Johnson Controls Unitary Products SUNLINE 2000 BQ 048 Installation guide

Category
Heat pumps
Type
Installation guide

This manual is also suitable for

INSTALLATION
MANUAL 50 Hz
CAUTION: READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
SUNLINE 2000™
SINGLE PACKAGE HEAT PUMP
BQ 036, 048 & 060
(EXPORT)
175619-XIM-C-0109
CONTENTS
UNIT CONTROL BOARD FLASH CODES
37GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . 4
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 33
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 33
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 37
See the following page for a complete Table of Con-
tents.
NOTES, CAUTIONS AND WARNINGS
Installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes
are intended to
clarify or make the installation easier. Cautions
are given
to prevent equipment damage. Warnings
are given to
alert installer that personal injury and/or equipment dam-
age may result if installation procedure is not handled
properly.
175619-XIM-C-0109
2 Johnson Controls Unitary Products
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION SAFETY INFORMATION: . . . . . . . .7
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . .8
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . .9
COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
SERVICE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . .10
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
POWER AND CONTROL WIRING . . . . . . . . . . . . . . 12
OPTIONS/ACCESSORIES . . . . . . . . . . . . . . . . . . . . 12
ECONOMIZER/MOTORIZED DAMPER AND RAIN
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
POWER EXHAUST/BAROMETRIC RELIEF
DAMPER AND RAIN HOOD . . . . . . . . . . . . . . . . . . .13
ECONOMIZER AND POWER EXHAUST DAMPER
SET POINT ADJUSTMENTS AND
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
MINIMUM POSITION ADJUSTMENT . . . . . . . . . . . .13
ENTHALPY SET POINT ADJUSTMENT . . . . . . . . . .13
POWER EXHAUST DAMPER SETPOINT (WITH
OR WITHOUT POWER EXHAUST) . . . . . . . . . . . . .14
INDOOR AIR QUALITY . . . . . . . . . . . . . . . . . . . . . . .14
PHASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SUPPLY AIR BLOWERS . . . . . . . . . . . . . . . . . . . . .27
CHECKING SUPPLY AIR FLOW RATE . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SEQUENCE OF OPERATIONS OVERVIEW . . . . . . 29
COOLING SEQUENCE OF OPERATION . . . . . . . . 29
CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . 29
INTERMITTENT BLOWER . . . . . . . . . . . . . . . . . . . . 29
NO OUTDOOR AIR OPTIONS . . . . . . . . . . . . . . . . . 29
ECONOMIZER WITH SINGLE ENTHALPY
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ECONOMIZER WITH DUAL ENTHALPY
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ECONOMIZER (SINGLE OR DUAL) WITH
POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MOTORIZED OUTDOOR AIR DAMPERS . . . . . . . . . 30
COOLING OPERATION ERRORS . . . . . . . . . . . . . . 30
HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . 30
LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . 30
FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . 31
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 31
COMPRESSOR PROTECTION . . . . . . . . . . . . . . . 31
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HEATING SEQUENCE OF OPERATIONS . . . . . . . 31
WITH OR WITHOUT ELECTRIC HEAT . . . . . . . . . . . 31
DEFROST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FORCED DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . 32
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 32
HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . 32
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . 33
PRESTART CHECK LIST . . . . . . . . . . . . . . . . . . . . 33
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . 33
POST START CHECK LIST . . . . . . . . . . . . . . . . . . 33
SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 33
COOLING TROUBLE SHOOTING GUIDE . . . . . . . 33
UNIT FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . 36
FAN ON AND OFF DELAYS . . . . . . . . . . . . . . . . . . 37
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
NORMAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 37
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OUTDOOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
175619-XIM-C-0109
Johnson Controls Unitary Products 3
LIST OF FIGURES
Fig. # Pg. #
1 RECOMMENDED DRAIN PIPING . . . . . . . . . . . . .9
2 COMPRESSOR RESTRAINING BRACKET . . . .10
3 TYPICAL FIELD POWER & CONTROL
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4 ENTHALPY SETPOINT ADJUSTMENT . . . . . . . .15
5 HONEYWELL ECONOMIZER CONTROL
