Sunlife Enterprises Sunline Dm240 User Manual

INSTALLATION  
MANUAL - 50Hz  
SUNLINE™ 2000  
GAS/ELECTRIC SINGLE PACKAGE  
AIR CONDITIONERS  
MODELS: DM180, 240 & 300  
(Export)  
CONTENTS  
See the following page 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.  
ISO 9001  
Certified Quality  
Management System  
CAUTION: READ ALL SAFETY GUIDES BEFORE YOU  
BEGIN TO INSTALL YOUR UNIT.  
SAVE THIS MANUAL  
356214-XIM-A-0108  
356214-XIM-A-0108  
LIST OF FIGURES  
LIST OF TABLES  
Fig. #  
Pg. #  
Tbl. #  
Pg. #  
5
8
FIELD WIRING - DM ELECTRIC/ELECTRIC AND  
GAS/ ELECTRIC UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
6
7
EXTERNAL SUPPLY CONNECTION EXTERNAL  
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
DM ELECTRICAL DATA -WITHOUT POWERED  
CONVENIENCE OUTLET. . . . . . . . . . . . . . . . . . . . . . . . . 21  
BOTTOM SUPPLY CONNECTION EXTERNAL  
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
9
DM ELECTRICAL DATA -WITH POWERED  
CONVENIENCE OUTLET. . . . . . . . . . . . . . . . . . . . . . . . . 22  
12 SUPPLY AIR BLOWER PERFORMANCE (15 TON) -  
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
13 SUPPLY AIR BLOWER PERFORMANCE (20 TON) -  
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
15 UNIT CLEARANCES AND RAIN HOOD DIMENSIONS  
(15, 20 & 25 TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
14 SUPPLY AIR BLOWER PERFORMANCE (15 TON) -  
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
15 SUPPLY AIR BLOWER PERFORMANCE (20 TON) -  
18 PRESSURE DROP ACROSS A DRY INDOOR COIL VS  
SUPPLY AIR CFM FOR ALL UNIT TONNAGES . . . . . . . 35  
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
16 SUPPLY AIR BLOWER PERFORMANCE (25 TON) -  
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
Johnson Controls Unitary Products  
3
356214-XIM-A-0108  
GENERAL  
YORK Model DM units are either single package air  
conditions equipped with optional factory installed elec-  
tric heaters, or single package gas-fired central heating  
furnaces with cooling unit. Both are designed for out-  
door installation on a rooftop or slab.  
FIRE OR EXPLOSION HAZARD  
Failure to follow safety warnings exactly could  
result in serious injury, death, or property dam-  
age.  
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.  
- 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.  
The supplemental electric heaters have nickel-chrome  
elements and utilize single point power connection.  
• Leave the building immediately.  
• Immediately call your gas supplier from a neigh-  
bor’s phone. Follow the gas supplier’s instructions.  
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.  
• 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.  
SAFETY CONSIDERATIONS  
INSPECTION  
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.  
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.  
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.  
REFERENCE  
Additional information on the design, installation, oper-  
ation and service of this equipment is available in the  
following reference forms:  
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.  
Technical Guide - 262257  
General Installation - 175240  
4
Johnson Controls Unitary Products  
       
