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INSTALLATION, OPERATION & MAINTENANCE

MILLENNIUM PACKAGED ROOFTOP

OPTILOGIC CONTROL SUPPLEMENT

R410A ONLY, GEN3

New Release

Form 100.50-NOM7 (808)

25 THROUGH 40 TONS

"J" SERIES, R410A

P/N 417631-A

Summary of Contents for J Series

Page 1: ...INSTALLATION OPERATION MAINTENANCE MILLENNIUM PACKAGED ROOFTOP OPTILOGIC CONTROL SUPPLEMENT R410A ONLY GEN3 New Release Form 100 50 NOM7 808 25 THROUGH 40 TONS J SERIES R410A P N 417631 A ...

Page 2: ...dividual will also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or environmental pollution Usually an instructi...

Page 3: ... owner that information if applicable can be obtained by con tacting the nearest YORK Engineered Systems Service office It is the responsibility of operating service personnel to verify the applicability of these documents to the equip ment in question If there is any question in the mind of operating service personnel as to the applicability of these documents then prior to working on the equip m...

Page 4: ...5 7 N 2 3 6 8 Y 1 3 9 8 N NATURAL GAS STAGED G AIR FOIL FAN Always Class II D 2 4 5 7 O 1 4 6 8 Z 2 3 9 8 S NATURAL GAS STAGED SS HEAT EXCHANGER Class I blower is limited to 15 HP in 25 30 Ton E 1 3 6 7 P 2 4 6 8 2 2 4 9 8 E ELECTRIC HEAT Class I blower is limited to 20 HP in 40 Ton F 2 3 6 7 Q 1 3 9 7 3 1 3 0 8 C COOLING ONLY Class II blowers are not HP limited G 1 4 6 7 R 2 3 9 7 4 2 3 0 8 EXHAU...

Page 5: ...Delays 19 Constant Volume Sequence Of Operation 19 Variable Air Volume Sequence Of Operation 24 Economizer Operation 29 Ventilation Option Operation 30 Controlling Excessive Supply Air Temperature Sat 32 Power Exhaust Operation 33 Time Clock Scheduling 34 Changeover Relay Operation 35 Comfort Ventilation Operation 35 Hot Water Freeze Protection Using RA Operation 36 Smoke Purge Operation 36 SECTIO...

Page 6: ...And Options Setpoints 52 Status Key Parameters 52 Setpoint Key Parameters 52 Unit Setup Key Parameters 53 Configuration Key Parameters 58 Service Key Parameters 59 Changing Setpoints 60 Passwords 61 SECTION 6 SERVICE 64 Binary Input Operation 68 Analog Input Operation 71 Fault Descriptions 77 Wiring Diagrams 84 ...

Page 7: ...UPIED STEPPED HEATING TEMPERATURE CONTROL 25 FIG 10 VAV UNOCCUPIED COOLING TEMPERATURE CONTROL 26 FIG 11 COMPRESSOR STAGING FOR VAV COOLING 26 FIG 12 OCCUPIED HEATING AND COOLING SETPOINT SELECTION ALGORITHM 27 FIG 13 OAD MINIMUM POSITION RESET 31 FIG 14 OAD POSITION CONTROL 33 FIG 15 BUILDING PRESSURE CONTROL 33 FIG 16 EXHAUST PROPORTIONAL BAND 34 FIG 17 EXHAUST FAN CONTROL PROPORTIONAL OPTION 34...

Page 8: ...MK Smoke Purge SP1 SP3 Suction Pressure Circuit 1 Through 3 ST Space Temperature STG1 STG6 Cooling Heating Stage 1 Through 6 UNOCC Unoccupied VAV Variable Air Volume VFD Variable Frequency Drive W1 Thermostat Input For The First Stage of Heating W2 Thermostat Input For The Second Stage of Heating X Alarm Output Y1 Thermostat Input For The First Stage of Cooling Y2 Thermostat Input For The Second S...

Page 9: ...rol panel only Note that 24 volts R terminal 16 must be used as the 24 volt AC source for switching the contact to the unit controller shutdown input Use of any power source SECTION 1 INSTALLATION external to the controller will result in damage to the unit controller CO2 Sensor The optional CO2 sensor is used for demand ventilation and must be wired to the field control wiring terminal block usin...

Page 10: ...ceed this amount isolation relays must be field supplied and installed to prevent overloading the unit con troller power supply This state is maintained until the input is deactivated contacts open Contacts Closed Smoke Purge Operation Contacts Open Normal Operation Note that 24 volts R terminal 16 must be used as the 24 volt AC source for switching the contact to the unit controller Shutdown inpu...

