Johnson Controls 100 Series Installation Operation & Maintenance Download

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JOHNSON CONTROLS

FORM 100.50-NOM12

ISSUE DATE: 04/02/2019

SECTION 4 – MAINTENANCE

Make sure power is removed from the unit

before performing the maintenance items

contained in this section of the manual.

GENERAL

A planned program of regularly scheduled maintenance

will return dividends by averting possible costly and un-

expected periods of down time. It is the responsibility of

the owner to provide the necessary maintenance for the

air handling units and coils. If a system failure occurs

due to improper maintenance during the warranty peri-

od, Johnson Controls will not be liable for costs incurred

to return the unit to satisfactory operation.

PERIODIC MAINTENANCE – MONTHLY
Filters

Check the cleanliness of the filters and replace or clean

as required.

Linkages

Examine the damper and operator linkages to insure

that each is free and operating smoothly.

Compressors

Oil Level Check:

The oil level can only be tested

when the compressor is running in stabilized condi-

tions, to ensure that there is no liquid refrigerant in the

lower shell of the compressor. When the compressor

is running in stabilized conditions, the oil level must

be between 1/4 and 3/4 in the oil sight glass. Note: at

shutdown, the oil level can fall to the bottom limit of

the oil sight glass.

Oil Analysis:

Use YORK Type “T” POE oil (clear) for

units charged with R-410a refrigerant. The type of re-

frigerant and amount per system is listed on the unit

rating plate. A change in the oil color or odor may be an

indication of contaminates in the refrigeration system.

If this occurs, an oil sample should be taken and ana-

lyzed. If contaminations are present, the system must

be cleaned to prevent compressor failure. This can be

accomplished through the installation of oversized suc-

tion and liquid line driers. The driers may have to be

changed several times to clean up the system depend-

ing on the degree of contamination.

Never use the scroll compressor to pump

the refrigerant system down into a vacu-

um. Doing so will cause internal arcing

of the compressor motor, which will result

in failure of compressor.

Fan Bearing Lubrication

Add grease slowly with shaft rotating until a slight

bead forms at the seals. If necessary, re-lubricate while

bearing is stationary. The fan data plate (attached to

the fan scroll) lists the type of grease that must be used

for lubricating the bearings. Refer to

Table 17 on page

for lubricating schedule.

Re-lubrication is generally accompanied by a tempo-

rary rise in operating temperature. Excess grease is

purged at seals.

TABLE 17 -

FAN BEARING – LUBRICATION INTERVALS

RELUBRICATION SCHEDULE (MONTHS) BALL BEARING PILLOW BLOCKS

SPEED (RPM)

500

1000

1500

2000

2500

3000

3500

4000

4500

Shaft Dia
1/2” thru 1-11/16”

1-15/16” thru 2-7/16”

1/2

1/4

2-11/16” thru 2-15/16”

1/2

3-7/16” thru 3-15/16”

1/2

Summary of Contents for 100 Series

Page 1: ...707 035 22722 010 SERIES 100 SINGLE PACKAGED UNITS YPAL DESIGN LEVEL G 70 THROUGH 105 TONS Issue Date April 2 2019 PACKAGED ROOFTOP UNITS INSTALLATION OPERATION MAINTENANCE NEW RELEASE Form 100 50 NOM12 419 ...

Page 2: ...enced materials This individual shall also be familiar with and comply with all applicable industry and governmental stan dards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious in jury if proper care is not taken ...

Page 3: ...ipment If there is any question regarding the applicability of these documents rig ging lifting and operating service personnel should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the equip ment CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand c...

Page 4: ...Special Product IPU E R 410A 7 200 3 60 8 230 3 60 6 460 3 60 5 400 3 50 8 575 3 60 0 380 3 60 C Constant Volume V VAV VFD F FlexSys B Bottom Return R Rear Return S Side Return C Cooling Only N Natural Gas Heat G Natural Gas Heat SS HX M Modulating Gas Heat E Electric Heat S Steam Heat H Hot Water Heat L Scroll P Packaged Rooftop A Air Cooled Y YORK 70 ton 75 ton 80 ton 90 ton 105 ton 0 5 0 0 5 7 ...

Page 5: ...as Heat Design and Control Options 14 Staged Gas Heat 14 Electric 14 Air Management 15 Controls 15 Indoor Air Quality 15 Electrical 16 Service And Installation 16 SECTION 2 INSTALLATION 17 Approvals 17 Limitations 17 Unit Inspection 17 Locations And Clearances 18 Rigging And Handling 18 Electrical Data 26 Electrical Service Sizing 26 Load Definitions 26 Filters 28 Condensate Drain 28 Condensate Dr...

Page 6: ...iping 39 Gas Connection 39 Gas Piping Recommendations 39 Combustion Vent 40 SECTION 3 START UP 41 Crankcase Heaters 41 Checking The System Prior To Initial Start No Power 41 Unit Checks 41 Unit Checks Power Applied 43 Verifying Compressor Rotation 43 Compressor Oil Level Check 43 Initial Start Up 43 Refrigerant Charge 44 Checking Superheat and Subcooling 44 Subcooling R 410A 44 Superheat R 410A 44...

Page 7: ...Sys 60 Unit Overall Status 60 Phase Monitor 60 Occupancy Unoccupancy Determination 61 Night Set Back 61 Night Set Back Setup 61 Night Set Back Sequence Of Operation 61 Current OperatinG Mode 61 Single Zone VAV SZVAV 62 SZVAV Setup 62 Supply Fan 63 Cooling And Heating Operation 64 Variable Air Volume VAV 66 VAV Setup 66 Supply Fan 67 Cooling And Heating Operation 69 Active Supply Air Temperature SA...

Page 8: ...Tempering 98 Ventilation 99 Ventilation Types Damper Hardware 99 Control Options 99 Ventilation Setup 99 2 Position Damper 99 Standard Damper 99 Tek Air Full IAQ 100 Continuous Ventilation 102 Comfort Ventilation 102 Exhaust Return Fan 102 Exhaust Fan Assembly 103 Return Fan Assembly 105 FlexSys 106 Basic FlexSys System Design 106 Factory Recommended Setpoints 106 FlexSys Setup 107 Current Operati...

Page 9: ...e IPU Board 142 Communication 142 Communication Ports 142 BACnet Wiring 142 Device Object Instance DE 143 Additional Settings 143 SECTION 7 PARAMETER DESCRIPTIONS AND OPTIONS 157 SECTION 8 SERVICE 165 Analog Input Operation 165 Temperature Sensors 165 Duct Pressure Transducer 165 Building Pressure Transducer 166 Return Fan Pressure Transducer 166 Discharge Pressure Transducer 167 Suction Pressure ...

Page 10: ...4 Split Bearing 57 FIGURE 25 Unit Options 59 FIGURE 26 Single Zone VAV SZVAV and Constant Volume CV Occupied and Unoccupied 66 FIGURE 27 Active Duct Static Pressure Setpoint Vs Duct Static Pressure Reset Voltage 68 FIGURE 28 Active SAT Setpoint Versus SAT Reset Voltage 70 FIGURE 29 Active SAT Setpoint Versus RAT 71 FIGURE 30 Active SAT Setpoint Versus OAT 71 FIGURE 31 Active SAT Setpoint Versus Su...

Page 11: ... Analog Outputs 173 FIGURE 66 I O Control Board Analog Inputs 173 LIST OF TABLES TABLE 1 Voltage Limitations 17 TABLE 2 Lifting Lug Locations 19 TABLE 3 Physical Data 20 TABLE 4 Supply Exhaust Return Fan Motor Data 26 TABLE 5 Condenser Fan Motor Data 26 TABLE 6 Miscellaneous Electrical Data 27 TABLE 7 Compressor Data R 410A 27 TABLE 8 Electric Heat Amp Draw 27 TABLE 9 Airflow And Entering Air Ambi...

Page 12: ...7 TABLE 44 Compressor Systems 1 2 Or 3 119 TABLE 45 Supply System 120 TABLE 46 Heating 121 TABLE 47 Economizer 124 TABLE 48 Ventilation 125 TABLE 49 Exhaust 126 TABLE 50 Operating Hours Start Counter 129 TABLE 51 Service 132 TABLE 52 Warning Fault Order 140 TABLE 53 BACnet MS TP Modbus BACnet IP 144 TABLE 54 Definitions 157 TABLE 55 Temperature Sensor Resistance 165 TABLE 56 Duct Pressure Transduc...

Page 13: ...le circuits These compressors are manifolded to gether in three independent circuits ECOLOGICAL AND ECONOMICAL DESIGN First packaged rooftop unit with R 410A optimized de sign Cooling and Heating Superior operating performance provides lower oper ating costs Smaller steps of cooling capacity provide tighter control of building environment and occupant comfort while optimizing energy efficiency Ind...

Page 14: ...vered panel provides protection around the entire condensing section giving the maximum protection to the coils and refrigerant components Hot Gas Reheat The Series 100 units have the option to order a hot gas reheat HGRH system The HGRH is used to help with dehumidification of the space HEATING SECTION Gas Heat Design and Control Options Include an unsurpassed 24 1 turndown modulating gas furnace...

Page 15: ...nd include a time and day stamp for easy troubleshooting BACNET The Series 100 can be adapted to operate with any building automation system that is BACnet compatible making it the most flexible large commercial rooftop units on the market NOTE This is a visual reference only Actual drain pan pitch varies LDO8022 Figure 2 DOUBLE SLOPED STAINLESS STEEL DRAIN PAN INDOOR AIR QUALITY Double Sloped Sta...

Page 16: ...This option is available to minimize time at installation of equipment and to reduce necessary field installed items SERVICE AND INSTALLATION Access Doors Full sized access doors provide easy access into the unit for routine maintenance and inspection Service Valves Oversized service valves to provide isolation and quick reclamation and charging of system refrigerant are available to minimize down...

Page 17: ... limitations If the variable air volume VAV boxes in the conditioned space have hydronic heat ing coils installed it is the responsibility of the installing contractor to take appropri ate measures to protect the hydronic coils against low unit supply air temperatures that could result in the freeze up and rup ture of the coils UNIT INSPECTION Immediately upon receiving the unit it should be inspe...

