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INSTALLATION
MANUAL

CAUTION:

READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.

SAVE THIS MANUAL

SUNLINE 2000™

SINGLE PACKAGE HEAT PUMP

MODEL: BQ 240

175245-YIM-C-1008

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .30

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .31

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

See the following page for a complete Table of
Contents.

NOTES, CAUTIONS AND WARNINGS

Installer should pay particular attention to the words:

NOTE

CAUTION

, and

WARNING

. Notes are intended to

clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to
alert installer that personal injury and/or equipment dam-
age may result if installation procedure is not handled
properly.

Содержание BQ240

Страница 1: ...STALLATION 6 OPERATION 26 START UP COOLING 30 TROUBLESHOOTING 31 MAINTENANCE 38 See the following page for a complete Table of Contents NOTES CAUTIONS AND WARNINGS Installer should pay particular attention to the words NOTE CAUTION and WARNING Notes are intended to clarify or make the installation easier Cautions are given to prevent equipment damage Warnings are given to alert installer that pers...

Страница 2: ...CORRECTIONS 20 PHASING 24 CHECKING SUPPLY AIR CFM 24 AIR BALANCE 25 OPERATION 26 SEQUENCE OF OPERATIONS OVERVIEW 26 COOLING SEQUENCE OF OPERATION 26 CONTINUOUS BLOWER 26 INTERMITTENT BLOWER 26 NO OUTDOOR AIR OPTIONS 26 ECONOMIZER WITH SINGLE ENTHALPY SENSOR 26 ECONOMIZER WITH DUAL ENTHALPY SENSORS 27 ECONOMIZER WITH POWER EXHAUST 27 MOTORIZED OUTDOOR AIR DAMPERS 27 COOLING OPERATION ERRORS 27 HIGH...

Страница 3: ... 16 UNIT CONTROL BOARD 37 LIST OF TABLES Tbl Pg 1 UNIT APPLICATION DATA 6 2 CONTROL WIRE SIZES 11 3 ELECTRIC HEAT APPLICATION DATA 12 4 FOUR AND SIX POINT LOADS 14 5 PHYSICAL DATA BASIC UNIT 15 6 OPERATING WEIGHTS LBS 15 7 VOLTAGE LIMITATIONS 16 8 ELECTRICAL DATA WITHOUT POWERED CONVENIENCE OUTLET 16 9 ELECTRICAL DATA WITH POWERED CONVENIENCE OUTLET 17 10 ELECTRIC HEAT CORRECTION FACTORS 17 11 MIN...

Страница 4: ... have a fire extinguisher available for all brazing operations INSPECTION As soon as a unit is received it should be inspected for possible damage during transit If damage is evident the extent of the damage should be noted on the car rier s freight bill A separate request for inspection by the carrier s agent should be made in writing REFERENCE Additional information on the design installation op...

Страница 5: ...ombination of Additional Options that Don t Have an Option Code Pre assigned AA None Standard Cabinet AB Phase Monitor AC Coil Guard AD Dirty Filter Switch AE Phase Monitor Coil Guard AF Phase Monitor Dirty Filter Switch AG Coil Guard Dirty Filter Switch AH Phase Monitor Coil Guard Dirty Filter Switch RC Coil Guard American Flag TA Technicoat Condenser Coil TJ Technicoat Evaporator Coil TS Technic...

Страница 6: ...the following guidelines to select a suitable loca tion for these units 1 Unit is designed for outdoor installation only 2 Condenser coils must have an unlimited supply of air 3 Where a choice of location is possible position the unit on either north or east side of building 4 For ground level installation use a level concrete slab with a minimum thickness of 4 inches The length and width should b...

Страница 7: ...r proper operation and service Installer must make provisions for ade quate ventilation air Refer to Unit Dimensions Figure 10 and Minimum Clearances Table 11 for the clearances required for combustible construction ser vicing and proper unit operation DUCTWORK Ductwork should be designed and sized according to the methods in Manual Q of the Air Conditioning Con tractors of America ACCA A closed r...

Страница 8: ...e On units with bottom return air application install the damper assembly over the opening in the side return air access panel Remove and discard the opening cover and the covering over the hood mounting holes used for shipping before installing Secure with the screws provided On units with side return air applications install the damper assembly on the return air ductwork as close to the unit as ...

Страница 9: ...n Minimum filter area and required sizes are shown in Physical Data Table 5 SERVICE ACCESS The following removable panels provide access to all serviceable components Compressor compartment Electric Heat compartment Side Supply Return Air compartments Two panels Blower compartment Three panels Main control box Filter compartment Outdoor Air compartment Two panels Refer to the Unit Dimensions Figur...

