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INSTALLATION
MANUAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPROVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
START-UP (COOLING). . . . . . . . . . . . . . . . . . . . . 49
START-UP (GAS HEAT). . . . . . . . . . . . . . . . . . . . 50
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 53
SEE THE FOLLOWING PAGE FOR A COMPLETE TABLE OF CONTENTS.
NOTES, CAUTIONS AND WARNINGS
The 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.
CAUTION:
READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
DW-03, -04 & -05
362247-BIM-B-0109
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Table of Contents
Troubleshooting
Related Manuals for Johnson Controls DW-03
Summary of Contents for Johnson Controls DW-03
- Page 1 AIR CONDITIONERS CONTENTS DW-03, -04 & -05 GENERAL ....... . 4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
FAN ON AND OFF DELAYS ..... 62 FREEZESTAT ....... . . 45 Johnson Controls Unitary Products... - Page 3 UNIT DIMENSIONS (3 - 5 TON COOLING ONLY/ DW-03 OPERATING PRESSURES ... . . 56 ELECTRIC HEAT) FRONT VIEW ....33 DW-04 OPERATING PRESSURES .
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Page 4: General
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. Johnson Controls Unitary Products... -
Page 5: Reference
Additional information is available in the following refer- ence forms: This product must be installed in strict compli- • Technical Guide - DW-03 thru -05, 282906 ance with the enclosed installation instructions and any applicable local, state, and national •... -
Page 6: Product Nomenclature
Y = Options 4 & 5 Z = Options 3, 4 & 5 Options 1 = Disconnect 2 = Non-Pwr'd Conv. Outlet 3 = Smoke Detector S.A. 4 = Smoke Detector R.A. 5 = Pwr'd Conv. Outlet Johnson Controls Unitary Products... -
Page 7: Installation
Unitary Products @ 1- 877-UPG-SERV guidance. Additional LIMITATIONS accessories may be needed for stable opera- tion at temperatures below 30° F. These units must be installed in accordance with the following national and local safety codes: Johnson Controls Unitary Products... -
Page 8: Location
B149.1 (in Canada) and/or applicable provisions of the masonry acid washing materials. local building codes. Refer to Dimensions and Clear- ances shown in Figures 10 through 13 and Tables 18 Johnson Controls Unitary Products... -
Page 9: Ductwork
The condensate drain operates in a negative NOTE: down. Minimum filter area and required sizes are pressure in the cabinet. The condensate drain shown in Physical Data Table 8. Johnson Controls Unitary Products... -
Page 10: Service Access
Electric Heat compartment Make sure that all screws and panel latches • Gas Heat compartment are replaced and properly positioned on the • Blower compartment unit to maintain an airtight seal. • Main control box • Filter compartment Johnson Controls Unitary Products... -
Page 11: Typical Field Power & Control Wiring
P6 ON UNITS WITH ECONOMIZER. TERMINALS A1 AND A2 PROVIDE A RELAY OUT-PUT TO CLOSE THE OUTDOOR ECONOMIZER DAMPERS WHEN THE THERMOSTAT SWITCHES TO THE SET-BACK POSITION. FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING Johnson Controls Unitary Products... -
Page 12: Thermostat
Table 3 for minimum CFM limitations and to Tables the unit must be replaced, replacement wire must be of 10 and 17 for electrical data. the type shown on the wiring diagram and the same minimum gauge as the replaced wire. Johnson Controls Unitary Products... -
Page 13: Gas Heat
NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with Kit Model No. 1NP0440 or 1NP0485 (2 Stage). All furnaces meet the latest California seasonal efficiency requirements. 1. Based on 1075 Btu/Ft 2. The air flow must be adjusted to obtain a temperature rise within the range shown. Johnson Controls Unitary Products... -
Page 14: Gas Piping
The sup- or other material suitable for the purpose. NEVER ply piping and fittings must lie below the bottom gas USE A FLAME. manifold to avoid interference with the burner assembly. Johnson Controls Unitary Products... -
Page 15: L.p. Units, Tanks And Piping
FIGURE 4 - EXTERNAL SUPPLY CONNECTION L.P./propane gas suppliers. EXTERNAL SHUT-OFF L.P./propane gas is an excellent solvent and special pipe compound must be used when assembling piping Johnson Controls Unitary Products... -
Page 16: Vent And Combustion Air Hoods