Page 18: ...nt twisting and damage to the unit Care must be taken to keep the unit in the upright posi tion during rigging and to prevent damage to the water tight seams in the unit casing Avoid unnecessary jar ring or rough handling See Figure 4 on page 19 for number and location of the lifting lugs by unit size It is also mandatory that an experienced and reliable rigger be selected to handle unloading and ...

Page 19: ...ARD 22 8 578 117 6 2981 181 9 4591 239 4 6172 296 3 7526 406 4 10323 D 070 STANDARD 29 9 759 77 0 1956 197 0 5004 270 5 6871 318 6 8093 373 8 9493 428 9 10894 070 EXTENDED 29 9 759 77 0 1956 197 0 5004 270 5 6871 381 6 9693 436 8 11093 491 9 12494 075 STANDARD 29 9 759 77 0 1956 197 0 5004 270 5 6871 318 6 8093 373 8 9493 428 9 10894 075 EXTENDED 29 9 759 77 0 1956 197 0 5004 270 5 6871 381 6 9693...

Page 20: ...s2 535 Final filters racks only2 297 Roof Curb Weights Lbs 14 Full Perimeter Roof Curb 1 020 14 Open Condenser Roof Curb 577 Compressor Data Quantity Size Nominal HP 6x10 Type Scroll Capacity Steps Qty x 6x16 MODEL SIZE 070 Refrigerant Charge R410A STD Cabinet SYS 1 LB KG 44 3 SYS 2 LB KG 38 5 SYS 3 LB KG 42 4 Refrigerant Charge R410A EXTD Cabinet SYS 1 LB KG 47 0 SYS 2 LB KG 41 2 SYS 3 LB KG 45 4...

Page 21: ...width in 16x20 25x16 25x20 Total Filter Face Area square feet 55 8 MODEL SIZE 070 Filters 12 Rigid 95 2 30 Prefilter Pre Filter Position Quantity 2 8 9 Size length x width in 16x20 25x16 25x20 Total Filter Face Area square feet 55 8 Filters 2 Carbon Pre Filter Position Quantity 10 15 Size length x width in 16x20 25x16 25x20 Total Filter Face Area square feet 77 1 Filters 12 rigid 95 in Post filter...

Page 22: ...146 146 162 162 Min AMS Measurement Station Mounting 45 45 50 50 Barometric only 45 45 55 55 375 MBH Gas Heat 162 162 162 162 750 MBH Gas Heat 324 324 324 324 1050 MBH Gas Heat 486 486 486 486 40 kW 415 3 60 or 40 kW 480 3 60 2 Steps Electric Heat NA NA NA NA 80 kW 208 3 60 or 108 kW 240 3 60 5 Steps Electric Heat 510 510 NA NA 108 kW 415 3 60 4 steps Electric Heat 470 470 510 510 150 kW 415 3 60 ...

Page 23: ...nge min to max cfm 15550 29000 15000 32000 17500 36000 21000 36000 Static Pressure Range min to max ESP 0 4 0 4 0 4 0 4 Optional Airfoil Supply Fan Quantity 1 1 1 1 1 1 1 1 Type AF AF AF AF Size 32 32 32 32 Motor Size Range min to max HP 15 50 15 50 15 50 15 50 Air Flow Range min to max cfm 15550 29000 15000 32000 17500 36000 21000 36000 Static Pressure Range min to max ESP 0 6 0 6 0 6 0 6 Optiona...

Page 24: ...ws fins per inch 3 17 3 17 3 17 5 17 Tube Diameter 3 8 3 8 3 8 3 8 Condenser Coil R410A Size square feet 164 164 164 164 Number of rows fins per inch 1 21 1 21 1 21 1 21 Tube Diameter Surface 1 mm microchannel 1 mm microchannel 1 mm microchannel 1 mm microchannel Condenser Fans Quantity 6 6 6 6 Type Prop Prop Prop Prop Diameter inches 36 36 36 36 Power hp each 2 2 2 2 Power hp each 2 2 2 2 Filters...

Page 25: ...e Sizes input output stages 375 mbh 300 mbh 2 stages 750 mbh 600 mbh 4 stages 1125 mbh 900 mbh 6 stages Inlet Gas Pressure Range min to max iwg Natural 4 5 10 5 iwg Propane 11 0 13 0 iwg Minimum Air ON Temperature 6 950 36 000 11 150 36 000 15 150 36 000 15 150 36 000 Airflow Range min to max cfm 375 mbh 300 mbh 8 1 turndown Modulating Furnace Sizes input output turndown 750 mbh 600 mbh 16 1 turnd...

Page 26: ...25 x LOAD1 LOAD2 LOAD3 LOAD4 MOP 2 25 x LOAD1 LOAD2 LOAD3 LOAD4 If the MOP does not equal a standard current rating of an overcurrent protective device then the marked maximum rating is to be the next lower standard rating However if the device selected for MOP is less than the MCA then select the lowest standard maximum fuse size greater than or equal to the MCA Table 4 SUPPLY EXHAUST RETURN FAN ...

Page 27: ...9 109 105 3 ZP182 26 9 173 23 7 132 3 ZP235 30 8 229 25 0 180 NOTE RLA data is per compressor Table 8 ELECTRIC HEAT AMP DRAW kW NOMINAL VOLTAGE 208 3 60 230 3 60 460 3 60 575 3 60 AMPS AMPS AMPS AMPS 80 193 193 96 80 108 260 260 130 109 150 181 151 200 241 201 250 301 251 NOTE Heaters are sized as follows 208V heaters are rated at 208V 230V heaters are rated at 240V 460V heaters are rated at 480V ...

Page 28: ... the building A trap must be installed to prevent this condensate water build up see Figure 5 on page 28 and Figure 6 on page 28 Condensate Drain Trap For Draw through applications install a trapped con densate drain line at unit drain connection see Figure 6 on page 28 according to all governing codes H dimension must be at least 1 inch greater than design Total Static Pressure TSP of fan The tra...

Page 29: ...ral time clock a ther mostat with scheduling or BAS system or a manual switch Contact Closure Occupied Contacts Open Unoccupied Note that 24 volts 24 VAC terminal 1 of the termi nal block CTB1 must be used as the 24 VAC source for switching the contact to the IPU board Occupied Unoccupied input Use of any power source external to the controller will result in damage to the IPU board Shutdown Input...

Page 30: ... compared to the return air temperature minus the supply air temperature As the mixed air temperature decreases the damper opens al lowing more air to bypass the evaporator coil resulting in a higher mixed air temperature supply to the under floor system The mixed air damper must be wired and installed into the system in the field The wires to connect the actua tor are located in the supply fan se...

Page 31: ... of voltage required to power the sensor depends on the sensor selected When the sensor uses 24VAC additional wires must be run to terminal 1 24VAC and terminal 2 24VAC COM of the CTB1 terminal block When the sensor requires a different power source than 24VAC it must be field supplied Supply Air Temp Setpoint Reset Duct Pressure Setpoint Reset 25 26 22 DSP DUCT STATIC RESET DSP DUCT STATIC RESET ...

Page 32: ...AL3 HRC HR AL2C AL2 AL1 AL1 AL2 AL3 HR ld08186C WIRING NOTES 1 Wiring shown indicates typical wiring Refer to the IOM for more detailed wiring methods and options 2 All wiring is Class 2 low voltage 3 Maximum power available from the 24VAC terminal is 40VA 4 Use shielded wire where shown 5 Relay contacts suitable for pilot duty to 1A from 24VAC to 120VAC CTB1 FIELD CONTROL WIRING OUTPUTS ...

Page 33: ...lations listed below from U L 1995 Based on the operating mode and configuration of the rooftop the calculations will yield different MCA minimum circuit ampacity and MOP maximum overcurrent protection MCA and Overcurrent Protection Device Data is supplied on the unit data plate The following calculations apply to electrical data for the rooftop unit All concurrent load conditions must be consider...

Page 34: ... 1995 Section 36 14 N E C Section 440 34 4 Maximum Dual Element Fuse size is based on U L Standard 1995 Section 36 15 N E C Section 440 22 5 Use copper conductors only 6 On units with an optional disconnect switch the supplied disconnect switch is a Disconnecting Means as defined in the N E C Section 100 and is intended for isolating the unit from the available power supply to perform maintenance ...

Page 35: ...ed on U L Standard 1995 Section 36 14 N E C Section 440 34 4 Maximum Dual Element Fuse size is based on U L Standard 1995 Section 36 15 N E C Section 440 22 5 Use copper conductors only 6 On units with an optional disconnect switch the supplied disconnect switch is a Disconnecting Means as defined in the N E C Section 100 and is intended for isolating the unit from the available power supply to pe...

Page 36: ...4 Maximum Dual Element Fuse size is based on U L Standard 1995 Section 36 15 N E C Section 440 22 5 Use copper conductors only 6 On units with an optional disconnect switch the supplied disconnect switch is a Disconnecting Means as defined in the N E C Section 100 and is intended for isolating the unit from the available power supply to perform maintenance and troubleshooting This disconnect switc...

Page 37: ...ield installed at the top of the rear corner post on the unit see Figure 12 on page 38 The factory supplied atmospheric pressure probe and associated mounting hardware are shipped inside the control panel The hardware consists of a mounting bracket and a short section of pneumatic tubing The pneumatic tubing must be field installed from a factory pressure tap next to the mounting location for the ...

Page 38: ...of a plenum Installation of elbows discharge damper and other abrupt flow area changes in stalled directly at the fan outlet will cause system losses These losses must be taken into account during the design phase and must be added to any field measurements SOUND AND VIBRATION TRANSMISSION All roof mounted air handling units generate some sound and vibration which may or may not require some speci...

Page 39: ... 13 TYPICAL GAS PIPING CONNECTION 1 1 2 FPT FACTORY PIPING ROOF CURB DRIP LEG UNIT BASERAIL UNION For Servicing 1 8 NPT PLUG MANUAL GAS VALVE PITCH POCKET ROOF LD11765A Gas Piping Recommendations 1 A drip leg and a ground joint union must be in stalled in the gas piping 2 When required by local codes a manual shut off valve has to be installed outside of the unit 3 Use wrought iron or steel pipe f...