Страница 10: ...s i ti o n 2 4 V o l t T r a n s fo r m e r 2 T O R E M O T E S E N S O R 2 E T 0 4 7 0 1 3 2 4 IF U S E D The thermostat must provide a G sig nal when there is a call for W1 The unit control board will energize the indoor blower when the compressors are energized however if the thermo stat calls for W2 during the anti short cycle delay the electric heat when installed will be energized immediatel...

Страница 11: ...t be replaced replacement wire must be of the type shown on the wiring diagram and the same mini mum gauge as the replaced wire Electrical line must be sized properly to carry the load Use copper conductors only Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused Refer to the Typical Field Wiring Figure 5 and to the appropriate unit wiring di...

Страница 12: ... single enthalpy operation carefully turn the set point adjusting screw found on the damper control module to the A B C or D setting corresponding to the lettered curve of the Enthalpy Setpoint Adjustment Figure 6 For a dual enthalpy operation carefully turn the set point adjusting screw fully clockwise past the D setting POWER EXHAUST DAMPER SETPOINT With power exhaust option each building pressu...

Страница 13: ...o panel latches Locate the economizer actuator where the following adjustment can be made With power exhaust option each building pressuriza tion requirement will be different The point at which the power exhaust comes on is determined by the econo mizer s outdoor damper position The actuator s auxil iary switch adjustment screw should be set at the damper position at which the power exhaust is ne...

Страница 14: ...r Quality Max Adjustment Screw Indoor Air Quality LED Indoor Air Quality Min Adjustment Screw Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw FIGURE 8 FOUR AND SIX POINT LOADS A B C D FRONT A E D B F C FRONT TABLE 4 FOUR AND SIX POINT LOADS UNIT 4 POINT LOADS LBS TOTAL A B C D 240 2340 504 641 669 526 NOTE These weights are with economizer and 72 kW electric heat UNIT 6 POINT LOADS...

Страница 15: ...FM TOTAL Each 7200 OUTDOOR COIL ROWS DEEP 3 FINS PER INCH 15 FACE AREA Sq Ft 43 3 COMPRESSOR Qty Per Unit SCROLL 2 AIR FILTERS QUANTITY PER UNIT 16 X 20 X 2 4 QUANTITY PER UNIT 16 X 25 X 2 4 TOTAL FACE AREA sq ft 20 0 CHARGE REFRIGERANT 22 lbs oz SYSTEM NO 1 25 8 SYSTEM NO 2 25 0 TABLE 6 OPERATING WEIGHTS LBS MODEL BQ240 Basic Unit BQ Heat Pump 2050 Options Economizer 250 Economizer with Power Exh...

Страница 16: ... FAN MOTORS FLA EACH ID BLOWER MOTOR FLA CONV OUTLET AMPS HEATER OPTION MIN CIRCUIT AMPACITY AMPS MAX FUSE BRKR1 SIZE AMPS RLA EACH LRA EACH MODEL KW2 STAGES AMPS BQ240 20 208 30 1 225 3 7 21 7 0 0 0 0 96 8 125 E18 13 5 1 37 5 143 7 150 E36 27 0 2 74 9 143 7 150 E54 40 6 2 112 7 168 0 175 E72 54 1 2 150 2 190 5 200 230 30 1 225 3 7 20 0 0 0 0 0 95 1 125 E18 18 0 1 43 3 149 3 150 E36 36 0 2 86 6 14...

Страница 17: ...EACH LRA EACH MODEL KW2 STAGES AMPS BQ240 20 208 30 1 225 3 7 21 7 10 0 0 0 106 8 125 E18 13 5 1 37 5 153 7 175 E36 27 0 2 74 9 153 7 175 E54 40 6 2 112 7 180 5 200 E72 54 1 2 150 2 200 5 225 230 30 1 225 3 7 20 0 10 0 0 0 105 1 125 E18 18 0 1 43 3 159 3 175 E36 36 0 2 86 6 159 3 175 E54 54 0 2 129 9 167 4 175 E72 72 0 2 173 2 213 4 225 460 15 5 114 1 9 10 0 5 0 0 0 53 7 60 E18 18 0 1 21 7 80 7 90...

