Johnson Controls TCS, TCL, TVS, TVL Fan Powered VAV Terminals Installation, Operation & Maintenance

FAN POWERED VAV TERMINALS

INSTALLATION, OPERATION & MAINTENANCE New Release Form 130.13-NOM3 (708)

MODELS TCS, TCL, TVS & TVL

LD13847

2

FORM 130.13-NOM3 (708)

TABLE OF CONTENTS

SAFETY CONSIDERATIONS ........................................................................................................................4

INSPECTION .................................................................................................................................................5

STORAGE .....................................................................................................................................................5

PRE-INSTALLATION INSPECTION ..............................................................................................................5

SEQUENCE OF OPERATION .......................................................................................................................6

Parallel Flow ...........................................................................................................................................6

Series Flow .............................................................................................................................................6

INSTALLATION .............................................................................................................................................6

Clearances .............................................................................................................................................7

Hanging and Mounting Equipment Overhead ....................................................................................7

Duct Connections ..................................................................................................................................7

Critically Sound Applications ...............................................................................................................7

Coil Connections ...................................................................................................................................8

Electrical .................................................................................................................................................8

OPERATION ..................................................................................................................................................8

Start-Up ..................................................................................................................................................8

Power Requirements ...........................................................................................................................8

Primary Air Damper and Fan Adjustment ...........................................................................................8

Series Flow, PSC Motor with SCR .......................................................................................................9

Parallel Flow, PSC Motor with SCR .....................................................................................................9

Series Flow ECM Motor Balancing ....................................................................................................10

Commissioning ....................................................................................................................................10

Balancing .............................................................................................................................................10

Manual Fan CFM Adjustment ............................................................................................................. 11

Remote Fan CFM Adjustment ............................................................................................................ 11

Status LED ........................................................................................................................................... 11

MAINTENANCE .......................................................................................................................................... 11

Factory Provided Damper Actuator ................................................................................................... 11

Damper Shaft ....................................................................................................................................... 11

Motor/Blower ........................................................................................................................................ 11

Cleaning ..........................................................................................................................................12

Replacement ...................................................................................................................................12

Coil ........................................................................................................................................................12

Cleaning ..........................................................................................................................................12

Replacement ...................................................................................................................................12

Electric Heat .........................................................................................................................................13

Replacement ...................................................................................................................................13

TROUBLESHOOTING GUIDELINES .........................................................................................................14

ECM SPECIFIC TROUBLESHOOTING GUIDELINES ...............................................................................15

Checking ECM Cables .........................................................................................................................15

VALVE CALIBRATION CHARTS ...............................................................................................................17

FAN CFM CALIBRATION CURVES - TABLE 3 ..........................................................................................18

IN-WARRANTY RETURN PROCEDURE ...................................................................................................19

SERIES FLOW TERMINAL UNIT WEIGHTS -TABLE 4 .............................................................................19

PARALLEL FLOW TERMINAL UNIT WEIGHTS - TABLE 5 ......................................................................20

REPLACEMENT PARTS LIST ....................................................................................................................20

JOHNSON CONTROLS

FORM 130.13-NOM3 (708)

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to areas of potential hazard:

DANGER indicates an im mi nent ly hazardous situation which, if not avoid ed, will re sult in death or se ri ous injury.

WARNING indicates a potentially haz ard ous sit u a tion which, if not avoid ed, could result in death or se-

ri ous in ju ry.

CAUTION identifi es a hazard which could lead to damage to the ma chine, damage to other equip ment and/or en vi ron men tal pollution. Usually an in struc tion will be given, together with a brief ex pla na tion.

NOTE is used to highlight ad di tion al information which may be helpful to you.

JOHNSON CONTROLS 3

SAFETY CONSIDERATIONS

The equipment covered in this manual is designed for safe and reliable operation when installed and operated within its’ design specifi cation limits. To avoid personal injury or damage to equipment or property while installing or operating this equipment, it is essential that qualifi ed, experience personnel familiar with local codes and regulations, perform these functions using good judgment and safe practices. See the following cautionary statements.

ELECTRICAL SHOCK HAZARDS

All power must be disconnected prior to installation and servicing this equipment. More then one source of power may be present. Disconnect, tag and lock out all power sources to avoid electrocution or shock hazards.

ROTATING EQUIPMENT HAZARD

Fans may start automatically. Disconnect all power and control circuits prior to servicing to avoid injury.

Caution should be exercised due to the possibility of fans “free wheeling” due to connected duct air movement.

HOT PARTS HAZARD

Electric heaters may start automatically. Disconnect all power and control circuits prior to servicing to avoid burns.

Check that rigging and lifting equipment can safely support the equipment assembly and component weights.

FORM 130.13-NOM3 (708)

All assemblies must be adequately secured during lifting and rigging by temporary supports and restraints until equipment is permanently fastened and set in its’ fi nal location per manufacturer’s guidelines.

All temporary and permanent equipment supports must be capable of safely supporting the equipment’s weight as well as any additional live, seismic or dead loads that may be encountered. All supports must be designed to meet applicable local codes and ordinances.

All fastening devices must be designed to mechanically lock the assembly in place without the capability of loosening or breaking away due to system operation and vibration.

Dampers may activate automatically.

Disconnect the control circuits or pneumatic control systems and secure all dampers when servicing damper, actuators or linkage to avoid injury.

Wear the appropriate personal protective equipment (gloves, safety glasses, leather closed toe shoes, etc) when handling this equipment recognizing that sheet metal components are being handled.

4 JOHNSON CONTROLS

INSPECTION

Upon receipt of equipment, carefully check all items against the bill of lading to ensure that all equipment has been received (including shipped loose items). Note any discrepancy on the bill of lading before signing. Note that “ship loose” items may be included with the base unit or shipped (bulk) on a separate pallet.

