Johnson Controls 100 Series User manual

FORM 100.50-EG12 (918)
SERIES 100
SINGLE PACKAGE ROOFTOP UNITS
ENGINEERING GUIDE
70–105 Tons
Cooling and Heating (Gas, Electric, Water, and Steam)
R-410A
Mod G
LD16707

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FORM100.50-EG12 (918)
Nomenclature
ASHRAE
90.1
COMPLIANT
BASE MODEL NUMBER YPAL070–105
Approvals
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
V : VAV, SZVAV
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 : Johnson Controls
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
GN : No Gas Heat
L : Low (375 MBH)
M : Med (750 MBH)
H : High (1125 MBH)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Base Product Type Nominal (Ton)
Capacity
Application Refrigerant Voltage Supply
Openings
Return
Openings
Design Special Gas Heat
Capacity

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NOMENCLATURE ................................................................................................................................................... 2
INTRODUCTION...................................................................................................................................................... 5
FEATURES AND BENEFITS................................................................................................................................... 6
APPLICATION DATA ............................................................................................................................................. 13
PHYSICAL DATA................................................................................................................................................... 19
WEIGHT DATA....................................................................................................................................................... 22
COOLING PERFORMANCE DATA – 70 TON MODEL......................................................................................... 25
COOLING PERFORMANCE DATA – 75 TON MODEL......................................................................................... 30
COOLING PERFORMANCE DATA – 80 TON MODEL......................................................................................... 35
COOLING PERFORMANCE DATA – 90 TON MODEL......................................................................................... 40
COOLING PERFORMANCE DATA – 105 TON MODEL....................................................................................... 45
HEATING PERFORMANCE DATA – GAS/ELECTRIC HEAT............................................................................... 50
SUPPLY FAN DATA............................................................................................................................................... 51
COMPONENT STATIC PRESSURE DROPS ........................................................................................................ 53
GAS HEAT PRESSURE DROPS........................................................................................................................... 54
ELECTRIC HEAT PRESSURE DROPS ................................................................................................................ 55
EXHAUST FAN DATA............................................................................................................................................ 56
RETURN FAN DATA.............................................................................................................................................. 57
ELECTRICAL DATA .............................................................................................................................................. 58
CONTROLS ........................................................................................................................................................... 61
POWER WIRING: YPAL070–105 .......................................................................................................................... 70
FIELD CONTROL WIRING ................................................................................................................................... 73
GENERAL ARRANGEMENT DRAWING – 70–80 TON MODELS ...................................................................... 75
GENERAL ARRANGEMENT DRAWING – 90–105 TON MODELS .................................................................... 81
GENERAL ARRANGEMENT DRAWING - CURB LAYOUT ................................................................................. 87
HOT WATER/STEAM COIL CONNECTION LOCATIONS .................................................................................... 89
POWER/CONTROL ENTRY DRAWING – 70-105 TON MODELS........................................................................ 90
GUIDE SPECIFICATIONS ..................................................................................................................................... 91
FORM 100.50-EG12 (918)
Table of Contents

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FORM100.50-EG12 (918)

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FORM 100.50-EG12 (918)
Introduction
The Johnson Controls Series 100 Single Packaged Units –
designed to meet the demands of the market for today and
tomorrow.
Better Economy...
Lower total cost of ownership
• Johnson Controls provides a standard product offering that meets the latest ASHRAE
90.1 energy efciency requirements.
• Fully modulating gas heat and greater steps of capacity control offer superior off-
design performance while maintaining optimum occupant comfort.
• Accurate ventilation control ensures that no more than the proper amount of ventila-
tion air is utilized. This avoids the energy cost of conditioning excess outside air and
simultaneously monitors all other unit functions for maximized energy efciency.
• Flexible design congurations simplify the design process and allows the Series 100
to be applied to virtually any building application.
• Accessibility through double-wall access doors, spacious compartments and sup-
portive oors improves serviceability.
Better Ecology...
Indoor air quality features for the indoor environment
• A double-sloped stainless steel drain pan with a single drain con-
nection ensures that all condensate is voided from the drain pan. It
is also visible and accessible for periodic inspection and cleaning re-
quired by the ASHRAE 62 IAQ standard.
• Double-wall construction of the roof, oor, doors, and walls pre-
vents insulation bers from entering the conditioned air. The inner liner
also facilitates periodic cleaning of the unit to prevent harmful build-up
of bacteria or contaminants.
• The single package unit control center uses microprocessor log-
ic to analyze and optimize ventilation decisions and perform demand
ventilation, airow compensation, and airow measurement to main-
tain the air quality at a healthy level.
LD07431
The Single Package Unit User Interface uses
microprocessor logic to optimize operation of the
Series 100 unit.

