Johnson Controls York VERSECON YSWD 012 Installation Operation & Maintenance

035-21989-000

INSTALLATION, OPERATION & MAINTENANCE

VERSECON AIR CONDITIONING UNIT

Supersedes 145.05-NOM1 (1107)

Form 145.05-NOM1(708)

MODEL YSWD & YSWU

JOHNSON CONTROLS

2

FORM 145.05-NOM1 (708)

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 identiﬁes 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 se-

rious injury.

External wiring, unless speciﬁed 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 YORK’s

published speciﬁcations and must be performed ONLY by qualiﬁed YORK personnel. YORK

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

FORM 145.05-NOM1 (708)

CHANGEABILITY OF THIS DOCUMENT

In complying with YORK’s policy for continuous

product improvement, the information contained in this

document is subject to change without notice. While

YORK 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 YORK Applied Systems ofﬁce.

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 modiﬁed and if current

literature is available.

JOHNSON CONTROLS

4

FORM 145.05-NOM1 (708)

CHANGEABILITY OF THIS DOCUMENT ...........................................................................................................3

TABLE OF CONTENTS .......................................................................................................................................4

LIST OF TABLES .................................................................................................................................................9

LIST OF FIGURES .............................................................................................................................................10

SECTION 1 – INTRODUCTION .........................................................................................................................11

ABOUT THIS MANUAL ..............................................................................................................................11

DESCRIPTION OF UNIT .............................................................................................................................11

NOMENCLATURE .......................................................................................................................................11

SECTION 2 – INSTALLATION ...........................................................................................................................13

APPROVALS ...............................................................................................................................................13

LIMITATIONS ...............................................................................................................................................13

UNIT INSPECTION ......................................................................................................................................13

LOCATION AND CLEARANCES ................................................................................................................14

RIGGING AND UNIT HANDLING ...............................................................................................................14

FACTORY-SUPPLIED PLENUM .................................................................................................................17

VIBRATION ISOLATORS ............................................................................................................................17

SEGMENTED UNIT ASSEMBLY ................................................................................................................17

REMOVE SHIPPING RESTRAINTS ...........................................................................................................18

ELECTRICAL DATA ....................................................................................................................................27

Field Power Wiring ..............................................................................................................................27

Disconnect ...........................................................................................................................................27

Electrical Service Sizing .....................................................................................................................27

MCA ................................................................................................................................................27

MOP ................................................................................................................................................27

Field Control Wiring ............................................................................................................................28

Pump Start .....................................................................................................................................28

Fan Start ........................................................................................................................................29

VAV Box Full Open ........................................................................................................................29

PHASE MONITOR .......................................................................................................................................29

DUCTING ....................................................................................................................................................29

Supply Air .............................................................................................................................................29

Return Air .............................................................................................................................................29

Ducted Return ...............................................................................................................................29

Free Return ....................................................................................................................................29

WATER PIPING ...........................................................................................................................................30

General .................................................................................................................................................30

Condenser Connections .....................................................................................................................30

Cooling Towers .............................................................................................................................31

Waterside Piping Arrangements ..................................................................................................31

Water Temperature Requirements ...............................................................................................31

Condensate Drain Connections .........................................................................................................31

TABLE OF CONTENTS

5

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

STATIC PRESSURE TRANSDUCER INSTALLATION (VAV UNITS ONLY) ..............................................31

Mounting Instructions .........................................................................................................................32

STATIC PRESSURE TRANSDUCER INSTALLATION (FLEXSYS UNITS ONLY) ....................................32

Installation Instructions ......................................................................................................................32

RETURN, OUTDOOR, SUPPLY AIR, AND MIXED AIR SENSORS ...........................................................33

Return Air Sensor ................................................................................................................................33

Supply Air Sensor ...............................................................................................................................33

Mixed Air Sensor .................................................................................................................................33

Outdoor Air Sensor .............................................................................................................................33

STEAM HEAT ..............................................................................................................................................33

Speciﬁcation ........................................................................................................................................33

Steam Piping ........................................................................................................................................33

HOT WATER HEAT .....................................................................................................................................33

Speciﬁcation ........................................................................................................................................33

Hot Water Piping ..................................................................................................................................34

ELECTRIC HEAT ........................................................................................................................................34

FILTERS ......................................................................................................................................................34

SECTION 3 – START-UP ...................................................................................................................................35

CRANKCASE HEATERS ............................................................................................................................35

PRE-STARTUP REQUIREMENTS ..............................................................................................................35

UNIT CHECKS – POWER APPLIED ..........................................................................................................36

Verifying Compressor Rotation ..........................................................................................................36

INITIAL START-UP ......................................................................................................................................36

Refrigerant Charge ..............................................................................................................................37

Subcooling ...........................................................................................................................................37

Superheat (R-22) ..................................................................................................................................37

Leak Checking .....................................................................................................................................37

SECTION 4 – MAINTENANCE ..........................................................................................................................39

GENERAL ...................................................................................................................................................39

