Johnson Controls 100 Series Owner's manual

LD16707
035-22722-010
SERIES 100
SINGLE PACKAGED UNITS
YPAL DESIGN LEVEL G
70 THROUGH 105 TONS
Issue Date:
April 2, 2019
PACKAGED ROOFTOP UNITS
INSTALLATION, OPERATION, MAINTENANCE NEW RELEASE Form 100.50-NOM12 (419)

JOHNSON CONTROLS
2
FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, materials under pressure,
rotating components, and both high and low voltage.
Each of these items has the potential, if misused or
handled improperly, to cause bodily injury or death. It
is the obligation and responsibility of rigging, instal-
lation, and operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to
comply with any of these requirements could result in
serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and others at the site.
This document is intended for use by owner-authorized
rigging, installation, and operating/service personnel.
It is expected that these individuals possess indepen-
dent training that will enable them to perform their as-
signed tasks properly and safely. It is essential that,
prior to performing any task on this equipment, this
individual shall have read and understood the on-prod-
uct labels, this document and any referenced materials.
This individual shall also be familiar with and comply
with all applicable industry and governmental stan-
dards and regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious in-
jury if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
WARNING: Cancer and Reproductive Harm — www.P65Warnings.ca.gov.

JOHNSON CONTROLS 3
FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts.
johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the equip-
ment.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
MANUAL DESCRIPTION FORM NUMBER
Shipping Damage Claims 50.15-NM
Static Pressure Probe Installation Instructions 100.50-N15
High Altitude Accessory Kit Installation Instructions 100.50-N16
Installation, Operation & Maintenance Manual 100.40-NO4
Literature Supplement (dated 706) 100.40-NO4 (LS02)
Quick Start-Up Guide 100.50-SU1
ASSOCIATED LITERATURE

JOHNSON CONTROLS
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FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
NOMENCLATURE
BASE MODEL NUMBER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
BASE PRODUCT TYPE NOMINAL CAPACITY APPLICATION REFRIGERANT VOLTAGE DUCT LOCATIONS DESIGN SPECIAL GAS HEAT CAPACITY
A : Std. Product, Simplicity Elite
B : Special Product, Simplicity Elite
X : Std. Product, IPU
S : Special Product, IPU
E : R-410A 7 : 200 / 3 / 60
8 : 230 / 3 / 60
6 : 460 / 3 / 60
5 : 400 / 3 / 50
8 : 575 / 3 / 60
0 : 380 / 3 / 60
C : Constant Volume
V : VAV, VFD
F : FlexSys
B : Bottom Return
R : Rear Return
S : Side Return
C : Cooling Only
N : Natural Gas Heat
G : Natural Gas Heat SS HX
M : Modulating Gas Heat
E : Electric Heat
S : Steam Heat
H : Hot Water Heat
L : Scroll
P : Packaged Rooftop
A : Air-Cooled
Y : YORK
: 70-ton
: 75-ton
: 80-ton
: 90-ton
: 105-ton
0
5
0
0
5
7
7
8
9
0
0
0
0
0
1
1
2
4
4
5
4
B : Bottom Supply
L : Left Supply
R : Right Supply
G
N : No Gas Heat
L : Low (375 MBH)
M : Med (750 MBH)
H : High (1125 MBH)

