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SERIES 40 ROOFTOP
25, 30 AND 40 TON
WITH IPU CONTROL
5276178-JIM-C-0118
LD14136
INSTALLATION, OPERATION & MAINTENANCE
PACKAGED ROOFTOP
AIR CONDITIONING UNITS
R-410A ONLY, GEN 5
Supersedes 5276178-JIM-B-0117
JOHNSON CONTROLS
2
5276178-JIM-C-0118
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components,
and both high and low voltage. Each of these items
has the potential, if misused or handled improperly, to
cause bodily injury or death. It is the obligation and
responsibility of operating/service personnel to identify
and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to
comply with any of these requirements could result in
serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will
enable them to perform their assigned tasks properly
and safely. It is essential that, prior to performing any
task on this equipment, this individual will have read
and understood this document and any referenced
materials. This individual 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 identiî‚¿es a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or seri-
ous injury.
External wiring, unless specied as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring is
allowed to be run through the micro panel. All wiring must be in accordance with Johnson
Controls published speciî‚¿cations and must be performed ONLY by qualiî‚¿ed Johnson Controls
personnel. Johnson Controls will not be responsible for damages/problems resulting from
improper connections to the controls or application of improper control signals. Failure to
follow this will void the manufacturer’s warranty and cause serious damage to property or
injury to persons.
3
JOHNSON CONTROLS
5276178-JIM-C-0118
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for
continuous product improvement, the information
contained in this document is subject to change without
notice. While Johnson Controls makes no commitment
to update or provide current information automatically
to the manual owner, that information, if applicable, can
be obtained by contacting the nearest Johnson Controls
Applied Systems oce.
It is the responsibility of operating/service personnel
to verify the applicability of these documents to the
equipment 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 equipment, they should verify with the owner
whether the equipment has been modiî‚¿ed and if current
literature is available.
JOHNSON CONTROLS
4
5276178-JIM-C-0118
Series 40 Model Number Nomenclature 25-40 Ton Single Package
1 = 1st Generation
V= JCI Brand R410A
S= JCI Under Floor R410A
A = Smart Equipmentâ„¢ COM Card
B = Smart Equipmentâ„¢ COM Card W/DISC & 110V OUTLET
C = Smart Equipmentâ„¢ COM Card W/DISC
D = Fault Detection Device
E = Fault Detection Device, DISC & 110V OUTLET
F = Fault Detection Device & DISC
A = Forward Curve Fan Class I w/1 Inch Deflection Spring
B = Forward Curve Fan Class I w/2 Inch Deflection Spring
C = Forward Curve Fan Class I w/Neoprene Isolators
D = Forward Curve Fan Class II w/1 Inch Deflection Spring
E = Forward Curve Fan Class II w/2 Inch Deflection Spring
F = Forward Curve Fan Class II w/Neoprene Isolators
G = Air Foil Fan w/1 Inch Deflection Spring
H = Air Foil Fan w/2 Inch Deflection Spring
A = NONE
B = BARO
C = MODULATING DAMPERS
D = NON-MOD. (ON/OFF)
E = VFD, MODULATING MOTOR
F = Power Exhaust VFD (Customer)
G = 8,000 CFM ERV
H = 13,000 CFM ERV
2 = 25 TON
3 = 30 TON
4 = 40 TON
Supply Fan
FORWARD CURVE FAN Class I
Class I blower is limited to 15 HP in 25/30 Ton.
Class I blower is limited to 20 HP in 40 Ton.
FORWARD CURVE FAN Class II
AIR FOIL FAN [Always Class II]
Class II blowers are not HP limited.
Air foil fan only available on Cooling Only.
A = NONE
B = SINGLE ENTHALPY, Low Leak seals type
C = DUAL ENTHALPY, Low Leak seals type
D = DRY BULB TEMP, Low Leak seals type
E = MANUAL DAMPER (Not w/PE), no seals type
A= NONE
B = 5 HP HI-EFF (25 Ton Only)
C = 7.5 HP HI-EFF
D = 10 HP HI-EFF
E = 15 HP HI-EFF (Except 25 T)
Blower Mount Isolation
1 inch deflection spring
2 inch deflection spring
A = 2" Throwaway [Standard]
B = 2" Pleated Filters [Merv 7]
C = 6" Rigid 65% Efficient [Merv 11]
D = 6" Rigid 95% Efficient [Merv 14]
1 = 7.5 High Efficiency (25 Ton Only)
2 = 10 High Efficiency
3 = 15 High Efficiency
4 = 20 High Efficiency
5 = 25 High Efficiency (30 & 40 Ton Only)
A = Drain Pan - Powder Coat
B = Drain Pan - Stainless Steel
1 = Constant Volume
2 =
VAV (Factory Insta
lled VFD)
3 = VAV Bypass (Factory Installed VFD)
4 =
VAV (Customer Insta
lled VFD)
5 = IntelliSpeed (Factory Installed VFD)
6 = IntelliSpeed (Factory Installed VFD w/Bypass)
7 = IntelliSpeed (Customer Installed VFD)
A = 1, 2
B = 1, 4
C = 1, 5
D = 3, 2
E = 3, 4
F = 3, 5
1 - BOTTOM RETURN
2 - BOTTOM SUPPLY
3 - END RETURN
4 - REAR SUPPLY
5 - FRONT SUPPLY
A = Standard Condenser & Evaporator Coils
C = Standard Condenser & Copper Evaporator Coil
F = Copper Condenser & Stand
ard Evaporator Coil
G = Copper Condenser & Copper Evaporator Coils
H = Standard Condenser & Technicoat Evaporator Coil
J = Technicoat Condenser & Standard Evaporator Coil
K = Technicoat Condenser & Evaporator Coils
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
7 = 380/415-3-50
(30
T/40 Ton Only)
FRONT SUPPLY - COOLING ONLY
HOT WATER, STEAM & ELECTRIC HEAT -
BOTTOM SUPPLY ONLY
GAS HEAT - BOTTOM OR REAR SUPPLY ONLY
CABINET
ECONOMIZER
FILTERS
1
18
C
3
GAS HEAT
3 = 267 MBH
5 = 533 MBH
8 = 800 MBH
N =
NATURAL GAS
, STAGED
S =
NATURAL GAS
, STAGED
with
SS HEAT EXCHANGER
D =
NATURAL GAS
, MODULATING HEAT
T =
NATURAL GAS
, MODULATING HEAT
with
SS HEAT EXCHANGER
E = ELECTRIC HEAT
C = COOLING ONLY
W1 = HOT WATER SINGLE COIL
W2 = HOT WATER TWO COIL
X1 = STEAM SINGLE COIL
2
6
A
7
B
8
A
9
1
10
A
11
1
12
PACKAGE
A
13
A
14
A
15
A
16
A
17
V
1
2
2
8
4
1
5
BASIC UNIT
VOLTAGE
AIR VOLUME
HEAT SOURCE
COILS
CONFIGURATION
ELECTRIC HEAT
4 = 40kW
8 = 80kW
1 = 108 kW
ID MOTOR
EXHAUST
EXHAUST MOTOR
CONTROL
GEN
ID BLOWER
REFRIGERATION
1 = Standard Refrigeration
2 = Head Pressure Control (Low Ambient)
3 = Hot Gas Bypass
4 = Head Pressure Control & Hot Gas Bypass
NOMENCLATURE
5
JOHNSON CONTROLS
5276178-JIM-C-0118
TABLE OF CONTENTS
SECTION 1 – INTRODUCTION .......................................................................................................17
ECOLOGICAL AND ECONOMICAL DESIGN ............................................................................. 17
Cooling and Heating .............................................................................................................17
Indoor Air Quality (IAQ) ........................................................................................................17
High-Eciency Motors ......................................................................................................... 17
Condensing Section .............................................................................................................17
Heating Section .....................................................................................................................18
AIR MANAGEMENT ....................................................................................................................18
CONTROLS .................................................................................................................................19
Rooftop Controller ................................................................................................................19
BACnet ...................................................................................................................................19
GENERAL ....................................................................................................................................19
SAFETY CONSIDERATIONS ......................................................................................................19
Notes, Cautions and Warnings ............................................................................................ 19
Gas Fired Models ..................................................................................................................19
What to Do If You Smell Gas ................................................................................................ 19
ALL MODELS ..............................................................................................................................20
INSPECTION ................................................................................................................................ 20
SECTION 2 – INSTALLATION ........................................................................................................23
APPROVALS................................................................................................................................23
