York XP SERIES W/SIMPLICITY Installation Manual Download

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R-410A
XP SERIES W/SIMPLICITY SE

15/20 Ton

60 Hertz

5168273-YIM-A-1115

TABLE OF CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 14

Field Installed Electric Heat Accessories . . . . . . . . . . . . . 23

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 23

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 23

Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Optional BAS-Ready Economizer Power Exhaust Damper

Set Point Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 36

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 36

Electric Heating Sequence Of Operations . . . . . . . . . . . . 37

Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Interval between Defrosts . . . . . . . . . . . . . . . . . . . . . . . 38

Forced Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 38

Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Normal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Blower Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Outdoor Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Simplicity™ SE (Smart Equipment) Firmware Version 3.

Basic Unit Control Board Navigation Examples: . . . . . . . . 42

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

LIST OF TABLES

1 XP180/240 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 6

2 XP180/240 Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 XP180/240 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9

4 XP180/240 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 12

5 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7 XP180/240 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 21

8 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 23

9 Simplicity SE Economizer Board Details . . . . . . . . . . . . 25

10 Altitude/Temperature Correction Factors . . . . . . . . . . . . 30

11 Air Flow Performance - Side Duct Application . . . . . . . . 32

12 Air Flow Performance - Bottom Duct Application . . . . . . 33

13 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

14 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . 34

15 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 34

16 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 35

17 Limit Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

18 Electric Heat Anticipator Setpoint . . . . . . . . . . . . . . . . . . 39

19 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . 44

LIST OF FIGURES

1 XP240 Component Location . . . . . . . . . . . . . . . . . . . . . . 6

2 XP240 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . 8

3 XP240 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . 8

4 XP180 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . 8

5 XP180 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . 8

6 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7 XP240 Unit Dimensions Front View . . . . . . . . . . . . . . . . . 9

8 XP180 Unit Dimensions Front View . . . . . . . . . . . . . . . . 10

9 XP180/240 Unit Dimensions Rear View . . . . . . . . . . . . 11

10 XP180/240 Unit Dimensions Rain Hood . . . . . . . . . . . . 12

11 XP180/240 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 12

12 Fixed Outdoor Air Damper . . . . . . . . . . . . . . . . . . . . . . . 13

13 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

14 Field Wiring Disconnect - Heat Pump Unit With/Without

Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

15 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . 16

16 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . 25

17 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

18 Altitude/Temperature Correction Factors . . . . . . . . . . . . 30

19 Pressure Drop Across A Dry Indoor Coil Vs. Supply Air CFM

For All Unit Tonnages . . . . . . . . . . . . . . . . . . . . . . . . . . 34

20 XP180 (15 Ton) Charging Chart . . . . . . . . . . . . . . . . . . 40

21 XP240 (20 Ton) Charging Chart . . . . . . . . . . . . . . . . . . 40

22 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Summary of Contents for XP SERIES W/SIMPLICITY

Page 1: ...XP180 240 Unit Clearances 12 5 Control Wire Sizes 15 6 Electrical Data 17 7 XP180 240 Physical Data 21 8 Electric Heat Minimum Supply Air 23 9 Simplicity SE Economizer Board Details 25 10 Altitude Tem...

Page 2: ...w all other applicable safety precautions and codes including ANSI Z223 1 or CSA B149 1 latest edition Wear safety glasses and work gloves Use quenching cloth and have a fire extinguisher available du...

Page 3: ...your local York parts distribution center for authorized replacement parts Approvals Design certified by CSA as follows 1 For use as a Heat Pump unit with supplemental electric heat 2 For outdoor inst...

Page 4: ...tric RLF1 C Economizer w o Barometric RLF D Economizer w Power EXH1 H Motorized Damper J Motorized Damper w Baro RLF1 Outdoor Air Option 1 No Service Options 2 DSC Disconnect Switch 3 NCO Non PWR Conv...

Page 5: ...C22 1 2 Installation Codes CSA B149 1 3 Local plumbing and waste water codes and 4 Other applicable local codes Refer to unit application data found in this document If components are to be added to...

Page 6: ...32 504 125 575 3 60 540 630 125 Simplicity SE Control Board 110 Volt Convenience Outlet Powered or Non Powered Optional Disconnect Location Optional Disconnect Switch Bottom Power and Control Wiring E...

Page 7: ...Refer to Table 4 for clearances required for combustible construction servicing and proper unit operation Rigging And Handling Exercise care when moving the unit Do not remove any packaging until the...

Page 8: ...Weight Figure 6 Center of Gravity A D B C A D E C F B A B C D FRONT A C D F B E FRONT Table 2 XP180 240 Unit Weight Size Tons Model Weight lbs Center of Gravity 4 Point Load Location lbs 6 Point Load...

Page 9: ...ont 3 4 NPS Fem Bottom B 3 5 8 KO Power Wiring Front 3 NPS Fem Bottom 6 7 8 A CONTROL WIRING ENTRY COIL GUARD KIT CONDENSER COILS B POWER WIRING ENTRY 5 43 3 4 9 3 4 35 5 7 8 136 1 4 DOT PLUG For pres...