Page 11: ... Common 24 VAC Signal Open Normal Potentiometer Common 0 5V Output Sensor Optional Common Signal CO Open Normal Common Signal Space Sensor 7 Wire Thermostat G Fan Y2 Cool Stage 2 Y1 Cool Stage 1 W2 Heat Stage 2 W1 Heat Stage 1 R 24VAC COMMON RTD Sensor 1K Nickel Q A I Q A I M O C A S S A S S S S S S C A V 4 2 R 3 1 2 4 5 8 6 7 9 10 13 11 12 14 15 1 Y 2 Y 1 W 2 W G M O C R H K M S C A V 4 2 R D S C...

Page 12: ...s UnderFloor Relative Humidity Sensor The FlexSys UnderFloor Relative Humidity Sensor is located in the under floor plenum and measures the relative humidity of the underfloor air FlexSys Evap Temperature Reset Input This is used to initiate reset of the SAT if enabled FlexSys Bypass Filter Dirty Filter Switch Input Is a field mounted differential pressure switch that indi cates the presence of a ...

Page 13: ...ere constant pressure is desired Static Pressure Probe Installation On units with duct static transducers VAV units and any unit with an optional building pressure a Static Pressure Probe must be field installed at the top of the rear corner post on the unit The factory supplied atmospheric pressure probe and associated mounting hardware are shipped inside the unit control panel The hardware consi...

Page 14: ...er and control Wiring MUST meet N E C and local codes 6 Check tightness of terminal lugs inside the power panel on both sides of the contactors overloads fuses and power connections 7 Verify fuse sizing in main circuits 8 Verify field wiring for thermostat if applicable optional zone sensor and optional CO2 sensor 9 VAV Heat Relay Output has to be wired to VAV boxes for VAV units and or for purge ...

Page 15: ...temperatures taken with manifold gauges and temperature sensors 6 With an ammeter verify that each phase of the con denser fans compressors supply fan and exhaust fan are within the RLA FLA as listed on the unit data plate GAS HEAT MODELS STAGED Pre Start Checks Startup of gas heat includes verification of incoming gas line pressure and leak checks in the field in stalled gas lines These checks ar...

Page 16: ...rners and or outside of the heat exchanger tubing Rollout switches are manual reset and need to physically reset if they open for any reason This is because the problem is usually block age of the flue passages and service personnel needs to observe the passages first hand The control circuit and burners are factory tested in to insure that all of these steps are followed GAS HEAT MODELS MODULATIN...

Page 17: ...If the compressor with the shortest total run time has expired it sASCD then that compressor will be started If the compressor with the shortest total run time has not expired it s ASCD but the other compressor has then the compressor with the longer run time will be started The OptiLogic controller has default programming for either 4 or 6 stages of cooling The R410A units are all 4 compressor th...

Page 18: ...nput from the Thermostat For gas or electric heat the Supply Fan will continue to run until the SAT is less than 100 F CV Operation For CV operation The Supply Fan will be ON whenever the G input from the Thermostat is present The Supply Fan will stay ON when the G input is no longer present to satisfy the Overrun requirement In Space Sensor or the Supply Fan will be ON whenever Heating or cooling...

Page 19: ...Heating Stage 1 W1 and W2 Active Heating Stage 2 W2 Active Only Heating Stage 2 TIMEOUTS AND DELAYS Table 2 lists the timeouts and delays that are to apply in all functions unless an exception for a specific function is specified TABLE 2 TIMEOUTS AND DELAYS Number Timeout or Delay Description 1 ASCD for cooling This minimum OFF time delay will not allow any compressor to turn on un less it has bee...

Page 20: ...unoccupied occupied signal determines what programmed space temperature setpoint to maintain in the controlled space For this option to function the configuration setting Space Sensor Enable must be set to ON and the sensor must be reliable During this mode of operation if the space sensor becomes unreliable a fault will be gener ated With this the unit will shut down unless a RAT return air tempe...

Page 21: ...roller generates a 0 100 output signal that responds to space cooling demand The output of the controller is used to calculate on and off time of the compressor most recently started based on the calculation method in Figure 4 PI gain values are to be determined by such that all compressors are on within 20 minutes with a 10 F space temperature error or 30 minutes for a 6 compressor system with a ...

Page 22: ...6 minutes 100 Hi gh Sat ur at i on O utp utofCool i ng Zone Tem p Cont ro l PI Low Sat ur at i on 0 M i n O N Tim e 6 minutes OFF Tim e minutes PI gain values are to be determined by such that all heating steps are on within 20 minutes with a 10 F space temperature error When the duty cycle reaches 100 the PI algorithm reaches a High Saturation state and a saturation time delay expires the modulat...

