Johnson Controls GVD Series Start-Up & Operation

Category
Split-system air conditioners
Type
Start-Up & Operation

This manual is also suitable for

5586996-JSG-A-0120
25–50 Tons
Premier
Rooftop Units
R-410A
LD26877
Table of Contents
Nomenclature ...................................................................... 4
Pre Start-Up Checklist ......................................................... 7
Start-Up ............................................................................... 9
Long Term Storage ......................................................... 9
Checking System Prior to Initial Start (No Power) ......... 9
Unit Checks (Power Applied) ....................................... 10
Initial Start-Up .............................................................. 16
Refrigerant Charge ............................................... 16
Checking Sub-Cooling and Superheat.................. 16
Leak Checking ...................................................... 17
Gas Heat Models .................................................. 17
Phase Monitor Adjustment .................................... 20
Commissioning Mode................................................... 20
Air Balancing Wizard .................................................... 20
Start-Up Wizard ............................................................ 24
Start-Up Wizard Sequence ................................... 26
Sequences of Operation .................................................... 30
Control Boards ............................................................. 30
Variable Frequency Drives (VFDs) ............................... 37
Unit Type ...................................................................... 38
Occupancy Mode ......................................................... 38
Morning Warm-up/Cool Down ............................... 38
Coast..................................................................... 38
Remote Safety Shutdown ............................................ 39
Low Voltage Monitoring ................................................ 39
Supply Fan Operation .................................................. 39
Supply Fan Alarm.................................................. 39
MZVAV Supply Fan ............................................... 39
SZVAV Supply Fan ............................................... 40
Redundant Supply Fan VFD ................................. 40
Cooling Operation ........................................................ 40
MZVAV Cooling Operation .................................... 40
SZVAV Cooling Operation ..................................... 42
Compressors and Refrigeration Circuits ............... 42
Compressor Staging Sequences .......................... 44
Condenser Systems and Fans.............................. 48
Dehumidiî‚¿cation (Hot Gas Reheat) ...................... 49
Economizer ........................................................... 51
Heating ......................................................................... 52
Gas Heating .......................................................... 52
Electric Heating ..................................................... 56
Hydronic Heating .................................................. 56
MZVAV Heating Operation .................................... 56
SZVAV Heating Operation .................................... 57
Ventilation..................................................................... 58
Ventilation Sequences .......................................... 58
Low Mixed Air Temperature Limiting ..................... 58
Demand Control Ventilation .................................. 58
Continuous Ventilation .......................................... 59
Pre-Occupancy Purge........................................... 59
Humidification............................................................... 60
Humidiî‚¿cation Sequence ...................................... 60
Exhaust System ........................................................... 60
Modulating Exhaust Fan ....................................... 60
Modulating Exhaust Damper with Fan .................. 60
External Control .................................................... 60
Return Fan ................................................................... 60
Return Fan Discharge Pressure ........................... 61
Supply Fan Airow Tracking.................................. 61
Energy Recovery Wheel .............................................. 61
Single Speed Energy Recovery Wheel ................. 61
Variable Speed Energy Recovery Wheel .............. 61
Ultraviolet Lights........................................................... 61
Smoke Control ............................................................. 62
Purge .................................................................... 62
Pressurization ....................................................... 62
Depressurize ......................................................... 62
START-UP & OPERATION
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
2
List of Tables
Table 1: Component Static Pressure Drops (iwg) ....................................................................................................................... 11
Table 2: 25–30 Ton Supply Fan Total Static Pressure ................................................................................................................ 13
Table 3: 40–50 Ton Supply Fan Total Static Pressure ................................................................................................................ 14
Table 4: 25–30 Ton Exhaust Fan Total Static Pressure .............................................................................................................. 14
Table 5: 40–50 Ton Exhaust Fan Total Static Pressure .............................................................................................................. 15
Table 6: 25–30 Ton Return Fan Total Static Pressure................................................................................................................. 15
Table 7: 40–50 Ton Return Fan Total Static Pressure................................................................................................................. 15
Table 8: R-410A Pressure/Temperature Chart ............................................................................................................................ 17
Table 9: Staged Gas Low Fire/High Fire Pressures .................................................................................................................... 19
Table 10: Staged and Modulating Gas Heat ............................................................................................................................... 20
Table 11: Air Balancing Wizard Points ........................................................................................................................................ 21
Table 12: Start-Up Wizard Signals .............................................................................................................................................. 24
Table 13: Main Control Board Field Terminal Points ................................................................................................................... 31
Table 14: Condenser Boards Field Terminal Points .................................................................................................................... 32
Table 15: Options Board Field Terminal Points ........................................................................................................................... 32
Table 16: Building System Interface Board Field Terminal Points .............................................................................................. 33
Table 17: VFD Field Parameters ................................................................................................................................................. 37
Table 18: Compressor Numbering .............................................................................................................................................. 43
Table 19: Compressor Layout ..................................................................................................................................................... 43
Table 20: Compressor Motor Protection ..................................................................................................................................... 47
Table 21: Saturated Liquid Line Temperature Setpoints and Values .......................................................................................... 48
Table 22: Gas Heating Stages and Turndown Ratios ................................................................................................................. 52
Table 23: Staged Gas Heating Faults List .................................................................................................................................. 53
Table 24: Modulating Gas Heating Faults List ............................................................................................................................ 55
Table 25: Electric Heating Steps ................................................................................................................................................. 56
Table 26: Menus and Submenus ................................................................................................................................................ 64
Table 27: Cable Recommendations for BACnet MS/TP, Modbus, and N2 ................................................................................. 95
Table 28: BACnet IP Settings ..................................................................................................................................................... 96
Table 29: BACnet MS/TP Settings .............................................................................................................................................. 96
Table 30: MAP Gateway Related Documentation ....................................................................................................................... 97
Table 31: Verasys Related Documentation ................................................................................................................................. 98
Table 32: BACnet Points List ...................................................................................................................................................... 98
Table 33: Faults List .................................................................................................................................................................. 117
Table of Contents
User Interface Display ....................................................... 62
Turning on the Unit ....................................................... 91
Using the USB Port ...................................................... 91
View Version ......................................................... 91
Load Firmware ...................................................... 91
Backup Function ................................................... 92
Restore Function .................................................. 92
Full Clone Function ............................................... 92
Partial Clone Function........................................... 93
Communication.................................................................. 93
BACnet Testing Laboratories (BTL) Certification ......... 93
BACnet Integration Setup ............................................ 94
Communication Components................................ 94
Setting Up Device Parameters.............................. 96
Mobile Access Portal (MAP) Gateway .................. 97
Verasys ................................................................. 97
Faults ................................................................................116
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
3
List of Figures
Figure 1: Trap Detail for Draw Through Application...................................................................................................................... 9
Figure 2: Manifold Gas Pressure Adjustment ............................................................................................................................. 19
Figure 3: Control Board Locations .............................................................................................................................................. 30
Figure 4: User Interface Display Board ...................................................................................................................................... 31
Figure 5: Main Control Board ..................................................................................................................................................... 31
Figure 6: Condenser Boards ...................................................................................................................................................... 32
Figure 7: Options Board ............................................................................................................................................................. 32
Figure 8: Building System Interface Board ................................................................................................................................. 33
Figure 9: Modulating Gas Heat Control Board ........................................................................................................................... 34
Figure 10: Staged Gas Heat Control Board................................................................................................................................ 34
Figure 11: Field Wiring to Building System Interface Board ....................................................................................................... 35
Figure 12: Field Wiring to Options Board ................................................................................................................................... 36
Figure 13: Field Wiring to Main Control Board ........................................................................................................................... 36
Figure 14: Three VFD Cutout Display Panel .............................................................................................................................. 37
Figure 15: Seven VFD Cutout Display Panel ............................................................................................................................. 37
Figure 16: Safety Switch Input.................................................................................................................................................... 39
Figure 17: Condenser Fan/Compressor Locations..................................................................................................................... 42
Figure 18: Safety Chain Wiring .................................................................................................................................................. 46
Figure 19: Low Pressure Cutout Switch Wiring .......................................................................................................................... 46
Figure 20: Active DAT Setpoint when Unit Is In Idle Mode ......................................................................................................... 50
Figure 21: Active EAT Setpoint Based on Humidity Level .......................................................................................................... 50
Figure 22: HGRH Schematic ...................................................................................................................................................... 51
Figure 23: Effective Indoor Air Quality ........................................................................................................................................ 59
Figure 24: Status Menu .............................................................................................................................................................. 63
Figure 25: Alarms Menu ............................................................................................................................................................. 63
Figure 26: Alarm Log Menu ........................................................................................................................................................ 63
Figure 27: Summary Menu ......................................................................................................................................................... 63
Figure 28: Commission Menu..................................................................................................................................................... 63
Figure 29: Controller Menu ......................................................................................................................................................... 63
Figure 30: Update Menu ............................................................................................................................................................. 64
Figure 31: Details Menu ............................................................................................................................................................. 64
Figure 32: Schedule Menu ......................................................................................................................................................... 64
Figure 33: Start-Up Wizard Menu ............................................................................................................................................... 64
Figure 34: Start-Up Display ........................................................................................................................................................ 91
Figure 35: Update Menu and Sub-Menus .................................................................................................................................. 91
Figure 36: Backup Conî‚¿guration Display ................................................................................................................................... 92
Figure 37: Restoration File Name Structure ............................................................................................................................... 92
Figure 38: Update-Restore Menu ............................................................................................................................................... 92
Figure 39: Applied Smart Equipment Controller (Main Control Board)....................................................................................... 94
Figure 40: FC Bus Daisy Chain .................................................................................................................................................. 94
Figure 41: SA Bus Daisy Chain .................................................................................................................................................. 95
Figure 42: Controller–Network Menu.......................................................................................................................................... 96
Figure 43: MAP Gateway Dashboard .........................................................................................................................................97
Figure 44: Verasys Dashboard ................................................................................................................................................... 98
WARNING: Cancer and Reproductive Harm — www.P65Warnings.ca.gov.