Inspect all equipment for any signs of damage caused during transit. On equipment with electric heat, make sure to check the coil fi ns and/or make sure that the resistance heat coils are not damaged. Note any visual damage on the bill of lading before signing.

Immediately report all visual and concealed damage to the carrier and fi le a claim with the carrier.

Locate the model number on the nameplate and check that the correct equipment has been received. Verify that all options have been included, such as controls, fi lters, heating coils, etc. Also check that equipment voltage agrees with the building parameters. If a discrepancy is discovered between what was ordered and received, contact your local Johnson Controls representative immediately.

Do not use fl ow sensor, connecting tubes, coil stubouts or damper shaft as a handle when lifting or moving equipment as damage may occur.

Do not handle by equipment’s heating elements, as permanent damage will occur.

Check assembly and component weights to be sure that the rigging equipment can handle them safely.

Note; also check the centers of gravity and any specifi c rigging instructions.

Check for adequate ventilation so fumes do not migrate through ductwork to occupied spaces when welding or cutting around the equipment.

FORM 130.13-NOM3 (708)

Do not work on damper until associated actuator is disconnected.

Never pressurize equipment above specifi ed test pressure.

Protect adjacent fl ammable materials when brazing. Use fl ame and heat protection barriers where need. Have a fi re extinguisher at hand and ready for immediate use.

STORAGE

If equipment is to be stored prior to installation, observe the following precautions:

1. Choose a dry storage site that is reasonably level and sturdy to prevent undue stress or permanent damage to the equipment. Set equipment off ground if in moisture prone areas.

2. Cover entire equipment with protective tarp or moisture proof cover. Extend cover under equipment if stored on ground. Secure cover with adequate tie downs. Be sure that piping connections have protective shipping caps installed.

3. Do not stack equipment any higher than how it was shipped. If equipment has been unpackaged since receipt from the factory, do not stack without equivalent support between units as was supplied from the factory.

PRE-INSTALLATION INSPECTION

Do not use fl ow sensor, connecting tubes, coil stubouts or damper shaft as a handle when lifting or moving equipment as damage may occur.

Do not handle by equipment’s heating elements, as permanent damage will occur.

JOHNSON CONTROLS 5

While viewing the damper from the discharge of the equipment, disengage the actuator by depressing the manual override button on the side of the actuator and rotate the shaft fully. The damper should close fully and there should be no gaps between the damper gasketing and the inside of the valve.

Units equipped with ECM or 1 horsepower motors will ship from the factory with a removable motor / wheel support installed in the fan housing. It is imperative that this shipping support be removed prior to equipment startup or damage may result to both the motor and the wheel. A label will be affi xed to the outside of the unit next to the power entry point, to identify the presence of this shipping insert.

Manually rotate the fan wheel to assure that there are no obstructions within the fan housing.

Equipment supplied with ECM motors, backward or reverse rotation of the blower is detrimental to the ECM motor.

SEQUENCE OF OPERATION

All fan-powered equipment is supplied with a rectangular discharge and comes in one of two confi gurations:

1. Parallel fl ow with hot water coils mounted on the plenum induction air opening.

2. Series fl ow with hot water coils mounted on the discharge opening.

Note that for either confi guration, electric heaters (if supplied) are always mounted on the unit discharge opening.

Parallel Flow

On parallel flow equipment, the primary air valve delivers cooled air to the equipment’s outlet. When the space temperature decreases beyond the control of the primary air valve, the fan is started along with the fi rst stage of heat. The fan delivers warm plenum air from the controlled space to the equipment’s outlet, which is mixed with the primary air prior to being delivered to the space.

FORM 130.13-NOM3 (708)

Either the primary air valve, fan or both can deliver airfl ow to the occupied space. A back draft damper is provided, when the fan is not operating. The effi ciency of this system is the same as standard single duct VAV equipment.

In a typical control sequence applied to parallel fl ow equipment, the air valve is closed to a zero minimum airfl ow before the fan is energized. After the fan has been energized, the reheat will be energized upon a further drop in space temperature. Therefore, little primary air is mixed with the heated air stream.

Series Flow

Fan must be energized prior to introduction of air through the primary air valve or the possibilities exist that the fan wheel will operate backwards

/ counter rotation.

On series fl ow equipment, the fan runs continuously whenever the central air handler is in operation.

In response to the space temperature, the air valve modulates the volume of primary air. The re-heat is typically off during the air valve’s modulation. Should the space temperature decrease to the point at which a decrease in primary air will not maintain the desired temperature, the reheat will be activated to increase the discharge air temperature.

INSTALLATION

Do not use fl ow sensor, connecting tubes, coil stubouts or damper shaft as a handle when lifting or moving equipment as damage may occur.

Do not handle by equipment’s heating elements, as permanent damage will occur.

6 JOHNSON CONTROLS

Terminal equipment with electric heat must be installed in a horizontal plane with respect to the air stream. Low height equipment can be fl ipped over in the fi eld to vary or change control section handing.

Consult factory for application utilizing mercury contactors.

Clearances

All equipment covered in this document, including those with electric heat, are ETL listed for 0.0” clearance to combustibles. Refer to NEC and/or local codes for minimum electrical clearances required for service. Equipment should not make contact with any structure located above or below the equipment without appropriate isolation. Equipment supplied with bottom access panels requires suffi cient clearance to remove access panels for service.

Hanging and Mounting Equipment Overhead

Johnson Controls strongly recommends that all equipment be suspended from the upper most ceiling or a structural element of the building, independent of the false ceiling grid. Suspension devices are fi eld supplied, sized and designed by others. Johnson Controls will not accept responsibility for equipment mounting supports.