JOHNSON CONTROLS 5
FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
TABLE OF CONTENTS
SECTION 1 – INTRODUCTION..............................................................................................................................13
Ecological And Economical Design ................................................................................................................13
Cooling and Heating..............................................................................................................................13
Indoor Air Quality (IAQ) .........................................................................................................................13
High-Efciency Motors ..........................................................................................................................13
Modulating Gas Heat.............................................................................................................................13
Condensing Section .......................................................................................................................................13
Scroll Compressors ...............................................................................................................................13
Multiple Compressor Staging ................................................................................................................13
Compressor Circuiting...........................................................................................................................14
Compressor Sound Blankets.................................................................................................................14
Replaceable Core Filter Driers ..............................................................................................................14
Low Ambient Operation .........................................................................................................................14
Condenser Fan Motors..........................................................................................................................14
Coils ......................................................................................................................................................14
Condenser Coil Protection ....................................................................................................................14
Heating Section ..............................................................................................................................................14
Gas Heat Design and Control Options ..................................................................................................14
Staged Gas Heat...................................................................................................................................14
Electric...................................................................................................................................................14
Air Management .............................................................................................................................................15
Controls ..........................................................................................................................................................15
Indoor Air Quality ...........................................................................................................................................15
Electrical.........................................................................................................................................................16
Service And Installation ..................................................................................................................................16
SECTION 2 – INSTALLATION................................................................................................................................17
Approvals .......................................................................................................................................................17
Limitations ......................................................................................................................................................17
Unit Inspection................................................................................................................................................17
Locations And Clearances..............................................................................................................................18
Rigging And Handling.....................................................................................................................................18
Electrical Data ................................................................................................................................................26
Electrical Service Sizing ........................................................................................................................26
Load Denitions.....................................................................................................................................26
Filters..............................................................................................................................................................28
Condensate Drain ..........................................................................................................................................28
Condensate Drain Piping ......................................................................................................................28
Condensate Drain Trap .........................................................................................................................28
Air Hoods For Economizer .............................................................................................................................28
Air Hoods For Fixed Outside Air (Units Without Economizer) ........................................................................29
Air Hoods For Exhaust Air ..............................................................................................................................29
Field Wiring ....................................................................................................................................................29
Thermostat ............................................................................................................................................29
Space Sensor........................................................................................................................................29
CO2Sensor ...........................................................................................................................................29
Occupied/Unoccupied Input ..................................................................................................................29
Shutdown Input .....................................................................................................................................29
Smoke Purge Input................................................................................................................................29
VAV Heat Relay Output .........................................................................................................................30

JOHNSON CONTROLS
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FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
TABLE OF CONTENTS (CONT'D)
Return Air Bypass Damper.............................................................................................................................30
BACnet Communication .................................................................................................................................30
Dirty Filter Switch ...........................................................................................................................................30
Alarm Contacts...............................................................................................................................................30
Electrical Service Sizing .................................................................................................................................33
Transducer Pneumatic Tubing........................................................................................................................37
Static Pressure Control Plastic Tubing (Pneumatic Tubing)..................................................................37
Duct Static Transducer ..........................................................................................................................37
Building Pressure Transducer ...............................................................................................................37
Static Pressure Probe Installation .........................................................................................................37
Roof Curb Installation.....................................................................................................................................37
General Information...............................................................................................................................37
Duct System ...................................................................................................................................................38
Duct Connection Guidelines..................................................................................................................38
Sound And Vibration Transmission.................................................................................................................38
Gas Heating ...................................................................................................................................................39
Gas Piping.............................................................................................................................................39
Gas Connection.....................................................................................................................................39
Gas Piping Recommendations..............................................................................................................39
Combustion Vent ...................................................................................................................................40
SECTION 3 – START-UP........................................................................................................................................41
Crankcase Heaters.........................................................................................................................................41
Checking The System Prior To Initial Start (No Power)..................................................................................41
Unit Checks ...........................................................................................................................................41
Unit Checks – Power Applied .........................................................................................................................43
Verifying Compressor Rotation..............................................................................................................43
Compressor Oil Level Check.................................................................................................................43
Initial Start-Up.................................................................................................................................................43
Refrigerant Charge ...............................................................................................................................44
Checking Superheat and Subcooling ....................................................................................................44
Subcooling (R-410A) .............................................................................................................................44
Superheat (R-410A) ..............................................................................................................................44
Leak Checking.......................................................................................................................................46
Gas Heat Models...................................................................................................................................46
Pre-Start Checks ...................................................................................................................................47
Post Start Checks..................................................................................................................................48
Manifold Pressure – Modulating Gas .............................................................................................................49
Manifold Gas Pressure Adjustment .......................................................................................................49
SECTION 4 – MAINTENANCE...............................................................................................................................51
General...........................................................................................................................................................51
Periodic Maintenance – Monthly ....................................................................................................................51
Filters.....................................................................................................................................................51
Linkages ................................................................................................................................................51
Compressors .........................................................................................................................................51
Fan Bearing Lubrication .......................................................................................................................51
Recommended Lubricant for Fan Bearings...........................................................................................52
Condenser Coils....................................................................................................................................52

