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R-410A
XP SERIES
6-1/2 - 12-1/2 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 15
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1 XP078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . .7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .8
3 XP078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . .9
4 XP078-150 Unit Physical Dimensions . . . . . . . . . . . . . . .10
5 XP078-150 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . .10
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .12
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9 XP078-150 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 26
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 27
11 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12 Altitude/Temperature Correction Factors . . . . . . . . . . . . 31
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
®
Component Location . . . . . . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 XP078-120 Physical Dimensions . . . . . . . . . . . . . . . . . . . 9
9 XP150 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 9
10 XP078-150 Unit Bottom Duct Openings . . . . . . . . . . . . 10
11 XP078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 11
12 XP078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . 11
13 XP150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 12
14 XP078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . 12
15 XP078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TABLE OF CONTENTS
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 41
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 42
Heating Sequence of Operation . . . . . . . . . . . . . . . . . . . . 43
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 43
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Unit Control Board Option Setup . . . . . . . . . . . . . . . . . . . . . . 46
Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
LIST OF TABLES
13 Airflow Performance - Side Duct Application . . . . . . . . . .33
14 Airflow Performance - Bottom Duct Application . . . . . . . .35
15 RPM Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
16 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . .37
17 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . .37
18 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . .39
19 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . .40
20 Electric Heat Limit Setting 50" Cabinet . . . . . . . . . . . . . . .44
21 Electric Heat Limit Setting 42" Cabinet . . . . . . . . . . . . . . .44
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 44
23 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . .45
24 Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
LIST OF FIGURES
16 XP078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . 13
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 14
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 14
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . 14
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
22 Typical Electronic Thermostat Field Wiring . . . . . . . . . . 17
23 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . 17
24 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . 29
25 Honeywell Economizer Control W7212 . . . . . . . . . . . . . 29
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
27 Altitude/Temperature Correction Factors . . . . . . . . . . . . 31
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
29 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
533629-YIM-E-0112
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Table of Contents
Related Manuals for Johnson Controls XP Series
Summary of Contents for Johnson Controls XP Series
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Page 1: Table Of Contents
R-410A XP SERIES 6-1/2 - 12-1/2 Ton 60 Hertz TABLE OF CONTENTS General ......... . 2 Air Balance . -
Page 2: General
This product must be installed in strict compliance with the installation instructions and any applicable local, state and national codes including, but not limited to building, electrical, and mechanical codes. Johnson Controls Unitary Products... - Page 3 This system uses R-410A Refrigerant which operates at For use as a cooling only unit, cooling unit with higher pressures than R-22. No other refrigerant may be supplemental electric heat or a forced air furnace. used in this system. Johnson Controls Unitary Products...
- Page 4 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...
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Page 5: Installation
Relief Hood AE-011-07 or call the applications department for in Shipping Unitary Products @ 1-877-UPG-SERV for guidance. Location Additional accessories may be needed for stable (if Included) operation at temperatures below 30° F. Figure 2: Condenser Covering Johnson Controls Unitary Products... -
Page 6: Predator ® Component Location
Roof curbs in eight- and motor fourteen-inch heights. Roof curbs for transitioning from Sunline™ footprint to the XP series footprint are also available (field installed accessory) Slide-out drain pain Side entry power Compressor #1 Access with steel 3/4” NPT,... -
Page 7: Location
All panels must be secured in place when the unit is inlet or vent outlets. lifted. The condenser coils should be protected from rigging cable damage with plywood or other suitable material. Johnson Controls Unitary Products... -
Page 8: Weights And Dimensions
Table 2: Weights and Dimensions Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.) 6 Point Load Location (lbs.) Size Model (Tons) Shipping Operating (6.5) (7.5) 1140 1135 25.5 (8.5) 1140 1135 25.5 (10) 1405 1400 25.5 (12.5) Johnson Controls Unitary Products... -
Page 9: Xp078-150 Unit Accessory Weights