Equipment must be installed in a level horizontal plane.

Failure to level equipment properly may prevent proper operation of controls. See Tables 3 and 4 for equipment weights.

When requested, equipment is supplied with optional hanger brackets for use with (up to) a 3/8” [10mm] diameter hanger rod. See submittal drawings for hanger bracket locations.

Hanger straps may be utilized as an alternate means of suspending the equipment. Do not secure hanger straps to electric heaters, coils or control enclosures. Hanger straps can be mounted directly to the sides and bottom of equipment casing, such that they do not interfere with working components or access panels using screws that are no longer than 1” [25mm].

When hanging equipment, always use the support method as prescribed for rectangular duct in the job specifi cations.

FORM 130.13-NOM3 (708)

Duct Connections

All duct connections should be confi gured and installed in accordance with SMACNA guidelines and all local code requirements. Check to see that duct fasteners are appropriate for the application and do not impinge any internal components. Pay particular attention to internal electrical components.

Fasten and seal all ductwork connections in accordance with project specifi cations.

Allow a minimum of 1½ duct diameters of straight duct prior to equipment inlet and after equipment discharge.

The diameter of the inlet duct for round valves must be equal to the listed size of the equipment. The round air valve inlet collar of the equipment is 1/8” smaller then listed size in order to allow the round ductwork to slip over the air valve inlet collar. DO NOT INSERT

DUCTWORK INTO AIR VALVE INLET COLLAR.

When making ductwork connection to air valve inlet collar and insulating air valve inlet, take caution not to damage or remove the fl ow sensor connections, which are vital to equipment control.

Provide insulation around entire inlet collar (all the way to the equipment casing).

Cut “slits” in the insulation for the fl ow tubes and secure with duct tape.

Permissible discharge duct connections are straight fl anged, slip and drive or drive and screw.

If equipment is to be installed in a location with high humidity, external insulation around the heating coil should be installed.

After all connections are made, check that the entire ductwork system is airtight. In some high-pressure systems, duct sealer may be necessary.

Sound Critical Applications

Flexible duct connectors are not recommended on equipment discharge. The sagging membrane of these fi ttings can cause turbulence and locally high air velocities that generate noise. Also, lightweight membrane material allows noise to breakout, which can increase sound levels in the space below.

JOHNSON CONTROLS 7

Coil Connections

Hot water and steam coils are male sweat connection.

Use appropriate brazing alloy for system temperature and pressure. Refer to equipment construction submittal drawing for specifi c connection size. MAXIMUM

HYDRONIC SYSTEM OPERATING PRESSURE

MUST NOT EXCEED 300 PSIG. MAXIMUM

STEAM SYSTEM PRESSURE MUST NOT

EXCEED 15 PSIG.

If necessary, you can change coil connection handing on one and two row coils from left-hand to right-hand (and vice-versa) by rotating the coil “like a steering wheel”

180° about its central axis when facing the fi ns. For three and four row coils, consult factory.

Electrical

All fi eld wiring must comply with NEC and all local codes. Electrical and control diagrams are affi xed to the interior of the control enclosure box.

Minimum circuit ampacity (MCA) designates the maximum operating load of the equipment for sizing wire feeders. Supply Circuit Protection designates the largest breaker in the electrical service panel that can be used to protect the equipment.

Use Copper conductors only.

OPERATION

Start-Up

Thorough safety precautions should always be taken when performing startup and service. Refer to safety considerations at the beginning of this Operation

Manual. Only qualifi ed individuals should perform these tasks.

Prior to start-up, the project control sequence/wiring diagram should be obtained and thoroughly understood.

If factory supplied analog or DDC controls are utilized, refer to the applicable Operation Manual for start-up and balancing information. Check that all electrical work is fi nished and properly terminated. Check that all electrical connections are tight and that the proper voltage is connected.

Check to make sure that heater elements are not damaged, free of all foreign material and proper control interlocks have been made before energizing the electric heater.

8

FORM 130.13-NOM3 (708)

Power Requirements

Three Phase AC power imbalance must not exceed 2%.

Be sure that the following guides are met:

1. AC power is within 10% of rated voltage at rated frequency. (See equipment nameplate for rat- ings)

2. AC power is within 5% of rated frequency at rated voltage.

3. A combined variation in the voltage and frequency of 10% (sum of absolute values) of rated values provided the frequency variation does not exceed

5% of rated frequency.

Primary Air Damper and Fan Adjustment

Unit should not be balanced until the incoming power supply is at the permanent voltage condition. All discharge ductwork must be connected. The minimum recommend discharge static pressure for all fanpowered equipment is 0.1” wg. and 0.2” on 3/4hp and larger. All foreign materials should be removed from the duct system. Optional fi lters should be installed as required.

Unless otherwise specifi ed, the fan motor has three speeds. Fan speed is selected in the electrical control enclosure by one of two methods. For units with dual motors, see Figure 1A showing how the fan speed is selected by placement of a factory supplied jumper wire on a terminal strip. Otherwise see Figure 1B which shows the wire to wire fan speed selection method. Simply insert the male quick connect (from control circuitry) into the female quick connect which corresponds to high (black), medium (blue), or low (red) motor speeds. Units are set to low speed at the factory as standard in order to optimize energy effi ciency. A three position rotary switch is optional.

ELECTRICAL SHOCK HAZARD

All power must be disconnected prior to changing jumper or serious injury or death will result.

All fan-power equipment is shipped with an electronic solid state fan speed controller (SCR) for PSC motors.

The SCR is located in the control enclosure. Using a 1/8” fl at blade screwdriver, adjusting the manual potentiometer clockwise will increase the motor speed; adjusting the potentiometer counterclockwise will decrease the motor speed.