Страница 18: ...CCESS BLOWER MOTOR ACCESS BLOWER COMPARTMENT ACCESS Auxiliary DOT PLUG For pressure Drop Reading FRONT VIEW ELECTRIC HEAT ACCESS CONTROL BOX ACCESS 136 1 4 20 TON 21 5 9 3 4 11 1 2 2 3 4 21 1 2 33 35 5 7 8 35 1 4 20 TON RETURN AIR SUPPLY AIR OUTDOOR AIR OUTDOOR AIR Economizer TABLE 11 MINIMUM CLEARANCES LOCATION CLEARANCE Front 36 Back 24 Less Economizer 49 With Economizer Left Side Filter Access ...

Страница 19: ...return air compartments with the side duct flange accessory kit panels 2 Connect ductwork to the flanges on those panels FIGURE 12 UNIT WITH RAIN HOOD DIMENSIONS 20 TON SUPPLY AIR RETURN AIR OUTDOOR AIR 5 1 8 18 5 8 27 3 4 39 5 8 40 1 2 OUTDOOR AIR COMPARTMENT ACCESS FILTER ACCESS 1 NPT FEMALE COND DRAIN CONNECTION DOT PLUG For pressure drop reading EVAPORATOR SECTION 40 3 8 COMPRESSOR ACCESS SUPP...

Страница 20: ...e the static pressure and BHP Since no temperature data is given we will assume an air temperature of 70 F Table 13 shows the correction factor to be 0 832 Corrected static pressure 1 5 x 0 832 1 248 IWC Corrected BHP 4 0 x 0 832 3 328 Example 2 A system located at 5 000 feet of elevation is to deliver 6 000 CFM at a static pressure of 1 5 Use the unit blower tables to select the blower speed and ...

Страница 21: ...175245 YIM C 1008 Johnson Controls Unitary Products 21 FIGURE 13 ALTITUDE TEMPERATURE CONVERSION FACTOR ...

Страница 22: ... 5 3 0 7 6 9 5 8 0 2 7 3 6 1 1010 4 0 1 8 5 8 4 9 1 7 6 3 5 3 1 5 6 9 5 8 1 0 7 5 6 3 0 5 7 9 6 7 1020 3 5 1 9 6 1 5 1 1 8 6 5 5 5 1 6 7 1 6 0 1 1 7 8 6 6 0 6 8 3 7 0 1035 3 0 2 0 6 2 5 2 1 9 6 8 5 7 1 7 7 4 6 2 1 2 8 1 6 8 0 7 8 6 7 3 1050 2 5 2 1 6 4 5 4 2 0 7 0 5 9 1 8 7 6 6 4 1 3 8 3 7 0 1075 2 0 2 3 6 6 5 5 2 1 7 2 6 0 1 9 7 8 6 6 1 5 8 6 7 2 1100 1 0 2 4 6 7 5 6 2 2 7 3 6 1 2 1 7 9 6 7 230 4...

Страница 23: ...rmance table TABLE 16 POWER EXHAUST PERFORMANCE MOTOR SPEED STATIC RESISTANCE OF RETURN DUCTWORK IWG 0 2 0 3 0 4 0 5 0 6 CFM KW CFM KW CFM KW CFM KW CFM KW HIGH 5250 0 83 4500 0 85 4200 0 88 3750 0 93 3000 0 99 MEDIUM 4900 0 77 3900 0 79 3500 0 82 2900 0 85 LOW 4400 0 72 3700 0 74 3000 0 78 TABLE 17 BLOWER MOTOR AND DRIVE DATA MODEL SIZE DRIVE BLOWER RANGE RPM MOTOR1 ADJUSTABLE MOTOR PULLEY2 FIXED...

Страница 24: ...ter belt are available for appli cations requiring the supply air blower to produce higher CFM s and or higher static pressures Use Model 1LD0417 for this 20 ton unit Refer to the Blower Motor and Drive Data Table 17 Note the following 1 The supply air CFM must be within the limitations shown in the Unit Application Data Table 1 2 Pulleys can be adjusted in half turn increments 3 The tension on th...

Страница 25: ...veloc ity pressure will not affect the static pressure readings 3 Using an inclined manometer determine the pres sure drop across a dry evaporator coil Since the moisture on an evaporator coil may vary greatly measuring the pressure drop across a wet coil under field conditions would be inaccurate To assure a dry coil the compressors should be deac tivated while the test is being run 4 Knowing the...

Страница 26: ...s completed For first stage cooling compressor 1 and condenser fan motor 1 are energized After com pleting the specified fan on delay for cooling the UCB will energize the blower motor When the thermostat calls for the second stage of cool ing the low voltage control circuit from R to Y2 is completed Compressor 2 and condenser fan motor 2 are energized provided it has not been locked out If there ...

