Johnson Controls SERIES 40 Installation Operation & Maintenance
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Johnson Controls SERIES 40 Installation Operation & Maintenance

Rooftop 25, 30 and 40 ton with ipu control
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PACKAGED ROOFTOP
AIR CONDITIONING UNITS
R-410A ONLY, GEN 5
INSTALLATION, OPERATION & MAINTENANCE
Supersedes 5276178-JIM-B-0117
5276178-JIM-C-0118
SERIES 40 ROOFTOP
25, 30 AND 40 TON
WITH IPU CONTROL
LD14136

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Summary of Contents for Johnson Controls SERIES 40

  • Page 1 PACKAGED ROOFTOP AIR CONDITIONING UNITS R-410A ONLY, GEN 5 INSTALLATION, OPERATION & MAINTENANCE Supersedes 5276178-JIM-B-0117 5276178-JIM-C-0118 SERIES 40 ROOFTOP 25, 30 AND 40 TON WITH IPU CONTROL LD14136...
  • Page 2 NOT be installed inside the micro panel. NO external wiring is allowed to be run through the micro panel. All wiring must be in accordance with Johnson Controls published specifications and must be performed ONLY by qualified Johnson Controls personnel. Johnson Controls will not be responsible for damages/problems resulting from improper connections to the controls or application of improper control signals.
  • Page 3 Johnson Controls whether the equipment has been modified and if current Applied Systems office.
  • Page 4 5276178-JIM-C-0118 NOMENCLATURE JOHNSON CONTROLS...

  • Page 5: Table Of Contents

    FILTERS ............................79 CONDENSATE DRAIN ........................79 Condensate Drain Piping .....................79 Condensate Drain Trap ......................79 COMPRESSORS .........................79 AIR HOODS ..........................79 Air Hoods for Fixed Outside Air ..................79 Air Hoods for Economizer ....................79 Air Hoods for Exhaust Air ....................80 FIELD WIRING ..........................80 JOHNSON CONTROLS...
  • Page 6 Piping Connections ......................88 STEAM HEAT..........................89 Piping Connections ......................90 SECTION 3 – START-UP .........................91 CRANKCASE HEATERS ......................91 CHECKING THE SYSTEM PRIOR TO INITIAL START (NO POWER) ........91 Unit Checks ...........................91 UNIT CHECKS – POWER APPLIED ...................92 Verifying Compressor Rotation ...................92 JOHNSON CONTROLS...
  • Page 7 ......................102 HOT WATER AND STEAM COILS ....................103 SECTION 4 – MAINTENANCE ......................114 GENERAL ..........................114 PERIODIC MAINTENANCE – MONTHLY .................114 Filters ...........................114 Linkages ..........................114 Compressors ........................114 Condenser Coils .........................114 PERIODIC MAINTENANCE – 3 TO 6 MONTHS ...............114 Motors ..........................114 JOHNSON CONTROLS...
  • Page 8 COMPRESSOR STAGING SEQUENCE ...................137 CONDENSER FAN OPERATION ....................138 LOW AMBEINT CONDENSER FAN OPERATION ..............138 ECONOMIZER ...........................138 Dry Bulb ..........................138 Single Enthalpy ........................138 Dual Enthalpy ........................139 Best Method ........................139 NonFlexSys Economizer ....................140 FlexSys Economizer ......................140 COMPRESSOR OPERATION....................140 Compressor Data ........................140 JOHNSON CONTROLS...
  • Page 9 MODULATING GAS HEAT ......................150 HOT WATER/STEAM HEAT ......................150 Programmed Data .......................150 Active SP ..........................150 Sequence of Operation ......................150 Freeze Protection ........................151 Freeze Fault .........................151 MORNING WARM UP ........................151 Sequence of Operation ......................152 ADAPTIVE MORNING WARM UP .....................152 Sequence of Operation ......................152 JOHNSON CONTROLS...
  • Page 10 PROGRAM ..........................175 OPTIONS ...........................175 DATE / TIME..........................175 SCHEDULE ..........................176 OPERATING HOURS / START COUNTER ................177 PRINTER ............................178 Set Up ..........................178 Report Section ........................178 SERVICE MODE ........................179 HISTORY ............................189 PASSWORD ..........................190 POWER UP BANNER ........................191 COMMUNICATION........................192 Communication Ports ......................192 JOHNSON CONTROLS...
  • Page 11 SECTION 7 – PARAMETER DEFENITIONS AND OPTIONS ............218 SECTION 8 – SERVICE .........................228 ANALOG INPUT OPERATION ....................228 Temperature Sensors ......................228 Duct Pressure Transducer ....................228 Building Pressure Transducer ...................229 Humidity Sensors .......................229 Sensor ..........................230 Furnace Status Input ......................230 FAULTS ............................231 MULTI MEDIA CARD .........................242 JOHNSON CONTROLS...
  • Page 12 TABLE 37 ELECTRICAL DATA 40 TON 460 VOLT WITH ERV ...........76 TABLE 38 ELECTRICAL DATA 40 TON 575 VOLT WITHOUT ERV ...........77 TABLE 39 ELECTRICAL DATA 40 TON 575 VOLT WITH ERV ...........78 TABLE 40 - PIPE SIZES ........................86 TABLE 41 - BLOWER SPEED RATE OF CHANGE ..............94 JOHNSON CONTROLS...
  • Page 13 TABLE 73 - POTENTIOMETER SETTINGS ................144 TABLE 74 - CFM ..........................147 TABLE 75 - HEAT STAGES ......................147 TABLE 76 - CFM ..........................148 TABLE 77 – HEAT STAGES ......................148 TABLE 79 - STATUS ........................162 TABLE 80 - UNIT DATA .........................163 JOHNSON CONTROLS...
  • Page 14 TABLE 100 - I/O CONTROL BOARD - ANALOG INPUT PIN OUTS .........236 TABLE 101 - WARNING DESCRIPTION ..................237 TABLE 102 - FAULT AUTO - RESET ....................239 TABLE 103 - FAULTS LOCKOUT ....................240 TABLE 104 - DATA LOG ERROR STATE ..................242 TABLE 105 - DATA LOG ERROR LOG DETAIL ................243 JOHNSON CONTROLS...
  • Page 15 FIGURE 37 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 40 GPM ........107 FIGURE 38 - HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 60 GPM ........108 FIGURE 39 - HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 80 GPM ........108 JOHNSON CONTROLS...
  • Page 16 FIGURE 76 - I/O CONTROL BOARD - BINARY OUTPUTS ............234 FIGURE 77 - I/O CONTROL BOARD - BINARY INPUTS ............235 FIGURE 78 - I/O CONTROL BOARD - ANALOG OUTPUTS .............235 FIGURE 79 - I/O CONTROL BOARD - ANALOG INPUTS (SEE TABLE 90 FOR PIN OUTS) 235 JOHNSON CONTROLS...

  • Page 17: Section 1 - Introduction

    Compressor Circuiting packaged rooftop air conditioner meet U.S. EPACT 1992 minimum requirements. The Series 40 is designed so that each scroll compressor has its own refrigeration circuit. This means more reliable compressors, and less equipment down time. With multiple circuits, if a compressor should ever fail on one circuit, the other circuit/s will remain operational to work to maintain occupied loads.

  • Page 18: Heating Section

    Condenser Fan Motors into the occupied zones of office and other commercial The condenser fan motors used on the Series 40 unit are buildings. This underfloor plenum incorporates the air Totally Enclosed Air Over (TEAO) to provide maximum distribution system with the building power, telecom, durability through any season.

  • Page 19: Controls

    If you cannot reach your gas supplier, call the fire department. BACnet The Series 40 can be adapted to operate with any The furnace and its individual shut-off building automation system that is BACnet compatible valve must be disconnected from the...

  • Page 20: All Models

    Follow all safety codes, including ANSI Z223.1-Latest Edition: wear safety glasses and work gloves; use quenching cloth for unbrazing operations; have fire extinguisher available for all brazing operations. JOHNSON CONTROLS...

  • Page 21: Figure 2 - Component Location

    COMPRESSOR ACCESS REAR RIGHT HEAT SECTION FRONT OPTIONAL POWER LEFT END OUTLET (115V) POWER EXHAUST ACCESS HEAT SECTION EVAPORATOR COIL AND DRAIN PAN ACCESS FILTER DRIERS FILTER ACCESS REAR SUPPLY BLOWER & MOTOR FIGURE 2 - COMPONENT LOCATION JOHNSON CONTROLS...
  • Page 22 5276178-JIM-C-0118 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 23: Section 2 - Installation

    JOHNSON CONTROLS...

  • Page 24: Talbe 3 - Standard Gas Heating Capacities

    • Cleaning solvents (such as perchloroethylene) • Printing inks, paint removers, varnishes, etc. • Hydrochloric acid • Cements and glues • Antistatic fabric softeners for clothes dryers • Masonry acid washing materials JOHNSON CONTROLS...

  • Page 25: Locations And Clearances

    LEFT RIGHT DO NOT use the unit roof to support any type of structure or bracing. LD14191A FIGURE 3 - UNIT CLEARANCES JOHNSON CONTROLS...

  • Page 26: Service Access

    These weights must be referred to when selecting a crane for rigging and figuring roof weight • Filter compartment economizer compartment loads. Contact your Johnson Controls Sales Office if (two doors). you have any questions regarding unit weights. •...

  • Page 27: Table 7 - Unit Center Of Gravity

    HOT WATER HEAT If a unit is to be installed on a roof curb 1 ROW COIL 2 ROW COIL other than a Johnson Controls roof curb, gasketing must be applied to all STEAM HEAT surfaces that come in contact with the 1 ROW COIL unit underside.

  • Page 28: Table 9 - Supply Fan Motor Vfd Weights

    10HP 15HP 15HP EXHAUST Note: If the Series 40 is VAV with ERV, add the weight of an NOTE: If the Millennium is VAV with ERV, add the SEE TABLE 10 exhaust VFD (it will be in the unit) MOTOR VFD weight of an exhaust VFD - it will be in the unit.

  • Page 29: Table 11 - General Physical Data

    6 / 1 6 / 1 6 / 1 STEPS (CV ONLY) 533 MBH “MODULATING” CAPACITY 12 / 2 12 / 2 12 / 2 STEPS (CV ONLY) 800 MBH “MODULATING” CAPACITY 17 / 3 STEPS (CV ONLY) JOHNSON CONTROLS...
  • Page 30 4 EA. 16 X 25 / 4 EA. 16 X 25 / 4 EA. 16 X 25 / NUMBER / SIZE 6 EA. 20 X 25 6 EA. 20 X 25 6 EA. 20 X 25 FACE AREA (SQ. FT.) 30.4 30.4 30.4 JOHNSON CONTROLS...

  • Page 31: Figure 6 - Bottom Supply And Return

    Ø 2-1/2” 1 -1 /2 " F P T 1-1/4” NPT DETAIL B DETAIL A DETAIL C (ELECTRICAL CONNECTION) (DRAIN CONNECTION) (GAS CONNECTION FOR COOLING ONLY AND ALL HEATING APPLICATIONS THROUGH CURB) FIGURE 6 - BOTTOM SUPPLY AND RETURN JOHNSON CONTROLS...

  • Page 32: Figure 7- End Return, Bottom Supply

    BASE RAIL 6.45" 2.31” 11” BASE RAIL 2-1/2" 1-1/2" FPT 1-1/4” NPT DETAIL B DETAIL A DETAIL C (DRAIN CONNECTION) (ELECTRICAL CONNECTION) (GAS CONNECTION THROUGH CURB) FOR COOLING ONLY AND ALL HEATING APPLICATIONS FIGURE 7- END RETURN, BOTTOM SUPPLY JOHNSON CONTROLS...