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
25–50 Ton Model Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
G V A 1 M – 1 B 1 A A – 1 A 6 0 A – A 2 4 1 B – F 2 B B H – 4 C 1 A 1 – B K AG 1 – 0 1 0 1 C – 0 1 0 B C – 0 0 0 1
Digits 1–2: Product Brand Name
GV: Johnson Controls
4
Nomenclature
Digit 3: Capacity
A: 25 Ton
B: 30 Ton
C: 40 Ton
D: 50 Ton
Digit 4: Efficiency
1: Standard Capacity, Standard Efficiency
2: Std Capacity, High Efficiency
3: High Capacity, Std Efficiency
4: Std Capacity, Std Efficiency, Low Sound
5: Std Capacity, High Efficiency, Low Sound
6: High Capacity, Std Efficiency, Low Sound
Digit 5: Heat Source
A: Cooling Only
B: Staged Gas Aluminized Burner
C: Staged Gas Stainless Steel (SST)
G: Modulating Gas Stainless Steel
K: Steam Coil
L: Hot Water Coil
M: Electric Heat
Digit 6A: Electric Heat Capacity
0: None
1: Low Heat
3: High Heat
4: Low Heat with Silicon Controlled Rectifier
(SCR)
6: High Heat with SCR
Digit 6B: Natural Gas Heat Capacity
0: None
1: 250 MBH
2: 500 MBH
3: 750 MBH
5: 1,250 MBH
Digit 6C: Hot Water or Steam
Heating Coil Option
0: None
1: Low Heat without Valves
2: Low Heat with Valves
3: High Heat without Valves
4: High Heat with Valves
Digit 7: Unit Type
A: Single Zone Variable Air Volume (SZVAV)
(No Duct Pressure Transducer)
B: Multi Zone Variable Air Volume (MZVAV)
(Duct Pressure Transducer)
Digit 8: Motor Control Options
1: Supply Fan Variable Frequency Drive
(VFD)
2: Supply Fan VFD with Line Reactor
3: Supply Fan VFD with Bypass (Redundant
VFD)
4: Supply Fan VFD with Line Reactor and
Bypass (Redundant VFD)
5: Supply Fan VFD and Return/Exhaust Fan
VFD
6: Supply Fan VFD with Line Reactor and
Return/Exhaust Fan VFD with Line Reactor
7: Supply Fan VFD and Return/Exhaust
Fan VFD with Bypass (Redundant VFD
for Supply Fan and Bypass for Return or
Exhaust Fan)
8: Supply Fan VFD with Line Reactor and
Return/Exhaust Fan VFD with Line Reactor
with Bypass (Redundant VFD for Supply
Fan and Bypass for Return or Exhaust Fan
Digit 9: Voltage
A: 208-230 V 3Ph 60 Hz, Single Point Termi-
nal Block
B: 208-230 V 3Ph 60 Hz, Dual Point Terminal
Block
C: 208-230 V 3Ph 60 Hz, Single Point Non-
Fused DISC
D: 208-230 V 3Ph 60 Hz, Single Point
Terminal
Block, 65KA Short-Circuit Current
Rating (SCCR)
E: 208-230 V 3Ph 60 Hz, Dual Point Terminal
Block, 65KA SCCR
F: 208-230 V 3Ph 60 Hz, Single Point Fused
DISC, 65KA SCCR
G: 460 V 3Ph 60 Hz, Single Point Terminal
Block
H: 460 V 3Ph 60 Hz, Dual Point Terminal
Block
J: 460 V 3Ph 60 Hz, Single Point Non-Fused
DISC
K: 460 V 3Ph 60 Hz, Single Point Terminal
Block,
65KA SCCR
L: 460 V 3Ph 60 Hz, Dual Point Terminal
Block, 65KA SCCR
M: 460 V 3Ph 60 Hz, Single Point Fused
DISC, 65KA SCCR
N: 575 V 3Ph 60 Hz, Single Point Terminal
Block
P: 575 V 3Ph 60 Hz, Dual Point Terminal
Block
Q: 575 V 3Ph 60 Hz, Single Point Non-Fused
DISC
R: 575 V 3Ph 60 Hz, Single Point Terminal
Block,
65KA SCCR
S: 575 V 3Ph 60 Hz, Dual Point Terminal
Block, 65KA SCCR
T: 575 V 3Ph 60 Hz, Single Point Fused
DISC, 65KA SCCR
Digit 10: Return Configuration
A: Bottom Return, Right Outside Air (OA),
Side Exhaust
B: Bottom Return, Right OA, Front Exhaust
C: Bottom Return, Left OA, Side Exhaust
D: Bottom Return, Left OA, Front Exhaust
E: Top Return, Right OA, Side Exhaust (No
Return Fan Available)
F: Top Return, Right OA, Front Exhaust (No
Return Fan Available)
G: Top Return, Left OA, Side Exhaust (No
Return Fan Available)
H: Top Return, Left OA, Front Exhaust (No
Return Fan Available)
J: Left Return, Right OA, Front Exhaust
K: Right Return, Left OA, Front Exhaust
L: Front Return, Left OA, Right Exhaust
M: Front Return, Right OA, Left Exhaust
N: Bottom Return, No OA, No Exhaust Air
(EA) (No Return Fan Available)
P: Top Return, No OA, No EA (No Return Fan
Available)
Q: Left Return, No OA, No EA (No Return
Fan Available)
R: Right Return, No OA, No EA (No Return
Fan Available)
S: Front Return, No OA, No EA (No Return
Fan Available)
Digit 11: Discharge Locations
1: Bottom Discharge, from Discharge Plenum
2: Bottom Discharge, Discharge through Heat
Section
3: Top Discharge, from Discharge Plenum
4: Right Discharge, from Discharge Plenum
5: Left Discharge, from Discharge Plenum
6: Left Discharge, Discharge through Heat
Section
Digit 12: Supply Configuration
A: None
B: Small Blank
C, D: Large Blank
E, G: Large Blank with Final Filter
F:
Small Blank with Humidifier and SST Drain
Pan
H, K: Large
Blank with Humidifier and SST
Drain Pan
L: Small Blank Sound Attenuator
M, N: Large Blank Sound Attenuator
P: Small Blank Final Filter
Q, T: Large Blank with Sound Attenuator and
Final Filter
S, V: Large Blank with Sound Attenuator and
Humidifier and SST Drain Pan
Digit 13: Final Filter Options
1:
MERV 15 Bag Final Filters with 2-inch
MERV 8
Filters
2: MERV 14 Rigid Final Filters with 2-inch
MERV 8 Filters
3: MERV 17 High Efficiency Particulate Air
(HEPA) Final Filters with 2-inch MERV 8
Filters
4: MERV 14/15 Filter Rack (No Filters)
5: HEPA Filter Rack (No Filters)
6: None
Digit 14: Final Filter Control Op-
tions
0: None
1: Combined Pre and Post Filter Transducer
2: Separate Pre and Post Filter Transducer
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
5
Nomenclature
3: Combined Pre and Post Filter Transducer
and Combined Magnehelic Gauge
4: Separate Pre and Post Filter Transducer
and Magnehelic Gauge
5: Combined Pre and Post Filter Magnehelic
Gauge
6:
Separate Pre and Post Filter Magnehelic
Gauge
7: Combined Pre and Post Filter Transducer,
Separate Pre and Post Filter Magnehelic
Gauge
Digit 15: Supply Fan
A: Direct Drive Plenum (DDP) Supply Fan with
1-inch Spring Isolation
B: DDP Supply Fan with 2-inch Spring Isolation
C: DDP Supply Fan with 2-inch Spring Isola-
tion and Seismic Restraint
Digit 16: Supply Fan Motor
Horsepower
A: 5 HP
B: 7.5 HP
C: 10 HP
Digit 17: Supply Fan Motor Type
2: ODP Premium Efficiency 1,800 RPM
4: TEFC Premium Efficiency 1,800 RPM
Digit 18: Supply Fan Options
0: None
1: Inlet Guard
2: Airflow Measurement Station
3: Shaft Grounding Ring
4: Inlet Guard and Airflow Measurement
Station
5: Inlet Guard and Shaft Grounding Ring
6: Airflow Measurement Station and Shaft
Grounding Ring
7: Shaft Grounding Ring, Inlet Guard and
Airflow Measurement Station
Digits 19: Building Pressure
Control
0: None
1: Barometric Damper
2: Exhaust with VFD and Backdraft Damper
3: Modulating Damper (On/Off Exhaust Fan
Only without VFD)
4:
Modulating Damper (Return Fan Only with
VFD)
Digit 20: Return/Exhaust Fan
A: None
B: Exhaust Fan with 1-inch Spring Isolation
C: Exhaust Fan with 2-inch Spring Isolation
D: Exhaust Fan with 2-inch Spring Isolation
and Seismic Restraint
E: Return Fan with 1-inch Spring Isolation
F: Return Fan with 2-inch Spring Isolation
G: Return Fan with 2-inch Spring Isolation and
Seismic Restraint
Digit 21: Return/Exhaust Fan
Motor Horsepower
A: None
E: 3 HP
F: 5 HP
G: 7.5 HP
H: 10 HP
J: 15 HP
K: 20 HP
Digit 22: Return/Exhaust Fan
Motor Type
0: None
2: ODP Premium Efficiency 1,800 RPM
4: TEFC Premium Efficiency 1,800 RPM
Digit 23: Return/Exhaust Fan
Options
A: None
B: Shaft Grounding Ring
C: Extended Grease Lines
D:
Extended Grease Lines and Shaft Ground-
ing Ring
E: Belt Guards
F: Belt Guards and Shaft Grounding Ring
G: Return Fan Airflow Measurement Station
H: Return Fan Airflow Measurement Station
and Shaft Grounding Ring
J: Extended Grease Lines and Belt Guards
K: Extended Grease Lines and Belt Guards
and Shaft Grounding Ring
L: Extended Grease Lines and Return Fan
Airflow Measurement Station
M: Extended Grease Lines and Return Fan
Airflow Measurement Station and Shaft
Grounding
N: Belt Guards and Return Fan Airflow Mea-
surement Station
