null  User manual
INSTALLATION
MANUAL
SUNLINE MagnaDRY™
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MODELS: WR180, 240 & 300
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .62
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .63
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .65
See the following pages 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 damage may result if installation procedure is not handled
properly.
CAUTION: READ ALL SAFETY GUIDES BEFORE
YOU BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
284813-YIM-C-1008
284813-YIM-C-1008
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION SAFETY INFORMATION: . . . . . . . . . . . . . . 7
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FIXED OUTDOOR AIR INTAKE DAMPER . . . . . . . . . . . . . . 9
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPACE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . . . 12
OPTIONAL ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . 12
OPTIONAL GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
L.P. UNITS, TANKS AND PIPING. . . . . . . . . . . . . . . . . . . . 15
VENT AND COMBUSTION AIR HOODS . . . . . . . . . . . . . . 15
OPTIONAL ECONOMIZER/MOTORIZED DAMPER
RAIN HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPTIONAL POWER EXHAUST/BAROMETRIC RELIEF
DAMPER RAIN HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPTIONAL ECONOMIZER AND POWER EXHAUST
DAMPER SETPOINT ADJUSTMENTS AND
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MINIMUM POSITION ADJUSTMENT. . . . . . . . . . . . . . . . . . . 16
ENTHALPY SETPOINT ADJUSTMENT . . . . . . . . . . . . . . . . . 16
POWER EXHAUST DAMPER SETPOINT . . . . . . . . . . . . . . . 17
INDOOR AIR QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPTIONAL BAS-READY ECONOMIZER POWER
EXHAUST DAMPER SET POINT ADJUSTMENT . . . . . . . 17
OPTIONAL VARIABLE AIR VOLUME (VAV) . . . . . . . . . . . 17
DUCT STATIC PRESSURE TRANSDUCER . . . . . . . . . . . . . 17
VAV CONTROL BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FACTORY-INSTALLED VFD . . . . . . . . . . . . . . . . . . . . . . . . . 19
MANUAL BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BAS-READY VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
'VFD-READY' FOR CUSTOMER-INSTALLATION . . . . . . . . . 20
OPTIONAL HOT GAS BYPASS (HGBP) . . . . . . . . . . . . . . 20
CFM, STATIC PRESSURE, AND POWER - ALTITUDE
AND TEMPERATURE CORRECTIONS . . . . . . . . . . . . . . . 33
PHASING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CHECKING SUPPLY AIR CFM. . . . . . . . . . . . . . . . . . . . . . 49
AIR BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ECONOMIZER (SINGLE OR DUAL ENTHALPY) WITH
POWER EXHAUST - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ECONOMIZER WITH OPTIONAL VAV OR INTELLICOMFORT™ CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ECONOMIZER WITH OPTIONAL VAV BLOWER WITH
POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ECONOMIZER WITH OPTIONAL INTELLI-COMFORT™
WITH POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
MOTORIZED OUTDOOR AIR DAMPERS - . . . . . . . . . . . . . 53
COOLING OPERATION ERRORS . . . . . . . . . . . . . . . . . . . . 53
HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . 53
LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . 53
FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR PROTECTION . . . . . . . . . . . . . . . . . . . . .
FLASH CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REHEAT MODE SEQUENCE OF OPERATION . . . . . . . .
54
54
54
54
54
“NORMAL” MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
"ALTERNATE” MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ELECTRIC HEATING SEQUENCE OF OPERATIONS . . . 58
HEATING OPERATION ERRORS . . . . . . . . . . . . . . . . . . . 59
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASH CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . . . . . .
GAS HEATING SEQUENCE OF OPERATIONS . . . . . . . .
GAS HEATING OPERATION ERRORS . . . . . . . . . . . . . . .
59
59
59
59
60
61
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
GAS VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASH CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . . . . . .
61
62
62
62
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PRESTART CHECK LIST. . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .
POST START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . .
SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
63
63
63
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PRE-START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . 63
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 63
TO LIGHT PILOT AND MAIN BURNERS:. . . . . . . . . . . . . . . 63
TO SHUT DOWN: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
POST-START CHECK LIST (GAS) . . . . . . . . . . . . . . . . . .
MANIFOLD GAS PRESSURE ADJUSTMENT . . . . . . . . . .
PILOT CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BURNER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .
BURNER AIR SHUTTER ADJUSTMENT . . . . . . . . . . . . . .
CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
64
64
64
64
64
NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . . . 65
BELT DRIVE BLOWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SEQUENCE OF OPERATIONS OVERVIEW . . . . . . . . . . . 51
COOLING SEQUENCE OF OPERATION. . . . . . . . . . . . . . 51
COOLING TROUBLESHOOTING GUIDE . . . . . . . . . . . . . 65
GAS HEAT TROUBLESHOOTING GUIDE . . . . . . . . . . . . 70
UNIT CONTROL BOARD FLASH CODES . . . . . . . . . . . . . 73
CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INTERMITTENT BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPTIONAL VAV BLOWER OPERATION . . . . . . . . . . . . . . . . 51
NO OUTDOOR AIR OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 51
ECONOMIZER WITH SINGLE ENTHALPY SENSOR - . . . . . 51
ECONOMIZER WITH DUAL ENTHALPY SENSORS - . . . . . 52
2
UNIT CONTROL BOARD OPTION SETUP . . . . . . . . . . . 75
OPTION BYTE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
HEAT DELAY SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
OPTIONAL VAV CONTROL BOARD FLASH CODES . . . . 76
Johnson Controls Unitary Products
284813-YIM-C-1008
LIST OF FIGURES
Fig. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Pg. #
TYPICAL RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . . 8
FIXED OUTDOOR AIR DAMPER . . . . . . . . . . . . . . . . 10
RECOMMENDED DRAIN PIPING . . . . . . . . . . . . . . . 10
TYPICAL FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . 11
EXTERNAL SUPPLY CONNECTION EXTERNAL
SHUT-OFF 15
BOTTOM SUPPLY CONNECTION EXTERNAL
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VENT AND COMBUSTION AIR HOOD . . . . . . . . . . . 16
ENTHALPY SETPOINT ADJUSTMENT . . . . . . . . . . . 21
HONEYWELL ECONOMIZER CONTROL W7212 . . . 21
FOUR AND SIX POINT LOADS . . . . . . . . . . . . . . . . . 22
FRONT VIEW DIMENSIONS . . . . . . . . . . . . . . . . . . . 30
REAR VIEW DIMENSIONS . . . . . . . . . . . . . . . . . . . . 31
UNIT CLEARANCE AND RAIN HOOD DIMENSIONS
(15, 20 & 25 TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ALTITUDE/TEMPERATURE CONVERSION
FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fig. #
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Pg. #
CHARGING CHART - 15 TON . . . . . . . . . . . . . . . . . . 48
CHARGING CHART - 20 TON . . . . . . . . . . . . . . . . . . 48
CHARGING CHART - 25 TON . . . . . . . . . . . . . . . . . . 49
BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 50
PRESSURE DROP ACROSS A DRY INDOOR COIL VS
SUPPLY AIR CFM FOR ALL UNIT TONNAGES . . . . 50
REHEAT CONTROL BOARD . . . . . . . . . . . . . . . . . . . 56
REHEAT CONTROLS - PART 1 . . . . . . . . . . . . . . . . 57
REHEAT CONTROLS - PART 2 . . . . . . . . . . . . . . . . 57
SYSTEM PIPING SCHEMATIC . . . . . . . . . . . . . . . . . 58
GAS VALVE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . 61
GAS VALVE AND CONTROLS . . . . . . . . . . . . . . . . . 62
TYPICAL GAS VALVES . . . . . . . . . . . . . . . . . . . . . . . 64
PROPER FLAME ADJUSTMENT . . . . . . . . . . . . . . . 64
TYPICAL FLAME APPEARANCE . . . . . . . . . . . . . . . 64
UNIT CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . 74
LIST OF TABLES
Tbl. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Pg. #
UNIT APPLICATION DATA . . . . . . . . . . . . . . . . . . . . . . 7
CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRIC HEAT APPLICATION DATA . . . . . . . . . . . 12
GAS HEAT APPLICATION DATA . . . . . . . . . . . . . . . . 13
PIPE SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FOUR AND SIX POINT LOADS . . . . . . . . . . . . . . . . . . 22
PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SUPPLY FAN VFD WEIGHTS, IN LBS. . . . . . . . . . . . . 23
WR ELECTRICAL DATA - STANDARD DRIVE MOTOR
W/O POWERED CONVENIENCE OUTLET . . . . . . . . 24
WR ELECTRICAL DATA - HIGH STATIC DRIVE MOTOR
W/O POWERED CONVENIENCE OUTLET . . . . . . . . 25
WR ELECTRICAL DATA - LOW STATIC DRIVE MOTOR
W/O POWERED CONVENIENCE OUTLET . . . . . . . . 26
WR ELECTRICAL DATA - STANDARD DRIVE MOTOR
WITH POWERED CONVENIENCE OUTLET . . . . . . . 27
WR ELECTRICAL DATA - HIGH STATIC DRIVE MOTOR
WITH POWERED CONVENIENCE OUTLET . . . . . . . 28
WR ELECTRICAL DATA - LOW STATIC DRIVE MOTOR
WITH POWERED CONVENIENCE OUTLET . . . . . . . 29
ALTITUDE CORRECTION FACTORS . . . . . . . . . . . . . 33
WR180 BLOWER PERFORMANCE - 15 TON
STANDARD DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
WR180 BLOWER PERFORMANCE - 15 TON
STANDARD DRIVE (GAS HEAT) DOWNFLOW . . . . . 36
WR180 BLOWER PERFORMANCE - 15 TON HIGH
STATIC DRIVE (COOLING ONLY) DOWNFLOW . . . . 37
WR180 BLOWER PERFORMANCE - 15 TON HIGH
STATIC DRIVE (GAS HEAT) DOWNFLOW . . . . . . . . 38
Johnson Controls Unitary Products
Tbl. #
Pg. #
20 WR240 BLOWER PERFORMANCE - 20 TON
STANDARD DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
21 WR240 BLOWER PERFORMANCE - 20 TON
STANDARD DRIVE (GAS HEAT) DOWNFLOW . . . . . .40
22 WR240 BLOWER PERFORMANCE - 20 TON HIGH
STATIC DRIVE (COOLING ONLY) DOWNFLOW . . . . .41
23 WR240 BLOWER PERFORMANCE - 20 TON HIGH
STATIC DRIVE (GAS HEAT) DOWNFLOW . . . . . . . . .42
24 WR300 BLOWER PERFORMANCE - 25 TON
STANDARD DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
25 WR300 BLOWER PERFORMANCE - 25 TON
STANDARD DRIVE (GAS HEAT) DOWNFLOW . . . . . .44
26 WR300 BLOWER PERFORMANCE - 25 TON HIGH
STATIC DRIVE (COOLING ONLY) DOWNFLOW . . . . .45
27 WR300 BLOWER PERFORMANCE - 25 TON HIGH
STATIC DRIVE (GAS HEAT) DOWNFLOW . . . . . . . . .46
28 STATIC RESISTANCES . . . . . . . . . . . . . . . . . . . . . . . .47
29 POWER EXHAUST PERFORMANCE . . . . . . . . . . . . . .47
30 BLOWER MOTOR AND DRIVE DATA . . . . . . . . . . . . .47
31 LIMIT CONTROL SETTING . . . . . . . . . . . . . . . . . . . . . .59
32 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . .60
33 LIMIT CONTROL SETTING . . . . . . . . . . . . . . . . . . . . . .62
34 GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . .62
35 GAS RATE - CUBIC FEET PER HOUR . . . . . . . . . . . .65
36 UNIT CONTROL BOARD FLASH CODES . . . . . . . . . .74
37 HEAT DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
38 VAV CONTROL BOARD FLASH CODES . . . . . . . . . . .76
3
284813-YIM-C-1008
GENERAL
YORK Model WR units are either single package cooling units equipped with optional factory installed electric heaters, or single package gas-fired central heating
furnaces with cooling unit. Both are designed for outdoor installation on a rooftop or slab.
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property damage.
The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant
charge, and electrical wiring is factory installed and
tested. The units require electric power, gas connection, duct connections, installation of combustion air
inlet hood, flue gas outlet hoods and fixed outdoor air
intake damper (units without economizer or motorized
damper option only) at the point of installation.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach the gas supplier, call
the fire department.
- Installation and service must be performed by
a qualified installer, service agency or the
gas supplier.
The supplemental electric heaters have nickel-chrome
elements and utilize single point power connection.
The gas-fired heaters have aluminized-steel or optional
stainless steel, tubular heat exchangers with spark
ignition with proven pilot. All gas heaters are shipped
from the factory equipped for natural gas use, but can
be field converted to L.P./Propane with Kit Model #
1NP0418.
SAFETY CONSIDERATIONS
INSPECTION
Due to system pressure, moving parts and electrical
components, installation and servicing of air conditioning equipment can be hazardous. Only qualified,
trained, service personnel should install, repair, maintain or service this equipment.
As soon as a unit is received, it should be inspected for
possible damage during transit. If damage is evident,
the extent of the damage should be noted on the carrier's freight bill. A separate request for inspection by
the carrier's agent should be made in writing.
Observe all precautions in the literature, on labels and
tags accompanying the equipment whenever working
on air conditioning equipment. Be sure to follow all
other safety precautions that apply.
REFERENCE
Wear safety glasses and work gloves, and follow all
safety codes. Use a quenching cloth and have a fire
extinguisher available for all brazing operations.
4
Additional information on the design, installation, operation and service of this equipment is available in the
following reference forms:
•
Technical Guide - 262292
•
General Installation - 284813
Johnson Controls Unitary Products
284813-YIM-C-1008
RENEWAL PARTS
Contact your local York® Parts Distribution Center for
authorized replacement parts.
APPROVALS
Design certified by CSA as follows:
•
For use as a cooling unit only with or without
optional electric heat.
•
For use as a forced air furnace with cooling unit
•
For outdoor installation only.
•
For installation on combustible material.
•
For use with natural gas or propane gas.
Improper installation may create a condition
where the operation of the product could cause
personal injury or property damage.
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 damage may result if installation procedure is not handled properly.
This product must be installed in strict compliance with the enclosed installation instructions
and any applicable local, state, and national
codes including, but not limited to, building,
electrical, and mechanical codes.
Johnson Controls Unitary Products
5
284813-YIM-C-1008
PRODUCT NOMENCLATURE
15-25 Ton Sunline MagnaDRY™ Model Number Nomenclature
W R 180 N24 A 2 A AA 1 0 1 2 4 A
Product Category
Product Style
W = A/C, Single Pkg.,
R-22 w/6-Row Evap.
A = Style A
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
Product Identifier
SS Drain Pan
R = 90.1 w/Reheat
CPC Controller, DFS, APS
Johnson Controller, DFS, APS
Nominal Cooling Capacity
Honeywell Controller, DFS, APS
180 = 15 Ton
240 = 20 Ton
300 = 25 Ton
Novar Controller, DFS, APS
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller w/ModLinc
Heat Type and Nominal Heat Capacity
Hot Gas Bypass (Standard on VAV, Optional on CV)
Variable Air Volume, VFD (not available with factory installed BAS options)
C00 = Cooling Only. No field installed
electric heat
Variable Air Volume, VFD with ModLINC (not available with factory installed BAS options)
Variable Air Volume, VFD and Manual Bypass (not available with factory installed BAS options)
Gas Heat Options
Variable Air Volume, VFD and Manual Bypass with ModLINC (not available with factory installed BAS options)
Variable Air Volume, VFD (BAS ready)
N24 = 240 MBH Output Aluminized Steel
N32 = 320 MBH Output Aluminized Steel
S24 = 240 MBH Output Stainless Steel
S32 = 320 MBH Output Stainless Steel
Variable Air Volume, VFD and Manual Bypass (BAS ready)
Variable Air Volume, VFD Ready (for customer provided, field installed drive)
Variable Air Volume, VFD Ready with ModLINC (for customer-provided, field-installed drive)
2" Pleated filters
Electric Heat Options
4" Pleated filters
BAS Ready Economizer (2-10 V.D.C. Actuator without a controller)
E18 = 18 KW
E36 = 36 KW
E54 = 54 KW
E72 = 72 KW
Double Wall Construction
Heat Reclaim Coil Options (2 or 3 Row, 1-5/8" or 2-1/8" Stub Out) (WJ and WR models only)
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
Airflow
Product Generation
A = Std. Motor
B = Std. Motor/Economizer
C = Std. Motor/Economizer/Power Exhaust
(Downflow Only)
D = Std. Motor/Motorized Damper
E = Std. Motor/Motorized Damper/Barometric Relief
J = Std. Motor/Economizer/Barometric Relief
N = Hi Static
P = Hi Static/Economizer
Q = Hi Static/Economizer/Power Exhaust
(Downflow Only)
R = Hi Static/Motorized Damper
K = Hi Static/Motorized Damper/Barometric Relief
S = Hi Static/Economizer/Barometric Relief
2 = Low Static
3 = Low Static/Economizer
4 = Low Static/Economizer/Power Exhaust
(Downflow Only)
5 = Low Static/Motorized Damper
6 = Low Static/Motorized Damper/Barometric Relief
7 = Low Static/Economizer/Barometric Relief
1 = First Generation
2 = Second Generation
Additional Options
Standard Cabinet
Hinged Filter Door & Tool Free Access Cabinet
AA = None
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
RC = Coil Guard & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
BA = Hinged Filter Door & Tool Free Access Panels
BB = Phase Monitor, Hinged Filter Door & Tool Free
Access Panels
BC = Coil Guard, Hinged Filter Door & Tool Free
Access Panels
BD = Dirty Filter Switch, Hinged Filter Door &
Tool Free Access Panels
BE = Phase Monitor & Coil Guard, Hinged Filter
Door & Tool Free Access Panels
BF = Phase Monitor & Dirty Filter Switch, Hinged
Filter Door & Tool Free Access Panels
BG = Coil Guard & Dirty Filter Switch, Hinged Filter
Door & Tool Free Access Panels
BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
Hinged Filter Door & Tool Free Access Panels
Voltage
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
Installation Options
A = No Options Installed
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
Options
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
6
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
Johnson Controls Unitary Products
284813-YIM-C-1008
INSTALLATION
INSTALLATION SAFETY INFORMATION:
Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit. The installer must assure that
these instructions are made available to the consumer
and with instructions to retain them for future reference.
1. Refer to the furnace rating plate for the approved
type of gas for this furnace.
•
Local gas utility requirements.
In Canada:
•
Current Canadian Electrical Code C22.1.
•
Current Gas Installation Codes CSA-B149.1.
•
Local plumbing and waste water codes.
•
Other applicable local codes.
Refer to the Unit Application Data Table 1 and to the
Gas Heat Application Data Table 4.
2. Install this furnace only in a location and position
as specified on Page 8 of these instructions.
If components are to be added to a unit to meet local
codes, they are to be installed at the dealer's and/or
the customer's expense.
3. Never test for gas leaks with an open flame. Use
commercially available soap solution made specifically for the detection of leaks when checking all
connections.
Size of unit for proposed installation should be based
on heat loss/heat gain calculation made according to
the methods of the Air Conditioning Contractors of
America (ACCA).
4. Always install furnace to operate within the furnace's intended temperature-rise range with the
duct system and within the allowable external static
pressure range, as specified on the unit name/rating plate.
This furnace is not to be used for temporary heating of
buildings or structures under construction.
5. This equipment is not to be used for temporary
heating or cooling of buildings or structures under
construction.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly
could result in serious injury, death or property
damage.
Never test for gas leaks with an open flame.
Use a commercially available soap solution
made specifically for the detection of leaks to
check all connections. A fire or explosion may
result causing property damage, personal
injury or loss of life.
LIMITATIONS
These units must be installed in accordance with the
following national and local safety codes:
In U.S.A.:
•
National Electrical Code ANSI/NFPA No. 70.
•
National Fuel Gas Code Z223.1.
•
Gas-Fired Central Furnace Standard ANSI
Z21.47a.
Johnson Controls Unitary Products
The Siyticlpm
® control board used in this
product will effectively operate the cooling
system down to 0°F when this product is applied
in a comfort cooling application for people. An
economizer is typically included in this type of
application. When applying this product for
process cooling applications (computer rooms,
switchgear, etc.), please reference applications
bulletin AE-011-07 or call the applications
department for Unitary Products @ 1-877-UPGSERV for guidance. Additional accessories may
be needed for stable operation at temperatures
below 30°F.
TABLE 1: UNIT APPLICATION DATA
UNIT MODEL NUMBER
Voltage Variation,
Min. / Max.1
WR180
WR240
208/230-3-60
187/253
460-3-60
414/506
575-3-60
Supply Air CFM, Min. / Max.
518/630
4,500/
7,500
6,000/
9,000
Wet Bulb Temperature (ºF) of Air on
Evaporator Coil, Min. / Max.
57/72
Dry Bulb Temperature (ºF) of Air on
Condenser Coil, Min. / Max.
0/125
1.
WR300
7,500/
9,300
Utilization range “A” in accordance with ARI Standard
110.
7
284813-YIM-C-1008
LOCATION
Use the following guidelines to select a suitable location for these units.
1. Unit is designed for outdoor installation only.
Units may also be moved or lifted with a forklift, from
the side only, providing that an accessory skid is used.
LENGTH OF FORKS MUST BE A MINIMUM OF 90".
Refer to the Physical Data Table 7 for unit weights and
to the Figure 2 for approximate center of gravity.
2. Condenser coils must have an unlimited supply of
air.
3. Where a choice of location is possible, position the
unit on either north or east side of building.
4. For ground level installation, use a level concrete
slab with a minimum thickness of 4 inches. The
length and width should be at least 6 inches
greater than the unit base rails. Do not tie slab to
the building foundation.
Before lifting a unit, make sure that all panels
are in place and that its weight is distributed
equally on all cables so it will lift evenly.
5. Roof structures must be able to support the weight
of the unit and its options and/or accessories. Unit
must be installed on a solid level roof curb or
appropriate angle iron frame.
6. Maintain level tolerance to 1/2 inch maximum
across the entire length or width of the unit.
Excessive exposure of this furnace to contaminated combustion air may result in equipment
damage or personal injury. Typical contaminates include: permanent wave solutions, chlorinated waxes and cleaners, chlorine based
swimming pool chemicals, water softening
chemicals, carbon tetrachloride, Halogen type
refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues,
antistatic fabric softeners for clothes dryers,
masonry acid washing materials.
If a unit is to be installed on a roof curb or special frame
other than a YORK roof curb, gasketing must be
applied to all surfaces that come in contact with the unit
underside.
RIGGING AND HANDLING
Exercise care when moving the unit. Do not remove
any packaging until the unit is near the place of installation. Rig the unit by attaching chain or cable slings to
the round lifting holes provided in the base rails.
Spreaders, whose length exceeds the largest dimension across the unit, MUST BE USED. Refer to
Figure 1.
8
FIGURE 1 - TYPICAL RIGGING
47.5" (15, 20, 25 TON)
FIGURE 2 - CENTER OF GRAVITY
CLEARANCES
All units require certain clearances for proper operation
and service. Installer must make provisions for adequate combustion and ventilation air in accordance
with Section 5.3, Air for Combustion and Ventilation of
the National Fuel Gas Code, ANSI Z223.1 (in U.S.A.)
or Sections 7.2, 7.3 or 7.4 of Gas Installation Codes
CSA-B149.1 (in Canada) and/or applicable provisions
of the local building codes. Refer to Figures 12, 13 and
14 for the dimensions and clearances required for combustible construction, servicing, and proper unit operation.
Johnson Controls Unitary Products
284813-YIM-C-1008
FIXED OUTDOOR AIR INTAKE DAMPER
Do not permit overhanging structures or shrubs
to obstruct outdoor air discharge outlet, combustion air inlet or vent outlets.
DUCTWORK
Ductwork should be designed and sized according to
the methods in Manual Q of the Air Conditioning Contractors of America (ACCA).
A closed return duct system shall be used. This shall
not preclude use of economizers or outdoor fresh air
intake. The supply and return air duct connections at
the unit should be made with flexible joints to minimize
noise.
The supply and return air duct systems should be
designed for the CFM and static requirements of the
job. They should NOT be sized to match the dimensions of the duct connections on the unit.
When fastening ductwork to side duct flanges
on unit, insert screws through duct flanges
only. DO NOT insert screws through casing.
Outdoor ductwork must be insulated and
waterproofed.
Refer to Figures 12 and 13 for information concerning
side and bottom supply and return air duct opening
dimensions.
