TempMaster M52, M53, M54 rooftop unit Installation manual

INSTALLATION
MANUAL
25, 30 & 40 TON ROOFTOP
MODELS:
CONTENTS
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GAS HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
GAS FURNACE OPERATING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
M52
M53
M54
START-UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . 97
See the following pages for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
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.
ISO 9001
Certified Quality
Management System
SAVE THIS MANUAL
5121842-TIM-A-0515
5121842-TIM-A-0515
TABLE OF CONTENTS
LIST OF FIGURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 7
NOTES, CAUTIONS AND WARNINGS. . . . . . . . . . . . . . . 7
GAS FIRED MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WHAT TO DO IF YOU SMELL GAS . . . . . . . . . . . . . . . . . . . . . 7
ALL MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PRECEDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . 12
CLEARANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AIR HOODS FOR FIXED OUTSIDE AIR
(UNITS WITH MANUAL ECONOMIZER) . . . . . . . . . . . . 13
AIR HOODS FOR ECONOMIZER . . . . . . . . . . . . . . . . . . 13
AIR HOODS FOR EXHAUST AIR . . . . . . . . . . . . . . . . . . 13
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SERVICE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMPRESSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
THERMOSTAT (CONSTANT VOLUME UNITS) . . . . . . . 14
SPACE SENSOR (VARIABLE AIR VOLUME UNITS). . . 15
POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . 15
POWER WIRING DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GAS HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
VENT AND COMBUSTION AIR. . . . . . . . . . . . . . . . . . . . 17
ELECTRIC HEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HOT WATER HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PIPING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STEAM HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PIPING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
STATIC PRESSURE CONTROL PLASTIC TUBING . . . 21
EXHAUST STATIC PRESSURE . . . . . . . . . . . . . . . . . . . 21
CFM, STATIC PRESSURE, AND POWER - ALTITUDE
AND TEMPERATURE CORRECTIONS . . . . . . . . . . . . 49
SUPPLY AIR FAN INSTRUCTIONS . . . . . . . . . . . . . . . . 63
CHECK BLOWER BEARING SET SCREWS . . . . . . . . . . . . .
CHECKING SUPPLY AIR CFM . . . . . . . . . . . . . . . . . . . . . . .
FAN ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BALANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AIR QUANTITY . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLY AIR DRIVE ADJUSTMENT . . . . . . . . . . . . . . . . . . .
63
63
63
63
63
64
65
SYSTEM SETPOINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CONSTANT VOLUME AND VARIABLE AIR VOLUME: . . . . . 65
GAS FURNACE OPERATING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
TO LIGHT THE MAIN BURNERS . . . . . . . . . . . . . . . . . .
TO SHUT DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POST-START CHECKLIST (GAS) . . . . . . . . . . . . . . . . .
MANIFOLD GAS PRESSURE ADJUSTMENT . . . . . . . .
BURNER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . .
CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
68
68
69
69
69
NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
ELECTRIC HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
COOLING OPERATING INSTRUCTIONS . . . . . . . . . . . 70
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INTERNAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CONDENSER FANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . 70
COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INDOOR BLOWER MOTORS. . . . . . . . . . . . . . . . . . . . . . . . .
POWER EXHAUST OR RETURN AIR FAN MOTORS . . . . .
CONDENSER FAN MOTORS . . . . . . . . . . . . . . . . . . . . . . . .
DRAFT MOTOR (GAS FURNACE). . . . . . . . . . . . . . . . . . . . .
70
70
70
70
GAS FURNACE SAFETY FEATURES . . . . . . . . . . . . . . 88
COMBUSTION AIR PROVING . . . . . . . . . . . . . . . . . . . . . . . . 88
ROLLOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
NORMAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 88
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN DRIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTDOOR COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
88
89
89
GAS BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
TO CLEAN BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
COMBUSTION AIR DISCHARGE. . . . . . . . . . . . . . . . . . . . . . 89
CLEANING FLUE PASSAGES AND HEATING ELEMENTS . 89
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SECURE OWNERS APPROVAL . . . . . . . . . . . . . . . . . . 90
COMPRESSOR ROTATION . . . . . . . . . . . . . . . . . . . . . . 63
START-UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . 97
2
Johnson Controls Unitary Products
5121842-TIM-A-0515
LIST OF FIGURES
Fig. #
Pg. #
1
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 6
2
TYPICAL RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3
CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . 11
4
RECOMMENDED DRAIN PIPING . . . . . . . . . . . . . . . . 14
5
TYPICAL THERMOSTAT WIRING . . . . . . . . . . . . . . . 14
6
TYPICAL GAS PIPING CONNECTION . . . . . . . . . . . . 16
7
VENT AND COMBUSTION AIR HOODS . . . . . . . . . . . 17
8
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9
CLEARANCES - HOOD/ECONOMIZER & MOTOR
DRIVE - SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10 CLEARANCES - HOOD/ECONOMIZER & MOTOR
DRIVE - FRONT & END . . . . . . . . . . . . . . . . . . . . . . . 19
Fig. #
Pg. #
33 HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 10
GPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
34 HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 20
GPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
35 HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 30
GPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
36 HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 40
GPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
37 HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 60
GPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
38 HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 80
GPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
39 HOT WATER COIL - 40 TON, 1 ROW, AT 10 GPM . . 77
11 HOT WATER PIPING CROSS-SECTION . . . . . . . . . . 20
40 HOT WATER COIL - 40 TON, 1 ROW, AT 20 GPM . . 77
12 STEAM PIPING CROSS-SECTION . . . . . . . . . . . . . . . 20
41 HOT WATER COIL - 40 TON, 1 ROW, AT 30 GPM . . 78
13 BOTTOM SUPPLY AND RETURN . . . . . . . . . . . . . . . 22
42 HOT WATER COIL - 40 TON, 1 ROW, AT 40 GPM . . 78
14 END RETURN, BOTTOM SUPPLY . . . . . . . . . . . . . . . 23
43 HOT WATER COIL - 40 TON, 2 ROW, AT 20 GPM . . 79
15 BOTTOM RETURN, FRONT & REAR SUPPLY . . . . . 24
44 HOT WATER COIL - 40 TON, 2 ROW, AT 40 GPM . . 79
16 END RETURN, FRONT & REAR SUPPLY . . . . . . . . . 25
45 HOT WATER COIL - 40 TON, 2 ROW, AT 60 GPM . . 80
17 FIELD INSTALLED DISCONNECT . . . . . . . . . . . . . . . 44
46 HOT WATER COIL - 40 TON, 2 ROW, AT 80 GPM . . 80
18 25 AND 30 TON UNIT OVERHEAD VIEW . . . . . . . . . 45
47 STEAM COIL - 25 & 30 TON (1 ROW) . . . . . . . . . . . . 81
19 40 TON UNIT OVERHEAD . . . . . . . . . . . . . . . . . . . . . 45
48 STEAM COIL - 40 TON (1 ROW) . . . . . . . . . . . . . . . . 81
20 25 AND 30 TON UNIT MAJOR COMPONENT
LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
49 TYPICAL CONTROL WIRING . . . . . . . . . . . . . . . . . . . 82
21 40 TON UNIT MAJOR COMPONENT LAYOUT . . . . . 46
22 UNIT CABINET DOOR CONFIGURATION . . . . . . . . . 47
23 PARTIAL ROOF CURB MODEL 1RC0455P . . . . . . . . 48
24 ALTITUDE/TEMPERATURE CONVERSION
FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
25 FAN PERFORMANCE - 25 TON . . . . . . . . . . . . . . . . . 52
26 FAN PERFORMANCE - 30 TON . . . . . . . . . . . . . . . . . 54
27 FAN PERFORMANCE - 40 TON . . . . . . . . . . . . . . . . . 56
28 POWER EXHAUST - ONE FORWARD CURVE FAN - 25
TONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
29 POWER EXHAUST - TWO FORWARD CURVED FANS 30 & 40 TONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
30 BELT TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . 63
31 TYPICAL GAS VALVES . . . . . . . . . . . . . . . . . . . . . . . . 69
32 TYPICAL FLAME APPEARANCE . . . . . . . . . . . . . . . . 70
Johnson Controls Unitary Products
50 TYPICAL CONTROL WIRING CONTINUED . . . . . . . . 83
51 LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
52 TYPICAL 25 TON POWER WIRING . . . . . . . . . . . . . . 85
53 TYPICAL STANDARD GAS HEAT WIRING . . . . . . . . 86
54 TYPICAL MODULATING GAS HEAT WIRING . . . . . . 87
55 TYPICAL FLUE BAFFLE . . . . . . . . . . . . . . . . . . . . . . . 90
56 25 TON CHARGING CURVE . . . . . . . . . . . . . . . . . . . 91
57 30 TON CHARGING CURVE . . . . . . . . . . . . . . . . . . . 92
58 40 TON CHARGING CURVE . . . . . . . . . . . . . . . . . . . 93
59 PRESSURE DROP DRY EVAPORATOR COIL VS
SUPPLY AIR CFM - 25 TON . . . . . . . . . . . . . . . . . . . . 94
60 PRESSURE DROP DRY EVAPORATOR COIL VS
SUPPLY AIR CFM - 30 TON . . . . . . . . . . . . . . . . . . . . 95
61 PRESSURE DROP DRY EVAPORATOR COIL VS
SUPPLY AIR CFM - 40 TON . . . . . . . . . . . . . . . . . . . . 96
62 R-410A QUICK REFERENCE GUIDE . . . . . . . . . . . . 103
3
5121842-TIM-A-0515
LIST OF TABLES
Tbl. #
Pg. #
Tbl. #
Pg. #
1
COOLING & ELECTRICAL APPLICATION . . . . . . . . . . 8
29 ALTITUDE CORRECTION FACTORS. . . . . . . . . . . . . 49
2
COOLING & ELEC. APP. LIMITATIONS . . . . . . . . . . . . 8
30FAN PERFORMANCE - 25 TON, . . . . . . . . . . . . . . . . . 51
3
STANDARD GAS HEATING CAPACITIES . . . . . . . . . . 9
31FAN PERFORMANCE - 30 TON , . . . . . . . . . . . . . . . . . 53
4
TEMPERATURE RISE . . . . . . . . . . . . . . . . . . . . . . . . . . 9
32FAN PERFORMANCE - 40 TON, . . . . . . . . . . . . . . . . . 55
5
MINIMUM HEATING CFM . . . . . . . . . . . . . . . . . . . . . . . 9
33COMPONENT STATIC RESISTANCE, . . . . . . . . . . . . 57
6
MODULATING GAS HEATING CAPACITIES . . . . . . . . 9
34 SUPPLY FAN MOTOR AND DRIVE DATA . . . . . . . . . 58
7
MODULATING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 10
35 EXHAUST FAN DRIVE DATA . . . . . . . . . . . . . . . . . . . 58
8
UNIT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9
SUPPLY FAN MOTOR VFD WEIGHTS . . . . . . . . . . . . 11
36POWER EXHAUST - ONE FORWARD CURVED FAN 25
TON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10 EXHAUST FAN MOTOR VFD WEIGHTS . . . . . . . . . . 11
11 UNIT CORNERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . 12
12 UNIT CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . 12
13 CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . 15
14 PIPE SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
15 GENERAL PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . 26
16 REFRIGERANT FACTORY CHARGE R-410A . . . . . . 27
17 ELECTRICAL DATA 25 TON BASIC UNIT R-410A . . . 27
18 ELECTRICAL DATA 30 TON BASIC UNIT R-410A . . . 28
37POWER EXHAUST - TWO FORWARD CURVED FANS 30 & 40 TON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
38 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 64
39 BLOWER SPEED RATE OF CHANGE . . . . . . . . . . . . 65
40 25 TON DRIVE ADJUSTMENT . . . . . . . . . . . . . . . . . . 66
41 30 TON DRIVE ADJUSTMENT . . . . . . . . . . . . . . . . . . 66
42 40 TON DRIVE ADJUSTMENT . . . . . . . . . . . . . . . . . . 67
43 DRIVE ADJUSTMENT FOR POWER EXHAUST - 25
TON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
19 ELECTRICAL DATA 40 TON BASIC UNIT R-410A . . . 28
44 DRIVE ADJUSTMENT FOR POWER EXHAUST - 30 & 40
TON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
20 ELECTRICAL DATA 25 TON W/ELECTRIC HEAT R410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
45 GAS RATE - CUBIC FEET PER HOUR . . . . . . . . . . . . 70
21 ELECTRICAL DATA 30 TON W/ELECTRIC HEAT R410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
47 STATIC RESISTANCE STEAM COIL (25 & 30 TON) . 71
22 ELECTRICAL DATA 40 TON W/ELECTRIC HEAT R410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
49 STATIC RESISTANCE STEAM COIL (40 TON) . . . . . 71
46 STEAM COIL (1 ROW, 40 TON) . . . . . . . . . . . . . . . . . 71
48 STEAM COIL (1 ROW, 25 & 30 TON) . . . . . . . . . . . . . 71
23 ELECTRICAL DATA 25 TON W/POWER EXHAUST R410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
50 HOT WATER COIL (1 ROW 25 & 30 TON) . . . . . . . . . 71
24 ELECTRICAL DATA 30 TON W/POWER EXHAUST R410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
52 WATER PRESSURE DROP (1 ROW, 25 & 30 TON) . 72
25 ELECTRICAL DATA 40 TON W/POWER EXHAUST R410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
54 HOT WATER COIL (2 ROW, 25 & 30 TON) . . . . . . . . 72
26 ELECTRICAL DATA 25 TON W/ELECTRIC HEAT AND
POWER EXHAUST R-410A . . . . . . . . . . . . . . . . . . . . . 35
56 WATER PRESSURE DROP (2 ROW, 40 TON) . . . . . 73
27 ELECTRICAL DATA 30 TON W/ELECTRIC HEAT AND
POWER EXHAUST R-410A . . . . . . . . . . . . . . . . . . . . . 38
28 ELECTRICAL DATA 40 TON W/ELECTRIC HEAT AND
POWER EXHAUST R-410A . . . . . . . . . . . . . . . . . . . . . 41
4
51 HOT WATER COIL (1 ROW, 40 TON) . . . . . . . . . . . . . 72
53 WATER PRESSURE DROP (1 ROW, 40 TONS) . . . . 72
55 WATER PRESSURE DROP (2 ROW, 25 & 30 TON) . 73
57 STATIC RESISTANCE HOT WATER COIL (25 & 30
TON). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
58 STATIC RESISTANCE HOT WATER COIL (40 TON) . 73
59 INDOOR BLOWER BEARING LUBRICATION
SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Johnson Controls Unitary Products
1
Johnson Controls Unitary Products
5
2 - BOTTOM SUPPLY
3 - END RETURN (5)
2
3
6
4
7
N = B, F, J
O = B, G, I
P = B, G, J
Q = C, F, I
R = C, F, J
S = C, G, I
T = C, G, J
U = D, E, H
C = A, F, J
D = A, G, J
E = A, E, H
F = A, E, I
G = A, E, J
H = A, F, H
I = D, F, I
J = D, F, J
7 = C, E, J
8 = C, F, H
9 = D, G, H
2 = B, E, J
3 = B, F, H
4 = C, E, H
6 = C, E, I
Z = B, E, I
Y = B, E, H
X = D, F, H
W = D, E, J
9
10
FILTERS
A
A = STAND.
B = 65%
C = 95%
D = 2" HI-EFF
A
11
field installed. If VFD Exh is also
HEAT CAPACITY
C = 0 (ZERO) NO HEAT
1 = 1 ROW
2 = 2 ROW
1 = 1 ROW
3 = 267 MBH
5 = 533 MBH
8 = 800 MBH (40T ONLY)
4 = 40 KW
8 = 80 KW
1 = 108 KW (1)
5 = 10 HI-EFF
6 = 15 HI-EFF
7 = 20 HI-EFF
8 = 25 HI-EFF (Except 25T)
0 = 7.5 HI-EFF (25T Only)
ID MOTOR (See note 2)
i = 1 inch deflection spring
j = 2 inch deflection spring
1
CONTROL
14
L = FAULT DETECTION DEVICE, DISC &
110V OUTLET
M = FAULT DETECTION DEVICE & DISC
N = CCS CONTROL
K = FAULT DETECTION DEVICE
J = SIMPLICITY SE COM CARD W/DISC
I = SIMPLICITY SE COM CARD W/DISC &
110V OUTLET
2
D = 2,4,5,7
A = 1,3,5,7
B = 2,3,5,7
C = 1,4,5,7
L = 2,4,5,8
Q = 1,3,9,7
R = 2,3,9,7
K = 1,4,5,8
7 = 1,4,9,8
9 = Non-Std
Config
2 = 2,4,9,8
Y = 1,3,9,8
Z = 2,3,9,8
REFRIGERATION
air foil applications.
Contact engineering for
6. Air foil fan available on cooling only.
available in end return configuration.
(See note 4)
5 = STANDARD
9 = STD W/TECHNICOAT
Evaporator Coil
3 = STANDARD 4 = HOT GAS BYPASS
Piping
I = 1,3,5,8
S = 1,4,9,7
T = 2,4,9,7
3 = 13,000 CFM ERV
9 = Non Std Config
Power Exhaust
L = 2, 7
M = 2, 8
N = NONE
P = 1, 0
R = 2, 0
V = A, 6
W = A, 7
X = A, 8
Z = A, 0
2 = 8,000 CFM ERV
EXHAUST (See note 5)
K = 2, 6
0 = 5 HP HI-EFF (25T Only)
6 = 7.5 HP HI-EFF
Motor
3
8 = 15 HP HI-EFF (Except 25 Ton)
7 = 10 HP HI-EFF
1 = MODULATING DAMPERS A = VFD MODULATING
MOTOR
2 = NON-MOD. (ON/OFF)
G = 1, 8
A = BARO
E = 1, 6
F = 1, 7
E = NONE
D = MANUAL Low leak (Not w/PE)
A = DUAL ENTH Low leak type
B, = SINGLE ENTH Low leak type
C, = DRY BULB ENTH Low leak type
ECONOMIZER
110V OUTLET
T = CCS-VAV CONTROL W/DISC.,
S = CCS-VAV CONTROL
110V OUTLET
R = CCS ZONING CONTROL W/DISC.,
Q = CCS ZONING CONTROL
Blower Mount
h = Neoprene
D
H = SIMPLICITY SE COM CARD
13
P = CCS CONTROL W/DISC., 110V OUTLET
A
5. Power exhaust and barometric relief not
12
4. VAV ID Blower requires hot gas bypass .
specified, it will also be cust supplied.
X = STEAM COIL
D = NATURAL GAS, MODULATING HEAT*
T = NATURAL GAS, MODULATING HEAT, SS *
C
only; VFD will be customer supplied and
3. (VFD-CUSTOMER) = Wired for VFD
1. 108KW not available with 208/230V.
NOTES:
1
Head Press. Ctrl.
8
7 = YES
8 = NO
B
Condenser Coil
Fan (See note 6)
a = CV
b = VAV (VFD-FACTORY INSTALLED)
c = BYPASS FACTORY VFD
d = VAV (VFD-CUSTOMER) (3)
Air Volume
V = D, E, I
M = B, F, I
B = A, G, I
K = D, G, I
L = D, G, J
ID BLOWER (See note 4)
7 = 380/415-50
(30T/40T)
2 = 208/230-60
3 = 380-60
4 = 460-60
5 = 575-60
VOLTAGE
3
A = A, F, I
5
1 = STANDARD
2 = TECHNICOAT
N
J = 2,3,5,8
4
Class I blower is limited to 15HP in 25/30Ton
Class I blower is limited to 20HP in 40Ton
Class II blowers are not HP limited
A
HEAT EXCHANGER
E = ELECTRIC HEAT
C = COOLING ONLY
W = HOT WATER COIL
3
e = FORWARD CURVE FAN Class I
f = FORWARD CURVE FAN Class II
g = AIR FOIL FAN [always Class II]
N = NATURAL GAS
S = NATURAL GAS, SS HEAT EXCHANGER
HEAT SOURCE
GAS HEAT - BOTTOM OR REAR SUPPLY ONLY
BOTTOM SUPPLY ONLY
HOT WATER, STEAM & ELECTRIC HEAT -
FRONT SUPPLY - COOLING ONLY
D = 3,2
E = 3,4
F = 3,5
4 - REAR SUPPLY
5 - FRONT SUPPLY
B = 1,4
C = 1,5
1 - BOTTOM RETURN
A = 1,2
CONFIGURATION
2 = 25 TON
3 = 30 TON
4 = 40 TON
BASIC UNIT
GENERATION
M = Tempmaster R-410A
PACKAGE
M
* Drain Pan - stainless steel
* Drain Pan - powder coat
* Premium Cabinet (6 doors)
* Standard Cabinet (4 doors)
Cu/Cu Condenser Coil
Cu/Cu Evaporator Coil
E-Coat Condenser Coil
E-Coat Evaporator Coil
Cu/Cu TECHNICOAT Condenser
Coil
Exhaust VFD (Customer)
(see note 3)
ADDITIONAL
CONFIGURATION
OPTIONS
4
5121842-TIM-A-0515
NOMENCLATURE
5
5121842-TIM-A-0515
EVAPORATOR COIL
AND DRAIN PAN ACCESS
FILTER ACCESS
POWER & CONTROL WIRING
COMPRESSOR ACCESS
REAR
RIGHT
END
HEAT SECTION
FRONT
OPTIONAL POWER
OUTLET (115V)
LEFT END
POWER EXHAUST ACCESS
HEAT SECTION
FILTER DRIERS
EVAPORATOR COIL
AND DRAIN PAN ACCESS
FILTER ACCESS
REAR
SUPPLY BLOWER & MOTOR
FIGURE 1 -
6
COMPONENT LOCATION
Johnson Controls Unitary Products
5121842-TIM-A-0515
GENERAL
Model M52/M53/M54 units are single package cooling only or
cooling with gas, electric, hot water or steam heating
designed for outdoor installation on a rooftop and for non-residential use.
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, steam, or hot water connections and duct
connections. Gas fired units also require installation of a flue
gas outlet hood.
Reference R-410A Quick Reference Guide, Figure 62 for
R-410A Refrigerant information.
SAFETY CONSIDERATIONS
NOTES, CAUTIONS AND WARNINGS
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.
GAS FIRED MODELS
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. Immediately
call your gas supplier from a neighbor’s phone. Follow the
gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department.
This Furnace is not to be used for temporary heating of buildings or structures under construction.