JOHNSON CONTROLS 7
FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
TABLE OF CONTENTS (CONT'D)
Periodic Maintenance – Three To Six Months ................................................................................................ 52
Motor Bearing Lubrication .....................................................................................................................52
Belt Tension...........................................................................................................................................52
Periodic Maintenance – Yearly .......................................................................................................................52
Entire Unit Inspection ............................................................................................................................52
Sheave Alignment .................................................................................................................................52
Belts ......................................................................................................................................................53
Belt Replacement ..................................................................................................................................53
Filter Drier Replacement .......................................................................................................................53
Forward Curved Fans............................................................................................................................54
Fan Motor ..............................................................................................................................................54
Fan Shaft Bearings................................................................................................................................55
Mounting Details....................................................................................................................................55
Bearing Lock Devices............................................................................................................................55
Eccentric Type.......................................................................................................................................56
Torquing of Set-screws .........................................................................................................................57
SECTION 5 – SEQUENCE OF OPERATION .........................................................................................................59
Unit Type ........................................................................................................................................................59
Variable Air Volume (VAV) .....................................................................................................................59
Single Zone VAV (SZVAV).....................................................................................................................59
FlexSys™..........................................................................................................................................................................................................................................................60
Unit Overall Status .........................................................................................................................................60
Phase Monitor .......................................................................................................................................60
Occupancy/Unoccupancy Determination .......................................................................................................61
Night Set-Back ...............................................................................................................................................61
Night Set-Back Setup ............................................................................................................................61
Night Set-Back Sequence Of Operation................................................................................................61
Current OperatinG Mode................................................................................................................................61
Single Zone VAV (SZVAV)..............................................................................................................................62
SZVAV Setup.........................................................................................................................................62
Supply Fan ............................................................................................................................................63
Cooling And Heating Operation.............................................................................................................64
Variable Air Volume (VAV) ..............................................................................................................................66
VAV Setup .............................................................................................................................................66
Supply Fan ............................................................................................................................................67
Cooling And Heating Operation.............................................................................................................69
Active Supply Air Temperature (SAT) Setpoint......................................................................................69
Compressors: Control and Operation.............................................................................................................73
Compressor Systems ............................................................................................................................73
Compressor Control ..............................................................................................................................73
Compressor Staging..............................................................................................................................73
Fast Compressor Start ..........................................................................................................................74
Compressor Operation ..........................................................................................................................74
Compressor Status................................................................................................................................75
Compressor Safety Circuits...................................................................................................................75
Resetting a Compressor System Safety Lockout..................................................................................78
Suction Temperature Monitoring ...........................................................................................................78
High Discharge Pressure Unloading .....................................................................................................79
Low Ambient Inhibit ...............................................................................................................................79

