiring between the room thermostat and the

UCB.

c. Loose wiring from the room thermostat to the UCB.

15. If none of the above correct the error, replace the UCB.

8. If 24 volts is present at the room thermostat but not at the

UCB, check for proper wiring between the thermostat

and the UCB, i.e. that the thermostat G terminal is con-

nected to the G terminal of the UCB, and for loose wir-

ing.

GAS HEAT TROUBLESHOOTING GUIDE

On calls for heating, the draft motor operates and the furnace

lights but the supply air blower motor does not energize after

a short delay (the room thermostat fan switch is in “AUTO”

position).

9. If the thermostat and UCB are properly wired, replace

the UCB.

10. If the blower motor runs with the fan switch in the “ON”

position but does not run shortly after the furnace has

ignited when the fan switch is in the “AUTO” position,

check the room thermostat for contact between R and G

during “W1” calls.

The furnace may shut down on a high temperature

condition during the procedure. If this occurs, the

UCB energize the supply air blower motor until the

high temperature limit has reset. Caution should be

used at all times as the supply air blower may ener-

gize regardless of the room thermostat fan switch

position.

On calls for heating, the supply air blower operates but the

draft motor does not (the room thermostat fan switch is in the

“AUTO” position).

1. The draft motor has inherent protection. If the motor

shell is hot to the touch, wait for the internal overload to

reset.

1. Place the thermostat fan switch in the “ON” position. If

the supply air blower motor energizes, go to Step 10.

2. If the motor shell is cold with the room thermostat calling

for heat, check for line voltage at the motor leads. If line

voltage is present, replace the draft motor.

2. If the supply air blower motor does not energize when

the fan switch is set to “ON,” check that line voltage is

being supplied to the contacts of the M3 contactor, and

that the contactor is pulled in. Check for loose wiring

between the contactor and the supply air blower motor.

3. If line voltage is not present, check for line voltage on the

ignition control at the “inducer” terminal draft motor relay

(DMR or DMC) contacts in the main control box and

check to see if the (DMR or DMC) is pulled in.

3. If M3 is pulled in and voltage is supplied at M3, lightly

touch the supply air blower motor housing. If it is hot, the

motor may be off on inherent protection. Cancel any

thermostat calls and set the fan switch to “AUTO”, wait

for the internal overload to reset. Test again when cool.

The draft motor runs but the furnace does not light and the

spark ignitor does not spark.

Unitary Products Group

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.

The draft motor runs and the spark ignitor sparks at the

burner, but the burner does not ignite and a gas odor is not

detected at the draft motor outlet.

1. Check to ensure gas is being supplied to the unit. Con-

firm that the gas pressure to the unit is within the proper

limits as described in the “POST START CHECKLIST”.

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.

2. Check the voltage at the gas valve and at the gas valve

terminals on the ICB. Check all wiring between the ICB

and the gas valve. Check to make sure the ground con-

nections are intact.

3. With the draft motor running, check for 24 volts at the

pressure switch terminal on the ICB. If not present,

check for 24 volts on the terminal from the pressure

switch. If present, go to step 4. If 24 volts is not present,

the either pressure or rollout switch is not closed. Or the

draft motor is not sufficiently evacuating the heat

exchanger tubes or the pressure switch has failed.

Check the operation of the pressure switch. Check the

line voltage to the unit; if line voltage is low, call the local

power company. If the problem persists, the draft motor

may need replacement.

3. If 24 volts is present, remove the pilot burner and the ori-

fice. The removal procedure is described in

“BURNER/ORIFICE INSTRUCTIONS.” Inspect the ori-

fice for obstruction. If it is clear, replace the gas valve.

Main burners light but exhibit erratic flame characteristics.

4. Check the main burner orifices for obstruction and align-

ment. The removal procedure is described in

4. If the furnace is hot, it may be out on a high temperature

limit open; wait for limit reset.

“BURNER/ORIFICE INSTRUCTIONS.” Clean or replace

burner orifices and burners as needed.

5. If all are intact replace the ICB.

Unitary Products Group

035-19046-002-B-0104

Unitary Products Group

Subject to change without notice. Printed in U.S.A.

035-19046-002-B-0104

Supersedes: 035-19046-002-A-0803

Unitary

Products

Group

5005

York

Drive

Norman

73069

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