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FORM100.50-EG12 (918)
Features and Benefits
AIRFLOW CONFIGURATIONS
Variable Air Volume (VAV) – Series 100 units are available for variable air volume (VAV)
applications. Control can be used with a zone sensor or building automation system. Sup-
ply fans are controlled to the supply duct static pressure setpoint, which can be reset via a
building automation system (BAS) or through a 0–5VDC analog input on the unit controller
for optimized duct static pressure control. The static pressure transducer is provided in the
single package unit, and 5/16-inch or 1/4-inch plastic tubing and static pressure sensor
must be supplied by others and installed approximately 3/4 down the longest duct run.
FlexSys™Underfloor Air VAV – Series 100 units are configurable for underfloor air VAV
applications. Control can be used with a zone sensor or building automation system. Sup-
ply fans are controlled to the supply duct static pressure setpoint, which can be reset via
a BAS, or through a 0–5VDC analog input on the unit controller for optimized duct static
pressure control. The static pressure transducer is provided in the single package unit,
and 5/16-inch or 1/4-inch plastic tubing and static pressure sensor must be supplied by
others and installed approximately 3/4 down the longest duct run. Refer to 100.50-EG8
engineering guide for more detailed information on this application.
Single Zone Variable Air Volume (SZVAV)– Series 100 units are available for single
zone variable air volume (SZVAV) applications. Control can be used with a zone sensor
or a BAS. Supply fans are controlled based on zone temperature.
COOLING AND HEATING CONFIGURATIONS
Cooling Only – For applications where no heat is required, or heating is provided else-
where within the building HVAC system, cooling only units include an empty discharge
plenum. Supply duct connections are configurable for bottom, left or right discharge. The
supply air temperature sensor is included and factory-installed.
Staged Gas Heat – For applications requiring gas heat for morning warm-up, or other
heating needs, a staged natural gas furnace is available. The furnace is located in the
discharge plenum, downstream of the supply fan. The supply air temperature sensor is
located across the face of the supply duct opening in the unit. Furnaces are designed in
375 MBH modules with two stages in each. For 70–105 ton units, optional Propane Con-
version Kits contain the necessary orifices and gas valve/parts to convert staged heat only
(not modulating) from natural gas to propane. Ignition and safety controls are included
and factory-wired. Units with staged gas heat are ETL listed.
Modulating Gas Heat – For applications requiring gas heat for morning warm-up, supply
air tempering or other heating needs, a modulating natural gas furnace is available for
finer temperature control. The furnace is located in the discharge plenum, downstream of
the supply fan. The supply air temperature sensor is located across the face of the sup-
ply duct opening in the unit. Furnaces are designed in 375 MBH modules in 8:1 turndown
increments. Three are available for the YPAL070–105 (8:1, 16:1 or 24:1 turndown). Igni-
tion and safety controls are included and factory-wired. Units with modulating gas heat
are ETL listed.
Electric Resistance Heat – For applications where electric heat is desired, a slip-in elec-
tric resistance heat element is available in sizes from 80–250 kW depending on the single
package unit model size. The number of stages varies by size and voltage, but all have a
minimum of two stages of capacity. Units with electric heat are ETL listed.

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FORM 100.50-EG12 (918)
Hot Water Heat – For applications where hot water is available for heating, a hot water
heating coil is available. A range of coil fin count selections are available to properly size the
heating for the application. Units with hot water heat are ETL listed.
Steam Heat – For applications where steam is available for heating, a steam heating coil
is available. A range of coil fin count selections are available to properly size the heating
for the application. Units with steam heat are ETL listed.
POWER OPTIONS
Single-Point Supply with Terminal Block –This configuration is standard, and includes
three terminals for the incoming 3-phase power and is the standard configuration for the
Series 100 product. It includes the enclosure, terminal-block, and interconnecting wiring
to the compressors, heater and furnace controls, all fans, etc. In this configuration, code
requires that a means of disconnect (not provided) must be installed at the site within line-
of-sight of the equipment.
Single-Point Supply with Non-Fused Disconnect Switch –This option is the same as
the single-point with terminal block option except it includes a unit-mounted through-the-
door manual non-fused disconnect switch with an external, lockable handle (in compli-
ance with Article 440-14 of N.E.C.). This option provides a means to isolate the unit power
voltage for servicing. Others must supply separate external fusing which must comply with
the National Electric Code and/or local codes.
Dual-Point Supply with Terminal Block – This option includes enclosure, terminal blocks
circuited to the supply and exhaust fans and control transformer and a second set of
terminal blocks with interconnecting wiring to the compressors, heat (if applicable) and
condenser.
Convenience Outlet – This options includes a powered 115V GFCI convenience outlet
that can be used for powering tools or lights for servicing. A protective cover plate is in-
cluded while not in use. The outlet is located on the bottom left hand corner of the power
panel.
CONTROL FEATURES AND OPTIONS
Microprocessor-Based Single Package Unit Controller –All Series 100 units are
equipped with a factory-installed, programmed and commissioned unit controller with all I/O
capabilities and control sequences. The controls include all on-board diagnostic, safety and
control features to operate the single package unit. A multimedia card interface is included
for software upgrades and can be used for data logging to simplify equipment troubleshoot-
ing. Communication ports are included as standard with three alarm outputs, a shutdown
contact, remote start/stop input, smoke ventilation controls, analog inputs for supply air
temperature and duct static pressure rest, along with a variety of other capabilities.
Standard Ambient – YPAL070–105 models operate down to 45.0°F as standard.
Low Ambient on Circuits One, [One and Two], or [One, Two, and Three] – This op-
tion includes low ambient control of the first [first and second] [first, second, and third]
circuit(s) down to 0.0°F through the use of suction and discharge pressure transducers
on the circuit(s).
Pressure Transducers with Readout Capability –This option includes suction and dis-
charge pressure transducers on each circuit and provides pressure readout of all circuits
at the unit control panel.