NOTE: It is recommended that, in Canada, the outlet
duct be provided with a removable access
panel. It is recommended that this opening be
accessible when the unit is installed in service,
and of a size such that smoke or reflected light
may be observed inside the casing to indicate
the presence of leaks in the heat exchanger.
The cover should be attached in a manner
adequate to prevent leakage.
Johnson Controls Unitary Products
This damper is shipped inside the return air compartment. It is completely assembled and ready for installation. A damper baffle inside of the hood is adjustable to
provide variable amounts of outdoor air intake on units
that are not provided with an economizer or a motorized damper option. Refer to the Fixed Outdoor
Damper Figure 3.
Gasketing and mounting screws are provided in a parts
bag attached to the hood assembly. Apply gasketing to
the three flange surfaces on the hood prior to installing
the hood. Extend gasketing 1/4 inch beyond the top
and bottom of the two side flanges to insure adequate
sealing.
Adjusting the damper to the desired air flow may be
done before mounting the hood into position or after
installation by removing the front hood panel or the
screen on the bottom of the hood. Damper baffle in
position 1 will allow approximately 10% outdoor air
flow, position 2 approximately 15% and, to allow
approximately 25%, remove the damper baffle.
On units with bottom return air application install the
damper assembly over the opening in the side return
air access panel. Remove and discard the opening
cover and the covering over the hood mounting holes
(used for shipping) before installing. Secure with the
screws provided.
On units with side return air applications, install the
damper assembly on the return air ductwork as close
to the unit as possible. Cut an opening 16 inches high
by 18 inches wide in the ductwork to accommodate the
damper. Using the holes in the hood flanges as a template, drill 9/64 inch dia. (#26 drill) holes into the ductwork and secure with the screws provided.
If outdoor air intake will not be required on
units with bottom return air applications, the
damper assembly should still be mounted on
the side return air access panel, per the
instructions above, to insure moisture is not
drawn into the unit during operation. The covering over the mounting holes only need be
removed. Do not remove the opening cover.
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284813-YIM-C-1008
COMPRESSORS
Units are shipped with compressor mountings factoryadjusted and ready for operation.
Do not loosen compressor mounting bolts.
FILTERS
FIGURE 3 - FIXED OUTDOOR AIR DAMPER
CONDENSATE DRAIN
Two-inch filters are supplied with each unit, but units
can be converted easily to four-inch filters. Filters must
always be installed ahead of the evaporator coil and
must be kept clean or replaced with same size and
type. Dirty filters will reduce the capacity of the unit and
will result in frosted coils or safety shutdown. Minimum
filter area and required sizes are shown in Physical
Data Table 7.
Plumbing must conform to local codes. Use a sealing
compound on male pipe threads. Install a condensate
drain line from the one-inch NPT female connection on
the unit to an open drain.
SERVICE ACCESS
NOTE: The condensate drain operates in a negative
pressure in the cabinet. The condensate drain
line MUST be trapped to provide proper drainage. See Figure 4.
•
•
•
•
The following removable panels provide access to all
serviceable components:
•
•
•
•
Compressor compartment
Electric Heat compartment
Gas Heat compartment (Two panels)
Side Supply & Return Air compartments
(Two panels)
Blower compartment (Three panels)
Main control box
Filter compartment
Outdoor Air compartment (Two panels)
Refer to Figures 12 and 13 for location of these access
panels.
FIGURE 4 - RECOMMENDED DRAIN PIPING
10
Make sure that all screws and panel latches
are replaced and properly positioned on the
unit to maintain an airtight seal.
Johnson Controls Unitary Products
284813-YIM-C-1008
THERMOSTAT
TERMINALS
1
( RCB )
REHEAT
CONTROL BOARD
RC
RH
R
Y1
Y1
Y2
Y2
W1
W1
W2
W2
G
G
C
C
OCC
X1
X3
208/230-3-60 and 380/415-3-50 units control
transformers are factory wired for 230v and 415v
power supply respectively. Change tap on
transformer for 208-3-60 or 380-3-50 operation.
TERMINAL BLOCK
RH
2
X4
A1
HUM
1
A2
HUM
2
T
See unit wiring diagram.
DEHUMIDISTAT 3
3
T
4
TO REMOTE SENSOR
2ET04701324 IF USED
1
Electronic programmable Thermostat 2ET0770010024
( includes subbase).
2
Terminals A1 and A2 provide a relay output to close the
outdoor economizer dampers when the thermostat
switches to the set-back position.
3
Dehumidistat closes on rise in humidity.
TYPICAL
THERMOSTAT
RC
R
RH
Y1
Y1
Y2
Y2
G
G
W1
W1
W2
W2
OCC
C
C
( RCB )
REHEAT
CONTROL
BOARD
TERMINAL
BLOCK
RH
1
DEHUMIDISTAT 1
2
3
4
HUM
1
Dehumidistat closes on rise in humidity.
TERMINAL BLOCK TB1
GROUND
LUG
FACTORY OR FIELD
SUPPLIED DISCONNECT
THREE
PHASE
POWER
SUPPLY
FIGURE 5 - TYPICAL FIELD WIRING
Johnson Controls Unitary Products
11
284813-YIM-C-1008
THERMOSTAT
The room thermostat should be located on an inside
wall approximately 56 inches above the floor where it
will not be subject to drafts, sun exposure or heat from
electrical fixtures or appliances. Follow the manufacturer's instructions enclosed with the thermostat for
general installation procedure. A minimum of seven
color-coded insulated wires (#18 AWG) should be used
to connect the thermostat to the unit.
cuits. Wire entry at knockout openings require conduit
fittings to comply with NEC (in U.S.A.), CEC (in Canada) and/or local codes. If any of the wire supplied with
the unit must be replaced, replacement wire must be of
the type shown on the wiring diagram and the same
minimum gauge as the replaced wire.
Use copper conductors properly sized to carry the load.
Each unit must be wired with a separate branch circuit
fed directly from the meter panel and properly fused.
SPACE SENSOR
The space sensor, if used, should be located on an
inside wall approximately 56 inches above the floor
where it will not be subject to drafts, sun exposure or
heat from electrical fixtures or appliances. Follow manufacturer's instructions enclosed with sensor for general installation procedure.
POWER AND CONTROL WIRING
Field wiring to the unit must conform to provisions of
the National Electrical Code, ANSI / NFPA No. 70 (in
U.S.A.), current Canadian Electrical Code C22.1 (in
Canada) and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC
(as specified above) and/or local codes. Voltage tolerances, which must be maintained at the compressor
terminals, during starting and running conditions, are
indicated on the unit Rating Plate and the Unit Application Data table.
208/230-3-60 and 380/415-3-50 units control
transformers are factory wired for 230v and 415v
power supply respectively. Change tap on
transformer for 208-3-60 or 380-3-50 operation.
See unit wiring diagram.
The internal wiring harness furnished with this unit is
an integral part of a CSA design certified unit. Field
alteration to comply with electrical codes should not be
required.
When connecting electrical power and control
wiring to the unit, waterproof type connectors
MUST BE USED so that water or moisture
cannot be drawn into the unit during normal
operation. The above waterproofing conditions
will also apply when installing a field-supplied
disconnect switch.
Refer to the Typical Field Wiring Figure 5 and to the
appropriate unit wiring diagram for control circuit and
power wiring information.
TABLE 2: CONTROL WIRE SIZES
Maximum Length1
150 Feet
Wire Size
18 AWG
1.
From the unit to the thermostat and back to the unit.
OPTIONAL ELECTRIC HEAT
The factory-installed heaters are wired for single point
power supply. Power supply need only be brought into
the single point terminal block and thermostat wiring to
the low voltage terminal strip located in the upper portion of the unit control box.
These CSA approved heaters are located within the
central compartment of the unit with the heater elements extending into the supply air chamber. Refer to
Figure 12 for access panel location.
Fuses are supplied, where required, by the factory.
Some KW sizes require fuses and others do not. Refer
to Table 3 for minimum CFM limitations and to Tables 9
thru 14 for electrical data.
A fused disconnect switch should be field provided for
the unit. The switch must be separate from all other cir-
12
Johnson Controls Unitary Products
284813-YIM-C-1008
OPTIONAL GAS HEAT
TABLE 3: ELECTRIC HEAT APPLICATION DATA
NOMINAL
HEATER
SIZE (KW)
VOLTAGE
3-PHASE,
60 HZ
15 TON
18
208/230,460,575
4500
36
208/230,460,575
4500
208/230
5000
460,575
4500
208/230
5000
460,575
4500
54
72
These gas-fired heaters have aluminized-steel or
optional stainless steel, tubular heat exchangers with
spark ignition with proven pilot.
MINIMUM CFM UNIT SIZE
20 TON
25 TON
6000
All gas heaters are shipped from the factory equipped
for natural gas use, but can be field converted to L.P./
Propane with Kit Model # 1NP0418. See Gas Heat
Application Data Table.
7500
TABLE 4: GAS HEAT APPLICATION DATA
0 To
2,000 Feet
Above
Sea Level
2,000 To
4,500 Feet
Above
Sea Level
Output Capacity (Mbh)
0 To
2,000 Feet
Above
Sea Level
2,000 To
4,500 Feet
Above
Sea Level
Available
on Models
Natural
Gas
Rate
(Ft./Hr.)
Temp.
Rise ºF
At
Full Input1
Max.
Min.
Max.
Min.
Max.
Max.
Min.
Max.
300
150
270
135
240
213
15, 20 & 25 Ton
279
20
50
400
200
360
180
320
281
15, 20 & 25 Ton
372
30
60
1.
On VAV units, individual VAV boxes must be full open in heating mode to insure airflow falls within
temperature rise range.
GAS PIPING
Proper sizing of gas piping depends on the cubic feet
per hour of gas flow required, specific gravity of the gas
and the length of run. "National Fuel Gas Code" Z223.1
(in U.S.A.) or the current Gas Installation Codes CSAB149.1 (in Canada) should be followed in all cases
unless superseded by local codes or gas utility requirements. Refer to the Pipe Sizing Table 5.
The heating value of the gas may differ with locality.
The value should be checked with the local gas utility.
NOTE: There may be a local gas utility requirement
specifying a minimum diameter for gas piping.
All units require a one-inch pipe connection at
the entrance fitting.
Johnson Controls Unitary Products
TABLE 5: PIPE SIZING
Length in Feet
Nominal Iron Pipe Size
1 in.
1-1/4 in.
10
520
1,050
20
350
730
30
285
590
40
245
500
50
215
440
60
195
400
70
180
370
80
170
350
90
160
320
100
150
305
Maximum capacity of pipe in cubic feet of gas per hour. (Based upon
a pressure drop of 0.3 inch water column and 0.6 specific gravity
gas).
13
284813-YIM-C-1008
GAS CONNECTION
The gas supply line can be routed through the knockouts located on the front of the unit or through the
opening provided in the unit's base. Refer to the
Dimensions and Clearances Figure 13 to locate these
access openings. Typical supply piping arrangements
are shown in the figures on page 15. All shaded items
are field-supplied.
If gas supply line is routed through the unit's base
ensure that the burner assembly can be removed for
maintenance without disturbing the supply line. The
supply piping and fittings must lie below the bottom gas
manifold to avoid interference with the burner assembly.
4. All piping should be cleaned of dirt and scale by
hammering on the outside of the pipe and blowing
out the loose dirt and scale. Before initial start-up,
be sure that all of the gas lines external to the unit
have been purged of air.
5. The gas supply should be a separate line and
installed in accordance with all safety codes as
prescribed under "Limitations". After the gas connections have been completed, open the main
shut-off valve admitting normal gas pressure to the
mains. Check all joints for leaks with soap solution
or other material suitable for the purpose. NEVER
USE A FLAME.
Two grommets are shipped in the blower compartment
(in parts bag taped to the blower housing) of every unit
with gas heat and should be used in the knockouts
when the gas piping penetrates the front of the unit.
FIRE OR EXPLOSION HAZARD
After the gas supply piping has been installed, the bottom opening in the unit should be sealed to prevent
water from leaking into the building.
Never test for gas leaks with an open flame.
Use a commerically available soap solution
made specifically for the detection of leaks to
check all connections. A fire or explosion may
result causing property damage, personal
injury or loss of life.
Gas piping recommendations:
1. A drip leg and a ground joint union must be
installed in the gas piping.
2. When required by local codes, a manual shut-off
valve may have to be installed outside of the unit.
3. Use wrought iron or steel pipe for all gas lines. Pipe
compound should be applied sparingly to male
threads only.
Natural gas may contain some propane. Propane, being an excellent solvent, will quickly
dissolve white lead or most standard commercial compounds. Therefore, a special pipe
compound must be applied when wrought iron
or steel pipe is used. Shellac base compounds
such as Gaskolac or Stalastic, and compounds
such as Rectorseal #5, Clyde's or John Crane
may be used.
14
Failure to follow the safety warning exactly
could result in serious injury, death or property
damage.
6. The furnace and its individual manual shut-off
valve must be disconnected from the gas supply
piping system during any pressure testing of that
system at test pressures in excess of 1/2 psig
(3.48kPa).
The furnace must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any pressure testing of the gas
supply piping system at test pressures equal to or
less than 1/2 psig (3.48kPa).
7. A 1/8 inch NPT plugged tap, accessible for test
gage connection, must be installed immediately
upstream of the gas supply connection to the furnace.
Johnson Controls Unitary Products
284813-YIM-C-1008
2. The proper pressure regulation. (Two-stage regulation is recommended from the standpoint of both
cost and efficiency.)
3. The pressure drop in the lines between regulators
and between the second stage regulator and the
appliance. Pipe size required will depend on the
length of the pipe run and the total load of all appliances.
Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and
L.P./propane gas suppliers.
FIGURE 6 - EXTERNAL SUPPLY CONNECTION
EXTERNAL SHUT-OFF
L.P./propane gas is an excellent solvent and special pipe
compound must be used when assembling piping for this
gas as it will quickly dissolve white lead or most standard
commercial compounds. Shellac base compounds such
as Rectorseal #5 are satisfactory for this type of gas.
Check all connections for leaks when piping is completed, using a soap solution. NEVER USE A FLAME.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly
could result in serious injury, death or property
damage.
FIGURE 7 - BOTTOM SUPPLY CONNECTION
EXTERNAL SHUT-OFF
L.P. UNITS, TANKS AND PIPING
All gas heat units are shipped from the factory
equipped for natural gas use only. The unit may be
converted in the field for use with L.P./propane gas
with accessory kit model number 1NP0418.
All L.P./propane gas equipment must conform to the
safety standards of the National Fire Protection Association.
For satisfactory operation, L.P./propane gas pressure
must be 10.0 I.W.C. at the unit manifold under full load.
Maintaining proper gas pressure depends on three
main factors:
1. The vaporization rate depends on (a) the temperature of the liquid and (b) the "wetted surface" area
of the container or containers.
Johnson Controls Unitary Products
Never test for gas leaks with an open flame.
Use a commerically available soap solution
made specifically for the detection of leaks to
check all connections. A fire or explosion may
result causing property damage, personal
injury or loss of life.
VENT AND COMBUSTION AIR HOODS
Two vent hoods and a combustion air hood (with
screens) are shipped attached to the blower housing in
the blower compartment. For units with factory installed
VFD option, the hoods and accompanying hardware
are shipped inside the gas heat section. These hoods
must be installed to assure proper unit function. All
hoods must be fastened to the outside of the gas heat
access panel with the screws provided in the bag also
attached to the blower housing.
The screen for the combustion air intake hood is
secured to the inside of the access panel opening with
four fasteners and the screws used for mounting the
hood to the panel. The top flange of this hood slips in
15
284813-YIM-C-1008
under the top of the access panel opening when installing. Refer to Vent and Combustion Air Hood Figure 8.
OPTIONAL POWER EXHAUST/BAROMETRIC RELIEF
DAMPER RAIN HOOD
Each vent hood is installed by inserting the top flange
of the hood into the slotted opening in the access panel
and securing in place.
The instructions for the power exhaust/barometric relief
damper rain hood can be found in the kit. The exhaust
fan, all supporting brackets, angles, and the wiring are
factory installed as part of the power exhaust option.
The products of combustion are discharged horizontally through these two screened, hooded vent openings on the upper gas heat access panel.
OPTIONAL ECONOMIZER AND POWER EXHAUST
DAMPER SETPOINT ADJUSTMENTS AND INFORMATION
Remove the economizer access panel from the unit.
Loosen but do not remove the two panel latches.
Locate the economizer control module, where the following adjustments will be made.
VENT AIR
OUTLET
HOODS
SLOTTED
OPENINGS IN
ACCESS PANEL
Extreme care must be excercised in turning all
setpoint, maximum, and minimum damper
positioning adjustment screws to prevent twisting them off.
COMBUSTION
A IR INTAKE
HOOD
GAS HEAT
ACCESS
PANELS
FIGURE 8 - VENT AND COMBUSTION AIR HOOD
Check that the damper blades move smoothly without
binding; carefully turn the Minimum Position Adjusting
screw (found on the damper control module) fully
clockwise and then set the thermostat indoor fan switch
to the on position and then off, or energize and deenergize terminals "R" to "G".
MINIMUM POSITION ADJUSTMENT
An adhesive backed label is provided over the
outside of the combustion air inlet opening to
prevent moisture from entering the unit, which
could cause damage to electrical components.
Allow this closure label to remain in place until
the combustion air hood is to be installed.
OPTIONAL ECONOMIZER/MOTORIZED DAMPER RAIN
HOOD
The instruction for the optional economizer/motorized
damper rain hood can be found in the kit. Use these
instructions when field assembling an economizer rain
hood onto a unit. The outdoor and return air dampers,
the damper actuator, the damper linkage, the outdoor
and return air divider baffles, and all the control sensors are factory mounted as part of the "Factory
installed" economizer option.
16
With thermostat set to indoor fan on position, or terminals "R" to "G" energized, turn the Minimum Position
Adjusting screw (located on the damper control module) counterclockwise until the desired minimum
damper position has been attained.
ENTHALPY SETPOINT ADJUSTMENT
The enthalpy setpoint may now be set by selecting the
desired setpoint shown in the Enthalpy Setpoint Adjustment Figure 9. Adjust as follows:
•
For a single enthalpy operation carefully turn the
setpoint adjusting screw (found on the damper
control module) to the "A", "B", "C" or "D" setting
corresponding to the lettered curve of the Enthalpy
Setpoint Adjustment Figure 9.
•
For a dual enthalpy operation, carefully turn the
setpoint adjusting screw fully clockwise past the
"D" setting.
Johnson Controls Unitary Products
284813-YIM-C-1008
POWER EXHAUST DAMPER SETPOINT
Replace the economizer access panel.
With power exhaust option, each building pressurization requirement will be different. The point at which the
power exhaust comes on is determined by the economizer damper position (Percent Open). The Exhaust
Air Adjustment Screw should be set at the Percent
Open of the economizer damper at which the power
exhaust is needed. It can be set from 0 to 100%
damper open.
OPTIONAL VARIABLE AIR VOLUME (VAV)
A variable air volume (VAV) option using a variable frequency drive (VFD) is available for applications requiring a constant supply duct static pressure. A differential
pressure transducer is used to monitor supply duct
static pressure and return a speed reference signal to
the VFD to control the output of the indoor blower
motor.
INDOOR AIR QUALITY
Indoor Air quality (indoor sensor input): Terminal AQ
accepts a +2 to +10 Vdc signal with respect to the
(AQ1) terminal. When the signal is below it's setpoint,
the actuator is allowed to modulate normally in accordance with the enthalpy and mixed air sensor inputs.
When the AQ signal exceeds it's setpoint setting and
there is no call for free cooling, the actuator is proportionately modulated from the 2 to 10 Vdc signal, with 2
Vdc corresponding to full closed and 10 Vdc corresponding to full open. When there is no call for free
cooling, the damper position is limited by the IAQ Max
damper position setting. When the signal exceeds it's
setpoint (Demand Control Ventilation Setpoint) setting
and there is a call for free cooling, the actuator modulates from the minimum position to the full open position based on the highest call from either the mixed air
sensor input or the AQ voltage input.
•
•
Optional CO2 Space Sensor Kit Part #
2AQ04700224
Optional CO2 Sensor Kit Part # 2AQ04700124
DUCT STATIC PRESSURE TRANSDUCER
A 0-5" WC pressure transducer, located in the control
box compartment, is used to sense static (gauge) pressure in the supply air duct and convert this pressure
measurement to a proportional 0-5 VDC electrical output.
Pressure-transmitting plastic tubing (1/4" diameter)
must be field supplied and installed from the transducer
to both the ductwork and to the atmosphere. Connect
the tubing from the 'HIGH' pressure tap of the transducer to a static pressure tap (field supplied) in the
supply duct located at a point where constant pressure
is expected. To prevent an unstable signal due to air
turbulence, there should be no obstructions, turns or
VAV terminal boxes up- or down-stream of the sensing
tube location for at least a distance of 6-10 times the
duct diameter. Tubing must also be run between the
'LOW' pressure tap of the transducer and atmospheric
pressure (outside of the unit).
Replace the economizer access panel.
OPTIONAL BAS-READY ECONOMIZER POWER
EXHAUST DAMPER SET POINT ADJUSTMENT
Remove the economizer access panel from the unit.
Loosen, but do not remove the two panel latches.
Locate the economizer actuator, where the following
adjustment can be made.
Do not run plastic tubing in the supply or return
air ducts as air movement could cause erroneous pressure measurements. If the tubing penetrates through the bottom of the unit be sure
openings are sealed to prevent air and water
leakage.
VAV CONTROL BOARD
With power exhaust option, each building pressurization requirement will be different. The point at which the
power exhaust comes on is determined by the economizer's outdoor damper position. The actuator's auxiliary switch adjustment screw should be set at the
damper position at which the power exhaust is needed.
The adjustment screw can be set between 25 to 85
degrees open.
Johnson Controls Unitary Products
A VAV control board, located in the top-left corner of
the control box, is used to convert the pressure transducer input signal into a speed reference signal that
the drive uses to control the speed of the blower motor.
This modulating speed reference signal is generated
using an internal algorithm which continuously calculates an output value.
17
284813-YIM-C-1008
A brief description of the VAV board's I/O terminals that
are used follows:
Outputs:
•
Inputs:
•
•
•
•
•
•
•
•
•
•
•
•
•
18
DUCT PRES - a 0-5 VDC analog input provided by
a factory-installed duct static pressure transducer
located in the unit's control box.
SAT - analog input provided by a factory-installed
10k-ohm, type 3 thermistor located in the unit's
supply air compartment.
RAT - analog input provided by a factory-installed
10k-ohm, type 3 thermistor located in the unit's
return air compartment.
OAT - analog input provided by a factory-installed
10k-ohm, type 3 thermistor located in the outdoor
air compartment or mounted within the evaporator
base rail for units without the installed economizer
option.
ST - analog input provided by field-installed space
temperature sensor.
OH - a 0-10 VDC analog input provided by a fieldinstalled outdoor air relative humidity sensor for
single enthalpy economizer configuration.
RH - a 0-10 VDC analog input provided by a fieldinstalled return air relative humidity sensor for dual
enthalpy economizer configuration (used with OH).
IAQ - a 0-10 VDC analog input provided by a fieldinstalled carbon dioxide sensor which monitors
indoor air quality (CO2 concentration) and enables
call for Demand Ventilation mode for units installed
with economizer option.
OAQ - a 0-10 VDC analog input provided by a
field-installed carbon dioxide sensor which monitors outdoor air quality (CO2 concentration) and,
along with IAQ, enables call for Differential
Demand Ventilation mode for units installed with
economizer option.
APS - a 24 VAC binary input provided by a fieldinstalled air proving switch which monitors the
pressure difference across the indoor blower.
PUR - a 24 VAC binary input for building purge
calls from an external source.
OCC - a 24 VAC binary input used to set the building occupancy status for the control.
LIMIT 2 - a 24 VAC binary input which either confirms 2nd-stage gas heat operation or receives an
error signal from the variable frequency drive.
•
•
•
FAN - a 2-10 VDC analog output signal sent to the
VFD to modulate the speed of the indoor blower
motor.
ECON - a 2-10 VDC analog output signal sent to
the economizer actuator to modulate position of
the return air and outdoor air dampers (optional).
EXH ~ - a 24 VAC binary output signal used to turn
on/off the power exhaust relay (optional).
VAV BOX (gas/electric heat only) - a normally open
relay contact connected to a terminal block, used
to drive the building's VAV boxes to full-open during
heating operation.
Programmable set points:
The duct static set point is the pressure that the drive
will maintain when operating the unit in VAV mode. The
set-point is adjustable between 0" WC and 5" WC with
the default setting of 1.5" WC.
