Johnson Controls R-410A Installation Manual
R-410a affinity series 2-5 ton
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- Technical manual (128 pages) ,
- Installation manual (63 pages) ,
- Installation and operation manual (20 pages)
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R-410A
AFFINITY™ SERIES
DNQ024-060
2-5 Ton
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 10
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Unit Dimensions Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 Single Stage Physical Data . . . . . . . . . . . . . . . . . . . . . . . 13
8 Two Stage Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 14
9 Natural Gas Pipe Sizing Chart . . . . . . . . . . . . . . . . . . . . 16
10 Propane (LP) Gas Pipe Sizing Chart . . . . . . . . . . . . . . . 16
11 Natural Gas Application Data-Single Stage . . . . . . . . . . 17
1 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Dimensions Front and Bottom . . . . . . . . . . . . . . . . . . . . . 8
5 Dimensions Back and Bottom . . . . . . . . . . . . . . . . . . . . . 8
6 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Thermostat-Single Stage Gas Heat . . . . . . . . . . . . . . . . 11
Thermostat-Two Stage Gas Heat . . . . . . . . . . . . . . . . . 11
Thermostat-Two Stage Gas Heat . . . . . . . . . . . . . . . . . 12
General
®
YORK
Affinity Model DNQ units are cooling/heating air
conditioners designed for outdoor installation. Only gas piping,
electric power and duct connections are required at the point of
installation.
The single or two stage gas-fired heaters have spark to pilot
ignition. The tubular heat exchangers are aluminized steel.
The refrigerant system is fully charged with R-410A Refrigerant,
and is tested and factory sealed.
TABLE OF CONTENTS
Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flue Vent Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Blower Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Heating Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 25
Cooling Sequence Of Operations . . . . . . . . . . . . . . . . . . . 27
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjustment of Temperature Rise . . . . . . . . . . . . . . . . . . . 30
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LIST OF TABLES
12 Natural Gas Application Data-Two Stage . . . . . . . . . . . . 17
13 Propane (LP) Gas Application Data-Single Stage . . . . . 17
14 Propane (LP) Gas Application Data-Two Stage . . . . . . . 17
15 Side Duct Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
16 Bottom Duct Application . . . . . . . . . . . . . . . . . . . . . . . . . 21
17 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 24
18 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . 25
19 Delay Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
20 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . 27
21 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 30
LIST OF FIGURES
10 Typical Field Power Wiring Diagram . . . . . . . . . . . . . . . 12
11 External Supply Connection External Shut-Off . . . . . . . 15
12 Flue Vent Outlet Air Hood . . . . . . . . . . . . . . . . . . . . . . . 16
13 Control Board Speed Tap Location . . . . . . . . . . . . . . . . 25
14 Single Stage Gas Valve Front . . . . . . . . . . . . . . . . . . . . 29
15 Two Stage Gas Valve Front . . . . . . . . . . . . . . . . . . . . . . 29
16 Single Stage Gas Valve Rear . . . . . . . . . . . . . . . . . . . . 29
17 Two Stage Gas Valve Rear . . . . . . . . . . . . . . . . . . . . . . 29
18 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . 29
19 R-410A Quick Reference Guide . . . . . . . . . . . . . . . . . . 43
Safety Considerations
This is a safety alert symbol
labels or in manuals, be alert to the potential for personal injury.
Understand and pay particular attention the signal words
DANGER, WARNING or CAUTION.
DANGER indicates an imminently hazardous situation, which,
if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if
not avoided may result in minor or moderate injury. It is also
used to alert against unsafe practices and hazards involving
only property damage.
SO 9001
Certified Quality
Management System
. When you see this symbol on
437758-YIM-A-0409
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Table of Contents
Related Manuals for Johnson Controls R-410A
Summary of Contents for Johnson Controls R-410A
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Page 1: Table Of Contents
Thermostat-Two Stage Gas Heat ....11 19 R-410A Quick Reference Guide ....43 9 Typical Field Control Wiring Diagram Two Stage Thermostat-Two Stage Gas Heat . - Page 2 1/2 PSIG, the gas containers and recovery systems must be designed to valve must be replaced. handle R-410A. If you are unsure, consult the equipment The furnace must be isolated from the gas supply piping manufacturer. Failure to use R-410A compatible servicing system by closing its individual manual shut-off valve equipment may result in property damage or injury.
