INSTALLATION, OPERATION & MAINTENANCE MANUAL - 50 Hz DMS Saber Series Air Cooled Packaged Air Conditioners 16 to 27 TR BY JOHNSON CONTROLSInstallation, Operation & Maintenance Manual # 036-1007(0608) GENERAL, Safety -onsiderations Inspecton Renewal parts Fooduct nomenclature INSTALLATION imitations Location Ri ging and han ching Aleavances uctwor Fixed outdoo. air wtake damper. Condensate drain Coup.essors Fitters Service access Tuermostat Power and contro! wiring Optiona’ electric neat Phasing Product data Dimensions and ciearances (DIS 120) Dimensions and clearances (DMS 240, 260, 220] Drive ond pulley dato Clectrical data Fan performance data Checking supply air cm SAFETY Terminology Operational safety Je and Cperation ‘Adherence to warnings Staff training Use of the unit Recommended safety practices Applicaule standards of EEC machinery directive (OPERATION Sound power ratings Volt free contact Se,uence of operations Cooling operation errors High pressure limit switch Low pressure limit switen Freecestat Low ambient cooling Safety controls Compressor protection Flash codes: Reset Electric heating sequence of operations Heating operation errors ial YORK BY JOHNSON CONTROLS v v v v v 18 8 8 18 18 18 18 18 10 START UP, Restart check list Operating instructions Post start check list Shut down Bel drive blower TROUBLE SHOOTING Cooling troutle shooting guide Unit flash codes MAINTENANCE Every month E-ery three months Every six months E-ery twelve months LisT OF FIGURES AND ILLUSTRATIONS. Typical unit configuration Praduct nomenclature “Typical rigging Fixed outdoor air intake damper Condensate drain Four point load Six point load Typical field wiring Dimensions and clearances (OMS 190) Dimensions and clearances (DMS 240, 260, 320) Bel adjustment Unit nameplate Motor nameplate Warnings LIST OF TABLES Unit application data Four point load Six point load Control wire sizes Minimum cfr limitation Product data Drive ond pulley dato Electrical data Fan performance data Applicable standards of EEC machinery directive Sound power levels (DMS Saber units) Unit flash codes Page 2 19 19 18 18 19 20 2 2B 2B 2B BInstallation, Operation & Maintenance Manual # 036-1007(0608) GENERAL YORK Saber units are single package air conditioners equipped with optional factory installed electric heaters and designed for ‘outdoor installation on a roattap or slab or steel structure. The units are completely assembled on rigid, permanently attached base rails. ll piping, refrigerant charge, and electrical Wiring is factory installed and tested. The units require electric power, duct connections and drain piping connections at the poiat 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 Iterature, on labels and tags accompanying the equipment whenever working on ait 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 ‘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 bil TYPICAL UNIT CONFIGURATION Page 3 RENEWAL PARTS. Refer to York USER'S MAINTENANCE and SE®VICE INFO“MATION MANUA: A cation THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUCTIONS AND ANY APPLICABLE LOCAL, STATE, ANC NATIONAL CODES INCLUDING, BUT NOT LIMITED TO, BUILDING, ELECTRICAL, ‘AND MECHANICAL CODES. A waanine 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 andi cor equipment damage may result installation procedure is not handled properly. Figure 1: Typical Unit Configuration Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) NOMENCLATURE Page 4 D S| 240| Coo; A|4/A/ 1/14 Product Category “— Product Generation D = AIC, Single Package 11= First generation Product Identifier Field Installed Options M = R22, Std. efficiency 1 = No option installed 2= 1B KW electric heater Series Name 3 = 36 kW electric heater = Saber 4 = Fresh air damper Nominal Cooling Capacity Factory Installed Options 190 = 16 Tons A= No options installed 240 = 20 Tons B = Heresite coating on 260 = 22 Tons condenser coil 320 = 27 Tons C= Heresite coating on evaporator col Mode D = 2" Aluminium washable C00 = Cooling only fiter wu {Cu condenser coil Motor Option Cu Cu evaporator coil A= Standard motor jisconnect switch B = Over size motor hase manitor BMS Power Supply High speed drive 4 = 380 - 415V / 3Ph / SOH2 Low speed drive UV lamp Dirty filter switch Low ambient kit moke detector 8 KW Heater 16 KW Heater femperature economizer ithalpy economizer = Volt free contact ressure guages resh air damper INSTALLATION LIMITATIONS Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling nit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference, These units must be installed in accordance with the applicable rational 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 andlor the customer's expense. Size of unit for proposed installation should be based (on heat loss/heat gain calculation. Unit Model Number DMs 190 Dus 200 DNS 255 DISSE ‘soltage Varian (Min/Max) 38-4 BV) 30, 15h 20/440 ‘Supply Aiiow Rate Min Max) tm 00078800 | 6400/8400 | 6000/8000 | 7000/1500 "un goll Wet lb Temperature (Min Max) 1 Brite “Ambient Air Temperature (Min / Ma: ) 300125 (907725 wth ow em ttn) ial YORK BY JOHNSON CONTROLS Table 4: Unit Application DataInstallation, Operation & Maintenance Manual # 036-1007(0608) LOCATION Use the following guidelines to select 3 suitable location for these units 1. Unit are designed for outdoor installation only. 2. Condenser colls must have an unlimited supply of ar 3. Where a choice of location is possible, position the unit on either north or east side of bulding 4. For ground level installation, use a level concrete slab with a ‘minimum thickness of 4 inches. The length and wicth should be at least 6 inches greater than the unit base ras. 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 curt ar appropriate angle ron frame 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 unt is near the place of installation. Rig the Lit By attaching chain or cable slings ta the round lifting holes provided in the base rails. Spreaders, whose length exceeds the largast dimension across the unit, MUST BE USED. Refer to Figure 3. Units may also be moved or lifted with a forklift, from the side only, provided that an accessory skid is used. LENGTH OF FORKS MUST BE A MINIMUM OF 90°, Refer to the Product Data Table 2 for unit weights Figure 2: Typical Rigging Page 5 Ac warnine ‘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. 