356214-XIM-A-0108  
RENEWAL PARTS  
®
Contact your local York Parts Distribution Center for  
authorized replacement parts.  
APPROVALS  
IMPROPER INSTALLATION MAY CREATE A  
CONDITION WHERE THE OPERATION OF  
THE PRODUCT COULD CAUSE PERSONAL  
INJURY OR PROPERTY DAMAGE.  
Design certified by CSA as follows:  
For use as a cooling unit only with or without  
optional electric heat.  
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.  
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.  
THIS PRODUCT MUST BE INSTALLED IN  
STRICT  
COMPLIANCE  
WITH  
THE  
ENCLOSED  
INSTALLATION  
INSTRUC-  
TIONS AND ANY APPLICABLE LOCAL,  
STATE, AND NATIONAL CODES INCLUD-  
ING, BUT NOT LIMITED TO, BUILDING,  
ELECTRICAL, AND MECHANICAL CODES.  
Johnson Controls Unitary Products  
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356214-XIM-A-0108  
PRODUCT NOMENCLATURE  
15-25 Ton Sunline & Magnum™ & MagnaDRY™ Model Number Nomenclature  
D M 180 N24 A 7 A AA 1 0 1 2 4 A  
Product Category  
Product Style  
A = Style A  
D = A/C, Single Pkg., R-22  
Product Identifier  
Configuration Options (not required for all units)  
These four digits will not be assigned until a quote is requested, or an order placed.  
M = 8.5-9.0 EER A/C  
SS Drain Pan  
CPC Controller, DFS, APS  
Johnson Controller, DFS, APS  
Nominal Cooling Capacity  
Honeywell Controller, DFS, APS  
Novar Controller, DFS, APS  
180 = 15 Ton  
240 = 20 Ton  
300 = 25 Ton  
Simplicity IntelliComfort Controller  
Simplicity IntelliComfort Controller w/ModLinc  
2" Pleated filters  
Heat Type and Nominal Heat Capacity  
4" Pleated filters  
BAS Ready Economizer (2-10 V.D.C. Actuator Without a Controller)  
Double Wall Construction  
C00 = Cooling Only. No field installed  
electric heat  
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned  
Gas Heat Options  
Product Generation  
N24 = 240 MBH Output Aluminized Steel  
N32 = 320 MBH Output Aluminized Steel  
S24 = 240 MBH Output Stainless Steel  
S32 = 320 MBH Output Stainless Steel  
1 = First Generation  
2 = Second Generation  
Electric Heat Options  
Additional Options  
Hinged Filter Door & Tool Free Access Cabinet  
E18 = 18 KW  
E36 = 36 KW  
E54 = 54 KW  
E72 = 72 KW  
Standard Cabinet  
AA = None  
BA = Hinged Filter Door & Tool Free Access Panels  
BB = Phase Monitor, Hinged Filter Door & Tool Free  
Access Panels  
AB = Phase Monitor  
AC = Coil Guard  
AD = Dirty Filter Switch  
BC = Coil Guard, Hinged Filter Door & Tool Free  
Access Panels  
Airflow  
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  
BD = Dirty Filter Switch, Hinged Filter Door &  
Tool Free Access Panels  
A = Std. Drive  
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  
B = Std. Drive/Single Input Econo.  
C = Std. Drive/Single Input Econo./Power Exhaust  
(Downflow Only)  
D = Std. Drive/Motorized Damper  
E = Std. Drive/Motorized Damper/Barometric Relief  
J = Std. Drive/Single Input Econo./Barometric Relief  
N = Hi Static Drive*  
BH = Phase Monitor, Coil Guard & Dirty Filter Switch,  
Hinged Filter Door & Tool Free Access Panels  
P = Hi Static Drive/Single Input Econo.  
Q = Hi Static Drive/Single Input Econo./Power Exhaust  
(Downflow Only)  
R = Hi Static Drive/Motorized Damper  
K = Hi Static Drive/Motorized Damper/Barometric Relief  
S = Hi Static Drive/Single Input Econo./Barometric Relief  
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be  
located in digits 15-18.  
Installation Options  
Voltage  
A = No Options Installed  
