Johnson Controls MagnaDRY DK-15 User manual

INSTALLATION
MANUAL
CAUTION: READ ALL SAFETY GUIDES BEFORE
YOU BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
MagnaDRY™
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
MODELS: DK-15, -20 & -25
335226-BIM-B-1008
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . .63
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . .64
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .66
See the following pages for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes are intended to
clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to
alert installer that personal injury and/or equipment dam-
age may result if installation procedure is not handled
properly.

335226-BIM-B-1008
2Johnson Controls Unitary Products
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION SAFETY INFORMATION: . . . . . . . . . . . . . . 7
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RIGGING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FIXED OUTDOOR AIR INTAKE DAMPER . . . . . . . . . . . . . . 9
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPACE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER AND CONTROL WIRING . . . . . . . . . . . . . . . . . . . 12
OPTIONAL ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . 12
OPTIONAL GAS HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
L.P. UNITS, TANKS AND PIPING. . . . . . . . . . . . . . . . . . . . 15
VENT AND COMBUSTION AIR HOODS . . . . . . . . . . . . . . 15
OPTIONAL ECONOMIZER/MOTORIZED DAMPER RAIN
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPTIONAL POWER EXHAUST/BAROMETRIC RELIEF
DAMPER RAIN HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPTIONAL ECONOMIZER AND POWER EXHAUST DAMPER
SETPOINT ADJUSTMENTS AND INFORMATION . . . . . . . . 16
MINIMUM POSITION ADJUSTMENT. . . . . . . . . . . . . . . . . . . 16
ENTHALPY SETPOINT ADJUSTMENT . . . . . . . . . . . . . . . . . 16
POWER EXHAUST DAMPER SETPOINT . . . . . . . . . . . . . . . 17
INDOOR AIR QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPTIONAL BAS-READY ECONOMIZER POWER EXHAUST
DAMPER SET POINT ADJUSTMENT . . . . . . . . . . . . . . . . 17
OPTIONAL VARIABLE AIR VOLUME (VAV) . . . . . . . . . . . 17
DUCT STATIC PRESSURE TRANSDUCER . . . . . . . . . . . . . 17
VAV CONTROL BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FACTORY-INSTALLED VFD . . . . . . . . . . . . . . . . . . . . . . . . . 19
MANUAL BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BAS-READY VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
'VFD-READY' FOR CUSTOMER-INSTALLATION . . . . . . . . . 20
OPTIONAL HOT GAS BYPASS (HGBP) . . . . . . . . . . . . . . 20
CFM, STATIC PRESSURE, AND POWER - ALTITUDE AND
TEMPERATURE CORRECTIONS . . . . . . . . . . . . . . . . . . . 33
PHASING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CHECKING SUPPLY AIR CFM. . . . . . . . . . . . . . . . . . . . . . 50
AIR BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SEQUENCE OF OPERATIONS OVERVIEW . . . . . . . . . . . 52
COOLING SEQUENCE OF OPERATION. . . . . . . . . . . . . . 52
CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INTERMITTENT BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPTIONAL VAV BLOWER OPERATION . . . . . . . . . . . . . . . . 52
NO OUTDOOR AIR OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 52
ECONOMIZER WITH SINGLE ENTHALPY SENSOR - . . . . . 52
ECONOMIZER WITH DUAL ENTHALPY SENSORS - . . . . . 53
ECONOMIZER (SINGLE OR DUAL ENTHALPY) WITH
POWER EXHAUST - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ECONOMIZER WITH OPTIONAL VAV OR INTELLI-
COMFORT™ CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ECONOMIZER WITH OPTIONAL VAV BLOWER WITH
POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ECONOMIZER WITH OPTIONAL INTELLI-COMFORT™ WITH
POWER EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
MOTORIZED OUTDOOR AIR DAMPERS - . . . . . . . . . . . . . 54
COOLING OPERATION ERRORS . . . . . . . . . . . . . . . . . . . . 54
HIGH-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . 54
LOW-PRESSURE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . 54
FREEZESTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
LOW AMBIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
COMPRESSOR PROTECTION . . . . . . . . . . . . . . . . . . . . . 55
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REHEAT MODE SEQUENCE OF OPERATION . . . . . . . . 55
“NORMAL” MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
"ALTERNATE” MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ELECTRIC HEATING SEQUENCE OF OPERATIONS . . . 59
HEATING OPERATION ERRORS . . . . . . . . . . . . . . . . . . . 60
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . . . . . . 60
GAS HEATING SEQUENCE OF OPERATIONS . . . . . . . . 61
GAS HEATING OPERATION ERRORS . . . . . . . . . . . . . . . 62
TEMPERATURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
GAS VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
RESETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . . . . . . . . . 63
START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . 63
PRESTART CHECK LIST. . . . . . . . . . . . . . . . . . . . . . . . . . 63
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 64
POST START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . 64
SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
START-UP (GAS HEAT) . . . . . . . . . . . . . . . . . . . . . . . . 64
PRE-START CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . 64
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 64
TO LIGHT PILOT AND MAIN BURNERS:. . . . . . . . . . . . . . . 64
TO SHUT DOWN: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
POST-START CHECK LIST (GAS) . . . . . . . . . . . . . . . . . . 64
MANIFOLD GAS PRESSURE ADJUSTMENT . . . . . . . . . . 65
PILOT CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
BURNER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 65
BURNER AIR SHUTTER ADJUSTMENT. . . . . . . . . . . . . . 65
CHECKING GAS INPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . . . 66
BELT DRIVE BLOWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . 66
COOLING TROUBLESHOOTING GUIDE . . . . . . . . . . . . . 66
GAS HEAT TROUBLESHOOTING GUIDE . . . . . . . . . . . . 71
UNIT CONTROL BOARD FLASH CODES . . . . . . . . . . . . . 74
UNIT CONTROL BOARD OPTION SETUP . . . . . . . 75
OPTION BYTE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
HEAT DELAY SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
OPTIONAL VAV CONTROL BOARD FLASH CODES . . . . 76