Page 23: ...s satisfied For supply fan setting of the For supply fan setting of Control is same as parameter Fan ON mode with the parameter Fan ON occupied heating except the Sensor Option determines mode with the Sensor space temperature is if the supply fan is ON Option determines if the controlled to a continuously or is in Auto supply fan is ON programmed unoccupied mode i e goes off when space continuous...

Page 24: ... described in the Fan 100 ON when heating is ON Controlled to maintain the Duct Static Pressure setpoint when cooling is ON ON and controlled for heating or cooling when the Thermostat G output is ON Ramped up to its operation condition using its variable output control when turned ON OFF when heating or cooling is OFF and oc cupancy is UNOCCUPIED An occupancy input is provided by the Ther mostat ...

Page 25: ...eating Occupied Cooling With A Space Sensor The programmable parameter VAV Operation with Thermostat must be set to OFF and Space Sensor signal must be reliable The SAT setpoint for cooling is the VAV Cool Low Temperature Setpoint or VAV Cool High Temperature Setpoint through comparison of the space temperature and the VAV Setpoint for SAT Reset as shown in Figure 12 Unoccupied Cooling With A Spac...

Page 26: ...ne Operation The programmable parameter VAV with Thermostat must be set to OFF Space Sensor signal must be unreliable or not de tected The SAT setpoint for occupied standalone cooling is the VAV Cool Low Temperature Setpoint Unoccupied Cooling In Standalone Operation In this mode the unit remains shut down unoc cupied cooling is never used SAT Control Algorithm in VAV Cooling The control of compre...

Page 27: ...d to the 2nd Stage Hydronic Heat Setpoint The VAV Relay output of the controller is set to 10 VAC during heating Morning Warm Up operation will end when An occupancy space is occupied input is received from the controller input The scheduled occupancy time occurs The Morning Warm Up operation times out based on the Max Morning Warm Up Time parameter The transition from cooling to occupied heating ...

Page 28: ... from Heat1 output If hydronic heat SAT controlled to 2nd stage hydronic heat setpoint Occupied heating is never used Same as occupied heat ing except stat uses its programmed unoccupied heating setpoint stat gen erates unoccupied output that overrides ODA damper min position to 0 Dur ing heating supply fan at 100 Similar to thermostat operation above stat W1 signal is replaced by a net work comma...

Page 29: ...be used The 10 F offset represents the high est outdoor air temperature that the DX cooling can reliably reduce to the SAT setpoint Outside Enthalpy Method Economizer will be suitable when OA Enthalpy Outside Enthalpy Number parameter value and OAT SAT setpoint 10 F A2 F hysteresis about the SAT setpoint 10 F will be used A 1 BTU LB hysteresis about the Outside Enthalpy Number will be used Differe...

Page 30: ...T a rela tively unusual case If the OAT then increases above the Cooling Lockout on OAT parameter value while the call for several compressors exists the compressors in this case and only in this case will turn ON simultaneously This is considered acceptable as this situation is not expected to occur frequently VENTILATION OPTION OPERATION The rooftop units will support several dif ferent ventila ...

Page 31: ...rations not installed or not enabled Occupancy status is Occupied Demand Ventilation control will operate in both heating and cooling modes and will increase the position of the economizer OA Damper from the minimum position or the control positions of economizer or economizer loading as required to meet the Demand Ventilation Setpoint Sensor If all conditions are met the control will look for an ...

Page 32: ...point During heating operation when the SAT rises above the Excessive Heating SAT setpoint for more than 1 minute the control will destage one step of heat An excessive SAT fault will be written to the error history buffer along with a snapshot of the points data Steps of heat will continually be destaged until the SAT drops below the Excessive Heating SAT setpoint When a step of heat is destaged ...

Page 33: ...f the OutsideAir Damper Two position operation requires Economizer ON Constant Volume ON Supply Fan ON This operation is not available when an OA Flow Sta tion is installed The Exhaust Fan will be controlled by the OAD position as follows Fan ON when the position OAD Position for the Exhaust Fan to Turn On Fan OFF when the position OAD Position for the Exhaust Fan to Turn OFF Fan OFF when Supply F...

Page 34: ...N setpoint the controller will energize the Exhaust Fan Output The Exhaust Fan Output will remain energized until the proportional exhaust output drops to or below EAO Position for the Exhaust Fan to Turn OFF setpoint The following figure illustrates the control of the exhaust fan for this control sequence FIG 16 EXHAUST PROPORTIONAL BAND 100 Exhaust Control Loop Output 0 minus Exhaust Control Off...