B = Option 1  
7 = 380/415-3-50  
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  
N = Options 2 & 3  
P = Options 2 & 4  
Q = Options 2, 3, & 4  
R = Options 3 & 4  
S = Option 5  
* Note: 50 Hz, DM180 -300 Models  
come standard with high  
static drive package.  
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  
Options  
1 = Disconnect  
2 = Non-Pwr'd Conv. Outlet  
3 = Smoke Detector S.A.  
4 = Smoke Detector R.A.  
5 = Pwr'd Conv. Outlet  
6
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
LIMITATIONS  
INSTALLATION  
These units must be installed in accordance with the  
following national and local safety codes:  
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.  
In U.S.A.:  
National Electrical Code ANSI/NFPA No. 70.  
National Fuel Gas Code Z223.1.  
1. Refer to the unit rating plate for the approved type  
of gas for this unit.  
Gas-Fired Central Furnace Standard ANSI  
Z21.47a.  
2. Install this unit only in a location and position as  
specified on Page 10 of these instructions.  
Local gas utility requirements.  
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, as specified on Pages 8, 16, 17 and  
40 of these instructions.  
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.  
4. Always install unit to operate within the furnace's  
intended temperature-rise range with the duct sys-  
tem and within the allowable external static pres-  
sure range, as specified on the unit name/rating  
plate, specified on Page 42 of these instructions.  
Refer to the Unit Application Data table and to the Gas  
Heat Application Data table.  
5. This equipment is not to be used for temporary  
heating of buildings or structures under construc-  
tion.  
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.  
FIRE OR EXPLOSION HAZARD  
FAILURE TO FOLLOW THE SAFETY WARN-  
ING EXACTLY COULD RESULT IN SERIOUS  
INJURY, DEATH OR PROPERTY DAMAGE.  
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).  
NEVER TEST FOR GAS LEAKS WITH AN  
OPEN FLAME. USE A COMMERICALLY  
AVAILABLE SOAP SOLUTION MADE SPE-  
CIFICALLY FOR THE DETECTION OF  
LEAKS TO CHECK ALL CONNECTIONS. A  
FIRE OR EXPLOSION MAY RESULT CAUS-  
ING PROPERTY DAMAGE, PERSONAL  
INJURY OR LOSS OF LIFE.  
This equipment is not to be used for temporary heating  
of buildings or structures under construction.  
International:  
Local Government/Agency Regulations  
Johnson Controls Unitary Products  
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TABLE 1: UNIT APPLICATION DATA  
UNIT MODEL NUMBER  
DM180  
DM240  
342/456  
DM300  
Voltage Variation,  
380/415-3-50  
1
Min. / Max.  
Supply Air CFM, Min. / Max.  
4,500 / 7,200  
6,000 / 9,400  
57 / 72  
7,500 / 12,500  
Wet Bulb Temperature (ºF) of Air on  
Evaporator Coil, Min. / Max.  
Dry Bulb Temperature (ºF) of Air on  
Condenser Coil, Min. / Max.  
0 / 125  
1.  
Utilization range “A” in accordance with ARI Standard 110.  
LOCATION  
6. Maintain level tolerance to 1/2 inch maximum  
across the entire length or width of the unit.  
Use the following guidelines to select a suitable loca-  
tion for these units.  
1. Unit is designed for outdoor installation only.  
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.  
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.  
If a unit is to be installed on a roof curb or special frame  
other than a YORK roof curb, gasketing must be  
applied to all surfaces that come in contact with the unit  
8
Johnson Controls Unitary Products  
   