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. Ac waanine DO NOT PERMIT OVERHANGING STRUCTURES OR SHRUBS TO| OBSTRUCT OUTDOOR AIR DISCHARGE OUTLET DUCTWORK AA 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 bbe made with flexible joints to minimize noise. The supply and retum 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 A warnine 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 WaT ERPROOFED. Refer to Dimensions and Clearances Figure 8 for information concerning supply and return air duct openings. FIXED OUTDOOR AIR INTAKE Di SPER 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 dasited air flow may be dane after installation by opening or closing dampers with handle. Damper provides maximum of 25% fresh air when fully opened. Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) Page 6 Figure 3: Fixed Outdoor Air Damper CONDENSATE DRAIN ae BS me Planting must conform to lca codes. Use a sealing compound aver eT Ba Gn male pipe threads. stalls condensate dai ine rom the tus wt {-ranee-[ wistig [-aege [sa2(o [oar Gne-nch PT female connection on the unt oan open cain waa ees eo are ae mise smear | caine asic [oar NOTE :The condensate dan operates in a negative pressure Fine 2 Foursoincoad inthe cabinet, The condensate doin ine MUST be tapped to provide proper drainage. See Figure 4. aN ase nas It > ran I Figure 4: Recommended Lrain Piping ows [a5 wr a | ows 755) oso J] (0 Fa 5] OMS Es (eae pen] a con] wo (wor ce] Figure 6: Six Point Load ial YORK BY JOHNSON CONTROLSInstallation, Operation & Maintenance Manual # 036-1007(0608) COMPRESSORS. Units are shipped with factory adjusted compressor mountings and ready for operation. CAUTION (DO NOT LOOSEN COMPRESSOR MOUNTING BOLTS. REMOVE COMPRESSOR SHIPPING BRACKETS BEFORE START-UP. FILTERS Two inch fiters can be supplied with each unit, Filters must always be installed ahead of the evaporator call and must be kept clean or replaced with same size and type. Dirty fiters will reduce the capacity of the unit and will result in frosted coils or safety shutdown. Minimum fiter 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 & for location of these access panels. THERMOSTAT The room thermostat should be located on an inside wall approximataly 56 inches above the floor where it will not be subject to drafts, sun exposure or heat from electrical fixtures cr 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 unt. POWER AND CONTROL WIRING Field wiring to the unit must conform to provisions of the National Electrical Code andor 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 fon the unit Rating Plate and the Unit Application Data table ‘Atused disconnect switch should be field provided based on the ‘tabulated rating, with a short circuit capactey of 10K or more, Page 7 for the unt. The switch must be separate from all ather circuits Wire entry at knockout openings require conduit fittings to comply with local codes, Refer to the Dimensions and Clearances Figure 8 for installation lacatin. Ifany 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 gouge 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 sef latching type and contacts must be of positive ‘opening operation, certified to EN6OO47 - 5 - 1 A 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 Wire se haxima.a Length TSANG: 120 Feet Fron the unitto tie emostr and back oe mk 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 inta 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 withia the central compartment of the unit with the heater elements extending into the supply air chamber. Refer to Figure 8 for access panel location. Fuses are supplied by the factory. Refer to Table 2 for minimum CFM limitations and to Table 5 for electrical data, Minimum CFM Dis, 19-] DMS 240] DMS 250 Nominal Heater size TERN. 2 Stages BERN, 2 Stages Vi ih SoH 380,415 | 4800 | $400 | 8000 Table 3: Minimum CFM Limitation Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) Page 8 Figure 7: Typical Field Wiring Schematic hh PHASING YORK Saber units ore properly phased at the factory. Check for proper compressor rotation. Ifthe blower or compressors rotate in the wrong direction at start up, the elactrical connection to the Unit is misphased, Change the incoming line connection phasing to obtain proper rotation. (Scroll compressors operate in only tone direction. Ifthe scroll is drawing low amperage, has similar suction and discharge pressures, or producing a high noise level, the scroll is misphased). DMS 190 models have reciprocating compressors, ial YORK BY JOHNSON CONTROLS Action 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 & Maintenance Manual # 036-1007(0608) Pages age PRODUCT DATA WEDS 7 fa fa aa oe a 0 7 oF wee] Tes Ht6 m0 at paings gaat] cc ' ' fain 8 ‘t ‘ 78 a 1 Corpus | HF = tes Be 22 overt | a “3 ns ‘ 2 Se | re om ia a it ‘80 180 tts He ie a 2 we we Certs) Onn bee Onion ww 330 360 60 60 Tee ager a ¥ a Ts 78 ae sap tr | hos Epo tm 2 16 2 2 t reo. | = co Ca aaa a @ 7 T t craonan | Fosmiens | ui ie Fi 2 we ¥ HE aT 23 25 ae a Ca ga DOW aay 7 . [ote TPS GBF WTO FORT PORE PTO -oerFons : = 2 ; Hote asf . . e oe a 3 : 5s we 7 3 7 3 iv ae aw £ EY 55 15, Te 7am a ‘ueniy | Z coca [Hi Ta Ca a a FC TO satis ; % sess | ® tea z Te al Compresser | Ounnity |e z im re cesaa Ts z 5 7 7 Revtigerant Ghew.e Gr gs 55 6a a 82 Sarwe pe 7 = 7 foes hes 5 i a7 82 ce} a a Heont mm 1333.0 13030 eye aT a i mm 1.760 2630 ite} eo Tet Leng nen zane wi70 es) En we Fiters habe iy nen 50BY 61D 0 5- te 508 4610 x50-3¢ aco re) a om ~~ 610,610 050-34 eae ca i 2 7 Weighs ut ky 105, co 920) 955, Table 4: Product Data Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) DIMENSIONS AND CLEARANCES : DMS 190 * Eres a i Front (Control Panel & Compressor Access) % 94 8 Let iter ess 2 Te Regt (Condenser oi % 14 ‘Above (Condenser Air Discharge) n 1829 ae 3 ae veonnees : ae / 2 53 — 5 id ‘te PN a z et 5 rt Sa —4 E & # if it $ ee SUPPLYAROPOWNO—aerunN amore cree 738T ial YORK BY JOHNSON CONTROLS Page 10 (20 ie (e271 (e287) Figure &: Dimensional Data and Clearances DMS 190Installation, Operation & Maintenance Manual # 036-1007(0608) Page 11 DIMENSIONS AND CLEARANCES : DMS 240, 260, 320 =e ae =a i 5 Front (Conte Pana cess) 5 oe é . eet Conroe Aen) ep ke N > Oi Lat ews a) j eit Gaviense: Cal pea : Ate Connor A ia) rn) . i x a ds ore a go |Vag cana ie i 7 ot i 4 E i a ¢ g E LJ 4 g 2 a ~ ws ‘og 4 3s i : ag g g ge 3 « 23 5 g: : os z E Pr i & os 38 i & 25 i 80 55 PR Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) Page 12 DRIVE AND PULLEY DATA ow Sate Wesel Fish Dis on eens | REMRange ous | aot .