York | 090 | Installation manual | York 090 Installation manual

INSTALLATION
MANUAL - 50 Hz
®
SINGLE PACKAGE AIR CONDITIONERS AND
SINGLE PACKAGE GAS/ELECTRIC UNITS
CONTENTS
DM090, 120 AND 150
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7-1/2, 10 AND 12-1/2 TON
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(9.0 TO 10.0 EER) 50 Hz
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . 48
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . 48
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 52
See the following pages for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes are intended to
clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to alert
installer that personal injury and/or equipment damage
may result if installation procedure is not handled properly.
CAUTION:
READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
127408-XIM-C-1208
127408-XIM-C-1208
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION SAFETY INFORMATION . . . . . . . . . . . . 8
PRECEDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . 8
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . 11
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DUCT COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
THERMOSTAT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . 18
POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . 18
POWER WIRING DETAIL . . . . . . . . . . . . . . . . . . . . . . . . 18
OPTIONAL ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . 23
OPTIONAL GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LP UNITS, TANKS AND PIPING . . . . . . . . . . . . . . . . . . . . . . . 25
VENT AND COMBUSTION AIR . . . . . . . . . . . . . . . . . . . . . . . 25
OPTIONS/ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . 25
ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MOTORIZED OUTDOOR DAMPER . . . . . . . . . . . . . . . . . . . . 25
ECONOMIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RAIN HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ECONOMIZER AND POWER EXHAUST SET POINT
ADJUSTMENTS AND INFORMATION . . . . . . . . . . . . . . 26
MINIMUM POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . 26
ENTHALPY SET POINT ADJUSTMENT . . . . . . . . . . . . . . . . . 26
POWER EXHAUST DAMPER SET POINT (WITH OR WITHOUT
POWER EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INDOOR AIR QUALITY AQ . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BLOWER ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AIR BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CHECKING AIR QUANTITY . . . . . . . . . . . . . . . . . . . . . . 37
METHOD ONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
METHOD TWO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SUPPLY AIR DRIVE ADJUSTMENT . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SEQUENCE OF OPERATIONS OVERVIEW . . . . . . . . . 43
COOLING SEQUENCE OF OPERATION . . . . . . . . . . . 43
CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INTERMITTENT BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
NO OUTDOOR AIR OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 43
ECONOMIZER WITH SINGLE ENTHALPY SENSOR - . . . . . 43
ECONOMIZER WITH DUAL ENTHALPY SENSORS - . . . . . . 43
ECONOMIZER WITH POWER EXHAUST - . . . . . . . . . . . . . . 44
MOTORIZED OUTDOOR AIR DAMPERS - . . . . . . . . . . . . . . 44
COOLING OPERATION ERRORS . . . . . . . . . . . . . . . . . . . . . 44
2
HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . .44
LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . .44
FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
COMPRESSOR PROTECTION . . . . . . . . . . . . . . . . . . . 45
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ELECTRIC HEATING SEQUENCE OF
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ELECTRIC HEAT OPERATION ERRORS . . . . . . . . . . . 45
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
LIMIT SWITCH (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . . . 45
GAS HEATING SEQUENCE OF OPERATIONS . . . . . . 46
IGNITION CONTROL BOARD . . . . . . . . . . . . . . . . . . . . 46
FIRST STAGE OF HEATING . . . . . . . . . . . . . . . . . . . . . . . . . .46
SECOND STAGE OF HEATING . . . . . . . . . . . . . . . . . . . . . . .46
RETRY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
RECYCLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
GAS HEATING OPERATION ERRORS . . . . . . . . . . . . . 46
LOCK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
FLAME SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
LIMIT SWITCH (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
AUXILIARY LIMIT SWITCH (ALS) . . . . . . . . . . . . . . . . . . . . . .47
PRESSURE SWITCH (PS) . . . . . . . . . . . . . . . . . . . . . . . . . . .47
ROLLOUT SWITCH (ROS) . . . . . . . . . . . . . . . . . . . . . . . . . . .47
INTERNAL MICROPROCESSOR FAILURE . . . . . . . . . . . . . .47
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
RESETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . 47
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . 48
PRESTART CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 48
POST START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . 48
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . 48
PRE-START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 48
LIGHTING THE MAIN BURNERS . . . . . . . . . . . . . . . . . . . . . .48
POST START CHECKLIST . . . . . . . . . . . . . . . . . . . . . .
SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD GAS PRESSURE ADJUSTMENT . . . . . . . .
CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . .
48
48
49
49
NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . 50
BURNERS/ORIFICES INSPECTION/SERVICING . . . . 50
CHARGING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . 52
PREDATOR® FLASH CODES . . . . . . . . . . . . . . . . . . . . 52
UNIT CONTROL BOARD OPTION SETUP . . . . . . . . 54
OPTION BYTE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT DELAY SETUP . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING TROUBLESHOOTING GUIDE . . . . . . . . . . .
GAS HEAT TROUBLESHOOTING GUIDE . . . . . . . . . .
54
54
57
60
Johnson Controls Unitary Products
127408-XIM-C-1208
LIST OF FIGURES
Fig. #
Pg. #
Fig. #
Pg. #
1
UNIT SHIPPING BRACKET . . . . . . . . . . . . . . . . . . . . . 8
18 TYPICAL FIELD WIRING 24 VOLT THERMOSTAT . 19
2
CONDENSER COVERING . . . . . . . . . . . . . . . . . . . . . 8
19 FIELD WIRING DISCONNECT - COOLING UNIT WITH
OR WITHOUT ELECTRIC HEAT . . . . . . . . . . . . . . . 20
3
COMPRESSOR SECTION . . . . . . . . . . . . . . . . . . . . . . 8
4
PREDATOR® COMPONENT LOCATION . . . . . . . . . 10
5
UNIT 4 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 12
6
UNIT 6 POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . 12
7
UNIT CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . 12
8
UNIT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9
BOTTOM DUCT OPENINGS (FROM ABOVE) . . . . . 15
10 REAR DUCT DIMENSIONS . . . . . . . . . . . . . . . . . . . . 15
11 PREDATOR® ROOF CURB DIMENSIONS . . . . . . . 16
12 SUNLINE™ TO PREDATOR® TRANSITION ROOF
CURBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
13 SIDE PANELS WITH HOLE PLUGS . . . . . . . . . . . . . 17
14 RETURN DOWNFLOW PLENUM WITH PANEL . . . . 17
15 DISCHARGE PANEL IN PLACE . . . . . . . . . . . . . . . . 17
16 CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . 17
17 TYPICAL ELECTRONIC THERMOSTAT FIELD
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Johnson Controls Unitary Products
20 FIELD WIRING DISCONNECT - COOLING UNIT WITH
GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
21 SIDE ENTRY GAS PIPING . . . . . . . . . . . . . . . . . . . . 23
22 BOTTOM ENTRY GAS PIPING . . . . . . . . . . . . . . . . . 23
23 ENTHALPY SET POINT CHART . . . . . . . . . . . . . . . . 27
24 HONEYWELL ECONOMIZER CONTROL W7212 . . 27
25 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 28
26 DRY COIL DELTA P 50" CABINET . . . . . . . . . . . . . . 38
27 DRY COIL DELTA P 42" CABINET . . . . . . . . . . . . . . 38
28 TYPICAL FLAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
29 TYPICAL GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . 51
30 UNIT CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . 53
31 BASIC TROUBLESHOOTING FLOWCHART . . . . . . 55
32 POWER ON FLOW CHART . . . . . . . . . . . . . . . . . . . 55
33 TRIP FAILURE FLOW CHART . . . . . . . . . . . . . . . . . 56
3
127408-XIM-C-1208
LIST OF TABLES
Tbl. #
Pg. #
1
UNIT VOLTAGE LIMITATIONS . . . . . . . . . . . . . . . . . 10
2
UNIT TEMPERATURE LIMITATIONS . . . . . . . . . . . . 10
3
UNIT WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4
4 POINT LOAD WEIGHT . . . . . . . . . . . . . . . . . . . . . . 12
5
6 POINT LOAD WEIGHT . . . . . . . . . . . . . . . . . . . . . . 12
6
UNIT HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7
UNIT CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . 14
8
REAR DUCT DIMENSIONS . . . . . . . . . . . . . . . . . . . . 15
9
CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . 18
10 ELECTRICAL DATA 7-1/2 TON . . . . . . . . . . . . . . . . . 21
11 ELECTRICAL DATA 10 TON . . . . . . . . . . . . . . . . . . . 21
12 ELECTRICAL DATA 12-1/2 TON . . . . . . . . . . . . . . . . 22
13 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14 ELECTRIC HEAT MINIMUM SUPPLY AIR CFM . . . . 23
Tbl. #
Pg. #
29 BLOWER PERFORMANCE 7-1/2 TON STANDARD
MOTOR - DOWNSHOT (METRIC) . . . . . . . . . . . . . . 32
30 BLOWER PERFORMANCE 7-1/2 TON OPTIONAL
MOTOR - DOWNSHOT (IMPERIAL) . . . . . . . . . . . . . 32
31 BLOWER PERFORMANCE 7-1/2 TON OPTIONAL
MOTOR - DOWNSHOT (METRIC) . . . . . . . . . . . . . . . 33
32 BLOWER PERFORMANCE 10 TON STANDARD
MOTOR - DOWNSHOT (IMPERIAL) . . . . . . . . . . . . . 33
33 BLOWER PERFORMANCE 10 TON STANDARD
MOTOR - DOWNSHOT (METRIC) . . . . . . . . . . . . . . 33
34 BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR
- DOWNSHOT (IMPERIAL) . . . . . . . . . . . . . . . . . . . . 34
35 BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR
- DOWNSHOT (METRIC) . . . . . . . . . . . . . . . . . . . . . . 34
36 BLOWER PERFORMANCE 12-1/2 TON - DOWNSHOT
(IMPERIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15 GAS APPLICATION DATA . . . . . . . . . . . . . . . . . . . . . 23
37 BLOWER PERFORMANCE 12-1/2 TON - DOWNSHOT
(METRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
16 GAS PIPE SIZING - CAPACITY OF PIPE . . . . . . . . . 24
38 INDOOR BLOWER SPECIFICATIONS . . . . . . . . . . . 35
17 SUPPLY AIR LIMITATIONS . . . . . . . . . . . . . . . . . . . . 28
39 ADDITIONAL STATIC RESISTANCE 50” CABINET
(IMPERIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
18 BLOWER PERFORMANCE 7-1/2 TON STANDARD
MOTOR - SIDE DUCT (IMPERIAL) . . . . . . . . . . . . . . 29
19 BLOWER PERFORMANCE 7-1/2 TON STANDARD
MOTOR - SIDE DUCT (METRIC) . . . . . . . . . . . . . . . . 29
20 BLOWER PERFORMANCE 7-1/2 TON OPTIONAL
MOTOR - SIDE DUCT (IMPERIAL) . . . . . . . . . . . . . . 29
21 BLOWER PERFORMANCE 7-1/2 TON OPTIONAL
MOTOR - SIDE DUCT (METRIC) . . . . . . . . . . . . . . . . 29
40 ADDITIONAL STATIC RESISTANCE 42” CABINET
(IMPERIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
41 ADDITIONAL STATIC RESISTANCE 50” CABINET
(METRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
42 ADDITIONAL STATIC RESISTANCE 42” CABINET
(METRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
43 MOTOR SHEAVE DATUM . . . . . . . . . . . . . . . . . . . . . 42
22 BLOWER PERFORMANCE 10 TON STANDARD
MOTOR - SIDE DUCT (IMPERIAL) . . . . . . . . . . . . . . 30
44 ELECTRIC HEAT LIMIT SETTING . . . . . . . . . . . . . . . 45
23 BLOWER PERFORMANCE 10 TON STANDARD
MOTOR - SIDE DUCT (METRIC) . . . . . . . . . . . . . . . . 30
46 GAS HEAT LIMIT SETTINGS . . . . . . . . . . . . . . . . . . . 47
45 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . 45
24 BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR
- SIDE DUCT (IMPERIAL) . . . . . . . . . . . . . . . . . . . . . 30
47 GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . 47
25 BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR
- SIDE DUCT (METRIC) . . . . . . . . . . . . . . . . . . . . . . . 31
49 GAS RATE CUBIC FEET PER HOUR . . . . . . . . . . . . 50
26 BLOWER PERFORMANCE 12-1/2 TON - SIDE DUCT
(IMPERIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
51 10 TON SUPERHEAT CHARGING . . . . . . . . . . . . . . . 52
48 GAS HEAT STAGES . . . . . . . . . . . . . . . . . . . . . . . . . 49
50 7.5 TON SUPERHEAT CHARGING . . . . . . . . . . . . . . 51
27 BLOWER PERFORMANCE 12-1/2 TON - SIDE DUCT
(METRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
52 UNIT CONTROL BOARD FLASH CODES . . . . . . . . . 53
28 BLOWER PERFORMANCE 7-1/2 TON STANDARD
MOTOR - DOWNSHOT (IMPERIAL) . . . . . . . . . . . . . 32
54 IGNITION CONTROL FLASH CODES . . . . . . . . . . . . 54
4
53 HEAT DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Johnson Controls Unitary Products
127408-XIM-C-1208
GENERAL
YORK“ Predator® units are single package air conditioners
with optional gas heating designed for outdoor installation on
a rooftop or slab and for non-residential use. These units can
be equipped with factory or field installed electric heaters for
heating applications.
These 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 supply (where applicable), and duct connections. The electric heaters have nickel-chrome elements
and utilize single-point power connection.
If the information in this manual is not followed
exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
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:
a.
Do not try to light any appliance.
b.
Do not touch any electrical switch; do not use
any phone in your building.
c.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
d.
If you cannot reach your gas supplier, call the fire
department.
SAFETY CONSIDERATIONS
Should overheating occur, or the gas supply fail to
shut off, shut off the manual gas valve to the furnace
before shutting off the electrical supply.
Do not use this furnace if any part has been under
water. Immediately call a qualified service technician
to inspect the furnace and to replace any part of the
control system and any gas control which has been
under water.
Due to system pressure, moving parts, and electrical components, installation and servicing of air conditioning equipment
can be hazardous. Only qualified, trained service personnel
should install, repair, or service this equipment. Untrained
personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags
accompanying the equipment whenever working on air conditioning equipment. Be sure to follow all other applicable
safety precautions and codes including ANSI Z223.1 or CSAB149.1- latest edition.
Wear safety glasses and work gloves. Use quenching cloth
and have a fire extinguisher available during brazing operations.
Johnson Controls Unitary Products
Installation and service must be performed by 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
the damage should be noted on the carrier’s freight bill. A
separate request for inspection by the carrier’s agent should
be made in writing.
This furnace is not to be used for temporary heating
of buildings or structures under construction.
Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. 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.
5
127408-XIM-C-1208
REFERENCE
APPROVALS
Additional information is available in the following reference
forms:
Design certified by CSA as follows:
1.
For use as a cooling only unit, cooling unit with supplemental electric heat or a forced air furnace.
2.
For outdoor installation only.
3.
For installation on combustible material and may be
installed directly on combustible flooring or, in the U.S.,
on wood flooring or Class A, Class B or Class C roof covering materials.
4.
For use with natural gas (convertible to LP with kit).
• Technical Guide - DM090-150, 259335
• General Installation - DM090 - 150, 127408
• Pre-start & Post-start Check List
• Economizer Accessory Downflow Factory Installed
Downflow Field Installed
Horizontal Field Installed
• Motorized Outdoor Air Damper
• Manual Outdoor Air Damper (0-100%)
• Manual Outdoor Air Damper (0-35%)
• Gas Heat Propane Conversion Kit
• Gas Heat High Altitude Kit (Natural Gas)
• Gas Heat High Altitude Kit (Propane)
• –60qF Gas Heat Kit
This product must be installed in strict compliance
with the enclosed installation instructions and any
applicable local, state, and national codes including,
but not limited to, building, electrical, and mechanical
codes.
• Electric Heater Accessory
RENEWAL PARTS
Contact your local York® parts distribution center for authorized replacement parts.
Incorrect installation may create a condition where the
operation of the product could cause personal injury
or property damage.
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. NOTES are intended to
clarify or make the installation easier. CAUTIONS are given
to prevent equipment damage. WARNINGS are given to alert
installer that personal injury and/or equipment damage may
result if installation procedure is not handled properly.
6
Johnson Controls Unitary Products
127408-XIM-C-1208
NOMENCLATURE
7.5-12.5 Ton York® Model Number Nomenclature
D M 090 N10 A 7 A AA 3 0 1 2 4 A
Product Category
Product Style
D = A/C, Single Pkg., R-22
A = Style A
B = Style B
C = Style C
Product Identifier
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
M = 9.0 EER A/C
SS Drain Pan
Honeywell Controller, DFS, APS
Nominal Cooling Capacity
Simplicity IntelliComfort Controller
090 = 7.5 Ton
120 = 10.0 Ton
150 = 12.5 Ton
Simplicity IntelliComfort Controller w/ModLinc
2" Pleated filters
BAS Ready Unit with Economizer
Shipping Bag
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
Heat Type and Nominal Heat Capacity
C00 = Cooling Only. No heat installed
Product Generation
Gas Heat Options
3 = Third Generation
4 = Fourth Generation
N10 = 100 MBH Output Aluminized Steel
N15 = 150 MBH Output Aluminized Steel
S10 = 100 MBH Output Stainless Steel
S15 = 150 MBH Output Stainless Steel
Additional Options
Electric Heat Options
AA = None
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
E09 = 9 KW
E18 = 18 KW
E24 = 24 KW
E36 = 36 KW
E54 = 54 KW
RC = Coil Guard, Shipping Bag & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
Airflow
A = Std. Motor
B = Std. Motor/Econo./Barometric Relief (Downflow
Only)
C = Std. Motor/Econo./Power Exhaust (Downflow Only)
D = Std. Motor/Motorized Damper (Downflow Only)
E = Std. Motor/Horizontal Economizer (No Baro.)
F = Std. Motor/Slab Econo./Power Exhaust
(Downflow Only)
G = Std. Motor/Slab Econo./Barometric Relief
(Downflow Only)
N = Hi Static
P = Hi Static/Econo./Barometric Relief
(Downflow Only)
Q = Hi Static/Econo./Power Exhaust
(Downflow Only)
R = Hi Static/Motorized Damper (Downflow Only)
S = Hi Static/Horizontal Economizer (No Baro.)
T = Hi Static/Slab Econo./Power Exhaust
(Downflow Only)
U = Hi Static/Slab Econo./Barometric Relief
(Downflow only)
Voltage
7 = 380/415-3-50
Installation Options
A = No Options Installed
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
Options
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
Johnson Controls Unitary Products
7
127408-XIM-C-1208
INSTALLATION
INSTALLATION SAFETY INFORMATION
Read these instructions before continuing this appliance
installation. This is an outdoor combination heating and cooling unit. The installer must assure that these instructions are
made available to the consumer and with instructions to
retain them for future reference.
FIGURE 1 -
1.
Refer to the furnace rating plate for the approved type of
gas for this furnace.
4.
2.
Install this furnace only in a location and position as
specified on Page 11 of these instructions.
3.
Never test for gas leaks with an open flame. Use commercially available soap solution made specifically for
the detection of leaks when checking all connections, as
specified on Pages 8, 24, 25 and 48 of these instructions.
4.
Always install furnace to operate within the furnace's
intended temperature-rise range with the duct system
and within the allowable external static pressure range,
as specified on the unit name/rating plate, specified on
Page 50 of these instructions.
5.
This equipment is not to be used for temporary heating
of buildings or structures under construction.
Bracket
Screws
Turn down
UNIT SHIPPING BRACKET
Remove the toolless doorknobs and instruction packet
prior to installation.
Condenser
Coil External
Protective
Covering
Barometric
Relief Hood in
Shipping Location (if included)
FIGURE 2 -
CONDENSER COVERING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
Toolless
Doorknobs
PRECEDING INSTALLATION
1.
Remove the two screws holding the brackets in the front,
rear and compressor side fork-lift slots.
2.
Turn each bracket toward the ground and the protective
plywood covering will drop to the ground.
3.
Remove the condenser coil external protective covering
prior to operation.
8
Installation
Instruction
Packet
FIGURE 3 -
COMPRESSOR SECTION
Johnson Controls Unitary Products
127408-XIM-C-1208
4.
Other applicable local codes.
Refer to Tables 1 & 2 for unit application data.
This product must be installed in strict compliance
with the enclosed installation instructions and any
applicable local, state and national codes including,
but not limited to, building, electrical, and mechanical codes.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system
during any pressure testing at pressures in excess
of 1/2 PSIG.
Pressures greater than 1/2 PSIG will cause gas
valve damage resulting in a hazardous condition. If it
is subjected to a pressure greater than 1/2 PSIG, the
gas valve must be replaced.