  • Page 33: Figure 8 - Bottom Return, Front & Rear Supply

    11” BASE RAIL 2-1/2" 1-1/2" FPT 1-1/4” NPT DETAIL B DETAIL A DETAIL C (DRAIN CONNECTION) (ELECTRICAL CONNECTION) (GAS CONNECTION THROUGH CURB) FOR COOLING ONLY AND ALL HEATING APPLICATIONS FIGURE 8 - BOTTOM RETURN, FRONT & REAR SUPPLY JOHNSON CONTROLS...

  • Page 34: Figure 9 - End Return, Front & Rear Supply

    11” BASE RAIL 2-1/2" 1-1/2" FPT 1-1/4” NPT DETAIL B DETAIL A DETAIL C (DRAIN CONNECTION) (ELECTRICAL CONNECTION) (GAS CONNECTION THROUGH CURB) FOR COOLING ONLY AND ALL HEATING APPLICATIONS FIGURE 9 - END RETURN, FRONT & REAR SUPPLY JOHNSON CONTROLS...

  • Page 35: Figure 10 - Partial Roof Curb Model 1Rc0455P

    5276178-JIM-C-0118 LD14177 FIGURE 10 - PARTIAL ROOF CURB MODEL 1RC0455P JOHNSON CONTROLS...

  • Page 36: Figure 11 - Field Installed Disconnect

    BE EXTENDED TO MOUNT A TALLER DISCONNECT DOOR WHEN OPEN SWITCH, BUT THESE FOUR POINTS SHOULD BE USED TO MOUNT THE RAILS TO THE UNIT. FIGURE 11 - FIELD INSTALLED DISCONNECT 259.68 35.42 39.31 93.43 15.00 241.22 FIGURE 12 – 25 TON OVERHEAD VIEW JOHNSON CONTROLS...

  • Page 37: Figure 13 - 30 And 40 Ton Overhead View

    FIGURE 14 – 25 TON MAJOR COMPONENT LAYOUT GAS HEAT BLOWER EVAPORATOR FILTER ECONOMIZER POWER CONDENSER SECTION SECTION SECTION SECTION SECTION EXHAUST SECTION 89.37” 27.40” 36.08” 29.73” 31.13” 41.94” 4.19” 64” FIGURE 15 – 30 AND 40 TON MAJOR COMPONENT LAYOUT JOHNSON CONTROLS...

  • Page 38: Figure 16 - Cabinet Door Configuration

    Doors # 1, 2, 3, 6, 7, 8. wide. Doors # 4, 5, 9 are dependent upon unit Heating Door configurations are the same on all tonnages and Power Exhaust Options. (40 ton shown). FIGURE 16 – CABINET DOOR CONFIGURATION JOHNSON CONTROLS...

  • Page 39: Cfm, Static Pressure, And Power - Altitude And Temperature Corrections

    0.801 0.772 0.743 0.715 0.688 0.982 0.947 0.913 0.880 0.848 0.817 0.787 0.758 0.730 0.702 0.676 0.964 0.929 0.897 0.864 0.833 0.802 0.772 0.744 0.716 0.689 0.663 0.946 0.912 0.880 0.848 0.817 0.787 0.758 0.730 0.703 0.676 0.651 JOHNSON CONTROLS...

  • Page 40: Figure 17 - Altitude/Temperature Conversion Factor

    Installation 5276178-JIM-C-0118 ALTITUDE/TEMPERATURE CONVERSION FACTOR 1.100 1.000 0.900 0.800 0.700 0.600 TEMPERATURE LD14179 FIGURE 17 – ALTITUDE/TEMPERATURE CONVERSION FACTOR JOHNSON CONTROLS...

  • Page 41: Figure 18 - 40 Ton Forward Curve Example

    5276178-JIM-C-0118 FIGURE 18 – 40 TON FORWARD CURVE EXAMPLE JOHNSON CONTROLS...

  • Page 42: Table 14 - Fan Performance - 25 Ton

    11.2 11.7 12.3 AVAILABLE EXTERNAL STATIC PRESSURE (IWG) AIRFLOW 4000 5000 6000 7000 8000 9000 10.0 10000 10.1 10.7 11.3 11000 10.5 11.1 11.7 12.3 12.9 12000 12.0 12.6 13.2 13.9 14.5 12500 12.9 13.6 14.2 14.8 15.5 JOHNSON CONTROLS...
  • Page 43 1. Fan performance is based on wet evaporator coils, clean 2” throwaway filters and system/cabinet effects at standard air density and 0 feet elevation. 2. Refer to Table 17 for component additions and deductions to fan performance tables. 3. BHP includes drive losses. 4. Shaded RPMs require Class II blower. JOHNSON CONTROLS...

  • Page 44: Figure 19 - Fan Performance - 25 Ton Forward Curve

    Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system and cabinet effects at standard air Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system density and 0' elevation. and cabinet effects at standard air density and 0' elevation. FIGURE 19 – FAN PERFORMANCE - 25 TON FORWARD CURVE JOHNSON CONTROLS...

  • Page 45: Table 15 - Fan Performance - 30 Ton

    10.1 10.7 11.3 12.0 11000 11.0 11.6 12.2 12.9 13.5 12000 12.5 13.2 13.8 14.4 15.0 13000 14.6 15.2 15.9 16.5 17.2 14000 16.6 17.3 18.0 18.7 1017 19.4 15000 18.9 19.6 1002 20.4 1021 21.1 1040 21.8 JOHNSON CONTROLS...
  • Page 46 1. Fan performance is based on wet evaporator coils, clean 2” throwaway filters and system/cabinet effects at standard air density and 0 feet elevation. 2. Refer to Table 17 for component additions and deductions to fan performance tables. 3. BHP includes drive losses. 4. Shaded RPMs require Class II blower. JOHNSON CONTROLS...

  • Page 47: Figure 20 - Fan Performance - 30 Ton Forward Curve

    Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system and cabinet effects at standard air and cabinet effects at standard air density and 0' elevation. density and 0' elevation. FIGURE 20 – FAN PERFORMANCE - 30 TON FORWARD CURVE JOHNSON CONTROLS...

  • Page 48: Table 16 - Fan Performance - 40 Ton

    11.8 12.5 13000 10.9 11.7 12.4 13.1 13.9 14000 12.2 12.9 13.7 14.4 15.2 15000 13.6 14.4 15.2 16.0 16.9 16000 15.1 15.9 16.8 17.6 18.4 17000 16.9 17.8 18.6 19.5 20.4 18000 18.7 19.6 20.5 21.4 22.3 JOHNSON CONTROLS...
  • Page 49 1. Fan performance is based on wet evaporator coils, clean 2” throwaway filters and system/cabinet effects at standard air density and 0 feet elevation. 2. Refer to Table 17 for component additions and deductions to fan performance tables. 3. BHP includes drive losses. 4. Shaded RPMs require Class II blower. JOHNSON CONTROLS...

  • Page 50: Figure 21 - Fan Performance - 40 Ton Forward Curve

    Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system and cabinet effects at standard air Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system density and 0' elevation. and cabinet effects at standard air density and 0' elevation. FIGURE 21 – FAN PERFORMANCE - 40 TON FORWARD CURVE JOHNSON CONTROLS...

  • Page 51: Table 17 - Component Static Resistance

    1. Baseline losses based on system/cabinet effects, wet standard coil and 2”throwaway filters at 70°F, 0 feet elevation with standard air. 2. See Tables 52, 53, 54 and 55 for hot water and steam water coil static resistance. JOHNSON CONTROLS...

  • Page 52: Table 18 - Supply Fan Motor And Drive Data

    86.5 1-3/8 11.3 1-11/16 30TON 215T 86.5 89.5 1-3/8 11.3 1-11/16 1069 254T 85.7 89.5 1-3/8 11.3 1-11/16 184T 86.5 1-3/8 11.3 1-11/16 40 TON 215T 86.5 89.5 1-3/8 11.3 1-11/16 1069 254T 85.7 89.5 1-3/8 11.3 1-11/16 JOHNSON CONTROLS...

  • Page 53: Table 20 - Power Exhaust - One Forward Curved Fan 25 Ton

    1077 10.1 1096 10.4 1119 10.8 1143 11.1 1167 11.4 1. Fan performance is based on system/cabinet effects and back draft damper effects at standard air density and 0 feet of elevation. 2. BHP includes 5% drive losses. JOHNSON CONTROLS...

  • Page 54: Figure 22 - Power Exhaust - One Forward Curve Fan - 25 Ton

    Power Exhaust 25 Ton 1600 1500 10 BHP 7.5 BHP 1400 5 BHP 1300 1200 1100 1000 10.0 12.0 14.0 16.0 18.0 CFM (x1000) LD14183 FIGURE 22 – POWER EXHAUST - ONE FORWARD CURVE FAN - 25 TON JOHNSON CONTROLS...

  • Page 55: Table 21 - Power Exhaust - Two Forward Curved Fans - 30 & 40 Ton

    15.54 1. Fan performance is based on system/cabinet effects and back draft damper effects at standard air density and 0 feet elevation. 2. BHP includes the sum of both exhaust fan motors. 3. BHP includes 5% drive losses. JOHNSON CONTROLS...

  • Page 56: Figure 23 - Power Exhaust - Two Forward Curved Fans - 30 & 40 Tons

    Installation 5276178-JIM-C-0118 LD14184 FIGURE 23 – POWER EXHAUST - TWO FORWARD CURVED FANS - 30 & 40 TONS JOHNSON CONTROLS...

  • Page 57: Electrical Data

    16.7 59.4 24.2 30.8 15.2 15.2 None/ 230-3-60 22.4 10.4 15.2 15.2 16.7 24.2 24.2 30.8 16.7 30.8 24.2 30.8 208-3-60 22.4 11.5 16.7 46.2 24.2 30.8 16.7 59.4 24.2 30.8 15.2 15.2 230-3-60 22.4 10.4 15.2 15.2 JOHNSON CONTROLS...
  • Page 58 16.7 30.8 24.2 30.8 208-3-60 22.4 60.1 11.5 16.7 46.2 24.2 30.8 16.7 59.4 24.2 30.8 15.2 15.2 230-3-60 22.4 10.4 15.2 15.2 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 59: Table 23 Electrical Data 25 Ton 230 Volt With Erv

    16.7 46.2 59.4 230-3-60 22.4 10.4 0.25 2.5 15.2 24.2 30.8 208-3-60 22.4 60.1 11.5 0.25 2.5 16.7 46.2 59.4 230-3-60 22.4 10.4 0.25 2.5 15.2 Minimum Circuit Ampacity. Dual Element, Time Delay Type. HACR type per NEC. JOHNSON CONTROLS...

