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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) . . . . . . . . . . . . . . . . . . . . . . . . .53
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: DW-15, -18, -20 & -25
284816-BIM-C-1008
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Related Manuals for Johnson Controls DW-15
Summary of Contents for Johnson Controls DW-15
- Page 1 GENERAL ........4 MODELS: DW-15, -18, -20 & -25 SAFETY CONSIDERATIONS .
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Page 2: Table Of Contents
SHUT DOWN ........53 Johnson Controls Unitary Products... - Page 3 24 GAS VALVE AND CONTROLS ..... 52 25 TYPICAL GAS VALVES ......54 Johnson Controls Unitary Products...
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Page 4: General
Wear safety glasses and work gloves, and follow all • Technical Guide - 263415 safety codes. Use a quenching cloth and have a fire • General Installation - 284816 extinguisher available for all brazing operations. Johnson Controls Unitary Products... -
Page 5: Renewal Parts
For use with natural gas or propane gas. This Product Must Be Installed In Strict Com- pliance With The Enclosed Installation Instruc- tions And Any Applicable Local, State, And National Codes Including, But Not Limited To, Building, Electrical, And Mechanical Codes. 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
CSA-B149.1 (in Canada) and/or applicable provisions of the local building codes. Refer to Figures 13, 14 and 15 for the dimensions and clearances required for com- bustible construction, servicing, and proper unit opera- FIGURE 1 - TYPICAL RIGGING tion. 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 FIGURE 4 - RECOMMENDED DRAIN PIPING unit to maintain an airtight seal. Johnson Controls Unitary Products... -
Page 12: Typical Field Wiring
o n o m i z e r d a m p e r s w h e n th e th e r m o s t a t s w i t c h e s to th e s e t - b a c k p o s i t i o n . T-STAT UNIT CONTROL BOARD 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
A fused disconnect switch should be field provided for to Table 3 for minimum CFM limitations and to Tables 9 the unit. The switch must be separate from all other cir- and 10 for electrical data. 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 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
Refer to Vent and Combustion Air Hood Figure 8. 2. The proper pressure regulation. (Two-stage regula- tion is recommended from the standpoint of both cost and efficiency.) Johnson Controls Unitary Products... -
Page 17: Optional Economizer/Motorized Damper Rain Hood
Loosen but do not remove the two panel latches. the actuator is allowed to modulate normally in accor- Locate the economizer control module, where the fol- dance with the enthalpy and mixed air sensor inputs. lowing adjustments will be made. Johnson Controls Unitary Products... -
Page 18: Optional Bas-Ready Economizer Power Exhaust Damper Set Point Adjustment
OH - a 0-10 VDC analog input provided by a field- Pressure-transmitting plastic tubing (1/4" diameter) installed outdoor air relative humidity sensor for must be field supplied and installed from the transducer single enthalpy economizer configuration. to both the ductwork and to the atmosphere. Connect Johnson Controls Unitary Products... -
Page 19: Factory-Installed Vfd
4.5" WC. If the duct static pressure • TEST - routes power to the VFD but not to the reaches the high-limit set point, then the supply fan motor to allow for drive programming and/or diag- motor will be shutdown. nostics. Johnson Controls Unitary Products... -
Page 20: Bas-Ready Vfd
AC-out- heat, a terminal block located in the unit's control box put or DC-output. See price pages for further details. and connected to the VAV board's "VAV BOX" termi- Johnson Controls Unitary Products... -
Page 21: Optional Hot Gas Bypass (Hgbp)
60 psig. HGBP is standard on all units with VAV and pressure-modulating bypass control valve installed on optional with CV units. the system #1 discharge line is used to divert high tem- perature, high pressure refrigerant around the TXV in FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT Johnson Controls Unitary Products... -
Page 22: Honeywell Economizer Control W7212
Screw 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 FIGURE 11 - FOUR AND SIX POINT LOADS Johnson Controls Unitary Products... -
Page 23: Center Of Gravity
6 Point Loads (lbs) Unit Size Shipping Weight -15 Gas 2660 -18 Gas 2928 -20 Gas 2960 -25 Gas 3046 -15 Elec 2460 -18 Elec 2728 -20 Elec 2760 -25 Elec 2846 FIGURE 12 - CENTER OF GRAVITY Johnson Controls Unitary Products... -
Page 24: Physical Data
WOOD SKID TABLE 8: 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 25: Dw Electrical Data Without Powered Convenience Outlet
43.2 18.0 21.7 43.2 12.8 10.0 36.0 43.3 66.6 54.0 65.0 77.5 72.0 86.6 99.1 None 35.0 18.0 17.3 35.0 10.3 36.0 34.6 53.6 54.0 52.0 62.2 72.0 69.3 79.5 NOTE 1: HACR Type per NEC. Johnson Controls Unitary Products... - Page 26 NOTE 1: HACR Type per NEC. ELECTRIC HEAT CORRECTION FACTORS VOLTAGE LIMITATIONS VOLTAGE NOMINAL VOLTAGE VOLTAGE kW CAP. MULTIPLIER POWER SUPPLY MIN. MAX. 1.00 208/230-3-60 0.92 460-3-60 0.92 575-3-60 0.92 Utilization Range “A” in accordance with ARI Standard 110. Johnson Controls Unitary Products...
