York MILLENIUM SIMPLICITY ELITE 25 Technical Application And Programming Manual Download Page 2

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351579-YTS-B-0608

Johnson Controls Unitary Products

TABLE OF CONTENTS

MILLENNIUM® 25-40 TON SINGLE PACKAGE
COMMERCIAL ROOFTOP UNIT EQUIPPED WITH
SIMPLICITY® CONTROLS  . . . . . . . . . . . . . . . . . . . . 1
RECOMMENDED TECHNICAL AND
INSTALLATION AIDS  . . . . . . . . . . . . . . . . . . . . . . . . 1
THE MILLENNIUM® SIMPLICITY® CONTROL  . . . . 3

INTRODUCTION AND OVERVIEW . . . . . . . . . . . . . . . . .  3
DIGITAL LINGO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4
ANALOG TO DIGITAL CONVERTER  . . . . . . . . . . . . . . .  4
COMMUNICATIONS BUS . . . . . . . . . . . . . . . . . . . . . . . .  5
OPTIONAL MODLINC TRANSLATOR. . . . . . . . . . . . . . .  5
COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . .  5

SIMPLICITY® PROGRAMMING OPTIONS . . . . . . . 11

INTERACTING THROUGH THE MILLENNIUM®

SIMPLICITY® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

INITIAL STARTUP OPTIONS . . . . . . . . . . . . . . . . . . . . 11
METRIC OPERATION (ENGLISH) . . . . . . . . . . . . . . . . 11

SETTABLE SYSTEM PARAMETERS . . . . . . . . . . . 11
MILLENNIUM® SEQUENCE OF OPERATION . . . . 18

CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Y2, Y3 AND Y4 INPUTS . . . . . . . . . . . . . . . . . . . . . . . . 30

OPERATION FOR HEATING WITH W1, W2, AND W3

INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SENSOR OPERATION  . . . . . . . . . . . . . . . . . . . . . . . . .  30
TYPES OF SPACE SENSORS  . . . . . . . . . . . . . . . . . . .  31
VAV OPERATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  32
SUPPLY DUCT PRESSURE CONTROL ALGORITHM.  34
MORNING WARM UP / VAV OCCUPIED HEATING

CONTROL ALGORITHM . . . . . . . . . . . . . . . . . . . . . . . 34

CONTROLLING EXCESSIVE SAT (SUPPLY AIR

TEMPERATURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

SAT SETPOINTS USED DURING COOLING WITH

ECONOMIZER OPERATION . . . . . . . . . . . . . . . . . . . . .36

DEMAND VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . .39
EXHAUST OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .40
SCHEDULING OPERATION . . . . . . . . . . . . . . . . . . . . . .41
COMPRESSOR STATUS MONITORING . . . . . . . . . . . .41

TROUBLESHOOTING A MILLENNIUM®
SIMPLICITY® CONTROL . . . . . . . . . . . . . . . . . . . . 43

STATUS LED CHART  . . . . . . . . . . . . . . . . . . . . . . . . . . .43
FAILURE MODES AND DEFAULT OPERATION  . . . . . .43
SENSOR FAILURES AND DEFAULT OPERATION . . . .43
SYSTEM ERRORS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

LIST OF FIGURES

Fig. #

Pg. #

SIMPLICITY® CONTROLLER . . . . . . . . . . . . . . . . . . . 3

SIMPLICITY® CONTROLS PUSH BUTTONS . . . . . . 3

ANALOG TO DIGITAL CONVERTER . . . . . . . . . . . . . 4

VFD CONTROL WIRING . . . . . . . . . . . . . . . . . . . . . . . 8

SEQUENCE OF SETTING THE SET POINTS . . . . . 14

COMFORT VENTILATION ECONOMIZER
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

SAT CONTROL BAND . . . . . . . . . . . . . . . . . . . . . . . 34

LIST OF TABLES

Tbl. #

Pg. #

ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INPUT SIGNAL TO Y1 ACTUATOR POSITION . . . . . 8

SIMPLICITY® CONTROL INPUTS . . . . . . . . . . . . . . . 9

SIMPLICITY® CONTROL OUTPUTS . . . . . . . . . . . . 10

SETTABLE SYSTEM PARAMETERS . . . . . . . . . . . . 16

COOLING STAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

IGNITION CONTROL BOARD FLASH CODES . . . . 23

MODULATING GAS HEAT . . . . . . . . . . . . . . . . . . . . 24

MODULATING GAS HEAT CONTROL BOARD FLASH
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