335226-BIM-B-1008
Johnson Controls Unitary Products 3
LIST OF FIGURES
Fig. # Pg. #
1 TYPICAL RIGGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 CENTER OF GRAVITY. . . . . . . . . . . . . . . . . . . . . . . . . 8
3 FIXED OUTDOOR AIR DAMPER . . . . . . . . . . . . . . . . 10
4 RECOMMENDED DRAIN PIPING . . . . . . . . . . . . . . . 10
5 TYPICAL FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . 11
6 EXTERNAL SUPPLY CONNECTION EXTERNAL
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 BOTTOM SUPPLY CONNECTION EXTERNAL
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 VENT AND COMBUSTION AIR HOOD . . . . . . . . . . . 16
9 ENTHALPY SETPOINT ADJUSTMENT . . . . . . . . . . . 21
10 HONEYWELL ECONOMIZER CONTROL W7212 . . . 21
11 FOUR AND SIX POINT LOADS . . . . . . . . . . . . . . . . . 22
12 FRONT VIEW DIMENSIONS . . . . . . . . . . . . . . . . . . . 30
13 REAR VIEW DIMENSIONS . . . . . . . . . . . . . . . . . . . . 31
14 UNIT CLEARANCES AND RAIN HOOD
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fig. # Pg. #
15 ALTITUDE/TEMPERATURE CONVERSION
FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
16 CHARGING CHART - 15 TON . . . . . . . . . . . . . . . . . . 48
17 CHARGING CHART - 20 TON . . . . . . . . . . . . . . . . . . 48
18 CHARGING CHART - 25 TON . . . . . . . . . . . . . . . . . . 49
19 BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 50
20 PRESSURE DROP ACROSS A DRY INDOOR
COIL VS SUPPLY AIR CFM FOR ALL UNIT
TONNAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
21 REHEAT CONTROL BOARD . . . . . . . . . . . . . . . . . . . 57
22 REHEAT CONTROLS - PART 1 . . . . . . . . . . . . . . . . 58
23 REHEAT CONTROLS - PART 2 . . . . . . . . . . . . . . . . 58
24 SYSTEM PIPING SCHEMATIC . . . . . . . . . . . . . . . . . 59
25 GAS VALVE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . 62
26 GAS VALVE AND CONTROLS . . . . . . . . . . . . . . . . . 63
27 TYPICAL GAS VALVES . . . . . . . . . . . . . . . . . . . . . . . 65
28 PROPER FLAME ADJUSTMENT . . . . . . . . . . . . . . . 65
29 TYPICAL FLAME APPEARANCE . . . . . . . . . . . . . . . 65
30 UNIT CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . 75
31 UNIT CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . 75
LIST OF TABLES
Tbl. # Pg. #
1 UNIT APPLICATION DATA . . . . . . . . . . . . . . . . . . . . . . 8
2 CONTROL WIRE SIZES . . . . . . . . . . . . . . . . . . . . . . . 12
3 ELECTRIC HEAT APPLICATION DATA . . . . . . . . . . . 13
4 GAS HEAT APPLICATION DATA . . . . . . . . . . . . . . . . 13
5 PIPE SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 FOUR AND SIX POINT LOADS . . . . . . . . . . . . . . . . . 22
7 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8 SUPPLY FAN VFD WEIGHTS, IN LBS. . . . . . . . . . . . 23
9 DK ELECTRICAL DATA - STANDARD DRIVE
MOTOR W/O POWERED CONVENIENCE
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10 DK ELECTRICAL DATA - HIGH STATIC DRIVE
MOTOR W/O POWERED CONVENIENCE
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11 DK ELECTRICAL DATA - LOW STATIC DRIVE
MOTOR W/O POWERED CONVENIENCE
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
12 DK ELECTRICAL DATA - STANDARD DRIVE
MOTOR WITH POWERED CONVENIENCE
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13 DK ELECTRICAL DATA - HIGH STATIC DRIVE
MOTOR WITH POWERED CONVENIENCE
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14 DK ELECTRICAL DATA - LOW STATIC DRIVE
MOTOR WITH POWERED CONVENIENCE
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
15 ALTITUDE CORRECTION FACTORS . . . . . . . . . . . . 33
16 DK-15 BLOWER PERFORMANCE - 15 TON
STANDARD DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
17 DK-15 BLOWER PERFORMANCE - 15 TON
HIGH STATIC DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Tbl. # Pg. #
18 DK-15 BLOWER PERFORMANCE - 15 TON
STANDARD DRIVE (GAS HEAT) DOWNFLOW . . . . 37
19 DK-15 BLOWER PERFORMANCE - 15 TON HIGH
STATIC DRIVE (GAS HEAT) DOWNFLOW . . . . . . . . 38
20 DK-20 BLOWER PERFORMANCE - 20
TON STANDARD DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
21 DK-20 BLOWER PERFORMANCE - 20 TON
HIGH STATIC DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
22 DK-20 BLOWER PERFORMANCE - 20 TON
STANDARD DRIVE (GAS HEAT) DOWNFLOW . . . . 41
23 DK-20 BLOWER PERFORMANCE - 20 TON
HIGH STATIC DRIVE (GAS HEAT) DOWNFLOW . . . 42
24 DK-25 BLOWER PERFORMANCE - 25 TON
STANDARD DRIVE (COOLING ONLY)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
25 DK-25 BLOWER PERFORMANCE - 25 TON HIGH
STATIC DRIVE (COOLING ONLY) DOWNFLOW . . . 44
26 DK-25 BLOWER PERFORMANCE - 25
TON STANDARD DRIVE (GAS HEAT)
DOWNFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
27 DK-25 BLOWER PERFORMANCE - 25 TON HIGH
STATIC DRIVE (GAS HEAT) DOWNFLOW . . . . . . . . 46
28 STATIC RESISTANCES . . . . . . . . . . . . . . . . . . . . . . . 47
29 POWER EXHAUST PERFORMANCE . . . . . . . . . . . . 47
30 BLOWER MOTOR AND DRIVE DATA . . . . . . . . . . . . 47
31 LIMIT CONTROL SETTING . . . . . . . . . . . . . . . . . . . . 60
32 ELECTRIC HEAT ANTICIPATOR SETPOINTS . . . . . 61
33 LIMIT CONTROL SETTING . . . . . . . . . . . . . . . . . . . . 63
34 GAS HEAT ANTICIPATOR SETPOINTS . . . . . . . . . . 63
35 GAS RATE - CUBIC FEET PER HOUR . . . . . . . . . . . 66
36 UNIT CONTROL BOARD FLASH CODES . . . . . . . . . 74
37 HEAT DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
38 VAV CONTROL BOARD FLASH CODES . . . . . . . . . 76
39 REHEAT CONTROL BOARD FLASH CODES . . . . . . 76

335226-BIM-B-1008
4Johnson Controls Unitary Products
GENERAL
DK units are either single package cooling units
equipped with optional factory installed electric heat-
ers, or single package gas-fired central heating fur-
naces with cooling unit. Both are designed for outdoor
installation on a rooftop or slab.
The units are completely assembled on rigid, perma-
nently attached base rails. All piping, refrigerant
charge, and electrical wiring is factory installed and
tested. The units require electric power, gas connec-
tion, duct connections, installation of combustion air
inlet hood, flue gas outlet hoods and fixed outdoor air
intake damper (units without economizer or motorized
damper option only) at the point of installation.
The supplemental electric heaters have nickel-chrome
elements and utilize single point power connection.
The gas-fired heaters have aluminized-steel or optional
stainless steel, tubular heat exchangers with spark
ignition with proven pilot. All gas heaters are shipped
from the factory equipped for natural gas use, but can
be field converted to L.P./Propane with Kit Model #
1NP0418.
SAFETY CONSIDERATIONS
Due to system pressure, moving parts and electrical
components, installation and servicing of air condition-
ing equipment can be hazardous. Only qualified,
trained, service personnel should install, repair, main-
tain or service this equipment.
Observe all precautions in the literature, on labels and
tags accompanying the equipment whenever working
on air conditioning equipment. Be sure to follow all
other safety precautions that apply.
Wear safety glasses and work gloves, and follow all
safety codes. Use a quenching cloth and have a fire
extinguisher available for all brazing operations.
INSPECTION
As soon as a unit is received, it should be inspected for
possible damage during transit. If damage is evident,
the extent of the damage should be noted on the car-
rier's freight bill. A separate request for inspection by
the carrier's agent should be made in writing.
REFERENCE
Additional information on the design, installation, oper-
ation and service of this equipment is available in the
following reference forms:
• Technical Guide: 347129
• General Installation: 335226
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property dam-
age.
- Do not store or use gasoline or other flamma-
ble vapors and liquids in the vicinity of this or
any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas sup-
plier’s instructions.
• If you cannot reach the gas supplier, call
the fire department.
- Installation and service must be performed by
a qualified installer, service agency or the
gas supplier.