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Page 27: Dw Electrical Data With Powered Convenience Outlet
48.2 18.0 21.7 48.2 12.8 10.0 36.0 43.3 72.9 54.0 65.0 83.7 72.0 86.6 105.4 None 39.0 18.0 17.3 39.0 10.3 36.0 34.6 58.6 54.0 52.0 67.2 72.0 69.3 84.5 NOTE 1: HACR Type per NEC. Johnson Controls Unitary Products... - Page 28 NOTE 1: HACR Type per NEC. ELECTRIC HEAT CORRECTION FACTORS VOLTAGE LIMITATIONS VOLTAGE NOMINAL VOLTAGE VOLTAGE kW CAP. MULTIPLIER POWER SUPPLY MIN. MAX. 1.00 208/230-3-60 0.92 460-3-60 0.92 575-3-60 0.92 Utilization Range “A” in accordance with ARI Standard 110. Johnson Controls Unitary Products...
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Page 29: Front View Dimensions 15, 17.5, 20 & 25 Ton
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 15, 17.5, 20 & 25 TON Johnson Controls Unitary Products... -
Page 30: 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 31: 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 32: 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 deliver 6,000 CFM at a static pressure of 1.5". Use the unit BHP at 5,000 ft = 3.2 x .832 = 2.66 Johnson Controls Unitary Products... -
Page 33: Factor
284816-BIM-C-1008 ltitude/Temperature Conversion Factor SEA LEVEL TEMPER TURE (°F) FIGURE 16 - ALTITUDE/TEMPERATURE CONVERSION FACTOR Johnson Controls Unitary Products... -
Page 34: 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 35: Pg. # 13 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 36: 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 37: 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 38: 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 39: 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 40: 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. Johnson Controls Unitary Products... -
Page 41: 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 42: Charging Chart - 15 Ton
2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply. FIGURE 18 - CHARGING CHART - 17.5 TON Johnson Controls Unitary Products... -
Page 43: Charging Chart - 20 Ton
2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply. FIGURE 20 - CHARGING CHART - 25 TON Johnson Controls Unitary Products... -
Page 44: Phasing
17.5 and 20 ton units, and Model 1LD0435 for 25 ton VFD units with bypass must not be in bypass units. Refer to the Blower Motor and Drive Data mode (‘LINE’ position) unless all individual Table 21. space dampers are full open. Johnson Controls Unitary Products... -
Page 45: Operation
"AUTO" or "HEAT" from the curve in Pressure Drop vs. Supply Air settings, the blower is energized whenever a cooling or CFM Figure 22. heating operation is requested. The blower is ener- Johnson Controls Unitary Products... -
Page 46: Optional Vav Blower Operation
Otherwise, the unit operates air and return air, whichever has the lowest enthalpy each cooling system until the minimum run times for value, to provide maximum operating efficiency. the compressors have been completed. Upon the final Johnson Controls Unitary Products... -
Page 47: Economizer (Single Or Dual Enthalpy) With Power Exhaust
First-Stage SAT Control setpoint, plus or minus one damper motor. When the "R" to "G" circuit is opened, degree. If free-cooling is unavailable, then 1st-stage the damper spring returns fully closed. mechanical cooling is initiated. Johnson Controls Unitary Products... -
Page 48: Cooling Operation Errors
If the call for cooling is still present The other refrigerant system will continue in operation unless it is affected by the fault as well. Johnson Controls Unitary Products... -
Page 49: Compressor Protection
This control is located inside the heater compart- the specified fan on delay for heating, the UCB will ment and is set to open at the temperature indi- energize the blower motor. cated in the Limit Control Setting Table 22. It resets Johnson Controls Unitary Products... -
Page 50: Flash Codes
Refer to Table 23 for the required heat anticipator set- and the presence of pilot flame detected at the "IC1" by ting. a signal sent back through the flame sensor is sparking terminated and the first stage main gas valve opened. Johnson Controls Unitary Products... -
Page 51: Gas Heating Operation Errors
