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INSTALLATION
MANUAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .52
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .53
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .56
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 dam-
age 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
MODELS: DU-15, -18, -20 & -25
284815-BIM-C-1008
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Summary of Contents for Johnson Controls DU-15
- Page 1 CONTENTS MODELS: DU-15, -18, -20 & -25 GENERAL ........4 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
TO SHUT DOWN: ......53 AIR BALANCE ....... . 44 Johnson Controls Unitary Products... - Page 3 SUPPLY FAN VFD WEIGHTS, IN LBS... 25 GAS HEAT TROUBLESHOOTING GUIDE ..60 10 DU-15, -18 & -20 ELECTRICAL DATA WITHOUT UNIT CONTROL BOARD FLASH CODES ..64 POWERED CONVENIENCE OUTLET .
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Page 4: General
Wear safety glasses and work gloves, and follow all • Technical Guide - 263416 safety codes. Use a quenching cloth and have a fire • General Installation - 284815 extinguisher available for all brazing operations. Johnson Controls Unitary Products... -
Page 5: Renewal Parts
Cau- tions are given to prevent equipment damage. Warn- ings are given to alert installer that personal injury and/ or equipment damage may result if installation proce- dure is not handled properly. Johnson Controls Unitary Products... -
Page 6: Product Nomenclature
M = Options 1, 2, 3, & 4 Z = Options 3, 4 & 5 Options 1 = Disconnect 4 = Smoke Detector R.A. 2 = Non-Pwr'd Conv. Outlet 5 = Pwr'd Conv. Outlet 3 = Smoke Detector S.A. Johnson Controls Unitary Products... -
Page 7: Installation
These units must be installed in accordance with the department for Unitary Products @ 1-877-UPG- following national and local safety codes: SERV for guidance. Additional accessories may be needed for stable operation at temperatures below 30°F. Johnson Controls Unitary Products... -
Page 8: Location
UP roof curb, gasketing must be applied to all surfaces that come in contact with the unit under- 6. Maintain level tolerance to 1/2 inch maximum side. across the entire length or width of the unit. Johnson Controls Unitary Products... -
Page 9: Rigging And Handling
L I F T I N G tion. T H A T I T W I L L L I F T H O L E S E V E N L Y FIGURE 1 - TYPICAL RIGGING Johnson Controls Unitary Products... -
Page 10: Ductwork
The cov- The cover should be attached in a manner ering over the mounting holes only need be adequate to prevent leakage. removed. Do not remove the opening cover. Johnson Controls Unitary Products... -
Page 11: Condensate Drain
Refer to Figures 13 and 14 for location of these access panels. Make sure that all screws and panel latches are replaced and properly positioned on the unit to maintain an airtight seal. FIGURE 4 - RECOMMENDED DRAIN PIPING Johnson Controls Unitary Products... -
Page 12: Typical Field Wiring
U N I T C O N T R O L B O A R D ERMINAL BLOCK B1 FAC ORY OR FIELD GROUND SUPPLIED DISCONNEC HREE PHASE POWER SUPPLY FIGURE 5 - TYPICAL FIELD WIRING Johnson Controls Unitary Products... -
Page 13: Thermostat
Table 3 for minimum CFM limitations and to Tables A fused disconnect switch should be field provided for 10 and 13 for electrical data. the unit. The switch must be separate from all other cir- cuits. Wire entry at knockout openings require conduit Johnson Controls Unitary Products... -
Page 14: Optional Gas Heat
All units require a one-inch pipe connection at Maximum capacity of pipe in cubic feet of gas per hour. (Based upon the entrance fitting. a pressure drop of 0.3 inch water column and 0.6 specific gravity gas). Johnson Controls Unitary Products... -
Page 15: Gas Connection
Shellac base compounds nace. such as Gaskolac or Stalastic, and compounds such as Rectorseal #5, Clyde's or John Crane may be used. Johnson Controls Unitary Products... -
Page 16: L.p. Units, Tanks And Piping
The top flange of this hood slips in ture of the liquid and (b) the "wetted surface" area under the top of the access panel opening when install- of the container or containers. ing. Refer to Vent and Combustion Air Hood Figure 8. Johnson Controls Unitary Products... -
Page 17: Optional Economizer/Motorized Damper Rain Hood