335226-BIM-B-1008
Johnson Controls Unitary Products 5
RENEWAL PARTS
Contact your local UP Parts Distribution Center for
authorized replacement parts.
APPROVALS
Design certified by CSA as follows:
• For use as a cooling unit only with or without
optional electric heat.
• For use as a forced air furnace with cooling unit
• For outdoor installation only.
• For installation on combustible material.
• For use with natural gas or propane gas.
The installer should pay particular attention to the
words: NOTE, CAUTION and WARNING. Notes are
intended to clarify or make the installation easier. Cau-
tions are given to prevent equipment damage. Warn-
ings are given to alert installer that personal injury and/
or equipment damage may result if installation proce-
dure is not handled properly.
This product must be installed in strict compli-
ance with the enclosed installation instructions
and any applicable local, state, and national
codes including, but not limited to, building,
electrical, and mechanical codes.
Improper installation may create a condition
where the operation of the product could cause
personal injury or property damage.

335226-BIM-B-1008
6Johnson Controls Unitary Products
PRODUCT NOMENCLATURE
D K -15 N30 A T A AA 1 0 1 2 4 A
D = A/C, Single Pkg., R-22
Product Category
Airflow
1 = First Generation
2 = Second Generation
Product Generation
C00 = Cooling Only. No field installed
electric heat
Heat Type and Nominal Heat Capacity
N30 = 300 MBH Output Aluminized Steel
N40 = 400 MBH Output Aluminized Steel
S30 = 300 MBH Output Stainless Steel
S40 = 400 MBH Output Stainless Steel
E18 = 18 KW
E36 = 36 KW
E54 = 54 KW
E72 = 72 KW
Gas Heat Options
Electric Heat Options
-15 = 15 Ton
Nominal Cooling Capacity
-20 = 20 Ton
-25 = 25 Ton
Product Identifier
K = 90.1 w/Reheat
Voltage
T = 208/230-3-60
W = 460-3-60
X = 575-3-60
Product Style
A = Style A
A = No Options Installed
Installation Options
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
Options
SS Drain Pan
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
CPC Controller, DFS, APS
Johnson Controller, DFS, APS
Honeywell Controller, DFS, APS
Novar Controller, DFS, APS
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller w/ModLinc
2" Pleated filters
4" Pleated filters
BAS Ready Economizer (2-10 V.D.C. Actuator without a controller)
Double Wall Construction
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
AA = None
Standard Cabinet
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
RC = Coil Guard & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
BA = Hinged Filter Door & Tool Free Access Panels
Additional Options
Hinged Filter Door & Tool Free Access Cabinet
BB = Phase Monitor, Hinged Filter Door & Tool Free
Access Panels
BC = Coil Guard, Hinged Filter Door & Tool Free
Access Panels
BD = Dirty Filter Switch, Hinged Filter Door &
Tool Free Access Panels
BE = Phase Monitor & Coil Guard, Hinged Filter
Door & Tool Free Access Panels
BF = Phase Monitor & Dirty Filter Switch, Hinged
Filter Door & Tool Free Access Panels
BG = Coil Guard & Dirty Filter Switch, Hinged Filter
Door & Tool Free Access Panels
BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
Hinged Filter Door & Tool Free Access Panels
15-25 Ton MagnaDRY™ Model Number Nomenclature
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
Hot Gas Bypass (Standard on VAV, Optional on CV)
Variable Air Volume, VFD (not available with factory installed BAS options)
Variable Air Volume, VFD with ModLINC (not available with factory installed BAS options)
Variable Air Volume, VFD and Manual Bypass (not available with factory installed BAS options)
Variable Air Volume, VFD and Manual Bypass with ModLINC (not available with factory installed BAS options)
Variable Air Volume, VFD (BAS ready)
Variable Air Volume, VFD and Manual Bypass (BAS ready)
Variable Air Volume, VFD Ready (for customer provided, field installed drive)
Variable Air Volume, VFD Ready with ModLINC (for customer-provided, field-installed drive)
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
A = Std. Motor
B = Std. Motor/Economizer
C = Std. Motor/Economizer/Power Exhaust
(Downflow Only)
D = Std. Motor/Motorized Damper
E = Std. Motor/Motorized Damper/Barometric Relief
J = Std. Motor/Economizer/Barometric Relief
N = Hi Static
P = Hi Static/Economizer
Q = Hi Static/Economizer/Power Exhaust
(Downflow Only)
R = Hi Static/Motorized Damper
K = Hi Static/Motorized Damper/Barometric Relief
S = Hi Static/Economizer/Barometric Relief
2 = Low Static
3 = Low Static/Economizer
4 = Low Static/Economizer/Power Exhaust
(Downflow Only)
5 = Low Static/Motorized Damper
6 = Low Static/Motorized Damper/Barometric Relief
7 = Low Static/Economizer/Barometric Relief

335226-BIM-B-1008
Johnson Controls Unitary Products 7
INSTALLATION
INSTALLATION SAFETY INFORMATION:
Read these instructions before continuing this appli-
ance installation. This is an outdoor combination heat-
ing and cooling unit. The installer must assure that
these instructions are made available to the consumer
and with instructions to retain them for future reference.
1. Refer to the furnace rating plate for the approved
type of gas for this furnace.
2. Install this furnace only in a location and position
as specified on Page 8 of these instructions.
3. Never test for gas leaks with an open flame. Use
commercially available soap solution made specifi-
cally for the detection of leaks when checking all
connections.
4. Always install furnace to operate within the fur-
nace's intended temperature-rise range with the
duct system and within the allowable external static
pressure range, as specified on the unit name/rat-
ing plate.
5. This equipment is not to be used for temporary
heating or cooling of buildings or structures under
construction.
LIMITATIONS
These units must be installed in accordance with the
following national and local safety codes:
In U.S.A.:
• National Electrical Code ANSI/NFPA No. 70.
• National Fuel Gas Code Z223.1.
• Gas-Fired Central Furnace Standard ANSI
Z21.47a.
• Local gas utility requirements.
In Canada:
• Current Canadian Electrical Code C22.1.
• Current Gas Installation Codes CSA-B149.1.
• Local plumbing and waste water codes.
• Other applicable local codes.
Refer to the Unit Application Data table and to the Gas
Heat Application Data table.
After installation, the unit must be adjusted to obtain a
temperature rise within the range specified on the unit
rating plate.
If components are to be added to a unit to meet local
codes, they are to be installed at the dealer's and/or
the customer's expense.
Size of unit for proposed installation should be based
on heat loss/heat gain calculation made according to
the methods of the Air Conditioning Contractors of
America (ACCA).
This furnace is not to be used for temporary heating of
buildings or structures under construction.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly
could result In serious injury, death or property
damage.
Never test for gas leaks with an open flame. A
Fire or explosion may result causing property
damage, personal injury or loss of life.
Use a commercially available soap solution
made specifically for the detection of leaks.
The Simplicity® control board used in this
product will effectively operate the cooling
system down to 0°F when this product is applied
in a comfort cooling application for people. An
economizer is typically included in this type of
application. When applying this product for
process cooling applications (computer rooms,
switchgear, etc.), please reference applications
bulletin AE-011-07 or call the applications
department for Unitary Products @ 1-877-UPG-
SERV for guidance. Additional accessories may
be needed for stable operation at temperatures
below 30°F.