All of the components, including the dampers, hard- ware, and mounting instructions are shipped in a single package external from the unit and must be field assembled and installed. Johnson Controls Unitary Products... -
Page 17: Economizer And Power Exhaust Damper Set Point Adjustments And Information
(found on the 2AQ04700424 damper control module) to the “A”, “B”, “C” or “D” setting corresponding to the lettered curve of the Enthalpy Setpoint Adjustment Figure 7. Replace the economizer access panel. Johnson Controls Unitary Products... -
Page 18: Enthalpy Setpoint Adjustment
Damper Min. Position Screw Indoor Air Quality Max. Adjustment Screw Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cool Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 8 - HONEYWELL ECONOMIZER CONTROL W7212 Johnson Controls Unitary Products... -
Page 19: Center Of Gravity (All Models)
FRONT OF UNIT FRONT OF UNIT FIGURE 9 - FOUR AND SIX POINT LOADING TABLE 6: CENTER OF GRAVITY (ALL MODELS) DIMENSION DW-03 thru -05 TABLE 7: DW 4 AND 6 POINT LOADS WEIGHT DISTRIBUTION 4-Point Loading (lb) 6-Point Loading (lb) UNIT... -
Page 20: Dw Physical Data
4 TON 5 TON DW (Cooling Only) BASIC UNIT (Gas/Electric) Economizer Motorized Damper OPTIONS 5 - 7 kW Electric Heater 10 - 15 kW 20 - 30 kW Roof Curb ACCY. Barometric Relief / Fixed Air Damper Johnson Controls Unitary Products... -
Page 21: Electrical Data - Dw-03, -04 & -05 Direct Drive W/O Powered Convenience Outlet
362247-BIM-B-0109 TABLE 10:ELECTRICAL DATA - DW-03, -04 & -05 DIRECT DRIVE W/O POWERED CONVENIENCE OUTLET OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages... - Page 22 362247-BIM-B-0109 TABLE 10:ELECTRICAL DATA - DW-03, -04 & -05 DIRECT DRIVE W/O POWERED CONVENIENCE OUTLET (CONT) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model...
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Page 23: Electrical Data - Dw-03, -04 & -05 Belt Drive W/O Powered Convenience Outlet
362247-BIM-B-0109 TABLE 11: ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE W/O POWERED CONVENIENCE OUTLET OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model... - Page 24 362247-BIM-B-0109 TABLE 11: ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE W/O POWERED CONVENIENCE OUTLET (CONT) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA...
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Page 25: Electrical Data - Dw-03, -04 & -05 Belt Drive High Static W/O Powered Convenience Outlet
362247-BIM-B-0109 TABLE 12:ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE HIGH STATIC W/O POWERED CONVENIENCE OUTLET OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA... - Page 26 362247-BIM-B-0109 TABLE 12:ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE HIGH STATIC W/O POWERED CONVENIENCE OUTLET (CONT) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA...
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Page 27: Electrical Data - Dw-03, -04 & -05 Direct Drive W/Powered Convenience Outlet
362247-BIM-B-0109 TABLE 13:ELECTRICAL DATA - DW-03, -04 & -05 DIRECT DRIVE W/POWERED CONVENIENCE OUTLET OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps... - Page 28 362247-BIM-B-0109 TABLE 13:ELECTRICAL DATA - DW-03, -04 & -05 DIRECT DRIVE W/POWERED CONVENIENCE OUTLET (CONT) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages...
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Page 29: Electrical Data - Dw-03, -04 & -05 Belt Drive With Powered Convenience Outlet
362247-BIM-B-0109 TABLE 14:ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE WITH POWERED CONVENIENCE OUTLET OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages... - Page 30 362247-BIM-B-0109 TABLE 14:ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE WITH POWERED CONVENIENCE OUTLET (CONT) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model...
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Page 31: Electrical Data - Dw-03, -04 & -05 Belt Drive High Static With Powered Convenience Outlet
362247-BIM-B-0109 TABLE 15:ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE HIGH STATIC WITH POWERED CONVENIENCE OUTLET OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA... - Page 32 362247-BIM-B-0109 TABLE 15:ELECTRICAL DATA - DW-03, -04 & -05 BELT DRIVE HIGH STATIC WITH POWERED CONVENIENCE OUTLET (CONT) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA...