The duct static high-limit set point is the maximum
allowable duct pressure to prevent damage from overpressurization of the ductwork in the event of either a
drive or damper failure. The high-limit set-point is
adjustable between 0" WC and 5" WC with the factory
default setting of 4.5" WC. If the duct static pressure
reaches the high-limit set point, then the supply fan
motor will be shutdown.
NOTE: Either of the set points described above can be
changed through the unit control board (UCB)
with the use of a USB-to-RS485 converter, personal computer or PDA and a down-loaded copy
of the Simplicity® software available at
www.yorkupg.com.
The customer must be aware of the duct pressure design limit, and what the duct pressure
sensor is reading when the peak pressure is
reached (i.e. the pressure transducer sensing
tube may not be located at the place of highest
pressure in the system).
Johnson Controls Unitary Products
284813-YIM-C-1008
FACTORY-INSTALLED VFD
The factory-installed VFD is mounted in the Blower
Access Compartment above the blower assembly. The
drive comes wired from the factory to include both 3phase power and control connections (run permit signal, speed reference signal & fault signal).
If the unit is operated with the manual bypass
switch in the LINE (BYPASS) position and
there are VAV boxes present in the duct system, then boxes must be driven to the full-open
position using a customer-supplied power
source to prevent over-pressurizing and possible damage to the ductwork.
All required drive parameters are pre-programmed at
the factory, except in the case of 208-volt applications,
in which the parameter that defines motor nameplate
voltage must be changed to a value of 208.00 and the
parameter that defines motor-rated current must be
changed to the appropriate value appearing on the
motor's nameplate. Refer to the enclosed drive material or access the UPGnet Commercial Product Catalog
website for instructions on changing parameter settings.
For units also equipped with gas/electric heat, a terminal block located in the unit's control box and connected to the VAV board's "VAV BOX" terminal, must
be field wired to the building's VAV boxes to ensure
fully open dampers during heating operation.
MANUAL BYPASS
An optional, factory-installed manual bypass switch
available with factory-installed VFD can be found in the
Blower Motor Access compartment and has the following three positions:
•
•
•
DRIVE - routes power through the VFD for modulating control of the indoor blower motor.
LINE (or BYPASS) - routes power directly to the
motor which provides full-speed motor operation
and complete electrical isolation of the drive.
TEST - routes power to the VFD but not to the
motor to allow for drive programming and/or diagnostics.
If a drive failure occurs, the unit does not automatically
switch to bypass mode. The LINE/DRIVE/TEST switch
must be manually switched to the LINE (BYPASS)
position. If there is a call for the fan, the indoor blower
motor will run at full-speed while in the bypass mode.
Johnson Controls Unitary Products
Before beginning any service, disconnect all
power to the drive. Be aware that high voltages
are present in the drive even after power has
been disconnected. Capacitors within the drive
must be allowed to discharge before beginning
service.
BAS-READY VFD
Factory-installed VFD is also available with 'BASready' models. Terminal blocks are provided in the control box (in place of the VAV control board) for field wiring of a customer-installed BAS to receive 24 VAC
power and to connect to the following control signals:
•
•
•
•
a duct static pressure transducer input signal (0-5
VDC)
an economizer actuator input signal (2-10 VDC)
an economizer actuator output signal (2-10 VDC)
a VFD speed reference output signal (2-10 VDC)
The use of shielded cable is recommended for the
above control wiring connections.
NOTE: Factory-installed VFD is not available with factory-installed BAS options due to space limitations in the control box.
A solid-state, lock-out relay (LR) and 100-μF, 50 VDC
capacitor must be field-supplied and installed to provide a means to transmit a potential fault signal back to
the BAS controller. The specific relay part number
required will depend upon the need for either AC-output or DC-output. See price pages for further details.
19
284813-YIM-C-1008
Once the appropriate relay and capacitor are obtained,
install the capacitor across LR terminals '3' & '4' and
make the following wiring connections:
•
•
•
•
The power leads to the drive (L1, L2, L3) and from the
motor (T1, T2, T3) along with the respective ground
wires are supplied with the unit and need to be connected after the drive is installed.
LR '1' to BAS controller
LR '2' to BAS controller
LR '3' to UCB 'X'
LR '4' to UCB 'C'
'VFD-READY' FOR CUSTOMER-INSTALLATION
Units configured as 'VFD-ready' provide provisions for
a customer-installed drive. The physical dimensions of
VFDs can vary greatly among manufacturers, horsepower ratings and voltage requirements. Keep in mind
that drive manufacturers also require various minimum
clearances to allow for adequate internal cooling of the
drive during operation.
The unit comes with a mounting bracket installed in the
Blower Access compartment which may accommodate
other vendor's drives depending on their size. In order
to utilize the unit's mounting bracket, the maximum recommended drive dimensions are as follows:
Do not connect AC power to the T1, T2, T3
drive terminals to prevent damage to the VFD.
A terminal block located in the control box is provided
for field connection of the VFD speed reference signal
(2-10 VDC) and to the normally-open, run-permit auxiliary contact. The use of shielded cable is recommended for the above control wiring connections.
For VFD-ready units also equipped with gas/electric
heat, a terminal block located in the unit's control box
and connected to the VAV board's "VAV BOX" terminal, must be field wired to the building's VAV boxes to
ensure fully open dampers during heating operation.
OPTIONAL HOT GAS BYPASS (HGBP)
For 5-hp motor applications13" H x 6" W x 7" D
For 7.5 thru 15-hp motor applications13" H x 8" W x 8" D
If the drive will not fit in the allotted space, then it will
need to be mounted elsewhere; either within the building on a perpendicular wall which is not subjected to
excessive temperature, vibration, humidity, dust, corrosive gas, explosive gas, etc., or within an appropriate
enclosure rated for outside installation to safeguard
against moisture, dust and excessive heat.
20
To allow for low cooling load operation, a direct-acting,
pressure-modulating bypass control valve installed on
the system #1 discharge line is used to divert high temperature, high pressure refrigerant around the TXV in
order to maintain a desired minimum evaporator pressure.
The opening pressure of the bypass valve is fully
adjustable between 0 and 80 psig with a factory-setting
of 60 psig. HGBP is standard on all units with VAV and
optional with CV units.
Johnson Controls Unitary Products
284813-YIM-C-1008
CONTROL
CURVE
CONTROL POINT
APPROX. 0F (0C)
AT 50% RH
A
73 (23)
B
70 (21)
67 (19)
63 (17)
C
D
85 90 95 100 105 110
(29) (32) (35) (38) (41) (43)
80
(27)
75
(24)
70
(21)
65
(18)
60
(16)
55
(13)
50
(10)
45
(7)
35
(2)
A
B
C
D
40
(4)
B
D C
35
(2)
40
(4)
45
(7)
A
50 55 60 65 70 75 80 85 90 95 100 105 110
(10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43)
APPROXIMATE DRY BULB TEMPERATURE - 0F (0C)
FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT
Exhaust Air
Adjustment
Screw
Exhaust Air LED
Damper Min.
Position
Screw
Indoor Air Quality
Max. Adjustment
Screw
N1
N
EXH
Set
TR
P1
P
EXH
24
Vac
HOT
T1
T
Min
Pos
IAQ
Max
Indoor Air Quality
LED
AQ1
AQ
IAQ
SO
IAQ
Min
TR1
24
Vac
COM
+
1
2
5
Indoor Air Quality
Min. Adjustment
Screw
Free Cooling LED
SO+
3
4
EF
EF1
Free
Cool
SR+
SR
B
A
C
D
Economizer Enthalpy
Set Point Adjustment
Screw
FIGURE 10 - HONEYWELL ECONOMIZER CONTROL W7212
Johnson Controls Unitary Products
21
284813-YIM-C-1008
TABLE 6: FOUR AND SIX POINT LOADS
4 Point Loads (lbs)
Unit Size
Operating
Weight
A
B
C
D
WR180 Gas
2900
495
924
965
516
WR240 Gas
3200
558
1042
1042
558
WR300 Gas
3300
575
1075
1075
575
WR180 Elec
2700
460
860
898
481
WR240 Elec
3000
523
977
977
523
WR300 Elec
3100
540
1010
1010
540
Unit Size
Operating
Weight
A
B
C
D
E
F
WR180 Gas
2900
330
344
494
643
616
473
WR240 Gas
3200
372
372
533
695
695
533
WR300 Gas
3300
383
383
550
717
717
550
WR180 Elec
2700
307
321
460
599
573
440
WR240 Elec
3000
349
349
500
651
651
500
WR300 Elec
3100
360
360
517
673
673
517
6 Point Loads (lbs)
NOTE: Weights include unit, economizer, economizer rain hood and high heat option (gas or electric).
B
F
E
C
D
C
A
A
D
B
FIGURE 11 - FOUR AND SIX POINT LOADS
22
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 7: PHYSICAL DATA
MODELS
EVAPORATOR
COIL
CONDENSER FAN
(FOUR PER UNIT)
CONDENSER
COIL
REHEAT COIL
COMPRESSOR
(QTY. PER UNIT)
FILTERS
CHARGE
CENTRIFUGAL BLOWER (Dia. x Wd.)
FAN MOTOR HP
ROWS DEEP
FINS PER INCH
FACE AREA (Sq. Ft.)
PROPELLER DIA. (In.)
FAN MOTOR HP
NOM. CFM TOTAL
ROWS DEEP
FINS PER INCH
FACE AREA (Sq. Ft.)
ROWS DEEP
FINS PER INCH
FACE AREA (Sq. Ft.)
15x15
5/7.5
(Each)
(Each)
(Each)
24
1/3
4,000
SCROLL
QUANTITY PER UNIT (16” X 25” X 2”)
QUANTITY PER UNIT (16” X 20” X 2”)
TOTAL FACE AREA (Sq. Ft.)
SYSTEM No. 1
REFRIGERANT 22
(Lb./Oz.)
SYSTEM No. 2
COOLING ONLY
BASIC
UNIT
GAS / ELECTRIC
N24
N32
DOUBLE WALL
ECONOMIZER
ECONOMIZER WITH
POWER EXHAUST
MOTORIZED DAMPER
18 KW
36 KW
ELECTRIC
HEATER
54 KW
72 KW
HOT GAS BYPASS
SUPPLY FAN VFD
ROOF CURB
BAROMETRIC DAMPER
ECONOMIZER / MOTORIZED
DAMPER RAIN HOOD
ECONOMIZER / POWER
EXHAUST RAIN HOOD
WOOD SKID
ACCESSORIES
OPERATING
WEIGHTS
(LBS.)
WR240
WR300
18x15
7.5/10.0/15.0
7.5/15.0
6
13
20.52
30
3/4
5,000
2
20
63.8
2
13
17.2
2
OPTIONS
EVAPORATOR
BLOWER
WR180
24/0
23/0
2410
2610
2650
4
4
20
28/8
27/0
2710
2910
2950
260
160
28/0
26/4
2810
3010
3050
245
150
25
30
35
40
10
See Table 8
185
45
55
90
220
TABLE 8: SUPPLY FAN VFD WEIGHTS, IN LBS.
SUPPLY FAN MOTOR
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
230V
460V
575V
25
25
30
30
30
30
30
30
35
30
30
40
30
30
35
35
35
35
35
35
40
40
35
45
23
284813-YIM-C-1008
TABLE 9: WR ELECTRICAL DATA - STANDARD DRIVE MOTOR W/O POWERED CONVENIENCE OUTLET
MODEL
(TONNAGE)
COMPRESSORS
VOLTAGE
RLA
EACH
OD FAN
MOTORS
FLA EACH
LRA
EACH
ID
BLOWER
MOTOR
FLA
CONV
OUTLET
AMPS
208
22.4
164
2.1
17.7
0.0
230
22.4
164
2.1
16.4
0.0
460
10.9
100
1.2
8.2
0.0
575
8.3
78
0.9
6.6
0.0
208
30.1
225
2.4
24.2
0.0
230
30.1
225
2.4
24.2
0.0
460
15.5
114
0.9
12.1
0.0
575
12.1
80
0.6
10.3
0.0
208
42.3
245
2.4
38.6
0.0
230
42.3
245
2.4
38.6
0.0
460
17.6
125
0.9
19.3
0.0
575
14.5
100
0.6
16.2
0.0
180
(15)
240
(20)
300
(25)
HEATER OPTION
MODEL
KW
STAGES
AMPS
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
MIN.
MAX. FUSE/
CIRCUIT
BRKR1
SIZE
AMPACITY
(AMPS)
(AMPS)
76.5
90
76.5
90
115.8
125
163.0
175
172.3
200
75.2
90
75.2
90
128.8
150
150.4
175
193.7
225
37.5
45
37.5
45
64.4
70
75.2
90
96.9
110
28.9
35
29.9
35
51.6
60
60.2
70
77.5
90
101.5
125
101.5
125
123.9
125
171.1
175
180.4
200
101.5
125
101.5
125
138.5
150
160.2
175
203.5
225
50.6
60
50.6
60
69.3
70
80.1
90
101.7
110
39.9
50
39.9
50
56.2
60
64.8
70
82.2
90
143.4
175
143.4
175
143.4
175
189.1
200
198.4
225
143.4
175
143.4
175
156.5
175
178.2
200
221.5
250
62.9
80
62.9
80
78.3
80
89.1
100
110.7
125
51.7
60
51.7
60
63.6
70
72.2
80
89.5
100
NOTE 1: HACR Type per NEC.
VOLTAGE LIMITATIONS
POWER SUPPLY
VOLTAGE
LIMITATIONS1
1.
24
208/230-3-60
460-3-60
575-3-60
MIN.
187
414
518
VOLTAGE
MAX.
253
506
630
ELECTRIC HEAT CORRECTION FACTORS
NOMINAL VOLTAGE
VOLTAGE
kW CAP. MULTIPLIER
208
208
1.00
240
230
0.92
480
460
0.92
600
575
0.92
Utilization Range “A” in accordance with ARI Standard 110.
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 10: WR ELECTRICAL DATA - HIGH STATIC DRIVE MOTOR W/O POWERED CONVENIENCE OUTLET
MODEL
(TONNAGE)
COMPRESSORS
VOLTAGE
RLA
EACH
OD FAN
MOTORS
FLA EACH
LRA
EACH
ID
BLOWER
MOTOR
FLA
CONV
OUTLET
AMPS
208
22.4
164
2.1
20.0
0.0
230
22.4
164
2.1
20.0
0.0
460
10.9
100
1.2
10.0
0.0
575
8.3
78
0.9
7.5
0.0
208
30.1
225
2.4
38.6
0.0
230
30.1
225
2.4
38.6
0.0
460
15.5
114
0.9
19.3
0.0
575
12.1
80
0.6
16.2
0.0
208
42.3
245
2.4
38.6
0.0
230
42.3
245
2.4
38.6
0.0
460
17.6
125
0.9
19.3
0.0
575
14.5
100
0.6
16.2
0.0
180
(15)
240
(20)
300
(25)
HEATER OPTION
MODEL
KW
STAGES
AMPS
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
MIN.
MAX. FUSE/
CIRCUIT
BRKR1
SIZE
AMPACITY
(AMPS)
(AMPS)
78.8
100
78.8
100
118.7
125
165.9
175
175.2
200
78.8
100
79.1
100
133.3
150
154.9
175
198.2
225
39.3
50
39.6
50
66.6
70
77.5
90
99.1
110
29.8
35
31.0
35
52.7
60
61.3
70
78.7
90
118.1
150
118.1
150
141.9
150
189.1
200
198.4
225
118.1
150
118.1
150
156.5
175
178.2
200
221.5
250
58.7
70
58.7
70
78.3
80
89.1
100
110.7
125
46.9
60
46.9
60
63.6
70
72.2
80
89.5
100
143.4
175
143.4
175
143.4
175
189.1
200
198.4
225
143.4
175
143.4
175
156.5
175
178.2
200
221.5
250
62.9
80
62.9
80
78.3
80
89.1
100
110.7
125
51.7
60
51.7
60
63.6
70
72.2
80
89.5
100
NOTE 1: HACR Type per NEC.
VOLTAGE LIMITATIONS
POWER SUPPLY
VOLTAGE
LIMITATIONS1
1.
208/230-3-60
460-3-60
575-3-60
MIN.
187
414
518
VOLTAGE
MAX.
253
506
630
ELECTRIC HEAT CORRECTION FACTORS
NOMINAL VOLTAGE
VOLTAGE
kW CAP. MULTIPLIER
208
208
1.00
240
230
0.92
480
460
0.92
600
575
0.92
Utilization Range “A” in accordance with ARI Standard 110.
Johnson Controls Unitary Products
25
284813-YIM-C-1008
TABLE 11: WR ELECTRICAL DATA - LOW STATIC DRIVE MOTOR W/O POWERED CONVENIENCE OUTLET
MODEL
(TONNAGE)
COMPRESSORS
VOLTAGE
RLA
EACH
OD FAN
MOTORS
FLA EACH
LRA
EACH
ID
BLOWER
MOTOR
FLA
CONV
OUTLET
AMPS
208
30.1
225
2.4
20.0
0.0
230
30.1
225
2.4
20.0
0.0
460
15.5
114
0.9
10.0
0.0
575
12.1
80
0.6
7.5
0.0
208
42.3
245
2.4
20.0
0.0
230
42.3
245
2.4
20.0
0.0
460
17.6
125
0.9
10.0
0.0
575
14.5
100
0.6
7.5
0.0
240
(20)
300
(25)
HEATER OPTION
MODEL
KW
STAGES
AMPS
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
0.0
13.5
27.0
40.6
54.1
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
0.0
13.5
27.0
40.6
54.1
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
37.5
75.1
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
75.1
112.6
150.1
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
MIN.
MAX. FUSE/
CIRCUIT
BRKR1
SIZE
AMPACITY
(AMPS)
(AMPS)
97.3
125
97.3
125
118.7
125
165.9
175
175.2
200
97.3
125
97.3
125
133.3
150
154.9
175
198.2
225
48.5
60
48.5
60
66.6
70
77.5
90
99.1
110
37.1
45
37.1
45
52.7
60
61.3
70
78.7
90
124.8
150
124.8
150
124.8
150
165.9
175
175.2
200
124.8
150
124.8
150
133.3
150
154.9
175
198.2
225
53.2
70
53.2
70
66.6
70
77.5
90
99.1
110
42.5
50
42.5
50
52.7
60
61.3
70
78.7
90
NOTE 1: HACR Type per NEC.
VOLTAGE LIMITATIONS
POWER SUPPLY
VOLTAGE
LIMITATIONS1
1.
26
208/230-3-60
460-3-60
575-3-60
MIN.
187
414
518
VOLTAGE
MAX.
253
506
630
ELECTRIC HEAT CORRECTION FACTORS
NOMINAL VOLTAGE
VOLTAGE
kW CAP. MULTIPLIER
208
208
1.00
240
230
0.92
480
460
0.92
600
575
0.92
Utilization Range “A” in accordance with ARI Standard 110.
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 12: WR ELECTRICAL DATA - STANDARD DRIVE MOTOR WITH POWERED CONVENIENCE OUTLET
MODEL
(TONNAGE)
COMPRESSORS
VOLTAGE
RLA
EACH
OD FAN
MOTORS
FLA EACH
LRA
EACH
ID
BLOWER
MOTOR
FLA
CONV
OUTLET
AMPS
208
22.4
164
2.1
17.7
10.0
230
22.4
164
2.1
16.4
10.0
460
10.9
100
1.2
8.2
5.0
575
8.3
78
0.9
6.6
4.0
208
30.1
225
2.4
24.2
10.0
230
30.1
225
2.4
24.2
10.0
460
15.5
114
0.9
12.1
5.0
575
12.1
80
0.6
10.3
4.0
208
42.3
245
2.4
38.6
10.0
230
42.3
245
2.4
38.6
10.0
460
17.6
125
0.9
19.3
5.0
575
14.5
100
0.6
16.2
4.0
180
(15)
240
(20)
300
(25)
HEATER OPTION
MODEL
KW
STAGES
AMPS
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
MIN.
MAX. FUSE/
CIRCUIT
BRKR1
SIZE
AMPACITY
(AMPS)
(AMPS)
86.5
100
86.5
100
128.3
150
175.5
200
184.8
200
85.2
100
87.1
100
141.3
150
162.9
175
206.2
225
42.5
50
43.6
50
70.6
80
81.5
90
103.1
110
32.9
40
34.9
40
56.6
60
65.2
70
82.5
90
111.5
125
111.5
125
136.4
150
183.6
200
192.9
200
111.5
125
111.5
125
151.0
175
172.7
175
216.0
225
55.6
70
55.6
70
75.5
80
86.3
90
108.0
110
43.9
50
43.9
50
61.2
70
69.8
70
87.2
90
153.4
175
153.4
175
154.4
175
201.6
225
210.9
225
153.4
175
153.4
175
169.0
175
190.7
225
234.0
250
67.9
80
67.9
80
84.5
90
95.3
110
117.0
125
55.7
70
55.7
70
68.6
70
77.2
90
94.5
100
NOTE 1: HACR Type per NEC.
VOLTAGE LIMITATIONS
POWER SUPPLY
VOLTAGE
LIMITATIONS1
1.
208/230-3-60
460-3-60
575-3-60
MIN.
187
414
518
VOLTAGE
MAX.
253
506
630
ELECTRIC HEAT CORRECTION FACTORS
NOMINAL VOLTAGE
VOLTAGE
kW CAP. MULTIPLIER
208
208
1.00
240
230
0.92
480
460
0.92
600
575
0.92
Utilization Range “A” in accordance with ARI Standard 110.
Johnson Controls Unitary Products
27
284813-YIM-C-1008
TABLE 13: WR ELECTRICAL DATA - HIGH STATIC DRIVE MOTOR WITH POWERED CONVENIENCE OUTLET
MODEL
(TONNAGE)
COMPRESSORS
VOLTAGE
RLA
EACH
OD FAN
MOTORS
FLA EACH
LRA
EACH
ID
BLOWER
MOTOR
FLA
CONV
OUTLET
AMPS
208
22.4
164
2.1
20.0
10.0
230
22.4
164
2.1
20.0
10.0
460
10.9
100
1.2
10.0
5.0
575
8.3
78
0.9
7.5
4.0
208
30.1
225
2.4
38.6
10.0
230
30.1
225
2.4
38.6
10.0
460
15.5
114
0.9
19.3
5.0
575
12.1
80
0.6
16.2
4.0
208
42.3
245
2.4
38.6
10.0
230
42.3
245
2/4
38.6
10.0
460
17.6
125
0.9
19.3
5.0
575
14.5
100
0.6
16.2
4.0
180
(15)
240
(20)
300
(25)
HEATER OPTION
MODEL
KW
STAGES
AMPS
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
MIN.
MAX. FUSE/
CIRCUIT
BRKR1
SIZE
AMPACITY
(AMPS)
(AMPS)
88.8
110
88.8
110
131.2
150
178.4
200
187.7
200
88.8
110
91.6
110
145.8
150
167.4
175
210.7
225
44.3
50
45.8
50
72.9
80
83.7
90
105.4
110
33.8
40
36.0
40
57.7
60
66.3
70
83.7
90
128.1
150
128.1
150
154.4
175
201.6
225
210.9
225
128.1
150
128.1
150
169.0
175
190.7
225
234.0
250
63.7
80
63.7
80
84.5
90
95.3
110
117.0
125
50.9
60
50.9
60
68.6
70
77.2
90
94.5
100
153.4
175
153.4
175
154.4
175
201.6
225
210.9
225
153.4
175
153.4
175
169.0
175
190.7
225
234.0
250
67.9
80
67.9
80
84.5
90
95.3
110
117.0
125
55.7
70
55.7
70
68.6
70
77.2
90
94.5
100
NOTE 1: HACR Type per NEC.
VOLTAGE LIMITATIONS
POWER SUPPLY
VOLTAGE
LIMITATIONS1
1.
28
208/230-3-60
460-3-60
575-3-60
MIN.
187
414
518
VOLTAGE
MAX.
253
506
630
ELECTRIC HEAT CORRECTION FACTORS
NOMINAL VOLTAGE
VOLTAGE
kW CAP. MULTIPLIER
208
208
1.00
240
230
0.92
480
460
0.92
600
575
0.92
Utilization Range “A” in accordance with ARI Standard 110.