335226-BIM-B-1008
8Johnson Controls Unitary Products
LOCATION
Use the following guidelines to select a suitable loca-
tion for these units.
1. Unit is designed for outdoor installation only.
2. Condenser coils must have an unlimited supply of
air.
3. Where a choice of location is possible, position the
unit on either north or east side of building.
4. For ground level installation, use a level concrete
slab with a minimum thickness of 4 inches. The
length and width should be at least 6 inches
greater than the unit base rails. Do not tie slab to
the building foundation.
5. Roof structures must be able to support the weight
of the unit and its options and/or accessories. Unit
must be installed on a solid level roof curb or
appropriate angle iron frame.
6. Maintain level tolerance to 1/2 inch maximum
across the entire length or width of the unit.
If a unit is to be installed on a roof curb or special frame
other than a UP roof curb, gasketing must be applied to
all surfaces that come in contact with the unit under-
side.
RIGGING AND HANDLING
Exercise care when moving the unit. Do not remove
any packaging until the unit is near the place of installa-
tion. Rig the unit by attaching chain or cable slings to
the round lifting holes provided in the base rails.
Spreaders, whose length exceeds the largest dimen-
sion across the unit, MUST BE USED. Refer to
Figure 1.
Units may also be moved or lifted with a forklift, from
the side only, providing that an accessory skid is used.
LENGTH OF FORKS MUST BE A MINIMUM OF 90".
Refer to the Physical Data Table 7 for unit weights and
to Figure 2 for approximate center of gravity.
TABLE 1: UNIT APPLICATION DATA
UNIT MODEL NUMBER DK-15 DK-20 DK-25
Voltage Variation,
Min. / Max.1
1. Utilization range “A” in accordance with ARI Standard
110.
208/230-3-60 187/253
460-3-60 414/506
575-3-60 518/630
Supply Air CFM, Min. / Max. 4,500/
7,500
6,000/
9,400
7,500/
11,500
Wet Bulb Temperature (ºF) of Air on
Evaporator Coil, Min. / Max. 57/72
Dry Bulb Temperature (ºF) of Air on
Condenser Coil, Min. / Max. 0/125
Excessive exposure of this furnace to contami-
nated combustion air may result in equipment
damage or personal injury. Typical contami-
nates include: permanent wave solutions, chlo-
rinated waxes and cleaners, chlorine based
swimming pool chemicals, water softening
chemicals, carbon tetrachloride, Halogen type
refrigerants, cleaning solvents (e.g. perchloro-
ethylene), printing inks, paint removers, var-
nishes, hydrochloric acid, cements and glues,
antistatic fabric softeners for clothes dryers,
masonry acid washing materials.
Before lifting a unit, make sure that all panels
are in place and that its weight is distributed
equally on all cables so it will lift evenly.
FIGURE 1 - TYPICAL RIGGING
FIGURE 2 - CENTER OF GRAVITY
47.5" (15, 20, 25 TON)

335226-BIM-B-1008
Johnson Controls Unitary Products 9
CLEARANCES
All units require certain clearances for proper operation
and service. Installer must make provisions for ade-
quate combustion and ventilation air in accordance
with Section 5.3, Air for Combustion and Ventilation of
the National Fuel Gas Code, ANSI Z223.1 (in U.S.A.)
or Sections 7.2, 7.3 or 7.4 of Gas Installation Codes
CSA-B149.1 (in Canada) and/or applicable provisions
of the local building codes. Refer to Figures 12, 13 and
14 for the dimensions and clearances required for com-
bustible construction, servicing, and proper unit opera-
tion.
DUCTWORK
Ductwork should be designed and sized according to
the methods in Manual Q of the Air Conditioning Con-
tractors of America (ACCA).
A closed return duct system shall be used. This shall
not preclude use of economizers or outdoor fresh air
intake. The supply and return air duct connections at
the unit should be made with flexible joints to minimize
noise.
The supply and return air duct systems should be
designed for the CFM and static requirements of the
job. They should NOT be sized to match the dimen-
sions of the duct connections on the unit.
Refer to Figures 12 and 13 for information concerning
side and bottom supply and return air duct opening
dimensions.
NOTE: It is recommended that, in Canada, the outlet
duct be provided with a removable access
panel. It is recommended that this opening be
accessible when the unit is installed in service,
and of a size such that smoke or reflected light
may be observed inside the casing to indicate
the presence of leaks in the heat exchanger.
The cover should be attached in a manner
adequate to prevent leakage.
FIXED OUTDOOR AIR INTAKE DAMPER
This damper is shipped inside the return air compart-
ment. It is completely assembled and ready for installa-
tion. A damper baffle inside of the hood is adjustable to
provide variable amounts of outdoor air intake on units
that are not provided with an economizer or a motor-
ized damper option. Refer to the Fixed Outdoor
Damper Figure 3.
Gasketing and mounting screws are provided in a parts
bag attached to the hood assembly. Apply gasketing to
the three flange surfaces on the hood prior to installing
the hood. Extend gasketing 1/4 inch beyond the top
and bottom of the two side flanges to insure adequate
sealing.
Adjusting the damper to the desired air flow may be
done before mounting the hood into position or after
installation by removing the front hood panel or the
screen on the bottom of the hood. Damper baffle in
position 1 will allow approximately 10% outdoor air
flow, position 2 approximately 15% and, to allow
approximately 25%, remove the damper baffle.
On units with bottom return air application install the
damper assembly over the opening in the side return
air access panel. Remove and discard the opening
cover and the covering over the hood mounting holes
(used for shipping) before installing. Secure with the
screws provided.
On units with side return air applications, install the
damper assembly on the return air ductwork as close
to the unit as possible. Cut an opening 16 inches high
by 18 inches wide in the ductwork to accommodate the
damper. Using the holes in the hood flanges as a tem-
plate, drill 9/64 inch dia. (#26 drill) holes into the duct-
work and secure with the screws provided.
Do not permit overhanging structures or shrubs
to obstruct outdoor air discharge outlet, com-
bustion air inlet or vent outlets.
When fastening ductwork to side duct flanges
on unit, insert screws through duct flanges
only. DO NOT insert screws through casing.
Outdoor ductwork must be insulated and
waterproofed.

335226-BIM-B-1008
10 Johnson Controls Unitary Products
CONDENSATE DRAIN
Plumbing must conform to local codes. Use a sealing
compound on male pipe threads. Install a condensate
drain line from the one-inch NPT female connection on
the unit to an open drain.
NOTE: The condensate drain operates in a negative
pressure in the cabinet. The condensate drain
line MUST be trapped to provide proper drain-
age. See Figure 4.
COMPRESSORS
Units are shipped with compressor mountings factory-
adjusted and ready for operation.
FILTERS
Two-inch filters are supplied with each unit, but units
can be converted easily to four-inch filters. Filters must
always be installed ahead of the evaporator coil and
must be kept clean or replaced with same size and
type. Dirty filters will reduce the capacity of the unit and
will result in frosted coils or safety shutdown. Minimum
filter area and required sizes are shown in Physical
Data Table 7.
SERVICE ACCESS
The following removable panels provide access to all
serviceable components:
• Compressor compartment
• Electric Heat compartment
• Gas Heat compartment (Two panels)
• Side Supply & Return Air compartments
(Two panels)
• Blower compartment (Three panels)
• Main control box
• Filter compartment
• Outdoor Air compartment (Two panels)
Refer to Figures 12 and 13 for location of these access
panels.
If outdoor air intake will not be required on
units with bottom return air applications, the
damper assembly should still be mounted on
the side return air access panel, per the
instructions above, to insure moisture is not
drawn into the unit during operation. The cov-
ering over the mounting holes only need be
removed. Do not remove the opening cover.
FIGURE 3 - FIXED OUTDOOR AIR DAMPER
FIGURE 4 - RECOMMENDED DRAIN PIPING
Do not loosen compressor mounting bolts.
Make sure that all screws and panel latches
are replaced and properly positioned on the
unit to maintain an airtight seal.