JOHNSON CONTROLS

JUMPER

FIGURE 1A - FAN SPEED CONTROL WITH JUMPER

FORM 130.13-NOM3 (708)

5. If balancing dampers are present, adjust and set proportionally to desired position. To minimize noise levels, leave these dampers in the most open position possible.

6. If total airfl ow is too low, de-energize unit and move jumper to next higher speed.

7. Energize unit and adjust Fan Speed Control (SCR) for desired total airfl ow.

8. The maximum primary air balance may be checked using the optional radiated sound damper, or by suspending a sheet of notebook paper over the inlet using a small piece of tape. If the damper or notebook paper is blowing out of the unit, the primary maximum airfl ow is too high. If the paper or damper is being pulled into the unit, the maximum primary airfl ow is too low. Optimum balance is achieved when the damper or paper hangs straight down.

FIGURE 1B - WIRE TO WIRE FAN SPEED SELECTION

Series Flow, PSC Motor with SCR

1. Make sure that the motor speed is at maximum by turning the potentiometer located on the Fan Speed

Control (SCR) all the way clockwise.

2. Energize motor and let motor operate for a minimum of 15 minutes. During this run-in, check ductwork for any leaks and repair as necessary.

3. If remote balancing dampers are present set them to full open.

4. Attach a manometer or magnehelic to the differential pressure ports in the pneumatic tubing leading to the high and low side of the inlet air probe and measure the velocity pressure. Adjust and set the primary maximum airfl ow as necessary to meet job site requirements. See Table 2, Airfl ow vs.

Velocity Pressure chart. This chart, with different inlet sizes, is also located on the side of the equipment.

Parallel Flow, PSC Motor with SCR

1. Make sure that the motor speed is at maximum by turning the potentiometer located on the Fan Speed

Control (SCR) all the way clockwise.

2. With primary air valve in the closed position, energize motor and let motor operate for a minimum of 15 minutes. During this run-in, check ductwork for any leaks and repair as necessary.

3. If balancing dampers are present, adjust and set proportionally to desired position. To minimize noise levels, leave these dampers in the most open position possible.

4. If fan airfl ow is too low, de-energize unit and move jumper to next higher speed.

5. De-energize motor and perform minimum and maximum primary air balance. See Table 2, Air-

fl ow vs. Velocity Pressure chart. This chart, with different inlet sizes, is also located on the side of the equipment.

An extra jumper is required on units with 480 VAC motors. See wiring diagram attached to unit.

JOHNSON CONTROLS 9

24 volts A/C

15 A & B

24 volts AC

16 A & B

FORM 130.13-NOM3 (708)

Remote

Manual jumper

Analog input 2-10 VDC

VDC test loop

Common test loop

FIGURE 2 - ETPWM BOARD LAYOUT

Series Flow ECM Motor Balancing

Fan must be energized prior to introduction of air through the primary air valve or the possibility exists that the fan wheel will operate backward

(counter rotation). Reverse / counter rotation of the blower over a period of time will damage the ECM motor.

See Figure 2 for ETPWM Board Layout.

Commissioning

1. If remote balancing dampers are present set them to full open.

2. Make sure there are no obstructions in the discharge ductwork and/or at the plenum opening. If the unit has a radiated sound damper at the plenum opening, make sure it swings freely.

3. With unit de-energized, disable fan by disconnecting one of the wires leading to fan relay coil or contacts.

4. Energize unit.

5. Verify that there is 22 to 28 VAC across terminals

15 and 16 of ETPWM board.

6. Verify that there is 15 VDC across terminals G (+) and COM (-) of ETPWM board.

7. Connect voltmeter to wire loop VDC (+) and wire loop COM (-) of ETPWM board. Verify DC voltage is between 5.1 and 9.9 VDC.

8. De-energize unit and reconnect wire to fan relay removed in step 3. Make sure that all wires are reconnected per electrical schematic shipped with unit.

10

Manual speed adjustment

“G” activation line

Signal common

PWM output

LD13841

9. Energize unit and let motor operate for a minimum of 15 minutes. During this run-in, check ductwork for any leaks and repair as necessary.

Balancing

1. Adjust fan to the design CFM using either the

Manual or Remote Fan CFM Adjustment method listed below.

2. Attach a manometer or magnehelic to the differential pressure ports in the pneumatic tubing leading to the high and low side of the inlet air probe and measure the velocity pressure. Adjust and set the primary maximum airfl ow as necessary to meet job site requirements. See Table 2, Airfl ow vs.

Velocity Pressure chart. This chart, with different inlet sizes, is also located on the side of the equipment.

3. If balancing dampers are present, adjust and set proportionally to desired position. To minimize noise levels, and prevent premature ECM motor failure, leave these dampers in the most open position possible.

4. The maximum primary air balance may be checked using the optional radiated sound damper, or by suspending a sheet of notebook paper over the inlet using a small piece of tape. If the damper or notebook paper is blowing out of the unit, the primary maximum airfl ow is too high. If the paper or damper is being pulled into the unit, the maximum primary airfl ow is too low. Optimum balance is achieved when the damper or paper hangs straight down.

JOHNSON CONTROLS

Manual Fan CFM Adjustment

1. Verify that the jumper on ETPWM board is in the

“MAN” position (shipped from factory in Manual mode)

2. Connect voltmeter to wire loop VDC (+) and wire loop COM (-).

3. Determine the DC voltage for required airfl ow from the Fan Calibration Curve supplied on the side of the equipment. Use the bottom (5 to 10 volts DC) scale on the chart. An example Fan Calibration curve is shown in Table 3; however, the curve on the side of the equipment should be used in determining the voltage.