- = 7 zl vistee | mye ine = bush [in| tox | FanPaliey | tush wt 7 ce a 180 20s 7% | m@ [sae | onsen | vo | a | w@ mo [eatin | aioe 7 | [samo | siren | oo [om | 2 a Zo [wriwa | aoxzem | 7 | ow [smae. | anion | ms | « 13 wo [akon | coxe | m | = [saa | mam | mo | = | | | oe Sona vie Set Wesel Pech Dis e Pechois | RPM Rye ous] eer sh ia ran is | Discs |e ine Rae push [in| tox | ranPalley | Bush et 8 nm | in | tx | om wo [varicear | zoxzenm | ve | m2 | srawor | veroazsm | vo | moe | ie | om wo | waRionAT | | ancem | me | ov [os | a | ae Table 5: Drive and Pulley Data ELECTRICAL DATA over Suny BOVIS TRO ‘Condenser | _ Supa Blower Motor . ‘Wim Creu | isimam Fuze naa ee Fantlotre |Sandard | ewreed | SAE Mee Amat | ster San Ruataer | URAESA | Azan FLA Ti [amperes | Ameres mses 72 a Das 8 27 a0 3 oo 8 eo | ae wz o Fa EE 2 o a a Dusan 7 ‘00 3 86 eo =a a seo ae on "3 o ese 187 1%0 3 86 ns (a [ae En @ seo et ny a2 i Dis-2, se 8 3 1s so [wo _|_ ae a2 0 sr) a2 0 Table 6: Electrical Data ial YORK BY JOHNSON CONTROLSPage 13 Installation, Operation & Maintenance Manual # 036-1007(0608) FAN PERFORMANCE a2uewioyieg ued i 321 ojo ores os ws) oe [ers] oie | ves] ese | evs | ame | var] cov | cer| eve | ocr] az | oor] sex | ze] om | we] om | our | emo: se | ss fave] oe zr) aa [ony] mn | exe | cee | ove | om | vee] om [eve | are | or] om | oz] am [ere] cio [are] eas | uo | comm exe | sie | see] sea | exe | woe | ose | ase [ oz | oz | arz| ew | ons | wre | ser | om | ovr | ows | os | crs | ove | coor exe | zee [ove | ore | cee] se | ove | ca [ove] om [az] ac] oz | ow | cee] ow | crc] om | oe | eos | sue | ame se | lave] ox exe | sim | saz | wen | ove | aoe | ewe | an [ oz | ox | ove | om | ov | wo | sit] one | orn | os | av | ers | ome | come exe| wee [ore | ase | exe | aoe | ove | are [eer | vee | oor | wo | ers [ vse | oer | oar | uv | ves | soo] oor | sexe | como ain | wer [oem | eve [econ] ze | oxo [ase | vee | eve ore | eve | oo | cee] use| we | vie | care | cone se | or sisi] ove or | ove [aves | eve | oss | sxe] ase [ ave | wie | oez | ove | arz| vee | ove | axe zi | 020 | coro | we | ao | ro | cao se | 901 | oe [ors | ose [cor | sae m9 | ance | one cua) 5 wwe [vz | ove [are] ove | eze| owe | ee | 2xz | cae | nme suat | ove [econ | ove | eau [we | ove | eve | vos | enz | ose | ov at | vez | owt | owe | ez | ome , © |suesi| oot rz | esos | az fowwr | ovz | oss | amv [ ze [ ons | owe | ort | one | ort | ons | zou | ox ta | cor | exo | vez | coos ot [eas | a0 [ ae sie [wr] oor [ee [oer [ven | [sees] owe [oes | oer [ees on [oes] oe [oe [oe [ae aa Teel | ov: [love | ew tera or [lesa oe [ise eo [teu] ova [a wo| 1s [eo reveudo | iepwees foal eta omega eure sven MN Johnson ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) CHECKING SUPPLY AIR CFM The RPM of the supply air blower will depend on the required CFM, the unit accessories or options and the static resistances cf both the supply and the return air duct systems. With this information, the RPM for the supply ar blower and the motor pulley adjustment (turns open) can be determined from the Fan Performance Data Tables. High speed drive accessories (containing a smaller blower pulley and 2 shorter belt) are available for applications requiring the supply ar blower to produce higher CFM andlor higher static pressures. Refer to the Drive and Pulley Data Table 6, Figure 10: Belt Adjustment Note the following, 1. The supply air CFM must be within the limitations shown in ‘the Unit Application Data Table 1 2. Pulleys can be adjusted in half turn increments. 3, The tension on the bel should be adjusted as shown in the Belt Adjustment Figure 10. 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 ‘hat this balancing be done by someone other than the equipment installer. “Acwaanins FAILURE TO PROPERLY ADJUST THE TOTAL SYSTEM AIR (QUANTITY CAN RESULT IN EXTENSIVE BLOWER DAMAGE ial YORK BY JOHNSON CONTROLS Page 14 SAFETY This section of the IOM covers Safety Aspects applicable to ‘the York DMS Saber Roof Top Air Conditioners. Adherance to the instructions detailed hereunder, will ensure the safety of the operators, prevent damage to the equipment and prevent accidents, su save, smart Most No: DMS 240 COOA4R11 1 Rs ERE Be [MADEN SAUDI ARABIA YORK UNITARY, PRODUCTS ‘GROUP Figure 11; Unit Nameplate WYORK {==> Figure 12: Motor Nameplate TERMINOLOGY The internal section of the unit adjacent to moving parts and electrical parts or devices is considered as the ‘danger zone’. Prior to gaining access to these parts, its necessary to acquire the proper tools to deactivate the safety davices. The operators are responsible for transport, installation, start up, service and ‘maintenance, including cleaning and trouble shooting. OPERATIONAL SAFETY York DMS Saber Roof Top Packages Air Conditioners in conformance to the highest standards of operational as well as ‘operator safety, Nevertheless, hazards may occur if the units are used for purposes other than the designed use(s), Units are ‘operated by untrained staff and / or Units are not operated in conformance with general standards prevalent in the industry.Installation, Operation & Maintenance Manual # 036-1007(0608) OPERATION AND USE OF THE UNIT IN CONFORMANCE WITH GENERAL STANDARDS AND. PROVISONS. YORK DMS Saber Roof Top Packaged Air Conditioners are desgined for and are able to cool, heat, fiter air and operate in the fan mode. Any other use is considered not in conformity with general provisions, The manufacturer is not responsible for ny resulting, damages. All responsibilty resuting from such non conformity rests with the user. In order to use the unit according to general provisions proper instructions for installation, exercise and transport must be observed. Installation and start up of the unit must satisfy the national ccodes and standards having legal validity in the country of use. The user is responsible for compliance with standards. ‘Additionally, any type of work that may compromise safety should be avoided. Arbitrary transformations or modifications to the unit by the user or operator are not permitted and nullify the warranty of the manufacturer, The manufacturer will also not be responsible for any damages to the equipment, to property or to personnel. ADHERENCE OF THE USER / OPERATOR TO THE WARNINGS AND OTHER INSTRUCTIONS. Clear signs are placed at appropriate locations on the unit showing 1. Prohibition to repair or adjustments during motion DIST DURING THE ‘MOVEMENT 2. Obligation to tum off the power before opening the access doors, TURN OFF POWER Page 15 3. Warnings against coming into contact with electrical parts. ccunRenT {All warnings and signs regarding the units must be absolutely observed. STAFF TRAINING The unit should be