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Page 33: Unit Dimensions
POWER SUPPLY 1.00 MIN. MAX. 0.92 208/230-1-60 0.92 208/230-3-60 0.92 460-3-60 575-3-60 1. Utilization Range “A” in accordance with ARI Standard 110. FIGURE 10 - UNIT DIMENSIONS (3 - 5 TON COOLING ONLY/ELECTRIC HEAT) FRONT VIEW Johnson Controls Unitary Products... -
Page 34: Unit Dimensions (3 - 5 Ton Cooling/Gas Heat)
362247-BIM-B-0109 FIGURE 11 - UNIT DIMENSIONS (3 - 5 TON COOLING/GAS HEAT) FRONT VIEW DETAIL “A” FIGURE 12 - UNIT WITH ECONOMIZER RAINHOOD Johnson Controls Unitary Products... -
Page 35: Unit With Fixed Outdoor Air/Motorized Damper Rainhood
362247-BIM-B-0109 DETAIL “B” FIGURE 13 - UNIT WITH FIXED OUTDOOR AIR/MOTORIZED DAMPER RAINHOOD FIGURE 14 - UNIT DIMENSIONS (REAR VIEW) Johnson Controls Unitary Products... -
Page 36: Utilities Entry
1. Units may be installed on combustible floors made from wood or class A, B, or C roof covering material. 2. Units must be installed outdoors. Overhanging struc- tures or shrubs should not obstruct condenser air dis- charge outlet. Johnson Controls Unitary Products... -
Page 37: Supply Air Blower Performance (Dw-03 Belt Drive) - Side Duct Application
362247-BIM-B-0109 TABLE 20:SUPPLY AIR BLOWER PERFORMANCE (DW-03 BELT DRIVE) - SIDE DUCT APPLICATION Available External Static Pressure - IWG Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP... -
Page 38: Supply Air Blower Performance (Dw-04 Belt Drive) - Bottom Duct Application
1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. Johnson Controls Unitary Products... -
Page 39: Supply Air Blower Performance (Dw-03, -04, & -05 Direct Drive) Side Duct
362247-BIM-B-0109 TABLE 26:SUPPLY AIR BLOWER PERFORMANCE (DW-03, -04, & -05 DIRECT DRIVE) SIDE DUCT APPLICATION AVAILABLE EXTERNAL STATIC PRESSURE - IWG UNIT MOTOR TONNAGE SPEED 1582 1538 1496 1458 1418 1381 1338 1298 1255 MED/HI 1488 1440 1396 1354 1309... -
Page 40: Belt Drive Blower Motor And Drive Data
5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Closed 1.73 1VL44 AK56 1060 1130 1195 1260 1VP56 AK56 1325 1395 1460 1525 1590 1660 Johnson Controls Unitary Products... - Page 41 1.100 1.050 1.000 Sea Level 0.950 1000 ft 0.900 2000 ft 3000 ft 0.850 4000 ft 0.800 5000 ft 6000 ft 0.750 7000 ft 8000 ft 0.700 9000 ft 10000 ft 0.650 0.600 Air Temperature (ºF) Johnson Controls Unitary Products...
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Page 42: Phasing
CFM. Adjustments of the blower speed and belt ten- sion are REQUIRED. Tighten blower pulley and motor sheave set screws after these adjustments. Re-checking set screws after 10- 12 hrs. run time is recommended. Johnson Controls Unitary Products... -
Page 43: Operation
Step 1. of a call for cooling. Heating always takes priority. De-energize the compressors before taking any NOTE: test measurements to assure a dry indoor coil. Johnson Controls Unitary Products... -
Page 44: Cooling Sequence Of Operation
“Y1”. If the compressor has satisfied its minimum The low-pressure limit switch is not monitored during run time, the compressor and condenser fan are de- the initial 30 seconds of a cooling system's operation. energized. Otherwise, the unit operates the cooling sys- Johnson Controls Unitary Products... -
Page 45: Freezestat
If the call for cooling is still present at the end of the ting higher than the conditioned space temperature. ASCD and the freezestat has closed, the unit will This resets any pressure or freezestat flash codes. resume operation. Johnson Controls Unitary Products... -
Page 46: Electric Heating Sequence Of Operations
Heat Limit Control Setting Table 31. It resets auto- matically. The limit switch operates when a high temperature condition, caused by inadequate sup- ply air flow occurs, thus shutting down the heater and energizing the blower. Johnson Controls Unitary Products... -
Page 47: Gas Heating Sequence Of Operation
An auxiliary limit or a roll out switch trip requires intervention to reset the ICB. The UCB also monitors the primary limit and gas valve. Johnson Controls Unitary Products... -
Page 48: Temperature Limits
UCB no longer senses voltage at the GV (W1 call for than 16 times during the same call for heat, then the heat removed or an ICB fault exists), then the UCB ICB will lock out furnace operation for 5 minutes. Johnson Controls Unitary Products... -
Page 49: Flash Codes