W7212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6 FOUR AND SIX POINT LOADING . . . . . . . . . . . .17
Fig. # Pg. #
7 UNIT DIMENSIONS (3 - 5 TON HEAT PUMP)
FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 UNIT WITH ECONOMIZER RAINHOOD . . . . . . . 20
9 UNIT WITH FIXED OUTDOOR AIR/MOTORIZED
DAMPER RAINHOOD . . . . . . . . . . . . . . . . . . . . . 21
10 UNIT DIMENSIONS (REAR VIEW) . . . . . . . . . . . 21
11 DISCONNECT/BLOWER ACCESS
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 27
13 PRESSURE DROP ACROSS COIL . . . . . . . . . . 28
14 UNIT CONTROL BOARD . . . . . . . . . . . . . . . . . . 36
LIST OF TABLES
Tbl. # Pg. #
1 UNIT APPLICATION DATA (BQ) . . . . . . . . . . . . . .7
2 CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . .12
3 ELECTRIC HEATER SUPPLY AIRFLOW
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4 BQ 4 POINT LOADS WEIGHT DISTRIBUTION
(KG / LBS.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5 BQ 6 POINT LOADS WEIGHT DISTRIBUTION
(KG / LBS.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6 CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . .17
7 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . .18
8 OPERATING WEIGHTS (KG / LBS.) . . . . . . . . . .18
9 ELECTRICAL DATA - BQ036, 048, & 060 . . . . . .19
10 ELECTRIC HEAT CORRECTION FACTORS . . .19
11 VOLTAGE LIMITATIONS . . . . . . . . . . . . . . . . . . .19
Tbl. # Pg. #
12 UTILITIES ENTRY . . . . . . . . . . . . . . . . . . . . . . . . 22
13 MINIMUM CLEARANCES . . . . . . . . . . . . . . . . . . 22
14 SUPPLY AIR BLOWER PERFORMANCE
(3 TON DIRECT DRIVE) - SIDE DUCT
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15 SUPPLY AIR BLOWER PERFORMANCE (
4 TON DIRECT DRIVE) - SIDE DUCT
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
16 SUPPLY AIR BLOWER PERFORMANCE
(5 TON BELT DRIVE) - SIDE DUCT
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
17 BELT DRIVE BLOWER MOTOR AND DRIVE
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
18 STATIC RESISTANCES. . . . . . . . . . . . . . . . . . . . 26
19 LIMIT CONTROL SETTING . . . . . . . . . . . . . . . . . 32
20 ELECTRIC HEAT ANTICIPATOR SETPOINTS . 33
175619-XIM-C-0109
4 Johnson Controls Unitary Products
UNIT CONTROL BOARD FLASH CODES
37
GENERAL
YORK Model BQ units are single package heat pumps
equipped with optional factory installed electric heat-
ers. These are designed for outdoor installation on a
rooftop or slab.
The units are completely assembled on rigid, perma-
nently attached base rails. All piping, refrigerant
charge, and electrical wiring is factory installed and
tested. The units require electric power, gas connec-
tion, duct connections, installation of combustion air
inlet hood, flue gas outlet hoods and fixed outdoor air
intake damper (units without economizer or motorized
damper option only) at the point of installation.
The supplemental electric heaters have nickel-chrome
elements and utilize single point power connection.
SAFETY CONSIDERATIONS
Due to system pressure, moving parts and electrical
components, installation and servicing of air condition-
ing equipment can be hazardous. Only qualified,
trained, service personnel should install, repair, main-
tain or service this equipment.
Observe all precautions in the literature, on labels and
tags accompanying the equipment whenever working
on air conditioning equipment. Be sure to follow all
other safety precautions that apply.
Wear safety glasses and work gloves, and follow all
safety codes. Use a quenching cloth and have a fire
extinguisher available for all brazing operations.
INSPECTION
As soon as a unit is received, it should be inspected for
possible damage during transit. If damage is evident,
the extent of the damage should be noted on the car-
rier's freight bill. A separate request for inspection by
the carrier's agent should be made in writing.
REFERENCE
Additional information on the design, installation, oper-
ation and service of this equipment is available in the
following reference forms:
175619 -General Installation
035-19404-000 -Economizer Accessory
530.18-N1.13V -Man. Outdoor Air Damper
Accessory 0 - 35%
530.18-N1.14V -Man. Outdoor Air Damper Accy
0 - 100%
035-07364-000 -Motorized Outdoor Air Damper
Accy.
035-19422-000 –Electric Heat Accessory
035-19405-000 -Barometric Relief Damper
530.46-N1.1V -Dual Enthalpy Accessory
530.18-N1.10V -Power Exhaust Accessory
175619-XIM-C-0109
Johnson Controls Unitary Products 5
RENEWAL PARTS
Contact your local York
®
parts distribution center for
authorized replacement parts.
APPROVALS
Design listed by CSA as follows:
For use as a heat pump only with or without
optional electric heat.
For outdoor installation only.
For installation on combustible material.