ALL MODELS
This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other
refrigerant may be used in this system. Gage sets,
hoses, refrigerant containers and recovery systems must be designed to handle R-410A. If you
are unsure, consult the equipment manufacturer.
Failure to use R-410A compatible servicing equipment may result in property damage or injury.
Installation and servicing of air conditioning equipment can
be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should
install, repair or service air conditioning equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other
operations should be performed by trained service personnel.
When working on air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit
and other safety precautions that may apply.
Follow all safety codes, including ANSI Z223.1-Latest Edition: wear safety glasses and work gloves; use quenching
cloth for unbrazing operations; have fire extinguisher available for all brazing operations.
Before performing service or maintenance operations on unit, turn off main power switch to unit.
Electrical shock could cause personal injury.
The furnace and its individual 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 0.5 psig. Pressures
greater than 0.5 will cause gas valve damage
resulting in a hazardous condition. If gas valve is
subjected to a pressure greater than 0.5 psig, it
must be replaced. The furnace must be isolated
from the gas supply piping system by closing its
individual manual shut-off valve during any pressure testing of that system at test pressures equal
to or less than 0.5 psig.
Johnson Controls Unitary Products
Improper installation, adjustment, alteration, service or maintenance can cause injury or property
damage. Refer to this manual. For assistance or
additional information consult a qualified installer,
service agency or the gas supplier.
INSPECTION
As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of
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.
7
5121842-TIM-A-0515
REFERENCE
Additional information is available in the following reference
form:
•
254574 - Technical Guide
APPROVALS
Designed certified by CSA, ETL, CETL as follows:
1.
For use as a forced air furnace with cooling unit (gas
heat models).
2.
For outdoor installation only.
3.
For installation on combustible material and may be
installed directly on combustible flooring or Class A,
Class B or Class C roof covering materials.
4.
For use with natural gas (convertible to LP with kit).
After installation, gas fired units must be adjusted to obtain a
temperature rise within the range specified on the unit rating
plate.
If components are to be added to a unit to meet local codes,
they are to be installed at the contractor's and/or the customer's expense.
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).
LOCATION
Use the following guidelines to select a suitable location for
these units:
TABLE 1: COOLING & ELECTRICAL APPLICATION
UNIT POWER
SUPPLY
Not suitable for use with conventional venting systems.
VOLTAGE VARIATIONS
MIN. VOLTS
MAX VOLTS
575-3-60
540
630
208/230-3-60
187
252
460-3-60
432
504
INSTALLATION
PRECEDING INSTALLATION
If a factory option convenience outlet is installed, the weatherproof outlet cover must be field installed. The cover shall be
located in the unit control box. To install the cover, remove
the shipping label covering the convenience outlet, follow the
instructions on the back of the weatherproof cover box, and
attach the cover to the unit using the (4) screws provided.
TABLE 2: COOLING & ELEC. APP. LIMITATIONS
MODEL
LIMITATIONS
208/230-3-60 and 380/415-3-50 units with factory
installed Powered Convenience Outlet Option are
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.
M52
M53
M54
Supply Air CFM
(min./max)
6,00012,500
6,00015,000
8,00020,000
Entering Wet Bulb
Temp (F°) (min./max)
57/75
57/75
57/75
Ambient Temp
40/125
40/125
40/125
LIMITATIONS
Min. Air Temperature on Gas Fired Heat Exchangers (°F)
The installation of this unit must conform to local building
codes, or in the absence of local codes, with ANSI Z223.1
Natural Fuel Gas Code and /or CAN/CGA B149 installation
codes.
Aluminized
25
25
25
Stainless
0
0
0
In U.S.A.:
1.
National Electrical Code ANSI/NFPA No. 70-Latest Edition.
2.
National Fuel Gas Code Z223.1-Latest Edition.
3.
Gas-Fired Central Furnace Standard ANSI Z21.47-Latest Edition.
4.
Local gas utility requirements.
Refer to Table 1 for Cooling and Electrical Application Data
and to Table 2 for Gas Heat Application Data.
8
1.
Unit is designed for outdoor installation only.
2.
Condenser coils must have an unlimited supply of air.
Where a choice of location is possible, position the unit
on either north or east side of building.
3.
Suitable for roof mount on curb.
4.
Roof structures must be able to support the weight of the
unit and its accessories. Unit must be installed on a solid
level roof curb or appropriate angle iron frame.
5.
Maintain level tolerance to 3/4 inches across width and 2
inches along length.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 3: STANDARD GAS HEATING CAPACITIES
INPUT CAPACITY (MBH)1
TOTAL
1ST STAGE
TOTAL
267
213
247
247
267
533
426
247
495
2674
800
638
247
742
AVAILABLE ON
MODELS
1ST STAGE
N3
M52/M53/M54
267
N5
M52/M53/M54
M54 ONLY
N8
1.
GAS RATE, CU. FT./HR.3
OUTPUT
CAPACITY
(MBH)2
GAS HEAT
OPTION
Heating capacity is only staged on CV models. VAV models use only one stage at full capacity.
Blower motor heat not included.
Based on a heat content of 1075 Btu/Ft.3
2.
3.
4.
Unit Control Board with 3 heating outputs only. For all other Unit Control Boards the 1st Stage is 533 MBH.
TABLE 4: TEMPERATURE RISE
TABLE 5: MINIMUM HEATING CFM
MODULES
MODULES
TON
TON
1
2
3
25
5-35
25-55
-
30
5-35
20-50
40
5-30
10-45
11
2
3
25
6,000
7,183
-
-
30
6,000
7,901
-
25-55
40
8,000
8,779
13,169
1.
Calculated minimum CFM for maximum heat
rise is 5,644 for 25/30T and 6,584 for 40T, 1
module.
TABLE 6: MODULATING GAS HEATING CAPACITIES
INPUT CAPACITY (MBH)
OUTPUT CAPACITY
(MBH)1
MINIMUM
MAXIMUM
267
6
213
64
247
69
533
12
426
64
495
69
800
17
638
64
744
AVAILABLE ON
MODELS
MINIMUM
MAXIMUM
D32
M52/M53/M54
69
D52
M52/M53/M54
D82
M54 ONLY
1.
2.
GAS RATE, CU. FT./HR.
STEPS
GAS HEAT OPTION
Output Capacity at Full Fire.
Modulating Gas Heat available on CV models only.
Johnson Controls Unitary Products
9
5121842-TIM-A-0515
TABLE 7: MODULATING HEAT
GAS HEAT OPTION
D3
(Turn down ratio
3.8 to 1)
D5
(Turn down ratio
7.7 to 1)
D8
(Turn down ratio
11.5 to 1)
STAGES OF GAS CONTROL (% OF FULL HEAT OUTPUT)
AVAILABLE ON MODELS
STEP
INPUT
OUTPUT
1
69,333
55,466
2
106,666
85,333
3
165,332
132,266
M52, M53, M54
4
202,665
162,132
5
229,332
183,466
6
266,666
213,333
1
69,333
55,466
2
106,666
85,333
3
165,332
132,266
4
202,665
162,132
5
229,332
183,466
6
266,666
213,333
M52, M53, M54
7
325,331
260,265
8
362,664
290,132
9
389,331
311,465
10
426,664
341,331
11
495,997
396,798
12
533,330
426,664
1
69,333
55,466
2
106,666
85,333
3
165,332
132,266
4
202,665
162,132
5
229,332
183,466
6
266,666
213,333
7
325,331
260,265
8
362,664
290,132
M54 Only
9
389,331
311,465
10
426,664
341,331
11
495,997
396,798
12
533,330
426,664
13
586,663
469,330
14
655,996
524,797
15
693,329
554,663
16
762,662
610,130
17
799,995
639,996
% OF TOTAL OUTPUT
26%
40%
62%
76%
86%
100%
13%
20%
31%
38%
43%
50%
61%
68%
73%
80%
93%
100%
9%
13%
21%
25%
29%
33%
41%
45%
49%
53%
62%
67%
73%
82%
87%
95%
100%
SPREADER BARS
(3 PLACES)
If a unit is to be installed on a roof curb other than a
TempMaster roof curb, gasketing must be applied to
all surfaces that come in contact with the unit underside.
If a unit is to be installed on an angle iron frame it is
recommended that it be sized to allow the bottom
rail to overhang to facilitate installation of condensate drains (see Fig. 4).
27”
CABLES
RIGGING:
(1) RIG WITH SIX CABLES AND THREE SPREADER
BARS AT LEAST 98” ACROSS THE WIDTH OF THE UNIT.
32”
(2) CENTER OF GRAVITY INCLUDES ECONOMIZER
AND POWER EXHAUST.
ALL PANELS MUST BE SECURED IN
PLACE WHEN THE UNIT IS LIFTED.
FIGURE 2 -
10
TYPICAL RIGGING
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 8: UNIT WEIGHTS
COMPONENT
TABLE 9: SUPPLY FAN MOTOR VFD WEIGHTS
25 TON
30 TON
40 TON
Basic Unit
4410
4565
Gas Heat
267 MBH
180
180
533 MBH
320
320
800 MBH
Electric Heat
40KW
40
40
80KW
105
105
108KW
110
110
Hot Water Heat
1 Row Coil
70
70
2 Row Coil
85
85
Steam Heat
1 Row Coil
85
85
Blower
Forward Curve Fan (Std Fan)
0
0
FC IGV
155
155
Air Foil Fan
135
135
AF IGV
155
155
Motor - Supply Fan
7.5hp
110
10hp
145
145
15hp
200
200
20hp
240
240
25hp
300
Supply Fan Motor VFD
See Table 9
Refrigeration
T-Coat Evap.
32
30
T-Coat cond.
32
30
Hot Gas Bypass
10
10
Low Ambient Head Pressure Control
208-230/380/460
5
5
575
25
25
Filters
6" Rigid
70
70
Supply Fan Motor VFD
4845
230V
460V
575V
W/O Bypass
180
320
450
7.5hp
60
25
30
10hp
60
25
30
15hp
75
50
60
40
105
110
20hp
75
50
60
25hp
115
50
60
70
85
7.5hp
155
90
120
10hp
155
90
120
85
15hp
185
140
155
20hp
185
140
155
25hp
255
140
155
0
175
155
180
W/Bypass
TABLE 10: EXHAUST FAN MOTOR VFD WEIGHTS
Exhaust Fan Motor
145
200
240
300
230V
460V
575V
5hp
15
10
20
7.5hp
50
15
20
10hp
50
15
20
15hp
65
40
50
W/O Bypass
40
40
10
NOTE: If the unit is VAV, add the weight of an exhaust
VFD - it will be in the unit.
.
5
25
REAR
CENTER OF
GRAVITY
C
B
RIGHT END
CONDENSER
COILS
70
D
Exhaust1
Exhaust Type
Barometric
Modulated
Exhaust Motor
5hp
7.5hp
10hp
15hp
Exhaust Motor VFD
Std. Econ.
Disconnect
110V outlet
Optilogic
Partial Curb
1.
X
92”
45
140
65
275
65
275
80
110
145
200
80
110
145
200
See Table 10
80
110
145
200
235
235
15
55
20
15
55
20
415
415
Economizer
235
Control
15
55
20
Roof Curb
415
Y
A
240”
FIGURE 3 1.
FRONT
CENTER OF GRAVITY1
Refer to Tables 11 and 12 for A, B, C, D and X and Y
data respectively.
If Supply Fan VAV is selected, add the weight of an
Exhaust VFD, Table 9.
Johnson Controls Unitary Products
11
5121842-TIM-A-0515
RIGGING AND HANDLING
This unit is not designed to be handled with a fork-truck.
All panels must be secured in place when the unit
is lifted.
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 cable slings to the lifting lugs provided in
the unit base rails. Spreaders MUST be used across the top
of the unit. Refer to Figure 2.
The condenser coils should be protected from
damage by the rigging cables with plywood or
other suitable material.
An adhesive backed cover is provided over the
outside of the combustion air inlet opening on gas
fired units 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
(Refer to Figures 7).
•
Rig with six cables and spread with three 98-inch
spreaders across width of unit.
•
Refer to Tables 8 and 11 for unit weight.
•
Center of gravity includes economizer, exhaust or return
air fan (Refer to Table 12).
TABLE 11: UNIT CORNERWEIGHT
25 TON
30 TON
40 TON
UNIT
DESCRIPTION
A
B
C
D
A
B
C
D
A
B
C
D
Basic Unit
870
949
1352
1239
930
972
1360
1303
969
969
1454
1454
Basic Unit With
Economizer
1018
1111
1313
1203
1076
1124
1328
1272
1058
1058
1482
1482
Basic Unit With
Economizer and
Gas or Electric Heat
994
1084
1418
1300
1073
1073
1403
1403
1102
1055
1503
1570
Basic Unit With
Economizer and
Gas or Electric Heat
and Power Exhaust
1220
1275
1318
1262
1275
1275
1410
1410
1335
1278
1485
1551
NOTES: Basic Unit = cooling only, 10hp FC fan.
+ Econ = +235lb
+ Heat = single stage gas, 180 lb
+ Power Exhaust = modulating 7.5hp
CLEARANCES
TABLE 12: UNIT CENTER OF GRAVITY
25 TON
30 TON
40 TON
MODEL
X
Y
X
Y
X
Y
Basic Unit
99”
48”
100”
47”
96”
46"
Basic Unit /w
Econ.
110”
48”
110”
47”
100”
46"
Basic Unit /w
Econ. & Gas or
Elect. Heat,
Steam or Hot
Water Heat
104”
48”
104”
46”
99”
45"
Basic Unit /w
Econ. & Gas or
Elect. Heat, &
Power Exhaust
118”
47”
114”
46”
111”
45"
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 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149
installation codes-Latest Edition and/or applicable provisions
of the local building codes. Refer to Figure 8 for clearances
required for combustible construction, servicing, and proper
unit operation.
(COOLING OPERATION) Do not permit overhanging structures or shrubs to obstruct condenser air
discharge outlet, combustion air inlet or vent outlets.
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Johnson Controls Unitary Products
5121842-TIM-A-0515
When the unit is equipped with power exhaust fans or return
air fan the return duct should have a 90 elbow before opening
to the building space to abate noise.
(GAS HEATING OPERATION)
Excessive exposure to contaminated combustion
air will result in safety and performance related
problems. To maintain combustion air quality, the
recommended source of combustion air is the outdoor air supply.
The outdoor air supplied for combustion should be
free from contaminants due to chemical exposure
that may be present from the following sources:
•
•
•
•
•
Commercial buildings
Indoor pools
Laundry rooms
Hobby or craft rooms
Chemical storage areas
The following substances should be avoided to
maintain outdoor combustion air quality:
•
•
•
•
•
•
•
•
•
•
•
•
•
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine based swimming pool cleaners
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
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 should be used. This will 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.
Johnson Controls Unitary Products
The supply and return air duct systems should be designed
for the CFM and static pressure requirements of the job. They
should NOT be sized to match the dimensions of the duct
connections on the unit.
If the unit is equipped with hot water or steam heat then the
supply air direction will be down only.
AIR HOODS FOR FIXED OUTSIDE AIR
(UNITS WITH MANUAL ECONOMIZER)
These hoods are factory installed. The dampers may be
adjusted by loosening the thumb screw, turning the lever to
the desired position, and retightening the thumb screw.
AIR HOODS FOR ECONOMIZER
There are (3) economizer outside air intake hoods provided
with the unit. The hood on the end of the unit is factory
mounted. The (2) front and rear hoods are made operational
per the following instructions.
Remove the screws holding the economizer hood shipping
covers in place. Discard covers.
Rotate the hoods out (each hood is hinged in the lower corner). Secure the hoods with screws along the top and sides.
Apply a bead of RTV sealer along the edge of both hoods
and each pivot joint to prevent water leakage.
Seal any unused screw holes with RTV or by replacing the
screw.
AIR HOODS FOR EXHAUST AIR
When furnished, these hoods and dampers are factory
installed.
CONDENSATE DRAIN
There is one condensate drain connection. Trap the connection per Figure 4. The trap and drain lines should be protected from freezing.
Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install condensate drain lines
from the 1-1/2 inch NPT female connections on the unit to an
open drain.
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5121842-TIM-A-0515
FILTERS
U N IT B A S E
D R A IN C O N N E C T IO N
F A C T O R Y IN S T A L L E D
Y
R O
C U
O
P E R IM
S U P P
S T R U C
R
O F
R B
E T E R
O R T
T U R E
Throwaway or rigid filters are supplied with each unit. Filters
must always be installed ahead of 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. Required filter sizes are
shown in Table 15. The unit should not be operated without
filters properly installed.
H
F IE L D S U P P L IE D
THERMOSTAT (CONSTANT VOLUME UNITS)
THERMOSTAT
TERMINALS
Y - M IN IM U M 2 "
H - 1 /2 " P L U S T O T A L S T A T IC P R E S S U R E - M IN IM U M
FIGURE 4 -
RECOMMENDED DRAIN PIPING
CONTROL
TERMINAL
BLOCK
W1
SERVICE ACCESS
W2
Access to all serviceable components is provided by the following hinged doors:
W3
W1
W2
•
Furnace compartment
•
Supply Air Fan compartment Evaporator Coil compartment (three doors)
•
Filter compartment economizer compartment (two doors)
•
Power Exhaust compartment (two doors)
•
Main control panels (one door)
Y1
G
Y1
OCC
Y2
P
Y3
P1
Y4
Y2
X
G
R
Refer to Figure 1 for location of these access panels.
R
SD
C
C
EXPANSION
BOARD
TERMINAL
BLOCK
1
Make sure that all screws and panel latches are
replaced and properly positioned on the unit to
maintain an air-tight seal.
RC
2
OCC
X
COMPRESSORS
Y3
3
Y4
Units are shipped with compressor mountings factoryadjusted and ready for operation.
DO NOT loosen compressor mounting bolts.
W3
TERMINALS ON A
LIMITED NUMBER
OF THERMOSTATS
1
Jumper is required for any combination of R, RC, or RH.
2
OCC is an output from the thermostat to indicate the Occupied condition.
3
X is an input to the thermostat to display Error Status conditions.
FIGURE 5 -
TYPICAL THERMOSTAT WIRING
The thermostat, if used, should be located on an inside wall
approximately 56 inches above the floor where it will not be
14
Johnson Controls Unitary Products
5121842-TIM-A-0515
subject to drafts, sun exposure or heat from electrical fixtures
or appliances. Follow manufacturer's instructions enclosed
with sensor for general installation procedure (See Figure 5).
Refer to Table 13 for control wire sizing and maximum length.
location in the baserail should be routed so that it does not
interfere with the doors of the unit access panels.
TABLE 13: CONTROL WIRE SIZES
WIRE SIZE
MAXIMUM LENGTH
20 AWG
100 Feet
18 AWG
150 Feet
SPACE SENSOR (VARIABLE AIR VOLUME UNITS)
The space sensor, if used, should be located on an inside
wall approximately 56 inch 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 National
Electrical Code (NEC) ANSI / NFPA 70-Latest Edition and / or
local ordinances. The unit must be electrically grounded in
accordance with the NEC 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 Table 1.
The internal wiring harnesses furnished with this unit are an
integral part of the design certified unit. Field alteration to
comply with electrical codes should not be required. 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.
Power supply to the unit must be NEC Class 1 and must
comply with all applicable codes. A disconnect switch must
be provided (factory option available). The switch must be
separate from all other circuits. Wire entry at knockout openings requires conduit fittings to comply with NEC and/or Local
Codes. Refer to Figures 13, 14, 15, and 16 for installation
location of openings.
If installing a field mounted disconnect on the unit, refer to
Figure 17 for the recommended mounting location.
Unitstrut™ or equivalent rails should be mounted as shown to
provide structure for mounting. The location of the rails
should be adjusted to fit the disconnect within the dimensions
shown. Conduit run from the disconnect to the power entry
Johnson Controls Unitary Products
Use care to avoid damage when drilling holes for
the disconnect mounting.
NOTE: Since not all local codes allow mounting a disconnect on the unit, please confirm compliance with
local code before mounting a disconnect on the unit.
Electrical wiring must be sized properly to carry the load.
Each unit must be wired with a separate branch circuit fed
directly from the meter panel and properly fused.
When connecting electrical power and control wiring to the unit, waterproof 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 Figure 5 for typical field wiring and to the appropriate
unit wiring diagram mounted inside control doors for control
circuit and power wiring information.
POWER WIRING DETAIL
Units are factory wired for the voltage shown on the unit
nameplate. The main power block requires copper wires.
Refer to Electrical Data Tables 17 through 28 to size power
wiring, fuses and disconnect switch. All field supplied wiring,
fuses and disconnects must comply with applicable NEC
codes.
Power wiring is brought into the unit through the side of the
baserail or the bottom of the unit/control box inside the curb.
The baserail has a 2-1/2” diameter hole for field wiring and a
3-5/8” hole is provided for a through-the-curb connection. A
removable patch plate covers both the openings.
Waterproof connections MUST be used to ensure
that water cannot penetrate the roof or roof curb.
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5121842-TIM-A-0515
GAS HEATING
On VAV units with gas fired furnace, ALL INDIVIDUAL ROOM DAMPER BOXES MUST BE CONTROLLED FULL OPEN DURING HEATING
OPERATION TO ENSURE PROPER AIRFLOW
OVER THE FURNACE. A control contact powered
by the “VAV OPEN” terminals on the Simplicity®
SE control is provided for the damper box interlock. this contact is normally open, and is closed
during heating operation.
FIGURE 6 -
TYPICAL GAS PIPING CONNECTION
Gas piping recommendations:
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-Latest Edition
should be followed in all cases unless superseded by local
codes or gas company requirements. Refer to Table 14.
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
will have to be installed outside of the unit.
3.
Use wrought iron or steel pipe for all gas lines. Pipe dope
should be applied sparingly to male threads only.
The heating value of the gas may differ with locality. The
value should be checked with the local gas utility.
TABLE 14: PIPE SIZES
NOMINAL IRON PIPE, SIZE
LENGTH IN
FEET
1-1/4 IN.1
1-1/2 IN.1
2 IN.1
10
1,050
1,600
3,050
20
730
1,100
2,100
30
590
890
1,650
40
-
760
1,450
50
-
-
1,270
60
-
-
1,150
70
-
-
1,050
80
-
-
990
1.
Natural gas may contain some propane. Propane,
is an excellent solvent and will quickly dissolve
white lead or most standard commercial pipe sealing compounds. Therefore, special shellac base
pipe dope compounds such as Gaskolac or Stalastic, and compounds such as Rectorseal #5,
Clyde’s or John Crane must be applied for wrought
iron or steel pipe.