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 14: WR ELECTRICAL DATA - LOW STATIC DRIVE MOTOR WITH POWERED CONVENIENCE OUTLET
MODEL
(TONNAGE)
COMPRESSORS
VOLTAGE
RLA
EACH
OD FAN
MOTORS
FLA EACH
LRA
EACH
ID
BLOWER
MOTOR
FLA
CONV
OUTLET
AMPS
208
30.1
225
2.4
20.0
10.0
230
30.1
225
2.4
20.0
10.0
460
15.5
114
0.9
10.0
5.0
575
12.1
80
0.6
7.5
4.0
208
42.3
245
2.4
20.0
10.0
230
42.3
245
2.4
20.0
10.0
460
17.6
125
0.9
10.0
5.0
575
14.5
100
0.6
7.5
4.0
240
(20)
300
(25)
HEATER OPTION
MODEL
KW
STAGES
AMPS
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
0.0
13.5
27.0
40.6
54.1
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
0.0
13.5
27.0
40.6
54.1
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
0.0
18.0
36.0
54.0
72.0
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
37.5
75.1
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
75.1
112.6
150.1
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
MIN.
MAX. FUSE/
CIRCUIT
BRKR1
SIZE
AMPACITY
(AMPS)
(AMPS)
107.3
125
107.3
125
131.2
150
178.4
200
187.7
200
107.3
125
107.3
125
145.8
150
167.4
175
210.7
225
53.5
60
53.5
60
72.9
80
83.7
90
105.4
110
41.1
50
41.1
50
57.7
60
66.3
70
83.7
90
134.8
175
134.8
175
134.8
175
178.4
200
187.7
200
134.8
175
134.8
175
145.8
175
167.4
175
210.7
225
58.2
70
58.2
70
72.9
80
83.7
90
105.4
110
46.5
60
46.5
60
57.7
60
66.3
70
83.7
90
NOTE 1: HACR Type per NEC.
VOLTAGE LIMITATIONS
POWER SUPPLY
VOLTAGE
LIMITATIONS1
1.
208/230-3-60
460-3-60
575-3-60
MIN.
187
414
518
VOLTAGE
MAX.
253
506
630
ELECTRIC HEAT CORRECTION FACTORS
NOMINAL VOLTAGE
VOLTAGE
kW CAP. MULTIPLIER
208
208
1.00
240
230
0.92
480
460
0.92
600
575
0.92
Utilization Range “A” in accordance with ARI Standard 110.
Johnson Controls Unitary Products
29
284813-YIM-C-1008
ECONOMIZER / MOTORIZED DAMPER
FIXED OUTDOOR INTAKE AIR AND
POWER EXHAUST RAIN HOODS
(See detail Y)
BLOWER MOTOR
ACCESS (Location of
Optional VFD Bypass)
BLOWER
COMPARTMENT
ACCESS
DOT PLUG
(For pressure
drop reading)
BLOWER ACCESS
(Location of
Optional VFD)
COMPRESSOR ACCESS
180-19/32
52-5/8
GAS OR ELECTRIC
HEAT
ACCESS
COIL
GUARD
KIT
VENT AIR
OUTLET
HOODS
COMBUSTION
AIR INLET HOOD
21.00
(C) GAS
SUPPLY
ENTRY
9-3/4
CONDENSER
COILS
7-1/8
136-1/4
(A) CONTROL WIRING
ENTRY
92
6-3/8
5
DISCONNECT
SWITCH
LOCATION
46-5/8
11-1/2
CONTROL BOX
ACCESS
5-7/8
(B) POWER
WIRING
ENTRY
35
BOTTOM SUPPLY
AND RETURN
AIR OPENINGS
(See Note)
35-1/4
33
2-3/4
UNIT BASE RAILS
Shown separately to illustrate
Bottom Duct openings. Power
and Gas Piping Connection
location.
(D)
GAS SUPPLY
ENTRY
RETURN
AIR
SUPPLY
AIR
21-1/2
3-3/4
(B) POWER WIRING
ENTRY
11-1/8
NOTE:
For curb mounted units, refer to the curb hanger
dimensions of the curb for proper size of the
supply and return air duct connections.
8-1/8
12-1/2
46-5/8
(A) CONTROL WIRING
ENTRY
9-1/4
9-3/4
UTILITIES ENTRY DATA
HOLE
OPENING SIZE
(DIA.)
1-1/8” KO
A
3/4” NPS (Fem.)
3-5/8” KO
B
3” NPS (Fem.)
C
2-3/8” KO
D
1-11/16” Hole
1.
2.
USED FOR
Control Wiring
Power Wiring
Side
Bottom
Side
Bottom
Gas Piping (Front)1
Gas Piping (Bottom)1,
2
One-inch gas piping NPT required.
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 12 - FRONT VIEW DIMENSIONS
30
Johnson Controls Unitary Products
284813-YIM-C-1008
EVAPORATOR
SECTION
DOT PLUG
(For pressure
drop reading)
40-3/8"
FILTER
ACCESS
SUPPLY
AIR
RETURN
AIR
COMPRESSOR
ACCESS
OUTDOOR
AIR
40-1/2"
SUPPLY AIR
ACCESS
Dimensions listed are for side
duct flange openings; see
Field Accessories for Side
Duct Flange Kit.
18-5/8"
1" NPT FEMALE
COND. DRAIN
CONNECTION
27-3/4"
RETURN AIR
ACCESS
5-1/8"
39-5/8"
REAR
VIEW
OUTDOOR AIR
COMPARTMENT
ACCESS
FIGURE 13 - REAR VIEW DIMENSIONS
NOTE: Units are shipped with the bottom duct openings covered. An accessory flange kit is available for connecting side ducts.
For bottom duct applications:
For side duct applications:
1.
Remove the side panels from the supply and return air
compartments to gain access to the bottom supply and
return air duct covers.
1.
Replace the side panels on the supply and return air
compartments with the side duct flange accessory kit
panels.
2.
Remove and discard the bottom duct covers. Duct
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.
2.
Connect ductwork to the flanges on those panels.
3.
Replace the side supply and return air compartment
panels.
Johnson Controls Unitary Products
31
284813-YIM-C-1008
NOTE:ELEC / ELEC Models: Units and ductwork are
CLEARANCE
LOCATION
CLEARANCE
Front
36”
Rear
24” (Less Economizer)
49” (With Economizer)
Left Side (Filter Access)
24” (Less Economizer)
36” (With Economizer)3
Right Side (Cond. Coil)
36”
Below
Above
approved for zero clearance to combustible material
when equipped with electric heaters.
GAS / ELEC Models: A 1” clearance must be
provided between any combustible material and the
supply air ductwork for a distance of 3 feet from the
unit.
Unit1
0”
Unit2
72” With 36” Maximum
Horizontal Overhang (For
Condenser Air Discharge)
The products of combustion must not be allowed to
accumulate within a confined space and recirculate.
Locate unit so that the vent air outlet hood is at least:
1.
Units may be installed on combustible floors made from wood or
class A, B, or C roof covering material.
2.
Units must be installed outdoors. Overhanging structures or
shrubs should not obstruct condenser air discharge outlet.
3. If economizer is factory installed, the unassembled rain hood
must be removed from its ride along position in front of evaporator coil, or in the outdoor air compartment, prior to final installation.
• Three (3) feet above any force air inlet located
within 10 horizontal feet (excluding those integral to
the unit).
• Four (4) feet below, four horizontal feet from, or one
foot above any door or gravity air inlet into the
building.
• Four (4) feet from electric and gas meters,
regulators and relief equipment.
SUPPLY AIR
COMPARTMENT
POWER EXHAUST
RAIN HOOD
(on Return Air Compartment)
ECONOMIZER
MOTORIZED
DAMPER
RAIN HOOD
(on Outdoor Air Compartment)
ECONOMIZER / MOTORIZED DAMPER
AND POWER EXHAUST RAIN HOODS
FIXED
OUTDOOR AIR
INTAKE HOOD
(located on
Return Air
Compartment)
36-5/8”
1“ CONDENSATE
DRAIN
(Must be trapped)
16-1/8”
5”
28-3/16”
92”
REAR VIEW
LH VIEW
DETAIL “Y”
UNIT WITH RAIN HOODS
FIGURE 14 - UNIT CLEARANCE AND RAIN HOOD DIMENSIONS (15, 20 & 25 TON)
32
Johnson Controls Unitary Products
284813-YIM-C-1008
CFM, STATIC PRESSURE, AND POWER - ALTITUDE AND TEMPERATURE CORRECTIONS
order to use the indoor blower tables for high altitude applications, certain corrections are necessary.
The information below should be used to assist in application
of product when being applied at altitudes at or exceeding
1000 feet above sea level.
A centrifugal fan is a "constant volume" device. This means
that, if the rpm remains constant, the CFM delivered is the
same regardless of the density of the air. However, since the
air at high altitude is less dense, less static pressure will be
generated and less power will be required than a similar
application at sea level. Air density correction factors are
shown in Table 15 and Figure 15.
The air flow rates listed in the standard blower performance
tables are based on standard air at sea level. As the altitude
or temperature increases, the density of air decreases. In
TABLE 15: ALTITUDE CORRECTION FACTORS
AIR TEMP
40
50
60
70
80
90
100
0
1.060
1.039
1.019
1.000
0.982
0.964
0.946
1000
1.022
1.002
0.982
0.964
0.947
0.929
0.912
2000
0.986
0.966
0.948
0.930
0.913
0.897
0.880
3000
0.950
0.931
0.913
0.896
0.880
0.864
0.848
ALTITUDE (FEET)
4000
5000
0.916
0.882
0.898
0.864
0.880
0.848
0.864
0.832
0.848
0.817
0.833
0.802
0.817
0.787
6000
0.849
0.832
0.816
0.801
0.787
0.772
0.758
7000
0.818
0.802
0.787
0.772
0.758
0.744
0.730
8000
0.788
0.772
0.757
0.743
0.730
0.716
0.703
9000
0.758
0.743
0.729
0.715
0.702
0.689
0.676
10000
0.729
0.715
0.701
0.688
0.676
0.663
0.651
The examples below will assist in determining the airflow performance of the product at altitude.
blower tables to select the blower speed and the BHP
requirement.
Example 1: What are the corrected CFM, static pressure,
and BHP at an elevation of 5,000 ft. if the blower performance
data is 6,000 CFM, 1.5 IWC and 4.0 BHP?
Solution: As in the example above, no temperature information is given so 70°F is assumed.
Solution: At an elevation of 5,000 ft the indoor blower will still
deliver 6,000 CFM if the rpm is unchanged. However, Table
15 must be used to determine the static pressure and BHP.
Since no temperature data is given, we will assume an air
temperature of 70°F. Table 15 shows the correction factor to
be 0.832.
The 1.5" static pressure given is at an elevation of 5,000 ft.
The first step is to convert this static pressure to equivalent
sea level conditions.
Sea level static pressure = 1.5 / .832 = 1.80"
Enter the blower table at 6000 sCFM and static pressure of
1.8". The rpm listed will be the same rpm needed at 5,000 ft.
Corrected static pressure = 1.5 x 0.832 = 1.248 IWC
Corrected BHP = 4.0 x 0.832 = 3.328
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
Johnson Controls Unitary Products
Suppose that the corresponding BHP listed in the table is 3.2.
This value must be corrected for elevation.
BHP at 5,000 ft = 3.2 x .832 = 2.66
33
284813-YIM-C-1008
FIGURE 15 - ALTITUDE/TEMPERATURE CONVERSION FACTOR
34
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 16: WR180 BLOWER PERFORMANCE - 15 TON STANDARD DRIVE (COOLING ONLY) DOWNFLOW
ESP
0.2
0.4
0.6
0.8
1.0
1.2
1.4
CFM
6284
5918
5590
5226
4801
4326
3650
RPM KW
956 3.50
957 3.25
958 3.05
959 2.79
961 2.52
962 2.28
965 1.95
1 turn
BHP
4.20
3.89
3.66
3.34
3.03
2.73
2.34
CFM
6080
5718
5379
4985
4529
3912
3199
RPM KW
922 3.14
923 2.92
925 2.74
926 2.45
928 2.23
930 1.95
931 1.62
2 turns
BHP
3.77
3.51
3.28
2.95
2.68
2.34
1.95
Blower Performance (Downflow Discharge)
CFM RPM KW BHP CFM RPM KW BHP
5800 889 2.84 3.41 5514 856 2.536 3.04
5434 889 2.61 3.13 5228 857 2.32 2.78
5098 891 2.41 2.90 4829 858 2.18 2.61
4639 893 2.18 2.62 4336 860 1.91 2.30
4141 894 1.95 2.34 3754 861 1.69 2.03
3405 896 1.59 1.91 2964 863 1.38 1.65
3 turns
4 turns
CFM
5290
4914
4452
3937
3222
-
RPM KW
821 2.209
822 2.04
823 1.81
825 1.58
826 1.35
5 turns
BHP
2.65
2.45
2.17
1.90
1.62
-
CFM
5056
4668
4175
3608
2752
-
RPM KW
788 1.992
789 1.85
790 1.67
791 1.42
792 1.13
6 turns
BHP
2.39
2.22
2.01
1.70
1.35
-
15-Ton Standard Drive, Cooling Only, Bottom Connection
1VP62 x BK105
7000
6500
1 Turn
2 Turns
3 Turns
6000
4 Turns
5 Turns
6 Turns
SCFM
5500
5000
4500
4000
3500
3000
2500
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
External Static ("WC)
Johnson Controls Unitary Products
35
284813-YIM-C-1008
TABLE 17: WR180 BLOWER PERFORMANCE - 15 TON STANDARD DRIVE (GAS HEAT) DOWNFLOW
ESP
0.2
0.4
0.6
0.8
1.0
1.2
1.4
Blower Performance (Downflow Discharge)
CFM RPM KW BHP CFM RPM KW BHP CFM RPM KW BHP CFM RPM KW BHP
6158 956 3.29 3.95 5958 922 2.96 3.55 5684 889 2.67 3.20 5404 856 2.38 2.86
5800 957 3.05 3.66 5604 923 2.75 3.30 5325 889 2.45 2.94 5123 857 2.18 2.62
5478 958 2.87 3.44 5271 925 2.57 3.09 4996 891 2.27 2.72 4732 858 2.05 2.46
5121 959 2.62 3.14 4885 926 2.31 2.77 4546 893 2.05 2.46 4249 860 1.80 2.16
4705 961 2.37 2.85 4438 928 2.10 2.52 4058 894 1.83 2.20 3679 861 1.59 1.91
4239 962 2.14 2.57 3834 930 1.83 2.20 3337 896 1.49 1.79 2905 863 1.29 1.55
3577 965 1.83 2.20 3135 931 1.52 1.83
1 turn
2 turns
3 turns
4 turns
CFM RPM KW BHP CFM RPM KW BHP
5184 821 2.08 2.49 4955 788 1.87 2.25
4816 822 1.92 2.31 4575 789 1.74 2.09
4363 823 1.70 2.04 4092 790 1.57 1.89
3858 825 1.48 1.78 3536 791 1.33 1.60
3158 826 1.27 1.52 2697 792 1.06 1.27
5 turns
6 turns
15-Ton Standard Drive, Gas Heat, Bottom Connection
1VP62 x BK105
7000
6500
1 Turn
2 Turns
3 Turns
4 Turns
5 Turns
6 Turns
6000
SCFM
5500
5000
4500
4000
3500
3000
2500
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
External Static ("WC)
36
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 18: WR180 BLOWER PERFORMANCE - 15 TON HIGH STATIC DRIVE (COOLING ONLY) DOWNFLOW
ESP
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
CFM
7695
7344
6994
6711
6415
6032
5659
5315
4733
RPM KW
1120 5.68
1122 5.34
1123 4.99
1125 4.77
1126 4.54
1127 4.22
1128 3.89
1130 3.60
1131 3.15
1 turn
BHP
6.93
6.51
6.08
5.83
5.54
5.15
4.67
4.32
3.78
CFM
7434
7089
6751
6478
6193
5823
5463
5042
4402
7.5 HP motor
RPM KW
1082 5.12
1083 4.80
1084 4.48
1086 4.29
1087 4.09
1088 3.80
1089 3.50
1090 3.23
1091 2.83
2 turns
BHP
6.25
5.86
5.47
5.24
4.90
4.56
4.20
3.88
3.40
Blower Performance (Downflow Discharge)
CFM RPM KW BHP CFM RPM KW BHP
7139 1043 4.55 5.55 6853 1005 4.10 4.92
6791 1044 4.32 5.28 6497 1005 3.80 4.57
6477 1046 4.06 4.87 6190 1006 3.63 4.36
6196 1046 3.85 4.62 5864 1007 3.41 4.09
5802 1048 3.58 4.30 5449 1008 3.07 3.68
5418 1049 3.28 3.93 5011 1009 2.79 3.34
4996 1049 3.00 3.60 4549 1010 2.48 2.98
4481 1050 2.68 3.21 4004 1011 2.20 2.64
3756 1052 2.28 2.73
3 turns
4 turns
CFM RPM KW BHP CFM RPM KW BHP
6537 966 3.614 4.34 6173 926 3.20 3.84
6157 966 3.28 3.94 5791 927 2.92 3.50
5855 967 3.25 3.90 5430 927 2.74 3.29
5434 968 2.95 3.54 5023 928 2.54 3.04
5017 969 2.71 3.25 4554 929 2.21 2.66
4554 970 2.40 2.88 4030 930 1.99 2.39
4120 970 2.09 2.51 3216 931 1.63 1.95
3222 971 1.75 2.09
5 turns
6 turns
5 HP motor
15-Ton High Static Drive, Cooling Only, Bottom Connection
1VP62 x BK90
8000
1 Turn
7500
7000
2 Turns
3 Turns
4 Turns
6500 5 Turns
6 Turns
SCFM
6000
5500
5000
4500
4000
3500
3000
0.0
0.2
0.4
Johnson Controls Unitary Products
0.6
0.8
1.0
1.2
External Static ("WC)
1.4
1.6
1.8
2.0
37
284813-YIM-C-1008
TABLE 19: WR180 BLOWER PERFORMANCE - 15 TON HIGH STATIC DRIVE (GAS HEAT) DOWNFLOW
ESP
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
CFM
7541
7197
6854
6576
6287
5911
5545
5209
4638
RPM KW
1120 5.34
1122 5.02
1123 4.69
1125 4.49
1126 4.27
1127 3.97
1128 3.66
1130 3.38
1131 2.96
1 turn
BHP
6.51
6.12
5.72
5.48
5.21
4.76
4.39
4.06
3.56
CFM
7285
6947
6616
6348
6069
5707
5354
4941
4314
7.5 HP motor
RPM KW
1082 4.81
1083 4.51
1084 4.21
1086 4.04
1087 3.84
1088 3.57
1089 3.29
1090 3.04
1091 2.66
2 turns
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW
5.87 6996 1043 4.28 5.22 6716 1005 3.85
5.50 6655 1044 4.06 4.88 6367 1005 3.58
5.14 6347 1046 3.81 4.58 6066 1006 3.41
4.84 6072 1046 3.62 4.35 5747 1007 3.20
4.61 5686 1048 3.37 4.04 5340 1008 2.88
4.29 5310 1049 3.08 3.69 4911 1009 2.62
3.95 4896 1049 2.82 3.38 4458 1010 2.33
3.65 4391 1050 2.51 3.02 3924 1011 2.07
3.19 3681 1052 2.14 2.57
3 turns
4 turns
BHP
4.63
4.29
4.09
3.84
3.46
3.14
2.80
2.48
-
CFM
6406
6034
5738
5325
4917
4463
4038
3158
-
RPM KW
966 3.40
966 3.08
967 3.06
968 2.78
969 2.54
970 2.25
970 1.96
971 1.64
5 turns
BHP
4.08
3.70
3.67
3.33
3.05
2.70
2.36
1.97
-
CFM
6050
5675
5321
4923
4463
3949
3152
-
RPM KW
926 3.00
927 2.74
927 2.58
928 2.38
929 2.08
930 1.87
931 1.53
6 turns
BHP
3.61
3.29
3.09
2.86
2.50
2.24
1.83
-
5 HP motor
15-Ton High Static Drive, Gas Heat, Bottom Connection
1VP62 x BK90
8000
7500
7000
1 Turn
2 Turns
3 Turns
4 Turns
6500
SCFM
6000
5 Turns
6 Turns
5500
5000
4500
4000
3500
3000
0.0
38
0.2
0.4
0.6
0.8
1.0
1.2
External Static ("WC)
1.4
1.6
1.8
2.0
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 20: WR240 BLOWER PERFORMANCE - 20 TON STANDARD DRIVE (COOLING ONLY) DOWNFLOW
ESP
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
CFM
9720
9345
8975
8590
8197
7795
7313
RPM KW BHP
1107 8.33 10.16
1108 8.04 9.81
1109 7.62 9.29
1110 7.32 8.93
1112 6.75 8.24
1113 6.40 7.81
1115 6.27 7.65
1 turn
10 HP motor
CFM
9557
9159
8775
8390
7977
7571
7086
-
RPM KW
1071 7.78
1073 7.58
1074 7.26
1076 6.82
1077 6.29
1078 5.98
1079 5.71
2 turns
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW
9.49 9313 1036 7.22 8.81 8842 1002 6.35
9.25 8901 1038 6.79 8.29 8426 1003 6.02
8.86 8503 1039 6.50 7.94 7980 1005 5.64
8.32 8089 1040 6.10 7.45 7576 1006 5.33
7.67 7643 1041 5.72 6.97 7123 1007 5.00
7.29 7218 1043 5.43 6.62 6638 1008 4.54
6.97 6729 1044 4.95 6.04
3 turns
4 turns
BHP
7.75
7.34
6.88
6.51
6.10
5.54
-
CFM RPM KW BHP CFM RPM KW BHP
8481 968 5.68 6.93 8267 932 5.22 6.38
8048 969 5.34 6.51 7805 934 4.83 5.90
7621 970 5.03 6.14 7340 935 4.39 5.35
7195 971 4.81 5.87 6858 936 4.21 5.13
6739 972 4.46 5.44 6288 937 3.79 4.62
5 turns
6 turns
7.5 HP motor
20-Ton Standard Drive, Cooling Only, Bottom Connection
VP68 x BK100
11000
10000
2 Turns
3 Turns
SCFM
9000
1 Turn
4 Turns
5 Turns
6 Turns
8000
7000
6000
5000
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
External Static ("WC)
Johnson Controls Unitary Products
39
284813-YIM-C-1008
TABLE 21: WR240 BLOWER PERFORMANCE - 20 TON STANDARD DRIVE (GAS HEAT) DOWNFLOW
ESP
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
CFM
9892
9526
9158
8796
8418
8033
7639
7167
RPM KW BHP
1106 8.30 10.13
1107 7.83 9.55
1108 7.56 9.23
1109 7.16 8.74
1110 6.88 8.40
1112 6.35 7.75
1113 6.01 7.34
1115 5.89 7.19
1 turn
CFM
9366
8976
8600
8222
7817
7420
6944
-
10 HP motor
RPM KW
1071 7.31
1073 7.12
1074 6.83
1076 6.41
1077 5.91
1078 5.62
1079 5.37
2 turns
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW
8.92 9127 1036 6.78 8.28 8665 1002 5.97
8.69 8723 1038 6.38 7.79 8257 1003 5.65
8.33 8333 1039 6.11 7.46 7820 1005 5.30
7.82 7927 1040 5.73 7.00 7424 1006 5.01
7.21 7490 1041 5.37 6.56 6981 1007 4.70
6.86 7074 1043 5.10 6.22 6505 1008 4.26
6.55 6594 1044 4.65 5.68
3 turns
4 turns
BHP
7.28
6.90
6.47
6.12
5.74
5.20
-
CFM RPM KW BHP CFM RPM KW BHP
8311 968 5.34 6.52 8102 932 4.91 5.99
7887 969 5.01 6.12 7649 934 4.54 5.55
7469 970 4.73 5.77 7193 935 4.12 5.03
7051 971 4.52 5.51 6721 936 3.95 4.83
6604 972 4.19 5.12 6162 937 3.56 4.35
5 turns
6 turns
7.5 HP motor
20-Ton Standard Drive, Gas Heat, Bottom Connection
VP68 x BK100
11000
10000
1 Turn
2 Turns
3 Turns
SCFM
9000
4 Turns
5 Turns
6 Turns
8000
7000
6000
5000
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
External Static ("WC)
40
