Johnson Controls 100 Series User manual

LD19506
CONTROL SEQUENCES
SERIES 100
50–130 TON - MOD F
120–150 TON - MOD G
50 HZ AND 60 HZ
R-410A
PACKAGED ROOFTOP UNITS
START-UP GUIDE NEW RELEASE Form 100.50-SU8 (116)
Issue Date:
January 28, 2016

JOHNSON CONTROLS
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FORM 100.50-SU8
ISSUE DATE: 1/28/2016
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 people 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 independent
training that will enable them to perform their assigned
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-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and governmental standards 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 injury
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.

JOHNSON CONTROLS 3
FORM 100.50-SU8
ISSUE DATE:1/28/2016
MANUAL DESCRIPTION FORM NUMBER
Installation, Operation, and Maintenance 50-65 Ton Unit, Mod F 100.50-NOM5
Installation, Operation, and Maintenance 70-105 Ton Unit, Mod F 100.50-NOM9
Installation, Operation, and Maintenance 120-130 Ton Unit, Mod F 100.50-NOM10
Installation, Operation, and Maintenance 120-150 Ton Unit, Mod G 100.50-NOM11
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 chiller.
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.
ASSOCIATED LITERATURE

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FORM 100.50-SU8
ISSUE DATE: 1/28/2016
7 : 200/3/60
5 : 208/3/60
230/3/60
8 : 230/3/60
0 : 380/3/60
5 : 400/3/50
6 : 460/3/60
8 : 575/3/60
NOMENCLATURE
BASE MODEL NUMBER
C : Constant Volume
V : VAV, VFD
F : FlexSys
C : Cooling Only
N : Staged Natural Gas Heat
G : Staged Natural Gas Heat SS HX
M : Full Modulating Gas Heat
F : Full Modulating Gas Heat SS Staged HX
E : Electric Heat
H : Hot Water Heat
S : Steam Heat
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
BASE PRODUCT TYPE NOMINAL APPLICATION REFRIGERANT VOLTAGE SUPPLY RETURN DESIGN SPECIAL GAS HEAT
A: Std. Product, Simplicity Elite
B: Special Product, Simplicity Elite
X: Std. Product, IPU
S: Special Product, IPU
B : R-407C
C : R-22
E : R-410A
B: Bottom
R: Rear
S: Side
L : Scroll
P : Packaged Rooftop
A : Air-Cooled
Y : YORK
0
1
0
1
0
5
0
0
5
0
0
0
0
0
5
5
6
6
7
7
8
9
0
2
2
3
3
5
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
2
2
4
4
4
5
B: Bottom
L: Left
R: Right
F : Revision Level
G : Revision Level
N : No Gas Heat
L : Low (375 MBH)
M : Med (750 MBH)
H : High (1125 MBH)
CAPACITY OPENINGS OPENINGS CAPACITY
: 50-Ton Std.
: 50-Ton High
: 60-Ton Std.
: 60-Ton High
: 70-Ton
: 75-Ton
: 80-Ton
: 90-Ton
: 105-Ton
: 120-Ton
: 120-Ton Mod G
: 130-Ton
: 130-Ton Mod G
: 150-Ton Mod G