PERIODIC MAINTENANCE – MONTHLY ...................................................................................................39

Filters ....................................................................................................................................................39

Linkages ...............................................................................................................................................39

Compressors .......................................................................................................................................39

Oil Analysis ..........................................................................................................................................39

Fan Bearing Lubrication .....................................................................................................................39

Recommended Lubricant for Fan Bearings ......................................................................................39

PERIODIC MAINTENANCE – THREE TO SIX MONTHS .............................................................................................40

Motor Bearing Lubrication ..................................................................................................................40

Belt Tension .........................................................................................................................................40

TABLE OF CONTENTS

JOHNSON CONTROLS

6

FORM 145.05-NOM1 (708)

PERIODIC MAINTENANCE – YEARLY ......................................................................................................40

Entire Unit Inspection .........................................................................................................................40

Sheave Alignment ...............................................................................................................................40

Belts ......................................................................................................................................................41

Belt Replacement ................................................................................................................................41

Belt Tensioning: ...................................................................................................................................41

Filter Drier Replacement .....................................................................................................................41

Supply Fan ...........................................................................................................................................41

Fan Motor .............................................................................................................................................42

Fan Shaft Bearings ..............................................................................................................................42

Mounting Details ...........................................................................................................................42

Bearing Locking Devices .............................................................................................................43

Condenser Coil Cleaning ....................................................................................................................43

WATER PRESSURE DROP TABLES .........................................................................................................44

SECTION 5 – SEQUENCE OF OPERATION ....................................................................................................47

ON / OFF .....................................................................................................................................................47

SUPPLY FAN OPERATION .........................................................................................................................47

Constant Volume Fan Operation ........................................................................................................47

VAV Fan Operation ..............................................................................................................................48

Communicated VFD Speed Input .......................................................................................................48

FLEXSYS DEW POINT CONTROL ............................................................................................................49

Sequence of Operation .......................................................................................................................49

ECONOMIZER OPERATION ......................................................................................................................49

Sequence of Operation .......................................................................................................................50

Waterside Economizer ..................................................................................................................50

Outdoor Air Economizer ...............................................................................................................50

CONDENSER WATER VALVE OPERATION ..............................................................................................51

Sequence of Operation .......................................................................................................................51

CONDENSER WATER BYPASS .................................................................................................................51

Sequence of Operation .......................................................................................................................51

MECHANICAL COOLING OPERATION .....................................................................................................51

Sequence of Operation .......................................................................................................................52

Supply Air Temperature Control ..................................................................................................52

Return Air Temperature Control ..................................................................................................52

Dew Point Temperature Control (FlexSys Units) .......................................................................52

Coil Leaving Temperature Control (FlexSys Units) ...................................................................52

Compressor Analog Output .........................................................................................................52

Compressor Staging .....................................................................................................................53

Lead Lag Operation .............................................................................................................................54

Two Compressor Units .................................................................................................................54

Four Compressor Units ................................................................................................................54

TABLE OF CONTENTS

7

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

FLEXSYS BYPASS DAMPER CONTROL ..................................................................................................54

Sequence of Operation .......................................................................................................................54

COMPRESSOR SAFETY CONTROL OPERATION ...................................................................................54

Compressor High Pressure (Fault / Alarm) .......................................................................................54

Compressor Low Pressure (Fault / Alarm) ........................................................................................55

Compressor Low Suction Pressure Control .....................................................................................55

High Pressure Switch ..........................................................................................................................55

Compressor Motor Protector .............................................................................................................55

HEATING OPERATION ...............................................................................................................................55

Sequence of Operation .......................................................................................................................55

Supply Air Temperature Control ..................................................................................................55

Return Air Temperature Control ..................................................................................................56

Staged Heat Operation .................................................................................................................56

Tristate Modulated Heat ...............................................................................................................57

SECTION 6 – USER INTERFACE CONTROL CENTER ...................................................................................59

KEYPAD ......................................................................................................................................................59

POWER UP BANNER SCREEN .................................................................................................................59

RUN STATUS SCREEN ..............................................................................................................................59

ALARM SCREEN ........................................................................................................................................60

FAULT SCREEN ..........................................................................................................................................60

INPUT ..........................................................................................................................................................61

Analog In ..............................................................................................................................................61

Digital In ...............................................................................................................................................61

OUTPUTS ....................................................................................................................................................61

Analog Out ...........................................................................................................................................61

PID Loop Out ........................................................................................................................................61

Digital Out ............................................................................................................................................61

SETPOINTS .................................................................................................................................................62

FORCED OUTPUTS ....................................................................................................................................64

SETTING DATE AND TIME .........................................................................................................................65

DAILY SCHEDULE ......................................................................................................................................67

HOLIDAY SCHEDULE ................................................................................................................................68

OVERRIDE SCHEDULE .............................................................................................................................68

COMMUNICATIONS ...................................................................................................................................69

Communication Wiring .......................................................................................................................69

Network Baud Rate ..............................................................................................................................69