Installer should pay particular attention to the words:
NOTE, CAUTION and WARNING. Notes are intended
to clarify or make the installation easier. Cautions are
given to prevent equipment damage. Warnings are
given to alert installer that personal injury and/or equip-
ment damage may result if installation procedure is not
handled properly.
This product must be installed in strict compli-
ance with the enclosed installation instructions
and any applicable local, state, and national
codes including, but not limited to, building,
electrical, and mechanical codes.
Improper installation may create a condition
where the operation of the product could cause
personal injury or property damage.
175619-XIM-C-0109
6 Johnson Controls Unitary Products
PRODUCT NOMENCLATURE
B Q 048 C00 A 7 A AA 1 0 1 2 4 A
Product Category
B = HP, Single Pkg., R-22
A = Direct Drive
Airflow
B = Direct Drive/Economizer
D = Direct Drive/Motorized Damper
N = Belt Drive
P = Belt Drive/Economizer
R = Belt Drive/Motorized Damper
Belt Drive Not Available on 3 and 4 Ton 50 Hz Models.
1 = First Generation
Product Generation
2 = Second Generation
C00 = Cooling Only. Suitable for Field
Installed Electric Heat
Heat Type and Nominal Heat Capacity
E05 = 5 KW
E07 = 7 KW
E10 = 10 KW
E15 = 15 KW
E20 = 20 KW
E30 = 30 KW
Electric Heat Options
036 = 3.0 Ton
Nominal Cooling Capacity
048 = 4.0 Ton
060 = 5.0 Ton
Product Identifier
Q = 10.0 SEER HP
Voltage
7 = 380/415-3-50
Product Style
A = Style A
A = No Options Installed
Installation Options
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
Options
SS Drain Pan
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
CPC Controller, DFS, APS
Johnson Controller, DFS, APS
Honeywell Controller, DFS, APS
Novar Controller, DFS, APS
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller w/ModLinc
2" Pleated filters
BAS Ready Economizer (2-10 V. D. C. Actuator without a Controller)
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
AA = None
Standard Cabinet
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
AS = Bottom Drain Connection
RC = Coil Guard & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator and Condenser Coil
Additional Options
Hinged Filter Door & Toolless Access Cabinet
3-5 Ton Sunline Model Number Nomenclature
BA = Hinged Filter Door & Toolless Access Panels
BB = Phase Monitor, Hinged Filter Door & Toolless
Access Panels
BC = Coil Guard, Hinged Filter Door & Toolless
Access Panels
BD = Dirty Filter Switch, Hinged Filter Door &
Toolless Access Panels
BE = Phase Monitor & Coil Guard, Hinged Filter
Door & Toolless Access Panels
BF = Phase Monitor & Dirty Filter Switch, Hinged
Filter Door & Toolless Access Panels
BG = Coil Guard & Dirty Filter Switch, Hinged Filter
Door & Toolless Access Panels
BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
Hinged Filter Door & Toolless Access Panels
BA = Hinged Filter Door & Toolless Access Panels
BA = Hinged Filter Door & Toolless Access Panels
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
175619-XIM-C-0109
Johnson Controls Unitary Products 7
INSTALLATION
INSTALLATION SAFETY INFORMATION:
Read these instructions before continuing this appli-
ance installation. This is an outdoor combination heat-
ing and cooling unit. The installer must assure that
these instructions are made available to the consumer
and with instructions to retain them for future reference.
1. Install this unit only in a location and position as
specified on page 8 of these instructions.
2. This equipment is not to be used for temporary
heating of buildings or structures under construc-
tion.
LIMITATIONS
These units must be installed in accordance with the
following national and local safety codes:
In U.S.A
.:
National Electrical Code ANSI/NFPA No. 70.
In Canada
:
Current Canadian Electrical Code C22.1.
Local plumbing and waste water codes.
Other applicable local codes.
Refer to the Unit Application Data table and to the Elec-
tric Heat Application Data table.
If components are to be added to a unit to meet local
codes, they are to be installed at the dealer's and/or
the customer's expense.
Size of unit for proposed installation should be based
on heat loss/heat gain calculation made according to
the methods of the Air Conditioning Contractors of
America (ACCA).
This unit is not to be used for temporary heating of
buildings or structures under construction.
The Simplicity® control board used in this product
will effectively operate the cooling system down to
0°F when this product is applied in a comfort cooling
application for people. An economizer is typically
included in this type of application. When applying
this product for process cooling applications (com-
puter rooms, switchgear, etc.), please reference
applications bulletin AE-011-07 or call the applica-
tions department for Unitary Products @ 1-877-
UPG-SERV for guidance. Additional accessories
may be needed for stable operation at temperatures
below 30° F.