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 22: WR240 BLOWER PERFORMANCE - 20 TON HIGH STATIC DRIVE (COOLING ONLY) DOWNFLOW
ESP
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
CFM
11465
11056
10697
10354
9993
9637
9229
8833
8446
7996
RPM KW
1201 11.98
1202 11.46
1203 10.97
1204 10.68
1205 10.12
1207 9.61
1208 9.20
1209 9.02
1210 8.27
1212 7.90
1 turn
BHP
14.62
13.98
13.39
13.03
12.35
11.73
11.23
11.01
10.09
9.64
15 HP motor
CFM
10938
10545
10169
9808
9450
9050
8658
8287
7916
-
RPM KW
1167 10.57
1168 10.23
1169 9.78
1170 9.42
1171 8.94
1172 8.48
1174 7.94
1175 7.83
1176 7.41
2 turns
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW
12.90 10528 1131 9.67 11.80 9886 1096 8.54
12.48 10137 1133 9.20 11.23 9488 1097 8.17
11.93 9769 1134 8.68 10.59 9109 1099 7.70
11.50 9370 1135 8.50 10.37 8721 1101 7.38
10.91 9000 1136 7.94 9.69 8355 1102 6.98
10.35 8624 1137 7.39 9.02 7990 1103 6.64
9.69 8239 1138 7.24 8.84 7591 1104 6.31
9.56 7852 1140 6.67 8.14 7135 1105 5.91
9.04 7356 1141 6.48 7.91
3 turns
4 turns
10 HP motor
BHP
10.43
9.98
9.39
9.01
8.52
8.10
7.70
7.21
-
CFM
9525
9092
8729
8314
7899
7500
7009
-
RPM KW
1063 7.55
1064 7.32
1065 7.28
1066 6.65
1067 6.03
1068 5.96
1069 5.58
5 turns
BHP
9.21
8.93
8.88
8.11
7.36
7.28
6.81
-
CFM
9054
8633
8237
7835
7412
6962
-
RPM KW
1027 7.05
1028 6.45
1029 6.18
1030 5.82
1031 5.53
1032 4.79
6 turns
BHP
8.60
7.87
7.54
7.11
6.75
5.84
-
7.5 HP motor
20-Ton High Static Drive, Cooling Only, Bottom Connection
VP71 x BK100
12000
1 Turn
11000
2 Turns
3 Turns
10000
4 Turns
SCFM
5 Turns
6 Turns
9000
8000
7000
6000
0.2
0.4
0.6
Johnson Controls Unitary Products
0.8
1.0
1.2
1.4
External Static ("WC)
1.6
1.8
2.0
2.2
41
284813-YIM-C-1008
TABLE 23: WR240 BLOWER PERFORMANCE - 20 TON HIGH STATIC DRIVE (GAS HEAT) DOWNFLOW
ESP
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
CFM
11236
10835
10483
10147
9793
9444
9044
8656
8277
7836
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW BHP CFM RPM KW
13.74 10719 1167 9.94 12.13 10317 1131 9.09 11.09 9688 1096 8.03
13.14 10334 1168 9.62 11.73 9934 1133 8.65 10.56 9298 1097 7.68
12.58 9966 1169 9.19 11.22 9574 1134 8.16 9.96 8927 1099 7.23
12.25 9612 1170 8.86 10.81 9183 1135 7.99 9.75 8547 1101 6.94
11.61 9261 1171 8.40 10.25 8820 1136 7.46 9.11 8188 1102 6.56
11.02 8869 1172 7.97 9.73 8452 1137 6.95 8.48 7830 1103 6.24
10.55 8485 1174 7.47 9.11 8074 1138 6.81 8.31 7439 1104 5.93
10.35 8121 1175 7.36 8.99 7695 1140 6.27 7.65 6992 1105 5.55
9.49 7758 1176 6.97 8.50 7209 1141 6.09 7.44
9.07
2 turns
3 turns
4 turns
RPM KW
1201 11.26
1202 10.77
1203 10.31
1204 10.04
1205 9.52
1207 9.03
1208 8.65
1209 8.48
1210 7.77
1212 7.43
1 turn
15 HP motor
10 HP motor
BHP
9.80
9.38
8.83
8.47
8.01
7.61
7.24
6.78
-
CFM
9335
8910
8554
8148
7741
7350
6869
-
RPM KW
1063 7.10
1064 6.88
1065 6.84
1066 6.25
1067 5.67
1068 5.61
1069 5.24
5 turns
1.8
2.0
BHP
8.66
8.39
8.35
7.62
6.92
6.84
6.40
-
CFM
8873
8460
8072
7678
7264
6823
-
RPM KW
1027 6.62
1028 6.06
1029 5.81
1030 5.48
1031 5.20
1032 4.50
6 turns
BHP
8.08
7.40
7.09
6.68
6.35
5.49
-
7.5 HP motor
20-Ton High Static Drive, Gas Heat, Bottom Connection
VP71 x BK100
12000
1 Turn
11000
2 Turns
3 Turns
10000
SCFM
4 Turns
5 Turns
9000
6 Turns
8000
7000
6000
0.2
42
0.4
0.6
0.8
1.0
1.2
1.4
External Static ("WC)
1.6
2.2
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 24: WR300 BLOWER PERFORMANCE - 25 TON STANDARD DRIVE (COOLING ONLY) DOWNFLOW
Blower Performance (Downflow Discharge)
ESP CFM RPM KW BHP CFM RPM KW BHP CFM RPM KW BHP CFM RPM KW
0.4 10636 1106 9.46 11.55 10163 1072 8.55 10.44 9813 1036 7.76 9.47 9394 999 6.98
0.6 10312 1106 9.06 11.06 9824 1072 8.17 9.97 9463 1036 7.37 8.99 9006 1000 6.60
0.8 9975 1107 8.76 10.69 9466 1073 7.75 9.46 9087 1036 6.99 8.53 8626 1001 6.31
1.0 9629 1108 8.34 10.18 9108 1073 7.41 9.04 8706 1037 6.64 8.11 8218 1001 5.91
1.2 9262 1109 7.97 9.73 8730 1074 7.11 8.67 8319 1038 6.33 7.72 7783 1002 5.55
1.4 8897 1110 7.56 9.22 8326 1075 6.72 8.21 7879 1039 5.85 7.14 7351 1002 5.18
1.6 8488 1111 7.15 8.73 7919 1076 6.28 7.67 7414 1039 5.46 6.66 6800 1003 4.79
1.8 8068 1112 6.74 8.23 7472 1076 5.92 7.22 6919 1040 5.09 6.22 6187 1004 4.29
2.0 7654 1113 6.38 7.79 6906 1077 5.37 6.56 6327 1041 4.67 5.70 5539 1005 3.88
2.2 7135 1114 5.92 7.22 6346 1078 4.91 5.99 5735 1042 4.25 5.19
1 turn
2 turns
3 turns
4 turns
15 HP motor
10 HP motor
BHP
8.52
8.05
7.69
7.22
6.77
6.32
5.84
5.24
4.73
-
CFM
8936
8553
8159
7717
7265
6804
6205
5478
4750
-
RPM KW
963 6.14
963 5.83
964 5.51
965 5.16
966 4.83
967 4.52
968 4.12
969 3.74
969 3.18
5 turns
BHP
7.49
7.11
6.73
6.29
5.89
5.51
5.03
4.56
3.88
-
CFM
8388
7987
7553
7118
6625
6087
5425
4665
-
RPM KW
927 5.45
927 5.10
928 4.84
929 4.49
929 4.21
930 3.82
931 3.51
931 3.02
6 turns
BHP
6.65
6.23
5.91
5.48
5.14
4.66
4.28
3.69
-
7.5 HP motor
25-Ton Standard Drive, Cooling Only, Bottom Duct Connection
1VP65 & B5V94
12000
11000
1 Turn
2 Turns
3 Turns
4 Turns
5 Turns
6 Turns
10000
SCFM
9000
8000
7000
6000
5000
4000
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
External Static ("WC)
Johnson Controls Unitary Products
43
284813-YIM-C-1008
TABLE 25: WR300 BLOWER PERFORMANCE - 25 TON STANDARD DRIVE (GAS HEAT) DOWNFLOW
ESP CFM RPM KW
0.4 10423 1106 8.89
0.6 10106 1106 8.52
0.8 9776 1107 8.24
1.0 9436 1108 7.84
1.2 9077 1109 7.49
1.4 8719 1110 7.10
1.6 8318 1111 6.72
1.8 7907 1112 6.34
2.0 7501 1113 6.00
2.2 6992 1114 5.56
1 turn
BHP
10.85
10.40
10.05
9.57
9.14
8.67
8.20
7.74
7.32
6.79
15 HP motor
CFM
9960
9628
9277
8926
8555
8159
7761
7323
6768
6219
RPM KW
1072 8.04
1072 7.68
1073 7.28
1073 6.97
1074 6.68
1075 6.32
1076 5.91
1076 5.56
1077 5.05
1078 4.62
2 turns
10 HP motor
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW
9.81 9617 1036 7.29 8.90 9206 999 6.56
9.38 9274 1036 6.92 8.45 8826 1000 6.20
8.89 8905 1036 6.57 8.01 8453 1001 5.93
8.50 8532 1037 6.24 7.62 8054 1001 5.56
8.15 8153 1038 5.95 7.26 7627 1002 5.21
7.71 7721 1039 5.50 6.71 7204 1002 4.87
7.21 7266 1039 5.13 6.26 6664 1003 4.50
6.79 6781 1040 4.79 5.84 6063 1004 4.03
6.16 6200 1041 4.39 5.36 5428 1005 3.65
5.63 5620 1042 4.00 4.88
3 turns
4 turns
BHP
8.01
7.57
7.23
6.78
6.36
5.94
5.49
4.92
4.45
-
CFM RPM KW BHP CFM RPM KW BHP
8757 963 5.77 7.04 8220 927 5.12 6.25
8382 963 5.48 6.68 7827 927 4.80 5.85
7996 964 5.18 6.33 7402 928 4.55 5.55
7563 965 4.85 5.91 6976 929 4.22 5.15
7120 966 4.54 5.53 6493 929 3.96 4.83
6668 967 4.25 5.18 5965 930 3.59 4.38
6081 968 3.87 4.73 5317 931 3.30 4.02
5368 969 3.52 4.29 4572 931 2.84 3.47
4655 969 2.99 3.65
5 turns
6 turns
7.5 HP motor
25-Ton Standard Drive, Gas Heat, Bottom Duct Connection
1VP65 & B5V94
12000
11000
1 Turn
2 Turns
3 Turns
4 Turns
5 Turns
6 Turns
10000
SCFM
9000
8000
7000
6000
5000
4000
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
External Static ("WC)
44
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 26: WR300 BLOWER PERFORMANCE - 25 TON HIGH STATIC DRIVE (COOLING ONLY) DOWNFLOW
ESP
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
CFM
11830
11546
11239
10923
10618
10302
9958
9605
9219
8796
8287
7782
RPM KW
1216 12.80
1217 12.31
1217 11.87
1218 11.48
1219 11.14
1221 10.66
1222 10.21
1223 9.71
1225 9.25
1226 8.82
1227 8.19
1229 7.98
1 turn
BHP
15.62
15.02
14.49
14.01
13.60
13.01
12.45
11.85
11.29
10.76
10.00
9.74
15 HP motor
CFM
11374
11079
10770
10388
10054
9703
9346
9032
8638
8250
7791
-
RPM KW
1181 11.51
1181 11.12
1182 10.79
1183 10.25
1185 9.82
1186 9.42
1186 9.05
1187 8.61
1189 8.18
1190 7.78
1191 7.26
2 turns
10 HP motor
BHP
11.59
11.12
10.82
10.24
9.77
9.21
8.69
8.37
7.77
7.31
-
CFM
10220
9885
9537
9171
8799
8407
7992
7513
6987
-
RPM KW
1075 8.67
1076 8.28
1077 7.94
1078 7.54
1079 7.18
1080 6.76
1081 6.42
1081 6.01
1082 5.53
5 turns
BHP
10.58
10.10
9.69
9.20
8.76
8.25
7.84
7.33
6.75
-
CFM
9928
9575
9207
8833
8439
7996
7565
7045
-
RPM KW
1041 7.91
1040 7.52
1042 7.08
1043 6.72
1044 6.39
1044 6.03
1045 5.66
1047 5.20
6 turns
BHP
9.65
9.18
8.63
8.21
7.80
7.36
6.90
6.35
-
7.5 HP motor
25-Ton High Static Drive, Cooling Only, Bottom Duct Connection
1VP71 & 1B5V94
13000
12000
1 Turn
2 Turns
3 Turns
4 Turns
5 Turns
6 Turns
11000
SCFM
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW
14.05 11030 1146 10.55 12.87 10572 1111 9.50
13.57 10600 1147 10.00 12.20 10231 1112 9.11
13.17 10232 1147 9.63 11.75 9912 1112 8.87
12.51 9919 1148 9.28 11.32 9607 1114 8.39
11.98 9591 1149 8.93 10.90 9201 1114 8.01
11.50 9228 1150 8.48 10.35 8793 1115 7.55
11.04 8861 1151 8.12 9.91 8394 1116 7.13
10.51 8484 1153 7.58 9.25 8008 1117 6.86
9.98 8092 1154 7.26 8.86 7624 1118 6.37
9.49 7637 1155 6.67 8.14 7134 1119 5.99
8.86
3 turns
4 turns
10000
9000
8000
7000
6000
0.2
0.4
0.6
Johnson Controls Unitary Products
0.8
1.0
1.2
1.4
1.6
External Static ("WC)
1.8
2.0
2.2
2.4
2.6
45
284813-YIM-C-1008
TABLE 27: WR300 BLOWER PERFORMANCE - 25 TON HIGH STATIC DRIVE (GAS HEAT) DOWNFLOW
ESP
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
CFM
11593
11315
11014
10705
10406
10096
9759
9413
9035
8620
8121
7626
RPM KW
1216 12.03
1217 11.57
1217 11.16
1218 10.79
1219 10.47
1221 10.02
1222 9.59
1223 9.13
1225 8.70
1226 8.29
1227 7.70
1229 7.50
1 turn
15 HP motor
BHP
14.68
14.12
13.62
13.17
12.78
12.23
11.71
11.14
10.61
10.12
9.40
9.15
CFM
11147
10857
10555
10180
9853
9509
9159
8851
8465
8085
7635
-
RPM KW
1181 10.82
1181 10.45
1182 10.14
1183 9.64
1185 9.23
1186 8.85
1186 8.51
1187 8.09
1189 7.69
1190 7.31
1191 6.82
2 turns
10 HP motor
BHP
10.90
10.45
10.17
9.62
9.19
8.66
8.17
7.87
7.30
6.87
-
CFM
10016
9687
9346
8988
8623
8239
7832
7363
6847
-
RPM KW
1075 8.15
1076 7.78
1077 7.46
1078 7.09
1079 6.75
1080 6.36
1081 6.04
1081 5.65
1082 5.20
5 turns
BHP
9.95
9.49
9.11
8.65
8.23
7.76
7.37
6.89
6.34
-
CFM
9729
9384
9023
8656
8270
7836
7414
6904
-
RPM KW
1041 7.43
1040 7.07
1042 6.65
1043 6.32
1044 6.01
1044 5.67
1045 5.32
1047 4.89
6 turns
BHP
9.07
8.63
8.12
7.71
7.33
6.92
6.49
5.97
-
7.5 HP motor
25-Ton High Static Drive, Gas Heat, Bottom Duct Connection
1VP71 & 1B5V94
13000
12000
1 Turn
2 Turns
3 Turns
11000
SCFM
Blower Performance (Downflow Discharge)
BHP CFM RPM KW BHP CFM RPM KW
13.20 10809 1146 9.91 12.10 10361 1111 8.93
12.76 10388 1147 9.40 11.47 10026 1112 8.56
12.38 10027 1147 9.05 11.05 9714 1112 8.34
11.76 9721 1148 8.72 10.65 9415 1114 7.88
11.26 9399 1149 8.39 10.24 9017 1114 7.53
10.81 9043 1150 7.97 9.73 8617 1115 7.10
10.38 8684 1151 7.63 9.31 8226 1116 6.70
9.88 8314 1153 7.13 8.70 7848 1117 6.45
9.38 7930 1154 6.82 8.33 7472 1118 5.98
8.92 7484 1155 6.27 7.65 6991 1119 5.63
8.33
3 turns
4 turns
4 Turns
5 Turns
6 Turns
10000
9000
8000
7000
6000
0.2
46
0.4
0.6
0.8
1.0
1.2
1.4
1.6
External Static ("WC)
1.8
2.0
2.2
2.4
2.6
Johnson Controls Unitary Products
284813-YIM-C-1008
TABLE 28: STATIC RESISTANCES1
DESCRIPTION
WET INDOOR COIL
18 KW
36 KW
54 KW
72 KW
ELECTRIC HEAT OPTIONS
ECONOMIZER OPTION
HORIZONTAL DUCT CONNECTIONS2
1.
2.
4500
0.1
0.3
0.3
0.4
0.4
0.1
15 TON
6000
0.1
0.4
0.4
0.5
0.5
0.1
7500
0.1
0.4
0.5
0.5
0.5
0.1
0.1
0.2
0.3
RESISTANCE, IWG
CFM
20 TON
6000
8000
9000
0.1
0.1
0.2
0.4
0.4
0.5
0.4
0.5
0.5
0.5
0.5
0.6
0.5
0.5
0.6
0.1
0.1
0.2
0.2
0.3
0.5
7500
0.1
0.4
0.5
0.5
0.5
0.1
25 TON
8000
0.1
0.4
0.5
0.5
0.5
0.1
9000
0.2
0.5
0.5
0.6
0.6
0.2
0.3
0.3
0.5
Deduct these resistance values from the available external static pressures shown in the respective Blower Performance Table.
Since the resistance to air flow will be less for horizontal duct connections than for bottom duct connections, add these pressures to the ESP values
on the respective unit’s blower performance table.
TABLE 29: POWER EXHAUST PERFORMANCE
MOTOR
SPEED
HIGH*
MEDIUM
LOW
0.2
CFM
5250
4900
4400
KW
0.83
0.77
0.72
CFM
4500
3900
3700
STATIC RESISTANCE OF RETURN DUCTWORK, IWG
0.3
0.4
0.5
KW
CFM
KW
CFM
KW
0.85
4200
0.88
3750
0.93
0.79
3500
0.82
2900
0.85
0.74
3000
0.78
-
0.6
CFM
3000
-
KW
0.99
-
* Factory Setting
Power Exhaust motor is a 3/4 HP, PSC type with sleeve bearings, a 48 frame and inherent protection.
TABLE 30: BLOWER MOTOR AND DRIVE DATA
MODEL
SIZE
DRIVE
MOTOR1
BLOWER
RANGE
(RPM) HP FRAME EFF.
(%)
Standard 790/970
15 TON
High
Static
Low
Static
Low
Static
184 T
213 T
91
7.5
213 T
91
10
215 T
91
1000/1180 15
254 T
91
7.5
213 T
91
910/1100
900/1100
DESIGNATION
OUTSIDE
DIA.
(IN.)
PITCH
DIA.
(IN.)
1VP62
5.95
4.9-5.92
1VP68
6.55
5.5-6.5
89.5
940/1130 7.5
20 TON Standard
High
Static
5
ADJUSTABLE MOTOR PULLEY
1VP71
7.1
5.4-6.6
1VP65
6.0
4.8-6.0
BORE DESIG(IN.) NATION
BK105
10.25
9.9
1-3/8
BK90
8.75
8.4
BK100
9.75
9.4
1.
2.
1000/1200
254 T
91
1VP71
7.1
5.5-6.5
PITCH
BORE DESIGLENGTH QTY.
(IN.) NATION
(IN.)
1
BX81
82.8
1
1-3/16
BX81
82.8
1
BX78
79.8
1-3/8
1-5/8
1-3/8
1-3/16
1B5V94
15
OUTSIDE PITCH
DIA.
DIA.
(IN.)
(IN.)
1-1/8
25 TON Standard
High
Static
BELT
(NOTCHED)
FIXED BLOWER PULLEY
1-5/8
9.7
9.5
1
1-7/16
BX81
82.8
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 pully below 1 turn open.
Johnson Controls Unitary Products
47
284813-YIM-C-1008
WR180 Charging Chart
Outdoor Temp (ºF)
340
Discharge Pressure (psi)
320
115º
300
280
105º
260
95º
240
220
85º
200
75º
180
65º
160
140
60
65
70
75
80
85
Suction Pressure (psi)
90
95
100
1. Make sure that both condenser fans are running when charging. One fan may switch off at
lower ambient temperatures making the chart above inaccurate.
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 16 - CHARGING CHART - 15 TON
WR240 Charging Chart
Outdoor Temp (ºF)
Discharge Pressure (psi)
350
330
115º
310
290
105º
270
250
95º
230
85º
75º
65º
210
190
170
150
60
65
70
75
80
Suction Pressure (psi)
85
90
1. Make sure that both condenser fans are running when charging. One fan may switch off at lower ambient
temperatures making the chart above inaccurate.
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 17 - CHARGING CHART - 20 TON
48
Johnson Controls Unitary Products
284813-YIM-C-1008
WR300 Charging Chart
Outdoor Temp (ºF)
350
115º
Discharge Pressure (psi)
330
105º
310
290
95º
270
85º
250
230
75º
210
65º
190
170
150
55
60
65
70
75
Suction Pressure (psi)
80
85
1. Make sure that both condenser fans are running when charging. One fan may switch off at
lower ambient temperatures making the chart above inaccurate.
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 - 25 TON
PHASING
Check for proper compressor rotation. If the blower or
compressors rotate in the wrong direction at start-up,
the electrical connection to the unit is misphased.
Change the incoming line connection phasing to obtain
proper rotation. (Scroll compressors operate in only
one direction. If the scroll is drawing low amperage,
has similar suction and discharge pressures, or producing a high noise level, the scroll is misphased).
Scroll compressors require proper rotation to
operate correctly. Do not change the internal
wiring to make the blower, condenser fans, or
compressor rotate correctly. Change the
incoming power to the main terminal block to
obtain proper rotation.
CHECKING SUPPLY AIR CFM
The RPM of the supply air blower will depend on the
required CFM, the unit accessories or options and the
static resistances of both the supply and the return air
duct systems. With this information, the RPM for the
supply air blower and the motor pulley adjustment
(turns open) can be determined from the Blower Performance Data Tables.
Johnson Controls Unitary Products
Belt drive blower systems MUST be adjusted to the
specific static and CFM requirements for the
application. The belt drive blowers are NOT set at the
factory for any specific static or CFM. Adjustments of
the blower speed an belt tension are REQUIRED.
Tighten blower pulley and motor sheave set screws
after these adjustments. Re-checking set screws
after 10-12 hrs. run time is recommended.
Note the following:
1. The supply air CFM must be within the limitations
shown in the Unit Application Data Table 1.
2. Pulleys can be adjusted in half turn increments.
3. The tension on the belt should be adjusted as
shown in the Belt Adjustment Figure 19.
4. Tighten blower pulley and motor sheave set screws
after any adjustments. Re-check set screws after
10-12 hrs. run time is recommended.
49
284813-YIM-C-1008
PROCEDURE FOR ADJUSTING BELT TENSION:
1. Loosen nuts (A) (top and bottom).
2. Adjust the tension by turning bolt (B).
3. Never loosen nuts (C) from each other.
4. Use a belt tension checker to apply a perpendicular force to be one belt at the
midpoint of the span as shown. The deflection force should be applied
until a specific deflection distance of 4mm (5/32") is obtained. To determine
the deflection distance from normal position, use a straight edge from
sheave to sheave as a reference line. The recommended deflection force
is as follows:
SPAN LENGTH
DEFL FORCE
NOTE: The tubes must be inserted and held in a position perpendicular to the air flow so that velocity pressure will not affect the static pressure
readings.
3. Using an inclined manometer, determine the pressure drop across a dry evaporator coil. Since the
moisture on an evaporator coil may vary greatly,
measuring the pressure drop across a wet coil
under field conditions would be inaccurate. To
assure a dry coil, the compressors should be deactivated while the test is being run.
PRESSURE DROP ACROSS A DRY COIL vs SUPPLY AIR CFM
(B)
1.2
WR24 & WR30
1.1
*Never Loosen
FIGURE 19 - BELT ADJUSTMENT
AIR BALANCE
PRESSURE DROP (IWG)
(A)
(C)*
Tension new belts at the max. deflection force recommended for the belt
section. Check the belt tension at least two times during the first 24 hours of
operation. Any re-tensioning should fall between the min. and max.
deflection force values.
5. After adjusting, re-tighten nuts (A).
1
0.9
0.8
0.7
WR18
0.6
0.5
0.4
0.3
0.2
0.1
4000
5000
6000
7000
8000
9000
10000 11000 12000
NOMINAL AIR FLOW (SCFM)
On VAV units be certain that the VFD drive is
set to maximum output, exhaust dampers are
closed and individual space damper boxes are
full open.