Device Object Instance (DE) ...............................................................................................................70

TABLE OF CONTENTS

JOHNSON CONTROLS

8

FORM 145.05-NOM1 (708)

SECTION 7 – PARAMETER DESCRIPTIONS AND OPTIONS ......................................................................107

SECTION 8 – SERVICE ...................................................................................................................................113

ANALOG INPUTS .....................................................................................................................................113

Temperature Sensors ........................................................................................................................113

Duct Pressure Transducer ................................................................................................................113

Coil Pressure Drop (FlexSys Units Only) ........................................................................................114

Discharge Pressure Transducer ......................................................................................................114

Suction Pressure Transducer ...........................................................................................................114

Humidity Sensor (FlexSys Units Only) ............................................................................................114

FAULTS AND ALARMS ............................................................................................................................115

Compressor High Pressure (Fault / Alarm) .....................................................................................115

Compressor Low Pressure (Fault / Alarm) ......................................................................................115

Dirty Filter (Alarm) .............................................................................................................................116

Duct High Static (Fault / Alarm) ........................................................................................................116

External Safety ...................................................................................................................................116

Fan Failure (Alarm) ............................................................................................................................116

Freeze (Fault / Alarm) ........................................................................................................................117

CONTROL BOARD CONFIGURATION ....................................................................................................118

Main Control Board ...........................................................................................................................118

Auxiliary Control Board ....................................................................................................................119

WIRING DIAGRAMS .................................................................................................................................124

Constant Volume, Variable Air Volume ............................................................................................124

CV, VAV, FlexSys ................................................................................................................................125

CV, VAV, FlexSys ................................................................................................................................126

FlexSys ...............................................................................................................................................127

TABLE OF CONTENTS

9

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

LIST OF TABLES

TABLE 1 – ACRONYM CHART .........................................................................................................................11

TABLE 2 – VOLTAGE LIMITATIONS ................................................................................................................13

TABLE 3 – OPERATING LIMITATIONS ............................................................................................................13

TABLE 4 – ACCESS REQUIREMENTS ............................................................................................................14

TABLE 5 – WEIGHTS ........................................................................................................................................15

TABLE 6 – DATA TABLE ...................................................................................................................................19

TABLE 7 – REFRIGERANT CHARGE DATA ....................................................................................................23

TABLE 8 – FAN MOTOR DATA .........................................................................................................................28

TABLE 9 – COMPRESSOR MOTOR DATA ......................................................................................................28

TABLE 10 – SETSCREW TORQUES ................................................................................................................35

TABLE 11 – TEMPERATURE/PRESSURE CHART – REFRIGERANT R-22 ...................................................38

TABLE 12 – FAN BEARING – LUBRICATION INTERVALS ............................................................................39

TABLE 13 – BELT TENSION DATA ..................................................................................................................40

TABLE 14 – WINDOW OF OPERATION, COMPRESSOR STAGING ..............................................................52

TABLE 16 – SETPOINT SCREEN PARAMETERS ...........................................................................................63

TABLE 17 – FORCED ON PARAMETERS .......................................................................................................64

TABLE 18 – BACnet MS/TP points ..................................................................................................................70

TABLE 19 – N2 POINTS LIST .........................................................................................................................102

TABLE 20 – DEFINITIONS ..............................................................................................................................107

TABLE 21 – TEMPERATURE SENSOR RESISTANCE ..................................................................................113

TABLE 22 – VAV DUCT STATIC PRESSURE TRANSDUCER ......................................................................113

TABLE 23 – FLEXSYS DUCT STATIC PRESSURE TRANSDUCER .............................................................113

TABLE 24 – COIL PRESSURE DROP (FLEXSYS) ........................................................................................114

TABLE 25 – REFRIGERANT PRESSURE TRANSDUCERS .........................................................................114

TABLE 26 – HUMIDITY SENSOR OUTPUT ...................................................................................................115

TABLE 27 – CONSTANT VOLUME / VARIABLE AIR VOLUME MAIN CONTROL BOARD * .......................120

TABLE 28 – CONSTANT VOLUME / VARIABLE AIR VOLUME EXPANSION CONTROL BOARD * ...........121

TABLE 29 – FLEXSYS MAIN CONTROL BOARD * .......................................................................................122

TABLE 30 – FLEXSYS EXPANSION CONTROL BOARD * ...........................................................................123

JOHNSON CONTROLS

10

FORM 145.05-NOM1 (708)

LIST OF FIGURES

FIG. 1 – RECOMMENDED SERVICE AND MAINTENANCE CLEARANCE ....................................................14

FIG. 2 – SHIPPING RESTRAINT LOCATIONS .................................................................................................18

FIG. 3 – SHEAVE ALIGNMENT .........................................................................................................................40

FIG. 4 – BELT TENSIONING GAUGE ...............................................................................................................41

FIG. 5 – KEYPAD / DISPLAY .............................................................................................................................59

FIG. 6 – COMMUNICATION WIRING ................................................................................................................69

