Johnson Controls SERIES 40 Owner's manual

SERIES 40 ROOFTOP
25, 30 AND 40 TON
WITH IPU CONTROL
5276178-JIM-C-0118
LD14136
INSTALLATION, OPERATION & MAINTENANCE
PACKAGED ROOFTOP
AIR CONDITIONING UNITS
R-410A ONLY, GEN 5
Supersedes 5276178-JIM-B-0117

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5276178-JIM-C-0118
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, 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 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
operating/service personnel. It is expected that this
individual possesses 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 will have read
and understood this document and any referenced
materials. This individual will also be familiar with and
comply with all applicable 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 areas of potential hazard:
CAUTION identies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or seri-
ous injury.
External wiring, unless specied as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring is
allowed to be run through the micro panel. All wiring must be in accordance with Johnson
Controls published specications and must be performed ONLY by qualied Johnson Controls
personnel. Johnson Controls will not be responsible for damages/problems resulting from
improper connections to the controls or application of improper control signals. Failure to
follow this will void the manufacturer’s warranty and cause serious damage to property or
injury to persons.

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CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for
continuous product improvement, the information
contained in this document is subject to change without
notice. While Johnson Controls makes no commitment
to update or provide current information automatically
to the manual owner, that information, if applicable, can
be obtained by contacting the nearest Johnson Controls
Applied Systems oce.
It is the responsibility of operating/service personnel
to verify the applicability of these documents to the
equipment in question. If there is any question in
the mind of operating/service personnel as to the
applicability of these documents, then prior to working
on the equipment, they should verify with the owner
whether the equipment has been modied and if current
literature is available.