  • Page 60: Table 24 Electrical Data 25 Ton 460 Volt Without Erv

    Stages Amps HP FLA HP FLA Amps Amps Amps Amps None/ 460-3-60 10.6 16.5 460-3-60 10.6 16.5 460-3-60 10.6 16.5 460-3-60 10.6 16.5 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 61: Table 25 Electrical Data 25 Ton 460 Volt With Erv

    10.6 75 16.5 2.15 0.25 1.2 460-3-60 10.6 75 16.5 2.15 0.25 1.2 460-3-60 10.6 75 16.5 2.15 0.25 1.2 460-3-60 10.6 75 16.5 2.15 0.25 1.2 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 62: Table 26 Electrical Data 25 Ton 575 Volt Without Erv

    Breaker Breaker Size Size QTY RLA Model kW Stages Amps HP FLA HP FLA Amps Amps Amps Amps None/ 575-3-60 575-3-60 575-3-60 575-3-60 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 63: Table 27 Electrical Data 25 Ton 575 Volt With Erv

    FLA HP FLA HP FLA AMPS AMPS AMPS AMPS NONE 575-3-60 0.25 0.95 5 575-3-60 0.25 0.95 5 575-3-60 0.25 0.95 5 575-3-60 0.25 0.95 5 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 64: Table 28 Electrical Data 30 Ton 208/230 Volt Without Erv

    230-3-60 10.4 7.5 24.2 10 30.8 10 30.8 15 46.2 7.5 24.2 15 46.2 10 30.8 15 46.2 208-3-60 11.5 7.5 24.2 20 59.4 10 30.8 15 46.2 7.5 24.2 25 74.8 10 30.8 15 46.2 230-3-60 10.4 JOHNSON CONTROLS...
  • Page 65 15 46.2 208-3-60 60.1 11.5 7.5 24.2 20 59.4 10 30.8 15 46.2 7.5 24.2 25 74.8 10 30.8 15 46.2 230-3-60 10.4 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 66: Table 29 Electrical Data 30 Ton 208/230 Volt With Erv

    0.25 2.5 15.2 0.25 2.5 16.7 10 30.8 0.25 2.5 7.5 24.2 16.7 15 46.2 0.25 2.5 7.5 24.2 208-3-60 25 164 60.1 11.5 16.7 20 59.4 0.25 2.5 7.5 24.2 16.7 25 74.8 0.25 2.5 7.5 24.2 JOHNSON CONTROLS...
  • Page 67 HP FLA HP FLA HP FLA AMPS AMPS AMPS AMPS 15.2 0.25 2.5 15.2 0.25 2.5 230-3-60 25 164 10.4 15.2 0.25 2.5 15.2 0.25 2.5 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 68: Table 30 Electrical Data 30 Ton 460 Volt Without Erv

    QTY RLA Model kW Stages Amps HP FLA HP FLA Amps Amps Amps Amps None/ 460-3-60 12.2 460-3-60 12.2 460-3-60 12.2 460-3-60 12.2 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 69: Table 31 Electrical Data 30 Ton 460 Volt With Erv

    21 0.25 1.2 460-3-60 12.2 100 27 0.25 1.2 34 0.25 1.2 14 0.25 1.2 21 0.25 1.2 460-3-60 12.2 100 27 0.25 1.2 34 0.25 1.2 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 70: Table 32 Electrical Data 30 Ton 575 Volt Without Erv

    Size Size QTY RLA LRA MCC Model kW Stages Amps HP FLA HP FLA Amps Amps Amps Amps None/ 575-3-60 575-3-60 575-3-60 575-3-60 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 71: Table 33 Electrical Data 30 Ton 575 Volt With Erv

    11 0.25 0.95 17 0.25 0.95 575-3-60 22 0.25 0.95 27 0.25 0.95 11 0.25 0.95 17 0.25 0.95 575-3-60 22 0.25 0.95 27 0.25 0.95 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 72: Table 34 Electrical Data 40 Ton 208/230 Volt Without Erv

    None/ 208-3-60 28.2 11.5 24.2 59.4 30.8 46.2 24.2 74.8 30.8 46.2 None/ 230-3-60 28.2 10.4 24.2 30.8 30.8 46.2 24.2 46.2 30.8 46.2 208-3-60 28.2 11.5 24.2 59.4 30.8 46.2 24.2 74.8 30.8 46.2 230-3-60 28.2 10.4 JOHNSON CONTROLS...
  • Page 73 24.2 30.8 30.8 46.2 24.2 46.2 30.8 46.2 208-3-60 28.2 60.1 11.5 24.2 59.4 30.8 46.2 24.2 74.8 30.8 46.2 230-3-60 28.2 10.4 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 74: Table 35 Electrical Data 40 Ton 230 Volt With Erv

    25 74.8 0.25 2.5 7.5 24.2 15.2 28 0.25 2.5 15.2 42 0.25 2.5 230-3-60 28.2 240 10.4 15.2 54 0.25 2.5 15.2 68 0.25 2.5 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 75: Table 36 Electrical Data 40 Ton 460 Volt Without Erv

    RLA LRA MCC Model kW Stages Amps HP FLA HP FLA Amps Amps Amps Amps None/ 460-3-60 14.7 460-3-60 14.7 460-3-60 14.7 460-3-60 14.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 76: Table 37 Electrical Data 40 Ton 460 Volt With Erv

    460-3-60 14.72 130 23 27 0.25 1.2 34 0.25 1.2 14 0.25 1.2 21 0.25 1.2 460-3-60 14.72 130 23 27 0.25 1.2 34 0.25 1.2 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 77: Table 38 Electrical Data 40 Ton 575 Volt Without Erv

    HP FLA HP FLA Amps Amps Amps Amps None/ 575-3-60 11.3 93.7 17.6 575-3-60 11.3 93.7 17.6 575-3-60 11.3 93.7 17.6 575-3-60 11.3 93.7 17.6 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. JOHNSON CONTROLS...

  • Page 78: Table 39 Electrical Data 40 Ton 575 Volt With Erv

    575-3-60 11.3 93.7 17.6 22 0.25 0.95 27 0.25 0.95 11 0.25 0.95 17 0.25 0.95 575-3-60 11.3 93.7 17.6 22 0.25 0.95 27 0.25 0.95 MINIMUM CIRCUIT AMPACITY. DUAL ELEMENT, TIME DELAY TYPE. HACR TYPE PER NEC. JOHNSON CONTROLS...

  • Page 79: Filters

    Air Hoods for Fixed Outside Air Condensate Drain Piping (Units with Manual Economizer) The Series 40 cooling coils are located in the units so These hoods are factory installed. The dampers may that the supply air is drawn through them. This results...

  • Page 80: Air Hoods For Exhaust Air

    No external power source may be used when field wiring any of the above inputs. The 24VAC source on terminal 2 and 16 (R) of the Terminal Block CTB3 must be used as the power source when field wiring these inputs, JOHNSON CONTROLS...

  • Page 81: Vav Heat Relay Output

    BACNET COMMUNICATION overloading the unit power supply. The Series 40 rooftop unit can communicate to any MS/TP building automation system using BACnet The VAV Heat Relay output can be found at terminals communication protocol.

  • Page 82: Ctb3 Field Control Wiring (Inputs)

    If the sensor uses 24VAC additional wires will need to be run to terminal 1 (24VAC) and terminal 2 (24VAC COM) of the CTB3 terminal block. If the sensor required a different power source than 24VAC it will need to be field supplied. FIGURE 26 – FIELD CONTROL WIRING - INPUTS JOHNSON CONTROLS...

  • Page 83: Power And Control Wiring

    A removable patch plate covers both the openings. Use care to avoid damage when drill- ing holes for the disconnect mount- Waterproof connections MUST be ing. used to ensure that water cannot pen- etrate the roof or roof curb. JOHNSON CONTROLS...

  • Page 84: Transducer Pneumatic Tubing

    (next to the mounting location for the static pressure probe) to the atmospheric pressure probe (see Installation Instructions, Form 100.50- N15) ld11072 FIGURE 27 – STATIC PRESSURE PROBE INSTALLATION JOHNSON CONTROLS...

  • Page 85: Roof Curb Installation

    Johnson Controls will not be responsible for the unit fit up, leak integrity, or sound level with field fabricated Installation of elbows, discharge roof curbs.

  • Page 86: Gas Heating

    Before initial start-up, fitting. Line should not be sized smaller be sure that all of the gas lines external to the unit have been purged of air. than the entrance fitting size. JOHNSON CONTROLS...

  • Page 87: Vent And Combustion Air

    COMBUSTION AIR INLET HOT WATER HEAT The Johnson Controls Series 40 units (25, 30, and 40 Ton sizes) can be furnished with a Johnson Controls hot water coil as the heat source. One or two row coil units VENT FLUE ASSEMBLY will be factory installed in the heating section.

  • Page 88: Piping Connections

    In one row hot water coil systems DO conditioned. NOT exceed 40 gallons per minute flow rate. In two row hot water coil systems DO NOT exceed 80 gallons per minute flow rate. JOHNSON CONTROLS...

  • Page 89: Steam Heat

    5276178-JIM-C-0118 STEAM HEAT The Johnson Controls Series 40 units (25, 30 and 40 Ton sizes) can be furnished with a Johnson Controls single row steam coil. Johnson Controls steam coils are a factory installed option. LD14190 FIGURE 30 – STEAM PIPING CROSS-SECTION...

  • Page 90: Piping Connections

    The following figure illustrates the location of the compartment and piping connections. Piping access holes should be sealed with a heat resistant mastic to prevent damage to equipment. LD14189 FIGURE 31 – HOT WATER PIPING CROSS-SECTION JOHNSON CONTROLS...

  • Page 91: Section 3 - Start-Up

    To protect warranty, this equipment CHECKING THE SYSTEM PRIOR TO INITIAL START (NO POWER) must be installed and serviced by an authorized Johnson Controls service Unit Checks mechanic or a qualified service person experienced in air handling and con- 1. Inspect the unit for shipping or installation dam- denser unit installation.

  • Page 92: Unit Checks - Power Applied

    Change the incoming line connection phasing to obtain proper rotation. UNIT CHECKS – POWER APPLIED The Series 40 rooftop unit uses hermetic scroll 1. Apply 3-phase power and verify its value. Voltage compressors, which only pump in one direction.

  • Page 93: Air Balance

    Figure the pitch diameter (PD) of the motor sheave using the 56 and 57. formula below: (Specified CFM/Measured CFM) x PD of standard sheave = PD of new sheave. JOHNSON CONTROLS...

  • Page 94: Table 41 - Blower Speed Rate Of Change

    BHP at original start-up with 11,000 CFM and 856 RPM = (1.119) x 11 BHP = 1.4012 x 11 BHP = 15.41 BHP New motor amps = (speed increase) x measured motor amps at original start-up with 11,000 CFM and 856 RPM. JOHNSON CONTROLS...

  • Page 95: Drive Adjustment Tables

    103.4 97.0 100.0 (STD.) 116.3 106.8 100.0 105.5 120.4 110.2 103.0 113.7 124.5 113.6 106.0 121.9 116.9 112.0 120.3 120.9 123.7 129.9 1. (STD), STANDARD FACTORY SUPPLIED DRIVE. ALL OTHER DRIVE COMBINATIONS MUST BE PURCHASED AND FIELD INSTALLED. JOHNSON CONTROLS...

  • Page 96: Table 44 - 40 Ton Drive Adjustment For Constant Volume & Vav Units Class

    93.7 94.2 100.0 (STD.) 5.5 96.8 97.1 103.6 (STD.) 6.3 100.0 (STD.) 6.9 107.3 103.2 102.9 110.9 106.3 108.7 114.5 109.5 117.4 1. (STD), STANDARD FACTORY SUPPLIED DRIVE. ALL OTHER DRIVE COMBINATIONS MUST BE PURCHASED AND FIELD INSTALLED. JOHNSON CONTROLS...

  • Page 97: Table 47- 25 Ton Drive Adjustment For Intellispeed (Discrete Fan Control)

    5276178-JIM-C-0118 JOHNSON CONTROLS...