356214-XIM-A-0108  
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  
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 the Figures 2 or 12 for approximate center of gravity.  
FIGURE 2 - CENTER OF GRAVITY  
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.  
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 (refer  
to Vent and Combustion Hood Figure 8).  
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 Dimensions and  
Clearances Figure 13 for the clearances required for  
combustible construction, servicing, and proper unit  
operation.  
FIGURE 1 - TYPICAL RIGGING  
Johnson Controls Unitary Products  
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356214-XIM-A-0108  
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.  
Do not permit overhanging structures or shrubs  
to obstruct outdoor air discharge outlet, com-  
bustion air inlet or vent outlets.  
DUCTWORK  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
Refer to Dimensions and Clearances Figure 13 for  
information concerning side and bottom supply and  
return air duct openings.  
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.  
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.  
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Johnson Controls Unitary Products  
   
356214-XIM-A-0108  
COMPRESSORS  
Units are shipped with compressor mountings factory-  
adjusted and ready for operation.  
Do not loosen compressor mounting bolts.  
FILTERS  
Two-inch or four-inch filters can be supplied with each  
unit. 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 shut-  
down. Minimum filter area and required sizes are  
shown in Physical Data Table 7.  
FIGURE 3 - FIXED OUTDOOR AIR DAMPER  
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.  
SERVICE ACCESS  
The following removable panels provide access to all  
serviceable components:  
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.  
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 the Dimensions and Clearances Figure 13 for  
location of these access panels.  
FIGURE 4 - RECOMMENDED DRAIN PIPING  
Make sure that all screws and panel latches  
are replaced and properly positioned on the  
unit to maintain an airtight seal.  
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356214-XIM-A-0108  
THERMOSTAT  
TERMINALS  
CONTROL  
TERMINAL  
BLOCK  
W1  
W1  
W2  
Y1  
G
1
W2  
Y1  
2
Y2  
OCC  
P
P1  
Y2  
X
G
R
C
Smoke  
Detector  
R
SD  
C
Jumper 3  
R
SD  
SD  
C
4
RC  
5
OCC  
24 VAC  
Class 2  
6
X
TERMINALS ON  
A LIMITED  
NUMBER OF  
THERMOSTATS  
1
2
3
4
5
6
Second stage heating not required on single stage heating units.  
Second stage cooling not required on single stage cooling units.  
Jumper is required if there is no Smoke Detector circuit.  
Jumper is required for any combination of R, RC, or RH.  
OCC is an output from the thermostat to indicate the Occupied condition.  
X is an input to the thermostat to display Error Status conditions.  
FIGURE 5 - FIELD WIRING - DM ELECTRIC/ELECTRIC AND GAS/ ELECTRIC UNITS  
12  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
THERMOSTAT  
with a separate branch circuit fed directly from the  
meter panel and properly fused.  
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 manufacturer's  
instructions enclosed with thermostat for general instal-  
lation procedure. A minimum of seven color-coded  
insulated wires (#18 AWG) should be used to connect  
thermostat to unit.  
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.  
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.  
Refer to the Typical Field Wiring Figure 5 and to the  
appropriate unit wiring diagram for control circuit and  
power wiring information.  
TABLE 2: CONTROL WIRE SIZES  
1
Wire Size  
18 AWG  
Maximum Length  
150 Feet  
1.  
From the unit to the thermostat and back to the unit.  
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.  
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.  
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. Refer to the Dimensions and  
Clearances Figure 13 for installation location. If any of  
the wire supplied with the unit must be replaced,  
replacement wire must be of the type shown on the wir-  
ing diagram and the same minimum gauge as the  
replaced wire.  
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 13 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 8  
and 9 for electrical data.  
Electrical line must be sized properly to carry the load.  
Use copper conductors only. Each unit must be wired  
TABLE 3: ELECTRIC HEAT APPLICATION DATA  
NOMINAL  
HEATER SIZE  
(KW)  
VOLTAGE  
3-PHASE,  
50 HZ  
MINIMUM CFM UNIT SIZE  
15 TON  
20 TON  
25 TON  
18  
36  
54  
72  
380/415  
380/415  
380/415  
380/415  
4500  
4500  
5000  
5000  
6000  
6000  
6000  
6000  
7500  
7500  
7500  
7500  
Johnson Controls Unitary Products  
13  
         
356214-XIM-A-0108  
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.  
TABLE 4: GAS HEAT APPLICATION DATA  
Output Capacity (Mbh)  
0 To  
2,000 Feet  
Above  
2,000 To  
4,500 Feet  
Above  
Temp.  
Rise ºF  
At  
0 To  
2,000 To  
Gas  
Rate  
(Ft./Hr.)  
2,000 Feet  
Above  
4,500 Feet  
Above  
Available  
on Models  
Sea Level  
Sea Level  
Full Input  
Sea Level  
Sea Level  
Max.  
Min.  
150  
175  
Max.  
Min.  
135  
160  
Max.  
240  
280  
Max.  
213  
Min.  
Max.  
50  
300  
350  
270  
320  
15, 20 & 25 Ton  
25 Ton  
279  
326  
20  
30  
241  
60  
GAS PIPING  
GAS CONNECTION  
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 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 the  
Dimensions and Clearances Figure 13 to locate these  
access openings. Typical supply piping arrangements  
are shown in the figures on page 15. All shaded items  
are field-supplied.  
The heating value of the gas may differ with locality.  
The value should be checked with the local gas utility.  
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.  
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.  
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.  
TABLE 5: PIPE SIZING  
Nominal Iron Pipe Size  
Length in Feet  
1 in.  
520  
350  
285  
245  
215  
195  
180  
170  
160  
150  
1-1/4 in.  
1,050  
730  
10  
20  
30  
40  
50  
60  
70  
80  
90  
100  
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.  
590  
500  
Gas piping recommendations:  
440  
400  
1. A drip leg and a ground joint union must be  
installed in the gas piping.  
370  
350  
2. When required by local codes, a manual shut-off  
valve may have to be installed outside of the unit.  
320  
305  
3. Use wrought iron or steel pipe for all gas lines. Pipe  
compound should be applied sparingly to male  
threads only.  
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).  
14  
Johnson Controls Unitary Products  
         
356214-XIM-A-0108  
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.  
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.  
FIGURE 6 - EXTERNAL SUPPLY CONNECTION  
EXTERNAL SHUT-OFF  
FIRE OR EXPLOSION HAZARD  
FAILURE TO FOLLOW THE SAFETY WARN-  
ING EXACTLY COULD RESULT IN SERIOUS  
INJURY, DEATH OR PROPERTY DAMAGE.  
NEVER TEST FOR GAS LEAKS WITH AN  
OPEN FLAME. USE A COMMERICALLY  
AVAILABLE SOAP SOLUTION MADE SPE-  
CIFICALLY FOR THE DETECTION OF  
LEAKS TO CHECK ALL CONNECTIONS. A  
FIRE OR EXPLOSION MAY RESULT CAUS-  
ING PROPERTY DAMAGE, PERSONAL  
INJURY OR LOSS OF LIFE.  
FIGURE 7 - BOTTOM SUPPLY CONNECTION  
EXTERNAL SHUT-OFF  
L.P. UNITS, TANKS AND PIPING  
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).  
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.  
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  
Johnson Controls Unitary Products  
15  
     