FIG. 7 – MAIN CONTROL BOARD PIN POSITIONS ......................................................................................118

FIG. 8 – AUXILIARY CONTROL BOARD PIN POSITIONS ............................................................................119

FIG. 9 – MAIN CONTROL BOARD .................................................................................................................119

FIG. 10 – AUXILIARY CONTROL BOARD ......................................................................................................119

FIG. 11 – ELEMENTARY CONTROL WIRING DIAGRAM, YWSU- ALL OPTIONS .......................................124

FIG. 12 – ELEMENTARY CONTROL WIRING DIAGRAM, YSWU .................................................................125

FIG. 13 – ELEMENTARY POWER WIRING DIAGRAM, YSWU .....................................................................126

FIG. 14 – ELEMENTARY CONTROL WIRING DIAGRAM, YSWU DOWNFLOW ..........................................127

11

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

1 2

3 4

5 6

7

U - Upflow

0

D - Downflow for FlexSys

W - Water Cooled

A - Air Cooled

C - Chilled Water Cooled

S - Self-contained

Y - York

3

9

Nominal TonnageBase Product Type

BASE MODEL NUMBER

YSWU039 - YORK Versacon Water Cooled, Upflow, 39 Nominal Tons

YSWU - YORK Floor X Floor, Water Cooled, Upflow

YSAU - YORK Floor X Floor, Air Cooled, Upflow

YSCU - YORK Floor X Floor, Chilled Water Cooled, Upflow

YSWD - YORK Floor X Floor, Water Cooled, Downflow

YSAD - YORK Floor X Floor, Air Cooled, Downflow

YSCD - YORK Floor X Floor, Chilled Water, Downflow

ABOUT THIS MANUAL

This manual applies to Versecon Models YSWD/

YSWU012 to YSWD/YSWU090. This manual pro-

vides speciﬁc instructions for installation, owner main-

tenances, and troubleshooting.

Due to the dedication of continuous product improve-

ment and enhancements, the information provided is

subject to change without notice

DESCRIPTION OF UNIT

Versecon, the indoor vertical self-contained air con-

ditioner is the ultimate solution addressing the energy

efﬁciency, reliability, indoor air quality, and sound

concerns for commercial, industrial and institutional

buildings. Versecon offers a simple system design,

increases system redundancy by providing individual

air conditioning systems per ﬂoor, lowers maintenance

costs, eases operation and maintenance and provides the

lowest life cycle cost available. Based on these features,

the self-contained unit has surpassed the traditional

chillers, air handlers and rooftop systems and is now

the system of choice.

Models YSWD/YSWU012 to YSWD/YSWU090 are

factory assembled, refrigerant charged and tested, wa-

ter-cooled packaged air conditioning units designed for

ducted applications.

Each unit contains multiple hermetic scroll compres-

sors, water cooled condensers, multi-circuit evaporator,

thermal expansion valves, interconnecting refrigerant

piping, plenum supply fan, belt drive, fan motor, pleated

ﬁlters and all necessary operating and required safety

controls to operate the unit.

All rigging, installation, power and control wiring ex-

ternal to the unit, and condenser water and condensate

piping are the responsibility of the installer.

NOMENCLATURE

TABLE 1 – ACRONYM CHART

ACRONYM TEXT

AO Analog Output

AFS Air Flow Switch

DHS Duct High Static Switch

DSP Duct High Pressure Sensor

DO Digital Output

IN Universal Input

LCD Logic Controller Display

MSF Supply Fan Relay

OLSF Supply Fan Overload

PM Phase Monitor

PWS Power Supply

RSF Supply Fan Relay

S Toggle Switch

T Transformer

VFD Variable Frequency Drive

SAT Supply Air Temp

MAT Mixed Air Temp

AFS Air Flow Switch

DHS Duct High Static

RAT Return Air Temp

1

SECTION 1 – INTRODUCTION

12

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

THIS PAGE INTENTIONALLY LEFT BLANK

13

2

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

APPROVALS

Designed certified by ETL for indoor installation

only.

LIMITATIONS

The installation of this unit must conform to local

building codes as well as the National Electrical Code

ANSI/NFPA No. 70 – latest edition.

Refer to Table 2 for voltage limitations and Table 3 for

operating limitations.

If the VAV boxes in the conditioned

space have hydronic heating coils

installed, it is the responsibility of the

installing contractor to take appropri-

ate measures to protect the hydronic

coils against low unit supply air tem-

peratures that could result in the freeze

up and rupture of the coils.

UNIT INSPECTION

Immediately upon receiving the unit, it should be

inspected for possible damage which may have

occurred during transit. If damage is evident, it should

be noted on the carrier’s freight bill. A written request

for inspection by the carrier’s agent should be made at

once. See “Instruction” manual Form 50.15-NM for

more information and details.

To ensure warranty coverage, this

equipment must be commissioned

and serviced by an authorized YORK

service mechanic or a qualiﬁed ser-

vice person experienced in packaged

rooftop installation. Installation must

comply with all applicable codes, par-

ticularly in regard to electrical wiring

and other safety elements such as relief

valves, HP cut-out settings, design

working pressures and ventilation re-

quirements consistent with the amount

and type of refrigerant charge.