335226-BIM-B-1008
Johnson Controls Unitary Products 11
FIGURE 5 - TYPICAL FIELD WIRING
THERMOSTAT
1
TERMINALS
( RCB )
REHEAT
CONTROL BOARD
RC
RH
Y1
Y2
W1
W2
G
C
X1
X3
X4
A1
A2
T
T
R
Y1
Y2
W1
W2
G
C
OCC
HUM
1
2
3
4
HUM
TERMINAL BLOCK
RH
3
2
1
Electronic programmable Thermostat 2ET0770010024
( includes subbase).
2
Terminals A1 and A2 provide a relay output to close the
outdoor economizer dampers when the thermostat
switches to the set-back position.
3
TO REMOTE SENSOR
2ET04701324 IF USED
DEHUMIDISTAT
Dehumidistat closes on rise in humidity.
RC
RH
Y1
Y2
G
W1
W2
CC
W2
W1
G
Y2
Y1
R
OCC
( RCB )
REHEAT
CONTROL
BOARD
HUM
TERMINAL
BLOCK
RH
1
1
2
3
4
1
DEHUMIDISTAT
Dehumidistat closes on rise in humidity.
TYPICAL
THERMOSTAT
TERMINAL BLOCK TB1
GROUND
LUG
THREE
PHASE
POWER
SUPPL
Y
FACTORY OR FIELD
SUPPLIED DISCONNECT
208/230-3-60 and 380/415-3-50 units control
transformers are factory wired for 230v and 415v
power supply respectively. Change tap on
transformer for 208-3-60 or 380-3-50 operation.
See unit wiring diagram.

335226-BIM-B-1008
12 Johnson Controls Unitary Products
THERMOSTAT
The room thermostat should be located on an inside
wall approximately 56 inches above the floor where it
will not be subject to drafts, sun exposure or heat from
electrical fixtures or appliances. Follow the manufac-
turer's instructions enclosed with the thermostat for
general installation procedure. A minimum of seven
color-coded insulated wires (#18 AWG) should be used
to connect the thermostat to the unit.
SPACE SENSOR
The space sensor, if used, should be located on an
inside wall approximately 56 inches above the floor
where it will not be subject to drafts, sun exposure or
heat from electrical fixtures or appliances. Follow man-
ufacturer's instructions enclosed with sensor for gen-
eral installation procedure.
POWER AND CONTROL WIRING
Field wiring to the unit must conform to provisions of
the National Electrical Code, ANSI / NFPA No. 70 (in
U.S.A.), current Canadian Electrical Code C22.1 (in
Canada) and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC
(as specified above) and/or local codes. Voltage toler-
ances, which must be maintained at the compressor
terminals, during starting and running conditions, are
indicated on the unit Rating Plate and the Unit Applica-
tion Data table.
The internal wiring harness furnished with this unit is
an integral part of a CSA design certified unit. Field
alteration to comply with electrical codes should not be
required.
A fused disconnect switch should be field provided for
the unit. The switch must be separate from all other cir-
cuits. Wire entry at knockout openings require conduit
fittings to comply with NEC (in U.S.A.), CEC (in Can-
ada) and/or local codes. If any of the wire supplied with
the unit must be replaced, replacement wire must be of
the type shown on the wiring diagram and the same
minimum gauge as the replaced wire.
Use copper conductors properly sized to carry the load.
Each unit must be wired with a separate branch circuit
fed directly from the meter panel and properly fused.
Refer to the Typical Field Wiring Figure 5 and to the
appropriate unit wiring diagram for control circuit and
power wiring information.
OPTIONAL ELECTRIC HEAT
The factory-installed heaters are wired for single point
power supply. Power supply need only be brought into
the single point terminal block and thermostat wiring to
the low voltage terminal strip located in the upper por-
tion of the unit control box.
These CSA approved heaters are located within the
central compartment of the unit with the heater ele-
ments extending into the supply air chamber. Refer to
Figure 12 for access panel location.
Fuses are supplied, where required, by the factory.
Some KW sizes require fuses and others do not. Refer
to Table 3 for minimum CFM limitations and to Tables 9
thru 14 for electrical data.
208/230-3-60 and 380/415-3-50 units control
transformers are factory wired for 230v and 415v
power supply respectively. Change tap on
transformer for 208-3-60 or 380-3-50 operation.
See unit wiring diagram.
When connecting electrical power and control
wiring to the unit, waterproof type connectors
MUST BE USED so that water or moisture
cannot be drawn into the unit during normal
operation. The above waterproofing conditions
will also apply when installing a field-supplied
disconnect switch.
TABLE 2: CONTROL WIRE SIZES
Wire Size Maximum Length1
1. From the unit to the thermostat and back to the unit.
18 AWG 150 Feet

335226-BIM-B-1008
Johnson Controls Unitary Products 13
OPTIONAL GAS HEAT
These gas-fired heaters have aluminized-steel or
optional stainless steel, tubular heat exchangers with
spark ignition with proven pilot.
All gas heaters are shipped from the factory equipped
for natural gas use, but can be field converted to L.P./
Propane with Kit Model # 1NP0418. See Gas Heat
Application Data Table.
GAS PIPING
Proper sizing of gas piping depends on the cubic feet
per hour of gas flow required, specific gravity of the gas
and the length of run. "National Fuel Gas Code" Z223.1
(in U.S.A.) or the current Gas Installation Codes CSA-
B149.1 (in Canada) should be followed in all cases
unless superseded by local codes or gas utility require-
ments. Refer to the Pipe Sizing Table 5.
The heating value of the gas may differ with locality.
The value should be checked with the local gas utility.
NOTE: There may be a local gas utility requirement
specifying a minimum diameter for gas piping.
All units require a one-inch pipe connection at
the entrance fitting. Maximum capacity of pipe in cubic feet of gas per hour. (Based upon
a pressure drop of 0.3 inch water column and 0.6 specific gravity
gas).
TABLE 3: ELECTRIC HEAT APPLICATION DATA
NOMINAL
HEATER
SIZE (KW)
VOLTAGE
3-PHASE,
60 HZ
MINIMUM CFM UNIT SIZE
15 TON 20 TON 25 TON
18 208/230,460,575 4500
6000 7500
36 208/230,460,575 4500
54
208/230 5000
460,575 4500
72
208/230 5000
460,575 4500
TABLE 4: GAS HEAT APPLICATION DATA
0 To
2,000 Feet
Above
Sea Level
2,000 To
4,500 Feet
Above
Sea Level
Output Capacity (Mbh)
Available
on Models
Natural
Gas
Rate
(Ft./Hr.)
Tem p.
Rise ºF
At
Full Input1
0 To
2,000 Feet
Above
Sea Level
2,000 To
4,500 Feet
Above
Sea Level
Max. Min. Max. Min. Max. Max. Min. Max.
300 150 270 135 240 213 15, 20 & 25 Ton 279 20 50
400 200 360 180 320 281 15, 20 & 25 Ton 372 30 60
1. On VAV units, individual VAV boxes must be full open in heating mode to insure airflow falls within
temperature rise range.
TABLE 5: PIPE SIZING
Length in Feet Nominal Iron Pipe Size
1 in. 1-1/4 in.
10 520 1,050
20 350 730
30 285 590
40 245 500
50 215 440
60 195 400
70 180 370
80 170 350
90 160 320
100 150 305