Page 40: ... Combustion Vent The combustion vent assembly is shipped in the return air section of the unit The combustion vent assembly must be mounted over the flue gas outlet fixed panel located to the right of the gas heat access door Install as follows 1 Remove the combustion vent assembly from the return compartment 2 Remove the vertical row of six screws on either side of the flue gas outlet fixed panel...

Page 41: ...re ment can lead to compressor damage and voiding of the compressor warranty CHECKING THE SYSTEM PRIOR TO INITIAL START NO POWER Unit Checks 1 Inspect the unit for shipping or installation dam age 2 Visually check for refrigerant piping leaks 3 The compressor oil level should be maintained so that an oil level is visible in the sight glass The oil level can only be tested when the compressor is ru...

Page 42: ...he bolt heads are red in color and a label identifies their location in the unit 13 Verify proper belt tension of supply fan exhaust fan or return fan refer to SECTION 4 MAINTE NANCE of this manual Belts must be checked after 24 hours of initial operation 14 Manually rotate condenser fan blades supply ex haust and return blower wheels and motors to as sure freedom of movement 15 Verify proper cond...

Page 43: ...decreases as the compressor cycles ON the compressor is properly phased and operating in the correct rotation Suction and discharge pressure may be monitored with the User Interface if the optional suction and discharge pressure transducers are installed for menu naviga tion refer to User Interface Control Center section on page 113 If the optional transducers are not in stalled pressures must be ...

Page 44: ...ture of each system can be cal culated by recording the temperature of the liquid line at the outlet of the condenser and subtracting it from the saturation temperature listed in Table 11 on page 45 for the corresponding discharge pressure Example On a YPAL070 the liquid pressure is 375 PSIG and the liquid temperature is 97 0 F Saturation Temperature for 375 PSIG 112 0 F Minus the liquid line temp...

Page 45: ...39 105 34 14 36 110 36 16 33 115 39 18 30 120 41 20 28 125 43 22 26 130 45 24 24 135 47 26 20 140 49 28 18 145 51 30 16 150 53 32 14 160 57 34 12 170 60 36 10 180 64 38 8 190 67 40 6 200 70 42 4 210 73 44 3 220 76 46 2 225 78 48 0 235 80 50 1 245 83 52 3 255 85 54 4 265 88 56 6 275 90 58 7 285 92 60 8 295 95 62 10 305 97 64 11 325 101 66 13 355 108 68 14 375 112 70 15 405 118 72 16 500 134 74 17 6...

Page 46: ...mage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing RISQUE D ÉLECTROCUTION D INCENDIE OU D EXPLOSION Si les consignes de sécurité ne sont pas suivies à la lettre cela peut entraîner la mort de graves blessures un fonc tionnement dangereux ou des dommages mat...

Page 47: ...ification of burner operation The minimum allow able flame current for operation is 0 7 DC microamps If the furnace ignition control does not prove flame in 7 seconds it will turn off the spark signal and close the gas valve It will wait 30 seconds and then initiate a second ignition sequence If flame is not proven during the second 7 second trial for ignition the control will turn off the spark s...

Page 48: ...light from right to left in a 2 5 second time frame Each burner lights in sequential order from right to left and establishes stable flame immediately upon ignition No gas leaks in the unit piping as well as the sup ply piping Correct manifold gas pressures See Manifold Gas Pressure Adjustment on page 49 The supply pressure is adequate It must be within the limitations shown in Table 12 on page 48...

Page 49: ... the valve 3 Install a brass adapter to allow the connection of a hose to the outlet pressure tap of the valve 4 Connect the hose to a manometer capable of read ing the required manifold pressure value 5 Turn the gas back ON 6 Place the heat section into high fire operation 7 Compare the high fire manifold pressure to Table 12 on page 48 8 To adjust the high fire manifold pressure remove the cap f...

Page 50: ...ERFORMANCE DATA UNIT GAS INPUT CAPACITY BTU HR X 1000 MAXIMUM OUTPUT CAPACITY BTU HR X 1000 AIRFLOW TEMP RISE F MIN MAX 70 85 375 300 6 950 27 750 10 40 750 600 11 150 27 750 20 50 1125 900 15 150 33 325 25 55 90 105 375 300 6 950 27 750 10 40 750 600 11 150 27 750 20 50 1125 900 15 150 33 325 25 55 ...

Page 51: ...charged with R 410a refrigerant The type of re frigerant and amount per system is listed on the unit rating plate A change in the oil color or odor may be an indication of contaminates in the refrigeration system If this occurs an oil sample should be taken and ana lyzed If contaminations are present the system must be cleaned to prevent compressor failure This can be accomplished through the inst...

Page 52: ...arings must be re lubricated periodically to assure long life Motor bearing should be lubricated yearly but may need lubrication more frequently depending on severe operating conditions Belt Tension Adjust the belt tension if necessary Required belt ten sion data is supplied on the fan skid data plate at tached to the fan housing Never use a belt dressing on the belts If belts slip with the proper...

Page 53: ... to pump down into a vacuum and damage the compressor due to internal arcing Belts New belts should be re checked after 24 hours of op eration On multiple belt adjustable pulleys the pitch depth should be checked to insure identical belt travel power transfer and wear Adjustable motor bases are provided for belt adjustment Motor pulleys and blower shaft pulleys are locked in position with either s...

Page 54: ... pletely free of the wheel Be sure that key does not get bent by allowing it to ride up the key way edge The slightest bend will prevent quick as sembly Should this occur replace the key stock 8 Remove the shaft supporting the weight of the wheel particularly for larger diameter wheels Do not allow the weight of the shaft to be supported by one bearing as you disassemble 9 Remove the wheel through...

Page 55: ...ored at the factory If it is necessary to purchase a bearing locally be sure it can be worked around in the housing with a short shaft made of wood or other soft material placed in the bearing Prior to installing the bearing on the shaft it should be worked around in the housing to make sure that self alignment is obtained where the bearing is installed After the shaft journal has been inspected f...

Page 56: ...ng s inner ring The wide inner ring is loose on the shaft By turning the collar in the direction of normal shaft rotation the eccentric recessed cam will drop over and engage with the corresponding cam on the bearing inner causing it to grip the shaft tightly with a positive binding action See Figure 23 on page 56 and Figure 24 on page 57 Make sure the two cams engage smoothly and the locking coll...

Page 57: ...arings Seal Lock Washer Tapered Sleeve Nut Table 18 SET SCREW TORQUE SET SCREW DIA HEX SIZE ACROSS FLATS LBS MIN RECOMMENDED TORQUE INCH LBS FOOT LBS 1 4 1 8 66 85 5 5 7 2 5 16 5 32 126 164 10 5 13 7 3 8 3 16 228 296 19 0 24 7 7 16 7 32 348 452 29 0 37 7 1 2 1 4 504 655 42 0 54 6 5 8 5 16 1104 1435 92 0 119 6 Torquing of Set screws 1 Torque screw A to 1 2 recommended torque 2 Torque screw B to ful...

Page 58: ...JOHNSON CONTROLS 58 FORM 100 50 NOM12 ISSUE DATE 04 02 2019 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 59: ...st of acronyms and abbreviations UNIT TYPE The Series 100 unit can operate as three different unit types The unit type can be viewed and selected through the OPTIONS UNIT DATA menu in the User Interface UI These three unit types are selected in the ordering process of the unit and should not need to be changed in the field Each of the unit types have different pro gramming and sequences of operati...

Page 60: ...ose units with dual point power The phase monitor is wired in series between CTB1 terminal 4 and the unit control or rocker switch It is factory set to the unit voltage but slight field adjustment may be necessary The location of the phase monitor varies per unit tonnage range Table 19 OVERALL STATUS MESSAGES LOCAL STOP1 Unit control switch is turned OFF No 24 VAC power to SD terminal on CTB1 Powe...

Page 61: ...xes should be left open during the Unocc mode Night Set Back Setup Night set back must be User Enabled in the PRO GRAM UNIT DATA menu on older software versions night set back was located in the PRO GRAM HEATING menu and could only be User Enabled if the Series 100 unit had a heating source installed Unocc zone cooling heating setpoints must be entered in the SETPOINTS COOLING or SET POINTS HEATIN...

Page 62: ...ere is a demand for dehumidification Occ Dehumidification Cool Low VAV or SZVAV There is a demand for low dehumidification Occ Dehumidification Cool High VAV or SZVAV There is a demand for high dehumidification Unocc Dehumidification with Cooling VAV or SZVAV There is a demand for dehumidification Unocc Dehumidification Cool Low VAV or SZVAV There is a demand for low dehumidification Unocc Dehumid...

Page 63: ...y fan blower assembly The APS senses the static pressure through a fac tory installed tube that passes through the supply fan wall into the next section of the unit The APS needs to close and prove supply fan sta tus within 45 seconds after the supply fan is com manded on Failure to prove supply fan status within 45 sec onds causes a Supply Fan Lockout to occur A Supply Fan Lockout also occurs whe...

Page 64: ...e of two ways 1 Zone temperature a Wired zone temperature b Communicated zone temperature 2 Staged input a Thermostat 2 stage cooling heating b BAS commands The zone control method must be selected under the PROGRAM UNIT DATA menu 1 Wired Zone Temperature Hardwired sensor to CTB1 10K Type III thermistor 2 Comm Zone Temperature Zone temperature signal from a BAS BACnet MS TP point AV40 ZONE_TEMP_BA...

Page 65: ...minal either from a thermostat or from the BAS Supply fan at 100 Unocc Standby There is no demand for cooling or heating and the supply fan is OFF Comfort Ventilation Cooling See description in Comfort Ventilation section on page 102 Comfort Ventilation Heating See description in Comfort Ventilation section on page 102 Morning Warm Up See description in Heating section on page 86 Unocc Cooling Low...

Page 66: ...age heating setpoint Unocc Heating High Active SAT setpoint is the 2nd stage heating setpoint LD28115 Figure 26 SINGLE ZONE VAV SZVAV AND CONSTANT VOLUME CV OCCUPIED AND UNOCCUPIED VARIABLE AIR VOLUME VAV An HVAC system that has VAV boxes installed in the ductwork operates as VAV Typical VAV sys tems have overhead ductwork that provides condi tioned air down into the space A VAV unit has a supply ...