Lethal voltages exist within the control

panels. Before servicing, open and tag

all disconnect switches.

TABLE 2 – VOLTAGE LIMITATIONS

UNIT POWER SUPPLY VOLTAGE VARIATIONS

MINIMUM VOLTS MAXIMUM VOLTS

208-3-60 180 228

230-3-60 207 253

480-3-60 415 506

575-3-60 518 632

TABLE 3 – OPERATING LIMITATIONS

MINIMUM MAXIMUM

ENTERING AIR DX COIL

– DRY BULB

68.0° F 90.0° F

ENTERING AIR DX COIL

– WET BULB

57.0° F 72.0° F

DC COOLING COIL AIRFLOW

VELOCITY

400

FPM

600

FPM

CONDENSER WATER FLOW

2.0

GPM/TON

3.0

GPM/TON

ENTERING COND. WATER

TEMP WITH WATER

ECONOMIZER

50.0° F 115.0° F

ENTERING COND. WATER

TEMP W/O WATER

ECONOMIZER

55.0° F 115.0° F

STEAM HEAT – STEAM

PRESSURE

5 PSIG 15 PSIG

HOT WATER HEAT ENTERING

WATER TEMP

140.0° F 160.0° F

SECTION 2 – INSTALLATION

14

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

LOCATION AND CLEARANCES

The following guidelines should be used to select a

suitable location for the unit installation:

• The unit is designed for indoor installation only

• Verify the ﬂoor or foundation is level. For proper

unit operation the unit should be level within a

1/16” side to side and 1/8” front to back tolerance.

Failure to level the unit properly could result in

condensate management problems, such as stand-

ing water inside the unit.

For installation, service and maintenance access, the

following clearances should be followed. Minimum

clearances required by local, state, or national codes,

such as NEC take precedence over those listed in Figure

1 and Table 4. Clearance is required to allow room for

side ﬁlter access, mechanical cleaning of the condenser

tubes and water economizer coil, access to expansion

valves and other control components and to allow for

possible fan shaft or compressor removal. Additional

clearance should be considered for component

replacement such as condenser, evaporator, water

economizer coil and supply fan. Even though there is

no vertical clearance speciﬁcation listed clearance above

the unit may be advantages during change out of any of

the above components.

FIG. 1 – RECOMMENDED SERVICE AND

MAINTENANCE CLEARANCE

RIGGING AND UNIT HANDLING

Units are shipped with a protective covering, which

should remain in place while the unit is being moved

to its ﬁnal location.

Never allow any part of the unit to fall

during unloading or moving as this

may result in serious damage.

Unit weights are listed in Table 5 in this manual. These

weights must be referred to when selecting a crane for

rigging. Contact your Johnson Controls Sales Ofﬁce if

you have any questions regarding unit weights.

Ensure lifting equipment capacity

exceeds unit weight by an adequate

safety factor to prevent injury, death,

or unit damage.

TABLE 4 – ACCESS REQUIREMENTS

AREA DISTANCE COMPONENT ACCESSED

UNIT FRONT 42"

MOST ELECTRICAL AND POW-

ER COMPONENTS, VFD, FAN

BELT ADJUSTMENTS, GREAS-

ING BOTH BEARINGS, FAN

WHEEL, FAN MOTOR, SHAFT

PULL, ETC.

UNIT REAR 18"

FILTER ACCESS, COIL ACCESS,

ETC.

UNIT LEFT 24"

COMPRESSOR A AND B, RE-

FRIGERANT COMPONENTS

UNIT RIGHT 24"

COMPRESSOR C AND D, RE-

FRIGERANT COMPONENTS

42"

LEFT

FRONT

RIGHT

BACK

24"

18"