Page 35: ...hip of the OAT to the specified SAT control band If the OAT is below the specified Cmfrt Vent Low SAT setpoint the action will be direct acting In this case the economizer control can lower the SATtem perature just by opening the economizer damper and using more outdoor air However if the economizer controller can not prevent the SAT from dropping below the bottom control band limit by closing the...

Page 36: ...OT WATER FREEZE PROTECTION USING RA OPERATION When programmed for Hot Water or Steam RA mon itoring will be used for freeze protection If the RA temperature is less than 40 F and the Supply Fan is OFF the Heating Valve output will open to 100 When the Supply Fan is ON or the RA temperature is greater than 50 F the Heating Valve output returns to normal operation No fault is generated by this opera...

Page 37: ...ntain this operation until the Smoke Purge input is deactivated then return to normal operation Setting 5 Purge w Duct Pressure Control If the smoke purge setting is set to 5 and the Smoke Purge input is activated the unit will do the follow ing Supply Fan VAV units Turn ON the Supply Fan VFD and control to the Duct Static Setpoint CV Turn ON fan variable output is 100 Turn ON the Exhaust Fan full...

Page 38: ... decrease Back Next Change Enter and Cancel NAVIGATING THE MENUS The primary means of navigation for the menus is per formed with the Back and Next keys Pressing the Back and Next keys will change the display to the previous or next display item respectively The entire menu is navigable using just the Back and Next keys exclusively However to facilitate navigation TheFunctionkeys mentionedinthepre...

Page 39: ...t Unit Mode Line 3 Current unit operating mode Line 4 Blank Line 3 displays the one of the following operating modes Occupied Cooling Warm up Occupied Heating Sys Start Delay Unoccupied Standby Preoccupancy Purge Unoccupied Cooling Smoke Purge Unoccupied Heating Emergency Shut Down Manual Override Fault Shutdown Line 2 Unit Controlled By Line 3 Determined by inputs and Setup settings Line 4 Blank ...

Page 40: ...ts for compressor systems 2 and 3 The unit is a 4 stage 4 compressor unit thus system 3 data will show N A for Status and Comps ON Line 2 Hydronic Heat System Line 3 Cntrl Output XXX Line 4 Freezestat NORMAL SAFETY TRIP N A N Ais used when a hydronic heat system HW or steam is not installed Line 2 Staged Steps Heat System Line 3 Stages ON X N A Line 4 Stages Avail X N A 0 6 N A is used when an ele...

Page 41: ...ation enabled and conditions are suitable Inactive Economizer operation enabled and conditions are not suitable Line 2 Ventilation System Line 3 Type Show Current Configuration Line 4 Status Unocc OFF Occ ON N A Fault Line 3 displays one of the following configurations None Line 4 Status N A Min Dampr Pos Minimum damper position Min Airflow 25 75 Airflow Full Airflow Line 2 Filter Status Line 3 St...

Page 42: ...ly Duct Pressure Press 1 48 inwg Setpt 1 50 inwg OPERATION DATA Sys 1 Compressors Comp A ON Comp B OFF OPERATION DATA Sys 1 Compressors Suc Press 100 psig Dis Press 325 psig OPERATION DATA Compressor Staging Next ON 2 B Next OFF Waiting OPERATION DATA OA Temp 73 4 F OA RH 48 OA Enth 26 8 btu lb Line 2 Sys X Compressors Line 3 Comp A ON OFF FAULT N A Line 4 Comp B ON OFF FAULT N A Line 2 Sys X Comp...

Page 43: ...PERATION DATA Outside Air Damper Position 2 30 Position 3 35 Line 2 Outside Air Damper Line 3 Position 2 XXX Line 4 Position 3 XXX OPERATION DATA FlexSys Supply Temp Temp XX X F Setpt XX X F OPERATION DATA FlexRH XXX Dewpoint XX X F Slab Temp XX X F OPERATION DATA FlexSys Bypass Dmpr Position XXX Line 2 FlexSys Supply Temp Line 3 Temp XX X F cfm 0 0 Line 4 Setpt XX X F Line 2 Flex RH XXX 0 0 Line ...

Page 44: ...vigation and Display Descriptions OPERATION DATA FlexSys Bypass Air Active Byp XXX Byp Setpt XXX OPERATION DATA Rooflink Status Active Line 2 FlexSys Bypass Air Line 3 Active Byp XXX Line 4 Byp Setpt XXX Line 2 Rooflink Line 3 Status Active Inactive ...

Page 45: ...PTIONS This format will list the setpoint description on Line 2 with Setpoint XXXX on Line 3 Line 4 is always blank UNIT SETUP NAVIGATION The Unit Setup key will move the display to the first item of the Unit Setup group The Unit Setup group of display items will allow the user to view and modify general Unit Setup data All Unit Setup parameters will show data however not all Unit Setup parameters...