started up and serviced (routine and corrective maintenance) by authorised and trained staff only. This staff must be informed about possible hazards regarding Electrical connections Piping connections Duct connections. Start up These operations must be executed only by trained persons. who, on bahalf of the user, attend to control and to perform extraordinary / ordinary maintenance of the unit. Itis necessary to establish and to respect the responsibilities for control and ‘maintenance to guaranty safety, without confusion USE OF THE UNIT The unit must be started up only by means of proper safety vices. The installer is obliged ta install the unit according to installation plans and conditions. Only authorised persons must operate the unit The staff in charge is obliged to immediately inform the user of ‘any changes that may compromise safety, For this reason itis necessary to inspect for eventual anomalies or damages at least once a week The user or operator must never dismount and deactivate safety devices. If these have to be removed for maintenance, all safety devices must be reinstalled at their correct locationonce the ‘maintenance is complete, For all operations of maintenance, the power source must be locked out. It itis necessary to undertake maintenance activities, the fan must be switched off, isolated and allowed to run down, RECOMMENDED SAFETY PRACTICES This publication explains the proper use and installation lof equipment in order to warn operating and maintenance personnel of the commonly recognised dangers associated Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) Page 16 with this equipment. In adeltion to following the manufacturer's with federal, state and local rules, regulations, codes and installation instructions, care must be taken to ensure compliance standards Applicable Standards of EEC Me.hinery Directive | Measures Token Reference to Harmonised Procecure Dain elarodir nate Manual Tizapeoet_rrivishs ofesehy gration efor safety co aderations init fon Manual 13 Mates end pecs Referteinsiucien anual = Desyincfmacineryt. facitatets | Design of unit with ussewentfor Ring b fon or pe, exng 2 115 handing of empress ings cur, tensor ENEN TEIO0 16 121002 Ti sway and Relay or eave sytem | Refer to Electcl schema pasiod nade await TREN ToHO0-T7 121002 Conol dances are postioned oulsde danger ove, Engen 122 Conta Devices stop tov proidod by customer, loop forsame provided & | UNIEN 12100-18 121002 Deserted in OM For Slat Resta, lular actuation © ured for change of 123° Staring tempera stings, Macrne does have several string | UNIEN 12100-18 121002 cotols eer 0 ecial sc:ematic paseo nse ne unt, Nore 124 Stopping devices sopping cen be acivatedby main disconnect swich,tsin. | UNIEN 12100-18 121002 caster scope 1.248 Emergency sop (Gesemars scape, Log for emeaency $00 ptowded NY Un en 12100-18 121002 Electical schematic Fale o power suppl wil sop machine, once powers restore, uray actuton rete io resi Macrin doesn sla without manual ineracon, Zp has Got 120. Falurcf he poner supply UNTEN 12100-18 121002 127 Faluecf tha conte crest UNIEN ‘2100-18 121002 rion ove start 12 Sofware efron for alas of ingly Programing MIEN 2100-18 121002 “Uperany condos sie cn teas out drawings, fequeney 12 Riscofbreslup dung operation cfmsinienace sted ine inst-con manual ne guss | UNIEN 12100-18 121002 cre provided ott breakage willbe coined 1134 Risks duo o suroces,euges oranges | Covers wile p (on stap edges of screms| UNIEN 12100 16 121042 jay Mesriabonol sts eaiedtonomg pats ‘Choke of proedien against visxs | Acness door openable wth specal cos, wrten warnings fie 128 ado moving pats nacre dor UNEN (2100-76 121002 Tt General Reg ements Ta2.1_Fved cwrarts st Beane se ja ESTO agg “ane ong] TEN ODE TOT 15 erra ings Felon uM ema 102 SNe eto Na UNE ona owo2 sven eri UN EN7tnae-ov002 161 sno nas eto gge a a a INE na DH te2_ Mes ocoata resin | ara tren eg 1 un ev anse 21002 (E2_stenteroy ease rains MENARD 164 Oper een finn oe pone aa NEN 124007 165 Gbong tba pe etre ene MENTO 002 Wietlen waning in proxy o eecical and oan pas, ops] forwaming devees is provided refer towing scheme 12 Waring of residual ik eter io 10M UNTEN 12100-18 121002 Nein on mel nae lel deployed on the ouside fan 111 Wening devices UNIEN 12100-18 12100-2 14.3 Marking eee een ben cteacicax UNIEN 12100-18 121002 Insialeion, use and martenance handbook, As bull rawngs und Instcons nd posse tached schemes fom an inter pt of UNIEN 12100-16 121002 infrmaton for use ial YORK BY JOHNSON CONTROLSInstallation, Operation & Maintenance Manual # 036-1007(0608) OPERATION ‘SOUND POWER RATINGS ‘A sound power level s a measure of the total noise radiated by the machine in all directions It is a property of the machine and is essentially independent of the measuring environment. Sound ower levels are useful to equipment manufacturers, buyers, installers, and users for Calculating the sound pressure level from 3 machine at a given distance in a given environment. Comparing the noise output from different machines. Setting specifications for the maximum permitted noise from a machine. Comparing machines before and after modifications to reduce the noise, Sound power is measured in watts or picowatts, and sound power levels are traditionally given in decibels (dB re 1pWN). Refer table 8 for sound power level of whole unit. aia Gel ale = Table 8: Sound Power Levels (OMS SABER UNIT) VOLT FREE CONTACT All Saber units are supplied with Volt free contact, Refer to Electrical wiring schematic that are pasted inside the unit. A caution HOOK UP EMERGENCY SHUT ~ OFF BUTTON SEQUENCE OF OPERATIONS OVERVIEW For these units, the thermostat makes a circuit between "R" and "YI" for the first stage of cooling. The call is passed to the Unit control board (UCB), which then determines whether the requested operation is avaliable and, if so, which components to ‘energize. 