4. Using a 1/8” fl at bladed screwdriver, adjust the manual speed potentiometer, labeled SPD, to obtain the required voltage. Clockwise increases airfl ow, counterclockwise decreases airfl ow.

5. Do not set the voltage lower than 5.1 VDC or higher than 9.9 VDC or motor may experience starting problems.

6. Do not set the balance voltage outside limits of the voltage/CFM curve or erratic motor operation and eventual failure may result.

Remote Fan CFM Adjustment

1. Relocate the jumper on ETPWM board to the REM position.

2. Determine the DC voltage for required airfl ow from the Fan Calibration Curve supplied on the side of the equipment. Use the top (2 to 10 Analog Input

Volts DC) scale on the chart. An example Fan

Calibration curve is shown in Table 3; however, the curve on the side of the equipment should be used in determining the voltage.

3. Remotely adjust the external voltage source to the desired volts DC for required airfl ow.

4. Do not operate motor at control voltage lower than

2.1 VDC or higher than 9.9 VDC or motor may experience starting problems.

5. Do not operate motor at control voltage outside limits of the voltage/CFM curve or erratic motor operation, and eventual failure may result.

FORM 130.13-NOM3 (708)

Status LED

When the motor is running, the LED alternates between

CFM and RPM indications. In the RPM mode, LED turns on for a period of approximately 220 microseconds at a rate of 36 pulses per revolution. This mode lasts for ten seconds. Due to the rapid rate, LED will appear to be dimly lit, not fl ashing. As RPM is increased, brightness will increase. In the CFM mode, the LED will fl ash slowly, and at maximum brightness, once for every 100 CFM. Accuracy is +/- one fl ash. LED will then return to RPM mode, and cycle will repeat.

MAINTENANCE

Factory Provided Damper Actuator

Equipment may be supplied with a fi eld or factory mounted damper actuator.

If actuator is factory provided, see

ACT24 Floating-Point Control Direct

Coupled Actuator document. See

Table 1 for maximum wire lengths for control voltage.

TABLE 1 - MAXIMUM WIRE LENGTHS

WIRE SIZE MAX FEET

16 GA

18 GA

20 GA

22 GA

1225 FT

725 FT

400 FT

200FT

Damper Shaft

There is an indicator on the end of the damper shaft that can be used to determine the position on the damper blade. If the indicator is horizontal, the damper is completely open.

Motor/Blower

Fan powered terminal unit motors are equipped with permanently lubricated bearings and require little or no maintenance. The frequency of required cleaning is dependent on the operating hours of the system, fi lter maintenance and effi ciency as well as dirt load.

Periodically inspect the motor and blower-housing wheel for accumulation of dust and clean as necessary.

JOHNSON CONTROLS 11

Cleaning

1. Disconnect all electrical power to the equipment, tag and lock out power source.

2. Gain access to motor housing through access panel.

3. Use soft brush and vacuum to remove loose debris from motor housing.

4. Replace access panels and restore electrical power to equipment.

5. Use caution to assure that any contaminated material does not contact other areas of the equipment or building. Properly dispose of all contaminated materials.

Replacement

1. Disconnect all electrical power to the equipment, tag and lock out power source.

2. Remove bottoms access doors by removing the screws from the access door and then remove side rail screws to access to the motor.

3. Disconnect fan motor wiring.

4. Remove securing fan assembly to discharge

5. Loosen fan wheel set screw.

6. Remove nuts securing motor to housing and remove motor.

7. Remove fan cut off.

8. Remove fan wheel and clean as needed.

9. Reinstall wheel, cut off, motor, and housing.

Cleaning

1. Disconnect all electrical power to the equipment, tag and lock out power source.

2. Put on appropriate personal protective equipment.

3. Gain access to coil either through ductwork or optional coil access panel.

4. Use soft brush and vacuum to remove loose debris from sides of coil.

5. Straighten any coil fi ns that may have been damaged during cleaning process with fi n comb.

6. Replace ductwork or access panel and restore electrical power to equipment.

7. Use caution to assure that any contaminated material does not contact other areas of the equipment or building. Properly dispose of all contaminated materials.

Replacement

1. Disconnect all electrical power to the equipment, tag and lock out power source.

2. Disconnect all ductwork, if applicable.

3. Remove fi lter rails/ fi lter clips, if applicable.

4. Cut or un-braze water connection at coil.

5. Disconnect coil from equipment by removing screws on the exterior perimeter of the coil. Low height equipment only has mounting screws located on the sides of the equipment.

Coil

The frequency of required cleaning is dependent on the operating hours of the system, fi lter maintenance and effi ciency as well as dirt load.

Important: Coils may become externally fouled as result of normal operation. Dirt on the surface of the coil reduces its ability to transfer heat that can result in reduced performance and increased operating energy cost.

If the dirt on the surface of the coil becomes wet, microbial growth (mold) can result, possibly causing unpleasant odors and serious health related indoor air quality problems.

FORM 130.13-NOM3 (708)

Fin edges are sharp. Fins are fragile; care must be exercised to avoid damaging fi ns. Do not use solutions to clean coils; drain pans are not present to remove collected solution.

12 JOHNSON CONTROLS

FORM 130.13-NOM3 (708)

Electric Heat

Electric heat requires a minimum of

0.1” W.G. downstream static pressure for proper operation.

Electric heaters come equipped with a primary auto-reset limit switch to provide protection against overheating.

The primary auto-reset limit switch automatically cuts the heater off when overheating occurs, and turns the heater back on when the elements have cooled down.

Should the secondary one-time trip limit switch trip, they will need to be replaced with a limit switch that has the same trip temperature as the one-time trip limit switch originally supplied with the electric heater.