  • Page 98: Initial Start-Up

    Evaporator Superheat = 15°F Refrigerant Charge The Series 40 unit comes fully charged from the factory When adjusting the expansion valve, the adjusting with Refrigerant R-410A. Table 41 is a Temperature/ screw should be turned not more than one turn at a time, Pressure chart for R-410A.

  • Page 99: Leak Checking

    TABLE 50 - R410-A PRESSURE / TEMPERATURE CHART PSIG TEMP ˚F PSIG TEMP ˚F JOHNSON CONTROLS...

  • Page 100: Gas Furnace Operating Instructions

    6 inches. If gas pressure is 4. Remove the heat shield on top of the manifold outside these limits, contact the local gas utility support. Burners are now accessible for service. for corrective action. Reverse the above procedure to replace the assemblies. JOHNSON CONTROLS...

  • Page 101: Adjustment Of Temperature Rise

    (with allowance being made for the permissible range of the regulator setting), replace the orifice spuds with Thermal Expansion Valves: The Series 40 units have spuds of the proper size. 4 independent refrigeration systems. These TXVs are set to maintain 15°F superheat leaving the evaporator To find the BTU input, multiply the coil.

  • Page 102: Compressors

    TABLE 54 - STATIC RESISTANCE STEAM COIL (25 & 30 TON) 6000 8000 10000 12000 15000 AIR PRESSURE DROP 0.11 0.18 0.26 0.36 0.54 TABLE 55 - STATIC RESISTANCE STEAM COIL (40 TON) 8000 11000 14000 17000 20000 AIR PRESSURE DROP 0.18 0.31 0.48 0.67 0.88 JOHNSON CONTROLS...

  • Page 103: Hot Water And Steam Coils

    1. Based on 60°F entering air temperature, 2.00” maximum pressure drop across the hot water coil. TABLE 57 - WATER PRESSURE DROP (1 ROW, 25 & 30 TON) WATER PRESSURE DROP 10.0 TABLE 58 - WATER PRESSURE DROP (1 ROW, 40 TONS) WATER PRESSURE DROP 10.0 JOHNSON CONTROLS...

  • Page 104: Table 59 - Hot Water Coil (1 Row, 40 Ton)

    317.4 371.1 8000 249.8 313.3 377.1 441.1 10000 283.3 355.6 428.2 501.0 12000 312.7 392.7 473.0 553.6 15000 351.0 440.9 531.3 622.1 1. Based on 60°F entering air temperature, 2.00” maximum pressure drop across the hot water coil. JOHNSON CONTROLS...

  • Page 105: Table 61 - Water Pressure Drop (2 Row, 25 & 30 Ton)

    NOTE: Water pressure drop numbers are based on 60°F entering air temperature, 2.00” maximum air pressure drop across the hot water coil(s). ARI certified ratings at covering other conditions are available upon request. Hot water coils are approved for use with glycol (rates available upon request). JOHNSON CONTROLS...

  • Page 106: Figure 34 - Hot Water Coil - 25 & 30 Ton, 1 Row, At 10 Gpm

    1 4 0 0 0 1 5 0 0 0 F L O W R A T E (C F M ) LD14114 FIGURE 35 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 20 GPM JOHNSON CONTROLS...

  • Page 107: Figure 36 - Hot Water Coil - 25 & 30 Ton, 1 Row, At 30 Gpm

    1 4 0 0 0 1 5 0 0 0 F L O W R A T E (C F M ) LD14116 FIGURE 37 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 40 GPM JOHNSON CONTROLS...

  • Page 108: Figure 38 - Hot Water Coil - 25 & 30 Ton, 2 Row, At 60 Gpm

    1 4 0 0 0 1 5 0 0 0 F L O W R A T E ( C F M ) LD14118 FIGURE 39 - HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 80 GPM JOHNSON CONTROLS...

  • Page 109: Figure 40 - Hot Water Coil - 40 Ton, 1 Row, At 10 Gpm

    1 9 0 0 0 2 0 0 0 0 F L O W R A T E ( C F M ) LD14159 FIGURE 41 – HOT WATER COIL - 40 TON, 1 ROW, AT 20 GPM JOHNSON CONTROLS...

  • Page 110: Figure 42 - Hot Water Coil - 40 Ton, 1 Row, At 30 Gpm

    1 9 0 0 0 2 0 0 0 0 F L O W R A T E ( C F M ) LD14161 FIGURE 43 – HOT WATER COIL - 40 TON, 1 ROW, AT 40 GPM JOHNSON CONTROLS...

  • Page 111: Figure 44 - Hot Water Coil - 40 Ton, 2 Row, At 20 Gpm

    1 8 0 0 0 1 9 0 0 0 2 0 0 0 0 F L O W R A T E (C F M ) LD14163 FIGURE 45 – HOT WATER COIL - 40 TON, 2 ROW, AT 40 GPM JOHNSON CONTROLS...

  • Page 112: Figure 46 - Hot Water Coil - 40 Ton, 2 Row, At 60 Gpm

    1 9 0 0 0 2 0 0 0 0 F L O W R A T E ( C F M ) LD14165 FIGURE 47 – HOT WATER COIL - 40 TON, 2 ROW, AT 80 GPM JOHNSON CONTROLS...

  • Page 113: Figure 48 - Steam Coil - 25 & 30 Ton (1 Row)

    1 8 0 0 0 1 9 0 0 0 2 0 0 0 0 F L O W R A T E (C F M ) LD14167 FIGURE 49 – STEAM COIL - 40 TON (1 ROW) JOHNSON CONTROLS...

  • Page 114: Section 4 - Maintenance

    The driers may have to be period, Johnson Controls will not be liable for costs changed several times to clean up the system depending incurred to return the unit to satisfactory operation.

  • Page 115: Belt Tension

    5. After adjusting, retighten bolts holding motor to (INCHES) RELUBRICATION CYCLE (MONTHS) base channel. 1-1/16 - 1-7/16 1-1/2 - 1-3/4 1-7/8 - 2-3/16 2 -1/4 - 3 LD14168 DETAIL “B” DETAIL “A” FIGURE 50 - BELT TENSION ADJUSTMENT AND GAGE JOHNSON CONTROLS...

  • Page 116: Belt Replacement

    All set screws and/or taper lock bolts must to ensure proper equipment operation. Items such as be checked for tightness and alignment before putting loose hardware, component operation, refrigerant leaks, equipment into operation. unusual noises, etc. should be investigated and corrected immediately. JOHNSON CONTROLS...

  • Page 117: Supply And Exhaust Fan Motor

    If necessary, clean to maintain adequate combustion One end of each flue baffle is provided air discharge. with a sharper bend than the other end. This sharper bend must be positioned at the tube and attached with a stain- less steel screw. JOHNSON CONTROLS...

  • Page 118: Forward Curved Fans

    - see Figure 53. This will preserve the balance of the shaft in this area should be thoroughly cleaned before rotating assembly. Proceed with the following steps: the bearing is removed and again before the new bearing is installed. JOHNSON CONTROLS...

  • Page 119: Figure 54 - Bearing With Setscrew Type Locking Device

    Screws Lube There are various degrees of self-alignment in bearings Fitting of the same manufacturer. The force required for the self-alignment of the bearings used in Johnson Controls Lock Seal manufactured units has been specified and is closely Ring monitored at the factory. If it is necessary to purchase...

  • Page 120: Figure 55 - Bearing With Eccentric Cam

    The wide inner ring is now locked to the shaft. Using a punch or similar tool in the drilled hole of the collar, tap the tool lightly to lock the collar in the direction of normal shaft rotation. LD06358 FIGURE 56 - ECCENTRIC CAM LOCKING COLLAR BEARING INSTALLATION JOHNSON CONTROLS...

  • Page 121: Table 67 - Set Screw Torque

    1. Torque screw “A” to 1/2 recommended torque. lock washer 2. Torque screw “B” to full min. recommended bearings value. tapered sleeve 3. Torque screw “A” to full recommended value. 00536vip seal FIGURE 57 - SPLIT BEARING JOHNSON CONTROLS...

  • Page 122: Figure 58 - 25 Ton Charging Curve

    FIGURE 58 - 25 TON CHARGING CURVE 30 TON CHARGING CURVE 30 TON CHARGING CURVE 30 TON CHARGING CURVE 105 F 95 F 85 F 75 F 65 F SUCTION PRESSURE (PSIG) LD14105 SUCTION PRESSURE (PSIG) FIGURE 59 – 30 TON CHARGING CURVE JOHNSON CONTROLS...

  • Page 123: Figure 60 - 40 Ton Charging Curve

    FIGURE 60 – 40 TON CHARGING CURVE PRESSURE DROP ACROSS A DRY EVAPORATOR COIL PRESSURE DROP ACROSS A DRY EVAPORATOR COIL NOMINAL CFM (THOUSANDS) LD14107 FIGURE61 – PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 25 TON JOHNSON CONTROLS...

  • Page 124: Figure 62 - Pressure Drop Dry Evaporator Coil Vs Supply Air Cfm - 30 Ton

    PRESSURE DROP ACROSS A DRY EVAPORATOR COIL PRESSURE DROP ACROSS A DRY EVAPORATOR COIL 10 11 12 13 14 15 16 17 18 NOMINAL CFM (THOUSANDS) LD14109 FIGURE 63 – PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 40 TON JOHNSON CONTROLS...

  • Page 125: Figure 64 - R410A Quick Reference Guide

    FIGURE 64 – R410A QUICK REFERENCE GUIDE FIGURE 55 - R-410A QUICK REFERENCE GUIDE Subject to change without notice. Printed in U.S.A. 363825-YIM-A-0708 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 172619-YIM-C-0306 Johnson Controls Unitary Products 5005 York Drive...

  • Page 126: Section 5 - Sequence Of Operation

    User Interface. • “OCC COOLING W/O BYP” • “OCCUPIED HEATING” • “OCC HEATING LOW” • “OCC HEATING HIGH” • “OCCUPIED STANDBY” • “UNOCCUPIED COOLING” • “UNOC COOLING LOW” • “UNOC COOLING HIGH” • “UNOCCUPIED HEATING” JOHNSON CONTROLS...

  • Page 127: Table 68 - Digital Inputs For Staged Input Staged Input Mode

    COOLING HIGH -2.0 -1.0 -0.5 +0.5 +1.0 +1.5 +2.0 HEATING LOW HEATING HIGH Difference Between "ZONE TEMP" and "OCC ZONE HEATING" or "UNOCC ZONE HEATING" Set Point LD010572 FIGURE 65 - DIFFERENCES (°F) BETWEEN ZONE TEMPERATURE AND SET POINTS JOHNSON CONTROLS...

  • Page 128: Variable Air Volume Mode

    0.5°F the Unit Controller will place the unit in the OCCUPIED HEATING mode. The unit will remain in the OCCUPIED HEATING mode until the “RETURN AIR TEMP” is equal to or greater than the “RAT HEATING SETPOINT” plus 0.5°F. JOHNSON CONTROLS...

  • Page 129: Flexsys

    OPERATION) UNOCCUPIED UNOCCUPIED COOLING LOW 1ST STAGE COOLING SETPOINT UNOCCUPIED UNOCCUPIED COOLING HIGH 2ND STAGE COOLING SETPOINT UNOCCUPIED UNOCCUPIED HEATING LOW 1ST STAGE HEATING SETPOINT ON/OFF UNOCCUPIED UNOCCUPIED HEATING HIGH 2ND STAGE HEATING SETPOINT UNOCCUPIED UNOCCUPIED STANDBY NONE JOHNSON CONTROLS...