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Page 3: Installation
This product must be installed in strict compliance with the enclosed installation instructions and any applicable This system uses R-410A Refrigerant which operates at local, state, and national codes including, but not limited higher pressures than R-22. No other refrigerant may be to, building, electrical, and mechanical codes. -
Page 4: Unit Limitations
Table 1: Unit Limitations Unit Limitations Size Unit Voltage Applied Voltage Outdoor DB Temp (Tons) Max (°F) 208/230-1-60 (2.0) 208/230-1-60 208/230-3-60 (2.5) 460-3-60 208/230-1-60 208/230-3-60 (3.0) 460-3-60 208/230-1-60 208/230-3-60 (3.5) 460-3-60 208/230-1-60 208/230-3-60 (4.0) 460-3-60 208/230-1-60 208/230-3-60 (5.0) 460-3-60 Johnson Controls Unitary Products... -
Page 5: Location
The condenser coils should be protected from rigging 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) - cable damage with plywood or other suitable material. Latest Edition, and/or applicable provisions of the local building Johnson Controls Unitary Products... -
Page 6: Weights And Dimensions
Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.) (Tons) Shipping Operating 24.5 (2.0) 24.25 (2.5) 24.25 (3.0) (3.5) (4.0) (5.0) Table 3: Unit Accessory Weights Weight (lbs.) Unit Accessory Model Shipping Operating Add Economizer Johnson Controls Unitary Products... -
Page 7: Unit Dimensions Front
3. Units must be installed outdoors. Over hanging structure or shrubs should not obscure condenser air discharge outlet. 4. Units may be installed on combustable floors made from wood or class A, B or C roof covering materials. Johnson Controls Unitary Products... -
Page 8: Dimensions Front And Bottom
SIDE SUPPLY 14-1/2 AIR OPENING 28-3/8 CONDENSER COIL 14-1/2 BACK BOTTOM SUPPLY AIR OPENING 3-3/8 SIDE RETURN AIR OPENING 14-1/2 4-1/4 1-3/4 1-3/4 BOTTOM RETURN 28-9/16 3-1/2 AIR OPENING 1-3/4 Figure 5: Dimensions Back and Bottom Johnson Controls Unitary Products... -
Page 9: Ductwork
Filters should be checked monthly; this is especially important NOTE: Be sure to note supply and return openings. since this unit is used for both heating and cooling. 1. 8” Roof Curb also available. Johnson Controls Unitary Products... -
Page 10: Condensate Drain
Failure to follow this warning can cause condensate drain line (3/4” NPTF) to spill into an open drain. serious personal injury. Refer to Figure 19 for the R-410A Quick Reference Guide. Thermostat Hand tighten only. The room thermostat should be located on an inside wall approximately 56"... -
Page 11: Typical Field Control Wiring Diagram Single Stage Thermostat-Single Stage Gas Heat
** = Minimum wire size of 18 AWG wire should be used for all field installed 24 volt wire. 24 VOLT TRANSFORMER PROGRAMMABLE THERMOSTAT ONLY Figure 8: Typical Field Control Wiring Diagram Single Stage Thermostat-Two Stage Gas Heat Johnson Controls Unitary Products... -
Page 12: Electrical Data
15.1 208/230-1-60 25.0 43.2 208/230-3-60 15.9 31.8 (5.0) 460-3-60 15.6 1. Minimum Circuit Ampacity. 2. Maximum Over Current Protection per standard UL 1995. 3. Fuse or HACR circuit breaker size installed at factory or field installed. Johnson Controls Unitary Products... -