4.
All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out the
loose particles. 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 shutoff 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.
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 0.5 psig.
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.
NOTE: There may be a local gas utility requirement specifying a minimum diameter for gas piping. All units
require a 1-1/4 inch pipe connection at the entrance
fitting. Line should not be sized smaller than the
entrance fitting size.
GAS CONNECTION
The gas supply line should be routed within the space and
penetrate the roof at the gas inlet connection of the unit.
Refer to Figures 13 through 16 to locate the access opening.
Typical supply piping arrangements are shown in Figure 6.
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Johnson Controls Unitary Products
5121842-TIM-A-0515
VENT AND COMBUSTION AIR
NOTE:
Disconnect gas piping from unit when leak testing
at pressures greater than 0.5 psig. Pressures
greater than 0.5 psig will cause gas valve damage
resulting in a hazardous condition. If gas valve is
subjected to pressure greater than 0.5 psig, it must
be replaced.
7.
A 1/8 inch N.P.T. plugged tapping, accessible for test
gage connection, must be installed immediately
upstream of the gas supply connection to the furnace.
EXHAUST VENT OUTLET
COMBUSTION
AIR INLET
All the hoods and hardware are shipped within the
evaporator section. Each hood must be properly
attached to the furnace doors to assure proper
operation and compliance with CSA/ETL safety certification. (Refer to Figure 7.)
The products of combustion are discharged horizontally
through hooded openings in the gas heat access doors.
(Figure 7)
1.
Remove the shipping covers that are attached to the
heat section door covering the flue outlets.
2.
Locate the flue which is shipped in the evaporator section.
3.
Place the flue over the flue outlet and attach with screws
provided.
4.
Refer to the Gas Furnace Operation Instruction in the
Start-up Section of this manual for further instructions.
VENT FLUE
ASSEMBLY
REMOVE SHIPPING
LABELS PRIOR TO
VENT INSTALLATION
FIGURE 7 -
HEAT SECTION DOOR
VENT AND COMBUSTION AIR
HOODS
Johnson Controls Unitary Products
17
5121842-TIM-A-0515
10'
LEFT
END
60"
RIGHT
END
60"
60"
FRONT
60"
REAR
* Front is the side with access to the Electrical/Gas Controls
LEFT
RIGHT
REAR
FRONT
TOP
FIGURE 8 -
60"
60"
60"
60"
10'
NOTE: DO NOT use the unit roof to support any type of
structure bracing.
CLEARANCES
25 AND 30 TON UNIT
25 - 40 TON UNIT
10’
ENDS
60”
FIGURE 9 -
18
40 TON UNIT
ENDS
60”
CLEARANCES - HOOD/ECONOMIZER & MOTOR DRIVE - SIDE
Johnson Controls Unitary Products
5121842-TIM-A-0515
LEFT END
15.93
79.0
FRONT SIDE
15.93
20.12
19.6
RAIN HOOD FOR
FIXED OUTSIDE AIR
OR ECONOMIZER
33.90
33.90
HOOD FOR
OPTIONAL
EXHAUST AIR
(NOT AVAILABLE WITH
END RETURN OR WITH
FIXED OUTSIDE AIR)
29.36
59.52
7.94
RAIN HOOD FOR
OPTIONAL POWER EXHAUST
OR BAROMETRIC RELIEF
(NOT AVAILABLE WITH
END RETURN OR WITH
FIXED OUTSIDE AIR)
FIGURE 10 - CLEARANCES - HOOD/ECONOMIZER & MOTOR DRIVE - FRONT & END
ELECTRIC HEAT
Units with electric heat are fully wired and operational when
shipped. Constant volume units are designed for two equal
steps of capacity for 80 and 108 kWH heat; 40 kW heat is one
step only. Heat outputs on VAV units are all turned on
together at full heat capacity.
The hot water coil is located downstream of the supply air fan
and just above the supply air opening in the bottom of the
unit.
Refer to Tables 50 through 58 and Figures 33 through 46 for
flow rate and capacity.
HOT WATER HEAT
The TempMaster units (25, 30, and 40 Ton sizes) can be furnished with a hot water coil as the heat source. One or two
row coil units will be factory installed in the heating section.
NOTE: The hot water control valve will not be provided. The
installer will need to provide a hot water control
valve, to connect the hot water piping and power
wiring at the job site for the hot water heat section to
be operational.
There are no provisions in the coil or control
sequence to prevent freezing of condensate. The
control valve, piping and field installed wiring connections are particularly vulnerable because they
are installed in the vestibule outside of the conditioned air stream. The installing party will be
responsible for properly insulating and installing
power and control wiring, to the actuator and piping.
In one row hot water coil systems DO NOT exceed
a 40 gallons per minute flow rate.
DO NOT use hot water coils as steam coils under
any circumstances.
All piping, control valves, and wiring that is field
installed must be properly insulated and conform
to all local and national codes.
NOTE: For all hot water coils the entering water temperature should not exceed 200°F.
Johnson Controls Unitary Products
In two row hot water coil systems DO NOT exceed
an 80 gallons per minute flow rate.
Condensate will freeze on the control valve and
piping if they are not properly insulated. Insulating
the control valve and piping is the responsibility of
the installing party.
PIPING CONNECTIONS
The hot water piping must enter the unit through the floor of
the heat section compartment. The access doors to the com-
19
5121842-TIM-A-0515
partment are gasketed so the compartment can be sealed.
However, as added protection for water leakage into the
space, the piping access holes should be sealed with a heat
resistant mastic Figure 11 shows the location of the compartment and piping connections.
Piping access holes should be sealed with a heat
resistant mastic to prevent damage to equipment.
DO NOT use tin based solder. Brazing with tin
based solder could cause equipment damage or
possible injury to tenants of the structure that is
being conditioned.
NOTE:
The steam control valve, power and control wiring to
the actuator of the valve is the responsibility of the
installing party.
All piping and control valves, and wiring that is
field installed must be properly insulated and conform to all local and national codes.
There are no provisions in the coil or control
sequence to prevent freezing of condensate. The
control valve, piping and field installed wiring connections are particularly vulnerable because they
are installed in the vestibule outside of the conditioned air stream. The installing party will be
responsible for properly insulating and installing
power and control wiring, to the actuator and piping.
DO NOT use steam coils as hot water coils under
any circumstances.
(1 O R 2 R O W )
In steam coil systems, the steam pressure shall
not exceed 15 PSI.
C O N D E N S IN G
S E C T IO N
H O T W A T E R
C O IL
2 6 "
IN L E T (2 ")
1 5 .8 "
PIPING CONNECTIONS
O U T L E T (2 ")
1 1 .8 8 "
O U T S ID E O F
B A S E R A IL
8 .3 8 "
2 .2 5 "
2 .5 5 "
Refer to Tables 46 through 49 and Figures 47 and 48 for flow
rate and capacity.
8 8 .7 5 "
H E A T S E C T IO N
C O M P A R T M E N T
CL
FIGURE 11 - HOT WATER PIPING CROSS-SECTION
STEAM HEAT
The steam piping must enter the unit through the floor of the
heat section compartment. The access doors to the compartment are gasketed so the compartment can be sealed. However, as added protection for condensate leakage into the
space, the piping access holes should be sealed with a heat
resistant mastic. The following figure illustrates the location of
the compartment and piping connections.
The TempMaster units (25, 30 and 40 Ton sizes) can be furnished with a single row steam coil. The steam coils are a
factory installed option.
Piping access holes should be sealed with a heat
resistant mastic to prevent damage to equipment.
T O P V IE W
C O N D E N S IN G
S E C T IO N
S T E A M
C O IL
2 6 "
O U T L E T (1 1 /2 ")
1 5 .8 "
IN L E T (2 ")
8 "
2 .5 5 "
9 "
H E A T S E C T IO N
C O M P A R T M E N T
O U T S ID E O F
B A S E R A IL
8 .3 8 "
8 8 .7 5 "
CL
DO NOT use tin based solder. Brazing with tin
based solder could cause equipment damage or
possible injury to tenants of the structure that is
being conditioned.
FIGURE 12 - STEAM PIPING CROSS-SECTION
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Johnson Controls Unitary Products
5121842-TIM-A-0515
STATIC PRESSURE CONTROL PLASTIC TUBING
EXHAUST STATIC PRESSURE
On units with variable frequency drives (VFD’s) or inlet guide
vanes (IGV's) on the supply blower and/or power exhaust
fans, pressure sensing tubing must be field supplied and
installed. All tubing must be installed from the transducers
(located in the unit) to the location in the building (or
ductwork) where a constant pressure is desired. The tubing
must also be installed from the transducers to a low-side reference to the atmosphere.
If a modulating-damper or variable frequency drive power
exhaust is installed, there will be a building pressure sensor
(BPS) in the control box directly below the unit Simplicity SE
control. This ± .25 IWG/0-5VDC transducer sends a building
pressure signal to the control. A sensing tube must be
installed from a representative location in the building to the
HI port of the transducer. Tubing must also be run between
the low pressure tap of the transducer to atmospheric pressure.
The supply air duct pressure sensor (DPS) is located in the
control box directly below the unit Simplicity SE control. Plastic tubing (1/4”) must be run 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
desired. Tubing must also be run between the low pressure
tap of the transducer to atmospheric pressure. Changing the
adjustment is done to the duct pressure setpoint in the control.
Johnson Controls Unitary Products
Changing the adjustment is done to the building pressure setpoint in the control.
Do not run plastic tubes in the supply or return air
ducts as air movement could cause erroneous
sensing. If tubes penetrate bottom of unit be sure
openings are sealed against air and water leakage.
21
5121842-TIM-A-0515
RETURN AIR
SUPPLY AIR
REAR
RIGHT
END
SEE
SEE DETAIL
C
DETAIL
B
64"
72.25”
99.5”
FRONT
92"
LEFT
END
131.5”
RIGHT
END
REAR
4.5"
OPEN
3.625"
80.93"
SEE
DETAIL
A
4.5"
26"
71.61"
12"
M IN
15.89"
6.46"
88.7"
38.59"
127.5"
83"
FRONT
LEFT
END
CL
240"
4.5"
CL
TO GAS VALVE
MANIFOLD
2-1/2”
DIA. HOLES
3-5/8"
4-5/8”
7”
BASE RAIL
2.31”
BASE RAIL
11”
Ø 2-1/2”
1 -1 /2 " F P T
DETAIL A
(DRAIN CONNECTION)
28”
6.45"
1-1/4” NPT
DETAIL B
(ELECTRICAL CONNECTION)
FOR COOLING ONLY AND ALL HEATING APPLICATIONS
DETAIL C
(GAS CONNECTION
THROUGH CURB)
FIGURE 13 - BOTTOM SUPPLY AND RETURN
22
Johnson Controls Unitary Products
5121842-TIM-A-0515
NOTE:
FACTORY INSTALLED POWER
EXHAUST CANNOT BE ORDERED
WITH END RETURN.
RETURN AIR
SUPPLY AIR
REAR
RIGHT END
SEE
DETAIL
B
7-7/8”
SEE
DETAIL
C
64"
72.25”
24.9”
"
6.25”
76-3/8”
LEFT END
99.5”
131.5”
92"
FRONT
RIGHT
END
REAR
4.5"
OPEN
80.93"
3.625"
SEE
DETAIL
A
71.61"
26"
12"
MIN
6.46"
15.89"
C
L
88.7"
FRONT
LEFT END
240"
TO GAS VALVE
MANIFOLD
2-1/2”
DIA. HOLES
3-5/8"
4-5/8”
7”
28”
BASE RAIL
2.31”
6.45"
11”
BASE RAIL
2-1/2"
1-1/2" FPT
DETAIL A
(DRAIN CONNECTION)
DETAIL B
(ELECTRICAL CONNECTION)
FOR COOLING ONLY AND ALL HEATING APPLICATIONS
1-1/4” NPT
DETAIL C
(GAS CONNECTION
THROUGH CURB)
FIGURE 14 - END RETURN, BOTTOM SUPPLY
Johnson Controls Unitary Products
23
5121842-TIM-A-0515
FRONT SUPPLY: FOR COOLING ONLY APPLICATIONS
REAR SUPPLY: FOR COOLING ONLY OR GAS HEAT APPLICATIONS
FRONT
REAR
RETURN AIR
SUPPLY AIR
REAR
RIGHT END
26"
55"
64"
SEE
DETAIL
B
92"
8.15"
SEE
DETAIL
C
RIGHT
END
REAR
80.93"
SEE
DETAIL
A
4.5"
99.5”
131.5”
FRONT
LEFT END
72.25”
OPEN
3.625"
12"
MIN
6.46"
38.59"
FRONT
83"
TO GAS VALVE
MANIFOLD
240"
LEFT END
4.5"
2-1/2”
DIA. HOLES
3-5/8"
4-5/8”
7”
28”
BASE RAIL
2.31”
6.45"
11”
BASE RAIL
1-1/2" FPT
DETAIL A
(DRAIN CONNECTION)
2-1/2"
DETAIL B
(ELECTRICAL CONNECTION)
FOR COOLING ONLY AND ALL HEATING APPLICATIONS
1-1/4” NPT
DETAIL C
(GAS CONNECTION
THROUGH CURB)
FIGURE 15 - BOTTOM RETURN, FRONT & REAR SUPPLY
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Johnson Controls Unitary Products
5121842-TIM-A-0515
FRONT SUPPLY: FOR COOLING ONLY APPLICATIONS
REAR SUPPLY: FOR COOLING ONLY OR GAS HEAT APPLICATIONS
FRONT
26
26""
55"
REAR
RETURN AIR
REAR
SUPPLY AIR
RIGHT
END
26"
55"
64”
7-7/8”
24.9”
72.25”
76-3/8”
8.15"
6.25”
SEE
DETAIL
B
92”
LEFT
END
SEE
DETAIL
C
99.5”
131.5”
FRONT
RIGHT
END
REAR
OPEN
3.625"
80.93"
SEE
DETAIL
A
12"
MIN
6.46"
FRONT
LEFT
END
240"
TO GAS VALVE
MANIFOLD
2-1/2”
DIA. HOLES
3-5/8"
4-5/8”
7”
28”
BASE RAIL
2.31”
6.45"
11”
BASE RAIL
2-1/2"
1-1/2" FPT
DETAIL B
(ELECTRICAL CONNECTION)
DETAIL A
(DRAIN CONNECTION)
FOR COOLING ONLY AND ALL HEATING APPLICATIONS
1-1/4” NPT
DETAIL C
(GAS CONNECTION
THROUGH CURB)
FIGURE 16 - END RETURN, FRONT & REAR SUPPLY
Johnson Controls Unitary Products
25
5121842-TIM-A-0515
TABLE 15: GENERAL PHYSICAL DATA
UNIT SIZE
UNIT EER / IPLV
(STANDARD CAPACITY EVAPORATOR)
NUMBER/SIZE
TYPE
UNIT CAPACITY STEPS
NUMBER / TYPE
DIAMETER X WIDTH (INCHES)
HP RANGE
CFM RANGE (FULL LOAD)
ESP RANGE
NUMBER/SIZE/TYPE
HP RANGE (SINGLE MOTOR)
CFM
SIZE (SQ. FT.)
ROWS/FPI
SIZE (SQ. FT.)
ROWS/FPI
QUANTITY / DIAMETER (INCHES)
NOMINAL CFM
MOTOR HP
KW RANGE
40 KW / CAPACITY STEPS (CV/VAV)
80 KW / CAPACITY STEPS (CV/VAV)
108 KW / CAPACITY STEPS (CV/VAV)
UNIT SIZE
267 MBH CAPACITY STEPS (CV/VAV)
533 MBH CAPACITY STEPS (CV/VAV)
800 MBH CAPACITY STEPS (CV/VAV)
267 MBH “MODULATING” CAPACITY STEPS (CV ONLY)
533 MBH “MODULATING” CAPACITY STEPS (CV ONLY)
800 MBH “MODULATING” CAPACITY STEPS (CV ONLY)
SIZE (INCHES)
CAPACITY
25 TON
10.5 / 12.3
COMPRESSOR DATA
4 x 5.7Ton
Scroll
25%, 50%, 75%, 100%
INDOOR FAN AND DRIVE
1 / FC
22 x20
7.5 - 20
6,000 - 12,500
0.2” - 4.0”
EXHAUST FAN
1/FC
5 - 10
3,000 - 9,000
EVAPORATOR COIL
26.0
3 / 16
CONDENSER COIL
65
2/16
CONDENSER FANS
4 / 24
6,800
1.0
ELECTRIC HEAT
40 - 108
1
2/1
3 / 12
NATURAL GAS HEAT
25 TON
1/1
2/1
6/1
12 / 2
HOT WATER COIL
22.5” x 65”
25 Ton
STEAM COIL
SIZE (INCHES)
TYPE
NUMBER / SIZE
FACE AREA (SQ. FT.)
NUMBER / SIZE
FACE AREA (SQ. FT.)
NUMBER / SIZE
FACE AREA (SQ. FT.)
NUMBER / SIZE
FACE AREA (SQ. FT.)
1.
2.
26
30 TON
1
40 TON
10.1 / 11.0
10.11 / 11.0
4 x 7 Ton
Scroll
25%, 50%, 75%, 100%
4 x 8.6 Ton
Scroll
25%, 50%, 75%, 100%
1 / FC
22 x 20
10 - 25
6,000 - 15,000
0.2" - 4.0”
1 / FC
25 x 22
10 - 25
8,000 - 18,000
0.2" - 4.0"
2/FC
7.5 - 15
4,000 - 15,000
2/FC
7.5 - 15
4,000 - 18,000
26.0
4 / 16
30.4
4 / 16
78
2 /16
104
2 /16
4 / 24
7,200
1.5
4 / 30
9,600
1.5
40 - 108
1
2/1
40 - 108
1
2/1
3 / 12
3 / 12
30 TON
1/1
2/1
40 TON
1/1
2/1
6/1
12 / 2
-
3 / 12
6/1
12 / 2
17 / 3
22.5" X 65”
30 Ton
22.5" X 65”
40 Ton
21" X 65"
Steam Coil
FILTERS 2" TA
4 / 16 x 25 & 6 / 20 x 25
4 / 16 x 25 & 6 / 20 x 25
30.4
30.4
FILTERS 2" PLEATED, 30%
4 / 16 x 25 & 6 / 20 x 25
4 / 16 x 25 & 6 / 20 x 25
30.4
30.4
FILTERS 65% RIGID W/ 2” TA PREFILTERS
4 / 16 x 25 & 6 / 20 x 25
4 /16 x 25 & 6 / 20 x 25
30.4
30.4
FILTERS 95% RIGID W/ 2” TA PREFILTERS
4 ea. 16 x 25 / 6 ea. 20 x 25
4 ea. 16 x 25 / 6 ea. 20 x 25
30.4
30.4
4 / 16 x 25 & 6 / 20 x 25
30.4
4 / 16 x 25 & 6 / 20 x 25
30.4
4 / 16 x 25 & 6 / 20 x 25
30.4
4 ea. 16 x 25 / 6 ea. 20 x 25
30.4
Cooling Only Unit Efficiency/ Gas Electric Unit Efficiency is 10.0/10.6
Unit Control Board with 3 heating outputs only, all other Unit Control Boards 2 / 1.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 16: REFRIGERANT FACTORY CHARGE R-410A
CHARGE
UNIT (TONS)
MODEL
SYSTEM #1
SYSTEM #2
SYSTEM #3
SYSTEM #4
25
wo/HGBP
14lb
12lb 8oz
12lb 8oz
12lb 8oz
25
w/HGBP
14lb 8oz
12lb 8oz
12lb 8oz
12lb 8oz
30
wo/HGBP
16lb
16lb 8oz
14lb
18lb 4oz
30
w/HGBP
16lb 8oz
17lb
14lb 8oz
18lb 12oz
40
wo/HGBP
17lb 10oz
17lb 10oz
19lb 13oz
19lb 13oz
40
w/HGBP
18lb 2oz
18lb 2oz
20lb 5oz
20lb 5oz
TABLE 17: ELECTRICAL DATA 25 TON BASIC UNIT R-410A
Compressors (each)
OD Fan Motors
Supply Blower
Motor
Qty
HP
FLA
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
24.2
30.8
46.2
59.4
22
28
42
54
11
14
21
27
9
11
17
22
Voltage
Qty
RLA
LRA
MCC
FLA
208-3-60
4
22.4
149
35
4
4.5
230-3-60
4
22.4
149
35
4
4.3
460-3-60
4
10.6
75
16.5
4
2.15
575-3-60
4
7.7
54
12
4
1.7
1.
2.
3.
MCA1
(Amps)
138
146
165
182
134
142
159
174
65
69
77
85
49
51
59
65
Max Fuse2/
Breaker3
Size
(Amps)
150
175
200
225
150
150
200
225
70
80
90
110
50
60
70
80
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
27
5121842-TIM-A-0515
TABLE 18: ELECTRICAL DATA 30 TON BASIC UNIT R-410A
Compressors (each)
OD Fan Motors
Supply Blower
Motor
HP
FLA
10
15
25
20
10
15
25
20
10
15
20
25
10
15
20
25
30.8
46.2
74.8
59.4
28
42
68
54
14
21
27
34
11
17
22
27
Voltage
Qty
RLA
LRA
MCC
Qty
FLA
208-3-60
4
25.0
164
39
4
5.8
230-3-60
4
25.0
164
39
4
5.8
460-3-60
4
12.0
100
19
4
2.9
575-3-60
4
9.0
78
14
4
2.2
1.
2.
3.
MCA1
(Amps)
162
181
217
197
158
176
208
191
77
86
93
102
59
66
72
79
Max Fuse2/
Breaker3
Size
(Amps)
175
225
250
250
175
200
250
225
90
100
110
125
60
80
90
100
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
TABLE 19: ELECTRICAL DATA 40 TON BASIC UNIT R-410A
Compressors (each)
OD Fan Motors
Supply Blower
Motor
Qty
HP
FLA
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
30.8
46.2
59.4
74.8
28
42
54
68
14
21
27
34
11
17
22
27
Voltage
Qty
LRA
MCC
FLA
208-3-60
4
30.1
255
47
4
5.8
230-3-60
4
30.1
255
47
4
5.8
460-3-60
4
16.7
114
26
4
2.9
575-3-60
4
12.2
80
19
4
2.2
1.
2.
3.