P: Belt Guards and Return Fan Airflow
Measurement Station and Shaft Ground-
ing Ring
Q: Extended Grease Lines and Belt Guards
and Return Fan Airflow Measurement
Station
R: Extended Grease Lines and Belt Guards
and Return Fan Airflow Measurement
Station and Shaft Grounding Ring
Digits 24: Return/Exhaust Fan
Drive
A: None
B–K: RPM
Digit 25: Evaporator Options
G: Aluminum Fin Evaporator with SST Drain
Pan
H: Aluminum Fin Evaporator with SST Drain
Pan with Condensate Overflow Switch
J: E-Coat Aluminum Fin Evaporator with SST
Drain Pan
K: E-Coat Aluminum Fin Evaporator with
SST Drain Pan with Condensate Overflow
Switch
L: Copper Fin Evaporator with SST Drain Pan
M: Copper Fin Evaporator with SST Drain
Pan with Condensate Overflow Switch
Digit 26: Condenser Coil Options
2: With Wire Guards
3: Full Louvered Panels
4: Partial Louvered Panels with Wire Guards
6: E-Coat Condenser with Wire Guards
7: E-Coat Condenser, Full Louvered Panels
8: E-Coat Condenser, Partial Louvered
Panels with Wire Guards
Digit 27: Draw-Thru Filter Options
A: Angled Filter Rack, No Filters
B: Angled Filter Rack, 2-Inch Throwaway
Filters
C: Angled Filter Rack, 2-Inch MERV 8 Filters
D: Rigid Filter Rack, No Filters
E: Rigid Filter Rack, MERV 15 Bag Filters
with 2-Inch MERV 8 Pre-Filters
F: Rigid Filter Rack, MERV 14 Rigid Filters
with 2-Inch MERV 8 Pre-Filters
G: Vertical Filter Rack, No Filters
H: Vertical Filter Rack, 4-Inch MERV 8 Filters
Digit 28: Draw-Thru Filter Control
Options
0: None
1: Combined Pre and Post Filter Transducer
2: Separate Pre and Post Filter Transducer
3: Combined Pre and Post Filter Transducer
and Combined Magnehelic Gauge
4: Separate Pre and Post Filter Transducer
and Magnehelic Gauge
5: Combined Pre and Post Filter Magnehelic
Gauge
6:
Separate Pre and Post Filter Magnehelic
Gauge
7: Combined Pre and Post Filter Transducer,
Separate Pre and Post Filter Magnehelic
Gauge
Digit 29: Economizer Options
A: None
C: Dry Bulb Economizer, Low Leak Dampers
D: Single Enthalpy Economizer, Low Leak
Dampers
E:
Dual Enthalpy Economizer, Low Leak
Dampers
F: Dry Bulb Economizer, Low Leak Dampers
with Airflow Measurement Station
G: Single Enthalpy Economizer, Low Leak
Dampers with Airflow Measurement Station
H: Dual Enthalpy Economizer, Low Leak
Dampers with Airflow Measurement Station
K: Dry Bulb Economizer, Ultra Low Leak
Dampers
L: Single Enthalpy Economizer, Ultra Low
Leak Dampers
S: Dual Enthalpy Economizer, Ultra Low Leak
Dampers
T: Dry Bulb Economizer, Ultra Low Leak
Dampers with Airflow Measurement Station
U: Single Enthalpy Economizer, Ultra Low
Leak Dampers with Airflow Measurement
Station
V: Dual Enthalpy Economizer, Ultra Low
Leak Dampers with Airflow Measurement
Station
Digit 30: Energy Recovery
Options
0: None
1: Low CFM Energy Recovery Wheel (ERW)
without VFD
2: Low CFM ERW with VFD
3: High CFM ERW without VFD
4: High CFM ERW with VFD
Digit 31: Refrigeration System
Piping Options
A: None
B: Suction and Discharge Valves
C: Suction, Discharge, and Liquid Valves
D: Suction, Discharge, and Liquid Valves with
Replaceable Core Filter Driers
E: Hot Gas Reheat (HGRH)
F: Suction and Discharge Valves with HGRH
G: Suction, Discharge, and Liquid Valves with
HGRH
D: 15 HP
E: 20 HP
F: 25 HP
G: 30 HP
H: 40 HP
J: 50 HP
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
6
H: Suction, Discharge, and Liquid Valves with
Replaceable Core Filter Driers with HGRH
N: E-Coat HGRH
P: Suction and Discharge Valves with E-Coat
HGRH
Q: Suction, Discharge, and Liquid Valves with
E-Coat HGRH
R: Suction, Discharge, and Liquid Valves with
Replaceable Core Filter Driers with E-Coat
HGRH
Digit 32: Lights/Detectors/
Convenience Options
A: None
B: Convenience Outlet
C: Convenience Outlet and Internal Lights
D: Supply Smoke Detector
E: Return Smoke Detector
F: Supply and Return Smoke Detector
G: Convenience Outlet with Supply Smoke
Detector
H: Convenience Outlet with Return Smoke
Detector
J: Convenience Outlet with Supply and
Return Smoke Detectors
K: Convenience Outlet and Internal Lights
with Supply Smoke Detector
L: Convenience Outlet and Internal Lights
with Return Smoke Detector
M: Convenience Outlet and Internal Lights
with Supply and Return Smoke Detectors
Digit 33: Controls Options
A: None
B: Low Ambient
D: Subcool and Superheat Measurement
E: Low Ambient with Subcool and Superheat
Measurement
Digit 34: Interface Options
A: BACnet
®
MS/TP, Modbus
â„¢
, N2
B: BACnet IP
G: BACnet MS/TP, Modbus, N2 with Mobile
Access Portal (MAP)
H: MAP with BACnet IP
K: BACnet MS/TP, Modbus, N2 with MAP
and Touchscreen
L: Touchscreen with MAP with BACnet IP
N: BACnet MS/TP, Modbus, N2 with Building
System Interface Board
P: BACnet IP with Building System Interface
Board
U: BACnet MS/TP, Modbus, N2 with MAP
and Building System Interface Board
V: MAP with BACnet IP and Building System
Interface Board
X: BACnet MS/TP, Modbus, N2 with Touch-
screen and MAP and Building System
Interface Board
Y: Touchscreen with MAP with BACnet IP and
Building System Interface Board
Digit 35: Indoor Air Quality (IAQ)
Options
0: None
1: Ultraviolet (UV) Lights
2: Carbon Dioxide (CO
2
) Sensors, Demand
Controlled Ventilation
3: UV Lights, CO
2
Sensors, Demand Con-
trolled Ventilation
Digit 36: Gas Heat Shipped Loose
Kits
0: None
1: Gas Heat, Side Penetration
2: Gas Heat, Bottom Penetration
3: Gas Heat, High Altitude Kit Natural Gas
(NG), Side Penetration
4: Gas Heat, High Altitude Kit NG, Bottom
Penetration
5: Gas Heat, High Altitude Kit Liquid Propane
(LP), Side Penetration
6: Gas Heat, High Altitude Kit LP, Bottom
Penetration
7: Gas Heat, LP Conversion Kit, Side Pen-
etration
8: Gas Heat, LP Conversion Kit, Bottom
Penetration
Digit 37: Security Options
0: None
1: Supply and Return Opening Burglar Bars
Digit 38: Door Options
0: None
1: Viewport
2: Single Handle with Padlock
3: Single Handle with Padlock and Viewport
Digit 39: Cabinet Shipping Op-
tions
1: Single Piece Construction
Digit 40: Curb Options
A: No Roof Curb
C: Pedestal Curb
Digit 41: Pre-Evap Options
0: None
1, 2: Blank Pre-Evap Extension, No Air
Blender
3, 4: Blank Pre-Evap Extension, with Air
Blender
Digit 42: Shipped Loose Options
0: None
1: Spare Belts for Return/Exhaust
Digit 43: Construction Standard
0: None
Digit 44: Supply Fan VFD Fre-
quency
A–Z: Internal Use Only
Digit 45: Supply Fan Brake
Horsepower
A–L: Internal Use Only
Digit 46: Future 3
0: None
Digit 47: Future 4
0: None
Digit 48: Testing and Special
Quotation (SQ)
0, Y, Z: None
T: Record Test Report
M: Mechanical Special
1: Mechanical Special and Record Test
Report
S: Software Special
3: Software Special and Record Test Report
B: Mechanical and Software Special
5: Mechanical and Software Special and
Record Test Report
Digit 49: Generation/Revision
Level
1: First Generation
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
NEW RELEASE
Pre Start-Up Checklist
Date: ______________ Customer: ____________________________________ Phone No: ___________________
Job Name: ______________________________________ Job Address: _______________________________________
Order No.: ______________________________________ City: _______________________________________
Contract No.: ____________________________________ State: ______________ Zip Code: _____________
Serial No.: ______________________________________ Country: _______________________________________
Model No.: ___________________________________________________________________________________________
Installation Completion Date: ________________________ Requested Start-Up Date: _____________________________
NOTE: Check off each item as required. Cross out (x) items that do not apply.