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 dealer’s and/or customer’s
expense.
Size of unit for proposed installation should be based on heat
loss/heat gain calculation made according to the methods of
Air Conditioning Contractors of America (ACCA).
This furnace is not to be used for temporary heating of buildings or structures under construction.
The furnace must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than 1/2 PSIG.
LIMITATIONS
These units must be installed in accordance with the following:
1.
Local building codes, and
2.
Local gas utility requirements
3.
Local plumbing and waste water codes, and
Johnson Controls Unitary Products
The Simplicity® control board used in this product
will effectively operate the cooling system down to
0°F when this product is applied in a comfort cooling
application for people. An economizer is typically
included in this type of application. When applying
this product for process cooling applications (computer rooms, switchgear, etc.), please reference
applications bulletin AE-011-07 or call the applications department for Unitary Products @ 1-877UPG-SERV for guidance. Additional accessories
may be needed for stable operation at temperatures
below 30° F.
9
127408-XIM-C-1208
Simplicity™ control board
Filter access
Disconnect location
w/screw connector for T-stat
(2” throw-away)
(optional
disconnect
switch)
wiring and network connections
Filter drier
(solid core)
Terminal block for
hi-voltage connection
Condenser section
Second model
nameplate
inside hinged
access panel
Slide-out motor and
blower assembly for
easy adjustment
and service
Dual stage
cooling for
maximum
comfort
Belt-drive
blower motor
Power ventor motor
Compressor #2
access (highefficiency
compressor
w/crankcase
heater)
20-gauge aluminized steel tubular
heat exchanger for
long life (stainless
steel option)
Base rails w/forklift
slots (three sides)
and lifting holes
Two-stage gas
heating to maintain
warm, comfortable
temperature
Roof curbs in eight- and
fourteen-inch heights. Roof
curbs for transitioning from
York Sunline™ footprint to
the ZH Series footprints are
also available (field-installed
accessory)
FIGURE 4 -
Slide-out drain pan
with steel 3/4” NPT,
female connection
Toolless
door latch
Compressor #1 access
(high-efficiency compressor
w/crankcase heater)
PREDATOR® COMPONENT LOCATION
TABLE 1: UNIT VOLTAGE LIMITATIONS
TABLE 2: UNIT TEMPERATURE LIMITATIONS
Power Rating*
Minimum
Maximum
Temperature
Min.
Max.
380/415-3-50
342
456
Wet Bulb Temperature qF(°C) of Air
on Evaporator Coil
57(14)
72(22)
Dry Bulb Temperature qF(°C) of Air
on Condenser Coil
0(-18)
125(52)
*.
10
Side entry power
and control wiring
knockouts
Intelligent control
board for safe and
efficient operation
Utilization range “A” in accordance with ARI Standard
110.
Johnson Controls Unitary Products
127408-XIM-C-1208
LOCATION
RIGGING AND HANDLING
Use the following guidelines to select a suitable location for
these units:
Exercise care when moving the unit. Do not remove any
packaging until the unit is near the place of installation. Rig
the unit by attaching chain or cable slings to the lifting holes
provided in the base rails. Spreader bars, whose length
exceeds the largest dimension across the unit, MUST be
used across the top of the unit.
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 mounting on roof curb.
4.
For ground level installation, use a level concrete slab
with a minimum thickness of 4 inches (102 mm). The
length and width should be at least 6 inches (152 mm)
greater than the unit base rails. Do not tie slab to the
building foundation.
5.
Roof structures must be able to support the weight of the
unit and its options/accessories. Unit must be installed on
a solid, level roof curb or appropriate angle iron frame.
6.
Maintain level tolerance to 1/2” (13 mm) across the entire
width and length of unit.
If a unit is to be installed on a roof curb other than a
YORK roof curb, gasketing must be applied to all surfaces that come in contact with the unit underside.
Before lifting, make sure the unit weight is distributed equally on the rigging cables so it will lift evenly.
Units may be moved or lifted with a forklift. Slotted openings
in the base rails are provided for this purpose.
Excessive exposure of this furnace to contaminated
combustion air may result in equipment damage or
personal injury. Typical contaminates include: permanent wave solution, chlorinated waxes and cleaners, chlorine based swimming pool chemicals, water
softening chemicals, carbon tetrachloride, Halogen
type refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes,
hydrochloric acid, cements and glues, antistatic fabric softeners for clothes dryers, masonry acid washing materials.
Johnson Controls Unitary Products
LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES
(1524 mm.).
All panels must be secured in place when the unit is
lifted.
The condenser coils should be protected from rigging cable damage with plywood or other suitable
material.
11
127408-XIM-C-1208
F R O N T
F R O N T
L E F T
B
L E F T
C
B
A
A
D
FIGURE 5 -
D
C
E
F
UNIT 4 POINT LOAD
FIGURE 6 -
UNIT 6 POINT LOAD
TABLE 3: UNIT WEIGHT
Model
Shipping Weight
lbs. (kg)
Operating Weight
lbs. (kg)
090
865 (392.4)
860 (390.1)
120
1143 (518.6)
1138 (516.3)
150
1202 (545.3)
1197 (543.1)
X
LEFT
TABLE 4: 4 POINT LOAD WEIGHT
Model
090
120
150
Location (lbs. (kg.))
A
B
C
D
192
(87.1)
245
(111)
262
(118)
143
(64.9)
209
(94)
224
(101)
224
(101.6)
305
(138)
327
(148)
301
(136.5)
357
(162)
382
(173)
Unit Model Number
DM090
DM120
DM150
FIGURE 7 -
Y
FRONT
X
38 (965.2)
47 1/2 (1206.5)
47 1/2 (1206.5)
Y
23 (584.2)
25 1/2 (647.7)
25 1/2 (647.7)
UNIT CENTER OF GRAVITY
TABLE 5: 6 POINT LOAD WEIGHT
Model
090
120
150
12
Locations (lbs. (kg.))
A
B
C
D
E
F
135
(61.2)
168
(76.2)
180
(81.6)
110
(49.9)
151
(68.4)
161
(73)
91
(41.3)
136
(61.7)
145
(65.8)
142
(64.4)
198
(89.8)
212
(96.2)
172
(78.0)
219
(99.3)
235
(107)
211
(95.71)
244
(110.7)
262
(118.8)
Johnson Controls Unitary Products
127408-XIM-C-1208
CLEARANCES
All units require particular clearances for proper operation and
service. Installer must make provisions for adequate combustion and ventilation air in accordance with section 5.3 of Air for
Combustion and Ventilation of the National Fuel Gas Code,
ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2, 7.3,
or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) Latest Edition, and/or applicable provisions of the local building
codes. Refer to Table 7 for clearances required for combustible
construction, servicing, and proper unit operation.
Do not permit overhanging structures or shrubs to
obstruct condenser air discharge outlet, combustion
air inlet or vent outlets.
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.
•
•
•
•
•
The following substances should be avoided to
maintain outdoor combustion air quality.
•
•
•
•
•
•
•
•
•
•
•
•
•
Johnson Controls Unitary Products
Commercial buildings
Indoor pools
Laundry rooms
Hobby or craft rooms
Chemical storage areas
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
Anti-static fabric softeners for clothes dryers
Masonry acid washing materials
13
127408-XIM-C-1208
30-11/32
(770)
8
See Detail
B
Control
Entry
Ø 7/8
(22)
Power
Entry
Ø 2-1/2
(65)
4-1/4
(110)
Power
Entry
Ø 2-1/2
(65)
59
(1500)
17-3/16
30-3/16
(435)
(765)
6-3/16
24-3/16
(155)
(615)
LEFT
11-1/2
(290)
Convenience
Power
Outlet
Entry
Ø 7/8
(22)
For Baserail
Dimensions
See Detail C
FRONT
For Drain
Dimensions
See Detail D
89
(2260)
27
(685)
NOTE: (xxx) indicates dimensions
given in millimeters
FIGURE 8 -
UNIT DIMENSIONS
NOTE: A one-inch clearance must be provided between
any combustible material and the supply ductwork
for a distance of 3 feet from the unit.
TABLE 6: UNIT HEIGHT
Unit Model Number
X
DM090
DM120
DM150
42 (1067)
50 3/4 (1289)
50 3/4 (1289)
G a s P ip e In le t
DETAIL B
5 -1 /4
(1 3 5 )
2 -3 /8
(6 0 )
DETAIL C
3 -3 /4
(9 5 )
B a s e
P a n
1 7 -1 3 /1 6
(4 5 0 )
3 -9 /1 6
(9 0 )
DETAIL D
V ie w o f W a ll A c r o s s fr o m
C o il
TABLE 7: UNIT CLEARANCES *
†
Top
Front
72(1830)
Right
12(305)
36(915)
Left
36(915)
Rear‡
36(915)
Bottom**
0(0)
*.
In inches and millimeters, in.(mm).
†.
Units must be installed outdoors. Overhanging structure or shrubs should not obstruct condenser air discharge outlet.
‡.
**.
14
5 -3 /8
(1 3 5 )
To remove the slide-out drain pan, a rear clearance of
60” (1525 mm) is required. If space is unavailable, the
drain pan can be removed through the front by separating the corner wall.
NOTE: If the unit includes gas heating, locate the unit so
the flue exhaust is at least:
•
Three (3) feet above any forced air inlet located within 10
horizontal feet (excluding those integral to the unit).
•
Four (4) feet below, four (4) horizontal feet from, or one
(1) foot above any door or gravity air inlet into the building.
•
Four (4) feet from electric meters, gas meters, regulators, and relief equipment.
Units may be installed on combustible floors.
Johnson Controls Unitary Products
127408-XIM-C-1208
.
3 2 -1 1 /1 6
(8 3 0 )
N O T E : (X X X ) IN D IC A T E S
D IM E N S IO N S IN
M IL L IM E T E R S
6 -1 3 /1 6
(1 7 5 )
6 -1 3 /1 6
(1 7 5 )
6 -1 3 /1 6
(1 7 5 )
2 4
(6 1 0 )
2 7 -1 /2
(7 0 0 )
L E F T
2 1
(5 3 5 )
1 8
(4 5 5 )
1 9 -3 /1 6
(4 8 5 )
2 1 -3 /1 6
(5 4 0 )
1 7 -3 /1 6
(4 3 5 )
1 2 -5 /1 6
(3 1 5 )
1 4 -2 3 /3 2
(3 7 5 )
B o
C o
C o
O u
E n
1 6 -3 /8
(4 1 5 )
1 8 -1 /1 6
(4 6 0 )
FIGURE 9 -
tto m
n tro
n v e
tle t
try
P o w e r,
l a n d
n ie n c e
W ir in g
B o tto m g a s
s u p p ly e n tr y
F R O N T
6 3 -1 /2
(1 6 1 0 )
BOTTOM DUCT OPENINGS (FROM ABOVE)
DOT PLUGS
18-1/4
(465)
A
Return
Air
Supply
Air
18-1/4
(465)
B
2-31/32
(75)
5-5/32
(130)
C
NOTE: (XXX) indicates millimeters
31-11/16
(805)
FIGURE 10 - REAR DUCT DIMENSIONS
TABLE 8: REAR DUCT DIMENSIONS
Cabinet Size
50 3/4 (1289)
42 (1067)
“A”
28 1/4 (717)
27 3/4 (705)
Johnson Controls Unitary Products
Dimensions
“B”
18 1/16 (459)
12 1/16 (308)
“C”
28 1/4 (717
27 1/2 (699)
15
127408-XIM-C-1208
DUCTWORK
DUCT COVERS
Ductwork should be designed and sized according to the
methods in Manual D of the Air Conditioning Contractors of
America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA.
Units are shipped with the side duct openings covered and a
covering over the bottom of the unit. For bottom duct application, no duct cover changes are necessary. For side duct
application, remove the side duct covers and install over the
bottom duct openings. The panels removed from the side
duct connections are designed to be reused by securing each
panel to its respective downflow opening. But keep in mind
that the supply panel is installed with the painted surface UP,
facing the heat exchanger, while the return panel is installed
with the painted surface DOWN, facing the downflow duct
opening. The supply panel is secured with the bracket
(already in place from the factory) and two screws. It’s a snug
fit for the panel when sliding it between the heat exchanger
and unit bottom, but there is room. The return panel is
secured with four screws.
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.
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.
Refer to Figure 9 for bottom air duct openings. Refer to Figure 10 for rear air duct openings.
R IG H T
8 0 -5 /8
(2 0 5 0 )
IN S U L A T E D D E C K U N D E R
C O N D E N S E R S E C T IO N
2 0
(5 1 0 )
S U P P L Y
6
2 0
(5 1 0 ) (1 5 0 )
2 T Y P .
(5 0 )
R E T U R N
3 0
(7 6 0 )
IN S U L A T E D D E C K U N D E R
C O M P R E S S O R S E C T IO N
5 0 -1 /2
(1 2 8 5 )
8
1 4
O R
(2 0 5 )
(3 5 5 )
F R O N T
N O T E : (X X X ) IN D IC A T E S
D IM E N S IO N S IN
M IL L IM E T E R S
FIGURE 11 - PREDATOR® ROOF CURB DIMENSIONS
2 T Y P
(5 0 )
5 0 -1 /2
(1 2 8 5 )
2 3
(5 8 5 )
3 0 -1 /2
(7 7 5 )
4
(1 0 0 )
2 6
(6 6 0 )
R E T U R N
8 0 -5 /8
(2 0 5 0 )
S U P P L Y
1 0
(2 5 5 )
7 6 -5 /8
(1 9 4 5 )
F R O N T
9 4
(2 3 9 0 )
5 9 -1 /4
(1 5 0 5 )
6 4 -1 /4
(1 6 3 0 )
R IG H T
FIGURE 12 - SUNLINE™ TO PREDATOR® TRANSITION ROOF CURBS
16
Johnson Controls Unitary Products
127408-XIM-C-1208
CONDENSATE DRAIN
When fastening ductwork to side duct flanges on
unit, insert screws through duct flanges only. DO
NOT insert screws through casing. Outdoor ductwork must be insulated and water-proofed.
The side condensate drain is reversible and maybe re-oriented to the rear of the cabinet to facilitate condensate piping. A condensate drain connection is available through the
base pan for piping inside the roof curb. Trap the connection
per Figure 16: Condensate Drain. 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 line
from the 3/4 inch (19 mm) NPT female connection on the unit
to an open drain.
3 " M in im u m
(7 6 .2 m m )
FIGURE 13 - SIDE PANELS WITH HOLE PLUGS
Note orientation. Panel is “insulation” side up.
FIGURE 16 - CONDENSATE DRAIN
COMPRESSORS
The compressors are mounted on elastomer insulators. The
mounting bolts have been fully tightened for shipping.
Do not loosen the compressor mounting bolts.
FIGURE 14 - RETURN DOWNFLOW PLENUM WITH
PANEL
FILTERS
Two-inch filters are supplied with each unit. One-inch filters
may be used with no modification to the filter racks. Filters
must always be installed ahead of evaporator coil and must
be kept clean or replaced with same size and type. Dirty filters reduce the capacity of the unit and result in frosted coils
or safety shutdown. All units use four (4) 20”x25”x2” filters.
The unit should not be operated without filters properly
installed.
Make sure that panel latches are properly positioned
on the unit to maintain an airtight seal.
FIGURE 15 - DISCHARGE PANEL IN PLACE
Johnson Controls Unitary Products
17
127408-XIM-C-1208
THERMOSTAT WIRING
The thermostat should be located on an inside wall approximately 56 inches (1422 mm) above the floor where it will not
be subject to drafts, sun exposure or heat from electrical fixtures or appliances. Follow the manufacturer's instructions
enclosed with thermostat for general installation procedure.
Seven (7) color-coded, insulated wires should be used to
connect the thermostat to the unit. Refer to Table 9 for control
wire sizing and maximum length.
TABLE 9: CONTROL WIRE SIZES
Wire Size
Maximum Length
18 AWG
150 Feet (45.72 meters)
POWER AND CONTROL WIRING
Field wiring to the unit, fuses, and disconnects must conform
to provisions of National Electrical Code (NEC), ANSI/NFPA
No. 70 – Latest Edition (in U.S.A.), current Canadian Electrical Code C221, and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC as
specified above and/or local codes.
A disconnect must be utilized for these units. When installing
a disconnect, refer to Figure 4 for the recommended mounting location.
Avoid damage to internal components if drilling
holes for disconnect mounting.
NOTE: Since not all local codes allow the mounting of a disconnect on the unit, please confirm compliance with
local code before mounting a disconnect on the unit.
Electrical line must be sized properly to carry the load. USE
COPPER CONDUCTORS ONLY. Each unit must be wired
with a separate branch circuit fed directly from the meter
panel and properly fused.
Refer to Figures 17, 18 and 19 for typical field wiring and to
the appropriate unit wiring diagram mounted inside control
doors for control circuit and power wiring information.
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.
208/230-3-60 and 380/415-3-50 units control transformers are factory wired for 230v and 415v power
supply respectively. Change tap on transformer for
208-3-60 or 380-3-50 operation. See unit wiring diagram.
The internal wiring 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.
18
When connecting electrical power and control wiring
to the unit, water-proof connectors must be used so
that water or moisture cannot be drawn into the unit
during normal operation. The above water-proofing
conditions will also apply when installing a field supplied disconnect switch.
POWER WIRING DETAIL
Units are factory wired for the voltage shown on the unit
nameplate. Refer to Electrical Data Tables 10 through 12 size
power wiring, fuses, and disconnect switch.
Power wiring is brought into the unit through the side of the
unit or the basepan inside the curb.
Johnson Controls Unitary Products
127408-XIM-C-1208
T H E R M
T E R M
O S T A T
IN A L S
1
U N IT T E R M IN A L S
S T R IP T B 1
R C
R H
R
Y 1
Y 1
Y 2
Y 2
W
1
W
W
2
W
G
208/230-3-60 and 380/415-3-50 units control
transformers are factory wired for 230v and
415v power supply respectively. Change tap
on transformer for 208-3-60 or 380-3-50 operation. See unit wiring diagram.
1
2
G
C
C
X 1
2 4
X
2
X 3
V o lt
T r a n s fo r m
e r
O C C
X 4
A 1
A 2
T
T
T O R E M O T E S E N S O R
2 E T 0 4 7 0 1 3 2 4 IF U S E D
1
2
E le c tr o n ic p r o g r a m m a b le T h e r m o s ta t 2 E T 0 7 7 0 0 1 0 0 2 4 ( in c lu d e s s u b b a s e ) .
T e r m in a ls A 1 a n d A 2 p r o v id e a r e la y o u tp u t to c lo s e th e o u td o o r
e c o n o m iz e r d a m p e r s w h e n th e th e r m o s ta t s w itc h e s to th e s e t- b a c k p o s itio n .
FIGURE 17 - TYPICAL ELECTRONIC THERMOSTAT FIELD WIRING
T -S T A T
W 1
W 1
W 2
W 2
Y 1
Y 1
G
G
Y 2
O C C
R H
R C
R E M O T E
M IN P O S
C
U N IT C O N T R O L
B O A R D
Y 2
X
R
S D
C
FIGURE 18 - TYPICAL FIELD WIRING 24 VOLT THERMOSTAT
Johnson Controls Unitary Products
19
127408-XIM-C-1208
TERMINAL BLOCK TB1
FIELD SUPPLIED
DISCONNECT
GROUND
LUG
THREE
PHASE
POWER
SUPPLY
FIGURE 19 - FIELD WIRING DISCONNECT - COOLING UNIT WITH OR WITHOUT ELECTRIC HEAT
CONTACTOR 1M
GROUND
LUG
T1
T2
T3
L1
L2
L3
FIELD SUPPLIED
DISCONNECT
THREE
PHASE
POWER
SUPPLY
FIGURE 20 - FIELD WIRING DISCONNECT - COOLING UNIT WITH GAS HEAT
20
Johnson Controls Unitary Products
127408-XIM-C-1208
TABLE 10: ELECTRICAL DATA 7-1/2 TON
Compressors
Voltage*
OD
Fan
Motors
Supply
Blower
Motor FLA
Pwr Exh
Motor
Electric
Heater
Model No.
Actual
kW
Heater
Amps
Min. Circuit
Ampacity
(Amps)
MCA
w/Power
Exhaust
(Amps)
Max Fuse†
Size (Amps)
Max Fuse Size
w/Power
Exhaust
(Amps)
3 HP
2 HP
3 HP
2 HP
RLA
ea.
LRA
ea.
FLA
ea.
3 HP
FLA
380
8.3
62
1.1
4.9
2.2
None
-
-
26.1
28.3
30
35
415
8.3
62
1.1
4.9
2.2
None
-
-
26.1
28.3
30
35
Max Fuse†
Size (Amps)
Max Fuse Size
w/Power
Exhaust
(Amps)
*.