28
RLA
MCA1
(Amps)
182
201
218
237
179
196
211
229
97
105
112
121
72
79
85
91
Max Fuse2/
Breaker3
Size
(Amps)
200
225
250
300
200
225
250
250
110
125
125
150
80
90
100
110
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 20: ELECTRICAL DATA 25 TON W/ELECTRIC HEAT R-410A
Voltage
Qty
208-3-60
230-3-60
460-3-60
575-3-60
1.
2.
3.
OD Fan
Motors
(each)
Compressors
(each)
4
4
4
4
RLA
22.4
22.4
10.6
7.7
LRA
149
149
75
54
MCC
35
35
16.5
12
FLA
4.5
4.3
2.15
1.7
Supply Blower
Motor
HP
FLA
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
7.5
10
15
20
24.2
30.8
46.2
59.4
24.2
30.8
46.2
59.4
22
28
42
54
22
28
42
54
11
14
21
27
11
14
21
27
11
14
21
27
9
11
17
22
9
11
17
22
9
11
17
22
Electric Heat Option
MCA1
(Amps)
Option
KW
Applied
Stages
Amps
E4
40
30
1
83
E8
80
60
2
167
E4
40
36.8
1
92
E8
80
73.6
2
184
E4
40
36.8
1
46
E8
80
73.6
2
92
E1
108
99.4
3
125
E4
40
36.8
1
40
E8
80
73.6
2
80
E1
108
99.4
3
108
138
146
165
182
197
205
225
241
143
150
168
183
212
220
237
252
71
75
84
91
106
110
119
126
138
142
151
158
62
64
72
78
92
94
102
108
120
122
130
136
Max Fuse2/
Breaker3
Size
(Amps)
150
175
200
225
225
225
250
300
150
150
200
225
250
250
250
300
80
80
90
110
125
125
125
150
150
175
175
175
70
70
80
80
110
110
110
125
150
150
150
150
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
29
5121842-TIM-A-0515
TABLE 21: ELECTRICAL DATA 30 TON W/ELECTRIC HEAT R-410A
Voltage
Qty
208-3-60
230-3-60
460-3-60
575-3-60
1.
2.
3.
30
OD Fan
Motors
(each)
Compressors
(each)
4
4
4
4
RLA
25.0
25.0
12.0
9.0
LRA
164
164
100
78
MCC
39
39
19
14
FLA
5.8
5.8
2.9
2.2
Supply Blower
Motor
HP
FLA
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
30.8
46.2
59.4
74.8
30.8
46.2
59.4
74.8
28
42
54
68
28
42
54
68
14
21
27
34
14
21
27
34
14
21
27
34
11
17
22
27
11
17
22
27
11
17
22
27
Electric Heat Option
MCA1
(Amps)
Option
KW
Applied
Stages
Amps
E4
40
30
1
83
E8
80
60
2
167
E4
40
36.8
1
92
E8
80
73.6
2
184
E4
40
36.8
1
46
E8
80
73.6
2
92
E1
108
99.4
3
125
E4
40
36.8
1
40
E8
80
73.6
2
80
E1
108
99.4
3
108
162
181
197
217
205
225
241
260
158
176
191
208
220
237
252
270
77
86
93
102
110
119
126
135
142
151
158
167
64
72
78
84
94
102
108
114
122
130
136
142
Max Fuse2/
Breaker3
Size
(Amps)
175
225
250
250
225
250
300
300
175
200
225
250
250
250
300
300
90
100
110
125
125
125
150
150
175
175
175
200
70
80
90
100
110
110
125
125
150
150
150
150
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 22: ELECTRICAL DATA 40 TON W/ELECTRIC HEAT R-410A
Voltage
Qty
208-3-60
230-3-60
460-3-60
575-3-60
1.
2.
3.
OD Fan
Motors
(each)
Compressors
(each)
4
4
4
4
RLA
30.1
30.1
16.7
12.2
LRA
255
255
114
80
MCC
47
47
26
19
FLA
5.8
5.8
2.9
2.2
Supply Blower
Motor
HP
FLA
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
10
15
20
25
30.8
46.2
59.4
74.8
30.8
46.2
59.4
74.8
28
42
54
68
28
42
54
68
14
21
27
34
14
21
27
34
14
21
27
34
11
17
22
27
11
17
22
27
11
17
22
27
Electric Heat Option
MCA1
(Amps)
Option
KW
Applied
Stages
Amps
E4
40
30
1
83
E8
80
60
2
167
E4
40
36.8
1
92
E8
80
73.6
2
184
E4
40
36.8
1
46
E8
80
73.6
2
92
E1
108
99.4
3
125
E4
40
36.8
1
40
E8
80
73.6
2
80
E1
108
99.4
3
108
182
201
218
237
205
225
241
260
179
196
211
229
220
237
252
270
97
105
112
121
110
119
126
135
142
151
158
167
72
79
85
91
94
102
108
114
122
130
136
142
Max Fuse2/
Breaker3
Size
(Amps)
200
225
250
300
225
250
300
300
200
225
250
250
250
250
300
300
110
125
125
150
125
125
150
150
175
175
175
200
80
90
100
110
110
110
125
125
150
150
150
150
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
31
5121842-TIM-A-0515
TABLE 23: ELECTRICAL DATA 25 TON W/POWER EXHAUST R-410A
Voltage
Qty
208-3-60
230-3-60
460-3-60
575-3-60
1.
2.
3.
32
OD Fan
Motors
(each)
Compressors
(each)
4
4
4
4
RLA
22.4
22.4
10.6
7.7
LRA
149
149
75
54
MCC
35
35
16.5
12
FLA
Supply Blower
Motor
HP
FLA
7.5
24.2
10
30.8
15
46.2
20
59.4
7.5
22
10
28
15
42
20
54
7.5
11
10
14
15
21
20
27
7.5
9
10
11
15
17
20
22
4.5
4.3
2.15
1.7
Pwr Exh Motor
HP
FLA
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
15.2
22
28
15.2
22
28
15.2
22
28
15.2
22
28
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
MCA1
(Amps)
155
162
170
163
170
177
182
190
196
199
206
213
150
156
164
157
164
170
175
181
187
190
196
202
72
76
80
76
80
83
85
88
91
92
96
99
55
58
60
57
60
62
65
68
70
71
74
76
Max Fuse2/
Breaker3
Size
(Amps)
175
175
200
175
200
200
225
225
225
250
250
250
150
175
175
175
175
175
200
200
225
225
250
250
80
80
90
90
90
90
100
100
110
110
110
125
60
60
70
60
70
70
80
80
80
90
90
90
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 24: ELECTRICAL DATA 30 TON W/POWER EXHAUST R-410A
Voltage
Qty
208-3-60
230-3-60
460-3-60
575-3-60
1.
2.
3.
OD Fan
Motors
(each)
Compressors
(each)
4
4
4
4
RLA
25.0
25.0
12.0
9.0
LRA
164
164
100
78
MCC
39
39
19
14
Qty
4
4
4
4
Supply Blower
Motor
FLA
HP
FLA
10
30.8
15
46.2
20
59.4
25
74.8
10
28
15
42
20
54
25
68
10
14
15
21
20
27
25
34
10
11
15
17
20
22
25
27
5.8
5.8
2.9
2.2
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
22
28
42
22
28
42
22
28
42
22
28
42
11
14
21
11
14
21
11
14
21
11
14
21
9
11
17
9
11
17
9
11
17
9
11
17
MCA1
(Amps)
186
193
212
205
212
227
222
228
244
241
248
263
180
186
204
198
204
218
213
219
233
230
236
250
88
91
100
97
100
107
104
107
114
113
116
123
68
70
77
75
77
83
81
83
89
88
90
96
Max Fuse2/
Breaker3
Size
(Amps)
200
200
250
250
250
250
250
250
300
300
300
300
200
200
225
225
225
250
250
250
250
250
300
300
100
100
110
110
110
125
125
125
125
125
150
150
70
80
90
90
90
100
100
100
110
110
110
110
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
33
5121842-TIM-A-0515
TABLE 25: ELECTRICAL DATA 40 TON W/POWER EXHAUST R-410A
Voltage
Qty
208-3-60
230-3-60
460-3-60
575-3-60
1.
2.
3.
34
OD Fan
Motors
(each)
Compressors
(each)
4
4
4
4
RLA
30.1
30.1
16.7
12.2
LRA
225
225
114
80
MCC
47.0
47.0
26.0
19.0
Qty
4
4
4
4
Supply Blower
Motor
FLA
HP
FLA
10
30.8
15
46.2
20
59.4
25
74.8
10
28.0
15
42.0
20
54.0
25
68.0
10
14.0
15
21.0
20
27.0
25
34.0
10
11.0
15
17.0
20
22.0
25
27.0
5.8
5.2
2.6
2.2
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
24
31
46
24
31
46
24
31
46
24
31
46
22
28
42
22
28
42
22
28
42
22
28
42
11
14
21
11
14
21
11
14
21
11
14
21
9
11
17
9
11
17
9
11
17
9
11
17
MCA1
(Amps)
206
213
232
226
232
248
242
249
264
261
268
283
199
205
222
216
222
236
231
237
251
248
254
268
108
111
119
116
119
126
123
126
133
132
135
142
81
83
90
88
90
96
94
96
102
100
102
108
Max Fuse2/
Breaker3
Size
(Amps)
225
225
250
250
250
250
300
300
300
300
300
350
225
225
250
250
250
250
250
250
300
300
300
300
110
125
125
125
125
150
150
150
150
150
150
175
90
90
100
100
100
110
110
110
110
125
125
125
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 26: ELECTRICAL DATA 25 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
KW
40
Stages
1
Amps
83
Qty
4
RLA
22.4
LRA
149
OD Fan Motors
(each)
MCC
35
Qty
4
FLA
Supply Blower
Motor
HP
FLA
7.5
24.2
10
30.8
15
46.2
20
59.4
7.5
24.2
10
30.8
15
46.2
20
59.4
7.5
22
10
28
15
42
20
54
7.5
22
10
28
15
42
20
54
4.5
208-3-60
E8
E4
80
40
2
1
167
92
4
4
22.4
22.4
149
149
35
35
4
4
4.5
4.3
230-3-60
E8
80
2
184
Johnson Controls Unitary Products
4
22.4
149
35
4
4.3
Pwr Exh Motor
HP
FLA
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
16.7
24.2
30.8
15.2
22
28
15.2
22
28
15.2
22
28
15.2
22
28
15.2
22
28
15.2
22
28
15.2
22
28
15.2
22
28
MCA1
(Amps)
155
162
170
163
170
177
182
190
196
199
206
213
214
221
230
222
230
236
241
249
256
258
265
272
158
165
172
166
172
178
183
190
196
198
205
211
227
234
242
235
242
248
252
259
265
267
274
280
Max Fuse2/
Breaker3
Size
(Amps)
175
175
200
175
200
200
225
225
225
250
250
250
225
225
250
250
250
250
250
250
300
300
300
300
175
175
175
175
175
200
200
200
225
225
250
250
250
250
250
250
250
250
300
300
300
300
300
300
35
5121842-TIM-A-0515
TABLE 26: ELECTRICAL DATA 25 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED)
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
460-3-60
E8
E1
36
KW
40
80
108
Stages
1
2
3
Amps
46
92
125
Qty
4
4
4
RLA
10.6
10.6
10.6
LRA
75
75
75
OD Fan Motors
(each)
MCC
16.5
16.5
16.5
Qty
4
4
4
FLA
Supply Blower
Motor
HP
FLA
7.5
11
10
14
15
21
20
27
7.5
11
10
14
15
21
20
27
7.5
11
10
14
15
21
20
27
2.15
2.15
2.15
Pwr Exh Motor
HP
FLA
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
7.6
11
14
MCA1
(Amps)
79
82
86
83
86
89
92
95
98
99
102
105
114
117
121
117
121
124
126
130
133
134
137
140
146
149
153
150
153
156
158
162
165
166
169
172
Max Fuse2/
Breaker3
Size
(Amps)
80
90
90
90
90
90
100
100
110
110
110
125
125
125
125
125
125
125
150
150
150
150
150
150
175
175
175
175
175
175
175
175
175
175
175
175
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 26: ELECTRICAL DATA 25 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED)
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
575-3-60
E8
E1
1.
2.
3.
KW
40
80
108
Stages
1
2
3
Amps
40
80
108
Qty
4
4
4
RLA
7.7
7.7
4
LRA
54
54
7.7
OD Fan Motors
(each)
MCC
12
12
54
Qty
4
4
12
FLA
Supply Blower
Motor
HP
FLA
7.5
9
10
11
15
17
20
22
7.5
9
10
11
15
17
20
22
7.5
9
10
11
15
17
20
22
1.7
1.7
4
Pwr Exh Motor
HP
FLA
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
5
7.5
10
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
6.1
9
11
MCA1
(Amps)
68
71
73
70
73
75
78
81
83
84
87
89
98
101
103
100
103
105
108
111
113
114
117
119
126
129
131
128
131
133
136
139
141
142
145
147
Max Fuse2/
Breaker3
Size
(Amps)
70
70
80
70
80
80
80
90
90
90
90
100
110
110
110
110
110
110
110
125
125
125
125
125
150
150
150
150
150
150
150
150
150
150
150
150
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
37
5121842-TIM-A-0515
TABLE 27: ELECTRICAL DATA 30 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
KW
40
Stages
1
Amps
83
Qty
4
RLA
25.0
LRA
164
OD Fan Motors
(each)
MCC
39
Qty
4
FLA
Supply Blower
Motor
HP
FLA
10
30.8
15
46.2
20
59.4
25
74.8
10
30.8
15
46.2
20
59.4
25
74.8
10
28
15
42
20
54
25
68
10
28
15
42
20
54
25
68
5.8
208-3-60
E8
E4
80
40
2
1
167
92
4
4
25.0
25.0
164
164
39
39
4
4
5.8
5.8
230-3-60
E8
38
80
2
184
4
25.0
164
39
4
5.8
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
MCA1
(Amps)
186
193
212
205
212
227
222
228
244
241
248
263
230
236
256
249
256
271
265
272
287
285
291
307
180
186
204
198
204
218
213
219
233
230
236
250
242
248
265
259
265
279
274
280
294
292
298
312
Max Fuse2/
Breaker3
Size
(Amps)
200
200
250
250
250
250
250
250
300
300
300
300
250
250
300
250
300
300
300
300
300
350
350
350
200
200
225
225
225
250
250
250
250
250
300
300
250
250
300
300
300
300
300
300
300
350
350
350
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 27: ELECTRICAL DATA 30 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED)
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
460-3-60
E8
E1
KW
40
80
108
Stages
1
2
3
Amps
46
92
125
Johnson Controls Unitary Products
Qty
4
4
4
RLA
12.0
12.0
12.0
LRA
100
100
100
OD Fan Motors
(each)
MCC
19
19
19
Qty
4
4
4
FLA
Supply Blower
Motor
HP
FLA
10
14
15
21
20
27
25
34
10
14
15
21
20
27
25
34
10
14
15
21
20
27
25
34
2.9
2.9
2.9
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
MCA1
(Amps)
88
91
100
97
100
107
104
107
114
113
116
123
121
124
133
130
133
140
137
140
147
146
149
156
153
156
165
162
165
172
169
172
179
178
181
188
Max Fuse2/
Breaker3
Size
(Amps)
100
100
110
110
110
125
125
125
125
125
150
150
125
125
150
150
150
150
150
150
150
175
175
175
175
175
175
175
175
175
175
175
200
200
200
200
39
5121842-TIM-A-0515
TABLE 27: ELECTRICAL DATA 30 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED)
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
KW
40
Stages
1
Amps
40
Qty
4
RLA
9.0
LRA
78
OD Fan Motors
(each)
MCC
14
Qty
4
FLA
E1
1.
2.
3.
40
80
108
2
3
80
108
4
4
9.0
9.0
78
78
14
14
4
4
HP
FLA
10
11
15
17
20
22
25
27
10
11
15
17
20
22
25
27
10
11
15
17
20
22
25
27
2.2
575-3-60
E8
Supply Blower
Motor
2.2
2.2
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
MCA1
(Amps)
73
75
83
81
83
89
87
89
95
93
95
101
103
105
113
111
113
119
117
119
125
123
125
131
131
133
141
139
141
147
145
147
153
151
Max Fuse2/
Breaker3
Size
(Amps)
80
80
90
90
90
100
100
100
110
110
110
110
110
110
125
125
125
125
125
125
125
150
150
150
150
150
150
150
150
150
150
150
175
175
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 28: ELECTRICAL DATA 40 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
KW
40
Stages
1
Amps
83
Qty
4
RLA
25.0
LRA
164
OD Fan Motors
(each)
MCC
39
Qty
4
FLA
Supply Blower
Motor
HP
FLA
10
30.8
15
46.2
20
59.4
25
74.8
10
30.8
15
46.2
20
59.4
25
74.8
10
28
15
42
20
54
25
68
10
28
15
42
20
54
25
68
5.8
208-3-60
E8
E4
80
40
2
1
167
92
4
4
25.0
25.0
164
164
39
39
4
4
5.8
5.8
230-3-60
E8
80
2
184
Johnson Controls Unitary Products
4
25.0
164
39
4
5.8
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
24.2
30.8
46.2
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
22
28
42
MCA1
(Amps)
186
193
212
205
212
227
222
228
244
241
248
263
230
236
256
249
256
271
265
272
287
285
291
307
180
186
204
198
204
218
213
219
233
230
236
250
242
248
265
259
265
279
274
280
294
292
298
312
Max Fuse2/
Breaker3
Size
(Amps)
200
200
250
250
250
250
250
250
300
300
300
300
250
250
300
250
300
300
300
300
300
350
350
350
200
200
225
225
225
250
250
250
250
250
300
300
250
250
300
300
300
300
300
300
300
350
350
350
41
5121842-TIM-A-0515
TABLE 28: ELECTRICAL DATA 40 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED)
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
460-3-60
E8
E1
42
KW
40
80
108
Stages
1
2
3
Amps
46
92
125
Qty
4
4
4
RLA
12.0
12.0
12.0
LRA
100
100
100
OD Fan Motors
(each)
MCC
19
19
19
Qty
4
4
4
FLA
Supply Blower
Motor
HP
FLA
10
14
15
21
20
27
25
34
10
14
15
21
20
27
25
34
10
14
15
21
20
27
25
34
2.9
2.9
2.9
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
11
14
21
MCA1
(Amps)
88
91
100
97
100
107
104
107
114
113
116
123
121
124
133
130
133
140
137
140
147
146
149
156
153
156
165
162
165
172
169
172
179
178
181
188
Max Fuse2/
Breaker3
Size
(Amps)
100
100
110
110
110
125
125
125
125
125
150
150
125
125
150
150
150
150
150
150
150
175
175
175
175
175
175
175
175
175
175
175
200
200
200
200
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 28: ELECTRICAL DATA 40 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED)
Compressors
(each)
Electric Heat Option
Voltage
Model
E4
KW
40
Stages
1
Amps
40
Qty
4
RLA
9.0
LRA
78
OD Fan Motors
(each)
MCC
14
Qty
4
FLA
E1
1.
2.
3.
80
108
2
3
80
108
4
4
9.0
9.0
78
78
14
14
4
4
HP
FLA
10
11
15
17
20
22
25
27
10
11
15
17
20
22
25
27
10
11
15
17
20
22
25
27
2.2
575-3-60
E8
Supply Blower
Motor
2.2
2.2
Pwr Exh Motor
HP
FLA
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
10
15
7.5
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
11
17
9
MCA1
(Amps)
73
75
83
81
83
89
87
89
95
93
95
101
103
105
113
111
113
119
117
119
125
123
125
131
131
133
141
139
141
147
145
147
153
151
Max Fuse2/
Breaker3
Size
(Amps)
80
80
90
90
90
100
100
100
110
110
110
110
110
110
125
125
125
125
125
125
125
150
150
150
150
150
150
150
150
150
150
150
175
175
Minimum Circuit Ampacity.
Dual Element, Time Delay Type.
HACR type per NEC.
Johnson Controls Unitary Products
43
5121842-TIM-A-0515
DRILL & BOLT
THROUGH UNIT
SHEET METAL
(4 PLACES)
31"
MAXIMUM
6-1/2"
MINIMUM
34"*
UNISTRUT ®
1-5/8" W x 7/8" H
OR EQUIVALENT
47"
MAXIMUM DOOR SWING
OF HEAT SECTION
DOOR WHEN OPEN
*34 INCHES IS THE MINIMUM LENGTH REQUIRED TO
MOUNT TO THE FOUR POINTS SHOWN. THE RAILS CAN
BE EXTENDED TO MOUNT A TALLER DISCONNECT
SWITCH, BUT THESE FOUR POINTS SHOULD BE USED
TO MOUNT THE RAILS TO THE UNIT.
FIGURE 17 - FIELD INSTALLED DISCONNECT
44
Johnson Controls Unitary Products
5121842-TIM-A-0515
259.68
35.42
39.31
93.43
241.22
FIGURE 18 - 25 AND 30 TON UNIT OVERHEAD VIEW
274.68
35.42
39.31
93.43
241.22
255.00
FIGURE 19 - 40 TON UNIT OVERHEAD
Johnson Controls Unitary Products
45
5121842-TIM-A-0515
CONDENSER SECTION
75.93”
GAS HEAT
SECTION
25.95”
BLOWER
SECTION
36.08”
EVAPORATOR
SECTION
29.73”
FILTER
SECTION
31.13”
ECONOMIZER POWER
EXHAUST SECTION
41.94”
4.19”
64”
FIGURE 20 - 25 AND 30 TON UNIT MAJOR COMPONENT LAYOUT
CONDENSER SECTION
89.37”
GAS HEAT
SECTION
27.40”
BLOWER
SECTION
36.08”
EVAPORATOR
SECTION
29.73”
FILTER
SECTION
31.13”
ECONOMIZER POWER
EXHAUST SECTION
41.94”
4.19”
64”
FIGURE 21 - 40 TON UNIT MAJOR COMPONENT LAYOUT
46
Johnson Controls Unitary Products
5121842-TIM-A-0515
Hinged,
Tool-Free
Door
Optional
Hinged,
Tool-Free
Door
Hinged,
Tool-Free
Door
Hinged, Tool-Free
w/PE Option
1
2
3
4
BACK VIEW
Hinged,
Tool-Free
Door
Optional
Hinged,
Tool-Free
Door
Hinged,
Tool-Free
Door
Hinged,
Tool-Free
w/Gas
or Other
Heat Source
6
7
8
9
Hinged, Tool-Free
w/PE Option
5
FRONT VIEW
1. STD Cabinet Option includes Hinged, Tool-Free
Doors # 1, 3, 6, 8.