JOHNSON CONTROLS
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FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
TABLE OF CONTENTS (CONT'D)
Low Ambient Operation .........................................................................................................................79
Hot Gas Reheat (HGRH)................................................................................................................................79
HGRH System.......................................................................................................................................79
HGRH Setup .........................................................................................................................................82
HGRH Status.........................................................................................................................................82
HGRH Sequence of Operation..............................................................................................................83
HGRH Faults .........................................................................................................................................84
Condenser Fan Control ..................................................................................................................................84
Low Ambient Kit..............................................................................................................................................85
Economizer ....................................................................................................................................................85
Economizer Setup .................................................................................................................................85
Economizer Operation...........................................................................................................................85
Heating ...........................................................................................................................................................86
Heating Setpoints ..................................................................................................................................86
Staged Natural/Propane Gas Heat........................................................................................................86
Modulating Natural/Propane Gas Heat .................................................................................................88
Electric Heat ..........................................................................................................................................94
Hot Water/Steam Heat ..........................................................................................................................95
Heating Sequences ...............................................................................................................................96
Supply Air Tempering ............................................................................................................................98
Ventilation.......................................................................................................................................................99
Ventilation Types (Damper Hardware) ..................................................................................................99
Control Options .....................................................................................................................................99
Ventilation Setup ...................................................................................................................................99
2 Position Damper.................................................................................................................................99
Standard Damper ..................................................................................................................................99
Tek-Air Full IAQ ...................................................................................................................................100
Continuous Ventilation.........................................................................................................................102
Comfort Ventilation ..............................................................................................................................102
Exhaust/Return Fan ....................................................................................................................................102
Exhaust Fan Assembly........................................................................................................................103
Return Fan Assembly ..........................................................................................................................105
FlexSys.........................................................................................................................................................106
Basic FlexSys System Design.............................................................................................................106
Factory Recommended Setpoints .......................................................................................................106
FlexSys Setup .....................................................................................................................................107
Current Operating Mode......................................................................................................................107
Fan Operation .....................................................................................................................................108
Cooling ................................................................................................................................................108
Heating ................................................................................................................................................ 110
Underoor Temperature Control.......................................................................................................... 110
Smoke Purge................................................................................................................................................ 112
Smoke Purge Setup ............................................................................................................................ 112
Smoke Purge Sequence of Operation................................................................................................. 112
SECTION 6 – USER INTERFACE CONTROL CENTER...................................................................................... 113
User Interface Control Center ...................................................................................................................... 113
Data Entry Keys .................................................................................................................................. 113
Navigation Keys .................................................................................................................................. 114
Menu Select Keys ............................................................................................................................... 114

JOHNSON CONTROLS 9
FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
TABLE OF CONTENTS (CONT'D)
Setpoints ......................................................................................................................................................127
Program........................................................................................................................................................127
Options .........................................................................................................................................................127
Date / Time ...................................................................................................................................................127
Schedule ......................................................................................................................................................128
Operating Hours / Start Counter...................................................................................................................129
Printer...........................................................................................................................................................130
Setup ...................................................................................................................................................130
Report Section.....................................................................................................................................130
Service .........................................................................................................................................................131
History ..........................................................................................................................................................140
Password......................................................................................................................................................141
Power Up Banner .........................................................................................................................................141
Connecting BAS to a Rooftop Unit with the IPU Board ................................................................................142
Communication ............................................................................................................................................142
Communication Ports ..........................................................................................................................142
BACnet Wiring.....................................................................................................................................142
Device Object Instance (DE) ...............................................................................................................143
Additional Settings...............................................................................................................................143
SECTION 7 – PARAMETER DESCRIPTIONS AND OPTIONS ...........................................................................157
SECTION 8 – SERVICE........................................................................................................................................165
Analog Input Operation ................................................................................................................................165
Temperature Sensors ..........................................................................................................................165
Duct Pressure Transducer...................................................................................................................165
Building Pressure Transducer .............................................................................................................166
Return Fan Pressure Transducer ........................................................................................................166
Discharge Pressure Transducer..........................................................................................................167
Suction Pressure Transducer ..............................................................................................................167
Humidity Sensors ................................................................................................................................167
CO2Sensor .........................................................................................................................................167
Furnace Status Input ...........................................................................................................................167
Faults............................................................................................................................................................169
Multi Media Card ..........................................................................................................................................179
Temperature .................................................................................................................................................181