JOHNSON CONTROLS 5
FORM 100.50-SU8
ISSUE DATE:1/28/2016
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION.................................................................................................................................7
SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH
THE IPU CONTROLLER ..........................................................................................................................................9
BACnet MS/TP .................................................................................................................................................9
BACnet IP.........................................................................................................................................................9
LON ................................................................................................................................................................ 11
N2................................................................................................................................................................... 11
Other Protocols .............................................................................................................................................. 11
End of Line Termination..................................................................................................................................12
Miscellaneous.................................................................................................................................................12
Technical Support...........................................................................................................................................12
SECTION 3 - UNIT MODE ......................................................................................................................................13
SECTION 4 - OCCUPIED/UNOCCUPIED OPERATION ........................................................................................15
SECTION 5 - COMMANDING THERMOSTAT INPUTS FROM THE BAS.............................................................17
SECTION 6 - COMMUNICATING A ZONE TEMPERATURE.................................................................................19
SECTION 7 - SINGLE ZONE VAV OPERATION....................................................................................................21
What is Single Zone VAV?..............................................................................................................................21
Modes of Operation........................................................................................................................................21
Occupied Standby .................................................................................................................................21
Occupied Cooling Low .........................................................................................................................21
Occupied Cooling High..........................................................................................................................21
Occupied Heating Low ..........................................................................................................................21
Occupied Heating High .........................................................................................................................21
Other Points ..........................................................................................................................................22
SECTION 8 - SUPPLY AIR TEMPERATURE (SAT) SP RESET ............................................................................23
Sequence of Operation ..................................................................................................................................23
Other Points That Can Be Written to for SAT SP Reset........................................................................ 24
Flexsys .................................................................................................................................................24
Constant Volume ..................................................................................................................................24
SECTION 9 - DUCT STATIC PRESSURE RESET (BAS) ......................................................................................25
SECTION 10 - MORNING WARM-UP ....................................................................................................................27
Morning Warm-Up Sequence.........................................................................................................................27

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FORM 100.50-SU8
ISSUE DATE: 1/28/2016
LIST OF TABLES
TABLE 1 - BACnet MS/TP Points ...........................................................................................................................33
TABLE 2 - Series 100 Flexsys BACnet MS/TP Points............................................................................................49
TABLE 3 - Warning Description Table.....................................................................................................................51
LIST OF FIGURES
FIGURE 1 - IPU Controller Port Locations ..............................................................................................................10
FIGURE 2 - E-Link Connections and Addressing Instructions ................................................................................ 11
TABLE OF CONTENTS (CONT'D)
SECTION 11 - SERIES 100: FLEXSYS OPERATION............................................................................................29
Flexsys: Current Operating Mode (Occupied)................................................................................................29
Flexsys: Fan Operation ..................................................................................................................................29
Flexsys: Cooling .............................................................................................................................................30
Occupied ...............................................................................................................................................30
Unoccupied ...........................................................................................................................................31
Flexsys: Compressor Control .........................................................................................................................31
Occupied Cooling w/o Bypass...............................................................................................................31
Occupied Cooling w/ Bypass.................................................................................................................31
Flexsys: Heating.............................................................................................................................................31
Flexsys: Underfloor Temperature Control.......................................................................................................31
Dew Point Reset....................................................................................................................................31
Active Slab Control................................................................................................................................32
Flexsys: All Other Sequences ........................................................................................................................32
Flexsys: BACnet Points..................................................................................................................................32
SECTION 12 - BACNET MS/TP POINTS...............................................................................................................33

JOHNSON CONTROLS 7
FORM 100.50-SU8
ISSUE DATE:1/28/2016
1
The Series 100 unit is a large tonnage rooftop unit, with
sizes ranging from 50-150 tons. It can be configured to
run as a Constant Volume unit, a Multizone Variable
Air Volume (VAV) unit, Single Zone VAV, or as a Flex-
Sys (underfloor air) unit. There are many different op-
tions that can be added to the machine, which will add
to its complexity.
This start up guide indicates control sequences to pro-
vide proper unit operation. This guide does not include
installation information. Please refer to the proper In-
stallation, Operation, and Maintenance (IOM) manual
for this information.
• 50-65 ton units, Mod F: Form 100.50-NOM5
(1115)
• 70-105 ton units, Mod F: Form 100.50-NOM9
(1115)
• 120-130 ton units, Mod F: Form 100.50-NOM10
(1115)
• 120-150 ton units, Mod G: Form 100.50-NOM11
(1115)
In addition, any system alarms indicated by the User
Interface should be diagnosed as referenced in the ap-
propriate IOM. You can refer to the Fault Description
Table located in the Service section of the IOM.
SECTION 1 - INTRODUCTION