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 If at any time 2 cal for both heating and cooling are present, the heating operation will be performed. f operating, the cooling system is halted as with a completion ofa call for cooling. Heating always takes priority, Page 17 COOLING SEQUENCE OF OPERATION CONTINUOW> BLOWER By setting the room thermostat fen switch to "ON" the supply air blower will operate continuously INTERMITTENT BLOWER 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 operation is, requested. The blower is energized after any specified deloy associated with the operation. When energized, the indoor blower has @ minimum run time of 30 seconds. Additionally, the indoor blower has a delay of 10 seconds between operations. No OUTDOOR AIR OPTIONS When the thermostat calls for the fist stage of cooling, the low-voltage control circuit from "R" to "YI" and °G’ is completed, For frst stage cooling, compressor #1, condenser fan mator # 1 & 2are energized. After completing the specified fan on delay for cooling, the UCB will energize the blower motor. When the thermostat calls for the second stage of cooling, the low-voltage control circuit from °R” to "Y2" is completed. Compressor # 2is energized, provided it has not been locked ut. If there is an initial cal for both stages of cooling, the UCB will delay energizing compressor # 2 by 30 seconds in order to avoid a power in rush. Once the thermostat has been satisfied, it will de-energize Y1 and Y2. Ifthe compressors have satisfied their minimum 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 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, 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 compressors HIGH PRESSURE LIMIT SWITCH During cooling operation, if a high pressure limit switch opens, ‘the UCB will de-energize the associated compressor, intiate the ASCD (anti short cycle delay), and, if the other compressor is idle, stop the condenser fans. If the call for cooling is stil present at the conclusion of the ASCD, the UCB will re-energize the halted compressor. Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) Should a high pressure switch open three times within two hours of operation, the UCB will lock out the associated compressor and flash a code (see Table 9). If the other compressor is inactive, the condenser fans will be de-energized, LOW PRESSURE LIMIT SWITCH The low pressure limit switch is not monitored during the initial 30 seconds af a cooling system's operation. For the following 30 seconds, the UCB will monitor the low pressure switch to ensure it closes. Ifthe low pressure switch fails to close after the 20 second monitoring phase, the UCB will de-energize the associated compressor, initiate the ASCD, and, ifthe other compressor is idle, stop the condenser fans. Once the low pressure switch has been proven (closed during the 30 second monitor period described above), the UCB will ‘monitor the low pressure limit switch for any openings. Ifthe 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 condenser fans. Ifthe cal for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the halted compressor. Should a low pressure ‘witch open three times within one hour of operation, the UCB will lock out the associated compressor and flash a code (Table 9). Ifthe other compressor is inactive, the condenser fans will be de-cnergized. 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. Ifthe cal for cooling is still present at the conclusion ef the ASCD, the UCB will eenergize the halted compressor. Should a freezestat open three times within two hours of operation, the UCB wil lock out the associated compressor and flash a code (Table 9). ifthe other Comprassor is inactive, the condenser fans will be de-energized, LOW AMBIENT COOLING (OPTIONAL) To determine when to operate in low ambient made, the UCB has a pair of terminals connected to a temperature activated switch set at 50 F. When the low ambient switch is closed and the thermostat is calling for cooling, the UCB will operate in the low ambient mode. Low ambient mode operates the compressors in this manner 410 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. Low ambient made always begins with ‘compressor operation. Compressor minimum run time may extend the minutes of compressor operation The defrost cycle will begin immediately following the elapse of the minimum run time. When operating in ow ambient mode, the UCB will not lockout the compressors due to a freezestat trip. However, a freezestat trip will de-energize the associated compressor. Ifthe call for cooling is still present at the end of the ASCD and the freezestat has closed, the unit will resume operation ial YORK BY JOHNSON CONTROLS Page 18 SAFETY CONTROLS The unit control board monitors the following inputs for each cooling system 1. A.sucton line freezestat to protect against low evaporator temperatures due too low air flow or alow Installation, fetuin air temperature, (opens at 26 + S°F and resets at 38 + sr. 2. igh pressure switch to protect against excessive discharge pressures due to a blocked condenser col ora condenser motor failure, (opens at 415 + 15 psig and resets at 280 + 15 psig 3. Alow pressure switch to protect agains loss of refrigerant charge, (opens at 35 + 5 psig and resets at 60 = § psig) The above pressure switches are hard soldered to the unit. ‘The refrigeration systems are independently monitored and controlled. On any feutt, only the associated system will be attected by any safety / preventive action. ‘The other refrigarant system will continue in operation unless it is affected by the fault as well. The unit control board monitors the temperature limit switch of electric heat units. COMPRESSOR PROTECTION 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 damage. ‘An anti short cycle delay (ASCD) is utilized to prevent operation cof a compressor to0 soon after its previous run. Adcltionally, ' minimum run time is imposed any time a compressor is energized. The ASCD is initiated on unt start up and on any compressor, reset or lock out. FLASH CODES The UCB will initiate a flash code associated with errors within the system. Refer to UNIT CONTROL BOARD FLASH CODES Table 9 RESET Remave the call for cooling, by rising thermostat setting higher than the conditioned space temperature. This resets any pressure or freezestat flash codes. ELECTRIC HEATING SEQUENCE OF OPERATIONS The following sequence describes the operation of the electric heat section. Two-stage heating (Heaters MUST use a two stoge thermostat) Upon a call fr first-stage heat by the thermostat, the heater contactor will be energized. After completing the specifiedInstallation, Operation & Maintenance Manual # 036-1007(0608) fan on delay for heating, the UCB will energize the blower ‘motor. I the second stage of heat is required, second heater contactor will be energized. After completing the specified fan on delay for heating, the UCB will energize the blower motor. b. The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space. HEATING OPERATION ERRORS TEMPERATURE LIMIT Ifthe UCB senses zero volts from the high temperature limit, the indoor blower motor is immediately energized. Ths limit is ‘monitored