10 COMPRESSOR MINIMUM OFF TIMES . . . . . . . . . .  30
11 WEEKLY SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . .  34
12 HOLIDAY SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . .  35
13 ALARM DEFAULT CODES . . . . . . . . . . . . . . . . . . . .  42
14 STATUS LED CHART . . . . . . . . . . . . . . . . . . . . . . . .  43

Summary of Contents for MILLENIUM SIMPLICITY ELITE 25

Page 1: ...ontrols These procedures are the same for all 25 40 Ton Millennium Rooftop units in this series except as noted This manual covers Simplicity controls only for unit installation information please refer to the following RECOMMENDED TECHNICAL AND INSTALLATION AIDS Millennium 25 40 Ton Single Package Installation and Operation Manual 336043 Millennium 25 40 Ton Technical Guide 246653 TECHNICAL APPLI...

Page 2: ...EATING WITH W1 W2 AND W3 INPUTS 30 SENSOR OPERATION 30 TYPES OF SPACE SENSORS 31 VAV OPERATION 32 SUPPLY DUCT PRESSURE CONTROL ALGORITHM 34 MORNING WARM UP VAV OCCUPIED HEATING CONTROL ALGORITHM 34 CONTROLLING EXCESSIVE SAT SUPPLY AIR TEMPERATURE 35 SAT SETPOINTS USED DURING COOLING WITH ECONOMIZER OPERATION 36 DEMAND VENTILATION 39 EXHAUST OPERATION 40 SCHEDULING OPERATION 41 COMPRESSOR STATUS MO...

Page 3: ...me clock function with minimum of ten hours Time of day retention with unit power off The Millennium Simplicity control is resistor configured for Constant Volume CV units or Variable Air Volume VAV units The option settings for a specific option configuration will be made as part of unit test at the factory however if there is doubt about how a unit is responding in the field check the option set...

Page 4: ...ensed input value s start up ramp time initial start value maximum output control value a status point to initiate the control action i e a fan ON status Direct or Reverse Controlling Action and several other parameters to calculate a simple 0 to 100 analog output control The PI algorithm is also called a PI loop because it loops the output back to the input feedback and determines a new output va...

Page 5: ...MODBUS communication protocol A communication protocol is simply a set of rules that determine how two systems communicate with each other over some medium such as a pair of wires phone line radio waves etc The transmission medium may also be called a gateway pathway or bus An open protocol such as MODBUS is a publicly published set of rules that any equipment manufacturer can use to network into ...

Page 6: ...4 C1O 4O Table 1 Acronyms Inputs Description APS Air Proving Switch IAQ Air Quality CO2 Sensor BAS Economizer Passes BAS economizer command through to Economizer output BPS Building Pressure Sensor C1O C4O Compressor Status DF Dirty Filter Status DPS Duct Pressure Sensor FSI Hot Water Coil Freeze Input G Thermostat input for Fan GV1 3 Monitors gas valve actuation call HPS1 4 High pressure switch m...

Page 7: ...tactor and flash the appropriate flash code This flash code is not an alarm If the control already has contactors pulled in it will monitor the voltage and drop the contactors and shut down if the voltage drops below 16 VAC and flash the appropriate flash code REMOTE the control will use 0 10 VDC from third party BAS to control SAT setpoints Thermostat inputs override if in conflict with Remote Co...

Page 8: ...FD and Heating water valves Since these outputs are analog they are continuous between 2 and 10 Volts and are proportional to the 0 to 100 drive position of the device ECO Economizer Actuator The modulating Economizer uses a Johnson Controls M9220GGAYK30 spring return actuator PN 025 30869 000A This actuator uses a 2 10 VDC signal to drive the dampers open The actuator drives 95 degree rotation No...

Page 9: ...2 24 VAC sense LPS3 18 30 VAC On Off 5 VAC Low Pressure Switch for Circuit 3 24 VAC sense LPS4 18 30 VAC On Off 5 VAC Low Pressure Switch for Circuit 4 24 VAC sense Limit Switch 1 18 30 VAC On Off 5 VAC High Limit Switch input 24 VAC sense For Burner section 1 Limit Switch 2 18 30 VAC On Off 5 VAC High Limit Switch input 24 VAC sense For Burner section 2 Limit Switch 3 18 30 VAC On Off 5 VAC High ...