Page 46: ...Fri HH MM HH MM Sat HH MM HH MM Line 2 General Setup Line 3 Language Option Line 4 Setting English DISPLAY SUBGROUP 4 Line 2 Econo Exhaust System Line 3 Economizer Enable Line 4 Setting OFF All the displays will follow the same format as shown above and are covered in sequence and explained in the section PARAMETER DESCRIPTIONAND OP TIONS SETPOINTS This format will list the Unit Setup setpoint des...

Page 47: ... the description of the selected function CONFIGURATION will be displayed on line 1 of the display Line 2 will display one of the selected subgroups pertaining to the setpoint being viewed changed The table below illustrates the four subgroups under Configuration CONFIGURATION Heat Cool System Freezestat Setting OFF Pressing the Up and Down keys at this display item will navigate the display curso...

Page 48: ...ts for compressor systems 1 2 and 3 If the unit is configured as a 4 compressor unit Display 3 Sys 3 Comp Runtimes will show N A for both compressors Display shows the number of starts on each compressor Line 2 Sys X Comp Starts Line 3 Comp A XXXXXX Line 4 Comp B XXXXXX Display repeats for compressor systems 1 2 3 If the unit is configured as a 4 compressor unit Display 3 Sys 3 Comp starts will sh...

Page 49: ... This display shows the status of the compressor safety chain which consists of a low pressure switch high pressure switch and compressor overload for each re frigerant circuit If any of the safeties are opened the display will show the respective system and display as follows Line 2 Sys X Safety Chain Line 3 Status Tripped NORMAL Line 4 Blank This display indicates the software revision Compresso...

Page 50: ... 2 Display Line 3 display shows the following see Service section for fault response details None No fault is recorder for History XX Alarm Afault has been detected that results in the unit shutting down Trouble A fault has been detected that does not result in the unit shutting down Clear One of the following conditions has oc curred A fault has been detected on an enabled sensor failed and the s...

Page 51: ...units 4 Not used on Millenniums Error Text Line 2 Classification Line 3 Error Text Line 2 Classification Line 3 COR Status Fault Alarm F RH Sensor Fault Trouble Duct Sensor Fault Alarm F Slab Sensor Fault Trouble Excess Duct Pressure Alarm Heat SAT Fault Trouble HW Freeze Fault Alarm IAQ Sensor Fault Trouble MSAT Sensor Fault Alarm OA Flow Sensor Fault Trouble SAT Sensor Fault Alarm1 OAH Sensor Fa...

Page 52: ...ing for second stage cooling VAV Cool Reset Temp This parameter is used only in VAV mode with the VAV Operation With Thermostat selection set to OFF This setpoint will be used to reset the SAT setpoint based on Space temperature or Outside Air temperature If the Outside Air SAT Reset selection is set to ON the control will monitor the outside air temperature and reset the SAT when the OAT is equal...

Page 53: ... not at full flow This value will be used for VAV units only and will be ignored on CV units Reason when using a VAV and operating at less then full flow the OA dampers need to open further to supply the required minimum air flow This value will indicate what the minimum position of the OAD should be when theVFD output is at 50 This value will be used with the OAD Minimum Position 1 value to linea...

Page 54: ...will be set The fault can be turned off by turning off this option Space Temp Alrm Diff This parameter and the Space TemperatureAlarm Time parameter below are used to generate a fault in case the space temperature deviates from the current space tem perature setpoint by more than the Space Temperature Alarm Differential and continues moving away from this setpoint for longer than the time entered ...

Page 55: ...Supply Fan does not operate with a problem that could cause ductwork damage When the static pressure reaches this setpoint The control will drive the Supply Fan control output to zero If there is no change in static pressure after 20 sec onds the control will generate a High Duct Static fault and shut down the unit VAV Occupied Heat This unit setup selection tells the control to allow VAV Occupied...

Page 56: ...When available and reliable the RAT RAH and OAH sen sors will be used for enthalpy control whether or not they are enabled Should a sensor fault be detected for the OAH sensor the fault is displayed and recorded only if the OAH Sensor Enable is ON If the controller is networked the network can be pro grammed to share the OAT and OAH sensed values with other controllers connected to the network or ...

Page 57: ...iding the outside air damper or AMS Air Measuring Station setpoints Altitude The value entered intoAltitude is the altitude of the unit above sea level This value is used only when an Air Measurement Station is installed and Outdoor Airflow Control is enabled The altitude value is to be entered within 1000 feet of actual Morning Warm Up When this option is turned ON the Morning Warm Up feature is ...