Optional secondary manual reset limit switches are available.

Electric heaters may be equipped with optional disconnect switch, fuses and airfl ow proving switch.

Replacement

1. Disconnect all electrical power to the equipment, tag and lock out power source.

2. Disconnect discharge ductwork from unit.

3. Remove electric heat assembly from equipment.

4. Before removing wires from the element rack

T-Plate, mark where the wires are connected so that they can be reconnected correctly on the new element rack.

5. Remove the wires and screws holding the heater

T-plate in the control enclosure and remove element rack.

6. Insert new element rack into control enclosure and replace screws to secure the element rack to control enclosure.

7. Replace wires.

8. Close control enclosure cover before turning on the power.

JOHNSON CONTROLS 13

FORM 130.13-NOM3 (708)

TROUBLESHOOTING GUIDELINES

PROBLEM POSSIBLE CAUSE

Blown fuse or open circuit breaker

CORRECTIVE ACTION

Replace fuse or reset circuit breaker; verify and correct source of overload.

Shipping Cardboard insert in fan wheel Remove insert and restart.

Improper wiring connections Check wiring with diagram supplied on unit.

Motor Fails to Start

Motor Overheats

Improper current supply

Compare actual supply power with motor nameplate recommendations. Contact power company for adjustments.

Check motor and confi rm rotates freely. Mechanical failure

Overloaded motor Reduce load or replace with a larger motor (refer factory).

Motor fan is clogged with dirt preventing proper ventilation

Remove fan cover, clean fan and replace cover. May be necessary to replace motor.

Lack of required external static pressure Add required external static pressure.

Excessive Motor

Noise

Motor mounting bolts loose

Fan wheel rubbing on fan housing

Loose fan wheel

Low Coil Capacity

Heater Does Not

Operate

Low or High Temperature Rise

Heater with SSR

Does Not Operate

SCR set too low

Incorrect airfl ow

Incorrect GPM

Dirty coil fi ns

Dirty fi lter (where applicable)

Incorrect water temperature

No Power

No Control Voltage

Blown Fuse

Open Limit (primary or secondary)

Airfl ow Incorrect Direction

Low External Static Pressure

Damaged elements

Incompatible Thermostat or Controller

Problems with Additional Stages

Incorrect CFM

Incorrect Signal Applied

Interface Board Fuse Blown

Tighten motor mounting bolts.

Align wheel in housing.

Align and tighten.

Select lower tap to Reduce motor speed and re-adjust fan SCR.

Check fan’s operating conditions.

Check water pumps, valves and lines for obstructions.

Clean coil Fins.

Replace fi lter.

Provide proper water temperature.

Check Disconnect.

Check transformer and transformer fusing (if applicable) replace if necessary.

Replace fuse.

Replace limits or reset as applicable.

Check for continuity across limit to determine if open, replace as necessary.

Check sensing tube, red tube = high and black tube = low, rotate if needed.

Increase airfl ow to obtain a minimum of .1 in. w.c. external static.

Check for open or damaged elements and replace as necessary.

Check Wiring.

Check for compatibility.

Check location of thermostat; might be installed in a

“too hot” or “too cold” location. Check heat outputs on controller.

Check contactors for open coil.

Check for damaged elements.

Check for blocked duct or location of heater.

Verify signal input.

Replace fuse.

14 JOHNSON CONTROLS

FORM 130.13-NOM3 (708)

ECM SPECIFIC TROUBLESHOOTING GUIDELINES

PROBLEM

Motor Fails to Start

Motor Surges

Excessive Motor

Noise

Poor Performance

POSSIBLE CAUSE CORRECTIVE ACTION

CFM Adjustment voltage above 9.9

VDC or below 5.1 VDC

Properly adjust CFM voltage.

ECM cables improperly seated at motor

Unplug cables from motor and re-install, making sure plugs on cables are fully seated in motor receptacles.

Replace cable(s). See section on checking cables below. ECM cables open or intermittent

Mechanical failure

Electrical failure

Check motor and confi rm it rotates freely.

Replace motor.

Fan Relay Contacts Oxidized/Sulfi dized Replace fan relay.

Fan CFM adjustment voltage outside range of Fan Calibration Curve

ESP (external static pressure) too high

Adjust voltage to value within range of Fan Calibration

Curve.

Verify balancing dampers as open as possible (at least one should be fully open). Verify radiated sound damper

(if supplied) swings freely. Verify plenum opening is unobstructed. Verify fi lter (if supplied) is not dirty and does not obstruct fl ow of plenum air.

Tighten motor mounting bolts.

Motor mounting bolts loose

Fan wheel rubbing on fan housing

Loose fan wheel

Align wheel in housing.

Align and tighten.

Lack of required external static pressure Add required external static pressure.

Wrong Program Contact Factory.

Motor Runs in

Reverse, Doesn’t

Respond to Speed

Adjustment

Motor Failure Replace.

Checking ECM Cables

Remove power from the unit. Unplug signal cable at motor, but leave quick connects attached to ETPWM board and fan relay or quick connect terminal block (see

Figure 3 and 4). Use ohmmeter to check continuity.

Repeat process for three wire power cable if signal cable does not appear to be defective (see Figure 3 and 5).

Only very light force is required when inserting meter probe into plug. Excess force will damage contacts.