VFD units with bypass must not be in bypass
mode (‘LINE’ position) unless all individual
space dampers are full open.
Start the supply air blower motor. Adjust the resistances in both the supply and the return air duct systems to balance the air distribution throughout the
conditioned space. The job specifications may require
that this balancing be done by someone other than the
equipment installer.
To check the supply air CFM after the initial balancing
has been completed:
1. Remove the two 5/16" dot plugs from the blower
motor and the filter access panels shown in Figures 12 and 13.
2. Insert at least 8" of 1/4 inch tubing into each of
these holes for sufficient penetration into the air
flow on both sides of the indoor coil.
50
FIGURE 20 - PRESSURE DROP ACROSS A DRY
INDOOR COIL VS SUPPLY AIR CFM
FOR ALL UNIT TONNAGES
4. Knowing the pressure drop across a dry coil, the
actual CFM through the unit can be determined
from the curve in Pressure Drop vs. Supply Air
CFM Figure 20.
Failure to properly adjust the total system air
quantity and static pressure can result in
extensive system damage.
After readings have been obtained, remove the tubes
and reinstall the two 5/16" dot plugs that were removed
in Step 1.
NOTE: DE-ENERGIZE THE COMPRESSORS BEFORE TAKING ANY TEST MEASUREMENTS
TO ASSURE A DRY INDOOR COIL.
Johnson Controls Unitary Products
284813-YIM-C-1008
OPERATION
SEQUENCE OF OPERATIONS OVERVIEW
For these units, the thermostat makes a circuit
between "R" and "Y1" for the first stage of cooling.
The call is passed to the unit control board (UCB),
which then determines whether the requested operation is available and, if so, which components to energize.
For gas heating, the UCB monitors the "W1" call but
does not handle the operation of the gas furnace. An
ignition control board controls the gas heater operation.
For electric heat units, the UCB passes the call to the
electric heater.
In both cases, when the "W1" call is sensed, the indoor
air blower is energized following a specified heating
delay.
If at any time a call for both heating and cooling are
present, the heating operation will be performed. If
operating, the cooling system is halted as with a completion of a call for cooling. Heating always takes priority.
COOLING SEQUENCE OF OPERATION
CONTINUOUS BLOWER
By setting the room thermostat fan switch to "ON," the
supply air blower will operate continuously.
INTERMITTENT BLOWER
With the room thermostat fan switch set to "AUTO" and
the system switch set to either the "AUTO" or "HEAT"
settings, the blower is energized whenever a cooling or
heating operation is requested. The blower is energized after any specified delay associated with the
operation.
When energized, the indoor blower has a minimum run
time of 30 seconds. Additionally, the indoor blower has
a delay of 10 seconds between operations.
OPTIONAL VAV BLOWER OPERATION
For units with VFD, the speed of the indoor blower
motor is controlled by duct static pressure. The duct
static set point is the pressure that the drive will maintain when operating the unit in VAV mode. If the duct
static pressure reaches or exceeds the high-limit setpoint, then the supply fan motor will be shutdown.
Johnson Controls Unitary Products
If the unit is operated with the manual bypass
switch in the LINE (BYPASS) position and
there are VAV boxes present in the duct system, then boxes must be driven to the full-open
position using a customer-supplied power
source to prevent over-pressurizing and possible damage to the ductwork.
NO OUTDOOR AIR OPTIONS
When the thermostat calls for the first stage of cooling,
the low-voltage control circuit from "R" to "Y1" and "G"
is completed. For first stage cooling, compressor #1,
condenser fan motor #1, and condenser fan motor #2
(if the ambient temperature is above 60°F), is energized. After completing the specified fan on delay for
cooling, the UCB will energize the blower motor.
When the thermostat calls for the second stage of cooling, the low-voltage control circuit from "R" to "Y2" is
completed. Compressor #2, condenser fan motor #3,
and condenser fan motor #4 (if the ambient temperature is above 60°F), is energized, provided it has not
been locked-out.
If there is an initial call for both stages of cooling, the
UCB will delay energizing compressor #2 by 30 seconds in order to avoid a higher than normal current in
rush.
Once the thermostat has been satisfied, it will de-energize Y1 and Y2. If the compressors have satisfied their
minimum run times, the compressors and condenser
fans are de-energized. Otherwise, the unit operates
each cooling system until the minimum run times for
the compressors have been completed. Upon the final
compressor de-energizing, the blower is stopped following the elapse of the fan off delay for cooling.
To be available, a compressor must not be locked-out
due to a high or low-pressure switch or freezestat trip
and the anti-short cycle delay (ASCD) must have
elapsed.
ECONOMIZER WITH SINGLE ENTHALPY SENSOR -
When the room thermostat calls for "first-stage" cooling, the low voltage control circuit from "R" to "G" and
"Y1" is completed. The UCB energizes the blower
motor (if the fan switch on the room thermostat is set in
the "AUTO" position) and drives the economizer damp-
51
284813-YIM-C-1008
ers from fully closed to their minimum position. If the
enthalpy of the outdoor air is below the setpoint of the
enthalpy controller (previously determined), "Y1" energizes the economizer. The dampers will modulate to
maintain a constant supply air temperature as monitored by the discharge air sensor. If the outdoor air
enthalpy is above the setpoint, "Y1" energizes compressor #1, condenser fan motor #1, and condenser
fan motor #2 (if the ambient temperature is above
60°F).
When the thermostat calls for "second-stage" cooling,
the low voltage control circuit from "R" to "Y2" is completed. The UCB energizes the first available compressor If the enthalpy of the outdoor air is below the
setpoint of the enthalpy controller (i.e. first stage has
energized the economizer), "Y2" will energize compressor #1. If the outdoor air is above the setpoint, "Y2"
will energize compressor #2.
Once the thermostat has been satisfied, it will de-energize Y1 and Y2. If the compressors have satisfied their
minimum run times, the compressors and condenser
fans are de-energized. Otherwise, the unit operates
each cooling system until the minimum run times for
the compressors have been completed. Upon the final
compressor de-energizing, the blower is stopped following the elapse of the fan off delay for cooling, and
the economizer damper goes to the closed position. If
the unit is in continues fan operation the economizer
damper goes to the minimum position.
ECONOMIZER WITH DUAL ENTHALPY SENSORS -
The operation with the dual enthalpy sensors is identical to the single sensor except that a second enthalpy
sensor is mounted in the return air. This return air sensor allows the economizer to choose between outdoor
air and return air, whichever has the lowest enthalpy
value, to provide maximum operating efficiency.
ECONOMIZER (SINGLE OR DUAL ENTHALPY) WITH
POWER EXHAUST -
This system operates as specified above with one
addition. The power exhaust motor is energized 45
seconds after the actuator position exceeds the
exhaust fan setpoint on the economizer control. When
the power exhaust is operating, the second stage of
mechanical cooling will not operate. As always, the "R"
to "G" connection provides minimum position but does
not provide power exhaust operation.
52
ECONOMIZER WITH OPTIONAL VAV OR INTELLI-COMFORT™ CONTROL
The position of the outside air and return air dampers
are controlled through a 2-10 VDC signal from the VAV
or Intelli-Comfort™ contro l board. The economizer is
enabled only in Occupied or Recovery mode. When the
control is not powered or is in Unoccupied mode, the
outside air dampers will be closed. When the supply
fan is powered and there is no Y1 call, or if free-cooling
is unavailable, the control opens the economizer
dampers to the minimum position setting.
Free-cooling is available if the outdoor air temperature
meets one of the three criteria discussed below, based
upon the unit's configuration.
•
Dry Bulb: The control refers to input from the Outside Air Temperature sensor and will allow freecooling when the outdoor temperature is less than
both the First-Stage SAT Control setpoint plus 5 °F,
and the Economizer OAT Enable setpoint.
•
Single Enthalpy (optional): A field-installed, Outdoor Air Humidity sensor is connected to the control. When the measured outdoor enthalpy is
below the Outside Air Enthalpy setpoint, and the
outdoor temperature is less than the First-Stage
SAT Control setpoint plus 5 °F, free-cooling is
available.
•
Dual Enthalpy (optional): Both the field-installed
Outdoor Air Humidity and the Return Air Humidity sensors are connected to the control. When
the measured outdoor air enthalpy is less than
the measured return air enthalpy, and the outdoor temperature is less than the First-Stage
SAT Control setpoint plus 5 °F, free-cooling is
available.
If free-cooling is available with a Y1 call, then the control modulates the economizer dampers to maintain the
First-Stage SAT Control setpoint, plus or minus one
degree. If free-cooling is unavailable, then 1st-stage
mechanical cooling is initiated.
If at anytime the outdoor air temperature rises above
the First-Stage SAT Control setpoint plus 5 °F, while
free-cooling is available, then a Y1 call will also initiate
1st-stage mechanical cooling.
For a Y2 call, free-cooling is available based upon the
criteria described above, except a Second-Stage SAT
Control setpoint is used in the determination.
Johnson Controls Unitary Products
284813-YIM-C-1008
Once the call for cooling has been satisfied, it will deenergize any compressors and condenser fans, after
the minimum compressor run times have been satisfied. Otherwise, the unit operates each cooling system
until the minimum run times for the compressors have
been completed.
Upon de-energizing the final compressor, the blower
will continue to run with the economizer damper in its
minimum position if in the Occupied mode; otherwise,
the blower will stop following the elapse of the fan-off
delay for cooling, and the economizer outdoor damper
will close.
ECONOMIZER WITH OPTIONAL VAV BLOWER WITH
POWER EXHAUST
HIGH-PRESSURE LIMIT SWITCH
During cooling operation, if a high-pressure limit switch
opens, the UCB will de-energize the associated compressor, initiate the ASCD (Anti-short cycle delay), and,
if the other compressor is idle, stop the condenser
fans. If the call for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the halted
compressor.
Should a high-pressure switch open three times within
two hours of operation, the UCB will lock-out the associated compressor and flash a code (see Table 36). If
the other compressor is inactive, the condenser fans
will be de-energized.
LOW-PRESSURE LIMIT SWITCH
The power exhaust motor is energized via the controller's EXH~ terminal and the ER relay, based on the
position of the economizer damper parameter settings
in the VAV control. Minimum run time is 10 seconds;
minimum off time is 60 seconds. The outlet pressure of
the power exhaust fan forces the barometric relief
dampers open; gravity closes the dampers when the
exhaust fan is off.
ECONOMIZER WITH OPTIONAL INTELLI-COMFORT™
WITH POWER EXHAUST
The power exhaust motor is energized via the exhaust
relay based on the position of the economizer actuator's auxiliary switch adjustment screw. The adjustment
screw represents the outdoor damper position at which
to activate power exhaust, and can be set between 25
to 85 degrees open. The outlet pressure of the power
exhaust fan forces the barometric relief dampers open;
gravity closes the dampers when the exhaust fan is off.
MOTORIZED OUTDOOR AIR DAMPERS -
This system operation is the same as the units with no
outdoor air options with one exception. When the "R" to
"G" circuit is complete, the motorized damper drives
open to a position set by the thumbwheel on the
damper motor. When the "R" to "G" circuit is opened,
the damper spring returns fully closed.
COOLING OPERATION ERRORS
Each cooling system is monitored for operation outside
of the intended parameters. Errors are handled as
described below. All system errors override minimum
run times for compressors.
Johnson Controls Unitary Products
The low-pressure limit switch is not monitored during
the initial 30 seconds of a cooling system's operation.
For the following 30 seconds, the UCB will monitor the
low-pressure switch to ensure it closes. If the low-pressure switch fails to close after the 30-second monitoring phase, the UCB will de-energize the associated
compressor, initiate the ASCD, and, if the other compressor is idle, stop the condenser fans.
Once the low-pressure switch has been proven (closed
during the 30-second monitor period described above),
the UCB will monitor the low-pressure limit switch for
any openings. If the low-pressure switch opens for
greater than 5 seconds, the UCB will de-energize the
associated compressor, initiate the ASCD, and, if the
other compressor is idle, stop the condenser fans.
If the call for cooling is still present at the conclusion of
the ASCD, the UCB will re-energize the halted compressor.
Should a low-pressure switch open three times within
one hour of operation, the UCB will lock-out the associated compressor and flash a code (Table 36). If the
other compressor is inactive, the condenser fans will
be de-energized.
FREEZESTAT
During cooling operation, if a freezestat opens, the
UCB will de-energize the associated compressor, initiate the ASCD, and, if the other compressor is idle, stop
the condenser fans. If the call for cooling is still present
at the conclusion of the ASCD, the UCB will re-energize the halted compressor.
53
284813-YIM-C-1008
Should a freezestat open three times within two hours
of operation, the UCB will lock-out the associated compressor and flash a code (Table 36). If the other compressor is inactive, the condenser fans will be deenergized.
LOW AMBIENT COOLING
To determine when to operate in low ambient mode,
the UCB has a pair of terminals connected to a temperature-activated switch set at 45ºF. When the low ambient switch is closed and the thermostat is calling for
cooling, the UCB will operate in the low ambient mode.
Low ambient mode operates the compressors in this
manner: 10 minutes on, 5 minutes off. The indoor
blower is operated throughout the cycle. The 5-minute
off period is necessary to defrost the indoor coil.
Low ambient mode always begins with compressor
operation. Compressor minimum run time may extend
the minutes of compressor operation. The defrost cycle
will begin immediately following the elapse of the minimum run time.
When operating in low ambient mode, the UCB will not
lockout the compressors due to a freezestat trip. However, a freezestat trip will de-energize the associated
compressor. If the call for cooling is still present at the
end of the ASCD and the freezestat has closed, the
unit will resume operation.
SAFETY CONTROLS
The unit control board monitors the following inputs for
each cooling system:
1. A suction line freezestat to protect against low
evaporator temperatures due to a low airflow or a
low return air temperature, (opens at 26 ± 5 °F and
resets at 38 ± 5°F).
2. A high-pressure switch to protect against excessive discharge pressures due to a blocked condenser coil or a condenser motor failure, (opens at
405 ± 7 psig and resets at 265 ± 20 psig).
3. A low-pressure switch to protect against loss of
refrigerant charge, (opens at 22 ± 5 psig and resets
at 45 ± 5 psig).
The above pressure switches are hard-soldered to the
unit. The refrigeration systems are independently monitored and controlled. On any fault, only the associated
system will be affected by any safety/preventive action.
54
The other refrigerant system will continue in operation
unless it is affected by the fault as well.
The unit control board monitors the temperature limit
switch of electric heat units and the temperature limit
switch and the gas valve of gas furnace units.
COMPRESSOR PROTECTION
The compressors also have inherent (internal) protection. If there is an abnormal temperature rise in a compressor, the protector will open to shut down the
compressor. The UCB incorporates features to minimize compressor wear and damage. An anti-short
cycle delay (ASCD) is utilized to prevent operation of a
compressor too soon after its previous run. Additionally, a minimum run time is imposed any time a compressor is energized.
The ASCD is initiated on unit start-up and on any compressor reset or lock-out.
FLASH CODES
The UCB will initiate a flash code associated with
errors within the system. Refer to UNIT CONTROL
BOARD FLASH CODES Table 36.
RESET
Remove the call for cooling, by raising thermostat setting higher than the conditioned space temperature.
This resets any pressure or freezestat flash codes.
REHEAT MODE SEQUENCE OF OPERATION
The reheat control board allows the user to select two
different modes of operation via a jumper connection
on the board. (See Figure 21.) Each mode is described
below. Refer to Figures 21 - 23 when reading this section.
“NORMAL” MODE
When the reheat control board (RCB) detects a need
for dehumidification (24VAC) at "HUM" via the field
supplied dehumidistat connected to RHTB-1 and
RHTB-2 and there is not a call for cooling, it energizes
the hot gas relay (HGR), which energizes the 3-way
valve (SOL 3), the condenser coil valve (SOL 2), and
de-energizes the reheat coil bleed valve (SOL 1). The
Y1 signal is passed to the unit control board (UCB),
which engages circuit # 1, resulting in circuit #1 reheat
mode operation.
When the room thermostat calls for first stage cooling,
with or without a call for dehumidification, the RCB
senses a signal through "Y1", de-energizing the HGR,
Johnson Controls Unitary Products
284813-YIM-C-1008
which de-energizes SOL 3 and SOL 2, and energizes
SOL 1, engaging circuit # 1, resulting in circuit #1 cooling mode operation.
When the room thermostat calls for second stage cooling, the RCB senses a signal through "Y1" & "Y2" and
engages circuit #1 and circuit #2 in the cooling mode.
Indoor blower operation is initiated upon a call for first
stage cooling, second stage cooling or dehumidification.
Anytime there is a call for 2 stages of cooling, the unit
will not operate in the reheat mode, even if there is a
call for dehumidification at "HUM".
The unit will not operate in the reheat mode if there is
any call for heating.
On units with economizers, the unit will not operate in
the reheat mode if there is a call for cooling and the
economizer is operating as first stage of cooling.
All safety devices function as previously described.
"ALTERNATE” MODE
When the RCB detects a need for dehumidification
(24VAC) at "HUM" via the field supplied dehumidistat
Johnson Controls Unitary Products
connected to RHTB-1 and RHTB-2, and there is not a
call for cooling, it energizes the HGR, which energizes
the SOL 3, SOL 2, and de-energizes SOL 1. The unit
then operates with circuit #1 in reheat mode and circuit
#2 in cooling mode.
When the room thermostat calls for first stage cooling
while there is still a call for dehumidification, no operational change is made. The call for cooling is ignored
and the unit continues to operate with circuit #1 in
reheat mode and circuit #2 in cooling mode.
When the room thermostat calls for second stage cooling, the RCB senses a signal through "Y1" & "Y2" and
de-energizes the HGR, which de-energizes SOL 3 and
SOL 2, and energizes SOL 1. Both circuits operate in
the cooling mode.
Indoor blower operation is initiated upon a call for first
stage cooling, second stage cooling or dehumidification.
Anytime there is a call for 2 stages of cooling, the unit
will not operate in the reheat mode, even if there is still
a call for dehumidification at "HUM".
The unit will not operate in the reheat mode if there is
any call for heating.
All safety devices function as previously described.
55
284813-YIM-C-1008
R
Y1
P4
Y2
K1
G
W1
K2
W2
OCC
K4
C
K3
COM
`
P6
P5
P3
HGRR
HGR
MODE
SELECTION
JUMPER
HUM
DEHUMIDISTAT
HARNESS
CONNECTION
FIGURE 21 - REHEAT CONTROL BOARD
56
Johnson Controls Unitary Products
284813-YIM-C-1008
UCB
RHB
UNIT CONTROL
BOARD
REHEAT CONTROL
BOARD
HUM
HUMIDIFY
TERMINAL
RHR
REHEAT
RELAY
RHTB
REHEAT
TERMINAL
BLOCK
FIGURE 22 - REHEAT CONTROLS - PART 1
REHEAT
SOLENOID 1
REHEAT
SOLENOID 3
REHEAT
SOLENOID 2
UCB
UNIT CONTROL
BOARD
RHB
REHEAT
CONTROL
BOARD
FIGURE 23 - REHEAT CONTROLS - PART 2
Johnson Controls Unitary Products
57
284813-YIM-C-1008
Check
Valve
Piping T
TXV
HPS
Condenser
Fan
Check
Valve
Air Flow
Air Flow
Condenser
Coil
Indoor Blower
FS
Air Flow
Evaporator
Coil
Hot Gas
Coil
Open in
Cooling
Refrigerant flow in cooling mode
Refrigerant flow in reheat mode
Bleed
Line to clear
Suction
line
the Hot Gas Coil
bleed
when it is not in use
HPS
LPS
Sol 1
Piping T
Accumulator
Sol 2
C1
Hot Gas Re-Heat
Solenoid Valve
(Sol 3)
Compressor
Open in
Reheat
FIGURE 24 - SYSTEM PIPING SCHEMATIC
ELECTRIC HEATING SEQUENCE OF OPERATIONS
The following sequence describes the operation of the
electric heat section.
For units with VFD and electric heat, the speed
of the indoor blower motor continues to be controlled by duct static pressure via the VAV control board.
If there are VAV boxes present in the duct system, the boxes must be driven to the full-open
position using a customer-supplied power
source to assure adequate airflow across the
heating elements.
58
Single-stage heating (applies only to 18 KW heater, all
other heaters MUST use a two-stage thermostat):
a.
Upon a call for heat by the thermostat, the heater
contactor (6M) will be energized. After completing
the specified fan on delay for heating, the UCB will
energize the blower motor.
b.
The thermostat will cycle the electric heat to satisfy
the heating requirements of the conditioned space.
Two-stage heating (applies to all heaters except 18
KW):
a.
Upon a call for first-stage heat by the thermostat, the
heater contactor (6M) (6M & 7M on 72 KW, 240V)
will be energized. After completing the specified fan
on delay for heating, the UCB will energize the
blower motor.
Johnson Controls Unitary Products
284813-YIM-C-1008
If the second stage of heat is required, heater
contactor (7M) will be energized. Note that on
the 54 KW, 240V heater, heater contactors
(7M & 8M) will be energized and on the 72 KW,
240V heater, heater contactors (8M & 9M) will
be energized. After completing the specified
fan on delay for heating, the UCB will energize
the blower motor.
b.
The thermostat will cycle the electric heat to satisfy
the heating requirements of the conditioned space.
NOTE: All 240 & 480V heaters are provided with manual reset backup protection limits. These will
de-energize the heaters should the primary
limit fail to open or the contactors fail to open in
a failure mode.
cated in the Limit Control Setting Table 31. It is a
manual reset limit. These limit switches will deenergize the heaters should the primary limit fail to
open or the contactors fail to open in a failure
mode.
TABLE 31: LIMIT CONTROL SETTING
UNIT
(Tons)
VOLTAGE
15
20, 25
240
240
HEATING OPERATION ERRORS
TEMPERATURE LIMIT
If the UCB senses zero volts from the high temperature
limit, the indoor blower motor is immediately energized.
This limit is monitored regardless of unit operation status, i.e. the limit is monitored at all times.
If the temperature limit opens three times within one
hour, it will lock-on the indoor blower motor and a flash
code is initiated (See Table 36).
SAFETY CONTROLS
The unit control board monitors the temperature limit
switch of electric heat units.
The control circuit includes the following safety controls:
1. Temperature Limit Switch (TLS 1, 2).
This control is located inside the heater compartment and is set to open at the temperature indicated in the Limit Control Setting Table 31. It resets
automatically. The limit switch operates when a
high temperature condition, caused by inadequate
supply air flow occurs, thus shutting down the
heater and energizing the blower.
2. Temperature Limit Switch (TLS 3, 4, 5 and 6).
This control is located inside the heater compartment and is set to open at the temperature indi-
Johnson Controls Unitary Products
15, 20,
25
15, 20,
25
460
600
HEATER
kW
TEMPERATURE
LIMIT SWITCH 1, 2
OPENS, ºF
TEMPERATURE
LIMIT SWITCH 3,
4, 5, 6 OPENS, ºF
18
120
170
36
120
170
54
120
170
72
120
170
18
140
200
36
140
200
54
140
200
72
140
200
18
120
170
36
120
170
54
120
170
72
120
170
18
120
-
36
120
-
54
120
-
72
120
-
FLASH CODES
The UCB will initiate a flash code associated with
errors within the system. Refer to UNIT CONTROL
BOARD FLASH CODES Table 36.
RESET
Remove the call for heating by lowering the thermostat
setting lower than the conditioned space temperature.
This resets any flash codes.
HEAT ANTICIPATOR SETPOINTS
It is important that the anticipator setpoint be correct.
Too high of a setting will result in longer heat cycles
and a greater temperature swing in the conditioned
space. Reducing the value below the correct setpoint
will give shorter "ON" cycles and may result in the lowering of the temperature within the conditioned space.
Refer to Table 32 for the required heat anticipator setting.
59
284813-YIM-C-1008
TABLE 32: ELECTRIC HEAT ANTICIPATOR
SETPOINTS
HEATER
KW
VOLTAGE
SETTING, AMPS
TH1
TH2
18
0.29
-
36
0.29
0.29
54
208/230-3-60
0.29
0.58
72
0.29
0.58
18
0.29
-
0.29
0.29
0.29
0.29
0.29
0.29
36
54
460-3-60
72
18
0.29
-
36
0.29
0.29
0.29
0.29
0.29
0.29
54
72
575-3-60
GAS HEATING SEQUENCE OF OPERATIONS
The following sequence describes the operation of the
gas heat section.
For units with VFD and gas heat, the speed of
the indoor blower motor continues to be controlled by duct static pressure via the VAV control board.