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Series 40 Model Number Nomenclature 25-40 Ton Single Package
1 = 1st Generation
V= JCI Brand R410A
S= JCI Under Floor R410A
A= Smart Equipment™ COM Card
B= Smart Equipment™ COM Card W/DISC & 110V OUTLET
C= Smart Equipment™ COM Card W/DISC
D = Fault Detection Device
E= Fault Detection Device, DISC & 110V OUTLET F = Fault Detection Device & DISC
A = Forward Curve Fan Class I w/1 Inch Deflection Spring
B = Forward Curve Fan Class I w/2 Inch Deflection Spring
C = Forward Curve Fan Class I w/Neoprene Isolators
D = Forward Curve Fan Class II w/1 Inch Deflection Spring
E = Forward Curve Fan Class II w/2 Inch Deflection Spring
F =Forward Curve Fan Class II w/Neoprene Isolators
G = Air Foil Fan w/1 Inch Deflection Spring H = Air Foil Fan w/2 Inch Deflection Spring
A= NONE B= BARO C= MODULATING DAMPERS D = NON-MOD. (ON/OFF)
E= VFD, MODULATING MOTOR
F = Power Exhaust VFD (Customer) G = 8,000 CFM ERV H = 13,000 CFM ERV
2 = 25 TON 3 = 30 TON 4 = 40 TON
SupplyFan
FORWARD CURVE FAN Class I Class I blower is limited to 15 HP in 25/30 Ton.
Class I blower is limited to 20 HP in 40 Ton.
FORWARD CURVE FAN Class II AIR FOIL FAN [Always Class II] Class II blowers are not HP limited.
Air foil fan only available on Cooling Only.
A= NONE B= SINGLE ENTHALPY, Low Leak seals type C= DUAL ENTHALPY, Low Leak seals type
D = DRY BULB TEMP, Low Leak seals type E= MANUAL DAMPER (Not w/PE), no seals type
A= NONE B= 5 HP HI-EFF (25 Ton Only) C= 7.5 HP HI-EFF D = 10 HP HI-EFF E= 15 HP HI-EFF (Except 25 T)
Blower MountIsolation
1 inch deflection spring
2 inch deflection spring
A= 2" Throwaway [Standard] B= 2" Pleated Filters [Merv 7] C= 6" Rigid 65% Efficient [Merv 11]
D = 6" Rigid 95% Efficient [Merv 14]
1 = 7.5 High Efficiency (25 Ton Only)
2 = 10 High Efficiency
3 = 15 High Efficiency
4 = 20 High Efficiency
5 = 25 High Efficiency (30 & 40 Ton Only)
A = Drain Pan - Powder Coat
B = Drain Pan - Stainless Steel
1 = Constant Volume
2 =
VAV (Factory Insta
lled VFD)
3 = VAV Bypass (Factory Installed VFD)
4 =
VAV (Customer Insta
lled VFD)
5 = IntelliSpeed (Factory Installed VFD)
6 = IntelliSpeed (Factory Installed VFD w/Bypass)
7 = IntelliSpeed (Customer Installed VFD)
A = 1, 2 B = 1, 4 C = 1, 5 D = 3, 2 E = 3, 4 F = 3, 5
1 - BOTTOM RETURN
2 - BOTTOM SUPPLY
3 - END RETURN 4 - REAR SUPPLY 5 - FRONT SUPPLY
A = Standard Condenser & Evaporator Coils
C = Standard Condenser & Copper Evaporator Coil
F = Copper Condenser & Standard Evaporator Coil
G = Copper Condenser & Copper Evaporator Coils
H = Standard Condenser & Technicoat Evaporator Coil
J = Technicoat Condenser & Standard Evaporator Coil
K = Technicoat Condenser & Evaporator Coils
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
7 = 380/415-3-50
(30
T/40 Ton Only)
FRONT SUPPLY - COOLING ONLY
HOT WATER, STEAM & ELECTRIC HEAT -
BOTTOM SUPPLY ONLY GAS HEAT - BOTTOM OR REAR SUPPLY ONLY
CABINET
ECONOMIZER
FILTERS
1 18
C 3
GAS HEAT
3 = 267 MBH 5 = 533 MBH 8 = 800 MBH N =
NATURAL GAS
, STAGED
S=
NATURAL GAS
, STAGED
with
SS HEAT EXCHANGER
D =
NATURAL GAS
, MODULATING HEAT
T=
NATURAL GAS
, MODULATING HEAT
with
SS HEAT EXCHANGER
E= ELECTRIC HEAT C= COOLING ONLY W1 = HOT WATERSINGLE COIL
W2 = HOT WATER TWO COIL
X1 = STEAM SINGLE COIL
2 6A 7B 8A 91 10 A 11 1 12
PACKAGE
A 13 A 14 A 15 A16 A 17
V 12 28 41 5
BASIC UNIT
VOLTAGE
AIR VOLUME
HEAT SOURCE
COILS
CONFIGURATION
ELECTRIC HEAT
4 = 40kW 8 = 80kW 1 = 108 kW
ID MOTOR
EXHAUST
EXHAUST MOTOR
CONTROL
GEN
ID BLOWER
REFRIGERATION
1 = Standard Refrigeration
2 = Head Pressure Control (Low Ambient)
3 = Hot Gas Bypass 4 = Head Pressure Control & Hot Gas Bypass
NOMENCLATURE