Page 13: Single Stage Physical Data
1 - 20 x 20 x 1 2 - 20 x 12 x 1 2 - 20 x 12 x 1 2 - 20 x 12 x 1 Rating established with a “Wire Form” coil guard which ships as standard. Johnson Controls Unitary Products... -
Page 14: Two Stage Physical Data
1 - 20 x 20 x 1 2 - 20 x 12 x 1 2 - 20 x 12 x 1 2 - 20 x 12 x 1 Rating established with a “Wire Form” coil guard which ships as standard. Johnson Controls Unitary Products... -
Page 15: Compressors
437758-YIM-A-0409 Compressors The scroll compressor used in this product is specifically designed to operate with R-410A Refrigerant and cannot be interchanged. Scroll compressors require proper rotation to operate properly. Failure to check and correct rotation may result in property damage. -
Page 16: Natural Gas Pipe Sizing Chart
The gas supply should be a separate line and installed in cycle. Flue hood surface and the immediate area reach accordance with all safety codes as prescribed under high temperatures during the heating cycle. Limitations, shown on Page 3. After the gas connections Johnson Controls Unitary Products... -
Page 17: Natural Gas Application Data-Single Stage
4% for each 1,000 feet above sea level. 3. Based on 2500 BTU/Ft. 4. The air flow must be adequate to obtain a temperature rise within the range shown. Continuous return air temperature should not be below 55°F. Johnson Controls Unitary Products... -
Page 18: Airflow Performance
1125 COOL-D 1250 HEAT-A HEAT-B N036 HEAT-C HEAT-D HEAT-A 1050 HEAT-B 1135 N056 (2.5) HEAT-C 1220 HEAT-D 1300 Heat HEAT-A HEAT-B HEAT-C HEAT-D D056 W1+W2 HEAT-A 1050 W1+W2 HEAT-B 1135 W1+W2 HEAT-C 1220 W1+W2 HEAT-D 1300 Johnson Controls Unitary Products... - Page 19 HEAT-B 1300 N065 HEAT-C 1400 HEAT-D 1500 HEAT-A 1325 HEAT-B 1400 N090 (3.5) HEAT-C 1500 HEAT-D 1600 Heat HEAT-A HEAT-B HEAT-C HEAT-D 1050 D090 W1+W2 HEAT-A 1330 W1+W2 HEAT-B 1400 W1+W2 HEAT-C 1500 W1+W2 HEAT-D 1600 Johnson Controls Unitary Products...
- Page 20 1400 Heat W1+W2 HEAT-C 1500 W1+W2 HEAT-D 1600 HEAT-A 1450 HEAT-B 1500 N110 HEAT-C 1600 HEAT-D 1700 HEAT-A HEAT-B HEAT-C 1035 HEAT-D 1100 D110 W1+W2 HEAT-A 1450 W1+W2 HEAT-B 1500 W1+W2 HEAT-C 1600 W1+W2 HEAT-D 1700 Johnson Controls Unitary Products...
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Page 21: Bottom Duct Application
1125 COOL-D 1250 HEAT-A HEAT-B N036 HEAT-C HEAT-D HEAT-A 1050 HEAT-B 1135 N056 (2.5) HEAT-C 1220 HEAT-D 1300 Heat HEAT-A HEAT-B HEAT-C HEAT-D D056 W1+W2 HEAT-A 1050 W1+W2 HEAT-B 1135 W1+W2 HEAT-C 1220 W1+W2 HEAT-D 1300 Johnson Controls Unitary Products... - Page 22 HEAT-B 1300 N065 HEAT-C 1400 HEAT-D 1500 HEAT-A 1325 HEAT-B 1400 N090 (3.5) HEAT-C 1500 HEAT-D 1600 Heat HEAT-A HEAT-B HEAT-C HEAT-D 1050 D090 W1+W2 HEAT-A 1330 W1+W2 HEAT-B 1400 W1+W2 HEAT-C 1500 W1+W2 HEAT-D 1600 Johnson Controls Unitary Products...
- Page 23 1400 Heat W1+W2 HEAT-C 1500 W1+W2 HEAT-D 1600 HEAT-A 1450 HEAT-B 1500 N110 HEAT-C 1600 HEAT-D 1700 HEAT-A HEAT-B HEAT-C 1035 HEAT-D 1100 D110 W1+W2 HEAT-A 1450 W1+W2 HEAT-B 1500 W1+W2 HEAT-C 1600 W1+W2 HEAT-D 1700 Johnson Controls Unitary Products...