Unit voltage limitations: minimum utilization 342 volts, maximum utilization 457 volts.
†.
Maximum HACR breaker of the same amp size is acceptable.
TABLE 11: ELECTRICAL DATA 10 TON
Compressors
OD
Fan
Motors
Supply Blower
Motor FLA
FLA
ea.
2 HP
4 HP
(1.5 kW) (3 kW)
Pwr Exh
Motor
Voltage*
RLA
ea.
LRA
ea.
Electric
Heater
Model No.
Actual Heater
kW
Amps
2 HP
4 HP
(1.5 kW) (3 kW)
FLA
None
380
415
9.6
9.6
80
80
1.1
1.1
5.2
5.2
7.5
7.5
2.2
2.2
Min. Circuit
Ampacity
(Amps)
-
-
29.0
31.3
2 HP
(1.5
kW)
31.2
4 HP
2 HP
4 HP
(3 kW) (1.5 kW) (3 kW)
33.5
35
40
2 HP
(1.5
kW)
4 HP
(3
kW)
40
40
2TP04521850
11.3
17.2
29.0
31.3
31.2
33.5
35
40
40
40
2TP04522450
15.0
22.8
35.0
37.9
37.7
40.6
35
40
40
45
2TP04523650
21.3
32.4
47.0
49.8
49.7
52.6
50
50
50
60
2TP04525450
33.8
51.4
70.7
73.6
73.4
76.3
80
80
80
80
None
-
-
29.0
31.3
31.2
33.5
35
40
40
40
2TP04521850
13.5
18.8
30.0
32.9
32.7
35.6
35
40
40
40
2TP04522450
17.9
24.9
37.6
40.5
40.4
43.3
40
45
45
45
2TP04523650
25.4
35.3
50.7
53.5
53.4
56.3
60
60
60
60
2TP04525450
40.4
56.2
76.8
79.6
79.5
82.4
80
80
80
90
*.
Unit voltage limitations: minimum utilization 342 volts, maximum utilization 457 volts.
†.
Maximum HACR breaker of the same amp size is acceptable.
Johnson Controls Unitary Products
MCA
w/Power
Exhaust
(Amps)
21
127408-XIM-C-1208
TABLE 12: ELECTRICAL DATA 12-1/2 TON
Compressors
Voltage*
RLA
ea.
380
415
12.0
12.0
LRA
ea.
91
101
OD
Fan
Motors
Supply Air
Blower
Motor FLA
Pwr Exh
Motor
FLA
ea.
4 HP (3 kW)
FLA
1.1
7.5
1.1
7.5
2.2
2.2
Electric
Heater
Model No.
Actual
kW
Heater
Amps
Min. Circuit
Ampacity
(Amps)
MCA
w/Power
Exhaust
(Amps)
Max
Fuse†
Size
(Amps)
Max Fuse
Size
w/Power
Exhaust
(Amps)
4 HP
(3 kW)
4 HP
(3 kW)
4 HP
(3 kW)
4 HP
(3 kW)
None
-
-
36.7
38.9
45
50
2TP04521850
11.3
17.2
36.7
38.9
45
50
2TP04522450
15.0
22.8
37.9
40.6
45
50
2TP04523650
21.3
32.4
49.8
52.6
50
60
2TP04525450
33.8
51.4
73.6
76.3
80
80
None
-
-
36.7
38.9
45
50
2TP04521850
13.5
18.8
36.7
38.9
45
50
2TP04522450
17.9
24.9
40.5
43.3
45
50
2TP04523650
25.4
35.3
53.5
56.3
60
60
2TP04525450
40.4
56.2
79.6
82.4
80
90
*.
Unit voltage limitations: minimum utilization 342 volts, maximum utilization 457 volts.
†.
Maximum HACR breaker of the same amp size is acceptable.
TABLE 13: PHYSICAL DATA
Models
Component
Evaporator
Blower
Evaporator
Coil
Condenser
Fan
(2 per Unit)
Condenser
Coil
(2 per unit)
Refrigerant
Charge
Compressors
Air Filters
22
090
120
150
Blower, Centrifugal
Dia. X Wd. in.
(Dia. X Wd. mm.)
12 x 12
(305 x 305)
15 x 15
(381 x 381)
15 x 15
(381 x 381)
Motor, Standard - HP (kW)
3 (2.2)
2 (1.5)
4 (3)
Motor, Optional - HP (kW)
3 (2.2)
4 (3)
N/A
Rows
2
3
4
Fins per 2.54 cm (1 in.)
15
15
15
Height - in. (mm.)
32 (810)
40 (1020)
40 (1020)
Face Area - ft.2 (m2)
10.6 (0.98)
13.2 (1.23)
13.2 (1.23)
Propeller Dia. - in. (mm.) ea.
24 (610)
24 (610)
24 (610)
Motor - HP (kW) ea.
3/4 (0.56)
3/4 (0.56)
3/4 (0.56)
Airflow - CFM (m3/s) ea.
3700 (1.75)
3700 (1.75)
3700 (1.75)
Rows (each)
1
1
2
Fins per inch (2.54 mm)
20
20
20
Height - in. (mm.)
28 (711)
44 (1120)
44 (1120)
Face Area - ft.2 (m2)
9.2 (.86)
14.5 (1.35)
14.5 (1.35)
System 1 - lbs. (kg.)
4.75 (2.15)
6.0 (2.72)
11.0 (4.99)
System 2 - lbs. (kg.)
4.0 (1.81)
5.75 (2.61)
10.0 (4.54)
Quantity
2
2
2
Type
Recip
Recip
Scroll
Size
Wd. x Ht. x Thickness in.
(Wd. x Ht. x Thickness mm.)
25 x 16 x 2
(635 x 406 x 51)
25 x 20 x 2
(635 x 508 x 51)
25 x 20 x 2
(635 x 508 x 51)
Number Per Unit
4
4
4
Johnson Controls Unitary Products
127408-XIM-C-1208
OPTIONAL ELECTRIC HEAT
GAS PIPING
The factory-installed heaters are wired for single point power
supply. Power supply need only be brought into the single
point terminal block.
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 should be
followed in all cases unless superseded by local codes or gas
utility requirements. Refer to the Pipe Sizing Table 16. The
heating value of the gas may differ with locality. The value
should be checked with the local gas utility.
These CSA approved heaters are located within the central
compartment of the unit with the heater elements extending
into the supply air chamber.
Fuses are supplied, where required, by the factory. Some kW
sizes require fuses and other do not. Refer to Table 14 for
minimum CFM limitations and to Tables 10 through 12 for
electrical data.
TABLE 14: ELECTRIC HEAT MINIMUM SUPPLY AIR
CFM
IMPERIAL
HEATER
T IO N A L
IL
A R D
O W N
UNIT MODEL SIZE, NOMINAL TONS
10
VOLTAGE
kW
O P
C O
G U
S H
12.5
MINIMUM SUPPLY AIR CFM
N/A
N/A
3000
3750
3000
3750
36
3000
3750
54
3000
3750
9
18
380/415
24
FIGURE 21 - SIDE ENTRY GAS PIPING
METRIC
HEATER
UNIT MODEL SIZE, NOMINAL TONS
VOLTAGE
kW
10
12.5
MINIMUM SUPPLY AIR CFM
9
N/A
N/A
18
1.41
1.76
1.41
1.76
36
1.41
1.76
54
1.41
1.76
380/415
24
OPTIONAL
COIL
GUARD
SHOWN
OPTIONAL GAS HEAT
These gas-fired heaters have aluminized-steel or optional
stainless steel, tubular heat exchangers with spark ignition.
TABLE 15: GAS APPLICATION DATA
Unit
Input (MBH)
Output (MBH)
Temp Rise (qF)
10
120
96
15-45
15
175
140
30-60
120
15
175
140
15-45
150
15
175
140
10-40
Size
Opt.
FIGURE 22 - BOTTOM ENTRY GAS PIPING
090
Johnson Controls Unitary Products
23
127408-XIM-C-1208
TABLE 16: GAS PIPE SIZING - CAPACITY OF PIPE
4.
All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out loose
particles. Before initial start-up, be sure that all 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”.
6.
A 1/8-inch (3.175 mm) NPT plugged tapping, accessible
for test gage connection, must be installed immediately
upstream of the gas supply connection to the unit.
7.
After the gas connections have been completed, open
the main shut-off valve admitting normal gas pressure to
the mains. Check all joints for leaks with soap solution or
other material suitable for the purpose. NEVER USE A
FLAME.
Nominal Iron Pipe Size
Length of
Pipe ft. (m)
3/4 in.
1 in.
1-1/4 in.
10 (3)
278 (7.8)
520 (14.7)
1050 (29.7)
20 (6)
190 (5.3)
350 (9.9)
730 (20.6)
30 (9.1)
152 (4.3)
285 (8)
590 (16.7)
40 (12.1)
130 (3.6)
245 (6.9)
500 (14.1)
50 (15.2)
115 (3.2)
215 (6)
440 (12.4)
60 (18.2)
105 (2.9)
195 (5.5)
400 (12.4)
70 (21.3)
96 (2.7)
180 (5)
370 (10.4)
80 (24.3)
90 (2.5)
170 (4.8)
350 (9.9)
90 (27.4)
84 (2.3)
160 (4.5)
320 (9)
100 (30.4)
79 (2.2)
150 (4.2)
305 (8.6)
NOTE: Maximum capacity of pipe in cubic feet of gas per
hour based upon a pressure drop of 0.3 inch W.C.
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 3/4 inch pipe connection at the entrance
fitting. Line should not be sized smaller than the
entrance fitting size.
GAS CONNECTION
The gas supply line can be routed within the space and roof
curb, exiting through the unit’s basepan. Refer to Figure 9 for
the gas piping inlet location. Typical supply piping arrangements are shown in Figures 21 and 22. All pipe nipples, fittings, and the gas cock are field supplied or may be
purchased in UP accessory kit #1GP0404.
Gas piping recommendations:
1.
A drip leg and a ground joint union must be installed in
the gas piping.
2.
Where required by local codes, a manual shut-off valve
must 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.
Natural gas may contain some propane. Propane is
an excellent solvent and will quickly dissolve white
lead and most standard commercial compounds. A
special pipe dope must be used when assembling
wrought iron or steel pipe. Shellac based compounds such as Gaskolac or Stalastic, and compounds such as Rectorseal #5, Clydes’s or John
Crane may be used.
24
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system
during any pressure testing at pressures in excess
of 1/2 PSIG.
Pressures greater than 1/2 PSIG will cause gas
valve damage resulting in a hazardous condition. If it
is subjected to a pressure greater than 1/2 PSIG, the
gas valve must be replaced.
The furnace must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than 1/2 PSIG.
Threaded joints should be coated with a sealing
compound that is resistant to the action of liquefied
petroleum gases. Do not use Teflon tape.
Johnson Controls Unitary Products
127408-XIM-C-1208
LP UNITS, TANKS AND PIPING
All gas heat units are shipped from the factory equipped for
natural gas use only. The unit may be converted in the field
for use with LP gas with accessory kit model number
1NP0441.
All LP gas equipment must conform to the safety standards of
the National Fire Protection Association.
For satisfactory operation, LP gas pressure must be 10.5
inch W.C. at the unit under full load. Maintaining proper gas
pressure depends on three main factors:
1.
The vaporization rate which depends on the temperature
of the liquid and the “wetted surface” area of the container(s).
2.
The proper pressure regulation. (Two-stage regulation is
recommended).
3.
The pressure drop in the lines between regulators and
between the second stage regulator and the appliance.
Pipe size required will depend on the length of the pipe
run and the total load of all appliances.
Complete information regarding tank sizing for vaporization,
recommended regulator settings, and pipe sizing is available
from most regulator manufacturers and LP gas suppliers.
LP gas is an excellent solvent and will quickly dissolve white
lead and most standard commercial compounds. A special
pipe dope must be used when assembling wrought iron or
steel pipe for LP. Shellac base compounds such as Gaskolac
or Stalastic, and compounds such as Rectorseal #5, Clyde’s,
or John Crane may be used.
Check all connections for leaks when piping is completed
using a soap solution. NEVER USE A FLAME.
with screen. If necessary, a flue exhaust extension may be
installed at the point of installation.
OPTIONS/ACCESSORIES
ELECTRIC HEAT
Electric heaters are available as field installed accessories.
Refer to electric heat instructions for installation. These heaters mount in the heat compartment with the heating elements
extending into the supply air chamber. All electric heaters are
fused and intended for use with single point power supply.
MOTORIZED OUTDOOR DAMPER
The Motorized Outdoor Damper can be a factory installed
option or a field installed accessory. If factory installed, refer
to the instructions included with the outdoor air hood to complete the assembly. Field installed Motorized Outdoor
Damper accessories include complete instructions for installation.
ECONOMIZER
The Economizer can be a factory installed option or a field
installed accessory. If factory installed, refer to the instructions included with the outdoor air hood to complete the
assembly. Field installed Economizer accessories include
complete instructions for installation.
There are two Economizer options:
1.
Down Flow application with barometric relief hood standard.
2.
Horizontal Flow application that requires the purchase of
a barometric relief hood.
POWER EXHAUST
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
VENT AND COMBUSTION AIR
Venting slots in the heating compartment access panel
remove the need for a combustion air hood. The gas heat
flue exhaust is routed through factory installed exhaust piping
Johnson Controls Unitary Products
The Power Exhaust can be a factory installed option or a field
installed accessory. If factory installed, refer to the instructions included with the outdoor air hood to complete the
assembly. Field installed Power Exhaust accessories include
complete instructions for installation.
The Power Exhaust factory installed option is for Down Flow
application only.
There are two field installed Power Exhaust accessories:
1.
Down Flow application.
2.
Horizontal Flow application that requires the purchase of
a barometric relief hood.
RAIN HOOD
All of the hood components, including the filters, the gasketing and the hardware for assembling, are packaged and
located between the condenser coil section and the main unit
25
127408-XIM-C-1208
cabinet, if the unit has factory installed options. If field
installed accessories are being installed all parts necessary
for the installation comes in the accessory.
ECONOMIZER AND POWER EXHAUST SET POINT
ADJUSTMENTS AND INFORMATION
Remove the top rear access panel from the unit. Locate the
economizer control module, where the following adjustments
will be made.
to the lettered curve of the Enthalpy Set Point Adjustment Figure 23.
•
For a dual enthalpy operation, carefully turn the set point
adjusting screw fully clockwise past the "D" setting.
POWER EXHAUST DAMPER SET POINT (WITH OR WITHOUT POWER EXHAUST)
•
With no power exhaust option, adjust the Exhaust Air
Adjustment Screw fully clockwise. This will allow 2nd
stage cooling to operate.
•
With power exhaust option, each building pressurization
requirement will be different. The point at which the
power exhaust comes on is determined by the economizer damper position (Percent Open). The Exhaust Air
Adjustment Screw should be set at the Percent Open of
the economizer damper at which the power exhaust is
needed. It can be set from 0 to 100% damper open.
Extreme care must be exercised in turning all set
point, maximum and minimum damper positioning
adjustment screws to prevent twisting them off.
MINIMUM POSITION ADJUSTMENT
INDOOR AIR QUALITY AQ
•
•
Check that the damper blades move smoothly without
binding; carefully turn the Minimum Position Adjust
screw (found on the damper control module) fully clockwise and then set the thermostat indoor fan switch to the
ON position and then OFF or energize and de-energize
terminals “R” to “G”.
With the thermostat set to the indoor fan ON position or
terminals “R” to “G” energized, turn the Minimum Position Adjusting screw (located on the damper control
module) counterclockwise until the desired minimum
damper position has been attained.
ENTHALPY SET POINT ADJUSTMENT
The enthalpy set point may now be set by selecting the
desired set point shown in the Enthalpy Set Point Adjustment
Figure 23. Adjust as follows:
•
26
For a single enthalpy operation carefully turn the set
point adjusting screw (found on the damper control
module) to the "A", "B", "C" or "D" setting corresponding
Indoor Air Quality (indoor sensor input): Terminal AQ accepts
a +2 to +10 Vdc signal with respect to the (AQ1) terminal.
When the signal is below it's set point, the actuator is allowed
to modulate normally in accordance with the enthalpy and
mixed air sensor inputs. When the AQ signal exceeds it's set
point setting and there is no call for free cooling, the actuator
is proportionately modulated from the 2 to 10 Vdc signal, with
2 Vdc corresponding to full closed and 10 Vdc corresponding
to full open. When there is no call for free cooling, the damper
position is limited by the IAQ Max damper position setting.
When the signal exceeds it's set point (Demand Control Ventilation Set Point) setting and there is a call for free cooling,
the actuator modulates from the minimum position to the full
open position based on the highest call from either the mixed
air sensor input or the AQ voltage input.
•
Optional CO2 Space Sensor Kit Part # 2AQ04700324
•
Optional CO2 Sensor Kit Part # 2AQ04700424
Replace the top rear access panel on the unit.
Johnson Controls Unitary Products
127408-XIM-C-1208
CONTROL
CURVE
CONTROL POINT
APPROX. 0F (0C)
AT 50% RH
A
73 (23)
B
C
70 (21)
67 (19)
D
63 (17)
85 90 95 100 105 110
(29) (32) (35) (38) (41) (43)
80
(27)
75
(24)
70
(21)
65
(18)
60
(16)
55
(13)
50
(10)
45
(7)
35
(2)
A
B
C
D
40
(4)
B A
D C
35
(2)
40 45 50 55 60 65 70 75 80 85 90 95 100 105 110
(4) (7) (10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43)
APPROXIMATE DRY BULB TEMPERATURE - 0F (0C)
FIGURE 23 - ENTHALPY SET POINT CHART
Exhaust Air
Adjustment
Screw
Exhaust Air LED
Damper Min.
Position
Screw
Indoor Air Quality
Max. Adjustment
Screw
N1
N
EXH
Set
TR
P1
P
EXH
24
Vac
HOT
T1
T
Min
Pos
IAQ
Max
Indoor Air Quality
LED
AQ1
AQ
IAQ
SO
IAQ
Min
TR1
24
Vac
COM
+
1
2
5
Indoor Air Quality
Min. Adjustment
Screw
Free Cooling LED
SO+
3
4
EF
EF1
Free
Cool
SR+
SR
B
A
C
D
Economizer Enthalpy
Set Point Adjustment
Screw
FIGURE 24 - HONEYWELL ECONOMIZER CONTROL W7212
Johnson Controls Unitary Products
27
127408-XIM-C-1208
PHASING
A
Predator® units are properly phased at the factory. Check for
proper compressor rotation. If the blower or compressors
rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the phasing of the Field
Line Connection at the factory or field supplied disconnect to obtain proper rotation. (Scroll compressors operate in
only one direction. If the scroll is drawing low amperage, has
similar suction and discharge pressures, or producing a high
noise level, the scroll is misphased.)
A
C*
* NEVER LOOSEN
A
B
SPAN LENGTH
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.
DEFL. FORCE
BLOWER ROTATION
Check for proper supply air blower rotation. If the blower is
rotating backwards, the line voltage at the unit point of power
connection is misphased (See ‘PHASING’).
FIGURE 25 - BELT ADJUSTMENT
TABLE 17: SUPPLY AIR LIMITATIONS
Minimum
Maximum
CFM (m3/sec)
CFM (m3/sec)
090
2250 (1)
3750 (1.7)
120
3000 (1.4)
5000 (2.3)
150
3750 (1.7)
6250 (2.9)
Unit Size
BELT TENSION
The tension on the belt should be adjusted as shown in
Figure 25.
Procedure for adjusting belt tension:
1.
2.
3.
4.
Loosen six nuts (top and bottom) A.
Adjust by turning (B).
Never loosen nuts (C).
Use belt tension checker to apply a perpendicular
force to one belt at the midpoint of the span as
shown. Deflection distance of 4mm (5/32”) is
obtained.
To determine the deflection distance from normal
position, use a straight edge from sheave to sheave
as reference line. The recommended deflection
force is as follows:
Tension new belts at the max. deflection force recommended for the belt section. Check the belt tension at least two times during the first 24 hours of
operation. Any retensioning should fall between the
min. and max. deflection force values.