LIMITATIONS ...............................................................................................................................23
LOCATIONS AND CLEARANCES ..............................................................................................25
SERVICE ACCESS ......................................................................................................................26
RIGGING AND HANDLING .........................................................................................................26
CFM, STATIC PRESSURE, AND POWER – ALTITUDE AND TEMPERATURE CORRECTIONS 39
ELECTRICAL DATA .....................................................................................................................57
FILTERS .......................................................................................................................................79
CONDENSATE DRAIN ................................................................................................................79
Condensate Drain Piping .....................................................................................................79
Condensate Drain Trap ........................................................................................................79
COMPRESSORS .........................................................................................................................79
AIR HOODS .................................................................................................................................79
Air Hoods for Fixed Outside Air ..........................................................................................79
Air Hoods for Economizer ...................................................................................................79
Air Hoods for Exhaust Air ....................................................................................................80
FIELD WIRING .............................................................................................................................80
JOHNSON CONTROLS
6
5276178-JIM-C-0118
TABLE OF CONTENTS (CONT'D)
Thermostat ............................................................................................................................80
Space Sensor ........................................................................................................................80
CO
2
Sensor ............................................................................................................................80
Occupied/Unoccupied Input ................................................................................................80
Shutdown Input .....................................................................................................................80
Smoke Purge Input ...............................................................................................................80
VAV Heat Relay Output ......................................................................................................... 81
RETURN AIR BYPASS DAMPER ...............................................................................................81
BACNET COMMUNICATION.......................................................................................................81
CTB3 Field Control Wiring (Inputs) ........................................................................................... 82
POWER AND CONTROL WIRING ........................................................................................83
General ..................................................................................................................................83
Power Wiring Detail ..............................................................................................................83
TRANSDUCER PNEUMATIC TUBING........................................................................................84
Static Pressure Control Plastic Tubing .............................................................................84
Duct Static Transducer .........................................................................................................84
Building Pressure Transducer .............................................................................................84
Static Pressure Probe Installation ......................................................................................84
ROOF CURB INSTALLATION .....................................................................................................85
General Information ..............................................................................................................85
DUCT SYSTEM ............................................................................................................................85
Duct Connection Guidelines ................................................................................................85
SOUND AND VIBRATION TRANSMISSION ...............................................................................85
GAS HEATING .............................................................................................................................86
Gas Piping .............................................................................................................................86
Gas Connection ....................................................................................................................86
Vent and Combustion Air .....................................................................................................87
ELECTRIC HEAT .........................................................................................................................87
HOT WATER HEAT ......................................................................................................................87
Piping Connections ..............................................................................................................88
STEAM HEAT...............................................................................................................................89
Piping Connections ..............................................................................................................90
SECTION 3 – START-UP .................................................................................................................91
CRANKCASE HEATERS ............................................................................................................. 91
CHECKING THE SYSTEM PRIOR TO INITIAL START (NO POWER) ......................................91
Unit Checks ...........................................................................................................................91
UNIT CHECKS – POWER APPLIED ...........................................................................................92
Verifying Compressor Rotation ........................................................................................... 92
7
JOHNSON CONTROLS
5276178-JIM-C-0118
TABLE OF CONTENTS (CONT'D)
Compressor Oil Level Check ............................................................................................... 92
Air Balance ............................................................................................................................93
Checking Supply Air CFM ....................................................................................................93
Supply Air Drive Adjustment ...............................................................................................93
DRIVE ADJUSTMENT TABLES ..................................................................................................95
INITIAL START-UP ......................................................................................................................98
Refrigerant Charge ...............................................................................................................98
Subcooling (R-410A) ............................................................................................................98
Superheat (R-410A) ..............................................................................................................98
Leak Checking ......................................................................................................................99
GAS FURNACE OPERATING INSTRUCTIONS .......................................................................100
To Light the Main Burners .................................................................................................100
To Shut Down ......................................................................................................................100
