Page 2 - Unitary Products Group; TABLE OF CONTENTS
035-19046-002-B-0104 2 Unitary Products Group TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - REFERENCE; • Economizer Accessory -; RENEWAL PARTS; Design certified by CSA as follows:
035-19046-002-B-0104 Unitary Products Group 5 REFERENCE Additional information is available in the following referenceforms: • Technical Guide - DJ150, 036-21484-002 • General Installation - DJ150, 035-19046-002 • Pre-start & Post-start Check List - 035-18466-000 • Economizer Accessory - Downflo...
Page 6 - NOMENCLATURE; 21⁄2 Ton Predator Model Number Nomenclature; D J
035-19046-002-B-0104 6 Unitary Products Group NOMENCLATURE 12½ Ton Predator Model Number Nomenclature Product Category D = Air Cond., Single Package Product Identifier J = R-22 Ultra High Efficiency Airflow Installation Options Additional Options (See Next Page) Product Generation 3 = Third Generati...
Page 8 - INSTALLATION; INSTALLATION SAFETY INFORMATION
035-19046-002-B-0104 8 Unitary Products Group INSTALLATION INSTALLATION SAFETY INFORMATION Read these instructions before continuing this applianceinstallation. This is an outdoor combination heating and cool-ing unit. The installer must assure that these instructions aremade available to the consum...
Page 10 - PREDATOR
035-19046-002-B-0104 10 Unitary Products Group FIGURE 3 - PREDATOR MAGNUM COMPONENT LOCATION " Simplicity ™" Control board w/screw connectors for T-stat wiring and Network connection Second model nameplate inside hinged access panel Dual stage cooling for maximum comfort Compressor #2 acce...
Page 11 - LOCATION; Unit is designed for outdoor installation only.; RIGGING AND HANDLING; UNIT TEMPERATURE LIMITATIONS; UNIT 4 POINT LOAD
035-19046-002-B-0104 Unitary Products Group 11 LOCATION Use the following guidelines to select a suitable location forthese units: 1. Unit is designed for outdoor installation only. 2. Condenser coils must have an unlimited supply of air. Where a choice of location is possible, position the unit on ...
Page 13 - UNIT DIMENSIONS; UNIT CLEARANCES; DETAIL A
035-19046-002-B-0104 Unitary Products Group 13 NOTE: A one-inch clearance must be provided betweenany combustible material and the supply ductworkfor a distance of 3 feet from the unit. NOTE: If the unit includes gas heating, locate the unit sothe flue exhaust is at least: • Three (3) feet above any...
Page 15 - DUCTWORK
035-19046-002-B-0104 Unitary Products Group 15 DUCTWORK Ductwork should be designed and sized according to themethods in Manual D of the Air Conditioning Contractors ofAmerica (ACCA) or as recommended by any other recog-nized authority such as ASHRAE or SMACNA. A closed return duct system should be ...
Page 16 - MAGNUM ROOF CURB DIMENSIONS; FIGURE 12 - SIDE PANELS WITH HOLE PLUGS
035-19046-002-B-0104 16 Unitary Products Group Note orientation. Panel is “insulation” side up. FIGURE 10 - PREDATOR MAGNUM ROOF CURB DIMENSIONS FIGURE 11 - SUNLINE™ TO PREDATOR MAGNUM TRANSITION ROOF CURBS 8 o r 1 4 5 0 - 1 / 2 3 0 2 0 2 0 8 0 - 5 / 8 6 2 T Y P . I N S U L A T E D D E C K U N D...
Page 17 - Do not loosen the compressor mounting bolts.; Wire Size
035-19046-002-B-0104 Unitary Products Group 17 CONDENSATE DRAIN 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 thebase pan for piping inside the roof curb. Trap the connect...
Page 18 - POWER WIRING DETAIL
035-19046-002-B-0104 18 Unitary Products Group The internal wiring harnesses furnished with this unit are anintegral part of the design certified unit. Field alteration tocomply with electrical codes should not be required. If any ofthe wire supplied with the unit must be replaced, replacementwire m...
Page 19 - FIGURE 17 - FIELD WIRING 24 VOLT THERMOSTAT; U N I T C O N T R O L
035-19046-002-B-0104 Unitary Products Group 19 FIGURE 17 - FIELD WIRING 24 VOLT THERMOSTAT O C C W 1 W 2 Y 1 G Y 2 X R S D C R E M O TE M IN P O S W 1 W 2 Y 1 G Y 2 C U N I T C O N T R O L B O A R D T - S T A T R H R C FIGURE 18 - FIELD WIRING DISCONNECT - COOLING UNIT WITH/WITHOUT ELECTRIC HEAT TER...