Table 3: XP078-150 Unit Accessory Weights Weight (lbs.) Unit Accessory Shipping Operating Economizer Power Exhaust Electric Heat 1. Weight given is for the maximum heater size available (54KW). Figure 8: XP078-120 Physical Dimensions Figure 9: XP150 Physical Dimensions Johnson Controls Unitary Products... -
Page 10: Xp078-150 Unit Physical Dimensions
1. Units must be installed outdoors. Over hanging structure or shrubs should not obscure condenser air discharge outlet. 2. Units may be installed on combustable floors made from wood or class A, B or C roof covering materials. Figure 10: XP078-150 Unit Bottom Duct Openings Johnson Controls Unitary Products... -
Page 11: Xp078-150 Unit Electrical Entry
A i r S u p p l y A i r 2 - 3 1 /3 2 5 - 5 /3 2 3 1 - 1 1 /1 6 Figure 12: XP078-120 Unit Side Duct Openings Johnson Controls Unitary Products... -
Page 12: Side Duct Dimensions
XP102 28 1/4 18 1/16 28 1/4 18 1/4 XP120 28 1/4 18 1/16 28 1/4 18 1/4 XP150 28 1/4 18 1/16 28 1/4 18 1/4 30-3/8 4-5/16 Figure 14: XP078-150 Unit Left Duct Opening Johnson Controls Unitary Products... -
Page 13: Ductwork
A closed return duct system should be used. This will not Refer to Figure 10 for bottom air duct openings. Refer to preclude use of economizers or outdoor fresh air intake. The Figures 12, 13 and Table 6 for side air duct openings. Johnson Controls Unitary Products... -
Page 14: Condensate Drain
POE. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oil can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere. Johnson Controls Unitary Products... -
Page 15: Filters
NEC and CEC as Power wiring is brought into the unit through the side of the unit specified above and/or local codes. or the basepan inside the curb. Johnson Controls Unitary Products... -
Page 16: Control Wire Sizes
Follow the manufacturer's instructions enclosed with thermostat for general installation procedure. Seven (7) 18 AWG 150 Feet color-coded, insulated wires should be used to connect the 1. From the unit to the thermostat and back to the unit. Johnson Controls Unitary Products... -
Page 17: Unit Control Board
Terminals A1 and A2 provide a relay output to close the outdoor economizer dampers when the thermostat switches to the set-back position. Figure 22: Typical Electronic Thermostat Field Wiring T-STAT UNIT CONTROL BOARD Figure 23: Typical Field Wiring 24 Volt Thermostat Johnson Controls Unitary Products... -
Page 18: Electrical Data
126.4 81.8 151.0 156.5 (8.5) None 25.3 27.5 10.8 38.8 41.0 13.5 21.7 52.3 54.5 28.9 61.4 63.6 40.9 76.4 78.6 None 19.9 21.7 30.7 32.5 10.5 17.3 41.5 43.3 23.1 48.7 50.5 32.7 60.8 62.6 Johnson Controls Unitary Products... - Page 19 87.1 89.3 65.0 87.1 89.3 None 26.1 27.9 17.3 47.7 49.5 13.5 23.1 54.9 56.7 32.7 67.0 68.8 52.0 67.0 68.8 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
- Page 20 129.1 81.8 153.7 159.2 (8.5) None 26.5 28.7 10.8 40.0 42.2 13.5 21.7 53.5 55.7 28.9 62.6 64.8 40.9 77.6 79.8 None 20.4 22.2 31.2 33.0 10.5 17.3 42.0 43.8 23.1 49.2 51.0 32.7 61.3 63.1 Johnson Controls Unitary Products...
- Page 21 89.9 92.1 65.0 89.9 92.1 None 28.0 29.8 17.3 49.6 51.4 13.5 23.1 56.8 58.6 32.7 68.9 70.7 52.0 68.9 70.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
- Page 22 (8.5) None – – 30.3 32.5 10.8 43.8 46.0 13.5 21.7 57.3 59.5 28.9 66.4 68.6 40.9 81.4 83.6 None – – 23.9 25.7 34.7 36.5 10.5 17.3 45.5 47.3 23.1 52.7 54.5 32.7 64.8 66.6 Johnson Controls Unitary Products...
- Page 23 65.0 92.1 94.3 None – – 30.1 31.9 17.3 51.7 53.5 13.5 23.1 58.9 60.7 32.7 71.0 72.8 52.0 71.0 72.8 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
- Page 24 (8.5) None – – 31.5 33.7 10.8 45.0 47.2 13.5 21.7 58.5 60.7 28.9 67.6 69.8 40.9 82.6 84.8 None – – 24.4 26.2 35.2 37.0 10.5 17.3 46.0 47.8 23.1 53.2 55.0 32.7 65.3 67.1 Johnson Controls Unitary Products...
- Page 25 65.0 94.9 97.1 None – – 32.0 33.8 17.3 53.6 55.4 13.5 23.1 60.8 62.6 32.7 72.9 74.7 52.0 72.9 74.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
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Page 26: Xp078-150 Physical Data
Circuitry Type Split-face Split-face Split-face Split-face Split-face Refrigerant control EVAPORATOR COIL DATA Face area (Sq. Ft.) 10.6 10.6 13.2 13.2 13.2 Rows Fins per inch Tube diameter Circuitry Type Split-face Split-face Split-face Split-face Split-face Refrigerant control Johnson Controls Unitary Products... -
Page 27: Optional Electric Heat
2550 2550 2550 2550 208/230-3-60 3000 3000 3000 3500 460-3-60 3000 3000 3000 3000 (10) 600-3-60 3000 3000 3000 3500 208/230-3-60 3750 3750 3750 4000 460-3-60 3750 3750 3750 3750 (12.5) 600-3-60 3750 3750 3750 3750 Johnson Controls Unitary Products... -
Page 28: Options/Accessories
Remove the top rear access panel from the unit. Locate the full open. When there is no call for free cooling, the damper economizer control module, where the following adjustments position is limited by the IAQ Max damper position setting. will be made. Johnson Controls Unitary Products... -
Page 29: Enthalpy Set Point Chart
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 25: Honeywell Economizer Control W7212 Johnson Controls Unitary Products... -
Page 30: Supply Air Limitations
(See ‘PHASING’). Table 11: Supply Air Limitations Figure 26: Belt Adjustment Unit Size (Ton) Minimum Maximum 078 (6.5) 1950 3250 090 (7.5) 2250 3750 102 (8.5) 2550 4250 120 (10) 3000 5000 150 (12.5) 3750 6250 Johnson Controls Unitary Products... -
Page 31: Altitude/Temperature Correction Factors
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) Figure 27: Altitude/Temperature Correction Factors Johnson Controls Unitary Products... -
Page 32: Airflow Performance
5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Open Closed 1.73 1VM50 AK74 1035 1079 1126 2.30 1VM50 AK64 1039 1094 1150 1207 1256 1308 Johnson Controls Unitary Products... -
Page 33: Airflow Performance - Side Duct Application
1. Blower performance includes 2” 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 34 1. Blower performance includes 2” 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...