LDO10371

Installation

15

2

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

TABLE 5 – WEIGHTS

UNIT WEIGHTS 012 016 021 025 032 039 048 050 055 060 072 079 090

COOLING COIL SECTION

CABINET 451 456 461 466 529 593 656 818 720 823 911 1135 1140

EVAPORATIVE COIL 168 206 244 282 350 418 486 528 554 592 694 761 855

WATERSIDE ECONOMIZER SECTION

4 ROW, 12 FPI 267 305 343 381 457 549 627 679 705 743 855 932 1,026

WATER WEIGHT 35 47 58 70 91 112 133 147 154 168 201 221 252

HEATING SECTION

HOT WATER HEAT 63 83 105 126 163 201 238 263 276 301 359 395 451

WATER WEIGHT 11 14 18 22 28 35 41 46 48 52 62 68 78

STEAM 63 83 105 126 163 201 238 263 276 301 359 395 451

ELECTRIC HEAT 21 21 21 21 21 21 42 42 42 42 42 42 42

RETURN AIR SECTION

FILTERS – 4" 30% 182 182 182 182 213 244 276 352 306 352 401 477 477

FAN SECTION

CABINET 451 456 461 466 529 593 656 818 720 823 911 1135 1140

FAN AND BASE

18" 203 203 203 203 - - - - - - - - -

20" 213 213 213 213 213 - - - - - - - -

22" - - - - 233 233 - - - - -

24" - - - - - 285 285 - - - - - -

27" - - - - - 428 428 - 428 - - - -

30" - - - - - - - 472 - 472 - - -

33" - - - - - - - 598 - 598 598 - -

36" - - - - - - - - - - 685 685 685

40" - - - - - - - - - - - 920 920

44" - - - - - - - - - - - - -

MOTOR HP

2 64 - - - - - - - - - - - -

3 100 100 - - - - - - - - - - -

5 117 117 117 117 - - - - - - - - -

7.5 194 194 194 194 194 194 - 194 - - - - -

10 213 213 213 213 213 213 213 213 213 213 213 213 -

15 - - 326 326 326 326 326 326 326 326 326 326 326

20 - - - - 368 368 368 368 368 368 368 368 368

25 - - - - - - 495 495 495 495 495 495 495

30 - - - - - - - - - 519 519 519 519

40 - - - - - - - - - - 602 602 602

50 - - - - - - - - - - - - -

VARIABLE FREQUENCY DRIVE

2 5 - - - - - - - - - - - -

3 8 8 - - - - - - - - - - -

5 13 13 13 13 - - - - - - - - -

7.5 51 51 51 51 51 51 - 51 - - - - -

10 51 51 51 51 51 51 51 51 51 51 51 51 -

15 - - 66 66 66 66 66 66 66 66 66 66 66

20 - - - - 66 66 66 66 66 66 66 66 66

25 - - - - - - 106 106 106 106 106 106 106

30 - - - - - - - - - 106 106 106 106

40 - - - - - - - - - - 106 106 106

50 - - - - - - - - - - - - -

16

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

TABLE 5 – WEIGHTS (CONT.)

UNIT

WEIGHTS

WATER

WEIGHT

012 016 021 025 032 039 048 050 055 060 072 079 090

COMPRESSOR/CONDENSER

(1) 4 & (1) 7 26 333 333 - - - - - - - - - - -

(1) 4 & (1) 10 34 358 358 - - - - - - - - - - -

(1) 7 & (1) 10 41 434 434 434 - - - - - - - - - -

(1) 7 & (1) 12 46 456 456 456 - - - - - - - - - -

(1) 7 & (1) 15 53 - 597 597 597 - - - - - - - - -

(1) 10 & (1) 15 60 - - 673 673 673 - - - - - - - -

(1) 12 & (1) 15 65 - - 694 694 694 - - - - - - - -

(1) 12 & (1) 20 77 - - - 856 856 - - - - - - - -

(1) 12 & (1) 25 89 - - - 905 905 - - - - - - - -

(1) 15 & (1) 25 96 - - - - 1,046 - - - - - - - -

(2) 7 & (2) 10 82 - - - - - 954 - - - - - - -

(2) 7 & (2) 12 91 - - - - - 1,016 1,016 - - - - - -

(4) 10 96 - - - - - 1,144 1,144 - - - - - -

(2) 7 & (2) 15 106 - - - - - 1,311 1,311 1,311 - - - - -

(4) 12 115 - - - - - 1,232 1,232 1,232 1,229 - - - -

(2) 10 & (2) 15 120 - - - - - - 1,483 1,483 1,490 1,483 - - -

(2) 12 & (2) 15 130 - - - - - - - 1,527 1,534 1,527 - - -

(4) 15 144 - - - - - - - 1,822 1,839 1,822 1,839 - -

(2) 12 & (2) 20 154 - - - - - - - - - 1,899 1,968 - -

(2) 15 & (2) 20 168 - - - - - - - - - 2,194 2,273 2,273 -

(2) 12 & (2) 25 178 - - - - - - - - - - 2,111 2,111 2,111

(2) 15 & (2) 25 192 - - - - - - - - - - 2,417 2,417 2,417

(2) 20 & (2) 25 216 - - - - - - - - - - - 2,851 2,851

(4) 25 240 - - - - - - - - - - - 2,994 2,994

(2) 25 & (4) 15 264 - - - - - - - - - - - - -

(6) 20 288 - - - - - - - - - - - - -

(2) 25 & (4) 20 312 - - - - - - - - - - - - -

(2) 20 & (4) 25 336 - - - - - - - - - - - - -

(6) 25 360 - - - - - - - - - - - - -

DISCHARGE PLENUM

FACTORY INSTALLED 492 492 492 492 560 627 695 759 763 759 846 1,073 1,073

Determine the approximate center of gravity for lifting

safety before lifting the unit.

Always test-lift the unit to determine the exact unit

balance and stability before hoisting it to the installation

location.

Units are provided with lifting lugs for rigging with a

crane. If the units are lifted by crane, protection against

chafﬁng damage by slings or cable must be provided,

and spreader bars must be used across the top of the

cabinet to prevent any structural damage to the frame.