Page 67: ...e next section of the unit The APS needs to close and prove supply fan sta tus within 45 seconds after the supply fan is com manded on Failure to prove supply fan status within 45 seconds causes a Supply Fan Lockout to occur A Supply Fan Lockout also occurs if the APS opens for more than 2 seconds once fan status is proven to be RUNNING Table 24 VAV SUPPLY FAN SPEED UNIT MODE STATUS Occ Standby Su...

Page 68: ... This is the duct static pressure that causes the unit to immediately shut down on a Duct High Pressure Alarm Supply Fan Sync Supply fan sync is only applicable for Series 100 units configured as VAV The Series 100 unit has the ability to synchronize the operation of the supply fans when units of the same tonnage are installed in a master satellite ar rangement also known as twinning Supply fan sy...

Page 69: ... the PRO GRAM UNIT DATA menu All setpoints are also available on a BAS Table 26 VAV UNIT MODE UNIT MODE ZONE TEMPERATURE Occ Standby No demand for cooling or heating exists Occ Cooling Current RAT is above the active cooling RAT setpoint by 0 5 F Occ Heating Current RAT is below the active heating RAT setpoint by 0 5 F Unocc Standby No demand for cooling or heating exists Unocc Cooling Current zon...

Page 70: ...tpoint Acurrent OAT that is equal to above the OAT setpoint for low SAT causes the active cool ing SAT setpoint to be the SAT low setpoint A current OAT that is between the OAT setpoint for high SAT and the OAT setpoint for low SAT causes the active cooling SAT setpoint to be between the high SAT and low SAT setpoints See Figure 30 on page 71 1 Hardwired This method uses built in logic that resets...

Page 71: ...d the fan speed for low SAT causes the active cooling SAT setpoint to be between the high SAT and low SAT setpoints See Figure 31 on page 72 SAT Reset Method Setpoint All setpoints for SAT reset method listed in the above sequences can be found under the SET POINTS COOLING menu The reset method setpoints for RAT OAT or sup ply fan VFD speed are only shown if that SAT reset method is the one select...

Page 72: ...ON Default 55 0 F Default 65 0 F Supply Fan Speed Active SAT Setpoint Increasing Supply Fan Speed SAT LOW SETPOINT SAT HIGH SETPOINT FAN SPEED FOR HIGH SAT FAN SPEED FOR LOW SAT LD10308A Figure 31 ACTIVE SAT SETPOINT VERSUS SUPPLY FAN SPEED LD28116 Figure 32 VARIABLE AIR VOLUME VAV OCCUPIED ...

Page 73: ... and program ming to stage compressors ON OFF to achieve and maintain the active cooling SAT setpoint Under normal operation each compressor has a 3 5 minute guaranteed ON OFF timer Under normal operating conditions there is a 3 5 minute Interstage Time Delay after any compressor is started stopped before starting stopping another compressor unless fast compressor start is User En abled Compressor...

Page 74: ...om a Standby mode to a Cooling mode Fast compressor start can be User Enabled User Disabled It can be found under the PROGRAM UNIT DATA menu Fast Compressor Start is User Enabled 1 When the IPU board switches from a Standby mode to a Cooling mode it uses internal program ming logic to determine the correct stage of cool ing that is needed 2 Once the correct stage is determined the IPU board stages...

Page 75: ...o high discharge pressure The IPU board starts stops compressors accord ingly to achieve and maintain the active cooling SAT setpoint when all of following are true The unit is in Active Cooling mode OAT is above the mechanical cooling lock out temperature 50 0 F Low ambient package not installed See Table 28 for details on the compressor HP tonnage for each compressor system Compressor Status The...

Page 76: ...switches open compres sor operation terminates immediately and a com pressor safety trip occurs Wiring of the compressor safety chain is shown in Figure 34 below and Figure 35 and Figure 36 on page 77 Comp Sys 1 shown Refer to the unit s wiring diagrams for other systems At this time the IPU board starts a 60 minute timer If the compressor safety circuit status remains faulted open for 60 minutes ...

Page 77: ...PERATION FORM 100 50 NOM12 ISSUE DATE 04 02 2019 5 LD28119 Figure 35 COMPRESSOR SAFETY CHAIN WITH COMPRESSOR PROTECTION MODULE LD28120 Figure 36 COMPRESSOR SYSTEM STATUS INPUT TO I O BOARD LD28121 Figure 37 LOW PRESSURE CUTOUT LPCO SWITCH WIRING ...

Page 78: ...Sys State Lockout The symbol is replaced by the compres sor system number 1 2 or 3 in the actual display on the unit e Press the PROGRAM key and use the left right arrows navigate until the top line of display shows Program Compressor Sys tem On older versions of software resetting the Comp Sys Safety Lockout was done in the Options menu If the reset is not found in the Program menu try finding it...

Page 79: ...F when a compressor system has no low ambient package installed or the dis charge pressure transducer reading is out of range The mechanical cooling lockout temperature is user adjustable on a compressor system with a low ambient package installed For compressor systems with a low ambient package installed mechanical cooling lockout temperature can be found under SETPOINTS COOLING menu Low Ambient...

Page 80: ... the discharge line CKT 2 OUTLET B TO HGRH COIL OUTLET A TO CONDENSER COIL FROM DISCHARGE LINE CKT 2 B A LD20876 Figure 38 HGRH 3 WAY STEPPER VALVE HGRH Control Board The HGRH control board is factory installed and programmed No field setup is required The HGRH control board is powered by 24 VAC The HGRH control board receives a 0 10 VDC signal from the IPU board The HGRH control board then sends ...

Page 81: ...20mA 0 10V 1200Ω 1000Ω 600Ω 300Ω Table 32 NUMBER OF STEPS 6386 3196 2500 1596 500 1 OFF OFF OFF OFF ON 2 OFF OFF ON ON OFF 3 OFF ON OFF ON OFF SW1 HGRH 3 way stepper valve configuration All switches should be set to the OFF position Table 33 VALVE TYPE OFF ON 4 Bipolar Unipolar 5 Std Direction Reverse 6 Std Response Quick 7 200pps 400pps 8 Std Operation Close Valve Input signal selector Jumper set...

Page 82: ...is not in an Active Cooling mode The OAT is less than 55 0 F Dehumidification is not required No Active HGRH Faults exist HGRH Bleed Solenoid The HGRH bleed solenoid is powered by 24 VAC The HGRH bleed solenoid is piped in between the HGRH coil and the suction line for CKT 2 The valve bleeds off any remaining or trapped liq uid in the HGRH coil when HGRH is inactive It is a normally closed valve t...

Page 83: ...or high supply air dewpoint and return air relative humidity for low supply air dewpoint setpoints Figure 41 The IPU board continuously compares the active supply air dewpoint setpoint to the active HGRH SAT setpoint The active HGRH SAT setpoint is a calculated value between the HGRH SAT high and low set points based on the current RAT and the HGRH RAT high and low setpoints Figure 42 EVAP AIR TEM...

Page 84: ...s than the current evaporator air temperature Lockout HGRH 3 The IPU board monitors the discharge pressure for compressor system 2 When a compressor starts from system 2 HGRH goes active and there is a rapid rise in discharge pressure then the HGRH 3 way stepper valve is blocked and not allowing refrigerant to flow to either the HGRH coil or the condenser coil HGRH is installed Either compressor 2...

Page 85: ...economizer types 1 Dry Bulb Economizer suitability determined by OAT only 2 Single Enthalpy Economizer suitability de termined by OAT and outside air relative hu midity 3 Dual Enthalpy Economizer suitability deter mined by comparing the OAT and relative hu midity against the RAT and relative humidity The Series 100 also has an option for economizer operation called Best Method Best method op erati...

Page 86: ...ches to a different method For example when the economizer type is dual enthalpy and the return air humid ity sensor reading becomes invalid the IPU board tries to control the economizer as sin gle enthalpy if the economizer method to use is set to best method HEATING The Series 100 unit can be ordered with an op tional heating system installed Natural gas is the standard for staged and modu latin...

Page 87: ... ON LOW Furnace is operating normally in Low Fire mode ON HIGH Furnace is operating normally in High Fire mode FAULT Ignition control did not prove flame or other safety switch opened FAULT LOCKOUT Multiplexor output to I O board is not accurate LD28124 Figure 45 DIGITAL MULTIPLEXOR CONNECTIONS FOR STAGED GAS HEAT Staged Gas Heat Sequence of Operation Once the IPU board determines there is a deman...

Page 88: ...duced draft motors and igni tion controls if applicable Each furnace is able to operate independently of the other furnaces except for furnace section 1 When either 1A or 1B is in a fault both halves are not al lowed to operate Furnace sections 2 and 3 are still allowed to operate Modulating Natural Gas Heat Setup Set the heating system type to modulating gas un der the OPTIONS HEATING menu Set th...

Page 89: ...e the pressure switches close 24 VAC runs through two limit switches and back into the igni tion control This lets the ignition control know that all safety switches are closed There is a 30 Second Purge Timer that allows the inducer motor to flush the furnace with clean air After the 30 Second Purge Timer expires the igni tion control 1 Sends 24 VAC to the low and high fire so lenoid of the gas v...

Page 90: ...e quence On a modulating gas heat unit furnace 1A is al ways the first ON and last OFF Furnace 1A has a 2 stage gas valve and a modu lating gas valve controlled by a Maxitrol Signal Conditioner The signal conditioner receives a 0 10 VDC sig nal from the IPU board depending on the required heating demand 1 Furnace 1A Low Fire Furnace 1Astarts with the low fire solenoid of the 2 stage gas valve bein...

Page 91: ... fire Furnace 1A starts at low fire min and goes through the low fire to high fire se quence as described above When more heat is still needed furnace 2 switches to high fire and furnace 1A starts at low fire min and goes through the low fire to high fire sequence as de scribed above When more heat is needed and furnace 2 is on high fire and furnace 1A is at high fire max the IPU brings on furnace...