Page 20 - FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT
035-19046-002-B-0104 20 Unitary Products Group FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT L1 T1 L2 T2 T3 L3 FACTORY OR FIELD SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY GROUND LUG CONTACTOR 1M
Page 22 - OPTIONAL ELECTRIC HEAT; Heater
035-19046-002-B-0104 22 Unitary Products Group OPTIONAL ELECTRIC HEAT The factory-installed heaters are wired for single point powersupply. Power supply need only be brought into the singlepoint terminal block. These CSA approved heaters are located within the centralcompartment of the unit with the...
Page 23 - OPTIONAL GAS HEAT; GAS PIPING; TABLE 12: GAS HEAT APPLICATION DATA; Unit; FIGURE 20 - SIDE ENTRY GAS PIPING; Length of
035-19046-002-B-0104 Unitary Products Group 23 OPTIONAL GAS HEAT These gas-fired heaters have aluminized-steel or optionalstainless steel, tubular heat exchangers with spark ignition. GAS PIPING Proper sizing of gas piping depends on the cubic feet perhour of gas flow required, specific gravity of t...
Page 24 - GAS CONNECTION; Gas piping recommendations:; LP UNITS, TANKS AND PIPING; FIRE OR EXPLOSION HAZARD
035-19046-002-B-0104 24 Unitary Products Group GAS CONNECTION The gas supply line can be routed within the space and roofcurb, exiting through the unit’s basepan. Refer to Figure 8 forthe gas piping inlet location. Typical supply piping arrange-ments are shown in Figures 20 and 21. All pipe nipples,...
Page 26 - MINIMUM POSITION ADJUSTMENT; Optional CO
035-19046-002-B-0104 26 Unitary Products Group ECONOMIZER AND POWER EXHAUST SET POINT ADJUSTMENTS AND INFORMATION Remove the top rear access panel from the unit. Locate theeconomizer control module, where the following adjustmentswill be made. MINIMUM POSITION ADJUSTMENT • Check that the damper blad...
Page 27 - FIGURE 22 - ENTHALPY SET POINT CHART; FIGURE 23 - HONEYWELL ECONOMIZER CONTROL W7212
035-19046-002-B-0104 Unitary Products Group 27 FIGURE 22 - ENTHALPY SET POINT CHART 40 (4) 70 (21) 50 (10) 55 (13) 60 (16) 65 (18) 35 (2) 45 (7) 75 (24) 80 (27) 35 (2) 40 (4) 45 (7) 50 (10) 55 (13) 60 (16) 65 (18) 70 (21) 75 (24) 80 (27) 85 (29) 85 (29) 90 (32) 90 (32) 105 (41) 110 (43) 100 (38) 95 ...
Page 28 - PHASING; Predator; BLOWER ROTATION; FIGURE 24 - BELT ADJUSTMENT; Procedure for adjusting belt tension:
035-19046-002-B-0104 28 Unitary Products Group PHASING Predator Magnum DJ units are properly phased and pro- tected by a Phase Monitor from the factory. If the unit doesnot start up, the electrical connection to the unit may be mis-phased. Check the Phase Monitor for a Red LED, indicating amisphas...
Page 30 - NOTES FOR TABLE 15 THROUGH TABLE 18:
035-19046-002-B-0104 30 Unitary Products Group NOTES FOR TABLE 15 THROUGH TABLE 18: • Blower performance includes dry coil and two-inchfilters. • Blower performance for gas heat includes the maximum number of heat tubes available for each tonnage. • ESP (External Static Pressure) given is that avail...
Page 31 - AIR BALANCE; METHOD ONE; TABLE 19: INDOOR BLOWER SPECIFICATIONS
035-19046-002-B-0104 Unitary Products Group 31 AIR BALANCE Start the supply air blower motor. Adjust the resistances in both the supply and the return air duct systems to balance the airdistribution throughout the conditioned space. The job specifications may require that this balancing be done by s...
Page 32 - SUPPLY AIR DRIVE ADJUSTMENT; EXAMPLE; FIGURE 25 - DRY COIL DELTA P; • Existing DD = New DD
035-19046-002-B-0104 32 Unitary Products Group SUPPLY AIR DRIVE ADJUSTMENT At unit start-up, the measured CFM may be higher or lowerthan the required CFM. To achieve the required CFM, thespeed of the drive may have adjusted by changing the datumdiameter (DD) of the variable pitch motor sheave asdesc...
Page 33 - OPERATION; SEQUENCE OF OPERATIONS OVERVIEW; For the Predator; COOLING SEQUENCE OF OPERATION
035-19046-002-B-0104 Unitary Products Group 33 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 ofcooling. The call is passed to the unit control board (UCB), which thendetermi...
Page 35 - LOW-PRESSURE LIMIT SWITCH; SAFETY CONTROLS; FLASH CODES
035-19046-002-B-0104 Unitary Products Group 35 Should a high-pressure switch open three times within twohours 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. LOW-PRESSURE LI...