If there are VAV boxes present in the duct system, the boxes must be driven to the full-open
position using a customer-supplied power
source to assure adequate airflow across the
heat exchanger tubes.
When the thermostat calls for the first stage of heating,
the low-voltage control circuit from "R" to "W1" and "G"
is completed, thru the UCB. The heat relay "RW1" is
energized. The "RW1-2" contacts close energizing the
draft motor control. The draft motor control contacts
close and start the draft motor. As the speed of the
draft motor reaches approximately 2500 RPM, the centrifugal switch contact, located on the end of the draft
motor shaft, closes to power the first stage ignition
module "IC1", thru the "RW1-1 contacts.
Ignition module "IC1" will immediately start the first
stage igniter sparking and will open the redundant
valve located inside the first stage main gas valve
"GV1" to allow a flow of gas to only the first stage carry-
60
over tube. Only after the pilot flame has been ignited
and the presence of pilot flame detected at the "IC1" by
a signal sent back through the flame sensor is sparking
terminated and the first stage main gas valve opened.
Gas flows into each of the main burners and is ignited
from the carryover tube flame.
After completing the specified fan on delay for heating,
the UCB will energize the blower motor.
If "IC1" fails to detect a pilot flame, it will continue to try
for a maximum of 85 seconds to ignite the pilot tube. If
the pilot flame is not detected, then "IC1" will lock out
first stage furnace operation for five minutes or until
24V power is removed from the module either at the
unit or by resetting the room thermostat.
When the thermostat calls for the second stage of
heating, the low-voltage control circuit from "R" to "W2"
is completed, thru the UCB. Heat relay "RW2" is energized. The "RW2-1" contact is closed energizing the
second stage ignition module "IC2". "IC2" will immediately start the second stage igniter sparking and will
open the redundant valve located inside the second
stage main gas valve "GV2" to allow a flow of gas to
the second stage carryover tube. Only after the pilot
flame has been ignited and the presence of pilot flame
detected at "IC2" by a signal sent back through the
flame sensor is sparking terminated and the main gas
valve opened.
Gas flows into each of the second stage main burners
and is ignited from the carryover tube flame.
If "IC2" fails to detect a pilot flame, it will continue to try
for a maximum of 85 seconds to ignite the pilot tube. If
the pilot flame is not detected, then "IC2" will lock out
first stage furnace operation for five minutes or until
24V power is removed from the module either at the
unit or by resetting the room thermostat.
NOTE: That the second stage furnace can operate
even if first stage has locked out.
When the thermostat satisfies de-energizing the
"RW2"and "RW1", thus opening all gas valves. The
blower motor will continue to run after the furnace is
shut down until the specified fan off delay for heating
has been satisfied. The UCB will de-energize the
blower motor.
Johnson Controls Unitary Products
284813-YIM-C-1008
REDUNDANT
VALVE
MAIN VALVE
SAFETY CONTROLS
GAS MAIN
GAS
VALVE
If voltage has been sensed at the GV for at least 15
seconds during the fan on delay for heating and GV
voltage or "W1" is lost, the indoor blower is forced on
for the length of the fan off delay for heating.
TO PILOT BURNER
TO MAIN
BURNER
FIGURE 25 - GAS VALVE PIPING
The unit control board monitors the temperature limit
switch and the gas valve of gas furnace units.
The control circuit includes the following safety controls:
When the thermostat calls for the first stage of heating,
the low-voltage control circuit from "R" to "W1" is com1. Limit Control (LS).
pleted. A call for heat passes through the UCB to the
ignition control board (ICB). The UCB monitors the
This control is located inside the heat exchanger
"W1" call and acts upon any call for heat. Once voltage
compartment and is set to open at the temperature
has been sensed at “W1”, the UCB will initiate the fan
indicated in the Limit Control Setting Table 33. It
on delay for heating, energizing the indoor blower after
resets automatically. The limit switch operates
the specified delay has elapsed.
when a high temperature condition, caused by
inadequate supply air flow occurs, thus shutting
When the thermostat has been satisfied, heating calls
down the ignition control and closing the main gas
are ceased. The GV is immediately de-energized. The
valves and energizing the blower.
blower is de-energized after the fan off delay for heating has elapsed. The draft motor performs a 25-second
2. Centrifugal Switch (CS).
post purge.
If the draft motor should fail, the centrifugal switch
GAS HEATING OPERATION ERRORS
attached to the shaft of the motor prevents the ignition controls and gas valves from being energized.
TEMPERATURE LIMIT
If the UCB senses zero volts from the high temperature
limit, the indoor blower motor is immediately energized.
When the UCB again senses 24 volts from the temperature limit, the draft motor will perform a 25-second
post-purge and the indoor blower will be de-energized
following the elapse of the fan off delay for heating.
This limit is monitored regardless of unit operation status, i.e. the limit is monitored at all times.
If the temperature limit opens three times within one
hour, it will lock-on the indoor blower motor and a flash
code is initiated (See Table 36).
GAS VALVE
The UCB continuously monitors the GV. Any time the
UCB senses voltage at the GV without a call for heat
for a continuous five-minute period, the UCB will lockon the indoor blower and a flash code is initiated
(Table 36). When voltage is no longer sensed at the
GV, the UCB will de-energize the indoor blower following the elapse of the fan off delay for heating.
Johnson Controls Unitary Products
3. Redundant Gas Valve.
There are two separate gas valves in the furnace.
Each valve contains a main and a redundant valve.
The redundant valves are located upstream of the
main gas valves. Should either or both of the main
gas valves fail in the open position the redundant
valves serve as back-ups and shut off the flow of
gas.
4. Flame Sensor Rod / 100% Ignition Control LockOut.
The flame rods and controls are located per Proper
Flame Adjustment Figure 28. If an ignition control
fails to detect a signal from the flame sensor indicating the pilot flame is properly ignited, then the
main gas valve will not open. It will continue to try
and ignite the pilot for a maximum of 85 seconds,
then if the pilot flame is not detected, the ignition
control will lock out furnace operation until 24V
power is removed from the module either at the
unit or by resetting the room thermostat.
61
284813-YIM-C-1008
5. Rollout Switch.
RESETS
This switch is located above the main burners in
the control compartment, which in the event of a
sustained main burner rollout shuts off and locks
out both ignition controls closing both gas valves.
The ignition controls lock out furnace operation
until 24V power is removed from the controls either
at the unit or by resetting the room thermostat.
NOTE: The auto reset rollout switch must reset before
allowing furnace operation.
6. Auxiliary limit switch (AUX) -
Remove the call for heating by lowering the thermostat
setting lower than the conditioned space temperature.
This resets any flash codes.
HEAT ANTICIPATOR SETPOINTS
It is important that the anticipator setpoint be correct.
Too high of a setting will result in longer heat cycles
and a greater temperature swing in the conditioned
space. Reducing the value below the correct setpoint
will give shorter "ON" cycles and may result in the lowering of the temperature within the conditioned space.
TABLE 34: GAS HEAT ANTICIPATOR SETPOINTS
This control is located inside the heat exchanger
compartment and is set to open at 190°F. It is a
manual reset switch. If AUX trips, then the primary
limit has not functioned correctly. Replace the primary limit.
Honeywell VR8440
White-Rodgers 36C68
ANTICIPATOR SETPOINT
1st STAGE
2nd STAGE
0.30 amp
0.11 amp
START-UP (COOLING)
TABLE 33: LIMIT CONTROL SETTING
CAPACITY, MBH
GAS VALVE
UNITS
(Tons)
INPUT
OUTPUT
LIMIT CONTROL
OPENS, ºF
15, 20, 25
300
240
195
15, 20, 25
400
320
195
PRESTART CHECK LIST
After installation has been completed:
1. Check the electrical supply voltage being supplied.
Be sure that it is the same as listed on the unit
nameplate.
IG N . C O N T R O L # 2
2. Set the room thermostat to the off position.
3. Turn unit electrical power on.
IG N . C O N T R O L # 1
4. Set the room thermostat fan switch to on.
5. Check indoor blower rotation.
R O L L O U T S W .
G V 1
G A S
V A L V E
S E N S O R # 1
G V 2
G A S
V A L V E
IG N IT O R # 2
•
IG N IT O R # 1
S E N S O R # 2
B U R N E R C O M P A R T M E N T
•
If blower rotation is in the wrong direction.
Refer to Phasing Section in general information section.
Check blower drive belt tension.
6. Check the unit supply air (CFM). See "CHECKING
SUPPLY AIR CFM" on page 49.
7. Measure evaporator fan motor's amp draw.
FIGURE 26 - GAS VALVE AND CONTROLS
8. Set the room thermostat fan switch to off.
FLASH CODES
9. Turn unit electrical power off.
The UCB will initiate a flash code associated with
errors within the system. Refer to UNIT CONTROL
BOARD FLASH CODES Table 36.
62
Johnson Controls Unitary Products
284813-YIM-C-1008
OPERATING INSTRUCTIONS
2. Turn room thermostat to lowest setting.
1. Turn unit electrical power on.
3. Turn gas valve knob or switch to “on” position.
2. Set the room thermostat setting to lower than the
room temperature.
4. Turn “on” electric power to unit.
4. The second stage of the thermostat will energize
second stage compressor if needed.
5. Set room thermostat to desired temperature.
(If thermostat “set” temperature is above room temperature, pilot burner ignition will occur and, after
an interval to prove pilot flame, main burners will
ignite).
POST START CHECK LIST
TO SHUT DOWN:
3. First stage compressors will energize after the
built-in time delay (five minutes).
1. Verify proper system pressures for both circuits.
2. Measure the temperature drop across the evaporator coil.
3. Measure the system Amperage draw across all
legs of 3 phase power wires.
4. Measure the condenser fan amp draw.
SHUT DOWN
1. Set the thermostat to highest temperature setting.
1. Turn “off” electric power to unit.
2. Depress knob of gas valve while turning to “off”
position, or turn gas valve switch to “off” position.
POST-START CHECK LIST (GAS)
After the entire control circuit has been energized and
the heating section is operating, make the following
checks:
1. Check for gas leaks in the unit piping as well as the
supply piping.
2. Turn off the electrical power to the unit.
START-UP (GAS HEAT)
PRE-START CHECK LIST
FIRE OR EXPLOSION HAZARD
Complete the following checks before starting the unit.
Failure to follow the safety warning exactly
could result in serious injury, death or property
damage.
1. Check the type of gas being supplied. Be sure that
it is the same as listed on the unit nameplate.
2. Make sure that the vent and combustion air hoods
have been properly installed.
OPERATING INSTRUCTIONS
Never test for gas leaks with an open flame.
Use a commerically available soap solution
made specifically for the detection of leaks to
check all connections. A fire or explosion may
result causing property damage, personal
injury or loss of life.
2. Check for correct manifold gas pressures. See
“Checking Gas Input” page 64.
This furnace is equipped with an intermittent
pilot and automatic re-ignition system. DO
NOT attempt to manually light the pilot.
TO LIGHT PILOT AND MAIN BURNERS:
1. Turn “off” electric power to unit.
Johnson Controls Unitary Products
3. Check the supply gas pressure. It must be within
the limits shown on rating nameplate. Supply pressure should be checked with all gas appliances in
the building at full fire. At no time should the
standby gas line pressure exceed 13", nor the
operating pressure drop below 5.0" for natural gas
units. If gas pressure is outside these limits, contact the local gas utility for corrective action.
63
284813-YIM-C-1008
ance for air to the desired level, (3) be sure to replace
cover screw after adjustment to prevent possible gas
leakage.
Put the system into operation and observe through
complete cycle to be sure all controls function properly.
BURNER INSTRUCTIONS
FIGURE 27 - TYPICAL GAS VALVES
To check or change burners, pilot or orifices, CLOSE
MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF
ALL ELECTRIC POWER TO THE UNIT.
MANIFOLD GAS PRESSURE ADJUSTMENT
1. Remove the screws holding either end of the manifold to the burner supports.
Small adjustments to the high-fire gas flow may be
made by turning the pressure regulator adjusting screw
on the automatic gas valve.
2. Open the union fitting in the gas supply line just
upstream of the unit gas valve and downstream
from the main manual shut-off valve.
Adjust as follows:
3. Remove the gas piping closure panel.
1. Remove the cap on the regulator. It's located next
to the push-on electrical terminals.
4. Disconnect wiring to the gas valves and spark ignitors. Remove the manifold-burner gas valve
assembly by lifting up and pulling back.
2. To decrease the gas pressure, turn the adjusting
screw counterclockwise.
3. To increase the gas pressure, turn the adjusting
screw clockwise.
NOTE: The correct manifold pressure for these furnaces is 3.65 IWG ±0.3.
B U R N E R A S S E M B L Y B R A C K E T
F L A M E S E N S O R B U L B
FIGURE 29 - TYPICAL FLAME APPEARANCE
Burners are now accessible for service.
Reverse the above procedure to replace the assemblies. Make sure that burners are level and seat at the
rear of the heat exchanger.
1 /8 " G A P B E T W E E N C A R R Y -O V E R
T U B E A N D F L A M E S E N S O R B U L B
C A R R Y -O V E R T U B E
BURNER AIR SHUTTER ADJUSTMENT
Adjust burner shutters so no yellow flame is observed
in the heat exchanger tubes.
FIGURE 28 - PROPER FLAME ADJUSTMENT
PILOT CHECKOUT
The pilot flame should envelope the end of the flame
sensor. To adjust pilot flame, (1) remove pilot adjustment cover screw, (2) increase or decrease the clear-
64
CHECKING GAS INPUT
NATURAL GAS
1. Turn off all other gas appliances connected to the
gas meter.
Johnson Controls Unitary Products
284813-YIM-C-1008
2. With the furnace turned on, measure the time
needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter usually
has a 1/2 or a 1 cubic foot test dial.
3. Using the number of seconds for each revolution
and the size of the test dial increment, find the
cubic feet of gas consumed per hour from the Gas
Rate - Cubic Feet Per Hour Table 35.
If the actual input is not within 5% of the furnace rating
(with allowance being made for the permissible range
of the regulator setting), replace the orifice spuds with
spuds of the proper size.
NOTE: To find the Btu input, multiply the number of
cubic feet of gas consumed per hour by the
Btu content of the gas in your particular locality
(contact your gas company for this information
- it varies widely from city to city.)
TABLE 35: GAS RATE - CUBIC FEET PER HOUR
Seconds
for One
Rev.
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
4
6
8
10
450
300
228
180
900
600
450
360
12
14
16
18
20
150
129
113
100
90
300
257
225
200
180
22
24
26
28
82
75
69
64
164
150
138
129
Example: By actual measurement, it takes 13 seconds for the hand on the 1cubic foot dial to make a revolution with just a 300,000 Btuh furnace running.
Read across to the column in the table above, headed “1 Cubic Foot”, where
you will see that 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.
After the temperature rise has been determined, the
cfm can be calculated as follows:
After about 20 minutes of operation, determine the furnace temperature rise. Take readings of both the return
air and the heated air in the ducts (about six feet from
the furnace) where they will not be affected by radiant
heat. Increase the blower cfm to decrease the temperature rise; decrease the blower cfm to increase the
rise. Refer to the Blower Motor and Drive Data
Table 30.
BELT DRIVE BLOWER
All units have belt drive single-speed blower motors.
The variable pitch pulley on the blower motor can be
adjusted to obtain the desired supply air CFM.
TROUBLESHOOTING
COOLING TROUBLESHOOTING GUIDE
Troubleshooting of components may require
opening the electrical control box with the
power connected to the unit. Use extreme care
when working with live circuits! Check the
unit nameplate for the correct line voltage and
set the voltmeter to the correct range before
making any connections with line terminals.
For troubleshooting of optional VFD, disconnect all power to the drive. Be aware that high
voltages are present in the drive even after
power has been disconnected. Capacitors
within the drive must be allowed to discharge
before beginning service.
Shut off all electric power to the unit prior to
any of the following maintenance procedures
to prevent personal injury.
ADJUSTMENT OF TEMPERATURE RISE
The temperature rise (or temperature difference
between the return air and the heated air from the furnace) must lie within the range shown on the rating
plate and the data in the Gas Heat Application Table 4.
CFM =
Btuh Input x 0.8
108
. x oF Temp. Rise
Johnson Controls Unitary Products
Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation, which
could cause injury to person and/or damage
unit components. Verify proper operation after
servicing.
65
284813-YIM-C-1008
On calls for cooling, if the compressors are operating
but the supply air blower motor does not energize after
a short delay (the room thermostat fan switch is in the
“AUTO” position).
1. Turn the thermostat fan switch to the ON position.
If the supply air blower motor does not energize, go
to Step 3.
2. If the blower motor runs with the fan switch in the
ON position but will not run after the first compressor has energized when the fan switch is in the
AUTO position, check the room thermostat for contact between R and G in the AUTO position during
calls for cooling.
3. If the supply air blower motor does not energize
when the fan switch is set to ON, check that line
voltage is being supplied to the contacts of the M3,
contactor, and that the contactor is pulled in. For
units with VFD, check that line voltage is being
supplied to the M3-Auxiliary contacts. Check for
loose wiring between the contactor and the supply
air blower motor.
4. If M3 is pulled in and voltage is supplied to M3,
lightly touch the supply air blower motor housing. If
it is hot, the motor may be off on internal
protection. Cancel any thermostat calls and set the
fan switch to AUTO. Wait for the internal overload
to reset. Test again when cool.
5. If M3 is not pulled in, check for 24 volts at the M3
coil. If 24 volts are present at M3 but M3 is not
pulled in, replace the contactor.
6. Failing the above, if there is line voltage supplied at
M3, M3 is pulled in, and the supply air blower
motor still does not operate, replace the motor.
For units with VFD, if there is line voltage supplied
at M3, M3 is pulled in, and the blower motor does
not operate, check all power & control wiring connections to and from the drive and for any fault/
warning messages displayed on the drive's digital
display (refer to the drive user manual for full
descriptions, if necessary). Clear any fault by
pressing 'RESET' on the drive's keypad and take
any corrective action as needed. If the motor still
does not operate, replace the motor.
7. If 24 volts is not present at M3, check that 24 volts
is present at the UCB supply air blower motor ter-
66
minal, “FAN”. If 24 volts is present at the FAN,
check for loose wiring between the UCB and M3.
8. If 24 volts is not present at the “FAN” terminal,
check for 24 volts from the room thermostat. If 24
volts are not present from the room thermostat,
check for the following:
a.
Proper operation of the room thermostat (contact
between R and G with the fan switch in the ON position and in the AUTO position during operation
calls).
b.
Proper wiring between the room thermostat and the
UCB.
c.
Loose wiring from the room thermostat to the UCB.
9. If 24 volts is present at the room thermostat but not
at the UCB, check for proper wiring between the
thermostat and the UCB, i.e. that the thermostat G
terminal is connected to the G terminal of the UCB,
and for loose wiring.
10. If the thermostat and UCB are properly wired,
replace the UCB.
On calls for cooling, the supply air blower motor is
operating but compressor #1 is not (the room thermostat fan switch is in the “AUTO” position).
1. If installed, check the position of the economizer
blades. If the blades are open, the economizer is
providing free cooling and the compressors will not
immediately operate. If both stages of cooling are
requested simultaneously and the economizer provides free cooling, following a short delay compressor #1 will be energized unless it is locked out. If
compressor #1 is locked out, compressor #2 is
energized. Compressor #2 is always energized in
place of compressor #1 when compressor #1 is
requested but locked out, unless this option has
been disabled through computer communications.
2. If no economizer is installed or the economizer is
not opening to provide free cooling and compressor #1 does not energize on a call for cooling,
check for line voltage at the compressor contactor,
M1, and that the contactor is pulled in. Check for
loose wiring between the contactor and the compressor.
3. If M1 is pulled in and voltage is supplied at M1,
lightly touch the compressor housing. If it is hot, the
compressor may be off on inherent protection.
Johnson Controls Unitary Products
284813-YIM-C-1008
Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool.
4. If M1 is not pulled in, check for 24 volts at the M1
coil. If 24 volts are present and M1 is not pulled in,
replace the contactor.
5. Failing the above, if voltage is supplied at M1, M1
is pulled in, and the compressor still does not operate, replace the compressor.
6. If 24 volts is not present at M1, check for 24 volts at
the UCB terminal, C1. If 24 volts is present, check
for loose wiring between C1 and the compressor
contactor.
7. If 24 volts is not present at the C1 terminal, check
for 24 volts from the room thermostat at the UCB
Y1 terminal. If 24 volts is not present from the room
thermostat, check for the following:
a.
24 volts at the thermostat Y1 terminal.
b.
Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2.
c.
Loose wiring from the room thermostat to the UCB.
8. If 24 volts is present at the UCB Y1 terminal, the
compressor may be out due to an open high-pressure switch, low-pressure switch, or freezestat.
Check for 24 volts at the HPS1, LPS1, and FS1
terminals of the UCB. If a switch has opened, there
should be a voltage potential between the UCB terminals, e.g. if LPS1 has opened, there will be a 24volt potential between the LPS1 terminals.
9. If 24 volts is present at the UCB Y1 terminal and
none of the protection switches have opened, the
UCB may have locked out the compressor for
repeat trips. The UCB should be flashing an alarm
code. If not, press and release the ALARMS button
on the UCB. The UCB will flash the last five alarms
on the LED. If the compressor is locked out, cancel
any call for cooling. This will reset any compressor
lock outs.
Johnson Controls Unitary Products
NOTE: While the above step will reset any lockouts,
compressor #1 may be held off for the ASCD.
See the next step.
10. If 24 volts is present at the UCB Y1 terminal and
none of the switches are open and the compressor
is not locked out, the UCB may have the compressor in an ASCD. Check the LED for an indication of
an ASCD cycle. The ASCD should time out within
5 minutes. Press and release the TEST button to
reset all ASCDs.
11. If 24 volts is present at the UCB Y1 terminal and
the compressor is not out due to a protective
switch trip, repeat trip lock out, or ASCD, the economizer terminals of the UCB may be improperly
wired. Check for 24 volts at the Y1 “OUT” terminal
of the UCB. If 24 volts is present, trace the wiring
from Y1 “OUT” for incorrect
wiring. If 24 volts is not
present at the Y1 “OUT” terminal, the UCB must be
replaced.
12. For units without economizers:If 24 volts is present
at the Y1 OUT terminal, check for 24 volts at the
Y1 “ECON” terminal. If 24 volts is not present,
check for loose wiring from the Y1 “OUT” terminal
to the Mate-N-Lock plug, the jumper in the Mate-NLock plug, and in the wiring from the Mate-N-Lock
plug to the Y1 “ECON” terminal.
13. For units with economizers: If 24 volts is present at
the Y1 "OUT" terminal, check for 24 volts at the Y1
"ECON" terminal. If 24 volts is not present, check
for loose wiring from the Y1 "OUT" terminal to the
Mate-N-Lock plug, a poor connection between the
UCB and economizer Mate-N-Lock plugs, loose
wiring from the Mate-N-Lock plug to the economizer, back to the Mate-N-Lock plug, and from the
Mate-N-Lock plug to the Y1 "ECON" terminal. If
nothing is found, the economizer control may have
faulted and is failing to return the 24-volt "call" to
the Y1 "ECON" terminal even though the economizer is not providing free cooling. To test, disconnect the Mate-N-Locks and jumper between the
WHITE and YELLOW wires of the UCB's MateNLock plug. If compressor #1 energizes, there is a
fault in the economizer wiring or economizer control.
67
284813-YIM-C-1008
14. The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions. These options are not enabled by
default. Local distributors can test the UCB for this
programming.
For units with factory installed economizers, the
UCB is programmed to lock out compressor operation when the LAS set point is reached.
For units without factory installed or with field
installed economizers, the UCB allows compressor
operation all the time. This programming can be
checked or changed by the local distributor.
15. If none of the above corrected the error, test the
integrity of the UCB. Disconnect the C1 terminal
wire and jumper it to the Y1 terminal. DO NOT
jump the Y1 to C1 terminals. If the compressor
engages, the UCB has faulted.
16. If none of the above correct the error, replace the
UCB.
On calls for the second stage of cooling, the supply air
blower motor and compressor #1 are operating but
compressor #2 is not (the room thermostat fan switch
is in the “AUTO” position).
1. If installed, check the position of the economizer
blades. If the blades are open, the economizer is
providing free cooling. If the second stage of cooling is requested, following a short delay, compressor #1 will be energized unless it is locked out.
Typically, compressor #2 is energized only during
free cooling if the call for the second stage of cooling persists for 20 minutes.