POST-START CHECKLIST (GAS) ............................................................................................100
MANIFOLD GAS PRESSURE ADJUSTMENT .......................................................................... 100
Burner Instructions ............................................................................................................100
Adjustment of Temperature Rise ......................................................................................101
Checking Gas Input ............................................................................................................101
ELECTRIC HEATING ................................................................................................................. 101
REFRIGERATION SYSTEM ......................................................................................................101
COMPRESSORS .......................................................................................................................102
MOTORS ....................................................................................................................................102
Indoor Blower Motors .........................................................................................................102
Power Exhaust Fan Motors ................................................................................................102
Condenser Fan Motors .......................................................................................................102
Draft Motor (Gas Furnace) .................................................................................................102
hot water and steam coils ........................................................................................................ 102
HOT WATER AND STEAM COILS ............................................................................................103
SECTION 4 – MAINTENANCE ......................................................................................................114
GENERAL ..................................................................................................................................114
PERIODIC MAINTENANCE – MONTHLY .................................................................................114
Filters ...................................................................................................................................114
Linkages ..............................................................................................................................114
Compressors .......................................................................................................................114
Condenser Coils .................................................................................................................114
PERIODIC MAINTENANCE – 3 TO 6 MONTHS .......................................................................114
Motors ..................................................................................................................................114
JOHNSON CONTROLS
8
5276178-JIM-C-0118
TABLE OF CONTENTS (CONT'D)
Belt Tension ........................................................................................................................115
Belt Replacement ................................................................................................................116
PERIODIC MAINTENANCE – YEARLY.....................................................................................116
Entire Unit Inspection .........................................................................................................116
Sheave Alignment ...............................................................................................................116
Belts .....................................................................................................................................116
Supply and Exhaust Fan Motor .........................................................................................117
Outdoor Coil ........................................................................................................................117
Gas Burner ..........................................................................................................................117
Forward Curved Fans .........................................................................................................118
SECTION 5 – SEQUENCE OF OPERATION ...............................................................................126
UNIT TYPE .................................................................................................................................126
CURRENT OPER MODE ...........................................................................................................126
Constant Volume Mode .....................................................................................................126
Variable Air Volume Mode ..................................................................................................128
FlexSys ................................................................................................................................129
ACTIVE SET POINT DETERMINATION .................................................................................... 129
Constant Volume ................................................................................................................129
Variable Air Volume ............................................................................................................130
FlexSys with Bypass Damper ............................................................................................ 133
FlexSys without Bypass Damper ......................................................................................133
COMPRESSOR CONTROL .......................................................................................................133
COMPRESSOR OPERATION WITH ECONOMIZER ................................................................134
No Compressors On When Economizer Becomes Active ..............................................134
Compressor On When Economizer Becomes Active ...................................................... 134
SUPPLY FAN OPERATION .......................................................................................................135
Constant Volume Operation ..............................................................................................135
Variable Air Volume (VAV) ..................................................................................................135
VAV Supply Fan Speed Control Set Point Determination ...............................................136
COMPRESSOR STAGING SEQUENCE ...................................................................................137
CONDENSER FAN OPERATION ..............................................................................................138
LOW AMBEINT CONDENSER FAN OPERATION ....................................................................138
ECONOMIZER ...........................................................................................................................138
Dry Bulb ...............................................................................................................................138
Single Enthalpy ...................................................................................................................138
Dual Enthalpy ......................................................................................................................139
Best Method ........................................................................................................................139
NonFlexSys Economizer ....................................................................................................140
FlexSys Economizer ...........................................................................................................140
COMPRESSOR OPERATION....................................................................................................140
Compressor Data ................................................................................................................140
9
JOHNSON CONTROLS
5276178-JIM-C-0118
TABLE OF CONTENTS (CONT'D)
Compressor Ready to Run ...............................................................................................140
Compressor Ready to Stop ...............................................................................................140
Compressor Safety Circuit ................................................................................................140
SUPPLY AIR TEMPERING ........................................................................................................141