TABLE 1: UNIT APPLICATION DATA (BQ)
UNIT MODEL NUMBER 036 048 060
Voltage Variation,
Min. / Max.
1
380 / 415 342 / 456
Supply Air m
3
/s (ft
3
/min.), Nom.
0.57 (1200) 0.76 (1600) 0.94 (2000)
Wet Bulb Temperature of Air on
Evaporator Coil, Min. / Max
14°C / 22°C
57°F / 72°F
Dry Bulb Temperature of Air on
Condenser Coil, Min. / Max.
-18°C / 49°C
0°F / 120°F
1.
Utilization range “A” in accordance with ARI Standard 110.
175619-XIM-C-0109
8 Johnson Controls Unitary Products
LOCATION
Use the following guidelines to select a suitable loca-
tion for these units.
1. Unit is designed for outdoor installation only.
2. Condenser coils must have an unlimited supply of
air.
3. Where a choice of location is possible, position the
unit on either north or east side of building.
4. For ground level installation, use a level concrete
slab with a minimum thickness of 101 mm (4”). The
length and width should be at least 6 inches
greater than the unit base rails. Do not tie slab to
the building foundation.
5. Roof structures must be able to support the weight
of the unit and its options and/or accessories. Unit
must be installed on a solid level roof curb or
appropriate angle iron frame.
6. Maintain level tolerance to 13 mm (1/2”) maximum
across the entire length or width of the unit.
If a unit is to be installed on a roof curb or special frame
other than a YORK roof curb, gasketing must be
applied to all surfaces that come in contact with the unit
underside.
RIGGING AND HANDLING
Exercise care when moving the unit. Do not remove
any packaging until the unit is near the place of installa-
tion. Rig the unit by attaching chain or cable slings to
the lifting holes provided in the base rails. Spreader
bars, whose length exceeds the largest dimension
across the unit, MUST BE USED.
Units may also be moved or lifted with a forklift. Slotted
openings in the base rails are provided for this pur-
pose. Fork lengths must be a minimum of 1067 mm
(42”).
Remove the nesting brackets from the four corners on
the top of the unit. All screws that are removed when
removing the brackets must be replaced on the unit.
Refer to Tables 4, 5 and 9 for unit weights and to Table
7 for approximate center of gravity.
CLEARANCES
All units require certain clearances for proper operation
and service. Installer must make provisions for ade-
quate ventilation air. Refer to Dimensions and Clear-
ances shown in Figures 7 through 11 and Table 14 for
the clearances required for combustible construction,
servicing, and proper unit operation.
Before lifting a unit, make sure that all panels
are in place and that its weight is distributed
equally on all cables so it will lift evenly.
Do not permit overhanging structures or shrubs
to obstruct outdoor air discharge outlet, com-
bustion air inlet or vent outlets.
175619-XIM-C-0109
Johnson Controls Unitary Products 9
DUCTWORK
Ductwork should be designed and sized according to
the methods in Manual Q of the Air Conditioning Con-
tractors of America (ACCA).
A closed return duct system shall be used. This shall
not preclude use of economizers or outdoor fresh air
intake. The supply and return air duct connections at
the unit should be made with flexible joints to minimize
noise.
The supply and return air duct systems should be
designed for the supply air flow rate and static pressure
requirements of the job. They should NOT be sized to
match the dimensions of the duct connections on the
unit.
Refer to Figures 7 and 10 for information concerning
side and bottom supply and return air duct openings.
CONDENSATE DRAIN
Plumbing must conform to local codes. Use a sealing
compound on male pipe threads. Install a condensate
drain line from the 3/4” NPT female connection on the
unit to an open drain.
NOTE: The condensate drain operates in a negative
pressure in the cabinet. The condensate drain
line MUST be trapped to provide proper drain-
age. See Figure 1.
When fastening ductwork to side duct flanges
on unit, insert screws through duct flanges
only. DO NOT insert screws through casing.
Outdoor ductwork must be insulated and
waterproofed.
FIGURE 1 - RECOMMENDED DRAIN PIPING
175619-XIM-C-0109
10 Johnson Controls Unitary Products
COMPRESSORS
Units are shipped with compressor mountings factory-
adjusted and ready for operation.
Units with scroll compressors have a shipping bracket
which must be removed after the unit is set in place.
See Figure 2.
FILTERS
Filters supplied with each unit can be 25 mm (1”) or 51
mm (2”) in width. Filters must always be installed
ahead of the evaporator coil and must be kept clean or
replaced with same size and type. Dirty filters will
reduce the capacity of the unit and will result in frosted
coils or safety shutdown. Minimum filter area and
required sizes are shown in Physical Data Table 8.