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Page 24: Additional Static Resistance
1. 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 25: Blower Speed Selection
The “Heat” Jumper on the CFM selection board should be purge period. If the call for heat is lost, the control de-energizes set to “A” from the factory. the inducer without post-purge and returns to standby. Johnson Controls Unitary Products... - Page 26 60 second period the control de main gas valve and induced draft motor de-energized. energizes the high gas output and steps the inducer to low speed. If W2 is energized the control remains on high heat. Johnson Controls Unitary Products...
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Page 27: Cooling Sequence Of Operations
The only way to recover from a hard lockout is to remove and When the thermostat calls for first-stage cooling, the then reapply 24VAC power to the control board. thermostat terminals G and Y energize, signaling the compressor, indoor blower and outdoor fan to operate. The Johnson Controls Unitary Products... -
Page 28: Start-Up
R-410A systems. R-22 pressure switches must 12. If the unit will not operate, follow the instructions To Turn not be used as replacements for the R-410A pressure switches. Off Gas To Appliance and call your service technician or gas supplier. -
Page 29: Single Stage Gas Valve Front
To adjust the pilot flame: " min. Manifold Pressure Adjustment (Under Cap) Line Pressure Tap (1/8” NPT) 1/2” NPT Spark Ignitor (Inlet) Pilot Flame Sensor Figure 16: Single Stage Gas Valve Rear Figure 18: Proper Flame Adjustment Johnson Controls Unitary Products... -
Page 30: Adjustment Of Temperature Rise
Turn off all other gas appliances connected to the gas meter. to the 100,000 BTUH rating of the furnace. With the furnace turned on, measure the time needed for one revolution of the hand on the smallest dial on the Johnson Controls Unitary Products... -
Page 31: Typical Wiring Diagrams
437758-YIM-A-0409 Typical Wiring Diagrams Typical DNQ024-048 Cooling Unit with Single Stage Gas Heat 208/230-1-60 volt Wiring Diagram Johnson Controls Unitary Products... - Page 32 437758-YIM-A-0409 Typical DNQ024-048 Cooling Unit with Two Stage Gas Heat 208/230-1-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 33 437758-YIM-A-0409 Typical DNQ060 Cooling Unit with Single Stage Gas Heat 208/230-1-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 34 437758-YIM-A-0409 Typical DNQ060 Cooling Unit with Two Stage Gas Heat 208/230-1-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 35 437758-YIM-A-0409 Typical DNQ036-048 Cooling Unit with Single Stage Gas Heat 208/230-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 36 437758-YIM-A-0409 Typical DNQ036-048 Cooling Unit with Two Stage Gas Heat 208/230-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 37 437758-YIM-A-0409 Typical DNQ060 Cooling Unit with Single Stage Gas Heat 208/230-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 38 437758-YIM-A-0409 Typical DNQ060 Cooling Unit with Two Stage Gas Heat 208/230-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 39 437758-YIM-A-0409 Typical DNQ036-048 Cooling Unit with Single Stage Gas Heat 460-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 40 437758-YIM-A-0409 Typical DNQ036-048 Cooling Unit with Two Stage Gas Heat 460-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 41 437758-YIM-A-0409 Typical DNQ060 Cooling Unit with Single Stage Gas Heat 460-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
- Page 42 437758-YIM-A-0409 Typical DNQ060 Cooling Unit with Two Stage Gas Heat 460-3-60 volt Wiring Diagram Johnson Controls Unitary Products...
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Page 43: 410A Quick Reference Guide
Do not install suction line driers in the liquid line. A liquid line drier is require on every unit. Do not use a R-22 TXV. If a TXV is to be used, it must be a R-410A TXV. Never open system to atmosphere when under a vacuum. - Page 44 Subject to change without notice. Printed in U.S.A. 437758-YIM-A-0409 Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: Nothing Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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