4. Doors 1, 2, 3, 6, 7, 8 & 9 are 56.31 inches high by
27.33 inches wide.
2. Premium Cabinet Option includes Hinged, Tool-Free
Doors # 1, 2, 3, 6, 7, 8.
5. Doors 4 & 5 are 26.5 inches high by 33.63 inches
wide.
3. Doors # 4, 5, 9 are dependent upon unit Heating
and Power Exhaust Options.
6. Door configurations are the same on all tonnages
(40 ton shown).
FIGURE 22 - UNIT CABINET DOOR CONFIGURATION
Johnson Controls Unitary Products
47
5121842-TIM-A-0515
2 3 5 .0 0
9 5 .0 9
3 8 .5 9
7 1 .6 1
R E T U R N
A IR
O P E N IN G
8 3 .0 0
2 6 .0 0
S U P P L Y
A IR
O P E N IN G
8 7 .0 0
1 1 .3 9
4 .0 0
2 .0 0
1 4 .0 0
In s u la tio
P ro te
(S h e e t
N o s e P
n E
c to
M e
ie c
r
d g e
ta l
e )
A
A
F IE L D
S U P P L IE D
D U C T
A
T y p ic a l In s u la tio n
B
A
S E E S E C T IO N "A -A "
B
- IF
- IF
U N IT
U N IT
IS
IS
N O T IN S T A L L E D
A L R E A D Y IN S T A L L E D
N O T E : P r o te c t in s u la tio n w ith a s h e e t m e ta l
n o s e p ie c e w h e n in s ta llin g a in te r n a lly in s u la te d
d u c t w o rk .
T Y P IC A L D U C T IN S T A L L A T IO N S
B A S E R A IL
(Y O R K U N IT )
C U R B G A S K E T
B A S E R A IL C R O S S -S E C T IO N
1 .2 5 "
1 .7 5 "
4 .6 3 "
2 " X 4 "
N A IL E R
2 .5 0 "
1 .5 0 "
(1 4 .0 0 )
1 4 G A . G A L V S T E E L
R O O F C U R B
2 .0 0 "
S E C T IO N "A -A "
FIGURE 23 - PARTIAL ROOF CURB MODEL 1RC0455P
48
Johnson Controls Unitary Products
5121842-TIM-A-0515
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 29 and Figure 24.
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 29: ALTITUDE CORRECTION FACTORS
ALTITUDE (FEET)
AIR TEMP
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
40
1.060
1.022
0.986
0.950
0.916
0.882
0.849
0.818
0.788
0.758
0.729
50
1.039
1.002
0.966
0.931
0.898
0.864
0.832
0.802
0.772
0.743
0.715
60
1.019
0.982
0.948
0.913
0.880
0.848
0.816
0.787
0.757
0.729
0.701
70
1.000
0.964
0.930
0.896
0.864
0.832
0.801
0.772
0.743
0.715
0.688
80
0.982
0.947
0.913
0.880
0.848
0.817
0.787
0.758
0.730
0.702
0.676
90
0.964
0.929
0.897
0.864
0.833
0.802
0.772
0.744
0.716
0.689
0.663
100
0.946
0.912
0.880
0.848
0.817
0.787
0.758
0.730
0.703
0.676
0.651
The examples below will assist in determining the airflow performance of the product at altitude.
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.
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?
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
Solution: At an elevation of 5,000 ft the indoor blower will still
deliver 6,000 CFM if the rpm is unchanged. However, Table
29 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 29 shows the correction factor to
be 0.832.
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
blower tables to select the blower speed and the BHP
requirement.
Solution: As in the example above, no temperature information is given so 70°F is assumed.
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"
Johnson Controls Unitary Products
49
5121842-TIM-A-0515
FIGURE 24 - ALTITUDE/TEMPERATURE CONVERSION FACTOR
50
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 30: FAN PERFORMANCE - 25 TON1, 2
AIRFLOW CFM
4000
5000
6000
7000
8000
9000
10000
11000
12000
12500
0.2
4000
5000
6000
7000
8000
9000
10000
11000
12000
12500
1.4
BHP3
1.8
2.4
2.9
3.6
4.4
5.3
6.3
7.7
9.1
10.0
RPM
568
582
596
615
633
658
682
713
743
760
RPM
609
621
633
650
666
688
710
739
767
784
2.2
2.4
BHP3
3.5
4.3
5.0
5.8
6.7
7.8
8.9
10.5
12.0
12.9
RPM
743
754
766
777
788
804
819
841
863
876
AIRFLOW CFM
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
RPM
365
396
427
459
491
527
563
605
647
664
1.2
AIRFLOW CFM
4000
5000
6000
7000
8000
9000
10000
11000
12000
12500
BHP3
0.5
0.9
1.2
1.8
2.3
3.2
4.2
5.5
6.8
7.4
RPM
302
341
380
416
452
492
532
578
623
639
AIRFLOW CFM
0.4
RPM
770
783
795
806
817
831
845
866
887
899
3.2
RPM
867
885
903
914
924
934
944
961
978
986
3.4
BHP3
5.4
6.4
7.3
8.3
9.3
10.6
11.9
13.6
15.2
16.2
RPM
890
909
928
939
949
959
968
984
1000
1008
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
0.6
0.8
BHP3
RPM
BHP3
RPM
BHP3
0.7
422
1.0
475
1.3
1.1
447
1.4
495
1.7
1.5
473
1.8
516
2.1
2.1
500
2.5
540
2.8
2.7
528
3.1
565
3.5
3.6
561
4.0
594
4.5
4.5
594
4.9
624
5.4
5.9
632
6.3
659
6.7
7.2
671
7.6
695
8.1
7.9
688
8.4
712
8.9
RPM
523
540
557
578
600
626
653
686
719
736
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
1.6
1.8
BHP3
RPM
BHP3
RPM
BHP3
2.2
646
2.5
681
2.8
2.7
657
3.1
692
3.5
3.3
669
3.7
702
4.1
4.0
683
4.5
716
4.9
4.8
698
5.3
729
5.7
5.8
718
6.3
747
6.8
6.8
738
7.3
766
7.8
8.2
765
8.8
791
9.3
9.7
791
10.2
815
10.8
10.6
807
11.2
830
11.7
RPM
713
724
735
747
759
776
793
816
839
853
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
2.6
2.8
BHP3
RPM
BHP3
RPM
3.9
796
4.3
821
4.7
810
5.1
836
5.4
824
5.9
851
6.3
834
6.8
861
7.2
844
7.7
871
8.3
857
8.9
883
9.5
870
10.1
896
11.1
890
11.7
914
933
12.6
910
13.2
921
14.2
943
13.6
BHP3
4.6
5.5
6.4
7.3
8.2
9.5
10.7
12.3
13.9
14.8
RPM
844
861
878
888
898
909
920
938
956
965
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
3.6
3.8
BHP3
RPM
BHP3
RPM
5.8
912
6.2
935
6.8
932
7.2
956
7.8
953
8.2
976
8.8
963
9.4
988
9.9
974
10.5
999
11.2
983
11.9
1007
12.6
992
13.2
1015
14.2
1007
14.9
1029
15.9
1022
16.6
1043
16.8
1029
17.5
1050
BHP3
6.6
7.6
8.7
9.9
11.2
12.5
13.8
15.6
17.3
18.2
RPM
958
979
1000
1012
1023
1030
1037
1051
1064
1070
1.0
BHP3
1.5
2.0
2.5
3.2
3.9
4.9
5.8
7.2
8.6
9.5
2.0
BHP3
3.2
3.9
4.5
5.4
6.2
7.3
8.4
9.9
11.4
12.3
3.0
BHP3
5.0
5.9
6.8
7.8
8.8
10.0
11.3
12.9
14.5
15.5
4.0
BHP3
6.9
8.0
9.1
10.5
11.8
13.2
14.5
16.2
18.0
19.0
1.
Fan performance is based on wet evaporator coils, clean 2” throwaway filters and system/cabinet effects at standard air density and 0 feet elevation.
Refer to Tables 57, 15, 21 and 33 for component additions and deductions to fan performance tables.
3.
BHP includes drive losses.
4. Shaded RPMs require Class II blower.
2.
Johnson Controls Unitary Products
51
5121842-TIM-A-0515
25 Ton Forward Curve
8.0
7.5
00
11
7.0
M
RP
6.5
6.0
20
00
10
15
5.0
BH
P
0
90
4.5
10
Total Static Pressure (IWG)
5.5
7.5
4.0
80
0
3.5
3.0
70
0
2.5
600
2.0
1.5
500
A
1.0
0.5
0.0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
CFM (x1000)
A - Standard Unit
Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system
and cabinet effects at standard air density and 0' elevation.
FIGURE 25 - FAN PERFORMANCE - 25 TON
52
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 31: FAN PERFORMANCE - 30 TON 1, 2
AIRFLOW (CFM)
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
0.2
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
1.
2.
3.
1.4
BHP3
3.1
3.8
4.6
5.6
6.7
8.2
9.7
11.5
13.3
15.6
RPM
612
634
655
680
704
735
766
798
830
864
RPM
649
668
687
710
732
761
790
820
851
884
2.2
2.4
BHP3
5.1
6.1
7.0
8.3
9.5
11.0
12.5
14.6
16.6
18.9
RPM
779
793
807
823
839
862
884
909
935
963
RPM
808
822
836
850
865
886
907
931
956
982
3.2
AIRFLOW (CFM)
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
RPM
450
485
519
554
588
629
671
709
748
786
1.2
AIRFLOW (CFM)
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
BHP3
1.3
1.9
2.6
3.5
4.5
5.7
7.0
8.9
10.7
12.7
RPM
405
444
483
520
558
603
647
687
728
767
AIRFLOW (CFM)
0.4
RPM
916
928
941
952
964
981
997
1017
1037
1059
3.4
BHP3
7.4
8.6
9.8
11.2
12.6
14.1
15.7
17.9
20.2
22.6
RPM
940
953
965
976
987
1003
1019
1038
1056
1078
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
0.6
BHP3
RPM
BHP3
RPM
1.6
494
2.0
535
2.3
524
2.7
562
2.9
555
3.3
589
3.9
586
4.3
618
4.8
618
5.2
647
6.2
656
6.7
683
7.5
695
8.1
718
9.3
731
9.9
753
11.2
768
11.6
789
13.2
805
13.8
825
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
1.6
BHP3
RPM
BHP3
RPM
3.5
683
3.9
717
4.3
701
4.7
733
5.1
719
5.5
749
6.1
739
6.6
768
7.2
760
7.7
787
8.7
787
9.3
812
10.3
814
10.8
837
12.1
843
12.7
865
13.9
872
14.6
893
16.3
904
16.9
923
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
2.6
BHP3
RPM
BHP3
RPM
5.5
837
6.0
864
6.6
850
7.0
877
7.6
863
8.1
890
8.8
877
9.4
902
10.1
890
10.7
915
934
11.6
910
12.2
930
13.8
953
13.2
15.2
953
15.9
975
17.3
976
18.0
997
19.6
1002
20.4
1021
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
3.6
BHP3
RPM
BHP3
RPM
7.9
964
8.3
988
9.1
977
9.6
1000
10.3
989
10.9
1013
11.8
1000
12.4
1023
13.2
1010
13.9
1033
14.8
1025
15.5
1047
16.4
1040
17.1
1061
18.6
1058
19.4
1078
20.9
1076
21.6
1094
23.3
1097
24.1
1115
0.8
1.0
BHP3
2.3
3.0
3.7
4.7
5.7
7.2
8.6
10.4
12.2
14.4
RPM
575
599
623
649
676
709
742
776
809
845
BHP3
4.3
5.1
6.0
7.2
8.3
9.8
11.4
13.3
15.2
17.6
RPM
748
763
779
796
813
837
861
887
914
943
BHP3
6.4
7.5
8.6
10.0
11.3
12.9
14.4
16.5
18.7
21.1
RPM
890
903
916
928
940
957
975
996
1017
1040
BHP3
8.8
10.1
11.5
13.0
14.5
16.1
17.8
20.1
22.4
24.9
RPM
1011
1023
1035
1045
1055
1069
1082
1097
1113
1134
1.8
BHP3
2.7
3.4
4.2
5.2
6.2
7.7
9.2
10.9
12.7
15.0
2.0
2.8
BHP3
4.7
5.6
6.5
7.7
8.9
10.4
12.0
13.9
15.9
18.3
3.0
3.8
BHP3
6.9
8.1
9.2
10.6
12.0
13.5
15.0
17.2
19.4
21.8
4.0
BHP3
9.3
10.7
12.0
13.6
15.1
16.8
18.5
20.8
23.1
25.7
Fan performance is based on wet evaporator coils, clean 2” throwaway filters and system/cabinet effects at standard air density and 0 feet elevation.
Refer to Tables 57, 15, 21 and 33 for component additions and deductions to fan performance tables.
BHP includes drive losses.
4. Shaded RPMs require Class II blower.
Johnson Controls Unitary Products
53
5121842-TIM-A-0515
30 Ton Forward Curv
8.0
7.5
R
00
11
7.0
PM
6.5
6.0
BH
P
15
5.0
0
90
4.5
10
4.0
80
3.5
0
Total Static Pressure (IWG)
20
00
10
5.5
3.0
70
0
2.5
A
2.0
600
1.5
500
1.0
0.5
0.0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
CFM (x1000)
A - Standard Unit
Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system
and cabinet effects at standard air density and 0' elevation.
FIGURE 26 - FAN PERFORMANCE - 30 TON
54
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 32: FAN PERFORMANCE - 40 TON1,2
0.2
AIRFLOW (CFM)
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
1.
2.
3.
1.4
BHP3
4.2
5.0
5.7
6.8
7.9
9.1
10.3
11.9
13.5
15.4
17.3
RPM
552
567
582
602
621
639
657
678
699
720
740
RPM
583
596
610
628
647
664
681
700
720
740
760
2.2
2.4
BHP3
6.7
7.7
8.7
9.9
11.1
12.5
14.0
15.6
17.3
19.4
21.5
RPM
690
701
712
726
740
755
769
785
801
819
836
AIRFLOW (CFM)
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
RPM
409
433
458
486
513
535
557
584
612
635
659
1.2
AIRFLOW (CFM)
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
BHP3
1.9
2.5
3.1
4.0
5.0
5.9
6.9
8.4
9.8
11.7
13.6
RPM
367
396
424
454
484
507
530
560
589
613
638
AIRFLOW (CFM)
0.4
RPM
713
725
736
749
762
776
790
805
820
837
855
3.2
RPM
799
811
823
834
846
858
870
882
895
910
925
3.4
BHP3
9.3
10.6
11.9
13.3
14.6
16.3
17.9
19.7
21.5
23.8
26.0
RPM
819
831
843
855
866
877
889
901
913
928
-
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
0.6
BHP3
RPM
BHP3
RPM
2.3
448
2.8
485
3.0
469
3.5
504
3.6
491
4.1
523
4.5
516
5.1
546
5.5
542
6.1
569
6.5
562
7.1
589
7.6
583
8.2
608
9.1
609
9.7
632
10.5
634
11.3
656
12.4
657
13.1
678
14.3
680
15.0
700
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
1.6
BHP3
RPM
BHP3
RPM
4.7
612
5.2
639
5.5
624
6.0
651
6.3
637
6.9
663
7.4
654
8.0
679
8.5
671
9.1
695
9.7
687
10.4
710
11.0
704
11.7
726
12.6
722
13.3
744
14.2
741
15.0
761
16.1
760
16.9
780
18.1
780
18.9
799
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
2.6
BHP3
RPM
BHP3
RPM
7.2
736
7.7
758
8.2
747
8.8
769
9.3
759
9.9
781
10.5
771
11.2
793
805
11.8
784
12.5
797
14.0
818
13.3
14.7
811
15.5
831
16.4
825
17.2
845
18.1
839
19.0
858
20.3
856
21.1
874
22.4
873
23.3
890
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
3.6
BHP3
RPM
BHP3
RPM
9.9
839
10.6
859
11.3
851
11.9
871
12.6
863
13.3
883
14.0
874
14.7
894
15.4
885
16.1
905
17.0
896
17.8
915
18.7
908
19.5
926
20.5
919
21.4
937
22.4
931
23.3
948
24.7
945
25.6
962
-
0.8
1.0
BHP3
3.3
4.0
4.6
5.6
6.6
7.8
8.9
10.4
12.0
13.8
15.7
RPM
519
536
553
574
596
614
633
655
678
699
721
BHP3
5.7
6.6
7.4
8.6
9.8
11.1
12.5
14.1
15.8
17.8
19.7
RPM
665
677
688
703
718
733
748
765
781
799
818
BHP3
8.2
9.4
10.6
11.9
13.2
14.7
16.3
18.0
19.8
22.0
24.2
RPM
779
790
802
814
826
838
851
864
877
892
908
BHP3
11.2
12.6
13.9
15.4
16.8
18.6
20.3
22.2
24.2
-
RPM
879
891
902
913
924
934
944
955
966
-
1.8
BHP3
3.8
4.5
5.2
6.2
7.2
8.4
9.6
11.2
12.7
14.6
16.5
2.0
2.8
BHP3
6.2
7.1
8.0
9.2
10.4
11.8
13.2
14.9
16.5
18.6
20.6
3.0
3.8
BHP3
8.8
10.0
11.2
12.6
13.9
15.5
17.1
18.9
20.6
22.9
25.1
4.0
BHP3
11.9
13.3
14.6
16.1
17.5
19.3
21.1
23.1
25.1
-
Fan performance is based on wet evaporator coils, clean 2” throwaway filters and system/cabinet effects at standard air density and 0 feet elevation.
Refer to Tables 58, 18, 49 and 33 for component additions and deductions to fan performance tables.
BHP includes drive losses.
4. Shaded RPMs require Class II blower.
Johnson Controls Unitary Products
55
5121842-TIM-A-0515
40 Ton Forward Curve
7.0
6.5
6.0
90
0R
PM
5.5
B
25
P
20
4.5
80
0
4.0
15
Total Static Pressure (IWG)
H
5.0
3.5
10
70
0
3.0
2.5
A
600
2.0
500
1.5
400
1.0
300
0.5
0.0
0
2
4
6
8
10
12
14
16
18
20
CFM (x1000)
A - Standard Unit
Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, system
and cabinet effects at standard air density and 0' elevation.
FIGURE 27 - FAN PERFORMANCE - 40 TON
56
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 33: COMPONENT STATIC RESISTANCE1, 2
COMPONENT COIL
LOSSES
CFM
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
3 Row, 16 FPI, dry
-0.14
-0.18
-0.24
-0.34
-0.45
-
-
-
3 Row, 16 FPI, wet
Baseline
Baseline
Baseline
Baseline
Baseline
-
-
-
4 Row, 16 FPI, dry
-0.18
-0.22
-0.32
-0.45
-0.60
-0.76
-
-
4 Row, 16 FPI, wet
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
-
-
4 Row, 16 FPI, dry
-0.15
-0.22
-0.26
-0.31
-0.42
-0.53
-.0.65
-0.79
4 Row, 16 FPI, wet
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Baseline
Rigid 6”, 65%
0.06
0.12
0.19
0.27
0.36
0.46
0.58
0.70
Rigid 6”, 95%
0.13
0.26
0.41
0.60
0.81
1.04
1.29
1.57
COIL LOSSES 25T
COIL LOSSES 30T
COIL LOSSES 40T
FILTER LOSSES
2” TA or HI EFF.
IGV LOSSES
25 & 30 Ton F.C.
0.02
0.05
0.08
0.13
0.19
0.26
0.34
0.43
40 Ton F.C.
0.01
0.03
0.05
0.08
0.11
0.15
0.19
0.25
GAS HEAT
267 MBH Heat
0.07
0.11
0.14
0.18
0.21
0.25
0.28
0.32
533 MBH Heat
0.14
0.21
0.28
0.35
0.42
0.49
0.57
0.64
800 MBH Heat
0.21
0.32
0.42
0.53
0.64
0.74
0.85
0.95
40KW
0.01
0.02
0.04
0.06
0.10
0.20
0.31
0.40
80KW
0.01
0.04
0.08
0.13
0.20
0.31
0.44
0.56
108KW
0.02
0.05
0.10
0.15
0.31
0.43
0.53
0.68
ECONOMIZER
0.03
0.06
0.10
0.15
0.21
0.28
0.35
0.43
POWER EXHAUST
0.02
0.05
0.08
0.13
0.18
0.25
0.32
0.41
ELECTRIC HEAT
1.
2.
Baseline losses based on system/cabinet effects, wet standard coil and 2” throwaway filters at 70°F, 0 feet elevation with standard air.
See Tables 57, 58, 15, 18 and 21 for hot water and steam water coil static resistance.
Johnson Controls Unitary Products
57
5121842-TIM-A-0515
TABLE 34: SUPPLY FAN MOTOR AND DRIVE DATA
Motor
Model
Blower
RPM
Range
Motor Pulley
Blower Pulley
Belts
HP
Frame
Size
Motor
Efficiency
(Std. Motor)
Motor
Efficiency
(Ultra Hi
Eff Opt)
Pitch Dia
(Inches)
Bore
(Inches)
Pitch Dia
(Inches)
Bore
(Inches)
Designation
Qty
567
7.5
213T
88.5
91.7
4.5
1-3/8
13.9
2-3/16
BX56
2
692
10
215T
89.5
91
5.5
1-3/8
13.9
2-3/16
BX56
2
793
15
254T
91
91.7
6.3
1-5/8
13.9
2-3/16
BX56
2
894
20
256T
91
93
7.1
1-5/8
13.9
2-3/16
BX56
2
617
10
215T
89.5
91
4.9
1-3/8
13.9
2-3/16
BX56
2
743
15
254T
91
91.7
5.9
1-5/8
13.9
2-3/16
BX56
2
856
20
256T
91
93
6.7
1-5/8
13.7
2-3/16
5VX610
2
907
25
284T
91.7
93.6
7.1
1-7/8
13.7
2-3/16
5VX610
2
617
10
215T
89.5
91
4.9
1-3/8
13.9
2-7/16
BX67
2
652
15
254T
91
91.7
5.1
1-5/8
13.7
2-7/16
5VX710
2
728
20
256T
91
93
5.7
1-5/8
13.7
2-7/16
5VX710
2
780
25
284T
91.7
93.6
6.1
1-7/8
13.7
2-7/16
5VX710
2
25 Ton
30 Ton
40 Ton
TABLE 35: EXHAUST FAN DRIVE DATA
Motor
Model
25
Ton
30
Ton
40
Ton
58
Motor Pulley
Blower Pulley
Belts
Blower
RPM
Range
HP
Frame
Size
Motor Eff
(Std.