4. Measure the condenser fan amp draw. Gas Valve Anticipator Setpoint Honeywell VR8204M 0.60 amp SHUT DOWN White-Rodgers 36E36 0.54 amp 1. Set the thermostat to highest temperature setting. 2. Turn off the electrical power to the unit. Johnson Controls Unitary Products... -
Page 50: Start-Up (Gas Heat)
“off” position. FIGURE 19 - TYPICAL SINGLE STAGE GAS VALVES POST-START CHECK LIST (GAS) After the entire control circuit has been energized and the heating section is operating, make the following checks: Johnson Controls Unitary Products... -
Page 51: Manifold Gas Pressure Adjustment
4. Disconnect wiring to the gas valves and spark ignit- these furnaces is 3.50 IWG. The actual mani- ors. Remove the manifold-burner gas valve fold pressure depends on the local fuel heating assembly by lifting up and pulling back. value. Johnson Controls Unitary Products... -
Page 52: Burner Air Shutter Adjustment
(contact your gas company for this information plate and the data in the Gas Heat Application Table 4. - it varies widely from city to city.) Johnson Controls Unitary Products... -
Page 53: Troubleshooting
1. Turn the thermostat fan switch to the ON position. 10. If the thermostat and UCB are properly wired, If the supply air blower motor does not energize, go replace the UCB. to Step 3. Johnson Controls Unitary Products... - Page 54 Mate-N-Lock plug to the econo- sure switch, low-pressure switch, or freezestat. mizer, back to the Mate-N-Lock plug, and from the Check for 24 volts at the HPS1, LPS1, and FS1 Mate-N-Lock plug to the Y1 “ECON” terminal. If Johnson Controls Unitary Products...
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Page 55: Charging The Unit
For units with factory installed economizers, the UCB is programmed to lock out compressor opera- tion when the LAS set point is reached. TABLE 37:DW-03 COOLING SUPERHEAT CHARGING TABLE SUPERHEAT AT COMPRESSOR SUCTION (°F) AIRFLOW=1200 CFM OUTDOOR TEMP (°F) -
Page 56: Normal Operating Pressures
NORMAL OPERATING PRESSURES 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 23 - DW-03 OPERATING PRESSURES 115°F Outdoor 105°F Outdoor 95°F Outdoor 85°F Outdoor 75°F Outdoor 65°F Outdoor Suction Pressure (psig) FIGURE 24 - DW-04 OPERATING PRESSURES... -
Page 57: Gas Heat Troubleshooting Guide
If the ICB has a flash code could cause injury to person and/or damage other than the heartbeat, then determine the flash code unit components. Verify proper operation after and locate its troubleshooting procedures in the flash servicing. Johnson Controls Unitary Products... -
Page 58: Flash Code Troubleshooting
ICB, then replace the ICB between terminals 3 and 8 of the harness connec- and verify proper operation of the furnace. Johnson Controls Unitary Products... -
Page 59: Pilot Flame Lockout
Verify both conditions are within the The temperature limits limit the temperature in the fur- published ranges. nace to a safe level. If a temperature higher than the Johnson Controls Unitary Products... -
Page 60: Unexpected Flame Presence
Proper wiring between the room thermostat and the UCB. If the control detects an internal hardware failure in the flame sense circuit, it shuts off all outputs and enters a Loose wiring from the room thermostat to the UCB. Johnson Controls Unitary Products... - Page 61 On 575 volt models, if voltage is present at the terminal, then check the draft motor relay 1. Check electrical connections between the ignition (DMR on single stage gas heat and DMR-2 on two control and the gas valve. If intact, check for 24 Johnson Controls Unitary Products...
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Page 62: Unit Flash Codes
The first time the button is pressed within five seconds, it scans the bus, then assigns itself the first available address {starts at 2}. It then flashes that address one time. FIGURE 26 - UNIT CONTROL BOARD Johnson Controls Unitary Products... -
Page 63: Unit Control Board
11 Flashes Economizer Is Using Free Cooling 13 Flashes Compressor Held Off Due To Low Voltage 14 Flashes EEPROM Storage Failure (Control Failure) No Power or Control Failure 1. These flash codes do not represent alarms. Johnson Controls Unitary Products... - Page 64 Subject to change without notice. Printed in U.S.A. 362247-BIM-B-0109 Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 362247-BIM-A-0208 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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