SERVICE ACCESS
The following removable panels provide access to all
serviceable components:
Compressor compartment
Electric Heat compartment
Blower compartment
Main control box
Filter compartment
Refer to the Dimensions and Clearances shown in Fig-
ures 8, 9 and 10 for location of these access panels.
FIGURE 2 - COMPRESSOR RESTRAINING
BRACKET
Do not loosen compressor mounting bolts.
WIRE TIE (CUT AND REMOVE)
MOUNTING
BRACKET TOP
(REMOVE)
MOUNTING
BRACKET BASE
REMOVE THESE
SCREWS (2)
COMPRESSOR
Make sure that all screws and panel latches
are replaced and properly positioned on the
unit to maintain an airtight seal.
175619-XIM-C-0109
Johnson Controls Unitary Products 11
TYPICAL POWER WIRING
TYPICAL CONTROL WIRING
FIGURE 3 - TYPICAL FIELD POWER & CONTROL WIRING
W1
W2
Y1
G
OCC
P
P1
Y2
X
R
SD
C
C
SD
SD
R
OCC
C
RC
G
Y2
Y1
W2
W1
Jumper
Smoke
Detector
24 VAC
Class 2
X
R
THERMOSTAT
TERMINALS
CONTROL
TERMINAL
BLOCK
TERMINALS ON
A LIMITED
NUMBER OF
THERMOSTATS
3
1
2
4
3
1
2
4
Second stage heating not required on single stage heating units.
Second stage cooling not required on single stage cooling units.
Jumper is required if there is no Smoke Detector circuit.
Jumper is required for any combination of R, RC, or RH.
6
5
5
6
OCC is an output from the thermostat to indicate the Occupied condition.
X is an input to the thermostat to display Error Status conditions.
175619-XIM-C-0109
12 Johnson Controls Unitary Products
THERMOSTAT
The room thermostat should be located on an inside
wall approximately 1422 mm (56”) above the floor
where it will not be subject to drafts, sun exposure or
heat from electrical fixtures or appliances. Follow man-
ufacturer's instructions enclosed with thermostat for
general installation procedure. A minimum of seven
color-coded insulated wires (#18 AWG) should be used
to connect thermostat to unit.
POWER AND CONTROL WIRING
Field wiring to the unit must conform to provisions of
the National Electrical Code, ANSI / NFPA No. 70 (in
U.S.A.), current Canadian Electrical Code C22.1 (in
Canada) and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC
(as specified above) and/or local codes. Voltage toler-
ances, which must be maintained at the compressor
terminals, during starting and running conditions, are
indicated on the unit Rating Plate and the Unit Applica-
tion Data table.
The internal wiring harness furnished with this unit is
an integral part of a CSA design certified unit. Field
alteration to comply with electrical codes should not be
required.
A fused disconnect switch should be field provided for
the unit. The switch must be separate from all other cir-
cuits. Wire entry at knockout openings require conduit
fittings to comply with NEC (in U.S.A.), CEC (in Can-
ada) and/or local codes. Refer to Figure 7, and 11 for
installation location. If any of the wire supplied with the
unit must be replaced, replacement wire must be of the
type shown on the wiring diagram and the same mini-
mum gauge as the replaced wire.
Electrical line must be sized properly to carry the load.
Use copper conductors only. Each unit must be wired
with a separate branch circuit fed directly from the
meter panel and properly fused.
Refer to the Typical Field Wiring Figure 3 and to the
appropriate unit wiring diagram for control circuit and
power wiring information.
OPTIONS/ACCESSORIES
The factory-installed heaters are wired for single point
power supply. Power supply need only be brought into
the single point terminal block and thermostat wiring to
the low voltage terminal strip located in the upper por-
tion of the unit control box.
These CSA approved heaters are located within the
central compartment of the unit with the heater ele-
ments extending into the supply air chamber. Refer to
Figure 7 for access panel location.
Fuses are supplied, where required, by the factory.
Some KW sizes require fuses and others do not. Refer
to Table 3 for minimum airflow limitations and to Table
for electrical data.
208/230-3-60 and 380/415-3-50 units control tran-
formers are factory wired for 230v and 415v power
supply respectively. Change tap on transformer for
208-3-60 or 380-3-50 operation.
See unit wiring diagram.
When connecting electrical power and control
wiring to the unit, waterproof type connectors
MUST BE USED so that water or moisture
cannot be drawn into the unit during normal
operation. The above waterproofing conditions
will also apply when installing a field-supplied
disconnect switch.
TABLE 2: CONTROL WIRE SIZES
Wire Size
Maximum Length
1
1.
From the unit to the thermostat and back to the unit.