Motor)
Motor
Eff (Hi
Eff opt)
Pitch Dia
(Inches)
Bore
(Inches)
Pitch Dia
(Inches)
Bore
(Inches)
Designation
Qty
758
5
213T
87.5
89.5
4.9
1-3/8
11.3
2-3/16
BX63
2
852
7.5
215T
88.5
91.7
5.5
1-3/8
11.3
2-3/16
BX63
2
976
10
215T
89.5
91
6.3
1-5/8
11.3
2-3/16
BX63
2
852
7.5
213T
84
86.5
5.5
1-3/8
11.3
1-11/16
B65
2
976
10
215T
86.5
89.5
6.3
1-3/8
11.3
1-11/16
B65
2
1069
15
254T
85.7
89.5
6.9
1-3/8
11.3
1-11/16
B65
2
852
7.5
184T
84
86.5
5.5
1-3/8
11.3
1-11/16
B65
2
976
10
215T
86.5
89.5
6.3
1-3/8
11.3
1-11/16
B65
2
1069
15
254T
85.7
89.5
6.9
1-3/8
11.3
1-11/16
B65
2
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 36: POWER EXHAUST - ONE FORWARD CURVED FAN 25 TON1
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
0.2
AIRFLOW CFM
2000
0.4
0.6
RPM
BHP2
RPM
BHP
---
---
---
---
2
0.8
2
1.0
RPM
BHP
RPM
BHP
524
0.3
609
0.4
2
RPM
BHP2
685
0.6
3000
---
---
450
0.4
531
0.5
605
0.7
672
0.8
4000
442
0.7
496
0.8
562
0.9
626
1.1
687
1.2
5000
524
1.2
566
1.4
609
1.5
663
1.7
717
1.8
6000
612
1.9
646
2.2
679
2.4
717
2.6
762
2.7
7000
703
3.0
731
3.3
759
3.5
787
3.7
820
4.0
8000
791
3.8
821
4.3
844
4.8
868
5.2
892
5.5
9000
877
5.8
911
6.2
932
6.5
953
6.9
974
7.3
10000
967
8.4
1004
8.8
1022
9.1
1041
9.4
1059
9.8
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
1.2
AIRFLOW CFM
1.
2.
1.4
1.6
1.8
2.0
RPM
BHP2
RPM
BHP2
RPM
BHP2
RPM
BHP2
RPM
BHP2
2000
754
0.7
819
0.8
878
0.9
933
1.1
986
1.2
3000
736
1.0
797
1.1
854
1.3
909
1.5
961
1.7
4000
743
1.4
799
1.5
850
1.7
900
1.9
948
2.1
5000
768
2.0
818
2.2
865
2.4
911
2.6
955
2.8
6000
806
2.9
850
3.1
895
3.3
937
3.6
978
3.8
7000
857
4.2
895
4.4
933
4.6
972
4.8
1010
5.0
8000
921
5.7
953
6.0
985
6.2
1018
6.5
1052
6.8
9000
995
7.6
1020
8.0
1048
8.3
1075
8.5
1103
8.8
10000
1077
10.1
1096
10.4
1119
10.8
1143
11.1
1167
11.4
Fan performance is based on system/cabinet effects and back draft damper effects at standard air density and 0 feet of elevation.
BHP includes 5% drive losses.
Johnson Controls Unitary Products
59
5121842-TIM-A-0515
Power Exhaust 25 Ton
8.0
7.5
7.0
6.5
1600
6.0
Total Static Pressure (IWG)
5.5
1500
10 BHP
5.0
7.5 BHP
1400
4.5
5 BHP
1300
4.0
1200
3.5
1100
3.0
1000
2.5
900
2.0
800
700
1.5
600
1.0
500
0.5
400
300
0.0
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
CFM (x1000)
FIGURE 28 - POWER EXHAUST - ONE FORWARD CURVE FAN - 25 TONS
60
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 37: POWER EXHAUST - TWO FORWARD CURVED FANS - 30 & 40 TON1
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
0.2
AIRFLOW CFM
RPM
0.4
BHP
23
.06
23
RPM
BHP
RPM
0.8
BHP
23
1.0
23
RPM
BHP
RPM
BHP2 3
4000
363
0.32
468
0.53
560
0.74
641
0.95
716
1.16
5000
402
0.53
494
0.74
576
1.05
652
1.26
722
1.47
6000
445
0.84
527
1.05
602
1.37
670
1.68
735
2.00
7000
494
1.26
565
1.58
633
1.79
697
2.10
757
2.52
8000
544
1.79
609
2.10
670
2.42
729
2.73
784
3.15
9000
597
2.42
654
2.84
711
3.15
765
3.47
817
3.89
10000
651
3.26
703
3.68
754
3.99
805
4.41
853
4.83
11000
705
4.31
753
4.73
801
5.15
847
5.57
893
5.99
12000
761
5.46
805
5.88
849
6.30
893
6.83
934
7.25
13000
817
6.93
858
7.35
899
7.77
939
8.30
979
8.82
14000
874
8.51
912
9.03
950
9.56
988
9.98
1025
10.50
15000
932
10.40
967
10.92
1002
11.55
1037
12.08
1072
12.60
16000
989
12.60
1022
13.23
1055
13.76
1088
14.28
-
-
AVAILABLE EXTERNAL STATIC PRESSURE (IWG)
1.2
AIRFLOW CFM
1.
2.
3.
1.4
1.6
1.8
2
RPM
BHP2 3
RPM
BHP2 3
RPM
BHP2 3
RPM
BHP2 3
RPM
BHP2 3
4000
783
1.47
844
1.68
903
1.89
956
2.21
1008
2.42
5000
788
1.79
848
2.10
906
2.42
959
2.63
1011
2.94
6000
798
2.21
855
2.63
911
2.94
963
3.26
1014
3.57
7000
814
2.84
869
3.15
922
3.47
972
3.89
1021
4.20
8000
837
3.47
889
3.89
938
4.20
987
4.62
1033
5.04
9000
866
4.31
915
4.73
961
5.15
1007
5.57
1050
5.99
10000
900
5.25
945
5.67
989
6.20
1032
6.62
1073
7.14
11000
936
6.41
979
6.93
1020
7.35
1061
7.88
1101
8.30
12000
976
7.77
1016
8.30
1055
8.72
1094
9.24
1131
9.77
13000
1018
9.35
1055
9.87
1093
10.40
1129
10.92
1165
11.55
14000
1061
11.13
1098
11.66
1133
12.29
1167
12.92
1202
13.44
15000
1107
13.23
1141
13.76
1175
14.39
1208
14.91
1240
15.54
Fan performance is based on system/cabinet effects and back draft damper effects at standard air density and 0 feet elevation.
BHP includes the sum of both exhaust fan motors.
BHP includes 5% drive losses.
Johnson Controls Unitary Products
61
5121842-TIM-A-0515
FIGURE 29 - POWER EXHAUST - TWO FORWARD CURVED FANS - 30 & 40 TONS
62
Johnson Controls Unitary Products
5121842-TIM-A-0515
START-UP
COMPRESSOR ROTATION
Check for proper compressor rotation (See page 70 for symptoms of reverse compressor operations). The units are properly phased at the factory. If the blower, condenser fan, or
compressor, 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.
condenser fans are rotating in the correct direction and the
supply fan is not, it will be necessary to switch leads on the
output side of the VFD, since changing phase on the input
side of a VFD does not change rotation on the output side. If
the VFD is equipped with a bypass, verify that rotation is correct in the bypass mode.
NOTE:
If unit is equipped with power exhaust fans or return
air fan also check them for proper rotation.
VFD units with bypass must not have the bypass activated
unless all individual space dampers are full open. It is the
responsibility of the installer to interconnect the bypass mode
to the signal to open all boxes on the circuit.
Scroll compressors require proper rotation to operate correctly. Units are properly phased at the factory. DO NOT change the internal wiring to make
the blower, condenser fans or compressor rotate
correctly.
BELT TENSION
The tension on the belt should be adjusted as shown in Figure 30 and Table 38.
NOTE:
SUPPLY AIR FAN INSTRUCTIONS
If unit is equipped with power exhaust fans or return
air fan check belt tension and adjust as necessary.
C A U T IO N
CHECK BLOWER BEARING SET SCREWS
•
The bearing set screws on the supply air blower are
properly torqued before shipment. However, in transit
they may loosen. Prior to start up they should be
rechecked. The set screws are 3/8" and the torque range
is 200 - 215 in.-lbs.
NOTE: If a unit is equipped with exhaust fans, those bearing set screws should also be rechecked. The set
screws are 1/4 inch and the torque range is 70 - 87
in.-lbs.
P R
1 .
2 .
3 .
O C E D U R E F O R A D J U S T IN G B E L T T E N S IO N
L o o s e n fo u r b o lts h o ld in g m o to r b a s e to c h a n n e ls
A d ju s t b e lt b y tu r n in g n u ts " A " ( s e e d e ta il " B " ) .
U s in g a b e lt te n s io n c h e c k e r , a p p ly a p e r p e n d ic u la r
to o n e b e lt a t th e m id p o in t o f th e s p a n a s s h o w n . T h
fo r c e s h o u ld b e a p p lie d u n til a s p e c ific d e fle c tio n d is
o f 1 /6 4 " p e r in c h o f s p a n le n g th is o b ta in e d .
4 . T o d e te r m in e th e d e fle c tio n d is ta n c e fr o m n o r m a l p o
u s e a s tr a ig h t e d g e fr o m s h e a v e to s h e a v e a s a r e fe
U s e th e r e c o m m e n d e d d e fle c tio n fo r c e p e r B e lt A d ju
fo rc e
e d e fle c tio n
ta n c e
s itio n ,
r e n c e lin e .
s tm e n t T a b le .
S P A N L E N G T H
D E F L E C T IO N
F O R C E
CHECKING SUPPLY AIR CFM
The RPM of the supply air blower will depend on the required
CFM, the static pressure resistances of the unit components
(Tables 33, 48, 49, 57, and 58) and the static pressure resistances of both the supply and the return air duct systems.
With this information, the RPM for the supply air blower can
be determined from the blower performance data in Tables
30, 31, and 32. See Table 34 for pulley and drive information
for the fixed pitch pulleys supplied on the unit.
The supply air CFM must be within the limitations shown in
Table 2, and Class II fans must be specified where conditions
exceed the rpm limitations of Class I.
NOTE: If unit is equipped with power exhaust fans or return
air fan see Tables 36 and 37 for fan performance
and for pulley and drive information see Table 35.
FAN ROTATION
Check for proper supply air blower rotation. If fans are rotating backwards the line voltage to unit point of power connection is misphased (see Compressor Rotation above.) If the
Johnson Controls Unitary Products
"A "
M O T O R B A S E
D E T A IL "B "
T e n s io
re c o m
d u r in g
s h o u ld
n n e
m e n
th e
fa ll
w b e lts
d e d . C h
fir s t 2 4
b e tw e e
a t th e
e c k th
h rs . o f
n th e m
m a x im
e b e lt
o p e ra
in . a n
u
te
tio
d
m d e
n s io n
n . A n
m a x .
fle c tio n fo r
a t le a s t tw
y r e - te n s io
d e fle c tio n
c e
o tim e s
n in g
fo r c e v a lu e s .
5 . A fte r a d ju s tin g , r e tig h te n b o lts h o ld in g m o to r b a s e to c h a n n e l.
FIGURE 30 - BELT TENSION ADJUSTMENT
AIR BALANCE
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.
63
5121842-TIM-A-0515
CHECKING AIR QUANTITY
On VAV and VFD units be certain all IGV’s on VAV
unit are full open, 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 have the bypass
activated unless all individual space dampers are
full open.
TABLE 38: BELT ADJUSTMENT
FAN MOTOR HORSE POWER
5
7.5
30 TON FORWARD CURVED SUPPLY FAN
10
15
20
25
SIZE: 22 X 20
Belt Deflection Force (lbs) new belts
-
-
10.5
12.6
15.2
22.1
Belt Deflection Force (lbs) old belts
-
-
7.1
8.5
10.2
14.8
40 TON FORWARD CURVED SUPPLY FAN
SIZE: 25 X 20
Belt Deflection Force (lbs) new belts
-
-
10.5
12.6
15.2
15.2
Belt Deflection Force (lbs) old belts
-
-
7.1
8.5
10.2
10.2
30 & 40 TON POWER EXHAUST FAN
SIZE: (2) 15 X 15
Belt Deflection Force (lbs) new belts
-
7.9
9.4
9.4
-
-
Belt Deflection Force (lbs) old belts
-
5.3
6.3
6.3
-
-
25 TON FORWARD CURVE SUPPLY FAN
SIZE: 22 X 20
New Belt
-
10.5
10.5
12.6
15.2
-
Old Belt
-
7.1
7.1
8.5
10.2
-
New Belt
10.5
10.5
12.6
-
-
-
Old Belt
7.1
7.1
8.5
-
-
-
25 TON POWER EXHAUST
1.
Remove the dot plugs from the two 5/16 inch holes in the
blower motor and the filter access doors.
2.
Insert at least 8 inch of 1/4 inch metal tubing into each of
these holes for sufficient penetration into the air flow on
both sides of the indoor coil.
3.
Using an inclined manometer or other high resolution
pressure measurement device, 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 de-activated while the test is being run.
4.
64
Knowing the pressure drop across a dry coil, the actual
CFM through the unit with clean 2 inch filters, can be
determined from the curve in Figure 59 and 60.
NOTE:
De-energize the compressors before taking any test
measurements to assure a dry evaporator coil.
Failure to properly adjust the total system air quantity can result in extensive blower or duct damage.
After readings have been obtained, remove the tubes and
reinstall the two 5/16 inch dot plugs.
It is especially important to limit the rpm of the fan in VFDbypass-equipped units; it may be tempting to set max rpm in
the VFD to less than 60 Hz - but the bypass will go to 60 Hz
immediately on activation.
Johnson Controls Unitary Products
5121842-TIM-A-0515
SUPPLY AIR DRIVE ADJUSTMENT
Before making any blower speed changes review
the installation for any installation errors, leaks or
undesirable systems effects that can result in loss
of air flow.
Even small changes in blower speed can result in
substantial changes in static pressure and BHP.
BHP or AMP draw of the blower motor will
increase (see table 39) by the cube ratio of the
blower speed. Static pressure will increase by the
square ratio of the blower speed. Tables 40, 41
and 42 are for reference only. All blower speed
changes must be made by qualified personnel with
strict adherence to the fan laws.
At unit start-up the measured CFM based on Figures 59 and
60 may be higher or lower than the specified CFM. To
achieve the specified CFM, the speed of the drive may have
to be decreased or increased by changing the pitch diameter
(PD) of the motor sheave as outlined below:
•
(Specified CFM/Measured CFM) X PD of standard
sheave = PD of new sheave.
Use the following tables and the PD calculated per the above
equation to select a new motor sheave.
EXAMPLE
•
•
•
A 30 ton unit was selected to deliver 12,000 CFM with a
20 HP motor and a 856 RPM drive, but the unit is only
delivering 11,000 CFM per Figure 26.
Use the equation to determine the required PD for the
new motor sheave (12,000 CFM/11,000 CFM X 6.7” =
7.3091 inch).
Use the 30 ton table to select a Browning 2B5V74 which
will increase the speed of the unit’s drive and its supply
air CFM to 111.9%. Thus select the 7.5” PD at 112%
increase over standard.
Johnson Controls Unitary Products
•
New drive speed = 1.1194 X 856 = 958.2 RPM
•
New supply air = 1.1194 X 11,000 = 12,313 CFM
•
Re-use the existing belts and blower sheave.
New motor BHP = (speed increase)3 x estimated motor
BHP at original start-up with 11,000 CFM and 856 RPM =
(1.119)3 x 11 BHP = 1.4012 x 11 BHP = 15.41 BHP New
motor amps = (speed increase)3 x measured motor amps
at original start-up with 11,000 CFM and 856 RPM.
.
TABLE 39: BLOWER SPEED RATE OF CHANGE
CHANGE IN
CFM
TSP
BHP AND
MOTOR
AMPS
.90
.90
.81
.73
.93
.93
.86
.79
.95
.95
.90
.86
.98
.98
.95
.93
1.00
1.00
1.00
1.00
1.03
1.03
1.05
1.08
1.05
1.05
1.10
1.16
1.08
1.08
1.16
1.24
1.10
1.10
1.21
1.33
1.13
1.13
1.27
1.42
1.15
1.15
1.32
1.52
1.18
1.18
1.38
1.62
1.20
1.20
1.44
1.73
CHANGE IN RPM
SYSTEM SETPOINTS
Constant Volume and Variable Air Volume:
Thermostat and space sensor offsets must be made external
to the unit. For internal settings, refer to the Settable Parameters in the Unit Control document. All parameters affecting
the unit with that specific set of options and for that specific
application must be reviewed. In many cases, the default settings will be fine - but verify and fine tune where necessary.
65
5121842-TIM-A-0515
TABLE 40: 25 TON DRIVE ADJUSTMENT
7.5 HP MOTOR & 567 RPM DRIVE
10 HP MOTOR & 692 RPM DRIVE
15 HP MOTOR & 793 RPM DRIVE
20 HP MOTOR & 894 RPM DRIVE
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
-
-
-
82
4.5
42
84
5.3
50
86
6.1
58
-
-
-
86
4.7
44
87
5.5
52
89
6.3
60
100
(Std.)4.5
42
89
4.9
46
90
5.7
54
91
6.5
62
104
4.7
44
93
5.1
48
94
5.9
56
94
6.7
64
109
4.9
46
96
5.3
50
97
6.1
58
97
6.9
66
52
100
(Std)
6.3
60
100
(Std.)
7.1
68
70
113
5.1
48
100
(Std.)
5.5
118
5.3
50
104
5.7
54
103
6.5
62
103
7.3
122
5.5
52
107
5.9
56
106
6.7
64
108
7.7
74
126
5.7
54
111
6.1
58
110
6.9
66
117
8.3
80
-
-
-
115
6.3
60
113
7.1
68
125
8.9
86
-
-
-
118
6.5
62
116
7.3
70
-
-
-
-
-
-
122
6.7
64
122
7.7
74
-
-
-
TABLE 41: 30 TON DRIVE ADJUSTMENT
10 HP MOTOR & 617 RPM DRIVE
15 HP MOTOR & 743 RPM DRIVE
20 HP MOTOR & 856 RPM DRIVE
25 HP MOTOR & 907 RPM DRIVE
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
91.8
4.5
42
86.4
5.1
48
82.1
5.5
54
86.3
6.1
60
95.9
4.7
44
89.8
5.3
50
85.1
5.7
56
89.0
6.3
62
100.0
(Std.)
4.9
46
93.2
5.5
52
88.1
5.9
58
91.8
6.5
64
104.1
5.1
48
96.6
5.7
54
91.0
6.1
60
94.5
6.7
66
56
94.0
6.3
62
97.3
6.9
68
66
108.2
5.3
50
100.0
(Std.)
5.9
112.2
5.5
52
103.4
6.1
58
97.0
6.5
64
100.0
(Std.)
7.1
70
116.3
5.7
54
106.8
6.3
60
100.0
(Std.)
6.7
66
105.5
7.5
74
120.4
5.9
56
110.2
6.5
62
103.0
6.9
68
113.7
8.1
80
124.5
6.1
58
113.6
6.7
64
106.0
7.1
70
121.9
8.7
86
-
-
-
116.9
6.9
66
112.0
7.5
74
-
-
-
-
-
-
120.3
7.1
68
120.9
8.1
80
-
-
-
-
-
-
123.7
7.3
70
129.9
8.7
86
-
-
-
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 42: 40 TON DRIVE ADJUSTMENT
10 HP MOTOR & 617 RPM DRIVE
15 HP MOTOR & 652 RPM DRIVE
20 HP MOTOR & 728 RPM DRIVE
25 HP MOTOR & 780 RPM DRIVE
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
% RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
%RPM
& CFM
REQ’D
PD
BROWNING
2B5V_ _
91.8
4.5
42
88.2
4.5
44
82.5
4.7
46
83.7
5.1
50
95.9
4.7
44
92.1
4.7
46
86.0
4.9
48
86.9
5.3
52
100.0
(Std.)
4.9
46
96.0
4.9
48
89.5
5.1
50
90.2
5.5
54
104.1
5.1
48
100.0
(Std.)
5.1
50
93.0
5.3
52
93.4
5.7
56
108.2
5.3
50
103.9
5.3
52
96.5
5.5
54
96.7
5.9
58
56
100.0
(Std.)
6.1
60
62
107.8
5.5
54
100.0
(Std.)
5.7
54
111.7
5.7
56
103.5
5.9
58
103.3
6.3
-
115.6
5.9
58
107.0
6.1
60
106.6
6.5
64
-
-
119.5
6.1
60
110.5
6.3
62
109.8
6.7
66
-
-
-
123.4
6.3
62
114.0
6.5
64
113.1
6.9
68
-
-
-
127.4
6.5
64
117.5
6.7
66
116.4
7.1
70
-
-
-
-
-
66
121.1
6.9
68
119.7
7.5
74
112.2
5.5
52
116.3
5.7
-
-
-
TABLE 43: DRIVE ADJUSTMENT FOR POWER EXHAUST - 25 TON
5 HP Motor & 758 RPM Drive
Browning
2b5v_ _
7.5 HP Motor & 852 RPM Drive
%RPM
& CFM
Req’d
PD
Browning
2b5v_ _
10 HP Motor & 976 RPM Drive
%RPM
& CFM
Browning
2b5v_ _
%RPM
& CFM
Req’d
PD
100
4.9 (Std.)
46
92
5.1
48
93
5.9
56
104
5.1
48
96
5.3
50
97
6.1
58
Req’d PD
109
5.3
50
100
5.5 (Std.)
52
100
6.3 (Std.)