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SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH
THE IPU CONTROLLER
A Series 100/YPAL rooftop unit with the IPU control-
ler ships from the factory ready to connect and com-
municate with a Building Automation System utilizing
BACnet MS/TP protocol.
The S100/YPAL unit can also communicate via BAC-
net IP, LON or N2 with the addition of a field provided/
installed component.
BACNET MS/TP
• Communication wires MUST be connected to
Port 1 using only terminals 3 and 4. Connecting
wires to any of the other terminals could result in
erratic or no communication. (See Figure 1)
a. Terminal 3: Receive (+)
b. Terminal 4: Transmit (-)
• MAC address can be set using dip switch SW2 or
in the Service Key. Preferred method is through
the Service Key. This prevents someone acciden-
tally hitting a dipswitch key and changing the
MAC address
• Using the Service Key to set the MAC address
a. Press the Service Key on the keyboard
b. Enter the level 2 password, 9725 and press
the checkmark
c. The screen should display “Data Log For-
mat”. If not, press the Service key again, and
“Data Log Format” should appear
d. Use the UP arrow to scroll up through the
menu until the screen displays “P1 Stop Bits
=1”
e. This is the part of the menu for Port 1
f. Press the UP arrow again to “P1 Protocol”
Should be set to BACnet
g. Use the UP arrow again until the screen dis-
plays “P1 Manual Mac Address”. If the val-
ue is set to -1, the unit address is set by the
dipswitches. Press the checkmark key and
enter the MAC address for the unit using the
numbered section of the keypad, then press
the checkmark to accept this value
h. Use the UP arrow again to find the “P1 Baud
Rate” Set this value to the required Baud
Rate.
i. Press the “X” key on the keypad to exit the
programming menu
j. Cycle main power OFF then ON for new val-
ues to be locked in.
• The S100 unit is now ready to communicate to
the BAS
BACNET IP
• Since the IPU controller does not have a function-
al IP port, a gateway must be used.
• We recommend using a JCI NCE (MS-
NCE2560-0)
• The gateway will be connected to Port 1 on the
IPU controller like above (See Figure 1 on page
10)

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FORM 100.50-SU8
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SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH THE IPU CONTROLLER
IPU Board
SW2: MAC Address Switch SD Card Slot
Port 3 (J2)
Port 1 (J4) BACnet MS/TP
MUST connect here
Port 4 (J3)Port 2 (J5)5 VDC Power
Battery
SW1: Not
Used
FIGURE 1 - IPU CONTROLLER PORT LOCATIONS
LD20051

JOHNSON CONTROLS 11
SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH THE IPU CONTROLLER
FORM 100.50-SU8
ISSUE DATE:1/28/2016
2
LON
• To communicate to a BAS utilizing LON proto-
col, a JCI E-Link must be used
a. YK-ELNK101-0
b. YK-ELNKE01-1 (with enclosure)
• The wires from the E-Link to the IPU controller
will be connected to Port 1 (See Figure 1 on page
10)
• P1 Protocol set to BACnet. See above under
BACnet MS/TP to locate P1 Protocol in the Ser-
vice Menu
See Figure 2 on page 11 for addressing the E-Link
to the IPU Controller.
FIGURE 2 - E-LINK CONNECTIONS AND ADDRESSING INSTRUCTIONS
N2
• To communicate to a BAS utilizing N2, a JCI E-
Link must be used
a. YK-ELNK100-0
b. YK-ELNKE00-0 (with enclosure)
• The wires from the E-Link to the IPU controller
will be connected to Port 1 (See Figure 1)
• P1 Protocol set to BACnet. See above under
BACnet MS/TP to locate P1 Protocol in the Ser-
vice Menu
See Figure 2 on page 11 for addressing the E-Link
to the IPU Controller
OTHER PROTOCOLS
• The IPU controller is also capable of communi-
cating with other BAS protocols
a. MODBUS Server
b. MODBUS Client
c. MODBUS I/O
d. Terminal
e. API