Page 10: ...cts Heat 1 contactor output Relay Contacts 24 VAC 120 VAC H2 Class 1 Relay Contacts Heat 2 contactor output Relay Contacts 24 VAC 120 VAC H3 Class 1 Relay Contacts Heat 3 contactor output Relay Contacts 24 VAC 120 VAC C1 Class 1 Relay Contacts Compressor number one contactor output Relay Contacts 24 VAC 120 VAC C2 Class 1 Relay Contacts Compressor number two contactor output Relay Contacts 24 VAC ...

Page 11: ...ol Also if there are field changes i e a modulating power exhaust option the control configuration will need to be modified for the new option METRIC OPERATION ENGLISH The factory default for this option is OFF The metric SI conversions are part of the controller software when the Metric parameter is selected temperature setpoints and readings will convert to Centigrade C SETTABLE SYSTEM PARAMETER...

Page 12: ...econd Stage Setpoint 50 F This tells the control what Supply Air Temperature to maintain for a call for second stage of cooling This is used only during Constant Volume cooling mode with Economizer operation This setpoint is set at 50 F with a range from 40 F to 65 F Outside Air Humidity OAH Sensor Enable OFF This setting tells the control that it is expected to use Outside Air Enthalpy calculated...

Page 13: ...re SAT Setpoint for Cooling 60 F The control will maintain this SAT when operating in VAV mode with a thermostat that is calling for first stage cooling This parameter may be adjusted from 40 F to 70 F with 60 F set as the default value VAV Low Temperature SAT Setpoint for Cooling 55 F The control will maintain this SAT when operating in VAV mode with a thermostat that is calling for second stage ...

Page 14: ... is operating the Fan it will close the Economizer fully until the freeze condition is over If the fan is off and the RAT drops below 40 F the Hot Water Valve will turn on 100 Supply AirTemp SAT Alarm Setpoint for Cooling 0 F If the SAT does not drive below this setpoint when all stages of compression are operating and 10 minutes has elapsed since the last compressor was energized the control will...

Page 15: ... 1 000 ppm Demand Ventilation Setpoint 1000 ppm This Setpoint is the maximum Indoor Air Quality IAQ level that the control will allow It is adjustable from 700 ppm to 1500 ppm IAQ Sensor Range 5 000 ppm This tells the control what the full range is for a specific IAQ sensor It can be changed from 0 to 10 000 ppm Cooling Mode Enable ON This tells the control if it has Cooling Available Mode Switch ...

Page 16: ... 80 180 150 21 Hydronic Heating Reverse Actuated Valve ON OFF ON OFF OFF 22 Remote Control ON OFF ON OFF OFF 23 VAV Upper Cooling SAT F 40 70 60 24 VAV Lower Cooling SAT F 40 70 55 25 VAV SAT Reset Setpoint F 40 85 72 26 VAV Occupied Setpoint ON OFF ON OFF OFF 27 VAV Occupied Heating Setpoint F 40 85 68 28 Morning Warm Up ON OFF ON OFF ON 29 Morning Warm Up RAT F 50 85 70 30 Duct Static Setpoint H...

Page 17: ... 180 Read Only Read Only 66 RAT Return Air Temp F 40 to 180 Read Only Read Only 67 OAT Outside Air Temp F 40 to 180 Read Only Read Only 68 ST Space Temp F 40 to 180 Read Only Read Only 69 OAH Outside Air Hum RH 0 to 100 Read Only Read Only 70 RAH Return Air Hum RH 0 to 100 Read Only Read Only 71 Occupied Input Enable ON OFF ON OFF OFF 72 Alarm Array These values represent the last 5 alarm codes in...

Page 18: ...ty holidays In addition to the programmed schedule the space sensor allows a single key press to provide up to a 4 hour unoccupied override into the occupied mode OCCUPIED MODE The supply fan operates continuously in the Occupied and Recovery modes The thermostat cycles cooling heating to maintain the space temperature to the Occupied setpoints Simplicity will enable optional economizer and power ...

Page 19: ...rops below 180 psi R22 300 psi R410a condenser fan 4 contactor 9M is brought on by PS6 monitoring discharge pressure on compressor 2 4 A control call for Compressor 2 powers contactor 2M through terminal C2 and CF2 fan 3 through CTB1 termi nal 10 on 25 ton units On 30 and 40 ton R22 and all R410a units because fans 1 and 2 pull through coils for both circuit 1 and circuit 2 the coil of contactor 7...