Installation

17

2

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

The unit base frame will accept dollies or Johnson bars

for transporting the unit. Furniture dollies can be placed

at both ends of the chassis or at one end, and a Johnson

bar used at the other end for maneuvering.

Do not attempt to install dollies in the

center of the unit. Units can become

unstable and tip over causing injury.

Do not use hooks to lift unit or hook

into open channels to lift unit. This

could cause unit damage.

FACTORY-SUPPLIED PLENUM

If the unit is provided with a factory plenum for ﬁeld

mounting, a forklift, slings or other suitable lifting

means is required to position the plenum above the unit.

Prior to placing the plenum on the top of the unit verify

the foam rubber gasket is in place around the perimeter

of the unit top. Align the plenum front with the control

panel side of the unit. Carefully set the plenum and

attach using the mounting hardware provided with the

plenum. Treat ﬁeld-cut holes to prevent ﬁberglass from

entering the air stream.

Do not remove more than two non-

adjacent panels at one time, failure

to do so will cause the plenum frame

to collapse and may cause personal

injury.

The plenum insulation strip must be

applied properly to prevent air bypass

around the plenum

VIBRATION ISOLATORS

Each Versecon unit includes 1-inch high vibration

isolation pads composed of 1/2 inch thick cork

sandwiched between ¼ inch thick neoprene pads.

The vibration isolators should be placed with the

2–inch width of the isolator supporting the 2-inch deep

frame.

For units with 6 pads (12, 16, 21, and 25 ton units) the

pad locations should be one near each of the corners and

one on the front and back of the unit near the center.

For units having more than six pads the pads should

be placed at each corner and then distributed evenly

between the front and back and sides. The 32 and 39

ton units have 8 pads, the 48 ton unit has 12 pads, the

55, 63, 73, 50, and 60 ton has 16 pads, the 72, 79, and

90 ton units have 20 pads.

SEGMENTED UNIT ASSEMBLY

For ease of handling and transport in a freight elevator

the Versecon product can be split and shipped in three

segments. The unit was assembled and tested at the

factory prior to shipment. The sections were then

separated for shipment. The three segments are as

follows:

• Compressor / Condenser / Coil section

• Control and supply air fan section

• Filter or ﬁlter and hydronic heat section (op-

tional)

Refer to publication Form 145.05-FA1 for detailed

instruction on how to reassemble the unit.

18

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

REMOVE SHIPPING RESTRAINTS

Mechanical restraints are used to secure the spring

mounted supply fan during shipment (see Figure 2).

Restraints and shipping blocks must

be removed after unit has been set in

its ﬁnal location.

TIE DOWN BOLTS

TYP FOUR PLACES

SUPPLY FAN ASSEMBLY

DETAIL A

SCALE 1:4

A

FIG. 2 – SHIPPING RESTRAINT LOCATIONS

LD12274

Installation

19

2

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

DATA 012 016 021 025 032 039 048

Capacity

Range

Min. capacity (tons) 10 15 20 25 30 35 40

Max. capacity (tons) 20 25 30 35 45 55 65

Airﬂow

Range

Min. VAV design CFM 3,300 4,400 5,600 6,700 8,700 10,700 12,700

Max.VAV design & operating CFM 5,000 6,700 8,400 10,000 13,000 16,000 19,000

Cabinet

Dimensions

Depth (excluding return section) 70 70 70 70 70 70 70

Length 52 52 52 52 64 76 88

Height (excluding discharge plenum) 79 79 79 79 79 79 79

Box type M1 M1 M1 M1 M2 M3 M4

EER

Based on ARI 340/360-93 15.7 15.7 14.5 13.9 13.8 14.2 13.6

Cooling Coil

Section

Face Area 8.3 11.1 13.9 16.7 21.7 26.7 31.7

Rows–12 FPI* 4 or 6 4 or 6 4 or 6 4 or 6 4 or 6 4 or 6 4 or 6

Waterside

Econo

Section

Face Area 8.3 11.1 13.9 16.7 21.7 26.7 31.7

Rows–12 FPI 2 or 4 2 or 4 2 or 4 2 or 4 2or 4 2 or 4 2 or 4

Heating

Section

Hot Water Heat–Face Area 8.3 11.1 13.9 16.7 21.7 26.7 31.7

Rows–10 FPI 1 or 2 1 or 2 1 or 2 1 or 2 1 or 2 1 or 2 1 or 2

Electric Heat–kW TBD TBD TBD TBD TBD TBD TBD

Steam–Face Area 8.3 11.1 13.9 16.7 21.7 26.7 31.7

Rows–8 FPI 1 1 1 1 1 1 1

Return Air

Section

Filter Type 2” or 4” PLEATED, 12” CARTRIDGE

Filter Area (ft

2

) 18.3 18.3 18.3 18.3 24.4 28.5 32.5

20 x 20 Filter Quantity 3 3 3 3 9 3 12

20 x 25 Filter Quantity 3 3 3 3 - 6 -

Pre-Filter 2” or 4 2” or 4 2” or 4 2” or 4 2” or 4 2” or 4 2” or 4

Efﬁciency (%) 30 to 95 30 to 95 30 to 95 30 to 95 30 to 95 30 to 95 30 to 95

Final-Filter 4” or 12” 4” or 12” 4” or 12” 4” or 12” 4” or 12” 4” or 12” 4” or 12”