Hot Water and Steam .......................................................................................................... 141
Staged Gas or Electric Heat ...............................................................................................142
COMFORT VENTILATION ......................................................................................................... 142
SYSTEM PUMP DOWN CONTROL ..........................................................................................143
HIGH DISCHARGE PRESSURE UNLOADING ........................................................................143
LOW AMBIENT LOCK OUT ......................................................................................................143
LOW AMBIENT FAN CONTROL OPTION ................................................................................143
Operation and Pressure Control Range ...........................................................................144
Conî‚¿guration (Jumpers and Potentiometers) .................................................................144
FLEXSYS BYPASS DAMPER OPERATION .............................................................................145
EVAPORATOR SUPERHEAT CALCULATION .........................................................................146
STAGED INPUT FAULT .............................................................................................................146
SYSTEM STABILITY CHECK ....................................................................................................146
ELECTRIC HEAT .......................................................................................................................146
Programmed Data ...............................................................................................................146
Heating Control Oset .......................................................................................................146
Active SP .............................................................................................................................146
Heating Control ...................................................................................................................146
STAGED GAS HEAT ..................................................................................................................147
Programmed Data ...............................................................................................................147
Heating Control Oset .......................................................................................................147
Active SP .............................................................................................................................148
Heating Control ...................................................................................................................148
Compressor Staged Gas Heat Mode of Operation When Economizer Status .............148
Staged Gas Heat Ignition Sequence .................................................................................149
MODULATING GAS HEAT ........................................................................................................150
HOT WATER/STEAM HEAT ......................................................................................................150
Programmed Data ...............................................................................................................150
Active SP .............................................................................................................................150
Sequence of Operation ......................................................................................................150
Freeze Protection ................................................................................................................151
Freeze Fault .........................................................................................................................151
MORNING WARM UP ................................................................................................................151
Sequence of Operation ......................................................................................................152
ADAPTIVE MORNING WARM UP ............................................................................................. 152
Sequence of Operation ......................................................................................................152
JOHNSON CONTROLS
10
5276178-JIM-C-0118
TABLE OF CONTENTS (CONT'D)
FLEXSYS UNDER FLOOR TEMPERATURE CONTROL .........................................................153
Programmed Data ...............................................................................................................153
Under Floor Heating Sequence of Operation ................................................................... 153
Dew Point Reset Sequence of Operation .........................................................................154
EXHAUST FAN OPERATION ....................................................................................................154
On/O Control Based On Damper Position .....................................................................154
On/O Control Based On Building Pressure ...................................................................154
Modulating Damper with Fixed Speed Exhaust ............................................................... 154
Modulating Exhaust with A VFD ........................................................................................155
RETURN FAN OPERATION ......................................................................................................155
VENTILATION SYSTEM ............................................................................................................155
Overview ..............................................................................................................................155
2-Position Damper ..............................................................................................................156
Demand Ventilation ............................................................................................................156
Fixed Minimum ....................................................................................................................157
Air Measuring Stations .......................................................................................................157
SMOKE PURGE ......................................................................................................................... 157
SECTION 6 – USER INTERFACE CONTROL CENTER ............................................................160
USER INTERFACE CONTROL CENTER .................................................................................. 160
Data Entry Keys ..................................................................................................................160
Navigation Keys ..................................................................................................................161
Menu Select Keys ...............................................................................................................161
SETPOINTS ...............................................................................................................................175
PROGRAM .................................................................................................................................175
OPTIONS ...................................................................................................................................175
DATE / TIME...............................................................................................................................175
SCHEDULE ................................................................................................................................176
OPERATING HOURS / START COUNTER ...............................................................................177
PRINTER ....................................................................................................................................178
Set Up ..................................................................................................................................178
Report Section ....................................................................................................................178
SERVICE MODE ........................................................................................................................179
HISTORY ....................................................................................................................................189