Page 92: ... capacity TB1 7 24 VAC common from T5 trans former Digital Multiplexer Control Board A Series 100 unit equipped with either staged or modulating gas heat utilizes a digital multi plexer control board The digital multiplexer control monitors numer ous 24 VAC inputs and then uses these inputs to send a 0 5 VDC signal back to the IPU board The IPU board uses this 0 5 VDC signal to deter mine the stat...

Page 93: ...e 36 STAGED GAS HEAT 0 5 VDC OUTPUTS TO IPU MIN VOLTS DC MAX VOLTS DC FURNACE 1 STATUS FURNACE 2 STATUS FURNACE 3 STATUS 0 086 0 166 OFF OFF OFF 0 224 0 313 ON OFF OFF 0 361 0 461 OFF ON OFF 0 499 0 609 ON ON OFF 0 637 0 756 OFF OFF ON 0 774 0 904 ON OFF ON 0 912 1 051 OFF ON ON 1 050 1 199 ON ON ON Table 37 MODULATING GAS HEAT 0 5 VDC OUTPUTS TO IPU MIN VOLTS DC MAX VOLTS DC MODULATING FURNACE 1A...

Page 94: ...aters installed Electric Heat Setup Set the heating system type to electric under the OPTIONS HEATING menu Set the Electric Heat Capacity to the appropriate selection under the OPTIONS HEATING menu Ensure that Heating System is User Enabled un der the PROGRAM HEATING menu TABLE 37 MODULATING GAS HEAT 0 5 VDC OUTPUTS TO IPU BOARD CONT D Troubleshooting the Multiplexer Control Board Ensure the digit...

Page 95: ...e options avail able The size of the hot water steam coil does not impact the hot water steam operation The hot water steam valve is field provided in stalled On a steam coil the steam trap is field provided installed A freezestat is factory installed on all Series 100 units built with a hot water steam coil Hot Water Steam Heat Setup Set the heating system type to hot water steam un der the OPTIO...

Page 96: ...ut Hot Water Freeze Fault is declared Heating Sequences The Series 100 unit has several different sequenc es associated with the different heating options Each of these sequences can be User Enabled User Disabled in the PROGRAM HEATING menu They can also be User Enabled User Disabled through a BAS Morning Warm Up Morning warm up is a sequence that typically warms a building to a comfortable temper...

Page 97: ...ime exceeds the morning warm up max time the morn ing warm up opt time becomes the morning warm up max time When the morning warm up opt time is deter mined to be less than 15 minutes the morning warm up opt time becomes 15 minutes The default values for daily warm up time day 1 day 2 day 3 shall be initially set to 60 minutes These values can be reset to the default val ues by turning morning war...

Page 98: ...e economizer output is less than 5 There has been no compressor opera tion for 10 minutes The heating source is controlled to the active cooling SAT setpoint mixed SAT setpoint for FlexSys Supply air tempering becomes INACTIVE when the following conditions are satisfied 1 Modulating Gas Heat The current SAT mixed SAT for FlexSys becomes 4 0 F warmer than the active cooling SAT setpoint mixed SAT s...

Page 99: ...h optional CO2 sen sors The IPU board monitors the indoor and out door CO2 values When the indoor CO2 level becomes greater than the outdoor CO2 level plus the CO2 offset setpoint demand ventila tion becomes active The outside air dampers modulates open closed based on the ventilation demand Ventilation Setup Damper hardware is set in the OPTIONS VENTI LATION menu Set whether there are CO2 sensors...

Page 100: ...ly fan is running the outside air damper is con trolled to the following 1 Supply fan at 100 outside air damper at minimum position 2 Supply fan at 50 outside air damper at maximum position 3 Supply fan at a speed between 50 and 100 outside air damper between minimum and maximum positions Be aware that if the economizer is active it can override this outside air maximum position setpoint to bring ...

Page 101: ...n Ventilation system must be set to User Enabled in the PROGRAM VENTILATION menu Damper hardware must be set to Tek Air full IAQ in the OPTIONS VENTILATION menu Control type must be set to Demand in the PRO GRAM VENTILATION menu CO2 sensors must be set to Installed in the OP TIONS VENTILATION menu CO2 offset setpoint must be set in the SET POINTS VENTILATION menu Minimum outside airflow setpoint m...

Page 102: ...e User Enabled in the PROGRAM VENTILATION menu The unit must be in an Occ mode The unit must have a valid zone temperature read ing When the current SAT becomes greater than the occ zone cooling setpoint by 5 0 F the IPU board starts the unit in occ cooling low When the current SAT becomes less than the occ zone cooling setpoint by 5 0 F for 5 minutes the IPU board stops comfort ventilation cool C...

Page 103: ...S EXHAUST menu Building pressure setpoint must be set in the SET POINTS EXHAUST menu Other setpoints specific to the power exhaust type must be set in the SETPOINTS EXHAUST menu ON OFF Damper Control Sequence of Operation Power exhaust type must be set to ON OFF Damper Control in the OPTIONS EXHAUST menu Building pressure setpoint must be set in the SET POINTS EXHAUST menu Economizer output for fa...

Page 104: ...OINTS EXHAUST menu This sequence uses a modulating exhaust damper with a single speed exhaust fan When the current building pressure becomes greater than the building pressure setpoint the IPU board starts sending a 0 10 VDC signal to the exhaust damper actuator When the exhaust damper position is greater than the exhaust output for fan start the exhaust fan is turned ON When the exhaust damper po...

Page 105: ... In this sequence the return plenum pressure setpoint is a fixed value of 0 05 iwg When the supply fan starts the return fan starts as well The IPU board monitors the return fan plenum pres sure and controls the speed of the return fan VFD up down to maintain the return fan plenum pressure setpoint Return Fan with Exhaust Sequence of Operation Power exhaust type must be set to Return Fan with Exha...

Page 106: ...ible 3 Six Foot Cooling Zone When designing for a UFAD only the first 6 feet up from the floor should be conditioned The remaining area above 6 feet is used to allow the air to mix with various heat loads in the space This mixing of air helps to ensure warm enough return air to use in the return air bypass duct Johnson Controls engineers have found during extensive testing that RATs cooler than 78...

Page 107: ...etpoint must be set in the SET POINTS COOLING menu Maximum bypass setpoint must be set in the SET POINTS COOLING menu Evaporator leaving air temperature high setpoint must be set in the SETPOINTS COOLING menu Evaporator leaving air temperature low setpoint must be set in the SETPOINTS COOLING menu Reset enthalpy setpoint must be set in the SET POINTS COOLING menu Current Operating Mode The current...

Page 108: ...mixed SAT setpoint plus the return air diff setpoint the unit remains in the Occ Cooling without By pass mode When in Occ Cooling without Bypass the re turn air bypass damper remains fully closed LD28133 Figure 57 FLEXSYS UNOCCUPIED Fan Operation The same as a VAV configured unit the supply fan is controlled by a VFD The VFD controls the speed of the supply fan up down to achieve and maintain the ...

Page 109: ...enthalpy is greater than the reset enthalpy setpoint Underfloor slab dewpoint is greater than the underfloor slab temperature minus 2 0 F for 120 seconds only applicable if dewpoint reset is user enabled Return Air Bypass Damper A FlexSys configured unit must have a re turn air bypass duct and damper installed for proper operation The return air bypass should be sized for no more than 40 of the to...

Page 110: ...ween 80 0 90 0 F Keeping the SAT heating setpoint between 80 0 90 0 F keeps the underfloor slab from becoming too warm and then radiating heat for an extended period of time after heating operation has stopped Underfloor Temperature Control A FlexSys configured unit has two specialized se quences built in to help control the environment in the underfloor plenum Dew Point Reset Active Slab Control ...

Page 111: ...nocc Standby mode When the underfloor slab temperature is greater than the current RAT minus 2 0 F the underfloor temp override becomes active The IPU board activates the unit heating source and start a 20 minute Active Slab Control Timer 1 Staged Gas or Electric Heat The IPU starts the first stage of heat 2 Modulating Gas or Hot Water Steam Heat The IPU board controls the heat to the active mixed...

Page 112: ...quence of Operation Purge Mode This mode is used to purge the space with fresh air 1 Start the supply fan 2 Start the return fan if applicable 3 Start the exhaust fan if applicable 4 Open outside air dampers to 100 if applicable 5 Close return air dampers to 0 if applicable 6 Open exhaust dampers to 100 if applicable Pressurization Mode This mode is used to pressurize the space in order to force t...

Page 113: ...le to access displays program pa rameters and initiate system commands The keypad consists of 36 keys that are divided into three catego ries Data Entry Navigation and Menu Selection keys A description of each of the keys is contained below Data Entry Keys The Data Entry keys provide a means to enter values for items that support edits The keys available to sup port numeric input are the 0 through...

Page 114: ...pressed pressing any Menu Select key will bring the user to the first screen under that menu even if it is the same menu being viewed Navigation through the circular list of items can also be achieved by repeated presses of the same Menu Select key as long as no other keys are pressed For example pressing the UNIT DATA key three times will bring the user to the third screen of the UNIT DATA menu p...

Page 115: ...lways COMP SYS 1 STATUS Normal Comp A On Normal Comp B On Normal Both On Normal Both Off Safety Trip Safety Fault Safety Lockout Low Amb Inhibit Low Suct Temp Unl High Dp Unload User Disabled Derived Always COMP SYS 2 STATUS Normal Comp A On Normal Comp B On Normal Both On Normal Both Off Safety Trip Safety Fault Safety Lockout Low Amb Inhibit Low Suct Temp Unl High Dp Unload User Disabled Derived...

Page 116: ...0 0 F To 180 0 F Look Up Table Unit Type Equals Constant Volume Or Variable Air Volum OCC ZONE COOLING SETPOINT 1 OCC Zone Heating Setpoint 2 0 F 72 0 F Setoints Unit Data ZONE TEMP CURRENT 20 0 F To 180 0 F Look Up Table Unit Type Equals Constant Volume Or Variable Air Volum UNOCC ZONE COOLING SETPOINT 1 Unocc Zone Heating Setpoint 2 0 F To 95 0 F 85 0 F Setoints Unit Data ZONE TEMP CURRENT 20 0 ...