DAMPER SET POINT ADJUSTMENTS AND INFOR- exhaust is needed. It can be set from 0 to 100% MATION damper open. Remove the economizer access panel from the unit. Loosen but do not remove the two panel latches. Johnson Controls Unitary Products... -
Page 18: Indoor Air Quality Aq
SAT - analog input provided by a factory-installed static pressure and return a speed reference signal to 10k-ohm, type 3 thermistor located in the unit's the VFD to control the output of the indoor blower supply air compartment. motor. Johnson Controls Unitary Products... -
Page 19: Factory-Installed Vfd
The factory-installed VFD is mounted in the Blower motor. Access Compartment above the blower assembly. The drive comes wired from the factory to include both 3- phase power and control connections (run permit sig- nal, speed reference signal & fault signal). Johnson Controls Unitary Products... -
Page 20: Manual Bypass
VAV boxes present in the duct sys- • LR '4' to UCB 'C' tem, then boxes must be driven to the full-open position using a customer-supplied power source to prevent over-pressurizing and possi- ble damage to the ductwork. Johnson Controls Unitary Products... -
Page 21: Vfd-Ready' For Customer-Installation
0 and 80 psig with a factory-setting nected after the drive is installed. of 60 psig. HGBP is standard on all units with VAV and optional with CV units. Johnson Controls Unitary Products... -
Page 22: Enthalpy Setpoint Adjustment
284815-BIM-C-1008 FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT Johnson Controls Unitary Products... -
Page 23: Honeywell Economizer Control
Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cool Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 10 - HONEYWELL ECONOMIZER CONTROL W7212 FRONT FRONT FIGURE 11 - FOUR AND SIX POINT LOADS Johnson Controls Unitary Products... -
Page 24: Center Of Gravity
(lb) DU-15C00 1900 DU-15N30 2100 DU-15N40 2140 DU-18C00 1950 DU-18N30 2150 DU-18N40 2190 DU-20C00 2100 DU-20N30 2300 DU-20N40 2340 DU-25C00 2345 DU-25N30 2545 DU-25N40 2585 (17.5, 20 & 25 Ton) FIGURE 12 - CENTER OF GRAVITY Johnson Controls Unitary Products... -
Page 25: Physical Data
Wood Skid TABLE 9: SUPPLY FAN VFD WEIGHTS, IN LBS. SUPPLY FAN MOTOR 230V 460V 575V W/O MANUAL BYPASS 5.0 hp 7.5 hp 10.0 hp 15.0 hp W/MANUAL BYPASS 5.0 hp 7.5 hp 10.0 hp 15.0 hp Johnson Controls Unitary Products... -
Page 26: Du-15, -18 & -20 Electrical Data Without Powered Convenience Outlet
284815-BIM-C-1008 TABLE 10: DU-15, -18 & -20 ELECTRICAL DATA WITHOUT POWERED CONVENIENCE OUTLET COMPRESSORS HEATER OPTION MAX. MIN. FUSE/ MODEL OD FAN CONV BLOWER CIRCUIT (TON- VOLTAGE MOTORS OUTLET BRKR MOTOR MODEL STAGES AMPS AMPACITY NAGE) EACH EACH FLA EACH... -
Page 27: Outlet
18.0 21.7 62.9 17.2 19.3 36.0 43.3 78.3 54.0 65.0 89.1 72.0 86.6 110.7 None 47.5 18.0 17.3 47.5 12.4 15.4 36.0 34.6 62.6 54.0 52.0 71.2 72.0 69.3 88.5 NOTE 1: HACR Type per NEC. Johnson Controls Unitary Products... -
Page 28: Du-15, -18 & -20 Electrical Data With Powered Convenience Outlet
284815-BIM-C-1008 TABLE 13: DU-15, -18 & -20 ELECTRICAL DATA WITH POWERED CONVENIENCE OUTLET COMPRESSORS HEATER OPTION MAX. MIN. FUSE/ MODEL OD FAN CONV BLOWER CIRCUIT (TON- VOLTAGE MOTORS OUTLET BRKR MOTOR MODEL STAGES AMPS AMPACITY NAGE) EACH EACH FLA EACH... -
Page 29: Electrical Data Standard Motor With Powered Convenience Outlet
18.0 21.7 67.9 17.2 19.3 36.0 43.3 84.5 54.0 65.0 95.3 72.0 86.6 117.0 None 51.5 18.0 17.3 51.5 12.4 15.4 36.0 34.6 67.6 54.0 52.0 76.2 72.0 69.3 93.5 NOTE 1: HACR Type per NEC. Johnson Controls Unitary Products... -
Page 30: Front View Dimensions
Opening in the bottom of the unit can be located by the slice in the insulation. NOTE: All entry holes should be field sealed to prevent rain water entry into the building. FIGURE 13 - FRONT VIEW DIMENSIONS Johnson Controls Unitary Products... -
Page 31: Rear View Dimensions
Connect ductwork to the flanges on those panels. openings are closed with sheet metal covers except when the unit includes a power exhaust option. The covering consists of a heavy black paper composition. Replace the side supply and return air compartment panels. Johnson Controls Unitary Products... -
Page 32: Unit Clearances And Rain Hood Dimensions
INTAKE HOOD (located on Return Air Compartment) 36-5/8” 1“ CONDENSATE DRAIN 16-1/8” (Must be trapped) 5” 28-3/16” 92” REAR VIEW LH VIEW DETAIL “Y” UNIT WITH RAIN HOODS FIGURE 15 - UNIT CLEARANCES AND RAIN HOOD DIMENSIONS Johnson Controls Unitary Products... -