PASSWORD ............................................................................................................................... 190
POWER UP BANNER ................................................................................................................191
COMMUNICATION.....................................................................................................................192
Communication Ports ........................................................................................................192
11
JOHNSON CONTROLS
5276178-JIM-C-0118
TABLE OF CONTENTS (CONT'D)
BACnet Wiring ....................................................................................................................192
Device Object Instance (DE) ..............................................................................................192
Additional Settings .............................................................................................................193
SECTION 7 – PARAMETER DEFENITIONS AND OPTIONS ....................................................218
SECTION 8 – SERVICE .................................................................................................................228
ANALOG INPUT OPERATION ..................................................................................................228
Temperature Sensors .........................................................................................................228
Duct Pressure Transducer .................................................................................................228
Building Pressure Transducer ...........................................................................................229
Humidity Sensors ...............................................................................................................229
CO
2
Sensor ..........................................................................................................................230
Furnace Status Input ..........................................................................................................230
FAULTS ......................................................................................................................................231
MULTI MEDIA CARD .................................................................................................................242
JOHNSON CONTROLS
12
5276178-JIM-C-0118
TABLE 1 - COOLING AND ELECTRICAL APPLICATION ...........................................................23
TABLE 2 - COOLING AND ELECTRICAL APPLICATION LIMITATIONS ..................................23
TALBE 3 - STANDARD GAS HEATING CAPACITIES .................................................................24
TABLE 4 -
TEMPERATURE RISE ................................................................................................... 24
TABLE 5 - MINIMUM HEATING CFM .............................................................................................24
TABLE 6 - UNIT CORNERWEIGHT ................................................................................................ 26
TABLE 7 - UNIT CENTER OF GRAVITY ........................................................................................ 27
TABLE 8 - UNIT WEIGHTS .............................................................................................................27
TABLE 9 - SUPPLY FAN MOTOR VFD WEIGHTS .......................................................................28
TABLE 10 - EXHAUST FAN MOTOR VFD WEIGHTS ..................................................................28
TABLE 11 - GENERAL PHYSICAL DATA ...................................................................................... 29
TABLE 12 - REFRIGERANT FACTORY CHARGE R-410A ..........................................................39
TABLE 13 - ALTITUDE CORRECTION FACTORS .......................................................................39
TABLE 14 - FAN PERFORMANCE - 25 TON ................................................................................. 42
TABLE 15 - FAN PERFORMANCE - 30 TON ................................................................................ 45
TABLE 16 - FAN PERFORMANCE - 40 TON ................................................................................ 48
TABLE 17 - COMPONENT STATIC RESISTANCE ......................................................................51
TABLE 18 - SUPPLY FAN MOTOR AND DRIVE DATA ................................................................52
TABLE 19 - EXHAUST FAN DRIVE DATA .....................................................................................52
TABLE 20 - POWER EXHAUST - ONE FORWARD CURVED FAN 25 TON ..............................53
TABLE 21 - POWER EXHAUST - TWO FORWARD CURVED FANS - 30 & 40 TON .................55
TABLE 22 ELECTRICAL DATA 25 TON 208/230 VOLT WITHOUT ERV ....................................57
TABLE 23 ELECTRICAL DATA 25 TON 230 VOLT WITH ERV ...................................................59
TABLE 24 ELECTRICAL DATA 25 TON 460 VOLT WITHOUT ERV ...........................................60
TABLE 25 ELECTRICAL DATA 25 TON 460 VOLT WITH ERV ...................................................61
TABLE 26 ELECTRICAL DATA 25 TON 575 VOLT WITHOUT ERV ...........................................62
TABLE 27 ELECTRICAL DATA 25 TON 575 VOLT WITH ERV ...................................................63
TABLE 28 ELECTRICAL DATA 30 TON 208/230 VOLT WITHOUT ERV ....................................64
TABLE 29 ELECTRICAL DATA 30 TON 208/230 VOLT WITH ERV ............................................66
TABLE 30 ELECTRICAL DATA 30 TON 460 VOLT WITHOUT ERV ...........................................68
TABLE 31 ELECTRICAL DATA 30 TON 460 VOLT WITH ERV ...................................................69
TABLE 32 ELECTRICAL DATA 30 TON 575 VOLT WITHOUT ERV ...........................................70
TABLE 33 ELECTRICAL DATA 30 TON 575 VOLT WITH ERV ...................................................71
TABLE 34 ELECTRICAL DATA 40 TON 208/230 VOLT WITHOUT ERV ....................................72
TABLE 35 ELECTRICAL DATA 40 TON 230 VOLT WITH ERV ...................................................74
TABLE 36 ELECTRICAL DATA 40 TON 460 VOLT WITHOUT ERV ...........................................75
TABLE 37 ELECTRICAL DATA 40 TON 460 VOLT WITH ERV ...................................................76
TABLE 38 ELECTRICAL DATA 40 TON 575 VOLT WITHOUT ERV ...........................................77
TABLE 39 ELECTRICAL DATA 40 TON 575 VOLT WITH ERV ...................................................78
TABLE 40
-
PIPE SIZES ..................................................................................................................86
TABLE 41 - BLOWER SPEED RATE OF CHANGE ...................................................................... 94
LIST OF TABLES
13
JOHNSON CONTROLS
5276178-JIM-C-0118
TABLE 42 - 25 TON DRIVE ADJUSTMENT FOR CONSTANT VOLUME & VAV UNITS CLASS 1 &
2 FC FAN ...........................................................................................................................................95
TABLE 43 - 30 TON DRIVE ADJUSTMENT FOR CONSTANT VOLUME & VAV UNITS CLASS 1 &
2 FC FAN ...........................................................................................................................................95
TABLE 44 - 40 TON DRIVE ADJUSTMENT FOR CONSTANT VOLUME & VAV UNITS CLASS 1 &
2 FC FAN ...........................................................................................................................................96
TABLE 45 - DRIVE ADJUSTMENT FOR POWER EXHAUST - 25 TON .....................................96
TABLE 46 - DRIVE ADJUSTMENT FOR POWER EXHAUST - 30 & 40 TON .............................96
TABLE 47- 25 TON DRIVE ADJUSTMENT FOR INTELLISPEED (DISCRETE FAN CONTROL) 97
TABLE 48- 30 TON DRIVE ADJUSTMENT FOR INTELLISPEED (DISCRETE FAN CONTROL) 97
TABLE 49- 40 TON DRIVE ADJUSTMENT FOR INTELLISPEED (DISCRETE FAN CONTROL) 97
TABLE 50 - R410-A PRESSURE / TEMPERATURE CHART ......................................................99
TABLE 51 - GAS RATE - CUBIC FEET PER HOUR ...................................................................101
TABLE 52 - STEAM COIL (1 ROW, 25 & 30 TON) ....................................................................... 102
TABLE 53 - STEAM COIL (1 ROW, 40 TON) ..............................................................................102
TABLE 54 - STATIC RESISTANCE STEAM COIL (25 & 30 TON) ............................................102
TABLE 55 - STATIC RESISTANCE STEAM COIL (40 TON) ......................................................102
TABLE 56 - HOT WATER COIL (1 ROW 25 & 30 TON)
1