335226-BIM-B-1008
14 Johnson Controls Unitary Products
GAS CONNECTION
The gas supply line can be routed through the knock-
outs located on the front of the unit or through the
opening provided in the unit's base. Refer to Figure 12
to locate these access openings. Typical supply piping
arrangements are shown in the figures on page 15. All
shaded items are field-supplied.
If gas supply line is routed through the unit's base
ensure that the burner assembly can be removed for
maintenance without disturbing the supply line. The
supply piping and fittings must lie below the bottom gas
manifold to avoid interference with the burner assem-
bly.
Two grommets are shipped in the blower compartment
(in parts bag taped to the blower housing) of every unit
with gas heat and should be used in the knockouts
when the gas piping penetrates the front of the unit.
After the gas supply piping has been installed, the bot-
tom opening in the unit should be sealed to prevent
water from leaking into the building.
Gas piping recommendations:
1. A drip leg and a ground joint union must be
installed in the gas piping.
2. When required by local codes, a manual shut-off
valve may have to be installed outside of the unit.
3. Use wrought iron or steel pipe for all gas lines. Pipe
compound should be applied sparingly to male
threads only.
4. All piping should be cleaned of dirt and scale by
hammering on the outside of the pipe and blowing
out the loose dirt and scale. Before initial start-up,
be sure that all of the gas lines external to the unit
have been purged of air.
5. The gas supply should be a separate line and
installed in accordance with all safety codes as
prescribed under "Limitations". After the gas con-
nections have been completed, open the main
shut-off valve admitting normal gas pressure to the
mains. Check all joints for leaks with soap solution
or other material suitable for the purpose. NEVER
USE A FLAME.
6. The furnace and its individual manual shut-off
valve must be disconnected from the gas supply
piping system during any pressure testing of that
system at test pressures in excess of 1/2 psig
(3.48kPa).
The furnace must be isolated from the gas supply
piping system by closing its individual manual shut-
off valve during any pressure testing of the gas
supply piping system at test pressures equal to or
less than 1/2 psig (3.48kPa).
7. A 1/8 inch NPT plugged tap, accessible for test
gage connection, must be installed immediately
upstream of the gas supply connection to the fur-
nace.
Natural gas may contain some propane. Pro-
pane, being an excellent solvent, will quickly
dissolve white lead or most standard commer-
cial compounds. Therefore, a special pipe
compound must be applied when wrought iron
or steel pipe is used. Shellac base compounds
such as Gaskolac or Stalastic, and compounds
such as Rectorseal #5, Clyde's or John Crane
may be used.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly
could result In serious injury, death or property
damage.
Never test for gas leaks with an open flame. A
Fire or explosion may result causing property
damage, personal injury or loss of life.
Use a commercially available soap solution
made specifically for the detection of leaks.

335226-BIM-B-1008
Johnson Controls Unitary Products 15
L.P. UNITS, TANKS AND PIPING
All gas heat units are shipped from the factory
equipped for natural gas use only. The unit may be
converted in the field for use with L.P./propane gas
with accessory kit model number 1NP0418.
All L.P./propane gas equipment must conform to the
safety standards of the National Fire Protection Associ-
ation.
For satisfactory operation, L.P./propane gas pressure
must be 10.0 I.W.C. at the unit manifold under full load.
Maintaining proper gas pressure depends on three
main factors:
1. The vaporization rate depends on (a) the tempera-
ture of the liquid and (b) the "wetted surface" area
of the container or containers.
2. The proper pressure regulation. (Two-stage regula-
tion is recommended from the standpoint of both
cost and efficiency.)
3. The pressure drop in the lines between regulators
and between the second stage regulator and the
appliance. Pipe size required will depend on the
length of the pipe run and the total load of all appli-
ances.
Complete information regarding tank sizing for vapor-
ization, recommended regulator settings, and pipe siz-
ing is available from most regulator manufacturers and
L.P./propane gas suppliers.
L.P./propane gas is an excellent solvent and special
pipe compound must be used when assembling piping
for this gas as it will quickly dissolve white lead or most
standard commercial compounds. Shellac base com-
pounds such as Rectorseal #5 are satisfactory for this
type of gas.
Check all connections for leaks when piping is com-
pleted, using a soap solution. NEVER USE A FLAME.
VENT AND COMBUSTION AIR HOODS
Two vent hoods and a combustion air hood (with
screens) are shipped attached to the blower housing in
the blower compartment. For units with factory installed
VFD option, the hoods and accompanying hardware
are shipped inside the gas heat section. These hoods
must be installed to assure proper unit function. All
hoods must be fastened to the outside of the gas heat
access panel with the screws provided in the bag also
attached to the blower housing.
The screen for the combustion air intake hood is
secured to the inside of the access panel opening with
four fasteners and the screws used for mounting the
FIGURE 6 - EXTERNAL SUPPLY CONNECTION
EXTERNAL SHUT-OFF
FIGURE 7 - BOTTOM SUPPLY CONNECTION
EXTERNAL SHUT-OFF
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly
could result In serious injury, death or property
damage.
Never test for gas leaks with an open flame. A
Fire or explosion may result causing property
damage, personal injury or loss of life.
Use a commercially available soap solution
made specifically for the detection of leaks.