Page 58: ...METERS These setpoints are intended to be programmed at the factory and should not be changed by field personnel Unit Type This tells the control that it is controlling one of the three selectable rooftop unit type options Constant Volume Variable Air Volume Dirty Filter Switch This configuration setting tells the control that a Dirty Filter Switch is installed and that the control is to monitor t...

Page 59: ...speed exhaust fan based on the static pressure within the building or space The control output is the same for either case Economizer Installed This setting tells the control that there is Economizer hardware installed on the unit Duct Sensor Hi Limit The Duct Sensor High Limit is used to select the upper measurement limit of the sensor used for measuring the static air pressure of the supply air ...

Page 60: ...d Cooling Setpoint 82 F Notice that the top line of the display shows what keypad group you have navigated to In this case the SETPOINTS key was pressed and SETPOINTS is displayed on the top line Now pressing the NEXT key advances from the Unoccupied Heating Setpoint to the Unoccupied Cooling Setpoint and will result in the display shown below When the CHANGE ENTER key is pressed you will enter in...

Page 61: ...display window will show the level of password required and XXXX as place holders for the password to be entered The cursor will be on the left most 5 The password will be entered by moving the cursor between the digits of the password with the Next or Back keys and changing the numbers 0 9 with the Up Arrow and Down Arrow keys When all numbers are entered the user will press the Change Enter key ...

Page 62: ...tpoint 25 VAV Cool High Temp F 60 50 70 Setpoint 26 VAV Cool Low Temp F 55 50 70 Setpoint 27 VAV Cool Reset Temp F 72 60 95 Setpoint 28 Duct Static Pressure inwg 1 50 0 00 5 00 Setpoint 29 Building Pressure inwg 0 100 0 200 0 200 Setpoint 30 Economizer 1st Stage F 55 40 65 Setpoint 31 Economizer 2nd Stage F 50 40 65 Setpoint 32 SAT Econo Load Heat F 150 100 195 Setpoint 33 Outside Air Enthalpy btu...

Page 63: ...AT Econo Loading ON ON or OFF Unit Setup 79 Power Exhaust Enable OFF ON or OFF Unit Setup 80 OA Flow Cntrl Enable OFF ON or OFF Unit Setup 81 Comfort Vent Mode OFF ON or OFF Unit Setup 82 Cmfrt Vent Max Dampr 75 0 100 Unit Setup 83 IAQ Sensor Enable OFF ON or OFF Unit Setup 84 IAQ Sensor Span ppm 5000 0 10000 Unit Setup 85 MAX DV Multiplier 1 25 1 2 Unit Setup 86 Altitude Ft 1000 0 10000 Ft Unit S...

Page 64: ...ure shows the Jack connection desig nated by J and the pin number located on the inside of the board diagram The input or output designations are shown on the outside of the figure Table 15 lists the description of the various inputs and outputs and the respective connections Figure 20 shows the MOD_DCU architecture as it re lates to the on board relays for the binary outputs and the associated LE...

Page 65: ...5 C AO 4 AO 4 C AO 3 AO 3 C AO 2 AO 2 C AO 1 AO 1 C 8 7 6 5 4 3 2 1 J13 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 J8 J9 P1 P2 J7 B I N A R Y I N P U T S BI 14 BI R BI 13 BI 12 BI R BI 11 BI 10 BI R BI 9 BI 8 BI R BI 7 BI 6 BI 5 BI 4 BI R BI 3 BI 2 BI R BI 1 24VAC COM 24V AC 15 VDC 15 15 A N A L O G I N P U T S P10 P11 P12 P13 7 8 9 10 N 2 N 2 N 2 G N D N 2 S H D N2 RDU RS 232 ETHE RNET 1 2 3...

Page 66: ...URE Hot Water Stat Change Over Relay Status LOWER RIGHT HAND CORNER OF MOD DCU Safety CKT 1 Safety CKT 2 Safety CKT 3 Emergency Stop Smoke Purge Air Proving Switch Flame CKT 1 Flame CKT 2 Filter Switch Evap F reeze Stat Flame CKT 3 G Input DCC UNDCC Input VFD Bypass LD07636 ...

Page 67: ...AT COOL SUPPLY FAN HEAT RELAY OUTPUT EXHAUST FAN C O RELAY CHANGEOVER 5TH STAGE HEAT COOL BINARY INPUT LED S REFER TO FIGURE 20 LED LED LED LED ALARM LED ETHER NET PORT RS 232 PORT DISPLAY PORT N2 PORT Hot Water Stat Change Over Relay Status Safety CKT 1 Safety CKT 2 Safety CKT 3 Emergency Stop Smoke Purge Air Proving Switch Flame CKT 1 Flame CKT 2 Filter Switch Evap F reeze Stat Flame CKT 3 G Inp...