............................................................103
TABLE 57 - WATER PRESSURE DROP (1 ROW, 25 & 30 TON) ...............................................103
TABLE 58 - WATER PRESSURE DROP (1 ROW, 40 TONS) .....................................................103
TABLE 59 -
HOT WATER COIL (1 ROW, 40 TON)
1
.......................................................................104
TABLE 60 - HOT WATER COIL (2 ROW, 25 & 30 TON)
1
...........................................................104
TABLE 61 - WATER PRESSURE DROP (2 ROW, 25 & 30 TON) ..............................................105
TABLE 62 - WATER PRESSURE DROP (2 ROW, 40 TON) ........................................................ 105
TABLE 63 - STATIC RESISTANCE HOT WATER COIL (25 & 30 TON) ....................................105
TABLE 64 - STATIC RESISTANCE HOT WATER COIL (40 TON) .............................................105
TABLE 65 - INDOOR BLOWER BEARING LUBRICATION SCHEDULE ................................. 115
TABLE 66 - BELT ADJUSTMENT .................................................................................................116
TABLE 67 - SET SCREW TORQUE .............................................................................................121
TABLE 68 - DIGITAL INPUTS FOR STAGED INPUT STAGED INPUT MODE ........................127
TABLE 69 - ACTIVE SAT SET POINT DETERMINATION, STAGED INPUT............................129
TABLE 70 - ACTIVE SAT SET POINT DETERMINATION, ZONE TEMPERATURE ...............130
TABLE 71 - COMPRESSOR STAGING .......................................................................................137
TABLE 72 - VFD JUMPERS ..........................................................................................................144
TABLE 73 - POTENTIOMETER SETTINGS ................................................................................144
TABLE 74 - CFM .............................................................................................................................147
TABLE 75 - HEAT STAGES ........................................................................................................... 147
TABLE 76 - CFM .............................................................................................................................148
TABLE 77 – HEAT STAGES ..........................................................................................................148
TABLE 79 - STATUS ......................................................................................................................162
TABLE 80 - UNIT DATA .................................................................................................................163
LIST OF TABLES (CONT'D)
JOHNSON CONTROLS
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5276178-JIM-C-0118
TABLE 81 - COOLING ...................................................................................................................164
TABLE 82 - COMPRESSOR SYSTEMS (1, 2, OR 3) ...................................................................166
TABLE 83 – SUPPLY SYSTEM .....................................................................................................167
TABLE 84 - HEATING ....................................................................................................................168
TABLE 85 - ECONOMIZER ...........................................................................................................171
TABLE 86 - VENTILATION ............................................................................................................172
TABLE 87 - EXHAUST ...................................................................................................................174
TABLE 88 - OPERATING HOURS / START COUNTER .............................................................177
TABLE 89 - SERVICE MODE ........................................................................................................180
TABLE 90 - BACNET MS/TP, MODBUS, BACNET IP ...............................................................194
TABLE 90 - LON POINTS LIST.....................................................................................................204
TABLE 92 - N2 POINTS LIST .......................................................................................................210
TABLE 93 - PARAMETER DEFINITIONS ....................................................................................218
TABLE 94 - TEMPERATURE SENSOR RESISTANCE ..............................................................228
TABLE 95 - DUCT PRESSURE TRANSDUCER .........................................................................229
TABLE 96 - BUILDING PRESSURE TRANSDUCER OUTPUT .................................................229
TABLE 97 - HUMIDITY SENSOR OUTPUTS ............................................................................... 229
TABLE 98 - CO
2
SENSOR OUTPUT ............................................................................................. 230
TABLE 99 - FURNACE STATUS INPUT STAGED GAS HEAT .................................................. 230
TABLE 100 - I/O CONTROL BOARD - ANALOG INPUT PIN OUTS ......................................... 236
TABLE 101 - WARNING DESCRIPTION ...................................................................................... 237
TABLE 102 - FAULT AUTO - RESET ............................................................................................239
TABLE 103 - FAULTS LOCKOUT .................................................................................................240
TABLE 104 - DATA LOG ERROR STATE ....................................................................................242
TABLE 105 - DATA LOG ERROR LOG DETAIL .......................................................................... 243
LIST OF TABLES (CONT'D)
15
JOHNSON CONTROLS
5276178-JIM-C-0118
LIST OF FIGURES
FIGURE 1 - PACKAGED ROOFTOP AIR CONDITIONING UNIT ............................................... 17
FIGURE 2 - COMPONENT LOCATION ..........................................................................................21
FIGURE 3 - UNIT CLEARANCES ...................................................................................................25
FIGURE 4 - TYPICAL RIGGING .....................................................................................................27
FIGURE 5 - CENTER OF GRAVITY ................................................................................................ 28
FIGURE 6 - BOTTOM SUPPLY AND RETURN .............................................................................31
FIGURE 7- END RETURN, BOTTOM SUPPLY .............................................................................32
FIGURE 8 - BOTTOM RETURN, FRONT & REAR SUPPLY ........................................................33
FIGURE 9 - END RETURN, FRONT & REAR SUPPLY ................................................................34
FIGURE 10 - PARTIAL ROOF CURB MODEL 1RC0455P............................................................35
FIGURE 11 - FIELD INSTALLED DISCONNECT ..........................................................................36
FIGURE 12 – 25 TON OVERHEAD VIEW ......................................................................................36
FIGURE 13 – 30 AND 40 TON OVERHEAD VIEW ........................................................................37
FIGURE 14 – 25 TON MAJOR COMPONENT LAYOUT ...............................................................37
FIGURE 15 – 30 AND 40 TON MAJOR COMPONENT LAYOUT .................................................37
FIGURE 16 – CABINET DOOR CONFIGURATION ......................................................................38
FIGURE 17 – ALTITUDE/TEMPERATURE CONVERSION FACTOR .........................................40
FIGURE 18 – 40 TON FORWARD CURVE EXAMPLE .................................................................41
FIGURE 19 – FAN PERFORMANCE - 25 TON FORWARD CURVE ...........................................44
FIGURE 20 – FAN PERFORMANCE - 30 TON FORWARD CURVE ...........................................47
FIGURE 21 – FAN PERFORMANCE - 40 TON FORWARD CURVE ...........................................50
FIGURE 22 – POWER EXHAUST - ONE FORWARD CURVE FAN - 25 TON ............................54
FIGURE 23 – POWER EXHAUST - TWO FORWARD CURVED FANS - 30 & 40 TONS ...........56
FIGURE 25 – RECCOMMENDED DRAIN PIPING ........................................................................79
FIGURE 24 – DRAIN TRAP SHOWING WATER
LOCATION DURING DRAW THROUGH OPERATION STAGES.........................79
FIGURE 26 – FIELD CONTROL WIRING - INPUTS .....................................................................82
FIGURE 27 – STATIC PRESSURE PROBE INSTALLATION ......................................................84