General Inspection Completed See Notes
1. Unit inspected for shipping, storage, or rigging damage ............................................................
2. Unit installed with proper clearances..........................................................................................
3. Unit installed with slope limitations .............................................................................................
4. Ductwork is completed and cleared of all obstructions ..............................................................
5. All î‚¿eld wiring (power and control) is complete (matching the nameplate) ................................
6. The building automation system (BAS) is connected to the unit and operational (if applicable)
7. Variable air volume (VAV) units:
a. The VAV boxes are verified as operational ................................................................................
b. Discharge air static pressure transducer tubing is installed in the appropriate location ........
8. Single zone VAV (SZVAV) units (check whichever option is applicable):
a. A NetSensor is connected to the SA bus on the main control board ....................................
b. The BAS is communicating a zone temperature to the unit ..................................................
9. Exhaust/return fan units:
a. Building static pressure transducer tubing is installed in the appropriate location ...................
10. When either of the discharge air static or building static pressure transducers are installed, an
outdoor pressure reference is also î‚¿eld installed via the shipped loose kit ..................................
11. Condensate drain is installed and trapped properly ...................................................................
12. Gas heat units:
a. The gas line is installed per local codes and purged of air ...................................................
b. The incoming gas pressure is within the range specified on the unit nameplate ..................
13. Hot water/steam units:
a. Field piping to the hot water/steam coil is completed ..............................................................
b. The shipped loose modulating valve is installed and field wiring to the valve is completed .....
Form 5773246-JCL-A-619
25–50 Tons
Johnson Controls
®
Premier Rooftop Units
R-410A
In an effort to provide the highest level of service, the following checklist is provided to ensure that all necessary installation
items are completed prior to a scheduled supervised start-up for the rooftop unit. Refer to the appropriate Installation and Main-
tenance Manual (Form 5586959-JIM) before evaluating the information on this Checklist. E-mail the completed checklist to
7
Start-Up
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
Month Day Year Name/Phone
Customer/Contractor Signature:
Form Completed by:
Title:
Request for Start-Up
General Inspection Completed See Notes
14. Steam units with humidiî‚¿er:
a. Steam control valve, Y type strainer, steam trap, and piping are installed .............................
b. Return and discharge air humidity sensors are installed ........................................................
c. Field wiring to the steam control valve is completed ...............................................................
15. Air î‚¿lters are installed correctly and clean ..................................................................................
16. Shipping bolts have all been removed from the fan assemblies ................................................
17. Refrigeration system is checked for gross leaks (presence of oil) .............................................
18. Terminal screws and wiring connections are checked for tightness ...........................................
19. Outside and exhaust air hoods are installed in operating position, if applicable ........................
20. All sensors are properly installed ...............................................................................................
21. The unit has been air balanced ..................................................................................................
22. Site is ready for equipment operation.........................................................................................
23. The unit was modiî‚¿ed by a third party manufacturer (such as Fisen) as speciî‚¿ed ....................
Observed Product Deficiencies, Concerns, and Notes
I have inspected the installation of the Johnson Controls Premier rooftop unit and verified the pre start-up checklist is complete
and the unit is ready to be started up by an approved technician.
Verified by: Date:
With reference to the terms of the above contract, we are requesting the presence of your Johnson Controls Authorized Representative at the
job site on ____ / ____ / ____ to start the system and instruct operating personnel. Please contact: __________________________________
We understand that the services of the Johnson Controls Authorized Representative will be furnished in accordance with the contract for a
period of time of not more than _______ consecutive normal working hours, and we agree that a charge of _________ per diem plus travel
expenses will be made to Johnson Controls
if services are required for longer than ________ consecutive normal hours or if repeated calls are
required, through no fault of Johnson Controls.
© 2019 Johnson Controls | 100 JCI Way, York, Pennsylvania USA 17406-8469 | www.johnsoncontrols.com
Subject to change without notice. | Form 5773246-JCL-A-619 | New Release | All rights reserved.
The Smart Equipment logo is a trademark of Johnson Controls in the United States and other countries. It is
a part of the Johnson Controls product portfolio.
8
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
Refer to the Premier 25–50 Ton Rooftop Units Instal-
lation and Maintenance Manual (5586959-JIM) that
shipped with the unit for additional information.
9
Start-Up
Start-Up
Long Term Storage
When a unit(s) is stored for an extended period of time,
conduct a visual inspection of the entire unit prior to
start-up to ensure there are no signs of damage, visible
leaks, or obstructions.
New motors should be relubricated on units kept in
long term storage for a year or more prior to start-up.
Apply power for 24 hours before starting the unit to en-
sure that any refrigerant that may have migrated to the
compressor has evaporated.
Checking System Prior to Initial Start (No
Power)
(multi zone variable air volume (MZVAV) units),
building static pressure transducer for power ex-
haust option, and outdoor static pressure probe.
10. Ensure the tie-down shipping bolts, washers,
and spacers for the supply, exhaust, and/or re-
turn fan isolator springs are removed.
11. Ensure the ultraviolet (UV) tube lights have been
installed if applicable.
12. Verify proper bearing and locking collar torque
values on supply and exhaust fans.
13. Verify proper drive alignment of return and ex-
haust fans.
14. Verify proper belt tension of the exhaust fan or
return fan in accordance with instructions in the
Installation and Maintenance Manual. Belts must
be checked after 24 hours of initial operation.
15. Manually rotate condenser fan blades; supply,
exhaust, and return blower wheels; and motors
to ensure freedom of movement.
16. If applicable, verify installation of air î‚¿lters.
17. If equipped, open the suction line ball valve, dis-
charge line ball valve, and liquid line ball valve
for each refrigerant system
18. Zero the magnehelic gauge. Use the external zero
adjust screw on the bottom of the cover to set the
indicating pointer exactly on the zero mark.
NOTE: The high and low pressure taps must both be
open to atmosphere in order to make the zero
adjustment.
19. Verify proper condensate drain trap installation.
Fill traps with water prior to unit start-up (Figure 1).
20. Verify the condensate oat switch is located just
before the top of the drain pan. Adjust if necessary.
21. Check for gas leaks in the unit piping and the
î‚¿eld supply piping.
H must be at least 1 + Fan Total
Static Pressure
H
X
X = 1/2(H)
LD05370
Figure 1: Trap Detail for Draw Through Application
1. Inspect the unit for shipping or installation damage.
2. Visually check for refrigerant piping leaks.
3. The compressor oil level should be maintained
so that an oil level is visible in the sight glass, if
equipped. The oil level can only be tested when
the compressor is running in stabilized condi-
tions, guaranteeing that there is no liquid refrig-
erant in the lower shell of the compressor. In this
case, the oil must be between 1/4 and 3/4 in the
sight glass. At shutdown, the oil level can fall to
the bottom limit of the oil sight glass.
For 40 and 50 ton high efficiency units ONLY, an
optical sensor is provided over the sight glass,
in which the unit controller monitors the correct
oil level. If too low, the unit controller adjusts the
compressor speed to try to recover oil to the com-
pressor. If that fails, then the unit controller shuts
off the compressor
4. Check the control panel to ensure it is free of for-
eign material (wires, metal chips, etc.).
5. Visually inspect î‚¿eld wiring (power and control).
Wiring MUST meet the National Electrical Code
®
(NEC) and local codes.
6. Check tightness of terminal lugs inside the power
panel on both sides of the contactors, overloads,
fuses, and power connections.
7. Verify fuse sizing in main circuits.
8. Verify î‚¿eld wiring for thermostat (if applicable),
optional zone sensor, etc.
9. Verify all applicable pneumatic tubing has been
î‚¿eld installed for duct static pressure transducer
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
10
Unit Checks (Power Applied)
1. Apply 3-phase power and verify its value. Volt-
age imbalance should be no more than 2% of the
average voltage.
2. Remove the protective î‚¿lm from the unit control-
ler display if still adhered.
3. Verify programmed unit controller setpoints.
4. Verify the variable frequency drive (VFD) set-
points for MZVAV units and optional VFD exhaust
or return fans. The VFD for the supply fan is in
the supply fan blower compartment. The VFD for
the exhaust or return fan is located in the return
air compartment.
5. Verify correct fan rotation (the fan should rotate
in the direction of the arrow on the fan housing).
6. Visually inspect the energy recovery wheel (ERW)
bypass dampers to ensure links are correctly con-
nected and there are no visual obstructions. En-
sure the dampers are aligned in a way that pro-
vides a sufî‚¿cient seal when closed. Modulate the
dampers via the commissioning mode. Open and
close the dampers to verify correct operation.
7. Power ON the crankcase heater 12 hours prior
to starting the unit to ensure any liquid that may
have migrated into the compressor shell evapo-
rates before compressor start-up.