  • Page 130: Variable Air Volume

    SETPOINTS key / COOLING subsection The “SUPPLY AIR TEMP ACTIVE SP” is always derived from three programmed parameters “SAT HIGH • “FAN SPEED SETP FOR HIGH SAT” – SETPOINT”, “SAT LOW SETPOINT” and the “SAT SETPOINTS key / COOLING subsection JOHNSON CONTROLS...

  • Page 131: Figure 66 - Active Sat Set Point Vs. Supply Air Temp Rst Voltage

    Active SAT Set Point SAT LOW SETPOINT (Default = 55.0 °F) OAT SETPOINT OAT SETPOINT Outside Air Temp FOR HIGH SAT FOR LOW SAT (OAT) Increasing OAT FIGURE 67 - ACTIVE SAT SET POINT VS. OUTSIDE AIR TEMP LD12588 JOHNSON CONTROLS...

  • Page 132: Figure 68 - Active Sat Set Point Vs. Return Air Temp

    Set Point SAT LOW SETPOINT (Default = 55.0 °F) FAN SPEED FAN SPEED Supply Fan Speed FOR LOW SAT FOR HIGH SAT LD10308A Increasing Supply Fan Speed FIGURE 69 - ACTIVE SAT SET POINT VS. SUPPLY FAN SPEED JOHNSON CONTROLS...

  • Page 133: Flexsys With Bypass Damper

    ON or OFF until the timer has timed down. Controller enters an active cooling mode, the Unit The only exception to this would be if the compressor Controller sets the “COOLING CONTROL OFFSET” protection circuit experienced a fault. to 2.0°F. The Unit Controller compares the current JOHNSON CONTROLS...

  • Page 134: Compressor Operation With Economizer

    After a “COOLING CONTROL OFFSET” calculation is made the Unit Controller initiates a 45 minute Cooling Control Offset Timer. If no compressor is turned ON or OFF before the Cooling Control Offset Timer has expired, the “COOLING CONTROL OFFSET” will be reset to 2.0°F. JOHNSON CONTROLS...

  • Page 135: Supply Fan Operation

    As the pressure state for 10 seconds. If the input does not go to a high goes up, the speed goes down. state during this time frame the Unit Controller will set JOHNSON CONTROLS...

  • Page 136: Vav Supply Fan Speed Control Set Point Determination

    DUCT STATIC RESET HIGH SETP Active DSP Set Point DUCT STATIC RESET LOW SETP 5 Volts 0 Volts Duct Static Pres Rst LD10309A Voltage (Volts DC) FIGURE 70 - ACTIVE DSP SET POINT VS. DUCT STATIC PRES RST VOLTAGE JOHNSON CONTROLS...

  • Page 137: Compressor Staging Sequence

    THE UNIT CONTROL WILL SET NEXT STAGE TO DISABLE TO THE REMAINING COMPRESSOR STAGE 2 TO 1 FROM THE STAGE 4 TO 3 TRANSITION. THE UNIT CONTROL WILL SET NEXT STAGE TO DISABLE TO THE COMPRESSOR REMAINING STAGE 1 TO 0 FROM THE STAGE 3 TO 2 TRANSITION. JOHNSON CONTROLS...

  • Page 138: Condenser Fan Operation

    SAT SETPOINT”. The following parameters must be • The “OUTSIDE AIR TEMP” is less than or equal programmed into the Unit Controller through the User to the “SUPPLY AIR TEMP ACTIVE SP” plus Interface to enable economizer operation: 8°F. JOHNSON CONTROLS...

  • Page 139: Dual Enthalpy

    HUMIDITY SENSOR RELIABLE” are all true. • The “OUTSIDE AIR TEMP” is less than or equal With this setting, all of the above logic for Dry Bulb, to the “SUPPLY AIR TEMP ACTIVE SP” plus Single enthalpy, and Dual Enthalpy apply. 8°F. JOHNSON CONTROLS...

  • Page 140: Nonflexsys Economizer

    The number symbol will vary to match the compressor number the data is being recorded for, 1A (1), 1B (2), 2A (3) etc. This data can be view under the OPERATING HOURS / START COUNTER key of the User Interface. JOHNSON CONTROLS...

  • Page 141: Supply Air Tempering

    1 A and 1B. Likewise for system 2 they are identified as 2A and 2B. Since the Series 40 unit uses If the safety circuit opens three times in a 120-minute...

  • Page 142: Staged Gas Or Electric Heat

    • Compressor operation must have been OFF for 10 minutes. If the “SUPPLY AIR TEMP” is equal to or greater than • The “HEAT ENTERING TEMP” must be less JOHNSON CONTROLS...

  • Page 143: System Pump Down Control

    LOCKOUT TEMP” can never be set lower than 0.0°F. LOW AMBIENT FAN CONTROL OPTION The addition of a condenser fan VFD is programmed If the refrigerant system is configured for low ambient through “LOW AMBIENT PKG” which is under the JOHNSON CONTROLS...

  • Page 144: Operation And Pressure Control Range

    The VFD controls the fan speed based on discharge efficiency. pressure. Configuration (Jumpers and Potentiometers) TABLE 73 - POTENTIOMETER SETTINGS The inverter is configured at the factory. The jumpers 350 PSIG 80 PSIG 6 O’CLOCK 6 O’CLOCK LD11300B FIGURE 71 - CONDENSER FAN VFD POTENTIOMETER SETTINGS JOHNSON CONTROLS...

  • Page 145: Flexsys Bypass Damper Operation

    “RETURN AIR BYPASS ACTIVE SP” = x 100 “RETURN AIR TEMP” - “FLEX EVAP TEMP ACTIVE SP” FORMULA 1 MX SUPPLY AIR TEMP”- “FLEX EVAP TEMP” “ “RETURN AIR BYPASS CURRENT” = x 100 “RETURN AIR TEMP” - “FLEX EVAP TEMP” FORMULA 2 JOHNSON CONTROLS...

  • Page 146: Evaporator Superheat Calculation

    “SUPPLY AIR TEMP ACTIVE SP” plus programmed for CONSTANT VOLUME units the HEATING CONTROL OFFSET” additional through the SETPOINTS key, HEATING subsec- stages will be turned OFF after an Interstage tion of the User Interface. Delay timer has expired. JOHNSON CONTROLS...

  • Page 147: Staged Gas Heat

    HCO = time. 2.16 x CFM Where: When UNIT MODE is “STANDBY” and “UNDER • HCO = “HEAT CONTROL OFFSET” FLR TEMP OVRD” is active, one stage of heat is turned ON. • CFM = (See Table 67) JOHNSON CONTROLS...

  • Page 148: Active Sp

    “SUPPLY AIR TEMP ACTIVE SP” plus the of operation for each gas heat sections “HEATING CONTROL OFFSET” additional stages will be turned OFF after an Interstage The following information can be viewed for each Delay timer has expired. JOHNSON CONTROLS...

  • Page 149: Staged Gas Heat Ignition Sequence

    The faulted heat that heat section as “SAFETY LOCKOUT”. section will then initiate an ignition sequence, provided 13. If the “SUPPLY AIR TEMP” continues to be less the heating demand is still present. Staged Gas Heat Ignition Sequence JOHNSON CONTROLS...

  • Page 150: Modulating Gas Heat

    If the “SUPPLY AIR TEMP” is less than the • “HW VALVE ACTION” must be set to “DI- RECT” OR REVERSE” through the PROGRAM key, HEATING subsection of the User Inter- face. • “1ST STAGE HEATING SETPOINT” must be JOHNSON CONTROLS...

  • Page 151: Freeze Protection

    100% or 0 % if the valve Action is • “MORNING WARM UP” is set to USER DIS- programmed for “REVERSE” The Primary Control will ABLED. start a 5 minute Freeze Trip Timer. The STATUS screen • The occupancy mode is OCCUPIED. JOHNSON CONTROLS...

  • Page 152: Sequence Of Operation

    The “OCCUPANCY SCHEDULE” must be pro- 4. If the Return Air Temperature is less than or grammed for the Occupied, Unoccupied start and equal to the “RAT HEATING SETPOINT” minus stop times. This is done through the SCHEDULE key of the User Interface. JOHNSON CONTROLS...

  • Page 153: Flexsys Under Floor Temperature Control

    TEMP2 = “RETURN AIR TEMP” when the FLOOR TEMP CONTROL SP” for modulating Warm Up stopped. heat. • TEMP1 = “RETURN AIR TEMP” when the 5. Heating operation will continue until: Warm Up started. • Set Point = “RAT HEATING SETPOINT”. JOHNSON CONTROLS...

  • Page 154: Dew Point Reset Sequence Of Operation

    “ECONO OUPUT FOR FAN START” must be set using using the SETPOINTS key, EXHAUST subsection of the SETPOINTS key, EXHAUST subsection of the the User Interface. User Interface. “EXHAUST OUTPUT FOR FAN START” must be set “ECONO OUPUT FOR FAN STOP” must be set using JOHNSON CONTROLS...

  • Page 155: Modulating Exhaust With A Vfd

    2-Position the User Interface. • Standard “EXHAUST OUTPUT FOR FAN START” must be set Everything except the NONE and 2-POSTION using the SETPOINTS key, EXHAUST subsection of the User Interface. “EXHAUST OUTPUT FOR FAN STOP” must be set JOHNSON CONTROLS...

  • Page 156: 2-Position Damper

    Terminal 14 (IAQ OD-) of the CTB3 terminal block. damper to lower the indoor CO level between the minimum and maximum settings. Sequence of Operation The indoor C0 level can be either hard wired or communicated. In order to communicate the indoor C0 JOHNSON CONTROLS...

  • Page 157: Fixed Minimum

    (negatively pressurize) the building or space in order • VFD = Output to supply Fan VFD. to draw air through the walls from adjacent spaces or Air Measuring Stations outside the building envelope. When this sequence is This feature is not available on this product. JOHNSON CONTROLS...
  • Page 158 Start the Return Fan, if not already ON. • Start the Exhaust Fan, if not already ON. • Set all Outside Air Damper Output(s) to 0%. • Set all Return Air Dampers to100%. • Set the Exhaust Damper Output to 100%. JOHNSON CONTROLS...
  • Page 159 5276178-JIM-C-0118 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 160: Section 6 - User Interface Control Center

    STATUS SETPOINTS UNIT DATA PROGRAM COOLING OPTIONS COMPRESSOR SYSTEMS DATE/TIME SUPPLY SYSTEM SCHEDULE OPERATING HOURS HEATING START COUNTER ECONOMIZER PRINT VENTILATION SERVICE EXHAUST HISTORY UNIT LD010669 FIGURE 72 - USER INTERFACE CONTROL PANEL JOHNSON CONTROLS...

  • Page 161: Navigation Keys

    The tables contain the Displayed Text, Pass Word Level (if applicable), Range of Values (if applicable), Default Value (if applicable), what key (Setpoints, Program, Options) to use to change the value (if applicable), and under what circumstances the item is displayed. JOHNSON CONTROLS...

  • Page 162: Table 79 - Status

    / SAFETY TRIP / SAFETY FAULT / SAFETY DERIVED ALWAYS STATUS LOCKOUT / USER DISABLED / NONE SENSOR / MISC NORMAL / WARNING / SAFETY TRIP / SAFETY DERIVED ALWAYS STATUS FAULT / SAFETY LOCKOUT FILTER STATUS OKAY / CHANGE DERIVED ALWAYS JOHNSON CONTROLS...