"W1" is lost, the indoor blower is forced on REDUNDANT MAIN VALVE for the length of the fan off delay for heating. VALVE GAS MAIN TO MAIN VALVE BURNER TO PILOT BURNER FIGURE 23 - GAS VALVE PIPING Johnson Controls Unitary Products... -
Page 52: Safety Controls
FIGURE 24 - GAS VALVE AND CONTROLS unit or by resetting the room thermostat. FLASH CODES The UCB will initiate a flash code associated with errors within the system. Refer to UNIT CONTROL BOARD FLASH CODES Table 27. Johnson Controls Unitary Products... -
Page 53: Resets
This furnace is equipped with an intermittent 7. Measure evaporator fan motor's amp draw. pilot and automatic re-ignition system. DO NOT attempt to manually light the pilot. 8. Set the room thermostat fan switch to off. 9. Turn unit electrical power off. Johnson Controls Unitary Products... -
Page 54: To Light Pilot And Main Burners
Supply pres- C A R R Y - O V E R T U B E sure should be checked with all gas appliances in FIGURE 26 - PROPER FLAME ADJUSTMENT Johnson Controls Unitary Products... -
Page 55: Pilot Checkout
278 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 278 x 1050 (the Btu rating of the gas obtained from the local gas company). The result is 292,425 Btuh, which is close to the 300,000 Btuh rating of the furnace. Johnson Controls Unitary Products... -
Page 56: Adjustment Of Temperature Rise
M3, M3 is pulled in, and the blower motor does nance procedures so as to prevent personal not operate, check all power & control wiring con- injury. nections to and from the drive and for any fault/ warning messages displayed on the drive's digital Johnson Controls Unitary Products... - Page 57 While the above step will reset any lockouts, NOTE: check for line voltage at the compressor contactor, compressor #1 may be held off for the ASCD. M1, and that the contactor is pulled in. Check for See the next step. Johnson Controls Unitary Products...
- Page 58 UCB is programmed to lock out compressor opera- tion when the LAS set point is reached. 6. If 24 volts is not present at M2, check for 24 volts at the UCB terminal, C2. If 24 volts are present, Johnson Controls Unitary Products...
- Page 59 UCB is programmed to lock out compressor opera- for 24 volts from the room thermostat at the UCB tion when the LAS set point is reached. Y1 terminal. If 24 volts are not present at the UCB Johnson Controls Unitary Products...
- Page 60 UCB. If 24 volts is present, trace the wiring from Y1 “OUT” for incorrect wiring. If 24 volts is not 15. If none of the above correct the error, replace the present at the Y1 “OUT” terminal, the UCB must be UCB. replaced. Johnson Controls Unitary Products...
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Page 61: Gas Heat Troubleshooting Guide
24 volts from the times as the supply air blower may energize room thermostat. If 24 volts is not present from the regardless of the room thermostat fan switch room thermostat, check for the following: position. Johnson Controls Unitary Products... - Page 62 IC1 or IC2. The draft motor runs but the furnace does not light and the sparker does not spark. Johnson Controls Unitary Products...
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Page 63: Unit Control Board Flash Codes
4. Make sure that the ground connections at the pilot check the alarm history. The UCB will cycle through the burner, gas valve and ignitor control are intact. last five (5) alarms, most recent to oldest, separating Johnson Controls Unitary Products... -
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
4 labeled options ((8) Fan Off at Heat Start, (4) saves the parameters for the currently dis- Low Ambient Lockout, (2) Free Cooling Lock- played mode (Option Byte or Heat Delay). out, and (1) Lead / Lag). Johnson Controls Unitary Products... -
Page 66: Heat Delay Setup
11 Flashes APS Sensor Failure TABLE 28: HEAT DELAY 12 Flashes Limit 2 Switch Open Heat Heat 13 Flashes Purge Fan On Fan Off LED 8 LED 4 LED 2 LED 1 Delay Delay Non-std Non-std Johnson Controls Unitary Products... - Page 67 284816-BIM-C-1008 Johnson Controls Unitary Products...
- Page 68 Subject to change without notice. Printed in U.S.A. 284816-BIM-C-1008 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 284816-BIM-B-0707 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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