Page 117: ... Zone Heating 2 0 F To 85 0 F 72 0 F Setpoints Cooling ZONE TEMP CURRENT 20 0 F To 180 0 F Look Up Table Unit Type Equals Constant Volume Or Variable Air Volum UNOCC ZONE COOLING SETPOINT 1 UNOCC Zone Heating 2 0 F To 95 0 F 85 0 F Setpoints Cooling RETURN AIR TEMP CURRENT 20 0 F To 180 0 F Look Up Table Unit Type Equals Variable Air Volum Or FLEXSYS RAT COOLING SETPOINT 1 RAT Heating Setp 2 0 F T...

Page 118: ...ts Cooling Unit Type Equals Variable Air Volum And Sat Reset Method Equals Return Temp HIGH SAT 1 RAT Cooling Setpoint To RAT Setpoint For Low Sat 5 0 F 80 0 F Setpoints Cooling Unit Type Equals Variable Air Volum And Sat Reset Method Equals Return Temp FAN SPEED SETP FOR LOW SAT 1 Fan Speed Setp For High Sat To 100 90 Setpoints Cooling Unit Type Equals Variable Air Volum And Sat Reset Method Equa...

Page 119: ...MP 20 0 F To 180 0 F Look Up Table Press Trans Pkg Indicates That Transducers Are Not Installed For The Applicable System PRESSURE DISCHARGE 0 to 320 PSIG Look Up Table Press Trans Pkg Indicates That Transducers Are Installed For The Applicable System SUCTION 0 800 PSIG Look Up Table TEMPERATURE SUCTION 1 20 0 F To 180 0 F Look Up Table Press Trans Pkg Indicates That Transducers Are Installed For ...

Page 120: ...Exhaust Fans STATUS Running Stopped Derived EXHAUST RETURN FAN VFD 0 100 Derived Power Exhaust Type Equals Return W Exhaust Return W O Exhaust Fans RETURN FAN PRESS CURRENT 1 00 To 1 00 iwg Look Up Table Power Exhaust Type Equals Return W Exhaust Return W O Exhaust Fans ACTIVE SP 0 00 1 00 iwg Derived DUCT PRESS TRANSDUCER SPAN 2 1 25 2 5 5 0 5 0 Setpoints Supply System Unit Type Equals Variable A...

Page 121: ...ng Heat Type Equals Electric SUPPLY AIR TEMP CURRENT 20 0 F To 180 0 F Look Up Table Heat Type Does Not Equal None ACTIVE SP 50 0 F To 120 0 F Derived ZONE TEMP CURRENT 20 0 F To 180 0 F Look Up Table Always OCC ZONE HEATING SETPOINT 1 60 0 F To Occ Zone Cooling Setpoint 2 0 F 68 0 F Setpoints Heating ZONE TEMP CURRENT 20 0 F To 180 0 F Look Up Table Always UNOCC ZONE HEATING SETPOINT 1 50 0 F To ...

Page 122: ... Modulating Gas APRX RATE 37 5 150 0 Mbh Derived FURNACE 1B MODE Off Purge Ignition On Safety Trip Safety Fault Safety Lockout Fault L O Derived Heat Type Equals Modulating Gas FURNACE 1 MODE Off Purge Ignition On Low On High Safety Trip Safety Fault Safety Lockout Fault L O Derived Heat Type Equals Staged Gas FURNACE 2 MODE Off Purge Ignition On Low On High Safety Trip Safety Fault Safety Lockout...

Page 123: ... Type Does Not Equal None And Unit Type Equals Constant Volume 2ND STAGE HEATING SETPOINT 1 95 0 F to 115 0 F 100 0 F Setpoints Heating Heat Type Does Not Equal None And Unit Type Equals Constant Volume DAILY WARM UP TIME DAY 1 0 Min To Morning Warm Up Max Time Derived Heat Type Does Not Equal None And Morn Warm Up Equals Enabled DAILY WARM UP TIME DAY 2 0 Min To Morning Warm Up Max Time Derived H...

Page 124: ...ONTROL OUTPUT 0 To 100 Derived Economizer Installed Does Not Equal None OUTSIDE AIR TEMP 20 0 F To 180 0 F Look Up Table Economizer Installed Does Not Equal None OUTSIDE AIR HUMIDITY 0 100 Look Up Table Economizer Installed Equals Single Enthalpy Or Dual Enthalpy ENTHALPY 7 2 204 9 BTU LB Look Up Table Economizer Installed Equals Single Enthalpy Or Dual Enthalpy RETURN AIR TEMP 20 0 F To 180 0 F L...

Page 125: ...R MINIMUM POSITION 1 0 to OA Damper Maximum Position 15 Setpoints Ventilation Damper Hardware Does Not Equal None Or 2 Position Damper OA DAMPER MAXIMUM POSITION 1 OA Damper Minimum Position To 100 30 Setpoints Ventilation Damper Hardware Does Not Equal None Or 2 Position Damper CONTINUOUS VENT 1 User Enabled User Disabled User Enabled Program Ventilation Unit Type Equals Constant Volume COMFORT V...

Page 126: ...n Off Dampers Ctrl On Off Press Cntrl Modulate Damper VFD Fan STATUS Stopped Running Derived EXHAUST DAMPER POSITION 0 100 Derived Power Exhaust Equals Modulate Damper VFD Or Return Fan W Exh EXHAUST RETURN FAN VFD 0 100 Derived Power Exhaust Equals Modulate Damper VFD BLDG PRESSURE CNTRL OFFSET 1 0 15 To 0 15 iwg 0 00 W C Setpoints Exhaust Power Exhaust Equals On Off Press Ctrl ECONO OUTPUT FOR F...

Page 127: ...subsection that contains the pa rameter to change Unit Cooling Compressor Systems Supply System Heating Economizer Ventilation or Exhaust The parameters contained under each of these menu subsections and their password level are contained in Table 41 on page 115 through Table 49 on page 126 Use the key and the key to navigate to the parameter to change Follow the instructions given in the section ...

Page 128: ...ed by pressing the key This process can be followed until the hour minutes and meridian of both the start and stop points are set Press the key to get the schedule for the next day to appear The start and stop time of each day may be programmed differently To view the schedule without making a change simply press the key until the day you wish to view appears The key scrolls back wards to the prev...

Page 129: ...ATION SHOW WHEN COMPRESSOR 1A OPER HRS COMPRESSOR 1A STARTS 1 Derived COMPRESSOR 1B OPER HRS COMPRESSOR 1B STARTS 1 Derived COMPRESSOR 2A OPER HRS COMPRESSOR 2A STARTS 1 Derived COMPRESSOR 2B OPER HRS COMPRESSOR 2B STARTS 1 Derived COMPRESSOR 3A OPER HRS COMPRESSOR 3A STARTS 1 Derived Number Of Comps 6 Unit Capacity Equals 70 Ton 75 Ton 80 Ton 90 Ton 105 Ton COMPRESSOR 3B OPER HRS COMPRESSOR 3B ST...

Page 130: ...ayed in the Hyper Terminal win dow When the reports finish transferring to the file se lect Transfer Capture Text Stop The file can then be printed from an application such as Microsoft Notepad or Word To use Hyper Terminal to print a report without saving it to a file Select Transfer Capture to Printer On the UI select the report to print See Report Section on page 130 to select the report As the...

Page 131: ...ilure to revert the forced output back to 0 0 leaves the forced output value in place until a different value is initiated by the operation of the unit The key can be used to jump to the beginning of the next section of displays and the key can be used to jump to the beginning of the previous section of dis plays The sections of displays are as follows Parameters Analog inputs Digital inputs Digit...

Page 132: ...s Of The Digital Output To Compressor 3B CONDENSER FAN 1A 1 Digital Output TB4 9 On Off I O Board Status Of Digital Output To Condenser Fan 1A CONDENSER FAN 1B 2 Digital Output TB4 9 On Off I O Board Status Of Digital Output To Condenser Fan 1B CONDENSER FAN 2A 3 Digital Output TB6 2 On Off I O Board Status Of Digital Output To Condenser Fan 2A CONDENSER FAN 2B 4 Digital Output TB6 2 On Off I O Bo...

Page 133: ... MOD GAS FURN 3 LOW Digital Output TB3 7 On Off I O Board Status Of Mod Gas Heat Digital Output To Stage 3 Low MOD GAS FURN 3 HIGH Digital Output TB3 8 On Off I O Board Status Of Mod Gas Heat Digital Output To Stage 3 High MOD GAS FURN 1B Digital Output TB3 9 On Off I O Board Status Of Mod Gas Heat Digital Output To Stage 1B PUMP DOWN LLSV 1 Digital Output TB5 2 On Off I O Board Status Of Pump Dow...

Page 134: ... TEMP CURRENT Analog Input J2 2 0 5 Volts I O Board Analog Input From The Return Air Temperature Sensor OUTSIDE AIR HUMIDITY Analog Input J2 3 0 5 Volts I O Board Analog Input From The Outdoor Air Humidity Sensor RETURN AIR HUMIDITY Analog Input J2 4 0 5 Volts I O Board Analog Input From The Return Air Humidity Sensor TEMPERATURE SUCTION 1 Analog Input J3 1 0 5 Volts I O Board Analog Input From Th...

Page 135: ...e Air Measuring Station Pressure Transducer ZONE TEMP CURRENT Analog Input J7 1 0 5 Volts I O Board Analog Input From The Zone Temperature Sensor UNDERFLOOR SLAB TEMP Analog Input J7 2 0 5 Volts I O Board Analog Input From The Under Floor Temperature Sensor UNDERFLOOR AIR HUMIDITY Analog Input J7 3 0 5 Volts I O Board Analog Input From The Underfloor Humidity Sensor SUPPLY AIR TEMP RST Analog Inpu...

Page 136: ... Board Digital Input From The Compressor System 1 Low Pressure Safety Circuit SAFETY INPUTS LPCO 2 Digital Input TB7 7 Okay Faulted I O Board Digital Input From The Compressor System 2 Low Pressure Safety Circuit SAFETY INPUTS LPCO 3 Digital Input TB7 8 Okay Faulted I O Board Digital Input From The Compressor System 3 Low Pressure Safety Circuit SUPPLY FAN OUTPUT Digital Input TB7 10 Running Stopp...