  • Page 163: Table 80 - Unit Data

    SEQ 3 EVACUATION UNIT DATA HARD WIRED OPTIONS / DISPLAY LANGUAGE ENGLISH ENGLISH ENGLISH ONLY AVAILABLE UNIT DATA IMPERIAL / METRIC IMPERIAL ALWAYS DISPLAY UNITS * ONLY THE ZONE TEMP SCREEN FOR THE CURRENT ACTIVE MODE WILL BE SHOWN. JOHNSON CONTROLS...

  • Page 164: Table 81 - Cooling

    AND DEWPOINT RESET EQUALS DEW POINT 30.0º F TO 100.0º F DERIVED ENABLED SETPOINTS/ 20.0 TO 40.0% UNIT TYPE EQUALS FLEXSYS MAXIMUM BYPASS COOLING * ONLY THE ZONE TEMP SCREEN FOR THE CURRENT ACTIVE MODE WILL BE SHOWN. JOHNSON CONTROLS...
  • Page 165 PRESS TRANS PKG AND LOW AMBIENT 0.0º F - 65.0º F 50.0º F COOLING PKG OTHER THAN NONE TEMP SETPOINTS/ PRESS TRANS PKG AND LOW AMBIENT MECH CLG LOCKOUT -10.0º F - 0.0º F 0.0º F TMP MINIMUM COOLING PKG OTHER THAN NONE JOHNSON CONTROLS...

  • Page 166: Table 82 - Compressor Systems (1, 2, Or 3)

    400 PSIG COMP SYS ON THIS UNIT. PRESSURE OPTIONAL/ PRESS TRANS PKG NONE / SYS 1 NONE ALWAYS COMP SYS OPTIONAL/ ALWAYS LOW AMBIENT PKG NONE / SYS 1 NONE COMP SYS * MAY BE 1, OR 2 JOHNSON CONTROLS...

  • Page 167: Table 83 - Supply System

    USER PROGRAM / UNIT TYPE EQUALS VARIABLE AIR INSTABILITY MONITOR USER DISABLED DISABLED SUPPLY SYSTEM VOLUM OR FLEXSYS RETURN PRESSURE SETPOINTS / THIS FEATURE IS NOT 0.15 TO 0.45 0.15 HIGH SETP SUPPLY SYSTEM AVAILABLE ON THIS UNIT. JOHNSON CONTROLS...

  • Page 168: Table 84 - Heating

    2 TO 6 DERIVED HW / STEAM VALVE POS 0.0 TO 100% DERIVED HEAT TYPE EQUALS HOT WATER HEAT STEAM FRZ STAT OK TRIPPED DERIVED * ONLY THE ZONE TEMP SCREEN FOR THE CURRENT ACTIVE MODE WILL BE SHOWN. JOHNSON CONTROLS...
  • Page 169 HEAT TYPE DOES NOT EQUAL HEATING SYSTEM PROGRAM / HEATING DISABLED ENABLED NONE HEAT TYPE DOES NOT USER ENABLED USER USER EQUAL NONE AND CONSTANT PROGRAM / HEATING MORNING WARM UP DISABLED DISABLED VOLUME CONTROL METHOD DOES NOT EQUAL STAGED JOHNSON CONTROLS...
  • Page 170 DERIVED NONE AND MORN WARM UP WARM UP MAX TIME OPT TIME EQUALS ENABLED HEAT TYPE DOES NOT EQUAL MORNING WARM UP 15 - 240 MIN. 120 MIN. SETPOINTS/HEATING NONE AND MORN WARM UP MAX TIME EQUALS ENABLED JOHNSON CONTROLS...

  • Page 171: Table 85 - Economizer

    EQUALS DUAL ENTHALPY OUTSIDE AIR ECONOMIZER INSTALLED 22.0 TO 40.0 BTU/LB 28.0 BTU/LB SETPOINTS / ECONOMIZER ENTHALPY DOES NOT EQUAL NONE SETPOINT ECONOMIZER USER ENABLED USER ECONOMIZER INSTALLED DISABLED PROGRAM / ECONOMIZER DISABLED DOES NOT EQUAL NONE SYSTEM JOHNSON CONTROLS...

  • Page 172: Table 86 - Ventilation

    VENTILATION OR 2 POSITION DAMPER POSITION CONTINUOUS USER ENABLED USER USER PROGRAM / UNIT TYPE EQUALS CONSTANT VOLUME DISABLED ENABLED VENTILATION VENT COMFORT USER ENABLED USER USER PROGRAM / UNIT TYPE EQUALS CONSTANT VOLUME VENTILATION DISABLED DISABLED VENTILATION JOHNSON CONTROLS...
  • Page 173 SYSTEM DISABLED ENABLED VENTILATION SETPOINTS / THIS FEATURE IS NOT AVAILABLE ON 0.5 - 1.5 AMS FACTOR 1 VENTILATION THIS UNIT. SETPOINTS / THIS FEATURE IS NOT AVAILABLE ON AMS FACTOR 2 0.5 - 1.5 VENTILATION THIS UNIT. JOHNSON CONTROLS...

  • Page 174: Table 87 - Exhaust

    SETPOINTS / POWER EXHAUST EQUALS FAN START STOP TO 100% EXHAUST MODULATE DAMPER - VFD 0 - TO EXHAUST OUTPUT SETPOINTS / POWER EXHAUST EQUALS EXHAUST OUTPUT FOR FAN STOP FOR FAN START EXHAUST MODULATE DAMPER - VFD JOHNSON CONTROLS...

  • Page 175: Setpoints

    Tables 69 thru 77. Then use the ▼ key and the ▲ key to navigate to the parameter you want to change. Follow the instructions given in the Data Entry Keys section to change the parameter to the desired value. JOHNSON CONTROLS...

  • Page 176: Schedule

    MMDD is displayed when the value is being edited to remind the operator what the format of this number is. Eg. 1225 represents December 25.  SCHEDULE TO EDIT START =06:00 AM STOP =10:00 PM  SCHEDULE TO EDIT START =06:00 AM STOP =10:00 PM JOHNSON CONTROLS...

  • Page 177: Operating Hours / Start Counter

    SUPPLY FAN OPER HRS DERIVED SUPPLY FAN STARTS RETURN FAN OPER HRS THIS FEATURE IS NOT AVAILABLE ON THIS DERIVED RETURN FAN STARTS UNIT. Shown below is a typical screen example. HOURS / STARTS OPER HRS. XXXXX COMPRESSOR 1A STARTS XXXXX JOHNSON CONTROLS...

  • Page 178: Printer

    As the report is uploading, from the Unit Control to the PC, it is displayed in the Hyper Terminal window. • After the reports finish transferring to the PC, select “Transfer – Capture to Printer” to send the last page to the printer. JOHNSON CONTROLS...

  • Page 179: Service Mode

    OFF position. To force an output ON terminal location (ID), Value Range, and when item is use the ◄ or ► key to navigate to the SERVICE AO displayed. section. Then use the ▲ or ▼ key to select the output JOHNSON CONTROLS...

  • Page 180: Table 89 - Service Mode

    STATUS OF ELECTRIC HEAT DIGITAL ELECTRIC HEAT TB3-4 ON / OFF I/O BOARD OUTPUT OUTPUT TO STAGE 3 STG 3 ELECTRIC HEAT DIGITAL STATUS OF ELECTRIC HEAT DIGITAL TB3-5 ON / OFF I/O BOARD OUTPUT OUTPUT TO STAGE 4 STG 4 JOHNSON CONTROLS...
  • Page 181 RETURN FAN DIGITAL THIS FEATURE IS NOT TB1-4 ON / OFF I/O BOARD OUTPUT OUTPUT AVAILABLE ON THIS UNIT. EXHAUST FAN DIGITAL STATUS OF EXHAUST FAN OR RETURN TB1-4 ON / OFF I/O BOARD OUTPUT OUTPUT FAN DIGITAL OUTPUT JOHNSON CONTROLS...
  • Page 182 HUMIDITY SENSOR ANALOG TEMPERATURE THIS FEATURE IS NOT J3-1 0-5 VOLTS I/O BOARD SUCTION 1 INPUT AVAILABLE ON THIS UNIT. ANALOG TEMPERATURE THIS FEATURE IS NOT J3-2 0-5 VOLTS I/O BOARD INPUT SUCTION 2 AVAILABLE ON THIS UNIT. JOHNSON CONTROLS...
  • Page 183 ANALOG INPUT FROM THE UNDER FLOOR J7-2 0-5 VOLTS I/O BOARD INPUT TEMPERATURE SENSOR SLAB TEMP UNDERFLOOR AIR A N A L O G ANALOG INPUT FROM THE UNDERFLOOR J7-3 0-5 VOLTS I/O BOARD HUMIDITY INPUT HUMIDITY SENSOR JOHNSON CONTROLS...
  • Page 184 SYSTEM 2 SAFETY CIRCUIT D I G I T A L S A F E T Y I N P U T THIS FEATURE IS NOT TB7-4 OKAY / FAULTED I/O BOARD CHAIN 3 INPUT AVAILABLE ON THIS UNIT. JOHNSON CONTROLS...
  • Page 185 GIVES THE STATUS OF THE MORNING WARM PORT COMMUN ON / OFF IPU BOARD COMMUNICATED MORNING WARM UP UP CMD COMMAND GIVES THE STATUS OF THE PORT OCCUPIED / OCCUPANCY COMMUN IPU BOARD COMMUNICATED OCCUPANCY COMMAND UNOCCUPIED COMMAND JOHNSON CONTROLS...
  • Page 186 PORT GIVES THE STATUS OF THE COMMUN ON / OFF IPU BOARD UNIT STOP COMMUNICATED UNIT STOP COMMAND GIVES THE STATUS OF THE W1 LOW HEAT PORT COMMUN ON / OFF IPU BOARD COMMUNICATED W1 LOW HEAT COMMAND JOHNSON CONTROLS...
  • Page 187 ESTABLISHES THE COMMUNICATION BAUD P2 BAUD RATE 9600, 19200, RATE FOR PORT 2 38400, 57600 ALLOWS THE MANUAL ENTRANCE OF P2 MANUAL MAC -1 TO 127 THE MAC ADDRESS FOR PORT 2. SEE ADDRESS SECTION 6 - COMMUNICATION JOHNSON CONTROLS...
  • Page 188 ERROR PAGE AND FIELD CONNEXSYS ERROR REASON DERIVED NOT FOR FIELD USE AND VALVE REAL TIME DERIVED NOT FOR FIELD USE PROBLEM STRING REAL TIME DERIVED NOT FOR FIELD USE PROBLEM NUMBER REAL TIME DERIVED NOT FOR FIELD USE PROBLEM JOHNSON CONTROLS...

  • Page 189: History

    SERVICE AO TB08-01 XX.X VDC buffer data. + SYS 1 FEED VALVE OUTPUT =XXX.X % HISTORY key pressed WARNING 1 WARNING 2 FAULT 1 FAULT 2 FAULT 3 FAULT 1 DATA FAULT 2 DATA FAULT 3 DATA JOHNSON CONTROLS...

  • Page 190: Password

    Entering the Level 2 password will also The ► key is pressed to move to the next older fault allow the changing of a Level 1 parameter. (fault # 2). HISTORY 02 31 OCT 2004 10:42:39 AM ◄► AUTO RESET-MSAT SENSOR JOHNSON CONTROLS...

