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Building 3 O&M (6-5-2014) - Paulson

1. 11 3 0 44 Units mm inches 2 6 DURAPULsE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring is Dimensions continued Frame C Part numbers GS3 27P5 GS3 2010 GS3 2015 GS3 47P5 GS3 4010 GS3 4015 200 0 7 88 185 6 7 31 Dia 7 0 0 28 183 2 7 22 303 0 11 94 323 0 12 73 d oro see ME ic CAS A e A LA y zi LO Dia 22 0 0 87 Dia 42 6 1 68 MEE S LO is 2 7 0 0 28 DETAIL A Units mm inches lst Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 7 Chapter 2 Installation and Wiring Dimensions continued Frame D Part numbers GS3 2020 GS3 2025 GS3 2030 GS3 4020 GS3 4025 GS3 4030 250 0 9 84 Dia 10 0 0 39 205 4 8 08 384 0 15 12 403 8 15 90 Dia 28 0 1 1 Dia 42 0 1 65 2X 10 0 0 39 13 0 0 51 Units mm inches 2 8 DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring EE o Dimensions continued Frame E Part Numbers GS3 2040 GS3 2050 GS3 4040 GS3 4050 GS3 4060 370 0 14 57 Bia des 59 260 0 10 24 335 0 13 19 o A Dia 18 0 0 71
2. 595 0 23 43 560 0 22 05 589 0 23 19 18 0 0 71 Di O 132 5 5 22 5 2 Dia 22 0 0 87 Dia 62 0 2 44 R6 5 0 25 21 0 0 83 13 0 0 51 AE COOK ij Units mm inches Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 9 Chapter 2 Installation and Wiring I Dimensions continued Frame F Part Numbers GS3 4075 GS3 4100 425 0 16 73 o 385 0 15 16 ge cg oio ES OIO G Mi O CO 0 N kh 130 4 5 13 280 0 11 02 2 94 _ mM 00 o e R6 5 0 25 CN LI 13 0 0 51 Units mm inches 2 10 BM DURAPUSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring Circuit Connections HAZARDOUS VOLTAGE Before making any connection to the AC drive disconnect all power to the AC drive and wait five minutes for DC bus capacitors to discharge WARNING Any electrical or mechanical modification to this equipment without prior written consent of AutomationD irect com Inc will void all warranties may result in a safety hazard and may void the UL listing Doing this will damage the AC drive WARNING Tighten all screws to the proper torque rating See Main Circui
3. os A 49 Communication Distribution Blocks Legacy GS Series do not use for new installations A 50 Replacement Accessories Cooling Fans A 51 Appendix B Using DURAPuLsE AC Drives with AutomationDirect PLCS oo oooooomoo B 1 Compatible AutomationDirect PLCs and Modules B 2 Typical PLC Connections to DURAPuLse AC Drives B 8 CLICK PLC and Sinking DC Output Modules B 8 CLICK PLC and Sourcing DC Output Modules B 9 CLICK PLC Sourcing Analog Current Output Modules B 10 CLICK PLC DC Input Modules ss ss Es Es es B 10 Direct LOGIC Sinking DC Output Modules B 11 DirectLOGIC Sourcing DC Output Modules B 12 DirectLOGIC Voltage or Current Sourcing Analog Output M odulesB 13 DirectLOGIC PLC DC Input Modules B 14 Digital Output Terminal Wiring o o oooo momo B 14 Relay Contact Output Terminal Wiring a B 14 Index 0 ee i 1 c 6 DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 GETTING STARTED Contents of this Chapter Manual Overview RR RR e nn 1 2 Overview of this Publication e n RII 1 2 Who Should Read This Manual len 1 2 Supplemental Publications EE Es Es ee 1 2 LZ esae ke dle ole ed ERA EA ER EE OR RE EE EET OE FEE TOR 1 2 Special SyMbolS LL 1 2 DURAPULSE AC Dr
4. 1627 200 200 38 6 2 Dual Element Time Delay Type 10 0 200 3 HACR type per NEC 70 30 100 Johnson Controls Unitary Products 23 860261 JIM B 0612 J25ZJ Low Static Drive Without Powered Convenience Outlet OD Fan Supply Pwr Max Fuse Size Vol EE Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each Motor Outlet Amps Size RLA LRA MCC FLA FLA FLA Model kW Stages Amps __ Amps 3 175 200 3 None 100 150 08 3 60 22 4 None __ 1500 150 150 150 149 P 30 3 60 22 4 149 J25 T 7 200 150 175 205 pool ho EE JB D 70 19 100 Ese 360 2 433 666 70 30 170 1 5 mo ee E 56 50 8 60 20 0 150 25 460 3 60 10 6 70 30 EN zu 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC J25ZJ Low Static Drive With Powered Convenience Outlet OD Fan Supply Pwr Max Fuse Size Vol dd Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each Motor Outlet Amps Size FLA FLA Model KW Stages Amps Amps None gt gt 1400 150 08 3 60 22 4 150 149 J25 205 None _ le 7 70 10 0 so 50 90 200 10 0 150 200 25 460 3 60 10 6 200 1 Minimum Circuit Ampacity None 1400 150 150 35 0 37 200 100 150 2 Dual Element Time Delay Type 175 3 HACR type per NEC 2
5. NL il lin 7 LY y II d HT LL III ANN p II 9p LL LL dl Bh ul lin III ANN TABLE OF CONTENTS A AA 2 Al BANC Crs A LOER SEED OE Dacis NG 43 ELE e o oo cd oe EP ene me DERE ED ORDE SR DOE GEE 5 Sn OE ON EE FEE EO 45 Mc E TT IT S Cooling Sequence Of Operation 45 EOGHUBE PAA AE T No Outdoor Air Options 45 Rigging And Handling 7 Cooling Operation Errors oooooooooooo 46 DUGBNDE s hara dE Fax E RE He ot om I AR ER 12 Electric Heating Sequence Of Operations 48 Condensate Drain 19 Electric Heat Operation Errors 48 Compressors LL 13 Gas Heating Sequence Of Operations 49 FIEIS METER IE EE PO PETE 13 Gas Heating Operation Errors 50 Power And Control WirinQ 14 Start Up Cooling oo 51 Optional Electric Heat oo oooooooooo 26 Start Up Gas Heal 1 nananana AUR CUR to ae e d 51 Optional Gas Heat xk x Ey ee we REP RR KNA 27 Checking Gas Heat Input oooooooooo 52 Options Accessories llle 29 Charging The UN uuu ire acies an eoo C mox 54 Economizer And Power Exhaust Set Point Adjustments 29 Troubleshooting llle 55 Optional BAS Ready Economizer Power Exhaust Unit Control Board Option Setup 62 Damper Set Point Adjustment 30 Option Byte SelUD us a6 tpa Ct era 62
6. e The display of the AC drive should default to the motor speed rpm when running 3 6 DURAPULse AC Drive User Manual IstEd Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart A A Parameter Setup In order to meet the needs of this application the parameters should be set as follows BuU Motor Nameplate Voltage Setting 460 Range 230V series 200 208 220 230 240 Default Setting 240 460V series 380 400 415 440 460 480 Default Setting 480 This parameter setting is determined by the motor nameplate XX Motor Nameplate Amps Setting 2 6 Range Drive Rated Amps x 1 to Default Setting Drive Rating A Drive Rated Amps x 1 0 This parameter setting is determined by the motor nameplate Motor Base Frequency Setting 60 Range 50 60 400 Default Setting 60 This parameter setting is determined by the motor nameplate NE Motor Base RPM Setting 1725 Range 375 to 24 000 RPM Default Setting 1750 This parameter setting is determined by the motor nameplate RS Motor Maximum RPM Setting 2000 Range P0 03 to 24 000 RPM Default Setting P0 03 This parameter setting is determined by the needs of the application WARNING The Motor Maximum RPM parameter P0 04 should never exceed the maximum RPM rating for the motor that you are using If this information is not readily available consult your motor manufacturer 2WI Stop Methods Setting 00 Range 00 Ramp to Stop Default Setting 00 01 Co
7. Ductwork Ductwork should be designed and sized according to the methods in Manual D of the Air Conditioning Contractors of America ACCA or as recommended by any other recognized authority such as ASHRAE or SMACNA A closed return duct system should be used This will 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 CFM 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 Figure 5 for bottom air duct openings Refer to Figure 6 for side air duct openings NOTE It is recommended that in Canada the outlet duct be provided with a removable access panel It is recommended that this opening be accessible when the unit is installed in service and of a size such that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger The cover should be attached ina manner adequate to prevent leakage Fixed Outdoor Air Intake Damper This damper is shipped inside the return air compartment It is completely assembled and ready for installation A damper baffle inside of the hood is adjustable to provide variable amounts of outdoor air intake on units that are not provided with an economizer or a motorized damper opti
8. Temperature Limit If the UCB senses zero volts from the high temperature limit the indoor blower motor is immediately energized This limit is monitored regardless of unit operation status i e the limit is monitored at all times If the temperature limit opens three times within one hour it will lock on the indoor blower motor and a flash code is initiated See Table 25 Safety Controls The UCB monitors the temperature limit switch of electric heat units The control circuit includes the following safety controls Temperature Limit Switch TLs 1 Temperature Limit Switch TLS 1 2 This control is located inside the heater compartment and is set to open at the temperature indicated in the Limit Control Setting Table 20 It resets automatically The limit switch operates when a high temperature condition caused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower 2 Temperature Limit Switch TLS 3 4 5 and 6 This control is located inside the heater compartment and is set to open at the temperature indicated in the Limit Control Setting Table 20 It is a manual reset limit These limit switches will de energize the heaters should the primary limit fail to open or the contactors fail to open in a failure mode Table 20 Limit Control Setting Temperature Temperature Unit Voltage Limit Switch Limit Switch Tons 1 2 3 4 5 6 Opens F Opens T 170 e lea 170 170
9. 1182 7 98 1198 8 48 1215 9 03 1233 9 61 1252 10 23 1272 10 89 1292 11 58 1313 12 32 1334 13 09 1356 13 89 1379 14 73 1402 15 60 16 15 1425 16 51 17 09 3 High Static 15 HP amp Drive 1221 1238 1255 1273 1292 1311 1332 1352 1374 1396 1418 1441 1465 8 33 8 84 9 38 9 97 10 59 11 24 11 94 12 67 13 44 14 25 15 08 15 96 16 87 SANG 8 dH OL P4EpuelsS 3 2 1263 1280 1297 1315 1334 1353 1373 1394 1416 1438 1460 1483 1507 15 HP 4 Field Supplied Drive 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table 8 68 9 19 9 74 10 32 10 94 11 60 12 29 13 02 13 79 14 60 15 44 16 31 17 22 3 4 BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1307 1324 1341 1359 1378 1397 1418 1438 1460 1482 1504 1528 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 82 42 Johnson Controls Unitary Products 860261 JIM B 0612 Table 17 RPM Selection Size Model HP Max Motor Blower 6 Turns 5Turns 4 Turns 3Turns 2Turns 1 Turn Fully Tons BHP Sheave Sheave Open Open Open Open Open Open Closed J15 ZJ 5 5 75 1VP65 BK110 815 850 885 920 950 985 N A 15 5 5 75 1VP65 BK090 1010 1055 1095 1135 1180 1220 N A J18 7 5 5 75 1VP60 BK110 730 765 800 835 870 905 N A 17 5 7 5 8 63 1VP60 BKO9O 905 950 990 1035 1075 1120 N A J20 ZJ 5 5 75 1VP60 BK110 730 765 800 835 870 905 N
10. 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual mM AVERTISSEMENT y Nous vous remercions d avoir achet l quipement d automatisation de Automationdirect com en faisant des affaires comme AutomationD irect Nous tenons a ce que votre nouvel quipement d automatisation fonctionne en toute s curit Toute personne qui installe ou utilise cet quipement doit lire la pr sente publication et toutes les autres publications pertinentes avant de l installer ou de l utiliser Afin de r duire au minimum le risque d ventuels probl mes de s curit vous devez respecter tous les codes locaux et nationaux applicables r gissant l installation et le fonctionnement de votre quipement Ces codes diff rent d une r gion l autre et habituellement voluent au fil du temps Il vous incombe de d terminer les codes respecter et de vous assurer que l quipement l installation et le fonctionnement sont conformes aux exigences de la version la plus r cente de ces codes Vous devez tout le moins respecter toutes les sections applicables du Code national de pr vention des incendies du Code national de l lectricit et des codes de la National Electrical M anufacturer s Association N EM A Des organismes de r glementation ou des services gouvernementaux locaux peuvent galement vous aider d terminer les codes ainsi que les normes respecter pour assurer une installation et un fonctionnement s rs L omission de res
11. 37 144 a 46030 9 6 70 150 19 72 575 360 74 53 115 15 ss Johnson Controls Unitary Products Max Fuse Breaker Size Amps 90 90 125 175 200 90 90 150 175 225 45 45 70 90 110 J15 thru 25 ZJ Standard Drive Without Powered Convenience Outlet Continued OD Fan Size Volt UE Motors Tons each RLA LRA MCC FLA FLA aai P30 3 60 22 4 149 3 7 J25 25 460 3 60 10 6 75 1 9 aaja 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC Johnson Controls Unitary Products Supply Blower A Pwr Conv Outlet Electric Heat Option MCA Amps Model kW Stages Amps None gt 1884 moi RE A EI None e 668 EE ER ers 180 1 173 497 Ee 360 2 346 562 E 540 2 520 648 er 720 2 893 22 Max Fuse Breaker Size Amps 150 150 150 200 200 150 150 150 175 225 860261 JIM B 0612 17 860261 JIM B 0612 J15 thru 25 ZJ Standard Drive With Powered Convenience Outlet OD Fan Supply Pwr Max Fuse Size Vol Kag Sb dE Motors Blower Conv Electric Heat Option MCA Breaker Tons YO each Motor Outlet Amps Size NO O Ee Co o 5 PBA ERA Ce FIA FIA PLA Wedel S Soe Amps Amps None 901 100 mnm Em pus arse 100 154 100 180 175 200 None 888 100 100 230 3 60 1 144 100 150 175 J15
12. 60 13 91 110 150 Rating Maximum Output Voltage Three phase 380 to 480V proportional to input voltage Rated frequency 0 1 to 400 Hz Rated Voltage Frequency Three phase 380 400 415 440 460 480 50 60 Hz Rated Input Current A 39 49 60 63 90 130 Voltage Frequency Tolerance Voltage 10 Frequency 5 Short Circuit Withstand SCCR A rms symmetrical SKA 480 VAC 10 KA 480 VAC Watt Loss 100 W 620 188 1290 1420 1680 2020 2910 3840 Weight Ib kg 26 5 12 26 5 12 26 5 12 11 2 35 11 2 35 11 2 35 116 8 53 116 8 53 All 3 phase power sources must be symmetrical Do not connect DU RApulse drives to grounded center tapped delta transformers which are typically used for lighting circuits 1 8 DURAPuL se AC Drive User Manual 1st Ed Please review the AutomationD irect Terms and Conditions for this product There is no 30 day money back guarantee on any drive over 10 hp Rev D 05 2013 Chapter 1 Getting Started A General Specifications Control Characteristics Control System Pulse Width M odulation Carrier frequency 1 15 kHz adjustable depending on the model This system determines the control methods of the AC drive 00 V Hz open loop control 01 V Hz closed loop con
13. P7 06 4 67 PID Setpoint O ffset P7 05 4 67 PID Setpoint O ffset Polarity P7 04 4 67 PID Setpoint Source P7 02 4 67 Proportional Control P10 02 4 78 Proportional Control P P7 20 4 69 PV 10096 Value P7 01 4 67 PWM Carrier Frequency P2 08 4 27 Restore to D efault P9 08 4 74 Reverse O peration Inhibit P6 03 4 58 Select M ethod for 2nd Accel D ecel P1 07 4 21 Serial Comm Direction Command P9 28 4 76 Serial Comm External Fault P9 29 4 76 Serial Comm Fault Reset P9 30 4 76 Serial Comm JOG Command P9 31 4 76 Serial Comm RUN Command P9 27 4 76 Serial Comm Speed Reference P9 26 4 76 Skip Frequency 1 P1 10 4 22 Skip Frequency 2 P1 11 4 22 Skip Frequency 3 P1 12 4 22 Skip Frequency 4 P1 13 4 22 Skip Frequency 5 P1 14 4 22 Skip Frequency Band P1 17 4 22 Slip Compensation P2 01 4 25 Source of Frequency Command P4 00 4 40 Source of O peration Command P3 00 4 29 Start point for DC Injection P1 22 4 23 Stop Methods P1 00 4 18 Time Out Detection P9 04 4 74 Time Out Duration P9 05 4 74 Torque Compensation Time Constant P2 03 4 25 Transmission Speed P9 01 4 73 Trim Mode Select P4 18 4 45 Trim Reference Frequency P4 17 4 44 Upper Bound for Integral Control P7 23 4 70 Upper Bound of Output Frequency P6 15 4 63 U ser Defined Display Function P8 00 4 72 Volts H ertz Settings P2 00 4 24 Parameters Lock 4 74
14. i MEN N EN EN EN EN EN EN EE EE EE outdoor n LLL col H EN EN N ON EN EN A N 200 110 115 120 125 130 135 140 145 150 155 160 165 170 110 115 120 125 130 135 140 145 150 155 160 165 170 Suction Pressure psig 360 340 85 F 320 Outdoor Discharge Pressure psig Discharge Pressure psig Suction Pressure psig Figure 27 J15ZJ 15 Ton Charging Chart PUTE A9 202 20 TOI Cuatging Shan 25 Ton Charging Chart 530 sol akr AI Y paar 490 470 450 430 410 390 370 350 Discharge Pressure psig MEE 310 75 F Outdoor 290 270 Outdoor si LL IL ILILILLLLL 230 95 100 105 110 115 120 125 130 135 140 145 150 155 Suction Pressure psig Figure 30 J25ZJ 25 Ton Charging Chart Figure 28 J18ZJ 17 5 Ton Charging Chart Johnson Controls Unitary Products 55 860261 JIM B 0612 Troubleshooting AWARNING Troubleshooting of components may require opening the electrical control box with the power connected to the unit Use extreme care when working with live circuits Check the unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any connections with line terminals For troubleshooting of optional VFD disconnect all power to the drive Be aware that high voltages are present in the drive even after power has been disconnected Capacitors within the drive must be allowed to discharge before beginning service When not n
15. 08 PID Feedback PV 09 Frequency Setpoint The AC drive display will default to indicate O utput Current A when running For a complete list and description of the parameters for the DURAPULSE AC drives see CHAPTER 4 Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual M 3 13 Chapter 3 Keypad Operation and Quickstart Auto Tune Procedure Auto tuning is required only for Sensorless Vector Control M odes P2 10 02 03 05 very important that no load be connected to the motor output shaft at the time the j WARNING The motor will rotate when executing the auto tuning procedure It is also auto tune procedure is performed The DURAPULSE AC drive is capable of performing an auto tune procedure when a motor is connected to the AC drive lt is also very important for safety and functional reasons that no load be physically connected to the motor output shaft during auto tuning The auto tune will begin when the RUN key is pressed on the AC drive keypad To enable the Auto Tune procedure do the following Press the PRO GRAM key repeatedly until the MOTOR GROUP P0 00 P0 07 is displayed on the keypad LCD display Press the ENTER key to display the various parameters for this group Use the UP DOWN keys to display parameter P0 05 MOTOR AUTO TUNE Press the ENTER key to display the current value for this parameter Select Parameter Use the UP DOWN keys to change the value in this parameter to either a em
16. 170 Johnson Controls Unitary Products 860261 JIM B 0612 Table 20 Limit Control Setting Temperature Temperature Unit Voltage Limit Switch Limit Switch Tons 1 2 3 4 5 6 Opens F Opens F 140 200 17 5 20 540 200 and 25 200 200 170 T 170 170 170 3 15 175 35 3 20 and 25 54 120 15 17 5 20 and 25 Flash Codes The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 25 Reset Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature This resets any flash codes Electric Heat Anticipator Setpoints It is important that the anticipator setpoint be correct Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space Reducing the value below the correct setpoint will give shorter ON cycles and may result in the lowering of the temperature within the conditioned space Refer to Table 21 for the required electric heat anticipator setting Table 21 Electric Heat Anticipator Setpoint Heater Setting Amps Kw SOROR Tha E 38 0 29 54 208 230 3 60 029 29 0 58 72 E 29 0 58 18 36 029 29 0 29 54 Siasa E 29 0 29 72 E 29 0 29 18 a 29 36 E 29 0 29 54 R 029 72 029 Gas Heating Sequence Of Operations The following sequence describes the operation of the gas heat section 49 8602
17. 5 After adjusting retighten nuts A CFM Static Pressure and Power Altitude and Temperature Corrections The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 feet above sea level The air flow rates listed in the standard blower performance tables are based on standard air at sea level As the altitude or temperature increases the density of air decreases In order to use the indoor blower tables for high altitude applications certain corrections are necessary A centrifugal fan is a constant volume device This means that if the rpm remains constant the CFM delivered is the same regardless of the density of the air However since the air at high altitude is less dense less static pressure will be generated and less power will be required than a similar application at sea level Air density correction factors are shown in Table 14 and Figure 19 Johnson Controls Unitary Products Table 14 Altitude Temperature Correction Factors Air Temp o 1000 2000 40 860261 JIM B 0612 Altitude Ft 3000 4000 5000 6000 8000 9000 0 950 0729 10000 50 0715 60 0701 70 0 588 80 0 676 90 0 563 100 0 651 Sa O o LL c O da o Vv us Sa O O 60 Sea Level 1000 ft 2000 ft 3000 ft 4000 ft 5000 ft 6000 ft 7000 ft 8000 ft 9000 ft 10000 ft 70 80 Air Temperature F Figure 19 Altitude T
18. After installation gas fired units must be adjusted to obtain a temperature rise within the range specified on the unit rating plate If components are to be added to a unit to meet local codes they are to be installed at the dealer s and or customer s expense Size of unit for proposed installation should be based on heat loss heat gain calculation made according to the methods of Air Conditioning Contractors of America ACCA This furnace is not to be used for temporary heating of buildings or structures under construction A CAUTION The 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 computer rooms switchgear etc please reference applications bulletin AE 01 1 07 or call the applications department for Unitary Products 1 877 UPG SERV for guidance Additional accessories may be needed for stable operation at temperatures below 30 F 860261 JIM B 0612 Unit Control Board Slide In Plug In Internal Economizer Optional 110 Volt Convenience Outlet Powered or Non Powered Optional 2 Disposable Filters 4 Filters Optional Disconnect Location Optional Disconnect Switch WA S Bottom Power and III Control Wiring Entry
19. BAS Ready Economizer 2 10 V D C Actuator without a controller Double Wall Construction For valid combinations of the above see the equipment price pages or the Unitary Sales Tool program all combinations are not available AA None BA Hinged Filter Door 8 Tool Free Access Panels AB Phase Monitor BB Phase Monitor Hinged Filter Door amp Tool Free AC Coil Guard Access Panels AD Dirty Filter Switch BC Coil Guard Hinged Filter Door amp Tool Free AE Phase Monitor 8 Coil Guard Access Panels AF Phase Monitor 8 Dirty Filter Switch BD Dirty Filter Switch Hinged Filter Door amp AG Coil Guard amp Dirty Filter Switch Tool Free Access Panels AH Phase Monitor Coil Guard amp Dirty Filter Switch BE Phase Monitor amp Coil Guard Hinged Filter RC Coil Guard amp American Flag Door 8 Tool Free Access Panels TA Technicoat Condenser Coil BF Phase Monitor amp Dirty Filter Switch Hinged TJ Technicoat Evaporator Coil Filter Door amp Tool Free Access Panels TS Technicoat Evaporator amp Condenser Coils BG Coil Guard amp Dirty Filter Switch Hinged Filter EA ElectroFin Condenser Coil Door amp Tool Free Access Panels EJ ElectroFin Evaporator Coil BH Phase Monitor Coil Guard 8 Dirty Filter Switch ES ElectroFin Cond 8 Evap Coils Hinged Filter Door 4 Tool Free Access Panels ZZ If desired option combination is not listed above ZZ will be assigned and configuration options will be l
20. Codes p LED 16 LED 8 LED 4 Led 2 LED 1 ig dd rFas T T 3 Pres GowolwingASOO eg On fa 3 Flashes HPSiCompessrlokou Of Of Of On on Flashes HPS2 Compressor Lockout Of Of On Of o 5 Flashes On 6 Flashes OF 7 Flashes On 8 Flashes Of 9 Flashes Of On 10 Flashes Compressors Locked Out on Low Outdoor Ar Temperature Flashing On off On Of TT ashes Compressore locked oul because e Economizerisusingiies o Fashing on OM on on T2Flashes Uni Locked Out due to Fan Overload Smich Faire H n on or o 13 Flashes On 14 Flashes Of 15 Flashes HPS Compressor Lockout of On On On On 16 Flashes HPS4CompressorLockout n Of Of Of Of 17 Flashes LPS3 Compressor Lockout On Of Of Of On 18 Flashes LPS4 Compressor Lockout On Of Of On Off 19 Flashes FS3 Compressor Lockout On Of Of On On 20 Flashes FS4 Compressor Lockout On Of On Of Off 21 Flashes Compressor Off due to Low SAT On OFF No Power or Control Failure Off 1 Non alarm conditions TEST OPTION 5 RESET SETUPS Check ia o m Hi c Alarm gt sera History E Pi VESTITI EL aan y 131194 3 do Reset All ASCDs ory B Um j 72 NG s ibn For One Cycle i DOWN Dis STORE D 67 TA M 8 dm Rocks wm OPTION BYTE AT ENI START D self HN oe 4 H Se Ee
21. Condenser coils must have an unlimited supply of air Code ANSI Z223 1 Latest Edition in U S A or Sections 7 2 Where a choice of location is possible position the uniton 7 3 or 7 4 of Gas Installation Codes CSA B149 1 in Canada either north or east side of building Latest Edition and or applicable provisions of the local building Suitable for mounting on roof curb codes Refer to Table 6 for clearances required for combustible construction servicing and proper unit operation For ground level installation use a level concrete slab with a minimum thickness of 4 inches The length and width should be at least 6 inches greater than the unit base rails Do not tie slab to the building foundation AWARNING 5 Roof structures must be able to support the weight of the Do not permit overhanging structures or shrubs to unit and its options accessories Unit must be installed on a obstruct condenser air discharge outlet combustion air solid level roof curb or appropriate angle iron frame inlet or vent outlets 6 Maintain level tolerance to 1 2 across the entire width and length of unit Rigging And Handling Exercise care when moving the unit Do not remove any AWARNING packaging until the unit is near the place of installation 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 across the
22. Left 24 W O Economizer 49 W Economizer 36 W Economizer 3 1 Units must be installed outdoors Over hanging structure or shrubs should not obscure condenser air discharge outlet 2 Units may be installed on combustable floors made from wood or class A B or C roof covering materials 3 If economizer is factory installed the unassembled rain hood must be removed from its ride along position in front of the evaporator coil or in the outdoor air compartment prior to final installation Note ELEC ELEC Models Units and ductwork are approved for zero clearance to combustible material when equipped with electric heaters GAS ELEC Models A 1 clearance must be provided between any combustible material and the supply air ductwork for a distance of 3 feet from the unit The products of combustion must not be allowed to accumulate within a confined space and recirculate Locate unit so that the vent air outlet hood is at least Three 3 feet above any force air inlet located within 10 horizontal feet excluding those integral to the unit Four 4 feet below four horizontal feet from or one foot above any door or gravity air inlet into the building Four 4 feet from electric and gas meters regulators and relief equipment Johnson Controls Unitary Products 11 860261 JIM B 0612 SUPPLY AIR BACK OF UNIT DUCT SIZES Supply Air 22 1 2 x 35 5 8 Return Air 32 7 8 x 35 5 8 Figure 8 J15 thru 25 ZJ Roof Curb
23. Main Circuit Wiring Main Circuit Terminals Description Input Power AC Drive O utput Braking Resistor Connection Under 20H P External Dynamic Brake Unit 20HP O ver Ground Main Circuit Wiring Specifications Terminal AC Drive nti Wire Range Tightening Model A AWG Torque kgf cm GS3 21PO B GS3 22P0 7 GS3 23P0 10 GS3 25P0 17 GS3 27P5 25 GS3 2010 33 GS3 2015 49 GS3 2020 65 GS3 2025 75 GS3 2030 90 GS3 2040 120 GS3 2050 145 GS3 41P0 2 7 GS3 42P0 4 2 GS3 43P0 55 GS3 45P0 8 5 GS3 47P5 13 GS3 4010 18 GS3 4015 24 GS3 4020 32 GS3 4025 38 GS3 4030 45 GS3 4040 60 GS3 4050 73 GS3 4060 91 GS3 4075 110 GS3 4100 150 18 2 0 3 0 2 0 3 0 Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 17 Chapter 2 Installation and Wiring Power Wiring Diagrams Drives under 20hp E U sers must connect wiring according to the circuit diagram shown below Braking resistor optional JUMPER A 1 BR F Power Source F B1 B2 200 240V 10 OVO 000 SOLI T1 DURAPULSE AC Motor 50 60Hz 5 000 H 380 480V 10 V EE G S3 XXXX le 50 60Hz 5 Na 500 L3 T3 Use any two of L1 L2 L3 for 230V 1 phase models Motor grounding O Note Grounding terminals O terminal are internally connected Grounding resistance less than 0 1
24. On 30 On of of Of 30 18 Of on On on 30 90 of on On Of 30 60 of On Of On 30 3 of on of o o 6 of of on On o 30 of of On of o to or of of o Non std Non std Of Off Off Off Optional VAV Control Board Flash Codes Flash codes are also utilized by the VAV add on board to aid in troubleshooting optional VAV applications Flash codes are displayed by a red LED located near the center of the board using a short on off cycle approximately 200 ms on and 200 ms off To verify that the board is functioning correctly the LED will display a repetitive 1 second on 1 second off heartbeat Do not confuse this heartbeat with the error flash codes shown in the table below To prevent confusion a 1 flash flash code is not used Table 27 VAV Control Board Flash Codes FLASH CODE On Steady 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes 9 Flashes 10 Flashes 11 Flashes 12 Flashes 13 Flashes 14 Flashes 15 Flashes OFF Johnson Controls Unitary Products 5005 York Drive Norman OK 73069 DESCRIPTION Control Failure Not Applicable Loss of Communication with UCB Space Sensor Failure SAT Sensor Failure RAT Sensor Failure OAT Sensor Failure OH Sensor Failure RH Sensor Failure IAQ Sensor Failure OAQ Sensor Failure APS Sensor Failure Limit 2 Switch Open Purge VFD Input Failure Dirty Fil
25. Place assembly B into rough in box A Secure with six screws C WIRING INSTRUCTIONS REF Diagrams WD1 WD2 WD3 WDA Field Conversion for Lower Wattage All units are factory wired for higher wattage rating See paragraph 9 for conversion to lower wattage rating B Bring service leads through knockout K on top or bottom of rough in box for flush or semi recessed mounting bottom knockout K only for surface mounting When wiring from the bottom install wire through cover G by removing screw H C Attach service leads to two black leads on 208 240 volt models and to black and white leads on 120 277 volt models attach ground lead to green wire with approved connectors Comply with all national and local codes Attach wiring compartment cover D to assembly with screw C DA FINAL STEPS Clean all construction dirt and debris from inside heater Attach front grille F with four screws L A parts bag containing DES O the cover screws and the thermostat knob is located inside of heater Attach thermostat knob T OPERATING INSTRUCTIONS Turn on power at the circuit breaker panel If there are two controls on the front grille of the heater the one on your left T is the thermostat control and should be set to the position to give the desired comfort heat in the room The switch on your right is the mode selection switch Two modes of heating operation are available CONSTANT Fan runs contin
26. Storage Conditions The AC drives should be kept in their shipping cartons or crates until they are installed In order to retain their warranty coverage they should be stored as described below if they are not to be installed and used within three months e Store in a clean and dry location free from direct sunlight and corrosive fumes e For storage of longer than 3 months store within an ambient temperature range of 20 C to 30 C 4 F to 86 F e For storage of 3 months or less store within an ambient temperature range of 20 C to 60 C 4 F to 140 F e Store within a relative humidity range of 0 to 90 and non condensing environment e Store within an air pressure range of 86 kPA to 106 kPA DO NOT store in an area with rapid changes in temperature It may cause condensation and frost DO NOT place directly on the ground If the drive is stored or is otherwise unused for more than a year the drive s internal DC ae link capacitors should be recharged before use Otherwise the capacitors may be damaged when the drive starts to operate We recommend recharging the capacitors of any unused drive at least once per year Refer to Chapter 6 Maintenance and Troubleshooting for information about recharging DC link capacitors 2 2 DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring Installation Install the AC drive in an enclosure that is specifically design
27. TBD TBD TBD TBD TBD TBD 8800 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 7 5 HP amp Field Supplied Drive 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 838 40 Johnson Controls Unitary Products J20ZJ 20 Ton Bottom Duct Air Flow CFM 5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600 0 4 0 6 0 8 RPM BHP RPM BHP RPM BHP Standard 5 HP amp Field Supplied Drive 694 1 43 713 1 82 Available External Static Pressure IWG 1 0 1 2 1 4 1 6 1 8 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP 4 Drive 2 0 RPM BHP RPM BHP RPM BHP 968 987 1008 1031 1055 1081 1108 1136 1166 High Static 7 5 HP 8 Drive 4 14 4 53 4 96 5 42 5 94 6 49 7 09 7 74 8 43 2 2 997 1017 1038 1060 1085 1110 1137 1166 1195 4 28 4 67 5 09 5 56 6 07 6 63 1 23 7 87 8 56 860261 JIM B 0612 2 4 1025 1045 1066 1088 1112 1138 1165 1194 7 5 HP 8 Field Supplied Drive 4 35 4 74 5 17 5 64 6 15 6 70 7 30 7 95 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x
28. 0 838 Johnson Controls Unitary Products 2 6 RPM BHP 41 860261 JIM B 0612 J25ZJ 25 Ton Bottom Duct Available External Static Pressure IWG Air Flow CFM 0 4 0 6 0 8 1 0 1 2 1 4 1 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Low Static 7 5 HP 8 Field Low Static 7 5 HP 8 Drive Supplied Drive 6600 787 2 67 819 3 23 850 3 76 881 4 27 912 4 75 943 5 21 974 5 65 7000 804 3 18 835 3 74 867 4 27 898 4 78 928 5 26 959 5 72 991 6 16 7400 853 4 28 884 4 82 915 5 32 946 5 80 977 6 26 1008 6 70 7800 6 85 1026 7 28 8200 1045 7 90 8600 1064 8 56 9000 1084 9 26 9400 1105 9 99 9800 1127 10 76 10200 994 9 14 1149 11 56 10600 1016 9 98 1109 11 51 1140 11 96 1171 12 40 11000 1039 10 86 1101 11 90 1132 12 38 1163 12 84 1194 13 28 11400 1063 11 76 1094 12 30 1125 12 80 1156 13 29 1187 13 75 1218 14 18 11800 1055 12 14 1087 12 70 1118 13 24 1149 13 74 1180 14 23 1211 14 69 1242 15 12 12200 1080 13 11 1111 13 68 1142 14 21 1173 14 72 1204 15 20 1235 15 66 1266 16 10 12600 1104 14 12 1136 14 68 1167 15 21 1198 15 72 1229 16 20 1260 16 66 1291 17 10 High Static 15 HP amp Drive Air Flow Available External Static Pressure IWG CFM 1 8 2 0 2 2 2 4 2 6 2 8 3 0 RPM BHP RPM BHP RPM BHP RPM Standard 10 HP amp Drive 6600 7000 7400 7800 8200 8600 9000 9400 9800 10200 10600 11000 11400 11800 12200 12600 for additional applications 1387 1411
29. 1 Altitude is 5 1 000m and lt 3 000m 1 altitude 1 000m x 0 0001 Altitude Result Multiply overload result x altitude entry Ambient Temperature C M aximum enclosure internal 1 temperature M EIT is 40 C 40 C MEIT lt 50 and 1 G51 2 AC drive up to 5hp 40 C MEIT lt 50 and GS1 2 AC drive gt 5hp or DURApuLSE AC drive Required Drive FLA Multiply altitude result x M EIT entry l 4 DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 1 Getting Started Model Number Explanation GS3 2 020 Lg Applicable Motor Capacity 1P0 1hp 5P0 5hp 015 15 hp 030 30 hp 060 60 hp Input Voltage 2 200 240VAC 4 380 480VAC Series Name Nameplate Information AC Drive Model gt Input Specification Output Specification Output Frequency Range 9 Serial Number Drive Package Contents 2P0 2hp 3P0 3hp 7P5 7 5 hp 010 10 hp 020 20 hp 025 25 hp 040 40 hp 050 50 hp 075 75 hp 100 100 hp 60 75 and 100HP models available in GS3 4xxx only MODEL GS3 2020 INPUT 200 240V 50 60Hz 3PH 80 Amps o OUTPUT 0 240V 20HP 65Amps 24 7KVA 3PH LISTED FREQUENCY RANGE 0 1 400Hz NALANG Ha GS3 2020 T331001 Automationdirect com Inc CE After receiving the AC motor drive please check for the following e Make sure that the package includes an AC drive the DURAPuLsE AC Dri
30. 110 None 151 60 60 6 36 5 60 70 90 EN 24 Johnson Controls Unitary Products Table 9 J15 thru 25 ZJ Physical Data Component Nominal Tonnage AHRI COOLING PERFORMANCE Gross Capacity AHRI A point Btu AHRI net capacity Btu EER SEER IEER Nominal CFM System power KW Refrigerant type Refrigerant charge Ib oz System 1 System 2 System 3 System 4 AHRI HEATING PERFORMANCE Heating model Heat input K Btu Heat output K Btu AFUE Steady state efficiency No burners No stages Temperature Rise Range F Gas Limit Setting F Gas piping connection in DIMENSIONS inches Length Width Height OPERATING WT Ibs COMPRESSORS Type Quantity Unit Capacity Steps 96 CONDENSER COIL DATA Face area Sq Ft Hows Fins per inch Tube diameter in Circuitry Type EVAPORATOR COIL DATA Face area Sq Ft Hows Fins per inch Tube diameter Circuitry Type Refrigerant control Johnson Controls Unitary Products Models ds ars 2 o HfEOO Hi TBD L4 ff BD EE i TBD TBD pu TED TED TED Do Ui AT MS TBD TBD 400 TBD 320 TBD 240 sia A BD 1 ow 80 80 TBD TBD 80 80 6 8 D TBD 6 8 TBD TBD TBD TBD TBD o CH FT 180 19 32 92 52 5 8 io 0f 217 Fi i TBD TBD LO O od TBD 3 8 TBD 3 8 po Rc TBD TBD 3 8 TBD 3 8 TXV TBD TXV N 00 N NM 860261 JIM B 0612 J25ZJ 25 290000 280000 10 5 10
31. 1193 4 34 1186 4 53 1223 4 83 1218 5 02 1255 5 36 1251 5 55 1289 5 HP amp Field Supplied Drive BHP 3 48 3 85 4 26 4 71 5 20 5 73 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 898 J18ZJ 17 5 Ton Side Duct Air Flow CFM 0 4 0 6 0 8 RPM BHP RPM BHP RPM BHP Standard 5 HP 8 Field Supplied Drive 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 TBD TBD 1 0 RPM BHP Available External Static Pressure IWG 1 2 1 4 1 6 RPM BHP RPM BHP RPM BHP Standard 5 HP 8 Drive 1 8 RPM BHP 2 0 2 2 2 4 BHP RPM BHP RPM BHP RPM BHP RPM TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD High Static 7 5 HP amp Drive TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 2 6 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 7 5 HP 8 Field Supplied Drive 1 Blower performance includes gas heat exchangers and 2 filters See STATIC
32. 12 310 8 for model numbers rated dual wattage 240 208 1500 1125 6 2 5 4 e 240 208 4000 3000 16 7 14 4 240 208 2000 1500 8 3 7 2 RED JUMPER RED JUMPER ELEMENT Pa ELEMENT A O o fi ms o GND q GND 120 277V WHITE 120 277V WHITE 3 208 240V BLACK THERMAL 208 240V BLACK dira Ob ruermostat PROTECTOR O gt O gt AIL AIL LINE LINE oe O 0 8 O gt O gt BLACK DISCONNECT BLACK z THERMOSTAT DISCONNECT Fi OPTIONAL OPTIONAL RED JUMPER ELEMENT RED JUMPER a ELEMENT ra ka A T o 277V WHITE x 120 277V WHITE oO 3 t AE TOR OY THERMOSTAT pa N E LINE LINE Oo Lo O gt O gt WD 3 THERMOSTAT OPTIONAL WD 4 OPTIONAL WD 1 3310 with Summer Fan Switch Double Pole T Stat and Optional Disconnect Switch WD 2 3310 with Summer Fan Switch Single Pole T Stat and Optional Disconnect Switch WD 3 3310 with Optional Double Pole T Stat and Disconne
