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
2
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

JOHNSON CONTROLS
4
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

JOHNSON CONTROLS
6
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

JOHNSON CONTROLS
8
FORM 100.50-SU8
ISSUE DATE: 1/28/2016
SECTION 1 - INTRODUCTION
THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 9
FORM 100.50-SU8
ISSUE DATE:1/28/2016
2
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)

JOHNSON CONTROLS
10
FORM 100.50-SU8
ISSUE DATE: 1/28/2016
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