5. After adjusting retighten nuts (A).
28
Johnson Controls Unitary Products
127408-XIM-C-1208
TABLE 18: BLOWER PERFORMANCE 7-1/2 TON STANDARD MOTOR - SIDE DUCT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
0.2
–
–
–
–
–
–
–
–
–
–
–
–
3193
1490
1.60
2981
1310
BHP
1.41
0.4
3690
2230
2.39
3468
1950
2.09
3294
1750
1.88
3105
1550
1.66
2922
1370
1.47
2694
1210
1.30
0.6
3478
2110
2.26
3239
1830
1.96
3044
1640
1.76
2850
1440
1.54
2651
1270
1.36
2423
1120
1.20
0.8
3243
1980
2.12
3001
1720
1.85
2790
1520
1.63
2576
1330
1.43
2370
1170
1.26
2105
1020
1.09
1.0
3006
1830
1.96
2758
1580
1.70
2544
1400
1.50
2303
1230
1.32
2017
1050
1.13
1624
880
0.94
1.2
2758
1720
1.85
2533
1510
1.62
2230
1290
1.38
1891
1080
1.16
–
–
–
–
–
–
1.4
2447
1570
1.68
2182
1350
1.45
1769
1110
1.19
–
–
–
–
–
–
–
–
–
1.6
2085
1410
1.51
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
TABLE 19: BLOWER PERFORMANCE 7-1/2 TON STANDARD MOTOR - SIDE DUCT (METRIC)
Turns Open
ESP
(Pa)
0
3
m /s
In
(kW)
1
Out
(kW)
3
m /s
In
(kW)
2
Out
(kW)
3
m /s
In
(kW)
3
Out
(kW)
3
m /s
In
(kW)
4
Out
(kW)
3
m /s
In
(kW)
5
Out
(kW)
3
m /s
In
(kW)
Out
(kW)
50
–
–
–
–
–
–
–
–
–
–
–
–
1.51
1.49
1.19
1.36
1.31
1.05
100
1.74
2.23
1.78
1.64
1.95
1.55
1.55
1.75
1.40
1.46
1.55
1.24
1.38
1.37
1.10
1.27
1.21
0.97
149
1.64
2.11
1.68
1.53
1.83
1.46
1.44
1.64
1.39
1.34
1.44
1.15
1.25
1.27
1.01
1.14
1.12
0.89
199
1.53
1.98
1.58
1.42
1.72
1.38
1.32
1.52
1.38
1.22
1.33
1.07
1.12
1.17
0.94
0.99
1.02
0.81
249
1.42
1.83
1.46
1.30
1.58
1.27
1.20
1.40
1.28
1.09
1.23
0.98
0.95
1.05
0.84
0.77
0.88
0.70
299
1.30
1.72
1.38
1.20
1.51
1.21
1.05
1.29
1.17
0.89
1.08
0.91
–
–
–
–
–
–
349
1.15
1.57
1.25
1.03
1.35
1.08
0.83
1.11
1.01
–
–
–
–
–
–
–
–
–
399
0.98
1.41
1.26
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
TABLE 20: BLOWER PERFORMANCE 7-1/2 TON OPTIONAL MOTOR - SIDE DUCT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
0.8
–
–
–
–
–
–
–
–
–
–
–
–
2783
1500
1.61
2507
1300
BHP
1.39
1.0
3555
2440
2.62
3285
2120
2.27
3047
1860
2.00
2778
1590
1.71
2507
1390
1.49
2209
1180
1.27
1.2
3320
2310
2.48
3034
1990
2.13
2799
1730
1.86
2510
1480
1.59
2213
1260
1.35
1846
1050
1.13
1.4
3101
2160
2.32
2796
1860
2.00
2466
1590
1.71
2188
1330
1.43
1721
1090
1.17
–
–
–
1.6
2864
2040
2.19
2489
1710
1.83
2145
1450
1.56
–
–
–
–
–
–
–
–
–
1.8
2524
1860
2.00
2182
1550
1.66
–
–
–
–
–
–
–
–
–
–
–
–
2.0
2189
1680
1.80
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
3
In
(kW)
TABLE 21: BLOWER PERFORMANCE 7-1/2 TON OPTIONAL MOTOR - SIDE DUCT (METRIC)
Turns Open
0
ESP
(Pa)
3
m /s
In
(kW)
1
Out
(kW)
3
m /s
In
(kW)
2
Out
(kW)
3
m /s
In
(kW)
3
Out
(kW)
3
m /s
In
(kW)
4
Out
(kW)
3
m /s
In
(kW)
5
Out
(kW)
m /s
Out
(kW)
100
–
–
–
–
–
–
–
–
–
–
–
–
1.31
1.5
1.20
1.18
1.3
1.04
149
1.68
2.44
1.95
1.55
2.12
1.70
1.44
1.86
1.49
1.31
1.59
1.27
1.18
1.39
1.11
1.04
1.18
0.94
199
1.52
2.31
1.85
1.43
1.99
1.59
1.32
1.73
1.38
1.18
1.48
1.18
1.04
1.26
1.01
0.87
1.05
0.84
249
1.46
2.16
1.73
1.31
1.86
1.49
1.16
1.59
1.27
1.03
1.33
1.06
0.81
1.09
0.87
–
–
–
299
1.35
2.04
1.63
1.17
1.71
1.36
1.01
1.45
1.16
–
–
–
–
–
–
–
–
–
349
1.19
1.86
1.49
1.03
1.55
1.24
–
–
–
–
–
–
–
–
–
–
–
–
399
1.03
1.68
1.34
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Johnson Controls Unitary Products
29
127408-XIM-C-1208
TABLE 22: BLOWER PERFORMANCE 10 TON STANDARD MOTOR - SIDE DUCT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
0.4
4820
2675
2.87
4582
2362
2.53
4319
2080
2.23
4086
1842
1.98
3863
1648
1.77
3590
1430
1.53
0.6
4522
2496
2.68
4307
2215
2.38
4025
1941
2.08
3713
1678
1.80
3464
1499
1.61
3149
1291
1.38
0.8
4223
2332
2.50
3973
2062
2.21
3656
1783
1.91
3363
1550
1.66
3026
1350
1.45
-
-
-
1.0
3913
2174
2.33
3679
1923
2.06
3262
1619
1.74
2721
1330
1.43
-
-
-
-
-
-
1.2
3521
1978
2.12
3104
1693
1.82
-
-
-
-
-
-
-
-
-
-
-
-
1.4
2790
1660
1.78
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TABLE 23: BLOWER PERFORMANCE 10 TON STANDARD MOTOR - SIDE DUCT (METRIC)
Turns Open
ESP
(Pa)
0
1
2
3
4
5
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
100
2.27
2.68
2.14
2.16
2.36
1.89
2.04
2.08
1.66
1.93
1.84
1.47
1.82
1.65
1.32
1.69
1.43
1.14
149
2.13
2.50
2.00
2.03
2.22
1.77
1.90
1.94
1.55
1.75
1.68
1.34
1.63
1.50
1.20
1.49
1.29
1.03
199
1.99
2.33
1.87
1.88
2.06
1.65
1.73
1.78
1.43
1.59
1.55
1.24
1.43
1.35
1.08
-
-
-
249
1.85
2.17
1.74
1.74
1.92
1.54
1.54
1.62
1.30
1.28
1.33
1.06
-
-
-
-
-
-
299
1.66
1.98
1.58
1.46
1.69
1.35
-
-
-
-
-
-
-
-
-
-
-
-
349
1.32
1.66
1.33
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TABLE 24: BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR - SIDE DUCT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
0.4
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
4960
2495
2.68
0.6
-
-
-
-
-
-
-
-
-
-
-
-
5091
2745
2.94
4646
2314
2.48
0.8
-
-
-
-
-
-
-
-
-
5078
2937
3.15
4839
2584
2.77
4347
2153
2.31
1.0
-
-
-
-
-
-
5075
3117
3.34
4767
2730
2.93
4487
2377
2.55
3946
1942
2.08
1.2
-
-
-
5068
3308
3.55
4742
2881
3.09
4427
2513
2.69
4108
2159
2.32
3501
1723
1.85
1.4
5079
3595
3.86
4787
3105
3.33
4452
2713
2.91
4012
2259
2.42
3665
1926
2.07
-
-
-
1.6
4739
3316
3.56
4482
2892
3.10
4098
2474
2.65
3543
2006
2.15
3057
1642
1.76
-
-
-
1.8
4461
3111
3.34
4070
2621
2.81
3552
2160
2.32
-
-
-
-
-
-
-
-
-
2.0
3997
2782
2.98
3400
2219
2.38
-
-
-
-
-
-
-
-
-
-
-
-
2.2
3496
2480
2.66
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
30
Johnson Controls Unitary Products
127408-XIM-C-1208
TABLE 25: BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR - SIDE DUCT (METRIC)
Turns Open
ESP
(Pa)
0
1
2
3
4
5
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
100
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2.34
2.50
2.00
149
-
-
-
-
-
-
-
-
-
-
-
-
2.40
2.75
2.20
2.19
2.31
1.85
199
-
-
-
-
-
-
-
-
-
2.40
2.94
2.35
2.28
2.58
2.07
2.05
2.15
1.72
249
-
-
-
-
-
-
2.40
3.12
2.49
2.25
2.73
2.18
2.12
2.38
1.90
1.86
1.94
1.55
299
-
-
-
2.39
3.31
2.65
2.24
2.88
2.30
2.09
2.51
2.01
1.94
2.16
1.73
1.65
1.72
1.38
349
2.40
3.60
2.88
2.26
3.11
2.48
2.10
2.71
2.17
1.89
2.26
1.81
1.73
1.93
1.54
-
-
-
399
2.24
3.32
2.65
2.12
2.89
2.31
1.93
2.47
1.98
1.67
2.01
1.60
1.44
1.64
1.31
-
-
-
448
2.11
3.11
2.49
1.92
2.62
2.10
1.68
2.16
1.73
-
-
-
-
-
-
-
-
-
498
1.89
2.78
2.23
1.60
2.22
1.78
-
-
-
-
-
-
-
-
-
-
-
-
548
1.65
2.48
1.98
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TABLE 26: BLOWER PERFORMANCE 12-1/2 TON - SIDE DUCT (IMPERIAL)
Turns Open
ESP
(iwg)
0.4
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
-
-
-
6130
4171
4.47
5915
3774
4.05
5610
3309
3.55
5396
2948
3.16
4960
2495
2.68
0.6
-
-
-
5850
3932
4.22
5648
3565
3.82
5363
3136
3.36
5091
2745
2.94
4646
2314
2.48
0.8
5870
4273
4.58
5567
3715
3.98
5406
3380
3.62
5078
2937
3.15
4839
2584
2.77
4347
2153
2.31
1.0
5652
4087
4.38
5327
3518
3.77
5075
3117
3.34
4767
2730
2.93
4487
2377
2.55
3946
1942
2.08
1.2
5350
3820
4.10
5068
3308
3.55
4742
2881
3.09
4427
2513
2.69
4108
2159
2.32
-
-
-
1.4
5079
3595
3.86
4787
3105
3.33
4452
2713
2.91
4012
2259
2.42
3665
1926
2.07
-
-
-
1.6
4739
3316
3.56
4482
2892
3.10
4098
2474
2.65
-
-
-
-
-
-
-
-
-
1.8
4461
3111
3.34
4070
2621
2.81
-
-
-
-
-
-
-
-
-
-
-
-
2.0
3997
2782
2.98
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Out
(kW)
m3/s
In
(kW)
Out
(kW)
2.36
2.34
2.50
2.00
TABLE 27: BLOWER PERFORMANCE 12-1/2 TON - SIDE DUCT (METRIC)
Turns Open
0
ESP
(Pa)
100
1
m3/s
In
(kW)
Out
(kW)
-
-
-
2
m3/s
In
(kW)
Out
(kW)
2.89
4.17
3.34
3
m3/s
In
(kW)
Out
(kW)
2.79
3.77
3.02
4
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
2.65
3.31
2.65
2.55
2.95
5
149
-
-
-
2.76
3.93
3.15
2.67
3.57
2.85
2.53
3.14
2.51
2.40
2.75
2.20
2.19
2.31
1.85
199
2.77
4.27
3.42
2.63
3.72
2.97
2.55
3.38
2.70
2.40
2.94
2.35
2.28
2.58
2.07
2.05
2.15
1.72
249
2.67
4.09
3.27
2.51
3.52
2.81
2.40
3.12
2.49
2.25
2.73
2.18
2.12
2.38
1.90
1.86
1.94
1.55
299
2.52
3.82
3.06
2.39
3.31
2.65
2.24
2.88
2.30
2.09
2.51
2.01
1.94
2.16
1.73
-
-
-
349
2.40
3.60
2.88
2.26
3.11
2.48
2.10
2.71
2.17
1.89
2.26
1.81
1.73
1.93
1.54
-
-
-
399
2.24
3.32
2.65
2.12
2.89
2.31
1.93
2.47
1.98
-
-
-
-
-
-
-
-
-
448
2.11
3.11
2.49
1.92
2.62
2.10
-
-
-
-
-
-
-
-
-
-
-
498
1.89
2.78
2.23
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Johnson Controls Unitary Products
-
31
127408-XIM-C-1208
TABLE 28: BLOWER PERFORMANCE 7-1/2 TON STANDARD MOTOR - DOWNSHOT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
0.2
3478
2110
2.26
3239
1830
1.96
3044
1640
1.76
2850
1440
1.54
2651
1270
1.36
2423
1120
1.20
0.4
3243
1980
2.12
3001
1720
1.85
2790
1520
1.63
2576
1330
1.43
2370
1170
1.26
2105
1020
1.09
0.6
3006
1830
1.96
2758
1580
1.70
2544
1400
1.50
2303
1230
1.32
2017
1050
1.13
1624
880
0.94
0.8
2758
1720
1.85
2533
1510
1.62
2230
1290
1.38
1891
1080
1.16
–
–
–
–
–
–
1.0
2447
1570
1.68
2182
1350
1.45
1769
1110
1.19
–
–
–
–
–
–
–
–
–
1.2
2085
1410
1.51
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
TABLE 29: BLOWER PERFORMANCE 7-1/2 TON STANDARD MOTOR - DOWNSHOT (METRIC)
Turns Open
ESP
(Pa)
0
1
2
3
4
5
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
50
1.64
2.11
1.68
1.53
1.83
1.46
1.44
1.64
1.39
1.34
1.44
1.15
1.25
1.27
1.01
1.14
1.12
0.89
100
1.53
1.98
1.58
1.42
1.72
1.38
1.32
1.52
1.38
1.22
1.33
1.07
1.12
1.17
0.94
0.99
1.02
0.81
149
1.42
1.83
1.46
1.30
1.58
1.27
1.20
1.40
1.28
1.09
1.23
0.98
0.95
1.05
0.84
0.77
0.88
0.70
199
1.30
1.72
1.38
1.20
1.51
1.21
1.05
1.29
1.17
0.89
1.08
0.91
–
–
–
–
–
–
249
1.15
1.57
1.25
1.03
1.35
1.08
0.83
1.11
1.01
–
–
–
–
–
–
–
–
–
299
0.98
1.41
1.26
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
TABLE 30: BLOWER PERFORMANCE 7-1/2 TON OPTIONAL MOTOR - DOWNSHOT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
0.4
–
–
–
–
–
–
–
–
–
–
–
–
2783
1500
1.61
2507
1300
1.39
0.6
–
–
–
3285
2120
2.27
3047
1860
2.00
2778
1590
1.71
2507
1390
1.49
2209
1180
1.27
0.8
–
–
–
3034
1990
2.13
2799
1730
1.86
2510
1480
1.59
2213
1260
1.35
1846
1050
1.13
1.0
3101
2160
2.32
2796
1860
2.00
2466
1590
1.71
2188
1330
1.43
1721
1090
1.17
–
–
–
1.2
2864
2040
2.19
2489
1710
1.83
2145
1450
1.56
–
–
–
–
–
–
–
–
–
1.4
2524
1860
2.00
2182
1550
1.66
–
–
–
–
–
–
–
–
–
–
–
–
1.6
2189
1680
1.80
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
32
Johnson Controls Unitary Products
127408-XIM-C-1208
TABLE 31: BLOWER PERFORMANCE 7-1/2 TON OPTIONAL MOTOR - DOWNSHOT (METRIC)
Turns Open
ESP
(Pa)
0
1
2
3
4
5
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
100
–
–
–
–
–
–
–
–
–
–
–
–
1.31
1.5
1.20
1.18
1.3
1.04
149
1.67
2.44
1.95
1.55
2.12
1.70
1.44
1.86
1.49
1.31
1.59
1.27
1.18
1.39
1.11
1.04
1.18
0.94
199
1.57
2.31
1.85
1.43
1.99
1.59
1.32
1.73
1.38
1.18
1.48
1.18
1.04
1.26
1.01
0.87
1.05
0.84
249
1.46
2.16
1.73
1.31
1.86
1.49
1.16
1.59
1.27
1.03
1.33
1.06
0.81
1.09
0.87
–
–
–
299
1.35
2.04
1.63
1.17
1.71
1.36
1.01
1.45
1.16
–
–
–
–
–
–
–
–
–
349
1.19
1.86
1.49
1.03
1.55
1.24
–
–
–
–
–
–
–
–
–
–
–
–
399
1.03
1.68
1.34
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
TABLE 32: BLOWER PERFORMANCE 10 TON STANDARD MOTOR - DOWNSHOT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
0.2
4543
2511
2.69
4362
2250
2.41
4139
1996
2.14
3911
1766
1.89
3719
1594
1.71
3518
1407
1.51
0.4
4311
2381
2.55
4115
2127
2.28
3862
1871
2.01
3611
1644
1.76
3386
1471
1.58
3153
1293
1.39
0.6
4032
2232
2.39
3804
1982
2.13
3508
1720
1.84
3246
1506
1.61
2971
1332
1.43
-
-
-
0.8
3706
2068
2.22
3428
1818
1.95
3078
1548
1.66
-
-
-
-
-
-
-
-
-
1.0
3333
1892
2.03
2989
1644
1.76
-
-
-
-
-
-
-
-
-
-
-
-
1.2
2914
1711
1.83
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TABLE 33: BLOWER PERFORMANCE 10 TON STANDARD MOTOR - DOWNSHOT (METRIC)
Turns Open
ESP
(Pa)
0
1
2
3
4
5
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
50
2.14
2.51
2.01
2.06
2.25
1.80
1.95
2.00
1.60
1.85
1.77
1.41
1.75
1.59
1.27
1.66
1.41
1.13
100
2.03
2.38
1.91
1.94
2.13
1.70
1.82
1.87
1.50
1.70
1.64
1.31
1.60
1.47
1.18
1.49
1.29
1.03
149
1.90
2.23
1.79
1.80
1.98
1.59
1.66
1.72
1.38
1.53
1.51
1.20
1.40
1.33
1.07
-
-
-
199
1.75
2.07
1.65
1.62
1.82
1.45
1.45
1.55
1.24
-
-
-
-
-
-
-
-
-
249
1.57
1.89
1.51
1.41
1.64
1.32
-
-
-
-
-
-
-
-
-
-
-
-
299
1.38
1.71
1.37
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Johnson Controls Unitary Products
33
127408-XIM-C-1208
TABLE 34: BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR - DOWNSHOT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
0.2
-
-
-
-
-
-
-
-
-
-
-
-
4966
2666
2.86
4605
2290
2.46
0.4
-
-
-
-
-
-
-
-
-
4919
2473
2.65
4721
2515
2.70
4344
2145
2.30
0.6
-
-
-
-
-
-
4929
3022
3.24
4665
2324
2.49
4450
2353
2.52
4048
1991
2.13
0.8
-
-
-
4908
3197
3.43
4668
2841
3.05
4391
2171
2.33
4151
2183
2.34
3717
1829
1.96
1.0
4915
3456
3.71
4651
3013
3.23
4388
2656
2.85
4096
2015
2.16
3825
2008
2.15
3352
1664
1.78
1.2
4653
3253
3.49
4377
2823
3.03
4089
2467
2.65
3779
1858
1.99
3471
1830
1.96
2951
1499
1.61
1.4
4372
3046
3.27
4087
2631
2.82
3771
2277
2.44
3442
1703
1.83
3090
1652
1.77
-
-
-
1.6
4070
2837
3.04
3780
2437
2.61
3434
2089
2.24
3084
1552
1.66
-
-
-
-
-
-
1.8
3748
2629
2.82
3455
2243
2.41
3078
1904
2.04
-
-
-
-
-
-
-
-
-
2.0
3406
2425
2.60
3114
2051
2.20
-
-
-
-
-
-
-
-
-
-
-
-
2.2
3044
2228
2.39
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TABLE 35: BLOWER PERFORMANCE 10 TON OPTIONAL MOTOR - DOWNSHOT (METRIC)
Turns Open
ESP
(Pa)
0
1
2
3
4
5
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
50
-
-
-
-
-
-
-
-
-
-
-
-
2.34
2.67
2.13
2.17
2.29
1.83
100
-
-
-
-
-
-
-
-
-
2.32
2.47
1.98
2.23
2.51
2.01
2.05
2.15
1.72
149
-
-
-
-
-
-
2.33
3.02
2.42
2.20
2.32
1.86
2.10
2.35
1.88
1.91
1.99
1.59
199
-
-
-
2.32
3.20
2.56
2.20
2.84
2.27
2.07
2.17
1.74
1.96
2.18
1.75
1.75
1.83
1.46
249
2.32
3.46
2.76
2.20
3.01
2.41
2.07
2.66
2.12
1.93
2.01
1.61
1.81
2.01
1.61
1.58
1.66
1.33
299
2.20
3.25
2.60
2.07
2.82
2.26
1.93
2.47
1.97
1.78
1.86
1.49
1.64
1.83
1.46
1.39
1.50
1.20
349
2.06
3.05
2.44
1.93
2.63
2.10
1.78
2.28
1.82
1.62
1.70
1.36
1.46
1.65
1.32
-
-
-
399
1.92
2.84
2.27
1.78
2.44
1.95
1.62
2.09
1.67
1.46
1.55
1.24
-
-
-
-
-
-
448
1.77
2.63
2.10
1.63
2.24
1.79
1.45
1.90
1.52
-
-
-
-
-
-
-
-
-
498
1.61
2.43
1.94
1.47
2.05
1.64
-
-
-
-
-
-
-
-
-
-
-
-
548
1.44
2.23
1.78
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
34
Johnson Controls Unitary Products
127408-XIM-C-1208
TABLE 36: BLOWER PERFORMANCE 12-1/2 TON - DOWNSHOT (IMPERIAL)
Turns Open
ESP
(iwg)
0
1
2
3
4
5
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
CFM
Watts
BHP
0.4
5576
4015
4.32
5370
3547
3.80
5171
3197
3.43
5007
2884
3.09
4721
2515
2.70
4344
2145
2.30
0.6
5376
3839
4.12
5147
3376
3.62
4929
3022
3.24
4735
2704
2.90
4450
2353
2.52
4048
1991
2.13
0.8
5155
3652
3.92
4908
3197
3.43
4668
2841
3.05
4411
2501
2.68
4151
2183
2.34
3717
1829
1.96
1.0
4915
3456
3.71
4651
3013
3.23
4388
2656
2.85
4035
2281
2.45
3825
2008
2.15
-
-
-
1.2
4653
3253
3.49
4377
2823
3.03
4089
2467
2.65
3608
2051
2.20
-
-
-
-
-
-
1.4
4372
3046
3.27
4087
3621
2.82
3771
2277
2.44
-
-
-
-
-
-
-
-
-
1.6
4070
2837
3.04
3780
2437
2.61
-
-
-
-
-
-
-
-
-
-
-
-
1.8
3748
2629
2.82
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TABLE 37: BLOWER PERFORMANCE 12-1/2 TON - DOWNSHOT (METRIC)
Turns Open
ESP
(Pa)
0
1
2
3
4
5
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
m3/s
In
(kW)
Out
(kW)
100
2.63
4.01
3.21
2.53
3.55
2.84
2.44
3.20
2.56
2.36
2.88
2.31
2.23
2.51
2.01
2.05
2.15
1.72
149
2.54
3.84
3.07
2.43
3.38
2.70
2.33
3.02
2.42
2.23
2.70
2.16
2.10
2.35
1.88
1.91
1.99
1.59
199
2.43
3.65
2.92
2.32
3.20
2.56
2.20
2.84
2.27
2.08
2.50
2.00
1.96
2.18
1.75
1.75
1.83
1.46
249
2.32
3.46
2.76
2.20
3.01
2.41
2.07
2.66
2.12
1.90
2.28
1.83
1.81
2.01
1.61
-
-
-
299
2.20
3.25
2.60
2.07
2.82
2.26
1.93
2.47
1.97
1.70
2.05
1.64
-
-
-
-
-
-
349
2.06
3.05
2.44
1.93
2.63
2.10
1.78
2.28
1.82
-
-
-
-
-
-
-
-
-
399
1.92
2.84
2.27
1.78
2.44
1.95
-
-
-
-
-
-
-
-
-
-
-
-
448
1.77
2.63
2.10
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
NOTES FOR TABLE 18 THROUGH TABLE 37:
•
•
Blower performance includes dry coil and two-inch
filters.