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FORM100.50-EG12 (918)
Wall-Mount Zone Sensor – A 10 kOhm thermister type III NTC zone sensor for wall
mounting. This zone sensor is for sensing temperature only, and does not include any
setpoint adjustment features.
COMMUNICATIONS
BACnet®MS/TP (RS-485) Communications – This communication option is standard on
every Series 100 unit. Communications to the unit are through a twisted pair, and the wire
terminations are on the primary unit control board. See supplemental information for the
available control points and PICS/Bibbs statements of conformity.
Modbus™RTU Communications – This communication option is standard on every Se-
ries 100 unit and can be used in lieu of the BACnet communications (only one can be
used at a time). See supplemental information for the available control points.
FILTER OPTIONS
Filter Options – Two-inch throwaway, cleanable, carbon coated MERV 8 or pleated
MERV 8 filters in an angled rack are available. For higher filtration requirements, optional
rigid filter racks are available with 12-inch 65% (MERV 11) or 95% (MERV 14) efficient
rigid filters. Two-inch MERV 8 pre-filters are included with rigid filter options. The rigid filter
rack option is available without filter media where field-supplied filters are required.
OUTSIDE AIR DAMPER OPTIONS
Manual Damper – This option includes a manually adjustable outside air damper. It is
manually adjustable at the unit by setting a mechanical stop between 0–100%.
Two-Position – This outside air damper option is controlled to a two positions, opened
and closed. Determination of the damper position is based on the occupancy schedule. In
the occupied mode, the outside air damper is positioned to the manually configured point
(set by mechanical stop). In the unoccupied mode, the damper is fully closed.
Modulating Economizer – This option includes modulating outdoor air and return air
dampers that are software interlocked (YPAL070–105 software interlock) and positioned
by fully modulating, solid state damper actuators. Control of the damper is via a standard
ambient outdoor air dry bulb sensor, or optional single or comparative enthalpy controls.
Airflow Measurement – Optional outside airflow measurement is available on units
equipped with a Modulating Economizer.
CO2Sensors – Optional carbon dioxide sensors for occupied space that operate demand
ventilation control opening outside air dampers to ventilate building. The CO2sensors can
operate in a single or comparative control scheme.
Rain Hoods on Outside Air Intakes – For all options with outside air intake openings,
rain hoods are provided as standard to keep moisture from entering the equipment. The
rain hoods are an integral part of the unit and are rotated into place at the jobsite.
RELIEF SYSTEM
Barometric Relief – This option does not include an exhaust or return fan, but rather
uses barometric relief dampers to exhaust air from the building. The dampers will open
relative to the building pressure. The opening pressure is adjustable via a spring tension
adjustment.
Features and Benefits (Cont'd)
Zone Sensor