JOHNSON CONTROLS
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FORM 100.50-NOM12
ISSUE DATE: 04/02/2019
FIGURE 1 - Packaged Rooftop Air Conditioning Unit .............................................................................................13
FIGURE 2 - Double Sloped SS Drain Pan ..............................................................................................................15
FIGURE 3 - Unit Clearances ...................................................................................................................................18
FIGURE 4 - Lifting Lug Locations............................................................................................................................19
FIGURE 5 - Drain Trap Showing Water Location During Draw Through Operation Stages....................................28
FIGURE 6 - Trap Detail For Draw Through Application...........................................................................................28
FIGURE 7 - Field Control Wiring - Inputs ................................................................................................................31
FIGURE 8 - Field Control Wiring - Outputs .............................................................................................................32
FIGURE 9 - Single-Point Power Supply Wiring....................................................................................................... 34
FIGURE 10 - Single-Point Power Supply Wiring With Non-Fused Disconnect ....................................................... 35
FIGURE 11 - Dual-Point Power Supply Wiring........................................................................................................36
FIGURE 12 - Static Pressure Probe Location ......................................................................................................... 38
FIGURE 13 - Typical Gas Piping Connection..........................................................................................................39
FIGURE 14 - Combustion Vent ...............................................................................................................................40
FIGURE 15 - Fan Isolator Spring Bolts (Total Of 8).................................................................................................42
FIGURE 16 - Manifold Gas Pressure Adjustment ...................................................................................................49
FIGURE 17 - Sheave Alignment..............................................................................................................................52
FIGURE 18 - Fan Data Plate - Belt Tension............................................................................................................53
FIGURE 19 - Belt Tensioning Gauge.......................................................................................................................53
FIGURE 20 - Forward Curved Fan Shaft/Wheel Marking .......................................................................................54
FIGURE 21 - Bearing With Setscrew Type Locking Device ....................................................................................55
FIGURE 22 - Bearing With Eccentric Cam..............................................................................................................56
FIGURE 23 - Eccentric Cam Locking Collar Bearing Installation............................................................................ 56
FIGURE 24 - Split Bearing ......................................................................................................................................57
FIGURE 25 - Unit Options.......................................................................................................................................59
FIGURE 26 - Single Zone VAV (SZVAV) and Constant Volume (CV) — Occupied and Unoccupied...................... 66
FIGURE 27 - Active Duct Static Pressure Setpoint Vs. Duct Static Pressure Reset Voltage..................................68
FIGURE 28 - Active SAT Setpoint Versus SAT Reset Voltage ................................................................................70
FIGURE 29 - Active SAT Setpoint Versus RAT .......................................................................................................71
FIGURE 30 - Active SAT Setpoint Versus OAT .......................................................................................................71
FIGURE 31 - Active SAT Setpoint Versus Supply Fan Speed.................................................................................72
FIGURE 32 - Variable Air Volume (VAV) — Occupied.............................................................................................72
FIGURE 33 - VAV — Unoccupied ...........................................................................................................................73
FIGURE 34 - Compressor Safety Chain — Without Compressor Protection Module ............................................. 76
FIGURE 35 - Compressor Safety Chain — With Compressor Protection Module .................................................. 77
FIGURE 36 - Compressor System Status Input To I/O Board.................................................................................77
FIGURE 37 - Low Pressure CutOut (LPCO) Switch Wiring ....................................................................................77
FIGURE 38 - HGRH 3-Way Stepper Valve..............................................................................................................80
FIGURE 39 - HGRH Control Board.........................................................................................................................81
FIGURE 40 - HGRH Piping Layout .........................................................................................................................82
FIGURE 41 - Evaporator Air Temperature Active Setpoint VS Return Air Humidity ................................................ 83
FIGURE 42 - HGRH SAT Active Setpoint vs Return Air Temperature.....................................................................83
FIGURE 43 - Condenser Fan Contactors — Fans 1A And 1B Only For Compressor System #1...........................84
FIGURE 44 - Condenser Fan VFD Wiring — Condenser Fan 1A Shown............................................................... 85
FIGURE 45 - Digital Multiplexor Connections For Staged Gas Heat ......................................................................87
FIGURE 46 - Modulating Gas Furnace Sections.....................................................................................................89
FIGURE 47 - Digital Multiplexor Connections For Modulating Gas Heat ................................................................ 90
LIST OF FIGURES