Page 36 - RESET; The control circuit includes the following safety controls:
035-19046-002-B-0104 36 Unitary Products Group RESET Remove the call for cooling, by raising thermostat settinghigher than the conditioned space temperature. This resetsany pressure or freezestat flash codes. ELECTRIC HEATING SEQUENCE OF OPERATIONS The following sequence describes the operation of t...
Page 37 - GAS HEATING SEQUENCE OF OPERATIONS; When “W1” is satisfied, both valves are closed.; GAS HEATING OPERATION ERRORS; The UCB and ICB continuously monitor the GV.
035-19046-002-B-0104 Unitary Products Group 37 GAS HEATING SEQUENCE OF OPERATIONS When the thermostat calls for the first stage of heating, thelow-voltage control circuit from “R” to “W1” is completed. Acall for heat passes through the UCB to the ignition controlboard (ICB). The UCB monitors the “W1...
Page 38 - INTERNAL MICROPROCESSOR FAILURE; TABLE 24: GAS HEAT LIMIT CONTROL SETTINGS; Main Limit Setting
035-19046-002-B-0104 38 Unitary Products Group If the ICB senses voltage at the GV when not requested, theICB will energize the draft motor. The ICB will not operate thefurnace until voltage is no longer sensed at the GV. The draftmotor is stopped when voltage is not sensed at the GV. Any time the U...
Page 39 - LIGHTING THE MAIN BURNERS
035-19046-002-B-0104 Unitary Products Group 39 GAS HEAT ANTICIPATOR SETPOINTS It is important that the anticipator setpoint be correct. Toohigh of a setting will result in longer heat cycles and a greatertemperature swing in the conditioned space. Reducing thevalue below the correct setpoint will gi...
Page 40 - NATURAL GAS; TABLE 26: GAS HEAT STAGES; nd Stage
035-19046-002-B-0104 40 Unitary Products Group POST START CHECKLIST After the entire control circuit has been energized and theheating section is operating, make the following checks: 1. Check for gas leaks in the unit piping as well as the sup-ply piping. 2. Check for correct manifold gas pressures...
Page 41 - TABLE 27: GAS RATE CUBIC FEET PER HOUR; Seconds
035-19046-002-B-0104 Unitary Products Group 41 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. 4. Using the number of seconds it takes for one revolution of the dial, calculate the cubic feet of g...
Page 42 - ADJUSTMENT OF TEMPERATURE RISE; CFM; FIGURE 27 - TYPICAL GAS VALVE
035-19046-002-B-0104 42 Unitary Products Group EXAMPLE: By actual measurement, it takes 19 seconds for the hand ona 1 cubic foot dial to make a revolution with a 192,000 Btuhfurnace running. To determine rotations per minute, divide 60by 19 = 3.16. To calculate rotations per hour, multiply 3.16 • 60...
Page 43 - CHARGING THE UNIT; TABLE 29: IGNITION CONTROL FLASH CODES
035-19046-002-B-0104 Unitary Products Group 43 CHARGING THE UNIT The DJ150 (12-1/2 Ton) High Efficiency Unit, uses a TXVmetering device. Charge unit to 10º sub-cooling at the TXV. TROUBLESHOOTING PREDATOR MAGNUM FLASH CODES Various flash codes are utilized by the unit control board(UCB) to aid tro...
Page 44 - FIGURE 28 - BASIC TROUBLESHOOTING FLOWCHART; Power to
035-19046-002-B-0104 44 Unitary Products Group FIGURE 28 - BASIC TROUBLESHOOTING FLOWCHART Monitor Monitored Systems Problem? C all for C ooling? Call for Heating? Call for He at Yes No No No Call for 1st Stage Cooling F irst S tage? Ca ll for 2nd Stage Cooling Yes Y es Loss of C all for H eating? L...
Page 45 - FIGURE 30 - TRIP FAILURE FLOW CHART
035-19046-002-B-0104 Unitary Products Group 45 FIGURE 30 - TRIP FAILURE FLOW CHART T r i p / F a i l u r e L o s s o f L S I n p u t E n e r g i z e b l o w e r : i n c r e a s e i n c i d e n t v a l u e b y 1 L S i n p u t r e g a i n e d ? I n c i d e n t v a l u e > = 3 ? L o c k o n b l o w ...
Page 46 - COOLING TROUBLESHOOTING GUIDE; Loose wiring from the room thermostat to the UCB.
035-19046-002-B-0104 46 Unitary Products Group COOLING TROUBLESHOOTING GUIDE On calls for cooling, if the compressors are operating but thesupply air blower motor does not energize after a short delay(the room thermostat fan switch is in the “AUTO” position). 1. Turn the thermostat fan switch to the...
Page 49 - GAS HEAT TROUBLESHOOTING GUIDE
035-19046-002-B-0104 Unitary Products Group 49 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 th...