2. Compressor #2 will not energize simultaneously
with compressor #1 if a call for both stages of cooling is received. The UCB delays compressor #2 by
30 seconds to prevent a power surge. If after the
delay compressor #2 does not energize on a second stage call for cooling, check for line voltage at
the compressor contactor, M2, and that the contactor is pulled in. Check for loose wiring between the
contactor and the compressor.
3. If M2 is pulled in and voltage is supplied at M2,
lightly touch the compressor housing. If it is hot, the
compressor may be off on inherent protection.
Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool.
68
4. If M2 is not pulled in, check for 24 volts at the M2
coil. If 24 volts is present and M2 is not pulled in,
replace the contactor.
5. Failing the above, if voltage is supplied at M2, M2
is pulled in, and the compressor still does not operate, replace the compressor.
6. If 24 volts is not present at M2, check for 24 volts at
the UCB terminal, C2. If 24 volts are present,
check for loose wiring between C2 and the compressor contactor.
7. If 24 volts is not present at the C2 terminal, check
for 24 volts from the room thermostat at the UCB
Y2 terminal. If 24 volts is not present from the room
thermostat, check for the following:
a.
24 volts at the thermostat Y2 terminal.
b.
Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2.
c.
Loose wiring from the room thermostat to the UCB.
8. If 24 volts is present at the UCB Y2 terminal, the
compressor may be out due to an open high-pressure switch, low-pressure switch, or freezestat.
Check for 24 volts at the HPS2, LPS2, and FS2
terminals of the UCB. If a switch has opened, there
should be a voltage potential between the UCB terminals, e.g. if LPS2 has opened, there will be 24
volts of potential between the LPS2 terminals.
9. If 24 volts is present at the UCB Y2 terminal and
none of the protection switches have opened, the
UCB may have locked out the compressor for
repeat trips. The UCB should be flashing a code. If
not, press and release the ALARMS button on the
UCB. The UCB will flash the last five alarms on the
LED. If the compressor is locked out, remove any
call for cooling at the thermostat or by disconnecting the thermostat wiring at the Y2 UCB terminal.
This will reset any compressor lock outs.
NOTE: While the above step will reset any lock outs,
compressor #1 will be held off for the ASCD,
and compressor #2 may be held off for a portion of the ASCD. See the next step.
10. If 24 volts is present at the UCB Y2 terminal and
none of the switches are open and the compressor
is not locked out, the UCB may have the compressor in an ASCD. Check the LED for an indication of
an ASCD cycle. The ASCD should time out within
Johnson Controls Unitary Products
284813-YIM-C-1008
5 minutes. Press and release the TEST button to
reset all ASCDs.
11. The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions. These options are not enabled by
default. Local distributors can test the UCB for this
programming.
For units with factory installed economizers, the
UCB is programmed to lock out compressor operation when the LAS set point is reached.
For units without factory installed or with field
installed economizers, the UCB allows compressor
operation all the time. This programming can be
checked or changed by the local distributor.
12. If none of the above corrected the error, test the
integrity of the UGB. Disconnect the C2 terminal
wire and jumper it to the Y2 terminal. DO NOT
jump the Y2 to C2 terminals. If the compressor
engages, the UCB has faulted.
13. If none of the above correct the error, replace the
UCB.
5. Failing the above, if voltage is supplied at M1, M1
is pulled in, and the compressor still does not operate, replace the compressor.
6. If 24 volts is not present at M1, check for 24 volts at
the UCB terminal, C1. If 24 volts is present, check
for loose wiring between C1 and the compressor
contactor.
7. If 24 volts is not present at the C1 terminal, check
for 24 volts from the room thermostat at the UCB
Y1 terminal. If 24 volts are not present at the UCB
Y1 terminal, the UCB may have faulted. Check for
24 volts at the Y1 ECON terminal. If 24 volts is not
present at Y1 “ECON”, the UCB has faulted. The
UCB should de-energize all compressors on a loss
of call for the first stage of cooling, i.e. a loss if 24
volts at the Y1 terminal.
8. If 24 volts are present at the UCB Y1 terminal, the
compressor may be out due to an open high-pressure switch, low-pressure switch, or freezestat.
Check for 24 volts at the HPS1, LPS1, and FS1
terminals of the UCB. If a switch has opened, there
should be a voltage potential between the UCB terminals, e.g. if LPS1 has opened, there will be a 24volt potential between the LPS1 terminals.
On a call for cooling, the supply air blower motor and
compressor #2 are operating but compressor #1 is not
9. If 24 volts is present at the UCB Y1 terminal and
(the room thermostat fan switch is in the “AUTO” posinone of the protection switches have opened, the
tion).
UCB may have locked out the compressor for
repeat trips. The UCB should be flashing a code. If
1. Compressor #2 is energized in place of compresnot, press and release the ALARMS button on the
sor #1 when compressor #1 is unavailable for coolUCB. The UCB will flash the last five alarms on the
ing calls. Check the UCB for alarms indicating that
LED. If the compressor is locked out, remove any
compressor #1 is locked out. Press and release
call for cooling. This will reset any compressor lock
the ALARMS button if the LED is not flashing an
outs.
alarm.
NOTE: While the above step will reset any lock outs,
2. Check for line voltage at the compressor contactor,
compressor #2 will be held off for the ASCD,
M1, and that the contactor is pulled in. Check for
and compressor #1 may be held off for a porloose wiring between the contactor and the comtion of the ASCD. See the next step.
pressor.
10. If 24 volts is present at the UCB Y1 terminal and
3. If M1 is pulled in and voltage is supplied at M1,
none of the switches are open and the compressor
lightly touch the compressor housing. If it is hot, the
is not locked out, the UCB may have the comprescompressor may be off on inherent protection.
sor in an ASCD. Check the LED for an indication of
Cancel any calls for cooling and wait for the interan ASCD cycle. The ASCD should time out within
nal overload to reset. Test again when cool.
5 minutes. Press and release the TEST button to
reset all ASCDs.
4. If M1 is not pulled in, check for 24 volts at the M1
coil. If 24 volts is present and M1 is not pulled in,
11. If 24 volts is present at the UCB Y1 terminal and
replace the contactor.
the compressor is not out due to a protective
switch trip, repeat trip lock out, or ASCD, the econ-
Johnson Controls Unitary Products
69
284813-YIM-C-1008
omizer terminals of the UCB may be improperly
GAS HEAT TROUBLESHOOTING GUIDE
wired. Check for 24 volts at the Y1 “OUT” terminal
of the UCB. If 24 volts is present, trace the wiring
from Y1 “OUT” for incorrect
wiring. If 24 volts is not
present at the Y1 “OUT” terminal, the UCB must be
replaced.
Troubleshooting of components may require
opening the electrical control box with the
12. For units without economizers: If 24 volts is present
power connected to the unit. Use extreme
at the Y1 “OUT” terminal, check for 24 volts at the
care when working with live circuits! Check
Y1 “ECON” terminal. If 24volts is not present,
the unit nameplate for the correct line voltage
check for loose wiring from the Y1 “OUT” terminal
and set the voltmeter to the correct range
to the Mate-N-Lock plug, the jumper in the Mate-Nbefore making any connections with line termiLock plug, and in the wiring from the Mate-N-Lock
nals.
plug to the Y1 “ECON” terminal.
For troubleshooting of optional VFD, disconnect all power to the drive. Be aware that high
For units with economizers: If 24 volts is present at
voltages are present in the drive even after
the Y1 "OUT" terminal, check for 24 volts at the Y1
power has been disconnected. Capacitors
"ECON" terminal. If 24 volts is not present, check
within the drive must be allowed to discharge
for loose wiring from the Y1 "OUT" terminal to the
before beginning service.
Mate-N-Lock plug, a poor connection between the
When not necessary, shut off all electric power
UCB and economizer Mate-N-Lock plugs, loose
to the unit prior to any of the following maintewiring from the Mate-N-Lock plug to the econonance procedures so as to prevent personal
mizer, back to the Mate-N-Lock plug, and from the
injury.
Mate-N-Lock plug to the Y1 "ECON" terminal. The
economizer control may have faulted and is not
returning the 24 volts to the Y1 "ECON" terminal
even though the economizer is not providing free
cooling. To test the economizer control, disconnect
the Mate-N-Locks and jumper between the WHITE
Label all wires prior to disconnection when serand YELLOW wires of the UCB's Mate-N-Lock
vicing controls. Wiring errors can cause
plug.
improper and dangerous operation, which
could cause injury to person and/or damage
13. The UCB can be programmed to lock out compresunit components. Verify proper operation after
sor operation during free cooling and in low ambiservicing.
ent conditions. These options are not enabled by
default. They can be checked by local distributors.
NOTE: To find the Btu input, multiply the number of
cubic feet of gas consumed per hour by the
For units with factory installed economizers, the
Btu content of the gas in your particular locality
UCB is programmed to lock out compressor opera(contact your gas company for this information
tion when the LAS set point is reached.
- it varies widely from city to city.).
For units without factory installed or with field
installed economizers, the UCB allows compressor
operation all the time. This programming can be
checked or changed by the local distributor.
14. If none of the above correct the error, replace the
UCB.
70
The furnace may shut down on a high temperature condition during the procedure. If
this occurs, the UCB energize the supply air
blower motor until the high temperature limit
has reset. Caution should be used at all
times as the supply air blower may energize
regardless of the room thermostat fan switch
position.
Johnson Controls Unitary Products
284813-YIM-C-1008
On calls for heating, the draft motor operates and the
furnace lights but the supply air blower motor does not
energize after a short delay (the room thermostat fan
switch is in “AUTO” position).
1. Place the thermostat fan switch in the “ON” position. If the supply air blower motor energizes, go to
Step 10.
a.
Proper operation of the room thermostat (contact
between R and G with the fan switch in the “ON”
position and in the “AUTO” position during operation
calls).
b.
Proper wiring between the room thermostat and the
UCB.
c.
Loose wiring from the room thermostat to the UCB.
8. If 24 volts is present at the room thermostat but not
2. If the supply air blower motor does not energize
at the UCB, check for proper wiring between the
when the fan switch is set to “ON,” check that line
thermostat and the UCB, i.e. that the thermostat G
voltage is being supplied to the contacts of the M3
terminal is connected to the G terminal of the UCB,
contactor, and that the contactor is pulled in. For
and for loose wiring.
units with VFD, check that line voltage is being
supplied to the M3-Auxiliary contacts. Check for
9. If the thermostat and UCB are properly wired,
loose wiring between the contactor and the supply
replace the UCB.
air blower motor.
3. If M3 is pulled in and voltage is supplied at M3,
lightly touch the supply air blower motor housing. If
it is hot, the motor may be off on inherent protection. Cancel any thermostat calls and set the fan
switch to “AUTO”, wait fo
r the internal overload to
reset. Test again when cool.
4. If M3 is not pulled in, check for 24 volts at the M3
coil. If 24 volts is present at M3 but M3 is not pulled
in, replace the contactor.
5. Failing the above, if there is line voltage supplied at
M3, M3 is pulled in, and the supply air blower
motor still does not operate, replace the motor.
For units with VFD, if there is line voltage supplied
at M3, M3 is pulled in, and the blower motor does
not operate, check all power & control wiring connections to and from the drive and for any fault/
warning messages displayed on the drive's digital
display (refer to the drive user manual for full
descriptions, if necessary). Clear any fault by
pressing 'RESET' on the drive's keypad and take
any corrective action as needed. If the motor still
does not operate, replace the motor.
6. If 24 volts is not present at M3, check that 24 volts
is present at the supply air blower motor terminal
on the UCB. If 24 volts is present at the UCB terminal, check for loose wiring between the UCB and
M3.
7. If 24 volts is not present at the UCB supply air
blower motor terminal, check for 24 volts from the
room thermostat. If 24 volts is not present from the
room thermostat, check for the following:
Johnson Controls Unitary Products
10. If the blower motor runs with the fan switch in the
“ON” position but does not run shortly after the furnace has ignited when the fan switch is in the
“AUTO” position, check the room thermostat for
contact between R and G during “W1” calls.
On calls for heating, the supply air blower operates but
the draft motor does not (the room thermostat fan
switch is in the “AUTO” position).
1. The draft motor has inherent protection. If the
motor shell is hot to the touch, wait for the internal
overload to reset.
2. If the motor shell is cold with the room thermostat
calling for heat, check for line voltage at the
motor's Mate-N-Lock connector attached to the
evaporator partition. If line voltage is present,
replace the draft motor.
3. If line voltage is not present, check for line voltage
at the heat relay (RW1) contacts in the main control box and check to see if the (RW1) is pulled in.
4. If the (RW1) relay is pulled in, check for a loose line
voltage connection.
5. If the (RW1) relay is not pulled in, check for 24 volts
at the (RW1) coil. If 24 volts is present, replace the
(RW1) relay. If 24 volts is not present, check for a
loose 24 volt connection back to the relay board
and check the connections from the room thermostat to the relay board. If all connections are correct, replace the relay board.
71
284813-YIM-C-1008
The draft motor runs but the furnace does not light and
the sparker does not spark.
1. The ignition control (IC1, IC2) may be locked out
due to either a flame roll out or 100% shut off.
These safety features are described above. If lockout has occurred, 24V must be removed from the
ignition controls. This is done at the unit or by
resetting the room thermostat. After resetting 24V,
check for proper furnace operation. If lock-out continues to occur, locate the source of the problem
and correct.
2. Check all 24 volt connections from the relay board
to and in the gas heat section. Check low voltage
connections to the (ETD) located in the control
box.
3. If the furnace is hot, it may be out on an over-temperature condition, wait for limit reset.
4. If the furnace is cold, check for 24 volts at wire 241
attached to the electrical time delay (ETD) located
in the main control box. If 24 volts is not found,
replace the ETD.
5. 24 volts is found at wire 241, remove the wires
attached to the (TDR) and with a VOM, check for
continuity across contacts 1 and 2. If none is found,
the (TDR) is open and must be replaced. If there is
continuity, re-attach the wires.With the draft motor
running, check for 24 volts at terminal 4 of (RW1-2)
and (RW2-1). If 24 volts is not present, the centrifugal switch (CS) has not closed or has gone bad.
Check the line voltage to the unit - if it is correct,
replace the draft motor. If line voltage is low, call
the power company.
6. Check for 24V at terminal 2 of (RW1-2 and RW21). If 24V is not present, check for 24V at (RW1
and RW2) relay coils. If these relays are pulled in,
then check for a loose connection at terminal 2 and
terminal 4 of each relay. If no problem is found,
then replace (RW1 and/or RW2) as required.
7. If 24 volts is present at the ignitor controls, check
all control wiring at the ignitor controls and the high
tension wire to the ignitors. Check that the ground
wires from the ignitor controls, the gas valves and
pilot burners are all intact and making good electrical connection. Check to make sure that the
ceramic insulator on the pilot ignitors or sensors is
not broken or cracked, if all are intact, replace the
ignition control IC1 or IC2.
72
The draft motor runs and the ignitor sparks at the pilot
burner but the pilot does not ignite and a gas odor is
not detected at the draft motor outlet.
1. Check to make sure gas is being supplied to the
unit. Make sure that the gas pressure to the unit is
within the proper limits as described in the “POST
START CHECK LIST” page 63 and that the pilot
adjust screw is allowing some flow of gas as
described in “PILOT CHECKOUT” page 64.
2. Check all wiring between the ignitor control and the
gas valve. Check to make sure the ground connections are intact.
3. If the wiring is intact, check for 24 volts across terminals “PV” and “COMMON” on the ignitor control.
If 24 volts is not present, replace the ignitor control.
4. If 24 volts is present, remove the pilot burner and
remove the pilot orifice from the pilot burner. The
orifice is removed in the direction opposite the flow
of gas. Inspect the orifice for obstruction. If it is
clear, replace the main gas valve.
The ignitor sparks at the pilot burner but the pilot does
not ignite and a gas odor is detected at the draft motor
outlet.
1. Adjust the pilot adjust screw on the gas valve as
described in “PILOT CHECKOUT” page 64.
2. Check the supply pressure as described in “POST
START CHECK LIST” page 63. Make adjustments
as necessary.
3. Check the pilot orifice and carryover tube for
obstruction as described in paragraph above.
Clean as needed but the problem should not be the
gas valve.
The pilot burner ignites but the ignitor continues to
spark and the main burners do not ignite.
1. Make the same checks and adjustment as
described in “PILOT CHECKOUT” page 64.
2. Check the supply pressure as described in “POST
START CHECK LIST” page 63. Make adjustments
as necessary.
3. Make sure that the pilot burner is not bent or damaged.
Johnson Controls Unitary Products
284813-YIM-C-1008
4. Make sure that the ground connections at the pilot
burner, gas valve and ignitor control are intact.
Check the high tension wire for good electrical connection. If all are intact, replace the ignitor module.
UNIT CONTROL BOARD FLASH CODES
Various flash codes are utilized by the unit control
board (UCB) to aid in troubleshooting. Flash codes are
distinguished by the short on and off cycle used
The pilot burner lights and the spark stops but the main
(approximately 200ms on and 200ms off). To show
burners do not light.
normal operation, the control board flashes a 1 second
on, 1 second off "heartbeat" during normal operation.
1. Check electrical connections between the ignitor
This is to verify that the UCB is functioning correctly.
control and the gas valve. If intact, check for 24
Do not confuse this with an error flash code. To prevent
volts across terminals “MV” and “COMMON” termi- confusion, a 1-flash, flash code is not used.
nals. If no voltage detected, replace ignitor control.
If voltage is present, replace gas valve.
Alarm condition codes are flashed on the UCB lower
left Red LED, See Figure 30. While the alarm code is
Furnace lights with roll-out or one burner has delayed
being flashed, it will also be shown by the other LEDs:
ignition.
lit continuously while the alarm is being flashed. The
total of the continuously lit LEDs equates to the number
1. Make sure that the carryover is aligned properly
of flashes, and is shown in the table. Pressing and
with the flame sensor as described in “PILOT releasing the LAST ERROR button on the UCB can
CHECKOUT” page 64.
check the alarm history. The UCB will cycle through the
last five (5) alarms, most recent to oldest, separating
Main burners light but exhibit erratic flame characteriseach alarm flash code by approximately 2 seconds. In
tics.
all cases, a flashing Green LED will be used to indicate
non-alarm condition.
1. Adjust air shutters as described in “BURNER AIR
SHUTTER ADJUSTMENT” page 64.
In some cases, it may be necessary to "zero" the
ASCD for the compressors in order to perform trouble2. Check the main burner orifices for obstruction and
shooting. To reset all ASCDs for one cycle, press and
alignment. Removal procedure is described in
release the UCB TEST/ RESET button once.
BURNER INSTRUCTIONS page 64. Clean or
replace burner orifices and burners as needed.
Flash codes that do and do not represent alarms are
listed in Table 36.
Johnson Controls Unitary Products
73
284813-YIM-C-1008
TABLE 36: UNIT CONTROL BOARD FLASH CODES
GREEN
LED
16
RED
LED
8
RED
LED
4
RED
LED
2
RED
LED
1
This is a Control Failure
-
-
-
-
-
Not Applicable
-
-
-
-
-
Flashing
Off
Off
On
Off
FLASH CODE
On Steady
1 Flash
2 Flashes
DESCRIPTION
Control waiting ASCD1
3 Flashes
HPS1 Compressor Lockout
Off
Off
Off
On
On
4 Flashes
HPS2 Compressor Lockout
Off
Off
On
Off
Off
5 Flashes
LPS1 Compressor Lockout
Off
Off
On
Off
On
6 Flashes
LPS2 Compressor Lockout
Off
Off
On
On
Off
7 Flashes
FS1 Compressor Lockout
Off
Off
On
On
On
8 Flashes
FS2 Compressor Lockout
Off
On
Off
Off
Off
9 Flashes
Ignition Control Locked Out / Ignition Control Failure
Off
On
Off
Off
On
10 Flashes
Compressors Locked Out on Low Outdoor Air Temperature1
Flashing
On
Off
On
Off
Flashing
On
Off
On
On
11 Flashes
Compressors locked out because the Economizer is using free
Cooling1
12 Flashes
Unit Locked Out due to Fan Overload Switch Failure
13 Flashes
Compressor Held Off due to Low Voltage1
14 Flashes
OFF
1.
Off
On
On
Off
Off
Flashing
On
On
Off
On
EEPROM Storage Failure
Off
On
On
On
Off
No Power or Control Failure
Off
Off
Off
Off
Off
Non-alarm condition.
Check
Alarm
History
Reset All
ASCDs for
One Cycle
Non Alarm
Condition Green
LED Flashing
Current Alarm
Flashed
Red LED
FIGURE 30 - UNIT CONTROL BOARD
74
Johnson Controls Unitary Products
284813-YIM-C-1008
UNIT CONTROL BOARD OPTION SETUP
•
Press the COMM SETUP / SELECT button to toggle into the Heat Delay Setup, the green LED will
turn off and the red LED for Heat Delay will turn on.
•
The 8, 4, 2 and 1 LEDs will then show the status of
the Heat Delay, (See Table 37). Press the UP or
Down button to change the LED status to correspond to the desired Heat Delay Value.
•
To save the current displayed value, push the
OPTION SETUP / STORE button and hold it for at
least 2 seconds. When the value is saved, the red
LED will flash a few times and then normal display
will resume.
OPTION BYTE SETUP
•
Enter the Option Setup mode by pushing the
OPTION SETUP / STORE button, and holding it for
at least 2 seconds.
•
The green status LED (Option Byte) will be turned
on and the red status LED (Heat Delay) is turned
off.
•
The 8, 4, 2 and 1 LEDs willthen show the status of
the 4 labeled options ((8) Fan Off at Heat Start, (4)
Low Ambient Lockout, (2) Free Cooling Lockout, and (1) Lead / Lag).
•
Press the UP or Down button to change the LED
status to correspond to the desired Option Setup.
•
To save the current displayed value, push the
OPTION SETUP / STORE button and hold it for at
least 2 seconds. When the value is saved, the
green LED will flash a few times and then normal
display will resume.
NOTE: While in either Setup mode, if no buttons are
pushed for 60 seconds, the display will revert
to its normal display, exiting the Option Setup
mode. When saving, the control board only
saves the parameters for the currently displayed mode (Option Byte or Heat Delay).
HEAT DELAY SETUP
•
Enter the Option Setup mode by pushing the
OPTION SETUP / STORE button, and holding it for
at least 2 seconds.
•
The green status LED (Option Byte) will be turned
on and the red status LED (Heat Delay) is turned
off.
Johnson Controls Unitary Products
NOTE: While in either Setup mode, if no buttons are
pushed for 60 seconds, the display will revert
to its normal display, exiting the Option Setup
mode. When saving, the control board only
saves the parameters for the currently displayed mode (Option Byte or Heat Delay).
TABLE 37: HEAT DELAY
Heat
Fan On
Delay
60
60
60
60
45
45
45
45
30
30
30
30
0
0
0
Non-std
Heat
Fan Off
Delay
180
90
60
30
180
90
60
30
180
90
60
30
60
30
10
Non-std
Red
LED 8
Red
LED 4
Red
LED 2
Red
LED 1
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
75
OPTIONAL VAV CONTROL BOARD FLASH CODES
Flash codes are also utilized by the VAV add-on board
to aid in troubleshooting optional VAV applications.
Flash codes are displayed by a red LED located near
the center of the board using a short on/off cycle
(approximately 200-ms on and 200-ms off).
To verify that the board is functioning correctly, the
LED will display a repetitive 1 second on, 1 second off
"heartbeat". Do not confuse this "heartbeat" with the
error flash codes shown in the table below. To prevent
confusion, a 1-flash, flash code is not used.
TABLE 38: VAV CONTROL BOARD FLASH CODES
FLASH CODE
DESCRIPTION
On Steady
Control Failure
1 Flash
Not Applicable
2 Flashes
Loss of Communication with UCB
3 Flashes
Space Sensor Failure
4 Flashes
SAT Sensor Failure
5 Flashes
RAT Sensor Failure
6 Flashes
OAT Sensor Failure
7 Flashes
OH Sensor Failure
8 Flashes
RH Sensor Failure
9 Flashes
IAQ Sensor Failure
10 Flashes
OAQ Sensor Failure
11 Flashes
APS Switch Failure
12 Flashes
Limit 2 Switch Open
13 Flashes
Purge
14 Flashes
VFD Input Failure
15 Flashes
OFF
Subject to change without notice. Printed in U.S.A.
Copyright © 2008 by Johnson Controls, Inc. All rights reserved.
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
Dirty Filter Switch
No Power or Control Failure
284813-YIM-C-1008
Supersedes: 284813-YIM-B-0707
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