Page 68: ...l be connected to the following binary inputs Compressor circuit 1 BI 1 Compressors 1 2 40 ton Compressor circuit 2 BI 2 Compressors 3 4 40 ton Compressor circuit 3 BI 3 not used High Pressure Switch settings are open 625 10 psig close 500 10 psig Low Pressure Switch settings are open 50 5 psig close 71 5 psig For normal operation the Compressor Circuit Status inputs must be present 24VAC to input...

Page 69: ...cond Set all binary outputs to low de energize Set all analog outputs to zero volts This input will have priority over all operation BI 10 Smoke Purge Input The Smoke Purge input will monitored by the control The control will interpret this input as follows Smoke purge required Smoke Purge 24VAC input present Smoke purge not required Smoke Purge 24VAC input not present When the Smoke Purge input h...

Page 70: ... will resume normal operation If the HW Freezestat input is open for 10 minutes the control will declare a HW Freeze Fault shut down the unit and maintain the heating value output at 100 A HW Freeze Fault will remain active as long as the hot water Freezestat input is open The fault will clear when the Freezestat input closes for 5 minutes HW hot water Thermostatic Switch Settings are open 35 4 2 ...

Page 71: ... then sent to the unit controller and compare against the Duct Static Pressure setpoint The control wiring is fac tory wired but pneumatic tubing must be field supplied and installed refer to Installation section in manual The duct pressure transducer measures dif ferential pres sure between the pressure in the duct and atmospheric pressure When verifying transducer operation the technician must i...

Page 72: ...e the differential pressure will be zero and output 2 5 VDC according to the Table 10 TABLE 10 BUILDING PRESSURE TRANSDUCER OUTPUT TABLE BUILDING PRESSURE TRANSDUCER OUTPUT DIFFERENTIAL INPUT OUTPUT VOLTAGE PRESSURE IWG VDC 0 50 0 00 0 40 0 50 0 30 1 00 0 20 1 50 0 10 2 00 0 00 2 50 0 10 3 00 0 20 3 50 0 30 4 00 0 40 4 50 0 50 5 00 FIG 23 MOD UNT 00492VIP FIG 24 MOD UNT WIRING DIAGRAM 4ACU OPTIONA...

Page 73: ...9 60 2400 4 80 5000 10 00 2600 5 20 TABLE 12 CO2 SENSOR OUTPUT Humidity Temperature Sensor Outside Return and UnderFloor MIT The humidity temperature sensor is a combination sen sor that will output a 0 to 5 volt DC voltage in response to a the relative humidity sensed The humidity sensor is used in conjunction with the economizer function The combination sensor also has a temperature sensor that ...

Page 74: ...that will output 24 volts when energized by the unit controller The 24 volt AC output will then energize the respective relays Table 14 lists the output designations Optional Thermostat Interface Board See Fig 25 There are no field connections required to the thermostat interface board Any thermostat that is field wired will be connected at CTB1 in the control panel of the rooftop unit and not to ...

Page 75: ...3 Analog voltage Y2 COOL 2 AI 3 Analog voltage W1 HEAT 1 AI 3 Analog voltage W2 HEAT 2 AI 3 Analog voltage G FAN G FAN OCC Occupied OC Occupied SD Shutdown SD Shutdown P Smoke Purge P Smoke Purge X To Status Indicator X Not Used C Common C Common from controller TABLE 14 THERMOSTAT INTERFACE BOARD CONNECTIONS FIG 25 THERMOSTAT INTERFACE BOARD OPTIONAL 00493VIP ...

Page 76: ...nace Model 2 Status BI 5 24VAC GAS HEAT 2 MODULE Furnace Model 3 Status BI 6 24VAC GAS HEAT 3 MODULE G fan Supply Fan BI 7 24VAC ALL Occupied Unoccupied Switch BI 8 24VAC ALL Shutdown BI 9 24VAC ALL Smoke Purge BI 10 24VAC ALL Supply Fan Status fan proving BI 11 24VAC ALL Filter Status dirty filter BI 12 24VAC DFS OPTION HW Freezestat BI 14 24VAC HW Cool Heat COR Status BI 15 24VAC ALL VFD Bypass ...

Page 77: ... for reliability according to the type of input connected and the range specified The controller monitors all AI inputs to determine if the value at the input is within an acceptable range These values are listed in Table 16 The engineer ing units represented are also listed as applicable Temperature Inputs Temperature inputs will be monitored for reliability If the controller determines that the ...