  • Page 191: Power Up Banner

    Pressing the X key during password entry will cancel Packaged Rooftop Air Conditioner Control Panel. the password entry process and take the user back to • ZZ = the Product Code. the Login Prompt. • YY = the Version Number. JOHNSON CONTROLS...

  • Page 192: Communication

    4 - Transmit (+) LD10821 FIGURE 69 - MAC ADDRESS SWITCHES 5 - Open PORT 1 (J4) PORT 4 (J3) PORT 2 (J5) NOT USED MAC ADDRESS SWITCH PORT 3 (J2) LD11197B FIGURE 73 - IPU CONTROL BOARD JOHNSON CONTROLS...

  • Page 193: Additional Settings

    DIP switches or a change to the above communication parameters using the SERVICE key of the User Interface the main power to the unit must be cycled OFF and back ON to change the value in memory. JOHNSON CONTROLS...

  • Page 194: Table 90 - Bacnet Ms/Tp, Modbus, Bacnet Ip

    THE NUMBER OF HOURS COMPRESSOR 4 HAS COMP_2B_OPER AI12 OPER HRS BEEN IN OPERATION (HOUR) THIS FEATURE IS NOT AVAILABLE ON COMP_3A COMPRESSOR 3A BI07 1288 THIS UNIT. THIS FEATURE IS NOT AVAILABLE ON COMPRESSOR 3A COMP_3A_OPER AI13 OPER HRS THIS UNIT. JOHNSON CONTROLS...
  • Page 195 TO BE TURNED ON AND OFF ON FLEXSYS UNITS (0 = OFF / 1 = ON) DUCT STATIC HIGH DSP_HI_LIMIT AV03 1028 THE DUCT STATIC UPPER SET POINT (“WC) LIMIT DUCT STATIC LOW DSP_LO_LIMIT AV04 1029 THE DUCT STATIC LOWER SET POINT (“WC) LIMIT JOHNSON CONTROLS...
  • Page 196 TO THE INDICATED HEAT SECTION (OFF - 0, ON - 1) FURNACE 1 HIGH ELECTRIC HEAT INDICATES THE STATUS OF THE BINARY OUTPUT FURN_OUT_3 STAGE 3 STG GAS BI28 1309 TO THE INDICATED HEAT SECTION (OFF - 0, ON - 1) FURNACE 2 LOW JOHNSON CONTROLS...
  • Page 197 MIXED SAT LIMIT AV14 1039 SETPOINT WHEN OPERATING WITHOUT A BYPASS DAMPER (F) A COMMUNICATED INPUT THAT ALLOWS MORNING MORNING WARM MORN_WARM_UP AV(BV)85 1110 WARM UP TO BE TURNED ON AND OFF (0 = UP ENABLE ENALBED; 1 = DISABLED) JOHNSON CONTROLS...
  • Page 198 USES WHEN USING OUTDOOR AIR SAT RESET TO SWITCH TO THE SAT LOW LIMIT SET POINT (F) IDENTIFIES THE OCCUPIED / UNOCCUPIED STATUS WITH HARD WIRED, COMMUNICATED OCCUPANCY OCC_MODE BI35 1316 OR INTERNAL CLOCK SCHEDULE INPUT MODE (ENA - ENABLED-OCCUPIED; DIS - DISABLED - UNOCCUPIED) JOHNSON CONTROLS...
  • Page 199 READY TO RUN IDENTIFIES IF COMPRESSOR 4 IS READY TO RUN RDY_RUN_C2B BI43 1324 COMP 2B IF THE COMPRESSOR IS OFF (YES / NO) THIS FEATURE IS NOT AVAILABLE ON READY TO RUN RDY_RUN_C3A BI44 1325 COMP 3A THIS UNIT. JOHNSON CONTROLS...
  • Page 200 AI43 (TEMPERATURES 1 THIS UNIT. SUCTION) SATURATED THIS FEATURE IS NOT AVAILABLE ON SUCTION TEMP SAT_SUC_TMP2 AI44 (TEMPERATURES 2 THIS UNIT. SUCTION) SATURATED THIS FEATURE IS NOT AVAILABLE ON SUCTION TEMP SAT_SUC_TMP3 AI45 (TEMPERATURES 3 THIS UNIT. SUCTION) JOHNSON CONTROLS...
  • Page 201 SUPPLY FAN VFD AI48 THE ACTUAL OUTPUT TO THE SUPPLY FAN VFD (%) THE STATUS OF THE BINARY OUTPUT FROM THE SUPPLY_FAN SUPPLY FAN BI59 1340 CONTROLLER TO THE SUPPLY FAN CIRCUIT (0 = OFF, 1 = ON) JOHNSON CONTROLS...
  • Page 202 THIS ALLOWS THE BAS SYSTEM TO INPUT A UNDER FLOOR TEMPERATURE VALUE TO THE UNDER FLOOR UND_TEMP_BAS AV37 1062 CONTROL ON A FLEXSYS SYSTEM (F). “UNDER TEMP BAS FLR TEMP BAS” MUST BE ENABLED USING THE SERVICE KEY IN ORDER TO USE THIS FEATURE JOHNSON CONTROLS...
  • Page 203 1343 WITH EITHER A HARDWIRED OR COMMUNCIATED INPUT (ON / OFF) A COMMUNICATED VALUE THAT ALLOWS THE W2 W2 HIGH HEAT W2_HI_HEAT_B AV(BV)97 1122 HEAT CALL TO BE TURNED ON AND OFF (0 = OFF; 1 = ON) JOHNSON CONTROLS...

  • Page 204: Table 90 - Lon Points List

    METHOD” MUST BE SET TO “COMM ZONE TEMP” Notes: 1. The most up to date listing of the Standard Points Mapping can be found in the Johnson Controls website. 2. In order to do BACnet IP a gateway model FS-B2010-02-01Y must be purchased from fieldserver technologies.
  • Page 205 DERIVED VALUE SHOWING THE NUMBER OF ELECTRIC OR nvoHEAT_STAGES STAGES GAS HEAT AI-023 STAGGED GAS HEAT STAGES AVAILABLE (1 - 7) STAGES SNVT_switch THE OUPUIT FROM THE CONTROL TO A HOT WATER, STEAM, nvoHEATING_VALV HEATING VALVE AI-024 (95) OR MODULATING GAS HEAT VALVE (%) JOHNSON CONTROLS...
  • Page 206 OCCUPIED OR UNOCCUPIED MODE (0 = UNOCCUPIED / 1 = MAND (95) OCCUPIED) OCCUPIED ZONE SNVT_count_f nviOCC_ZN_COOL AV-021 THE OCCUPIED ZONE COOLING SET POINT (F) COOLING SETP (51) OCCUPIED ZONE SNVT_count_f nviOCC_ZN_HEAT AV-022 THE OCCUPIED ZONE HEATING SET POINT (F) HEATING SETP (51) JOHNSON CONTROLS...
  • Page 207 (51) SUCTION) SATURATED SUCTION TEMP SNVT_count_f nvoSAT_SUC_TMP2 AI-044 THIS FEATURE IS NOT AVAILABLE ON THIS UNIT. (TEMPERATURES 2 (51) SUCTION) SATURATED SUCTION TEMP SNVT_count_f nvoSAT_SUC_TMP3 AI-045 THIS FEATURE IS NOT AVAILABLE ON THIS UNIT. (TEMPERATURES 3 (51) SUCTION) JOHNSON CONTROLS...
  • Page 208 TEM (F). "UNDER FLR TEMP BAS" MUST BE ENABLED USING THE SERVICE KEY IN ORDER TO USE THIS FEATURE UNDER FLOOR SNVT_count_f TEMPERATURE OF THE AIR UNDER THE FLOOR THE CONTROL nvoUND_FLR_TEMP AI-057 TEMP (51) IS CONTROLLING TO IN A FLEXSYS SYSTEM (F) JOHNSON CONTROLS...
  • Page 209 (51) Notes: 1. The most up to listing of the Standard Points Mapping can be found in the Johnson Controls website 2. In order to do LON protocol a e-link gateway part number YK-ELNK101-0 or YK-ELNKE01-0 must be used JOHNSON CONTROLS...

  • Page 210: Table 92 - N2 Points List

    CUTOUT CIRCUIT (0 - FAULTED / 1 - NO FAULT ) COMPRESSOR STATUS OF COMPRESSOR 3 or 4 LOW PRESSURE COMP_LPCO_2 BI10 0, 1 DI 9 LPCO 2 CUTOUT CIRCUIT (0 - FAULTED / 1 - NO FAULT ) JOHNSON CONTROLS...
  • Page 211 DEG F AI 13 TEMP 1 EVAPORATOR COIL ON A FLEXSYS UNIT (F) THE STATUS OF THE BINARY OUTPUT FOR THE EXHAUST_FAN EXHAUST FAN BI22 0, 1 DI 15 EXHAUST ( 0 = OFF / 1 = ON) JOHNSON CONTROLS...
  • Page 212 SETPOINT WHEN OPERATING WITHOUT A BYPASS DAMPER (F) A BAS GENERATED COMMAND TO ALLOW THE MORN_WUP_ MORNING WARM AV 86 0, 1 AO 37 MORNING WARM UP FEATURE TO BE TURNED ON UP CMND AND OFF (0 = OFF / 1 = ON) JOHNSON CONTROLS...
  • Page 213 THE OCCUPIED ZONE HEATING SET POINT (F) HEATING SETP PRESSURES 1 THIS FEATURE IS NOT AVAILABLE ON PRS_1_DISCH AI31 AI 24 DISCHARGE THIS UNIT. PRS_1_ PRESSURES 1 THIS FEATURE IS NOT AVAILABLE ON AI32 AI 25 SUCTION SUCTION THIS UNIT. JOHNSON CONTROLS...
  • Page 214 AND 5 VOLTS USES SAT LOW LIMIT (V). “SAT RST BAS” MUST BE ENABLED USING THE SERVICE KEY IN ORDER TO USE THIS FEATURE SATURATED SAT_SUC_ SUCTION TEMP THIS FEATURE IS NOT AVAILABLE ON AI43 DEG F AI 36 TMP1 (TEMPERATURES THIS UNIT. 1 SUCTION) JOHNSON CONTROLS...
  • Page 215 TURNS OFF COMPRESSOR SYSTEM 3 TEMP_1_ TEMPERATURE 1 THIS FEATURE IS NOT AVAILABLE ON AI49 DEG F AI 42 SUCTION SUCTION THIS UNIT. TEMP_2_ TEMPERATURE 2 THIS FEATURE IS NOT AVAILABLE ON AI51 DEG F AI 43 SUCTION SUCTION THIS UNIT. JOHNSON CONTROLS...
  • Page 216 19 - MORNING WARM UP 20 - POWER UP STANDBY THIS COMMAND ALLOWS THE UNIT TO BE SHUT UNIT_STOP UNIT STOP AV93 0, 1 AO 40 DOWN THROUGH THE BAS SYSTEM (0 = NORMAL OPERATION/ 1 = STOPPED JOHNSON CONTROLS...
  • Page 217 Notes: 1 The most up to date listing of the Standard Points Mapping can be found in the Johnson Controls website. 2. In order to do N2 protocol, an e-link gateway part number YK-ELNK 100-0 or YK-ELINK 00-0 must be used.