8. Verify proper compressor rotation.
CAUTION
This unit uses scroll compressors, which will only
operate in one direction. Operation of the compres-
sor in the reverse direction does not produce any
capacity and will cause the compressor to cycle on
internal overload. Failure to observe these steps
could lead to compressor failure.
a. Monitor the suction and discharge pressures
of the respective refrigerant circuit while the
compressor cycles ON.
b. If the discharge pressure increases and suc-
tion pressure decreases as the compres-
sor cycles ON, the compressor is properly
phased and operating in the correct rotation.
c. If the optional suction and discharge pres-
sure transducers are installed, the suction
and discharge pressures can be monitored
via the unit controller.
d. If the optional suction and discharge pres-
sure transducers are not installed, pressures
must be monitored with a manifold gauge
connected to the service valves located on
the suction and discharge lines.
9. Check the compressor oil level to ensure that
there is no liquid refrigerant in the lower shell of
the compressor.
a. When the compressor is running in stabilized
conditions, the oil level must be between 1/2
and 3/4 in the oil sight glass.
NOTE: At shutdown, the oil level can fall to the bottom
limit of the oil sight glass.
10. Adjust the high duct static pressure switch. The
adjustment range is 0.4 iwg ± 0.02 iwg to 12.0 iwg.
a. Turn the adjusting screw counterclockwise
until motion stops.
b. Turn the adjusting screw clockwise for four
complete turns to engage the spring.
c. The next ten turns are use for calibration.
Each full turn represents approximately 1.16 iwg.
NOTE: Properly calibrate the high duct static pressure
switch using a digital manometer or equal mea-
suring device to confirm the actual setpoint.
11. Check the supply air CFM.
The unit may be equipped with an optional supply
fan airflow measuring station (AMS). When appli-
cable, check to ensure the unit airflow is deliver-
ing the correct airflow.
a. The supply air blower RPM depends on the
required CFM and the static pressure resis-
tances of the unit components as well as
both the supply and return air duct systems.
b. Use Table 2 on page 13 or Table 3 on page
14 to determine the RPM for the supply air
blower.
c. The supply air CFM must be within the limita-
tion shown in Table 1 on page 11.
When the unit is not equipped with an AMS, the
field can order and install a kit using the following
part numbers.
a. 25–30 ton: transducer (S1-02550574000)
and silicone tube (S1-02811957000)
b. 40–50 ton: transducer (S1-0255057500) and
silicone tube (S1-02811957000)
NOTE: If the unit is equipped with a power exhaust fan
or return air fan, refer to Table 4 on page 14
through Table 7 on page 15 for fan perfor-
mance for pulley and drive information.
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
11
Start-Up
12. Check the air balance.
a. Start the supply air blower motor.
b. Adjust the resistances in both the supply and
the return air duct systems to balance the
air distribution throughout the conditioned
space.
NOTE: Job specifications may require that air balanc-
ing be completed by someone other than the
start-up contractor.
Table 1: Component Static Pressure Drops (iwg)
Component
SCFM
5,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
25 Ton
Evaporator Coil - Std. Capacity,
Std. Efî‚¿ciency
0.14 0.18 0.28 0.41 0.55 - - - -
Evaporator Coil - High Capacity, Std.
Efî‚¿ciency and Std. Capacity, High
Efî‚¿ciency
0.15 0.20 0.32 0.46 0.62 - - - -
30 Ton
Evaporator Coil - Std. Capacity,
Std. Efî‚¿ciency
0.16 0.22 0.36 0.51 0.69 - - - -
Evaporator Coil - High Capacity, Std.
Efî‚¿ciency and Std. Capacity, High
Efî‚¿ciency
0.18 0.24 0.38 0.55 0.75 - - - -
40 Ton
Evaporator Coil - Std. Capacity,
Std. Efî‚¿ciency
- - 0.21 0.30 0.40 0.51 0.64 0.77 0.91
Evaporator Coil - High Capacity, Std.
Efî‚¿ciency and Std. Capacity, High
Efî‚¿ciency
- - 0.21 0.30 0.40 0.51 0.64 0.77 0.91
50 Ton
Evaporator Coil - Std. Capacity,
Std. Efî‚¿ciency
- - 0.21 0.30 0.40 0.51 0.64 0.77 0.91
Evaporator Coil - High Capacity, Std.
Efî‚¿ciency and Std. Capacity, High
Efî‚¿ciency
- - 0.25 0.35 0.47 0.61 0.76 0.92 1.09
25–30 Ton Hot Gas Reheat (HGRH) Coil
0.11 0.13 0.27 0.39 0.53 - - - -
40–50 Ton
HGRH Coil - - 0.18 0.25 0.33 0.43 0.53 0.64 0.76
Return Air Opening
25–30T
Bottom, Top, Front, Sides 0.01 0.02 0.03 0.05 0.07 - - - -
Bottom with ERW 0.01 0.01 0.03 0.04 0.06 - - - -
Damper 0.01 0.02 0.03 0.05 0.07 - - - -
40–50T
Bottom, Top, Front, Sides - - 0.01 0.02 0.03 0.04 0.05 0.06 0.08
Bottom with ERW 0.01 0.01 0.01 0.02 0.03 0.04 0.05 0.06 0.08
Damper - - 0.01 0.02 0.03 0.04 0.05 0.06 0.08
Exhaust Air Opening
25–30 Ton Hood and Damper 0.30 0.33 0.37 0.40 0.42 - - - -
40–50 Ton Hood and Damper - - 0.19 0.22 0.25 0.28 0.30 0.32 0.34
Supply Air Opening
25–30T
Bottom 0.02 0.02 0.04 0.06 0.09 - - - -
Side 0.02 0.02 0.04 0.06 0.09 - - - -
All Discharges in Blank Section 0.01 0.01 0.02 0.03 0.05 - - - -
40–50T
Bottom - - 0.02 0.03 0.05 0.06 0.08 0.10 0.13
Side - - 0.02 0.03 0.05 0.06 0.08 0.10 0.13
All Discharges in Blank Section - - 0.01 0.02 0.03 0.04 0.05 0.06 0.08
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
12
Table 1: Component Static Pressure Drops (iwg) (Continued)
Component
SCFM
5,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
Outside Air
25–30T
Hood and Dampers - Low Leak 0.19 0.22 0.26 0.30 0.33 - - - -
Hood and Dampers - Ultra Low Leak 0.20 0.23 0.28 0.33 0.38 - - - -
40–50T
Hood and Dampers - Low Leak - - 0.19 0.22 0.25 0.28 0.30 0.32 0.34
Hood and Dampers - Ultra Low Leak - - 0.22 0.26 0.30 0.34 0.38 0.42 0.46
ERW - Low CFM
25–30 Ton 1.14 1.38 1.89 2.44 3.01 - - - -
40–50 Ton - - 0.89 1.13 1.37 1.63 1.89 2.15 2.43
ERW - High CFM
25–30 Ton 1.09 1.31 1.77 2.24 2.73 - - - -
40–50 Ton - - 0.89 1.11 1.34 1.57 1.80 2.04 2.29
Draw-Thru Filters
25–30 Ton
Angled Filter Rack - 2-inch
Throwaway Filters
0.04 0.05 0.09 0.11 0.13 - - - -
Angled Filter Rack - 2-inch MERV 8
Filters
0.05 0.06 0.08 0.11 0.14 - - - -
Rigid Filter Rack - MERV 15 Bag
Filters with 2-inch MERV 8 Pre-Filters
0.40 0.44 0.57 0.69 0.81 - - - -
Rigid Filter Rack - MERV 14 Rigid
Filters with 2-inch MERV 8 Pre-Filters
0.19 0.20 0.28 0.35 0.43 - - - -
Vertical Filter Rack - 4-inch MERV 8
Filters
0.03 0.03 0.06 0.09 0.12 - - - -
40–50 Ton
Angled Filter Rack - 2-inch
Throwaway Filters
- - 0.06 0.08 0.09 0.11 0.13 0.15 0.17
Angled Filter Rack - 2-inch MERV 8
Filters
- - 0.06 0.08 0.10 0.12 0.15 0.18 0.21
Rigid Filter Rack - MERV 15 Bag
Filters with 2-inch MERV 8 Pre-Filters
- - 0.43 0.52 0.61 0.70 0.77 0.85 0.91
Rigid Filter Rack - MERV 14 Rigid
Filters with 2-inch MERV 8 Pre-Filters
- - 0.19 0.24 0.30 0.35 0.41 0.47 0.53
Vertical Filter Rack - 4-inch MERV 8
Filters
- - 0.04 0.05 0.07 0.09 0.12 0.15 0.18
Final Filters
25–30T
MERV 14 Rigid Filters with 2-inch
Pre-Filters
0.19 0.20 0.28 0.35 0.43 - - - -
MERV 15 Bag Filters with 2-inch
Pre-Filters
0.40 0.44 0.57 0.69 0.81 - - - -
MERV 17 HEPA Filters with 2-inch
Pre-Filters
0.58 0.63 0.83 1.03 1.23 - - - -
40–50T
MERV 14 Rigid Filters with 2-inch
Pre-Filters
- - 0.19 0.24 0.30 0.35 0.41 0.47 0.53
MERV 15 Bag Filters with 2-inch
Pre-Filters
- - 0.43 0.52 0.61 0.70 0.77 0.85 0.91
MERV 17 HEPA Filters with 2-inch
Pre-Filters
- - 0.67 0.83 0.99 1.15 1.31 1.47 1.63
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
13
Start-Up
Table 1: Component Static Pressure Drops (iwg) (Continued)
Component
SCFM