Efﬁciency (%) 65–95 65–95 65–95 65–95 65–95 65–95 65–95

Fan Section

Type AIRFOIL PLENUM FAN (SWSI)

Quantity–Dia. (in): standard capacity 1–18 1–18 1–18 1–18 1–20 1–24 1–24

Quantity–Dia. (in): high capacity 1–20 1–20 1–20 1–20 1–24 1–27 1–27

Motor HP range 1.0–20.0 1.0–20.0 1.0–20.0 1.0–20.0 1.5–20.0 2.0–20.0 2.0–20.0

Compressor

Section

Type SCROLL

Quantity 2 2 2 2 2 4 4

Stages–VAV systems 3 3 3 3 3 4–6 4–6

TABLE 6 – DATA TABLE

Due to �

* Aluminum ﬁns standard. ** M-Available Modular Construction, N- for New Construction.

Continued on next page

PHYSICAL & ELECTRICAL DATA

20

JOHNSON CONTROLS

FORM 145.05-NOM1 (708)

DATA 050 055 060 072 079 090

Capacity

Range

Min. capacity (tons) 40 50 55 65 70 80

Max. capacity (tons) 70 75 80 100 105 120

Airﬂow Range

Min. VAV design CFM 14,000 14,700 16,000 19,100 21,000 24,000

Max.VAV design & operating CFM 21,000 22,000 24,000 28,700 31,500 36,000

Cabinet

Dimensions

Depth (excluding return section) 84 70 84 84 96 96

Length 84 100 84 98 120 120

Height (excluding discharge plenum) 99 79 99 99 99 99

Box type N1 M5 N1 N2 N3 N3

EER

Based on ARI 340/360-93 14.1 13.6 14.2 14.6 14.5 14.3

Cooling Coil

Section

Face Area 35 36.7 40 47.8 52.5 60.0

Rows–12 FPI* 4 or 6 4 or 6 4 or 6 4 or 6 4 or 6 4 or 6

Waterside

Econo

Section

Face Area 35 36.7 40 47.8 52.5 60.0

Rows–12 FPI 2 or 4 2 or 4 2 or 4 2 or 4 2 or 4 2 or 4

Heating

Section

Hot Water Heat–Face Area 35 36.7 40 47.8 52.5 60.0

Rows–10 FPI 1 or 2 1 or 2 1 or 2 1 or 2 1 or 2 1 or 2

Electric Heat–kW TBD TBD TBD TBD TBD TBD

Steam–Face Area 35 36.7 40 47.8 52.5 60

Rows–8 FPI 1 1 1 1 1 1

Return Air

Section

Filter Type 2” or 4” PLEATED, 12” CARTRIDGE

Filter Area (ft

2

) 40.8 36.7 40.8 48.9 62.5 62.5

20 x 20 Filter Quantity - 6 - 8 8 8

20 x 25 Filter Quantity 12 6 12 8 12 12

Pre-ﬁlter 2” or 4 2” or 4 2” or 4 2” or 4 2” or 4 2” or 4

Efﬁciency (%) 30 to 95 30 to 95 30 to 95 30 to 95 30 to 95 30 to 95

Final-Filter 4” or 12” 4” or 12” 4” or 12” 4” or 12” 4” or 12” 4” or 12”

Efﬁciency (%) 65–95 65–95 65–95 65–95 65–95 65–95

Fan Section

Type AIRFOIL PLENUM FAN (SWSI)

Quantity–Dia. (in): standard capacity 1–30 1–27 1–30 1-33 1-36 1-36

Quantity–Dia. (in): high capacity 1–33 n/a 1–33 1-36 1-40 1-40

Motor HP range 3.0–30.0 3.0–20.0 3.0–30.0 3.0-40.0 5.0-50.0 5.0-50.0

Compressor

Section

Type SCROLL

Quantity 4 4 4 4 4 4

Stages–VAV systems 4–6 4–6 4–6 4–6 4–6 4–6

Condenser

Section

Type WATER-COOLED, MECHANICALLY CLEANABLE

Quantity 4 4 4 4 4 4

GPM Range 2.0 to 3.0 GPM/Ton 100–150 110–165 120–180 144-216 158-237 180-270

TABLE 6 – DATA TABLE (CONTINUED)

Due to �

* Aluminum ﬁns standard. ** M-Available Modular Construction, N- for New Construction.

Installation

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Johnson Controls York VERSECON YSWD 012 Installation Operation & Maintenance

Johnson Controls York VERSECON YSWD 012 Installation Operation & Maintenance

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