  • Page 218: Section 7 - Parameter Defenitions And Options

    Normal - Comp A On, Normal - Comp B On, Normal - Both ON, Normal - Both Off, COMP SYS 1 STATUS Safety Trip, Safety Fault, Safety Lockout, Low Amb Inhibit, Low Suct Temp Unl, High DP Unload, or User Disabled. JOHNSON CONTROLS...
  • Page 219 This is the Morning Warm Up time the Unit Controller recorded during the previous DAILY WARM UP TIME DAY 1 day 1. This value is used to calculate the current Morning Warm initiate time for Adaptive Morning Warm Up. JOHNSON CONTROLS...
  • Page 220 ON the exhaust fan in an ON/OFF DAMPER CTRL. This parameter is set through the SETPOINTS key and identifies the position of the ECONO OUTPUT FOR FAN STOP economizer damper required to turn OFF the exhaust fan in an ON/OFF DAMPER CTRL option. JOHNSON CONTROLS...
  • Page 221 FAN SPEED SETP FOR LOW SAT speed is equal to or greater than this value the Active Supply Air Temperature Set Point on a Variable Air Volume Unit will be set to the SAT Set Point Low Limit. JOHNSON CONTROLS...
  • Page 222 Unit Controller controls the heating option to try and maintain this temperature. This is the current operating mode of the Heating Section. The display will show HEATING SYS STATUS Normal - Active, Normal - Inactive, Safety Trip, Safety Fault, Safety Lockout, User Disabled, or None. JOHNSON CONTROLS...
  • Page 223 USER ENABLED or USER DISABLED. This parameter is programmed through the SETPOINTS key. This establishes the OA DAMPER MAXIMUM POSITION maximum amount of ventilation air to be used in a Demand Ventilation situation. * May be 1, 2, or 3 JOHNSON CONTROLS...
  • Page 224 (THIS FEATURE IS NOT AVAILABLE ON THIS UNIT) This is the suction pressure and is shown for each compressor system if pressure PRESSURE SUCTION* transducers are installed and configured for the system. (THIS FEATURE IS NOT AVAILABLE ON THIS UNIT) JOHNSON CONTROLS...
  • Page 225 RETURN FAN PRESS CURRENT (THIS FEATURE IS NOT AVAILABLE ON THIS UNIT) RETURN FAN PRESSURE ACTIVE This is the current mixed air chamber pressure that the Unit Controller is trying to maintain. (THIS FEATURE IS NOT AVAILABLE ON THIS UNIT) JOHNSON CONTROLS...
  • Page 226 This is the Binary output from the Unit Controller to the Supply Fan control system. This is a Binary input into the Unit Controller that identifies the Supply Fan is SUPPLY FAN OUTPUT PROOF functioning. SUPPLY FAN VFD SPEED This indicates the output, in percent, to the Supply Fan VFD. JOHNSON CONTROLS...
  • Page 227 This parameter is programmed using the SETPOINTS key. This is the temperature ZONE TEMP UNOCC ZONE HEATING that the Unit Controller compares the actual space temperature to, to decide when SETPOINT to switch into the Unoccupied Heating Mode. JOHNSON CONTROLS...

  • Page 228: Section 8 - Service

    5,487 40.56 1.48 35,639 -3.89 3.76 4,951 43.34 1.62 31,269 -1.11 3.85 4,475 46.11 1.77 27,490 1.67 3.94 4,050 48.89 1.91 24,219 4.44 4.02 3,671 51.66 2.06 21,377 7.22 4.09 3,332 54.44 2.21 18,900 10.00 4.16 3,029 57.22 JOHNSON CONTROLS...

  • Page 229: Building Pressure Transducer

    0.75 3.25 inputs will now be exposed to the same pressure, the differential pressure will be zero, and the output 2.5VDC 1.00 3.50 according to Table86. 1.25 3.75 1.50 4.00 1.75 4.25 2.00 4.50 2.25 4.75 2.50 5.00 JOHNSON CONTROLS...

  • Page 230: Co 2 Sensor

    TABLE 99 - FURNACE STATUS INPUT STAGED GAS HEAT MIN VDC MAX VDC FURNACE 1 STATUS FURNACE 2 STATUS FURNACE 3 STATUS 0.086 0.166 0.224 0.313 0.361 0.461 0.499 0.609 0.637 0.756 0.774 0.904 0.912 1.051 1.050 1.199 JOHNSON CONTROLS...

  • Page 231: Faults

    2 password must be entered in order to view the data. warnings. A warning is defined as an abnormal condition under which the unit continues to operate. Warnings will not require the unit to shut down; however, they may JOHNSON CONTROLS...
  • Page 232 60 minutes it will be “COMPRESSOR SYSTEM (1,2,OR 3) CLEAR” shows replaced with a “COMPRESSOR SYSTEM (1,2,OR 3) the time it took for the fault to clear in the HISTORY TIME OUT” message. buffer. JOHNSON CONTROLS...

  • Page 233: Figure 75 - I/O Control Board

    See Fig. 8-4 BINARY OUTPUTS See Fig. 8-2 BINARY INPUTS See Fig. 8-3 J11-1 GND J11-3 12 VDC 12 VDC FUSE BINARY BINARY BINARY INPUTS OUTPUTS OUTPUTS LD10790D See Fig. 8-3 See Fig. 8-2 FIGURE 75 - I/O CONTROL BOARD JOHNSON CONTROLS...

  • Page 234: Figure 76 - I/O Control Board - Binary Outputs

    TB4-2 COMP 1 (111) 24V TB4-1 (100) TB1-12 VAV HEAT OUTPUT (424) TB1-11 VAV HEAT COMM (423) LD14100 TB1-4 EXHAUST/RETURN FAN (109) TB1-3 24V (100) TB1-2 SUPPLY FAN (108) TB1-1 24V (100) FIGURE 76 - I/O CONTROL BOARD - BINARY OUTPUTS JOHNSON CONTROLS...

  • Page 235: Figure 77 - I/O Control Board - Binary Inputs

    TB9-12 BYPASS DAMPER COM (411) LD14102 FIGURE 78 - I/O CONTROL BOARD - ANALOG OUTPUTS I/O CONTROL J4, J5, J6, J7 PINOUTS J1, J2, J3 PINOUTS LD10794 FIGURE 79 - I/O CONTROL BOARD - ANALOG INPUTS (SEE TABLE 90 FOR PIN OUTS) JOHNSON CONTROLS...

  • Page 236: Table 100 - I/O Control Board - Analog Input Pin Outs

    SHIELD FLEXSYS SLAB SENSOR (367) J2-7 COM OA HUM (319) J7-12 REF FLEXSYS SLAB SENSOR 5VDC (365) J2-4 INPUT RA HUM (320) J7-3 INPUT FLEXSYS UNDER FLOOR HUM (368) J2-8 COM RA HUM (321) J7-8 COM FLEXSYS UNDER FLOOR HUM (369) JOHNSON CONTROLS...

  • Page 237: Table 101 - Warning Description

    OUTSIDE AIR TEMP MORE THAN OR EQUAL TO ECONO INSTALLED SENSOR/ SENSOR/ OUTSIDE AIR 32 F FOR 10 SECONDS OUTDOOR AIR AUTO RESET SINGLE ENTHALPY MISC STATUS MISC FAULT HUMIDITY < 5% FOR 10 SECONDS OR DUAL ENTHALPY WARNING JOHNSON CONTROLS...
  • Page 238 FLEXSYS AND DEW SENSOR/ FLOOR RH AUTO RESET MISC STATUS THAN OR EQUAL TO 5 MINUTES POINT RESET IS MISC FAULT SENSOR WARNING USER ENABLED * CAN BE 1, 2, OR 3 # CAN BE A OR B JOHNSON CONTROLS...

  • Page 239: Table 102 - Fault Auto - Reset

    - ZONE TEMP OF RANGE FOR MORE THAN OR EQUAL SET TO CV AND MISC RESET SAFETY SENSOR TO 10 SECONDS THE CONTROL FAULT LOCKOUT METHOD IS SET TO ZONE SENSOR HARDWIRED * CAN BE 1, 2, OR 3 JOHNSON CONTROLS...

  • Page 240: Table 103 - Faults Lockout

    COMMUNICATED INPUT COMP SYS * STATUS SAFETY OUTSIDE AIR TEMP SENSOR IS OUT SENSOR/ LOCKOUT - OAT UNIT LOCKOUT; OF RANGE FOR MORE THAN OR MISC SENSOR LOCKOUT ECONO SYS EQUAL TO 10 SECONDS FAULT STATUS SAFETY LOCKOUT JOHNSON CONTROLS...
  • Page 241 SYSTEM * CLEAR” SHOWS THE TIME IT TOOK FOR THE FAULT TO CLEAR IN THE HISTORY BUFFER. “LOCKOUT-COMPRESSOR SYSTEM * TIME OUT” – IF THE “COMPR STATUS CLEAR TIME *” TIMER REACHES 60 MINUTES A “LOCKOUT - COMPRESSOR SYSTEM * TIME OUT” WILL BE INDICATED IN THE HISTORY BUFFER. JOHNSON CONTROLS...

  • Page 242: Multi Media Card

    Each line of data will be timed and date stamped. OPEN A FILE Each file will include a header line detailing what data WRITE A FILE is stored in each column. DELETE A FILE CLOSE A FILE JOHNSON CONTROLS...

  • Page 243: Table 105 - Data Log Error Log Detail

    OUT OF MEMORY RESOURCE BUSY NO SUCH DEVICE NOT A DIRECTORY IS A DIRECTORY INVALID ARGUMENT TOO MANY OPEN FILES IN SYSTEM FILE TOO LARGE NO SPACE LEFT ON DEVICE ILLEGAL SEEK READ-ONLY FILE SYSTEM FILE NAME TOO LONG JOHNSON CONTROLS...
  • Page 244 Service 5276178-JIM-C-0118 NOTES JOHNSON CONTROLS...
  • Page 245 EQUIPMENT STARTUP warranty policy and warranty manual found on UPGnet for details. In the event that communication with Johnson Controls/UPG is Use the local LCD or Mobile Access Portal (MAP) Gateway to required regarding technical and/or warranty concerns, all parties complete the start-up.
  • Page 246 1034349-UCL-E-0817 SAFETY WARNINGS The inspections and recording of data outlined in this procedure are required for start-up of Johnson Controls/UPG's packaged Lethal voltages are present during some start-up products. Industry recognized safety standards and practices checks. Extreme caution must be used at all times.
  • Page 247 Check economizer setting (Reference Smart Equipment™ Control Board LCD   menu location) Prove economizer open/close through Smart Equipment™ Board Setting   Reheat Mode Normal  or Alternate  Not Applicable  Humidity Sensor (2SH0401) _____________________________________________ Unitary Products Group JOHNSON CONTROLS...
  • Page 248 1. VAV units with heat section - simulate heat call to drive VAV boxes and VFD/IGV to maximum design airflow position. 2. VAV units without heat section - VAV boxes must be set to maximum design airflow position. Unitary Products Group JOHNSON CONTROLS...
  • Page 249 Stage 2 (If Equipped)  Stage 3 (If Equipped)  Supply gas pressure at full fire  Check temperature rise  measured at full fire °F  1. Input X Eff. (BTU output) 1.08 X Temp. Rise Unitary Products Group JOHNSON CONTROLS...
  • Page 250 ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ Subject to change without notice. Printed in U.S.A. 1034349-UCL-E-0817 Copyright © 2017 by Unitary Products Group. All rights reserved. Supersedes: 1034349-UCL-D-0516 York International Corporation 5005 York Drive Norman, OK 73069 JOHNSON CONTROLS...
  • Page 251 ©2017 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 5276178-JIM-C-0118 www.johnsoncontrols.com Supersedes 5276178-JIM-B-0117...

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