FIGURE 28 –
TYPICAL GAS PIPING CONNECTION ....................................................................... 86
FIGURE 29 – VENT AND COMBUSTION AIR HOODS ................................................................87
FIGURE 30 – STEAM PIPING CROSS-SECTION ........................................................................89
FIGURE 31 – HOT WATER PIPING CROSS-SECTION ...............................................................90
FIGURE 32 - TYPICAL GAS VALVE ............................................................................................100
FIGURE 33 - TYPICAL FLAME APPEARANCE .........................................................................101
FIGURE 34 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 10 GPM ....................................... 106
FIGURE 35 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 20 GPM ....................................... 106
FIGURE 36 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 30 GPM ....................................... 107
FIGURE 37 - HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 40 GPM ....................................... 107
FIGURE 38 - HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 60 GPM ....................................... 108
FIGURE 39 - HOT WATER COIL - 25 & 30 TON, 2 ROW, AT 80 GPM ....................................... 108
JOHNSON CONTROLS
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5276178-JIM-C-0118
FIGURE 40 - HOT WATER COIL - 40 TON, 1 ROW, AT 10 GPM ...............................................109
FIGURE 41 – HOT WATER COIL - 40 TON, 1 ROW, AT 20 GPM ..............................................109
FIGURE 42 – HOT WATER COIL - 40 TON, 1 ROW, AT 30 GPM ..............................................110
FIGURE 43 – HOT WATER COIL - 40 TON, 1 ROW, AT 40 GPM ..............................................110
FIGURE 44 – HOT WATER COIL - 40 TON, 2 ROW, AT 20 GPM .............................................. 111
FIGURE 45 – HOT WATER COIL - 40 TON, 2 ROW, AT 40 GPM .............................................. 111
FIGURE 46 – HOT WATER COIL - 40 TON, 2 ROW, AT 60 GPM ..............................................112
FIGURE 47 – HOT WATER COIL - 40 TON, 2 ROW, AT 80 GPM ..............................................112
FIGURE 48 – STEAM COIL - 25 & 30 TON (1 ROW) ................................................................... 113
FIGURE 49 – STEAM COIL - 40 TON (1 ROW) ..........................................................................113
FIGURE 50 - BELT TENSION ADJUSTMENT AND GAGE ........................................................115
FIGURE 51 - SHEAVE ALIGNMENT ............................................................................................116
FIGURE 52- TYPICAL FLUE BAFFLE ......................................................................................... 118
FIGURE 53 - EXAMPLE OF FC FAN SHAFT/WHEEL MARKING .............................................118
FIGURE 54 - BEARING WITH SETSCREW TYPE LOCKING DEVICE .................................... 119
FIGURE 55 - BEARING WITH ECCENTRIC CAM ......................................................................120
FIGURE 56 - ECCENTRIC CAM LOCKING COLLAR BEARING INSTALLATION .................120
FIGURE 57 - SPLIT BEARING ...................................................................................................... 121
FIGURE 58 - 25 TON CHARGING CURVE ..................................................................................122
FIGURE 59 – 30 TON CHARGING CURVE .................................................................................122
FIGURE 60 – 40 TON CHARGING CURVE .................................................................................123
FIGURE61 – PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 25 TON 123
FIGURE 62 – PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 30 TON 124
FIGURE 63 – PRESSURE DROP DRY EVAPORATOR COIL VS SUPPLY AIR CFM - 40 TON 124
FIGURE 64 – R410A QUICK REFERENCE GUIDE ....................................................................125
FIGURE 65 - DIFFERENCES (°F) BETWEEN ZONE TEMPERATURE AND SET POINTS ....127
FIGURE 66 - ACTIVE SAT SET POINT VS. SUPPLY AIR TEMP RST VOLTAGE ................... 131
FIGURE 67 - ACTIVE SAT SET POINT VS. OUTSIDE AIR TEMP ............................................131
FIGURE 68 - ACTIVE SAT SET POINT VS. RETURN AIR TEMP .............................................132
FIGURE 69 - ACTIVE SAT SET POINT VS. SUPPLY FAN SPEED ........................................... 132
FIGURE 70 - ACTIVE DSP SET POINT VS. DUCT STATIC PRES RST VOLTAGE ................136
FIGURE 71 - CONDENSER FAN VFD
POTENTIOMETER SETTINGS .............................................................................144
FIGURE 72 - USER INTERFACE CONTROL PANEL .................................................................160
FIGURE 73 - IPU CONTROL BOARD ..........................................................................................192
FIGURE 69 - MAC ADDRESS SWITCHES ..................................................................................192
FIGURE 75 - I/O CONTROL BOARD ...........................................................................................233
FIGURE 76 - I/O CONTROL BOARD - BINARY OUTPUTS .......................................................234
FIGURE 77 - I/O CONTROL BOARD - BINARY INPUTS ...........................................................235
FIGURE 78 - I/O CONTROL BOARD - ANALOG OUTPUTS .....................................................235
FIGURE 79 - I/O CONTROL BOARD - ANALOG INPUTS (SEE TABLE 90 FOR PIN OUTS) 235
LIST OF FIGURES (CONT'D)
17
JOHNSON CONTROLS
5276178-JIM-C-0118
1
Condensing Section
Scroll Compressors
Reliable, ecient, trouble-free operation is the true
measure of a packaged rooftop’s value. That’s why
Johnson Controls Series 40 Packaged Rooftop Air
Conditioners use established scroll-compressor
technology to deliver dependable, economical
performance in a wide range of applications. With
the Series 40 Packaged Rooftop, you get the latest
generation of compressor enhancements added to the
scroll’s inherent strengths. The simplicity of a hermetic
scroll compressor allows the use of fewer moving parts
to minimize breakdown.
Multiple Compressor Staging
Through the use of the scroll compressor, the Series
40 has the ability to stage it’s cooling by enabling and
disabling multiple single stage compressors on multiple
circuits.
Compressor Circuiting
The Series 40 is designed so that each scroll compressor
has its own refrigeration circuit. This means more
reliable compressors, and less equipment down time.
With multiple circuits, if a compressor should ever fail
on one circuit, the other circuit/s will remain operational
to work to maintain occupied loads. The Series 40 has
4 compressor; 4 circuits.
ECOLOGICAL AND ECONOMICAL DESIGN
First packaged RTU with R410A optimized design.
Cooling and Heating
Superior operating performance provides lower
operating costs. Smaller steps of cooling capacity
provide tighter control of building environment and
occupant comfort while optimizing energy eciency.
Indoor Air Quality (IAQ)
Outside air economizers provide energy savings in
free cooling mode, and can provide a healthier and
more comfortable building environment by introducing
fresh outside air into the building as needed. Indoor Air
Quality (IAQ) requirements for building ventilation
and comfort are controlled through the microprocessor
control panel.
High-Eciency Motors
High-efficiency motors are available for optimum
energy eciency. All motors used on the Series 40
packaged rooftop air conditioner meet U.S. EPACT
1992 minimum requirements.
SECTION 1 – INTRODUCTION
FIGURE 1 - PACKAGED ROOFTOP AIR CONDITIONING UNIT
LD14136
18
JOHNSON CONTROLS
5276178-JIM-C-0118
Introduction
Compressor Sound Blankets
Optional factory installed sound blankets can be installed
to further reduce compressor sound attenuation.
Low Ambient Operation
Head-pressure control is accomplished via a VFD motor
controller rather than an inecient and noisy condenser
fan damper. By varying the speed of the condenser fan,
better control and quieter operation is obtained during
the colder months. Low ambient controls are available
on all systems oîµµering higher rooftop cooling capacity
than competitive units.
Condenser Fan Motors
The condenser fan motors used on the Series 40 unit are
Totally Enclosed Air Over (TEAO) to provide maximum
durability through any season.
Condenser Coils
The condenser coils are available in various materials
and coatings to suit almost any type of application. Either
aluminum or post-coated î‚¿ns are available. The coating
is applied using a phenolic coating on the aluminum coil.