18 AWG 46 m (150 ft)
175619-XIM-C-0109
Johnson Controls Unitary Products 13
ECONOMIZER/MOTORIZED DAMPER AND RAIN HOOD
The instruction for the optional economizer/motorized
damper and rain hood can be found in form 035-
07364-000. Use these instructions when field assem-
bling an economizer rain hood onto a unit. The outdoor
and return air dampers, the damper actuator, the
damper linkage, the outdoor and return air divider baf-
fles, and all the control sensors are factory mounted as
part of the “Factory installed” economizer/motorized
damper options.
POWER EXHAUST/BAROMETRIC RELIEF DAMPER AND
RAIN HOOD
The instructions for the power exhaust/barometric relief
damper and rain hood can be found in form 530.18-
N1.10V.
All of the components, including the dampers, hard-
ware, and mounting instructions are shipped in a single
package external from the unit, and must be field
assembled and installed.
Power exhaust is only available as a field installed
accessory.
ECONOMIZER AND POWER EXHAUST DAMPER
SET POINT ADJUSTMENTS AND INFORMATION
Remove the economizer access panel from the unit.
Loosen but do not remove the two panel latches.
Locate the economizer control module, where the fol-
lowing adjustments will be made.
Check that the damper blades move smoothly without
binding; carefully turn the Minimum Position Adjusting
screw (found on the damper control module) fully
clockwise and then set the thermostat indoor fan switch
to the on position and then off, or energize and de-
energize terminals “R” to “G”.
MINIMUM POSITION ADJUSTMENT
With thermostat set to indoor fan on position, or termi-
nals “R” to “G” energized, turn the Minimum Position
Adjusting screw (located on the damper control mod-
ule) counterclockwise until the desired minimum
damper position has been attained.
ENTHALPY SET POINT ADJUSTMENT
The enthalpy set point may now be set by selecting the
desired setpoint shown in the Enthalpy Setpoint Adjust-
ment Figure 4. Adjust as follows:
For a single enthalpy operation carefully turn the
set point adjusting screw (found on the damper
control module) to the “A”, “B”, “C” or “D” setting
corresponding to the lettered curve of the Enthalpy
Setpoint Adjustment Figure 4.
For a dual enthalpy operation, carefully turn the set
point adjusting screw fully clockwise past the “D
setting.
TABLE 3: ELECTRIC HEATER SUPPLY AIRFLOW LIMITATIONS
7 10152030
M
3
/S
0.47 0.57 0.57 0.61 -
CFM 1100 1200 1200 1300 -
M
3
/S
0.61 0.61 0.61 0.61 -
CFM 1300 1300 1300 1300 -
M
3
/S
0.75 0.75 0.75 0.75 0.75
CFM 1600 1600 1600 1600 1600
HEATER SIZE NOMINAL KW
MINIMUM
SUPPLY AIR
VOLTAGE
UNIT MODEL SIZE
NOMINAL TONS
3
4
5
380/415-3-50
380/415-3-50
380/415-3-50
Extreme care must be exercised in turning all
setpoint, maximum, and minimum damper
positioning adjustment screws to prevent twist-
ing them off.
175619-XIM-C-0109
14 Johnson Controls Unitary Products
POWER EXHAUST DAMPER SETPOINT (WITH OR WITH-
OUT POWER EXHAUST)
With no power exhaust option, adjust the Exhaust
Air Adjustment Screw fully clockwise.
With power exhaust option, each building pressur-
ization requirement will be different. The point at
which the power exhaust comes on is determined
by the economizer damper position (Percent
Open). The Exhaust Air Adjustment Screw should
be set at the Percent Open of the economizer
damper at which the power exhaust is needed. It
can be set from 0 to 100% damper open.
INDOOR AIR QUALITY
Indoor Air quality (indoor sensor input): Terminal AQ
accepts a +2 to +10 Vdc signal with respect to the
(AQ1) terminal. When the signal is below it's setpoint,
the actuator is allowed to modulate normally in accor-
dance with the enthalpy and mixed air sensor inputs.
When the AQ signal exceeds it's setpoint setting and
there is no call for free cooling, the actuator is propor-
tionately modulated from the 2 to 10 Vdc signal, with 2
Vdc corresponding to full closed and 10 Vdc corre-
sponding to full open. When there is no call for free
cooling, the damper position is limited by the IAQ Max
damper position setting. When the signal exceeds it's
setpoint (Demand Control Ventilation Setpoint) setting
and there is a call for free cooling, the actuator modu-
lates from the minimum position to the full open posi-
tion based on the highest call from either the mixed air
sensor input or the AQ voltage input.