JOHNSON CONTROLS 15

FORM 130.13-NOM3 (708)

FIGURE 3

Black wire to P3 (PWM) of ETPWM board

Green wire to P2 (Fan On/Off*) of Fan Relay or Curtis Block

Red wire to P6 (LED) of ETPWM board

9

10

11

12

13

14

15

16

5

6

7

8

1

2

3

4

FIGURE 4

White wire to P2 (COM) of ETPWM board

Blue wire to P7 (LCOM) of ETPWM board

LD13842

BLACK

WHITE

GREEN

RED

BLUE

LD13843

FIGURE 5

16

LD13844

JOHNSON CONTROLS

VALVE CALIBRATION CHARTS

Applicable calibration charts are affi xed to each unit.

TABLE 2

FORM 130.13-NOM3 (708)

JOHNSON CONTROLS

LD13845

17

18

FAN CFM CALIBRATION CURVES - TABLE 3

FORM 130.13-NOM3 (708)

Applied

Model

XX40

XX24

N/A

XX21

N/A

XX11

Where XX

Implies

Valve

Size

LD13846

JOHNSON CONTROLS

FORM 130.13-NOM3 (708)

IN-WARRANTY RETURN PROCEDURE

Refer to Johnson Controls Warranty Parts Policy.

SERIES FLOW TERMINAL UNIT WEIGHTS -TABLE 4

BASE UNIT WEIGHT

SIZE

SINGLE

WALL

1230

1430

1630

1440

1640

1644

1844

1218

1021

1221

1421

1224

1424

0506

0606

0806

0611

0811

1011

0818

1018

174

177

179

181

184

194

209

79

79

81

83

108

111

60

61

75

77

58

57

58

59

DOUBLE

WALL

38

39

39

40

40

42

46

17

17

18

18

24

24

14

14

16

17

13

13

13

13

21

21

21

21

21

21

21

9

9

7

9

11

11

5

5

7

7

5

5

1 ROW

5

5

TCS (22 GA)

ADDERS TO BASE UNIT WEIGHT

WATER COIL

2 ROW 3 ROW

7

7

10

10

7

7

7

7

11

11

10

10

10

10

16

16

11

11

11

11

23

23

42

42

42

42

42

42

42

63

63

63

63

63

63

63

16

16

16

16

34

34

84

84

84

84

84

84

84

22

22

22

22

45

45

4 ROW

13

13

13

13

13

13

22

22

ELEC.

HEAT

42

42

42

42

42

52

52

23

23

23

23

27

27

20

20

23

23

20

20

20

20

JOHNSON CONTROLS 19

FORM 130.13-NOM3 (708)

BASE UNIT WEIGHT

SIZE

SINGLE

WALL

10

12

14

16

6

8

4

5

85

87

118

120

44

44

46

48

PARALLEL FLOW TERMINAL UNIT WEIGHTS - TABLE 5

DOUBLE

WALL

PENDING

1 ROW

10

10

TVS (22 GA)

ADDERS TO BASE UNIT WEIGHT

WATER COIL

2 ROW 3 ROW

14

14

18

18

10

10

14

14

16

16

14

14

19

19

21

21

18

18

25

25

29

29

4 ROW

22

22

22

22

30

30

34

34

ELECTRIC

HEAT

27

31

26

31

18

18

18

20

REPLACEMENT PARTS LIST

SIZE

XX04

XX06

XX11

XX18

XX21

XX24

XX30

XX40

XX44

H/P

1/12

1/6

1/4

1/2

3/4

1

2 @ 1/2

2 @ 3/4

2 @ 1

SERIES FLOW TERMINALS

MOTORS AND BLOWERS, MODEL TCS

120

PM-02-1412

MOTOR

208/230 277

PM-02-1414

PM-02-0026

PM-02-0046

PM-02-1413

PM-02-0030

PM-02-0051

PM-02-0032

PM-02-0052

PM-02-0068

PM-02-0098

PM-02-0124

PM-02-0068

PM-02-0098

PM-02-0124

PM-02-0072

PM-02-0104

PM-02-0126

PM-02-0072

PM-02-0104

PM-02-0126

PM-02-0076

PM-02-0106

PM-02-0128

PM-02-0076

PM-02-0106

PM-02-0128

BLOWER

SIZE

5.75-7

9-4T

9-7T

9-9R

10-10T

10-9R

2 @ 9-9R

2 @ 10-10T

2 @ 10-9R

PART NO.

PM-06-0005

PM-06-0119

PM-06-0122

PM-06-0124

PM-06-0135

PM-06-0134

PM-06-0124

PM-06-0135

PM-06-0134

20 JOHNSON CONTROLS

FORM 130.13-NOM3 (708)

SIZE

XX06

XX08

XX10

XX19

SIZE

XX06

XX08

XX10

XX19

SIZE

XX04

XX06

XX11

XX18

XX21

XX24

SIZE

XX11

XX18

XX19

XX21

XX24

XX40

H/P

1/3

1/2

1/2

3/4

1

2 @ 1/2

ECM MOTOR OPTION FOR MODELS TCS

MOTOR

120/240

PM-02-1334

277

PM-02-1302

PM-02-1335

PM-02-1335

PM-02-1336

PM-02-1337

PM-02-1335

PM-02-1303

PM-02-1303

PM-02-1304

PM-02-1305

PM-02-1303

H/P

1/6

1/4

1/4

2 @ 1/4

H/P

1/3

1/3

1/2

2 @1/3

H/P

1/12

1/6

1/4

1/2

3/4

1

MOTORS AND BLOWERS, MODEL TCL

MOTOR

120

PM-02-0026

208/230

PM-02-0030

277

PM-02-0032

PM-02-1404

PM-02-1404

PM-02-1404

PM-02-1403

PM-02-1403

PM-02-1403

PM-02-1402

PM-02-1402

PM-02-1402

ECM MOTOR OPTIONS FOR MODEL TCL

MOTOR

120/240

PM-02-1405

277

PM-02-1406

PM-02-1405

PM-02-1407

PM-02-1405

PM-02-1406

PM-02-1408

PM-02-1406

PARALLEL FLOW TERMINALS

MOTORS AND BLOWERS, MODEL TVS

120

PM-02-1412

PM-02-0026

PM-02-0046

MOTOR

208/230

PM-02-1413

PM-02-0030

PM-02-0051

PM-02-0072

277

PM-02-1414

PM-02-0032

PM-02-0052

PM-02-0068

PM-02-0098

PM-02-0124

PM-02-0104

PM-02-0126

PM-02-0076

PM-02-0106

PM-02-0128

BLOWER

SIZE

9-4R

10-4R

10-5R

2 @ 10-4R

BLOWER

SIZE

5.75-7

9-4T

9-7T

10-9T

10-10T

10-9R

PART NO.