335226-BIM-B-1008
16 Johnson Controls Unitary Products
hood to the panel. The top flange of this hood slips in
under the top of the access panel opening when install-
ing. Refer to Vent and Combustion Air Hood Figure 8.
Each vent hood is installed by inserting the top flange
of the hood into the slotted opening in the access panel
and securing in place.
The products of combustion are discharged horizon-
tally through these two screened, hooded vent open-
ings on the upper gas heat access panel.
OPTIONAL ECONOMIZER/MOTORIZED DAMPER RAIN
HOOD
The instruction for the optional economizer/motorized
damper rain hood can be found in the kit. Use these
instructions when field assembling an economizer rain
hood onto a unit. The outdoor and return air dampers,
the damper actuator, the damper linkage, the outdoor
and return air divider baffles, and all the control sen-
sors are factory mounted as part of the "Factory
installed" economizer option.
OPTIONAL POWER EXHAUST/BAROMETRIC RELIEF
DAMPER RAIN HOOD
The instructions for the power exhaust/barometric relief
damper rain hood can be found in the kit. The exhaust
fan, all supporting brackets, angles, and the wiring are
factory installed as part of the power exhaust option.
OPTIONAL ECONOMIZER AND POWER EXHAUST
DAMPER SETPOINT ADJUSTMENTS AND INFORMATION
Remove the economizer access panel from the unit.
Loosen but do not remove the two panel latches.
Locate the economizer control module, where the fol-
lowing adjustments will be made.
Check that the damper blades move smoothly without
binding; carefully turn the Minimum Position Adjusting
screw (found on the damper control module) fully
clockwise and then set the thermostat indoor fan switch
to the on position and then off, or energize and de-
energize terminals "R" to "G".
MINIMUM POSITION ADJUSTMENT
With thermostat set to indoor fan on position, or termi-
nals "R" to "G" energized, turn the Minimum Position
Adjusting screw (located on the damper control mod-
ule) counterclockwise until the desired minimum
damper position has been attained.
ENTHALPY SETPOINT ADJUSTMENT
The enthalpy setpoint may now be set by selecting the
desired setpoint shown in the Enthalpy Setpoint Adjust-
ment Figure 9. Adjust as follows:
• For a single enthalpy operation carefully turn the
setpoint adjusting screw (found on the damper
control module) to the "A", "B", "C" or "D" setting
corresponding to the lettered curve of the Enthalpy
Setpoint Adjustment Figure 9.
• For a dual enthalpy operation, carefully turn the
setpoint adjusting screw fully clockwise past the
"D" setting.
FIGURE 8 - VENT AND COMBUSTION AIR HOOD
An adhesive backed label is provided over the
outside of the combustion air inlet opening to
prevent moisture from entering the unit, which
could cause damage to electrical components.
Allow this closure label to remain in place until
the combustion air hood is to be installed.
VENT AIR
OUTLET
HOODS
SLOTTED
OPENINGS IN
ACCESS PANE
L
COMBUSTION
A
IR INTAKE
HOOD GAS HEAT
ACCESS
PANELS
Extreme care must be excercised in turning all
setpoint, maximum, and minimum damper
positioning adjustment screws to prevent twist-
ing them off.

335226-BIM-B-1008
Johnson Controls Unitary Products 17
POWER EXHAUST DAMPER SETPOINT
With power exhaust option, each building pressuriza-
tion requirement will be different. The point at which the
power exhaust comes on is determined by the econo-
mizer damper position (Percent Open). The Exhaust
Air Adjustment Screw should be set at the Percent
Open of the economizer damper at which the power
exhaust is needed. It can be set from 0 to 100%
damper open.
INDOOR AIR QUALITY
Indoor Air quality (indoor sensor input): Terminal AQ
accepts a +2 to +10 Vdc signal with respect to the
(AQ1) terminal. When the signal is below it's setpoint,
the actuator is allowed to modulate normally in accor-
dance with the enthalpy and mixed air sensor inputs.
When the AQ signal exceeds it's setpoint setting and
there is no call for free cooling, the actuator is propor-
tionately modulated from the 2 to 10 Vdc signal, with 2
Vdc corresponding to full closed and 10 Vdc corre-
sponding to full open. When there is no call for free
cooling, the damper position is limited by the IAQ Max
damper position setting. When the signal exceeds it's
setpoint (Demand Control Ventilation Setpoint) setting
and there is a call for free cooling, the actuator modu-
lates from the minimum position to the full open posi-
tion based on the highest call from either the mixed air
sensor input or the AQ voltage input.
• Optional CO2Space Sensor Kit Part #
2AQ04700224
• Optional CO2Sensor Kit Part # 2AQ04700124
Replace the economizer access panel.
OPTIONAL BAS-READY ECONOMIZER POWER
EXHAUST DAMPER SET POINT ADJUSTMENT
Remove the economizer access panel from the unit.
Loosen, but do not remove the two panel latches.
Locate the economizer actuator, where the following
adjustment can be made.
With power exhaust option, each building pressuriza-
tion requirement will be different. The point at which the
power exhaust comes on is determined by the econo-
mizer's outdoor damper position. The actuator's auxil-
iary switch adjustment screw should be set at the
damper position at which the power exhaust is needed.
The adjustment screw can be set between 25 to 85
degrees open.
Replace the economizer access panel.
OPTIONAL VARIABLE AIR VOLUME (VAV)
A variable air volume (VAV) option using a variable fre-
quency drive (VFD) is available for applications requir-
ing a constant supply duct static pressure. A differential
pressure transducer is used to monitor supply duct
static pressure and return a speed reference signal to
the VFD to control the output of the indoor blower
motor.
DUCT STATIC PRESSURE TRANSDUCER
A 0-5" WC pressure transducer, located in the control
box compartment, is used to sense static (gauge) pres-
sure in the supply air duct and convert this pressure
measurement to a proportional 0-5 VDC electrical out-
put.
Pressure-transmitting plastic tubing (1/4" diameter)
must be field supplied and installed from the transducer
to both the ductwork and to the atmosphere. Connect
the tubing from the 'HIGH' pressure tap of the trans-
ducer to a static pressure tap (field supplied) in the
supply duct located at a point where constant pressure
is expected. To prevent an unstable signal due to air
turbulence, there should be no obstructions, turns or
VAV terminal boxes up- or down-stream of the sensing
tube location for at least a distance of 6-10 times the
duct diameter. Tubing must also be run between the
'LOW' pressure tap of the transducer and atmospheric
pressure (outside of the unit).
VAV CONTROL BOARD
A VAV control board, located in the top-left corner of
the control box, is used to convert the pressure trans-
ducer input signal into a speed reference signal that
the drive uses to control the speed of the blower motor.
This modulating speed reference signal is generated
using an internal algorithm which continuously calcu-
lates an output value.
Do not run plastic tubing in the supply or return
air ducts as air movement could cause errone-
ous pressure measurements. If the tubing pen-
etrates through the bottom of the unit be sure
openings are sealed to prevent air and water
leakage.

335226-BIM-B-1008
18 Johnson Controls Unitary Products
A brief description of the VAV board's I/O terminals that
are used follows:
Inputs:
•DUCT PRES - a 0-5 VDC analog input provided by
a factory-installed duct static pressure transducer
located in the unit's control box.
•SAT - analog input provided by a factory-installed
10k-ohm, type 3 thermistor located in the unit's
supply air compartment.
•RAT - analog input provided by a factory-installed
10k-ohm, type 3 thermistor located in the unit's
return air compartment.
•OAT - analog input provided by a factory-installed
10k-ohm, type 3 thermistor located in the outdoor
air compartment or mounted within the evaporator
base rail for units without the installed economizer
option.
•ST - analog input provided by field-installed space
temperature sensor.
•OH - a 0-10 VDC analog input provided by a field-
installed outdoor air relative humidity sensor for
single enthalpy economizer configuration.
•RH - a 0-10 VDC analog input provided by a field-
installed return air relative humidity sensor for dual
enthalpy economizer configuration (used with OH).
•IAQ - a 0-10 VDC analog input provided by a field-
installed carbon dioxide sensor which monitors
indoor air quality (CO2 concentration) and enables
call for Demand Ventilation mode for units installed
with economizer option.
•OAQ - a 0-10 VDC analog input provided by a
field-installed carbon dioxide sensor which moni-
tors outdoor air quality (CO2 concentration) and,
along with IAQ, enables call for Differential
Demand Ventilation mode for units installed with
economizer option.
•APS - a 24 VAC binary input provided by a field-
installed air proving switch which monitors the
pressure difference across the indoor blower.
•PUR - a 24 VAC binary input for building purge
calls from an external source.
•OCC - a 24 VAC binary input used to set the build-
ing occupancy status for the control.
•LIMIT 2 - a 24 VAC binary input which either con-
firms 2nd-stage gas heat operation or receives an
error signal from the variable frequency drive.
Outputs:
•FAN - a 2-10 VDC analog output signal sent to the
VFD to modulate the speed of the indoor blower
motor.
•ECON - a 2-10 VDC analog output signal sent to
the economizer actuator to modulate position of
the return air and outdoor air dampers (optional).
•EXH ~ - a 24 VAC binary output signal used to turn
on/off the power exhaust relay (optional).
•VAV BOX (gas/electric heat only) - a normally open
relay contact connected to a terminal block, used
to drive the building's VAV boxes to full-open during
heating operation.
Programmable set points:
The duct static set point is the pressure that the drive
will maintain when operating the unit in VAV mode. The
set-point is adjustable between 0" WC and 5" WC with
the default setting of 1.5" WC.
The duct static high-limit set point is the maximum
allowable duct pressure to prevent damage from over-
pressurization of the ductwork in the event of either a
drive or damper failure. The high-limit set-point is
adjustable between 0" WC and 5" WC with the factory
default setting of 4.5" WC. If the duct static pressure
reaches the high-limit set point, then the supply fan
motor will be shutdown.
NOTE: Either of the set points described above can be
changed through the unit control board (UCB)
with the use of a USB-to-RS485 converter,
personal computer or PDA and a down-loaded
copy of the Simplicity® software available at
the UPGnet Commercial Product Catalog web-
site.
The customer must be aware of the duct pres-
sure design limit, and what the duct pressure
sensor is reading when the peak pressure is
reached (ie the pressure transducer sensing
tube may not be located at the place of highest
pressure in the system).