60
113
5.5
52
104
5.7
54
103
6.5
62
117
5.7
54
108
5.9
56
107
6.7
64
122
5.9
56
112
6.1
58
110
6.9
66
Johnson Controls Unitary Products
67
5121842-TIM-A-0515
TABLE 44: DRIVE ADJUSTMENT FOR POWER EXHAUST - 30 & 40 TON
7.5 HP Motor & 852 RPM Drive
% RPM
& CFM
REQ’D
PD (in)
Browning
2B5V_ _
10 HP Motor & 976 RPM Drive
% RPM
& CFM
REQ’D
PD (in)
Browning
2B5V_ _
% RPM
& CFM
REQ’D
PD (in)
Browning
2B5V_ _
96.4
5.3
52
93.7
5.9
58
94.2
6.5
64
100.0
(Std.) 5.5
54
96.8
6.1
60
97.1
6.7
66
103.6
5.7
56
100.0
(Std.) 6.3
62
100.0
(Std.) 6.9
68
107.3
5.9
58
103.2
6.5
64
102.9
7.1
70
110.9
6.1
60
106.3
6.7
66
108.7
7.5
74
114.5
6.3
62
109.5
6.9
68
117.4
8.1
80
GAS FURNACE OPERATING
INSTRUCTIONS
Each furnace module is equipped with an automatic re-ignition system. DO NOT attempt to manually light the burners.
POST-START CHECKLIST (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.
Check for correct manifold gas pressures. See Checking
Gas Input.
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 pressure exceed
13 inches, nor the operating pressure drop below 6
inches. If gas pressure is outside these limits, contact the
local gas utility for corrective action.
TO LIGHT THE MAIN BURNERS
1.
Turn off electric power to unit.
2.
Turn space temperature sensor to lowest setting.
3.
Turn gas valve knobs to on position (Refer to Figure 31).
4.
Turn on electric power to unit.
5.
On Constant Volume units, set space setpoint to warmer
or cooler as desired. (If sensor set point temperature is
above room temperature, the main burners will ignite). If
a second stage of heat is called for, the main burners for
second stage heat will ignite for the second stage heat.
For VAV units set morning warm-up thermostat far above
the return air temperature and cycle the time clock OFF,
then ON.
TO SHUT DOWN
1.
Turn off electric power to unit.
2.
Depress knob of gas valve while turning to off position or
move switch to off position. (Refer to Figure 31).
68
15 HP Motor & 1069 RPM Drive
MANIFOLD GAS PRESSURE ADJUSTMENT
Small adjustments to the gas flow may be made by turning
the pressure regulator adjusting screw on the automatic gas
valve. Refer to Figure 31.
Adjust as follows:
1.
Remove the cap on the regulator. It's located next to the
push-on electrical terminals.
2.
To decrease the gas pressure, turn the adjusting screw
counterclockwise.
3.
To increase the gas pressure, turn the adjusting screw
clockwise.
NOTE:
The factory manifold pressure for each furnace
module is 3.50 IWG.
Johnson Controls Unitary Products
5121842-TIM-A-0515
Reverse the above procedure to replace the assemblies.
Make sure that burners are level and seat at the rear of the
gas orifice.
VALVE
SWITCH
ADJUSTMENT OF TEMPERATURE RISE
ELECTRICAL
TERMINALS
VALVE
INLET
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 CGA/ETL rating plate and the data in
Table 3.
After the temperature rise has been determined, the CFM can
be calculated as follows:
Btuh  0.8
CFM= -------------------------------------------------------------------------1.08  F Degrees Temp Rise
STANDARD GAS VALVE
ELECTRICAL
TERMINALS
VALVE
SWITCH
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 Table 34 for supply air
blower motor and drive data. Minimum allowable CFM is
6,000 CFM. Limit will open below this rating.
CHECKING GAS INPUT
NATURAL GAS
VALVE
INLET
1.
Turn off all other gas appliances connected to the gas
meter.
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 Table 45.
2 STAGE GAS VALVE USED
ON MODULATING GAS HEAT
FIGURE 31 - TYPICAL GAS VALVES
BURNER INSTRUCTIONS
To check or change burners, pilot or orifices, CLOSE MAIN
MANUAL SHUT-OFF VALVE AND SHUT OFF ALL POWER
TO THE UNIT.
1.
Remove the screws holding either end of the manifold to
the burner supports.
2.
Open the union fitting in the gas supply line just
upstream of the unit gas valves and downstream from
the main manual shut-off valve.
3.
Disconnect wiring to the gas valves and spark ignitors.
Remove the manifold-burner gas valve assemblies by
pulling back.
4.
Remove the heat shield on top of the manifold support.
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).
Burners are now accessible for service.
Johnson Controls Unitary Products
69
5121842-TIM-A-0515
TABLE 45: GAS RATE - CUBIC FEET PER HOUR
Size of Test Dial
Seconds for One
Rev.
1/2 cu. Ft.
1 cu. Ft.
2
900
1800
4
450
900
6
300
600
8
225
450
10
180
360
SERVICE
REFRIGERATION SYSTEM
H E A T E X C H A N G E R
CHARGE: Each system is fully factory charged with R-410A.
The correct charge appears on the unit nameplate.
Thermal Expansion Valves: The 30 ton unit has 3 and the 40
ton unit has 4 independent refrigeration systems. These
TXVs are set to maintain 15°F superheat leaving the evaporator coil. The superheat on each valve is adjustable, however, adjustments should only be made if absolutely
necessary.
T U B E
G A S
S U P P L Y
P IP E
FILTER DRIER: Each system is equipped with a filter drier.
The drier should be replaced whenever moisture is indicated
in the system.
COMPRESSORS
B U R N E R F L A M E
(B L U E O N L Y )
B U R N E R
B U R N E R B R A C K E T
IG N IT O R
FIGURE 32 - TYPICAL FLAME APPEARANCE
Example: By actual measurement, it takes 7 seconds for the
hand on the one cubic foot dial to make a revolution with just
a 570,000 Btuh furnace running. Read across to the column
in Table 24, headed 1 Cubic Foot where you will determine
that 525 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 525 x 1050 (the Btu rating of the
gas obtained from the local gas company). The result of
551,000 Btuh is within 5% of the 570,000 Btuh rating of the
furnace.
ELECTRIC HEATING
The electric furnace is operational as shipped from the factory and does not receive any field adjustments.
Each compressor is inherently protected from over current
and over temperature. High and low pressure switches are
installed on the discharge and suction lines respectively for
high and low pressure protection. Scroll compressors operate
in only one direction. If the compressor is experiencing low
amperage draw, similar discharge and suction pressure or
increased noise level, it is operating in reverse. Switch two
line voltage connections to correct (See Compressor Rotation
page 63).
MOTORS
INDOOR BLOWER MOTORS
All indoor blower motors are non-inherently protected three
phase motors. Overcurrent protection is provided by a manual reset starter/overload relay and short circuit protection is
provided by fuses. Where there is a supply fan VFD, an auxiliary contact provides the over-current indication to the Simplicity SE control.
POWER EXHAUST OR RETURN AIR FAN MOTORS
COOLING OPERATING INSTRUCTIONS
COMPRESSOR
Compressors are factory mounted ready for operation (See
page 63 Compressor Rotation).
All motors are non-inherently protected three phase motors.
Overcurrent protection is provided by a manual reset
starter/overload relay and short circuit protection is provided
by fuses.
CONDENSER FAN MOTORS
INTERNAL WIRING
All condenser fan motors are inherently protected three
phase motors. Short circuit protection is provided by fuses.
Check all electrical connections in the unit control box;
tighten as required.
DRAFT MOTOR (GAS FURNACE)
CONDENSER FANS
All draft motors are line voltage, inherently protected, single
phase PSC motors. Short circuit protection is provided by
fuses.
Check for proper condenser fan rotation; clockwise facing the
air discharge. If condenser fans are rotating backwards, line
voltage to unit single point power connection is misphased
(See page 63 Compressor Rotation).
70
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 46: STEAM COIL (1 ROW, 25 & 30 TON)1
Capacity (MBH) at Steam Pressure (PSI)
TABLE 49: STATIC RESISTANCE STEAM COIL
(40 TON)
CFM
2
6
10
15
6000
194.1
207.9
219.8
232.6
8000
221.1
236.9
250.4
265.0
10000
243.2
260.5
275.4
291.4
12000
261.9
280.6
296.6
313.9
15000
285.6
306.0
323.5
342.4
1.
CFM
8000
11000
14000
17000
20000
Air Pressure
Drop
0.18
0.31
0.48
0.67
0.88
TABLE 50: HOT WATER COIL (1 ROW 25 & 30 TON)1
GPM
Based on 60°F entering air temperature, 2.00” maximum air pressure drop across the coil.
TABLE 47: STEAM COIL (1 ROW, 40 TON)1
Capacity (MBH) at Steam Pressure (PSI)
CFM
2
6
10
15
8000
221.1
236.9
250.4
265.0
11000
252.9
271.0
286.4
303.1
14000
278.2
298.0
315.0
333.4
17000
299.4
320.7
339.0
358.8
20000
317.6
340.2
359.6
380.6
1.
10
20
Based on 60°F entering air temperature, 2.00” maximum air pressure drop across the coil.
TABLE 48: STATIC RESISTANCE STEAM COIL (25 &
30 TON)
CFM
6000
8000
10000
12000
15000
Air Pressure
Drop
0.11
0.18
0.26
0.36
0.54
30
40
1.
Johnson Controls Unitary Products
CFM
Capacity (MBH) at Entering Water
Temperature
140 °F
160 °F
180 °F
200 °F
6000
91.4
115.3
139.3
163.6
8000
102
128.8
155.8
182.9
10000
110.4
139.5
168.8
198.4
12000
117.3
148.4
179.6
211.2
15000
125.9
159.2
192.9
226.9
6000
103
129.4
156
182.7
8000
116.8
147
177.2
207.7
10000
128.2
161.3
194.7
228.2
12000
137.8
173.6
209.5
245.6
15000
150
189
228.2
267.8
6000
107.6
135
162.5
190.1
8000
122.8
154.3
185.8
217.5
10000
135.5
170.3
205.1
240.2
12000
146.4
184
221.8
259.7
15000
160.3
201.6
243
284.8
6000
110.1
138
166
194.1
8000
126.1
158.2
190.5
222.8
10000
139.6
175.2
210.9
246.8
12000
151.2
189.8
228.5
267.5
15000
166.1
208.6
251.3
294.1
Based on 60°F entering air temperature, 2.00” maximum
pressure drop across the hot water coil.
71
5121842-TIM-A-0515
TABLE 51: HOT WATER COIL (1 ROW, 40 TON)1
GPM
CFM
10
20
Capacity (MBH) at Entering Water
Temperature
140 °F
160 °F
180 °F
200 °F
8000
102
128.8
155.8
182.9
11000
114
144.1
174.4
205.1
14000
123.2
155.9
188.8
222.1
17000
130.6
165.4
200.4
235.8
20000
136.8
173.3
210.1
247.3
8000
116.8
147
177.2
207.7
11000
133.2
167.7
202.3
237.2
14000
146.2
184.2
222.4
260.8
TABLE 53: WATER PRESSURE DROP (1 ROW, 40
TONS)
GPM
10
20
30
40
Water
Pressure
Drop
0.9
3.0
6.0
10.0
TABLE 54: HOT WATER COIL (2 ROW, 25 & 30
TON)1
GPM
40
1.
140 °F
160 °F
180 °F
200 °F
6000
177.5
223.8
270.4
317.3
8000
203.8
257.2
311.1
365.5
10000
224.8
284.1
343.9
404.2
12000
242.2
306.4
371.1
436.4
157
197.9
239
280.5
20000
166.2
209.6
253.2
297.3
8000
122.8
154.3
185.8
217.5
15000
263.6
333.8
404.6
476.1
11000
141.2
177.4
213.8
250.3
6000
198.1
248.9
300.0
351.3
8000
232.2
292.0
352.2
412.7
10000
260.7
328.1
395.9
464.1
14000
155.9
196.1
236.4
276.9
17000
168.3
211.8
255.4
299.3
12000
285.0
359.0
433.4
508.3
15000
316.0
398.4
481.3
564.8
6000
206.1
258.7
311.4
364.2
20000
179.1
225.3
271.8
318.6
8000
126.1
158.2
190.5
222.8
11000
145.6
182.7
220
257.5
14000
161.4
202.6
244.1
17000
174.7
219.5
20000
186.3
234.2
40
8000
243.6
305.9
368.4
431.1
10000
275.3
345.9
416.8
488.0
285.8
12000
302.9
380.7
458.9
537.6
264.5
309.7
15000
338.4
425.7
513.4
601.7
6000
210.5
263.9
317.4
371.1
282.3
330.6
8000
249.8
313.3
377.1
441.1
10000
283.3
355.6
428.2
501.0
12000
312.7
392.7
473.0
553.6
15000
351.0
440.9
531.3
622.1
Based on 60°F entering air temperature, 2.00” maximum
pressure drop across the hot water coil.
TABLE 52: WATER PRESSURE DROP (1 ROW, 25 &
30 TON)
GPM
10
20
30
40
Water
Pressure
Drop
0.9
3.0
6.0
10.0
72
Capacity (MBH) at Entering Water
Temperature
17000
20
30
CFM
60
80
1.
Based on 60°F entering air temperature, 2.00” maximum
pressure drop across the hot water coil.
Johnson Controls Unitary Products
5121842-TIM-A-0515
TABLE 55: WATER PRESSURE DROP (2 ROW, 25 &
30 TON)
GPM
Water
Pressure
Drop
20
0.9
40
3.0
60
6.0
Water
Pressure
Drop
20
0.9
40
3.0
60
6.0
CFM
6000
8000
10000
15000
Air Pressure
Drop 1 Row
0.07
0.11
0.16
0.32
Air Pressure
Drop 2 Row
0.14
0.23
0.33
0.65
80
10.0
TABLE 56: WATER PRESSURE DROP (2 ROW, 40
TON)
GPM
TABLE 57: STATIC RESISTANCE HOT WATER COIL
(25 & 30 TON)
80
TABLE 58: STATIC RESISTANCE HOT WATER COIL
(40 TON)
CFM
8000
11000
14000
20000
Air Pressure
Drop 1 Row
0.11
0.19
0.29
0.52
Air Pressure
Drop 2 Row
0.23
0.39
0.58
1.06
10.0
NOTE:
Johnson Controls Unitary Products
Water pressure drop numbers are based on 60°F
entering air temperature, 2.00” maximum air pressure drop across the hot water coil(s). AHRI certified ratings at covering other conditions are
available upon request. Hot water coils are
approved for use with glycol (rates available upon
request.
73
5121842-TIM-A-0515
2 3 0 .0
2 2 0 .0
2 1 0 .0
2 0 0 .0
1 9 0 .0
CAPACITY (MBH)
1 8 0 .0
1 7 0 .0
140
160
180
200
1 6 0 .0
1 5 0 .0
°F
°F
°F
°F
1 4 0 .0
1 3 0 .0
1 2 0 .0
1 1 0 .0
1 0 0 .0
9 0 .0
8 0 .0
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
F L O W R A T E (C F M )
FIGURE 33 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 10 GPM
2 7 0 .0
2 6 0 .0
2 5 0 .0
2 4 0 .0
2 3 0 .0
2 2 0 .0
CAPACITY (MBH)
2 1 0 .0
2 0 0 .0
1 9 0 .0
140
160
180
200
1 8 0 .0
1 7 0 .0
°F
°F
°F
°F
1 6 0 .0
1 5 0 .0
1 4 0 .0
1 3 0 .0
1 2 0 .0
1 1 0 .0
1 0 0 .0
9 0 .0
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
F L O W R A T E (C F M )
FIGURE 34 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 20 GPM
74
Johnson Controls Unitary Products
5121842-TIM-A-0515
2 9 0 .0
2 8 0 .0
2 7 0 .0
2 6 0 .0
2 5 0 .0
2 4 0 .0
2 3 0 .0
CAPACITY (MBH)
2 2 0 .0
2 1 0 .0
2 0 0 .0
1 9 0 .0
1 8 0 .0
140
160
180
200
°F
°F
°F
°F
140
160
180
200
°F
°F
°F
°F
1 7 0 .0
1 6 0 .0
1 5 0 .0
1 4 0 .0
1 3 0 .0
1 2 0 .0
1 1 0 .0
1 0 0 .0
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
F L O W R A T E (C F M )
FIGURE 35 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 30 GPM
5 8 0 .0
5 6 0 .0
5 4 0 .0
5 2 0 .0
5 0 0 .0
4 8 0 .0
4 6 0 .0
CAPACITY (MBH)
4 4 0 .0
4 2 0 .0
4 0 0 .0
3 8 0 .0
3 6 0 .0
3 4 0 .0
3 2 0 .0
3 0 0 .0
2 8 0 .0
2 6 0 .0
2 4 0 .0
2 2 0 .0
2 0 0 .0
1 8 0 .0
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
F L O W R A T E (C F M )
FIGURE 36 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 40 GPM
Johnson Controls Unitary Products
75
5121842-TIM-A-0515
6 1 0 .0
5 9 0 .0
5 7 0 .0
5 5 0 .0
5 3 0 .0
5 1 0 .0
4 9 0 .0
CAPACITY (MBH)
4 7 0 .0
4 5 0 .0
4 3 0 .0
140
160
180
200
4 1 0 .0
3 9 0 .0
3 7 0 .0
°F
°F
°F
°F
3 5 0 .0
3 3 0 .0
3 1 0 .0
2 9 0 .0
2 7 0 .0
2 5 0 .0
2 3 0 .0
2 1 0 .0
1 9 0 .0
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
F L O W R A T E (C F M )
FIGURE 37 - HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 60 GPM
6 4 0 .0
6 2 0 .0
6 0 0 .0
5 8 0 .0
5 6 0 .0
5 4 0 .0
5 2 0 .0
5 0 0 .0
CAPACITY (MBH)
4 8 0 .0
4 6 0 .0
140
160
180
200
4 4 0 .0
4 2 0 .0
4 0 0 .0
°F
°F
°F
°F
3 8 0 .0
3 6 0 .0
3 4 0 .0
3 2 0 .0
3 0 0 .0
2 8 0 .0
2 6 0 .0
2 4 0 .0
2 2 0 .0
2 0 0 .0
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
F L O W R A T E (C F M )
FIGURE 38 - HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 80 GPM
76
Johnson Controls Unitary Products
5121842-TIM-A-0515
2 5 0 .0
2 4 0 .0
2 3 0 .0
2 2 0 .0
2 1 0 .0
2 0 0 .0
CAPACITY (MBH)
1 9 0 .0
1 8 0 .0
1 7 0 .0
1 6 0 .0
140
160
180
200
°F
°F
°F
°F
140
160
180
200
°F
°F
°F
°F
1 5 0 .0
1 4 0 .0
1 3 0 .0
1 2 0 .0
1 1 0 .0
1 0 0 .0
9 0 .0
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 39 - HOT WATER COIL - 40 TON, 1 ROW, AT 10 GPM
3 0 0 .0
2 9 0 .0
2 8 0 .0
2 7 0 .0
2 6 0 .0
2 5 0 .0
2 4 0 .0
CAPACITY (MBH)
2 3 0 .0
2 2 0 .0
2 1 0 .0
2 0 0 .0
1 9 0 .0
1 8 0 .0
1 7 0 .0
1 6 0 .0
1 5 0 .0
1 4 0 .0
1 3 0 .0
1 2 0 .0
1 1 0 .0
1 0 0 .0
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 40 - HOT WATER COIL - 40 TON, 1 ROW, AT 20 GPM
Johnson Controls Unitary Products
77
5121842-TIM-A-0515
320 .0
310 .0
300 .0
290 .0
280 .0
270 .0
260 .0
250 .0
CAPACITY (MBH)
240 .0
230 .0
220 .0
210 .0
200 .0
140
160
180
200
°F
°F
°F
°F
140
160
180
200
°F
°F
°F
°F
190 .0
180 .0
170 .0
160 .0
150 .0
140 .0
130 .0
120 .0
110 .0
80 00
9000
1 0000
1100 0
120 00
1 3000
1400 0
1 5000
1600 0
17 000
18 000
1900 0
20 000
F L O W R AT E (C F M )
FIGURE 41 - HOT WATER COIL - 40 TON, 1 ROW, AT 30 GPM
3 4 0 .0
3 3 0 .0
3 2 0 .0
3 1 0 .0
3 0 0 .0
2 9 0 .0
2 8 0 .0
2 7 0 .0
CAPACITY (MBH)
2 6 0 .0
2 5 0 .0
2 4 0 .0
2 3 0 .0
2 2 0 .0
2 1 0 .0
2 0 0 .0
1 9 0 .0
1 8 0 .0
1 7 0 .0
1 6 0 .0
1 5 0 .0
1 4 0 .0
1 3 0 .0
1 2 0 .0
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 42 - HOT WATER COIL - 40 TON, 1 ROW, AT 40 GPM
78
Johnson Controls Unitary Products
5121842-TIM-A-0515
5 3 0 .0
5 1 0 .0
4 9 0 .0
4 7 0 .0
4 5 0 .0
4 3 0 .0
CAPACITY (MBH)
4 1 0 .0
3 9 0 .0
140
160
180
200
3 7 0 .0
3 5 0 .0
°F
°F
°F
°F
3 3 0 .0
3 1 0 .0
2 9 0 .0
2 7 0 .0
2 5 0 .0
2 3 0 .0
2 1 0 .0
1 9 0 .0
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 43 - HOT WATER COIL - 40 TON, 2 ROW, AT 20 GPM
6 5 0 .0
6 3 0 .0
6 1 0 .0
5 9 0 .0
5 7 0 .0
5 5 0 .0
5 3 0 .0
5 1 0 .0
CAPACITY (MBH)
4 9 0 .0
4 7 0 .0
140
160
180
200
4 5 0 .0
4 3 0 .0
4 1 0 .0
°F
°F
°F
°F
3 9 0 .0
3 7 0 .0
3 5 0 .0
3 3 0 .0
3 1 0 .0
2 9 0 .0
2 7 0 .0
2 5 0 .0
2 3 0 .0
2 1 0 .0
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 44 - HOT WATER COIL - 40 TON, 2 ROW, AT 40 GPM
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7 0 0 .0
6 8 0 .0
6 6 0 .0
6 4 0 .0
6 2 0 .0
6 0 0 .0
5 8 0 .0
5 6 0 .0
5 4 0 .0
CAPACITY (MBH)
5 2 0 .0
5 0 0 .0
4 8 0 .0
4 6 0 .0
4 4 0 .0
140
160
180
200
°F
°F
°F
°F
140
160
180
200
°F
°F
°F
°F
4 2 0 .0
4 0 0 .0
3 8 0 .0
3 6 0 .0
3 4 0 .0
3 2 0 .0
3 0 0 .0
2 8 0 .0
2 6 0 .0
2 4 0 .0
2 2 0 .0
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 45 - HOT WATER COIL - 40 TON, 2 ROW, AT 60 GPM
7 3 0 .0
7 1 0 .0
6 9 0 .0
6 7 0 .0
6 5 0 .0
6 3 0 .0
6 1 0 .0
5 9 0 .0
5 7 0 .0
CAPACITY (MBH)
5 5 0 .0
5 3 0 .0
5 1 0 .0
4 9 0 .0
4 7 0 .0
4 5 0 .0
4 3 0 .0
4 1 0 .0
3 9 0 .0
3 7 0 .0
3 5 0 .0
3 3 0 .0
3 1 0 .0
2 9 0 .0
2 7 0 .0
2 5 0 .0
2 3 0 .0
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 46 - HOT WATER COIL - 40 TON, 2 ROW, AT 80 GPM
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350
340
330
320
310
300
CAPACITY (MBH)
290
280
2 psi
6 psi
10 psi
15 psi
270
260
250
240
230
220
210
200
190
180
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
F L O W R A T E (C F M )
FIGURE 47 - STEAM COIL - 25 & 30 TON (1 ROW)
390
380
370
360
350
340
CAPACITY (MBH)
330
320
310
2 psi
6 psi
10 psi
15 psi
300
290
280
270
260
250
240
230
220
210
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
F L O W R A T E (C F M )
FIGURE 48 - STEAM COIL - 40 TON (1 ROW)
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FIGURE 49 - TYPICAL CONTROL WIRING
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FIGURE 50 - TYPICAL CONTROL WIRING CONTINUED
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FIGURE 51 - LEGEND
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FIGURE 52 - TYPICAL 25 TON POWER WIRING
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FIGURE 53 - TYPICAL STANDARD GAS HEAT WIRING
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FIGURE 54 - TYPICAL MODULATING GAS HEAT WIRING
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GAS FURNACE SAFETY FEATURES
MOTORS
COMBUSTION AIR PROVING
Outdoor fan motors are permanently lubricated and require
no maintenance. Lubrication, if desired, is to be performed by
a qualified service agency.
