Johnson Controls York DMS Saber Series, DMS 360 Series, DMS 420 Series, DMS 480 Series, DMS 600 Series Installation, Operation & Maintenance Manual

NOTES

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Installation, Operation and Maintenance Manual : 036-1011(0806)

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Installation, Operation & Maintenance Manual IOM # 036-1011(0806)

60 Hz

TABLE OF CONTENTS

Belt drive blower ........................................................ 21

GENERAL

Safety considerations ................................................3

Inspection ..................................................................3

Renewal parts ............................................................3

Product nomenclature ................................................ 4

INSTALLATION

Limitations .................................................................. 4

Location......................................................................5

Rigging and handling.................................................. 5

Clearances ................................................................ 5

Ductwork ..................................................................5

Fixed outdoor air intake damper ................................5

Condensate drain ......................................................6

Compressors ............................................................7

Filters ........................................................................7

Service access .......................................................... 7

Thermostat ................................................................ 7

Power and control wiring............................................7

Optional electric heat.................................................. 7

Phasing ......................................................................8

Product data ..............................................................9

Dimensions and clearances ...................................... 10

Drive and pulley data.................................................. 11

Electrical data ............................................................11, 12

Fan performance data................................................13

Additional pressure drops .......................................... 14

Checking supply air cfm ............................................ 15

SAFETY

Terminology................................................................ 15

Operational safety......................................................15

Use and Operation .................................................... 16

Adherence to warnings .............................................. 16

Staff training .............................................................. 16

Use of the unit ............................................................ 16

Recommended safety practices ................................16

Applicable standards of EEC machinery directive...... 17

OPERATION

Sound power ratings ..................................................18

Volt free contact..........................................................18

Sequence of operations ............................................18

Cooling operation errors ............................................19

High pressure limit switch .......................................... 19

Low pressure limit switch ..........................................19

Freezestat ..................................................................19

Low ambient cooling .................................................. 19

Safety controls............................................................ 19

Compressor protection ..............................................19

Flash codes................................................................20

Reset..........................................................................20

Electric heating sequence of operations ....................20

Heating operation errors ............................................ 20

TROUBLE SHOOTING

Cooling trouble shooting guide ..................................21

Unit flash codes..........................................................25

MAINTENANCE

Every month .............................................................. 26

Every three months Every six months Every twelve months

LIST OF FIGURES AND ILLUSTRATIONS

Typical unit configuration............................................ 3

Product nomenclature ................................................ 4

Typical rigging ............................................................ 5

Fixed outdoor air intake damper ................................6

Condensate drain ......................................................6

Loading points ..........................................................6

Typical field wiring......................................................8

Dimensions and clearances ...................................... 10

Addtional Pressure Drops ..........................................14

Belt adjustment .......................................................... 15

Unit nameplate .......................................................... 15

Motor nameplate ........................................................15

Warnings .................................................................... 16

LIST OF TABLES

Unit application data ..................................................4

Loading points ..........................................................6

Control wire sizes ......................................................7

Minimum cfm limitation ..............................................7

Product data ..............................................................9

Drive and pulley data.................................................. 11

Electrical data ............................................................11, 12

Fan performance data................................................13

Applicable standards of EEC machinery directive...... 17

Sound power levels (DMS Saber units) ....................18

Sound power levels (Standard fans) .......................... 18

Compressors, contactors & terminal numbers .......... 25

Unit flash codes..........................................................25

START UP

Restart check list........................................................20

Operating instructions ................................................20

Post start check list ....................................................20

Shut down ..................................................................21

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GENERAL

RENEWAL PARTS

YORK Saber units are single package air conditioners equipped with optional factory installed electric heaters and designed for outdoor installation on a rooftop or steel structure.

The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested. The units require electric power, duct connections and drain piping connections at the point of installation.

The supplemental electric heaters have nickel-chrome elements and utilize single point power connection.

SAFETY CONSIDERATIONS

Due to system pressure, moving parts and electrical components, installation and servicing of air conditioning equipment can be hazardous. Only qualified, trained, service personnel should install, repair, maintain or service this equipment.

Observe all precautions in the literature, on labels and tags accompanying the equipment whenever working on air conditioning equipment. Be sure to follow all other safety precautions that apply.