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FORM 100.50-SU8
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SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH THE IPU CONTROLLER
END OF LINE TERMINATION
• While it is not always required to have End-of-
Line Termination, it is strongly recommended
• For BACnet MS/TP and N2 protocols, JCI factory
recommends using our End-Of-Line Terminator,
p/n: MS-BACEOL-0
• Other communication protocols may need to pro-
vide/install their own end-of-line terminators if
applicable
MISCELLANEOUS
• Whenever a change is made to a communication
setting, please cycle power on/off to the unit to
“lock in” the new setting
• Points list are available in section 6 of the unit
Installation, Operation, and Maintenance manual
for BACnet MS/TP, BACnet IP, MODBUS, LON,
and N2
TECHNICAL SUPPORT
• For technical support on connecting to and com-
municating with the IPU controller in the Series
100 rooftop unit, please contact Applied DX
Product Technical Support
a. 1-877-329-7430 option 2
b. [email protected]
• For technical support with E-Links or End-of-
Line termination, please contact the Field Support
Center
a. 1-800-524-1330 options 6-1-2

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There are numerous operating modes for the Series 100
unit depending on the unit configuration. The list of
unit configurations below list describes the different
unit modes and what type configuration they apply to.
Unit Configurations:
1. Constant Volume (CV) Eliminated after 12/31/15
2. Single Zone VAV (SZ VAV) Added 9/1/15
3. Variable Air Volume (VAV)
4. Flexsys
UNIT_MODE (AI58): Displays the Series 100 Current
Operating Mode
0. OCC COOLING (VAV)
1. OCC COOLING LOW (CV or SZ VAV)
2. OCC COOLING HIGH (CV or SZ VAV)
3. OCC COOLING w/ BYPASS (FLEXSYS)
4. OCC COOLING w/o BYPASS (FLEXSYS)
5. OCC HEATING (VAV or FLEXSYS)
6. OCC HEATING LOW (CV or SZ VAV)
7. OCC HEATING (CV or SZ VAV)
8. OCC STANDBY ( All Configurations)
9. UNOCC COOLING (VAV or FLEXSYS)
10. UNOCC COOLING LOW (CV or SZ VAV)
11. UNOCC COOLING HIGH (CV or SZ VAV)
12. UNOCC HEATING (VAV or FLEXSYS)
UNOCC HEATIING LOW (CV or SZ VAV)
14. UNOCC HEATING HIGH (CV or SZ VAV)
15. UNOCC STANDBY (All Configurations)
16. COMFORT VENT COOLING (CV or SZ VAV)
17. COMFORT VENT HEATING (CV or SZ VAV)
18. NIGHT SET BACK ( All Configurations)
19. MORNING WARMUP (All Configurations)
20. POWER UP STANDBY (All configurations)
The BAS will show the numeric value for the Unit
Mode. It will be the programmer’s responsibility to
translate the numeric value to the actual verbiage for
graphic display purposes.
SECTION 3 - UNIT MODE

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The Series 100 can be placed into Occupied/Unoccu-
pied modes by three different methods:
1. 24 VAC to the OCC terminal on CTB1
2. Using the internal clock schedule built into the
unit controller
3. Commands from a Building Automation System
The three methods listed above are listed in the order
of priority. (i.e., if 24 VAC is applied to OCC at CTB1,
neither the internal clock schedule nor the BAS can
command the unit to Unoccupied.)
If the BAS is experiencing difficulties placing the unit
into the Unoccupied mode, please ensure that 24 VAC
is not present at the OCC terminal on CTB1 and the
internal clock schedule is “User Disabled.”
• OCCUPNCY_CMD (AV88 or BV12): A BAS
command that places the unit into the OCC mode
• OCC_STATE (BI36): Displays the status of the
Hardwired Input
• OCC_MODE (BI35): Displays the OCC/UNOCC
with Hardwired, Internal Schedule, or BAS com-
mand
SECTION 4 - OCCUPIED/UNOCCUPIED OPERATION