Page 20: ...as listed below Dry Bulb The control relies on the RAT OAT and SAT readings connected to those terminals on the control Free cooling will be available until the outdoor tempera ture rises above the indicated temperature range Free cooling is disabled when the outdoor temperature rises above the temperature range and cannot be enabled until the outdoor temperature falls below the indicated temperat...

Page 21: ...ode the duct pres sure controller if that option is installed is activated the optional power exhaust system is activated power is applied to the airflow proving switch APS and to the sup ply fan motor contactor 5M to engage the supply fan If the supply fan operates correctly proper rotation the pres sure difference between the supply fan section and the heating section increases and APS closes to...

Page 22: ...ted The optional power exhaust system is activated In heat mode cooling is disabled and the optional econo mizer outside air dampers are closed This operation is maintained until the space temperature rises above the heating setpoint or Occupied mode is engaged 11 Gas Heat Single Stage Module Each module installed has it own ignition control and its own set of safeties When there is a call for hea...

Page 23: ...two stage ignition control For faster heat exchanger warm up the ICB will automatically run each module on high fire for 30 seconds given a low fire only call for heat Because the use of two stage modules is restricted to modulating gas heat there is a Modulating Furnace Control MFC with a dedi cated discharge air temperature sensor added between the UCB and the two stage ignition control for each...

Page 24: ...465 73 On On On Off On Off 10 426 664 341 331 80 On On On On On Off 11 495 997 396 798 93 On On On Off On On 12 533 330 426 664 100 On On On On On On Gas Heat Module Step Input Output of Total Output LF1 HF1 LF2 HF2 LF3 HF3 LF4 HF4 3 1 69 333 55 466 9 Off Off On Off Off Off Off Off 2 106 666 85 333 13 Off Off On On Off Off Off Off 3 165 332 132 266 21 On Off On Off Off Off Off Off 4 202 665 162 13...

Page 25: ...ontrol calculates a 2 10VDC signal to the inlet guide vane actuator 17 Duct Pressure Control VFD Variable Frequency Drive Option The duct pressure controls are powered with a call for the supply fan Once powered the VFD responds to a VDC control signal from the DPS Duct Pres sure transducer In the heating mode the VDC DPS pres sure signal forces the fan to full volume VAV boxes should be tied to t...

Page 26: ...sed and are not modulated The BPS signal is proportional with the dif ference between outside ambient pressure and build ing pressure The VFD is set for a minimum speed of 33 and a maximum of 100 The VFD parameters are factory set specific for each control system and are detailed on a sticker by the drive The drive man ual is shipped with the unit NOTE For smoke purge etc special connections for s...

Page 27: ...ng and very little peripheral hardware This reduces the costs associated with manufacturing and servicing equipment with this level of interacting features but you can t see the status of interlocked rules as you can with discreet relays Several control modes will override other modes of operation For example The Demand Ventilation or Indoor Air Quality control may override Comfort Ventilation Eco...

Page 28: ... the ventilation air temperature is trimmed to be within the specified SAT control band Comfort Ventilation mode terminates when there is a call for heating or cooling from the space temperature control Comfort Ventilation can be used only on units equipped with an Economizer Comfort Ventilation only operates in an Occupied mode Comfort Ventilation Mode must be set to ON default set ting is OFF Th...

Page 29: ...t cycling between a satisfied and a heating state under control of a zone thermostat or zone sensor In its OFF state the control algorithm continues monitoring the SAT and performs calculations necessary to set its output that controls the hot water valve to have the same value on starting the ON cycle as it had when it went into the OFF cycle in spite of some decrease in the SAT during the OFF cy...

Page 30: ...n case G ON The operation of the thermostat s G signal is determined by the thermostat s fan mode switch NOTE During Economizer operation using Economizer First Stage Setpoint for SAT control one or more compres sors may be running in addition to economizer damper partially or fully open to provide free cooling The num ber of compressors running will mainly depend on out door air temperature There...

Page 31: ...A zone heating demand of 1 5 F will generate a request for first stage heat A zone heating demand of 2 0 F will generate a request for second stage heat A zone heating demand of 2 5 F will generate a request for third stage heat There is a three minute minimum off delay and a thirty second delay between stages When the zone temperature is 0 1 F or less below the zone setpoint for at least 1 minute...

Page 32: ...one thermostat The setpoint setting should prevent a possibility of cooling turned off while other zone s in the system still have a cooling demand VAV OPERATION WITH A ZONE SENSOR The Space Sensor is placed in a selected representative zone of a VAV system It is used to reset SAT in cooling and to control occupied heating based on comparison of zone temperature to a programmed VAV SAT Reset Setpo...