Blower performance for gas heat includes the maximum
number of heat tubes available for each tonnage.
•
ESP (External Static Pressure) given is that available for
the supply and return air duct system. All internal resistances have been deducted from the total static pressure
of the blower.
•
TABLE 38: INDOOR BLOWER SPECIFICATIONS
MOTOR
MOTOR SHEAVE
BLOWER SHEAVE
MODEL
BELT
HP
RPM
Eff.
SF
Frame
Datum Dia. (in.)
Bore (in.)
Model
Datum Dia. (in.)
Bore (in.)
Model
3
1725
80%
1.15
56
3.4 - 4.4
7/8
1VM50
5.5
1
AK59
A49
3
1725
80%
1.15
56
3.4 - 4.4
7/8
1VM50
5.0
1
AK54
A47
2
1725
80%
1.15
56
3.4 - 4.4
7/8
1VM50
7
1
AK74
A54
4
1725
80%
1.15
184T
4.3 - 5.3
1-1/8
1VP56
6.2
1
BK72
BX56
4
1725
87%
1.15
184T
4.3 - 5.3
1-1/8
1VP56
6.2
1
BK72
BX56
DM090
DM120
DM150
Johnson Controls Unitary Products
35
127408-XIM-C-1208
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.
Belt drive blower systems MUST be adjusted to the
specific static and CFM requirements for the application. The Belt drive blowers are NOT set at the
factory for any specific static or CFM. Adjustments of
the blower speed and belt tension are REQUIRED.
Tighten blower pulley and motor sheave set screws
after these adjustments. Re-checking set screws
after 10-12 hrs. run time is recommended.
36
Johnson Controls Unitary Products
127408-XIM-C-1208
CHECKING AIR QUANTITY
METHOD ONE
1.
Remove the dot plugs from the duct panel (for location of
the dot plugs see Figure 10).
2.
Insert eight-inches of 1/4 inch metal tubing into the airflow on both sides of the indoor coil.
NOTE: The tubes must be inserted and held in a position
perpendicular to the air flow so that velocity pressure will not affect the static pressure readings.
3.
Use an Inclined Manometer or Magnehelic to determine
the pressure drop across a dry evaporator coil. Since the
moisture on an evaporator coil can vary greatly, measuring the pressure drop across a wet coil under field conditions could be inaccurate. To assure a dry coil, the
compressors should be de-activated while the test is
being run.
METHOD TWO
1.
Drill two 5/16 inch holes, one in the return air duct as
close to the inlet of the unit as possible, and another in
the supply air duct as close to the outlet of the unit as
possible.
2.
Using the whole drilled in step 1, insert eight inches of
1/4 inch metal tubing into the airflow of the return and
supply air ducts of the unit.
NOTE: The tubes must be inserted and held in position perpendicular to the airflow so that velocity pressure
will not affect the static pressure readings.
3.
Use an Inclined Manometer or Magnehelic to determine
the pressure drop across the unit. This is the External
Static Pressure (ESP). In order to obtain an accurate
measurement, be certain that the air filters are clean.
4.
Determine the number of turns the variable motor
sheave is open.
5.
Select the correct blower performance table for the unit
from Tables 18 - 37. Tables are presented for horizontal
and downflow configuration.
6.
To adjust Measured CFM to Required CFM, see ’SUPPLY AIR DRIVE ADJUSTMENT’.
Determine the unit Measured CFM from the Blower Performance Table, External Static Pressure and the number of turns the variable motor sheave is open.
7.
To adjust Measured CFM to Required CFM, see ’SUPPLY AIR DRIVE ADJUSTMENT’.
6.
After readings have been obtained, remove the tubes
and replace the dot plugs.
8.
After reading has been obtained, remove the tubes and
seal holes.
7.
Tighten blower pulley and motor sheave set screws after
any adjustments. Re-check set screws after 10-12 hrs.
run time is recommended.
9.
Tighten blower pulley and motor sheave set screws after
any adjustments. Re-check set screws after 10-12 hrs.
run time is recommended.
NOTE: De-energize the compressors before taking any test
measurements to assure a dry evaporator coil.
4.
5.
The CFM through the unit can be determined from the
pressure drop indicated by the manometer by referring to
Figure 26. In order to obtain an accurate measurement,
be certain that the air filters are clean.
NOTE: With the addition of field installed accessories
repeat this procedure.
Failure to properly adjust the total system air quantity can result in extensive blower damage.
Failure to properly adjust the total system air quantity can result in extensive blower damage.
Johnson Controls Unitary Products
37
127408-XIM-C-1208
PREDATOR® 50” CABINET, 50 HZ UNITS
INDOOR COIL PRESSURE DROP VS AIRFLOW
0.9
0.8
Dry Coil Delta P (IWG)
0.7
DM 150
0.6
0.5
0.4
DM 120
0.3
0.2
0.1
0
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
Airflow (CFM)
FIGURE 26 - DRY COIL DELTA P 50" CABINET
PREDATOR® 42" CABINET, 50 HZ UNITS
INDOOR COIL PRESSURE DROP VS AIRFLOW
0.55
DM 090
0.5
Dry Coil Delta P (IWG)
0.45
0.4
0.35
0.3
0.25
0.2
2000
2500
3000
3500
4000
4500
Airflow (CFM)
FIGURE 27 - DRY COIL DELTA P 42" CABINET
38
Johnson Controls Unitary Products
127408-XIM-C-1208
SUPPLY AIR DRIVE ADJUSTMENT
EXAMPLE
A 12.5 ton unit was selected to deliver 4,000 CFM with a 3
HP motor, but the unit is delivering 3,800 CFM. The variable
pitch motor sheave is set at 2 turns open.
Before making any blower speed changes review
the installation for any installation errors, leaks or
undesirable systems effects that can result in loss of
airflow.
Even small changes in blower speed can result in
substantial changes in static pressure and BHP.
BHP and AMP draw of the blower motor will
increase by the cube of the blower speed. Static
pressure will increase by the square of the blower
speed. Only qualified personnel should make blower
speed changes, strictly adhering to the fan laws.
Use the equation to determine the required DD for the new
motor sheave.
CFM
• 4.0 in. = 4.21 in.
( 4,000
3,750 CFM )
Use Table 43 to locate the DD nearest to 4.21 in. Close the
sheave to 1 turn open.
New BHP
3
= (Speed increase) • BHP at 3,800 CFM
3
= (Speed increase) • Original BHP
At unit start-up, the measured CFM may be higher or lower
than the required CFM. To achieve the required CFM, the
speed of the drive may have adjusted by changing the datum
diameter (DD) of the variable pitch motor sheave as
described below:
= New BHP
New motor Amps
3
(
)
Required CFM
Measured CFM
= (Speed increase) • Amps at 3,800 CFM
• Existing DD = New DD
Use the following tables and the DD calculated per the above
equation to adjust the motor variable pitch sheave.
3
= (Speed increase) • Original Amps
= New Amps
Belt drive blower systems MUST be adjusted to the
specific static and CFM requirements for the application. The Belt drive blowers are NOT set at the
factory for any specific static or CFM. Adjustments of
the blower speed and belt tension are REQUIRED.
Tighten blower pulley and motor sheave set screws
after these adjustments. Re-checking set screws
after 10-12 hrs. run time is recommended.
Johnson Controls Unitary Products
39
127408-XIM-C-1208
TABLE 39: ADDITIONAL STATIC RESISTANCE 50” CABINET (IMPERIAL)
Cooling Only*
Economizer† ‡
1900
0.06
2100
0.07
2300
CFM
Electric Heat KW†
9
18
24
36
54
0.02
0.05
0.06
0.07
0.08
0.10
0.02
0.06
0.07
0.08
0.09
0.11
0.08
0.02
0.07
0.08
0.09
0.10
0.13
2500
0.09
0.02
0.08
0.09
0.10
0.11
0.14
2700
0.11
0.03
0.09
0.10
0.12
0.13
0.16
2900
0.12
0.03
0.10
0.11
0.13
0.14
0.18
3100
0.14
0.03
0.12
0.13
0.15
0.16
0.20
3300
0.16
0.03
0.13
0.14
0.17
0.18
0.22
3500
0.18
0.04
0.15
0.16
0.19
0.20
0.24
3700
0.20
0.04
0.17
0.18
0.21
0.22
0.26
3900
0.23
0.04
0.19
0.20
0.23
0.24
0.28
4100
0.25
0.04
0.21
0.22
0.25
0.26
0.31
4300
0.28
0.05
0.23
0.24
0.28
0.29
0.34
4500
0.30
0.05
0.25
0.26
0.30
0.31
0.37
4700
0.33
0.05
0.28
0.29
0.33
0.34
0.40
4900
0.36
0.05
0.30
0.31
0.35
0.37
0.43
5100
0.39
0.06
0.33
0.34
0.38
0.40
0.46
5300
0.42
0.06
0.35
0.37
0.41
0.43
0.49
5500
0.45
0.06
0.38
0.40
0.44
0.46
0.53
5700
0.48
0.06
0.41
0.43
0.47
0.49
0.56
5900
0.52
0.07
0.44
0.46
0.50
0.53
0.59
6100
0.56
0.07
0.47
0.49
0.53
0.56
0.62
6300
0.60
0.07
0.50
0.53
0.56
0.59
0.65
*.
Add these resistance values to the available static resistance in the respective Blower Performance Tables.
†.
Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.
‡.
The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return
air duct system is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation.
TABLE 40: ADDITIONAL STATIC RESISTANCE 42” CABINET (IMPERIAL)
40
CFM
Cooling Only*
Economizer† ‡
1900
-0.004
0.07
2100
0.01
0.09
2300
0.01
0.11
2500
0.02
0.13
2700
0.03
0.16
2900
0.04
0.18
3100
0.05
0.20
3300
0.06
0.22
3500
0.07
0.24
3700
0.08
0.27
3900
0.09
0.29
4100
0.09
0.31
4300
0.10
0.33
*.
Add these resistance values to the available static resistance in the respective Blower Performance Tables.
†.
Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.
‡.
The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return
air duct system is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation.
Johnson Controls Unitary Products
127408-XIM-C-1208
TABLE 41: ADDITIONAL STATIC RESISTANCE 50” CABINET (METRIC)
M3S
Cooling Only*
Electric Heat kW†
Economizer† ‡
9
18
24
36
54
0.89
14.9
5.0
12.4
14.9
17.4
19.9
24.8
0.99
17.4
5.0
14.9
17.4
19.9
22.4
27.3
1.08
19.9
5.0
17.4
19.9
22.4
24.8
32.3
1.18
22.4
5.0
19.9
22.4
24.8
27.3
34.8
1.27
27.3
7.5
22.4
24.8
29.8
32.3
39.7
1.36
29.8
7.5
24.8
27.3
32.3
34.8
44.7
1.46
34.8
7.5
29.8
32.3
37.3
39.7
49.7
1.55
39.7
7.5
32.3
34.8
42.2
44.7
54.6
1.65
44.7
9.9
37.3
39.7
47.2
49.7
59.6
1.74
49.7
9.9
42.2
44.7
52.2
49.7
64.6
1.83
57.1
9.9
47.2
49.7
57.1
59.6
69.5
1.93
62.1
9.9
52.2
54.6
62.1
64.6
77.0
1.02
69.5
12.4
57.1
59.6
69.5
72.0
84.4
2.12
74.5
12.4
62.1
64.6
74.5
77.0
91.9
2.21
82.0
12.4
69.5
72.0
82.0
84.4
99.3
2.30
89.4
12.4
74.5
77.0
86.9
91.9
106.8
2.40
96.9
14.9
82.0
84.4
94.4
99.3
114.2
2.49
104.3
14.9
86.9
91.9
101.8
106.8
121.7
2.59
111.8
14.9
94.4
99.3
109.3
114.2
131.6
2.68
119.2
14.9
101.8
106.8
116.7
121.7
139.1
2.77
129.1
17.4
109.3
114.2
124.2
131.6
146.5
2.87
139.1
17.4
116.7
121.7
131.6
139.1
154.0
2.96
149.0
17.4
124.2
131.6
139.1
146.5
161.4
*.
Add these resistance values to the available static resistance in the respective Blower Performance Tables.
†.
Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.
‡.
The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return
air duct system is less than 62.1 Pa, the unit will deliver less M3S during full economizer operation.
TABLE 42: ADDITIONAL STATIC RESISTANCE 42” CABINET (METRIC)
CFM
Cooling Only*
Economizer† ‡
0.9
-0.99
17.40
0.99
2.50
22.40
1.09
2.50
27.40
1.18
4.98
32.40
1.27
7.50
39.90
1.37
10.00
44.83
1.46
12.50
49.81
1.56
14.90
54.80
1.65
17.40
59.80
1.75
19.90
67.20
1.84
22.40
72.20
1.93
22.40
77.20
2.03
24.90
82.20
*.
Add these resistance values to the available static resistance in the respective Blower Performance Tables.
†.
Deduct these resistance values from the available external static pressure shown in the respective Blower Performance Table.
‡.
The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return
air duct system is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation.
Johnson Controls Unitary Products
41
127408-XIM-C-1208
TABLE 43: MOTOR SHEAVE DATUM
1VM50x7/8
(1-1/2, 2 & 3 HP Motor)
42
1VP56x1-1/8
(5 HP Motor)
Turns Open
Datum Dia.
in.(mm.)
Turns Open
Datum Dia.
in.(mm.)
0
4.4 (111.7)
1
5.3 (134.6)
1/2
4.3 (109.2)
1-1/2
5.2 (132)
1
4.2 (106.6)
2
5.1 (129.5)
1-1/2
4.1 (104.1)
2-1/2
5.0 (127)
2
4.0 (101.6)
3
4.9 (124.4)
2-1/2
3.9 (99)
3-1/2
4.8 (121.9)
3
3.8 (96.5)
4
4.7 (119.3)
3-1/2
3.7 (94)
4-1/2
4.6 (116.8)
4
3.6 (91.4)
5
4.5 (114.3)
4-1/2
3.5 (88.9)
5-1/2
4.4 (111.7)
5
3.4 (86.3)
6
4.3 (109.2)
Johnson Controls Unitary Products
127408-XIM-C-1208
OPERATION
second stage of cooling continues for 20 minutes, compressor #2 is energized, provided it has not been locked-out.
SEQUENCE OF OPERATIONS OVERVIEW
If there is an initial call for both stages of cooling, the UCB will
delay energizing compressor #2 by 30 seconds in order to
avoid a power rush.
For the Predator® series of units, the thermostat makes a circuit between "R" and "Y1" for the first stage of cooling.
The call is passed to the Unit Control Board (UCB), which
then determines whether the requested operation is available
and, if so, which components to energize.
For gas heating, the UCB monitors the "W1" call but does not
handle the operation of the gas furnace. An ignition control
board controls the gas heater operation. For electric heat
units, the UCB passes the call to the electric heater. In both
cases, when the "W1" call is sensed, the indoor air blower is
energized following a specified heating delay.
If at any time a call for both heating and cooling are present,
the heating operation will be performed. If operating, the cooling system is halted as with a completion of a call for cooling.
Heating always takes priority.
COOLING SEQUENCE OF OPERATION
CONTINUOUS BLOWER
By setting the room thermostat fan switch to "ON," the supply
air blower will operate continuously.
INTERMITTENT BLOWER
With the room thermostat fan switch set to "AUTO" and the
system switch set to either the "AUTO" or "HEAT" settings,
the blower is energized whenever a cooling or heating operation is requested. The blower is energized after any specified
delay associated with the operation.
When energized, the indoor blower has a minimum run time
of 30 seconds. Additionally, the indoor blower has a delay of
10 seconds between operations.
NO OUTDOOR AIR OPTIONS
When the thermostat calls for the first stage of cooling, the
low-voltage control circuit from “R” to “Y1” and “G” is completed. The UCB energizes the economizer (if installed and
free cooling is available) or the first available compressor*
and the condenser fans. For first stage cooling, compressor
#1 is energized. If compressor #1 is unavailable, compressor
#2 is energized. After completing the specified fan on delay
for cooling, the UCB will energize the blower motor.
When the thermostat calls for the second stage of cooling,
the low-voltage control circuit from “R” to “Y2” is completed.
The control board energizes the first available compressor. If
free cooling is being used for the first stage of cooling, compressor #1 is energized. If compressor #1 is active for first
stage cooling or the first compressor is locked-out, compressor #2 is energized. In free-cooling mode, if the call for the
Johnson Controls Unitary Products
Once the thermostat has been satisfied, it will de-energize Y1
and Y2. If the compressors have satisfied their minimum run
times, the compressors and condenser fans are de-energized. Otherwise, the unit operates each cooling system until
the minimum run times for the compressors have been completed. Upon the final compressor de-energizing, the blower
is stopped following the elapse of the fan off delay for cooling.