The use of a phenolic coated coil is recommended for
units installed in a corrosive environment.
Heating Section
Staged Gas Heat
The Series 40 rooftop gas furnace is an induced-draft gas
furnace designed for high eciency and reliability. The
furnace uses an aluminized steel tubular heat exchanger
and operates at temperatures sucient to prevent acidic
exhaust gases from condensing in the heat exchanger at
low î‚¿re rates, unlike drum and tube style furnaces that
generate condensation formation.
Electric
The Series 40 is also available with an electrical heater
that can range from 40kW up to 108kW. The Series 40
can have 3 steps of control helping to provide tighter
control of the supply and zone conditioned air. With the
utilization of this multi step function, the Series 40 can
eîµµectively reduce energy consumption by bringing on
smaller stages of heat while maintaining the maximum
level of comfort.
AIR MANAGEMENT
The Johnson Controls FlexSys Underoor Air system
provides a cutting edge, cost competitive alternative to
conventional overhead air distribution systems based on
the performance and system exibility benets that it
can provide. When combined with a Johnson Controls
Series 40 Packaged Rooftop Unit, the system oîµµers a
completed package that provides an optimum solution
for building comfort control.
FlexSys technology uses the open space between the
structural concrete slab and the underside of a raised
access oor system to deliver conditioned air directly
into the occupied zones of oce and other commercial
buildings. This underoor plenum incorporates the air
distribution system with the building power, telecom,
and data cabling in one easily accessed service
plenum.
The raised access oor concept is a proven design
ideal for oce buildings that house today’s modern
business that relies on critical information technologies
to maintain high productivity levels. The unmatched
exibility oered by raised oor systems allows for
significant costs savings and reduced downtimes
when a fast-paced economy demands office space
reconî‚¿guration.
DWDI Airfoil Fans
High eciency fans are used to improve application
flexibility, and address sound and application
concerns.
Building Pressure Control
Exhaust fans, and barometric relief dampers are available
to meet building pressure control requirements. Select
the most appropriate option for a given application.
Variable Frequency Drives
when a VAV unit is ordered, the Series 40 comes standard
with variable frequency drives (VFD’s). The VFD can
optimize a systems performance by modulating the
supply fan motor speed to reduce energy consumption
by as much as 40% while maximizing occupant comfort.
19
JOHNSON CONTROLS
5276178-JIM-C-0118
1
Gas Fired Models
DO NOT store or use gasoline or other ammable
vapors and liquids in the vicinity of this or any other
appliance.
What to Do If You Smell Gas
Do not try to light any appliance. Do not touch any
electrical switch. Do not use any phone in your
building. Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the î‚¿re
department.
The furnace and its individual shut-o
valve must be disconnected from the
gas supply piping system during any
pressure testing of that system at test
pressures in excess of 0.5 PSIG. Pres-
sures greater than 0.5 will cause gas
valve damage resulting in a hazardous
condition. If the gas valve is subjected
to a pressure greater than 0.5 PSIG,
it must be replaced. The furnace must
be isolated from the gas supply piping
system by closing its individual manual
shut-off valve during any pressure
testing of that system at test pressures
equal to or less than 0.5 PSIG.
This Furnace is not to be used for
temporary heating of buildings or
structures under construction.
CONTROLS
Rooftop Controller
The ColdFireâ„¢ processor-based controller uses the
latest in processor technology to provide the highest
level of rooftop control with BACnet open protocol
communication capabilities. An 80-character display
and keypad are standard for simple, and easy to
understand manipulation of control setpoints and readout
of operating parameters and diagnostics. Shutdown and
alarm faults are all recorded in memory, and include a
time and day stamp for easy troubleshooting.
BACnet
The Series 40 can be adapted to operate with any
building automation system that is BACnet compatible
making it the most exible large commercial rooftop
units on the market.
GENERAL
Johnson Controls Model S2/S3/S4 units are single
package cooling only or cooling with gas, electric, hot
water or steam heating designed for outdoor installation
on a rooftop and for non-residential use.
The units are completely assembled on rigid, permanently
attached base rails. All piping, refrigerant charge, and
electrical wiring is factory installed and tested. The
units require electric power, gas, steam, or hot water
connections and duct connections. Gas î‚¿red units also
require installation of a ue gas outlet hood.
Reference R-410A Quick Reference Guide, Figure 64
for R-410A Refrigerant information.
SAFETY CONSIDERATIONS
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
damage may result if installation procedure is not
handled properly.
20
JOHNSON CONTROLS
5276178-JIM-C-0118
Introduction
Before performing service or mainte-
nance operations on unit, turn OFF
main power switch to unit. Electrical
shock could cause personal injury.
Improper installation, adjustment,
alteration, service or maintenance
can cause injury or property damage.
Refer to this manual. For assistance
or additional information consult a
qualiî‚¿ed installer, service agency or
the gas supplier.
INSPECTION
As soon as a unit is received, it should be inspected for
possible damage during transit. If damage is evident,
the extent of damage should be noted on the carrier’s
freight bill. A separate request for inspection by the
carrier’s agent should be made in writing.
ALL MODELS
This system uses R-410A Refrigerant
which operates at higher pressures
than R-22. No other refrigerant may be
used in this system. Gage sets, hoses,
refrigerant containers and recovery
systems must be designed to handle
R-410A. If you are unsure, consult
the equipment manufacturer. Failure
to use R-410A compatible servicing
equipment may result in property dam-
age or injury.
Installation and servicing of air conditioning equipment
can be hazardous due to system pressure and electrical
components. Only trained and qualified service
personnel should install, repair or service air conditioning
equipment.
Untrained personnel can perform basic maintenance
functions of cleaning coils and î‚¿lters and replacing
filters. All other operations should be performed
by trained service personnel. When working on air
conditioning equipment, observe precautions in the
literature, tags and labels attached to the unit and other
safety precautions that may apply.
Follow all safety codes, including ANSI Z223.1-Latest
Edition: wear safety glasses and work gloves; use
quenching cloth for unbrazing operations; have î‚¿re
extinguisher available for all brazing operations.
/