Combustion air proving is provided by a pressure switch. As
the motor approaches full speed, this switch closes before
any other circuit or gas component can be energized.
ROLLOUT
Rollout protection is provided by a switch mounted on the
heat shield of each furnace module. The switch senses any
flame or excessive heat in the burner compartment. When
the switch opens, the furnace module is immediately locked
out until there is a break in power to the specific furnace module and the manual itch is reset. Note that only the module
with the open rollout switch will be locked out, the remaining
modules will continue to operate although all should be
inspected.
A trip of the rollout switch likely indicates a flue restriction, an
opening in the flue passageway, defective pressure switch or
a loose combustion blower wheel. Corrective action should
be taken accordingly.
MAINTENANCE
Ventor motors are factory lubricated for an estimated 10-year
life.
Indoor Fan Motors - The indoor blower motor features ballbearings that do not require periodic lubrication. Periodic
lubrication of the motor bearings can extend the life but is
optional.
Damage can occur if the bearings are over lubricated. Use grease sparingly.
To go to bypass mode, the bypass VFD as installed in this
unit must be switched by hand on the front of the bypass
enclosure in the fan cabinet of the rooftop unit. It does not
automatically go to bypass mode if the drive fails.
The switches on the front of the bypass box control its run
mode. For normal running:
NORMAL MAINTENANCE
•
•
Prior to any of the following maintenance procedures, shut off all power to the unit. Failure to do
so could cause personal injury.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
Periodic maintenance normally consists of changing or cleaning filters and (under some conditions) cleaning the main
burners.
FILTERS
•
•
The ON/OFF rotary power switch must be in the ON
position.
The BYPASS/OFF/DRIVE switch S1 should be in the
DRIVE position.
The HAND/STOP/AUTO switch S2 should be in the
AUTO position, so that the unit control will properly run
the fan and control the speed.
The TEST/NORMAL switch S3 should be in the NORMAL position.
If the unit is operated with the manual bypass
switch in the LINE (BYPASS) position and there
are VAV boxes present, the boxes must be driven
to the full-open position using a customer-supplied
power source to prevent over-pressuring the
ductwork.
Inspect once a month. Replace disposable or clean permanent type as necessary. The dimensional size of the replacement filter must be the same as the replaced filter (Refer to
Table 15).
Perform all maintenance operations on the blower
motor with power disconnected from the unit. Do
not attempt to lubricate bearings with the unit in
operation.
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NOTE:
TABLE 59: INDOOR BLOWER BEARING
LUBRICATION SCHEDULE
Operating Speed (RPM)
Shaft Size (Inches)
500
1000
1500
2000
Re lubrication Cycle (Months)
1-1/16 - 1-7/16
6
6
6
6
1-1/2 - 1-3/4
6
6
6
4
1-7/8 - 2-3/16
6
6
4
4
2 -1/4 - 3
6
4
4
2
On an annual basis, check the motor for accumulations of
dust, etc. That may block the cooling slots in the motor shell.
Check for loose, damaged or misaligned drive components.
Check that all mounting bolts are tight. Replace defective
parts as required.
If desired, every three years remove both pipe plugs at each
end shell and clean out any hardened grease or foreign matter. Replace one plug on each end with a clean grease fitting.
Using a low pressure grease gun, pump grease (Chevron
SRI-2 or equivalent) into the bearing cavity until new grease
shows at the open port. Do not over-lubricate. Run the motor
for ten minutes until excess grease is purged from the cavity.
Replace the plugs.
Exercise care when cleaning the coil so that the coil
fins are not damaged.
Do not permit the hot condenser air discharge to be
obstructed by overhanging structures or shrubs.
GAS BURNER
Periodically (at least annually at the beginning of each heating season) make a visual check of the main burner flame.
TO CLEAN BURNERS
Remove them from the furnace as explained in BURNER
INSTRUCTIONS. Clean burners with hot water applied along
top of the burner.
COMBUSTION AIR DISCHARGE
Visually inspect discharge outlet periodically to make sure
that the buildup of soot and dirt is not excessive. If necessary,
clean to maintain adequate combustion air discharge.
CLEANING FLUE PASSAGES AND HEATING ELEMENTS
With proper combustion adjustment, the heating element of a
gas fired furnace will seldom need cleaning. If the element
should become sooted, it can be cleaned as follows:
1.
Remove the burner assembly as outlined in BURNER
INSTRUCTIONS.
2.
Lubricate with a premium quality NLGI 2 grade multi-purpose
roller bearing grease having corrosion inhibitors, anti-oxidant
additives and mechanical stability for high speed operation.
The grease should also have a minimum base oil viscosity of
500 SUS at 100°F. Do not use a heavy, long fibered grease.
Remove the screws holding the top of the flue collector
box. Carefully remove the top of the flue collector box.
The draft wheel, housing, and draft motor can remain
assembled to the flue box top, if cleaning of these components is not required.
3.
The presents of dirt, moisture or chemical fumes around the
bearings requires more frequent lubrication.
This will provide access to flue baffles, then remove the
flue baffles from the tube interiors. To remove, the flue
baffles, remove the stainless steel screws from the vest
panel. Refer to Figure 55.
4.
Using a wire brush on a flexible wand, brush out the
inside of each heat exchanger from the burner inlet and
flue outlet ends.
5.
Brush out the inside of the flue collector box, and the flue
baffles.
6.
Run the wire brush down the vent hoods from the flue
collector end.
7.
If soot build-up is particularly bad, remove the vent motor
and clean the wheels and housings. Run the wire brush
down the flue extension at the outlet of the vent housings.
8.
After brushing is complete, blow all brushed areas with
air or nitrogen. Vacuum as needed.
9.
Replace parts in the order they were moved in steps 1 to
4.
FAN DRIVES
Units are supplied with fan shaft bearings that do not require
maintenance but may be relubricated per Table 59.
Fill bearings with lubricant prior to extended shutdown or storage. Rotate the shaft monthly during idle periods.
Avoid excessive grease purging from seals during lubrication,
this reduces the life of the bearing.
OUTDOOR COIL
Dirt should not be allowed to accumulate on the outdoor coil
surface or other parts in the air circuit. Cleaning should be as
often as necessary to keep coil clean. Use a brush, vacuum
cleaner attachment, or other suitable means. If water is used
to clean coil, be sure power to the unit is shut off prior to
cleaning.
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10. Assure that all seams on the vent side of the combustion
systems are air tight. Apply a high temperature (+500°F)
sealing compound where needed (Dow Corning, Silastic
736, Loctite Superflex 596 or equivalent).
NOTE:
One end of each flue baffle is provided
with a sharper bend than the other end - this
sharper bend must be positioned at the tube and
attached with a stainless steel screw.
OUTLET TUBES
"A"
The restrictor plate must also be sealed to furnace tube
sheet.
SECURE OWNERS APPROVAL
When the system is functioning properly, secure the owner’s
approval. Show him the location of all disconnect switches
and the room temperature sensors. Teach him how to start
and stop the unit and how to adjust the temperature settings
within the limitations of the system.
"A"
FLUE BAFFLE
REMOVE
SCREWS
SECTION "A" - "A"
FIGURE 55 - TYPICAL FLUE BAFFLE
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DISCHARGE PRESSURE (PSIG)
25 TON CHARGING CURVE
550
105 F
500
95 F
450
85 F
400
75 F
350
65 F
300
250
200
75
100
125
150
175
SUCTION PRESSURE (PSIG)
FIGURE 56 - 25 TON CHARGING CURVE
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DISCHARGE PRESSURE (PSIG)
30 TON CHARGING CURVE
550
500
105 F
450
95 F
400
85 F
350
75 F
65 F
300
250
200
75
100
125
150
175
SUCTION PRESSURE (PSIG)
FIGURE 57 - 30 TON CHARGING CURVE
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40 TON CHARGING CURVE
DISCHARGE PRESSURE (PSIG)
550
500
105 F
450
95 F
400
85 F
350
75 F
300
65 F
250
200
75
100
125
150
175
SUCTION PRESSURE (PSIG)
FIGURE 58 - 40 TON CHARGING CURVE
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PRESSURE DROP ACROSS A DRY EVAPORATOR COIL
25T
PRESSURE DROP (in. wg.)
0.6
0.5
0.4
0.3
0.2
0.1
0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
NOMINAL CFM (THOUSANDS)
FIGURE 59 - PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 25 TON
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PRESSURE DROP ACROSS A DRY EVAPORATOR
COIL - 30T
PRESSURE DROP (in. wg.)
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15
NOMINAL CFM (THOUSANDS)
FIGURE 60 - PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 30 TON
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PRESSURE DROP ACROSS A DRY EVAPORATOR COIL
40T
PRESSURE DROP (in. wg.)
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18
NOMINAL CFM (THOUSANDS)
FIGURE 61 - PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 40 TON
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START-UP SHEET
START-UP & SERVICE DATA INSTRUCTION
COMMERCIAL PACKAGE UNITS
3.0 To 40.0 TONS
START-UP CHECKLIST
Date: ________________________________________________________________________________________________________
Job Name: ___________________________________________________________________________________________________
Customer Name: ______________________________________________________________________________________________
Address: _____________________________________________________________________________________________________
City: ______________________________ State: ______________________________ Zip: ________________________________
Model Number: _________________________________________ Serial Number:___________________________________________
Qualified Start-up Technician: _________________________________ Signature: __________________________________________
HVAC Contractor: _________________________________________________________ Phone: ______________________________
Address: _____________________________________________________________________________________________________
Contractor’s E-mail Address: _____________________________________________________________________________________
Electrical Contractor: _____________________________________________________ Phone: ______________________________
Distributor Name: ________________________________________________________ Phone: ______________________________
WARRANTY STATEMENT
Johnson Controls/UPG is confident that this equipment will
operate to the owner's satisfaction if the proper procedures are
followed and checks are made at initial start-up. This confidence is
supported by the 30 day dealer protection coverage portion of our
standard warranty policy which states that Johnson Controls/UPG
will cover parts and labor on new equipment start-up failures that
are caused by a defect in factory workmanship or material, for a
period of 30 days from installation. Refer to current standard
warranty policy and warranty manual found on UPGnet for details.
In the event that communication with Johnson Controls/UPG is
required regarding technical and/or warranty concerns, all parties
to the discussion should have a copy of the equipment start-up
sheet for reference. A copy of the original start-up sheet should be
filed with the Technical Services Department.
The packaged unit is available in constant or variable air volume
versions with a large variety of custom options and accessories
available. Therefore, some variation in the startup procedure will
exist depending upon the products capacity, control system,
options and accessories installed.
This start-up sheet covers all startup check points common to all
package equipment. In addition it covers essential startup check
points for a number of common installation options. Depending
upon the particular unit being started not all sections of this startup
sheet will apply. Complete those sections applicable and use the
notes section to record any additional information pertinent to your
particular installation.
Warranty claims are to be made through the distributor from whom
the equipment was purchased.
EQUIPMENT STARTUP
Use the local LCD or Mobile Access Portal (MAP) Gateway to
complete the start-up.
A copy of the completed start-up sheet should be kept on file
by the distributor providing the equipment and a copy sent to:
Johnson Controls/UPG
Technical Services Department
5005 York Drive
Norman, OK 73069
1034349-UCL-C-0315
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SAFETY WARNINGS
The inspections and recording of data outlined in this procedure
are required for start-up of Johnson Controls/UPG's packaged
products. Industry recognized safety standards and practices
must be observed at all times. General industry knowledge and
experience are required to assure technician safety. It is the
responsibility of the technician to assess all potential dangers
and take all steps warranted to perform the work in a safe
manner. By addressing those potential dangers, prior to
beginning any work, the technician can perform the work in a
safe manner with minimal risk of injury.
Lethal voltages are present during some start-up
checks. Extreme caution must be used at all times.
Moving parts may be exposed during some startup
checks. Extreme caution must be used at all times.
NOTE: Read and review this entire document before beginning
any of the startup procedures.
DESIGN APPLICATION INFORMATION
This information will be available from the specifying engineer
who selected the equipment. If the system is a VAV system the
CFM will be the airflow when the remote VAV boxes are in the
full open position and the frequency drive is operating at 60 HZ.
Do not proceed with the equipment start-up without the
design CFM information.
Design Supply Air CFM: __________________________ Design Return Air CFM:______________________________________
Design Outdoor Air CFM At Minimum Position: ________________________________________________________
Total External Static Pressure: _____________________________________________________________________
Supply Static Pressure: __________________________________________________________________________
Return Static Pressure: __________________________________________________________________________
Design Building Static Pressure: ___________________________________________________________________
Outside Air Dilution: Economizer Position Percentage: ___________________________________ _ CFM: ________________
Supply Gas Pressure After Regulator W/o Heat Active ___________________________ Inches_________________
ADDITIONAL APPLICATION NOTES FROM SPECIFYING ENGINEER:
2
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REFERENCE
Completed
See Notes
Unit inspected for shipping, storage, or rigging damage
General Inspection
…
…
Unit installed with proper clearances
…
…
Unit installed within slope limitations
…
…
Refrigeration system checked for gross leaks (presence of oil)
…
…
Terminal screws and wiring connections checked for tightness
…
…
Filters installed correctly and clean
…
…
Economizer hoods installed in operating position
…
…
Condensate drain trapped properly, refer to Installation Manual
…
…
Economizer damper linkage tight
…
…
Gas Heat vent hood installed
…
…
All field wiring (power and control) complete
…
…
Completed
See Notes
Alignment of drive components
Air Moving Inspection
…
…
Belt tension adjusted properly
…
…
Blower pulleys tight on shaft, bearing set screws tight, wheel tight to shaft
…
…
Pressure switch or transducer tubing installed properly
…
…
Exhaust Inspection
Powered …Barometric Relief …
Completed
See Notes
Check hub for tightness
…
…
Check fan blade for clearance
…
…
Check for proper rotation
…
…
Check for proper mounting (screen faces towards unit)
…
…
Prove operation by increasing minimum setting on economizer
…
…
Completed
See Notes
…
…
Check economizer setting (Reference SSE Control Board LCD menu location)
…
…
Prove economizer open/close through SSE Board Setting
…
…
Economizer Inspection Standard …BAS …
CO2 sensor installed
Yes …No …
Reheat Mode Normal …or Alternate …Not Applicable …
Humidity Sensor (2SH0401) _____________________________________________
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Operating Measurements - Air Flow
Fan operates with proper rotation ID Fans …Exh. Fans …Cond. Fans …
Pressure drop across dry evaporator coil (At maximum design CFM) 1
IWC
External Static Pressure
IWC
Return Static Pressure
IWC
Supply Static Pressure
IWC
Supply Air CFM Using Dry Coil Chart
CFM
Final Adjusted Supply Air CFM2
CFM
1. Consult the proper airflow to pressure drop table to obtain the actual airflow at the measured pressure differential.
2. Was a motor pulley adjustment or change required to obtain the correct airflow?
Was it necessary to increase of decrease the airflow to meet the design conditions?
If the motor pulley size was changed, measure the outside diameters of the motor and blower pulleys and record those diameters here;
Blower Motor HP _______________________________ FLA________ RPM________
Pulley Pitch Diameter ______________Turns Out________ Final Turns Out________
Blower Pulley Pitch Diameter ________________ Fixed Sheave_________________
ELECTRICAL DATA
T1 - T2 ____________________________ Volts
T2 - T3 ____________________________ Volts
Control Voltage ______________________ Volts
T1 - T3 ____________________________ Volts
Device
Measured
List All Three Amperages
Nameplate
Supply Fan Motor1, 2
AMPS
AMPS
Exhaust Motor (Dampers 100%)
AMPS
AMPS
Condenser Fan #1
AMPS
AMPS
Condenser Fan #2 (if equipped)
AMPS
AMPS
Condenser Fan #3 (if equipped)
AMPS
AMPS
Condenser Fan #4 (if equipped)
AMPS
AMPS
Compressor #1
AMPS
AMPS
Compressor #2 (if equipped)
AMPS
AMPS
Compressor #3 (if equipped)
AMPS
AMPS
Compressor #4 (if equipped)
AMPS
AMPS
1. VAV units with heat section - simulate heat call to drive VAV boxes and VFD/IGV to maximum design airflow position.
2. VAV units without heat section - VAV boxes must be set to maximum design airflow position.
4
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OPERATING MEASUREMENTS - COOLING
Discharge
Pressure
Stage
Discharge
Temp.
Liquid Line
Temp.1
Suction
Pressure
Subcooling2
Suction
Temp.
Superheat
First
#
°
°
°
#
°
°
Second (if equipped)
#
°
°
°
#
°
°
Third (if equipped)
#
°
°
°
#
°
°
Fourth (if equipped)
#
°
°
°
#
°
°
Reheat 1st Stage
#
°
°
°
#
°
°
1. Liquid temperature should be taken before filter/drier.
2. Subtract 10 psi from discharge pressure for estimated liquid line pressure
Outside air temperature
________________ °F db
________________ °F wb
________________ %RH
Return Air Temperature
________________ °F db
________________ °F wb
________________ %RH
Mixed Air Temperature
________________ °F db
________________ °F wb
________________ %RH
Supply Air Temperature
________________ °F db
________________ °F wb
________________ %RH
REFRIGERANT SAFETIES
Action
Completed
See Notes
Prove Compressor Rotation (3 phase only) by gauge pressure
…
…
Prove High Pressure Safety, All Systems
…
…
Prove Low Pressure Safety, All Systems
…
…
OPERATING MEASUREMENTS - GAS HEATING
…
Fuel Type:
…
Natural Gas
Action
LP Gas
Completed
See Notes
Check for gas leaks
…
…
Prove Ventor Motor Operation
…
…
Prove Primary Safety Operation
…
…
Prove Auxiliary Safety Operation
…
…
Prove Rollout Switch Operation
…
…
…
Prove Smoke Detector Operation
Manifold Pressure
IWC
…
Stage 2 (If Equipped)
IWC
…
Stage 3 (If Equipped)
IWC
…
IWC
…
°F
…
Supply gas pressure at full fire
Check temperature rise
1
…
Stage 1
… measured at full fire
1. Input X Eff. (BTU output)
1.08 X Temp. Rise
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OPERATIONAL MEASUREMENTS - STAGING CONTROLS
Verify Proper Operation of Heating/Cooling Staging Controls
Create a cooling demand at the Thermostat, BAS System or Simplicity SE
Verify that cooling/economizer stages are energized.
…
Create a heating demand at the Thermostat, BAS System or Simplicity SE
Verify that heating stages are energized.
…
Verify Proper Operation of the Variable Frequency Drive (If Required)
…
Verify that motor speed modulates with duct pressure change.
FINAL - INSPECTION
Verify that all operational control set points have been set to desired value
Scroll through all setpoints and change as may be necessary to suit the occupant requirements.
…
Verify that all option parameters are correct
Scroll through all option parameters and ensure that all installed options are enabled in the software and all
others are disabled in the software. (Factory software settings should match the installed options)
…
Verify that all access panels have been closed and secured
…
OBSERVED PRODUCT DIFFICIENCIES & CONCERNS:
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
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R-410A QUICK REFERENCE GUIDE
Refer to Installation Instructions for specific installation requirements.
R-410A Refrigerant operates at 50 - 70 percent higher pressures than R-22. Be sure that servicing
equipment and replacement components are designed to operate with R-410A.
R-410A Refrigerant cylinders are rose colored.
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400, or DOT BW400.
Recovery equipment must be rated for R-410A.
Do Not use R-410A service equipment on R-22 systems. All hoses, gages, recovery cylinders, charging
cylinders and recovery equipment must be dedicated for use on R-410A systems only.
Manifold sets must be at least 700 psig high side, and 180 psig low side, with 550 psig retard.
All hoses must have a service pressure rating of 800 psig.
Leak detectors must be designed to detect HFC refrigerants.
Systems must be charged with liquid refrigerant. Use a commercial type metering device in the
manifold hose.
R-410A can only be used with POE type oils.
POE type oils rapidly absorb moisture from the atmosphere.
Vacuum pumps will not remove moisture from POE type oils.
Do not use liquid line driers with a rated working pressure rating less than 600 psig.
Do not install suction line driers in the liquid line.
A liquid line drier is required on every unit.
Do not use a R-22 TXV. If a TXV is to be used, it must be a R-410A TXV.
Never open system to atmosphere when under a vacuum.
If system must be opened for service, evacuate system then break the vacuum with dry nitrogen and
replace all filter driers.
FIGURE 62 - R-410A QUICK REFERENCE GUIDE
Subject to change without notice. Printed in U.S.A.
Copyright © 2015 by Johnson Controls, Inc. All rights reserved.
York International Corporation
5005 York Drive
Norman, OK 73069
5121842-TIM-A-0515
Supersedes: Nothing