Page 137: ... The Status Of The Communicated Occupancy Command SMOKE PURGE 1 BAS Commun Port P1 On Off IPU Board Gives The Status Of The Communicated Smoke Purge 1 Command SMOKE PURGE 2 BAS Commun Port P1 On Off IPU Board Gives The Status Of The Communicated Smoke Purge 2 Command SMOKE PURGE 3 BAS Commun Port P1 On Off IPU Board Gives The Status Of The Communicated Smoke Purge 3 Command SAT RESET BAS Commun Po...

Page 138: ...f The Communicated Zone Temperature FIRMWARE CRC Derived 0 To 99999 Always This Is The Size Of The Code In The Software And Is Not For Field Use REAL TIME UI PEAK 5 SEC AND AVERAGE Derived The Average And Peak Over The Last 5 Seconds Time Used By The User Interface This Is Not For Field Use REAL TIME UI LOST AND PEAK Derived The Lost And Peak Time Used By The User Interface This Is Not For Field U...

Page 139: ...d Rate For Port 3 P3 MANUAL MAC ADDRESS 1 To 127 Allows The Manual Entrance Of The Mac Address For Port 3 See Communication section on page 142 P3 PARITY None Even Odd Ignore Establishes The Parity For Communication Port 3 P3 PROTOCOL Terminal Modbus I O Modbus Server Api Modbus Client Establishes The Protocol For Communication Port 3 P3 STOP BITS 1 2 Establishes The Stop Bit Setting For Communica...

Page 140: ...ayed the key advanc es to the next HISTORY or Warning 1 after the last fault The key returns to the previous HISTORY or the highest warning number before the first fault Buffer number 1 is the most recent and buffer num ber 10 is the oldest HISTORY saved A maximum of 10 HISTORY s are saved The and key can be used to scroll forward and backward through the his tory buffer data The data following th...

Page 141: ... OPTIONS DATE TIME SCHEDULE OPERATING HOURS START COUNTER PRINT SERVICE or HISTORY key takes the user to the login prompt When the user is first presented with the login prompt the password field is blank When the user wishes to change Level 1 or Level 2 parameters the user must know the ap propriate password At that point only the parameters changeable under the specific password level are dis pl...

Page 142: ...TION The IPU board is designed to communicate with a Building Automation System and a printer The Building Automation System communication uses BACnet protocol MS TP Modbus I O Modbus Serv er Modbus Client or Terminal Other Building Auto mation system networks can be connected by using a router The printer communication uses ASCII protocol and RS 232 hardware Communication Ports The IPU Control bo...

Page 143: ...rder to make the MAC Address switches active again a value of 1 would need to be entered for the PI MANUAL MAC ACCESS In order to use the above procedure to establish the Device Object Instance DE the value for DE MODIFIER OFFSET MUST BE SET TO 1 In most applications the above procedure allows the Device Object Instance DE to be established Some applications may request that the Device Object In s...

Page 144: ...xSys Only R W AV77 BV01 1102 Allows The Active Slab Control To Be Turned On Off 0 Off 1 On AMORN_WA_ ACT Adaptive Morning Warmup Status Only Used With Internal Time Clock R BI01 Displays The Status Of The Adaptive Morning Warm Up BLD_STAT_ PRS Building Pressure Current R AI05 518 Displays The Current Building Press W C BULD_PRES_ SP Bldg Press Sp R W AV01 1026 Displays The Active Building Pressure...

Page 145: ...nly R BI08 1289 Displays The Status Of Comp 3B 0 Off 1 On COMP_3B_ OPER Comp 3B Operating Hrs 70 150 Ton Only R AI14 527 Displays The Operating Hrs Of Comp 3B COMP_ LPCO_1 Safety Input LPCO Ckt 1 Status R BI09 1290 Displays The Status Of The Low Press Switch On Ckt 1 0 Fault 1 No Fault COMP_ LPCO_2 Safety Input LPCO Ckt 2 Status R BI10 1291 Displays The Status Of The Low Press Switch On Ckt 2 0 Fa...

Page 146: ...t Reset FlexSys R W AV80 BV04 1105 Allows The Dew Point Reset Feature To Be Turned On Off 0 Off 1 On DSP_HI_LIMIT Duct Static Reset High Sp VAV Or FlexSys R W AV03 1028 Displays The Duct Static High Sp W C DSP_LO_LIMIT Duct Static Reset Low Sp VAV Or FlexSys R W AV04 1029 Displays The Duct Static Low Sp W C DSP_RST_BAS Duct Static Press Reset BAS VAV Or FlexSys R W AV05 1030 A BAS Value That Cause...

Page 147: ...tatus R BI23 1304 Displays The Status Of The Supply Exhaust Or Return Fan Fault 0 No Fault 1 Fault FAN_G Fan G Status R BI24 1305 Displays The Status Of The Fan G Input Either Hardwired Ctb1 Or Communicated BAS 0 Off 1 On FAN_G_BAS Fan G BAS R W AV82 BV06 1107 A BAS Command That Allows The Fan G Input To Be Turned On Off 0 Off 1 On FILTER_STATS Filter Status R BI25 1306 Displays The Status Of The ...

Page 148: ... 536 Displays The Number Of Elect Or Staged Gas Heat Stages Available HEAT_ VACTION Hw Valve Action R W AV84 BV08 1109 A BAS Command That Allows The Hot Water Steam Valve Action To Be Changed 0 Direct 1 Reverse HEATING_SAT Heating Suppy Sir Temp Sp VAV Or FlexSys R W AV09 1034 Displays The Active Supply Air Temp Sp For Heating HEATING_VLV Heating Valve R AI24 537 Displays The Ouput From The Contro...

Page 149: ... 0 Off 1 On OA_DAMP_ POS1 OA Damper Minimum Position R W AV16 1041 Displays The Active Sp For The Min OA Damper When Using Fixed Minimum Ventilation And The Supply Fan VFD Is At 100 OA_DAMP_ POS2 OA Damper Maximum Position R W AV17 1042 Displays The Max Position For The OA Damper When Using Fixed Minimum Ventilation And The Supply Fan VFD Is At 50 OA_DAMPER OA Damper Position Current R AI25 538 Di...

Page 150: ..._ CMD Occupancy Command R W AV88 BV12 1113 A BAS Command That Allows The Unit To Be Placed In The OCC UNOCC Mode 0 UNOCC 1 OCC PRS_1_DISCH Disch Press Ckt 1 R AI31 544 Displays The Current Disch Press Of Ckt 1 Psig PRS_1_SUCT Suct Press Ckt 1 R AI32 545 Displays The Current Suct Press Of Ckt 1 Psig PRS_2_DISCH Disch Press Ckt 2 R AI33 546 Displays The Current Disch Press Of Ckt 2 Psig PRS_2_ SUCTI...

Page 151: ...eady To Run If The Comp Is Off Yes No RDY_RUN_ C2B Ready To Run Comp 2B Status R BI43 1324 Displays The Status Of Comp 2B Ready To Run If The Comp Is Off Yes No RDY_RUN_C3A Ready To Run Comp 3A Status 70 150 Ton Only R BI44 1325 Displays The Status Of Comp 3A Ready To Run If The Comp Is Off Yes No RDY_RUN_ C3B Ready To Run Comp 3B Status 70 150 Ton Only R BI45 1326 Displays The Status Of Comp 3B R...

Page 152: ...Sp On A VAV Unit F SAT_RST_BAS Supply Air Temp Reset BAS R W AV28 1053 Displays The Analog Input From The BAS System That Allows The Reset Of Ther Active Supply Air Temp Sp 0 Uses Sat High Sp Amd 5 Uses Sat Low Sp Sat RST BAS Must Be Enabled In The Service Menu For This Point To Function SAT_SUC_ TMP1 Saturated Suct Temp Ckt 1 R AI43 556 Displays The Saturation Temp Of System 1 Suction Gas Based O...

Page 153: ... The Active Supply Air Temp Sp For A 1St Stage Heating Input W1 STG_2_COOL 2nd Stage Cooling SP CV SZVAV R W AV33 1058 Displays The Active Supply Air Temp Sp For A 2Nd Stage Cooling Input Y2 STG_2_HEAT 2nd Stage Heating SP CV SZVAV R W AV34 1059 Displays The Active Supply Air Temp Sp For A 2Nd Stage Heating Input W2 SUP_AIR_ TEMP Supply Air Temp Current R AI46 559 Displays The Actual Supply Air Te...

Page 154: ..._FLR_ TEMP Undefloor Slab Temp FlexSys R AI57 570 Displays The Temp Of The Underfloor Air That The Unit Is Contolling To F UND_HUMD_ BAS Underfloor Air Humidity BAS R W AV36 1061 Allows The BAS System To Input An Underfloor Air Humidity Value To The Control Under Flr Humi BAS Must Be Enabled In The Service Menu For This Point To Function UND_TEMP_ BAS Underfloor Slab Temp BAS R W AV37 1062 Allows ...

Page 155: ... Either Hardwired Or Communicated From A BAS On Off W2_HI_ HEAT_B W2 High Heat BAS CV Only R W AV97 BV21 1122 A BAS Command That Allows An Input For W2 Second Stage Heat 0 Off 1 On W2_HIGH_ HEAT W2 High Heat Status R BI63 1344 Displays The Status Of The W2 Heat Input Either Hardwired Or Communicated From A BAS On Off Y1_LO_ COOL_B Y1 Lo Cool BAS CV Only R W AV98 BV22 1123 A BAS Command That Allows...

Page 156: ...JOHNSON CONTROLS 156 FORM 100 50 NOM12 ISSUE DATE 04 02 2019 SECTION 6 USER INTERFACE CONTROL CENTER THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 157: ...AM key This function is only used on a Constant Volume unit The IPU board monitors the Return Air Temperature and energizes stages of cooling or heating prior to a demand from the space This function is only active when the unit is in the Occupied mode The choices are USER ENABLED or USER DISABLED COMP SYS 1 STATUS This is the current operating mode of the system 1 compressors The display will sho...