PM-06-0118

PM-06-0145

PM-06-01

PM-06-0145

PART NO.

PM-06-0005

PM-06-0119

PM-06-0122

PM-06-0133

PM-06-0135

PM-06-0134

JOHNSON CONTROLS 21

22

SIZE

XX06

XX11

XX18

XX21

XX24

SIZE

XX04

XX09

XX15

AMPS

25

30

35

40

50

FORM 130.13-NOM3 (708)

H/P

1/3

1/2

1/2

3/4

1

ECM MOTOR OPTIONS FOR MODEL TVS

MOTOR

120/240

PM-02-1334

277

PM-02-1302

PM-02-1335

PM-02-1335

PM-02-1336

PM-02-1337

PM-02-1303

PM-02-1303

PM-02-1304

PM-02-1305

MOTORS AND BLOWERS, MODEL TVL

MOTOR

120

PM-02-0001

208/230

PM-02-0003

277

PM-02-0005

PM-02-1367

PM-02-1376

PM-02-1368

PM-02-1377

PM-02-1369

PM-02-1378

BLOWER

PART NO.

PM-06-00148

PM-06-00148

PM-06-00150

H/P

1/8

1/4

1/2

# OF POLES

2

3

3

1

2

3

1

2

3

1

3

1

2

1

2

MAGNETIC CONTACTORS

COIL VOLTAGE

24

PE-05-1251

120

PE-05-1252

240

PE-05-1256

PE-05-2251

N/A

PE-05-1301

PE-05-2301

PE-05-2252

N/A

PE-05-1302

PE-05-2302

PE-05-2256

N/A

PE-05-1306

PE-05-2306

PE-05-3301

N/A

PE-05-2351

PE-05-3351

PE-05-1401

PE-05-2401

PE-05-3401

PE-05-1501

PE-05-2501

PE-05-3501

PE-05-3302

N/A

PE-05-2352

PE-05-3352

PE-05-1402

PE-05-2402

PE-05-3402

N/A

PE-05-2502

PE-05-3502

PE-05-3306

N/A

PE-05-2356

PE-05-3356

PE-05-1406

PE-05-2406

PE-05-3406

PE-05-1506

PE-05-2506

PE-05-3506

277

PE-05-1255

PE-05-2255

N/A

PE-05-1305

PE-05-2305

PE-05-3305

N/A

PE-05-2355

PE-05-3355

PE-05-1405

PE-05-2405

PE-05-3405

N/A

PE-05-2505

PE-05-3505

480

PE-05-1257

PE-05-2257

N/A

PE-05-1307

PE-05-2307

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

JOHNSON CONTROLS

FORM 130.13-NOM3 (708)

AMPS

35

50

# OF POLES

1

2

3

1

2

3

MERCURY CONTACTORS

COIL VOLTAGE

24

PE-26-1351

PE-26-2351

120

PE-26-1352

PE-26-2352

240

PE-26-1356

PE-26-2356

PE-26-3351

PE-26-1501

PE-26-2501

PE-26-3501

PE-26-3352

PE-26-1502

PE-26-2502

PE-26-3502

PE-26-3356

PE-26-1506

PE-26-2506

PE-26-3506

277

PE-26-1355

PE-26-2355

PE-26-3355

PE-26-1505

PE-26-2505

PE-26-3505

480

PE-26-1357

PE-26-2357

PE-26-3357

PE-26-1507

PE-26-2507

PE-26-3507

4

5

µf

3

6

7.5

10

12.5

15

20

3

VA

50

75

TYPE CC

600 VOLT

MINI

CAPACITORS

PART #

PE-12-0499

PE-12-0500

PE-12-0501

PE-12-0502

PE-12-0503

PE-12-0504

PE-12-0505

PE-12-0506

PE-12-0508

PE-12-0509

VOLTAGE

370

370

370

370

370

370

370

370

370

440

120

TO 24 VAC

PE-10-2105

PE-10-2107

TRANSFORMERS

208/240 277

TO 24 VAC

PE-10-6105

PE-10-6107

TO 24 VAC

PE-10-5105

PE-10-5107

6

10

15

20

25

30

AMPS

1

2

3

4

5

FUSES

STANDARD

PE-06-0001

PE-06-0002

PE-06-0003

PE-06-0004

PE-06-0005

PE-06-0006

PE-06-0010

PE-06-0015

PE-06-0020

PE-06-0025

PE-06-0030

TIME DELAY

N/A

PE-06-0035

PE-06-0037

PE-06-0039

PE-06-0040

PE-06-0041

PE-06-0044

PE-06-0046

PE-06-0047

PE-06-0048

PE-06-0049

480

TO 24 VAC

PE-10-7105

PE-10-7107

575

TO 24 VAC

PE-10-9105

PE-10-9107

JOHNSON CONTROLS 23

©2008 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 www.johnsoncontrols.com

Printed in USA 130.13-NOM3 (708)

New Release