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FORM 100.50-EG12 (918)
On/Off Powered Exhaust –This option provides simple building pressure control. It can
be controlled via a building pressure signal, or via outside air damper control. This option
is not available for VAV units.
Modulating Powered Exhaust with Damper Control – This option consists of a con-
stant-speed exhaust fan with a discharge damper that is modulated to control the flow
of exhaust air. The damper control logic is based on the building static pressure setpoint
within the single package unit controller. The static pressure transducer is provided in
the return plenum of the single package unit, and 5/16-inch or 1/4-inch plastic tubing and
static pressure sensor must be supplied by others and installed in a representative loca-
tion in the building.
Modulating Powered Exhaust with a VFD – This option consists of a VFD to modulate the
speed of the exhaust fan to control the flow of exhaust air. The VFD control logic is based
on the building static pressure setpoint within the single package unit controller. The static
pressure transducer is provided in the return plenum of the single package unit, and 5/16-
inch or 1/4-inch plastic tubing and static pressure sensor must be supplied by others and
installed in a representative location in the building.
Powered Return Fan with Exhaust – This option uses single width, single inlet (SWSI)
plenum fan(s) to control building pressure. The fan motors are driven by a VFD to maintain
a constant return plenum pressure. An exhaust hood with a modulating control damper
is used to maintain building pressure via the building static pressure. The static pressure
transducer is provided in the return plenum of the single package unit, and 5/16-inch or
1/4-inch plastic tubing and static pressure sensor must be supplied by others and installed
in a representative location in the building. The powered return fan is also available with-
out the exhaust capabilities. For units with no exhaust capabilities, the HVAC system must
provide alternate means of controlling building pressure.
SUPPLY FAN OPTIONS
Double Width, Double Inlet (DWDI) Forward-Curved Supply Fan – The standard sup-
ply air blower in the YPAL070–80 models is a forward-curved supply fan. This fan is good
for medium static pressures and high airflows.
DWDI Airfoil Supply Fan –The standard supply air blower in the YPAL090–105 is an
airfoil blade supply fan. This fan is also available as an option on YPAL070–080 for higher
static conditions. This fan offers higher efficiency and lower sound in certain applications.
Fan Skid Isolation – The entire supply fan assembly is isolated from the unit base with
one- (standard) or two-inch deflection springs, or one (standard) or two-inch deflection
springs with seismic restraints.
Supply and Exhaust Fan Motors – Premium efficiency ODP and premium efficiency
TEFC motors are available all meeting the Energy Policy Act of 1992 (EPACT).
Supply Fan VFD and Manual Bypass – For VAV applications, VFDs are provided to
modulate airflow. Optional manual bypass can also be provided to allow full airflow in the
event of a VFD failure.
Direct Drive Plenum (DDP) Fan – A direct drive plenum (DDP) supply fan provides out-
standing reliability and efficiency, eliminating the possibility of conditioned air supply inter-
ruption due to a broken belt and the pollution of conditioned air with belt dust. The supply
fan can be optionally equipped with a piezo ring to precisely measure the amount of air
delivered to the conditioned space. The speed of the supply fan is controlled by a VFD.

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FORM100.50-EG12 (918)
EVAPORATOR SECTION
Double Sloped Stainless Steel Drain Pan – The Series 100’s stainless steel drain pan is
factory-mounted and installed on every unit. A condensate drain trap is needed, and must
be provided and installed in the field by others.
LD08022
NOTE
This is a visual reference only. Actual drain pan pitch will vary.
FIGURE 1 - DRAIN PAN DETAIL
Double Wall Construction – Double-wall construction is the standard construction of the
Series 100 and incorporates powder coated outer panels and corner post for maximum
exterior surface protection.
Factory Shrink-wrap – All Series 100 single package units are shipped from the factory
with factory-fresh shrink-wrap packaging. No longer does the contractor need to worry
about dirt and debris clogging up condenser coils or moisture leaking into the air handler
on the units way to the job site or rigging yard.
Copper Fins – For more extreme climates that aggressively can attack aluminum, cop-
per tube evaporator coils with copper fins are available. (This is not recommended for
units in areas where they may be exposed to acid rain or environments where ammonia
is present)
CONDENSER FEATURES AND OPTIONS
Scroll Compressors – Reliable, efficient, trouble-free operation is the true measure of
a single package unit’s value. That’s why Johnson Controls Series 100 Single package
units use established scroll compressor technology to deliver dependable, economical
performance in a wide range of applications. With the Series 100 Single package units,
you get the latest generation of compressor enhancements added to the scroll’s inherent
strengths. The simplicity of a hermetic scroll compressor allows the use of fewer moving
parts to minimize breakdown.
Multiple Compressor Staging – Through the use of the scroll compressor, the Series
100 has the ability to stage it’s cooling by enabling and disabling multiple single stage
compressors on multiple circuits.
Compressor Circuiting – The Series 100 is designed so that only 2 scroll compressors
are in tandem within one refrigeration circuit. This means more reliable compressors,
and less equipment down time. With multiple circuits, if a compressor should ever fail on
one circuit, the other circuit/s will remain operational to maintain occupied loads. In sizes
70–105T, the Series 100 has three independent refrigeration circuits per unit.
Condenser Fan Motors – The condenser fan motors used on the Series 100 unit are
Totally Enclosed Air Over (TEAO) to provide maximum durability through any season.
Features and Benefits (Cont'd)