regardless of unit operation status, i.e the limit is ‘monitored at all times. If the temperature limit opens three times within one hour, it will lock-cn the indoor blower motor and 3 flash code is initiated (See Table 9). SAFETY CONTROLS The unit control board monitors the temperature limit switch of electric heat units. The contral circuit includes the following safety contvols Temperature Limit Switch (AUTO) This control is located inside the heater compartment and is set to open at 120°F. It resets automatically. The limit switch ‘operates when a high temperature condition, caused by inadequate supply ar flow occurs, thus shutting down the heater and energizing the blower. RESET Remove the call for cooling, by raising thermostat setting higher than the conditioned space temperature. This resets any pressure or freezestat flash codes. FLASH CODES ‘The UCB will initiate a flash cade associated with errors within the system. Refer to UNIT CONTROL BOARD FLASH CODES Table 9. START UP (COOLING) PRESTART CHECK LIST After installation has been completed 1. Check the electrical supply voltage being supplied. Be sure that itis the same as listed on the unit nameplate 2. Set the room thermostat to the on position, 3, Turn unit electrical power on. 4, Set the room thermostat fan switch to on. Page 19 5, Check indoor blower rotation. If lower ratatin isin the wrong direction, Refer to Phasing Section in general information section. Check blower dive belt tension. Check bearing lubrication. I t requires lubrication, grease it. 6. Check the unit supply air (CFM). 7. Measure evaporator fan motor amp draw, 8. Set the room thermostat fan switch to off 9, Turn unit electrical power off OPERATING INSTRUCTIONS. 1. Turn unit electrical power on. 2. Set the room thermostat setting to lower than the room temperature. 3, ist stage comprescors will energize after the builtin time delay (five minutes) 4. The second stage of the thermostat will energize econd stage compressor if needed. POST START CHECK LIST 1. Verify proper system pressures for both circuits 2. Measure the temperature drop across the evaporator coil 3, Measure the system Amperage draw across all legs of 3 phase power wires, 4. Measure the condenser fan amp draw. SHUT DOWN 1. Set the thermostat to highest temperature setting 2. Turn aff the electrical power tothe unt BELT DRIVE BLOWER ‘All units have belt drive single-speed blower mators. The variable pitch pulley on the blower motor can be adjusted to obtain the desired supply air CFM, Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) TROUBLE SHOOTING COOLING TROUBLE SHOOTING GUIDE WARNING ‘TROUBLESHOOTING OF COMPONENTS MAY REQUIRE OPENING| THE ELECTRICAL CONTROL BOX WITH THE POWER CONNECTED TO THE UNIT. USE EXTREME CARE WHEN WORKING WITH LIVE, CIRCUITS! CHECK THE UNIT NAMEPLATE FOR THE CORRECT LINE | VOLTAGE AND SET THE VOLTMETER TO THE CORRECT RANGE | BEFORE MAKING ANY CONNECTIONS WITH LINE TERMINALS. Troubleshooting of components may require opening the electrical control box with the power connected to the unit. Use extreme care when working with lve circuits! Check the Unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any Connections with fine terminals. When not necessary, shut off all electric power to the unt prior to any of the following maintenance procedures so as to prevent personal injury. A caution LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING! CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND! DANGEROUS OPERATION, WHICH COULD CAUSE INJURY’ TO PERSON AND/OR DAMAGE UNIT COMPONENTS. VERIFY! PROPER OPERATION AFTER SERVICING, On calls for cooling, ifthe compressors are operating but the supply ar 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 ON position. Ifthe supply ar blower motor does not energize, go to Step 3 2. Ifthe blower motar runs with the fan switch in the ON position but will not run after the frst compressor has. energized when the fon 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. Ifthe supply air blower motor does not energize when the fan switch is set to ON, check that line voltage is being supplied to the blower contactor, and that the contactor is pulled in. Check for loase wiring between the contactor and the supply air blower motor. 4, Ifblower contactor is pulled in and voltage is supplied to contactor, lightly touch the supply air blower motor housing, If tis hot, the motor may be off on intemal protection Cancal any thermostat calls and set the fan switch to AUTO. Wait for the internal overload to reset. Test again when cool ial YORK BY JOHNSON CONTROLS Page 20 5, Ifblower contactor is not pulled in, check for 24 volts at the contactor col. f 24 volts are present but itis not pulled in, replace the contactor, 6. Failing the above, if there is line voltage supplied at Contactor and its pulled in, and the supply air blower motor sii does not operate, replace the motor. 7. If 24-volts is not present at blower contactor, 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 blower 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 thermactat, check for the following 2. 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), b. Proper wiring between the room thermostat and the UCB, and Loose wiring from the room thermostat to the UCB. 9, 124 volts is present at the room thermostat but nat at the UCB, check for proper wiring between the thermostat and the UCB, ie. that the thermostat G terminalis connected to ‘the G terminal of the UCB, and for loose wiring, 20. Ifthe thermostat and UCB are properly wired, replace the cB, (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) 1. If compressor # 1 does not energize on a cal for cooling, check for line voltage at the compressor contactor 1, and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor. 2. If compressor contactor 1 is pulled in and voltage is suppliag, lightly touch the compressor housing. If itis hot, the compressor may be off on inherent protection, Cancel any calls for cooling and wait forthe internal overload to reset, Test again when cool 3. If compressor contactor 1 is not pulled in, check for 24 volts atthe coil. If 24 volts are present and contactor is net pulled in, replace the contactor, 4. Failing the above, if voltage is supplied at compressor Contactor 4, its pulled in, and the comprescor still does not operate, replace the compressor, 5, If 24.vots is not present at compressor contactor 1, check for 24 volts at the UCB terminal, C1. iF 28 vols is present, check for loose wiring between Cl and the compressor contactor 6. If 24-vots is not present at the C1 terminal, check for 24 volts from the room thermostat at the UCB Y1 terminal. 