Wear safety glasses and work gloves, and follow all safety codes. Use a quenching cloth and have a fire extinguisher available for all brazing operations.

INSPECTION

Refer to York USER’S MAINTENANCE and SERVICE INFORMATION MANUAL. It is strongly suggested that only genuine YORK Spare Parts are used to ensure efficient working of the unit and safety.

CAUTION

THIS PRODUCT MUST BE INST ALLED 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.

WARNING

IMPROPER INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY OR PROPERTY DAMAGE.

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.

As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier’s freight bill.

TYPICAL UNIT CONFIGURATION

FIGURE 1 : TYPICAL UNIT CONFIGURATION

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NOMENCLATURE

INSTALLATION

Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference.

Installation, Operation and Maintenance Manual : 036-1011(0806)

LIMITATIONS

These units must be installed in accordance with the applicable national and local safety codes. (Refer to Unit Application Data table).

If components are to be added to a unit to meet local codes, they are to be installed at the dealer’s and/or the customer’s expense. Size of unit for proposed installation should be based on heat loss/heat gain calculation.

TABLE 1 : UNIT APPLICATION DATA

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LOCATION

Use the following guidelines to select a suitable location for these units :

1. Unit are designed for outdoor installation only.

WARNING

BEFORE LIFTING A UNIT, MAKE SURE THAT ALL PANELS ARE IN PLACE AND THAT ITS WEIGHT IS DISTRIBUTED EQUALLY ON ALL CABLES SO IT WILL LIFT EVENLY.

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

3. Where a choice of location is possible, position the unit on either north or east side of building.

4. For ground level installation, use a level concrete slab. The length and width should be at least 6 inches greater than the unit base rails. Do not tie slab to the building foundation.

5. Roof structures must be able to support the weight of the unit and its options and/or accessories. Unit must be installed on a solid level roof curb.

6. Maintain level tolerance to 1/2 inch maximum across the entire length or width of the unit.

RIGGING AND HANDLING

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 round lifting holes provided in the base rails. Spreaders, whose length exceeds the largest dimension across the unit, MUST BE USED. Refer to Figure 2. Units may also be moved or lifted with a forklift, from the side only, provided that an accessory skid is used.

CLEARANCES

All units require certain clearances for proper operation and service. Installer must make provisions for adequate ventilation air in accordance with applicable provisions of the local building codes. Refer to Dimensions and Clearances. Refer Figure 8 for the clearances required for servicing, and proper unit operation.

WARNING

DO NOT PERMIT OVERHANGING STRUCTURES OR SHRUBS TO OBSTRUCT OUTDOOR AIR DISCHARGE OUTLET.

DUCTWORK

A closed return duct system should be used. This should not preclude use of 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 requirements of the job. They should NOT be sized to match the dimensions of the duct connections on the unit.

LENGTH OF FORKS MUST BE A MINIMUM OF 90”. Refer to the Product Data Table 5 for unit weights.

WARNING

WHEN FASTENING DUCTWORK TO SIDE DUCT FLANGES ON UNIT, INSERT SCREWS THROUGH DUCT FLANGES ONLY. DO NOT INSERT SCREWS THROUGH CASING. OUTDOOR DUCTWORK MUST BE INSULATED AND WATERPROOFED.

Refer to Dimensions and Clearances Figure 7 for information concerning supply and return air duct openings.

FIXED OUTDOOR AIR INTAKE DAMPER

This damper is shipped inside the return air compartment. It is completely assembled and ready for installation. Refer to the Fixed Outdoor Damper Figure 3.

Gasketing and mounting screws are provided in a parts bag. Adjusting the damper to the desired air flow may be done after installation by opening or closing dampers with handle.

Damper provides maximum of 25% fresh air when fully opened.

FIGURE 2 : TYPICAL RIGGING

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FIGURE 3 : FIXED OUTDOOR AIR DAMPER

CONDENSATE DRAIN

Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install a condensate drain line from the one-inch FPT female connection on the unit to an open drain.

NOTE : The condensate drain operates in a negative pressure in the cabinet. The condensate drain line MUST be trapped to provide proper drainage. See Figure 4.

FIGURE 4 : RECOMMENDED DRAIN PIPING

FIGURE 5 : LOADING POINTS

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COMPRESSORS

Units are shipped with factory adjusted compressor mountings and ready for operation.

the tabulated rating, with a short circuit capacity of 10K or more, for the unit. The switch must be separate from all other circuits. Wire entry at knockout openings require conduit fittings to comply with local codes. Refer to the Dimensions and Clearances Figure 7 for installation location.

CAUTION

DO NOT LOOSEN COMPRESSOR MOUNTING BOLTS. REMOVE COMPRESSOR SHIPPING BRACKETS BEFORE START-UP.

FILTERS

Two inch filters can be supplied with each unit. Filters must always be installed ahead of the evaporator coil and must be kept clean or replaced with same size and type. Dirty filters will reduce the capacity of the unit and will result in frosted coils or safety shutdown. Minimum filter area and required sizes are shown in Product Data Table 4.

SERVICE ACCESS

The following removable panels provide access to all serviceable components :

• Compressor compartment

• Electric Heat compartment

• Blower compartment

• Main control box

• Filter compartment

Refer to the Dimensions and Clearances Figure 7 for location of these access panels.

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.

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.

Emergency stop button should be field installed as per wiring diagram. The activator should be red in colour with a yellow outline background, and should be easily accessible. The device should be self latching type and contacts must be of positive opening operation, certified to EN60947 - 5 - 1.

CAUTION

WHEN CONNECTING ELECTRICAL POWER AND CONTROL WIRING TO THE UNIT, WATERPROOF TYPE CONNECTORS MUST BE USED SO THAT WATER OR MOISTURE CANNOT BE DRAWN INTO THE UNIT DURING NORMAL OPERATION. THE ABOVE WATERPROOFING CONDITIONS WILL ALSO APPLY WHEN INSTALLING A FIELD SUPPLIED DISCONNECT SWITCH.

Refer to Typical Wiring Diagram, Figure 7 and to the appropriate unit wiring diagram for control circuit and power wiring information.

THERMOSTAT

4 Stage Cooling

The room thermostat should be located on an inside wall approximately 56 inches above the floor where it will not be subject to drafts, sun exposure or heat from electrical fixtures or appliances. Follow manufacturers instructions enclosed with thermostat for general installation procedure. A minimum of seven color coded insulated wires (#18 AWG) should be used to connect thermostat to unit.

POWER AND CONTROL WIRING

Field wiring to the unit must conform to provisions of the National Electrical Code and/or local ordinances. The unit must be electrically grounded in accordance with NEC and/or local codes.

Voltage tolerances, which must be maintained at the compressor terminals, during starting and running conditions, are indicated on the unit Rating Plate and the Unit Application Data table.

A fused disconnect switch should be field provided based on

TABLE 2 : CONTROL WIRE SIZES

OPTIONAL ELECTRIC HEAT

The factory installed heaters are wired for single point power supply. Power supply need only be brought into the single point terminal block and thermostat wiring to the low voltage terminal strip located in the upper portion of the unit control box.

These heaters are located within the supply air chamber. Refer to Figure 8 for access panel location. Fuses are supplied by the factory. Refer to Table 3 for minimum CFM limitations and to Table 5 for electrical data.

TABLE 3 : MINIMUM CFM LIMITATION

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FIGURE 6 : TYPICAL FIELD WIRING SCHEMATIC

PHASING

YORK Saber units are properly phased at the factory . Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start up, the electrical connection to the unit is mis-phased. Change the incoming line connection phasing to obtain proper rotation. (Scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar suction and discharge pressures, or producing a high noise level, the scroll is mis-phased).

CAUTION

SCROLL COMPRESSORS REQUIRE PROPER ROTATION TO OPERATE CORRECTLY. UNITS ARE PROPERLY PHASED AT THE FACTORY. DO NOT CHANGE THE INTERNAL WIRING TO MAKE THE BLOWER, CONDENSER FANS, OR COMPRESSOR ROTATE CORRECTLY.

Installation, Operation and Maintenance Manual : 036-1011(0806)

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Johnson Controls York DMS Saber Series, DMS 360 Series, DMS 420 Series, DMS 480 Series, DMS 600 Series Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

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