* To be available, a compressor must not be locked-out due
to a high or low-pressure switch or freezestat trip and the
Anti-Short Cycle Delay (ASCD) must have elapsed.
ECONOMIZER WITH SINGLE ENTHALPY SENSOR When the room thermostat calls for "first-stage" cooling, the
low voltage control circuit from "R" to "G" and "Y1" is completed. The UCB energizes the blower motor (if the fan switch
on the room thermostat is set in the "AUTO" position) and
drives the economizer dampers from fully closed to their minimum position. If the enthalpy of the outdoor air is below the
set point of the enthalpy controller (previously determined),
"Y1" energizes the economizer. The dampers will modulate to
maintain a constant supply air temperature as monitored by
the discharge air sensor. If the outdoor air enthalpy is above
the set point, "Y1" energizes compressor #1.
When the thermostat calls for "second-stage" cooling, the low
voltage control circuit from "R" to "Y2" is completed. The UCB
energizes the first available compressor. If the enthalpy of the
outdoor air is below the set point of the enthalpy controller
(i.e. first stage has energized the economizer), "Y2" will energize compressor #1. If the outdoor air is above the set point,
"Y2" will energize compressor #2.
Once the thermostat has been satisfied, it will de-energize
“Y1” and “Y2”. If the compressors have satisfied their minimum run times, the compressors and condenser fans are deenergized. Otherwise, the unit operates each cooling system
until the minimum run times for the compressors have been
completed. Upon the final compressor de-energizing, the
blower is stopped following the elapse of the fan off delay for
cooling, and the economizer damper goes to the closed position. If the unit is in continues fan operation, the economizer
damper goes to the minimum position.
ECONOMIZER WITH DUAL ENTHALPY SENSORS The operation with the dual enthalpy sensors is identical to
the single sensor except that a second enthalpy sensor is
mounted in the return air. This return air sensor allows the
economizer to choose between outdoor air and return air,
whichever has the lowest enthalpy value, to provide maximum operating efficiency.
43
127408-XIM-C-1208
ECONOMIZER WITH POWER EXHAUST A unit equipped with an economizer (single or dual enthalpy)
and a power exhaust operates as specified above with one
addition. The power exhaust motor is energized 45 seconds
after the actuator position exceeds the exhaust fan set point
on the economizer control. When the power exhaust is operating, the second stage of mechanical cooling will not operate. As always, the "R" to "G" connection provides minimum
position but does not provide power exhaust operation.
MOTORIZED OUTDOOR AIR DAMPERS This system operation is the same as the units with no outdoor air options with one exception. When the "R" to "G" circuit is complete, the motorized damper drives open to a
position set by the thumbwheel on the damper motor. When
the "R" to "G" circuit is opened, the damper spring returns
fully closed.
COOLING OPERATION ERRORS
Each cooling system is monitored for operation outside of the
intended parameters. Errors are handled as described below.
All system errors override minimum run times for compressors.
HIGH-PRESSURE LIMIT SWITCH
During cooling operation, if a high-pressure limit switch
opens, the UCB will de-energize the associated compressor,
initiate the ASCD (Anti-short cycle delay), and, if the other
compressor is idle, stop the condenser fans. If the call for
cooling is still present at the conclusion of the ASCD, the
UCB will re-energize the halted compressor.
Should a high-pressure switch open three times within two
hours of operation, the UCB will lock-out the associated compressor and flash a code (see Table 52). If the other compressor is inactive, the condenser fans will be de-energized.
LOW-PRESSURE LIMIT SWITCH
The low-pressure limit switch is not monitored during the initial 30 seconds of a cooling system's operation. For the following 30 seconds, the UCB will monitor the low-pressure
switch to ensure it closes. If the low-pressure switch fails to
close after the 30-second monitoring phase, the UCB will deenergize the associated compressor, initiate the ASCD, and,
if the other compressor is idle, stop the condenser fans.
Once the low-pressure switch has been proven (closed during the 30-second monitor period described above), the UCB
will monitor the low-pressure limit switch for any openings. If
the low-pressure switch opens for greater than 5 seconds,
the UCB will de-energize the associated compressor, initiate
the ASCD, and, if the other compressor is idle, stop the condenser fans.
If the call for cooling is still present at the conclusion of the
ASCD, the UCB will re-energize the halted compressor.
44
Should a low-pressure switch open three times within one
hour of operation, the UCB will lock-out the associated compressor and flash a code (Table 52). If the other compressor
is inactive, the condenser fans will be de-energized.
FREEZESTAT
During cooling operation, if a freezestat opens, the UCB will
de-energize the associated compressor, initiate the ASCD,
and, if the other compressor is idle, stop the condenser fans.
If the call for cooling is still present at the conclusion of the
ASCD, the UCB will re-energize the halted compressor.
Should a freezestat open three times within two hours of
operation, the UCB will lock-out the associated compressor
and flash a code (Table 52). If the other compressor is inactive, the condenser fans will be de-energized.
LOW AMBIENT COOLING
To determine when to operate in low ambient mode, the UCB
has a pair of terminals connected to a temperature-activated
switch set at 45ºF. When the low ambient switch is closed
and the thermostat is calling for cooling, the UCB will operate
in the low ambient mode.
Low ambient mode operates the compressors in this manner:
10 minutes on, 5 minutes off. The indoor blower is operated
throughout the cycle. The 5-minute off period is necessary to
defrost the indoor coil.
Low ambient mode always begins with compressor operation. Compressor minimum run time may extend the minutes
of compressor operation. The defrost cycle will begin immediately following the elapse of the minimum run time.
When operating in low ambient mode, the UCB will not lockout the compressors due to a freezestat trip. However, a
freezestat trip will de-energize the associated compressor. If
the call for cooling is still present at the end of the ASCD and
the freezestat has closed, the unit will resume operation.
SAFETY CONTROLS
The unit control board monitors the following inputs for each
cooling system:
1.
A suction line freezestat to protect against low evaporator temperatures due to a low airflow or a low return air
temperature, (opens at 26 ± 5 °F and resets at 38 ± 5°F).
2.
A high-pressure switch to protect against excessive discharge pressures due to a blocked condenser coil or a
condenser motor failure, (opens at 405 ± 10 psig or 440
± 10 psig depending on unit model).
3.
A low-pressure switch to protect against loss of refrigerant charge, (opens at 22 ± 5 psig or 45 ± 5 psig).
The above pressure switches are hard-soldered to the unit.
The refrigeration systems are independently monitored and
controlled. On any fault, only the associated system will be
Johnson Controls Unitary Products
127408-XIM-C-1208
affected by any safety/preventive action. The other refrigerant
system will continue in operation unless it is affected by the
fault as well.
If the temperature limit opens three times within one hour, it
will lock-on the indoor blower motor and a flash code is initiated (See Table 52).
The unit control board monitors the temperature limit switch
of electric heat units and the temperature limit switch and the
gas valve of gas furnace units.
SAFETY CONTROLS
COMPRESSOR PROTECTION
In addition to the external pressure switches, the compressors
also have inherent (internal) protection. If there is an abnormal
temperature rise in a compressor, the protector will open to shut
down the compressor. The UCB incorporates features to minimize compressor wear and damage. An Anti-Short Cycle
Delay (ASCD) is utilized to prevent operation of a compressor
too soon after its previous run. Additionally, a minimum run time
is imposed any time a compressor is energized.
The ASCD is initiated on unit start-up and on any compressor
reset or lock-out.
FLASH CODES
The UCB monitors the temperature limit switch of electric
heat units.
The control circuit includes the following safety controls:
LIMIT SWITCH (LS)
This control is located inside the heater compartment and is
set to open at the temperature indicated in the Electric Heat
Limit Setting Table 44. It resets automatically. The limit switch
operates when a high temperature condition, caused by inadequate supply air flow occurs, thus shutting down the heater
and energizing the blower.
TABLE 44: ELECTRIC HEAT LIMIT SETTING
UNIT (TONS)
The UCB will initiate a flash code associated with errors
within the system. Refer to UNIT CONTROL BOARD FLASH
CODES Table 52.
VOLTAGE
HEATER
kW
LIMIT SWITCH
OPENS °F
18
150
24
150
34
150
54
130
10, 12.5
10, 12.5
10, 12.5
RESET
380/415
10, 12.5
Remove the call for cooling, by raising thermostat setting
higher than the conditioned space temperature. This resets
any pressure or freezestat flash codes.
ELECTRIC HEATING SEQUENCE OF OPERATIONS
The following sequence describes the operation of the electric heat section.
Two-stage heating:
a.
b.
Upon a call for first stage heat by the thermostat, the
heater relay (RA) will be energized. After completing
the specified fan on delay for heating, the UCB will
energize the blower motor. If the second stage of
heat is required, heater relay (RB) will be energized.
After completing the specified fan on delay for heating, the UCB will energize the blower motor.
The thermostat will cycle the electric heat to satisfy
the heating requirements of the conditioned space.
ELECTRIC HEAT OPERATION ERRORS
TEMPERATURE LIMIT
FLASH CODES
The UCB will initiate a flash code associated with errors
within the system. Refer to UNIT CONTROL BOARD FLASH
CODES Table 52.
RESET
Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature.This
resets any flash codes.
ELECTRIC HEAT ANTICIPATOR SETPOINTS
It is important that the anticipator setpoint be correct. Too
high of a setting will result in longer heat cycles and a greater
temperature swing in the conditioned space. Reducing the
value below the correct setpoint will give shorter “ON” cycles
and may result in the lowering of the temperature within the
conditioned space. Refer to Table 45 for the required electric
heat anticipator setting.
TABLE 45: ELECTRIC HEAT ANTICIPATOR
SETPOINTS
If the UCB senses zero volts from the high temperature limit,
the indoor blower motor is immediately energized.
This limit is monitored regardless of unit operation status, i.e.
the limit is monitored at all times.
Johnson Controls Unitary Products
SETTING, AMPS
W1
W2
0.13
0.1
45
127408-XIM-C-1208
GAS HEATING SEQUENCE OF OPERATIONS
RECYCLE OPERATION
When the thermostat calls for the first stage of heating, the
low-voltage control circuit from “R” to “W1” is completed. A
call for heat passes through the UCB to the Ignition Control
Board (ICB). The UCB monitors the “W1” call and acts upon
any call for heat by monitoring the Gas Valve (GV). Once
voltage has been sensed at the GV, the UCB will initiate the
fan on delay for heating, energizing the indoor blower the
specified delay has elapsed.
When a flame is lost after the flame stabilization period, a
recycle operation occurs. If the unit fails after five recycle
attempts, the furnace is locked-out for one hour.
GAS HEATING OPERATION ERRORS
LOCK-OUT
When the thermostat has been satisfied, heating calls are
ceased. The GV is immediately closed. The blower is deenergized after the fan off delay for heating has elapsed. The
draft motor performs a 30-second post purge.
A one-hour lockout occurs following three retries or five recycles. During the one-hour lockout, flame detection, limit conditions, and main valves are tested. Any improper results will
cause the appropriate action to occur. Recycling the low voltage power cancels the lock-out.
IGNITION CONTROL BOARD
TEMPERATURE LIMIT
FIRST STAGE OF HEATING
If the UCB senses zero volts from the high temperature limit,
the indoor blower motor is immediately energized. When the
UCB again senses 24 volts from the temperature limit, the
draft motor will perform a 15-second post-purge and the
indoor blower will be de-energized following the elapse of the
fan off delay for heating.
When the ICB receives a call for first stage of heating, “W1,” the
draft motor is energized. Once the draft motor has been proven,
a 30-second purge is initiated. At the end of the purge, the GV
is opened, and the spark ignitor is energized for 10 seconds.
The ICB then checks for the presence of flame. If flame is
detected, the ICB enters a flame stabilization period. If flame
was not detected, the GV closes, and a retry operation begins.
This limit is monitored regardless of unit operation status, i.e.
this limit is monitored at all times.
During the flame stabilization period, a loss of the flame for 2
seconds will cause the GV to close and the retry operation to
begin. After the flame stabilization period, a loss of flame for
3/4 second will cause the GV to close and the retry operation
to begin.
If the temperature limit opens three times within one hour, it
will lock-on the indoor blower motor and flash code is initiated
(See Table 52).
At the conclusion of the flame stabilization period, the ICB will
operate the gas heat in high fire for an additional 60 seconds
(for a total for 120 seconds of high fire operation). After this
60 seconds, the ICB will then use the call for the second
stage of heat to control second stage operation of the GV.
Flame sensing occurs at all times. If “W1” is not present and
a flame is sensed for 2 seconds, the draft motor is energized
and the GV is kept off. The ICB halts any operation until a
flame is not detected. Once the flame detection is lost, the
ICB performs a post-purge. Normal operation is allowed concurrently with the purge (i.e. this purge can be considered the
purge associated with a call for “W1”).
When “W1” is satisfied, both valves are closed.
SECOND STAGE OF HEATING
When the ICB receives a call for the second stage of heating,
“W2,” the ICB conducts a complete first stage ignition
sequence. If this sequence is satisfied, the second main
valve of the GV is opened.
When “W2” is satisfied, the second main valve is closed.
RETRY OPERATION
FLAME SENSE
If “W1” is present, a flame is sensed, but the GV is not energized, the draft motor is energized until the flame detection is
lost. Normal operation is now allowed.
The flame detection circuitry continually tests itself. If the ICB
finds the flame detection circuitry to be faulty, the ICB will not
permit an ignition sequence and the draft motor is energized.
If this failure should occur during an ignition cycle the failure
is counted as a recycle.
When a flame is lost or is not detected during an attempt to
achieve ignition, a retry operation occurs. A 30-second purge
is performed between ignition attempts.
GAS VALVE
If the unit fails after three ignition attempts, the furnace is
locked-out for one hour. The furnace is monitored during this
one-hour period for unsafe conditions.
If the ICB senses voltage at the GV when not requested, the
ICB will energize the draft motor. The ICB will not operate the
furnace until voltage is no longer sensed at the GV. The draft
motor is stopped when voltage is not sensed at the GV.
46
The UCB and ICB continuously monitor the GV.
Johnson Controls Unitary Products
127408-XIM-C-1208
Any time the UCB senses voltage at the GV without a call for
heat for a continuous five-minute period, the UCB will lock-on
the indoor blower and a flash code is initiated (Table 52).
When voltage is no longer sensed at the GV, the UCB will deenergize the indoor blower following the elapse of the fan off
delay for heating.
If voltage has been sensed at the GV for at least 15 seconds
during the fan on delay for heating and GV voltage or “W1” is
lost, the indoor blower is forced on for the length of the fan off
delay for heating.
During a call for heat, if the UCB does not sense voltage at
the GV for a continuous five-minute period the UCB will initiate a flash code (Table 52). The indoor blower motor will not
be locked-on while there is no GV voltage.
SAFETY CONTROLS
PRESSURE SWITCH (PS)
Once the draft motor has reached full speed and closes the
pressure switch during a normal ignition sequence, if the
pressure sw opens for 2 seconds, the GV will be de-energized, the ignition cycle is aborted, and the ICB flashes the
appropriate code. See Table 54 Ignition Control Flash Codes.
The draft motor is energized until the pressure switch closes
or “W1” is lost.
ROLLOUT SWITCH (ROS)
The rollout switch is wired in series with the pressure switch.
As such, the ICB cannot distinguish the rollout switch operation from that of the pressure switch.
Consequently, the control will only respond in the same manner as outlined above under “Pressure Switch”. An open rollout will inhibit the gas valve from actuating.
The UCB monitors the temperature limit switch of electric
heat units.
INTERNAL MICROPROCESSOR FAILURE
The control circuit includes the following safety controls:
If the ICB detects an internal failure, it will cease all outputs,
ignore inputs, and display the proper flash code for control
replacement. The ICB remains in this condition until replaced.
LIMIT SWITCH (LS)
This control is located inside the heater compartment and is
set to open at the temperature indicated in the Electric Heat
Limit Setting Table 44. It resets automatically. The limit switch
operates when a high temperature condition, caused by inadequate supply air flow occurs, thus shutting down the heater
and energizing the blower.
FLASH CODES
AUXILIARY LIMIT SWITCH (ALS)
Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature. This
resets any flash codes.
This control is located inside the supply air compartment and
is set to open at the temperature indicated in the Gas Heat
Limit Control Settings Table 46. It resets manually. The limit
switch operates when a high temperature condition, caused
by inadequate supply air flow occurs, thus shutting down the
heater and energizing the blower.
The UCB will initiate a flash code associated with errors
within the system. Refer to UNIT CONTROL BOARD FLASH
CODES Table 52.
RESETS
GAS HEAT ANTICIPATOR SETPOINTS
The auxiliary limit switch is wired in series with the limit
switch. As such, the UCB cannot distinguish the auxiliary limit
and the gas heat limit switch operation except the auxiliary is
manual reset. Consequently, the control will respond in the
same manner as outlined above under “Limit Switch”.
It is important that the anticipator setpoint be correct. Too
high of a setting will result in longer heat cycles and a greater
temperature swing in the conditioned space. Reducing the
value below the correct setpoint will give shorter “ON cycles
and may result in the lowering of the temperature within the
conditioned space. Refer to Table 47 for the required gas
heat anticipator setting.
TABLE 46: GAS HEAT LIMIT SETTINGS*
TABLE 47: GAS HEAT ANTICIPATOR SETPOINTS
Unit
Size
Main Limit Setting
Opt.
Natural Gas
LPG
10
165°F (73.9°C)
175°F (79.4°C)
15
165°F (73.9°C)
185°F (85°C)
DM120
15
195°F (90.5°C)
195°F (90.5°C)
DM150
15
195°F (90.5°C)
195°F (90.5°C)
DM090
*.
SETTING, AMPS
W1
W2
0.65
0.1
H E A T E X C H A N G E R T U B E
Rollout = 300°F (148.9°C), Auxiliary Limit = 200°F (93.3°C)
The ICB monitors the Pressure and Rollout switches of gas
heat units.
The control circuit includes the following safety controls:
G A S
S U P P L Y
B U R N E R
P IP E
B U R N E R B R A C K E T
B U R N E R F L A M E
(B L U E O N L Y )
IG N IT O R
FIGURE 28 - TYPICAL FLAME
Johnson Controls Unitary Products
47
127408-XIM-C-1208
START-UP (COOLING)
OPERATING INSTRUCTIONS
PRESTART CHECK LIST
After installation has been completed:
This furnace is equipped with an automatic re-ignition
system. DO NOT attempt to manually light the pilot.
1.
Check the electrical supply voltage being supplied. Be
sure that it is the same as listed on the unit nameplate.
2.
Set the room thermostat to the off position.
LIGHTING THE MAIN BURNERS
3.
Turn unit electrical power on.
1.
Turn “OFF” electric power to unit.
4.
Set the room thermostat fan switch to on.
2.
Turn room thermostat to lowest setting.
5.
Check indoor blower rotation.
3.
Turn gas valve counter-clockwise to “ON” position (see 19).
•
If blower rotation is in the wrong direction. Refer to
Phasing Section in general information section.
4.
Turn “ON” electric power to unit.
•
Check blower drive belt tension.
5.
If thermostat set 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.
6.
Check the unit supply air (CFM).
7.
Measure evaporator fan motor's amp draw.
8.
Set the room thermostat fan switch to off.
POST START CHECKLIST
9.
Turn unit electrical power off.
After the entire control circuit has been energized and the
heating section is operating, make the following checks:
OPERATING INSTRUCTIONS
1.
1.
Turn unit electrical power on.
NOTE: Prior to each cooling season, the crankcase heaters
must be energized at least 10 hours before the system is put into operation.
2.
Set the room thermostat setting to lower than the room
temperature.
3.
First stage compressors will energize after the built-in
time delay (five minutes).
4.
The second stage of the thermostat will energize second
stage compressor if needed.
Check for gas leaks in the unit piping as well as the supply piping.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could
result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property
damage, personal injury or loss of life.
POST START CHECK LIST
1.
Verify proper system pressures for both circuits.
2.
Check for correct manifold gas pressures. (See ’CHECKING GAS INPUT’.)
2.
Measure the temperature drop across the evaporator
coil.
3.
Check the supply gas pressure. It must be within the limits shown on the 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 in. or the operating pressure drop below 5.0 in
for natural gas units. If gas pressure is outside these
limits, contact the local gas utility or propane supplier for
corrective action.
START-UP (GAS HEAT)
PRE-START CHECK LIST
Complete the following checks before starting the unit.
1.
Check the type of gas being supplied. Be sure that it is
the same as listed on the unit nameplate.
SHUT DOWN
2.
Make sure that the vent outlet and combustion air inlet
are free of any debris or obstruction.
1.
Set the thermostat to the lowest temperature setting.
2.
Turn “OFF” all electric power to unit.
48
Johnson Controls Unitary Products
127408-XIM-C-1208
3.