Page 10: ...proper size of the supply and return air duct connections UNIT BASE WITH RAILS Shown separately to illustrate Bottom Duct openings and Power Connection locations 12 1 2 9 1 4 8 1 8 9 3 4 3 3 4 B POWER...

Page 11: ...ncludes a power exhaust option The covering consists of a heavy black paper composition 3 Replace the side supply and return air compartment panels For side duct applications 1 Replace the side panels...

Page 12: ...y be installed on combustable floors made from wood or class A B or C roof covering materials 0 Rear 24 W O Economizer Left 24 W O Economizer 49 W Economizer 36 W Economizer 3 3 If economizer is facto...

Page 13: ...nges to insure adequate sealing Adjusting the damper to the desired air flow may be done before mounting the hood into position or after installation by removing the front hood panel or the screen on...

Page 14: ...ssor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 1 The internal wiring harnesses furnished with this unit are an integral part of the design certi...

Page 15: ...ns enclosed with thermostat for general installation procedure Seven 7 color coded insulated wires should be used to connect the thermostat to the unit Refer to Table 5 for control wire sizing and max...

Page 16: ...Smoke Detector circuit Jumper is required for any co of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupied on X is an input to the thermostat to display Error Status condi on...

Page 17: ...15 6 5 0 NONE 38 3 50 E18 18 1 21 7 65 3 70 E36 36 2 43 3 65 3 70 E54 54 2 65 73 1 80 E72 72 2 86 6 94 7 110 575 3 60 9 78 14 1 6 5 2 0 NONE 28 7 35 E18 18 1 17 3 50 3 60 E36 36 2 34 6 50 3 60 E54 54...

Page 18: ...129 9 158 7 175 E72 72 2 173 2 202 225 460 3 60 12 2 100 19 2 15 6 5 5 NONE 43 3 50 E18 18 1 21 7 70 3 80 E36 36 2 43 3 70 3 80 E54 54 2 65 79 3 90 E72 72 2 86 6 101 110 575 3 60 9 78 14 1 6 5 2 4 NO...

Page 19: ...4 54 2 129 9 154 2 175 E72 72 2 173 2 197 5 225 460 3 60 12 2 100 19 2 15 9 7 0 NONE 41 5 50 E18 18 1 21 7 68 5 70 E36 36 2 43 3 68 5 70 E54 54 2 65 77 1 90 E72 72 2 86 6 98 7 110 575 3 60 9 78 14 1 6...

Page 20: ...54 2 129 9 166 7 175 E72 72 2 173 2 210 225 460 3 60 12 2 100 19 2 15 9 7 5 NONE 46 5 50 E18 18 1 21 7 73 5 80 E36 36 2 43 3 73 5 80 E54 54 2 65 83 3 90 E72 72 2 86 6 105 110 575 3 60 9 78 14 1 6 7 8...

Page 21: ...stem power KW COP 14 62 3 25 23 80 3 20 17 F Net Capacity Btu hr 99 500 146 000 System power KW COP 13 62 2 05 20 96 2 00 DIMENSIONS inches Length 136 1 4 180 19 32 Width 92 92 Height 52 5 8 52 5 8 OP...

Page 22: ...BK090 Belt BX81 BX78 BX78 BX75 Motor HP each 5 7 5 7 5 10 RPM 1750 1750 1750 1760 Frame size 184T 213T 213T 215T FILTERS Quantity Size 4 16 x 25 x 2 12 12 x 24 x 2 1 2 4 16 x 20 x 2 1 2 4 16 x 25 x 4...

Page 23: ...ly fan system both set points should be set to the same value Free Cooling Four types of free cooling options are available dry bulb changeover single enthalpy dual enthalpy changeover and Auto Dry Bu...

Page 24: ...mpressor output be turned ON if the economizer output is less than 100 even if the differential between zone or return temperature and the current cooling setpoint is great enough to demand more than...

Page 25: ...omizer actuator position feedback Connects through circuit trace to 24V IN pin HOT C COM Mixed Air Temperature sensor input from 10K 77 F Type III negative temperature coefficient thermistor MAT param...

Page 26: ...per Used to ramp the power exhaust fan VFD position the discharge damper actuator COM 24 VAC common 0 10 VDC negative for the power exhaust variable frequency drive discharge damper modulating power e...

Page 27: ...Range parameter sets the CO2 parts per million measured by the indoor air quality sensor when it outputs 10 VDC IAQ parameter reports input status 0 5000ppm Used for demand ventilation functions if th...

Page 28: ...Adjustment Remove the economizer access panel from the unit Loosen but do not remove the two panel latches Locate the economizer actuator where the following adjustment can be made With power exhaust...

Page 29: ...ses In order to use the indoor blower tables for high altitude applications certain corrections are necessary A centrifugal fan is a constant volume device This means that if the rpm remains constant...

Page 30: ...given is at an elevation of 5 000 ft The first step is to convert this static pressure to equivalent sea level conditions Sea level static pressure 1 5 832 1 80 Enter the blower table at 6000 sCFM and...