Страница 27: ... intended parameters Errors are handled as described below All system errors override minimum run times for compressors HIGH PRESSURE LIMIT SWITCH During cooling operation if a high pressure limit switch opens the UCB will de energize the associated com pressor initiate the ASCD Anti short cycle delay and if the other compressor is idle stop the condenser fans If the call for cooling is still pres...

Страница 28: ...ociated system will be affected by any safety preventive action The other refrigerant system will continue in operation unless it is affected by the fault as well The unit control board monitors the temperature limit switch of electric heat units and the temperature limit switch and the gas valve of gas furnace units COMPRESSOR PROTECTION In addition to external pressure switches the compres sors ...

Страница 29: ...g two conditions must be met before a DC will enter a defrost mode 1 The DC must first satisfy its accumulated minimum run time This is factory set at 90 minutes but is field adjustable to 30 60 or 90 minutes 2 Defrost thermostats DF1 or DF2 must be closed These normally open thermostats are mounted on their respective outdoor coil return bend and are set to close at 28 4 F If the defrost thermost...

Страница 30: ...rors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 20 RESET Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature This resets any flash codes HEAT ANTICIPATOR SETPOINTS It is important that the anticipator setpoint be correct Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditi...

Страница 31: ...power to the unit TROUBLESHOOTING COOLING TROUBLESHOOTING GUIDE On calls for cooling if the compressors are operating but the supply air blower motor does not energize after a short delay the room thermostat fan switch is in the AUTO position 1 Turn the thermostat fan switch to the ON position If the supply air blower motor does not energize go to Step 3 2 If the blower motor runs with the fan swi...

Страница 32: ...ompressors will not immediately operate If both stages of cooling are requested simultaneously and the economizer pro vides free cooling following a short delay compres sor 1 will be energized unless it is locked out If compressor 1 is locked out compressor 2 will be energized Compressor 2 is always energized in place of compressor 1 when compressor 1 is requested but locked out 2 If no economizer...

Страница 33: ...on nect the Mate N Locks and jumper between the WHITE and YELLOW wires of the UCB s Mate N Lock plug If compressor 1 is energized there is a fault in the economizer wiring or the economizer control 14 The UCB can be programmed to lock out compres sor operation during free cooling and in low ambi ent conditions These options are not enabled by default Local distributors can test the UCB for this pr...

Страница 34: ...ocked out the UCB may have the compres sor in an ASCD Check the LED for an indication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs 11 The UCB can be programmed to lock out compres sor operation during free cooling and in low ambi ent conditions These options are not enabled by default Local distributors can test the UCB for this pr...

Страница 35: ...rip lock out or ASCD the econ omizer terminals of the UCB may be improperly wired Check for 24 volts at the Y1 OUT terminal of the UCB If 24 volts is present trace the wiring from Y1 OUT for incorrect wiring If 24 volts is not present at the Y1 OUT terminal the UCB must be replaced 12 For units without economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON term...

Страница 36: ...es it may be necessary to zero the ASCD for the compressors in order to perform trouble shooting To reset all ASCDs for one cycle press and release the UCB TEST RESET button once Flash codes that do and do not represent alarms are listed in Table 20 TABLE 20 UNIT CONTROL BOARD FLASH CODES FLASH CODE DESCRIPTION GREEN LED 16 RED LED 8 RED LED 4 RED LED 2 RED LED 1 On Steady This is a Control Failur...

Страница 37: ...eters for the currently dis played mode Option Byte or Heat Delay HEAT DELAY SETUP Enter the Option Setup mode by pushing the OPTION SETUP STORE button and holding it for at least 2 seconds The green status LED O ption Byte will be turned on and the red status LED Heat Delay is turned off Press the COMM SETUP SELECT button to tog gle into the Heat Delay Setup the green LED will turn off and the re...

Страница 38: ...cavity Replace the plugs BLOWER SHAFT BEARING Blower shaft bearings should be inspected on a monthly basis At a minimum the bearings should be relubricated every 6 months using a lithium based grease NLGI grade 2 recommended for ball bearing service OUTDOOR COIL Dirt should not be allowed to accumulate on the out door coil surface or other parts in the air circuit Clean ing should be as often as n...

Страница 39: ...175245 YIM C 1008 Johnson Controls Unitary Products 39 ...

Страница 40: ... change without notice Printed in U S A 175245 YIM C 1008 Copyright 2008 by Johnson Controls Inc All rights reserved Supersedes 175245 YIM B 0707 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069 ...

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