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Page 35: Airflow Performance - Bottom Duct Application
1. Blower performance includes 2” 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 36: Rpm Selection
2.30 1VM50 AK89 (8.5) 3.45 1VM50 AK74 1016 1067 1110 2.30 1VM50 AK84 (10) 3.45 1VM50 AK74 1016 1067 1110 3.45 1VM50 AK74 1016 1067 1110 (12.5) 5.75 1VP56 BK77 1052 1095 1136 1175 1216 1272 Johnson Controls Unitary Products... -
Page 37: Air Balance
Use an Inclined Manometer or Magnehelic to determine air ducts of the unit. the pressure drop across a dry evaporator coil. Since the moisture on an evaporator coil can vary greatly, measuring Johnson Controls Unitary Products... -
Page 38: Dry Coil Delta P
XP078 0.45 XP102 XP090 XP120 XP150 0.35 0.25 0.15 0.05 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 Airflow (CFM) Figure 28: Dry Coil Delta P Johnson Controls Unitary Products... -
Page 39: Motor Sheave Datum Diameters
10-12 hrs. run time is recommended. Table 18: Motor Sheave Datum Diameters 1VM50x7/8 1VP56x1-1/8 (1-1/2, 2 & 3 HP Motor) (5 HP Motor) Turns Open Datum Diameter Turns Open Datum Diameter 1-1/2 1-1/2 2-1/2 2-1/2 3-1/2 3-1/2 4-1/2 4-1/2 5-1/2 Johnson Controls Unitary Products... -
Page 40: Additional Static Resistance
2. The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation. Johnson Controls Unitary Products... -
Page 41: Operation
Cooling Sequence Of Operation If there is an initial call for both stages of cooling, the UCB will For the XP series of units, the thermostat makes a circuit delay energizing compressor #2 by 30 seconds in order to between "R" and "Y1" for the first stage of cooling. -
Page 42: Cooling Operation Errors
Should a low-pressure switch open three times within one hour units with electric heat. of operation, the UCB will lock-out the associated compressor and flash a code (Table 23). If the other compressor is inactive, the condenser fans will be de-energized. Johnson Controls Unitary Products... -
Page 43: Heating Sequence Of Operation
The DC must first satisfy its accumulated minimum run units. time. This is factory set at 60 minutes, but is field adjustable to 30, 60 or 90 minutes. The control circuit includes the following safety controls: Johnson Controls Unitary Products... -
Page 44: Start-Up (Cooling)
All XP units use Thermal Expansion Devices. Charge the unit to It is important that the anticipator setpoint be correct. Too high 10° subcooling. of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space. Reducing the Johnson Controls Unitary Products... -
Page 45: Troubleshooting
Flashing Cooling 12 Flashes Unit Locked Out due to Fan Overload Switch Failure 13 Flashes Compressor Held Off due to Low Voltage Flashing 14 Flashes EEPROM Storage Failure No Power or Control Failure 1. Non-alarm condition. Johnson Controls Unitary Products... -
Page 46: Unit Control Board Option Setup
LED (Heat Delay) is turned off. • Press the COMM SETUP / SELECT button to toggle into the Heat Delay Setup, the green LED will turn off and the Non-std Non-std red LED for Heat Delay will turn on. Johnson Controls Unitary Products... - Page 47 10. If 24 volts is present at the UCB Y1 terminal and none of cooling and the compressors will not immediately operate. the switches are open and the compressor is not locked If both stages of cooling are requested simultaneously and Johnson Controls Unitary Products...
- Page 48 #1 will be held off for the ASCD, and If installed, check the position of the economizer blades. If compressor #2 may be held off for a portion of the the blades are open, the economizer is providing free ASCD. See the next step. Johnson Controls Unitary Products...
- Page 49 If 24 volts is not present at Y1 “ECON”, the UCB UCB’s Mate-N-Lock plug. has faulted. The UCB should de-energize all compressors 13. The UCB can be programmed to lock out compressor operation during free cooling and in low ambient Johnson Controls Unitary Products...
- Page 50 15. If none of the above correct the error, replace the UCB. Subject to change without notice. Printed in U.S.A. 533629-YIM-E-0112 Copyright © 2012 by Johnson Controls, Inc. All rights reserved. Supersedes: 533629-YIM-D-0511 Johnson Controls Unitary Products 5005 York Drive...
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