Optional CO
2
Space Sensor Kit Part #
2AQ04700324
Optional CO
2
Unit Sensor Kit Part # 2AQ04700424
Replace the economizer access panel.
175619-XIM-C-0109
Johnson Controls Unitary Products 15
FIGURE 4 - ENTHALPY SETPOINT ADJUSTMENT
175619-XIM-C-0109
16 Johnson Controls Unitary Products
FIGURE 5 - HONEYWELL ECONOMIZER CONTROL W7212
N1
N
P1
P
EXH
Set
EXH
Min
Pos
IAQ
Max
IAQ
IAQ
Min
Free
Cool
T
T1
AQ1 AQ
SO+ SO
SR+
SR
A
BC
D
TR TR1
24
Vac
HOT
24
Vac
COM
EF EF1
2
3
4
5
1
+
Exhaust Air
Adjustment
Screw
Exhaust Air LED
Damper Min.
Position
Screw
Indoor Air Quality
Max. Adjustment
Screw
Indoor Air Quality
LED
Indoor Air Quality
Min. Adjustment
Screw
Free Cooling LED
Economizer Enthalpy
Set Point Adjustment
Screw
175619-XIM-C-0109
Johnson Controls Unitary Products 17
FIGURE 6: FOUR AND SIX POINT LOADING
TABLE 4: BQ 4 POINT LOADS WEIGHT DISTRIBUTION (kg / Lbs.)
UNIT TOTALABCD
BQ036
252 / 555 56 / 123 55 / 121 70 / 154 71 / 157
BQ048
270 / 595 60 / 132 59 / 130 75 / 165 76 / 168
BQ060
281 / 620 62 / 138 61 / 135 78 / 172 79 / 175
TABLE 5: BQ 6 POINT LOADS WEIGHT DISTRIBUTION (kg / Lbs.)
UNIT TOTAL A B C D E F
BQ036
252 / 555 37 / 82 37 / 81 36 / 80 46 / 102 47 / 104 48 / 105
BQ048
270 / 595 40 / 88 40 / 87 39 / 86 50 / 110 50 / 111 51 / 112
BQ060
281 / 620 42 / 92 41 / 91 41 / 90 52 / 114 52 / 116 53 / 117
1140
[44
7
/
8
]
2089
[82
1
/
4
]
Y
X
A
B
C
D
CONDENSER COIL
END OF UNIT
FRONT OF UNIT
APPROXIMATE
CENTER OF GRAVITY
BACK OF UNIT
mm[inch]
1140
[44
7
/
8
]
2089
[82
1
/
4
]
Y
X
A
B
C
D
CONDENSER COIL
END OF UNIT
FRONT OF UNIT
APPROXIMATE
CENTER OF GRAVITY
BACK OF UNIT
mm[inch]
E
F
TABLE 7: CENTER OF GRAVITY
DIMENSION
3 - 5 TON
(mm / in)
X 1035 / 40-¾
Y 502 / 19-¾
175619-XIM-C-0109
18 Johnson Controls Unitary Products
TABLE 8: PHYSICAL DATA
MODELS
BQ
036 048 060
EVAPORATOR
BLOWER
Centrifugal Blower (Dia. x Wd. mm) (in.)
305 X 254
(12X10)
305 X 254
(12X10)
305 X 254
(12X10)
Fan Motor HP (Direct Drive) 1/2 3/4 N/A
Fan Motor HP (Belt Drive) N/A N/A 1 1/2
EVAPORATOR
COIL
Rows Deep 4 3 3
Fins Per Inch (25mm) 16 15 15
Face Area m
2
(ft
2
)
0.40 (4.3) 0.57 (5.1) 0.57 (5.1)
CONDENSER
FANS
Propeller Dia. mm (in.) 610 (24) 610 (24) 610 (24)
Fan Motor Hp 1/3 1/2 1/2
Nom. Air Flow Rate 4300 4200 4500
CONDENSER
COILS
Rows Deep 1 1 1
Fins Per Inch (25mm) 20 20 20
Face Area m
2
(ft
2
)
1.60 (17.1) 1.60 (17.1) 1.60 (17.1)
COMPRESSOR
(Qty. Per Unit)
Type/Quantity Reciprocating/1 Reciprocating/1 Scroll/1
AIR
FILTERS
Quantity Per Unit (15” X 20” X 1” or 2“) 2 2 2
Quantity Per Unit (14” X 25” X 1” or 2“) 1 1 1
Face Area m
2
(ft
2
)
0.59 (6.6) 0.59 (6.6) 0.59 (6.6)
CHARGE
Refrigerant 22 kg (lbs./oz.) 3.6 (8/0) 4.2 (9/2) 3.7 (8.4)
TABLE 9: OPERATING WEIGHTS (kg / Lbs.)