5,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
Gas Heat
250 MBH 0.01 0.01 0.01 0.02 0.04 - - - -
500 MBH 0.03 0.05 0.06 0.08 0.10 0.12 0.15 0.19 0.23
750 MBH 0.02 0.02 0.03 0.05 0.07 0.10 0.14 0.19 0.25
1250 MBH - 0.03 0.04 0.06 0.08 0.11 0.15 0.20 0.26
Electric Heat
Low and High Heat 0.05 0.05 0.06 0.07 0.07 0.08 0.09 0.10 0.11
Hot Water/Steam Coil Heat
25–30 Ton
1 Row Hot Water, Low Heat 0.04 0.06 0.1 0.15 0.21 - - - -
2 Rows Hot Water, High Heat 0.07 0.10 0.16 0.24 0.32 - - - -
Steam, Low Heat 0.10 0.13 0.20 0.30 0.42 - - - -
Steam, High Heat 0.11 0.15 0.25 0.36 0.49 - - - -
40–50 Ton
1 Row Hot Water, Low Heat - - 0.05 0.07 0.09 0.12 0.15 0.19 0.24
2 Rows Hot Water, High Heat - - 0.08 0.12 0.16 0.21 0.27 0.33 0.40
Steam, Low Heat - - 0.07 0.10 0.13 0.17 0.21 0.26 0.30
Steam, High Heat - - 0.10 0.15 0.20 0.26 0.33 0.41 0.49
Options
Humidiî‚¿er 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02
25–30T
Sound Attenuator 0.01 0.01 0.02 0.03 0.04 - - - -
Inlet Guard - Supply Fan 0.08 0.11 0.19 0.30 0.43 - - - -
Air Blender 0.08 0.11 0.19 0.30 0.43 - - - -
40–50T
Sound Attenuator - - 0.01 0.02 0.03 0.04 0.05 0.06 0.08
Inlet Guard - Supply Fan - - 0.13 0.20 0.28 0.39 0.51 0.64 0.79
Air Blender - - 0.13 0.20 0.29 0.39 0.51 0.65 0.80
Table 2: 25–30 Ton Supply Fan Total Static Pressure
CFM
1.0 TSP 1.5 TSP 2.0 TSP 2.5 TSP 3.0 TSP 3.5 TSP 4.0 TSP 4.5 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
5,000 746 1.12 855 1.68 964 2.30 1068 3.05 1165 3.79 1256 4.58 1342 5.42 1424 6.15
6,000 816 1.41 906 2.01 997 2.68 1088 3.36 1178 4.18 1265 5.09 1348 5.99 1426 6.88
7,000 894 1.74 974 2.44 1051 3.14 1129 3.89 1207 4.70 1285 5.51 1362 6.46 1437 7.51
8,000 978 2.11 1049 2.90 1119 3.70 1186 4.51 1254 5.32 1322 6.24 1390 7.16 1458 8.08
9,000 1068 2.58 1130 3.41 1193 4.32 1255 5.21 1315 6.12 1375 7.02 1435 7.98 1495 9.04
10,000 1161 3.14 1216 4.01 1272 4.98 1329 5.99 1385 6.98 1439 7.99 1493 8.99 1547 9.99
11,000 1256 3.82 1306 4.71 1356 5.72 1407 6.80 1459 7.92 1511 9.00 1560 10.11 1609 11.22
12,000 1352 4.61 1398 5.55 1444 6.57 1491 7.70 1538 8.89 1585 10.11 1633 11.29 1678 12.49
CFM
5.0 TSP 5.5 TSP 6.0 TSP 6.5 TSP 7.0 TSP 7.5 TSP 8.0 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
5,000 1500 6.98 1571 7.91 1637 8.90 1701 9.89 1762 10.83 1821 11.73 1878 12.61
6,000 1501 7.83 1574 8.84 1644 9.84 1711 10.72 1775 11.64 1836 12.70 1894 13.85
7,000 1510 8.58 1580 9.62 1647 10.67 1712 11.75 1776 12.88 1838 14.07 1898 15.25
8,000 1526 9.14 1593 10.30 1659 11.52 1722 12.73 1783 13.92 1843 15.11 1901 16.32
9,000 1556 10.06 1617 11.09 1678 12.20 1738 13.45 1797 14.77 1855 16.14 1912 17.51
10,000 1601 11.09 1656 12.27 1710 13.41 1765 14.54 1820 15.71 1874 16.99 1928 18.37
11,000 1658 12.31 1707 13.43 1756 14.63 1806 15.92 1855 17.21 1905 18.45 1955 19.69
12,000 1723 13.70 1768 14.91 1813 16.10 1858 17.32 1903 18.62 1949 20.00 1994 21.42
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
14
Table 3: 40–50 Ton Supply Fan Total Static Pressure
CFM
1.0 TSP 1.5 TSP 2.0 TSP 2.5 TSP 3.0 TSP 3.5 TSP 4.0 TSP 4.5 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
8,000 - - - - 778 4.03 866 5.20 946 6.46 1020 7.80 1089 9.21 1153 10.68
9,000 - - - - 787 4.42 870 5.65 949 6.96 1021 8.34 1092 9.80 1157 11.33
10,000 - - - - 803 4.84 879 6.14 954 7.51 1026 8.96 1095 10.44 1160 12.01
11,000 - - 758 4.04 826 5.31 894 6.67 963 8.10 1032 9.60 1099 11.16 1162 12.77
12,000 - - 791 4.49 854 5.82 916 7.24 978 8.73 1042 10.29 1105 11.92 1167 13.59
13,000 762 3.65 826 4.99 885 6.39 942 7.86 1000 9.41 1058 11.03 1116 12.72 1175 14.46
14,000 800 4.11 862 5.53 918 7.00 972 8.54 1025 10.15 1079 11.83 1132 13.57 1187 15.37
15,000 838 4.60 899 6.12 953 7.67 1005 9.28 1055 10.95 1104 12.68 1154 14.48 1204 16.34
16,000 877 5.15 936 6.76 989 8.39 1039 10.07 1086 11.80 1133 13.60 1180 15.46 1226 17.37
17,000 917 5.74 974 7.44 1026 9.16 1074 10.92 1120 12.72 1164 14.58 1208 16.50 1252 18.48
18,000 956 6.38 1013 8.17 1063 9.99 1110 11.83 1154 13.71 1197 15.64 1239 17.62 1281 19.65
19,000 997 7.08 1051 8.96 1101 10.87 1147 12.80 1190 14.76 1231 16.76 1272 18.80 1311 20.90
20,000 1038 7.84 1090 9.80 1139 11.81 1184 13.83 1226 15.87 1267 17.95 1306 20.07 1344 22.23
CFM
5.0 TSP 5.5 TSP 6.0 TSP 6.5 TSP 7.0 TSP 7.5 TSP 8.0 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
8,000 1214 12.19 1271 13.74 1326 15.31 1378 16.92 1429 18.55 1477 20.21 1524 21.90
9,000 1218 12.91 1276 14.55 1331 16.23 1383 17.95 1434 19.69 1483 21.47 1530 23.27
10,000 1221 13.64 1279 15.34 1334 17.10 1387 18.90 1438 20.74 1487 22.62 1535 24.52
11,000 1224 14.44 1282 16.18 1338 17.98 1391 19.84 1442 21.75 1491 23.70 1539 25.70
12,000 1227 15.32 1285 17.10 1340 18.94 1394 20.83 1445 22.78 1495 24.79 1542 26.85
13,000 1232 16.25 1289 18.09 1343 19.98 1396 21.92 1448 23.91 1497 25.95 1545 28.05
14,000 1241 17.23 1295 19.14 1348 21.09 1400 23.08 1451 25.12 1500 27.21 1548 29.35
15,000 1255 18.26 1306 20.23 1356 22.25 1406 24.31 1456 26.41 1504 28.56 1551 30.74
16,000 1273 19.36 1320 21.38 1368 23.46 1416 25.59 1463 27.76 1510 29.97 1556 32.22
17,000 1296 20.51 1340 22.60 1384 24.70 1429 26.92 1474 29.16 1519 31.43 1563 33.75
18,000 1322 21.74 1363 23.89 1405 26.08 1447 28.33 1489 30.62 1531 32.96 1574 35.34
19,000 1351 23.05 1390 25.26 1429 27.51 1468 29.81 1508 32.16 1548 34.56 1588 37.00
20,000 1381 24.44 1419 26.71 1456 29.02 1493 31.38 1530 33.78 1568 36.24 1605 38.73
Table 4: 25–30 Ton Exhaust Fan Total Static Pressure
CFM
0.5 TSP 1.0 TSP 1.5 TSP 2.0 TSP 2.5 TSP 3.0 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
5,000 - - 654 1.82 769 2.49 878 3.33 974 4.08 1060 4.72
6,000 - - 688 2.46 796 3.24 892 4.01 987 4.97 1074 6.00
7,000 616 2.60 729 3.36 832 4.18 922 5.07 1004 5.94 1087 6.96
8,000 672 3.61 777 4.54 867 5.30 958 6.33 1037 7.35 1109 8.32
9,000 731 4.90 825 5.88 914 6.90 991 7.74 1073 8.94 1145 10.11
10,000 791 6.48 877 7.53 962 8.72 1036 9.73 1106 10.69 1179 12.01
11,000 850 8.38 932 9.52 1009 10.75 1085 12.07 1150 13.11 1213 14.16
12,000 910 10.62 990 11.89 1060 13.17 1131 14.60 - - - -
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
15
Start-Up
Table 5: 40–50 Ton Exhaust Fan Total Static Pressure
CFM
0.5 TSP 1.0 TSP 1.5 TSP 2.0 TSP 2.5 TSP 3.0 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
8,000 293 1.23 399 2.19 487 3.23 559 4.35 622 5.56 679 6.84
9,000 302 1.50 400 2.46 488 3.68 561 4.85 625 6.12 682 7.46
10,000 312 1.81 404 2.83 488 4.11 563 5.42 628 6.73 685 8.14
11,000 324 2.20 411 3.31 490 4.51 564 6.03 629 7.44 688 8.89
12,000 338 2.67 420 3.84 494 5.05 565 6.56 630 8.21 689 9.73
13,000 351 3.21 429 4.40 500 5.73 567 7.13 631 8.91 690 10.65
14,000 366 3.82 439 5.03 508 6.50 571 7.89 633 9.56 691 11.52
15,000 381 4.52 451 5.77 518 7.31 577 8.81 636 10.38 692 12.30
16,000 396 5.30 464 6.63 527 8.15 586 9.83 640 11.41 695 13.18
17,000 411 6.17 478 7.58 536 9.08 595 10.90 647 12.60 699 14.31
18,000 427 7.14 492 8.64 548 10.17 604 12.00 656 13.89 704 15.65
19,000 443 8.21 506 9.80 561 11.39 613 13.17 665 15.23 712 17.13
20,000 459 9.39 520 11.08 574 12.73 624 14.49 674 16.59 721 18.70
Table 6: 25–30 Ton Return Fan Total Static Pressure
CFM
0.5 TSP 1.0 TSP 1.5 TSP 2.0 TSP 2.5 TSP 3.0 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
5,000 - - - - 878 2.24 976 3.01 1070 3.86 1158 4.81
6,000 - - 835 1.96 936 2.76 1026 3.60 1110 4.49 1191 5.43
7,000 - - 903 2.42 1000 3.37 1085 4.30 1163 5.26 1237 6.28
8,000 872 1.92 976 2.96 1066 4.04 1149 5.11 1224 6.18 1294 7.26
9,000 955 2.40 1051 3.61 1137 4.78 1215 6.00 1288 7.21 1356 8.40