Page 78: ...e Furnace Module 2 Status BI 24 VAC Gas Heat 2 Module Furnace Module 3 Status BI 24 VAC Gas Heat 3 Module G Blower BI 24 VAC All Occupied Unoccupied Switch BI 24 VAC All Shutdown BI 24 VAC All Smoke Purge BI 24 VAC All Supply Fan Status BI 24 VAC Filter Status BI 24 VAC DFS Option HW Freezestat BI 24 VAC HW Cool Heat COR Status BI 24 VAC All VFD Bypass Input BI 24 VAC VAV w VFD Bypass Supply Fan V...

Page 79: ... parameter programmed ON AND HW Freezestat Input is OPEN for 10 minutes HW Freezestat Tstat closes for 5 minutes 6 HW valve 100 open Sys X Sfty Lockout 1 or Sys X Sfty Lockout 2 Three Comp Safety Trips within one hour Cycle power on controller OR the corresponding Compressor Safety Trip Closes for 60 min 7 SAT Sensor Fault SAT sensor is not reliable SAT sensor is not reliable OpData Supply Air Tem...

Page 80: ...Fault SAT is equal to or less than the Heating SAT Alarm setpoint AND all heating stages have been ON for at least 20 minutes SAT is greater than the Heating SAT Alarm setpoint Excess Cooling Fault Only one comp running AND SAT is less than Stage 1 Cooling SAT Limit for one minute Two or more compressors running SAT is less than Stage 2 6 Cooling SAT Limit for one minute If Stage 1 Cooling Limit c...

Page 81: ...mp Safety Trips within one hour Cycle power on controller OR the corresponding Compressor Safety Trip Closes for 60 min 7 SAT Sensor Fault SAT sensor is not reliable SAT sensor is not reliable OpData Supply Air Temp Temp Thermostat Conflict Y1 OR Y2 ON AND W1 OR W2 ON Y1 OR Y2 ON AND NOT W1 OR W2 ON OR Y1 AND Y2 AND W1 AND W2 OFF MSAT Sensor Fault Mixed Supply Air Temp input is unreliable Mixed Su...

Page 82: ...r is not reliable Unit programmed to disable RAT sensor OR RAT sensor is reliable 14 OpData RA Temp OpData RA Enth Air Switch Fault Supply fan has been off for at least for 5 minutes AND the Air Proving Switch remains closed Supply fan has been off for at least 5 minutes AND Air Proving Switch opens Unit Filter Fault Unit Filter Switch input closes for at least 1 minute Unit Filter Switch input op...

Page 83: ...ay operate 9 All trip counters are reset to zero after a power cycle to the controller Counter 1 for each system An individual trip counter resets if trip counter 1 0 AND one or both compressors are operating in the as sociated system AND 15 minutes has passed since the last trip added to trip counter 1 Counter 2 for each system An individual trip counter resets if trip counter 2 0 AND both compre...

Page 84: ...JOHNSON CONTROLS 84 FORM 100 50 NOM7 808 Service WIRING DIAGRAM MILLENNIUM OPTILOGIC ROOFLINK CONTROLLER CONTROLLER DETAIL WIRING DIAGRAMS ROOFLINK AI ...

Page 85: ...FORM 100 50 NOM7 808 85 JOHNSON CONTROLS 6 ELECTRICAL NOTES AND LEGEND LD13862 ...

Page 86: ...JOHNSON CONTROLS 86 FORM 100 50 NOM7 808 Service LD13863 CONNECTION DIAGRAM 25 40 TON CV VAV IGV ...

Page 87: ...FORM 100 50 NOM7 808 87 JOHNSON CONTROLS 6 LD13864 ...

Page 88: ...JOHNSON CONTROLS 88 FORM 100 50 NOM7 808 Service OPTI CONVERSION TO 25 40 TON LD13854 ...

Page 89: ...FORM 100 50 NOM7 808 89 JOHNSON CONTROLS 6 LD13865 ELEMENTARY DIAGRAM ALL UNITS ...

Page 90: ...JOHNSON CONTROLS 90 FORM 100 50 NOM7 808 Service LD13860 ELEMENTARY DIAGRAM GAS HEAT 25 40 TON 230V ...

Page 91: ...FORM 100 50 NOM7 808 91 JOHNSON CONTROLS 6 ELEMENTARY DIAGRAM GAS HEAT 25 40 TON 575V LD13861 ...

Page 92: ... 2008 Johnson Controls Inc P O Box 423 Milwaukee WI 53203 www johnsoncontrols com Printed in USA 100 50 NOM7 808 New Release ...

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