Page 31: ...5 0 HP motor The 7 5 HP motor is required 6 1020 RPM is within the range of the 7 5 HP drives 7 Using the 7 5 HP motor and drive 3 5 turns open will achieve 1020 RPM Example Supply Air Blower Perform...

Page 32: ...880 5 52 916 5 90 954 6 27 992 6 61 1030 6 94 1067 7 26 1103 7 58 7 5 HP Field Supplied Drive XP240 20 Ton Side Duct Air Flow CFM Available External Static Pressure IWG1 1 Blower performance includes...

Page 33: ...1 7 49 7600 852 4 73 885 5 21 920 5 63 956 6 01 992 6 36 1027 6 68 1063 6 98 1097 7 27 1130 7 56 7 5 HP Field Supplied Drive XP240 20 Ton Bottom Duct Air Flow CFM Available External Static Pressure IW...

Page 34: ...actual CFM through the unit can be determined from the curve in Pressure Drop vs Supply Air CFM Figure 19 After readings have been obtained remove the tubes and reinstall the two 5 16 dot plugs that...

Page 35: ...tment Figure 17 4 Tighten blower pulley and motor sheave set screws after any adjustments Re check set screws after 10 12 hours run time recommended Belt drive blower systems MUST be adjusted to the s...

Page 36: ...the cooling system is halted as with a completion of a call for cooling Heating always takes priority Continuous Blower By setting the room thermostat fan switch to ON the supply air blower will oper...

Page 37: ...uts for each cooling system 1 An evaporator low limit sensor EC1 2 Located on the Suction Line at the Evaporator Coil to protect against low evaporator temperatures due to a low airflow or a low retur...

Page 38: ...of a heating cycle For defrost the UCB will signal the energizing of the reversing valve and de energizing the systems condenser fan motor s The unit s optional electric first stage heater is also ene...

Page 39: ...in the wrong direction Refer to Phasing Section in general information section Check blower drive belt tension 6 Check the unit supply air CFM 7 Measure evaporator fan motor s amp draw 8 Set the room...

Page 40: ...inaccurate 2 This chart is applicable to unit with the TXV s left to the factory setting If the TXV s have been adjusted in the field the charging chart may no longer apply 200 250 300 350 400 450 500...

Page 41: ...pressure grease gun pump grease Chevron SRI 2 or equivalent into the bearing cavity until new grease shows at the open port Do not over lubricate Run the motor for ten minutes until excess grease is p...

Page 42: ...is on the top Status line hit the ENTER button This action steps the LCD display into the status mode Hit ENTER to view the status menu Press Enter Step 2 7KH UVW LWHP XQGHU WKH status menu is DVent M...

Page 43: ...ER CANCEL JOY C PWR 7 7 77 Clg Engaged LeadLag Engaged Press Enter Joy Stick Down 2 Step 6 By toggling down twice the screen reaches the ClgOcc SP screen or Cooling Occupied Set Point ENTER CANCEL JOY...

Page 44: ...microprocessor connects through circuit trace to the SD 24 terminal SD 24 24 VAC hot out for factory accessory smoke detector condensate overflow and or user shutdown relay switching in series Connec...

Page 45: ...Lit indicates 24 VAC is present at C and 24V terminals FAULT Red hard lockout networking error and firmware error indicator 1 2 second on off flashing indicates one or more alarm is currently active 1...

Page 46: ...stor Input required for operation of 2 compressor units not active for 1 compressor units 3 625 VDC reading EC2 to EC2 with open circuit Used in suction line temperature safety Pinned connections on r...

Page 47: ...reheat components Effective only for reheat units output with reheat operation FAN 24 VAC hot output for indoor blower contactor coil indoor blower VFD enable relay coil Output with heat cool operati...

Page 48: ...nter of the board Positive of the 15 VDC reading to C circuit for powering an optional netstat and or Multi Touch gateway C Common for SA BUS power and communication circuits Also incorporated in the...

Page 49: ...C Field Connected BUS BACnet MSTP communication circuit Earth ground reference of the cable to prevent interference on the FC bus BACnet MSTP communication circuit Item Selector in red housing at left...

Page 50: ...start up This confidence is supported by the 30 day dealer protection coverage portion of our standard warranty policy which states that Johnson Controls UPG will cover parts and labor on new equipmen...

Page 51: ...ll open position and the frequency drive is operating at 60 HZ Do not proceed with the equipment start up without the design CFM information Design Supply Air CFM __________________________ Design Ret...

Page 52: ...and control complete Air Moving Inspection Completed See Notes Alignment of drive components Belt tension adjusted properly Blower pulleys tight on shaft bearing set screws tight wheel tight to shaft...

Page 53: ...to increase of decrease the airflow to meet the design conditions If the motor pulley size was changed measure the outside diameters of the motor and blower pulleys and record those diameters here Bl...

Page 54: ...Return Air Temperature ________________ F db ________________ F wb ________________ RH Mixed Air Temperature ________________ F db ________________ F wb ________________ RH Supply Air Temperature ____...

Page 55: ...__________________________________________________________________ _______________________________________________________________________________________________________ _____________________________...

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