Page 33: Cfm, Static Pressure, And Power - Altitude And Temperature Corrections
This value must be corrected for elevation. Example 2: A system, located at 5,000 feet of elevation, is to BHP at 5,000 ft = 3.2 x .832 = 2.66 deliver 6,000 CFM at a static pressure of 1.5". Use the unit Johnson Controls Unitary Products... -
Page 34: Altitude/Temperature Conversion Factor
284815-BIM-C-1008 ltitude/Temperature Conversion Factor SEA LEVEL TEMPER TURE (°F) FIGURE 16 - ALTITUDE/TEMPERATURE CONVERSION FACTOR Johnson Controls Unitary Products... -
Page 35: Supply Air Blower Performance (15 Ton) - Cooling Only 180 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Johnson Controls Unitary Products... -
Page 36: Supply Air Blower Performance (17.5 Ton) - Cooling Only 210 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Johnson Controls Unitary Products... -
Page 37: Supply Air Blower Performance (20 Ton) - Cooling Only 240 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Johnson Controls Unitary Products... -
Page 38: Supply Air Blower Performance (15 Ton) - Gas Heat 180 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Johnson Controls Unitary Products... -
Page 39: Supply Air Blower Performance (17.5 Ton) - Gas Heat 210 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Johnson Controls Unitary Products... -
Page 40: Supply Air Blower Performance (20 Ton) - Gas Heat 240 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. Johnson Controls Unitary Products... -
Page 41: Supply Air Blower Performance (25 Ton) - Gas Heat 300 Mbh - Bottom Duct Connections
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total static pressure of the blower. * Do NOT close the pulley below 1 turn open. ** Factory setting. 15 HP Motor is required. Johnson Controls Unitary Products... -
Page 42: Static Resistances
All motors have a nominal speed of 1800 RPM, a 1.15 service factor and a solid base. They can operate to the limit of their service factor because they are located in the moving air, upstream of any heating device. Do NOT close this pulley below 1 turn open. Johnson Controls Unitary Products... -
Page 43: Phasing
CFM's and/or higher static pressures. Use Model 1LD0416 for 15 ton units and Model 1LD0417 for 20 ton units. Refer to the Blower Motor and Drive Data Table 26. Johnson Controls Unitary Products... -
Page 44: Air Balance
MENTS TO ASSURE A DRY INDOOR COIL. SUPPLY AIR 0.65 210, 240MBH 180MBH 300MBH 0.55 0.45 0.35 0.25 NOMINAL CFM (THOUSANDS) SUPPLY AIR FIGURE 18 - PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM FOR ALL UNIT TONNAGES Johnson Controls Unitary Products... -
Page 45: Operation
"R" to "G" and tain when operating the unit in VAV mode. If the duct "Y1" is completed. The UCB energizes the blower Johnson Controls Unitary Products... -
Page 46: Economizer With Dual Enthalpy Sensors
Second-Stage SAT mechanical cooling will not operate. As always, the "R" Control setpoint is used in the determination. to "G" connection provides minimum position but does not provide power exhaust operation. Johnson Controls Unitary Products... -
Page 47: Economizer With Optional Vav Blower With Power Exhaust
Errors are handled as gize the halted compressor. described below. All system errors override minimum Should a freezestat open three times within two hours run times for compressors. of operation, the UCB will lock-out the associated com- Johnson Controls Unitary Products... -
Page 48: Low Ambient Cooling
The unit control board monitors the temperature limit Two-stage heating (applies to all heaters except 18 switch of electric heat units and the temperature limit KW): switch and the gas valve of gas furnace units. Johnson Controls Unitary Products... -
Page 49: Heating Operation Errors
The limit switch operates when a Refer to Table 28 for the required heat anticipator set- high temperature condition, caused by inadequate ting. supply air flow occurs, thus shutting down the heater and energizing the blower. Johnson Controls Unitary Products... -
Page 50: Gas Heating Sequence Of Operations
The UCB will de-energize the stage igniter sparking and will open the redundant blower motor. valve located inside the first stage main gas valve "GV1" to allow a flow of gas to only the first stage carry- Johnson Controls Unitary Products... -
Page 51: Gas Heating Operation Errors