33. 2 13 Main Circuit Wiring RR RI RI 2 17 Power Wiring Diagrams ros 2 18 Control Terminal Designations ce eee 2 20 Control Wiring Diagram Sinking Inputs 2 21 Control Wiring Diagram Sourcing Inputs 2 22 External Accessorles nns 2 23 Chapter 3 Keypad Operation and Quickstart 3 1 The DURAPuLsE Digital Keypad elles 3 2 ODDIO Lese m esq ac EE EE EE EE a 3 2 LED pelle io o eee eee een dee eee ees bss 3 2 Function KEYS LL 3 3 Displaying the Status of the DURAPuLseE AC Drive 3 4 Programming the DURAPULSE AC Drive LL 3 5 DURAPULSE Quickstart m mee 3 6 Example 1 Constant torque e g conveyors compressors etc 3 6 Example 2 Variable torque e g fans centrifugal pumps etc 3 10 Auto Tune Procedure 3 14 Copy Keypad Function LL 3 16 Enable Copy Keypad Function LL 3 16 Write Parameter Settings to Keypad 3 17 Write Parameter Settings to Dre a 3 18 C 2 DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 Table of Contents ees Chapter 4 AC Drive Parameters 4 1 DURAPULSE Parameter Summary leen 4 2 Parameters available only in later firmware versions Of DURAPULSE AC drives RR RR 4 2 Detailed Parameter Listings lle 4 15 Motor Parameters 0 0 RR e e Rh 4 15 Ramp Parameters sls rrr 4 18 Volts Hertz Parameters
34. 3 Make sure that the pilot burner is not bent or damaged Make sure that the ground connections at the pilot burner gas valve and ignitor control are intact Check the high tension wire for good electrical connection If all are intact replace the ignitor module The pilot burner lights and the spark stops but the main burners do not light 1 Check electrical connections between the ignitor control and the gas valve lf intact check for 24 volts across terminals MV and COMMON terminals If no voltage detected replace ignitor control If voltage is present replace gas valve Furnace lights with roll out or one burner has delayed ignition 1 Make sure that the pilot burner is aligned properly with the carryover as described in PILOT CHECKOUT page 54 2 Make sure that the carryovers on adjoining burners are screwed fast and are level with respect to one another Main burners light but exhibit erratic flame characteristics 1 Adjust air shutters as described in BURNER AIR SHUTTER ADJUSTMENT page 54 Johnson Controls Unitary Products 860261 JIM B 0612 2 Check the main burner orifices for obstruction and alignment Removal procedure is described in BURNER INSTRUCTIONS page 54 Clean or replace burner orifices and burners as needed Unit Control Board Flash Codes Various flash codes are utilized by the unit control board UCB to aid in troubleshooting Flash codes are distinguished by the shor
35. 8 to size power wiring fuses and disconnect switch Power wiring is brought into the unit through the side of the unit or the basepan inside the curb FACTORY OR FIELD SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY Figure 11 Field Wiring Disconnect Cooling Unit With Without Electric Heat 14 Johnson Controls Unitary Products Thermostat Wiring The thermostat should be located on an inside wall approximately 56 inch above the floor where it will not be subject to drafts sun exposure or heat from electrical fixtures or appliances Follow the manufacturer s instructions enclosed with thermostat for general installation procedure Seven 7 color coded insulated wires should be used to connect the thermostat to the unit Refer to Table 7 for control wire sizing and maximum length CONTROL THERMOSTAT TERMINAL TERMINALS BLOCK 860261 JIM B 0612 Space Sensor The space sensor if used should be located on an inside wall approximately 56 inches above the floor where it will not be subject to drafts sun exposure or heat from electrical fixtures or appliances Follow manufacturer s instructions enclosed with sensor for general installation procedure Table 7 Control Wire Sizes Wire Size Maximum Length 18 AWG 150 Feet 1 From the unit to the thermostat and back to the unit A CAUTION 208 230 3 60 and 380 41 5 3 50 units control transformers are factory wired for 230v and 415v power supply respectively C
36. A 20 7 5 8 63 1VP60 BK090 905 950 990 1035 1075 1120 N A 7 5 8 63 1VP60 1B5V94 810 850 885 920 960 1000 N A ZJ 10 11 50 1VP75X 1B5V110 975 1005 1040 1070 1100 1135 1165 15 17 25 1VP75X 1B5V94 1140 1180 1215 1255 1290 1330 1365 Table 18 Indoor Blower Specifications Motor Sheave Blower Sheave TTT Tons EE EG T TB 1725 1841 52 64 11 8 1VP65 i o BRITO BX83 15 5 s ter 52 64 118 tres 64 1 BKoeo exe BX78 BX75 JE BX78 ERE BX75 s a Pa BX78 5VX840 ses os IS 2947 82 74 88 ivex os 4716 gevee 5vx680 Table 19 Power Exhaust Specifications a 17 5 CFM Voltage 0 1 ESP 208 230 1 60 1075 5250 460 1 60 5250 575 1 60 5250 1 Motors are multi tapped and factory wired for high speed Air Balance To check the supply air CFM after the initial balancing has been completed 1 Remove the two 5 16 dot plugs from the blower motor and A CAUTION the filter access panels shown in the Unit Dimensions and Rear View Clearances Figure 6 On VAV units be certain that the VFD drive is set to 2 Insert at least 8 of 1 4 inch tubing into each of these holes maximum output exhaust dampers are closed and for sufficient penetration into the air flow on both sides of individual space damper boxes are full open the indoor coil VFD units with bypass must not be in bypass mode LINE position unless all individual space dampers are NOTE The tubes must be inserted and held in a position perp
37. Adjust PID Setpoint The ability to adjust the PID setpoint with the UP and DOWN keys will be true if parameter P7 00 is set to a value of 01 02 03 or 04 parameter P7 02 00 and the LCD display shows the PID setpoint Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 3 3 Chapter 3 Keypad Operation and Quickstart Displaying the Status of the DURAPULSE AC Drive Press the DISPLAY key on the keypad repeatedly to cycle through the status messages on the AC drive The diagram below shows the order of the status messages as you cycle through them and shows the definition of the status messages The status of the AC drive can be shown in RUN or STOP mode T Actual O perating Frequency Displays the actual operating frequency present at the T1 T2 and T3 terminals Example 60 0H z Output Frequency 60 0 Hz 01 RPM Displays the present estimated speed of the motor Example 1750 RPM Motor Speed 1750RPM Scaled Frequency Displays the result of output frequency x parameter P8 01 Example 60Hz x 1 5 90 0 Scaled Frequency Displays the output current present at the T1 T2 and T3 terminals Example 0 9A Output Current 0 3 AMP Q5 Motor Load Displays the amount of load on the AC drive Motor Load Example O utput Current Drive Rated Current x 100 18 0 96 Output Voltage Displays the output voltage present at the T1 T2 and T3 em Output Voltage terminals Example 465V 4
38. Adjusting screw located on the damper control module counterclockwise until the desired minimum damper position has been attained Enthalpy Set Point Adjustment e The enthalpy set point may now be set by selecting the desired set point shown in the Enthalpy Set Point Adjustment Figure 16 Adjust as follows e For a single enthalpy operation carefully turn the set point adjusting screw found on the damper control 29 860261 JIM B 0612 module to the A B C or D setting corresponding to the lettered curve of the Enthalpy Set Point Adjustment Figure 17 For a dual enthalpy operation carefully turn the set point adjusting screw fully clockwise past the D setting Power Exhaust Damper Set Point With power exhaust option each building pressurization 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 AQ 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 set point the actuator is allowed to modulate normally in accordance with the enthalpy and mixed air sensor inputs When the AQ signal exceeds it s set point setting and th
39. BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard SHE RIO Standard 5 HP amp Drive High Static 7 5 HP amp Drive Supplied Drive 6400 719 255 933 4 98 966 5 24 998 545 1028 5 59 1056 5 67 11083 5 68 6800 742 3 02 955 5 46 988 5 72 1020 5 92 1050 6 07 1078 6 15 1105 6 16 7200 765 39 54 979 5 98 1012 6 24 1044 6 44 10 4 6 59 1102 6 67 1129 6 68 7600 790 4 11 1004 6 55 1037 6 81 1069 7 01 1099 7 16 1127 7 24 1154 7 25 7 5 HP 8 Field Supplied Drive Table X RPM Selection Size Model HP Max Motor Blower 6 Turns 5Turns d Turns 3Turns 2 Turns 1 Turn Fully Tons BHP Sheave Sheave Open Open Open Open Open Open Closed X Y 5 5 75 1VP60 BK110 730 765 800 835 870 905 N A 7 5 8 63 1VP60 BKO9O 905 950 990 1035 1075 1120 N A 36 Johnson Controls Unitary Products Table 15 Air Flow Performance Side Duct Application J15ZJ 15 Ton Side Duct Air Flow CFM 0 4 0 6 0 8 RPM BHP RPM BHP RPM BHP Standard 5 HP 8 Field Supplied Drive 4000 4400 4800 5200 5600 6000 6400 6800 7200 1025 5 53 1 0 RPM BHP Available External Static Pressure IWG 1 2 1 4 1 6 RPM BHP RPM BHP RPM BHP Standard 5 HP 4 Drive 1 8 RPM 1020 1046 1074 1105 1137 1170 1205 BHP RPM BHP RPM BHP RPM 2 93 3 29 3 70 4 15 4 64 5 17 5 74 860261 JIM B 0612 2 0 2 2 2 4 1061 1087 1116 1146 1178 1212 High Static 5 HP amp Drive 3 12 1101 3 30 1138 3 48 1127 3 67 1165 3 89 1155 4 08
40. CONTACT SCREWS STATIONARY CONTACTS MOLDEO COVER Na 2 RETURN SPRING x MOVABLE CONTACTS Figure 2 Check For Welded Contacts In Overload Relay This feature permits the maintenance person to check for welded contacts With power dis connected from the device disconnect the control wiring from the terminals of the relay and place a bell set or resistance measuring instrument across the relay terminals Depress and release the reset arm to insure the relay is reset In this condition there should be continu ity between the terminals Depress the white manual check operator to trip the relay In the tripped condition the circuit between the termi nals should be open indicating the contacts are operating normally Remove the bell set or resistance measuring apparatus rewire the relay terminals and reset the relay for normal operation Maintenance Coil Data Fortwo and three pole devices order Cat No 15D22G plus number in table For four and five pole devices order Cat No 15D23G plus number in table o gt a we we 04 des we 300 Line starters require virtually no corrective maintenance Preventive maintenance will assure many years of dependable on line service 1 Always remove power from device before performing any maintenance 2 Keep magnet mating surfaces free of accu mulated dirt or dust 3 DO NOT OIL OH GREASE the magnet Danna SUR Accessory Kits 4 Contacts ar
41. JIM B 0612 Nomenclature 15 25 Ton Series 20 Model Number Nomenclature J15 Z J N24 A 2 A AA 10 1 2 4 Al TEE Nominal Cooling Capacity MIA J20 20 Ton J25 25 Ton Configuration Options not required for all units These four digits will not be assigned until a quote is requested or an order placed SS Drain Pan Johnson UNT 1126 Controller N2 protocol DFS APS Johnson Commercial Controls System CCS Rtu Controller Johnson Controller Metasys FEC 2611 BACnet MS TP Protocol SAS RAS OAS DFS APS CPC Controller DFS APS Honeywell Controller DFS APS Novar Controller DFS APS Simplicity IntelliComfort II Controller Product Category Z 7 AIC Single Pkg R 410A Product Identifier J 11 01 EER A C Heat Type and Nominal Heat Capacity Simplicity IntelliComfort Il Controller w Simplicity LINC Hot Gas Bypass Standard on VAV Optional on CV Variable Air Volume VFD Variable Air Volume VFD and Manual Bypass C00 Cooling Only No field installed electric heat Gas Heat Options N24 240 MBH Output Aluminized Steel N32 320 MBH Output Aluminized Steel 24 240 MBH Output Stainless Steel 32 320 MBH Output Stainless Steel Electric Heat Options E18 18 KW E36 36 KW E54 54 KW Product Generation E72 72 KW 1 First Generation A Std Motor Additional Options B Std Motor Economizer 2 C Std Motor Economizer Power Exhaust Standard Cabinet Hinged Filter Door amp T
42. Keypad STOP is disabled 03 Operation determined by RS 485 interface Keypad STOP is enabled 04 Operation determined by RS 485 interface Keypad STOP is disabled The AC drive operation will be determined by external control terminals and the keypad stop will be disabled If parameter P3 00 00 01 or 03 enabling the keypad STOP key the drive will stop if the keypad is removed from the drive 3 8 DURAPULsE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart Wig Source of Frequency Command Setting 02 D efault 01 Settings 01 Frequency determined by digital keypad up down 02 Frequency determined by 0 to 10V input on All terminal 03 Frequency determined by 4 to 20 mA input on AI2 terminal 04 Frequency determined by 0 to 20 mA input on AI2 terminal 05 Frequency determined by RS 485 communication interface 06 Frequency determined by 10V 10V input on Al3 terminal In order to set P4 00 02 you must first change the value of P4 13 to some value other than two 02 in order to avoid the Error Duplicate Function error message P4 13 default value is 02 xA Electronic Thermal Overload Relay Setting 00 Default 00 Settings 00 Constant Torque inverter vector duty motor 01 Variable Torque fan cooled standard motor 02 Inactive This function setting 00 is the standard overload protection curve used to protect inverter vector duty motors XANI User Defined Disp
43. L i d i Con Power Ventor Motor Electric Heater Location Optional Electric Electric Units Pad a Location of VFD Optional Location of VFD Bypass Optional Copper Tube Aluminum Fin Thermal Evaporator Expansion 1 NPT Coils Valve Condensate Drain Belt Drive Blower Motor 14 Gauge Base Rails Hs with Lifting Holes Outdoor Fan 2 Outdoor Fan 1 Outdoor Fan 4 Outdoor Fan 3 Copper Tube Aluminum Fin Condenser Coils Compressor 4 Compressor 2 Compressor 1 Compressor 3 High Efficiency Scroll Compressors Figure 1 J15 thru 25 ZJ Component Location Johnson Controls Unitary Products 860261 JIM B 0612 Table 1 J15 thru 25 ZJ Unit Limitations Unit Limitations Size Tons Unit Voltage Applied Voltage Outdoor DB Temp Max F 208 230 3 60 252 125 460 3 60 432 504 125 575 3 60 540 630 125 208 230 3 60 252 125 E 460 3 60 504 125 575 3 60 540 630 125 208 230 3 60 252 125 n 460 3 60 504 125 575 3 60 540 630 125 208 230 3 60 252 125 J15 15 575 3 60 540 630 125 Location Clearances Use the following guidelines to select a suitable location for All units require particular clearances for proper operation and these units service Installer must make provisions for adequate combustion and ventilation air in accordance with section 5 3 of 1 Unit is desi d for outdoor installation only lia j i T Air for Combustion and Ventilation of the National Fuel Gas 2
44. TBD B TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD D TBD TBD TBD TBD TBD _ TBD TBD TBD TBD TBD TBD TBD S Ed A E ME TBD RENE i Pa 125 208 3 60 3 7 Ese 27 0 2 749 1312 150 E54 406 2 1127 1784 200 E72 541 2 1502 1877 200 CEE ERE 125 125 230 3 60 3 7 E36 360 2 866 1458 150 E54 540 2 1299 1674 175 J20 E72 72 0 2 1732 2107 225 20 o ul GG 70 460 3 60 1 9 E36 360 2 433 729 80 E54 540 2 650 837 90 E72 720 2 866 1054 110 mef ea E 50 50 resp seo pe er 70 E72 720 2 693 845 90 22 Johnson Controls Unitary Products 860261 JIM B 0612 J15 thru 25 ZJ High Static Drive With Powered Convenience Outlet Continued OD Fan Supply Pwr Max Fuse Size Vol kain baban ad Motors Blower Conv Electric Heat Option MCA Breaker Tons olt teach Motor Outlet Amps Size FLA Modei KW Stages Amps Amps Nans tear 200 08 3 60 22 4 149 Woo FLA 200 35 0 3 7 230 3 60 22 4 149 35 0 3 7 225 J25 250 None a 99 90 165 19 5 0 30 110 125 No 70 70 4 0 10 0 200 225 25 460 3 60 10 6 75 225 1 Minimum Circuit Ampacity FLA F None
45. TIT 1 to have the drive determine only MOTOR VOLTAGE the motor line to line resistance R1 Dim P0 06 or 2 to determine R1 P0 06 m Su and motor no load current P0 07 ALA O Press the ENTER key to accept this A 0 LY value and enable the AUTO TUNE MOTOR P AA function The LCD display will indicate MOTOR FREQUENCY with MOTOR AUTO TUNE STOP TO CAN CEL message for 3 seconds Proceed to the next page for steps to initiate the auto tune procedure D Select Parameter Group ENTER RAMPS GROUP P 100P Lee U HZ GROUP P2BO P S MOTOR P HAS ENTER O Enable Function MOTOR RUTO TLHE DISPLAY GROUP P BBB P 807 O MOTOR AUTO TUNE MOTOR RESISTANCE COMMS GROUP P aBB P 942 e 4 CY CA t da MOTOR P BE B ENC FBRCK CROUP MOTOR NO LOAD P1B BB P1B B5 nOTOR AUTO a MOTOR AUTO TUHE lt 5TOP gt TO CANCEL The MOTOR AUTO TUNE display text flashes during this step 3 14 BM DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart Do NOT set auto tuning without a motor connected to the drive Do NOT set auto tuning with any mechanical load connected to the motor output shaft It is not necessary to set up the encoder and control mode before performing the auto tuning function Auto tuning is required only for the sensorless vect
46. Technical Support By Telephone 770 844 4200 Mon Fri 9 00 a m 6 00 p m E T On the Web www automationdirect com Our technical support group is glad to work with you in answering your questions If you cannot find the solution to your particular application or if for any reason you need additional technical assistance please call technical support at 770 844 4200 We are available weekdays from 9 00 a m to 6 00 p m Eastern Time We also encourage you to visit our web site where you can find technical and non technical information about our products and our company Visit us at www automationdirect com Special Symbols I When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note W hen you see the exclamation mark icon in the left hand margin the paragraph to its immediate right will be a WARNING This information could prevent injury loss of property or even death in extreme cases 1 2 DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 1 Getting Started is DURAPULSE AC Drive Introduction Purpose of AC Drives AC drives are generally known by many different names Adjustable Frequency Drives AFD Variable Frequency Drives VFD and Inverters Drives are used primarily to vary the speed of three phase AC induction motors and they also provide non emergency start and stop control acceleration and deceleration and overload pro
47. Write EEPROM Fault Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 6 7 Chapter 6 Maintenance and Troubleshooting Warning Messages Error Name Description Rating Mismatch Data range doesn t match Group Overflow W hen the copy function is enabled P 9 40 keypad s group number data is more than the drive s No Space W hen the copy function is enabled P 9 40 EEPRO M data block in the keypad is full Delete Failure W hen the copy function is enabled P 9 40 delete EEPROM block fails No Data When the copy function is enabled P 9 40 EEPROM data block is null R1 Detect Error Failure to detect motor resistance during Auto tune procedure 1 Check to make sure the motor is connected to the drive correctly 2 Check line power to drive 3 STOP key was pressed during Auto Tune procedure No Load Error Failure to detect any motor load during Auto tune procedure 1 Check to make sure the motor is connected to the drive correctly 2 Check line power to drive 3 STOP key was pressed during Auto Tune procedure Copy Error COMMS Communications error during Copy Keypad function 1 Check connection between the keypad and drive and make sure itis not loose 2 Check communications protocol for correct settings Copy Error Data Data error during Copy Keypad function 1 Check connection between the keypad and drive and make sure it is not loo
48. air and water leakage Vav Control Board A VAV control board located in the top left corner of the control box is used to convert the pressure transducer input signal into a speed reference signal that the drive uses to control the speed of the blower motor This modulating speed reference signal is generated using an internal algorithm which continuously calculates an output value A brief description of the VAV board s VO terminals that are used follows Inputs DUCT PRES a 0 5 VDC analog input provided by a factory installed duct static pressure transducer located in the unit s control box SAT analog input provided by a factory installed 10k ohm type 3 thermistor located in the unit s supply air compartment RAT analog input provided by a factory installed 10k ohm type 3 thermistor located in the unit s return air compartment OAT analog input provided by a factory installed 10k ohm type 3 thermistor located in the outdoor air compartment or mounted within the evaporator base rail for units without the installed economizer option ST analog input provided by field installed space temperature sensor Johnson Controls Unitary Products e OH a 0 10 VDC analog input provided by a field installed outdoor air relative humidity sensor for single enthalpy economizer configuration RH a 0 10 VDC analog input provided by a field installed return air relative humidity sensor for dual enthalpy econo
49. airflow across the heating elements Single stage heating applies only to 18 KW heater all other heaters MUST use a two stage thermostat a Upon a call for heat by the thermostat the heater contactor 6M will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space Two stage heating applies to all heaters except 18 KW a Upon a call for first stage heat by the thermostat the heater contactor 6M 6M amp 7M on 72 KW 240V will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor If the second stage of heat is required heater contactor 7M will be energized Note that on the 54 KW 240V heater heater contactors 7M amp 8M will be energized and Johnson Controls Unitary Products on the 72 KW 240V heater heater contactors 8M 9M will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space NOTE All 240 amp 480V heaters are provided with manual reset backup protection limits These will de energize the heaters should the primary limit fail to open or the contactors fail to open in a failure mode Electric Heat Operation Errors
50. and return air dampers are controlled through a 2 10 VDC signal from the VAV or Intelli Comfort II control board The economizer is enabled only in Occupied or Recovery mode When the control is not powered or is in Unoccupied mode the outside air dampers will be closed When the supply fan is powered and there is no Y1 call or if free cooling is unavailable the control opens the economizer dampers to the minimum position setting Free cooling is available if the outdoor air temperature meets one of the three criteria discussed below based upon the unit s configuration Johnson Controls Unitary Products Dry Bulb The control refers to input from the Outside Air Temperature sensor and will allow free cooling when the outdoor temperature is less than both the First Stage SAT Control setpoint plus 5 F and the Economizer OAT Enable setpoint Single Enthalpy optional A field installed Outdoor Air Humidity sensor is connected to the control When the measured outdoor enthalpy is below the Outside Air Enthalpy setpoint and the outdoor temperature is less than the First Stage SAT Control setpoint plus 5 F free cooling is available Dual Enthalpy optional Both the field installed Outdoor Air Humidity and the Return Air Humidity sensors are connected to the control When the measured outdoor air enthalpy is less than the measured return air enthalpy and the outdoor temperature is less than the First Stage SAT Control setp
51. blocks are furnished in either the prelubricated sealed for life type or the greasable type depending on what was ordered The prelubricated type requires no servicing for 7 to 10 years of normal use and the greasable type are factory greased eliminating the need for greasing initially Follow the lubricating schedule recommended by the factory This practice should not supersede any safety considerations Use low pressure A CAUTION grease guns only High pressure guns tend to blow out or unseat bearing seals leaving the bearing open to collect grime dust and foreign particles LUBRICATION SCHEDULE Always follow the bearing manufacturer s recommended lubrication schedule If none is available us the following general schedule a Under average conditions where ambient temperatures do not exceed 120 F lubrication is required 1 to 2 times a year b Under dirt laden atmosphere where there is a temperature range of 120 F to 150 F lubrication is required from 3 to 6 times a year c Under extreme temperature condi tions and extremely dirty atmos pheres lubrication should be sched uled at least once or twice a month d Belt drive units maximum tempera ture should not exceed 160 F Direct driven models have temperature range stamped on motor MOTOR LUBRICATION In general standard motors are furnished with prelubricated sealed for life ball bearings which require no lubrication for 7 to 10 years of norma
52. by 18 inches wide in the ductwork to accommodate the damper Using the holes in the hood flanges as a template drill 9 64 inch diameter 26 drill holes into the ductwork and secure with the screws provided A CAUTION If outdoor air intake will not be required on units with bottom return air applications the damper assembly should still be mounted on the side return air access panel per the instructions above to insure moisture is not drawn into the unit during operation The covering over the mounting holes only need be removed Do not remove the opening cover Johnson Controls Unitary Products Side Supply Air Access Panel Damper Baffle Side Return Air O Access Panel Outd Opening Cover Gasketed Flange Rear View Figure 9 Fixed Outdoor Air Damper Condensate Drain Plumbing must conform to local codes Use a sealing compound on male pipe threads Install a condensate drain line from the one inch 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 drainage See Figure 10 Base Pan Unit Condensate Connection Figure 10 Condensate Drain Compressors The scroll compressor used in this product is specifically designed to operate with R 410A Refrigerant and cannot be interchanged 4x CAUTION This system uses R 410A Refrigerant which o
53. by the factory Some kW sizes require fuses and others do not refer to Table 10 for minimum CFM limitations and to Table 8 for electrical data Table 10 Electric Heat Minimum Supply Air Minimum Supply Air CFM Tons 39 is 9 7 5000 8 4500 4500 6000 7 8000 8000 8000 20 8000 8000 7500 e 7500 7500 26 Johnson Controls Unitary Products Optional Gas Heat These gas fired heaters have aluminized steel or optional stainless steel tubular heat exchangers with spark ignition with proven pilot Table 11 Gas Application Data Unit Input Temp Rise MBH Size Opt MBH OUPut MBH cp mos 20 50 30 60 NES 20 50 30 60 m 20 50 30 60 pe 20 50 30 60 1 On VAV units individual VAV boxes must be full open in heating mode to insure airflow falls within temperature rise range Gas Piping Proper sizing of gas piping depends on the cubic feet per hour of gas flow required specific gravity of the gas and the length of run National Fuel Gas Code Z223 1 in U S A or the current Gas Installation Codes CSA B149 1 in Canada should be followed in all cases unless superseded by local codes or gas utility requirements Refer to the Pipe Sizing Table 12 The heating value of the gas may differ with locality The value should be checked with the local gas utility NOTE There may be a local gas utility requirement specifying a minimum diameter for gas piping All units require a one inch pipe connection at
54. bypass valve is fully adjustable between 0 and 80 psig with a factory setting of 60 psig HGBP is standard on all units with VAV and optional with CV units Johnson Controls Unitary Products 860261 JIM B 0612 CONTROL POINT p APPROX F C 85 90 95 100 105 110 AT 50 RH 29 32 35 38 41 43 K NO Y A Ne x gt s Y O OX XV XR ARS DAR FAL PO LM al B 0 45 50 55 60 65 70 75 80 85 90 95 100 105 110 4 7 10 13 16 18 21 24 27 29 32 35 38 41 43 APPROXIMATE DRY BULB TEMPERATURE F C N Figure 16 Enthalpy Set Point Chart Exhaust Air Adjustment Screw Exhaust Air LED Damper Min 24 24 Position Vac Vac D Screw HOT COM Indoor Air Quality O Max Adjustment Screw 2 Il Indoor Air Quality LED Indoor Air Quality Min Adjustment Screw Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw Figure 17 Economizer Control Excludes VFD and BAS Options Johnson Controls Unitary Products 33 860261 JIM B 0612 Phasing Johnson Controls Model J ZJ units are properly phased at the factory Check for proper compressor rotation If the blower or compressors rotate in the wrong direction at start up the electrical connection to the unit is misphased Change the phasing of the Field Line Connection at the factory or field supplied disconnect to obtain proper rotation Scroll compressors oper
55. 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 6 If a factory option convenience outlet is installed the weatherproof outlet cover must be field installed The cover shall be located in the unit control box To install the cover remove the shipping label covering the convenience outlet follow the instructions on the back of the weatherproof cover box and attach the cover to the unit using the 4 screws provided 4x CAUTION 208 230 3 60 and 380 415 3 50 units with factory installed Powered Convenience Outlet Option are 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 Johnson Controls Unitary Products 860261 JIM B 0612 Limitations These units must be installed in accordance with the following In U S A 1 National Electrical Code ANSI NFPA No 70 Latest Edition National Fuel Gas Code ANSI Z223 1 Latest Edition 3 Gas Fired Central Furnace Standard ANSI Z21 47a Latest Edition 4 Local building codes and 5 Local gas utility requirements In Canada 1 Canadian Electrical Code CSA C22 1 2 Installation Codes CSA B149 1 3 Local plumbing and waste water codes and 4 Other applicable local codes Refer to unit application data found in this document
56. elsewhere either within the building on a perpendicular wall which is not subjected to excessive temperature vibration humidity dust corrosive gas explosive gas etc or within an appropriate enclosure rated for outside installation to safeguard against moisture dust and excessive heat The power leads to the drive L1 L2 L3 and from the motor T1 T2 T3 along with the respective ground wires are supplied with the unit and need to be connected after the drive is installed 4x CAUTION Do not connect AC power to the T1 T2 T3 drive terminals to prevent damage to the VFD A terminal block located in the control box is provided for field connection of the VFD speed reference signal 2 10 VDC and to the normally open run permit auxiliary contact The use of shielded cable is recommended for the above control wiring connections For VFD ready units also equipped with gas electric heat a terminal block located in the unit s control box and connected to the VAV board s VAV BOX terminal must be field wired to the building s VAV boxes to ensure fully open dampers during heating operation Optional Hot Gas Bypass HGBP To allow for low cooling load operation a direct acting pressure modulating bypass control valve installed on the system 1 discharge line is used to divert high temperature high pressure refrigerant around the TXV in order to maintain a desired minimum evaporator pressure The opening pressure of the
57. maintained in accordance with good industry practice and any specific PennBarry recommendations Exclusions These warranties do not cover defects caused by 1 Improper design or operation of the system into which the PennBarry Product is incorporated 2 Improper installation 3 Accident abuse or misuse 4 Unreasonable use including any use for non commercial purposes failure to provide reasonable and necessary maintenance as specified by PennBarry misapplication and operation in excess of stated performance characteristics 5 Components not manufactured by PennBarry Limitations 1 In all cases PennBarry reserves the right to fully satisfy its obligations under the Limited Warranties by refunding the invoice price of the defective PennBarry Product or if the PennBarry Product has been discontinued of the most nearly comparable current product 2 PennBarry reserves the right to furnish a substitute or replacement component or product in the event a PennBarry Product or any component of the product is discontinued or otherwise unavailable 3 PennBarry s only obligation with respect to components not manufactured by PennBarry shall be to pass through the warranty made by the manufacturer of the defective component General The foregoing warranties are exclusive and in lieu of all other warranties except that of title whether written oral or implied in fact or in law including any warranty of merchantability or fitne
58. must be replaced replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire A disconnect must be utilized for these units Factory installed disconnects are available If installing a disconnect field supplied or Unitary Products supplied accessory refer to Figure 1 for the recommended mounting location TERMINAL BLOCK TB1 GROUND LUG A CAUTION Avoid damage to internal components if drilling holes for disconnect mounting NOTE Since not all local codes allow the mounting of a disconnect on the unit please confirm compliance with local code before mounting a disconnect on the unit 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 Figures 11 and 12 for typical field wiring and to the appropriate unit wiring diagram mounted inside control doors for control circuit and power wiring information A CAUTION When connecting electrical power and control wiring to the unit water proof connectors must be used so that water or moisture cannot be drawn into the unit during normal operation The above water proofing conditions will also apply when installing a field supplied disconnect switch Power Wiring Detail Units are factory wired for the voltage shown on the unit nameplate Refer to Electrical Data Table
59. n increment to the next parameter in the MID group e 6 DISPLAY GROUP COMMS P 9 31 P BHH P ade JOG COMMAND O Enable Function COPY KEYPAD iL P 948 COMMS P 2 40 O COPY KEYPAD P10 00 P18 85 CS SERIES COMMS P qe MFG MODEL INFO Value Accepted FBHLE GROUP COMMS P Hal O 3 16 B DURAPUSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart Write Parameter Settings to Keypad WARNING Do not remove the Keypad during transfer of program parameter settings to or from the AC drive After P9 40 COPY KEYPAD is enabled the LCD display will show an additional group called CO PY KEYPD GROUP Press the PRO GRAM key and then the UP DOWN or PROGRAM keys until this new group is displayed Press the ENTER key to display the copy mode selections Select the WRITETO KEYPAD mode using the UP DOWN keys Press the ENTER key to display the four 4 available program numbers to write from the AC drive to the keypad The program name will automatically be named the part number of the AC drive for example G53 22P0 Q Q Use the UP DOWN keys to select the desired program number PGM 1 thru PGM4 and press the EN TER key Use the UP DOWN keys to select Yes to confirm and press the EN TER key The LCD display will show the message Drive gt Keypad Loading while the parameters are being copied and ret
60. of the temperature within the conditioned space Refer to Table 23 for the required gas heat anticipator setting 51 860261 JIM B 0612 Table 23 Gas Heat Anticipator Setpoints Anticipator Setpoint and Stage 0 30 amp Start Up Cooling Gas Valve Prestart Check List After installation has been completed 1 Check the electrical supply voltage being supplied Be sure that it is the same as listed on the unit nameplate Set the room thermostat to the off position Turn unit electrical power on Set the room thermostat fan switch to on a EMM I Check indoor blower rotation If blower rotation is in the wrong direction Refer to Phasing Section in general information section Check blower drive belt tension 6 Check the unit supply air CFM 7 Measure evaporator fan motors amp draw 8 Set the room thermostat fan switch to off 9 Turn unit electrical power off Operating Instructions 1 Turn unit electrical power on 2 Set the room thermostat setting to lower than the room temperature 3 First stage compressors will energize after the built in time delay five minutes 4 The second stage of the thermostat will energize second stage compressor if needed Post Start Check List 1 Verify proper system pressures for both circuits Measure the temperature drop across the evaporator coil 3 Measure the system amperage draw across all legs of 3 phase power wires 4 Measure
61. pressure for these furnaces is 3 65 IWG 0 3 Adjustment Of Temperature Rise The temperature rise the difference of temperature between the return air and the heated air from the furnace must lie within the range shown on the CSA rating plate and the data in Table 11 After the temperature rise has been determined the CFM can be calculated as follows 0 8 CFM Btu Input 1 08 AF 53 860261 JIM B 0612 After about 20 minutes of operation determine the furnace temperature rise Take readings of both the return air and the heated air in the ducts about 6 feet from the furnace where they will not be affected by radiant heat Increase the blower CFM to decrease the temperature rise decrease the blower CFM to increase the rise See SUPPLY AIR DRIVE ADJUSTMENT NOTE Each gas heat exchanger size has a minimum allowable CFM Below this CFM the limit will open Pa Burner Assembly Bracket pa Flame Sensor Bulb E O f 8 Gap Between Carry over Tube and Flame Sensor Bulb Carry over Tube Figure 24 Proper Pilot Flame Adjustment Pilot Checkout The pilot flame should envelope the end of the flame sensor To adjust pilot flame 1 remove pilot adjustment cover screw 2 increase or decrease the clearance for air to the desired level 3 be sure to replace cover screw after adjustment to prevent possible gas leakage Put the system into operation and observe through complete cycl
62. show DETECTING MOTOR flashing lt sTOP gt TO CANCEL If the STOP key is pressed the Auto Tune procedure will terminate the keypad LCD display will show either a R1 Detect Error or No Load Error warning message and the value in parameter P0 05 will reset to 0 Use the STO P RESET key to clear the warning message and return the drive to the display mode Then repeat the procedure The Auto Tune procedure will take approximately 15 seconds to execute plus the acceleration and deceleration times in parameters P1 01 and P1 02 The greater the horsepower of the AC drive and motor the more acceleration and deceleration time will be required Upon completion of the Auto Tune procedure the display will show the message TUNING COMPLETE PRESS lt ENTER gt At this time the determined values for parameters P0 06 and P0 07 will be filled in automatically Please check these parameters to make sure a value was determined If no value was determined then repeat the procedure If the STO P RESET key on the keypad is pressed during auto tuning or if the RUN key is not pressed within 60 seconds once the message PRESS lt RU N gt TO CONTINUE is displayed the Auto Tune procedure will terminate and the value in parameter P0 05 will reset to 0 The DURAPULSE AC drive will return to the normal display mode 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 3 15 Chapter 3 Keypad Operation and Quicksta
63. the control box A solid state lock out relay LR and 100 LF 50 VDC capacitor must be field supplied and installed to provide a means to transmit a potential fault signal back to the BAS controller The specific relay part number required will depend upon the need for either AC output or DC output See price pages for further details Once the appropriate relay and capacitor are obtained install the capacitor across LR terminals 3 amp 4 and make the following wiring connections e LR 1 to BAS controller e LR 2 to BAS controller e LR 3 to UCB X LR 4 to UCB C 32 VFD Ready For Customer installation Units configured as VFD ready provide provisions for a customer installed drive The physical dimensions of VFDs can vary greatly among manufacturers horsepower ratings and voltage requirements Keep in mind that drive manufacturers also require various minimum clearances to allow for adequate internal cooling of the drive during operation The unit comes with a mounting bracket installed in the Blower Access compartment which may accommodate other vendor s drives depending on their size In order to utilize the unit s mounting bracket the maximum recommended drive dimensions are as follows For 5 hp motor applications 13 Hx 6 W x 7 D For 7 5 thru 15 hp motor applications 13 H x 8 W x 8 D If the drive will not fit in the allotted space then it will need to be mounted
64. the entrance fitting Figure 13 External Supply Connection External Shut Off Johnson Controls Unitary Products 860261 JIM B 0612 Drip Leg Figure 14 Bottom Supply Connection External Shut Off Table 12 Gas Pipe Sizing Capaclty of Pipe Length of Nominal Iron Pipe Size Pipe ft din 1 1 4 in TO 1050 20 730 30 590 40 500 50 440 60 400 70 370 80 350 90 320 100 305 NOTE Maximum capacity of pipe in cubic feet of gas per hour based upon a pressure drop of 0 3 inch W C and 0 6 specific gravity gas Table 13 Gas Heat Minimum Supply Air Size Supply Air CFM Heating diae Min Max Min Max TEZ 7000 15 7000 J18ZJ 6000 6000 8750 17 5 6000 6000 8750 J207 6000 6000 9400 20 6000 6000 9400 1252 12500 25 12500 27 860261 JIM B 0612 Gas Connection The gas supply line can be routed within the space and roof curb exiting through the unit s basepan Refer to Figure 5 for the gas piping inlet location Typical supply piping arrangements are shown in Figures 13 and 14 All pipe nipples fittings and the gas cock are field supplied Gas piping recommendations 1 28 A drip leg and a ground joint union must be installed in the gas piping Where required by local codes a manual shut off valve must be installed outside of the unit Use wrought iron or steel pipe for all gas lines Pipe dope should be applied sparingly to male threads only Natural gas may contain so
65. 0 O Main circuit power terminals Drives 20 30hp 230VAC amp 20 60hp 460VAC E Users must connect wiring according to the circuit diagram shown below Dynamic F 1 BR H Brake Unit Braking resistor JUMPER A eboney i optional eno Power Source 3 phase AC Motor 2 200 240V 10 O Y O 000 OLI 50 60Hz 5 DURAPULSE 380 480V 10 9 9 9 DLE GS3 xxxx lr O 50 60Hz 5 AN O GOOOL3 O Note Grounding terminals O are internally connected Motor grounding terminal Grounding resistance less than 0 10 O Main circuit power terminals 2 18 B DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring Power Wiring Diagrams continued Drives 40 50hp 230VAC 75 100hp 460VAC Users must connect wiring according to the circuit diagram shown below Dynamic p 1 BR Fr naka L ei optional H i optional optional l Dynamic 1 L BR F4 Brake Unit La resistor optional optional optional JUMPER 7 L y 2 AC Motor 200 240V 10 O Y O 000 OLI T1O 50 60Hz 5 DURAPULSE GEM 380 480V 10 9 V OL QS3 xxxx 50 60Hz 5 o 5 000 OL3 130 Power Source 3 phase O Note Grounding terminals D are internally connected Motor grounding terminal Grounding resistance less than 0 1Q O Main circuit power terminals Ist
66. 00 7800 8200 8600 9000 9400 9800 10200 10600 11000 11400 11800 12200 12600 Available External Static Pressure WGT 1 4 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 0 4 0 6 0 8 Low Static 7 5 HP 8 Field Supplied Drive 824 3 68 839 4 17 856 4 69 873 5 24 890 5 84 909 6 47 958 8 83 980 9 66 1003 10 52 1025 11 43 1057 12 00 1017 11 76 1049 12 37 1081 12 94 1040 12 74 1073 13 34 1104 13 91 1065 13 75 1097 14 35 1129 14 92 1 0 856 871 887 904 922 940 1066 1089 1112 1136 1160 Low Static 7 5 HP Drive 4 23 887 4 71 902 5 23 918 5 78 935 6 38 953 7 01 972 991 11 64 1097 12 54 1120 13 48 1143 14 46 1167 15 47 1192 High Static 15 HP 4 Drive 1 2 4 74 5 22 5 74 6 30 6 89 7 53 8 20 12 15 13 06 14 00 14 97 15 98 919 934 950 967 985 1003 1106 1128 1151 1175 1199 1223 5 23 5 72 6 24 6 79 7 39 8 02 11 78 12 64 13 55 14 49 15 46 16 47 Available External Static Pressure IWG 3 0 2 0 2 2 2 4 2 6 RPM BHP RPM BHP RPM BHP RPM Standard 10 HP amp Drive 2 8 BHP RPM 15 60 16 51 1202 1217 1233 1250 1268 1286 1305 1325 1346 1367 1389 1412 1434 High Static 15 HP amp Drive 8 58 9 06 9 58 10 13 10 73 11 36 12 04 12 75 13 50 14 29 15 12 15 99 16 89 1 6 950 966 982 1138 1160 1183 1207 1231 1255 1 8 5 70 98
67. 11 Minor changes and corrections throughout Ch2 Wiring diagram terminal spec modifications Ch4 Parameter description modifications P2 10 P3 11 3 14 P6 00 P6 18 P9 04 Ch5 PLC communication cable notes AppxA New accessories LR xxxx line reactors 1 phase EMI filters 1 phase fuses amp blocks GS EDRV100 GS replacement cooling fans AppxB CLICK PLCs amp connections First Edition Revision D 05 2013 Minor changes and corrections throughout Chl New info for Selecting the Proper Drive Rating Ch2 Storage conditions capacitor recharge and short circuit information Ch3 Clarification of P4 00 in examples Ch4 New parameter info especially for firmware v1 05 new analog input example Ch5 New and revised info regarding parameters wiring and cabling and CLICK and DirectLO GIC PLC programming Ch6 Storage conditions capacitor recharge info AppxA Fusing and SCCR specs ZIPLink GS cables AppxB New PLC components Revision History h 2 DURAPULSE AC Drive User Manual Table of Contents Ep Chapter 2 Installation and Wiring 2 1 Ambient Conditions see e 2 2 Storage Conditions lese mns 2 2 Installation PAP PAS 2 3 Minimum Clearances and Air Flow se se eee ee 2 3 DIMENSIONS es serenti terene FER 2 4 Circuit CONNECTIONS o 2 11 DANGER Warning Notes aaa 2 11 Terminal Wiring Diagrams aaa
68. 2 PSIG the gas valve must be replaced The furnace must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG Reference Additional information is available in the following reference forms Technical Guide J15 thru 25 ZJ ZR ZF 349690 e General Installation J15 thru 25 ZJ 860261 Johnson Controls Unitary Products 860261 JIM B 0612 Renewal Parts For authorized replacement parts call Johnson Controls Inc National Source 1 Parts outlet at 1 866 523 9670 Approvals Design certified by CSA as follows 1 For use as a cooling only unit cooling unit with supplemental electric heat or a forced air furnace For outdoor installation only For installation on combustible material For use with natural gas convertible to LP with kit 44 CAUTION This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes AWARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage 4x CAUTION This system uses R 410A Refrigerant which operates at higher pressures than R 22 No other refrigerant may be used in this system 860261
69. 24 volts from the temperature limit the draft motor will perform a 25 second post purge and the indoor blower will be de energized following the elapse of the fan off delay for heating This limit is monitored regardless of unit operation status i e this limit is monitored at all times If the temperature limit opens three times within one hour it will lock on the indoor blower motor and flash code is initiated See Table 25 Gas Valve The UCB continuously monitors the GV Any time the UCB senses voltage at the GV without a call for heat for a continuous five minute period the UCB will lock on the indoor blower and a flash code is initiated Table 25 When voltage is no longer sensed at the GV the UCB will de energize the indoor blower following the elapse of the fan off delay for heating Johnson Controls Unitary Products If voltage has been sensed at the GV for at least 15 seconds during the fan on delay for heating and GV voltage or W1 is lost the indoor blower is forced on for the length of the fan off delay for heating Safety Controls The UCB monitors the temperature limit switch of gas heat units The control circuit includes the following safety controls Limit Switch LS This control is located inside the gas heat compartment and is set to open at the temperature indicated in the Gas Heat Limit Control Settings Table 22 It resets automatically The limit switch operates when a high temperature condition c
70. 3 32 1126 3 50 1165 3 67 1202 3 84 1237 4 02 4800 1116 3 76 1157 3 94 1196 4 11 1233 4 28 1267 4 46 5200 1148 4 24 1189 4 42 1228 4 59 1265 4 77 1300 4 94 5600 1182 4 76 1223 4 94 1262 5 11 1299 5 28 1334 5 46 6000 1218 5 31 1259 5 49 1298 5 66 2 6400 B 5 S 3 R 6800 3 7200 S 5 HP amp Field Supplied Drive 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 898 J18ZJ 17 5 Ton Bottom Duct Air FI Available External Static Pressure IWG GEM 0 4 0 6 0 8 1 0 1 2 1 4 1 6 18 2 0 2 2 24 2 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP standard 5 HP amp Fi Standard 5 HP Drive High Static 7 5 HP Drive ield Supplied Drive 4400 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 4800 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 5200 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 5600 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 6000 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 6400 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 6800 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 7200 TBD TBD TBD TBD TBD TBDITBD TBD TBD TBD 7600 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 8000 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD 8400 TBD TBD TBD TBD
71. 3 6 15 6 19 6 70 7 26 12 25 13 11 14 02 14 96 15 93 16 94 3 2 1244 1259 1275 1292 1310 1329 1348 1368 1389 1410 1432 1454 8 95 9 44 9 96 10 51 11 11 11 74 12 41 13 13 13 88 14 67 15 50 16 36 15 HP 8 Field Supplied Drive 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 82 Johnson Controls Unitary Products 998 1014 1031 1049 1067 1087 1107 1127 1148 1170 1193 1216 1239 1263 6 64 7 16 7 11 8 31 8 94 9 61 10 33 11 08 11 87 12 70 13 56 14 47 15 41 16 38 3 4 BHP RPM BHP RPM BHP RPM BHP 1289 1304 1320 1337 1355 1374 1393 1413 1434 1455 1477 1499 9 33 9 82 10 34 10 89 11 49 12 12 12 79 13 51 14 26 15 05 15 88 16 74 SAU 8 dH OL PIepuels 860261 JIM B 0612 39 860261 JIM B 0612 Table 16 Air Flow Performance Bottom Duct Application J15ZJ 15 Ton Bottom Duct Air FI Available External Static Pressure IWG ci 0 4 0 6 0 8 1 0 1 2 14 1 6 18 2 0 2 2 2 4 2 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP amp Field Supplied Drive 4000 2 32 9 2 2 53 1056 2 91 1097 3 09 1136 3 27 1173 3 44 1208 3 61 Standard 5 HP amp Drive High Static 5 HP amp Drive 4400 1085
72. 6 7000 26 67 R 410a 12 4 12 8 12 8 12 8 32 U 400 U 320 80 20 50 30 60 195 195 2783 Scroll 4 25 50 75 100 63 8 2 20 3 8 Split face 25 4 13 5 3 8 Split face TXV 25 860261 JIM B 0612 Table 9 J15 thru 25 ZJ Physical Data Continued Component Nominal Tonnage CONDENSER FAN DATA Quantity Fan diameter Inch Type Drive type No speeds Number of motors Motor HP each RPM Nominal total CFM BELT DRIVE EVAP FAN DATA Quantity Fan Size Inch Type Motor Sheave Blower Sheave Belt Motor HP each RPM Frame size FILTERS Quantity Size Models 12523 5 18 2 25 peu En LES 30 Prop TBD Direci 4 1 3 TBD 1 3 1 3 850 870 870 TED 5000 pu LESE Centrifugal ETER G 5VX840 5VXB60 E 1725 2547 12 12x24x2 9 TBD 2 12x24x2 12 12x 24 x 2 2 20 x 24 x4 TBD 2 20 x 24 x 4 2 20 x 24 x 4 4 24 x 24 x 4 4 24 x 24 x 4 4 24 x 24 x 4 1 2 In Throwaway Standard MERV Minimum Efficiency Reporting Value 3 2 2 In Pleated Optional MERV 7 3 4 In Pleated Optional MERV 13 Optional Electric Heat The factory installed heaters are wired for single point power supply Power supply need only be brought into the single point terminal block These CSA approved heaters are located within the central compartment of the unit with the heater elements extending in to the supply air chamber Fuses are supplied where required
73. 6 amp up Figure 3 Blower Accessories Optional Pre Drilied Standord Outlet Flange Access KANO Backdraft Damper Optional B Weather Optional Cover Companion Flange PAGA 0 Inlet Flange d Vas Guard PARTS LISTS 1 Blower Scroll Housing Figure 4 Correct Inlet 4 Outlet Duct Arrangements 2 Outlet Duct Flange optional 1wheel diameter 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 n Fax 972 497 0468 3 Centrifugal Wheel aluminum non overloading Spun Inlet Ball Bearing Motor Belt and Pulleys Drive Frame Support Assembly Adjustable Motor Mouthing Plate KO cgo Sco col uam Fan Shaft and Bearings 10 Support Legs with Mounting Holes 11 Belt and Bearing Enclosure optional 12 Round Inlet Ring PENNBARRY 3 Operation amp Maintenance Manual Dynamo Fans Dynapak Typical Installation Figure 6 A Mem Hinged amp latched access door t Discharge K o rd Positively sealed access door z 4 ka adjustable tension latches Continuously welded plenum Grease drain and downspout Vented curb by others Disconnect ESEG 27 AN w23 ASAN A ili amp AA RADA Ar A J Ceiling Table 2 Dimensions Figure 7 Model Bp eap e AECA E E Ca Table 3 Dimensions Model S T D10DP 8 1 4 11 1 4 D13DP 10 1 2 14 3 8 2 DIA CONDUIT CLEARANCE HOLES GREASEBOX OPTIONAL N CURS
74. 61 JIM B 0612 A CAUTION For units with VFD and gas heat the speed of the indoor blower motor continues to be controlled by duct static pressure via the VAV control board If there are VAV boxes present in the duct system the boxes must be driven to the full open position using a customer supplied power source to assure adequate airflow across the heat exchanger tubes When the thermostat calls for the first stage of heating the low voltage control circuit from R to W1 and G is completed thru the UCB The heat relay RW1 is energized The RW1 2 contacts close energizing the draft motor control The draft motor control contacts close and start the draft motor As the speed of the draft motor reaches approximately 2500 RPM the centrifugal switch contact located on the end of the draft motor shaft closes to power the first stage ignition module IC1 thru the RW1 1 contacts Ignition module IC1 will immediately start the first stage igniter sparking and will open the redundant valve located inside the first stage main gas valve GV1 to allow a flow of gas to only the first stage carryover tube Only after the pilot flame has been ignited and the presence of pilot flame detected at the C1 by a signal sent back through the flame sensor is sparking terminated and the first stage main gas valve opened Gas flows into each of the main burners and is ignited from the carryover t
75. 65 0 V DC Bus Voltage Displays the DC Bus Voltage Example 662 VDC DC Bus Voltage oe PID Setpoint Displays the PID setpoint Note It is possible to change the PID setpoint with the a and w keys when the PID setpoint value is displayed on the keypad The PID function P7 00 must be enabled and the PID Setpoint source P7 02 must be set to keypad 00 PID Setpoint 0 0 san PID Feedback 0 0 PID Feedback Signal PV Displays the PID feed back signal Freq Setpoint D Frequency Setpoint BOD Ng Displays the frequency setting of the AC drive Example 60 0Hz 3 4 DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart Programming the DURAPULSE AC Drive The DURAPULSE AC Drive parameters are organized into eleven 11 different groups according to their functions plus a special Copy Keypad function for storing up to four 4 different sets of program parameters into the keypad The illustration below shows you how to navigate through the parameter groups and parameter settings For a complete list of parameters see CHAPTER 4 O SelB erp arameo e Hop Press the PROGRAM key and then use the UP DOWN or PROGRAM keys to cycle through the parameter groups The LCD display will show the parameter group that is currently selected O O Press the ENTER key to display the various parameters for the P0 00 P0 07 selected group and use the UP D
76. AC drive to operate a standard 3 phase induction motor notice that the energy loss is greater than for an inverter duty motor 2 Avoid running a standard induction motor at low speed which may cause the motor temperature to exceed the motor rating due to limited airflow produced by the motor s fan 3 When the standard motor operates at low speed the output load must be decreased 4 If 100 output torque is desired at low speed it may be necessary to use a special inverter duty rated motor Short Circuit Withstand SCCR M odels through 50 hp are suitable for use on a circuit capable of delivering not more than 5 000 rms symmetrical amperes 10 000A for models 60 hp through 100 hp The maximum voltage is 240V for all 230V models and 480V for all 460V models Applicable Codes All DURAPULSE AC drives are U nderwriters Laboratories Inc UL and Canadian U nderwriters Laboratories cU L listed and therefore comply with the requirements of the National Electrical Code N EC and the Canadian Electrical Code CEC Installation intended to meet the UL and cUL requirements must follow the instructions provided in Wiring Notes as a minimum standard Follow all local codes that exceed UL and cUL requirements Refer to the technical data label affixed to the AC drive and the motor nameplate for electrical data The Circuit Protection Devices section in APPENDIX A lists the recommended fuse part number for each DURAPULSE part num
77. AMBIENT TEMPERATURES MUST NOT EXCEED 40 C 104 F Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 3 Chapter 2 Installation and Wiring E Dimensions Frame A Part numbers GS3 21P0 GS3 22P0 GS3 41P0 GS3 42PO 118 0 4 65 160 0 6 30 108 0 4 25 Dia 5 5 0 22 173 0 6 81 185 0 7 28 C JC L JE 7 L 7 EME EE CD EED ED LE pina IC j E AE J AO ME EM ING 7 L L Dia 22 0 0 87 94M o219 d R5 N 00 _ l 5 5 0 22 Units mm inches 2 4 DURAPULSE AC Drive User Manual lst Ed Rev D 05 2013 Chapter 2 Installation and Wiring Dimensions continued Frame A with Fan Part Numbers GS3 43P0 145 0 5 71 118 0 4 65 108 0 4 25 Dia 5 5 0 22 173 0 6 81 185 0 7 28 Dia 22 0 0 87 Dia 28 0 1 10 2X 8 7 0 34 2 18 T EM 5 0 22 Units mm inches lst Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 5 Chapter 2 Installation and Wiring Dimensions continued Frame B Part numbers GS3 23P0 GS3 25P0 GS3 45P0 l 135 0 5 32 S Es N d co 9 e i st st N 260 0 10 24
78. AND PLATE N Pa BY OTHERS 1401 North Plano Road Richardson Texas 75081 4 PENNBARRY Phone 972 234 3202 n Fax 972 497 0468 Dynamo Fans Troubleshooting Checklist Symptom Excessive noise Fan inoperative Insufficient airflow Water leaking into ductwork or collection of grease under fan Motor overheating Possible Cause s Defective or loose motor bearings Ventilator base not securely anchored Loose or unbalanced wheel propeller Misaligned pulleys or shaft Loose or damaged wheel propeller Wheel running in wrong direction Blown fuse or open circuit breaker Loose or disconnected wiring Defective motor Broken belts Open access doors or loose sections of ducts Clogged filters Operation in wrong direction Insufficient make up air direction Fan installed with slope in the wrong direction Clogged drain spout Cooling tube or motor dome top removed Grease container full Belt slippage Overvoltage or under voltage Operation in wrong direction Fan speed too high Incorrect motor service factor 1 0 low ambient temperature Blocked cooling tube or leaky gasket Insufficient airflow to kitchen hood fan operating on low speed with kitchen in full operation Undersized motor Operation amp Maintenance Manual Corrective Action Replace motor with same frame size RPM HP Reset properly Tighten screws remove build up balance wheel propeller correct alignment Replace whe
79. AT will be maintained at 5 degrees of the VAV Cooling Supply Air Temp Lower Set point When the Return Air Temp RAT is below the VAV Supply Air Temp Reset Set point the SAT will be maintained at 5 degrees of the VAV Cooling Supply Air Temp Upper Set point When the Outdoor air condition is sufficient for free cooling the economizer will modulate to control the SAT to 1 degrees of the operational set point The following components are needed to access the control points in the Simplicity amp controller Installation and operation guide is located on UPGNET 1 Computer running Windows software with a standard USB port 45 860261 JIM B 0612 2 Simplicity PC Software http www yorkupg com software asp 3 Freenet USB adapter driver http www yorkupg com software asp 4 Simplicity Freenet USB Adapter S1 03101967000 Freenet service cable S1 02538682000 No Outdoor Air Options When the thermostat calls for the first stage of cooling the low voltage control circuit from R to Y1 and G is completed The UCB energizes the economizer if installed and free cooling is available or the first available compressor and the condenser fans For first stage cooling compressor 1 is energized If compressor 1 is unavailable compressor 2 is energized After completing the specified fan on delay for cooling the UCB will energize the blower motor When the thermostat calls for the second sta
80. AUTION The furnace and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing at pressures in excess of 1 2 PSIG Pressures greater than 1 2 PSIG will cause gas valve damage resulting in a hazardous condition If it is subjected to a pressure greater than 1 2 PSIG the gas valve must be replaced The furnace must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG AWARNING Threaded joints should be coated with a sealing compound that is resistant to the action of liguefied petroleum gases Do not use Teflon tape Lp Units Tanks And Piping All gas heat units are shipped from the factory equipped for natural gas use only The unit may be converted in the field for use with LP gas with accessory kit model number 1NP0418 All LP gas equipment must conform to the safety standards of the National Fire Protection Association For satisfactory operation LP gas pressure must be 10 0 inch W C at the unit under full load Maintaining proper gas pressure depends on three main factors 1 The vaporization rate which depends on the temperature of the liquid and the wetted surface area of the container s The proper pressure regulation Two stage regulation is recommended The pressure drop in the lines betwee
81. AV boxes to full open during heating operation Programmable set points The duct static set point is the pressure that the drive will maintain when operating the unit in VAV mode The set point is adjustable between 0 WC and 5 WC with the default setting of 1 5 WC The auct static high limit set point is the maximum allowable duct pressure to prevent damage from over pressurization of the ductwork in the event of either a drive or damper failure The high limit set point is adjustable between 0 WC and 5 WC with the factory default setting of 4 5 WC If the duct static pressure reaches the high limit set point then the supply fan motor will be shutdown Johnson Controls Unitary Products 860261 JIM B 0612 NOTE Either of the set points described above can be changed through the unit control board UCB with the use of a USB to RS485 converter personal computer or PDA and a down loaded copy of the Simplicity amp software available at the UPGnet Commercial Product Catalog website A CAUTION The customer must be aware of the duct pressure design limit and what the duct pressure sensor is reading when the peak pressure is reached i e the pressure transducer sensing tube may not be located at the place of highest pressure in the system Factory installed VFD The factory installed VFD is mounted in the Blower Access Compartment above the blower assembly The drive comes wired from the factory to include both 3 pha
82. Data Table Safety Considerations This is a safety alert symbol When you see this symbol on labels or in manuals be alert to the potential for personal injury Understand and pay particular attention the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It is also used to alert against unsafe practices and hazards involving only property damage AWARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or for additional information consult a qualified contractor installer or service agency A CAUTION This product must be installed in strict compliance with the installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes AWARNING Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injur
83. Ed Rev D 05 2013 DURAPULsE AC Drive User Manual B 2 19 Chapter 2 Installation and Wiring I Control Terminal Designations Control Circuit Terminals Description Remarks 124V 20mA used only for AC drive digital inputs wired for DC Voltage Source source mode operation Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 InputVoltage Internally Supplied see WARNING below Digital Input 5 Sink M ode Low active Vin Min 0V Vin Max 15V Digital Input 6 lin Min 2 1mA lin Max 7 0mA E Source M ode High active Viny Min 8 5V Vin Max Digital Input 7 24V lin Min 2 1mA lin Max 7 0mA Digital Input 8 Input response 12 15 msec Digital Input 9 Also see Basic Wiring Diagram on the next pages Digital Input 10 Digital Input 11 Digital Common Intemal Power Supply 10VDC 10mA maximum load Analog Input 0 to 10 V input only Analog Input 0 to 20 mA 4 to 20 MA input Analog Input 10 to 10 V input only Analog Common Rel tout 1 N Resistive Load E RM ANO 24VDC 5A N O Inductive Load 240VAC 1 5A i Relay O utput 1 Common Relay O utput 1 Normally Closed Photocoupled digital output Photocoupled digital output Photocoupled digital output Digital O utput Common 12 48 VDC 50 mA Maximum 50mA 48VDC Scalable squarewave 50 duty cycle output Analog O utput O to 10V 2mA Outpu
84. External Shut Off 27 28 J20ZJ 20 Ton Charging Chart 54 14 Bottom Supply Connection External Shut Off 27 29 J25ZJ 25 Ton Charging Chart 54 15 Vent and Combustion Air Hood 29 30 Unit Control Board ii Es ai RATER ER Rek x 61 860261 JIM B 0612 860261 JIM B 0612 General Johnson Controls Series 20 J ZJ models are either single package air conditioners equipped with optional factory installed electric heaters or single package gas fired central heating furnaces with cooling unit Both are designed for outdoor installation on a rooftop or slab The units are completely assembled on rigid permanently attached base rails All piping refrigerant charge and electrical wiring is factory installed and tested The units require electric power gas connection 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 These gas fired heaters have aluminized steel or optional stainless steel tubular heat exchangers with spark ignition with proven pilot All gas heaters are shipped from the factory equipped for natural gas use but can be field converted to L P Propane with Kit Model 1NP0418 See Gas Heat Application
85. FI 225 15 IENE None 428 50 50 460 3 60 E 72 50 70 90 110 Zn Nm 926 s 35 575 3 60 59 40 60 70 90 TED meel el TED TBD TBD TBD TBD TED TED TED TED TED TBD meel TBD TED TED J18 TBD 17 5 TBD TBD TBD B TBD TBD TBD TBD Pee TBD TBD TBD TBD TBD B TBD TBD TBD TBD TBD leal o TBD eld e None 1163 125 125 208 3 60 3 7 15 4 10 0 150 175 200 noble None 1153 125 125 230 3 60 3 7 14 4 10 0 150 175 J20 225 20 None 606 7o 460 3 60 19 72 50 70 90 110 None 44 50 50 70 90 18 Johnson Controls Unitary Products 860261 JIM B 0612 J15 thru 25 ZJ Standard Drive With Powered Convenience Outlet Continued OD Fan Supply Pwr Max Fuse Size Vol UE Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each Motor Outlet Amps Size RLA LRA MCC FLA FLA FLA Model kW Stages Amps Amps None 1494 175 H 175 08 3 60 22 4 149 35 0 3 7 28 0 10 0 175 200 200 Nm 1469 150 180 30 3 60 22 4 149 35 0 3 7 26 0 10 0 175 J25 175 225 25 None 73 80 80 460 3 60 10 6 75 16 5 1 9 13 0 5 0 80 ZH Bn EERS 90 110 None 397 60 modi e Hn B 60 75 3 60 7 7 54 12 0 1 5 10 3 4 0 70 70 90 1 Minimum Circuit Ampacity 2 Dual Element Time Del
86. Gas Heat Minimum Supply Air 27 27 VAV Control Board Flash Codes 62 14 Altitude Temperature Correction Factors 35 LIST OF FIGURES 1 J15thru 25 ZJ Component Location 6 16 Enthalpy Set Point Chart oooooo 33 2 Unit 4 Point Load Weight 8 17 Economizer Control a 33 3 Unit 6 Point Load Weight 8 18 Belt Adjustment nooo 34 4 Center of Gravity 8 19 Altitude Temperature Correction Factors 35 5 J15 thru 25 ZJ Unit Dimensions Front View 9 20 Pressure Drop Across A Dry Indoor Coil Vs Supply 6 J15thru 25 ZJ Unit Dimensions Rear View 10 Air CFM For All Unit Tonnages 44 7 J15 thru 25 ZJ Unit Dimensions Rain Hood 11 21 Gas Valve Piping 0 0 cee es 50 8 Ji5thru 25 ZJ Roof Curb 12 22 Gas Valve and Controls SESSE EE SEE Es 51 9 Fixed Outdoor Air Damper 13 23 Proper Pilot Flame Adjustment 53 10 Condensate Drain a 13 24 Typical Flame o 53 11 Field Wiring Disconnect Cooling Unit With 25 Typical Gas Valve 0 00 ee 53 Without Electric Heat aa 14 26 J15ZJ 15 Ton Charging Chart 54 12 Typical Field Wiring 24 Volt Thermostat 15 27 J18ZJ 17 5 Ton Charging Chart 54 13 External Supply Connection
87. OWN keys to view each one RAMPS GROUP O When the desired parameter is shown press the ENTER key to P1 00 P1 22 select G Use the UP DOWN keys to cycle through the available settings V HZ GROUP G Press the ENTER key to select the P2 00 P2 10 DIM DIGITAL GROUP 6 Select Parameter setting The phrase Value Accepted will be displayed for a moment to show that the MOTOR P0 00 P3 00 P3 30 MOTOR VOLTAGE parameter value has been GO ON LAOT ON Salon ANALOG GROUP MOTOR P0 01 D After the parameter value has been P4 00 P4 12 MOTOR AMPERAGE set the LCD display will cycle to the next parameter in the selected group PRESETS GROUP P5 00 P5 15 PROTECT GROUP P6 00 P6 36 ENTER MOTOR P0 03 MOTOR BASE RPM Q Select Parameter Value PID GROUP P7 00 P7 27 DISPLAY GROUP P8 00 P8 02 MOTOR P0 04 MOTOR MAX RPM MOTOR P0 05 MOTOR AUTO TUNE MOTOR FREQUENCY P0 02 400 Hz COMMS GROUP P9 00 P9 42 DIM ENC FBACK GROUP P10 00 P10 05 MOTOR P0 06 MOTOR RESISTANCE CAOT C MOTOR P0 07 MOTOR NO LOAD O MOTOR FREQUENCY Q P0 02 50 Hz ers ENTER Value Accepted Ist Ed Rev D 05 2013 DURAPULsE AC Drive User Manual 3 5 Chapter 3 Keypad Operation and Quickstart DURAPULSE Quickstart The following examples will help you quickly s
88. Optional Variable Air Volume VAV 30 Heat Delay Setup a 62 Optional Hot Gas Bypass HGBP 32 Optional VAV Control Board Flash Codes 62 LIST OF TABLES 1 J15thru 25 ZJ Unit Limitations LL 7 15 Air Flow Performance Side Duct Application 37 2 Weights and Dimensions ess 8 16 Air Flow Performance Bottom Duct Application 40 3 J15thru 25 ZJ Unit Accessory Weights 9 17 RPM Selecion sev esa cet eswaeeterca trest RR 43 4 MNES ENNY ss suec hacen ed oan EE Stoici ee n emo LA 9 18 Indoor Blower Specifications 43 5 Supply Fan VFD Weights In LbsS 9 19 Power Exhaust Specifications 43 6 J15thru 25 ZJ Unit Clearances 11 20 Limit Control Setting oooooooo 48 7 Control Wire Sizes 0a 15 21 Electric Heat Anticipator Setpoint 49 8 Electrical Data 16 22 Gas Heat Limit Control Setting 50 9 Jibthru 25 ZJ Physical Data 25 23 Gas Heat Anticipator Setpoints 51 10 Electric Heat Minimum Supply Air 26 24 Gas Rate Cubic Feet Per Houwr 52 11 Gas Application Data o oooooooo 27 25 Unit Control Board Flash Codes 61 12 Gas Pipe Sizing Capaclty of Pipe 27 26 Heal Delay xix obs ERK RE Ee WAL 62 13
89. Parameters Memory Addresses 5 4 Parameters Restore to Default Settings 4 74 1st Ed Rev D 05 2013 DURAPu se AC Drive User Manual I 5 Index I P continued Parameters Summary 4 2 Analog Parameters 4 7 Communications Parameters 4 12 Digital Parameters 4 5 Display Parameters 4 12 Encoder Feedback Parameters 4 14 M otor Parameters 4 2 PID Parameters 4 11 Presets Parameters 4 8 Protection Parameters 4 9 Ramp Parameters 4 3 Volts H ertz Parameters 4 4 Parameters available in firmware versions 4 2 PID Disable 4 30 4 35 PID Parameters 4 66 PID Setpoint Bits 4 30 4 32 PLC compatible ADC PLC modules B 2 PLC connections to ADC PLC modules B 8 PLC GS3 communicate with ADC 5 14 CLICK M odbus Programming 5 23 DirectLO GIC M odbus Programming 5 38 Power Circuit Terminals 2 13 Power Supply 2 23 Power Wiring Diagrams 2 18 Programming the AC Drive 3 5 Q Quickstart 3 6 R Reactor 2 23 Reactors Line A 2 Wiring Connections A 17 Recharge capacitors 6 2 Remote Panel Adapter A 49 Reset Speed to Zero 4 30 4 35 Resistor braking 2 23 Revision History of User Manual h 1 RF Filter A 37 S Safety Codes w 1 2 12 Canadian Electrical Code CEC 2 12 CUL 2 12 National Electrical Code NEC w 1 2 12 National Electrical M anufacturers Association NEMA w 1 National Fire Code w 1 UL 2 11 2 12 Safety Information w 1 w 3 Second Accel Decel Time 4 30 4 33 Serial Comm
90. Paulson Cheek Mechanical 6145 Northbelt Parkway Suite F Norcross GA 30071 170 729 0076 170 729 1076 Fax Paulson Cheek MECHANICAL Pinewood Atlanta Phase 1A Building 3 Fayetteville GA HVAC O amp M Manuals 6 5 2014 General Contractor Group VI Construction LLC Mechanical Engineer Paulson Cheek Mechanical Inc Mechanical Contractor Paulson Cheek Mechanical Inc Section 1 Rooftop Units Section 2 Exhaust Fans Section 3 Electric Heaters Section 4 Variable Frequency Drives Section 5 Starters Paulson Cheek MECHANICAL O amp M COVER SHEET SECTION 1 PRODUCT ROOFTOP UNITS Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Building 3 PHONE 770 729 0076 FAX 770 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc ARCHITECT S ENGINEER S STAMP Paulson Cheek Mechanical Inc DATE RECEIVED 06 05 14 MANUFACTURER JCI SUPPLIER JCI SUBMITTED DATE 06 05 14 NO ERRORS DETECTED CORRECT EXCEPTIONS NOTED THIS APPROVAL OF SHOP DRAWINGS DOES NOT RELIEVE THE SUBCONTRACTOR OR VENDOR FROM THE REQUIREMENTS OF THE CONTRACT DOCUMENTS CHECKED BY WILLIAM HAGLER DATE CHECKED 06 09 14 O amp M Section Sheets 6 5 2014 i p w Il lin T TTT TTT T TTT lmn MAL Il lin LULA lug NEEEEEEEEEEE II all R 410A SERIES 20 J ZJ 15 25 Ton 60 Hertz
91. RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 838 Johnson Controls Unitary Products 37 860261 JIM B 0612 J20ZJ 20 Ton Side Duct Available External Static Pressure IWG pios 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 24 2 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP E PE g Standard 5 HP amp Drive High Static 7 5 HP amp Drive 5200 4 24 972 4 39 1000 4 47 1027 4 48 5600 4 61 989 4 76 1017 4 84 1044 4 85 6000 5 01 1007 5 15 1036 5 24 1062 5 25 6400 5 45 1028 5 59 1056 5 67 1083 5 68 6800 5 92 1050 6 07 1078 6 15 1105 6 16 7200 6 44 1074 6 59 1102 6 67 1129 6 68 7600 7 01 1099 7 16 1127 7 24 1154 7 25 8000 7 62 1125 7 77 1154 7 85 1180 7 86 8400 8 28 1153 8 43 1182 8 51 1208 8 52 8800 les ea 9200 ale als call 9600 Ne ale alle z 10000 T Ng l 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 838 38 Johnson Controls Unitary Products J25ZJ 25 Ton Side Duct Air Flow CFM 6600 7000 7400 7800 8200 8600 9000 9400 9800 10200 10600 11000 11400 11800 12200 12600 Air Flow CFM 6600 7000 74
92. RIVE TEST switch must be manually switched to the LINE BYPASS position If there is a call for the fan the indoor blower motor will run at full speed while in the bypass mode 31 860261 JIM B 0612 A CAUTION If the unit is operated with the manual bypass switch in the LINE BYPASS position and there are VAV boxes present in the duct system then boxes must be driven to the full open position using a customer supplied power source to prevent over pressurizing and possible damage to the ductwork AWARNING Before beginning any service disconnect all power to the drive Be aware that high voltages are present in the drive even after power has been disconnected Capacitors within the drive must be allowed to discharge before beginning service BAS Ready VFD Factory installed VFD is also available with BAS ready models Terminal blocks are provided in the control box in place of the VAV control board for field wiring of a customer installed BAS to receive 24 VAC power and to connect to the following control signals a duct static pressure transducer input signal 0 5 VDC an economizer actuator input signal 2 10 VDC an economizer actuator output signal 2 10 VDC a VFD speed reference output signal 2 10 VDC The use of shielded cable is recommended for the above control wiring connections NOTE Factory installed VFD is not available with factory installed BAS options due to space limitations in
93. RR RR RII 4 24 Digital Parameters e e mn 4 29 Analog Parameters lese rn 4 40 Presets Parameters ee rs 4 55 Protection Parameters RR RR I t n 4 57 PID Parameters RR RR RR RR 4 66 Display Parameters is ese RR rr 4 72 Communications Parameters o 4 73 Encoder Feedback Parameters aaa 4 78 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual C 3 Table of Contents Ep Chapter 5 DURAPULSE MODBUS Communications 5 1 Communications Parameters Summary 5 2 DURAPULSE Parameter Memory Addresses oo ooo 5 4 DURAPULSE Status Addresses 0 0A 0 aaa aa 5 11 Communicating with AutomationDirect PLCs 5 14 Step 1 Choose the Appropriate CPU ee 5 14 Step 2 Make the Connections aaa 5 14 Step 3 Set AC Drive Parameters is EE ss se Es ks 5 19 Step 4 Configure the PLC CPU 5 19 CLICK Modbus Ladder Programming 5 23 Separate Run Command Write Instruction 5 23 Block Transfer Parameters for Modbus Programs 5 23 CLICK Communication Program for CLICK PLCs 5 24 DirectLOGIC Modbus Ladder Programming 5 38 Separate Run Command Write Instruction 5 38 Block Transfer Parameters for Modbus Programs 5 38 DirectLOGIC Basic Communication Program start with this code 5 39 Programming Differences for Direc
94. ST page 52 and that the pilot adjust screw is allowing some flow of gas as described in PILOT CHECKOUT page 54 2 Check all wiring between the ignitor control and the gas valve Check to make sure the ground connections are intact 3 If the wiring is intact check for 24 volts across terminals PV and COMMON on the ignitor control If 24 volts is not present replace the ignitor control 4 f 24 volts is present remove the pilot burner and remove the pilot orifice from the pilot burner The orifice is removed in the direction opposite the flow of gas Inspect the orifice for obstruction If it is clear replace the main gas valve The ignitor sparks at the pilot burner but the pilot does not ignite and a gas odor is detected at the draft motor outlet 1 Adjust the pilot adjust screw on the gas valve as described in PILOT CHECKOUT page 54 2 Check the supply pressure as described in POST START CHECK LIST page 52 Make adjustments as necessary Johnson Controls Unitary Products 3 Check the pilot orifice for obstruction as described in paragraph above Clean as needed but the problem should not be the gas valve The pilot burner ignites but the ignitor continues to spark and the main burners do not ignite 1 Make the same checks and adjustment as described in PILOT CHECKOUT page 54 2 Check the supply pressure as described in POST START CHECK LIST page 52 Make adjustments as necessary
95. Started 460V Class Three Phase Model Name GS3 xxx 41PO 42PO 43PO 45P0 47P5 4010 I Maximum Motor Output 1 2 B 5 1 5 10 15 kW 0 75 1 5 2 2 3 1 5 5 La 11 Output Rating Rated Output Current A 2 1 4 2 5 5 8 5 13 18 24 Maximum Output Voltage Three phase 380 to 480V proportional to input voltage Rated freguency 0 1 to 400 Hz Rated Voltage Frequency Three phase 380 400 415 440 460 480VAC 50 60 Hz Rated Input Current A 4 3 5 9 11 2 14 19 Voltage Frequency Tolerance Voltage 10 Frequency 5 Short Circuit Withstand SCCR A rms symmetrical 5kA 480 VAC Watt Loss 100 W 10 102 132 176 250 345 445 Weight Ib kg 3 9 1 759 4 4 1 994 4 1 1 857 9 4 4 24 13 2 6 002 13 5 6 106 14 4 6 525 All 3 phase power sources must be symmetrical Do not connect D U RApulse drives to grounded center tapped delta transformers which are typically used for lighting circuits 460V Class Three Phase continued Model Name GS3 xxx 4025 Maximum Motor Output HP 20 25 30 40 50 60 Jo 100 kW 15 18 5 22 30 37 45 55 15 Output Rated Output Current A 32 38 45
96. T RELIEVE THE SUBCONTRACTOR OR VENDOR FROM THE REQUIREMENTS OF THE CONTRACT DOCUMENTS CHECKED BY WILLIAM HAGLER DATE CHECKED 06 09 14 O amp M Section Sheets 6 5 2014 FPQ 3310 SERIES 1 LOCATION OF HEATER A Heater is mounted on the wall near ceiling or floor air flow down CAUTION Do not obstruct the front grille of the heater with curtains furniture etc since the proper operation of the heater requires a free flow intake and exhaust of air Minimum mounting height is 8 above finished floor For surface mounting use adapter FQP 3310EX33 BEFORE MOUNTING Insure that the supply voltage matches voltage rating on the label of the heater Turn off electrical power to heater circuit MOUNTING INSTRUCTIONS Disassemble heater by removing 7 screws C as shown in Figure 1 and 2 B Flush mounting see Fig 1 Place rough in box A between studs at desired height secure to studs through holes M The flanges on the rough in box must rest on the surface of the finished wall if the box is installed prior to the application of the finished wall allowance must be made for the wall thickness C Surface mounting See Fig 2 Insert rough in box A into surface adapter E Secure the heater rough in box to wall at desired height through holes X Be sure that the rough in box is centered in surface adapter For surface mounting bring wiring through bottom knockout K only SN OD PW U D
97. These can only be reset by cycling power to the UCB NOTE While the above step will reset any lock outs compressor 2 will be held off for the ASCD and compressor 1 may be held off for a portion of the ASCD See the next step 10 If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out the UCB may have the compressor in an ASCD Check the LED for an indication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs 1f 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip repeat trip lock out or ASCD the economizer terminals of the UCB may be improperly wired Check for 24 volts at the Y1 OUT Johnson Controls Unitary Products terminal of the UCB If 24 volts is present trace the wiring from Y1 OUT for incorrect wiring If 24 volts is not present at the Y1 OUT terminal the UCB must be replaced 12 For units without economizers f 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug the jumper in the Mate N Lock plug and in the wiring from the Mate N Lock plug to the Y1 ECON terminal For units with economizers f 24 volts is present at the Y 1 OUT terminal check for 24 v
98. This Chapter Maintenance and Inspection LL 6 2 Monthly Inspection sov x rienda yah 6 2 Annual Inspection rn 6 2 Recharge Capacitors for unused drives 6 2 Troubleshooting LL 6 3 Fault Messages ss ss Es Es ek m eras 6 3 Warning Messages Serial Communication and Keypad Errors 6 7 Chapter 6 Maintenance and Troubleshooting Maintenance and Inspection Modern AC drives are based on solid state electronics technology Preventive maintenance is required to operate the AC drive in its optimal condition and to ensure a long life We recommend that a qualified technician perform a regular inspection of the AC drive Some items should be checked once a month and some items should be checked yearly If the drive is stored or is otherwise unused for more than a year the drive s internal DC E link capacitors should be recharged before use Otherwise the capacitors may be damaged when the drive starts to operate We recommend recharging the capacitors of any unused drive at least once per year discharged before inspecting the AC drive f WARNING Disconnect AC power and ensure that the internal capacitors have fully W ait at least two minutes after all display lamps have turned off Monthly Inspection Check the following items at least once a month 1 Make sure the motors are operating as expected Make sure the installation environment is normal Make sure the cooling system is opera
99. Type OD Fan Supply Pwr Max Fuse Size Vol SO Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each A Outlet Amps Size 38 6 1527 175 25 None 74 9 460 3 60 10 6 75 3 HACR type per NEC Johnson Controls Unitary Products 21 860261 JIM B 0612 J15 thru 25 ZJ High Static Drive With Powered Convenience Outlet OD Fan Supply Pwr Max Fuse Size Vol Me dE Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each Motor Outlet Amps Size FLA Cm E e a Amps None 901 100 08 3 60 Hu 2 a 150 175 E72 541 2 1502 1819 200 NEE CEN Ne E FD 100 100 230 3 60 1 E36 36 0 2 86 6 138 8 150 E54 540 2 1299 1604 175 J15 BEE iii 225 IO E 50 460 3 60 1 ese 360 2 433 694 70 E54 540 2 650 802 90 E72 720 2 866 1019 110 ee el E 35 575 3 60 ese 360 2 346 557 60 E54 540 2 520 643 70 JEZ2 5729 327 BOS Nair i 90 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD D TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD _ TBD TBD TBD TBD TBD TBD _ TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD D TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD J18 ia Ki Ad od RN E TBD x BEE 160 160 180 160 180 TBD
100. UCB Gas Heat Troubleshooting Guide On calls for heating the draft motor operates and the furnace lights but the supply air blower motor does not energize after a short delay the room thermostat fan switch is in AUTO position Johnson Controls Unitary Products 860261 JIM B 0612 AWARNING The furnace may shut down on a high temperature condition during the procedure If this occurs the UCB energize the supply air blower motor until the high temperature limit has reset Caution should be used at all times as the supply air blower may energize regardless of the room thermostat fan switch position For troubleshooting of optional VFD disconnect all power to the drive Be aware that high voltages are present in the drive even after power has been disconnected Capacitors within the drive must be allowed to discharge before beginning service Place the thermostat fan switch in the ON position If the supply air blower motor energizes go to Step 9 If the supply air blower motor does not energize when the fan switch is set to ON check that line voltage is being supplied to the contacts of the M3 contactor and that the contactor is pulled in For units with VFD check that line voltage is being supplied to the M3 Auxiliary contacts Check for loose wiring between the contactor and the supply air blower motor If M3 is pulled in and voltage is supplied at M3 lightly touch the supply air blower motor hou
101. Users must provide this environment for DURAPULSE Series AC D rive WARNING The AC drive may be destroyed beyond repair if incorrect cables are connected to the input output terminals Never connect the AC drive output terminals T1 T2 and T3 directly to the AC main circuit power supply All DU RApulse drives require a symmetrical 3 phase power source Do not connect them to grounded center tapped delta transformers of the type typically used for lighting circuits MP gt gt E gt gt W 3 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual W 4 DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 DURAPULSE AC DRIVE USER MANUAL iN Y pa o N BE mi AN utomation Direct wy j A REVISION HISTORY Please include the Manual Number and the Manual Issue both shown below when communicating with Technical Support regarding this publication Manual Number Issue Issue Date Issue Date GS3 M First Edition Revision D 05 2013 Publication History Description of Changes First Edition 12 03 2003 O riginal First Edition Revision A 2 26 2004 Corrected Watt loss information in Chapter One Minor changes corrections and addtn l information throughout First Edition Revision B 06 2007 Minor changes and corrections throughout Ch4 New parameters amp revised parameter explanations Ch5 New PLC program First Edition Revision C 06 24 20
102. VAC Watt Loss 100 W 60 82 130 194 301 4 5 4 5 9 4 9 4 DE Weight Ib kg 2 034 2 034 4 24 4 24 6 031 Rated Voltage Frequency All 3 phase power sources must be symmetrical Do not connect DU RApulse drives to grounded center tapped delta transformers which are typically used for lighting circuits 230V Class continued Model Name GS3 xxx 2010 2025 10 15 20 25 30 40 50 1 5 14 15 18 22 30 37 Rated Output Current A 33 49 65 75 90 120 145 Maximum Output Voltage Three phase 200 to 240V proportional to input voltage Rated frequency 0 1 to 400 Hz Three phase 200 208 220 230 240 VAC 50 60 Hz Input Rated Input Current A 50 60 75 90 110 Rating Voltage Frequency Tolerance Voltage 10 Frequency 5 Short Circuit Withstand SCCR A rms symmetrical 5KA 240 VAC Watt Loss 100 I W 380 660 750 920 1300 1340 1430 13 3 14 3 265 265 26 5 772 11 2 Weight Ib kg 6 031 6 487 12 12 12 35 35 All 3 phase power sources must be symmetrical Do not connect DU RApulse drives to grounded center tapped delta transformers which are typically used for lighting circuits Maximum Motor Output Output Rating Rated Voltage Frequency Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 1 7 Chapter 1 Getting
103. Y 1 and Y2 If the compressors have satisfied their minimum run times the compressors and condenser fans are de energized Otherwise the unit operates each cooling system until the minimum run times for the compressors have been completed Upon the final compressor de energizing the blower is stopped following the elapse of the fan off delay for cooling and the economizer damper goes to the closed position If the unit is in continues fan operation the economizer damper goes to the minimum position Economizer With Dual Enthalpy Sensors The operation with the dual enthalpy sensors is identical to the single sensor except that a second enthalpy sensor is mounted in the return air This return air sensor allows the economizer to choose between outdoor air and return air whichever has the lowest enthalpy value to provide maximum operating efficiency Economizer With Power Exhaust A unit equipped with an economizer single or dual enthalpy and a power exhaust operates as specified above with one addition The power exhaust motor is energized 45 seconds after the actuator position exceeds the exhaust fan set point on the economizer control When the power exhaust is operating the second stage of mechanical cooling will not operate As always the R to G connection provides minimum position but does not provide power exhaust operation Economizer With Optional VAV Or Intelli comfort IITM Control The position of the outside air
104. and the UCB i e that the thermostat G terminal is connected to the G terminal of the UCB and for loose wiring If the thermostat and UCB are properly wired replace the UCB On calls for cooling the supply air blower motor is operating but compressor 1 is not the room thermostat fan switch is in the AUTO position 1 If installed check the position of the economizer blades If the blades are open the economizer is providing free cooling and the compressors will not immediately operate If both stages of cooling are requested simultaneously and the economizer provides free cooling following a short delay compressor 1 will be energized unless it is locked out If compressor 1 is locked out compressor 2 is energized Compressor 2 is always energized in place of compressor 1 when compressor 1 is requested but locked out If no economizer is installed or the economizer is not opening to provide free cooling and compressor 1 does not energize on a call for cooling check for line voltage at the compressor contactor M1 and that the contactor is pulled in Check for loose wiring between the contactor and the compressor If M1 is pulled in and voltage is supplied at M1 lightly touch the compressor housing If it is hot the compressor may be off on inherent protection Cancel any calls for cooling and wait for the internal overload to reset Test again when cool If M1 is not pulled in check for 24 volts at the M1 co
105. ast to stop The application requires that this parameter be set to Ramp to Stop because the motor needs to stop under power If the AC drive is set for Coast to Stop the AC drive will ignore the D eceleration Time setting WARNING If the Stop Method for the DURAPULSE AC drive is set for Coast to Stop the AC drive will ignore the P1 02 setting for Deceleration Time 1st Ed Rev D 05 2013 DURAPULse AC Drive User Manual 3 7 Chapter 3 Keypad Operation and Quickstart ZA Acceleration Time Setting 5 0 Range 0 1 to 600 sec D efault Setting 10 sec The motor should accelerate from 0 RPM to Maximum M otor RPM P0 04 in 5 seconds ANY Deceleration Time Setting 5 0 Range 0 1 to 600 sec D efault Setting 30 sec The motor should decelerate from 2000 rpm M aximum M otor RPM P0 04 to O RPM in 5 seconds GET Volts Hertz Settings Setting 01 Range 00 General Purpose D efault Setting 0 0 01 High Starting Torque 02 Fans and Pumps 03 Custom The DURAPULSE AC drive has some predefined torque settings that meet the needs of most applications A custom setting is available if needed In this example the application requires a high starting torque ENT Source of Operation Command Setting 02 D efault Setting 00 Settings 00 Operation Determined by Digital Keypad 01 Operation determined by external control terminals Keypad STOP is enabled 02 Operation determined by external control terminals
106. ate in only one direction If the scroll is drawing low amperage has similar suction and discharge pressures or producing a high noise level the scroll is misphased A CAUTION Scroll compressors require proper rotation to operate correctly Units are properly phased at the factory Do not change the internal wiring to make the blower condenser fans or compressor rotate correctly Blower Rotation Check for proper supply air blower rotation If the blower is rotating backwards the line voltage at the unit point of power connection is misphased See PHASING Belt Tension The tension on the belt should be adjusted as shown in Figure 18 i Span Length Defl Force Figure 18 Belt Adjustment 34 4x CAUTION Procedure for adjusting belt tension 1 Loosen six nuts top and bottom A 2 Adjust by turning B 3 Never loosen nuts C 4 Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the span as shown Deflection distance of 4mm 5 32 is obtained To determine the deflection distance from normal position use a straight edge from sheave to sheave as reference line The recommended deflection force is as follows Tension new belts at the max deflection force recommended for the belt section Check the belt tension at least two times during the first 24 hours of operation Any retensioning should fall between the min and max deflection force values
107. aused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower Centrifugal Switch CS If the draft motor should fail the centrifugal switch attached to the shaft of the motor prevents the ignition controls and gas valves from being energized Redundant Gas Valve There are two separate gas valves in the furnace Each valve contains a main and a redundant valve The redundant valves are located upstream of the main gas valves Should either or both of the main gas valves fail in the open position the redundant valves serve as back ups and shut off the flow of gas Flame Sensor Rod 10096 Ignition Control Lock Out The flame rods and controls are located per Proper Flame Adjustment Figure 24 If an ignition control fails to detect a signal from the flame sensor indicating the pilot flame is properly ignited then the main gas valve will not open It will continue to try and ignite the pilot for a maximum of 85 seconds then if the pilot flame is not detected the ignition control will lock out furnace operation until 24V power is removed from the module either at the unit or by resetting the room thermostat Rollout Switch This switch is located above the main burners in the control compartment which in the event of a sustained main burner rollout shuts off and locks out both ignition controls closing both gas valves The ignition controls lock out furnace operation until 24V power is removed
108. ay Type 3 HACR type per NEC Johnson Controls Unitary Products 19 860261 JIM B 0612 J15 thru 25 ZJ High Static Drive Without Powered Convenience Outlet Size Tons 17 5 20 J15 15 J18 J20 20 OD Fan Supply Pwr iiie ua Motors Blower Conv Electric Heat Option MCA olt each Motor Outlet Amps A PER pA A A A e ARE None pe 89 I 08 3 60 83 205 21 154 NEE EE SE 230 3 60 83 205 21 144 460 3 60 61 41 95 11 72 575 3 60 44 33 5 9 TBD TBD 180 TBD TED TBD TBD TBD TBD TBD TED TBD M TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD no TBD TBD TBD TBD TBD TBD pos 3 60 17 9 120 280 37 200 pso 3 60 17 9 120 280 37 200 Nnm 595 460 3 60 70 150 19 100 E86 360 2 433 666 Nnm 49 115 82 Johnson Controls Unitary Products Max Fuse Breaker Size Ups 50 125 175 200 90 90 150 175 225 45 45 70 90 110 860261 JIM B 0612 125 PONE ERES E EER 70 H 70 50 J15 thru 25 ZJ High Static Drive Without Powered Convenience Outlet Continued RLA LRA MCC FLA FLA FLA Model kW Stages Amps Amps None __ tear 175 175 08 3 60 22 4 149 87 200 225 None 927 17 175 230 3 60 22 4 149 37 386 175 200 J25 250 90 19 193 90 100 575 3 60 7 7 54 1 5 100 1 Minimum Circuit Ampacity 2 Dual Element Time Delay
109. azardous Only qualified trained service personnel should install repair or service this equipment Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters Observe all precautions in the literature labels and tags accompanying the equipment whenever working on air conditioning equipment Be sure to follow all other applicable safety precautions and codes including ANSI Z223 1 or CSA B149 1 latest edition Johnson Controls Unitary Products Wear safety glasses and work gloves Use quenching cloth and have a fire extinguisher available during 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 carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing A CAUTION This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes The furnace and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing at pressures in excess of 1 2 PSIG Pressures greater than 1 2 PSIG will cause gas valve damage resulting in a hazardous condition If it is subjected to a pressure greater than 1
110. ber These fuses or equivalent must be used on all installations where compliance with U L standards is required 2 12 BM DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring Terminal Wiring Diagrams GS3 21P0 GS3 22P0 GS3 41P0 GS3 42P0 GS3 43PO SSSSSSSSSSSSSS GS3 23P0 GS3 25P0 GS3 45PO SSSOSSSSSSSSSS 1 SOOIIIIIIIIIOS EE rr Manuela US Tn Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 13 Chapter 2 Installation and Wiring I Terminal Wiring Diagrams continued GS3 27P5 GS3 47P5 GS3 2010 GS3 4010 GS3 2015 GS3 4015 ur ud dil T Te mg pa MOTOR GS3 2020 GS3 4020 GS3 2025 GS3 4025 GS3 2030 GS3 4030 O i J o ralralralralralralralralralral LRN JH H KH H HOH H H H H pi Za NS 2 14 Bl DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring Terminal Wiring Diagrams continued GS3 2040 GS3 2050 GS3 4040 GS3 4050 GS3 4060 Z E E E o o Baa 0 0 0 BS ol 0 0 0 S nla G o Ist Ed Rev D 05 2013 DURAPULsE AC Drive User Manual B 2 15 Chapter 2 Installation and Wiring E Terminal Wiring Diagrams continued GS3 4075 GS3 4100 2 16 B DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring EE EE EE EE Di
111. check for a loose line voltage connection 5 If the RW1 relay is not pulled in check for 24 volts at the RW1 coil If 24 volts is present replace the RW1 relay If 24 volts is not present check for a loose 24 volt connection back to the relay board and check the connections from the room thermostat to the relay board If all connections are correct replace the relay board The draft motor runs but the furnace does not light and the sparker does not spark 1 The ignition control IC1 IC2 may be locked out due to either a flame roll out or 100 shut off These safety features are described above If lock out has occurred 24V must be removed from the ignition controls This is done at the unit or by resetting the room thermostat After resetting 24V check for proper furnace operation If lock out continues to occur locate the source of the problem and correct 60 2 Check all 24 volt connections from the relay board to and in the gas heat section Check low voltage connections to the ETD located in the control box 3 Ifthe furnace is hot it may be out on an over temperature condition wait for limit reset 4 If the furnace is cold check for 24 volts at wire 241 attached to the electrical time delay ETD located in the main control box If 24 volts is not found replace the ETD 24 volts is found at wire 241 remove the wires attached to the TDR and with a VOM check for continuity across contacts 1 and 2 If n
112. correct voltage or encoder set up 4 Check both the mechanical and electrical integrity of the encoder recorded If P 10 05 0 warn and continue operation Encoder feedback loss would not be recorded ENC SIGNAL ERROR 1 Verify power to the encoder feedback card 2 Verify encoder and feedback card wiring Encoder A B phase signal is in error when 5 siate encoder feedback card dip switch settings and encoder the control mode is from the encoder voltage requirements 6 6 DURAPULsE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting Warning Messages Serial Communication and Keypad Errors There are several Warning M essages that a DURAPuLse AC Drive may give The DU RAputse AC Drive allows you to decide its response to these messages The descriptions of the Warning M essages are listed below Warning Messages Error Name Description 1 The Keypad LCD display has failed 2 Check input power 3 Make sure the keypad is tightly connected to the drive No display shown on the keypad Invalid Cmd Code Invalid Command Code when communicating Invalid Address Invalid Address when communicating Invalid Data Invalid Data when communicating Slave Comm Fault Slave Comm Fault device failure Comm Time Out Communication Time O ut Drive Error Drive model doesn t match keypad EEPROM Fault When the copy function is enabled P 9 40 there is a Read
113. ct Switch WD 4 3310 with Single Pole T Stat and Optional Disconnect Switch AIL Alarm Indicator Lights Form 9821 ECO 1 5340 IMPORTANT OWNER SHOULD RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Paulson Cheek MECHANICAL O amp M COVER SHEET SECTION 4 PRODUCT VARIABLE FREQUENCY DRIVES Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Building 3 PHONE 770 729 0076 FAX 770 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc ARCHITECT S ENGINEER S STAMP Paulson Cheek Mechanical Inc DATE RECEIVED 06 05 14 MANUFACTURER GE SUPPLIER GAA SUBMITTED DATE 06 05 14 NO ERRORS DETECTED CORRECT EXCEPTIONS NOTED THIS APPROVAL OF SHOP DRAWINGS DOES NOT RELIEVE THE SUBCONTRACTOR OR VENDOR FROM THE REQUIREMENTS OF THE CONTRACT DOCUMENTS CHECKED BY WILLIAM HAGLER DATE CHECKED 06 09 14 O amp M Section Sheets 6 5 2014 C Drive A DI IRA Se al e i aa LSE son H H U i P I S L IN T EC IR D ATION M O UT VA Thank you for purchasing automation equipment from Automationdirect com doing business as AutomationDirect We want your new automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should
114. d result in personal injury and or property damage Retain POSITIONING AND RUNNING POWER LINES Power is normally brought from within the building and placed inside one corner of the curb Feed power line through the clearance hole provided in the damper and in turn through the electrical conduit hole provided in the base of the exhauster fed through rubber grommets on smaller units If local codes require special elec trical wire of unusually large size then remove and discard the electrical conduit or grommets INSTALLING THE FAN For access to motor and drive assembly simply remove or lift access hood and make necessary power connections to motor through disconnect switch if required Provide a generous amount of slack in power line between motor and disconnect switch to allow for motor deflections and to permit movement or motor for belt tension adjustments ANCHORING OR SECURING THE UNIT Whenever possible anchor the fan by fastening through the vertical portion of the mounting flange The type of fastener depends upon curb construction and using two fasteners per side constitutes adequate anchoring under normal condi tions lf code or specification prescribes fastening through the top horizontal por tion of the mounting flange use neo prene or lead washers under the head of each fastener to prevent water leaks Guy down large A CAUTION units installed in areas subject to high winds or unusual field condi
115. e carefully designed for maxi mum life They need only be replaced when nearly all the silver tip is gone and the con tact tip support is exposed DO NOT FILE the contacts Filing or otherwise dressing the contacts only results in lost tip material Use 022 for 120V 60 Hertz 110V 50 Hertz coll 1 st NO aux contact for CR305 right side mounting sesde AE EE ERA OE nmn 1 st NC aux contact for CR305 right side mounting seen nnne 1 st NO NC aux contact for CR305 right side MOUNtINg ee ser nanana mmm CR305X200C Additional NO aux contact for all forms aa CA305X100D and reduces starter life Additional NC aux contact for all forms u s CR305X100E 5 The ultimate tripping current of the installed PUSN DUHON O Cn EREER ERREUR A Gee QUERER VEI Pe LU eta STR ee UOI ATE VIVERE AR GAAN CR305X220N relay heater can be adjusted 10 by Selector Switch H O A JJ naaa rre a NGANGA NBI UNAN NITA GAAN EE Sii o ed Gi s CR305X230N using adjustment dial shown in Figure 1 Selector Switch Orr ON Se N Ge No ER ERREUR BUE uel dicun ER eie rd CR305X230D indicating LIEW EA on rv Ya EP eto teda Lap v RR EO IE CR305X250N Fifth pole for adding to 4 pole form on ees sees ee Re SR enne nee nennen Gontrol elei E T a avd Principal Renewal Parts Description Catalog Number Quantity Required 1 Coil Retalner Assembly 546A780G052 2 Overload relay 3 heate
116. e is 10 seconds minimum off time is 60 seconds The outlet pressure of the power exhaust fan forces the barometric relief dampers open gravity closes the dampers when the exhaust fan is off Economizer With Optional Intelli comfort II With Power Exhaust The power exhaust motor is energized via the exhaust relay based on the position of the economizer actuator s auxiliary switch adjustment screw The adjustment screw represents the outdoor Johnson Controls Unitary Products 860261 JIM B 0612 damper position at which to activate power exhaust and can be set between 25 to 85 degrees open The outlet pressure of the power exhaust fan forces the barometric relief dampers open gravity closes the dampers when the exhaust fan is off Motorized Outdoor Air Dampers This system operation is the same as the units with no outdoor air options with one exception When the R to G circuit is complete the motorized damper drives open to a position set by the thumbwheel on the damper motor When the R to G circuit is opened the damper spring returns fully closed Cooling Operation Errors Each cooling system is monitored for operation outside of the intended parameters Errors are handled as described below All system errors override minimum run times for compressors High Pressure Limit Switch During cooling operation if a high pressure limit switch opens the UCB will de energize the associated compressor init
117. e limit switch of electric heat units and the temperature limit switch and the gas valve of gas furnace units 48 Compressor Protection In addition to the external pressure switches the compressors also have inherent internal protection If there is an abnormal temperature rise in a compressor the protector will open to shut down the compressor The UCB incorporates features to minimize compressor wear and damage An Anti Short Cycle Delay ASCD is utilized to prevent operation of a compressor too soon after its previous run Additionally a minimum run time is imposed any time a compressor is energized The ASCD is initiated on unit start up and on any compressor reset or lock out Flash Codes The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 25 Reset Remove the call for cooling by raising thermostat setting higher than the conditioned space temperature This resets any pressure or freezestat flash codes Electric Heating Sequence Of Operations The following sequence describes the operation of the electric heat section A CAUTION For units with VFD and electric heat the speed of the indoor blower motor continues to be controlled by duct static pressure via the VAV control board If there are VAV boxes present in the duct system the boxes must be driven to the full open position using a customer supplied power source to assure adequate
118. e the gas heat section These hoods must be installed to assure proper unit function All hoods must be fastened to the outside of the gas heat access panel with the screws provided in the bag also attached to the blower housing The screen for the combustion air intake hood is secured to the inside of the access panel opening with four fasteners and the screws used for mounting the hood to the panel The top flange of this hood slips in under the top of the access panel opening when installing Refer to Vent and Combustion Air Hood Figure 15 Each vent hood is installed by inserting the top flange of the hood into the slotted opening in the access panel and securing in place The products of combustion are discharged horizontally through these two screened hooded vent openings on the upper gas heat access panel Slotted Openings in Access Panel VentAir 7 Outlet Hoods INT Combustion Air Intake Hood Gas Heat C A Access Panels J Figure 15 Vent and Combustion Air Hood Johnson Controls Unitary Products 860261 JIM B 0612 Options Accessories Electric Heat Electric heaters are available as a factory installed option These heaters mount in the heat compartment with the heating elements extending into the supply air chamber All electric heaters are fused and intended for use with single point power supply Economizer Motorized Outdoor Damper Rain Hood The instruction for the optional economizer mo
119. e to be sure all controls function properly Burner Instruction To check or change burners pilot or orifices CLOSE MAIN MANUAL SHUT OFF VALVE AND SHUT OFF ALL ELECTRIC POWER TO THE UNIT 1 Remove the screws holding either end of the manifold to the burner supports 54 2 Open the union fitting in the gas supply line just upstream of the unit gas valve and downstream from the main manual shut off valve 3 Remove the gas piping closure panel Disconnect wiring to the gas valves and spark ignitors Remove the manifold burner gas valve assembly by lifting up and pulling back Heat Tube Adjustable Shutter Exchanger Burner Flame Pilot Tube Blue Only Gas Supply Pipe Figure 25 Typical Flame Burners are now accessible for service Reverse the above procedure to replace the assemblies Make sure that burners are level and seat at the rear of the heat exchanger Burner Air Shutter Adjustment Adjust burner shutters so no yellow flame is observed in the heat exchanger tubes Figure 26 Typical Gas Valve Johnson Controls Unitary Products 860261 JIM B 0612 Charging The Unit 15 Ton Charging Chart 20 Ton Charging Chart ka TTT el ER 460 Outdoor 460 UHH ET Ta 420 m 105 F LA 420 Outdoor BI EE e T Ta IO 380 95 F Outdoor 95 F e LLLI FH 340 EER xol ar hm Et mm soo maal 300 _ TT O EL 280 T 75 F 280 Outdoor ui Li EE py di or
120. ecessary shut off all electric power to the unit prior to any of the following maintenance procedures so as to prevent personal injury A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation which could cause injury to person and or damage unit components Verify proper operation after servicing Cooling Troubleshooting Guide On calls for cooling if the compressors are operating but the supply air blower motor does not energize after a short delay the room thermostat fan switch is in the AUTO position i 56 Turn the thermostat fan switch to the ON position If the supply air blower motor does not energize go to Step 2 If the supply air blower motor does not energize when the fan switch is set to ON check that line voltage is being supplied to the contacts of the M3 contactor and that the contactor is pulled in For units with VFD check that line voltage is being supplied to the M3 Auxiliary contacts Check for loose wiring between the contactor and the supply air blower motor If M3 is pulled in and voltage is supplied to M3 lightly touch the supply air blower motor housing If it is hot the motor may be off on internal protection Cancel any thermostat calls and set the fan switch to AUTO Wait for the internal overload to reset Test again when cool If Ma is not pulled in check for 24 volts at the M3 coil If 24 volts are prese
121. ed to house electrical and electronic control equipment Provide proper spacing within the enclosure to allow the dissipation of heat produced by the drive and any other included electrical and electronic equipment Ventilation or air conditioning may also be required depending upon the application WARNING Failure to observe these precautions may damage the drive and void the warranty Improper installation of the AC drive will greatly reduce its life Observe the following precautions when installing the drive Do not mount the AC drive near heat radiating elements or in direct sunlight e Do not install the AC drive in a place subjected to high temperature high humidity excessive vibration corrosive gases or liquids or airborne dust or metallic particles e Mount the AC drive securely on a flat rigid non flammable surface e Mount the AC drive vertically and do not restrict the air flow to the heat sink fins Auxiliary cooling methods are typically required in order not to exceed maximum T WARNING AC drives generate a large amount of heat which may damage them ambient temperatures Minimum Clearances and Air Flow Air Flow 150mm 6 inches or more L 50mm 50mm 2 inches 2 inches or more 4 Enclosure or more Minimum Clearances 150mm 6 inches and Air Flow or more MAXIMUM
122. ei HEAT DE LOW AMB Non Alarm Condition FT o ar 0 Green LED Flashing ad e Be 022 jui o LN m o TE Boone L Ri RZO 200 sir alas R86 E 1 NO ya 023 2 G E apat e eu S sa lng H LEAD LAG y 25 ex v bn ee Current Alarm RS le r y e i Flashed Red LED R1 60 THS e s Di R32e r P a pa 1 R24 amp aae x AB AVI 23 ey Figure 31 Unit Control Board PT 62 Johnson Controls Unitary Products Unit Control Board Option Setup Option Byte Setup e Enter the Option Setup mode by pushing the OPTION SETUP STORE button and holding it for at least 2 seconds The green status LED Option Byte will be turned on and the red status LED Heat Delay is turned off e The 8 4 2 and 1 LEDs will then show the status of the 4 labeled options 8 Fan Off at Heat Start 4 Low Ambient Lockout 2 Free Cooling Lockout and 1 Lead Lag Press the UP or Down button to change the LED status to correspond to the desired Option Setup To save the current displayed value push the OPTION SETUP STORE button and hold it for at least 2 seconds When the value is saved the green LED will flash a few times and then normal display will resume NOTE While in either Setup mode if no buttons are pushed for 60 seconds the display will revert to its normal display exiting the Option Setup mode When saving the control board only saves the parameters for the currently displayed mode Opt
123. el propeller Reverse direction Replace fuses or circuit breaker Shut off power and check wiring for proper connections Repair or replace motor Replace belts Check for leakage Clean filters Correct rotation of wheel propeller Add make up fan or louver opening Slope should be fitted in the direction of the drainage opening or grease collection box and drain spout Clean drain spout Install new cooling tube with gasket and dome top Empty grease box Adjust tension or replace bad belts Contact power supply company Reverse direction of motor Slow down fan by opening variable pitch pulley on motor shaft Replace motor with correct open NEMA service factors 1 15 or higher with 40 degrees ambient Remove blockage and seal cooling tube in place Check airflow under hood and adjust kitchen equipment output Check motor ratings with catalog speed and air capacity chart Note Care should be taken to follow all local electrical safety and building codes Provisions of the National Electric Code NEC as wells as the Occupational Safety and Health Act OSHA should be followed All motors are checked prior to shipment If motor defects should develop prompt service can be obtained from the nearest author ized service station of the motor manufacturer while under warranty Exchange repair or replacement will be provided on a no charge basis if the motor is defective within the warranty period The PennBarry
124. eme care when adjusting belts as not to misalign the pulleys Any misalignment will cause a sharp reduction in belt life and produce squeaky annoying noises See figure 1 On units equipped with two or three groove pulleys adjust all belts with equal tension Figure 1 Pulley Alignment 8 Tension Whenever belts A CAUTION are removed or installed never force belts over pulleys without loosening motor first to relieve belt tension Before applying power to the motor check the following a Check line voltage with motor nameplate b On single phase motors set up the terminal blocks in accordance with the nameplate instructions or wiring diagram The set up must match the line voltage 2 PENNBARRY c If the motor is three phase group and connect the winding leads as shown on the wiring diagram The line voltage must correspond with proper grouping of motor leads d On two speed motors follow the wiring diagram explicitly or serious motor damage will occur e Activate the blower and allow it to operate f Carefully check the rotation of the wheel to insure operation in the proper direction Incorrect rotation A CAUTION overloads motor severely and results in serious motor damage To change rotation of three phase units simply interchange any two of the three line leads On single phase units change the terminal block set up following the wiring diagram g Check that bearing temperatures are no
125. emperature Correction Factors The examples below will assist in determining the airflow performance of the product at altitude Example 1 What are the corrected CFM static pressure and BHP at an elevation of 5 000 ft if the blower performance data is 6 000 CFM 1 5 IWC and 4 0 BHP Solution At an elevation of 5 000 ft the indoor blower will still deliver 6 000 CFM if the rpm is unchanged However Table 14 must be used to determine the static pressure and BHP Since no temperature data is given we will assume an air temperature of 70 F Table 14 shows the correction factor to be 0 832 Corrected static pressure 1 5 x 0 832 1 248 IWC Corrected BHP 4 0 x 0 832 3 328 Example 2 A system located at 5 000 feet of elevation is to deliver 6 000 CFM at a static pressure of 1 5 Use the unit Johnson Controls Unitary Products blower tables to select the blower speed and the BHP requirement Solution As in the example above no temperature information is given so 70 F is assumed The 1 5 static pressure given is at an elevation of 5 000 ft The first step is to convert this static pressure to equivalent sea level conditions Sea level static pressure 1 5 832 1 80 Enter the blower table at 6000 sCFM and static pressure of 1 8 The rpm listed will be the same rpm needed at 5 000 ft Suppose that the corresponding BHP listed in the table is 3 2 This value must be corrected for elevation BHP at 5 000 f
126. endicular to the air flow so that velocity pressure full open will not affect the static pressure readings Start the supply air blower motor Adjust the resistances in both 3 Using an inclined manometer determine the pressure drop the supply and the return air duct systems to balance the air across a dry evaporator coil Since the moisture on an distribution throughout the conditioned space The job evaporator coil may vary greatly measuring the pressure specifications may require that this balancing be done by drop across a wet coil under field conditions would be someone other than the equipment installer inaccurate To assure a dry coil the compressors should be deactivated while the test is being run Johnson Controls Unitary Products 43 860261 JIM B 0612 Pressure Drop Across A Dry Indoor Coil VS Supply Air CFM Supply Air Drive Adjustment The RPM of the supply air blower will depend on the required M CFM the unit accessories or options and the static resistances 0 35 of both the supply and the return air duct systems With this information the RPM for the supply air blower and the motor pulley adjustment turns open can be determined from the 0 25 Blower Performance Data Tables 4x CAUTION Belt drive blower systems MUST be adjusted to the specific static and CFM requirements for the application Pressure Drop IWG D D Oi The belt drive blowers are NOT set at the factory for any specific static or CFM Adjustmen
127. ere is no call for free cooling the actuator is proportionately modulated from the 2 to 10 Vdc signal with 2 Vdc corresponding to full closed and 10 Vdc corresponding 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 set point Demand Control Ventilation Set Point setting and there is a call for free cooling the actuator modulates from the minimum position to the full open position 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 Sensor Kit Part 2AQ04700424 Replace the top rear access panel on the unit Optional BAS Ready Economizer Power Exhaust Damper Set Point Adjustment Remove the economizer access panel from the unit Loosen but do not remove the two panel latches Locate the economizer actuator where the following adjustment can be made With power exhaust option each building pressurization requirement will be different The point at which the power exhaust comes on is determined by the economizer s outdoor damper position The actuator s auxiliary switch adjustment screw should be set at the damper position at which the power exhaust is needed The adjustment screw can be set between 25 to 85 degrees open Replace the economizer access panel Optional Variable Air Volume VAV A variable air volume VAV optio
128. eries A 6 Line Reactor Dimensions Legacy GS Series not for new installations 0 ee es A 16 Line Reactor Applications and Wiring Connections A 17 Braking Units and Braking Resistors A 20 Braking IS saka EE RE ET we N ok EE ET EE A 20 Braking Unit WIE seit NG KARERA A 21 Braking Unit DIMENSIONS LL A 22 Braking Resistors LL A 23 Braking Resistor Wiring aa A 24 Braking Resistor Dimensions enn A 24 EMI Input Filters I RR se ke Re A 29 EMI Filter Dimensions RR RR I m mI A 30 EMI Filter Wiring Connections n n A 36 RF Filter AA AA eae A 37 RF Filter Dimensions ss EE RR RR RII m IR A 37 RF Filter Wiring sanear abe ee ea EE AE OE A 37 Fuses and Fuse Kits o A 38 Fuse Block Dimensions LL A 39 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual c 5 Table of Contents Ep Appendix A Accessories continued GS3 FB Feedback Card A 41 GS3 FB Terminal Descriptions Wiring Notes A 42 GS3 FB Basic Wiring Diagram aa A 43 Types of Encoders and Dip Switch Settings A 44 Ethernet Interface A 45 ZIPLink Cables for RS 485 Modbus RIU A 46 GS Drive Configuration Software A 47 Miscellaneous Accessories AA aaa aao A 48 Configuration Cable nasaan aeaaea A 48 Spare Keypad RR rh A 48 Keypad Cables ss SE EE EE EE ke RR RR RR ke A 48 Remote Panel Adapter
129. es n h sitez pas nous t l phoner au 770 844 4200 Cette publication s appuie sur l information qui tait disponible au moment de l impression la soci t AutomationD irect nous nous efforcons constamment d am liorer nos produits et services C est pourquoi nous nous r servons le droit d apporter des modifications aux produits ou aux publications en tout temps sans pr avis ni quelque obligation que ce soit La pr sente publication peut aussi porter sur des caract ristiques susceptibles de ne pas tre offertes dans certaines versions r vis es du produit Marques de commerce La pr sente publication peut contenir des references a des produits fabriques ou offerts par d autres entreprises Les d signations des produits et des entreprises peuvent tre des marques de commerce et appartiennent exclusivement leurs propri taires respectifs AutomationDirect nie tout int r t dans les autres marques et d signations Copyright 2003 2004 2007 2009 2011 2013 Automationdirect com Incorporated Tous droits r serv s Nulle partie de ce manuel ne doit tre copi e reproduite ou transmise de quelque facon que ce soit sans le consentement pr alable crit de la soci t Automationdirect com Incorporated AutomationD irect conserve les droits exclusifs l gard de tous les renseignements contenus dans le pr sent document DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 WARNING Read this manual thoroughly be
130. eset External DI 4 30 Fault Reset Keypad 3 3 Fault Reset Serial Comm 4 76 Fault tolerant w 1 Feedback Card A 41 Filter EMI 2 23 Filter RF 2 23 Firmware Version 4 2 4 76 Frequency O utput 2 20 2 21 4 39 Function Keys 3 3 Fuses 2 23 Fuses and Fuse Kits A 38 i 2 DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 Index EE X G GFCI Ground Fault Circuit Interrupt 2 12 Grounding w 3 2 11 GS ED RV 100 5 18 H Hazardous Voltage 2 11 Heat 2 3 High Risk Activities w 1 Increase Speed 4 30 4 34 Input Disable 4 30 4 35 Inspection and Maintenance 6 2 Installation 2 3 Inverter 1 3 Jog 4 30 4 32 4 76 K Keypad 3 2 Copy Keypad Function 3 16 Manual Keypad Control 4 30 4 32 W rite Parameter Settings to Drive 3 18 W rite Parameter Settings to Keypad 3 17 Keypad Cables A 48 Keypad Spare A 48 L LCD Display 3 2 LED Indicators 3 2 Line Start Lockout 4 64 Lock Parameters 4 74 M Maintenance and Inspection 6 2 Manual Keypad Control 4 30 4 32 M arques de commerce w 2 Memory Addresses for Drive Status 5 11 Memory Addresses for Parameters 5 4 Minimum Clearances and Air Flow 2 3 Miscellaneous Accessories A 48 MODBUSRTU 5 14 5 19 5 23 5 38 5 67 Motors Single phase 2 12 Motors Three phase 1 3 2 12 Mounting Enclosure w 3 Multi Speed Bits 4 30 4 32 N National Electrical Code NEC w 1 2 12 National Electrical M anufacture
131. et up your DURAPULSE AC Drive for two common applications The first example applies to an application that requires constant torque and the second example requires variable torque in its application E For a complete list and description of the parameters for the DURAPULSE AC drives see CHAPTER 4 Example 1 Constant torque e g conveyors compressors etc In this example the AC drive needs to operate a motor that is connected to a conveyor In order to decide which parameters need modifications we will make a list of the needs for the application Application Needs e The AC drive must control a 460V 1hp inverter duty motor We will use a model GS3 41P0 AC drive for this application An example of the motor nameplate is shown below INVERTER DUTY MOTOR Volts 460 PHASE 3 TYPE P AMB 40 C INSUL CLASS F DUTY CONT ENCL TEFC CODE K e The maximum speed for the motor is 2000 rpm e The motor should accelerate to maximum speed in 5 seconds eThe motor should decelerate from maximum speed in 5 seconds Applications with high starting torque redirements and or high inertia loads may require optional braking resistors e The motor will require a high torque when starting The operation of the motor start stop etc will be controlled by remote control terminals All keys on the DURAPULSE keypad should be disabled The frequency of the AC drive will be determined by remote potentiometer that has a O to 10V signal
132. eter Settings to Drive leen 3 18 Chapter 3 Keypad Operation and Quickstart D O ISO The DURAPULSE Digital Keypad The digital keypad includes a 2 line x 16 character LCD display 5 status LED Indicators and 9 function keys The diagram below shows all of the features of the digital keypad and an overview of their functions The lit LED Indicators will blink when there is a Fault or a Warning LCD Display Up Down Keys NE Enter Key Fwd Rev Key AUTOMATION Stop Reset Key LCD Display The LCD Display shows the operation values and parameter settings of the AC drive LED Indicators The RUN LED indicates the AC drive is in Run Mode STOP The STOP LED indicates the AC drive is notin Run Mode The FWD LED indicates the AC drive is running the motor in the forward direction The REV LED indicates the AC drive is running the motor in the reverse REV direction The JOG LED indicates the AC drive is in the Jog Mode E If the STOP key on the keypad is active and the keypad is removed the drive will stop 3 2 DURAPULsE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart EE ee E Function Keys Program Key Pressing the PRO GRAM key will display the parameter groups U se the UP DOWN or PROGRAM keys to cycle through the parameter groups The LCD display will show which parameter group is currently selected Display Key Pressin
133. etween R and G with the fan switch in the ON position and in the AUTO position during operation calls Proper wiring between the room thermostat and the UCB and Loose wiring from the room thermostat to the UCB 7 If 24 volts is present at the room thermostat but not at the UCB check for proper wiring between the thermostat and the UCB i e that the thermostat G terminal is connected to the G terminal of the UCB and for loose wiring 8 If the thermostat and UCB are properly wired replace the UCB 9 If the blower motor runs with the fan switch in the ON position but does not run shortly after the furnace has ighited when the fan switch is in the AUTO position check the room thermostat for contact between R and G during W1 calls On calls for heating the supply air blower operates but the draft motor does not the room thermostat fan switch is in the AUTO position 1 Thedraft motor has inherent protection If the motor shell is hot to the touch wait for the internal overload to reset 2 the motor shell is cold with the room thermostat calling for heat check for line voltage at the motor s Mate N Lok connector attached to the evaporator partition If line voltage is present replace the draft motor 3 If line voltage is not present check for line voltage at the heat relay RW1 contacts in the main control box and check to see if the RW1 is pulled in 4 If the RW1 relay is pulled in
134. etween terminals R OCC on the VAV add on board to put the unit into Occupied Mode Additionally the unit can be switched between Unoccupied Occupied mode Johnson Controls Unitary Products 860261 JIM B 0612 through network communications with Simplicity PC and other BAS control systems pea TEE rede or en MT BES ig F N i s a Ha i Q T ri KR Lt gt m y e de EE 500 Jumper Wire i dE Eu HRS up m AT de E n b a FN t _ lt e UR i vene PE P ti Fl iti Figure 21 Occupied Jumper Once placed into the Occupied Mode the speed of the indoor blower motor is controlled by duct static pressure The Duct Static set point default 1 5 is the pressure that the VFD drive will maintain when operating the unit in VAV mode If the duct static pressure reaches or exceeds the high limit set point default 4 5 then the supply fan motor will be shutdown The Supply Air Temperature SAT is controlled by staging compressors on and off to satisfy the Operating Cooling Supply Air Temp Set point There are 3 set points that determine the resulting Operating Cooling Supply Air Temp Set point 1 VAV Cooling Supply Air Temp Upper Set point default 60 F 2 VAV Cooling Supply Air Temp Lower Set point default 55 F 3 VAV Supply Air Temp Reset Set point default 72 F When the Return Air Temp RAT is above the VAV Supply Air Temp Reset Set point the S
135. f the proper size NOTE To find the Btu input multiply the number of cubic feet of gas consumed per hour by the Btu content of the gas in your particular locality contact your gas company for this information it varies widely from city to city Table 24 Gas Rate Cubic Feet Per Hour Seconds for Size of Test Dial One Rev 1 cu ft 2 300 6 600 450 10 360 12 300 14 257 16 225 18 200 20080 22 164 24 150 s o 188 28 129 Johnson Controls Unitary Products 860261 JIM B 0612 EXAMPLE By actual measurement it takes 13 seconds for the hand on the 1 cubic foot dial to make a revolution with just a 300 000 Btuh furnace running Read across to the column in the table above headed 1 Cubic Foot where you will see that 278 cubic feet of gas per hour are consumed by the furnace at that rate Multiply 278 x 1050 the Btu rating of the gas obtained from the local gas company The result is 292 425 Btuh which is close to the 300 000 Btuh rating of the furnace Manifold Gas Pressure Adjustment Small adjustments to the high fire gas flow may be made by turning the pressure regulator adjusting screw on the automatic gas valve Adjust as follows 1 Remove the cap on the regulator It s located next to the push on electrical terminals 2 To decrease the gas pressure turn the adjusting screw counterclockwise 3 To increase the gas pressure turn the adjusting screw clockwise NOTE The correct manifold
136. follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time Itis your responsibility to determine which codes should be followed and to verify that the equipment installation and operation is in compliance with the latest revision of these codes Ata minimum you should follow all applicable sections of the N ational Fire Code National Electrical Code and the codes of the National Electrical M anufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for your product design installation or operation Our products are not fault tolerant and are not designed manufactured or intended for use or resale as on line control equipment in hazardous environments requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems in which the failure of the product could lead directly to death personal injury or severe
137. fore using DURAPuLse Series AC Motor Drives WARNING AC input power must be disconnected before performing any maintenance Do not connect or disconnect wires or connectors while power is applied to the circuit Maintenance must be performed only by a qualified technician WARNING There are highly sensitive MO S components on the printed circuit boards and these components are especially sensitive to static electricity To avoid damage to these components do not touch these components or the circuit boards with metal objects or your bare hands WARNING A charge may still remain in the DC link capacitor with hazardous voltages even if the power has been turned off To avoid personal injury do not remove the cover of the AC drive until all DISPLAY LED lights on the digital keypad are off Please note that there are live components exposed within the AC drive Do not touch these live parts WARNING Ground the DURAPUuLse AC Drive using the ground terminal The grounding method must comply with the laws of the country where the AC drive is to be installed Refer to Basic Wiring Diagram in CHAPTER 2 WARNING The mounting enclosure of the AC drive must comply with EN50178 Live parts shall be arranged in enclosures or located behind barriers that meet at least the requirements of the Protective Type IP20 The top surface of the enclosures or barrier that is easily accessible shall meet at least the requirements of the Protective Type IP40
138. from the controls either at the unit or by resetting the room thermostat Auxiliary Limit Switch AUX This control is located inside the heat exchanger compartment and is set to open at 190 F It is a manual reset switch If AUX trips then the primary limit has not functioned correctly Replace the primary limit Johnson Controls Unitary Products 860261 JIM B 0612 Table 22 Gas Heat Limit Control Setting Units Capacity MBH Limit Control Tons Input Output Opens F BEEE 795 15 175 20 825 196 The ICB monitors the Pressure and Rollout switches of gas heat units The control circuit includes the following safety controls a gu Ignitor Control 1 Rollout itch Sensor 1 suo Valve DE 3 F r 1 EUM AN Sensor 2 Ignitor 2 Burner Compartment Figure 23 Gas Valve and Controls Flash Codes The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 25 Resets Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature This resets any flash codes Gas Heat Anticipator Setpoints It is important that the anticipator setpoint be correct Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space Reducing the value below the correct setpoint will give shorter ON cycles and may result in the lowering
139. g Inputs mar X X XDCM 10V Power Source 20mA max Potentiometer AH KO 0 to 10V Ps NG Al2 dc 0 20mA or 4 20mA kk X ACM Al3 10 to 10V ACMAAA er Analog Signal Common t Frequency command source O can be one of the three analog inputs up down keys on keypad see Power or via the RS 485 serial comm Wiring Diagram port See parameter settings Factory default setting Multi function Output Contact KAC Drive Running 240VAC 24VDC 3A Resistive N 240VAC 24VDCOO 5A Inductive e N C 240VAC 24VDC BA Resistive N O 240VAC 24VDC 1 5A Inductive N O Multi function Digital Outputs C 12 48VDC 50mA KAC Drive Fault 12 48VDC 50mA XAt Speed 12 48VDC 50mA Zero Speed T 12 48VDC Digital Frequency Output 48VDC 50mA max 1 1 Duty 50 Multi function Analog Output ES i N Voltmeter K Output Frequency indication 0 10 VDC O 2mA RS 485 Serial Comm Port 1 15V 2 GND 4 SG 3 SG 5 NC Kk Factory default source of frequency command is via the keypad up down keys XXX ACM and DCM are isolated from each other O Main circuit power terminals Control circuit terminal Shielded leads lst Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 21 Chapter 2 Installation and Wiring Control Wiring Diagram Sourcing Inputs Users must connect wiring according to the circuit diagram shown below WARNING Do not plug a modem
140. g the DISPLAY key on the keypad repeatedly will cycle through the status messages on the AC drive Fwd Rev Key Pressing the FW D REV key changes the direction in which the motor operates Run Pressing the RUN key starts the AC drive operation This key has no function if the AC drive is controlled by the external control terminals Up Down Keys The UP DOWN keys are used to scroll through the parameter groups the various parameters in each group and also change the parameter settings in single unit increments To quickly run through the range of settings press and hold the UP or DOWN key Enter Key Press the ENTER key to view parameters and store parameter settings Stop Reset Key Used to stop AC drive operation If the AC drive has stopped due to a fault clear the fault first then press this key to reset the AC drive Jog Key Pressing the JO G key controls the jog function 2009 After a one 1 minute key inactivity the keypad LCD display will automatically revert E to the display mode and display the user defined display function selected in parameter P8 00 Adjust Frequency Setpoint If the UP and DOWN keys are pressed when the LCD is in DISPLAY mode and the AC drive frequency is being controlled by the keypad P4 00 1 then the keypad will display the frequency setpoint and have the ability to adjust the frequency setpoint with the UP DOWN keys accordingly The frequency setpoint will be stored even if the drive is powered off
141. ge of cooling the low voltage control circuit from R to Y2 is completed Compressor 2 is energized provided it has not been locked out and condenser fan motor 1 and condenser fan motor 2 remain energized If the ambient temperature is above 60 F If there is an initial call for more than one stage of cooling the UCB will delay energizing compressors 2 3 amp 4 by 30 seconds each depending on how many stages are called for in order to avoid a power in rush Once the thermostat has been satisfied it will de energize Y1 Y2 Y3 and Y4 If the compressors have satisfied their minimum run times the compressors and condenser fans are de energized Otherwise the unit operates each cooling system until the minimum run times for the compressors have been completed Upon the final compressor de energizing the blower is stopped following the elapse of the fan off delay for cooling To be available a compressor must not be locked out due to a high or low pressure switch or freezestat trip and the Anti Short Cycle Delay ASCD must have elapsed These units utilize a lead lag feature that results in an equal amount of run hours on all compressors thereby extending the life of the compressors This feature works as follows If the thermostat requires for more than one stage of cooling the currently off compressor with the least number of run hours will be the next to be energized When the thermostat requires fewer stages
142. gs covered An accessory flange kit is available for connecting side ducts For bottom duct applications For side duct applications 1 Remove the side panels from the supply and return air 1 Replace the side panels on the supply and return air compartments to gain access to the bottom supply and compartments with the accessory flange kit panels return air duct covers 2 Connect ductwork to the flanges on those panels 2 Remove and discard the bottom duct covers Duct openings are closed with sheet metal covers except when the unit includes a power exhaust option The covering consists of a heavy black paper composition 3 Replace the side supply and return air compartment panels 10 Johnson Controls Unitary Products Power Exhaust Rain Hood on Return Air Compartment Supply Air Compartment Rear View 860261 JIM B 0612 Economizer Motorized Damper Rain Hood on Outdoor Air Compartment Economizer Motorized Damper and Power Exhaust Rain Hood Fixed Outdoor Air Intake Hood Located on ele 1 Condensate Drain Must be Trapped OO aie L 28 3 16 a 92 LH View Detail Y Unit with Rain Hoods Figure 7 J15 thru 25 ZJ Unit Dimensions Rain Hood Table 6 J15 thru 25 ZJ Unit Clearances Direction Distance in Directon Distance in 72 With 36 Maximum Top Horizontal Overhang For Right 36 Condenser Air Discharge Front 36 Bottom 0 Rear 24 W O Economizer
143. h the compressor housing If it is hot the compressor may be off on inherent protection Cancel any calls for cooling and wait for the internal overload to reset Test again when cool If M2 is not pulled in check for 24 volts at the M2 coil If 24 volts is present and M2 is not pulled in replace the contactor Failing the above if voltage is supplied at M2 M2 is pulled in and the compressor still does not operate replace the compressor If 24 volts is not present at M2 check for 24 volts at the UCB terminal C2 If 24 volts are present check for loose wiring between C2 and the compressor contactor If 24 volts is not present at the C2 terminal check for 24 volts from the room thermostat at the UCB Y2 terminal If b7 860261 JIM B 0612 24 volts is not present from the room thermostat check for the following a 24 volts at the thermostat Y2 terminal b Proper wiring between the room thermostat and the UCB i e Y1 to Y1 Y2 to Y2 and C Loose wiring from the room thermostat to the UCB If 24 volts is present at the UCB Y2 terminal the compressor may be out due to an open high pressure switch low pressure switch or freezestat Check for 24 volts at the HPS2 LPS2 and FS2 terminals of the UCB If a switch has opened there should be a voltage potential between the UCB terminals e g if LPS2 has opened there will be 24 volts of potential between the LPS2 terminals If 24 volts is present at the UCB Y2 terminal and
144. hange tap on transformer for 208 3 60 or 380 3 50 operation See unit wiring diagram Smoke Detector Ma 2 R Jumper SD EXPANSION BOARD TERMINAL BLOCK 24 VAC Class 2 1 TERMINALS ON A LIMITED NUMBER OF THERMOSTATS Second stage heating not required on single stage heating 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 Figure 12 Typical Field Wiring 24 Volt Thermostat Johnson Controls Unitary Products 15 860261 JIM B 0612 Table8 Electrical Data J15 thru 25 ZJ Standard Drive Without Powered Convenience Outlet Size Tons 17 5 16 J15 15 J18 J20 20 OD Fan Supply Pwr n ici ue Motors Blower Conv Electric Heat Option MCA olt each Motor Outlet Amps RLA LRA MCC FLA FLA FLA Model kW Stages Amps More poem IA E 08 3 60 191 amp 3 205 21 154 None 768 zt 205 144 mak o E O 46030 61 41 os 11 72 BL RE ES EEE 5755 60 4 4 33 5 9 l Bi TBD TBD TED 160 TBD TBD TED TED Tap TBD TBD TBD TED TED Tap TBD TBD TBD M TED Tap TBD TBD None __ 393 pos 3 60 17 9 120 280 37 154 H None 903 3039 90 17 9 120 280
145. he AC drive must be derated D Determine max enclosure internal temp AC drives generate a significant amount of heat and will cause the internal temperature of an enclosure to exceed the rating of the AC drive even when the ambient temperature is less than 104 F 40 C Enclosure ventilation and or cooling may be required to maintain a maximum internal temperature of 104 F 40 C or less Ambient temperature measurements calculations should be made for the maximum expected temperature Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 1 3 Chapter 1 Getting Started E Selecting the Proper Drive Rating continued E Calculate required output amperage U se the chart below to calculate the required FLA of the AC drive as shown by the following examples Select the rating that equals the motors voltage and equals or exceeds the calculated amperage e Example 1 GS1 or GS2 drive Motor FLA 26A Overload 200 p 45s Altitude 800m MEIT 45 C e Example 2 DURAPuLse G S3 drive Motor FLA 8A Overload 135 9 75s Altitude 1100m MEIT 35 Calculating Required Drive Current Example 2 GS3 GS1 or GS2 DURAPULSE Then Enter Emp Overload Derate overload If overload is 15096 and 60 seconds 1 If overload is gt 150 and lt 60 seconds overload 150 If overload is 5 60 seconds overload 100 O verload Result Multiply FLA x overload entry Altitude D erate meters Altitude is lt 1 000m
146. he last five alarms on the LED If the compressor is locked out cancel any call for cooling This will reset any compressor lock outs If the LPS is still open after the ASCD the compressor will not be energized for 30 seconds The second and third times that the UCB sees an open LPS will count towards the three occurrences that will cause a UCB lock out NOTE While the above step will reset any lockouts compressor 1 may be held off for the ASCD See the next step 10 If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out the UCB may have the compressor in an ASCD Check the LED for an indication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs 11 If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip repeat trip lock out or ASCD the economizer terminals of the UCB may be improperly wired Check for 24 volts at the Y1 OUT terminal of the UCB If 24 volts is present trace the wiring from Y1 OUT for incorrect wiring If 24 volts is not present at the Y1 OUT terminal the UCB must be replaced 12 For units without economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug the jumpe
147. he motor when a forward operation command is received To reverse the direction of motor rotation switch the connections of any of the two motor leads 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 2 11 Chapter 2 Installation and Wiring eee 8 Make sure that the power source is capable of supplying the correct voltage and required current to the AC drive 9 Do not attach or remove wiring when power is applied to the AC drive 10 Do not inspect components unless inside PO W ER lamp is turned off 11 Do not monitor the signals on the circuit board while the AC drive is in operation 12 GS3 series DU RAPULSE drives cannot be used with single phase motors 13 Route the power and control wires separately or at 90 degree angle to each other 14 If a filter is required for reducing EMI Electro M agnetic Interference install it as close as possible to the AC drive EMI can also be reduced by lowering the Carrier Frequency 15 If the AC drive is installed in a place where a load reactor is needed install the filter close to the T1 T2 and T3 side of AC drive Do not use a Capacitor L C Filter Inductance Capacitance or R C Filter Resistance Capacitance unless approved by AutomationD irect 16 When using a GFCI Ground Fault Circuit Interrupt select current sensor with sensitivity of 200mA and not less than 0 1 second detection to avoid nuisance tripping Motor O peration Precautions 1 When using the
148. iate the ASCD Anti short cycle delay and if the other compressor is idle stop the condenser fans If the call for cooling is still present at the conclusion of the ASCD the UCB will re energize the halted compressor Should a high pressure switch open three times within two hours of operation the UCB will lock out the associated compressor and flash a code see Table 25 If the other compressor is inactive the condenser fans will be de energized Low Pressure Limit Switch The low pressure limit switch is not monitored during the initial 30 seconds of a cooling system s operation For the following 30 seconds the UCB will monitor the low pressure switch to ensure it closes If the low pressure switch fails to close after the 30 second monitoring phase the UCB will de energize the associated compressor initiate the ASCD and if the other compressor is idle stop the condenser fans If the LPS is still open after the ASCD the compressor will not be energized for 30 seconds The second and third times that the UCB sees an open LPS will count towards the three occurrences that will cause a UCB lock out Once the low pressure switch has been proven closed during the 30 second monitor period described above the UCB will monitor the low pressure limit switch for any openings If the low pressure switch opens for greater than 5 seconds the UCB will de energize the associated compressor initiate the ASCD and if the other compress
149. ies analog gain amp bias adjustment jog electronic thermal relay automatic torque boost trip history software protection lst Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 1 9 Chapter 1 Getting Started I General Specifications cont Protective Functions Electronic Thermal O verload Relay Auto Restart after Fault M omentary Power Loss Reverse O peration Inhibit Auto Voltage Regulation O ver Voltage Stall Prevention Auto Adjustable Accel D ecel O ver Torque D etection M ode O ver Torque D etection Level O ver Torque D etection Time O ver Current Stall Prevention during Acceleration O ver Current Stall Prevention during O peration O perator D evices 9 key 2 line x 16 character LCD display 5 status LED s Programming Parameter values for setup and review fault codes Operator l Interface Status Display O utput Frequency M otor Speed Scaled Frequency O utput Current Motor Load O utput Voltage DC Bus Voltage PID Setpoint PID Feedback Frequency Setpoint Key Functions RUN STO P RESET FW D REV PROGRAM DISPLAY lt UP gt DOWN gt ENTER Enclosure Rating Protected Chassis IP20 Ambient Temperature 10 C to 40 C 14 F to 104 F Environment Ambient H umidity 20 to 90 RH non condensing Vibration 9 8 m s 1G less than 10 Hz 5 9 m s 0 6G 10 to 60 Hz Installation Location Altitude 1000m or lower above sea level keep fro
150. il If 24 volts are present and M1 is not pulled in replace the contactor Failing the above if voltage is supplied at M1 M1 is pulled in and the compressor still does not operate replace the compressor If 24 volts is not present at M1 check for 24 volts at the UCB terminal C1 If 24 volts is present check for loose wiring between C1 and the compressor contactor Johnson Controls Unitary Products 7 l 24 volts is not present at the C1 terminal check for 24 volts from the room thermostat at the UCB Y1 terminal If 24 volts is not present from the room thermostat check for the following a 24 volts at the thermostat Y1 terminal b Proper wiring between the room thermostat and the UCB i e Y1 to Y1 Y2 to Y2 and c Loose wiring from the room thermostat to the UCB 8 If 24 volts is present at the UCB Y1 terminal the compressor may be out due to an open high pressure switch low pressure switch or freezestat Check for 24 volts at the HPS1 LPS1 and FS1 terminals of the UCB If a switch has opened there should be a voltage potential between the UCB terminals e g if LPS1 has opened there will be a 24 volt potential between the LPS1 terminals 9 If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing an alarm code If not press and release the ALARMS button on the UCB The UCB will flash t
151. ion Byte or Heat Delay Heat Delay Setup e Enter the Option Setup mode by pushing the OPTION SETUP STORE button and holding it for at least 2 seconds he green status LED Option Byte will be turned on and the red status LED Heat Delay is turned off Press the COMM SETUP SELECT button to toggle into the Heat Delay Setup the green LED will turn off and the red LED for Heat Delay will turn on e The 8 4 2 and 1 LEDs will then show the status of the Heat Delay See Table 26 Press the UP or Down button to change the LED status to correspond to the desired Heat Delay Value To save the current displayed value push the OPTION SETUP STORE button and hold it for at least 2 seconds When the value is saved the red LED will flash a few times and then normal display will resume NOTE While in either Setup mode if no buttons are pushed for 60 seconds the display will revert to its normal display exiting the Option Setup mode When saving the control board only saves the parameters for the currently displayed mode Option Byte or Heat Delay Subject to change without notice Printed in U S A Copyright 2012 by Johnson Controls Inc All rights reserved Table 26 Heat Delay Heat Heat Red Red Red Red Delay Delay 60 180 On On On On so o On On On of so 60 On On Of On so 30 On On Of Of 4 18 on of On On so On of On Of eo On Of Of
152. isplay of the AC drive should default to output current A when running Parameter Setup In order to meet the needs of this application the parameters should be set as follows Mii Motor Nameplate Voltage Setting 208 Range 230V series 200 208 220 230 240 Default Setting 240 460V series 380 400 415 440 460 480 Default Setting 480 This parameter setting is determined by the motor nameplate GYS Motor Nameplate Amps Setting 9 2 Range Drive Rated Amps x 0 1 Default Setting Drive Rating A to Drive Rated Amps x 1 0 This parameter setting is determined by the motor nameplate 3 10 B DURAPUSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart EX Motor Base Frequency Setting 60 Range 50 60 400 D efault Setting 60 This parameter setting is determined by the motor nameplate NE Motor Base RPM Setting 3525 Range 375 to 24 000 RPM Default Setting 1750 This parameter setting is determined by the motor nameplate INTE Motor Maximum RPM Setting 3600 Range P0 03 to 24 000 RPM Default Setting P0 03 This parameter setting is determined by the needs of the application maximum rpm rating for the motor you are using If this information is not readily T WARNING The Motor Maximum RPM parameter P0 04 should never exceed the available consult your motor manufacturer GET Stop Methods Setting 01 Range 00 Ramp to Stop D efault Setting 00 01 Coast to stop The app
153. ive 3 18 W rite Parameter Settings to Keypad 3 17 Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual I 7 Index i 8 DURAPuLsE AC Drive User Manual Ist Ed Rev D 05 2013 G S 3 V 3 M 0 4 Paulson Cheek MECHANICAL O amp M COVER SHEET SECTION 5 PRODUCT STARTERS Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Building 3 PHONE 770 729 0076 FAX 770 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc ARCHITECT S ENGINEER S STAMP Paulson Cheek Mechanical Inc DATE RECEIVED 06 05 14 MANUFACTURER GE SUPPLIER GAA SUBMITTED DATE 06 05 14 NO ERRORS DETECTED CORRECT EXCEPTIONS NOTED THIS APPROVAL OF SHOP DRAWINGS DOES NOT RELIEVE THE SUBCONTRACTOR OR VENDOR FROM THE REQUIREMENTS OF THE CONTRACT DOCUMENTS CHECKED BY WILLIAM HAGLER DATE CHECKED 06 09 14 O amp M Section Sheets 6 5 2014 Caution Before installing in a nuclear application determine that the product is intended for such use Warnin g Disconnect power before installing or servicing Description GE s 300 Line full voltage magnetic motor starters include a magnetic contactor and a three leg block overload relay providing motor protection against running and stalled motor overloads The overload relay is pro vided with a yellow trip indicator which is located to the right of the reset arm and is visible when the overload relay is
154. ive Introduction 1 3 Purpose of AC Drives LL 1 3 Selecting the Proper Drive Rating LL 1 3 Model Number Explanation aaaea ss eee ke Ee n n n 1 5 Nameplate Information 1 5 Drive Package Contents 0 00 ccc sk se se hn 1 5 External Parts and Labels 0 00 Sk ee n n RR IRI 1 6 DURAPuLsE AC Drive Specifications 1 7 Chapter 1 Getting Started E Manual Overview Overview of this Publication The DURAPULSE AC Drive User Manual describes the installation configuration and methods of operation of the DURAPULSE Series AC Drive Who Should Read This Manual This manual contains important information for those who will install maintain and or operate any of the GS3 Series AC Drives Supplemental Publications The National Electrical M anufacturers Association N EM A publishes many different documents that discuss standards for industrial control equipment Global Engineering Documents handles the sale of NEMA documents For more information you can contact Global Engineering Documents at 15 Inverness Way East Englewood CO 80112 5776 1 800 854 7179 within the U S 303 397 7956 international www global ihs com N EM A documents that might assist with your AC drive systems are e Application G uide for AC Adjustable Speed D rive Systems e Safety Standards for Construction and Guide for Selection Installation and O peration of Adjustable Speed Drive Systems
155. l service Where motors have been ordered with greasable bearings these bearings are factory lubri cated and require no attention for one year under normal conditions If grease relief fittings are provided remove them when performing maintenance to allow grease to flow out Whenever possible apply grease while the motor is running This practice should not supersede any safety considerations DO NOT OVER GREASE as most lubricants deteriorate motor windings thereby reducing motor life 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 Dynamo Fans Table 1 Recommended Lubricants Guterown EPA poloy 30 F Imperial Oil Unirex EP 1 0 C Shell Alvania R 1 Energrease MPMK11 Replacement Parts Replace parts with components which duplicate original parts correctly Incorrectly sized shafts belts pulleys etc can damage the fan 32 F to 150 F 0 C to 66 C Spare or replacement parts and prices are available upon request Please supply the following information Factory Order Number Customer s Name and Order Number and Date If this information is not available furnish a complete description of the part required Names of parts are shown on the following drawing To order motors provide the HP RPM voltage phase hertz and type of enclosure Operation amp Maintenance Manual Figure 2 Dynamo Centrifugal Blower Class 1 S W S I ANGLE SUPPORTS UNIT SIZES 1
156. l units determine the minimum safe floor or roof loading requirement for prop er support minimally by multiplying the total weight of the unit by two Follow local codes and good practices to ensure prop er anchoring of roof top units A minimum of 12 clearance should be provided for adequate heat dissipation For Dynamos flex pads etc are available to reduce the transmission of vibration to the surround ing areas See suggested ductwork instal lations See dimensional information fol lowing Blowers suitable for Restaurant Exhaust Appliances YZHW are accordingly labeled These units require installation according to NFPA96 Standards local codes and general practices For curb mounting to assure a positive seal apply a high tem perature gasket material on the roof curb INSTALLING DAMPERS When required install dampers prior to mounting the unit on the curb or frame Secure dampers to the inside of the curb without undue twisting which may distort the damper frame Damper frame must be reasonably level on all sides Check for free operation If dampers are motor operated type ascertain that proper volt age is impressed on motor terminals Operation amp Maintenance Manual Please read and save these instructions Read carefully before attempting to assemble install operate or maintain the product described Protect yourself and others by observing all safety information Failure to comply with instructions coul
157. lay Function Setting 01 Default Setting 00 Settings 00 Output Frequency Hz 01 Motor Speed RPM 02 Scaled Frequency 03 Output Current A 04 Motor Load 96 05 Output Voltage V 06 DC BusVoltage V 07 PID Setpoint 08 PID Feedback PV 09 Frequency Setpoint The AC drive display will default to motor speed rom when running Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 3 9 Chapter 3 Keypad Operation and Quickstart Ep Example 2 Variable torque e g fans centrifugal pumps etc In this example the AC drive needs to operate a motor that is connected to a centrifugal pump Asin Example 1 we will make a list of the needs for the application in order to decide which parameters need modifications Application Needs e The AC drive must control a 208V 3hp fan cooled standard duty motor The AC drive model we will be using for this application is a GS3 23P0 An example of the motor nameplate is shown below STANDARD DUTY MOTOR DESIGN B AMB 40 C INSUL CLASS F DUTY CONT ENCL TEFC CODE K e The maximum speed for the motor is 3600 rpm e The motor should accelerate to maximum speed in 20 seconds e The motor should coast to stop when operation is terminated e The motor will be turning a centrifugal pump The operation of the motor start stop etc will be controlled by the DURAPULSE digital keypad The frequency of the AC drive will be determined by the DURAPULSE keypad potentiometer The d
158. le G 53 2025 Use the UP DOWN keys to select the desired program number PGM 1 thru PGM4 and press the ENTER key O Use the UP DOWN keys to select Yes to confirm and press the EN TER key The LCD display will show the message Keypad gt Drive Loading while the parameters are being copied and return to the program selection when finished D Select Parameter Group O Select Program to Write CA WRITE TO DRIUE PGMI 6353 4040 WRITE TO DRIVE PGA C53 24PH Select Copy Mode WRITE TO DRIVE PLIH4 Empty Go Confirm Selection CA Hre you sure HO CT o Loading TES The gt 4 Loading display text flashes during copy keypad 3 18 B DURAruse AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart Use the PROGRAM key to back out of the various menu selections without saving changes The warning message RATING MISMATCH will be displayed on the LCD display if trying to do a WRITE TO DRIVE copy mode and selecting an existing program that does not match the drive being used IG ME Ist Ed Rev D 05 2013 DURAPULsE AC Drive User Manual 3 19 Chapter 3 Keypad Operation and Quickstart P j j j j 4 jk 4 j j j KU 3 20 Bl DURAPUSE AC Drive User Manual Ist Ed Rev D 05 2013 M AINTENANCE AND TROUBLESHOOTING In
159. lication requires that this parameter be set to Coast to Stop WARNING If the Stop Method for the DURAPULSE AC drive is set for Coast to Stop the AC drive will ignore the Deceleration Time P1 02 setting 20 Acceleration Time Setting 20 0 Range 0 1 to 600 sec Default Setting 10 sec The motor should accelerate from 0 RPM to Maximum Motor RPM P0 04 in 20 seconds Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 3 11 Chapter 3 Keypad Operation and Quickstart GET Volts Hertz Settings Setting 02 Range 00 General Purpose Default Setting 00 01 High Starting Torque 02 Fans and Pumps 03 Custom The DURAPULSE AC drive has some predefined torque settings that meet the needs of most applications A custom setting is available if needed In this example the motor will be running a pump In some applications it is perfectly acceptable to leave this parameter set for 00 General Purpose EXT Source of Operation Command Setting 00 D efault Setting 00 Settings 00 Operation Determined by Digital Keypad 01 Operation determined by external control terminals Keypad STOP is enabled 02 Operation determined by external control terminals Keypad STOP is disabled 03 Operation determined by RS 485 interface Keypad STOP is enabled 04 Operation determined by RS 485 interface Keypad STOP is disabled The AC drive operation will be determined by the Digital Keypad f paramete
160. lows compressor operation all the time This programming can be checked or changed by the local distributor If none of the above corrected the error test the integrity of the UCB Disconnect the C1 terminal wire and jumper it to the Y1 terminal DO NOT jump the Y1 to C1 terminals If the compressor engages the UCB has faulted If none of the above correct the error replace the UCB On calls for the second stage of cooling the supply air blower motor and compressor 1 are operating but compressor 2 is not the room thermostat fan switch is in the AUTO position 1 If installed check the position of the economizer blades If the blades are open the economizer is providing free cooling If the second stage of cooling is requested following a short delay compressor 1 will be energized unless it is locked out Typically compressor 2 is energized only during free cooling if the call for the second stage of cooling persists for 20 minutes Compressor 2 will not energize simultaneously with compressor 1 if a call for both stages of cooling is received The UCB delays compressor 2 by 30 seconds to prevent a power surge If after the delay compressor 2 does not energize on a second stage call for cooling check for line voltage at the compressor contactor M2 and that the contactor is pulled in Check for loose wiring between the contactor and the compressor If M2 is pulled in and voltage is supplied at M2 lightly touc
161. lter O ptional Input EMI filters reduce electromagnetic interference or noise on the input side of the AC drive They are required for CE compliance and recommended for installations prone to or sensitive to electromagnetic interference i G RF filter O ptional RF filters reduce the radio frequency interference or noise DURAPULSE 9 on the input or output side of the inverter AC Drive GS3 XXxx Braking Resistor O ptional 9 I Dynamic braking allows the AC drive to produce additional braking stopping torque AC drives can gt typically produce between 15 20 braking torque without the addition of any external components O ptional braking may be required for applications that have high inertia loads or require rapid deceleration AC Line Reactor O ptional Output line load reactors protect the motor insulation against AC drive short circuits and IG BT reflective wave damage and also smooth the motor current waveform allowing the motor to run cooler They are recommended for operating non inverter duty motors and when the length of wiring between the AC drive and motor exceeds AN Motor grounding 75ft terminal E Please refer to Appendix A for specifications on DURAPurse AC Drive Accessories Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual M 2 23 Chapter 2 Installation and Wiring External Accessories Power Supply continued Please follow the specific power sup
162. lustrate Bottom Duct openings Power D and Gas Piping Connection GAS SUPPLY location ENTRY NOTE For curb mounted units refer to the curb hanger ENTRY A CONTROL WIRING dimensions of the curb for proper size of the ENTRY supply and return air duct connections Figure 5 J15 thru 25 ZJ Unit Dimensions Front View Table 4 Utilities Entry Table 5 Supply Fan VFD Weights In Lbs Opening Size Supply Fan Motor 230V 460V 575V Hole Used For Diameter W O Manual Bypass 5 5 5 A L UNG Control Wiring Front 5 0 hp 30 3 4 NPS Fem Bottom 7 5 hp 80 30 30 3 5 8 KO qm Front 10 0 hp 35 3 NPS Fem J Bottom 15 0 hp 40 C 2 3 8 KO Gas Piping Front W Manual Bypass D 1 11 16 Hole Gas Piping Bottom 5 0 hp 35 1 One inch Gas Piping NPT Required 7 5 hp 35 2 Opening in the bottom to the unit can be located by the slice in the 10 0 hp 40 insulation 15 0 hp 45 Note All entry holes should be sealed to prevent rain water entry into building Johnson Controls Unitary Products 9 860261 JIM B 0612 de Dot Plug _ a for Pressure Evaporator Drop Reading Section 40 3 8 Outdoor Air Supply Air Access Dimensions listed are for side duct Return Air EN 1 NPT Female f TN Palda A Outdoor Air Cond Drain ANJE petas Aalan aaas Compartment Connector for Side Duct Flange Kit Access Figure 6 J15 thru 25 ZJ Unit Dimensions Rear View NOTE Units are shipped with the bottom duct openin
163. m To Finished Floor SERVICE CABLE OR CONDUIT F 8 203 2 Minimum To Finished Floor Note This heater employs a visual alarm light to warn that parts of the heater are getting excessively hot If the alarm illuminates immediately disconnect power from heater and inspect for any objects on or adjacent to the heater that may cause high temperatures DO NOT OPERATE HEATER WITH THE ALARM LIGHT ILLUMINATED Form 9821 ECO 1 5340 IMPORTANT OWNER SHOULD RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE 3310 SERIES TROUBLE SHOOTING Symptom Possible Fault s Remedy Heater Does Not Operate 1 Electrical Circuit Open 1 A Close electric circuit B Verify correct supply voltage C Adjust thermostat to higher setting 2 Defective Thermostat 2 Check continuity with an ohm meter Replace defective part if necessary 3 Thermal Cut Out Open 3 A Remove any obstruction from front of heater Alarm Light On B Verify correct supply voltage Heat On But Fan Does Not Operate 1 Fan Motor Failure 1 A Verify correct supply voltage B Check motor wiring connections C Replace defective motor if necessary FIGURE 3 MODEL NO VOLTAGE WATTAGE AMPERAGE 9 Field Conversion For Lower Wattage To convert heater to 1500 a lower wattage rating Remove Red Jumper from heating E3313RP element See WD1 WD2 WD3 and WD4 The wattage will l be reduced to half of the nameplate wattage See Figure 3 HF3315RP 3203 30022290
164. m corrosive gas liquid and dust N oise filter input AC reactor output AC reactor cable for remote operator programming software D ynamic braking resistor input fuses 1 10 B DURAPUSE AC Drive User Manual Ist Ed Rev D 05 2013 INSTALLATION AND WIRING Contents of this Chapter Ambient Conditions commons 2 2 Storage Conditions 2 2 Installation RR AE ER N EE OO apnea 2 3 Minimum Clearances and Air Flow LL 2 3 DIMENSIONS lle m rans 2 4 Circuit CONNECTIONS lessen 2 11 DANGER Warning Notes a 2 11 Terminal Wiring Diagrams leen 2 13 Main Circuit Wiring see I ee 2 17 Power Wiring Diagrams lene 2 18 Control Terminal Designations 2 20 Control Wiring Diagram Sinking Inputs 2 21 Control Wiring Diagram Sourcing Inputs 2 22 External Accessories annaa 00 AA hrs 2 23 Chapter 2 Installation and Wiring I Ambient Conditions Ambient environmental conditions for use Ambient Conditions Ambient Temperature 10 C to 40 C 14 F to 104 Relative Humidity 0 to 90 non condensing 86 kPa to 106 kPa 9 8 mis 1G less than 10 Hz 5 9 m s 0 6G 10 to 60 Hz Altitude 1000m or lower above sea level keep from corrosive gas liquid and dust IP20 Protection against contact by fingers Protection against medium size foreign objects Installation Location Enclosure Rating
165. me propane Propane is an excellent solvent and will quickly dissolve white lead and most standard commercial compounds A special pipe dope must be used when assembling wrought iron or steel pipe Shellac based compounds such as Gaskolac or Stalastic and compounds such as Rectorseal 5 Clydes s or John Crane may be used All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out loose particles Before initial start up be sure that all gas lines external to the unit have been purged of air The gas supply should be a separate line and installed in accordance with all safety codes as prescribed under Limitations A 1 8 inch NPT plugged tapping accessible for test gage connection must be installed immediately upstream of the gas supply connection to the unit After the gas connections have been completed open the main shut off valve admitting normal gas pressure to the mains Check all joints for leaks with soap solution or other material suitable for the puroose NEVER USE A FLAME AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result 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 A C
166. mizer configuration used with OH IAQ a 0 10 VDC analog input provided by a field installed carbon dioxide sensor which monitors indoor air quality CO2 concentration and enables call for Demand Ventilation mode for units installed with economizer option OAQ a 0 10 VDC analog input provided by a field installed carbon dioxide sensor which monitors outdoor air quality CO2 concentration and along with IAQ enables call for Differential Demand Ventilation mode for units installed with economizer option APS a 24 VAC binary input provided by a field installed air proving switch which monitors the pressure difference across the indoor blower PUR a 24 VAC binary input for building purge calls from an external source OCC a 24 VAC binary input used to set the building occupancy status for the control LIMIT 2 a 24 VAC binary input which either confirms 2nd stage gas heat operation or receives an error signal from the variable frequency drive Outputs FAN a 2 10 VDC analog output signal sent to the VFD to modulate the speed of the indoor blower motor ECON a 2 10 VDC analog output signal sent to the economizer actuator to modulate position of the return air and outdoor air dampers optional EXH a 24 VAC binary output signal used to turn on off the power exhaust relay optional VAV BOX gas electric heat only a normally open relay contact connected to a terminal block used to drive the building s V
167. motor thermal overload fault OVER TORQUE If P 6 07 is set to 2 to enable detection during accel decel 1 Reduce the motor overload Parameter settings P 6 07 to P 6 09 2 Adjust the over torque detection setting to an appropriate level An external condition has occurred to cause an over torque fault x OVER CURRENT ACC DS UN KA Check for possible poor insulation at the output line Decrease the torque boost setting in P 2 02 Increase the acceleration time P 1 01 and P 1 05 Replace the AC drive with one that has a higher output capacity O ver current during acceleration 1 Short circuit at motor output 2 Torque boost too high 3 Acceleration time too short 4 AC drive output capacity is too small OVER CURRENT DEC Check for possible poor insulation at the output line Increase the deceleration time P 1 02 and P 1 06 Replace the AC drive with one that has a higher output capacity m N O ver current during deceleration 1 Short circuit at motor output 2 Deceleration time too short 3 AC drive output capacity is too small UJ OVER CURRENT STD m Check for possible poor insulation at the output line O ver current during steady state operation 7 Check for possible motor stall 1 Short circuit at motor output 3 Replace the AC drive with one that has a higher output capacity 2 Sudden increase in motor loading 3 AC drive output capacity is too
168. mperature sensor detects excessive heat Ensure that the ambient temperature falls within the specified temperature range Make sure that the ventilation holes are not obstructed Remove any foreign objects on the heat sinks and check for possible dirty heat sink fins Provide enough spacing for adequate ventilation UNDER VOLTAGE The AC drive detects that the DC bus voltage has fallen below its minimum allowable value Check whether the input voltage falls within the rated AC drive input voltage OVERLOAD The AC drive detects excessive drive output current lst Ed Rev D 05 2013 1 Check whether the motor is overloaded 2 Reduce torque compensation setting as set in P 2 03 3 Increase the AC drive s output capacity Note The AC drive can withstand up to 150 of the rated current for a maximum of 60 seconds DURAPuLsE AC Drive User Manual 6 3 Chapter 6 Maintenance and Troubleshooting Fault Messages Fault Name Description Corrective Actions THERMAL OVERLOAD If P 6 07 is set to 1 to enable during steady state Check for possible motor overload Check electronic thermal overload relay setting P 6 00 Increase motor capacity Reduce the current level so that the AC drive output current does not exceed the value set by the M otor Rated Current P 0 01 UJ N e Parameter settings P 6 07 to P 6 09 An external condition has occurred to 4 cause an internal electronic or
169. n regulators and between the second stage regulator and the appliance Pipe size required will depend on the length of the pipe run and the total load of all appliances Complete information regarding tank sizing for vaporization recommended regulator settings and pipe sizing is available from most regulator manufacturers and LP gas suppliers AWARNING LP gas is an excellent solvent and will guickly dissolve white lead and most standard commercial compounds A special pipe dope must be used when assembling wrought iron or steel pipe for LP Shellac base compounds such as Gaskolac or Stalastic and compounds such as Rectorseal 5 Clyde s or John Crane may be used Johnson Controls Unitary Products Check all connections for leaks when piping is completed using a soap solution NEVER USE A FLAME AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result 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 Vent And Combustion Air Two vent hoods and a combustion air hood with screens are shipped attached to the blower housing in the blower compartment For units with factory installed VFD option the hoods and accompanying hardware are shipped insid
170. n using a variable frequency drive VFD is available for applications requiring a constant supply duct static pressure A differential pressure transducer is used to monitor supply duct static pressure and return a speed 30 reference signal to the VFD to control the output of the indoor blower motor Duct Static Pressure Transducer A 0 5 WC pressure transducer located in the control box compartment is used to sense static gauge pressure in the supply air duct and convert this pressure measurement to a proportional 0 5 VDC electrical output Pressure transmitting plastic tubing 1 4 diameter must be field supplied and installed from the transducer to both the ductwork and to the atmosphere Connect the tubing from the HIGH pressure tap of the transducer to a static pressure tap field supplied in the supply duct located at a point where constant pressure is expected To prevent an unstable signal due to air turbulence there should be no obstructions turns or VAV terminal boxes up or down stream of the sensing tube location for at least a distance of 6 10 times the duct diameter Tubing must also be run between the LOW pressure tap of the transducer and atmospheric pressure outside of the unit 4x CAUTION Do not run plastic tubing in the supply or return air ducts as air movement could cause erroneous pressure measurements If the tubing penetrates through the bottom of the unit be sure openings are sealed to prevent
171. nbalanced load 2 Possible current leakage m Check the motor for possible insulation damage Check for possible poor insulation at the output line EXT BASE BLOCK N AC drive output is turned off 1 When the external input terminal base block is active the AC drive output will be turned off Disable this connection and the AC drive will begin to work again INPUT POWER LOSS N One phase of the input power is lost I Check for possible poor connection on the input power line Check for possible loss of phase on input power line OUTPUT SHORTED IGBT Short Circuit Contact ADC Support for assistance PID FBACK LOSS 1 If P 7 27 0 warn and AC drive stop PID feedback loss recorded 2 If P 7 27 1 warn and continue PID Warning PID Feedback Loss The 4 20mA PID signal has been lost The corrective action can be set with the PID Feedback Loss parameter P 7 27 The available settings are 00 Warn and AC Drive Stop 01 Warn and Continue operation PID feedback loss not ior RE The default setting is 00 lst Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 6 5 Chapter 6 Maintenance and Troubleshooting Fault M essages Fault Name Description Corrective Actions ENCODER LOSS 1 Verify that the encoder board has power If P 10 05 1 or 2 warn and AC drive 2 Check to be sure it is not mis wired stop Encoder feedback loss would be 3 Check for in
172. nit but units can be converted easily to four inch filters 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 9 A CAUTION Make sure that panel latches are properly positioned on the unit to maintain an airtight seal 860261 JIM B 0612 Power And Control Wiring Field wiring to the unit fuses and disconnects must conform to provisions of National Electrical Code NEC ANSI NFPA No 70 Latest Edition in U S A current Canadian Electrical Code C221 and or local ordinances The unit must be electrically grounded in accordance with NEC and CEC as specified above and or local codes A CAUTION 208 230 3 60 and 380 415 3 50 units control transformers 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 Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 1 The internal wiring harnesses furnished with this unit are an integral part of the design certified unit Field alteration to comply with electrical codes should not be required If any of the wire supplied with the unit
173. none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing a code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms on the LED If the compressor is locked out remove any call for cooling at the thermostat or by disconnecting the thermostat wiring at the Y1 Y2 Y3 and Y4 on the UCB terminal This will reset any compressor lock outs except LPS lockouts these can only be reset by cycling power to UCB NOTE While the above step will reset any lock outs 10 11 12 13 compressor 1 will be held off for the ASCD and compressor 2 may be held off for a portion of the ASCD See the next step If 24 volts is present at the UCB Y2 terminal and none of the switches are open and the compressor is not locked out the UCB may have the compressor in an ASCD Check the LED for an indication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions These options are not enabled by default Local distributors can test the UCB for this programming For units with factory installed economizers the UCB is programmed to lock out compressor operation when the LAS set point is reached For units without factory installed or with field installed economize
174. nt at M3 but M3 is not pulled in replace the contactor Failing the above if there is line voltage supplied at M3 M3 is pulled in and the supply air blower motor still does not operate replace the motor For units with VFD if there is line voltage supplied at M3 M3 is pulled in and the blower motor does not operate check all power amp control wiring connections to and from the drive and for any fault warning messages displayed on the drive s digital display refer to the drive user manual for full descriptions if necessary Clear any fault by pressing RESET on the drive s keypad and take any corrective action as needed If the motor still does not operate replace the motor If 24 volts is not present at M3 check that 24 volts is present at the UCB supply air blower motor terminal FAN If 24 volts is present at the FAN check for loose wiring between the UCB and M3 If 24 volts is not present at the FAN terminal check for 24 volts from the room thermostat If 24 volts are not present from the room thermostat check for the following a Proper operation of the room thermostat contact between R and G with the fan switch in the ON position and in the AUTO position during operation calls b Proper wiring between the room thermostat and the UCB and C Loose wiring from the room thermostat to the UCB If 24 volts is present at the room thermostat but not at the UCB check for proper wiring between the thermostat
175. nt mode always begins with compressor operation Compressor minimum run time may extend the minutes of compressor operation The defrost cycle will begin immediately following the elapse of the minimum run time When operating in low ambient mode the UCB will not lockout the compressors due to a freezestat trip However a freezestat trip will de energize the associated compressor If the call for cooling is still present at the end of the ASCD and the freezestat has closed the unit will resume operation Safety Controls The unit control board monitors the following inputs for each cooling system 1 A suction line freezestat to protect against low evaporator temperatures due to a low airflow or a low return air temperature opens at 26 5 PF and resets at 38 5 F 2 Ahigh pressure switch to protect against excessive discharge pressures due to a blocked condenser coil or a condenser motor failure opens at 625 25 psig and resets 500 25 psig 3 Alow pressure switch to protect against loss of refrigerant charge opens at 50 5 psig and resets at 71 5 psig The above pressure switches are hard soldered to the unit The refrigeration systems are independently monitored and controlled On any fault only the associated system will be affected by any safety preventive action The other refrigerant system will continue in operation unless it is affected by the fault as well The unit control board monitors the temperatur
176. ntil 24V power is removed from the module either at the unit or by resetting the room thermostat NOTE That the second stage furnace can operate even if first stage has locked out When the thermostat satisfies de energizing the RW2 and RW1 thus opening all gas valves The blower motor will continue to run after the furnace is shut down until the specified fan off delay for heating has been satisfied The UCB will de energize the blower motor Redundant valve A Main valve YY Gas main To main burner Gas Valve To pilot burner Figure 22 Gas Valve Piping When the thermostat calls for the first stage of heating the low voltage control circuit from R to W1 is completed A call for heat passes through the UCB to the ignition control board ICB The UCB monitors the W1 call and acts upon any call for heat Once voltage has been sensed at W1 the UCB will initiate the fan on delay for heating energizing the indoor blower after the specified delay has elapsed When the thermostat has been satisfied heating calls are ceased The GV is immediately de energized The blower is de energized after the fan off delay for heating has elapsed The draft motor performs a 25 second post purge Gas Heating Operation Errors Temperature Limit If the UCB senses zero volts from the high temperature limit the indoor blower motor is immediately energized When the UCB again senses
177. ocated in digits 15 18 4 460 3 60 5 575 3 60 2 Non Pwr d Conv Outlet 5 Pwr d Conv Outlet 3 Smoke Detector S A 4 Johnson Controls Unitary Products Installation Installation Safety Information Read these instructions before continuing this appliance installation This is an outdoor combination heating 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 Refer to the unit rating plate for the approved type of gas for this product 2 Install this unit only in a location and position as specified on Page 7 of these instructions 3 Never test for gas leaks with an open flame Use commercially available soap solution made specifically for the detection of leaks when checking all connections as specified on Pages 5 28 and 52 of these instructions 4 Always install furnace to operate within the furnace s intended temperature rise range with the duct system and within the allowable external static pressure range as specified on the unit name rating plate specified on Page 27 of these instructions 5 This equipment is not to be used for temporary heating of buildings or structures under construction AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury death or property damage Never test for gas leaks with an open flame use a
178. of cooling the currently running compressor with the most run hours will be the first to be de energized Economizer With Single Enthalpy Sensor When the room thermostat calls for first stage cooling the low voltage control circuit from R to G and Y1 is completed The UCB energizes the blower motor if the fan switch on the room thermostat is set in the AUTO position and drives the economizer dampers from fully closed to their minimum position If the enthalpy of the outdoor air is below the set point of the enthalpy controller previously determined Y1 46 energizes the economizer The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor If the outdoor air enthalpy is above the set point Y 1 energizes compressor 1 When the thermostat calls for second stage cooling the low voltage control circuit from R to Y2 is completed The UCB energizes the first available compressor If the enthalpy of the outdoor air is below the set point of the enthalpy controller i e first stage has energized the economizer Y2 will energize compressor 1 If the outdoor air is above the set point Y2 will energize compressor 2 If Y2 brings on compressor 1 and this condition remains for more than 20 minutes then compressor 2 will be energized until the thermostat is satisfied Once the thermostat has been satisfied it will de energize
179. oint plus 5 F free cooling is available If free cooling is available with a Y1 call then the control modulates the economizer dampers to maintain the First Stage SAT Control setpoint plus or minus one degree If free cooling is unavailable then 1st stage mechanical cooling is initiated If at anytime the outdoor air temperature rises above the First Stage SAT Control setpoint plus 5 F while free cooling is available then a Y1 call will also initiate 1st stage mechanical cooling For a Y2 call free cooling is available based upon the criteria described above except a Second Stage SAT Control setpoint is used in the determination Once the call for cooling has been satisfied it will de energize any compressors and condenser fans after the minimum compressor run times have been satisfied Otherwise the unit operates each cooling system until the minimum run times for the compressors have been completed Upon de energizing the final compressor the blower will continue to run with the economizer damper in its minimum position if in the Occupied mode otherwise the blower will stop following the elapse of the fan off delay for cooling and the economizer outdoor damper will close Economizer With Optional VAV Blower With Power Exhaust The power exhaust motor is energized via the controller s EXH terminal and the ER relay based on the position of the economizer damper parameter settings in the VAV control Minimum run tim
180. olts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug a poor connection between the UCB and economizer Mate N Lock plugs loose wiring from the Mate N Lock plug to the economizer back to the Mate N Lock plug and from the Mate N Lock plug to the Y1 ECON terminal The economizer control may have faulted and is not returning the 24 volts to the Y1 ECON terminal even though the economizer is not providing free cooling To test the economizer control disconnect the Mate N Locks and jumper between the WHITE and YELLOW wires of the UCB s Mate N Lock plug 13 The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions These options are not enabled by default They can be checked by local distributors For units with factory installed economizers the UCB is programmed to lock out compressor operation when the LAS set point is reached For units without factory installed or with field installed economizers the UCB allows compressor operation all the time This programming can be checked or changed by the local distributor 14 If none of the above corrected the error test the integrity of the UCB Disconnect the C1 terminal wire and jumper it to the Y1 terminal DO NOT jump the Y1 to C1 terminals If the compressor engages the UCB has faulted 15 If none of the above correct the error replace the
181. on Refer to the Fixed Outdoor Damper Figure 9 12 MIN ROOF OPENING 39 7 8 Wide X 61 7 8 Long hi OUTDOOR COIL END OF UNIT 126 1 4 A FRONT OF UNIT Supply and Return Alr including duct support rails as shown are typical for bottom duct applications For location of horizontal duct applications on back of unit refer to Unit Dimension details Gasketing and mounting screws are provided in a parts bag attached to the hood assembly Apply gasketing to the three flange surfaces on the hood prior to installing the hood Extend gasketing 1 4 inch beyond the top and bottom of the two side flanges to insure adequate sealing Adjusting the damper to the desired air flow may be done before mounting the hood into position or after installation by removing the front hood panel or the screen on the bottom of the hood Damper baffle in position 1 will allow approximately 1096 outdoor air flow position 2 approximately 1596 and to allow approximately 25 remove the damper baffle On units with bottom return air application install the damper assembly over the opening in the side return air access panel Remove and discard the opening cover and the covering over the hood mounting holes used for shipping before installing Secure with the screws provided On units with side return air applications install the damper assembly on the return air ductwork as close to the unit as possible Cut an opening 16 inches high
182. one is found the TDR is open and must be replaced If there is continuity re attach the wires With the draft motor running check for 24 volts at terminal 4 of RW1 2 and RW2 1 If 24 volts is not present the centrifugal switch CS has not closed or has gone bad Check the line voltage to the unit if it is correct replace the draft motor If line voltage is low call the power company 6 Check for 24V at terminal 2 of RW1 2 and RW2 1 If 24V is not present check for 24V at RW1 and RW2 relay coils If these relays are pulled in then check for a loose connection at terminal 2 and terminal 4 of each relay If no problem is found then replace RW1 and or RW2 as required 7 1f 24 volts is present at the ignitor controls check all control wiring at the ignitor controls and the high tension wire to the ignitors Check that the ground wires from the ignitor controls the gas valves and pilot burners are all intact and making good electrical connection Check to make sure that the ceramic insulator on the pilot ignitors or sensors is not broken or cracked if all are intact replace the ignition control IC1 or IC2 The draft motor runs and the ignitor sparks at the pilot burner but the pilot does not ignite and a gas odor is not detected at the draft motor outlet Check to make sure gas is being supplied to the unit Make sure that the gas pressure to the unit is within the proper limits as described in the POST START CHECK LI
183. ool Free Access Cabinet Downflow Only D Std Motor Motorized Damper E Std Motor Motorized Damper Barometric Relief J Std Motor Economizer Barometric Relief N Hi Static P Hi Static Economizer Q Hi Static Economizer Power Exhaust Downflow Only R Hi Static Motorized Damper K Hi Static Motorized Damper Barometric Relief S Hi Static Economizer Barometric Relief 2 Low Static 3 Low Static Economizer 4 Low Static Economizer Power Exhaust Downflow Only 5 Low Static Motorized Damper 6 Low Static Motorized Damper Barometric Relief 7 Low Static Economizer Barometric Relief 2 208 230 3 60 Installation Options A No Options Installed N Options 2 amp 3 B Option 1 P Options 2 amp 4 C Option 2 Q Options 2 3 amp 4 D Options 1 amp 2 R Options 3 amp 4 E Option 3 S Option 5 F Option 4 T Options 1 8 5 G Options 1 8 3 U Options 1 3 amp 5 H Options 1 44 V Options 1 4 8 5 J Options 1 2 amp 3 W Options 1 3 4 amp 5 K Options 1 2 8 4 X Options 38 5 L Options 1 3 44 Y Options 4 8 5 M Options 1 2 3 8 4 Z Options 3 48 5 1 Disconnect 4 Smoke Detector R A Variable Air Volume VFD BAS ready for customer provided VFD controller Variable Air Volume VFD and Manual Bypass BAS ready Variable Air Volume VFD Ready for customer provided field installed drive 2 Pleated Filters MERV 7 4 Pleated Filters MERV 13
184. or control modes Auto Tune Instructions If the drive is set to auto tune with no motor connected the drive will go into an infinite auto tune loop without access to the parameter groups To correct this situation simply power down the unit connect the motor complete auto tuning even if incorrect reset factory default 9 08 99 and then start over 1 2 ES o NI M ake sure all wiring is correctly connected to the AC drive and motor M ake sure there is no load connected to the motor s output shaft including any belts or gear boxes Program parameters P0 00 P0 01 P0 02 P0 03 and P0 04 with the correct values for the motor being used After enabling the Auto Tune parameter P0 05 as shown on the previous page for either a 1 to have the AC drive determine only the motor line to line resistance R1 P0 06 or a 2 to determine R1 P0 06 and the motor s no load current P0 07 the message MOTOR AUTO TUNE flashing sSTOP TO CANCEL will appear on the keypad LCD display for a 3 second period If the STOP key is pressed during this time the Auto Tune procedure will terminate the value in parameter P0 05 will reset to 0 and the LCD display will return to the display mode After the confirmation message is shown the AC drive is ready to perform an Auto Tune the keypad LCD will display the message PRESS lt RU N gt TO CONTINUE for 60 seconds Once the RUN key is pressed the display will
185. or is idle stop the condenser fans If the call for cooling is still present at the conclusion of the ASCD the UCB will re energize the halted compressor Should a low pressure switch open three times within one hour of operation the UCB will lock out the associated compressor and flash a code Table 25 If the other compressor is inactive the condenser fans will be de energized 47 860261 JIM B 0612 Freezestat During cooling operation if a freezestat opens the UCB will de energize the associated compressor initiate the ASCD and if the other compressor is idle stop the condenser fans If the call for cooling is still present at the conclusion of the ASCD the UCB will re energize the halted compressor Should a freezestat open three times within two hours of operation the UCB will lock out the associated compressor and flash a code Table 25 If the other compressor is inactive the condenser fans will be de energized Low Ambient Cooling To determine when to operate in low ambient mode the UCB has a pair of terminals connected to a temperature activated switch set at 45 F When the low ambient switch is closed and the thermostat is calling for cooling the UCB will operate in the low ambient mode Low ambient mode operates the compressors in this manner 10 minutes on 5 minutes off The indoor blower is operated throughout the cycle The 5 minute off period is necessary to defrost the indoor coil Low ambie
186. or telephone into the DURAPULSE RJ 12 Serial Comm Port or permanent damage may result DURAPULSE AC Drive Multi function Digital Inputs E GS3 XXXX Multi function Output Contact 24V Power Source R1 i i ui 20mA max AC Drive Running 5 aes DIT n RIC ga 240VAC 24VDC 3A Resistive N C bea E Input Mode Setting 240VAC 24VDC 0 5A Inductive N C AO DI Sink n R1O4 240VAC 24VDC BA Resistive N O External Fault NO m 240VAC 24VDC 1 5A Inductive N O OO DI3 LP Multi function Digital Outputs Multi Speed 1 Ho Sink DO1 A Multi Speed 2 3 12 48VDC 50mA i DIS CEO AAC Drive Fault QO 0 DI6 X Multi speed 4 0 6 DI7 12 48VDC 50mA KJOG Hp DI N A At Speed X External Reset Om O DI9 b A Second Accel Decel Time 12 48VDC 50mA oO DI10 CETO Ak Zero Speed X External Base Block N O NE O O K DH1 12 48VDC DCMXXX Digital Output Com Digital Signal Com Digital Frequency Output 2 OO FOG agvDC 50mA max See Power 1 1 Duty 50 Wiring Diag EO Analog Inputs m X X XDCM 10V Power Source 20mA max Potentiometer AH Multi function Analog Output 5kQ O to 10V gt AO ni 0 20mA or 4 20mA E N Voltmeter Kk X X X ACM Ld AI3 i 10 to 410V eo ACM Kk e Analog Signal Common RS 485 Serial Comm Port T Frequency command source O l can be one of the three analog E a 1 15V inputs up down keys on ke
187. osion may result causing property damage personal injury or loss of life 2 Check for correct manifold gas pressures See CHECKING GAS INPUT 3 Check the supply gas pressure It must be within the limits shown on the rating nameplate Supply pressure should be checked with all gas appliances in the building at full fire At no time should the standby gas pressure exceed 13 in or the operating pressure drop below 5 0 in for natural gas units If gas pressure is outside these limits contact the local gas utility or propane supplier for corrective action Shut Down 1 Setthe thermostat to the lowest temperature setting Turn OFF all electric power to unit Open gas heat access panel Bm Turn gas valve clockwise to OFF position See Figure 26 Johnson Controls Unitary Products Checking Gas Heat Input 1 Turn off all other gas appliances connected to the gas meter 2 With the furnace turned on measure the time needed for one revolution of the hand on the smallest dial on the meter A typical gas meter usually has a 1 2 or a 1 cubic foot test dial 3 Using the number of seconds for each revolution and the size of the test dial increment find the cubic feet of gas consumed per hour from the Gas Rate Cubic Feet Per Hour Table 24 If the actual input is not within 5 of the furnace rating with allowance being made for the permissible range of the regulator setting replace the orifice spuds with spuds o
188. ource 1 6 Introduction to DuraPulse G S3 AC drive 1 3 Keypad 1 6 Model Number Explanation 1 5 Mounting Screw Holes 1 6 Nameplate Information 1 5 Nameplate Label 1 6 Purpose of AC drives 1 3 Selecting the Proper Drive Rating 1 3 Serial Communication Port 1 6 Specifications 1 7 Terminal Diagrams 2 13 Terminals braking 1 6 Terminals control 1 6 Terminals power 1 6 Ventilation Slots 1 6 Accessories 2 23 A 1a Braking Resistors A 20 Braking Units A 20 Configuration Cable A 48 Configuration Software A 47 EMI Input Filters A 29 Ethernet Interface A 45 External Accessories 2 23 Fans Cooling A 51 Feedback Card A 41 Fuses and Fuse Kits A 38 Keypad Cables A 48 Miscellaneous A 48 Part Numbering A 2 Reactors Line A 2 Remote Panel Adapter A 49 RF Filter A 37 Spare Keypad A 48 AFD 1 3 Air Flow and Minimum Clearances 2 3 Ambient Conditions 1 10 2 2 Analog Input Parameter Setup Examples 4 46 Auto Restart after Fault 4 58 Auto tune Procedure 3 14 AVERTISSEMENT w 2 Braking Resistor Dimensions A 24 Braking Resistors A 20 Braking Units A 20 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 1 1 Index C Cable Configuration A 48 Cables Keypad A 48 Cables PLC Communication 5 14 thru 5 18 A 46 Canadian Electrical Code CEC 2 12 Capacitors recharge 6 2 Circuit Connections 2 11 Circuit Protection Devices 2 11 2 12 Communicating with AutomationD irec
189. pecter la totalit des codes et des normes applicables peut entrainer des dommages a l quipement ou causer de graves blessures au personnel N ous ne garantissons pas que les produits d crits dans cette publication conviennent votre application particuli re et nous n assumons aucune responsabilit l gard de la conception de l installation ou du fonctionnement de votre produit Nos produits ne sont pas insensibles aux d faillances et ne sont ni concus ni fabriqu s pour l utilisation ou la revente en tant qu quipement de commande en ligne dans des environnements dangereux n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les systemes de navigation a rienne ou de communication le contr le de la circulation a rienne les quipements de survie ou les syst mes d armes pour lesquels la d faillance du produit peut provoquer la mort des blessures corporelles ou de graves dommages mat riels ou environnementaux activit s a risque lev La soci t AutomationDirect nie toute garantie expresse ou implicite d aptitude l emploi en ce qui a trait aux activit s risque lev Pour des renseignements additionnels touchant la garantie et la s curit veuillez consulter la section M odalit s et conditions de notre documentation Si vous avez des questions au sujet de l installation ou du fonctionnement de cet quipement ou encore si vous avez besoin de renseignements suppl mentair
190. perates at higher pressures than R 22 No other refrigerant may be used in this system Johnson Controls Unitary Products 860261 JIM B 0612 The compressor also uses a polyolester POE oil Mobil 3MA POE This oil is extremely hygroscopic meaning it absorbs water readily POE oil can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere A CAUTION Do not leave the system open to the atmosphere Unit damage could occur due to moisture being absorbed by the POE oil in the system This type of oil is highly susceptible to moisture absorption POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials A CAUTION Exposure even if immediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service that may risk exposure of compressor oil to the roof take precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch metering device or coil Units are shipped with compressor mountings which are factory adjusted and ready for operation A CAUTION Do not loosen compressor mounting bolts Filters Two inch filters are supplied with each u
191. physical or environmental damage High Risk Activities AutomationDirect specifically disclaims any expressed or implied warranty of fitness for High Risk Activities For additional warranty and safety information see the Terms and Conditions section of our catalog If you have any questions concerning the installation or operation of this equipment or if you need additional information please call us at 770 844 4200 This publication is based on information that was available at the time it was printed At AutomationD irect we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product This publication may contain references to products produced and or offered by other companies The product and company names may be trademarked and are the sole property of their respective owners AutomationD irect disclaims any proprietary interest in the marks and names of others Copyright 2003 2004 2007 2009 2011 2013 Automationdirect com Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated AutomationD irect retains the exclusive rights to all information included in this document W 1
192. pically produce between 15 amp 20 braking torque without the addition of any external components O ptional braking may be required for applications that have high inertia loads or require rapid deceleration Q AC Line Reactor O ptional Output line load reactors protect the motor insulation against AC drive short circuits and IG BT reflective wave damage and also smooth the motor current waveform allowing the motor to run cooler They are recommended for operating non inverter duty motors and when the length of wiring between the AC drive and motor exceeds Motor grounding terminal 7 5ft 2 24 Wl DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 KEYPAD OPERATION AND QUICKSTART Contents of this Chapter The DURAPuLse Digital Keypad LL 3 2 IC DUDISDIQV S ee eee oo bes EE EUR AUR RE T RERO ERE E XU RO 3 2 LED Indicators eo AM KAKANAN EO ga nen WG NN ME WA AWAN ENGE 3 2 Function KOS a a serra ina a AA RR E i 3 3 Displaying the Status of the DURAPuLsE AC Drive 3 4 Programming the DURAPULSE AC Drive LL 3 5 DURAPULSE Quickstart 00 ee 3 6 Example 1 Constant torque e g conveyors compressors etc 3 6 Example 2 Variable torque e g fans centrifugal pumps etc 3 10 Auto Tune Procedure ce aa aao 3 14 Copy Keypad Function LL 3 16 Enable Copy Keypad Function LL 3 16 Write Parameter Settings to Keypad aa 3 17 Write Param
193. ply requirements shown in CHAPTER 1 20hp amp Over Fuse Input fuses protect the AC drive from excessive input From power supply current due to line surges short circuits and ground faults They are recommended for all installations and may be required for U L listed installations Mm MES Q Contactor O ptional Do NOT use a power circuit contactor or disconnect O O O switch for run stop control of the AC drive and motor This will reduce the operating life cycle of the AC drive 5 5 5 Cycling a power circuit switching device while the AC drive is in run mode should be done only in emergency O situations AC Line Reactor O ptional Input line reactors protect the AC drive from transient overvoltage conditions typically caused by utility capacitor switching Input line reactors also reduce harmonics associated with AC drives and are recommended for all installations Q EMI filter O ptional Input EMI filters reduce electromagnetic interference or noise on the input side of the AC drive They are required for CE compliance and recommended for installations prone to or sensitive to electromagnetic interference Q RF filter O ptional DURAPULSE RF filters reduce the radio frequency interference or noise AC Drive on the input or output side of the inverter ASTRO Braking Unit and Braking Resistor O ptional Dynamic braking allows the AC drive to produce additional braking stopping torque AC drives can ty
194. pping Handle units with care to prevent damage to components or finishes If the unit is scratched due to mishandling the protective coating may be damaged Incorrect lifting may damage the fan and void the warranty Storage Long term storage requires special atten tion Store units on a level solid surface preferably indoors If outside storage is necessary protect the units against mois ture and dirt by encasing the cartons in plastic or in some similar weatherproof material Periodically inspect units and rotate wheels to spread bearing lubricant Failure to rotate wheels results in reduced bearing life and may void the manufactur er s warranty lf the unit will be stored for an extended time remove belts Belts which remain under tension in a station ary position for extended periods are like ly to have a reduced operating life 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 n Fax 972 497 0468 Unpacking Place the carton in an upright position and remove the staples or use a sharp knife edge tool to carefully cut or scribe the sealing tape on both sides at the top of the carton Open carton flaps Remove any cardboard and wooden filler pieces as well as loose components or acces sories shipped with the unit Carefully remove the unit from the carton Inspect the unit for any damage that may have occurred during transit and check for loose missing or damaged parts Installation For al
195. r non compensated form 1 NC contact CR324D310FX 3 Overload relay 3 heater non compensated form 1 NO 1 NC contacts CR324D360F 4 Set of statlonary and movable contacts with springs and screws for 3 poles 546A780G051 5 Molded cover for stationary and movable contacts 546A780G054 6 Return spring for movable contact support 547A524G001 7 Molded movable contact support for 2 3 poles 188D700P001 8 Armature and frame ma net with retainer 546A780G053 9 Operating coil for 2 and 3 pole forms 15D22G 10 Soring retainer for armature 546A627P001 11 Cross electrical interlock CR305X200C A dd suffix numbers for particular coil rating required See COIL TABLE above These Instructions do not purport to cover all details or variations In equipment nor to provide for every possible contingency to be met In connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the Purchaser s purposes the matter should be referred to the nearest GE Sales Office GE Industrial Systems General Electric Company 41 Woodford Avenue Plainville CT 06062 GEH 4774E 0797 Bl 1997 General Electric Company
196. r P3 00 0 1 or 3 enabling the keypad STOP key the drive will stop if the keypad is removed from the drive 3 12 B DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 3 Keypad Operation and Quickstart VAL Source of Frequency Command Setting 00 D efault 01 Settings 01 Frequency determined by digital keypad up down 02 Frequency determined by 0 to 10V input on All terminal 03 Frequency determined by 4 to 20 mA input on Al2 terminal 04 Frequency determined by 0 to 20 mA input on Al2 terminal 05 Frequency determined by RS 485 communication interface 06 Frequency determined by 10V 10V input on Al3 terminal In order to set P4 00 02 you must first change the value of P4 13 to some value other than two 02 in order to avoid the Error Duplicate Function error message P4 13 default value is 02 NB Electronic Thermal Overload Relay Setting 01 Default Setting 00 Settings 00 01 02 Constant Torque inverter vector duty motor Variable Torque fan cooled standard motor Inactive This function setting 01 is used to derate the AC drive output current overload protection to protect a fan cooled standard motor running at low speeds smite User Defined Display Function Setting 03 Default Setting 00 Settings 00 Output Frequency Hz 01 Motor Speed RPM 02 Scaled Frequency 03 Output Current A 04 Motor Load 96 05 Output Voltage V 06 DC BusVoltage V 07 PID Setpoint
197. r in the Mate N Lock plug and in the wiring from the Mate N Lock plug to the Y1 ECON terminal 13 For units with economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug a poor connection between the UCB and economizer Mate N Lock plugs loose wiring from the Mate N Lock plug to the economizer back to the Mate N Lock plug and from the Mate N Lock plug to the Y1 ECON terminal If nothing is found the economizer control may have faulted and is Johnson Controls Unitary Products 16 860261 JIM B 0612 failing to return the 24 volt call to the Y1 ECON terminal even though the economizer is not providing free cooling To test disconnect the Mate N Locks and jumper between the WHITE and YELLOW wires of the UCB s Mate N Lock plug If compressor 1 energizes there is a fault in the economizer wiring or the economizer control The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions These options are not enabled by default Local distributors can test the UCB for this programming For units with factory installed economizers the UCB is programmed to lock out compressor operation when the LAS set point is reached For units without factory installed or with field installed economizers the UCB al
198. r still does not operate replace the compressor If 24 volts is not present at M1 check for 24 volts at the UCB terminal C1 If 24 volts is present check for loose wiring between C1 and the compressor contactor If 24 volts is not present at the C1 terminal check for 24 volts from the room thermostat at the UCB Y1 terminal If 24 volts are not present at the UCB Y1 terminal the UCB may have faulted Check for 24 volts at the Y1 ECON terminal If 24 volts is not present at Y1 ECON the UCB has faulted The UCB should de energize all compressors on a loss of call for the first stage of cooling i e a loss if 24 volts at the Y1 terminal If 24 volts are present at the UCB Y1 terminal the compressor may be out due to an open high pressure switch low pressure switch or freezestat Check for 24 volts at the HPS1 LPS1 and FS1 terminals of the UCB If a switch has opened there should be a voltage potential between the UCB terminals e g if LPS1 has opened there will be a 24 volt potential between the LPS1 terminals If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing a code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms on the LED If the compressor is locked out remove any call for cooling This will reset any compressor lock outs except LPS lockouts
199. representative in your area will provide a name and address of an authorized service station if requested WARNING Motor guarantee is void unless overload protection is provided in motor wiring circuit 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 PENNBARRY 5 Operation amp Maintenance Manual Dynamo Fans Limited One Year Warranty What Products Are Covered PennBarry Fans and Ventilators each a PennBarry Product One Year Limited Warranty For PennBarry Products PennBarry warrants to the original commercial purchaser that the PennBarry Products will be free from defects in material and workmanship for a period of one 1 year from the date of shipment Exclusive Remedy PennBarry will at its option repair or replace without removal or installation the affected components of any defective PennBarry Product repair or replace without removal or installation the entire defective PennBarry Product or refund the invoice price of the PennBarry Product In all cases a reasonable time period must be allowed for warranty repairs to be completed What You Must Do In order to make a claim under these warranties 1 You must be the original commercial purchaser of the PennBarry Product 2 You must promptly notify us within the warranty period of any defect and provide us with any substantiation that we may reasonably request 3 The PennBarry Product must have been installed and
200. rs the UCB allows compressor operation all the time This programming can be checked or changed by the local distributor If none of the above corrected the error test the integrity of the UCB Disconnect the C2 terminal wire and jumper it to the Y2 terminal DO NOT jump the Y2 to C2 terminals If the compressor engages the UCB has faulted If none of the above correct the error replace the UCB Ona call for cooling the supply air blower motor and compressor 2 are operating but compressor 1 is not the room thermostat fan switch is in the AUTO position 1 58 Compressor 2 is energized in place of compressor 1 when compressor 1 is unavailable for cooling calls Check the UCB for alarms indicating that compressor 1 is locked out Press and release the ALARMS button if the LED is not flashing an alarm Check for line voltage at the compressor contactor M1 and that the contactor is pulled in Check for loose wiring between the contactor and the compressor If M1 is pulled in and voltage is supplied at M1 lightly touch the compressor housing If it is hot the compressor may be off on inherent protection Cancel any calls for cooling and wait for the internal overload to reset Test again when cool If M1 is not pulled in check for 24 volts at the M1 coil If 24 volts is present and M1 is not pulled in replace the contactor Failing the above if voltage is supplied at M1 M1 is pulled in and the compresso
201. rs Association NEMA w 1 1 2 National Fire Code w 1 Network Adapter FA ISOCON 5 16 Notes 1 2 O O ptimizing Communications 5 74 O verload Protection 4 57 1st Ed Rev D 05 2013 DURAPULSE AC Drive User Manual i 3 Index I P Parameters 4 1 Parameters Communications Parameters Summary 5 2 Parameters Detailed Listings 4 15 2nd Analog Input Gain P4 16 4 44 2nd Analog Input Offset P4 15 4 43 2nd Analog Input O ffset Polarity P4 14 4 43 2nd Source of Frequency Command P4 13 4 42 2nd Source of O peration Command P3 31 4 39 Accel 1 to Accel 2 Frequency Transition P1 08 4 21 Accel S Curve P1 03 4 19 Acceleration Time 1 P1 01 4 18 Acceleration Time 2 P1 05 4 20 Analog Input Gain P4 03 4 41 Analog Input O ffset P4 02 4 40 Analog Input O ffset Polarity P4 01 4 40 Analog Input Reverse Motion Enable P4 04 4 41 Analog Output Gain P4 12 4 42 Analog O utput Signal P4 11 4 41 Auto Adjustable Accel D ecel P6 06 4 60 Auto Restart after Fault P6 01 4 58 Auto Voltage Regulation P6 04 4 59 Auto torque Boost P2 02 4 25 Backlight Timer P8 02 4 72 Base Block Time for Speed Search P6 13 4 62 Block Transfer Parameters P9 11 P9 25 4 75 Braking Voltage Level P6 18 4 64 Communication Address P9 00 4 73 Communication Protocol P9 02 4 73 Control Mode P2 10 4 28 DC Injection Current Level P1 18 4 23 DC Injection during Sta
202. rt Copy Keypad Function The COPY KEYPAD function has the ability to permanently store up to four 4 different program parameter settings within the keypad device The stored parameter settings can be for any of the DU RAputse AC Drives This allows the parameter settings to be backed up and readily available for either duplicating the same multiple AC drives or for maintenance use if a drive needs to be replaced It is recommended that once the application has been programmed the parameter settings be backed up in the keypad for future use and maintenance Enable Copy Keypad Function Press the PROGRAM key repeatedly until the COMMS GROUP P9 00 P9 42 is displayed on the keypad LCD display Press the ENTER key to display the various parameters for this group Use the UP DOWN keys to display parameter P9 40 the COPY KEYPAD function Select Parameter Group Press the ENTER key to display the Select Parameter current value for this parameter Usethe UP DOWN keysto change the MOTOR GROUP COMMS P 3 88 value in this parameter to a 1 A value P HBB P 0 87 POS of 1 is used to enable the COPY KEYPAD function ad 122 aon T E Q Pressthe ENTER key to acceptthis value and enable the COPY KEYPAD CA t Ga CA t GA function The LCD display will indicate U H2 GROUP COMMS P ode Value Accepted for a moment P ZAA P 2 16 COMM PROTOCOL The LCD display will automatically
203. rtup P1 20 4 23 DC Injection during Stopping P1 21 4 23 Decel 2 to Decel 1 Frequency Transition P1 09 4 21 Decel S Curve P1 04 4 20 Deceleration Time 1 P1 02 4 18 Deceleration Time 2 P1 06 4 20 Derivative Control D P7 22 4 69 Derivative Filter Time Constant P7 24 4 70 Desired Current P3 17 4 38 Desired Frequency P3 16 4 38 Desired Frequency 2 P3 20 4 38 Electronic Thermal O verload Relay P6 00 4 57 Encoder Control O utput Limit P10 04 4 79 Encoder Loss Detection P10 05 4 79 Encoder Pulses Per Revolution P10 00 4 78 Encoder Type Input P10 01 4 78 Fault Records P6 31 P6 36 4 65 Feedback Signal Loss Detection Time P7 26 4 70 Firmware Version P9 39 4 76 Frequency O utput FO Scaling Factor P3 30 4 39 Frequency Scale Factor P8 01 4 72 GS Series Number P9 41 4 77 Input Terminal for PID Feedback P7 00 4 66 Integral Control P10 03 4 78 Integral Control I P7 21 4 69 Jog Speed 4 55 Keypad PID Setpoint P7 10 4 68 Line Start Lockout P6 30 4 64 Loss of AI2 Signal 4 20mA P4 05 4 41 Lower Bound of O utput Frequency P6 16 4 63 M anufacturer M odel Information P9 42 4 77 Maximum Allowable Power Loss Time P6 12 4 62 M aximum Speed Search Current Level P6 14 4 62 M id point Frequency P2 04 4 26 M id point Voltage P2 05 4 26 Minimum Output Frequency P2 06 4 26 Minimum O utput Voltage P2 07 4 26 M omen
204. s Once a fault is detected the corresponding protective functions will be activated The fault messages are then displayed on the digital keypad LCD display The six most recent faults can be read on the digital keypad display by viewing parameters P06 31 to P06 36 Fault Name Description Fault Messages Corrective Actions OVER CURRENT The AC drive detects an abnormal increase IN current Check whether the motor s horsepower is equal to or less than the AC drive output power Check the wiring connections between the AC drive and motor for possible short circuits Increase the Acceleration time P 1 01 or P 1 05 Check for possible excessive loading conditions at the motor If there are any abnormal conditions when operating the AC drive after short circuit is removed or fault does not clear call ADC Support for assistance OVER VOLTAGE The AC drive detects that the DC bus voltage has exceeded its maximum allowable value Check whether the input voltage falls within the rated AC drive input voltage Check for possible voltage transients Bus over voltage may also be caused by motor regeneration Either increase the decel time or add an optional braking resistor Check whether the required braking power is within the specified limits Check braking resistor on drives under 20H P and dynamic brake unit amp braking resistor on drives 20H P and above OVER TEMPERATURE The AC drive te
205. s sensed the indoor air blower is energized following a specified heating delay If at any time a call for both heating and cooling are present the heating operation will be performed If operating the cooling system is halted as with a completion of a call for cooling Heating always takes priority Continuous Blower By setting the room thermostat fan switch to ON the supply air blower will operate continuously Intermittent Blower With the room thermostat fan switch set to AUTO and the system switch set to either the AUTO or HEAT settings the blower is energized whenever a cooling or heating operation is requested The blower is energized after any specified delay associated with the operation When energized the indoor blower has a minimum run time of 30 seconds Additionally the indoor blower has a delay of 10 seconds between operations econds between operations Optional VAV Startup and Control 44 CAUTION If the unit is operated with the manual bypass switch in the LINE BYPASS position and there are VAV boxes present in the duct system then boxes must be driven to the full open position using a customer supplied power source to prevent over pressurizing and possible damage to the ductwork For units with VFD and VAV control the unit must first be put into the Occupied Mode to start operation The default setting for all VAV units is Unoccupied therefore the installer must add a jumper wire b
206. se 2 Check communications protocol for correct settings 6 8 DURAPuLSE AC Drive User Manual 1st Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting Warning Messages Error Name Description 1 Ensure that the ambient temperature falls within the specified temperature range 2 Make sure that the ventilation holes are not obstructed The AC drive temperature has exceeded 3 Remove any foreign objects on the heat sinks and check for 85 of the O ver temperature condition possible dirty heat sink fins 4 Provide enough spacing for adequate ventilation Overheat Warning Write Failure W hen the copy function is enabled P 9 40 W rite to EEPRO M fails Parameter Locked Parameters have been locked read only cannot be set cannot write Error The configuration is not accepted or the parameter is locked Value Accepted Value Accepted Error Duplicate This occurs when attempting to set two mutually exclusive parameters to the same value This is most commonly seen when P4 00 and P4 13 are both set to the same value Firmware version 1 04 or higher only Function lst Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 6 9 Chapter 6 Maintenance and Troubleshooting fj 6 10 B DURAruse AC Drive User Manual Ist Ed Rev D 05 2013 INDEX A AC Drive Cover 1 6 Dimensions 2 4 External Parts and Labels 1 6 Heat Sink Fins 1 6 Input Mode Switch Sink S
207. se power and control connections run permit signal speed reference signal amp fault signal All required drive parameters are pre programmed at the factory except in the case of 208 volt applications in which the parameter that defines motor nameplate voltage must be changed to a value of 208 00 and the parameter that defines motor rated current must be changed to the appropriate value appearing on the motor s nameplate Refer to the enclosed drive material or access the UPGnet Commercial Product Catalog website for instructions on changing parameter settings For units also equipped with gas electric heat a terminal block located in the unit s control box and connected to the VAV board s VAV BOX terminal must be field wired to the building s VAV boxes to ensure fully open dampers during heating operation Manual Bypass An optional factory installed manual bypass switch available with factory installed VFD can be found in the Blower Motor Access compartment and has the following three positions DRIVE routes power through the VFD for modulating control of the indoor blower motor LINE or BYPASS routes power directly to the motor which provides full speed motor operation and complete electrical isolation of the drive TEST routes power to the VFD but not to the motor to allow for drive programming and or diagnostics If a drive failure occurs the unit does not automatically switch to bypass mode The LINE D
208. sing If it is hot the motor may be off on inherent protection Cancel any thermostat calls and set the fan switch to AUTO wait for the internal overload to reset Test again when cool If Ma is not pulled in check for 24 volts at the Ma coil If 24 volts is present at M3 but M3 is not pulled in replace the contactor Failing the above if there is line voltage supplied at M3 M3 is pulled in and the supply air blower motor still does not operate replace the motor For units with VFD if there is line voltage supplied at M3 M3 is pulled in and the blower motor does not operate check all power amp control wiring connections to and from the drive and for any fault warning messages displayed on the drive s digital display refer to the drive user manual for full descriptions if necessary Clear any fault by pressing RESET on the drive s keypad and take any corrective action as needed If the motor still does not operate replace the motor 59 860261 JIM B 0612 6 If 24 volts is not present at M3 check that 24 volts is present at the supply air blower motor terminal on the UCB If 24 volts is present at the UCB terminal check for loose wiring between the UCB and M3 a If 24 volts is not present at the UCB supply air blower motor terminal check for 24 volts from the room thermostat If 24 volts is not present from the room thermostat check for the following Proper operation of the room thermostat contact b
209. small Switch off power supply Check whether the input voltage falls within the AC drive s rated input voltage Internal memory IC cannot be programmed 3i Switch the AC drive back on If fault does not clear contact ADC Support for assistance Reset drive to factory defaults P 9 08 to 99 Switch off power supply Switch the AC drive back on If fault does not clear contact ADC Internal memory IC cannot be read Support for assistance CPU FAILURE 1 NI e CPU FAILURE 2 UJ N IP CPU FAILURE 3 1 Check all connections at L1 L2 and L3 2 Verify correct voltage at L1 L2 L3 3 Contact ADC Support for assistance Intemal memory IC failed to receive outputstatus 6 4 DURArucse AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting Fault Messages Fault Name Description Corrective Actions HARDWARE FAILURE H ardware protection failure 1 Check all connections at L1 L2 and L3 2 Verify correct voltage at L1 L2 L3 3 Contact ADC Support for assistance MOM POWER LOSS Input power has been lost Check line power to drive EXTERNAL FAULT The external terminal EF CM goes from OFF to ON W hen external terminal EF CM is closed the output will be turned off under N ormally O pen External Fault AUTO RAMP FAULT Auto accel decel failure Refer to O ver current or O ver voltage error GROUND FAULT N 1 Possible u
210. ss for a particular purpose PennBarry hereby disclaims any liability for special punitive indirect incidental or consequential damages including without limitation lost profits or revenues loss of use of equipment cost of capital cost of substitute products facilities or services downtime shutdown or slowdown costs The remedies of the original commercial purchaser set forth herein are exclusive and the liability of PennBarry with respect to the PennBarry Products whether in contract tort warranty strict liability or other legal theory shall not exceed the invoice price charged by PennBarry to its customer for the affected PennBarry Product at the time the claim is made Inquiries regarding these warranties should be sent to PennBarry 1401 North Plano Road Richardson TX 75081 1401 North Plano Road Richardson Texas 75081 B PENNBARRY Phone 972 234 3202 Fax 972 497 0468 Paulson Cheek MECHANICAL O amp M COVER SHEET SECTION 3 PRODUCT ELECTRIC HEATERS Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Building 3 PHONE 770 729 0076 FAX 770 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc ARCHITECT S ENGINEER S STAMP Paulson Cheek Mechanical Inc DATE RECEIVED 06 05 14 MANUFACTURER RAYWALL SUPPLIER GAA SUBMITTED DATE 06 05 14 NO ERRORS DETECTED CORRECT EXCEPTIONS NOTED THIS APPROVAL OF SHOP DRAWINGS DOES NO
211. t Control Terminal Wire Range 24 12 AWG Control Terminal Tightening Torque 5kgf cm 4Ibf in Digital Frequency O utput WARNING Do NOT connect external voltage sources to the Digital Inputs Permanent damage may result is recommended to run all signal wiring in a separate steel conduit The shield wire Use twisted shielded twisted pair or shielded lead wires for the control signal wiring It should only be connected at the AC drive Do not connect shield wire on both ends 2 20 BW DURAPuLSE AC Drive User Manual 1st Ed Rev D 05 2013 Chapter 2 Installation and Wiring Control Wiring Diagram Sinking Inputs O O U O U sers must connect wiring according to the circuit diagram shown below WARNING Do not plug a modem or telephone into the DURAPULSE RJ 12 Serial Comm Port or permanent damage may result DURAPULSE AC Drive GS53 xxxXx Multi function Digital Inputs IDAN Power Source RI X Forward Stop OM ms RIC OTO DIT O X Reverse Stop EE Input Mode Setting O uo O O DI2 Sink C X External Fault N O X Swi o O DI3 Source Multi Speed 1 DIA Sink DO1 X Multi Speed 2 OO DI5 CETO X Multi Speed 3 OO DIE X Multi speed 4 OTO DI7 XJOG OTO DI8 x External Reset OTO DI9 X Second Accel Decel Time OO DI10 EK External Base Block N O OO DI11 AG DCMA AA Digital Output Com e Digital Signal Com MEN e FO See Power Wiring Diag ED Analo
212. t 2 3 2 x 832 2 66 35 860261 JIM B 0612 Drive Selection 1 Determine side or bottom supply duct application 2 Determine desired airflow 3 Calculate or measure the amount of external static pressure 4 Using the operating point determined from steps 1 2 amp 3 locate this point on the appropriate supply air blower performance table Linear interpolation may be necessary 9 Noting the RPM and BHP from step 4 locate the appropriate motor and or drive on the RPM selection table Review the BHD compared to the motor options available Select the appropriate motor and or drive 7 Review the RPM range for the motor options available Select the appropriate drive if multiple drives are available for the chosen motor 8 Determine turns open to obtain the desired operation point Example h 6800 CFM 2 0 iwg Using the supply air blower performance table below the following data point was located 1020 RPM 8 5 92 BHP Using the RPM selection table below Size X and Model Y is found 5 92 BHP exceeds the maximum continuous BHP rating of the 5 0 HP motor The 7 5 HP motor is required 1020 RPM is within the range of the 7 5 HP drives Using the 7 5 HP motor and drive 3 5 turns open will achieve 1020 RPM pols LOX 9m EB Os IN Example Supply Air Blower Performance Available External Static Pressure IWG joi 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM
213. t Ibs Center of Gravity 4 Point Load Location Ibs 6 Point Load Location Ibs Tons Seepma opang eee F 1582 17 5 8 Johnson Controls Unitary Products 860261 JIM B 0612 Table 3 J15 thru 25 ZJ Unit Accessory Weights Unit Accessory Me iban Shipping Operating Economizer 165 160 Power Exhaust BO 85 Electric Heat 40 Gas Heat 240 Double Wall 260 260 Motorized Damper 150 Barometric Damper 45 Econ Motorized Damper Rain Hood 60 55 Econ Power Exhaust Rain Hood 90 Wood Skid 220 Roof Curb 185 Hot Gas Bypass 10 Supply Fan VFD See Table 5 1 Weight given is for the maximum heater size available 54KW 2 Weight given is for the maximum number of tube heat exchangers available 8 tube gt ECONOMIZER MOTORIZED DAMPER FIXED OUTDOOR INTAKE AIR AND p di POWER EXHAUST RAIN HOODS See detail Y BLOWER MOTOR ACCESS Location BLOWER ACCESS BLOWER of Optional VFD Bypass Location of COMPARTMENT Optional VFD ACCESS Auxiliary SIN DOT PLUG 52 5 8 KIN For pressure N S drop reading GAS OR ELECTRIC HEAT PUE ACCESS VENT AIR L OUTLET SS HOODS To COMBUSTION Ou AIR INLET HOOD 11 180 19 32 COMPRESSOR ACCESS COIL GUARD KIT CONDENSER COILS T A CONTROL WIRING 93 ENTRY DISCONNECT SWITCH LOCATION ACCESS B POWER WIRING ENTRY BOTTOM SUPPLY AND RETURN AIR OPENINGS See Note UNIT BASE RAILS E Shown separately to il
214. t Adjustment Figure 18 4 Tighten blower pulley and motor sheave set screws after any adjustments Re check set screws after 10 12 hours run time recommended Additional Static Resistance Size 1 03 Electric Heat kW dom ete cru cooing ony R sc 35 0 20 cla 0 40 0 60 0 20 J18 17 5 0 40 320 20 24 0 60 J25 25 1050 ots O 015 020 ow oso oso 0 90 Add these values to the available static resistance in the respective Blower Performance Tables Deduct these values from the available external static pressure shown in the respective Blower Performance Tables 3 The pressure drop through the economizer is greater for 100 outdoor air than for 100 return air If the resistance of the return air duct is less than 0 25 IWG the unit will deliver less CFM during full economizer operation N 44 Johnson Controls Unitary Products Operation Cooling Sequence Of Operation For J ZJ units the thermostat makes a circuit between R and Y 1 for the first stage of cooling The call is passed to the Unit Control Board UCB which then determines whether the requested operation is available and if so which components to energize For gas heating the UCB monitors the W1 call but does not handle the operation of the gas furnace An ignition control board controls the gas heater operation For electric heat units the UCB passes the call to the electric heater In both cases when the W1 call i
215. t PLCs 5 14 CLICK Modbus Programming 5 23 Configure the PLC 5 19 DirectLO GIC M odbus Programming 5 38 Drive Parameters 5 19 Ethernet Connection 5 18 G S ED RV 100 Ethernet Interface 5 18 PLC Wiring Connections 5 14 Communicating with Third party Devices 5 67 ASCII 5 67 command code 5 70 Communication Protocol 5 2 5 69 data characters 5 70 D ata Format 5 68 Entivity Studio 5 67 KEPSERVER 5 67 MODSCAN 5 67 RTU 5 67 Think amp Do Live 5 67 Communications O ptimizing 5 74 Communications Delay 5 74 5 76 5 77 5 78 Communications Parameters Summary 5 2 Configuration Software A 47 Contactor 2 11 2 23 Contents Table of c 1 Control CircuitTerminals 2 20 Control Wiring Diagrams 2 21 Cooling Fans A 51 Copy Keypad Function 3 16 CUL 2 12 I D DC Injection 4 23 Decrease Speed 4 30 4 34 D efault Restore Parameters to Default 4 74 Digital Keypad 3 2 Dimensions 2 4 Display 3 2 Electronic Motor O perated Potentiometer 4 34 EMI Electro Magnetic Interference 2 12 EMI Input Filters A 29 Enclosure 2 3 Encoders A 42 Environment 1 10 2 2 Error Codes 5 11 Errors Keypad 6 7 Errors Serial Comm 6 7 Ethernet Interface A 45 Examples Analog Input Parameter Setup 4 46 External Base Block 4 30 4 33 External Fault 4 30 4 31 4 76 External Fault Serial Comm 4 76 External Reset 4 30 4 31 FA ISOCON 5 16 Fail safe w 1 Fault M essages 6 3 Fault R
216. t Wiring later in this chapter T WARNING Do not connect the AC input power to the T1 T2 and T3 output terminals Wiring N otes PLEASE READ PRIOR TO INSTALLATION 1 During installation follow all local electrical construction and safety codes for the country in which the AC drive is to be installed Make sure the appropriate protective devices circuit breaker or fuses are connected betw een the power supply and AC drive Make sure that the leads are connected correctly and the AC drive is properly grounded Ground resistance should not exceed 0 10 Use ground leads that comply with AW G M CM standards and keep them as short as possible Do not use a power circuit contactor or disconnect switch for run stop control of the AC drive and motor This will reduce the operating life cycle of the AC drive Cycling a power circuit switching device while the AC drive isin run mode should be done only in emergency situations Multiple DURAPULSE units can be installed in one location All of the units should be grounded directly to a common ground terminal The DURAPULSE ground terminals may also be connected in parallel as shown in the figure below Make sure there are no ground loops Correct Incorrect UY Ubay When the AC drive output terminals T1 T2 and T3 are connected to the motor terminals T1 T2 and T3 respectively the motor will rotate counterclockwise as viewed from the shaft end of t
217. t excessively hot h Check that all bolts and hangers are secure after one 1 hour of continu ous operation NOTE Take care to follow all local electrical safety and building codes Follow provisions of the National Electrical Code as well as the Occupational Safety and Health Act Always disconnect A CAUTION power source before working on the unit GUARD AND PROTECT ALL MOVING PARTS All motors are checked prior to shipment However if motor defects should develop prompt service can be obtained from the nearest authorized service station of the motor manufacturer under the warranty Exchange repair or replace ment will be provided on a no charge basis if the motor is defective within the warranty period Do not return defec tive motors to PennBarry Motor guaran tee is void unless overload protection is provided in motor wiring circuit Maintenance Do not attempt maintenance on fan until the electrical supply has been completely disconnected If a disconnect switch has not been provided remove all fuses from the circuit and lock the fuse panel so they cannot be accidentally replaced Lubrication is a primary maintenance responsibility Check all bearings periodi cally Inspect belts for tightness If the fan is installed in a corrosive or dirty atmos phere periodically clean the centrifugal wheel inlet motor housing and other moving parts Dynamo Fans FAN SHAFT LUBRICATION Fan shaft bearing pillow
218. t on and off cycle used approximately 200ms on and 200ms off To show normal operation the control board flashes a 1 second on 1 second off heartbeat during normal operation This is to verify that the UCB is functioning correctly Do not confuse this with an error flash code To prevent confusion a 1 flash flash code is not used Alarm condition codes are flashed on the UCB lower left Red LED See Figure 31 While the alarm code is being flashed it will also be shown by the other LEDs lit continuously while the alarm is being flashed The total of the continuously lit LEDs equates to the number of flashes and is shown in the table Pressing and releasing the LAST ERROR button on the UCB can check the alarm history The UCB will cycle through the last five 5 alarms most recent to oldest separating each alarm flash code by approximately 2 seconds Flash code 21 is a non alarm condition but due to the space constraints of the UCB will be indicated by the Red LED In all other cases a flashing Green LED will be used to indicate non alarm conditions In some cases it may be necessary to zero the ASCD for the compressors in order to perform troubleshooting To reset all ASCDs for one cycle press and release the UCB TEST RESET button once Flash codes that do and do not represent alarms are listed in Table 25 61 860261 JIM B 0612 Table 25 Unit Control Board Flash Codes Flash Descrivtion Green Red Red Red Red
219. tLOGIC PLCs 5 40 DL MRX MWX Communication Program for DLO6 D2 260 PLCs o 5 41 DL RX WX Communication Program for DLO5 D2 250 1 D4 450 nos 5 54 Communicating with Third party Devices 5 67 Common Third party MODBUS RTU Masters 5 67 Data Format rana boa MG ABALA NAKED EE EK 5 68 Communication Protocol s xoig ace gues En d ERAS EY ORE E E 5 69 CMD Command code and DATA data characters 5 70 Comm Delay Optimizing Communications 5 74 Optimizing Communications to GS Drives 5 74 Types of Messages Sent to GS Drives is es 5 75 Additional Message Delay TIMES 5 76 Communication Delay Summary aaa 5 78 C 4 i DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 Table of Contents ees Chapter 6 Maintenance and Troubleshooting 6 1 Maintenance and Inspection LL 6 2 Monthly Inspection wi coc en eee AAR ee ee DOORDA seas es 6 2 Annual Inspection is 99 x ssa federati 6 2 Recharge Capacitors for unused drives eee ees 6 2 Troubleshooting RR IR I hn 6 3 Fault Messages e hrs 6 3 Warning Messages Serial Communication and Keypad Errors 6 7 Appendix A Accessories LL A 1 Accessories Part Numbering lene A 2 Line Reactors RR mm ern A 2 Line Reactors LR Series e me A 3 Line Reactors Legacy GS Series do not use for new installations A 5 Line Reactor Dimensions LR S
220. tary Power Loss P6 02 4 58 1 4 DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 Index mom X 6 6 T5 5F5 5TT3TPT3r35 9393 3 Parameters Detailed Listings continued M otor Auto Tune P0 05 4 16 M otor Base Frequency P0 02 4 15 M otor Base RPM P0 03 4 16 M otor Line to Line Resistance R1 P0 06 4 17 Motor Maximum RPM P0 04 4 16 M otor Nameplate Amps P0 01 4 15 M otor Nameplate Voltage P0 00 4 15 Motor No Load Current P0 07 4 17 M ulti Function Inputs DI P3 01 P3 10 4 29 M ulti Function Output RO P3 11 4 36 M ulti Function Outputs DO P3 11 P3 14 4 36 M ulti Speeds P5 01 P5 15 4 56 O ver current Stall Prevention during Accel P6 10 4 61 O ver current Stall Prevention during O peration P6 11 4 61 O ver Torque Detection Level P6 08 4 60 O ver Torque D etection M ode P6 07 4 60 O ver Torque D etection Time P6 09 4 60 O ver Voltage Stall Prevention P6 05 4 59 O ver Voltage Stall Prevention Level P6 17 4 64 Parameter Copy P9 40 4 77 Parameter Lock P9 07 4 74 PID Deviation Level P3 18 4 38 PID Deviation Time P3 19 4 38 PID Feedback Gain P7 03 4 67 PID Feedback Loss O peration P7 27 4 71 PID Feedback Loss Preset Speed P7 28 4 71 PID Multi setpoints P7 11 P7 17 4 68 PID Output Frequency Limit P7 25 4 70 PID Setpoint Gain
221. tection By gradually accelerating the motor drives can reduce the amount of motor startup inrush current AC drives function by converting incoming AC power to DC which is then synthesized back into three phase output power The voltage and frequency of this synthesized output power is directly varied by the drive where the frequency determines the speed of the three phase AC induction motor Selecting the Proper Drive Rating A Determine motor full load amperage FLA M otor FLA is located on the nameplate of the motor Note FLA of motors that have been rewound may be higher than stated B Determine motor overload requirements M any applications experience temporary overload conditions due to starting requirements or impact loading Most AC drives are designed to operate at 150 overload for 60 seconds If the application requires an overload greater than 150 or longer than 60 seconds the AC drive must be oversized NOTE Applications that require replacement of existing motor starters with AC drives may require up to 600 overload C Installation altitude AC drives rely upon the cooling properties of air for cooling As the altitude increases the air becomes less dense and this decrease in air density decreases the cooling properties of the air Therefore the AC drive must be oversized to compensate for the decrease in cooling MostAC drives are designed to operate at 100 capacity up to altitudes of 1000 meters Above 1000m t
222. ted coil is impervious to mois ture contaminants and oil It resists mechanical damage and failures due to high humidity No tools are required to remove coil 1 Remove all power from device 2 Press against coil while pulling up slightly on coil retainers A Fig 1 and move retainers away from coll 3 Withdraw magnet assembly coil molded cover and movable arm from device 4 Withdraw spring clip B Fig 1 and remove armature from movable arm 5 Remove coil from magnet 6 Replace coil 7 Reassemble device by reversing procedure Contact Removal Movable contacts can be inspected and replaced in seconds without tools 1 Perform steps 1 through 5 under Coil Removal 2 Remove magnet from molded cover and movable am 3 Remove return spring from center of mov able arm 4 Remove molded cover from movable arm 5 Depress and slide movable contact and spring from movable am 00 Line Magnetic Contactors and Starters CR305 CR306 NEMA Size 2 6 Remove screws holding stationary contacts in place and remove stationary contacts 7 Reassemble device by reversing procedure NOTE Do not attempt to remove or replace Arc Traps in Arc Chute Cover When reassembling note that the Arc Chute Cover will only fit one way and is marked TOP in upper right hand comer Magnet and movable arm will fit either way but will be quieter if reassembled the same way they were taken apart STATIONARY
223. ter Switch No Power or Control Failure 860261 JIM B 0612 Supersedes 860261 JIM A 0612 Paulson Cheek MECHANICAL O amp M COVER SHEET SECTION 2 PRODUCT EXHAUST FANS Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Building 3 PHONE 770 729 0076 FAX 770 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc ARCHITECT S ENGINEER S STAMP Paulson Cheek Mechanical Inc DATE RECEIVED 06 05 14 MANUFACTURER PENN BARRY SUPPLIER GAA SUBMITTED DATE 06 05 14 NO ERRORS DETECTED CORRECT EXCEPTIONS NOTED THIS APPROVAL OF SHOP DRAWINGS DOES NOT RELIEVE THE SUBCONTRACTOR OR VENDOR FROM THE REQUIREMENTS OF THE CONTRACT DOCUMENTS CHECKED BY WILLIAM HAGLER DATE CHECKED 06 09 14 O amp M Section Sheets 6 5 2014 pa instructions for future reference BARRY Dynamo Fans ne R I d H dii PennBarry fans are carefully inspected before leaving the factory When the unit is received inspect the carton for any signs of tampering Inspect the unit for any damage that may have occurred dur ing transit and check for loose missing or damaged parts Mishandled units can void the warranty provisions If units are damaged in transit it is the responsibility of the receiver to make all claims against the carrier PennBarry is not responsible for damages incurred during shipment Avoid severe jarring and or dro
224. the condenser fan amperage draw Start Up Gas Heat Pre Start Check List Complete the following checks before starting the unit 1 Check the type of gas being supplied Be sure that it is the same as listed on the unit nameplate 2 Make sure that the vent and combustion hoods have been properly installed 92 Operating Instructions 4a CAUTION This furnace is equipped with an intermittent pilot and automatic re ignition system DO NOT attempt to manually light the pilot Lighting The Main Burners 1 Turn OFF electric power to unit Turn room thermostat to lowest setting Turn gas valve knob or switch to ON position See Figure 26 Turn ON electric power to unit Set room thermostat to desired temperature If thermostat set temperature is above room temperature pilot burner ignition will occur and after an interval to prove pilot flame main burners will ignite Post Start Checklist After the entire control circuit has been energized and the heating section is operating make the following checks 1 Check for gas leaks in the unit piping as well as the supply piping AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result 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 expl
225. ting as expected Check for irregular vibrations or sounds during operation Make sure the motors are not overheating during operation Check the input voltage of the AC drive and make sure the voltage is within the Operating range Check the voltage with a voltmeter D UI Bm W N Annual Inspection Check the following items once annually 1 Tighten and reinforce the screws of the AC drive if necessary They may loosen due to vibration or changing temperatures Make sure the conductors and insulators are not corroded or damaged Check the resistance of the insulation with a megohmmeter Check the capacitors and relays and replace if necessary Clean off any dust and dirt with a vacuum cleaner Pay special attention to cleaning the ventilation ports and PCBs Always keep these areas clean Accumulation of dust and dirt in these areas can cause unforeseen failures 6 Recharge the capacitors of any drive that is in storage or is otherwise unused Ui Dm W N Recharge Capacitors for unused drives Recharge the DC link before using any drive that has not been operated within a year 1 Disconnect the motor from the drive 2 Apply input power to the drive for 2 hours DURAPULSE AC Drive User Manual lst Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting Troubleshooting Fault M essages The AC drive has a comprehensive fault diagnostic system that includes several different alarms and fault message
226. tions To complete the re assembly of the unit secure hood to frame by replacing all spacers washers and nuts exactly as they were found prior to removal The unit is now ready for service Apply power and check rotation as indicated by arrow in motor compartment The rotation of all centrifugal ventilators is counterclockwise when viewing the unit from above the motor compartment Printed in the USA Jan 2005 PART 59652 0 Operation amp Maintenance Manual Start Up and Operation Carefully inspect the unit before start up All motor bearings should be properly lubricated and all fasteners should be securely tightened Rotate blower wheels by hand to insure free movement Make sure the inlets and approaches to the exhauster are clean and free from obstruction To assure maximum air movement adequate supply air must be available Rough shipping or handling may cause the wheel or propeller to move away from the venturi inlet That condition can cause the fan to move less air If that occurs loosen set screws and adjust the impeller closer to the inlet Retighten all hardware securely Check condition of belts and the amount of tension prior to start up When it becomes necessary to adjust belt tension do not overtighten as bearing damage will occur Recommended belt tension should permit deflection of 1 64 per inch of span of the belt on each side of the belt measured halfway between the pulley centerline Exercise extr
227. top of the unit 4a CAUTION Excessive exposure of this furnace to contaminated combustion air may result in equipment damage or personal injury Typical contaminates include permanent wave solution chlorinated waxes and cleaners chlorine based swimming pool chemicals water softening chemicals carbon tetrachloride Halogen type refrigerants cleaning solvents e g perchloroethylene printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers masonry acid washing materials If a unit is to be installed on a roof curb other than a Unitary Products roof curb gasketing must be applied to all surfaces that come in contact with the unit underside Johnson Controls Unitary Products 7 860261 JIM B 0612 A CAUTION Before lifting make sure the unit weight is distributed equally on the rigging cables so it will lift evenly Units may be moved or lifted with a forklift from the side only providing an accessory skid is used LENGTH OF FORKS MUST BE A MINIMUM OF 90 INCHES A CAUTION All panels must be secured in place when the unit is lifted The condenser coils should be protected from rigging cable damage with plywood or other suitable material LEFT Figure 4 Center of Gravity Figure 2 Unit 4 Point Load Weight Table 2 Weights and Dimensions Size Weigh
228. torized damper rain hood can be found in the rain hood kit Use these instructions when field assembling 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 baffles and all the control sensors are factory mounted as part of the Factory installed economizer option Power Exhaust Barometric Relief Damper and Rain Hood The instructions for the power exhaust barometric relief damper and rain hood can be found in the rain hood kit The exhaust fan all supporting brackets angles and the wiring are factory installed as part of the power exhaust option Economizer And Power Exhaust Set Point Adjustments Remove the top rear access panel from the unit Locate the economizer control module where the following adjustments will be made A CAUTION Extreme care must be exercised in turning all set point maximum and minimum damper positioning adjustment screws to prevent twisting them off Minimum Position Adjustment e Check that the damper blades move smoothly without binding carefully turn the Minimum Position Adjust 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 QG e With the thermostat set to the indoor fan ON position or terminals R to G energized turn the Minimum Position
229. tripped Series A forms will not have this trip indica tor feature To insure against welded over load relay contacts in the tripped condition perform the Check For Welded Contacts In Overload Helay as described below MAGNET ASSEMBLY HEATER SLOTS ADJUSTMENT DIAL OVERLOAD RELAY Figure 1 Typical 300 Line magnetic starter Ratings CR305 contactors are suitable for use on a cir cuit capable of delivering not more than 5 000 rms symmetrical amperes 600 volts maximum when protected by H J K1 K5 RK1 RK5 class fuses or a circuit breaker having an inter rupting rating not less than 5 000 rms symmet rical amperes 600 volts maximum Provide motor branch and control circuit over current protection in accordance with the National Electrical Code Installation Before connecting the starter 1 Remove all packing 2 Clean magnet mating surfaces of any dirt or foreign matter 3 Select and install heater s in accordance with heater table which accompanies each starter unit 4 Operate movable magnet and operating arm by pressing on the armature to assure free movement 5 Mount starter on a sturdy vertical support 6 Make the electrical connections 7 The overload relay can be reset manually by depressing and releasing the reset arm The optional normally open contact on overload relays is electrically isolated from the nor mally closed contact Coil Removal The encapsula
230. trol 02 Sensorless Vector 03 Sensorless Vector with external feedback Rated Output Frequency 0 1 to 400 0 Hz Output Frequency Resolution 0 1 Hz Overload Capacity 150 of rated current for 1 minute Includes auto torque boost auto slip compensation Torque Characteristics starting torque 125 0 5 Hz 150 1 0 Hz 20 without dynamic braking 125 with optional braking resistor Braking Torque braking circuit built in only for units under 20 hp DC Braking O peration frequency 60 0 Hz O 100 rated current Start time 0 0 5 0 seconds Stop time 0 0 25 0 seconds Acceleration Deceleration Time 0 1 to 600 seconds linear or non linear acceleratondeceleration second acceleration deceleration available Voltage Frequency Pattern Settings available for Constant Torque low amp high starting torque Variable Torque low amp high starting torque and user configured Stall Prevention Level 20 to 200 of rated current Operation Specification Keypad Setting by lt U P gt or lt DOW N gt buttons Frequency Potentiometer 3 5 kO 0 to 10 VDC input impedance 10 kO External Setting Sianal 0 to 20 mA 4 to 20 MA input impedance 2500 g M ulti Speed Inputs 1 to 4 RS 232C RS 485 communication interface ec Keypad Setting by RUN STOP JO G gt buttons Setting External Forward Stop Reverse Stop run stop fwd rev 3
231. ts of the blower speed and belt tension are REQUIRED Tighten blower pulley Figure 20 Pressure Drop Across A Dry Indoor Coil Vs and motor sheave set screws after these adjustments Supply Air CFM For All Unit Tonnages Re checking set screws after 10 12 hours run time is recommended 0 400 5000 6000 7000 800 8900 10000 11000 12000 Nominal Air Flow CFM 4 Knowing the pressure drop across a dry coil the actual CFM through the unit can be determined from the curve in Pressure Drop vs Supply Air CFM Figure 20 High speed drive accessories containing a smaller blower pulley and a shorter belt are available for applications requiring the supply air blower to produce higher CFM s and or higher A WARNING static pressures Use Model 1LD0460 for 15 ton units Model 1LD0417 for 17 5 and 20 ton units and Model 1LD0435 for 25 ton units Refer to the Blower Motor and Drive Data Table 18 Failure to properly adjust the total system air quantity can result in extensive blower damage Note the following 1 The supply air CFM must be within the limitations shown in After readings have been obtained remove the tubes and the Blower Performance Tables 15 and 16 reinstall the two 5 16 dot plugs that were removed in Step 1 2 Pulleys can be adjusted in half turn increments NOTE De energize the compressors before taking any test 3 Thetension on the belt should be adjusted as shown in the measurements to assure a dry indoor coil Be
232. ube flame After completing the specified fan on delay for heating the UCB will energize the blower motor If IC1 fails to detect a pilot flame it will continue to try for a maximum of 85 seconds to ignite the pilot tube If the pilot flame is not detected then IC1 will lock out first stage furnace operation for five minutes or until 24V power is removed from the module either at the unit or by resetting the room thermostat When the thermostat calls for the second stage of heating the low voltage control circuit from R to W2 is completed thru the UCB Heat relay RW2 is energized The RW2 1 contact is closed energizing the second stage ignition module IC 2 C2 will immediately start the second stage igniter sparking and will open the redundant valve located inside the second stage main gas valve GV2 to allow a flow of gas to the second stage carryover tube Only after the pilot flame has been ignited and the presence of pilot flame detected at IC2 by a signal sent back through the flame sensor is sparking terminated and the main gas valve opened Gas flows into each of the second stage main burners and is ignited from the carryover tube flame If IC2 fails to detect a pilot flame it will continue to try for a maximum of 85 seconds to ignite the pilot tube If the pilot flame is not detected then IC2 will lock out first stage furnace 50 operation for five minutes or u
233. unication Port 1 6 4 76 5 14 5 67 Short Circuit Withstand 1 7 2 12 Software Configuration A 47 Source Select 4 30 4 35 Special Symbols 1 2 Notes 1 2 Warnings 1 2 Specifications Control CircuitTerminals 2 20 Main Circuit Wiring Terminals 2 17 Specifications GS3 AC Drives 1 7 Speed Hold 4 30 4 34 Status Addresses 5 11 Status Monitor 5 11 Status of the Drive Keypad Display 3 4 Storage Conditions 2 2 Supplemental Publications 1 2 National Electrical M anufacturers Association NEMA 1 2 T Table of Contents c 1 Technical Support 1 2 Terminal Diagrams 2 13 Trademarks w 1 Troubleshooting 6 3 I 6 DURAPULSE AC Drive User Manual 1st Ed Rev D 05 2013 Index EDO Ro H UL 2 11 2 12 Underwriters Laboratories Inc 2 12 User Manual Revision History h 1 V VFD 1 3 W Warning Messages 6 7 Warnings w 1 w 3 1 2 2 11 Warranty Information w 1 Wiring Diagrams control circuit 2 21 Wiring Diagrams power circuit 2 18 Wiring Specifications 2 17 Wiring Warnings w 3 2 11 Wiring 1st 2nd Source Select 4 35 Wiring Braking Resistors 2 18 Wiring Braking Units 2 18 Wiring Digital Output 4 36 Wiring EMI Filters A 36 Wiring External Fault 4 31 Wiring Feedback Card GS3 FB A 42 Wiring Line Reactors A 17 Wiring Multi Speed PID SP 4 32 Wiring Relay Output 4 36 Wiring RF Filters A 37 Wiring Start Stop Direction 4 29 W rite Parameter Settings to Dr
234. uously while thermostat cycles heating elements on and off as required by setting and AUTO Fan and heating elements cycle on and off simultaneously on thermostat control The fan can be operated separately to circulate room temperature air by turning thermostat to its lowest setting and placing fan selector switch in the CONSTANT position C After the desired temperature is reached turn thermostat stem counter clockwise until a click is heard from the thermostat D Models with double pole thermostats Turn thermostat adjustment knob fully counter clockwise to the OFF position This will de energize the heating element and fan DEP o INSTALLATION INSTRUCTIONS TPI Corporation P O Box 4973 Johnson City TN 37602 4973 America s Comfort Conditioning Company 0 Wall Installation 0 are 0 8 203 2 mm 7 CLEANING AND MAINTENANCE INSTRUCTIONS A At the beginning of each heating season disconnect electrical power at circuit breaker panel Remove front grille B Use the narrow crevice suction attachment of the vacuum cleaner to remove dust and lint from heater and heating element C Lubricate the motor with SAE No 10 oil Two 2 oil spouts are located on front and back of motor D Reinstall front grille with previously removed screws Restore power to the heater FIG 1 FLUSH MOUNT L AN l M P 19 3 16 490 5mm 8 203 2 Minimu
235. urn to the program selection when finished Does not restore P9 40 back to Disable Copy Keypad Function Select Parameter Group O Select Program to Write E Select Copy Mode e A WRITE TO KEYPAD i PCHMi C53 4848 P BBB P 0 07 RAMPS CROUP P 1BB P 122 e 5 WRITE TO KEYPAD n POMS D53 B825 M o WRITE TO KEYPAD COMMS CROUP Pel Empty P oBB P 942 CY ENC FBREK CROUP O Pi1H HH Pi1H H5 Confirm Selection Cd COPY KETFO CROUP Are you sure ENTER HO Loading YES The gt 8 Loading display text flashes during copy keypad Ist Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 3 17 Chapter 3 Keypad Operation and Quickstart Write Parameter Settings to Drive WARNING Do not remove the Keypad during transfer of program parameter settings to or from the AC drive After the CO PY KEYPAD parameter is enabled the LCD display will show an additional group called COPY KEY DD GROUP Press the PROGRAM key and then the UP DOWN or PROGRAM keys until this new group is displayed Press the ENTER key to display the copy mode selections Select the WRITE TO DRIVE mode using the UP DOWN keys Press the ENTER key to display the four 4 available program numbers to write from the keypad to the AC drive The program name must match the part number of the AC drive being programmed for examp
236. ve User M anual and the DURAPULSE AC Drive Quick Reference Inspect the unit to insure it was not damaged during shipment Make sure that the part number indicated on the nameplate corresponds with the part number of your order lst Ed Rev D 05 2013 DURAPULSE AC Drive User Manual 1 5 Chapter 1 Getting Started External Parts and Labels GS3 25PO shown 1 Mounting Screw Holes 2 Ventilation Slots Nameplate Label Cover 5 Digital Keypad 6 Heat Sink Fins 7 Input Power Terminals Braking Terminals 9 Control Terminals O utput Power Terminals Input M ode Switch Sink Source 2 Serial Communication Port 9 1 6 DURAPuLse AC Drive User Manual 1st Ed Rev D 05 2013 Chapter 1 Getting Started DURAPUuLseE AC Drive Specifications Please review the AutomationDirect Terms and Conditions for this product There is no 30 day money back guarantee on any drive over 10 hp 230V Class Model Name GS3 xxx Maximum Motor Output Output Rating Rated Output Current A Maximum Output Voltage Three phase 200 to 240V proportional to input voltage Rated frequency 0 1 to 400 Hz Single Three phase 50 60 Hz Three phase 50 60 Hz 200 208 220 230 240 VAC 200 208 220 230 240 VAC Rated Input Current A 11 9 5 7 15 3 7 6 22 15 5 20 6 26 Voltage Frequency Tolerance Voltage 1096 Frequency 5 Short Circuit Withstand SCCR A rms symmetrical SKA 240
237. wire control Signal Serial Communication RS 232C amp RS 485 Modbus RTU Inputs 11 user programmable FW D STOP REV STO P RU N STO P u REV FW D RUN momentary N O STOP momentary N C Digital External Fault N O N C External Reset M ulti Speed Bit 1 4 Sink Source M anual Keyboard Control Jog External Base Block N O N C Input Selectable Second Accel D ecel Time Speed Hold Increase Speed Decrease Terminals Speed Reset Speed to Zero PID Disable N O PID Disable N C Input Disable 3 user configurable 0 to 10 VDC input impedance 10 kQ Analog O to 20mA 4 to 20mA input impedance 250 10 bit resolution 10V to 10V 10 bit resolution 4 user programmable Inverter Running Inverter Fault At Speed Zero D igital Speed Above Desired Frequency Below Desired Frequency At 3 transistors Maximum Speed O ver Torque D etected Above Desired Current O utput Below Desired Current PID Deviation Alarm H eatsink O verheat Terminals 9 Y Warning OH Soft Braking Signal Above desired Frequency 2 Below desired Frequency 2 Encoder Loss 1 user programmable 0 to 10 VDC 8 bit resolution frequency Outputs Analog current process variable PV Automatic voltage regulation voltage frequency characteristics selection non linear acceleration deceleration upper and lower frequency limiters 15 stage speed operation adjustable carrier Operating Functions frequency 1 to 15 kHz PID control 5 skip frequenc
238. y Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier A CAUTION This system uses R 410A Refrigerant which operates at higher pressures than R 22 No other refrigerant may be used in this system Gage sets hoses refrigerant containers and recovery systems must be designed to handle R 410A If you are unsure consult the equipment manufacturer Failure to use R 410A compatible servicing equipment may result in property damage or injury AWARNING If the information in this manual is not followed exactly a fire or explosion may result causing property 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 Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Due to system pressure moving parts and electrical components installation and servicing of air conditioning equipment can be h
239. ypad Wig BIS 2 GND 4 SG or via the RS 485 serial comm UIS rere 3 SG 5 NC port See parameter settings Factory default setting Kk Factory default source of frequency command is via the keypad up down keys Ak ACM and DCM are isolated from each other O Main circuit power terminals Control circuit terminal E Shielded leads 2 22 DURAPULSE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 2 Installation and Wiring External O Power Supply Please follow the specific power supply requirements Accessories shown in CHAPTER 1 Fuses Under 20h Input fuses protect the AC drive from excessive input Eram powers current due to line surges short circuits and ground P PP y faults They are recommended for all installations and o may be required for U L listed installations Contactor O ptional a aaa tag Do NOT use a power circuit contactor or disconnect switch for run stop control of the AC drive and motor This will reduce the operating life cycle of the AC drive Cycling a power circuit switching device while the AC Y Y Y drive is in run mode should be done only in emergency situations o AC Line Reactor O ptional Input line reactors protect the AC drive from transient O e e e overvoltage conditions typically caused by utility gt P S capacitor switching Input line reactors also reduce o harmonics associated with AC drives and are recommended for all installations 9 pg Q EMI fi

Building 3 O&M (6-5-2014) - Paulson

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Building 3 O&amp;M (6-5-2014) - Paulson

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Building 3 O&M (6-5-2014) - Paulson