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TABLE OF CONTENTS
SECTION 1 – INTRODUCTION.......................................................................................................17
ECOLOGICAL AND ECONOMICAL DESIGN.............................................................................17
Cooling and Heating.............................................................................................................17
Indoor Air Quality (IAQ) ........................................................................................................17
High-E󰀩ciency Motors.........................................................................................................17
Condensing Section.............................................................................................................17
Heating Section.....................................................................................................................18
AIR MANAGEMENT ....................................................................................................................18
CONTROLS .................................................................................................................................19
Rooftop Controller ................................................................................................................19
BACnet...................................................................................................................................19
GENERAL ....................................................................................................................................19
SAFETY CONSIDERATIONS ......................................................................................................19
Notes, Cautions and Warnings............................................................................................19
Gas Fired Models..................................................................................................................19
What to Do If You Smell Gas................................................................................................19
ALL MODELS ..............................................................................................................................20
INSPECTION................................................................................................................................20
SECTION 2 – INSTALLATION ........................................................................................................23
APPROVALS................................................................................................................................23
LIMITATIONS ...............................................................................................................................23
LOCATIONS AND CLEARANCES ..............................................................................................25
SERVICE ACCESS ......................................................................................................................26
RIGGING AND HANDLING .........................................................................................................26
CFM, STATIC PRESSURE, AND POWER – ALTITUDE AND TEMPERATURE CORRECTIONS39
ELECTRICAL DATA.....................................................................................................................57
FILTERS.......................................................................................................................................79
CONDENSATE DRAIN ................................................................................................................79
Condensate Drain Piping.....................................................................................................79
Condensate Drain Trap ........................................................................................................79
COMPRESSORS .........................................................................................................................79
AIR HOODS .................................................................................................................................79
Air Hoods for Fixed Outside Air ..........................................................................................79
Air Hoods for Economizer ...................................................................................................79
Air Hoods for Exhaust Air....................................................................................................80
FIELD WIRING.............................................................................................................................80

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TABLE OF CONTENTS (CONT'D)
Thermostat ............................................................................................................................80
Space Sensor........................................................................................................................80
CO2 Sensor ............................................................................................................................80
Occupied/Unoccupied Input................................................................................................80
Shutdown Input.....................................................................................................................80
Smoke Purge Input...............................................................................................................80
VAV Heat Relay Output.........................................................................................................81
RETURN AIR BYPASS DAMPER ...............................................................................................81
BACNET COMMUNICATION.......................................................................................................81
CTB3 Field Control Wiring (Inputs)...........................................................................................82
POWER AND CONTROL WIRING ........................................................................................83
General ..................................................................................................................................83
Power Wiring Detail..............................................................................................................83
TRANSDUCER PNEUMATIC TUBING........................................................................................84
Static Pressure Control Plastic Tubing .............................................................................84
Duct Static Transducer.........................................................................................................84
Building Pressure Transducer.............................................................................................84
Static Pressure Probe Installation ......................................................................................84
ROOF CURB INSTALLATION .....................................................................................................85
General Information..............................................................................................................85
DUCT SYSTEM............................................................................................................................85
Duct Connection Guidelines................................................................................................85
SOUND AND VIBRATION TRANSMISSION...............................................................................85
GAS HEATING.............................................................................................................................86
Gas Piping.............................................................................................................................86
Gas Connection ....................................................................................................................86
Vent and Combustion Air.....................................................................................................87
ELECTRIC HEAT .........................................................................................................................87
HOT WATER HEAT......................................................................................................................87
Piping Connections..............................................................................................................88
STEAM HEAT...............................................................................................................................89
Piping Connections..............................................................................................................90
SECTION 3 – START-UP .................................................................................................................91
CRANKCASE HEATERS.............................................................................................................91
CHECKING THE SYSTEM PRIOR TO INITIAL START (NO POWER) ......................................91
Unit Checks...........................................................................................................................91
UNIT CHECKS – POWER APPLIED ...........................................................................................92
Verifying Compressor Rotation...........................................................................................92