335226-BIM-B-1008
Johnson Controls Unitary Products 19
FACTORY-INSTALLED VFD
The factory-installed VFD is mounted in the Blower
Access Compartment above the blower assembly. The
drive comes wired from the factory to include both 3-
phase power and control connections (run permit sig-
nal, speed reference signal & fault signal).
All required drive parameters are pre-programmed at
the factory, except in the case of 208-volt applications, in
which the parameter that defines motor nameplate volt-
age must be changed to a value of 208.00 and the
parameter that defines motor-rated current must be
changed to the appropriate value appearing on the
motor's nameplate. Refer to the enclosed drive material
or access the UPGnet Commercial Product Catalog
website for instructions on changing parameter settings.
For units also equipped with gas/electric heat, a termi-
nal block located in the unit's control box and con-
nected to the VAV board's "VAV BOX" terminal, must
be field wired to the building's VAV boxes to ensure
fully open dampers during heating operation.
MANUAL BYPASS
An optional, factory-installed manual bypass switch
available with factory-installed VFD can be found in the
Blower Motor Access compartment and has the follow-
ing three positions:
•DRIVE - routes power through the VFD for modu-
lating control of the indoor blower motor.
•LINE (or BYPASS) - routes power directly to the
motor which provides full-speed motor operation
and complete electrical isolation of the drive.
•TEST - routes power to the VFD but not to the
motor to allow for drive programming and/or diag-
nostics.
If a drive failure occurs, the unit does not automatically
switch to bypass mode. The LINE/DRIVE/TEST switch
must be manually switched to the LINE (BYPASS)
position. If there is a call for the fan, the indoor blower
motor will run at full-speed while in the bypass mode.
BAS-READY VFD
Factory-installed VFD is also available with 'BAS-
ready' models. Terminal blocks are provided in the con-
trol box (in place of the VAV control board) for field wir-
ing of a customer-installed BAS to receive 24 VAC
power and to connect to the following control signals:
• a duct static pressure transducer input signal (0-5
VDC)
• an economizer actuator input signal (2-10 VDC)
• an economizer actuator output signal (2-10 VDC)
• a VFD speed reference output signal (2-10 VDC)
The use of shielded cable is recommended for the
above control wiring connections.
NOTE: Factory-installed VFD is not available with fac-
tory-installed BAS options due to space limita-
tions in the control box.
A solid-state, lock-out relay (LR) and 100-μF, 50 VDC
capacitor must be field-supplied and installed to pro-
vide a means to transmit a potential fault signal back to
the BAS controller. The specific relay part number
required will depend upon the need for either AC-out-
put or DC-output. See price pages for further details.
Once the appropriate relay and capacitor are obtained,
install the capacitor across LR terminals '3' & '4' and
make the following wiring connections:
• LR '1' to BAS controller
• LR '2' to BAS controller
• LR '3' to UCB 'X'
• LR '4' to UCB 'C'
If the unit is operated with the manual bypass
switch in the LINE (BYPASS) position and
there are VAV boxes present in the duct sys-
tem, then boxes must be driven to the full-open
position using a customer-supplied power
source to prevent over-pressurizing and possi-
ble damage to the ductwork.
Before beginning any service, disconnect all
power to the drive. Be aware that high voltages
are present in the drive even after power has
been disconnected. Capacitors within the drive
must be allowed to discharge before beginning
service.

335226-BIM-B-1008
20 Johnson Controls Unitary Products
'VFD-READY' FOR CUSTOMER-INSTALLATION
Units configured as 'VFD-ready' provide provisions for
a customer-installed drive. The physical dimensions of
VFDs can vary greatly among manufacturers, horse-
power ratings and voltage requirements. Keep in mind
that drive manufacturers also require various minimum
clearances to allow for adequate internal cooling of the
drive during operation.
The unit comes with a mounting bracket installed in the
Blower Access compartment which may accommodate
other vendor's drives depending on their size. In order
to utilize the unit's mounting bracket, the maximum rec-
ommended drive dimensions are as follows:
For 5-hp motor applications ....................... 13" H x 6" W x 7" D
For 7.5 thru 15-hp motor applications........ 13" H x 8" W x 8" D
If the drive will not fit in the allotted space, then it will
need to be mounted elsewhere; either within the build-
ing on a perpendicular wall which is not subjected to
excessive temperature, vibration, humidity, dust, corro-
sive gas, explosive gas, etc., or within an appropriate
enclosure rated for outside installation to safeguard
against moisture, dust and excessive heat.
The power leads to the drive (L1, L2, L3) and from the
motor (T1, T2, T3) along with the respective ground
wires are supplied with the unit and need to be con-
nected after the drive is installed.
A terminal block located in the control box is provided
for field connection of the VFD speed reference signal
(2-10 VDC) and to the normally-open, run-permit auxil-
iary contact. The use of shielded cable is recom-
mended for the above control wiring connections.
For VFD-ready units also equipped with gas/electric
heat, a terminal block located in the unit's control box
and connected to the VAV board's "VAV BOX" termi-
nal, must be field wired to the building's VAV boxes to
ensure fully open dampers during heating operation.
OPTIONAL HOT GAS BYPASS (HGBP)
To allow for low cooling load operation, a direct-acting,
pressure-modulating bypass control valve installed on
the system #1 discharge line is used to divert high tem-
perature, high pressure refrigerant around the TXV in
order to maintain a desired minimum evaporator pres-
sure.
The opening pressure of the bypass valve is fully
adjustable between 0 and 80 psig with a factory-setting
of 60 psig. HGBP is standard on all units with VAV and
optional with CV units.
Do not connect AC power to the T1, T2, T3
drive terminals to prevent damage to the VFD.