Johnson Controls Unitary Products SUNLINE 2000 BQ 048 Installation guide

Brand: Johnson Controls Unitary Products

Model: SUNLINE 2000 BQ 048

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

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

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.

380 / 415 342 / 456

Supply Air m

/s (ft

/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

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

OCC

Jumper

Smoke

Detector

24 VAC

Class 2

THERMOSTAT

TERMINALS

CONTROL

TERMINAL

BLOCK

TERMINALS ON

A LIMITED

NUMBER OF

THERMOSTATS

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.

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

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

0.47 0.57 0.57 0.61 -

CFM 1100 1200 1200 1300 -

0.61 0.61 0.61 0.61 -

CFM 1300 1300 1300 1300 -

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

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

Space Sensor Kit Part #

2AQ04700324

• Optional CO

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

EXH

Set

EXH

Min

Pos

IAQ

Max

IAQ

Min

Free

Cool

AQ1 AQ

SO+ SO

SR+

TR TR1

Vac

HOT

Vac

COM

EF EF1

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

]

2089

[82

]

CONDENSER COIL

END OF UNIT

FRONT OF UNIT

APPROXIMATE

CENTER OF GRAVITY

BACK OF UNIT

mm[inch]

1140

[44

]

2089

[82

]

CONDENSER COIL

END OF UNIT

FRONT OF UNIT

APPROXIMATE

CENTER OF GRAVITY

BACK OF UNIT

mm[inch]

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

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

(ft

)

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

(ft

)

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

(ft

)

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

2CE04510746

4.3 6.5 17.8

2CE04511046

6.3 9.6 21.6

2CE04511546

8.5 12.9 25.8

2CE04512046

12.2 18.5 32.8

0.0 9.6

2CE04510746

5.1 7.1 18.5

2CE04511046

7.5 10.4 22.7

2CE04511546

10.2 14.2 27.4

2CE04512046

14.6 20.3 35.0

0.0 15.3

2CE04510746

4.3 6.5 23.5

2CE04511046

6.3 9.6 27.3

2CE04511546

8.5 12.9 31.4

2CE04512046

12.2 18.5 38.5

0.0 15.3

2CE04510746

5.1 7.1 24.2

2CE04511046

7.5 10.4 28.3

2CE04511546

10.2 14.2 33.0

2CE04512046

14.6 20.3 40.7

0.0 16.5

2CE04510746

4.3 6.5 24.7

2CE04511046

6.3 9.6 28.5

2CE04511546

8.5 12.9 32.6

2CE04512046

12.2 18.5 39.7

2CE04513046

18.1 27.5 50.9

0.0 16.5

2CE04510746

5.1 7.1 25.4

2CE04511046

7.5 10.4 29.5

2CE04511546

10.2 14.2 34.2

2CE04512046

14.6 20.3 41.9

2CE04513046

21.5 29.9 53.9

Note 1: HACR T

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

380-3-50 10.0 74

1.3 2.0

415-3-50 9.6 66 1.3 2.0

380-3-50 9.6 66

1.3 1.7

415-3-50 5.3 37.7 1.3 1.7

380-3-50 5.3 37.7

Heater

Amps

Minimum

Circuit

Ampacity

Amps

Max

Fuse /

BRKR

Size

RLA

Each

LRA

Each

Blower

Motor

FLA

Electric

Heater Model

No.

Heater

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

POWER SUPPLY

VOLTAGE

MIN. MAX.

380/415-3-50

342 456

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

829

[32

]

1140

[44

]

213

]

292

[11

]

445 [17

]

445 [17

]

181

]

171 [6

]

206

]

137

]

2089

[82

]

165 [6

]

mm[inch]

DETAIL “A”

699

[27

]

699

[27

]

260

[10

]

1140

[44

]

502

[19

]

mm[inch]

Page is loading ...

Johnson Controls Unitary Products SUNLINE 2000 BQ 048 Installation guide

Brand: Johnson Controls Unitary Products

Model: SUNLINE 2000 BQ 048

Category: Heat pumps

Type: Installation guide

This manual is also suitable for

Download PDF

report

Johnson Controls Unitary Products SUNLINE 2000 BQ 048 Installation guide

This manual is also suitable for

Johnson Controls Unitary Products SUNLINE 2000 BQ 048 Installation guide

Related papers

Other documents