Johnson controls York dms saber series Instruction manual

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 27

NOTES

............................................................................................................................................................

Installation, Operation & Maintenance Manual IOM # 036-1011(0806) 60 Hz

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 2

TABLE OF CONTENTS

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

START UP

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

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

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

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

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

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

GENERAL

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

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.

RENEWAL PARTS

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.

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.

TYPICAL UNIT CONFIGURATION

CAUTION

THIS PRODUCT MUSTBE INSTALLED IN STRICT COMPLIANCE

WITH THE ENCLOSED INSTALLATION INSTRUCTIONS AND

ANY APPLICABLE LOCAL, STATE, AND NATIONAL CODES

INCLUDING, BUT NOT LIMITED TO, BUILDING, ELECTRICAL,

AND MECHANICAL CODES.

WARNING

IMPROPER INSTALLATION MAY CREATE A CONDITION

WHERE THE OPERATION OF THE PRODUCT COULD CAUSE

PERSONAL INJURY OR PROPERTY DAMAGE.

Page 3

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

FIGURE 1 : TYPICAL UNIT CONFIGURATION

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 4

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.

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

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 5

LOCATION

Use the following guidelines to select a suitable location for

these units :

1. Unit are designed for outdoor installation only.

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.

LENGTH OF FORKS MUST BE A MINIMUM OF 90”. Refer

to the Product Data Table 5 for unit weights.

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.

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.

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

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.

WARNING

DO NOT PERMIT OVERHANGING STRUCTURES OR SHRUBS

TO OBSTRUCT OUTDOORAIR DISCHARGE OUTLET.

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.

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 6

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

FIGURE 3 : FIXED OUTDOOR AIR DAMPER

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 7

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.

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.

Afused disconnect switch should be field provided based on

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.

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 AFIELD SUPPLIED DISCONNECT SWITCH.

Refer to Typical Wiring Diagram, Figure 7 and to the

appropriate unit wiring diagram for control circuit and power

wiring information.

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 2 : CONTROL WIRE SIZES

TABLE 3 : MINIMUM CFM LIMITATION

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 8

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.

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).

FIGURE 6 : TYPICAL FIELD WIRING SCHEMATIC

Installation, Operation and Maintenance Manual : 036-1011(0806) Page 9

PRODUCT DATA

TABLE 4 : PRODUCT DATA

Johnson Controls York DMS Saber Series Instruction manual

Popular Air Conditioner manuals by other brands