MODEL SIZE 3 TON 4 TON 5 TON
BASIC UNIT
BQ 252 / 555 270 / 595 281 / 620
OPTIONS
Economizer 23 / 50
Motorized Damper 12 / 26
Electric Heater
5 - 7 kW 8 / 18
10 - 15 kW 10 / 23
20 - 30 kW 13 / 28
ACCY.
Roof Curb 42 / 92
Barometric Relief / Fixed Air Damper 5 / 10
Belt-Drive Blower 2.3 / 5
175619-XIM-C-0109
Johnson Controls Unitary Products 19
TABLE 10: ELECTRICAL DATA - BQ036, 048, & 060
0.0 9.6
15
2CE04510746
2
4.3 6.5 17.8
20
2CE04511046
2
6.3 9.6 21.6
25
2CE04511546
2
8.5 12.9 25.8
30
2CE04512046
2
12.2 18.5 32.8
35
0.0 9.6
15
2CE04510746
2
5.1 7.1 18.5
20
2CE04511046
2
7.5 10.4 22.7
25
2CE04511546
2
10.2 14.2 27.4
30
2CE04512046
2
14.6 20.3 35.0
40
0.0 15.3
20
2CE04510746
2
4.3 6.5 23.5
30
2CE04511046
2
6.3 9.6 27.3
30
2CE04511546
2
8.5 12.9 31.4
35
2CE04512046
2
12.2 18.5 38.5
40
0.0 15.3
20
2CE04510746
2
5.1 7.1 24.2
30
2CE04511046
2
7.5 10.4 28.3
35
2CE04511546
2
10.2 14.2 33.0
35
2CE04512046
2
14.6 20.3 40.7
45
0.0 16.5
25
2CE04510746
2
4.3 6.5 24.7
30
2CE04511046
2
6.3 9.6 28.5
35
2CE04511546
2
8.5 12.9 32.6
35
2CE04512046
2
12.2 18.5 39.7
45
2CE04513046
2
18.1 27.5 50.9
60
0.0 16.5
25
2CE04510746
2
5.1 7.1 25.4
30
2CE04511046
2
7.5 10.4 29.5
35
2CE04511546
2
10.2 14.2 34.2
40
2CE04512046
2
14.6 20.3 41.9
45
2CE04513046
2
21.5 29.9 53.9
60
Note 1: HACR T
y
pe per NEC
Note 2: These electric heaters DO NOT include a fuse box. If a fuse box is required to meet a local
code, the fuse block accessory
2FB04700546 is available for field installation.
Note 3: Heaters are suitable for operation on 380/415V-3-50Hz power supply.
1.3 2.7
415-3-50 10.0 74 1.3 2.7
5
380-3-50 10.0 74
1.3 2.0
415-3-50 9.6 66 1.3 2.0
4
380-3-50 9.6 66
1.3 1.7
415-3-50 5.3 37.7 1.3 1.7
3
380-3-50 5.3 37.7
Heater
Amps
Minimum
Circuit
Ampacity
Amps
Max
Fuse /
BRKR
1
Size
RLA
Each
LRA
Each
ID
Blower
Motor
FLA
Electric
Heater Model
No.
3
Heater
kW
Model
Tonnage
Voltage
Compressors
OD Fan
Motors
FLA
Each
NONE
0.0
NONE
0.0
NONE
0.0
NONE
0.0
NONE
0.0
NONE
0.0
TABLE 11: ELECTRIC HEAT CORRECTION FACTORS
NOMINAL VOLTAGE VOLTAGE
kW CAP. MULTI-
PLIER
380
380 .627
415
415 0.75
TABLE 12: VOLTAGE LIMITATIONS
1
POWER SUPPLY
VOLTAGE
MIN. MAX.
380/415-3-50
342 456
1.
Utilization Range “A” in accordance with ARI Standard
110.
175619-XIM-C-0109
20 Johnson Controls Unitary Products
FIGURE 7: UNIT DIMENSIONS (3 - 5 TON HEAT PUMP) FRONT VIEW
FIGURE 8: UNIT WITH ECONOMIZER RAINHOOD
DETAIL “A”
699
[27
1
/
2
]
699
[27
1
/
2
]
41
[1
5
/
8
]
260
[10
1
/
4
]
1140
[44
7
/
8
]
502
[19
3
/
4
]
mm[inch]
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40

Johnson Controls Unitary Products SUNLINE 2000 BQ 048 Installation guide

Category
Heat pumps
Type
Installation guide
This manual is also suitable for

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI