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O&M (6-12-2014) Studio 9 - Pinewood L&G - Paulson

1. SFashes Compressor Lockout Of Of Of On on Fishes HPS2 Compressor Lockout 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 Air Temperature Flashing On On Of s looked oul because ti Economizris o Fashing on of on on Uni Locked Out due to Fan Overload n Or O 13 Flashes On 14 Flashes Of ibFashes HPSSCompresselokou L of On On On On ibFashes HPS4 Compressor ocko On Of Of Of Of 17 Flashes LPS3 Compressor Lockout On Of Of 18 Flashes LPS4 Compressor Lockout On 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 RESET SETUPST Check LA o Alarm gt History Fd VESTITI paeem meg g 131194 2 Reset All ASCDs B Um 72 V Wa For One Cycle DOWN 019 STORE D TA 8 dm 0200 gt OPTION BYTE ENI START GU d Hine 444 ia HEAT LOW
2. Modei Throat C E Sq F H LDia Damper Dia Sq Figure 11 Pilot Light WCF06 7 N A 3 1 2 16 7 8 8 11 1 2 12 NA Mounts in Grill Grid WCFO08 9 N A 5 1 2 21 1 4 8 13 1 2 18 1 2 NA WCF10 11 N A 5 1 2 21 1 4 10 15 1 2 21 NA WCF12 13 N A 7 24 10 17 25 NA WCF14 15 N A 7 28 10 17 28 NA Housing WCF20 21 N A 10 1 2 32 12 22 1 2 37 06 7 1 3 1 2 15 4 8 1 2 12 8 3 4 Amber Light WCC08 9 11 2 5 1 2 18 1 2 4 11 18 1 2 11 1 4 WCC10 11 1 1 2 5 1 2 18 1 2 4 11 21 11 1 4 WCC12 13 2 7 20 4 2 4 13 25 15 3 4 See instructions included with Pilot Light Kit for proper wiring and installation WCC14 15 2 7 24 3 4 4 13 28 15 3 4 WCC20 21 2 101 2 28 1 2 5 1 2 18 37 19 3 4 Figure 12 Brick Vents Figure 13 Weather Caps Dia C Model B68 for Z3 Z5 Z6 Z8 and Z81 I ESq WCF Model B120 for 2101 5 2102 212 2121 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 PENNBARRY 5 Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Operation amp Maintenance Manual Tahle 3 Dimensional Data TDA Intake Duct Outlet Duct 3 4 3 1 4 10 LO 1 1 4 1 1 4 1 7 8 9 1 8 11 3 8 14 1 8 16 17 3 8 27 1 2 9 1 8 11 3 8 14 1 8 12 1 2 13 7 8 24 Z3H Z5H Z6S H Z8S H Z81S 2101 21025
3. 15 Electrical Data For Multi Source Power Supply Air Flow Data 60 Hz Models 208 230 Volt AHR TC 16 Copper Wire 208 230 1 60 AHR 13 Air Flow Data 60 Hz Models 208 Volt 17 Electrical Data For Multi Source Power Supply Air Flow Data 60 Hz Models 230 Volt 18 Copper Wire 208 230 1 60 13 SECTION I GENERAL The AHR AHE single piece air handler provides the flexibility for instal lation in any upflow or horizontal application These versatile models may be used for cooling or heat pump operation with or without electric heat A BRAND LABEL available from Distribution may be applied to the center of the blower access panel The unit can be positioned for bottom return air in the upflow position and right or left return in the horizontal position Top and side power wiring and control wiring accessible screw termi nals for control wiring easy to install drain connections and electric heaters all combine to make the installation easy and minimize installa tion cost SECTION II SAFETY This is a safety alert symbol When you see this symbol on labels or manuals be alert to the potential for personal injury Understand and pay particular attention to the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which
4. S co o 0 Oi ol cO N AHR42C 6HK06501525 03 MedHigh 4 108 14 LEE U 35 t 5 AHR AHE48 s 6 16502025 45 14 GHKOGSO 1526 High 5 AHR AHE60 6HK16502025 High 5 14 4 Co O cO A ak 7 E N A co A Ni e col A cO ol gt cO N no cO O gt e O1 IN no IN e al 19 2 gt N P Co Co no A 6HK16502525 0 3 High 5 1 May 0 no circuit breaker or 1 with circuit breaker 2 See conversion Table 3 O gt Ta Johnson Controls Unitary Products 697883 UIM A 0711 TABLE 11 Electrical Data For Single Source Power Supply Copper Wire 208 230 3 60 Amps Min Circuit Ampacity Max Amps Type 75 C Wire Size AWG 208V 230V 208V zd AHR24B SHR06501525 4320 a 4 AHR30B SHK06501525 525 5 ue 6 06501525 46 20 Heater 1 Models 240V 6 16502025 6009 6 AHR42C 6 06501525 4
5. SINGLE STAGE HEAT PUMP AND ELECTRIC HEAT 10 KW AND BELOW AIR THERMOSTAT HANDLER HEAT B 6 a p FIELD INSTALLED JUMPER IF REQUIRED LE STAGE HEAT PUMP AND TRIC HEAT 13 KW AND ABOVE TO CHANGE THE QUANTITY OF HEAT DURING HEAT PUMP DEFROST CYCLE REVERSE THE BROWN AND WHITE WIRE CONNECTIONS ON THE SEQUENCERS IN THE HEATER KIT FIGURE 19 Typical Wiring Diagram ECM Johnson Controls Unitary Products 1 41V LIM 1 90510591 9 HN 1 0089 1 391103 13 1VISONS3HL WOOU 1009 J9Vis lt 1V3H 39VIS E 697883 UIM A 071 1 Supersedes 661693 UIM C 031 1 FIGURE 20 Typical Thermostat Wiring for 2 Stage Heat Pump with ECM Blower Motor ECM Copyright O 2011 by Johnson Controls Inc All rights reserved Subject to change without notice Published in U S A T O a s gt s LO SE c Johnson Controls Unitary Products Paulson Cheek MECHANICAL O amp M SECTION SHEET SECTION 2 PRODUCT ROOFTOP UNITS Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Phase 1A PHONE 770 729 0076 Stage 9 FAX 110 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc ARCHITECT S ENGINEER S STAMP Paulson Cheek Mechanical Inc DATE RECEIVED 06 12 14 MANUFACTURER JCI SUPPLIER JCI SUBMITTED DATE 06 12 14 NO ERRORS D
6. 985 970 985 900 925 785 645 279 272 262 252 259 823 184 Low 18 AHR24B High 1580 1315 1245 1160 1075 990 885 368 349 325 561 277 248 Low AHR36B AHR42C High 1480 1335 1270 1190 119 990 800 395 374 356 353 51 277 290 Low Low Low Low AHR48D AHR60D Low 230 Volt Low Low Low Low Low AHR42C AHR48D AHR60D 1455 1880 1300 1245 1170 980 980 375 372 364 349 328 277 274 Low Dry coil conditions only tested without filters Air handler units are CSA listed to UL 1995 CSA C22 2 236 05 up to 0 30 w c external static pressure including air filter wet coil and largest kW size heater unless otherwise noted Low 1 Johnson Controls Unitary Products 16 697883 UIM A 0711 TABLE 16 Air Flow Data 60 Hz Models 208 Volt AHE m3 min 2 External static pressure Pascal External Static Pressure IWC LO WI hum w e o e LO 2 e o Ha eM hum 208 Volt 1074 1025 999 954 885 204 588 280 267 255 242 2270 Med 3 663 610 556 482 334 219 173 18 6 17 1 15 6 13 5 9 4 6 1 4 8 _ Med 3 663 610 556 482 334 156 1 1 15 6
7. 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 J18 RN TBD i DEBER eo ren reo 86 TBD 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 D TBD TBD TBD TBD TBD TBD TBD TBD TBD P TBD RENE 125 208 3 60 3 7 Ese 27 0 2 749 1912 150 254 406 2 1127 1784 200 E72 541 2 1502 1877 200 8085 5 125 125 30 3 60 3 7 E36 360 2 866 1458 150 E54 540 2 1299 1674 175 J20 72 720 2 1732 2107 225 20 851 70 460 3 60 1 9 E36 360 2 433 729 80 E54 540 2 650 837 90 E72 720 2 866 1054 110 x Jr s T 50 50 s seo 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 Motors Blower Conv Electric Heat Option MCA Breaker Tons olt teach Motor Outlet Amps Size FLA M
8. NN Y A t 7 7 N QUOD DOO NN XX Storage Long term storage requires special atten tion Units should be stored on a level solid surface preferably indoors If out side storage is necessary protect the units against moisture and dirt by encas ing the cartons in plastic or some similar weatherproof material Unpacking Place carton in an upright position and remove 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 general ventilating A CAUTIO use only do not use to exhaust hazardous or explosive materials and vapors Remove internal protective shipping trays and fillers Check for and remove any loose hardware or particles from the inside of the fan housing Disconnect motor cord and plug from internal terminal box and receptacle On installations made before a final ceiling is installed with access from below the following proce dure applies Assemble adjustable flanges to fan housing with four self tap ping metal screws provided The adjustable flanges should be located as illustra
9. 13 Gas Heating Operation Errors 50 Power And Control 14 Start Up 51 Optional Electric 26 Start Up Gas Heal 51 Optional Gas Heat 27 Checking Gas Heat 52 5 5 5 29 Charging The 54 Economizer And Power Exhaust Set Point Adjustments 29 Troubleshooting 55 Optional BAS Ready Economizer Power Exhaust Unit Control Board Option 62 Damper Set Point 30 Option Byte Setup 62 Optional Variable Air Volume 30 Heat Delay 62 Optional Hot Gas Bypass HGBP 32 Optional Control Board Flash Codes 62 LIST OF TABLES 1 J15thru 25 ZJ Unit Limitations 7 15 Air Flow Performance Side Duct Application 37 2 Weights and Dimensions 8 16 Air Flow Performance Bottom Duct Application 40 J15thru 25 ZJ Unit Accessory Weights 9 17 RPM Selecion sev esa cet eswaeeterca trest RR 43 4 MNES uu ou sss eon
10. 2125 21215 Figure 16 Models Z85 H AND 2815 and ZBS H Figure 15 Models Z3H 11025 7125 AND 21215 Figure 18 Models 71015 Figure 17 Model 2105 1 Figure 20 Figure 19 Discharge Duct Flange lt w Access Panel 1401 North Plano Road Richardson Texas 75081 Fax 972 497 0468 Phone 972 234 3202 PENNBARRY Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Operation amp Maintenance Manual Typical Exploded Views Figure 21 Models Z3H 5H BS H 85 815 and 105 Figure 22 Models 71018 1025 H 125 and 1215 Legend 9 Insulation Parts A B amp C 17 TDA Panel Blank Off Plate i not shown 1 Housing 10 Damper Stop 2 End 18 Wiring Assembly 2 amp 3 Lead 11 Blower Bracket Versions 3M Connector 3 Access Panel 12 Blower Housing Assembly 19 Grill 4 Wiring Box Cover Plate 13 Inlet 20 Grill Button 5 Duct Flange 14 Wheel 21 Grill Spring 6 Damper Blade 15 Grommets 2 Part Male amp Female 22 Box Brace 7 Junction Box single blower units only double blower units only 8 16 Motor 115 1 60 23 Motor Plate Housing Bracket double blower units only Parts Replacement If replacing parts do so with properly selected components which duplicate the original parts correctly Incorrectly sized parts can damage the fan 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468
11. 9 18 Indoor Blower 43 5 Supply Fan VFD Weights In 05 9 19 Power Exhaust 5 43 6 15 25 ZJ Unit 11 20 Limit Control Setting 48 7 Control Wire 15 21 Electric Heat Anticipator Setpoint 49 8 Electrical 16 22 Gas Heat Limit Control Setting 50 9 15 thru 25 ZJ Physical Data 25 23 Gas Heat Anticipator 51 10 Electric Heat Minimum Supply 26 24 Gas Rate Cubic Feet Per 52 11 Gas Application Data 27 25 Unit Control Board Flash Codes 61 12 Gas Pipe Sizing Capaclty of Pipe 27 20 Heal Delay xix 62 13 Gas Heat Minimum Supply Air 27 27 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 33 2 Unit 4 Point Load Weight 8 17 Economizer 33 3 Unit 6 Point Load 8 18
12. A N N S 9 N S NJ S S N D S N RS NN N T A 501306 37 5 41 3 26 3 28 2 40 45 30 30 6501506 43 3 47 8 29 1 31 4 45 50 30 35 6501806 38 9 42 9 46 4 50 4 40 45 50 60 D IL 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 4 4 TABLE 10 Electrical Data 208 230 3 60 Total Heat kW Staging Heater PSC Min ECM Min Xm WOW Wie Models Speed Tap Speed Tap iii 208V 230V 208V 230V 208V 230V 208V 230V AHE22 6HK06501525 High 5 10 8 AHR AHE24 6HK06501525 High 5 P O Co IN O 1 Co IN IN IN O E O Co IN O Co IN O O Co IN Co pP AHR AHE30 6HK06501525 IEEE 25 03 High Mohss 144 AUREAS 6HK06501525 Med High 4 10 GHKT6502028 High 5 Med pP O co O Co O Co sar 4 192 817144 4 162 81744 81744 4 192 PN no IB D eoo gt IB cO N Co O pP A
13. BD 1 TBD TBD pu TBD TBD TBD ene TBD TBD 400 TBD 320 TBD 240 jp ow 80 TBD 80 80 6 8 6 8 TBD TBD TBD TBD TBD Lom 180 19 32 92 52 5 8 Po 217 Hh 2 7 7j TBD TBD C TBD 3 8 TBD 3 8 po Rc TBD TBD 3 8 TBD 3 8 TXV TBD TXV Co N 860261 JIM B 0612 J25ZJ 25 290000 280000 10 5 10 6 7000 26 67 R 410a 12 4 12 8 12 8 12 8 32 0 400 0 320 80 20 50 30 60 195 195 2 83 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 2257 18 18 29 25 peu 30 Prop TBD Direci 4 1 3 TBD 1 3 1 3 850 870 870 TBD 5000 pu LESE Centrifugal IVPTEX TB5V94 5VX840 SVX860 1725 2547 12 12x24x2 TBD 2 12x24x2 12 12x 24 x 2 2 20 x 24 x 4 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 3 1 2 In Throwaway Standard MERV Minimum Efficiency R
14. 6HK Low 0 6HK Med Med 0 6HK 1 6HK Med Med 5502006 5502506 maybe 0 no circuit breaker or 1 with circuit breaker 1 2 maybe 1 with circuit breaker no breaker jumper bar or 2 with circuit breaker amp breaker jumper bar 6HK See conversion Table 3 0 1 1 2 3 Johnson Controls Unitary Products 10 TABLE 6 Electrical Data For Single Source Power Supply Copper Wire 208 230 1 60 AHR Heater Field Wiring Models Amps Min Circuit Ampacity Max O C P 3 Amps Type 75 C Wire Size AWG odels 240V 208V 230V 208V 230V 208V 230V 5500206 gar im 38 8 5500506 35 w 5501306 so 650156 600 ese 70 o Heater 6HK I AS ese AHR18B3XH21 O L A 5 5 sim A m m e 12 O Oo I AA 5 5 AHR24B3XH21 O GO O gt gt gt O L A S 5 A 501306 5500806 5501006 5501306 15 25 40 45 15 30 40 45 70 20 30 40 50 70 70 20 30 40 50 70 20 30 40 50 70 70 20 30 40 50 70 70 0 0 40 50 70 70 um A AHR30B3XH21 as A gt AS alc HK 12 10 12 4 4 12 10 4 12 10 AHR36B3XH21 2 0 4 650186 720 8230 10 _ 6502006 00206 109 181 387 30 e500506 200
15. o o D WAWAWANWANAWANAQN omm Table 4 Parts List O Q 5 9 5 9 O 5 gt lt cu lt Screen Guard 3 8 16 X 1 Whiz Bolt 3 8 16 Whiz Nut 390 X 1 875 Diameter Washer Quantity Item NOTES 1 Equally space hardware connecting both halves of guard 2 Guards 24 thru 48 are 1 piece with no assembly required 1401 North Plano Road Richardson Texas 75081 Fax 972 497 0468 Phone 972 234 3202 PENNBARRY Breezeway Panel Fans Direct and Belt Drive Operation amp Maintenance Manual Rear Front Guard Assembly Figure 10 All bends to the outside Table 5 Parts List Quantity Rear Front 4 4 Guard Panel i 1 4 20 X 3 4 Self Tapping Screw Description Screen Guard 3 8 16 X 1 Whiz Bolt 3 8 16 Whiz Nut 390 X 1 875 Diameter Washer NOTES 1 Assemble the sheet metal parts first then attach the screen second 2 Make sure that all bends are to the outside 3 Use caulk to seal all seams 4 Varies by model size 5 Guards 24 thru 48 are 1 piece with no assembly required 54 amp 60 are 2 pieces 6 Equally space hardware connecting both halves of guard 54 amp 60 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 PENNBARRY 9 Operation amp Maintenance Man
16. 1 Operation below this temperature is permissible for a short period of time during morning warm up The comfort control switch is assumed to be in the OFF position If the main power supply to the outdoor and indoor units is off turn the appro priate disconnects to the ON position Place the system into operation as follows 1 Set temperature adjustment to the desired temperature on your thermostat COOLING The higher the setting the lower the amount of energy con sumed Federal Guidelines recommend a setting of 78 F HEATING The lower the setting the lower the amount of energy con sumed Federal guidelines recommend a setting of 65 F or lower If your cooling and heating temperature adjustments are separate be sure to set both 2 After considering Fan Operation Selection above select and set the fan operation mode you desire 3 Move the comfort control switch to the desired mode of operation Cooling or Heating found on your particular thermostat POWER FAILURE When accidents wind storms etc disrupt electrical power supply to your house switch thermostat to OFF position SYSTEM OPERATION MANUAL CHANGE OVER THERMOSTAT COOLING YOUR HOME With the comfort control switch in the COOL position the system will operate as follows When the indoor temperature rises above the level indicated by the temperature adjust ment setting the system will start The outdoor unit will operate
17. 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 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 Standard 5 HP amp Drive 2 0 RPM BHP RPM BHP RPM 968 987 1008 1031 1055 1081 1108 1136 1166 High Static 7 5 HP amp 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 7 23 7 87 8 56 860261 0612 2 4 1025 1045 1066 1088 1112 1138 1165 1194 7 5 HP amp 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 BHP x 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 RPM RPM RPM RPM Low Static 7 5 H
18. 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 Checkthe 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 amp 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 Checkthe unit supply air CFM 7 Measure evaporator fan motor s amp draw 8 Setthe room thermostat fan switch to off 9 Turn unit electrical power off Operating Instructions 1 unit electrical power on 2 Setthe room thermostat setting to lower than the room temperature 3 First stage compressors will energize after the built in time delay five minutes 4 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 the condenser fan amperage draw Start Up Gas Heat Pre Start Check List Complete the following checks b
19. AUTO the fan will run intermit tently as required for either heating or cooling This position will provide the lowest operating cost If you purchased one of our thermostats they have an Intelligent fan mode which continually circulates the air during occupied modes or when you are at home and can cycle the fan during unoccupied mode or during the night while you sleep to further con serve energy ON CONTINUOUS FAN OPERATION With the thermostat fan switch set to the indoor fan will not shut off However the cooling AC or heat ing heat pump systems will still operate as required by room tempera tures This provides continuous air filtering and more even temperature distribution to all conditioned spaces FAN ONLY OPERATION On moderate days usually during spring and fall when neither heating nor cooling is required you may want to run only the fan to ventilate circulate and filter the air in your home or build ing Set the comfort control switch to OFF and the fan switch to Be sure to return the switches to their original positions for normal oper ation START UP The maximum and minimum conditions for operation must be observed to assure a system that will give maximum performance with minimum service TABLE 1 Application Limitations Air Temperature at Air Temperature at M Coil IE I n B eo 58 m n B m i D B Fe 5 57 2
20. Size 1 _ 23 Electric Heat kW ete crm cooing ony Economize 0 20 0 40 0 60 020 J18 17 5 0 40 320 20 z 0 60 225 25 1050 015 05 02 040 06 oso 050 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 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 is 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 opera
21. 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 airflow across the heating elements Single stage heating applies only to 18 KW heater all other heate
22. Dirty Filter Switch No Power or Control Failure 860261 JIM B 0612 Supersedes 860261 JIM A 0612 Paulson Cheek MECHANICAL O amp M SECTION SHEET SECTION 3 PRODUCT EXHAUST FANS Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Phase 1A PHONE 770 729 0076 Stage 9 FAX 110 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc Paulson Cheek Mechanical Inc DATE RECEIVED 06 12 14 MANUFACTURER PennBarry SUPPLIER Georgia Air Associates SUBMITTED DATE 06 12 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 12 14 O amp M Section Sheets xls ARCHITECT S ENGINEER S STAMP 6 16 2014 Operation amp Maintenance Manual Read carefully before attempting to assemble install operate or maintain the product described Protect yourself and others by BARRY observing all safety information Failure to comply with instructions could result in personal injury and or property damage Retain instructions for future reference Zephyr Ceiling amp Inline Fans Models Z3H Through 2121 MN MM 4 Y ANA WA NUN MN MANN MW MN NN t 9 AN XX NW N NN AN
23. GROUND ce esr HEATER KITS 6HK16501306 6HK16501506 EQUIPMENT GROUND SOM YEL BLU HEATER KITS 6HK16501806 6HK16502006 6 WHT 3 EQUIPMENT a BLU GROUND 4 iSI RED L2 S4 BLK 1 HEATER KIT 6HK16502506 Diagram ECM Single Phase Heat Kits GROUND SEE INSTALLATION INSTRUCTIONS FOR PROPER LOW VOLTAGE FIELD WIRING CONNECTIONS W EQUIPMENT WITH NO HEAT WIRING DIAGRAM AIR HANDLER 208 240 VOLT FL LS SEQ or RLY HEI T 112131415 Qs BLOWER pa XFORMER 13 KW AND ABOVE 10 KW AND BELOW LEGEND LS LIMIT SWITCH SEQ SEQUNECER HE HEATING ELEMENT FL FUSIBLE LINK H SEQUNECER HEATER RC RUN CAPACITOR USE COPPER CONDUCTORS ONLY IF ALUMINUM CONDUCTORS ARE PRESENT ALL APPLICABLE LOCAL AND NATIONAL CODES MUST BE FOLLOWED 661691 UWD B 0111I Johnson Controls Unitary Products 697883 UIM A 0711 HEATER KIT 6HK06501525 EQUIPMENT GROUNB 5 2 2 S e e a 5 L LS BLU S BLU HEATER KITS 6HK16502025 6HK16502525 EQUIPMENT GROUND EQUIPMENT GROUND EE RED WH BLK 2 22 2 FIGURE 17 Wiring Diagram ECM 3 Phase Heat Kits Johnson Controls Unitary Products 21 697883 UIM A 0711 SECTION XI TYPICAL THERMOSTAT CONNECTIONS AIR AIR THERMOSTAT HANDLER
24. 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 If 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 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 short on and off cycle used approximately 200ms on and 200ms off To
25. Temperature Temperature Unit Voltage Limit Switch Limit Switch Tons 1 2 3 4 5 6 Opens F Opens F 144 200 17 5 20 240 200 25 200 200 170 T 170 170 170 15 175 35 o 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 Th 36 0 29 54 208 230 3 60 029 29 0 58 72 a 29 0 58 36 029 29 0 29 54 29 0 29 72 a 29 0 29 18 a 29 36 29 0 29 54 0 29 72 0 29 Gas Heating Sequence Of Operations The following sequence describes the operation of the gas heat section 49 860261 JIM B 0612 CAUTION For units with VFD and gas heat the speed of the indoor blower motor
26. 135 94 AHE18B Med Low 2 630 466 346 196 170 67 28 177 30 97 55 48 19 o lows 630 456 346 i96 170 67 88 77 30 97 55 48 96 826 765 744 690 659 56 501 231 220 208 193 179 159 140 Med Low 2 654 590 56 479 419 807 251 182 165 156 134 17 86 79 AHE22B 880 491 425 517 224 199 78 162 38 89 63 53 21 826 765 744 690 659 566 500 231 220 208 193 179 159 140 Med Low 2 654 590 556 479 419 307 251 18 3 16 5 15 6 13 4 11 7 7 0 2 654 590 556 479 419 163 165 156 134 AHE24B tows 580 491 425 317 224 199 78 162 38 63 53 en Wea 826 785 744 690 639 56 501 231 220 208 193 179 159 140 Med Low 2 654 590 556 479 419 807 251 183 165 156 34 17 88 79 AHESOB 580 401 425 51 224 189 78 162 38 89 63 53 21 4 Lowsi 869 668 504 447 593 284 NA 246 189 142 127 80 NA AHES36C AHE42D AHE48D AHE60D tow ai 3259 1168 1067 972 900 797 353 335 219 299 272 252 223 Dry coil conditions only tested without filters Air handler units are CSA listed to UL 1995 CS
27. 9 38 9 97 10 59 11 24 11 94 12 67 13 44 14 25 15 08 15 96 16 87 3 dH 01 3 2 1263 1280 1297 1315 1334 1353 1373 1394 1416 1438 1460 1483 1507 15 HP amp 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 RPM RPM RPM RPM 1307 1324 1341 1359 1378 1397 1418 1438 1460 1482 1504 1528 2 See HPM 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 1 65 110 815 850 885 920 950 985 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 090 905 950 990 1035 1075 1120 420 ZJ 5 5 75 1VP60 BK110 730 765 800 835 870 905 N 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 2 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
28. 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 DRIVE 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 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 A WARNING 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
29. 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 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 10 PENNBARRY Phone 972 234 3202 Fax 972 497 0468 Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Operation amp Maintenance Manual Notes 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 F
30. For Unit Tonnages Re checking set screws after 10 12 hours run time is recommended 0 4000 5000 6000 700 800 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 11100435 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 Bet 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
31. 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 IC2 4102 will immediately start the second stage igniter sparking and will open the redundant valve located inside the second stage main gas valve GV 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 until 24V power is removed from the module either at the unit or by resetting the room thermostat NOTE That the second stage fu
32. If this unit is to be installed over a tub or shower it must be marked as appropriate for the application F NEVER place a switch where it can be reached from a tub or shower For general ventilating CAUTIO use only Do not use to exhaust hazardous or explosive materials and vapors Use caution when handling sheet metal products Protection should be used to avoid contact with sharp edges or injury may occur 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Table 1 Accessories Matrix Roof Caps Z3H Curb Mnt 5120 Switches Speed Ctrl LT30 Time Delay Radiationt Damper Z5H 5120 LT30 Z6S H SL20 LT30 Z8S H SL20 LT30 Z81S 5120 LT30 Z10S H 5120 LT50 Z101S WCF10T LT30 21025 WCF10T LT50 2125 WCF12T LT50 21215 WCF12T LT50 Z102H WCF14T LT40 Z12H WCF14T LT40 Z14 CF LT40 Z15 CF LT35 Operation amp Maintenance Manual Figure 9 Roof Caps Models 5120 and WC10 Manufactured of galvanized steel All other accessories manufactured of aluminum t Kit is field installed shipped separate from fan Z6H unit only Use brick vent T4 in 12 max pitch Tahle 2 Roof Caps
33. Johnson Controls Unitary Products 860261 JIM B 0612 through network communications with Simplicity PC and other BAS control systems send ot or Dr en E P a T i 147 T ri 1 Lt m e 1 EG Jumper Wire gt dE Eu HRS up m AT de m FN Um UR 4 san P 11 ES 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 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 SAT 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
34. O 3 Co iow 18 22 64 Mei Wedlowi 38 Mei menon 58 7 Mei 72 8 18 WMeilow 35 Wes 58 MEM Med ol N ol C3 6500206 6500506 6500806 6501006 O C3 j O EN Co S S cO O gt I A no E C1 Co HK no N cO cO N no N no NI N O N N cO N O CO E L s 6501006 6501306 6501506 Med High 4 Med High 4 co co oo CO D N Co CO N N gt co High 5 S S gt I 27 ki k N Ol N A N N w ed ed ed w w ed ed w w ed ed z D N gt 9 i gt N gt N gt o gt gt S gt N o eo N HK HK HK no 23 Co Co no 6501306 Med High 4 I 521506 5 EN O O A A O 2 2 2 2 pol pol 2 2
35. Off and wash the coil with your garden hose Avoid getting water into the fan motor and control box Flush dirt from base pan after cleaning the coil SERVICE CALLS There are a few instances where the user can avoid unnecessary ser vice calls If unit stops functioning properly check the following items before calling your servicing dealer 1 Indoor section for dirty filter 2 Outdoor section for leaf or debris blockage Eliminate problem turn off the thermostat for 10 seconds and attempt start Wait 5 minutes If system does not start call your servicing dealer A WARNING Your system contains environmentally friendly refrigerant R 410A which operates at high pressures You may be in danger if you try to make an attempt to repair your unit Please contact your local dealer Johnson Controls Unitary Products 813196 UUM C 0412 FILTER CARE Inspect the air filter s at least once a month If they are dirty wash reusable filters with a mild detergent per manufacturer s recommenda tions Replace disposable filters with new filters Install the clean filters with air flow arrow in the same direction as the air flow in your duct Filters should be clean to assure maximum efficiency and adequate air circulation CLEARANCES The minimum clearances shown below must be maintained should any patio or yard improvements be done around the outdoor unit 10 Clearance Coil Area 60 Overhead Clearance 18 to
36. On or Of On 5 30 On of of Of 30 18 or on On 3 99 of On On Of 6 or On Of On 3 3 or On of o o 6 of of On On o 3 or of On o or of of Non std Non sid Of 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
37. 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 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 596 of the furnace rating with allowance being made for the permissible range of the regulator setting replace the orifice spuds with spuds of the proper size NOTE To find the Btu input multiply the number of cubic feet of gas consumed per hour by the
38. Smoke Detector 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 ue Motors Blower Conv Electric Heat Option olt each Motor Outlet Amps FLA FLA FLA Model kW Stages Amps 3 60 191 205 21 154 768 255 205 144 mak pc pesas 46030 61 41 95 11 72 BL E 5755 60 4 4 5 9 TBD TBD TBD M None j 1063 08 3 60 179 120 280 37 154 P H 1053 230 3 60 1
39. position during operation calls Proper wiring between the room thermostat and the UCB and Loose wiring from the room thermostat to the UCB 7 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 position but does not run shortly after the furnace has ignited 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 The draft motor has inherent protection If the motor shell is hot to the touch wait for the internal overload to reset 2 Ifthe 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 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 Ifthe RW1 relay is pulled in check for loose line voltage connection 5 If the RW1
40. 100 100 230 3 60 1 144 100 150 175 J15 FI 225 15 44451 Nm 428 5 50 460 3 60 E 72 50 70 90 110 Zn Nm 926 35 575 3 60 59 40 60 70 90 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD J18 TBD 17 5 TBD TBD TBD B TBD TBD TBD TBD TBD TBD TBD TBD B TBD TBD TBD TBD TBD 8 TBD ZEB Nnm 1163 125 125 2008 3 60 3 7 15 4 10 0 150 175 200 1153 125 125 230 3 60 3 7 14 4 10 0 150 175 120 225 20 Nm 606 70 460 3 60 19 72 50 70 90 110 44 5 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 FLA FLA FLA Model kW Stages Amps Amps None 3494 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 Noe 73 80 460 3 60 10 6 75 16 5 1 9 13 0 5 0 80 ZH 90 110 537 60 60 75 3 60 77 54
41. 12 0 1 5 10 3 4 0 70 70 90 1 Minimum Circuit Ampacity 2 Dual Element Time Delay 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 olt each Motor Outlet Amps n None 28042 7 08 3 60 205 21 164 NN CEN NE IS m 230 3 60 205 21 144 460 3 60 61 41 95 11 72 575 3 60 44 33 5 9 TED TBD TBD M TBD TBD TBD TBD s 2083 60 17 9 120 280 37 200 30 3 60 17 9 120 280 37 200 Nnm 585 460 3 60 70 150 19 100 360 2 433 666 Nnm 49 115 82 Johnson Controls Unitary Products Max Fuse Breaker Size Amps 50 125 175 200 90 90 150 175 225 45 45 70 90 110 860261 JIM B 0612 125 ERES 70 H 70 80 J15 thru 25 ZJ High Static Drive Without Powered Convenience Outlet Continued FLA FLA FLA Model kW Stages Amps Amps tear 175 175 08 3 60 2
42. 24 is the minimum service panel access depending on model Refer to the installation manual for details 24 Unit to Unit Distance PARTS INFORMATION Replacement parts are available from local contractor dealer EXTENDED WARRANTY Special warranty packages called York Care Performance Promise are available through your contractor These packages reduce the potential cost of service calls following the first year of operation on your cooling or heating cooling system SOME EFFICIENCY DO S DON TS DON T heat or cool unused household area Reduce supply and return air flow to a minimum in areas which are not living spaces storage rooms garages basements etc DON T be a thermostat jiggler Moving your thermostat setting will not make your system heat or cool any faster Adjust your thermostat to a comfortable setting and leave it there DON T restrict air circulation Placing furniture rugs etc in such a way that they interfere with air vents will make your system work harder to achieve a comfortable temperature level This requires more energy which means greater cost to you DON T locate lamps or other heat producing appliances radios TV s heaters etc near your thermostat The heat from these items will give your thermostat false information about the temperature in the room DO select a comfortable thermostat setting but keep in mind that mod eration in temperature selection will save energy DO
43. 280 287 30 00806 320 390 431 4 01006 476 527 5 50135 s20 06 oo 70 650156 600 930 7680 70 650026 109 181 67 30 4 wa m m w N O L A oe as AHR42C3XH21 an 4 3 3 4 HK 15 30 45 50 15 30 50 50 70 20 30 45 70 20 30 45 70 20 30 45 70 20 30 45 70 0 0 45 70 O L A oe 1 1 A 5500806 01306 S20 908 670 01006 400 476 527 5 m m E A AHR48D3XH21 Or TT lt NA O O GD T TE Ti SA A gt O O O O gt gt gt AHR60D3XH21 6HK 49 01306 S20 908 670 m 1 maybe 0 no circuit breaker or 1 with circuit breaker 2 maybe 1 with circuit breaker no breaker jumper bar or 2 with circuit breaker amp breaker jumper bar C P Over current protection device must be HACR type circuit breaker or time delay fuse Ol O O gt GD O T T T T TX T AL N Pol N N pol pol pol pol pol 4 pol pol N N SB 5 pol Sal pol Sa Sa a I N K Johnson Controls U
44. 38 3 4 RPM RPM RPM 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 3 01 860261 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 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 Standard 5 HP amp Field Supplied Drive 4000 2 32 972 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 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 6400 a I gt I 6800 I 7200 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 A
45. AMB Non Alarm Condition FT e 0 Green LED Flashing t 022 jui LN m TE Boone Ri R2ZO 200 93 8861 5 1 d ER ee een 272 4 dam LEAD LAG y 25 s lt Current Alarm 12279 r gt e Flashed Red LED R1 279 THS e R32e r es a 5 R24 amp aae x vC R28 2 Figure 31 Unit Control Board PT 62 Johnson Controls Unitary Products Unit Control Board Option Setup Option Byte Setup 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 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
46. Belt Adjustment 34 4 Center of Gravity 8 19 Altitude Temperature Correction Factors 35 5 15 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 For All Unit Tonnages 44 7 J15 thru 25 ZJ Unit Dimensions Rain Hood 11 21 Gas Valve Piping 50 8 J15thru 25 ZJ 12 22 Gas Valve and 51 9 Fixed Outdoor Air 13 23 Proper Pilot Flame Adjustment 53 10 Condensate Drain 13 24 53 11 Field Wiring Disconnect Cooling Unit With 25 Typical Gas Valve 53 Without Electric Heat 14 26 J15ZJ 15 Ton Charging 54 12 Typical Field Wiring 24 Volt Thermostat 15 27 J18ZJ 17 5 Ton Charging Chart 54 13 External Supply Connection External Shut Off 27 28 202 20 Ton Charging 54 14 Bottom Supply Connection External Shut Off 27 29 252 25 Ton Charging 54 15 Vent and Combustion Air Hood 29 30 Unit Control
47. Board 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 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 DAN
48. 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 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 in a 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 option Refer to the Fixed Outdoor Damper Figure 9 12 MIN ROOF OPENING 39 7 B Wide X 61 7 8
49. HEAT THERMOSTAT HANDLER li m PUMP CONDENSING E UNIT SINGLE STAGE HEAT PUMP AND WHT ELECTRIC HEAT 10 KW AND BELOW CONDENS I NG UNIT COOLING WITH ELECTRIC HEAT 10 KW AND BELOW G h sa G R RN FIELD 6 6 INSTALLED gt JUMPER IF WHT REQUIRED BRN CONDENSING M SINGLE STAGE HEAT PUMP AND COOLING WITH ELECTRIC HEAT ELECTRIC HEAT 13 KW AND ABOVE 13 KW AND ABOVE HEAT AN 2nd STAGE TRIC HEAT 151 STAGE RED 24V HOT gt gt e gt lt 6 BRN BLOWER 6 s TIME BLU WHT 010 RED WHT BLK 3 m BLU WH 6HK16501506 HEAT KIT SHOWN TO CHANGE THE QUANTITY OF HEAT DURING HEAT PUMP DEFROST CYCLE D REVERSE THE BROWN AND WHITE WIRE CONNECTIONS ON THE SEQUENCERS IN THE HEATER KIT 2 THE PURPLE WIRE MUST BE MOVED FROM 1 ON SEQUENCER I TO 3 ON SEQUENCER 2 FIGURE 18 Typical Wiring Diagram PSC 22 Johnson Controls Unitary Products sx G CONDENS ING UNIT WHT CONDENSING UNIT Om O 0 0 COOLING WITH ELECTRIC HEAT 10 KW AND BELOW R THERMOSTAT HANDLER BRN CONDENSING UNIT O 0 COOLING WITH ELECTRIC HEAT 13 KW AND ABOVE EOUIPMENT 6HK16501506 HEAT KIT SHOWN 697883 UIM A 0711 THERMOSTAT HANDLER HEAT A RD 5 ES aun T FIELD U INSTALLED JUMPER IF REQUIRED 29
50. 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 100 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 from the controls either at the unit or by resetting the room thermostat Auxiliary Limit Switch AUX This control is located
51. M TDA Panel gt Screws Access Panel n 10 5 Screws Locking Tabs 2 Reassemble both the TDA and access panels after exchanging locations First slide the 3 locking tabs of the TDA panel into the housing flange Second slide the 3 tabs of the access panel into the housing Third engage the access panel return flange into the 3 locking tabs the TDA panel Finally reinstall the six 10 sheet metal screws See figure 27 1401 North Plano Road Richardson Texas 75081 8 PENNBARRY Phone 972 234 3202 Fax 972 497 0468 Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Operation amp Maintenance Manual Conversion Instructions Models 21015 21025 2125 7102H amp 712 RA TD Ceiling Fan Conversions Right Angle RA To Top Discharge TD Conversion Note As a standard Zephyr TD s are furnished with a Right Angle RA discharge as shown in Figure 28 1 Disassemble the access panel from the housing by first removing the four 10 sheet metal screws and then removing the panel as shown in figure 28 Figure 28 RR Right ange Figure 29 TD Top Discharge Housing Housing Access Panel 4 10 S M Screws 4 10 S M Screws 2 Reassemble the access panel by rotating the access panel 90 and remount it to the housing Finally reinstall the four 10 sheet metal screws See figure 29 TDA In line Fan Conversions TDA IN LINE TO RIGHT ANGLE D
52. Motor Outlet Amps Size FLA FLA Model kW Stages Amps Amps 1400 150 08 3 60 22 4 150 149 J25 225 None 87 7 70 100 50 90 200 100 150 200 25 460 3 60 10 6 200 1 Minimum Circuit Ampacity None 1400 150 150 350 37 200 100 150 2 Dual Element Time Delay Type 175 3 HACR type per NEC 2 110 54 6 60 6 36 8 60 70 50 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 CONDENSER COIL DATA Face area Sq Ft Rows Fins per inch Tube diameter in Circuitry Type EVAPORATOR COIL DATA Face area Sq Ft Rows Fins per inch Tube diameter Circuitry Type Refrigerant control Johnson Controls Unitary Products Models 15 5 2 E TBD L4
53. Physical and Electrical Data AHR MODELS 24B 30B 36B 42C 48D Blower Diameter x Width Motor 3 4 1075 volags 2087230 Amps 088290 38 DISPOSABLE OR PERMANENT Fiter IEIS Shipping Operating Weight bs 1 Field supplied AHE MODELS 26 28 sc 4 45 5 Ams poaae 28 28 28 28 4i 4i 4 66 9 Fiter Shipping 115 103 120 105 120 105 120 105 152 137 152 137 168 150 171 153 174 156 Operating Weight Ibs 1 Field supplied 8 Johnson Controls Unitary Products 697883 UIM A 0711 TABLE 3 Conversion Table kW amp MBH Conversions for Total Power Input Requirement 208V OPERATION 240V TABULATED kW amp 230V REND 240V MN TABLE 4 Electrical Data Cooling Only 60 Hz Total Motor Amps Minimum Circuit Ampacity Max Minimum Wire 00 Size A W G AHR MODELS 30B 5 34 38 43 48 1 1 AHE MODELS EE 25 22 2 8 3 5 3 5 15 14 no e F N N N A 5 5 5 1 OCP Over current protection device must HACR type circuit breaker or time delay fuse TABLE 5 Electrical Data 208 230 1 60 Total Heat kW Staging Heater ECM Min Models Speed Tap Speed Tap W1 Only W1 W2 208V 230V 208V 230V 208V 230V 208V 230V 1 6HK HK
54. Tech Guide to verify which TXV is installed in this coil and that this is a valid system match for the AC or HP unit installed The temperature sensing bulb is attached to the coil suction header line NOTICE For models that have factory installed TXV s take caution not to apply high temperatures to the TXV assembly or equalizer line while braz ing TXV BULB Cover completely with insulation SUCTION LINE FIGURE 11 Proper Bulb Location ACAUTION COIL UNDER PRESSURE Relieve pressure by depressing schrader core Coil may have factory installed TXV or may require orifice or TXV to be added See outdoor unit documentation for correct orifice or TXV to be used Refer to coil nameplate for orifice or TXV identification for this unit NOTICE The coil should be open to the air for no more than 2 minutes to keep moisture and contaminates from entering the system If the coil can not be brazed into the refrigeration system in that time the ends should be temporarily closed or plugged For a short term delay use masking tape over the ends of the copper tubing to close the tube to the air For a longer term delay use plugs or caps There is no need to purge the coil if this procedure is followed REFRIGERANT LINE CONNECTION ACAUTION Dry nitrogen should always be supplied through the tubing while it is being brazed because the temperature required is high enough to cause oxidation of the copper unless an inert atmosphere
55. 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 phase 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
56. 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 option 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 obstructio
57. al pol 6 2 2 ay a O O O O N O O O 4 NI CO OI N iM OO O 6 iw 18 iow Weilowg2 36 Mei 58 Mei Hg T A N gl PO G l N A AY rS AI pol 00 O emn p 00 O AY j O A N HK HK HK HK eHK 1 c gt a cO N C2 O O RO CO O CO O C2 e O A Al Z gt e Pod Bo E om Lo M M M Lo Lo M M Lo Lo M M o Co Co no O N cO cO LUECA 0 6501006 Med High 4 6501306 03 High Med High 4 6501506 High 5 10 8 O gt gt 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 N w no O gt RII O PN For notes see 10 Johnson Controls Unitary Products 9 697883 UIM A 0711 TABLE 5 Electrical Data 208 230 1 60 Continued N z Oo S T U G I 5 5 Speed Speed Tap ws 18 22 67 75 18 22 r 22 1 6500206 1 6500506 1 65008
58. and the indoor fan will circulate the cooled filtered air When the room tempera ture is lowered to the setting selected the system will shut off HEATING YOUR HOME your system includes a heating unit and the comfort control switch is in the HEAT position the system will operate as follows When the indoor temperature drops below the level indi cated by the temperature adjustment setting the system will start The heating system will operate and the indoor fan will circulate the filtered air When the room temperature rises to the setting selected the sys tem will shut off Whether heating or cooling the fan will continue to operate if the fan switch was set in the ON or Intelligent position The AUTO setting on the fan switch will allow the fan to shut off when your system does ELECTRONIC THERMOSTAT The computerized electronic thermostat when programmed will func tion automatically to operate the system as follows When the indoor temperature rises above the higher COOL setting the outdoor unit will operate and the indoor fan will circulate the cooled filtered air When the room temperature is lowered to the selected level the system will shut off The indoor fan will either shut off or run continuously depend ing upon your choice of fan switch setting When the indoor tempera ture drops below the lower HEAT setting the heating system will operate and the indoor fan will circulate the heated filtered air When
59. ceiling opening determine the exact location of framing or support members Cut hole in ceiling using care not to exceed the dimensions of the ceiling grille Note The ceiling hole should be cut so that one edge of the hole is in line with the inside face of the joist The hole must be large enough to permit passage of the fan housing into the ceiling space Care should be taken not to exceed the ceiling grill dimensions when cutting Remove the blower assembly from the housing For single blower units remove two 10 sheet metal screws near the blower slide power pack to the left to release it from the housing For double blower units remove one 1 4 bolt Figure 4 2 PENNBARRY Hangar Support Rods To Building Structure By others Adjustable Mounting Flanges Electrical service should now be brought up to the fan location This should be done in accordance with the instructions listed in the previous section To secure housing in ceiling space raise the housing into place with one edge of the housing against joist A see Figure 3 Determine if it is necessary to build out from joist B so that the housing can be secured from both sides If building out is necessary an appropriate piece s of wood should be utilized These wood spacers should be nailed to joist B to increase the thickness of the joist at the point where the fan will be installed The fan housing should fit snugly between joist A and
60. d Spin propeller to see if rotation is free e Check all set screws and keys tighten if necessary f Torqued set screws have a colored Torque Seal mark indicating the cor rect torque has been applied g Check belt or direct drive coupling for alignment use recommended belt tension gauges h Check belt for proper sheave selection i Make sure there is no foreign or loose material in ductwork leading to and from fan or in the fan itself Properly secure all safety guards k Secure all access doors to fan and ductwork Check line voltage with motor nameplate m Check wiring On single phase CAUTION motors the terminal block must be set up in accordance with the nameplate instructions and or wiring diagram This set up must match the line voltage If the motor is multi speed or multi voltage the winding leads must be grouped and connected as shown on the motor wiring diagram The line voltage must correspond with proper grouping of motor leads The wiring diagram must be followed explicitly or serious motor or starter damage will occur The fan has been checked at the factory prior to shipment for mechanical noises If mechanical noises should develop a Check rotating components for adequate clearance b Check proper belt tension and pulley alignment c Check installation and anchoring d Check fan bearings Switch on electrical supply and allow fan to reach full speed Check
61. 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 Ifthe 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 3 Make sure that the pilot burner is not bent or damaged
62. guards even at the cost of some performance Unprotected fans located less than 7 above the floor require guarding as specified in the Occupational Safety and Health Act OSHA UL listed fans to maintain their personal safety listing must be installed not less than 10 feet above the floor PennBarry recommends the use of guards on all exposed non ducted fans INSTALLING THE PANEL FAN Wall openings must be square and must be mini mum 1 2 greater than the outside dimension of the panel fan housing when recessed within the wall Level and securely anchor the fan to the wall through holes pre drilled in the mounting flange Use the type size and number of fasteners suitable to the unit size and wall construction If the contrac tor removes ventilator parts reassemble by placing all spacers washers nuts bolts fasteners and components exactly as they were prior to removal Tighten and secure all fasteners Minimum Clearance Between Fan and Shutter Figure 2 Dimension C Inches epee eee ee eee _ 8 L5 L8 7 15 151591717 17 Figure 2 Wall Sleeve ES A Figure 1 Rear Guard Printed in the USA Jan 2005 PART 59277 Operation amp Maintenance Manual Figure 3 Typical Mounting Arrangements Breezeway Fan Breezeway Wall Shutter Re
63. 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 fitness 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
64. 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 15175 20 835 195 15 175 20 8 28 195 The monitors the Pressure and Rollout switches of gas heat units The control circuit includes the following safety controls Ignitor Control 1 Rollout itch Sensor 1 suo Valve 3 F r 1 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 cycles and may result in the lowering of the temperature within the conditioned space Refer to Table 23 for the required gas heat anticipator setting 51
65. 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 170 170 170 170 Johnson Controls Unitary Products 860261 JIM B 0612 Table 20 Limit Control Setting
66. 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 inside 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 Combustion Air Intake Hood Gas Heat 8 Access Panels J Figure 15 Ven
67. 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 1 Y2 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 of cooling the currently running compressor with the most run hours will be the first to be de energized Economizer With Singl
68. mode Option Byte or Heat Delay Heat Delay Setup 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 he 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 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 1800 On On O on 6 o On On On 6 On On Of On On On Of Of 45 18 On of On On 5 5 On of On Of 5 6
69. new home construction In some states registration is not required but proof of installation is required to qualify for 10 year parts warranty Guardian Brand products have 5 year compressor and 5 year parts warranty and are not eligible for10 year parts warranty 1 Lifetime Compressor Warranty requires the following Unit registration must occur within 90 days of installation date on www upgproductregistra tion com website The warranty is non transferrable and is limited to the original owner Company strongly recommends regular periodic preventative maintenance on this equipment The person most familiar with the equipment in your HVAC sys tem is a Company dealer The Company dealer can ensure your maintenance program meets the Company Warranty conditions maximize the equipment efficiency and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere EXCLUSIONS This warranty does not cover any 1 Shipping labor or material charges or damages resulting from transportation installation or servicing 2 Damages resulting from accident abuse fire flood alteration or acts of God Tampering altering defacing or removing the product serial number will serve to void this warranty 3 Damages resulting from use of the product in a corrosive atmosphere 4 Damages resulting from inadequacy or interruption of electrical service or fuel supply improper voltage conditions blo
70. of CAUTIO injury disconnect from power supply before servicing The blower wheel housing and grille should be cleaned of dust and grease if required Power should be disconnected before cleaning the internal parts of the ceiling fan Figure B Internal Electrical Connections Single Speed Motors Motor Plug Ground Junction Bo Figure 7 Internal Electrical Connections Two Speed Motors Motor Plug 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 Junction Bo Operation amp Maintenance Manual Remove the grill Use a vacuum cleaner with the appropriate attachments and vac uum dust from the grill Wash the grill with a warm soapy solution of water Allow grill to air dry thoroughly before reinstalling To clean blower wheel s and housing unplug blower from integral terminal box Remove the blower assembly from the housing For single blower units remove two 10 sheet metal screws near the blower discharge and slide to the left For double blower units remove one 1 4 bolt next to motor Vacuum blower wheel if necessary the wheel can be washed Use extreme caution do not allow water to enter motor Wipe blower wheel dry with an absorbent cloth Before replacing blower motor assembly wipe out interior of housing Replace blower motor assem bly and secure with self tapping screws Plug in blower motor to terminal box Figure 8 External Electri
71. 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 12 PENNBARRY Phone 972 234 3202 Fax 972 497 0468 PENN BARRY Breezeway Panel Fans Direct amp Belt Drive TYPE BC 1401 North Plano Road Richardson Texas 75081 Fax 972 497 0468 Phone 972 234 3202 w 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 could result in personal injury and or property damage Retain instructions for future reference PennBarry fans are carefully inspected before leav ing the factory When the unit is received inspect for any signs of tampering Inspect the unit for any damage that may have occurred during transit and check for loose missing or d
72. 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 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 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 must be replaced replacement wire must be of the type shown on the wiring diagram and the same m
73. on the equipment For help finding a servicing dealer contact Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman OK 73069 Or by phone 877 874 7378 All warranty service or repair will be performed during regular business hours Monday through Friday 9 00am 5 00pm Product Model Number Installation Date Unit Serial Number Installing Dealer FOR PRODUCT REGISTRATION For your benefit and protection return the Warranty Registration Card to Company promptly after installation This will initiate the warranty period and allow us to contact you should it become necessary This warranty extends only to the original consumer purchaser and is nontransferable For this warranty to apply the product must be installed according to Company recommendations and specifications and in accordance with all local state and national codes and the product must not be removed from its place of original installation The warranty period for repair or replacement parts provided hereunder shall not extend beyond the warranty period stated below In the absence of a recorded Warranty Registration Card the warranty period will begin upon product shipment from Company If you are unaware of the date the warranty became effective contact Com pany at 877 874 7378 or visit www upgproductregistration com You can register your product online at www upgproductregistration com or by returning the Warranty Registration Card on the back page of this
74. 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 touch the compressor housing If it is hot the compressor may be off on
75. 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 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 economizer 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
76. solution or other material suitable for the purpose 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 CAUTION 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 liquefied 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 1 0418 All LP gas equipment must con
77. 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 Btu Input 1 08 A F 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 Pd Burner Assembly Bracket pa Flame Sensor Bulb 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 cycle to be sure all controls function properly Burner Instruction To check or change burners pilo
78. 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 terminal and the ER relay based on the position of the economizer damper parameter settings in the VAV control Minimum run time is 10 seconds minimum off time is 60 seconds The outlet pressure of the power exhaust fan forces the barometri
79. 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 A WARNING 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 A WARNING 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 top of the unit CAUTION Excessive exposure of this furnace to contaminated combustion air may result in equipment damage or personal injury Typical conta
80. turn on your kitchen exhaust fan when cooking and your bathroom exhaust fan when showering Also make sure your clothes dryer is properly vented these items are neglected an excess heat and humidity condition may be created causing your air conditioning sys tem to run longer DO set your thermostat a few degrees lower than normal several hours before entertaining a large group of people in a relatively small area People give off a considerable amount of heat and moisture in a closed area DO keep drapes and venetian blinds closed when practical These items provide insulation against heat loss gain DO contact a qualified service person to make repairs or adjustments to your system He has been trained to perform this service Limited Warranty Johnson Controls Unitary Products hereinafter Company warrants this product to be free from defects in factory workmanship and material under nor mal use and service and will at its option repair or replace any parts without charge subject to the exclusions below that prove to have such defects according to the terms outlined on this warranty This warranty covers only the equipment described by the Product Model Number and Serial Number on the equipment or listed on the Warranty Registration Card and applies only to products installed in the United States or Canada FOR WARRANTY SERVICE OR REPAIR Contact the installer or a Company dealer You may find the installer s name on this page or
81. 06 1 6501006 1 6501306 2 6501506 0 6HK 03 36 44 23 150 36 44 38 44 0 6HK 03 58 70 167 240 58 70 58 70 0 6HK 72 88 246 29 72 88 72 88 0 6HK 389 81 38 94 r4_ 0 6HK 4 os 108 152 369 429 36 44 108 132 1 6HK Hons 130 158 442 88 68 79 139 158 2 6501806 1 6HK 03 142 175 494 599 72 88 144 1776 2 6502006 1 6HK Low 1 6500206 1 6500506 1 6500806 0 6HK Low 0 6HK 5501306 5501506 6HK 1 2 6HK 1 2 6HK 1 2 6HK 1 2 Med Med 0 6HK Low 6501806 6502006 36 Low 6HK 0 1 6500806 6HK 1 2 6HK 1 2 1 6500506 0 6HK Med Med Low 5501306 5501506 42 Low Low 6HK 0 6HK 0 1 6500806 1 6500506 Med Med 6501006 6HK 1 2 6501506 6HK 1 2 6501806 6HK 1 2 6HK 0 1 6500206 2 6501306 J 1 6HK 0 1 6HK 48 Med Med Low 5502006 S 1 2 6501506 1 2 1 2 6HK 6HK Low 1 6500506 1 6500806 1 6501006 2 6501306 0
82. 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 ese 9200 S amp 9600 alls alle 10000 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 7400 7800 8200 8600 9000 9400 9800 10200 10600 11000 11400 11800 12200 12600 Available External Static Pressure 1 4 RPM RPM RPM RPM RPM RPM RPM RPM 0 4 0 6 0 8 Low Static 7 5 HP amp 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 amp Drive 4 23 887 4 71 902 5 23 918 5 8 935 6 38 953 7 01 972 991 11 64 1097 12 54 1120 13 48 1143 14 46 1167 15 47
83. 1192 High Static 15 HP amp 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 3 0 2 0 2 2 2 4 2 6 RPM RPM RPM RPM Standard 10 HP amp Drive 2 8 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 0 983 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 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 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 71 8 31 8 94 9 61 10 33 11 08 11 87 12 70 13 56 14 47 15 41 16
84. 2 4 149 37 200 225 927 175 175 30 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 Type OD Fan Supply Pwr Max Fuse Size Vol Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each A Outlet Amps Size 38 6 1527 175 25 Nm 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 a Amps None 901 10 08 3 60 LE 2 150 175 E72 541 2 1502 1819 200 E m 100 100 230 3 60 1 4ES6 360 2 866 1388 150 54 540 2 1299 1604 175 J15 225 _ 50 460 3 60 ese 360 2 433 694 70 54 540 2 650 802 90 E72 720 2 866 1019 110 1842151 35 575 3 60 360 2 346 557 60 E54 540 2 520 643 70 JEZ2 720 527 15939 18600 90 TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD D TBD TBD TBD TBD TBD TBD TBD TBD TBD TBD
85. 230 208 230 208 230 208 230 6HK AHE22B3XH 1 6501306 37 5 41 3 22 3 24 2 40 45 25 25 6501506 43 3 47 8 25 1 27 4 45 50 30 30 HK I AHE24B3XH21 AHE30B3XH21 6501306 37 5 41 3 22 3 24 2 40 45 25 25 6501506 43 3 47 8 25 1 27 4 45 50 30 30 AHE34C3XH21 AHE36C3XH21 6501306 37 5 41 3 22 3 24 2 40 45 25 25 6501506 43 3 47 8 26 8 27 4 45 50 30 30 6501306 37 5 41 3 23 9 25 8 40 45 25 30 6501506 43 3 47 8 27 7 29 0 45 50 30 30 6501806 38 9 42 9 44 1 48 0 40 45 45 50 6502006 43 3 47 8 48 4 53 0 45 50 50 60 6501306 37 5 41 3 23 9 25 8 40 45 25 30 AHE42D3XH21 AHE48D3XH21 AHE60D3XH21 6HK I 6502006 43 3 47 8 50 8 55 3 45 50 60 60 6HK 6502506 64 9 71 7 50 8 55 3 70 80 60 60 If wire other than non plated 75 ambient copper wire is used consult applicable tables of the NEC and local codes 0 1 maybe 0 no circuit breaker or 1 with circuit breaker 1 2 maybe 1 with circuit breaker no breaker jumper bar or 2 with circuit breaker amp breaker jumper bar Over current protection device must be type circuit breaker or time delay fuse 208 230 12 12 10 10 12 12 10 10 12 12 10 10 12 10 10 10 8 8 6 6 12 10 10 10 8 8 6 6 12 10 10 10 10 10 10 10 8 8 6 6 10 10 10 10 8 8 6 6 6 6 A ss EAA Ms I A I XN Pin D L A I A 5501306 5501306 O OD x I I AETA EA D Oo x NN
86. 230V GHK 1 6500208 GHK 0 1 6500508 akoes 320 422 458 5 8 8 AuEapsxuo OKOD 400 508 o o 6 6 2 6501308 266015 6 725 o 4 4 SHK gjpsoro 720 ss 3 98 SHK T 210502000 GHK 0 1 6500508 10 eHK esoso 320 422 458 konee 400 508 o 8 8 6HK 12 6501306 maese 00 75 794 89 4 4 ekma 720 855 0 3 8 1 0 1 maybe 0 no circuit breaker or 1 with circuit breaker 2 1 2 maybe 1 with circuit breaker no breaker jumper bar or 2 with circuit breaker amp breaker jumper bar 3 O C P Over current protection device must HACR type circuit breaker or time delay fuse TABLE 8 Electrical Data For Multi Source Power Supply Copper Wire 208 230 1 60 AHR Min Circuit Ampacity Max O C P Amps Type 75 C Wire Size AWG Models it it 208 230 208 230 208 230 208 230 208 230 208 230 6HK AHR24B3XH21 6HK 6501306 37 5 41 3 20 3 22 4 40 45 25 25 12 12 AHR30B3XH21 6501506 43 3 47 8 23 2 25 5 45 50 25 30 12 10 AHR36B3XH21 6501306 37 5 41 3 23 0 25 4 40 45 25 30 10 10 6501506 43 3 47 8 25 9 28 7 45 50 30 30 10 10 6501306 37 5 41 3 23 0 25 4 40 45 25 30 12 12 501506 43 3 47 8 25 9 28 7 45 50 30 35 10 10 6501806 38 9 42 9 43 2 47 7 40 45 50 50 6502006 43 3 47 8 47 6 52 6 45
87. 234 3202 Fax 972 497 0468 PENNBARRY 5 Operation amp Maintenance Manual Breezeway Panel Fans Direct and Belt Drive Wall Mounting Sleeve Assembly Figure 7 All bends to the outside Typical conduit access Description Wall Sleeve Panel 1 4 20 X 3 4 Self Tapping Screw 1 4 20 X 3 4 Whiz Bolt 1 4 20 Whiz Nut NOTES 1 Make sure all bends are to the outside 2 Use caulk to seal all seams 3 Varies by model side 4 This hardware is used to attach the fan not illustrated into wall sleeve 1401 North Plano Road Richardson Texas 75081 PENNBARRY Phone 972 234 3202 Fax 972 497 0468 Breezeway Panel Fans Direct and Belt Drive Operation amp Maintenance Manual Weathershield Assembly Figure 8 All bends to the outside Table 3 Parts List Quantity Description Weather Cover Side LEFT Weather Cover Side RIGHT Weather Cover Top 1 Weather Cover Top 2 Weather Cover Bottom 1 4 20 X 3 4 Self Tapping Screw NOTES 1 Make sure all bends are to the outside 2 Use caulk to seal all seams A Q Varies by model side 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 PENNBARRY 7 Breezeway Panel Fans Direct and Belt Drive g Sleeve Weather Shield Guard Operation amp Maintenance Manual o 9 lt SLO qua e amp cN Figure 9 ic O So
88. 50 50 60 1906 575415 230254 1242 AHRA2CAXH21 6501306 37 5 41 3 3 0 25 0 45 5 30 AHR48D3XH21 AHR60D3XH21 6HK 6502006 43 3 47 8 47 6 52 6 45 50 50 60 K 1 2 6502506 64 9 71 7 47 6 52 6 70 80 50 60 If wire other than non plated 75 ambient copper wire is used consult applicable tables of the NEC and local codes 0 1 maybe 0 no circuit breaker or 1 with circuit breaker 1 2 maybe 1 with circuit breaker no breaker jumper bar or 2 with circuit breaker amp breaker jumper bar O C P Over current protection device must be type circuit breaker or time delay fuse J OOO ee an x 5 8 6 6501506 43 3 47 8 25 9 28 7 45 50 30 30 10 10 6501806 38 9 42 9 43 2 47 7 40 45 45 50 8 6502006 43 3 47 8 47 6 52 6 45 50 50 60 6 8 6 6 6501306 37 5 41 3 23 0 25 4 40 45 25 30 E 6501506 43 3 47 8 25 9 28 7 45 50 30 30 6501806 38 9 42 9 43 2 47 7 40 45 45 50 N N S S N N S S N S N S S D T T ho 5501506 5501306 Johnson Controls Unitary Products 13 697883 UIM A 0711 TABLE 9 Electrical Data For Multi Source Power Supply Copper Wire 208 230 1 60 Min Circuit Ampacity Max O C P Amps Type 75 C Wire Size AWG 208 230 208
89. 620 45 GHKO6501525 46 20 GHK16502025 80 09 SHKOGROTS2S 525 34 6 41 7 46 20 AHR60D 6HK16502025 6502025 46 2 54 3 60 09 6 CGHKT6502525 7587 4 E May be 0 no circuit breaker or 1 with circuit breaker O C P Over current protection device must be HACR type circuit breaker or time delay fuse TABLE 12 Electrical Data For Single Source Power Supply Copper Wire 208 230 3 60 AHE Field lm Heater Heater 2 60650155 348 410 449 45 5 24 45 _____ __ GHK06501525 410 4 45 50 ekoo 346 426 4657 45 5 me 8HKiG502025 462 552 60 GHKOGSOTS2S 4657 6 6502025 7 80 70 6 06501525 657 45 o mee SHK16502025 _ 7 80 W 855 5 5 6 6502025 62 84 SFHR09501525 34 6 45 0 4855 50 AHEGOD 6HKT0502025__ 6282 80 COHR6502525 ne May be 0 no circuit breaker or 1 with circuit breaker Over current protection device must be HACR type circuit breaker or time delay fuse TABLE 13 Electrical Data For Multi Source Power Supply Copper Wire 208 230 3 60 AHR Min Circuit P Amps Type 75 C Wire Size AWG Heater Models m T m NL L mt 253956 AHRGOD 1 If wire other than non p
90. 79 120 280 144 46030 96 70 150 19 72 576390 74 53 115 15 59 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 FLA FLA qon 230 3 60 22 4 149 3 7 J25 25 460 3 60 10 6 75 1 9 MONES 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 1894 BE _ 1 63 E i80 1 173 497 Ee 360 2 346 562 E 540 2 520 648 720 2 92 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 Me dE Motors Blower Conv Electric Heat Option Breaker Tons ot each Motor Outlet Amps Size NO kN PBA ERA PCE ma Mese ages Amps Amps 901 100 mnm Em pus 100 154 100 180 175 200 Nm 888
91. 846 amp 3 8 8910408901008 1 40 4846 5 8 8 6 s20 e 70 79 6 4 _ 09 8 4 4 720 9138 30 39 3 3 FRC S200 300 9179 30096 2 F 0 7 6500608 00 05 320 3378 4846 amp 8 8 8910408901006 4846 3804 5 8 6 mazeo 20 e Gap 70 79 6 4 _ 2 5 09 7613 89 4 4 720 3313 9138 39 39 3 3 HK S200 300 9179 30096 2 moneo 320 3976 4346 40 49 8 eonen 400 3894 6 6 soie s20 046 Gp o 6 _ 6601506 89 8 4 O NI NI NI NI oim O Oo NI NI NI N eo AHE42D3XH21 N 6HK 1 6HK 1 For notes see Page 13 2 Johnson Controls Unitary Products 697883 UIM A 0711 TABLE 7 Electrical Data For Single Source Power Supply Copper Wire 208 230 1 60 AHE Continued Heater Field Wiring Heater Models Amps Min Circuit Ampacity Max O C P Amps Type 75 C Wire Size AWG 9 208V 230V 208V 230V 208V
92. A C22 2 236 05 up to 0 30 w c external static pressure including air filter wet coil and largest kW size heater unless otherwise noted 1 17 Johnson Controls Unitary Products 697883 UIM A 0711 TABLE 17 Air Flow Data 60 Hz Models 230 Volt AHE Blower Motor Speed Q External Static Pressure IWC m3 min 9 External static pressure Pascal 230 Volt AHE18B 647 895 845 808 767 709 647 i56 187 98 75 54 181 2 629 468 356 197 175 68 23 176 i31 100 55 49 19 06 lowsi 829 468 356 197 175 68 25 E 862 295 284 266 243 AHE22B 496 435 745 95 836 244 AHE24B 585 234 AHE30B 122 Med High 4 1301 1248 1198 1147 1008 999 927 368 353 339 325 285 283 268 AHE34C Med 3 1097 1044 972 906 915 748 680 296 275 257 284 AHES36C lowsi 903 707 ait 323 265 152 NA 253 i98 115 99 74 43 NA Med High 4 1430 1390 1346 1294 1298 1168 960 400 377 362 347 327 269 AHE42D Med Low 2 1118 1020 947 851 734 886 563 313 286 265 238 206 187 158 lowsi 998 772 477 418 NA 278 216 134 117 NA NA AHE48D B 3 2 AHE60D 1 Dry coil conditions only tested without filters Air handler units are CSA listed
93. 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 operate 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 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 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 perpendi
94. 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 7 300 6 600 8 450 10 360 i2 300 14 257 16 225 18 200 2 90 180 22 164 24 150 2 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 decrease the gas pressure turn the adjusting screw counterclockwise increase the gas pressure turn the adjusting screw clockwise NOTE The correct manifold pressure for these furnaces is 3 65 IWG 0 3 Adjustment Of Temperature Rise The temperature rise
95. Checklist Symptom Possible Cause s Corrective Action Excessive noise Fan inoperative Insufficient airflow Motor overheating 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 Clogged filters Operation in wrong direction Insufficient make up air direction Belt slippage Overvoltage or under voltage Operation in wrong direction Fan speed too high Incorrect motor service factor 1 0 low ambient temperature Undersized motor Replace motor with same frame size RPM HP Reset properly Tighten screws remove build up balance wheel propeller correct alignment Replace wheel propeller Reverse direction Replace fuses or circuit breaker Shut off power and check wiring for proper connections Repair or replace motor Replace belts Clean filters Correct rotation of propeller Add make up fan or louver opening Adjust tension or replace 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 Check motor ratings with catalog speed and air capacity chart Note Care should be taken to follow a
96. 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 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 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 CAUTION Do not loosen compressor mounting bolts Filters Two inch filters are supplied with each unit but units can be converted easily to four inch filters Filters must always be installed ahead
97. ETECTED 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 12 14 O amp M Section Sheets xls 6 16 2014 TT MAL TT J SEEHFEEEEEEEHE l R 410A SERIES 20 J ZJ 15 25 Ton 60 Hertz TM 4 LY y 9p p 9p Bh ul TABLE CONTENTS RI sss 2 Au BANC Crs d Dacis s 43 If 5 SU 45 MOL MEET CET I S Cooling Sequence 45 EOGHUBE ics asas Steen sed gaa T No Outdoor Air Options 45 Rigging And 0 7 Cooling Operation 5 46 DUGBNDE s hara ap QR E 12 Electric Heating Sequence Of Operations 48 Condensate 19 Electric Heat Operation 48 5 13 Gas Heating Sequence Of Operations 49
98. Flow CFM 0 4 0 6 0 8 RPM BHP RPM BHP RPM BHP Standard 5 HP amp 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 Standard 5 HP amp Drive 1 8 RPM 1020 1046 1074 1105 1137 1170 1205 RPM RPM 2 93 3 29 3 70 4 15 4 64 5 17 5 74 860261 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 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 BHP RPM BHP RPM BHP Standard 5 HP amp 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 amp Drive 1 8 RPM BHP 2 0 2 2 2 4 BHP RPM RPM TBD
99. GER 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 A WARNING 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 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 injury 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 CAUTION T
100. ISCHARGE CONVERSION Note As a standard Zephyr are furnished with an In line discharge as shown in Figure 30 1 Disassemble the TDA panel from the housing by removing the four 10 sheet metal screws securing the TDA panel to the housing and then remove the access panel by removing the four 10 sheet metal screws Remove both panels as shown in figure 30 Figure 30 TDA In Line Figure 31 TDA Right Angle ww Housing TDA Panel 4 Screws Access Panel E 4 10 S M f Screws 10 5 Housing Flange Screws m 4 10 Access Panel Screws 4 Screws 2 Reassemble both the TDA and access panels after exchanging locations First slide the 3 locking tabs of the TDA panel into the housing flange Second engage the access panel return flange into the 3 locking tabs on the TDA panel Finally reinstall the eight 10 sheet metal screws See figure 31 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 PENNBARRY 9 Operation amp Maintenance Manual 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 Loo
101. Indoor Blower Specifications Motor Sheave Blower Sheave a her Tons T 5 1725 47 52 64 11 8 iVP65 i BX83 15 5 52 64 tres 6090 exe BX78 BX75 120 78 ERE 75 78 5VX840 e e os L 2947 L 82 74 88 iVPTEX 55 T 76 185784 5 56 Table 19 Power Exhaust Specifications 17 5 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 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 perpendicular 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 det
102. LU 24 COM EQUIPMENT GROUND 1 HEATER KITS 5 6HK 16500806 6HK16501006 DE EQUIPMENT ec GROUND EQUIPMENT LA Ku GROUND RS EL BLU WHT NO BLU 12 yop ay karen ii oi 208 240 VOLT HEATER KITS 6HK16501306 6HK16501506 EQUIPMENT GROUND im gt BLU HEATER KITS 6HK16501806 6HK16502006 BLOWER SEQ or RLY AIR HANDLER WITH NO HEAT KIT MOTOR COM BLOWER CONTROL RELAY L COIL H C BLOWER CONTR GRN o 0 EQUIPMENT LEGEND GROUND ST LS LIMIT SWITCH SEQ SEQUNECER CODES MUST BE FOLLOWED FIGURE 15 Wiring Diagram PSC Single Phase Heat Kits Johnson Controls Unitary Products XFORMER a 13 KW AND ABOVE 10 KW AND BELOW HE HEATING ELEMENT FL FUSIBLE LINK H SEQUNECER HEATER RC RUN CAPACITOR USE COPPER CONDUCTORS ONLY IF ALUMINUM CONDUCTORS ARE PRESENT ALL APPLICABLE LOCAL AND NATIONAL 661690 UWD A 1110 19 697883 UIM A 0711 FIGURE 16 Wiring 20 BE SURE THE BLOWER SPEED 15 OR THE AIR HANDLER HEATER KIT NSTALLATION INSTRUCTIONS WHEN INSTALLING HEATE SET TO THE SPEED SPEC COMBINATION ON THIS U HEATER KITS 6HK 6500206 6HK 6500506 IT ED 5 RK NIT F EQUIPMENT GROUND sees HEATER KITS 6HK 6500806 6HK 6501006 208 240 VAC 60HZ PHASE wey EQUIPMENT
103. Long OUTDOOR COIL END OF UNIT 126 1 4 d FRONT OF UNIT Supply and Return Air 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 by 18 inches wide in the ductwork to accommodate the damper Using the holes in the hood flanges as
104. P amp Field Low Static 7 5 HP amp 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 2011260 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 RPM RPM 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 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 High Static 15 HP amp Drive 1221 1238 1255 1273 1292 1311 1332 1352 1374 1396 1418 1441 1465 8 33 8 84
105. PENNBARRY 7 Operation amp Maintenance Manual Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Conversion Instructions Models Z3H Z5H 785 785 7815 8 7105 RA TD Ceiling Fan Conversions HIGHT ANGLE RA TO TOP DISCHARGE TD CONVERSION Note As a standard Zephyr RA TD s are furnished with a Right Angle RA discharge as shown in Figure 24 1 Disassemble the access panel from the housing by removing the two 10 sheet metal screws and then removing the panel by pulling it towards the housing opening as shown in figure 24 Figure 24 Right Angle Figure 25 TD Top Discharge Housing Housing TD Access Panel Top Discharge 10 SM Screws Housing Flange Access Panel 10 SIM Screws Locking Tabs 2 Reassemble the access panel by rotating the access panel 90 and remount it to the housing Slide in the 3 locking tabes to the housing flange and reinstall the two 10 sheet metal screws See figure 25 TDA In line Fan Conversions TDA IN LINE TO RIGHT ANGLE DISCHARGE CONVERSION Note As a standard Zephyr TDAs are furnished with an In line discharge as shown in Figure 26 1 Disassemble the TDA panel from the housing by removing the four 10 sheet metal screws Remove both panels as shown in figure 26 Figure 26 TDA In Line Figure 27 TDA Right Angle Housing TDA Panel Access Panel 5 10 S M 75 Screws 10 S
106. PSIG Reference Additional information is available in the following reference forms e 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 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 A WARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage 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 JIM B 0612 Nomenclature 15 25 Ton Series 20 Model Number Nomenclature J15 Z J N24 A 2 A AA 1 0 1 2 4 Nominal Cooling Capacity MIA J20 20 Ton 425 25 Configuration Options not required for all units These four d
107. Paulson Cheek Mechanical 6145 Northbelt Parkway Suite F Norcross GA 30071 770 729 0076 770 729 1076 Paulson Cheek MECHANICAL Pinewood Atlanta Phase Stage 9 Fayetteville GA O amp M Manuals 6 12 2014 General Contractor Group VI Construction LLC Mechanical Engineer Paulson Cheek Mechanical Inc Mechanical Contractor Paulson Cheek Mechanical Inc Section 1 Split Systems Section 2 Rooftop Units Section 3 Exhaust Fans Paulson Cheek MECHANICAL O amp M SECTION SHEET SECTION 1 PRODUCT SPLIT SYSTEM Paulson Cheek Mechanical Inc 6145 Norhtbelt Parkway Suite F Norcross GA 30071 PROJECT Pinewood Atlanta Phase 1A PHONE 770 729 0076 Stage 9 FAX 110 729 1076 LOCATION Fayetteville GA Paulson Cheek Mechanical Inc ARCHITECT S ENGINEER S STAMP Paulson Cheek Mechanical Inc DATE RECEIVED 06 12 14 MANUFACTURER JCI SUPPLIER JCI SUBMITTED DATE 06 12 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 12 14 O amp M Section Sheets xls 6 16 2014 USER S INFORMATION MANUAL OUTDOOR SPLIT SYSTEM AIR CONDITIONING OR HEAT PUMP MODELS SINGLE PHASE amp THREE PHASE AD CERTIFIED Unitary Small AC www ahr
108. 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 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 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 Johnson Controls Unitary Products 37 860261 JIM B 0612 J20ZJ 20 Ton Side Duct Available External Static Pressure 1 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 20 22 2 4 26 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 8 Drive High Static 7 5 8 Drive 5200 424 972 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 1082 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
109. TEN Management System LIST OF SECTIONS GENERAL 1 BLOWER SPEED CONNECTIONS 8 SAFETY J 1 UNIT DATA d dace sonus 8 UNIT INSTALLATION 2x nu ma 3 MAINTENANCE EEG ERRARE PR E EE 18 ELECTRIC HEATER INSTALLATION 7 WIRING DIAGRAM 19 LINE POWER CONNECTIONS 7 TYPICAL THERMOSTAT CONNECTIONS 22 LOW VOLTAGE CONTROL CONNECTIONS 7 LIST OF FIGURES Return Duct Attachment amp Component Location 2 Proper Bulb eue uice ym onm nce Rmi xs 6 Dimensions amp Duct Connection Dimensions 3 Blower Delay Control Board 7 Typical Installation 4 Line Power Connections 7 Condensate Deflector on Vertical Drain Pan 4 Blower Speed Connections 8 Condensate Deflector on Horizontal Drain Pan Edge 4 Wiring Diagram PSC Single Phase Heat Kits 19 Installall fi uuu RC Pr 4 Wiring Diagram Single Phase Heat Kits 20 pumpu 4 Wiring Diagram Phase Heat Kits 21 Ductwork Transiti
110. TER DOOR uM WHEN ATTACHING DUCT WORK WITH SCREWS SCREWS WITHIN 5 8 OF SIDES AND BACK OF AIR HANDLER Johnson Controls Unitary Products Blower Compartment Refrigerant Connections Drain Connections for Upflow Applications Access FIGURE 2 Dimensions amp Duct Connection Dimensions TABLE 1 Dimensions 697883 UIM A 0711 Top Outlet Dimensions Circuit Breaker Panel 18 9327 Bottom Inlet Dimensions Drain Pan Connections for Horizontal Applications Wiring Knockouts Refrigerant Connections EIE Height Width Depth Le p usi vn A n lv Hr eth eth AHR18B AHE18B AHE22B AHR42C AHE36C AHR48D AHE42D AHE48D AHR60D AHE60D 1 Actual size conduit size SECTION III CLEARANCES Clearances must be taken into consideration and provided for as fol lows UNIT INSTALLATION 1 Refrigerant piping and connections minimum 12 recommended 2 Maintenance and servicing access minimum 36 from front of unit recommended for blower motor coil replacement 3 Condensate drain lines routed to clear filter and panel access Filter removal minimum 36 recommended 5 The ductwork and plenum connected to this unit are designed for zer
111. 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 amp PC Software http www yorkupg com software asp 3 Freenet USB adapter driver http www yorkupg com software asp 4 Simplicity amp Freenet USB Adapter 51 03101967000 Freenet service cable 51 02538682000 No Outdoor Air Options When the thermostat calls for the first stage of cooling the low voltage control circuit from to Y1 and 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 15 energized If compressor 1 is unavailable compressor 2 15 energized After completing the specified fan on delay for cooling the UCB will energize the blower motor When the thermostat calls for the second stage of cooling the low voltage control circuit from to Y2 is completed Compressor 2 is energized provided it has not been
112. VED MULTI SOURCE 15 25 KW 25 KW SHOWN ELECTRIC HEAT WITHOUT CIRCUIT BREAKER 3 PHASE 10 15 KW TERMINAL BLOCK ELECTRIC HEAT WITHOUT CIRCUIT BREAKER SINGLE SOURCE 2 5 10 KW 1 PHASE ELECTRIC HEAT WITH CIRCUIT BREAKER AS SHIPPED FROM FACTORY SINGLE SOURCE 2 5 25 KW 25 KW SHOWN GND LUG GND LUG QE POWER GND LUG h SND T POWER SUPPLY14 _ POWER SUPPLY 2 3 POWER SUPPLY 3 SUPPLY MAY BE 1 2 OR 3 CIRCUIT BREAKERS FIGURE 13 Line Power Connections SECTION VI LOW VOLTAGE CONTROL CONNECTIONS The 24 volt power supply is provided by an internally wired low voltage transformer which is standard on all models However if the unit is con nected to a 208 volt power supply the low voltage transformer must be rewired to the 208 volt tap See the unit wiring label Field supplied low voltage wiring can exit the unit on the top right hand corner or the right hand side panel Refer to Figure 5 Johnson Controls Unitary Products GND LUG SUPPLY JUMPER MAY BE 1 2 OR CIRCUIT BREAKERS LUG TERMINAL BLOCK POWER WIRING 208 230 1 60 Remove desired knockout and pierce foil faced insulation to allow wir ing to pass through Use as small of a hole as possible to minimize air leakage Install a 7 8 plastic bushing in the selected hole and keep low voltage wiring as short as possible inside the control box To further minimize air lea
113. YCLE HEAT PUMPS During the heating cycle your system will remove heat and humidity from the outdoor air and will transfer this heat to your home This is pos sible because even 09 outdoor air contains a great deal of heat Remember that your heat pump doesn t generate much heat it merely transfers it from one place to another System Operation Your thermostat puts full control of the comfort level in your home at your fingertips DO NOT switch your thermostat rapidly ON and OFF or between HEAT to COOL This could damage your equipment Always allow at least 5 minutes between changes SETTING THE THERMOSTAT ACAUTION The main power to the system must be kept ON at all times to pre vent damage to the outdoor unit compressor If necessary the ther mostat control switch should be used to turn the system OFF Should the main power be disconnected or interrupted for 8 hours or longer DO NOT attempt to start the system for 8 hours after the power has been restored to the outdoor unit If heat is needed dur ing this 8 hour period use emergency heat Johnson Controls Unitary Products START UP ance bere ae bp ee eee ee he eee 2 SYSTEM 2 LIMITED WARRANTY 4 Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman OK 73069 THERMOSTATS YOUR KEY TO COMFORT Although thermostats may vary widely in appe
114. 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 Q 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 CAUTION This system uses R 410A Refrigerant which operates at higher pressures than R 22 No other refrigerant may be used in this system Johnson
115. amaged parts Mishandled units can void the warranty provisions If units are damaged in transit it is the responsibil ity of the receiver to make all claims against the carrier PennBarry is not responsible for damages incurred during shipment Avoid severe jarring and or dropping Handle units with care to prevent damage to components or fin ishes 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 attention Store units on a level solid surface preferably indoors If outside storage is necessary protect the units against moisture and dirt by encasing 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 manufacturer s warranty If the unit will be stored for an extended time remove belts Belts that remain under tension in a stationary position for extended periods are likely to have a reduced operating life Installation Any accessories which have been provided knocked down can be assembled per illustra tions provided pages 6 9 LOCATION AND GUARDS All fans have moving parts which require guarding in the same way as other moving machin ery Where the fan is accessible to untrained per sonnel or the general public use maximum safety
116. arance they are all designed to perform the same basic function to control the operation of your air conditioning or heat pump system Regardless of size or shape each thermostat will feature a temperature indicator a dial arm or push button for selection of the desired temperature a fan switch to choose the indoor fan operation and a comfort switch for you to select the system mode of operation Only approved thermostats have been tested and are fully compatible with this equipment Please be aware that many different thermostats operate on batteries or power stealing principals These types of ther mostats can not be supported as trouble free when used with this product If your system has been designed to allow both cooling and heating operation you may have either a manual change over type or a pro grammable electronic type thermostat Manual change over simply means that the comfort switch must be manually positioned every time you wish to switch from the cooling to heating or heating to cooling modes of operation A complete operating instruction is provided by the manufacturer for each thermostat Familiarize yourself with its proper operation to obtain the maximum comfort with minimum energy consumption The computerized electronic thermostat is actually a sophisticated elec tronic version of a manual change over type This thermostat includes features which allow set back temperature variations for periods of sl
117. ax 972 497 0468 PENNBARRY 11 Operation amp Maintenance Manual Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Limited 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 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
118. be liable for special incidental or consequential damages including but not limited to loss of use of the equipment or associated equipment lost revenues or profits cost of substitute equipment or cost of fuel or electricity The above limitations shall inure to the benefit of Company s suppliers and subcontractors The above limitation on consequential damages shall not apply to injuries to persons in the case of consumer goods Company does not assume or authorize any other person to assume for Company any other liability for the sale of this product Some states do not allow the exclusion or limitation of incidental or consequently damages so the above limitation may not apply to you This warranty gives you specific legal rights You may also have other rights which vary from state to state Subject to change without notice Published in U S A 813196 UUM C 0412 Copyright 2012 by Johnson Controls Inc All rights reserved Supersedes 813196 UUM B 0412 York International Corp 5005 York Drive Norman OK 73069 nid 4 4 y IIB Ban SINGLE PIECE 3 POSITION AIR HANDLERS lt y P 4 Daa LUI LIT 62 NV 9000 REGISTR CERTIFIED www ahridirectory org 25 n MODELS AHR AHE SERIES
119. be set at the Percent Open of the economizer damper at which the power exhaust is needed can be set from 010 10096 damper open Indoor Air Quality AQ Indoor Air Quality indoor sensor input Terminal AQ accepts a 2 to 10 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 there 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 Space Sensor Kit Part 2AQ04700324 Optional Sensor Kit Part 24004700424 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
120. c 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 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 initiate the ASCD Anti short cycle delay and if the other compressor is idle stop the condenser fans If the cal
121. cal Connections c Volts Non fused UL recogni ed Single Pole Disconnect Switch gt Rated in H P B Voltage 115 1 60 Powerlines Volts Non fused UL recogni ed Single Pole Disconnect Switch Rated in H P B Voltage Starter 115 1 60 Pow erlines PENNBARRY 3 Operation amp Maintenance Manual Note 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 while under warranty Exchange repair or replacement will be provided on a no charge basis if the motor is defective with in the warranty period The PennBarry representative in your area will provide a name and address of an authorized serv ice station if requested Do not return defective motors to Pennbarry WARN ING Motor guarantee is void unless over load protection is provided in motor wiring circuit Hidden Danger In addition to the normal dangers of rotat ing machinery fans present an additional hazard in their ability to suck in not only air but loose materials as well Solid objects can pass through the fan and be discharged by the impeller as potentially dangerous projectiles Intake to duct work should whenever possible be screened to prevent the acci dental entrance of solid objects Access doors or grill to a duct system should never be opened with the fan running When a fan
122. carefully for 1 Correct rotation of the impeller Incorrect rotation CAUTION overloads motor severely and results in serious motor damage To change rotation of three phase units interchange any 2 of the 3 line leads On single phase units change the terminal block set up following the wiring diagram on the motor 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 972 497 0468 Breezeway Panel Fans Direct and Belt Drive 2 Check motor and bearing tempera tures for excessive heat against the manufacturer s recommendations Use care when touch CAUTION ing the exterior of an operating motor Modern motors normally run hot They are designed to operate at higher temperatures This is a normal condition but they may be hot enough to be painful or injurious to the touch If any problem is indicated TURN OFF POWER TO UNIT IMMEDIATELY Lock out the electrical supply check carefully for the cause of the trouble and correct as needed Even if the fan appears to be operating satisfactorily shut down after a brief period and check all fasteners set screws and keys for tightness During the first eight 8 hours of operation check the periodically for excessive vibration or noise At this time also check motor input current and motor bearing temperatures to insure that they do not exceed manufacturer s recommendations After eight hours of satisfactory operation shut down the fan a
123. cated 1020 RPM amp 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 O 19 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 Standard SHE RIO Standard 5 HP amp Drive High Static 7 5 HP amp Drive Supplied Drive 6400 719 2 55 933 4 98 966 5 24 998 5 45 1028 5 59 1056 5 67 1083 5 68 6800 742 302 955 5 46 988 5 72 1020 5 92 1050 6 07 1078 6 15 1105 6 16 7200 765 3 54 979 5 98 1012 6 24 1044 6 44 1074 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 amp Field Supplied Drive Table X 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 X Y 5 5 75 1VP60 BK110 730 765 800 835 870 905 N A 7 5 8 63 1VP60 BK090 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
124. cess Mounting Follow all local electri A CAUTION cal safety and building codes the provisions of the National Electrical Code and the Occupational Safety and Health Act POSITIONING AND RUNNING POWER LINES Power is normally brought from within the building through proper conduit lines to the wall opening and in turn to the dis connect switch if furnished motor When power lines are brought up to the unit provide a generous amount of slack to allow for motor adjustments and to per mit movement of motor for belt tension adjustments Ground motor adequately and securely Protect power lines from sharp objects Do not kink power line or permit it to contact hot surfaces chemi cals grease or oil Use only UL recog nized electrical parts rated for proper voltage load and environment INSTALLING THE WALL SHUTTER When required level and fasten the wall shutter through the mounting holes provided in the shutter mounting flange Consult Figure 1 for the proper mounting arrange ments Secure the shutter to the wall open ing without undue twisting which may distort the frame Check for free operation If shut ters are motor operated type ascertain the proper voltage is present on motor terminals The fan is now ready for service 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 propeller by
125. 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 to W1 and 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 4 1 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 IC1 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 tube flame After completing the specified fan on delay for heating the UCB will energize the blower motor
126. cts 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 A WARNING 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 persona
127. cular 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 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 Figur
128. 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 the control box A solid state lock out relay LR and 100 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 2 to BAS controller e LR 3 to UCB X 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
129. d 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 Or Intelli comfort II Control The position of the outside air and return air dampers are controlled through a 2 10 VDC signal from the VAV or Intelli Comfort II control board T
130. d by use of a transition to match unit opening All ducts should be suspended using flexible hang ers and never fastened directly to the structure This unit is not designed for non ducted freeblow applications Size outlet plenum or transition to discharge opening sizes shown in Figure 5 Ductwork should be fabricated and installed in accordance with local and or national codes This includes the standards of the National Fire Protection Association for Installation of Air Conditioning and Ventilat ing Systems NFPA No 90B DUCTWORK TRANSITION Ductwork that is not designed to match the supply air opening can cause turbulence inside the plenum box This turbulence can change the air flow patterns across the heat kit limit switch If the factory sug gested transition can not be fabricated it is recommended a block off plate approximately 8 in height and running the full width of the ple num be attached to the supply opening Please refer to Figure 9 as a visual aid The use of this block off plate will keep better air circulation across the limit switch e mmm N N N a a RECOMMENDED SUGGESTED LOCATION TRANSITION OF BLOCK OFF PLATE FIGURE 8 Ductwork Transition AIR FILTERS Air filters must be field supplied A 1 filter access rack has been built into the unit See Figure 5 Remove filter access cover shown Install proper size filter Standard 1 size permanent or throw away filter may be used or permanent
131. d 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 caused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower Centrifugal Switch CS
132. d 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 4 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 economizers the UCB allows compressor operation all the time This programm
133. drive Outputs e FAN 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 VAV 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
134. e 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 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 3 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 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 and the UCB i e that the thermostat G t
135. e 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 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 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
136. e the greater the load on your sys tem Therefore do not be alarmed when your system continues to run after the sun has set on a hot day Heat is stored in your outside walls during the day and will continue to flow into your home for several hours after sunset Use your kitchen exhaust fan when cooking One surface burner on HIGH requires one ton of cooling Turn on your bathroom exhaust fan while showering to remove humidity However exhaust fans should not be run excessively It would decrease efficiency by removing condi tioned air You can also help your system in the summer by closing drapes or blinds and by lowering awnings on windows that get direct sunlight CARE OF SYSTEM It is strongly recommended that regular periodic preventative mainte nance be performed on this equipment The person most familiar with the equipment in your H V A C system is a dealer The dealer can ensure your maintenance program meets the conditions of the War ranty maximize the efficiency of the equipment and service your unit within the federally mandated guidelines with regard to unlawful dis charge of refrigerants into the atmosphere COIL CARE Keep the outdoor unit free of foliage grass clippings leaves paper and any other material which could restrict the proper air flow in and out of the unit The coil may be vacuumed to remove any debris from between the fins If the coil becomes excessively dirty turn the main disconnect switch to
137. e 19 Johnson Controls Unitary Products Table 14 Altitude Temperature Correction Factors Air Temp 1000 2000 40 860261 JIM B 0612 Altitude Ft 3000 4000 5000 6000 8000 9000 0 950 0 729 10000 50 0 715 60 0701 70 0 688 80 0 676 90 0 663 100 0 651 O LL c 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 Temperature 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 rom 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 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 Solutio
138. e Enthalpy Sensor When the room thermostat calls for first stage cooling the low voltage control circuit from 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 Y1 energizes compressor 1 When the thermostat calls for second stage cooling the low voltage control circuit from 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 2 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 Y 1 and Y2 If the compressors have satisfied their minimum run times the compressors and condenser fans are de energize
139. e 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 ambient mode always begins with compressor operation Compressor minimum run time may extend the minutes of compressor
140. e secondary drain is not used it must be capped 5 When an evaporator coil is installed in an attic or above a finished ceiling an auxiliary drain pan should be provided under the air han dler as is specified by most local building codes 6 Proper electrical supply must be available 7 If unit is located in an area of high humidity i e an unconditioned garage or attic nuisance sweating of casing may occur On these installations unit duct connections and other openings should be properly sealed and a wrap of 2 fiberglass insulation with vinyl vapor barrier should be used 697883 UIM A 0711 UPFLOW ccc ctctoeeOCcCOnpDDPp lC z Q E h esa n h HORIZONTAL RIGHT HORIZONTAL LEFT FIGURE 3 Typical Installation HORIZONTAL CONVERSION These air handler units are supplied ready to be installed in a upflow and right hand horizontal position If unit requires left hand positioning the unit must have the coil assembly repositioned For both horizontal applications the condensate deflector should be positioned as shown in Figure 5 1 Remove blower coil and filter access panels NOTICE Conversion must be made before brazing the refrigerant connections to the coil For horizontal left installations follow steps 2 8 Remove tubing connection panel Slide coil assembly out of air handler Rotate cabinet 180 so blower outlet is facing do
141. eep or while you are away during the day and means energy savings for you The thermostat also features a digital clock COOLING ONLY If your air conditioning system is designed to provide cooling only AC with no capability for heating operation heat pump a two stage cool ing only thermostat with a manual one position Cool and Off com fort switch is all that is required for system operation COOLING AND HEATING HEAT PUMP If your system has been designed to allow both cooling and heating operation you may have either a manual change over type or a pro grammable electronic type thermostat with 2 stages of cooling and 2 stages of heat MANUAL CHANGE OVER Manual change over simply means that the comfort switch must be manually positioned every time you wish to switch from the cooling to heating or heating to cooling modes of operation 813196 UUM C 0412 8131 96 UUM C 0412 PROGRAMMABLE ELECTRONIC THERMOSTATS The computerized electronic thermostat is actually a sophisticated elec tronic version of a manual change over type This thermostat includes features which allow set back temperature variations for periods of sleep or while you are away during the day and means energy savings for you The thermostat also features a digital clock FAN OPERATION SELECTION A multi position fan switch allows you to choose the type of fan opera tion of the indoor fan AUTO With the thermostat fan switch set to
142. efore starting the unit 1 Checkthe 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 52 Operating Instructions 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 Checkfor gas leaks in the unit piping as well as the supply piping A WARNING 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 2 Check for correct manifold gas pressures
143. eporting Value 2 2 n Pleated Optional MERV 7 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 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 Tons 39 5 7 5000 8 4500 4500 8000 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 mos 20 50 30 60 NES 20 50 30 60 w 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 Fue
144. ere 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 7 124 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 LIST page 52 and that the pilot adjust screw is allowing some
145. erminal 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 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 coil If 24 volts are present and M1 is no
146. ermine 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 025 Blower Performance Data Tables CAUTION Belt drive blower systems MUST be adjusted to the specific static and CFM requirements for the application Pressure Drop IWG ce belt drive blowers set at the factory for any specific static or CFM Adjustments 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
147. essor 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 jumper in the Mate N Lock plug and in the wiring from the Ma
148. fire electric shock or injury to persons observe the following A Use this unit only in the manner intended by the manufacturer if you have questions contact the manufacturer B Before servicing or cleaning unit switch power OFF at service panel and lock the service panel to prevent power from being switched ON accidentally When the service disconnecting means cannot be locked securely fasten a prominent warning device such as a tag to the service panel Figure 23 Cooking Area Do Not Install Above Or Inside This Area Cooking Equipment Floor To reduce the risk of WARNING fire electric shock or injury to persons observe the following A Installation work and electrical wiring must be done by qualified person s in accordance with all applicable codes and standards including fire rated construction B Sufficient air is needed for proper combustion and exhausting of gases through the flue chimney of fuel burning equipment to prevent back drafting Follow the heating equip ment manufacturer s guideline and safety standards such as those published by the National Fire Protection Association the American Society for Heating Refrigeration and Air Conditioning Engineers ASHRAE and local code authorities C When cutting or drilling into wall or ceiling do not damage electrical wiring and other hidden utilities D Ducted fans must always be vented to the outdoors E
149. form 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 between 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 A WARNING LP gas 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 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 A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury death or property damage Never test for gas
150. hand to insure free movement Before placing hand on A CAUTION impeller or belts lock out power source Check all set screws and keys Tighten when necessary 2 PENNBARRY Breezeway Panel Fans Direct and Belt Drive 4 Shutte Breezewoy Fan Wall Shutter Surface Mounting Louver BELT TENSION AND PULLEY ALIGNMENT Check condition of belts and the amount of tension prior to start up DO NOT over tighten as bearing damage will occur Recommended belt tension should permit deflection of 1 64 per inch of span on each side of belt measured halfway between pulley centerline Exercise extreme care when adjusting belts so as not to misalign the pulleys Any misalign ment will cause a sharp reduction in belt life an produce squeaky annoying noises On units equipped with two groove pul leys adjust all belts with equal tension Whenever belts A CAUTION are removed or installed never force belts over pulleys without loosening motor first to relieve belt tension Make sure inlets and approaches to the unit are free from obstruction To assure maximum air movement make sure ade quate supply air is available Before putting fan into operation com plete the following check list a Turn off and LOCK OUT power source b Make sure installation is in accordance with manufacturer s instructions c Check and tighten all fasteners Figure 4 Pulley Alignment
151. he 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 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 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 volts at the Y1 ECON terminal If 24 volts is not present check for loose
152. he 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 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 setpoint plus 5 F free cooling is available If free cooling is available with a Y1 call then the control modulates
153. hermostat calls and set the fan switch to AUTO wait for the internal overload to reset Test again when cool If M3 is not pulled in check for 24 volts at the M3 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 the motor still does not operate replace the motor 59 860261 JIM B 0612 6 24 volts is not present at 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 between R and G with the fan switch in the position and in the AUTO
154. hin the air handler s intended maximum outlet air temperature Only connect the air han dler to a duct system which has an external static pressure within the allowable range as specified on the air handler rating plate When air handler is installed so that supply ducts carry air circu lated by the air handler to areas outside the space containing the air handler the return air shall also be handled by duct s sealed to the air handler casing and terminating in the space to be cooled heated 4 The air handler is not to be used for temporary heating of buildings or structures under construction 5 The size of the unit should be based on an acceptable heat loss or gain calculation for the structure ACCA Manual J or other approved methods may be used SAFETY REQUIREMENTS 1 This air handler should be installed in accordance with all national and local building safety codes and requirements local plumbing or wastewater codes and other applicable codes 2 Refer to the unit rating plate for the air handler model number and then see the dimensions page of this instruction for supply air ple num dimensions in Figure 5 The plenum must be installed accord ing to the instructions 3 Provide clearances from combustible materials as listed under Clearances 4 Provide clearances for servicing ensuring that service access is allowed for electric heaters and blower 5 Failure to carefully read and follow all instruction
155. his 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 A WARNING 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 hazardous 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 literatur
156. ical 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 some 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
157. idirectory org i e Zu CERTIFIED US sees UU UE EIE ISO 9001 Certified Quality Management System Unitary Small HP AHRI Standard 210 240 Certification applies only when the complete system is li TABLE OF CONTENTS dm aec O 1 HOW YOUR SYSTEM WORKS 1 THERMOSTATS lt x u as acie Kuwa ana ww RO n cars 1 PROGRAMMABLE ELECTRONIC THERMOSTATS 2 CONTACT INFORMATION Go to website at www york com then click on Contact Us and follow the instructions Contact us by mail The manufacturer recommends that the user read this manual and keep the manual for future reference SAFETY A WARNING This product must be installed and serviced by a qualified installer or service agency Improper installation adjustment alteration ser vice or maintenance can cause injury or property damage HOW YOUR SYSTEM WORKS COOLING CYCLE If your hand is wet and you blow on it it feels cool because some of the moisture is evaporating and becoming a vapor This process requires heat The heat is being taken from your hand so your hand feels cool That s what happens with an air conditioner During the cooling cycle your system will remove heat and humidity from your home and will transfer this heat to the outdoor air HEATING C
158. 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 is also used to alert against unsafe practices and hazards involving only property dam A WARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage age Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assis tance or for additional information consult a qualified contractor installer or service agency ACAUTION 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 697883 UIM A 071 1 697883 UIM A 0711 A WARNING FIRE OR ELECTRICAL HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage A fire or electrical hazard may result causing property damage personal injury or loss of life 1 Install this air handler only in a location and position as specified in SECTION III of these instructions 2 Always install the air handler to operate wit
159. igits 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 Controller Product Category Z 7 AIC Single Pkg 410 Product Identifier 11 0 EER A C Heat Type and Nominal Heat Capacity Simplicity IntelliComfort Controller w Simplicity LINC Hot Gas Bypass Standard on VAV Optional on CV Variable Air Volume VFD Variable Air Volume VFD and Manual Bypass Cooling Only No field installed electric heat Gas Heat Options N24 240 MBH Output Aluminized Steel N32 320 MBH Output Aluminized Steel 524 240 MBH Output Stainless Steel 532 320 MBH Output Stainless Steel Electric Heat Options E18 18 KW E36 36 KW E54 54 KW Product Generation E72 72 KW 1 First Generation Std Motor Additional Options B Std Motor Economizer Std MotoriEconomizer Power Exhaust Standard Cabinet Hinged Filter Door amp Tool 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 Econom
160. ing 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 Y2 to C2 terminals the compressor engages the UCB has faulted If none of the above correct the error replace the UCB On a call for cooling the supply air blower motor and compressor 2 are operating but compressor 1 15 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 compressor still does not operate replace the compressor If 24 volts is n
161. 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 2 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 2 terminal If 57 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 none of the protection switches have opened the UCB may have locke
162. inimum 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 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 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 8 to size power wiring fuses and disconnect switch Power wiring is brought into the unit
163. is being started for the first time a complete inspection of the duct work and interior of the fan should be made with the power locked off to make certain there is no foreign material which can be sucked into or blown through the duct work Fan Guards All fans have moving parts which require guarding in the same way as other mov ing machinery In areas which are acces sible only to experienced personnel a standard industrial type guard may be adequate This type of guard will prevent the entry of thrown or dropped objects with a minimum restriction of air flow 4 PENNBARRY Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Where the fan is accessible to untrained personnel or the general public maximum safety guards should be used even at the cost of some loss of performance To reduce the risk of CAUTIO injury of a person install the fan at least 7 feet above the floor if no guard is installed Roof mounted equipment will require guards when access is possible for example by climbing children Centrifugal fans may be connected direct ly to duct work which will prevent contact with the internal moving parts but when the inlet or outlet is exposed a suitable guard should be installed Do not install in cooking or shower stall area see Figure 23 Units are designed to CAUTIO handle clean are only Avoid installation in corrosive and dusty environments To reduce the risk of WARNING
164. is provided The flow of dry nitrogen should continue until the joint has cooled Always use a pressure regulator and safety valve to insure that only low pressure dry nitrogen is introduced into the tubing Only a small flow is necessary to displace air and prevent oxidation Connect lines as follows NOTICE Route the refrigerant lines to the coil in a manner that will not obstruct service access to the coil air handling system or filter 1 Suction and liquid line connections are made outside the cabinet Leave the tubing connection panel attached to the cabinet with the tubes protruding through it Coil access panel should be removed for brazing The lines are swedged to receive the field line set tubes 2 Remove the heat shield from the Customer Packet soak in water and install over coil tubing to prevent overheating of cabinet 3 Wrap a water soaked rag around the coil connection tubes inside the cabinet to avoid damaging the TXV bulb 4 Remove grommets where tubes exit the cabinet to prevent burning them during brazing 5 Purge refrigerant lines with dry nitrogen 6 Braze the suction and liquid lines Suction line must be insulated 7 Remove the heat shield 8 Re attach the grommets to the lines carefully to prevent air leakage 9 Attach the coil access panel to the cabinet ALWAYS evacuate the coil and line Set tubing to 500 microns before opening outdoor unit service valves Refer to Outdoor uni
165. izer 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 2 208 230 3 60 Installation Options A No Options Installed N Options 2 amp 3 Option 1 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 amp 5 G Options 1 amp 3 U Options 1 3 amp 5 H Options 1 amp 4 V Options 1 4 amp 5 J Options 1 2 amp 3 W Options 1 3 4 amp 5 K Options 1 2 amp 4 X Options 3 amp 5 L Options 1 3 amp 4 Y Options 4 amp 5 M Options 1 2 3 amp 4 Z Options 3 4 amp 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 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 progra
166. joist B or the built out sec tion of joist B If spacers are required for joist B they should be sized according to the dimension of the fan housing Using care to avoid damage to the housing secure the housing to the joists by nailing through the pre punched holes found at the top and bottom of housing sides These pre punched holes would normally be utilized as a point of attachment for the adjustable flanges however these flanges will not be necessary with this type of installation 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Before the nails are driven snug care should be taken to assure that the housing is 1 4 above the ceiling level Nails should now be secured Care should be taken to assure that the nail head is large enough to prevent slipping through the pre punched holes A washer can be used to increase the bearing surface Re attach blower assembly to housing Lock out primary and secondary power source and secure electrical lines to the terminal box This should be done in accordance with the procedure outlined For all of the installation situations described above the egg crate ceiling grill should be installed as a final step This is done by first assembling the two torsion springs to the grill Use the torsion springs and grill buttons from the hardware kit provided Insert the grille buttons i
167. kage seal the wiring entry point at the outside of the unit The field wiring is to be connected at the pigtails supplied with the con trol board harness Refer to SECTIONS X and XI for system wiring 697883 UIM A 0711 SECTION VII BLOWER SPEED NOTICE CONNECTIONS All wiring must comply with local and national electrical code require Adjust blower motor speed to provide airflow within the minimum and ments Read and heed all unit caution labels maximum limits approved for evaporator coil electric heat and outdoor unit Speed tap adjustments are made at the motor terminal block Air N OTI C E flow data is shown in Table 15 Connect motor wires to motor speed tap receptacle for speed desired It is possible to vary the amount of electric heat turned on during the See unit wiring label for motor wiring details defrost cycle of a heat pump Standard wiring will only bring on the first stage of electric heat during defrost See Heat Output and Limit Connections and Table 6 for additional information on heat during defrost cycle AHR STANDARD MOTOR AHE HIGH EFFICIENCY MOTOR RED 12 FACTORY WIRED CONTROL BOARD TRANSFORMER BLU WHT X13G COM FACTORY WIRED TO FAN MOTOR RELAY TERMINAL ON CONTROL BOARD GRN TO BLK WHT CONTROL BLK BOARD REDAWHT X13 SPD 208 230V uid BLOWER MOTOR FAN MOTOR TO RN TRANSFORMER BLOWER s FIGURE 14 Blower Speed Connections SECTION VIII UNIT DATA TABLE 2
168. l 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 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 lin _ 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 iiis Max Min 1157 7000 5 7000 182 6000 6000 8750 17 5 6000 6000 8750 1002 6000 6000 9400 20 6000 6000 9400 12574 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 Typ
169. l 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 compressor is idle stop the condenser fans If the call for cooling is still present at the conclusion of the ASCD th
170. l injury or loss of life 6 Ifa 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 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 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
171. lated 75 ambient copper wire is used consult applicable tables of the NEC and local codes 2 O C P Over current protection device must be HACR type circuit breaker or time delay fuse TABLE 14 Electrical Data For Multi Source Power Supply Copper Wire 208 230 3 60 Min Circuit Ampacity Max O C P Amps Type 75 C Wie PEE AWG LEE Models 208 230 208 230 208 230 208 230 208 230 AHEMC 6HK16502025 6502025 30 30 1840 0 25 28 9 35 35 30 30 10 10 10 10 6502025 30 0 25 28 9 35 35 30 30 10 10 10 10 e ae 6502025 30 ee 0 25 28 9 35 35 30 30 10 10 10 10 AHE48D 6HK16502025 32 5 36 4 25 28 9 35 40 30 30 10 8 10 10 6HK16502025 32 5 36 4 25 28 9 35 40 30 30 10 8 10 10 6HK16502525 38 8 43 6 31 3 36 1 40 45 35 40 10 8 1 If wire other than non plated 75 ambient copper wire is used consult applicable tables of the NEC and local codes 2 O C P Over current protection device must HACR type circuit breaker or time delay fuse AHE60D Johnson Controls Unitary Products 15 697883 UIM A 0711 TABLE 15 Air Flow Data 60 Hz Models 208 230 Volt AHR m3 min 9 External static pressure Pascal External Static Pressure IWC T LO T E re gt Y o o LO E _ o p Ha Y 52 e Wc 208 Volt
172. ll 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 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 4 PENNBARRY Phone 972 234 3202 Fax 972 497 0468 Breezeway Panel Fans Direct and Belt Drive Operation amp Maintenance Manual Parts Replacement If replacing parts do so with properly selected com ponents which duplicate the original parts correctly Incorrectly sized shafts belts pulleys impellers etc can damage the fan Typical Parts List 1 Panel Venturi Orifice Fan Blade Cast Aluminum or Fabricated Steel Ball Bearing Motor Structural Supports Motor Mounting Plate Fan Shaft and Bearings Belt Drive Only Belt and Pulleys Belt Drive Only OR D EY eS Se Figure 9 Direct Drive Figure B Belt Drive 1401 North Plano Road Richardson Texas 75081 Phone 972
173. m all combinations are not available AA None BA Hinged Filter Door amp 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 amp Coil Guard Access Panels AF 7 Phase Monitor amp 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 amp 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 4 Dirty Filter Switch Hinged Filter EA ElectroFin Condenser Coil Door amp Tool Free Access Panels EJ ElectroFin Evaporator Coil BH Phase Monitor Coil Guard amp Dirty Filter Switch ES ElectroFin Cond amp Evap Coils Hinged Filter Door amp Tool Free Access Panels ZZ If desired option combination is not listed above ZZ will be assigned and configuration options will be located in digits 15 18 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 Produ
174. minates 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 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 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 Weight Ibs Center of Gravity 4 Point Load Location 165 6 Point Load Location 165 Tons 1582 17 5 8 Johnson Cont
175. n 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 ft 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 BHP 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 6800 CFM 2 0 iwg Using the supply air blower performance table below the following data point was lo
176. nal Copper Tube Aluminum Fin Thermal Evaporator Expansion 1 NPT Coils Valve Condensate Drain Belt Drive Blower Motor 14 Gauge Base Rails Hs Co 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 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 Tu 460 3 60 504 125 575 29 60 540 630 125 208 230 3 60 252 125 a 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 i 4 Air for Combustion and Ventilation of the National Fuel Gas 2 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
177. nd lock out the electrical power to check the following items and adjust if necessary All set screws keys and fasteners a b Drive coupling alignment e Belt alignment d Belt tension SUPPLY APPLICATIONS FIELD MODIFICATIONS BHM BHH ONLY To modify to the exhuast supply propeller must be flipped so that blade leading edge is closest to the motor SPECIAL PURPOSE SYSTEMS Explosive corrosive high temperatures etc may require special construction inspection and maintenance t is necessary to observe the fan manufactur ers recommendations and limitations concerning the type of material to be handled by the fan and its application to special conditions 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 accidentally be replaced 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 m Fax 972 497 0468 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 impeller inlet and other moving parts FAN SHAFT LUBRICATION Fan shaft bearing pillow blocks are factory greased eliminating the need for greasing initially Follow the lubricating schedule recommended by
178. nitary Products 1 697883 UIM A 0711 TABLE 7 Electrical Data For Single Source Power Supply Copper Wire 208 230 1 60 AHE Heater Field Wiring ii 12 Amps Min Circuit Ampacity Max O C P Amps Type 75 Wire Size AWG odels 240V 208V 230V 208V 230V 208V 230V 12 12 SHK 0 006500206 sae 3 e HK 0 1 650080 417 274 AHE18B3XH21 ae E Heater FR 0 1 6500806 s 438 4 4 8 8 HK 0 1 6501006 46 83 51 42 Or HK 0 6 5500206 320 er amp 5 8 onesmo 400 4883 39 enaos S20 5683 6 4 FRC 26507608 eso 7538 o 8 4 4 _ mones 320 er amp 8 50106 400 4883 s 6 SWq2G53 S20 5683 6 4 FRC 26501608 eso 7538 o 4 4 _ F 0 1 6500608 1650066 320 er 8 8 eonen 400 s 6 6 20 88 6 4 7538 70 8 4 AHE22B3XH 1 NI NI AHE24B3XH21 NI NI AHE30B3XH21 O HK 1 6500206 F 0 7 6500608 00805 320 3378 4
179. ns 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 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 air and water leakage Vav Control Board 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 board s I O 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
180. nto the ceiling grill as shown in Figure 5a through the slot in the grill buttons The grill is now ready for assembly to the housing Lift the grill into position below the housing Insert the two torsion springs into the keyhole slots located in the center of the housing as shown in Figure 5B Push the grill towards the housing Electrical Connections Before attempting any CAUTIO repair or installation work be certain that all power to the motor and electrical accessories are turned off and locked in off position 1 Connect Motor per nameplate to correct power supply 2 Install all wiring protection and grounding in accordance with national electrical code and local requirements 3 Follow all local electrical and safety codes as well as the National Electrical Code NEC and the Occupational Safety and Health Act OSHA 4 n order to prevent motor failure when speed controller is used unit must be started on high speed before turning to low speed CAUTIO shown on Figure 7 For high speed CAUTIO insulate red lead and connect black to black with wire nut For low speed insu late black lead as Note On Model 265 H when using a variable speed control wire to the high H setting only Make all of the necessary connections by using two wire nuts A Separate ground wire must be connected to the grounding screw Reinstall the cover of the junction box Maintenance To reduce the risk
181. o clearance to combustible materials 6 Acombustible floor base accessory is available for downflow appli cations of this unit if required by local code LOCATION Location is usually predetermined Check with owner s or dealer s installation plans If location has not been decided consider the follow ing in choosing a suitable location 1 Select a location with adequate structural support space for service access clearance for air return and supply duct connections 2 Use hanging brackets to wall mount this single piece air handler unit is not recommended Johnson Controls Unitary Products 1512 16 161 2 ESL Uu 211 2 16 Bl 13 ee 16 1 2 7 8 1 2 3 8 1232 21 17 17 13 32 13 13 29 32 16 1 2 7 8 1 2 1 3 8 1 3 Normal operating sound levels may be objectionable if the air han dler is placed directly over some rooms such as bedrooms study etc 4 Select a location that will permit installation of condensate line to an open drain or outdoors allowing condensate to drain away from NOTICE The primary and secondary drain line must be trapped to allow proper drainage of condensate water If the secondary arain line is not used it must be capped The coil is provided with a secondary drain It should be piped to a loca tion that will give the occupant a visual warning that the primary drain is clogged If th
182. odei KW Stages Amps _ Amps None tear 200 08 3 60 22 4 149 MCC FLA 200 35 0 3 7 230 3 60 22 4 149 35 0 3 7 225 J25 250 None 99 90 165 19 5 0 90 110 125 maj eon 70 70 4 0 10 0 200 225 25 460 3 60 10 6 75 225 1 Minimum Circuit Ampacity FLA F 1627 200 200 38 6 2 Dual Element Time Delay Type 10 0 200 3 HACR type per NEC 70 90 100 Johnson Controls Unitary Products 23 860261 JIM B 0612 42524 Low Static Drive Without Powered Convenience Outlet OD Fan Supply Pwr Max Fuse Size Vol Muse eda Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each Motor Outlet Amps Size MCC FLA FLA FLA Model KW Stages Amps _ Amps 3 175 200 3 CNoe 150 08 3 60 22 4 1300 150 150 150 149 2030 3 60 22 4 149 J25 7 7 200 150 175 225 r NE NO REN 70 19 100 E36 360 2 433 666 70 30 110 1 5 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 eee Motors Blower Conv Electric Heat Option MCA Breaker Tons olt each
183. 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 H x 6 W x 7 D For 7 5 thru 15 motor applications 13 Hx8 W x 8 D If the drive will not fit in the allotted space then it will need to be mounted 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 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
184. on 5 Typical Wiring Diagram PSC 22 Typical Horizontal Installation 5 Typical Wiring Diagram 23 jp 5 Typical Thermostat Wiring for 2 Stage Heat Pump with ECM Blower Motor 24 LIST OF TABLES DIMENSIONS Er 3 Electrical 208 230 3 60 14 Physical and Electrical Data 8 Electrical Data For Single Source Power Supply Conversion 8 Copper Wire 208 230 3 60 14 Electrical Data Cooling Only 60 Hz 9 Electrical Data For Single Source Power Supply Electrical Data 208 230 1 60 10 Copper Wire 208 230 3 60 14 Electrical Data For Single Source Power Supply Electrical Data For Multi Source Power Supply Copper Wire 208 230 1 60 AHR 11 Copper Wire 208 230 3 60 15 Electrical Data For Single Source Power Supply Electrical Data For Multi Source Power Supply Copper Wire 208 230 1 60 12 Copper Wire 208 230 3 60
185. 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 suction line freezestat to protect against low evaporator temperatures due to a low airflow or a low return air temperature opens at 26 5 F 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 temperature limit switch of electric heat units and the temperature limit switch and the gas valve of gas furnace units
186. or _ LL col tt iT hf 200 410 115 120 125 130 135 140 145 150 155 160 165 170 110 115 120 125 130 135 140 145 150 155 160 165 170 Suction Pressure psig 360 340 85 320 Outdoor Discharge Pressure psig Discharge Pressure psig Suction Pressure psig Figure 27 J15ZJ 15 Ton Charging Chart 25 Charging Chart 530 so dE eee 490 470 450 430 410 390 370 350 Discharge Pressure psig MEE 310 75 F Outdoor 290 270 Outdoor 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 A WARNING 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 necessary shut off all electric power to the
187. or 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 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 3 lightly touch the supply air blower motor housing If it is hot the motor may be off on inherent protection Cancel any t
188. ot 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 These can only be reset by cycling power to the UCB NOTE While t
189. own 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 10 PENNBARRY Phone 972 234 3202 Fax 972 497 0468
190. packet The warranty period in years depending on the part and the claimant is as shown in the chart below CONDENSING UNITS CONDENSING UNITS COMPRESSOR PARTS CONDENSER COIL R 410A Models GCGD 22 Dry Ship Models GCGD GHGD R 410A Models T C H GD 5 or 1011 5 or 101 R 410A Models T C H JD Y C H JD Y T HJR T C H GF T C H JF TCHD 10 5 Except TCHD models which are NA R 410A Models C Y ZF C Y ZH AC 6 8 B AL 6 8 B HC 6 8 B HL 6 8 B 10 or Lifetime 5 or 101 NA All 3 phase models with 43 44 voltage codes have 5 year compressor and 1 year parts warranty and are not eligible for 10 year parts warranty To qualify for the E Coat Coil warranty the homeowner must register online at www upgproductregistration com within 90 days of installation for replace ment units or within 90 days of closing for new home construction In some states registration is not required but proof of installation is required The warranty for models equipped with E Coat Coil option only covers condenser coil failures due to corrosion The warranty provides the homeowner with the option of replacement of either a the condenser coil or b the condensing unit at the discretion of the servicing dealer t To qualify for extended 10 year parts and compressor warrantytt the unit must be registered online at www upgproductregistration com within 90 days of installation for replacement or 90 days of closing for
191. pended ceiling systems require a minimum 10 gauge solid wire for hanging or suspend ing the ceiling fan Four wires per unit should be connected to the pre punched holes of the adjustable mounting flanges after the flanges have been mounted to the fan housing as outlined above Note For the Z12 and Z121 1 4 threaded rods or perforated steel strips should be used per fan as illustrated in Figure 4 If installation is to be made with ceiling in place access must be from above The following procedure should be used for installing the Zephyr Ceiling Fans Assemble the adjustable flanges to the fan housing as illustrated in Figures 2 or 2A Position adjustable flanges so the unit is flush with top side of ceiling surface Tighten the adjustable flanges and secure them with the appropriate hardware wood screws or sheet metal screws depending on framing construction Use the housing as a template punch or drill a small hole through the ceiling at each cor ner of the housing and cut an opening in the ceiling using these holes as a guide Install the duct and electrical service in accordance with the instructions listed in the previous section Figure 3 Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Figure 9a Outlet Duct By others Housing In installations where the ceiling is already installed and there is no access from above the following procedure should be followed Before cutting
192. plications 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 40 1 Condensate Drain Must be Trapped OQ 28 3 16 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 Direction Distance in 72 With 36 Maximum Top Horizontal Overhang For Right 36 Condenser Air Discharge Front 6 Bot 0 Hear 24 W O Economizer Left 24 W O Economizer 49 W Economizer 36 W Economizer 1 Units must be installed outdoo
193. r 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 fitness 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 shutd
194. 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 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 Ifthe furnace is hot it may be out on over temperature condition wait for limit reset 4 lf 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 none is found the TDR is open and must be replaced If th
195. rnace 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 UUU 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 24 volts from the temperature limit the draft motor will perform a 25 second post purge and the indoor blower will be de energize
196. rols Unitary Products 860261 JIM B 0612 Table3 15 thru 25 ZJ Unit Accessory Weights Unit Accessory A Shipping Operating Economizer 165 160 Power Exhaust 85 Electric Heat 40 Gas 240 Double Wall 260 260 Motorized Damper 150 Barometric Damper 45 Econ Motorized Damper Hood 60 ___ 55 Econ Power Exhaust Rain Hood 90 Wood Skid 220 Roof Curb 185 Hot Gas Bypass iO 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 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 SRY DOT PLUG 52 5 8 QN For pressure DN S drop reading s GAS OR ELECTRIC i HEAT ACCESS VENT AIR OUTLET ow HOODS lt COMBUSTION SN AIR INLET HOOD 180 19 32 COMPRESSOR ACCESS COIL GUARD KIT CONDENSER COILS lt CONTROL WIRING 92 ENTRY DISCONNECT SWITCH LOCATION ACCESS B POWER WIRING ENTRY BOTTOM SUPPLY AND RETURN AIR OPENINGS See Note UNIT BASE RAILS Shown separately to illustrate Bottom Duct openings Power D and Gas Piping Connection GAS SUPPLY location ENTRY NOTE For curb mounted
197. rs 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 B x 35 5 8 Figure 8 J15 thru 25 ZJ Roof Curb Ductwork Ductwork should be designed and sized according to the methods in Manual D of the Air
198. rs 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 amp 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 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 Temperature Limit If the UCB senses zero volts from the high temperature limit the indoor blower motor
199. s clogged If the secondary drain is not used it must be capped The drain pan connections are designed to ASTM Standard D 2466 Schedule 40 Use 3 4 PVC or steel threaded pipe Since the drains are not subject to any pressure it is not necessary to use Schedule 40 pipe for drain lines Johnson Controls Unitary Products SECTION IV ELECTRIC HEATER INSTALLATION If the air handler requires electric heat install the electric heat kit according to the installation instructions included with the kit After installing the kit mark the air handler nameplate to designate the heater kit that was installed If no heater is installed mark the name plate appropriately to indicate that no heat kit is installed FUSE 3A G SPEEDUP AHR PSC CONTROL BOARD 697883 UIM A 0711 Use only 6HK heater kits as listed on Air Handler name plate and in these instructions Use data from Tables 5 through 9 for information on required minimum motor speed tap to be used for heating operation maximum over current protection device required and minimum electri cal supply wiring size required for listed combination of Air Handler and Heater Kit 9 X136G Xi3COM Xi3SPD 9 lt Y 24VAC uu 4 AHE ECM CONTROL BOARD FIGURE 12 Blower Delay Control Board SECTION V LINE POWER CONNECTIONS Power may be brought into the unit through the supply air end of the unit top when unit is vertical or the lef
200. s control box and connected to the board s 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 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 APPROX F C 85 90 95 100 105 110 AT 50 RH 29 32 35 38 41 43 222 N f gt s gt gt OX XV XR ARS 22 FAL Z 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 Screw HOT COM Indoor Air Quality Max Adjustment Screw 2 Il Indoor Air Quality LED Indoor Air Quality Min Adjustment Screw Free Cooling LED Economizer Enthalpy Set Point
201. s in this manual can result in air handler malfunction death personal injury and or property damage 6 Check the rating plate and power supply to be sure that the electri cal characteristics match 7 Air handler shall be installed so the electrical components are pro tected from water FRONT VIEW BLOWER COMPARTMENT VERTICAL DRAIN PAN REFRIGERANT LINE CONNECTIONS THREADED 1029 ih s DUCT WORK MAY BE FASTENED CAUTIOUSLY WITH gt SCREWS THE SIDES AND REAR OF UNIT PRIMARY DRAIN e UPFLOW 3 4 mS dii UPFLOW 3 4 THREADED FIGURE 1 Return Duct Attachment amp Component Location l SECONDARY DRAIN 8 Installing and servicing heating cooling equipment can be hazard ous due to the electrical components Only trained and qualified personnel should install repair or service heating cooling equip ment Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters When work ing on heating cooling equipment observe precautions in the man uals and on the labels attached to the unit and other safety precautions that may apply 9 These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those who have not kept up with changing residential and non HUD modular home construc
202. se 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 Zephyr Ceiling amp Inline Fans Models Z3H Through Z12H Corrective Action Replace motor with same frame size RPM HP Reset properly Tighten screws remove build up balance wheel propeller correct alignment Replace wheel 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
203. 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 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 DescHpton Green Red Red Red Red Codes p LED 16 LED 8 LED 4 Led 2 LED 1 s i rFas
204. t Installation Manual for evacuation leak check and charging instructions Lines should be sound isolated by using appropriate hangers or strap ping All evaporator coil connections are copper to copper and should be brazed with a phosphorous copper alloy material such as Silfos 5 or equivalent DO NOT use soft solder DRAIN CONNECTIONS All drain lines should be trapped a minimum of three inches should be pitched away from unit drain pan and should be no smaller than the coil drain connection ACAUTION Threaded drain connection should be hand tightened plus no more than 1 16 turn Route the drain line so that it does not interfere with accessibility to the coil air handling system or filter and will not be exposed to freezing temperatures See Figures 2 and 4 for drain connection locations ACAUTION When the coil is installed in an attic or above a finished ceiling an auxiliary drain pan should be provided under the coil if specified by local building codes When this exterior secondary drain pan is used that drain should be piped to a location that will give the occupant a visual warning that the primary drain is clogged Coils should be installed level or pitched slightly toward the drain end Suggested pitch should not exceed 1 4 inch per foot of coil The coil is provided with a secondary drain that should be trapped and piped to a location that will give the occupant a visual warning that the primary drain i
205. t 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 motorized 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 t
206. t 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 460 460 LI 420 105 L 420 Outdoor L Ta mms 380 95 F Outdoor 95 F e 340 i xol ano 300 EM Li _ we 280 EE 75 F 280 Outdoor ae _ or outdo
207. t 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 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 f 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 f24 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 the last five alarms on the LED If the compr
208. t side panel Use the hole appro priate to the unit s orientation in each installation to bring conduit from the disconnect The power lead conduit should be terminated at the electrical control box Refer to Tables 11 12 14 and 15 to determine proper wire sizing Also see Figure 3 To minimize air leakage seal the wiring entry point at the outside of the unit All electrical connections to air handlers must be made with copper con ductors Direct connection of aluminum wiring to air handlers is not approved If aluminum conductors are present all applicable local and national codes must be followed when converting from aluminum to copper con ductors prior to connection to the air handler If wire other than uncoated non plated 75 C ambient copper wire is used consult applicable tables of the National Electric Code ANSI NFPA 70 The chosen conductor and connections all must meet or exceed the amperage rating of the overcurrent protector circuit breaker or fuse in the circuit Additionally existing aluminum wire within the structure must be sized correctly for the application according to National Electric Code and local codes Caution must be used when sizing aluminum rather than copper conductors as aluminum conductors are rated for less current than copper conductors of the same size TYPICAL WIRING WITHOUT ELECTRIC HEAT GND LUG OND LUG pa 1 PHASE ELECTRIC HEAT WITH CIRCUIT BREAKER amp BREAKER BAR REMO
209. te N Lock plug to the Y1 ECON terminal 13 For units with economizers 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 allows compressor operation all the time This programming can be checked
210. ted in Figure 1 1401 North Plano Road Richardson Texas 75081 Phone 972 234 3202 Fax 972 497 0468 PennBarry Ceiling Fans are quiet They are designed for applications where a low noise high reliability ceiling or cabinet fan is required With air capacities from 30 to 1600 CFM they re ideally suited for use in ventilating bathrooms or other low to medi um CFM applications Housings are fabricated of sturdy galvanized steel to ensure durability Acoustic insulation in combination with matched motor and wheel assem blies lowers sound levels and improves air performance Further motors are mounted on vibration isolators to minimize noise levels Together these features ensure years of problem free quiet operation 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 dam age that may have occurred during transit and check for loose missing or damaged parts Mishandled units can void the warranty provisions PennBarry is not responsible for damages incurred during shipment Avoid severe jarring and or dropping Handle units with care to prevent damage to com ponents or special finishes Note standard Zephyrs are set up for RA right angle discharge For TD top discharge TDA Inline see conversion instructions Figure 2 Note On model 265 H when using variable speed controller wire to high h set
211. the factory When required apply grease while the shaft is rotating This practice should not supersede any safety considerations Use low pressure 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 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 atmospheres or 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 at least once or twice a month Recommended Lubricants Gulfcrown EP 1 Temp Range Below 32 F 0 C Imperial Oil Unirex EP 1 Shell Alvania R 1 Energrease MPMK11 32 F to 150 F 0 to 66 C Operation amp Maintenance Manual 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 normal service Where motors have been ordered with greasable bearings these bearings are factory lubricated 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 r
212. the indoor temperature rises to the selected setting the system will shut off The indoor fan will either shut off or run continuously depending upon your choice of fan switch setting TO MAXIMIZE OPERATING EFFICIENCY HEATING CONSERVATION For the most efficient operation keep storm windows and doors closed all year long They not only help insulate against heat and cold but they also keep out dirt pollen and noise Closing drapes at night keeping fireplace dampers closed when not in use and running exhaust fans only when necessary will help you to retain the air you have already paid to heat Keep lamps televisions or other heat producing sources away from the thermostat The thermostat will sense this extra heat and will not be able to maintain the inside temperature to the desired comfort level Johnson Controls Unitary Products COOLING CONSERVATION To comfortably cool your home your air conditioner must remove both heat and humidity Don t turn your system off even though you will be away all day On a hot day your system may have to operate between 8 to 12 hours to reduce the temperature in your home to a normal comfort level Keep windows closed after sundown While the outdoor temperature at night may be lower than indoors the air is generally loaded with mois ture which is soaked up by furniture carpets and fabrics This moisture must be removed when you restart your system The hotter the outside temperatur
213. they must remain in the rotated down posi tion as shipped FACTORY INSTALLED FOR DUCT ATTACHMENT IF NEEDED FIGURE 7 Duct Attachment Johnson Controls Unitary Products DUCT CONNECTIONS A WARNING Use 1 2 screws to connect ductwork to bottom of unit Longer screws will pierce the drain pan and cause leakage If pilot holes are drill only though field duct and unit bottom flange Air supply and return may be handled in one of several ways best suited to the installation See Figure 5 for dimensions for duct inlet and outlet connections The vast majority of problems encountered with combination heating and cooling systems can be linked to improperly designed or installed duct systems It is therefore highly important to the success of an instal lation that the duct system be properly designed and installed Use flexible duct collars to minimize the transmission of vibration noise into the conditioned space electric heat is used non flammable material must be used Where return air duct is short or where sound may be a problem sound absorbing glass fiber should be used inside the duct Insulation of ductwork is a must where it runs through an unheated space during the heating season or through an uncooled space during the cooling season The use of a vapor barrier is recommended to prevent absorp tion of moisture from the surrounding air into the insulation The supply air duct should be properly size
214. through the side of the unit or the basepan inside the curb FACTORY OR FIELD SUPPLIED DISCONNECT 7 THREE 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 Change tap on transformer for 208 3 60 or 380 3 50 operation See unit wiring diagram
215. ting only Use appropriate hardware i e wood screws or sheet metal screws depending on joist construction secure the adjustable flanges to each joist Attach a properly sized duct to duct sleeve mount ed on the fan housing Run this duct sys tem to an appropriate wall or roof cap Discharge side must be guarded unless it is connected to duct Ceiling Figure 2a Figure 1 Attach appropriate duct to exhuast duct sleeve Install electrical service and run conduit to wall Switch or speed control accessory roof or wall cap Run to s System or Screw through adjustable flanges to each joist Ceiling Adjustable Flange Printed in the USA Jan 2005 PART 59575 0 Operation amp Maintenance Manual Normally power is brought up from within the building through conduit lines and located at the terminal box Before wiring is attempted always lock out primary and secondary power source Utilizing the pre punched hole found at the terminal box on the fan housing insert a 3 8 elec trical connector All wiring furnished should be in strict accordance with the National Electrical Code and local state and federal standards Complete the installation by cutting a 9 1 2 by 12 1 2 ceiling opening for the Z3 Z5 and Z6 11 718 by 13 3 4 for the Z8 and 281 14 1 2 by 18 for the Z10 and 14 1 2 by 23 3 4 for 2101 2102 212 and Z121 ceiling fan Installation of ceiling fans in sus
216. tion practices These instruc tions are required as a minimum for a safe installation INSPECTION As soon as a unit is received it should be inspected for possible dam age 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 Also before installation the unit should be checked for screws or bolts which may have loosened in transit There are no shipping or spacer brackets which need to be removed Also check to be sure all accessories such as heater kits suspension kits and coils are available Installation of these accessories or field conversion of the unit should be accomplished before setting the unit in place or connecting any wiring electric heat ducts or piping LIMITATIONS These units must be wired and installed in accordance with all national and local safety codes Voltage limits are as follows Normal Operating Voltage Range 187 253 Air Handler Voltage Voltage code 1 Rated in accordance with ARI Standard 110 utilization range A Airflow must be within the minimum and maximum limits approved for electric heat evaporator coils and outdoor units 208 230 1 60 COIL COMPARTMENT Access panel removed HORIZONTAL DRAIN PAN SIDE VIEW HORIZONTAL SECONDARY DRAIN HORIZONTAL PRIMARY DRAIN ALTERNATE DRAIN CONNECTIONS UPFLOW RETURN AIR E DUCT FIL
217. tion 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 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 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 between terminals R OCC on the add on board to put the unit into Occupied Mode Additionally the unit can be switched between Unoccupied Occupied mode
218. to UL 1995 CSA C22 2 236 05 up to 0 30 w c external static pressure including air filter wet coil and largest kW size heater unless otherwise noted SECTION IX MAINTENANCE Filters must be cleaned or replaced when they become dirty Inspect at least once per month The frequency of cleaning depends upon the hours of operation and the local atmospheric conditions Clean filters keep unit efficiency high COIL CLEANING If the coil needs to be cleaned it should be wash with a evaportor coil cleaner Follow directions from coil cleaner 8 LUBRICATION The bearings of the blower motor are permanently lubricated CONDENSATE DRAINS During the cooling season check the condensate drain lines to be sure that condensate is flowing from the primary drain but not from the sec ondary drain If condensate ever flows from the secondary drain the unit should be promptly shut off and the condensate pan and drains cleaned to insure a free flowing primary drain Johnson Controls Unitary Products SECTION X WIRING DIAGRAM 697883 UIM A 0711 WHEN INSTALLING HEATER KIT BE SURE THE BLOWER SPEED 15 SEE INSTALLATION INSTRUCTIONS FOR PROPER SET TO THE SPEED SPECIFIED FOR THE AIR HANDLER HEATER KIT LOW VOLTAGE FIELD WIRING CONNECTIONS COMBINATION ON THIS UNIT S INSTALLATION INSTRUCTIONS HEATER KITS 6HK16500206 6HK16500506 AUXILIARY HEAT 2nd STAGE ELECTRIC HEAT Ist STAGE RED 24V HOT GRN B
219. ual Breezeway Panel Fans Direct and Belt Drive Limited 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 PennBarry Product must have been installed and 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 o
220. unit prior to any of the following maintenance procedures so as to prevent personal injury 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 1 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 is pulled in and voltage is supplied to 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 M3 is not pulled in check for 24 volts at the M3 coil If 24 volts are present at M3 but M3 is not pulled in replace th
221. 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 9 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 SQ Bottom Power and Control Wiring Entry L 1 Power Ventor Motor Electric Heater Location Optional Electric Electric Units Location of VFD Optional Location of VFD Bypass Optio
222. units refer to the curb hanger ENTRY 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 i Used For Diameter W O Manual Bypass 5 U 5 5 Control Wiring Front 5 0 hp 30 3 4 NPS Fem Bottom 7 5 hp 30 3 0 30 3 5 8 KO qm Front 10 0 hp 35 3 NPS 9 15 0 40 2 3 8 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 Dot Plug 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 A Outdoor Air Cond Drain ANJE C 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 openings covered An accessory flange kit is available for connecting side ducts For bottom duct ap
223. unning This practice should not Supersede any safety considerations DO NOT OVERGREASE as most lubricants deteriorate motor windings thereby reducing motor life Hidden Danger In addition to the normal dangers of rotat ing machinery fans present an additional hazard in their ability to suck in not only air but loose material as well Solid objects can pass through the fan and be discharged by the impeller as potentially dangerous projectiles Therefore screen intake to ductwork whenever possible to prevent the accidental entrance of solid objects Never open access doors to a duct system with the fan running When starting the fan for the first time completely inspect the ductwork and inte rior of the fan with power locked off to make certain there is no foreign material which can be sucked into or blown through the ductwork Guards All fans have moving parts which require guarding in the same way as other moving machinery Where the fan is accessible to untrained personnel or the general public use maximum safety guards even at the cost of some performance loss Unprotected fans located less than 7 above the floor also require guarding as specified in the Occupational Safety and Health Act OSHA PennBarry recommends the use of guards on all exposed nonducted fans ceiling and wall mounted PENNBARRY 3 Operation amp Maintenance Manual Breezeway Panel Fans Direct and Belt Drive Troubleshooting
224. vailable External Static Pressure IWG GEM 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 BHP RPM BHP RPM BHP RPM standard 5 HP amp Fi Standard 5 HP amp Drive High Static 7 5 HP amp Drive ield Supplied Drive 4400 TBD TBD TBD TBD TBD 4800 TBD TBD 5200 TBD TBD TBD TBD TBD 5600 TBD TBD TBD TBD TBD 6000 TBD TBD TBD 6400 TBD TBD TBD 6800 TBD TBD TBD 7200 TBD TBD TBD TBD 7600 TBD TBD TBD TBD 8000 TBD TBD 8400 TBD TBD TBD TBD TBD 8800 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
225. washable filters are available using model num bers 1PF0601 602 or 603BK See Table 2 for filter size A CAUTION Equipment should never be operated without filters Johnson Controls Unitary Products 697883 UIM A 0711 HORIZONTAL SUSPENSION For suspension of these units in horizontal applications it is recom mended to use angle steel support brackets with threaded rods sup porting the units from the bottom at the locations shown in Figure 10 When an evaporator coil is installed in an attic or above a finished ceil ing an auxiliary drain pan should be provided under the air handler as is specified by most local building codes SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS MIN 3 8 THREADED ROD _ MIN 1 1 2 x 1 1 2 Angle Recommended length 26 minimum with 2 clearance on both sides of Air Handler Dimension Nominal Tons FIGURE 9 Typical Horizontal Installation TXV METERING DEVICES If the model number is of the following model series 3X the coil will require a R22 or R410A Orifice or TXV to be installed in the field Refer to installation manual with TXV kit It is recommended to install the TXV kit prior to brazing line sets VAPOR LINE THERMAL EXPANSION VALVE BULB with insulation fe 245 LIQUID provided AA LINE THERMAL EXPANSION VALVE TXV EQUALIZER LINE DISTRIBUTOR BODY FIGURE 10 TXV 697883 UIM A 0711 Please refer to Outdoor Unit
226. 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 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 UCB Gas Heat Troubleshooting Guide On calls for heating the draft mot
227. wisting 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 G e With the thermostat set to the indoor fan ON position or terminals R to G energized turn the Minimum Position Adjusting screw located on the damper control module counterclockwise until the desired minimum damper position has been attained Enthalpy Set Point Adjustment 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 single enthalpy operation carefully turn the set point adjusting screw found on the damper control 29 860261 JIM B 0612 module to the 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
228. wn Re install coil assembly on coil support bracket Re attach tubing connection panel For horizontal applications rotate air handler 90 into desired orien tation 8 Re position drain plugs as necessary based on air handler orienta tion 9 Re position and replace access panels SUCTION FEEDER TUBECONDENSATE DEFLECTOR UPFLOW No action required See Figure 6 DUE Qr P 9 Iw lt NE TX DAS ILOA VERTICAL CONDENSATE DRAIN PAN DEFLECTOR FIGURE 4 Condensate Deflector on Vertical Drain Pan HORIZONTAL LEFT OR RIGHT Use an appropriate tool to pry out water deflector with two or three s clips from the vertical drain pan see Figure 4 Relocate the deflector with s clips on the Horizontal Drain Pan lined up to the coil support bracket See Figure 2 This positions the deflector below the feeder tubes to channel the condensate to the drain pan NOTICE The condensate deflector should be installed in the s clip section which is inside the drain pan edge See Figure 8 CONDENSATE DEFLECTOR CONDENSATE DEFLECTOR DRAIN PAN FIGURE 6 S Clip Installation DUCT FLANGES Four flanges are provided to attach ductwork to the furnace These flanges are rotated down for shipment In order to use the flanges remove the screw holding an individual flange rotate the flange so it is in the upward position and reinstall the screw then repeat this for all 4 flanges If the flanges are not used
229. wn fuses or other like dam ages 5 Cleaning or replacement of filters or damages resulting from operation with inadequate supply of air or water 6 Damages resulting from failure to properly and regularly clean air and or water side of condenser and evaporator 7 Damages resulting from I freezing of condenser water or condensate inadequate or interrupted water supply Ill use of corrosive water IV fouling or restriction of the water circuit by foreign material or like causes 8 Damages resulting from use of components or accessories not approved by Company vent dampers etc 9 Increase in fuel or electric cost This warranty is in lieu of all other warranties expressed or implied including the implied warranties of merchantability and fitness for a particular purpose Some states do not allow the disclaimer of implied warranty so that the above disclaimer may not apply to you Some states only allow a partial limitation on implied warranties to limit the duration of implied warranties to the duration of the express warranty In such states the duration of implied warranties is hereby expressly limited to the duration of the express warranty on the face hereof Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you In no event whether as a result of breach of warranty or contract tort including negligence strict lia bility or otherwise shall Company

O&M (6-12-2014) Studio 9 - Pinewood L&G - Paulson

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O&amp;M (6-12-2014) Studio 9 - Pinewood L&amp;G - Paulson

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O&M (6-12-2014) Studio 9 - Pinewood L&G - Paulson