24 volts is not present from the room thermostat, check for the followingInstallation, Operation & Maintenance Manual # 036-1007(0608) 24 volts at the thermostat ¥1 terminal Proper wiring between the room thermostat and the UCB, Le Vito Y2, Y2to ¥2 Loose wiring from the room thermostat to the UCB, 7.1 24.volts is present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure switch, low- pressure switch, or freezestat. Chack for 24 votts at the HPS1, LPS1, and FS1 terminals of the UCB. If switch has ‘opened, there should be a voltage potential between the UCB terminals, €.. if LPS1 has opened, there will be 2 24 volt potential between the LPS1 terminals 8, 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 an alarm code. Ifnot, press and ralease the [ALARMS burtan on the UCB. Te UCB will fash the last five alarms on the LED. Ifthe compressor is locked out, cancel any call for cooling, This will reset any compressor lock outs. NOTE : While the above step will reset any locxouts. curapresso: ¢ 1 may be held off for the ASLD. See the next, step. 9. If 24 vols 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. 10. Ifnone of the above corrected the errar, test the intagrty of the UCB, Disconnect the C1 terminal wire and jumper it to the YI terminal, DO NOT jump the YI to C1 terminals, Ifthe compressor engages, the UCB has fauited 11. Ifnone of the above correct the errar, replace the UCB. On calls for the second stage of cooling, the supply ar blower ‘motor and compressor # 1 are operating but compressor # 2 is, rot (the room thermastat fan switch is in the “AUTO” position) 1. Compressor # 2 will nt energize simultaneously with compressor #1 ifa call for both stages of cooling is received. The UCB delays compressor # 2 by 30 seconds to prevent power surge. If after the delay compressor # 2 does not energize on a second stage call for cooling, check for line voltage at the compressor contactor 2, and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor, 2. If compressor contactor 2 is pulled in and voltage is supplied, lightly touch the compressor housing. Ifit is hot, the compressor may be off on inherent protection. Cancel any cals for cooling and wait forthe internal overload to reset. Test again when coal 3. If compressor contactor 2is not pulled in, check for 24 volts at the compressor contactor coil f 24 volts is present and Page 21 compressor contactor is not pulled in, replace the contactor. 4. Failing the above, if voltage is supplied at compressor contactor 2, and itis pulled in, and the compressor stil does not operate, replace the compressor. 5. If 24 volts is not present at compressor contactor 2, check for 24 volts at the UCB terminal, C2. If 24 volts are present, check for loose wiring between C2 and the compressor contactor. 6. 1f24 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 24 volts at the thermostat ¥2 terminal Proper wiring between the room thermostat and the UCB, Le Vito ¥1, Y2 to ¥2 Loose wiring from the room thermastat to the UC. 7. 1 24-vots is present at the UCB Y2 terminal, the compressor may be out due to an open high pressure switch, low pressure switch, or freezestat. Chack for 24 volts at the HPS2, LPS2, and F52 terminals of the UCB. fa 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 terminals. 8. 1f24:vols is present at the UCB Y2 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 LCB will fash the last five alarms fon the LED. if the compressor is locked out, remove any call for cooling at the thermostat or by disconnecting the thermostat wiring at the Y2 UCB terminal. This will reset any Installation, compressor lock outs. NOTE : While the above step will reset any lock outs, compressor # 1 will be held off for the ASCD, and compressor # 2 may be held otf for a portion of the ASLD. See the riext step. 9, 1f 24 vols 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, 20. The UCB con be programmed to lock out compressor ‘operation during free cooling and in low ambient conditions, These options are not enabled by default. Local distributors can test the UCB for this programming, U1, Ifnone of the above corrected the error, test the integrity of ‘the UGB. Disconnect the C2 terminal wire and jumper it to ‘the Y2 terminal. DO NOT jump the Y2 to C2 terminals. if the Compressor engages, the UCB has faulted 12. Ifnone of the above correct the error, replace the UCB. Johnson WK ControlsInstallation, Operation & Maintenance Manual # 036-1007(0608) On a call for cooling, the supply air blower motor and compressor # 2 are operating but compressor # 1 is not (the room thermostat fan switch is in the “AUTO” position) 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 ifthe LED is nat flashing an alarm, 2. Check for line voltage at the compressor contactor 1 and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor. 3, If compressor contactor 1 is pulled in and voltage is supplied at the contactor 1, lightly touch the compressor housing. If itis hot, the compressor 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 compressor contactor 1is not pulled in, check for 24 volts at the coil. If24 volts is present and compressor contactor 1 isnot pulled in, replace the contactor. 5, Failing the above, if voltage is supplied at compressor contactor 1, and its pulled in, and the compressor still does rot operate, replace the compressor. 6. If 24 volts is not present at compressor contactor, check for 24 volts at the UCB terminal, C1 I 24 volts is present, check for loose wiring between Cl and the compressor contactor 1 7. 124 volts is not present at the C1 terminal, check for 24 volts from the room thermostat at the UCB Yi terminal 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 lass of call for the fist stage of cooling, i. a loss if 24 volts at the Yi terminal 8. 1f24 volts are present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure ‘witch, low-pressure switch, or feeezestat. Check for 24 volts at the HPS1, LPS1, and FS1 terminals of the UCB, Ifa switch has opened, threshold be a voltage potential between ‘the UCB terminals, eg. if LPS1 has opened, there willbe 3 24- volt potential between the LPSt terminals. 9,24 volts is present at the UCB Y1 terminal and none of the protection switches have opened, the UCB may have lacked out the compressor for repeat trips. The UCB should be flashing a cade. If not, press and release the ALARMS button on the UCB. The UCB will flach the last five alarms on the LED. IF the compressor is locked out, remove any call for cooling. This will eset any compressor lock outs. NOTE : While the above step will reset any lock outs, compressor # 2 will be held off for the ASLD, and compressor # 1 may be held off for « portion of the ASCD. ial YORK BY JOHNSON CONTROLS Page 22 See the next step. 10. 1f 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, 11. 1f24 volts is present at the UCB Y1 terminal and the Compressor is nat 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 YI “OUT terminal of the UCB. IF 24 vols is present, trace the wiring from Y1 “OUT” for incorrect witing. If 24 volts is nat present at the Y1 "OUT" terminal, the UCB must be replaced 12, Ifnone of the above corrected the errar, test the integrity of the UCB. Disconnect the C1 terminal wire and jumper it to the Y1 terminal. DO NOT jump the ¥1 to C3 terrninas. Ifthe compressor engages, has faulted. 12. I none of the above correct the error, replace the UCB, UNIT FLASH CODES Various flash codes are utilized by the unit control board (UCB) to aid in 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 @ 1 second on, 1 second off heortbeat during normal operation. This is to veify thatthe UCB is functioning correctly Do not confuse this with an error lash code. To prevent Confusion, 0 1-flash, lash code is not used. Current alarms are flashed on the UCB LED. Pressing and releasing the ALARMS button on the UCB can check the alarm history. The UCB will cycle through the last five (6) alarms, most recent to oldest, separating each alarm flash code by approximately 2 seconds 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 releose the UCB TEST button once. ‘See page 23 for Table 9, Unit Fash Codes.Installation, Operation & Maintenance Manual # 036-1007(0608) UNIT FLASH CODES Fish Code | Devcon On Sisady | C= Wel Faive Rap ave Oo] Heart Beat | eral Option Fish | ppicabie 2Flashes | Cont visting ASLO" eFlshes | HOS! Compressor tocie.t “dFlastes | Hse Compress Losiut Flashes | .-St-Conyresor oat Flashes | _.PS2-Conpre sor ocecut “Flashes | FSI. Compress oct TFastes | SP Conpeeor conan “Flashes | No arper Ploy al Secion ‘e saahes | Con.pressors chad Ov on Lay Our. Terps T1Fasnes | Nt Aicabie TeFasnes | Fan U-ef020 Sich To 13 Faahes | Compressor Hel Of Due fo ow Valape ‘eFishes. | EEPROM Storage Fsiue (Conta Fale OFF No Powe of Conta Fale 7 These sh codes co nol erase Bam Table 9: Unit Flash Codes MAINTENANCE ‘The Saber Packaged Air Conditioners are premium quality machines with very low maintenance requirements, Compressors used in Saber Packaged Units are of Scroll type and are charged with the correct amount of refrigerant and lubricating oil. Unless there is a leak in the system, no topping up is generally required. Standard DMS Saber Models except 16TR models (OMS 190) need lubrication every 12 months. EVERY MONTH Remove the filters and blow compressed air over them to get rid of loose dust, Visually inspect the fier conditions replace them with new ones of same sizes if require. Saber Packaged Air Conditioners are provided with a specially designed drain pan, for proper maintenance check and clean blockages at drain connections if any. EVERY 3 MONTHS In eddtion to the monthly maintenance above, check the belt tension of evaporator fan. A correct tension is indicated when the belt has a relaxation of approximately 10mm to 13mm when pressed lightly with a finger. EVERY SIX MONTHS. In addition to the maintenance done every three months The condenser coils should be cleaned by spraying water ver it at low pressure or with a brush while ensuring that the fins are not damaged Page 23 Check al electrical connections and tighten them if required. Clean all accassible electrical panels of dirt and dust. Before Cleaning the contral panels, ENSURE that the electrical power to the unit is switched off. EVERY 12 MONTHS In addition to the maintenance done every six months. Use a proper cleaning cloth to clean fan blades and motors. Ensure thatthe unit is working properly by checking, current, voltages, pressures and temperatures, CCheck the earthing or grounding ofthe unit. CCheck the exterior of the unit for any signs of corrosion, Even though it s highly unlikely, if any corrosion that is seen, should be removed by proper sanding the surface. Repaint the unit with proper touch up paint, available from York, CCheck the unt for any unusual vibrations or noise, locate the ‘cause and rectify it by changing mounts, base isolators etc, as required Johnson WK ControlsJohnson Controls provides comfortable environments wherever you Live, Work or Travel Whether you're at home, it. car, or it office oF workplace, chafwes are there's 8 ohnson Co.trols product or service nearby, helpiig to make your envirorma,:t mere comfortable, safe and sustainable. Johnson controls creates smart environments that improve the places .chere people syend most of ‘heir time their homes, workplaces and vehicies. we anticipate consumer reeds, ana then integrate technologies, products and services to snake lite better and easier ror Johnson Controls, sustainability matters at every levet and thro_zh our products, service operations and ‘community involvement, we promote the efficient use o resources to benefit all people and the world Our triple bottom line of sustainability that i, economic prosperity, environmental stewardship and social resporsibilty impacts each and every aspect of our business. York products are now a prewier brand ‘manufactured by Johnson Controls. vhe ac,uisition of York, gives us a unique insight into designing t¥AC products that match your exact reyuirements. We provide solutions for today's most critical concerns eneray efficiency, refrigerant alternatives and indoor air quality Johnson Controls has a wide range of York products for residential, ight commerial and commercial ‘applications. Our offering includes package & split air conditioners and heat pumps. In addition, Johnson Controls offers chillers, air handling units, ventilation equipment and controls for larger projects. ur advanced technology is leading the way in developing efficient and environment friendly solutions for your homes, offies and places of leisure Let us create the ideal envi vent fo you Installation, Operation & Maintenance Manual 036-1007(0608) ‘Supersedes 10M 036-100710506) so He ema sige cnt er rin be pcs y sensen Corl Mise Est Hand Oe Johnson YK P.O. Box 31065, API World Tower, Sheikh Zayed Road Dabo Unted Ao Ete. Controls Tel +9714 3326050 Fax +9714 1326074 INGENUITY WELCOME