Page 158: ...lculate the current Morning Warm initiate time for Adaptive Morning Warm Up DAILY WARM UP TIME DAY 3 This is the Morning Warm Up time the IPU board recorded during the previous day 3 This value is used to calculate the current Morning Warm initiate time for Adaptive Morning Warm Up DAMPER HARDWARE This parameter is programmed through the OPTIONS key and identifies the type of ventilation system in...

Page 159: ...nary output to energize the exhaust fan circuit EXHAUST FAN STATUS This verifies a Binary input to the IPU board is present when the exhaust fan is operating EXHAUST OUTPUT FOR FAN START This parameter is set through the SETPOINTS key and identifies the position of the exhaust damper required to turn ON the exhaust fan in an ON OFF PRESS CNTRL option EXHAUST OUTPUT FOR FAN STOP This parameter is s...

Page 160: ... Temperature Setpoint for heating operation The IPU board controls the heating option to try and maintain this temperature HEATING SYS STATUS This is the current operating mode of the Heating Section The display will show Normal Active Normal Inactive Safety Trip Safety Fault Safety Lockout User Disabled or None HEATING SYSTEM TYPE This parameter is programmed through the OPTIONS key This paramete...

Page 161: ...is the outdoor air dry bulb temperature OAT SETPOINT FOR HIGH SAT This parameter is programmed through the SETPOINTS key When the outdoor temperature is equal to or less than this temperature the Active Supply Air Temperature Setpoint on a Variable Air Volume Unit is set to the SAT HIGH SETPOINT OAT SETPOINT FOR LOW SAT This parameter is programmed through the SETPOINTS key When the outdoor temper...

Page 162: ... A of the system is ready to be energized The User Interface will display either YES or NO READY TO RUN COMP B This means the minimum OFF time has been achieved and all the safety circuits are closed and compressor B of the system is ready to be energized The User Interface will display either YES or NO READY TO STOP COMP A This means the minimum ON time has been achieved and compressor A of the s...

Page 163: ...the SETPOINTS key This value is used in a Constant Volumn unit as the Active SAT Setpoint for 1st Stage heating operation 2ND STAGE 2 COOLING SETPOINT This parameter is programmed through the SETPOINTS key This value is used in a Constant Volumn unit as the Active SAT Setpoint for 2nd Stage cooling operation 2ND STAGE 2 HEATING SETPOINT This parameter is programmed through the SETPOINTS key This v...

Page 164: ...urge or Smk Purge Evac VENT SYS STATUS This is the active status of the Ventilation System The display will show Normal Active Normal Inactive Safety Trip Safety Fault Safety Lockout User Disabled or None VENTILATION CONTROL This parameter is programmed through the OPTIONS key and identifies whether the unit will operate with a Fixed Minimum or Demand ventilation system VENTILATION DEMAND This is ...

Page 165: ...age The DC voltage is sent to the IPU board and compared against the duct static press active setpoint The transducer is factory wired but pneumatic tubing must be field supplied and installed refer to SECTION 2 INSTALLATION The duct static pressure transducer measures differential pressure between the pressure in the duct and atmo spheric pressure When verifying transducer operation the technicia...

Page 166: ...high side connections on the transducer Since both of the inputs will now be exposed to the same pressure the differential pressure is zero and the output 2 5VDC according to Table 57 on page 166 Return Fan Pressure Transducer If the unit is order with the Return Fan Option the unit has a Return Fan Pressure Transducer The transducer is mounted in the return compartment and compares the pressure i...

Page 167: ...sors The humidity sensor outputs a 0 to 5VDC in response to the relative humidity sensed An outdoor air humidity sensor is used whenever the economizer is configured for single or dual enthalpy A return air humidity sensor is used whenever the economizer is configured for dual enthalpy A humidity sensor is also used to monitor the humidity in the space between the slab and raised floor system used...

Page 168: ...NACE 3 STATUS FURNACE 1B STATUS 0 086 0 166 OFF OFF OFF OFF OFF 0 224 0 313 ON OFF OFF OFF OFF 0 361 0 461 OFF ON OFF OFF OFF 0 499 0 609 ON ON OFF OFF OFF 0 637 0 756 OFF OFF ON OFF OFF 0 774 0 904 ON OFF ON OFF OFF 0 912 1 051 OFF ON ON OFF OFF 1 050 1 199 ON ON ON OFF OFF 1 187 1 346 OFF OFF OFF ON OFF 1 325 1 494 ON OFF OFF ON OFF 1 463 1 641 OFF ON OFF ON OFF 1 600 1 789 ON ON OFF ON OFF 1 73...

Page 169: ...t One of the compressor systems or other component is shutdown and locked out A manual reset is required to restart the system after the fault has been corrected Unit Auto Reset The complete unit is shutdown but the unit will restart automatically when the fault condition is cleared System Auto Reset One of the compressor sys tems or other component is shut down but the sys tem or component will r...

Page 170: ...ord protected and a level 2 password must be entered in order to view the data When the HISTORY key is pressed the password prompt will appear After the proper level 2 password has been entered the screen will show the first active warning If there are no active warnings present the first fault is displayed If there are no faults in the HIS TORY buffer the screen will display NO FAULT For menu nav...

Page 171: ... BINARY INPUTS See Figure 44 BINARY INPUTS See Figure 44 BINARY OUTPUTS See Figure 43 BINARY OUTPUTS See Figure 43 ANALOG INPUTS See Figure 46 ANALOG INPUTS See Figure 46 J12 3 5VDC J12 1 GND FLASH CARD J11 1 GND J11 3 12 VDC 12 VDC FUSE See Figure 63 on page 172 See Figure 63 on page 172 See Figure 64 on page 173 See Figure 64 on page 173 See Figure 65 on page 173 See Figure 66 on page 173 See Fi...

Page 172: ...JOHNSON CONTROLS 172 FORM 100 50 NOM12 ISSUE DATE 04 02 2019 SECTION 8 SERVICE LD10791C Figure 63 I O CONTROL BOARD BINARY OUTPUTS ...

Page 173: ...E FORM 100 50 NOM12 ISSUE DATE 04 02 2019 8 LD10792B Figure 64 I O CONTROL BOARD BINARY INPUTS LD10793A Figure 65 I O CONTROL BOARD ANALOG OUTPUTS NOTE See Table 64 on page 174 for pinouts LD10794A Figure 66 I O CONTROL BOARD ANALOG INPUTS ...

Page 174: ... Sys2 5VDC 333 J4 2 Input Suct Press Sys3 334 J4 7 Com Suct Press Sys3 335 J4 12 Ref Suct Press Sys3 5VDC 336 J4 3 Input Disch Press Sys1 337 J4 8 Com Disch Press Sys1 338 PIN NUMBER SIGNAL J4 13 Ref Disch Press Sys1 5VDC 339 J4 4 Input Disch Press Sys2 340 J4 9 Com Disch Press Sys2 341 J4 14 Ref Disch Press Sys2 5VDC 342 J4 5 Input Disch Press Sys3 343 J4 10 Com Disch Press Sys3 344 J4 15 Ref Dis...

Page 175: ...ult WRN EXHAUST FAN The exhaust fan output is on for 45 seconds and the run verification input is low open for 10 seconds Auto Reset Power Exhaust Other Than None Exhaust System Status Warning Sensor Misc Fault WRN FREEZESTAT TRIP The hw steam freezstat circuit goes high closed but goes low open within 5 minutes Auto Reset Heating System Type Equals Hot Water Steam Sensor Misc Status Warning Cooli...

Page 176: ...0 F for 10 seconds return air humidity 5 for 10 seconds Auto Reset Econo Installed Dual Enthalpy Sensor Misc Status Warning Sensor Misc Fault WRN RETURN FAN XDCR Supply fan output is on and return fan press current 0 95 W C or 0 95 W C for 30 seconds or supply fan output is off and return fan pressure current 0 1 W C or 0 1 W C for 5 minutes Auto Reset Power Exhaust Type Is Return Fan W Exh Or Ret...

Page 177: ...r or both compressor of the system on and this is the first trip in a 120 minute span Auto Reset Comp System Status Safety Trip Cooling Heating Fault AUTO RESET LPCO TRIP 2 The low pressure cutout input chain is open faulted for more than two seconds with either or both compressor of the system on and this is the second trip in a 120 minute span Auto Reset Comp System Status Safety Trip Cooling He...

Page 178: ... Overall Status Local Stop LOCKOUT OAT SENSOR Outside air temp sensor is out of range for 10 seconds Unit Lockout Comp Sys Status Safety Lockout Econo Sys Status Safety Lockout Sensor Misc Fault LOCKOUT RETURN FAN Return fan status is low and time from start 30 sec unit lockout Unit Lockout Power Exhaust Type Is Return Fan W Exh Or Return Fan W O Exh And The Supply Fan Is On Unit Overall Status Un...

Page 179: ...tory identified by Rm200501 the year followed by the month The subdirectory for this day would be identified as 20050111 csv the year followed by the month followed by the day Each of these files con tains all the data monitored for the day specified by the file name All connected Analog Inputs Analog Outputs Digital Inputs Digital Outputs Serial Data and Derived Data is collected The data is coll...

Page 180: ...old directory 11 Creating a directory 14 Creating a file 15 Open a file 16 Write a file 17 Delete a file 18 Close a file Table 69 DATA LOG ERROR LOG DETAIL DATA LOG ERROR DETAIL THIS ERROR OCCURRED 1 Not permitted 2 No such entity 3 No such process 4 Operation interrupted 5 I O error 6 Bad file handle 11 Try again later 12 Out of memory 16 Resource busy 19 No such device 20 Not a directory 21 Is a...

Page 181: ...o Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 70 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect ton 3 516 Kilowatts kW Power Horsepower 0 7457 Kilowatts kW Flow Rate Gallons Minute gpm 0 0631 Liters Second l s Length Feet ft 0 3048 Meters m Inches in 25 4 Millimeters mm Weight Pounds lbs ...

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Johnson Controls 100 Series, Installation Operation & Maintenance

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