Open gas heat access panel.
CHECKING GAS INPUT
4.
Turn gas valve clockwise to “OFF” position (See Figure 29).
NATURAL GAS
MANIFOLD GAS PRESSURE ADJUSTMENT
This gas furnace has two heat stages. Therefore, the gas
valve has two adjustment screws located under a plastic protective cover. The second stage (100% input) adjustment
screw is adjacent to the “HI” marking on the valve and the
first stage (60% input) adjustment screw is located adjacent
to the “LO” marking on the valve (See Figure 29).
This unit has two stages of gas heat. The first stage is 60% of
the full fire input and is considered the minimum input for the
furnace. The intended input for each furnace is shown in the
table below. The following Table applies to units operating on
60 Hz power only.
To determine the rate of gas flow (Second Stage).
1.
Turn off all other gas appliances connected to the gas
meter.
Adjust second stage (100% input) pressure first, then adjust
first stage (60% input) pressure.
2.
Turn on the furnace and make sure the thermostat is
calling for Second stage (100% input) heat.
1.
Turn off all power to the unit.
3.
2.
Using the outlet pressure port on the gas valve, connect
a manometer to monitor the manifold pressure.
Measure the time needed for one revolution of the hand
on the smallest dial on the meter. A typical gas meter
has a 1/2 or a 1 cubic foot test dial.
3.
Remove plastic cap covering HI and LO pressure adjustment screws.
4.
Using the number of seconds it takes for one revolution
of the dial, calculate the cubic feet of gas consumed per
hour. (See example below).
4.
Turn on power to the unit.
5.
5.
Set thermostat to call for second stage heat and start furnace.
6.
If necessary, using a screwdriver, turn the second stage
adjustment screw (adjacent to the “HI” marking on the
valve) clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure. Be sure
not to over-fire the unit on second stage.
If necessary, adjust the high pressure regulator as
discussed in the section “Manifold Gas Pressure
Adjustment”. Be sure not to over-fire the furnace on
Second stage. If in doubt, it is better to leave the Second
stage of the furnace slightly under-fired. Repeat Steps 15.
Manifold pressure adjustment procedure.
7.
After the high manifold pressure has been checked,
adjust the thermostat to call for first stage heat.
8.
If necessary, using a screwdriver, turn the first stage
adjustment screw (adjacent to the “LO” marking on the
valve) clockwise to increase manifold pressure or
counterclockwise to decrease manifold pressure. Be
sure not to under-fire the unit on first stage.
9.
To determine the rate of gas flow (First Stage)
1.
Turn off all other gas appliances connected to the gas
meter.
2.
Turn on the furnace and make sure the thermostat is
calling for first stage (60% input) heat.
3.
Even when the thermostat is calling for first stage heat,
the unit will light on second stage and will run on Second
stage for 1 minute. Allow this one-minute time period to
expire and be certain the unit is running on first stage.
4.
Measure the time needed for one revolution of the hand
on the smallest dial on the meter. A typical gas meter
has a 1/2 or a 1 cubic foot test dial.
5.
Using the number of seconds it takes for one revolution
of the dial, calculate the cubic feet of gas consumed per
hour (See example below).
6.
If necessary, adjust the low pressure regulator as discussed in the section “Manifold Gas Pressure Adjustment”. Be sure not to under-fire the furnace on first
stage. If in doubt, it is better to leave the first stage of the
furnace slightly over-fired (greater than 60% input).
Repeat Steps 1-6.
Once pressure has been checked, replace the plastic
cap covering the HI and LO pressure adjustment screws.
NOTE: When using natural gas, the manifold pressure for
second stage (100% input) should be 3.5 IWG ±
0.3. The manifold pressure for first stage (60%
input) when using natural gas should be 1.5 IWG ±
0.3.
TABLE 48: GAS HEAT STAGES
# of Burner Tubes
2nd Stage
Input (100%
Btuh)
1st Stage
Input (60%)
Btuh
4
120,000
72,000
6
175,000
105,000
Johnson Controls Unitary Products
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127408-XIM-C-1208
TABLE 49: GAS RATE CUBIC FEET PER HOUR
Seconds
for One
Rev.
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
ADJUSTMENT OF TEMPERATURE RISE
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
180
150
129
113
100
90
82
75
69
64
60
56
53
50
47
45
43
41
39
37
36
35
34
32
31
30
360
300
257
225
200
180
164
150
138
129
120
113
106
100
95
90
86
82
78
75
72
69
67
64
62
60
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 as it varies widely from
area to area).
EXAMPLE:
By actual measurement, it takes 19 seconds for the hand on
a 1 cubic foot dial to make a revolution with a 192,000 Btuh
furnace running. To determine rotations per minute, divide 60
by 19 = 3.16. To calculate rotations per hour, multiply 3.16 x
60 = 189.6. Multiply 189.6 x 1 (0.5 if using a 1/2 cubic foot
dial) = 189.6. Multiply 189.6 x (the Btu rating of the gas). For
this example, assume the gas has a Btu rating of 1050
Btu/ft.3. The result of 199,000 Btuh is within 5% of the
192,000 Btuh rating of the furnace.
The temperature rise (the difference of temperature between
the return air and the heated air from the furnace) must lie
within the range shown on the CSA rating plate and the data
in Table 47.
After the temperature rise has been determined, the CFM can
be calculated as follows:
0.8
CFM = Btu Input x ---------------------------- 1.08 ˜ '°F 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 6 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 (See ’SUPPLY AIR DRIVE
ADJUSTMENT’).
NOTE: Each gas heat exchanger size has a minimum
allowable CFM. Below this CFM, the limit will open.
BURNERS/ORIFICES INSPECTION/SERVICING
Before checking or changing burners, pilot or orifices,
CLOSE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF
ALL POWER TO THE UNIT.
1.
Open the union fitting just upstream of the unit gas valve
and downstream from the main manual shut-off valve in
the gas supply line.
2.
Remove the screws holding each end of the manifold to
the manifold supports.
3.
Disconnect wiring to the gas valves and spark igniter(s).
Remove the manifold & gas valve assembly. Orifices can
now be inspected and/or replaced.
To service burners, complete step 4.
4.
Remove the heat shield on top of the manifold supports.
Burners are now accessible for inspection and/or
replacement.
NOTE: Reverse the above procedure to replace the assemblies.
Make sure that burners are level and seat at the rear of the
gas orifice.
50
Johnson Controls Unitary Products
127408-XIM-C-1208
H IG H & L O W
H I
G A S A D J U S T M E N T
L O
O N
IN L E T
P R E S S U R E
T A P
O F F
O U T L E T
P R E S S U R E
T A P
M A T E -N -L O C K
C O N N E C T O R S
M V
C
H I
FIGURE 29 - TYPICAL GAS VALVE
CHARGING THE UNIT
When charging each system, superheat data should be taken
at the compressor inlet.
These units should be charged using the superheat method.
Super heat charging data is shown in Tables 50 thru 51.
TABLE 50: 7.5 TON SUPERHEAT CHARGING
Superheat at Compressor Suction (°F)
Airflow = 3000 CFM
Outdoor
Temp (°F)
Indoor WB Temp (°F)
55
57
59
61
63
65
67
65
7.8
10.9
14.0
17.1
20.1
23.2
26.3
70
6.5
9.4
12.3
15.2
18.1
21.0
23.9
75
5.1
7.9
10.6
13.3
16.0
18.7
21.4
80
-
6.3
8.8
11.4
13.9
16.4
19.0
85
-
-
7.1
9.5
11.8
14.2
90
-
-
-
6.7
8.8
10.9
69
71
73
75
27.1
28.0
28.8
29.7
25.0
26.2
27.3
28.5
22.9
24.4
25.8
27.3
20.8
22.6
24.4
26.2
16.5
18.6
20.7
22.9
25.0
13.1
15.9
18.7
21.6
24.4
95
-
-
-
-
5.8
7.7
9.6
13.2
16.7
20.3
23.8
100
-
-
-
-
-
5.8
7.2
11.0
14.8
18.5
22.3
105
-
-
-
-
-
-
-
8.8
12.8
16.8
20.8
110
-
-
-
-
-
-
-
6.6
10.8
15.1
19.3
115
-
-
-
-
-
-
-
-
8.9
13.3
17.8
Johnson Controls Unitary Products
51
127408-XIM-C-1208
TABLE 51: 10 TON SUPERHEAT CHARGING
Superheat at Compressor Suction (°F)
Airflow = 4000 CFM
Outdoor
Temp (°F)
Indoor WB Temp (°F)
55
57
59
61
63
65
67
69
71
73
75
65
26.8
27.4
28.0
28.6
29.3
29.9
30.5
31.1
31.7
32.4
33.0
70
25.3
26.0
26.6
27.3
28.0
28.7
29.3
30.0
30.7
31.4
32.0
75
23.8
24.5
25.3
26.0
26.7
27.5
28.2
28.9
29.6
30.4
31.1
80
22.8
23.5
24.3
25.0
25.8
26.5
27.3
28.0
28.8
29.5
30.3
85
21.8
22.5
23.3
24.1
24.8
25.6
26.4
27.1
27.9
28.7
29.4
90
20.2
21.0
21.8
22.5
23.3
24.1
24.9
25.6
26.4
27.2
28.0
95
18.7
19.5
20.2
21.0
21.8
22.6
23.4
24.1
24.9
25.7
26.5
100
17.1
17.9
18.6
19.4
20.2
20.9
21.7
22.5
23.2
24.0
24.8
105
15.5
16.3
17.1
17.8
18.6
19.3
20.1
20.8
21.6
22.3
23.1
110
14.1
14.9
15.6
16.4
17.2
18.0
18.7
19.5
20.3
21.1
21.8
115
12.6
13.4
14.2
15.0
15.8
16.6
17.4
18.2
19.0
19.8
20.6
12-1/2 ton unit uses TXV. Charge the unit to 10° subcooling.
TROUBLESHOOTING
Troubleshooting of components may require opening the electrical control box with the power connected to the unit. Use extreme care when
working with live circuits! Check the unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any
connections with line terminals.
When not necessary, shut off all electric power to the
unit prior to any of the following maintenance procedures so as to prevent personal injury.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation which could cause injury to person
and/or damage unit components. Verify proper operation after servicing.
PREDATOR® FLASH CODES
Various flash codes are utilized by the unit control board
(UCB) to aid in troubleshooting. Flash codes are
distinguished by the short on and off cycle used
(approximately 200ms on and 200ms off). To show normal
operation, the control board flashes a 1 second on, 1 second
off "heartbeat" during normal operation. This is to verify that
the UCB is functioning correctly. Do not confuse this with an
error flash code. To prevent confusion, a 1-flash, flash code
is not used.
Alarm condition codes are flashed on the UCB lower left Red
LED, See Figure 30. While the alarm code is being flashed, it
will also be shown by the other LEDs: lit continuously while
the alarm is being flashed. The total of the continuously lit
LEDs equates to the number of flashes, and is shown in the
table. Pressing and releasing the LAST ERROR button on
the UCB can check the alarm history. The UCB will cycle
through the last five (5) alarms, most recent to oldest,
separating each alarm flash code by approximately 2
seconds. In all cases, a flashing Green LED will be used to
indicate non-alarm condition.
In some cases, it may be necessary to "zero" the ASCD for
the compressors in order to perform troubleshooting. To reset
all ASCDs for one cycle, press and release the UCB TEST/
RESET button once.
Flash codes that do and do not represent alarms are listed in
Table 52.
52
Johnson Controls Unitary Products
127408-XIM-C-1208
TABLE 52: UNIT CONTROL BOARD FLASH CODES
FLASH CODE
On Steady
1 Flash
DESCRIPTION
GREEN
LED
16
RED
LED
8
RED
LED
4
RED
LED
2
RED
LED
1
This is a Control Failure
-
-
-
-
-
Not Applicable
-
-
-
-
-
2 Flashes
Control waiting ASCD*
Flashing
Off
Off
On
Off
3 Flashes
HPS1 Compressor Lockout
Off
Off
Off
On
On
4 Flashes
HPS2 Compressor Lockout
Off
Off
On
Off
Off
5 Flashes
LPS1 Compressor Lockout
Off
Off
On
Off
On
6 Flashes
LPS2 Compressor Lockout
Off
Off
On
On
Off
7 Flashes
FS1 Compressor Lockout
Off
Off
On
On
On
8 Flashes
FS2 Compressor Lockout
Off
On
Off
Off
Off
9 Flashes
Ignition Control Locked Out / Ignition Control Failure
Off
On
Off
Off
On
10 Flashes
Compressors Locked Out on Low Outdoor Air Temperature1
Flashing
On
Off
On
Off
Flashing
On
Off
On
On
11 Flashes
12 Flashes
13 Flashes
14 Flashes
OFF
*.
Compressors locked out because the Economizer is using free
Cooling1
Unit Locked Out due to Fan Overload Switch Failure
Off
On
On
Off
Off
Flashing
On
On
Off
On
EEPROM Storage Failure
Off
On
On
On
Off
No Power or Control Failure
Off
Off
Off
Off
Off
Compressor Held Off due to Low Voltage
1
Non-alarm condition.
Check
Alarm
History
Reset All
ASCDs for
One Cycle
Non Alarm
Condition Green
LED Flashing
Current Alarm
Flashed
Red LED
FIGURE 30: UNIT CONTROL BOARD
Johnson Controls Unitary Products
53
127408-XIM-C-1208
UNIT CONTROL BOARD OPTION SETUP
OPTION BYTE SETUP
•
•
•
•
•
Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2 seconds.
The green status LED (Option Byte) will be turned on
and the red status LED (Heat Delay) is turned off.
The 8, 4, 2 and 1 LEDs will then show the status of the 4
labeled options ((8) Fan Off at Heat Start, (4) Low
Ambient Lockout, (2) Free Cooling Lockout, and (1)
Lead / Lag).
Press the UP or Down button to change the LED status
to correspond to the desired Option Setup.
To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2 seconds. When the value is saved, the green LED will flash
a few times and then normal display will resume.
NOTE: While in either Setup mode, if no buttons are
pushed for 60 seconds, the display will revert to its
normal display, exiting the Option Setup mode.
When saving, the control board only saves the
parameters for the currently displayed mode
(Option Byte or Heat Delay).
HEAT DELAY SETUP
•
•
•
•
•
Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2 seconds.
The green status LED (Option Byte) will be turned on
and the red status LED (Heat Delay) is turned off.
Press the COMM SETUP / SELECT button to toggle into
the Heat Delay Setup, the green LED will turn off and the
red LED for Heat Delay will turn on.
The 8, 4, 2 and 1 LEDs will then show the status of the
Heat Delay, (See Table 53). Press the UP or Down button to change the LED status to correspond to the
desired Heat Delay Value.
To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2 seconds. When the value is saved, the red LED will flash a
few times and then normal display will resume.
NOTE: While in either Setup mode, if no buttons are
pushed for 60 seconds, the display will revert to its
normal display, exiting the Option Setup mode.
When saving, the control board only saves the
parameters for the currently displayed mode
(Option Byte or Heat Delay).
54
TABLE 53: HEAT DELAY
Heat
Fan On
Delay
60
60
60
60
45
45
45
45
30
30
30
30
0
0
0
Non-std
Heat
Fan Off
Delay
180
90
60
30
180
90
60
30
180
90
60
30
60
30
10
Non-std
Red
LED 8
Red
LED 4
Red
LED 2
Red
LED 1
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
TABLE 54: IGNITION CONTROL FLASH CODES
FLASHES
FAULT CONDITIONS
STEADY ON
Control Failure
HEARTBEAT
Normal Operation
CHECK
Control
1
Not Applicable
2
Pressure Switch
Stuck Closed
Pressure Switch
3
Pressure Switch Failed
To Close
Venter Pressure Switch
Vent Blocked
4
Limit Switch Open
Main Limit
AUX Limit
5
Flame Present With Gas
Off First Stage Gas Valve
Energized With W1 Off
Second Stage Gas Valve
Energized With First
Stage
Gas Valve Off
Gas Valve
6
Ignition Lockout
Gas Flow
Gas Pressure
Gas Valve
Flame Sensor
No Power Or Control
Failure
24VAC or Control
STEADY OFF
Johnson Controls Unitary Products
127408-XIM-C-1208
Monitored
Systems
Problem?
No
No
Call for
Heating?
Programming?
Yes
Yes
Program
Unit
Control
Board
Call for
Heat
Yes
Trip/Failure
Loss of
Call for
Heating?
No
Yes
Heat Off
No
Call for 2nd
Stage
Cooling
No
Energize ID
Blower Motor
Monitor
Call for
Cooling?
Yes
First
Stage?
Yes
No
Yes
No
Turn off ID
Blower Motor
Yes
No
Fan on
>30 secs?
Yes
Yes
No
Call for 1st
Stage
Cooling
Fan off
>10 secs?
No
Lossof Call
for ID Blower?
Call for
ID Blower?
No
Loss of Call
for Cooling?
Yes
Cool Off
FIGURE 31 - BASIC TROUBLESHOOTING FLOWCHART
Power to
Unit
Call for
heat?
No
Initialize ASCD
Yes
Voltage @
Gas Valve?
Yes
No
Energize ID
Blower
Montior
FIGURE 32 - POWER ON FLOW CHART
Johnson Controls Unitary Products
55
127408-XIM-C-1208
H P
S w itc h
O p e n 1
N o
L o s s o f
L S In p u t
T r ip /F a ilu r e
L P
S w itc h O p e n
> 5 S e c s2
N o
Y e s
Y e s
T
c o m
in itia
in c r e a
v a
E n e r g iz e b lo w e r :
in c r e a s e in c id e n t
v a lu e b y 1
N o
Y e s
u rn
p r
te
s e
lv e
o ff
e s s o r;
A S C D ;
in c id e n t
b y 1
N o
F re e z e s ta t
O p e n ?1
Y e s
T u rn o ff
C o m p re s s o r,
in itia te A S C D ;
in c r e a s e in c id e n t
v a lu e b y 1
T u rn
c o m p r
in itia te
in c r e a s e
v a lu e
o ff
e s s o r,
A S C D ;
in c id e n t
b y 1
N o
In c id e n t
v a lu e > = 3 ?
N o
Y e s
N o
L S in p u t
r e g a in e d ?
Y e s
L o c k o n b lo w e r ;
fla g a la r m
N o
In c id e n t
v a lu e > = 3
Y e s
N o
In c id e n t
v a lu e > = 3
Y e s
L o c k -o u t
c o m p r e s s o r , fla g
a la r m
L o a d F o ffD
In c id e n t
v a lu e > = 3
Y e s
L o c k -o u t
c o m p r e s s o r , fla g
a la r m
L o c k
c o m p re s
o ff ID b lo
o ff c o n
fa n s , fla
-o u t
s o r,
w e r,
d e n s
g a la
tu rn
tu rn
e r
rm
M o n ito r
L o s s o f
F O S in p u t
> 5 S e c s ?
C a ll fo r
H e a t w /o u t G V
v o lta g e ?
N o
Y e s
Y e s
T u rn
c o m p r
c o n d e n
in itia te
N o
o ff fa n
e s s o r &
s e r fa n s ;
A S C D
G V
v o lta g e
w /o u t c a ll fo r
h e a t?
N o
G V v o lta g e
> 5 m in ?
Y e s
F la g A la r m
N o
v o lta g e > 5
m in ?
N o
Y e s
F la g a la r m , lo c k
o n ID b lo w e r
N o
In c id e n t
v a lu e > = 3
F O S in p u t
r e g a in e d ?
N o
Y e s
c o m
o ff
o
fa
L o c k -o
p re s s o
ID b lo w
ff c o n d e
n s , fla g
N o
F O S in p u t > 1 5
m in u te s ?
N o
Y e s
u t
rs ,
e r,
n s
a la
tu rn
tu rn
e r
rm
Y e s
In c r e a s e in c id e n t
v a lu e b y 1
F la g a la r m , tu r n o n
X lin e
Y e s
L o s s o f G V
V o lta g e ?
N o
E n e rg
b lo w e r ,
O ff D e
h e a
iz e ID
lo a d 'F a n
la y ' fo r
tin g
M o n ito r
1 T h e
2 T h e
a n d
lo n g
c o n
lo w
a d d
e r h
tro l b o a rd
-p re s s u re
itio n a l 3 0
a n d le s th
o n ly
s w itc
s e c o
e lo w
m
h
n d
-p
o n ito r s
is n o t m
s , th e c
re s s u re
th e in
o n ito
o n tro
s w itc
p u t
re d
l b o
h d
w h e n th e c o m p re s s o r re a
fo r th e fir s t 3 0 s e c o n d s o f
a r d tu r n s o ff th e a s s o c ia te
iffe r e n tly th a n o th e r in p u ts
lly is e n e r g iz e d .
c o m p r e s s o r a c tiv ity . T h e c o n tr o l b o a r d th e n m o n ito r s th e s w itc h to e n s u r e it c lo s e s . If th e s w itc h r e m a in s o p e n
d c o m p r e s s o r a n d in itia te s th e A S C D . O n c e it h a s c lo s e d d u r in g th e s ta r t u p p e r io d , th e c o n tr o l b o a r d n o
.