(Table 32). When voltage is no longer sensed at the power is removed from the module either at the GV, the UCB will de-energize the indoor blower follow- unit or by resetting the room thermostat. ing the elapse of the fan off delay for heating. Johnson Controls Unitary Products... -
Page 52: Flash Codes
B U R N E R C O M P A R T M E N T 6. Check the unit supply air (CFM). See "CHECKING FIGURE 20 - GAS VALVE AND CONTROLS SUPPLY AIR CFM" on Page 43. Johnson Controls Unitary Products... -
Page 53: Operating Instructions
13", pilot and automatic re-ignition system. DO nor the operating pressure drop below 5.0" for NOT attempt to manually light the pilot. natural gas units. If gas pressure is outside these Johnson Controls Unitary Products... -
Page 54: Manifold Gas Pressure Adjustment
A N D F L A M E S E N S O R B U L B C A R R Y - O V E R T U B E FIGURE 22 - PROPER FLAME ADJUSTMENT Johnson Controls Unitary Products... -
Page 55: Burner Air Shutter Adjustment
1/2 cu. ft. 1 cu. ft. Rev. Table 26. BELT DRIVE BLOWER All units have belt drive single-speed blower motors. The variable pitch pulley on the blower motor can be adjusted to obtain the desired supply air CFM. Johnson Controls Unitary Products... -
Page 56: Troubleshooting
G terminal of the UCB, tact between R and G in the AUTO position during and for loose wiring. calls for cooling. 10. If the thermostat and UCB are properly wired, replace the UCB. Johnson Controls Unitary Products... - Page 57 Y1 "ECON" terminal even though the econo- terminals of the UCB. If a switch has opened, there mizer is not providing free cooling. To test, discon- should be a voltage potential between the UCB ter- Johnson Controls Unitary Products...
- Page 58 UCB may have the compres- 3. If M2 is pulled in and voltage is supplied at M2, sor in an ASCD. Check the LED for an indication of lightly touch the compressor housing. If it is hot, the Johnson Controls Unitary Products...
- Page 59 ASCD, the econ- omizer terminals of the UCB may be improperly wired. Check for 24 volts at the Y1 “OUT” terminal Johnson Controls Unitary Products...
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Page 60: Gas Heat Troubleshooting Guide
Btu content of the gas in your particular locality integrity of the UCB. Disconnect the C1 terminal (contact your gas company for this information wire and jumper it to the Y1 terminal. DO NOT - it varies widely from city to city.). Johnson Controls Unitary Products... - Page 61 (RW1) contacts in the main con- descriptions, if necessary). Clear any fault by trol box and check to see if the (RW1) is pulled in. pressing 'RESET' on the drive's keypad and take Johnson Controls Unitary Products...
- Page 62 Clean as needed but the prob- and RW2) relay coils. If these relays are pulled in, lem should not be the gas valve. then check for a loose connection at terminal 2 and Johnson Controls Unitary Products...
- Page 63 Removal procedure is described in control and the gas valve. If intact, check for 24 BURNER INSTRUCTIONS Page 54. Clean or volts across terminals “MV” and “COMMON” termi- replace burner orifices and burners as needed. Johnson Controls Unitary Products...
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Page 64: Unit Control Board Flash Codes
11 Flashes Flashing Cooling 12 Flashes Unit Locked Out due to Fan Overload Switch Failure 13 Flashes Flashing Compressor Held Off due to Low Voltage 14 Flashes EEPROM Storage Failure No Power or Control Failure Non-alarm condition. Johnson Controls Unitary Products... -
Page 65: Unit Control Board Option Setup
Heat Delay, (See Table 33). Press the UP or green LED will flash a few times and then normal Down button to change the LED status to corre- display will resume. spond to the desired Heat Delay Value. Johnson Controls Unitary Products... -
Page 66: Codes
10 Flashes OAQ Sensor Failure 11 Flashes APS Switch Failure 12 Flashes Limit 2 Switch Open Non-std Non-std 13 Flashes Purge 14 Flashes VFD Input Failure 15 Flashes Dirty Filter Switch No Power or Control Failure Johnson Controls Unitary Products... - Page 67 284815-BIM-C-1008 Johnson Controls Unitary Products...
- Page 68 Subject to change without notice. Printed in U.S.A. 284815-BIM-C-1008 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 284815-BIM-B-0707 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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