10,000 1042 2.97 1127 4.35 1211 5.63 1285 6.96 1354 8.31 1420 9.66
11,000 1129 3.66 1207 5.16 1285 6.61 1358 8.02 1424 9.50 - -
12,000 1218 4.49 1290 6.05 1361 7.71 1432 9.24 - - - -
Table 7: 40–50 Ton Return Fan Total Static Pressure
CFM
0.5 TSP 1.0 TSP 1.5 TSP 2.0 TSP 2.5 TSP 3.0 TSP
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
8,000 - - - - - - - - - - 1075 6.94
9,000 - - - - - - - - 1043 6.39 1109 7.66
10,000 - - - - - - - - 1086 7.19 1149 8.54
11,000 - - - - - - 1065 6.47 1130 7.98 1192 9.50
12,000 - - - - 1048 5.84 1114 7.25 1176 8.79 1236 10.44
13,000 - - 1034 5.04 1101 6.57 1165 8.16 1224 9.70 1282 11.40
14,000 - - 1094 5.82 1156 7.37 1218 9.12 1275 10.77 1329 12.47
15,000 1091 5.15 1154 6.70 1213 8.29 1271 10.10 1327 11.96 1380 13.71
16,000 1156 6.02 1215 7.68 1271 9.34 1325 11.16 1380 13.17 1431 15.10
17,000 1220 6.99 1277 8.76 1331 10.51 1382 12.36 1433 14.41 1484 16.55
18,000 1285 8.06 1340 9.96 1391 11.80 1440 13.70 1488 15.76 1537 18.01
19,000 1351 9.25 1403 11.26 1452 13.21 1499 15.18 1544 17.26 1590 19.53
20,000 1416 10.56 1466 12.69 1514 14.75 1559 16.80 1602 18.92 - -
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
16
Initial Start-Up
After the preceding checks are completed and the con-
trol panel has been programmed as required, the unit
may be placed into operation.
1. Place the unit switch in the control panel to the
ON position.
2. With a demand for cooling, the supply fan cycles
ON and permits compressor operation when the
air proving pressure switch for the supply fan has
closed.
3. The î‚¿rst compressor starts. After several minutes
of operation, a ow of refrigerant is noted in the
sight glass, the vapor in the sight glass clears,
and there should be a solid column of liquid vis-
ible in the sight glass when the thermostatic ex-
pansion valve (TXV) stabilizes.
4. Allow the compressor to run a short time, and be
ready to stop it immediately if any unusual noise
or adverse conditions develop.
5. Verify the system operating parameters by
checking evaporator superheat and condensing
sub-cooling using the unit controller or manually
with the following steps.
a. Connect a gauge manifold set to the Schrad-
er
®
service valve connections on the liquid
and common suction line in the condensing
section of the unit.
b. After the system is running and the pressures
have stabilized, measure the temperature at
the liquid and common suction lines near the
Schrader service valves.
c. Calculate evaporator superheat and con-
densing sub-cooling. The sub-cooling,
should be approximately 15.0°F, and the su-
perheat should be 12.0°F.
d. Repeat the above process for each of the re-
frigerant systems.
e. When the unit has liquid and suction trans-
ducers, the unit controller can also be used
to measure superheat and sub-cooling.
6. With an ammeter, verify that each phase of the
condenser fans, compressors, supply fan, and
exhaust fan are within the RLA/FLA as listed on
the unit nameplate.
Refrigerant Charge
This rooftop unit comes fully charged from the factory
with refrigerant R-410A as standard.
Refer to the unit nameplate for the factory charge.
Checking Sub-Cooling and Superheat
An R-410A temperature and pressure chart lists the
associated saturation temperature in one column, with
the associated pressure in another column. As a re-
sult, only one temperature/pressure column is needed
to show the relationship.
Sub-cooling
When the refrigerant charge is correct, there is no va-
por in the liquid sight glass with the system operating
under full load conditions.
The sub-cooling temperature of each system can be
calculated by recording the temperature of the liquid
line at the outlet of the condenser and subtracting it
from the saturation temperature listed in Table 8 for the
corresponding discharge pressure.
If the rooftop unit does not have an access port for liq-
uid access, subtract the condenser coil pressure drop
value from the discharge pressure to determine the
equivalent saturation temperature. Convert that value
to a saturation temperature in Table 8. Subtract the
liquid line temperature from the converted saturation
temperature to determine sub-cooling.
EXAMPLE: The discharge pressure is 388 PSIG and
the liquid line temperature is 95.0°F.
Liquid pressure = 388.0 PSIG – 33.0 PSIG*
Saturation temperature for 355.0 PSIG = 108.0°F
Minus the liquid line temperature = 95.0°F
Liquid line sub-cooling = 13.0°F
Sub-cooling should be 15.0°F at design conditions.
*NOTE: Assume condenser coil pressure drop.
Superheat
The superheat should be checked only after steady
state operation of the unit is established, the discharge
air temperature is pulled down to within the control
range, and the unit is running in a fully loaded condition.
The superheat is calculated as the difference between
the actual temperature of the refrigerant gas in the suc-
tion line and the temperature corresponding to the suc-
tion pressure as shown in Table 8 on page 17.
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
17
Start-Up
EXAMPLE: The suction pressure is 130 PSIG and the
suction line temperature is 57.0 F.
Suction line temperature = 57.0°F
Saturation temperature for 130 PSIG = 45.0°F
Evaporator superheat = 12.0°F
CAUTION
When adjusting the expansion valve, DO NOT turn
the adjusting screw more than one turn at a time.
Allow for sufficient time (approximately 15 minutes)
between adjustments for the system and the TXV
to respond and stabilize.
The superheat setting should be adjusted to 12.0°F at
design conditions.
Leak Checking
Leak check compressors, fittings, and piping to ensure
there are no leaks. Verify the evaporator distributor tubes
do not have bare copper touching each other and that
they are not against a sheet metal edge. If leak checking
a unit charged with R-410A, ensure the leak test device
is capable of sensing refrigerant R-410A.
If the unit is functioning satisfactorily during the initial
operating period, no safeties trip, and the unit controls
are properly functioning, the rooftop unit is ready to be
placed into operation.
Gas Heat Models
WARNING
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly, as well as
improper servicing, can result in dangerous opera-
tion, serious injury, death, or property damage.
• Before servicing, disconnect all electrical
power to furnace.
• When servicing controls, label all wires prior
to disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.
Table 8: R-410A Pressure/Temperature Chart
PSIG TEMP (ËšF) PSIG TEMP (ËšF) PSIG TEMP (ËšF) PSIG TEMP (ËšF)
0 -60 40 -6 80 21 210 73
2 -58 42 -4 85 24 220 76
4 -54 44 -3 90 26 225 78
6 -50 46 -2 95 29 235 80
8 -46 48 0 100 32 245 83
10 -42 50 1 105 34 255 85
12 -39 52 3 110 36 265 88
14 -36 54 4 115 39 275 90
16 -33 56 6 120 41 285 92
18 -30 58 7 125 43 295 95
20 -28 60 8 130 45 305 97
22 -26 62 10 135 47 325 101
24 -24 64 11 140 49 355 108
26 -20 66 13 145 51 375 112
28 -18 68 14 150 53 405 118
30 -16 70 15 160 57 500 134
32 -14 72 16 170 60 600 149
34 -12 74 17 180 64 700 159
36 -10 76 19 190 67
38 -8 78 20 200 70
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
18
WARNING
If the information in this manual is not followed ex-
actly, a fire or explosion can result and cause prop-
erty damage, personal injury, or loss of life.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
WHAT TO DO IF YOU SMELL GAS:
1. Do not try to light any appliance.
2. Do not touch any electrical switch, and do
not use any phone in your building.
3. Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
4. If you cannot reach your gas supplier, call
the î‚¿re department.
Installation and service must be performed by a qual-
ified installer, service agency, or the gas supplier.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could re-
sult in serious injury, death, or property damage.
Never test for gas leaks with an open flame.
Use a commercially available soap solution made
specifically for the detection of leaks to check all
connections. A fire or explosion may result causing
property damage, personal injury, or loss of life.
CAUTION
The gas heat exchangers may have a light oil film
on them from the manufacturing process. This oil
burns off on initial start-up and can produce smoke
and an unpleasant odor.
Pre-Start Checks
When starting up these units, it is imperative that ALL gas
fittings within the unit (in addition to the field installed gas
connections) are leak checked with a soap solution as
part of the unit commissioning process. The heat section
must be fired when checking the joints on the manifold
side of the gas valve. If any leaks are detected, the leaks
must be repaired immediately and all joints rechecked.
Verify wiring inside the burner compartment to ensure
the wiring/terminals are tight and securely connected
to the components, such as the ignition control, flame
sensor, gas valve, rollout switches, and igniter.
The gas heat start-up sequence begins with a 30-sec-
ond pre-purge. The next step in the sequence is clos-
ing the air proving switch. The heat section has a
combustion air proving switch. This switch must close
before the ignition sequence can initiate. If the air prov-
ing switch is closed after the 30-second pre-purge, the
ignition control energizes the spark igniter and opens
the gas valve.
The furnace ignition control uses flame rectification as
verification of burner operation. The minimum allow-
able flame current for operation is 0.7 DC microamps.
When the furnace ignition control does not prove a
flame in 7 seconds, it turns off the spark signal and
closes the gas valve. It waits 30 seconds and then initi-
ates a second ignition sequence.
When a flame is not proven during the second 7-sec-
ond trial for ignition, the control turns off the spark sig-
nal, closes the gas valve, waits 30 seconds, and then
initiates a third ignition sequence.
When flame rectification is not proven on the third try,
the ignition control locks out.
The heat section has two rollout switches mounted
above the burners. The purpose of the rollout switch is
to protect the gas heat section from flame rollout, or the
flame burning outside the heat exchanger. A restriction
in the heat exchanger or breach in the flue passages
can result in a rollout situation. The rollout switch is a
manual reset device.
The unit has two high temperature limit switches. One
is located at the heat exchanger vestibule panel, and
the other located in the area of the heat exchanger re-
turn bend. These limits are automatic reset devices.
When the limit opens, the ignition control de-energizes
the gas valve. On staged gas heat, as soon as the limit
closes, the ignition control re-initiates the ignition se-
quence. When the limit opens on a modulating gas heat
section, the ignition controller locks out the heat section.
Johnson Controls
Start-Up & Operation Guide | 5586996-JSG-A-0120
19
Start-Up
The control circuit is tested in the factory to ensure that
all of these steps are followed. The gas heat circuit is
tested in the factory with natural gas to ensure proper
operation of the unit.
Post Start Checks
When a signal is received at the gas heat control mod-
ule from the unit controller, verify:
• Combustion blower starts and runs for 30 sec-
onds before the spark is initiated
• Spark igniter sparks
• Gas valve opens
• Burners light from left to right in a 2.5 second time
frame in sequential order, as well as establish a
stable ame immediately upon ignition
• There are no gas leaks in the unit piping and the
supply piping
• Correct manifold gas pressures in accordance
with Manifold Staged Gas Pressure Adjustment
on page 19
• Supply pressure
• Supply pressure must be within the limita-
tions shown in Table 9.
• Supply pressure should be checked with all
gas appliances in the building at full fire.
• At no time should the standby gas pressure
exceed 10.5 iwg, nor the operating pressure
drop below 4.5 iwg for natural gas; or the
standby gas pressure exceed 13.0 iwg, nor
the operating pressure drop below 11.0 iwg
for propane. When the gas pressure is out-
side these limits, contact the installing me-
chanical contractor for corrective action.
• The ame is stable, with ame present only at the
end of the burner, no burning is occurring inside
the burner. There should be little yellow tipping of
the ame.
• There may be some smoke through the ue, due to
tooling oil burning off of the heat exchanger tubing.
Manifold Staged Gas Pressure Adjustment
Small adjustments to the manifold gas pressure can be
made by following the procedure outlined below. Refer
to Figure 2 for the high and low fire pressure regulator
adjustment locations.
HIGH FIRE PRESSURE
REGULATOR
LOW FIRE
PRESSURE
REGULATOR
TWO STAGE
PRESSURE
REGULATOR
REGULATOR VENT COVER
INLET
LD11760A
Figure 2: Manifold Gas Pressure Adjustment
Table 9: Staged Gas Low Fire/High Fire Pressures
Type of
Gas
Line Pressure
Manifold Pressure
Min Max
Low Fire
+/- 0.3 iwg
High Fire
+/- 0.3 iwg
Natural 4.5 iwg 10.5 iwg 1.2 iwg 3.5 iwg
Propane 11.0 iwg 13.0 iwg 3.5 iwg 10.0 iwg
1. Turn OFF the gas to the unit.
2. Use a 3/16 inch Allen wrench to remove the 1/8
inch NPT plug from the outlet pressure tap of the
manifold.
3. Install a brass adapter to allow the connection
of a hose to the outlet pressure tap of the valve.
4. Connect the hose to a manometer capable of
reading the required manifold pressure value.
5. Turn ON the gas to the unit.
6. Adjust the high î‚¿re manifold pressure:
a. Place the heat section into high fire operation.
b. Compare high fire manifold pressure to Table
9.
c. Remove the cap from the high fire pressure
regulator.
d. Use a 3/32 Allen wrench to make the mani-
fold pressure adjustment. Increase manifold
pressure by turning the screw clockwise;
decrease manifold pressure by turning the
screw counterclockwise.
e. Place a finger over the adjustment opening
while verifying the manifold pressure.
Johnson Controls
5586996-JSG-A-0120 | Start-Up & Operation Guide
Phase Monitor Adjustment
To adjust the phase monitor trip points, review the in-
structions in Phase Monitor Checks and Adjustments
in the Maintenance section of the Johnson Controls
Premier 25–50 Ton Rooftop Units Installation and
Maintenance Manual (Form 5586959-JIM).
20
7. Adjust the low î‚¿re manifold pressure:
a. Place the heat section into low fire operation.
b. Compare low fire manifold pressure to Table
9.
c. Remove the cap from the low fire pressure
regulator.
d. Use a 3/32 inch Allen wrench to make the
manifold pressure adjustment. Increase
manifold pressure by turning the screw clock-
wise; decrease manifold pressure by turning
the screw counterclockwise.
e. Place a finger over the adjustment opening
while verifying the manifold pressure.
8. Turn OFF the heat.
9. Turn OFF the gas.
10. Remove the brass tubing adapter and replace
the plug in the outlet pressure tap.
Commissioning Mode
Commissioning mode is a function used for manually
operating the unit during a service call or commission-
ing demonstration. It allows for the unit components
to be operated individually. The unit must not be op-
erated in this mode for an extended period, therefore
commissioning mode terminates automatically after 60
minutes unless extended at the local unit display for
another 60 minutes.
Cooling and heating is disabled unless supply fan sta-
tus is proven. Unit protection and safeties remain ac-
tive and logged during commissioning mode.
When a compressor is manually turned on, a condens-
er fan in the associated refrigeration circuit is automati-
cally turned on. This is to protect the compressor from
a high-pressure condition.
See Commission > Commissioning Mode > Air Handler,
Cooling, and Heating menus in Table 28 on page 71.
Air Balancing Wizard
The air balancing wizard is a grouping of configuration
screens used for testing and calibrating airflow measur-
ing stations (AMS), overriding damper positions, over-
riding fan speeds, and other functions to assist service
technicians and air balancers. See Table 11.
When the air balancer mode is set to enable, all heating
and cooling stages are disabled via the state table.
When the air balancer mode is set to disable, either from
the user or from a fixed 60 minute time-out value, all
overrides are set back to none.
See Commission > Air Balance > Supply, Return, and
Exhaust menus in Table 28 on page 68.
Table 10: Staged and Modulating Gas Heat
Staged and Modulating Gas Heat
Staged Gas
Heat
Modulating Gas
Heat
Model
Gas Input
Capacity (MBH)
Maximum Output
Capacity (MBH)
Minimum
Airow (CFM)
Gas Connection
Size (inches)
Steps Turndown
25–30
250 202.5 5,000 1.00 2 10:1
500 405 5,000 1.00 2 20:1
750 607.5 5,000 1.00 4 30:1
40–50
500 405 8,000 1.25 2 20:1
750 607.5 8,000 1.25 4 30:1
1250 1012.5 8,000 1.25 6 50:1
NOTES:
For proper operation, the building supplied natural gas pressure should be 7–14 iwg (liquid propane pressure should be 12–14 iwg).
Temperature rise can be calculated where temperature rise = (gas input capacity (Btu) x 0.81) / (CFM x 1.085).
Maximum leaving air temperature cannot exceed 120.0°F
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Johnson Controls GVD Series Start-Up & Operation

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