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Constant Volume (CV) conguration was
discontinued in December of 2015.
The Series 100 with IPU controller can accept thermo-
stat commands from a BAS (Building Automation Sys-
tem). This would allow a unit configured for Constant
Volume to operate without connecting a thermostat to
the unit. This allows a controls engineer to determine
when the unit starts and stops cooling or heating.
The following list describes the different Bacnet points
that can be used in place of a thermostat
• Y1_LOW_COOL_B: AV98 or BV22 (First stage
cooling command)
• Y2_HIGH_COOL_B: AV99 or BV23 (Second
stage cooling command)
• W1_LOW_HEAT_B: AV96 or BV20 (First stage
heating command)
• W2_HIGH_HEAT_B: AV97 or BV21 (Second
stage heating command)
• FAN_G_BAS: AV82 or BV06 (Supply fan com-
mand)
The below points can be used to set the different tem-
perature SP’s for the different unit modes
• STG_1_COOL: AV31 (Y1 command from BAS.
The unit controller will control the compressors
and/or economizer to achieve and maintain this
SP)
• STG_2_COOL: AV33 (Y2 command from BAS.
The unit controller will control the compressors
and/or economizer to achieve and maintain this
SP)
• STG_1_HEAT: AV32 (W1 command from BAS.
The unit controller will control the heating stages
of gas or electric heat or modulate the HW/Steam
valve to achieve and maintain this SP)
• STG_2_HEAT: AV34 (W1 command from BAS.
The unit controller will control the heating stages
of gas or electric heat or modulate the HW/Steam
valve to achieve and maintain this SP)
A unit configured for Constant Volume will not auto-
matically run the supply fan in the Occupied Mode like
a VAV or Flexsys configured unit. Under normal CV
operation, the supply fan will only run with a Y1, Y2,
W1, W2, or G command. Without any of these com-
mands present, the fan will not run. If the control se-
quence calls for the supply fan to run with the unit in
the Occupied Mode, the below Bacnet point will allow
this to happen.
• CONTINU_VENT: AV79 or BV03 (With the
point turned ON, the supply fan will run whenever
the unit is in the Occupied Mode. Turned OFF, the
supply fan will only run with a Y1, Y2, W1, W2,
or G command. 0=OFF 1=ON)
SECTION 5 - COMMANDING THERMOSTAT INPUTS FROM THE BAS

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The Series 100 with the IPU controller has the abil-
ity to accept a communicated zone temperature from
a BAS (Building Automation System). This allows the
BAS to use their own sensor or take an average reading
of all zones and send to the IPU controller.
Whether the BAS will use the communicated zone
temp feature for VAV, Flexsys, SZVAV or CV opera-
tion, setting the IPU controller to accept the BAS zone
temperature will all be the same.
With the rocker switch turned OFF, perform the fol-
lowing steps:
1. Push the Unit Data key, and use the up/down ar-
rowstondtheUnitTypescreen
2. If Unit Type is set for Constant Volume or SZVAV,
proceed to step “c”. If Unit Type is set for Variable
Air Volume, or Flexsys, the Unit Type will need
to be temporarily changed to Constant Volume or
S Z VAV.
a. To temporarily change to CV or SZVAV,
press the checkmark key, then enter the pass-
word, 9725.
b. Press the checkmark key again, and use the
right/left arrows to change Unit Type to Con-
stant Volume, then press checkmark to ac-
cept.
3. With Unit Type at Constant Volume or SZVAV,
use the down arrow to nd the Control Method
screen.
4. If Control Method is set to “Comm Zone Temp,”
proceed to Step 9.
5. If Control Method is not set to “Comm Zone
Temp,” press the checkmark, and enter the pass-
word if necessary, 9725.
6. Using the right/left arrows, change the Control
Method type to read “Comm Zone Temp.”
7. The unit controller is now set to accept a commu-
nicated zone temperature from a BAS.
8. If the Unit Type was VAV or Flexsys, go back to
the Unit Type screen and change back to the origi-
nal value.
9. The BAS can now communicate a Zone Tempera-
ture utilizing Bacnet point AV40 (ZONE_TEMP_
BAS).
SECTION 6 - COMMUNICATING A ZONE TEMPERATURE

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