Page 33: ... the Space Sensor algorithm requests heating no heating all heating stages OFF when the Space Sensor algorithm is satisfied note that in this case the control will use all available heating stages regardless of setting of the programmable parameter Heat Stages The supply fan is controlled to 100 during unoccupied heating and cycles OFF when the Space Sensor control algorithm is satisfied if there ...

Page 34: ...eekly schedule MWU Morning Warm Up is initiated upon all transitions from Unoccupied to Occupied mode The system clock is used to identify for the Morning Warm Up a 1 hour period before actual occupancy begins also see Intelli Start If the MWU option is disabled the occupancies should be scheduled at their regular time An Occupied Override signal will initiate a warm up of up to two hours the setp...

Page 35: ...lowing control algorithm OCCUPIED VAV HEATING COOLING CONTROL ALGORITHM WITH A SPACE SENSOR In the occupied mode the control will compare the temperature in a selected VAV zone to the programmed VAV SAT Reset Setpoint and request heating or cooling using the following control algorithm The transition from cooling to occupied heating occurs at 2 F below the VAV SAT Reset Setpoint There is no satisf...

Page 36: ...sition setting represents the minimum opening of the outdoor air damper open This setting will be maintained any time the unit is in Occupied mode The minimum position setting will be determined by an Economizer Min Position programmable parameter set by a Palm Pilot The minimum position setting will be ignored during the Unoccupied mode During the Unoccupied mode the minimum position is 0 the Eco...

Page 37: ...a 2 F and 1 BTU LB differentials respectively on both sides of these limits This is similar to the Outside Enthalpy method except instead of a programmed Enthalpy Number an actually sensed return air enthalpy is used SAT Control with Economizer If the economizer is suitable free cooling is available and cooling is required the unit is not in satisfied state the algorithm will be active and modulat...

Page 38: ...l for several compressors exists the compressors will turn on with a delay between compressors Economizer Loading Option This is a programmable option The user has the ability to turn this function off It is automatically disabled if the unit does not use an economizer The on off programming choice is common to both cooling and heating The default setting is ON This programmable Economizer Loading...

Page 39: ...n heating controls SAT to a fixed temperature deadband of programmed Econo mizer Loading Setpoint in Heating and 5 F below this setpoint the setpoint is programmable between 100 F 195 F default is 160 F In units that use hydronic heat the Economizer Loading function may be enabled in order to be used for cooling the on off programming choice for this function is common to both cooling and heating ...

Page 40: ...r 10 open whichever is greater Default Setpoint settings for the EF to turn ON at Economizer 60 open turn OFF at Economizer 20 open The EF has a minimum run time of 10 seconds and a minimum off time of 60 seconds PROPORTIONAL CONTROL FAN WITH MODULATING EXHAUST AIR DAMPER EAD CONTROLLED FROM BUILDING STATIC PRESSURE In this mode the Power Exhaust Modulating Exhaust Economizer and Building Pressure...

Page 41: ...equency drive speed signal Where a unit has both ERV and an economizer the ERV will stop wheel rotation when the economizer dampers open far enough to trigger the user settable switch in the damper actuator If free cooling is available the heat exchange wheel does not need to rotate the wheel will cycle on schedule to keep the air passages blown clean Also refer to the ERV Installation Instruction...

Page 42: ...r this stage of heating 18 Third stage of heating is locked out because the ignition board failed to turn on the gas valve after 5 minutes of operation or the gas valve has voltage on it and the control is not calling for this stage of heating 19 Space Temperature Sensor has failed open or shorted 20 Supply Air Temperature Sensor has failed open or shorted 21 Return Air Temperature Sensor has fail...

Page 43: ... automatically terminate when the sensor is again detected as reliable If the unit is shut down as a result of a sensor failure the alarm must be reset after the sensor problem has been corrected by resetting the controller power cycle or reset command issued by the Palm Pilot Configuration Tool SAT SENSOR CV operation If the SAT sensor fails the Economizer excessive SAT control and predicted SAT ...

Page 44: ...r this SAT failure error will be activated The error will be written to the Error History Buffer In networked application the error flag will be readable by the network SUPPLY FAN FAILURE The conditions under which this failure is declared and the follow up actions of the control when this error occurs are described in a paragraph on Air Proving Switch Operation earlier in this document The error ...

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