Johnson Controls 40 40 TON Installation Operation & Maintenance

Brand: Johnson Controls

Model: 40 40 TON

Category: Split-system air conditioners

Type: Installation Operation & Maintenance

This manual is also suitable for

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

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 identi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 specications and must be performed ONLY by quali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.

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 modied and if current

literature is available.

JOHNSON CONTROLS

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 Equipment™ COM Card

B = Smart Equipment™ COM Card W/DISC & 110V OUTLET

C = Smart Equipment™ 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

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

PACKAGE

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

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

5276178-JIM-C-0118

TABLE OF CONTENTS (CONT'D)

Thermostat ............................................................................................................................80

Space Sensor ........................................................................................................................80

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

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

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

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

Con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

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

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

Sensor ..........................................................................................................................230

Furnace Status Input ..........................................................................................................230

FAULTS ......................................................................................................................................231

MULTI MEDIA CARD .................................................................................................................242

JOHNSON CONTROLS

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

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)

............................................................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)

.......................................................................104

TABLE 60 - HOT WATER COIL (2 ROW, 25 & 30 TON)

...........................................................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

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

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)

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

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)

JOHNSON CONTROLS

5276178-JIM-C-0118

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

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 oering 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 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 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

eectively 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 oers 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

recon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.

JOHNSON CONTROLS

5276178-JIM-C-0118

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 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 ColdFire™ 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 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.

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

quali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 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 re

extinguisher available for all brazing operations.

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Johnson Controls 40 40 TON Installation Operation & Maintenance

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Model: 40 40 TON

Category: Split-system air conditioners

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