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TABLE OF CONTENTS (CONT'D)
Compressor Oil Level Check...............................................................................................92
Air Balance............................................................................................................................93
Checking Supply Air CFM....................................................................................................93
Supply Air Drive Adjustment ...............................................................................................93
DRIVE ADJUSTMENT TABLES ..................................................................................................95
INITIAL START-UP ......................................................................................................................98
Refrigerant Charge ...............................................................................................................98
Subcooling (R-410A) ............................................................................................................98
Superheat (R-410A) ..............................................................................................................98
Leak Checking ......................................................................................................................99
GAS FURNACE OPERATING INSTRUCTIONS .......................................................................100
To Light the Main Burners .................................................................................................100
To Shut Down......................................................................................................................100
POST-START CHECKLIST (GAS) ............................................................................................100
MANIFOLD GAS PRESSURE ADJUSTMENT..........................................................................100
Burner Instructions ............................................................................................................100
Adjustment of Temperature Rise ......................................................................................101
Checking Gas Input............................................................................................................101
ELECTRIC HEATING.................................................................................................................101
REFRIGERATION SYSTEM ......................................................................................................101
COMPRESSORS .......................................................................................................................102
MOTORS....................................................................................................................................102
Indoor Blower Motors.........................................................................................................102
Power Exhaust Fan Motors................................................................................................102
Condenser Fan Motors.......................................................................................................102
Draft Motor (Gas Furnace) .................................................................................................102
hot water and steam coils........................................................................................................102
HOT WATER AND STEAM COILS ............................................................................................103
SECTION 4 – MAINTENANCE......................................................................................................114
GENERAL ..................................................................................................................................114
PERIODIC MAINTENANCE – MONTHLY .................................................................................114
Filters...................................................................................................................................114
Linkages ..............................................................................................................................114
Compressors.......................................................................................................................114
Condenser Coils .................................................................................................................114
PERIODIC MAINTENANCE – 3 TO 6 MONTHS .......................................................................114
Motors..................................................................................................................................114

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TABLE OF CONTENTS (CONT'D)
Belt Tension ........................................................................................................................115
Belt Replacement................................................................................................................116
PERIODIC MAINTENANCE – YEARLY.....................................................................................116
Entire Unit Inspection.........................................................................................................116
Sheave Alignment...............................................................................................................116
Belts.....................................................................................................................................116
Supply and Exhaust Fan Motor.........................................................................................117
Outdoor Coil........................................................................................................................117
Gas Burner ..........................................................................................................................117
Forward Curved Fans.........................................................................................................118
SECTION 5 – SEQUENCE OF OPERATION...............................................................................126
UNIT TYPE.................................................................................................................................126
CURRENT OPER MODE ...........................................................................................................126
Constant Volume Mode .....................................................................................................126
Variable Air Volume Mode..................................................................................................128
FlexSys ................................................................................................................................129
ACTIVE SET POINT DETERMINATION....................................................................................129
Constant Volume ................................................................................................................129
Variable Air Volume ............................................................................................................130
FlexSys with Bypass Damper............................................................................................133
FlexSys without Bypass Damper ......................................................................................133
COMPRESSOR CONTROL.......................................................................................................133
COMPRESSOR OPERATION WITH ECONOMIZER................................................................134
No Compressors On When Economizer Becomes Active..............................................134
Compressor On When Economizer Becomes Active......................................................134
SUPPLY FAN OPERATION .......................................................................................................135
Constant Volume Operation ..............................................................................................135
Variable Air Volume (VAV) ..................................................................................................135
VAV Supply Fan Speed Control Set Point Determination ...............................................136
COMPRESSOR STAGING SEQUENCE ...................................................................................137
CONDENSER FAN OPERATION ..............................................................................................138
LOW AMBEINT CONDENSER FAN OPERATION....................................................................138
ECONOMIZER ...........................................................................................................................138
Dry Bulb...............................................................................................................................138
Single Enthalpy...................................................................................................................138
Dual Enthalpy......................................................................................................................139
Best Method ........................................................................................................................139
NonFlexSys Economizer....................................................................................................140
FlexSys Economizer...........................................................................................................140
COMPRESSOR OPERATION....................................................................................................140
Compressor Data................................................................................................................140

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TABLE OF CONTENTS (CONT'D)
Compressor Ready to Run ...............................................................................................140
Compressor Ready to Stop ...............................................................................................140
Compressor Safety Circuit ................................................................................................140
SUPPLY AIR TEMPERING ........................................................................................................141
Hot Water and Steam..........................................................................................................141
Staged Gas or Electric Heat...............................................................................................142
COMFORT VENTILATION.........................................................................................................142
SYSTEM PUMP DOWN CONTROL ..........................................................................................143
HIGH DISCHARGE PRESSURE UNLOADING ........................................................................143
LOW AMBIENT LOCK OUT ......................................................................................................143
LOW AMBIENT FAN CONTROL OPTION ................................................................................143
Operation and Pressure Control Range ...........................................................................144
Conguration (Jumpers and Potentiometers) .................................................................144
FLEXSYS BYPASS DAMPER OPERATION .............................................................................145
EVAPORATOR SUPERHEAT CALCULATION .........................................................................146
STAGED INPUT FAULT.............................................................................................................146
SYSTEM STABILITY CHECK....................................................................................................146
ELECTRIC HEAT .......................................................................................................................146
Programmed Data...............................................................................................................146
Heating Control O󰀨set .......................................................................................................146
Active SP .............................................................................................................................146
Heating Control...................................................................................................................146
STAGED GAS HEAT..................................................................................................................147
Programmed Data...............................................................................................................147
Heating Control O󰀨set .......................................................................................................147
Active SP .............................................................................................................................148
Heating Control...................................................................................................................148
Compressor Staged Gas Heat Mode of Operation When Economizer Status.............148
Staged Gas Heat Ignition Sequence .................................................................................149
MODULATING GAS HEAT ........................................................................................................150
HOT WATER/STEAM HEAT ......................................................................................................150
Programmed Data...............................................................................................................150
Active SP .............................................................................................................................150
Sequence of Operation ......................................................................................................150
Freeze Protection................................................................................................................151
Freeze Fault.........................................................................................................................151
MORNING WARM UP................................................................................................................151
Sequence of Operation ......................................................................................................152
ADAPTIVE MORNING WARM UP.............................................................................................152
Sequence of Operation ......................................................................................................152

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TABLE OF CONTENTS (CONT'D)
FLEXSYS UNDER FLOOR TEMPERATURE CONTROL.........................................................153
Programmed Data...............................................................................................................153
Under Floor Heating Sequence of Operation...................................................................153
Dew Point Reset Sequence of Operation .........................................................................154
EXHAUST FAN OPERATION ....................................................................................................154
On/O󰀨 Control Based On Damper Position .....................................................................154
On/O󰀨 Control Based On Building Pressure ...................................................................154
Modulating Damper with Fixed Speed Exhaust...............................................................154
Modulating Exhaust with A VFD........................................................................................155
RETURN FAN OPERATION ......................................................................................................155
VENTILATION SYSTEM ............................................................................................................155
Overview..............................................................................................................................155
2-Position Damper..............................................................................................................156
Demand Ventilation ............................................................................................................156
Fixed Minimum....................................................................................................................157
Air Measuring Stations.......................................................................................................157
SMOKE PURGE.........................................................................................................................157
SECTION 6 – USER INTERFACE CONTROL CENTER ............................................................160
USER INTERFACE CONTROL CENTER..................................................................................160
Data Entry Keys ..................................................................................................................160
Navigation Keys..................................................................................................................161
Menu Select Keys ...............................................................................................................161
SETPOINTS ...............................................................................................................................175
PROGRAM.................................................................................................................................175
OPTIONS ...................................................................................................................................175
DATE / TIME...............................................................................................................................175
SCHEDULE................................................................................................................................176
OPERATING HOURS / START COUNTER ...............................................................................177
PRINTER....................................................................................................................................178
Set Up ..................................................................................................................................178
Report Section ....................................................................................................................178
SERVICE MODE ........................................................................................................................179
HISTORY....................................................................................................................................189
PASSWORD...............................................................................................................................190
POWER UP BANNER................................................................................................................191
COMMUNICATION.....................................................................................................................192
Communication Ports ........................................................................................................192