FIGURE 33 - TRIP FAILURE FLOW CHART
56
Johnson Controls Unitary Products
127408-XIM-C-1208
COOLING TROUBLESHOOTING GUIDE
On calls for cooling, if the compressors are operating but the
supply air blower motor does not energize after a short delay
(the room thermostat fan switch is in the “AUTO” position):
1.
If installed, check the position of the economizer blades.
If the blades are open, the economizer is providing free
cooling and the compressors will not immediately operate. If both stages of cooling are requested simultaneously and the economizer provides free cooling,
following a short delay compressor #1 will be energized
unless it is locked out. If compressor #1 is locked out,
compressor #2 is energized. Compressor #2 is always
energized in place of compressor #1 when compressor
#1 is requested but locked out.
2.
If no economizer is installed or the economizer is not
opening to provide free cooling and compressor #1 does
not energize on a call for cooling, check for line voltage
at the compressor contactor, M1, and that the contactor
is pulled in. Check for loose wiring between the contactor and the compressor.
3.
If M3 is not pulled in, check for 24 volts at the M3 coil. If
24 volts are present at M3 but M3 is not pulled in,
replace the contactor.
If M1 is pulled in and voltage is supplied at M1, lightly
touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls
for cooling and wait for the internal overload to reset.
Test again when cool.
4.
Failing the above, if there is line voltage supplied at M3,
M3 is pulled in, and the supply air blower motor still does
not operate, replace the motor.
If M1 is not pulled in, check for 24 volts at the M1 coil. If
24 volts are present and M1 is not pulled in, replace the
contactor.
5.
If 24 volts is not present at M3, check that 24 volts is
present at the UCB supply air blower motor terminal,
“FAN”. If 24 volts is present at the FAN, check for loose
wiring between the UCB and M3.
Failing the above, if voltage is supplied at M1, M1 is
pulled in, and the compressor still does not operate,
replace the compressor.
6.
If 24 volts is not present at M1, check for 24 volts at the
UCB terminal, C1. If 24 volts is present, check for loose
wiring between C1 and the compressor contactor.
7.
If 24 volts is not present at the C1 terminal, check for 24
volts from the room thermostat at the UCB Y1 terminal. If
24 volts is not present from the room thermostat, check
for the following:
1.
Turn the thermostat fan switch to the ON position. If the
supply air blower motor does not energize, go to Step 3.
2.
If the blower motor runs with the fan switch in the ON
position but will not run after the first compressor has
energized when the fan switch is in the AUTO position,
check the room thermostat for contact between R and G
in the AUTO position during calls for cooling.
3.
If the supply air blower motor does not energize when
the fan switch is set to ON, check that line voltage is
being supplied to the contacts of the M3, contactor, and
that the contactor is pulled in. Check for loose wiring
between the contactor and the supply air blower motor.
4.
If M3 is pulled in and voltage is supplied to M3, lightly
touch the supply air blower motor housing. If it is hot, the
motor may be off on internal protection. Cancel any
thermostat calls and set the fan switch to AUTO. Wait for
the internal overload to reset. Test again when cool.
5.
6.
7.
8.
If 24 volts is not present at the “FAN” terminal, check for
24 volts from the room thermostat. If 24 volts are not
present from the room thermostat, check for the following:
a.
b.
c.
9.
On calls for cooling, the supply air blower motor is operating
but compressor #1 is not (the room thermostat fan switch is in
the “AUTO” position):
Proper operation of the room thermostat (contact
between R and G with the fan switch in the ON position and in the AUTO position during operation
calls).
Proper wiring between the room thermostat and the
UCB, and
Loose wiring from the room thermostat to the UCB
If 24 volts is present at the room thermostat but not at the
UCB, check for proper wiring between the thermostat and
the UCB, i.e. that the thermostat G terminal is connected
to the G terminal of the UCB, and for loose wiring.
10. If the thermostat and UCB are properly wired, replace
the UCB.
Johnson Controls Unitary Products
8.
a.
24 volts at the thermostat Y1 terminal
b.
Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and
c.
Loose wiring from the room thermostat to the UCB
If 24 volts is present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure switch,
low-pressure switch, or freezestat. Check for 24 volts at
the HPS1, LPS1, and FS1 terminals of the UCB. If a
switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS1 has opened,
there will be a 24-volt potential between the LPS1 terminals.
57
127408-XIM-C-1208
9.
If 24 volts is present at the UCB Y1 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing an alarm code. If not, press and
release the ALARMS button on the UCB. The UCB will
flash the last five alarms on the LED. If the compressor is
locked out, cancel any call for cooling. This will reset any
compressor lock outs.
NOTE: While the above step will reset any lockouts, compressor #1 may be held off for the ASCD. See the
next step.
10. If 24 volts is present at the UCB Y1 terminal and none of
the switches are open and the compressor is not locked
out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and
release the TEST button to reset all ASCDs.
For units without factory installed or with field installed
economizers, the UCB allows compressor operation all
the time. This programming can be checked or changed
by the local distributor.
15. If none of the above corrected the error, test the integrity
of the UCB. Disconnect the C1 terminal wire and jumper
it to the Y1 terminal. DO NOT jump the Y1 to C1 terminals. If the compressor engages, the UCB has faulted.
16. If none of the above correct the error, replace the UCB.
On calls for the second stage of cooling, the supply air blower
motor and compressor #1 are operating but compressor #2 is
not (the room thermostat fan switch is in the “AUTO” position):
1.
11. If 24 volts is present at the UCB Y1 terminal and the
compressor is not out due to a protective switch trip,
repeat trip lock out, or ASCD, the economizer terminals
of the UCB may be improperly wired. Check for 24 volts
at the Y1 “OUT” terminal of the UCB. If 24 volts is present, trace the wiring from Y1 “OUT” for incorrect wiring.
If 24 volts is not present at the Y1 “OUT” terminal, the
UCB must be replaced.
If installed, check the position of the economizer blades.
If the blades are open, the economizer is providing free
cooling. If the second stage of cooling is requested, following a short delay, compressor #1 will be energized
unless it is locked out. Typically, compressor #2 is energized only during free cooling if the call for the second
stage of cooling persists for 20 minutes.
2.
12. For units without economizers: If 24 volts is present at
the Y1 OUT terminal, check for 24 volts at the Y1
“ECON” terminal. If 24 volts is not present, check for
loose wiring from the Y1 “OUT” terminal to the Mate-NLock plug, the jumper in the Mate-N-Lock plug, and in
the wiring from the Mate-N-Lock plug to the Y1 “ECON”
terminal.
Compressor #2 will not energize simultaneously with
compressor #1 if a call for both stages of cooling is
received. The UCB delays compressor #2 by 30 seconds to prevent a power surge. If after the delay compressor #2 does not energize on a second stage call for
cooling, check for line voltage at the compressor contactor, M2, and that the contactor is pulled in. Check for
loose wiring between the contactor and the compressor.
3.
If M2 is pulled in and voltage is supplied at M2, lightly
touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls
for cooling and wait for the internal overload to reset.
Test again when cool.
4.
If M2 is not pulled in, check for 24 volts at the M2 coil. If
24 volts is present and M2 is not pulled in, replace the
contactor.
5.
Failing the above, if voltage is supplied at M2, M2 is
pulled in, and the compressor still does not operate,
replace the compressor.
6.
If 24 volts is not present at M2, check for 24 volts at the
UCB terminal, C2. If 24 volts are present, check for
loose wiring between C2 and the compressor contactor.
7.
If 24 volts is not present at the C2 terminal, check for 24
volts from the room thermostat at the UCB Y2 terminal. If
24 volts is not present from the room thermostat, check
for the following:
13. For units with economizers: If 24 volts is present at the
Y1 “OUT” terminal, check for 24 volts at the Y1 “ECON”
terminal. If 24 volts is not present, check for loose wiring
from the Y1 “OUT” terminal to the Mate-N-Lock plug, a
poor connection between the UCB and economizer
Mate-N-Lock plugs, loose wiring from the Mate-N-Lock
plug to the economizer, back to the Mate-N-Lock plug,
and from the Mate-N-Lock plug to the Y1 “ECON” terminal. If nothing is found, the economizer control may have
faulted and is failing to return the 24-volt “call” to the Y1
“ECON” terminal even though the economizer is not providing free cooling. To test, disconnect the Mate-N-Locks
and jumper between the WHITE and YELLOW wires of
the UCB’s Mate-N-Lock plug. If compressor #1 energizes, there is a fault in the economizer wiring or the
economizer control.
14. The UCB can be programmed to lock out compressor
operation during free cooling and in low ambient conditions. These options are not enabled by default. Local
distributors can test the UCB for this programming.
For units with factory installed economizers, the UCB is
programmed to lock out compressor operation when the
LAS set point is reached.
58
8.
a.
24 volts at the thermostat Y2 terminal
b.
Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and
c.
Loose wiring from the room thermostat to the UCB
If 24 volts is present at the UCB Y2 terminal, the compressor may be out due to an open high-pressure switch,
low-pressure switch, or freezestat. Check for 24 volts at
the HPS2, LPS2, and FS2 terminals of the UCB. If a
Johnson Controls Unitary Products
127408-XIM-C-1208
switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS2 has opened,
there will be 24 volts of potential between the LPS2 terminals.
9.
If 24 volts is present at the UCB Y2 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last
five alarms on the LED. If the compressor is locked out,
remove any call for cooling at the thermostat or by disconnecting the thermostat wiring at the Y2 UCB terminal.
This will reset any compressor lock outs.
NOTE: While the above step will reset any lock outs, compressor #1 will be held off for the ASCD, and compressor #2 may be held off for a portion of the
ASCD. See the next step.
3.
If M1 is pulled in and voltage is supplied at M1, lightly
touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls
for cooling and wait for the internal overload to reset.
Test again when cool.
4.
If M1 is not pulled in, check for 24 volts at the M1 coil. If
24 volts is present and M1 is not pulled in, replace the
contactor.
5.
Failing the above, if voltage is supplied at M1, M1 is
pulled in, and the compressor still does not operate,
replace the compressor.
6.
If 24 volts is not present at M1, check for 24 volts at the
UCB terminal, C1. If 24 volts is present, check for loose
wiring between C1 and the compressor contactor.
7.
If 24 volts is not present at the C1 terminal, check for 24
volts from the room thermostat at the UCB Y1 terminal.
If 24 volts are not present at the UCB Y1 terminal, the
UCB may have faulted. Check for 24 volts at the Y1
ECON terminal. If 24 volts is not present at Y1 “ECON”,
the UCB has faulted. The UCB should de-energize all
compressors on a loss of call for the first stage of cooling, i.e. a loss if 24 volts at the Y1 terminal.
8.
If 24 volts are present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure switch,
low-pressure switch, or freezestat. Check for 24 volts at
the HPS1, LPS1, and FS1 terminals of the UCB. If a
switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS1 has opened,
there will be a 24-volt potential between the LPS1 terminals.
9.
If 24 volts is present at the UCB Y1 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last
five alarms on the LED. If the compressor is locked out,
remove any call for cooling. This will reset any compressor lock outs.
10. If 24 volts is present at the UCB Y2 terminal and none of
the switches are open and the compressor is not locked
out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and
release the TEST button to reset all ASCDs.
11. The UCB can be programmed to lock out compressor
operation during free cooling and in low ambient conditions. These options are not enabled by default. Local
distributors can test the UCB for this programming.
For units with factory installed economizers, the UCB is
programmed to lock out compressor operation when the
LAS set point is reached.
For units without factory installed or with field installed
economizers, the UCB allows compressor operation all
the time. This programming can be checked or changed
by the local distributor.
12. If none of the above corrected the error, test the integrity
of the UCB. Disconnect the C2 terminal wire and jumper
it to the Y2 terminal. DO NOT jump the Y2 to C2 terminals. If the compressor engages, the UCB has faulted.
13. If none of the above correct the error, replace the UCB.
On a call for cooling, the supply air blower motor and compressor #2 are operating but compressor #1 is not (the room
thermostat fan switch is in the “AUTO” position):
1.
Compressor #2 is energized in place of compressor #1
when compressor #1 is unavailable for cooling calls.
Check the UCB for alarms indicating that compressor #1
is locked out. Press and release the ALARMS button if
the LED is not flashing an alarm.
2.
Check for line voltage at the compressor contactor, M1,
and that the contactor is pulled in. Check for loose wiring
between the contactor and the compressor.
Johnson Controls Unitary Products
NOTE: While the above step will reset any lock outs, compressor #2 will be held off for the ASCD, and compressor #1 may be held off for a portion of the
ASCD. See the next step.
10. If 24 volts is present at the UCB Y1 terminal and none of
the switches are open and the compressor is not locked
out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and
release the TEST button to reset all ASCDs.
11. If 24 volts is present at the UCB Y1 terminal and the
compressor is not out due to a protective switch trip,
repeat trip lock out, or ASCD, the economizer terminals
of the UCB may be improperly wired. Check for 24 volts
at the Y1 “OUT” terminal of the UCB. If 24 volts is pres-
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127408-XIM-C-1208
ent, trace the wiring from Y1 “OUT” for incorrect wiring.
If 24 volts is not present at the Y1 “OUT” terminal, the
UCB must be replaced.
The furnace may shut down on a high temperature
condition during the procedure. If this occurs, the
UCB energize the supply air blower motor until the
high temperature limit has reset. Caution should be
used at all times as the supply air blower may energize regardless of the room thermostat fan switch
position.
12. For units without economizers: If 24 volts is present at
the Y1 “OUT” terminal, check for 24 volts at the Y1
“ECON” terminal. If 24 volts is not present, check for
loose wiring from the Y1 “OUT” terminal to the Mate-NLock plug, the jumper in the Mate-N-Lock plug, and in
the wiring from the Mate-N-Lock plug to the Y1 “ECON”
terminal.
For units with economizers:If 24 volts is present at the
Y1 “OUT” terminal, check for 24 volts at the Y1 “ECON”
terminal. If 24 volts is not present, check for loose wiring
from the Y1 “OUT” terminal to the Mate-N-Lock plug, a
poor connection between the UCB and economizer
Mate-N-Lock plugs, loose wiring from the Mate-N-Lock
plug to the economizer, back to the Mate-N-Lock plug,
and from the Mate-N-Lock plug to the Y1 “ECON”
terminal. The economizer control may have faulted and
is not returning the 24 volts to the Y1 “ECON” terminal
even though the economizer is not providing free
cooling. To test the economizer control, disconnect the
Mate-N-Locks and jumper between the WHITE and
YELLOW wires of the UCB’s Mate-N-Lock plug.
13. The UCB can be programmed to lock out compressor
operation during free cooling and in low ambient conditions. These options are not enabled by default. They
can be checked by local distributors.
that the contactor is pulled in. Check for loose wiring
between the contactor and the supply air blower motor.
3.
If M3 is pulled in and voltage is supplied at M3, lightly
touch the supply air blower motor housing. If it is hot, the
motor may be off on inherent protection. Cancel any
thermostat calls and set the fan switch to “AUTO”, wait
for the internal overload to reset. Test again when cool.
4.
If M3 is not pulled in, check for 24 volts at the M3 coil. If
24 volts is present at M3 but M3 is not pulled in, replace
the contactor.
5.
Failing the above, if there is line voltage supplied at M3,
M3 is pulled in, and the supply air blower motor still does
not operate, replace the motor.
6.
If 24 volts is not present at M3, check that 24 volts is
present at the supply air blower motor terminal on the
UCB. If 24 volts is present at the UCB terminal, check
for loose wiring between the UCB and M3.
For units with factory installed economizers, the UCB is
programmed to lock out compressor operation when the
LAS set point is reached.
a.
For units without factory installed or with field installed
economizers, the UCB allows compressor operation all
the time. This programming can be checked or changed
by the local distributor.
14. If none of the above corrected the error, test the integrity
of the UCB. Disconnect the C1 terminal wire and jumper
it to the Y1 terminal. DO NOT jump the Y1 to C1 terminals. If the compressor engages, the UCB has faulted.
15. If none of the above correct the error, replace the UCB.
GAS HEAT TROUBLESHOOTING GUIDE
On calls for heating, the draft motor operates and the furnace
lights but the supply air blower motor does not energize after
a short delay (the room thermostat fan switch is in “AUTO”
position).
1.
2.
60
Place the thermostat fan switch in the “ON” position. If
the supply air blower motor energizes, go to Step 9.
If the supply air blower motor does not energize when
the fan switch is set to “ON,” check that line voltage is
being supplied to the contacts of the M3 contactor, and
If 24 volts is not present at the UCB supply air
blower motor terminal, check for 24 volts from the
room thermostat. If 24 volts is not present from the
room thermostat, check for the following:
i.
Proper operation of the room thermostat (contact between R and G with the fan switch in the
“ON” position and in the “AUTO” position during
operation calls)
ii.
Proper wiring between the room thermostat and
the UCB, and
iii.
Loose wiring from the room thermostat to the
UCB
7.
If 24 volts is present at the room thermostat but not at the
UCB, check for proper wiring between the thermostat
and the UCB, i.e. that the thermostat G terminal is connected to the G terminal of the UCB, and for loose wiring.
8.
If the thermostat and UCB are properly wired, replace
the UCB.
9.
If the blower motor runs with the fan switch in the “ON”
position but does not run shortly after the furnace has
ignited when the fan switch is in the “AUTO” position,
check the room thermostat for contact between R and G
during “W1” calls.
Johnson Controls Unitary Products
127408-XIM-C-1208
On calls for heating, the supply air blower operates but the
draft motor does not (the room thermostat fan switch is in the
“AUTO” position).
1.
The draft motor has inherent protection. If the motor
shell is hot to the touch, wait for the internal overload to
reset.
2.
If the motor shell is cold with the room thermostat calling
for heat, check for line voltage at the motor leads. If line
voltage is present, replace the draft motor.
3.
If line voltage is not present, check for line voltage on the
ignition control at the “inducer” terminal draft motor relay
(DMR or DMC) contacts in the main control box and
check to see if the (DMR or DMC) is pulled in.
exchanger tubes or the pressure switch has failed.
Check the operation of the pressure switch. Check the
line voltage to the unit; if line voltage is low, call the local
power company. If the problem persists, the draft motor
may need replacement.
4.
If the furnace is hot, it may be out on a high temperature
limit open; wait for limit reset.
5.
If all are intact replace the ICB.
The draft motor runs and the spark ignitor sparks at the
burner, but the burner does not ignite and a gas odor is not
detected at the draft motor outlet.
1.
Check to ensure gas is being supplied to the unit. Confirm that the gas pressure to the unit is within the proper
limits as described in the “POST START CHECKLIST”.
2.
Check the voltage at the gas valve and at the gas valve
terminals on the ICB. Check all wiring between the ICB
and the gas valve. Check to make sure the ground connections are intact.
3.
If 24 volts is present, remove the pilot burner and the orifice. The removal procedure is described in “BURNER/
ORIFICE INSPECTION/SERVICING.” Inspect the orifice
for obstruction. If it is clear, replace the gas valve.
The draft motor runs but the furnace does not light and the
spark ignitor does not spark.
1.
Check for 24 volts at the spark ignitor from the ignition
control board (ICB). Check the 24-volt wiring from the
ICB to the spark ignitor. Check for 24 volts at the ICB
spark ignitor terminal.
2.
Check the ground wiring for the ICB and the gas valve is
intact and making good electrical connection. Check the
ceramic insulator on the spark ignitor for breaks or
cracks. Replace the spark ignitor if damaged.
3.
With the draft motor running, check for 24 volts at the
pressure switch terminal on the ICB. If not present,
check for 24 volts on the terminal from the pressure
switch. If present, go to step 4. If 24 volts is not present,
the either pressure or rollout switch is not closed. Or the
draft motor is not sufficiently evacuating the heat
Johnson Controls Unitary Products
Main burners light but exhibit erratic flame characteristics.
4.
Check the main burner orifices for obstruction and alignment. The removal procedure is described in
“BURNER/ORIFICE INSPECTION/SERVICING”. Clean
or replace burner orifices and burners as needed.
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127408-XIM-C-1208
62
Johnson Controls Unitary Products
127408-XIM-C-1208
Johnson Controls Unitary Products
63
Subject to change without notice. Printed in U.S.A.
Copyright © 2009 by Johnson Controls, Inc. All rights reserved.
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
127408-XIM-C-1208
Supersedes: 127408-YIM-B-0606
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