356214-XIM-A-0108  
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:  
the blower compartment. 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.  
1. The vaporization rate depends on (a) the tempera-  
ture of the liquid and (b) the "wetted surface" area  
of the container or containers.  
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  
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.  
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.  
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.  
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.  
SLOTTED  
OPENINGS IN  
ACCESS PANEL  
VENT AIR  
OUTLET  
HOODS  
Check all connections for leaks when piping is com-  
pleted, using a soap solution. NEVER USE A FLAME.  
COMBUSTION  
AIR INTAKE  
HOOD  
GAS HEAT  
FIRE OR EXPLOSION HAZARD  
ACCESS  
PANELS  
FAILURE TO FOLLOW THE SAFETY WARN-  
ING EXACTLY COULD RESULT IN SERIOUS  
INJURY, DEATH OR PROPERTY DAMAGE.  
FIGURE 8 - VENT AND COMBUSTION AIR HOOD  
NEVER TEST FOR GAS LEAKS WITH AN  
OPEN FLAME. USE A COMMERICALLY  
AVAILABLE SOAP SOLUTION MADE SPE-  
CIFICALLY FOR THE DETECTION OF  
LEAKS TO CHECK ALL CONNECTIONS. A  
FIRE OR EXPLOSION MAY RESULT CAUS-  
ING PROPERTY DAMAGE, PERSONAL  
INJURY OR LOSS OF LIFE.  
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.  
VENT AND COMBUSTION AIR HOODS  
Two vent hoods and a combustion air hood (with  
screens) are shipped attached to the blower housing in  
16  
Johnson Controls Unitary Products  
     
356214-XIM-A-0108  
OPTIONAL POWER EXHAUST/BAROMETRIC RELIEF  
DAMPER RAIN HOOD  
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.  
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 SET POINT ADJUSTMENTS AND INFORMA-  
TION  
For a dual enthalpy operation, carefully turn the set  
point adjusting screw fully clockwise past the "D"  
setting.  
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.  
INDOOR AIR QUALITY AQ  
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.  
EXTREME CARE MUST BE EXCERCISED IN  
TURNING ALL SETPOINT, MAXIMIUM, AND  
MINIMUM DAMPER POSITIONING ADJUST-  
MENT SCREWS TO PREVENT TWISTING  
THEM OFF.  
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  
Optional CO Space Sensor Kit Part #  
2
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.  
2AQ04700324  
Optional CO Unit Sensor Kit Part # 2AQ04700424  
2
Replace the economizer access panel.  
OPTIONAL BAS-READY ECONOMIZER POWER  
EXHAUST DAMPER SET POINT ADJUSTMENT  
ENTHALPY SET POINT ADJUSTMENT  
The enthalpy set point may now be set by selecting the  
desired setpoint shown in the Enthalpy Setpoint Adjust-  
ment Figure 9. Adjust as follows:  
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.  
For a single enthalpy operation carefully turn the  
set point 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.  
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.  
For a dual enthalpy operation, carefully turn the set  
point adjusting screw fully clockwise past the "D"  
setting.  
Replace the economizer access panel.  
Johnson Controls Unitary Products  
17  
             
356214-XIM-A-0108  
FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT  
Exhaust Air  
Adjustment  
Screw  
EXH  
Set  
N
N1  
P1  
T1  
TR  
TR1  
Exhaust Air LED  
Damper Min.  
Position  
Screw  
24  
Vac  
HOT  
24  
Vac  
COM  
EXH  
P
T
Min  
Pos  
Indoor Air Quality  
Max. Adjustment  
Screw  
+
IAQ  
Max  
1
2
Indoor Air Quality  
LED  
IAQ  
AQ1  
SO+  
AQ  
SO  
5
4
Indoor Air Quality  
Min. Adjustment  
Screw  
IAQ  
Min  
3
Free  
Cool  
Free Cooling LED  
SR  
B
A
SR+  
EF  
EF1  
C
D
Economizer Enthalpy  
Set Point Adjustment  
Screw  
FIGURE 10 - HONEYWELL ECONOMIZER CONTROL W7212  
18  
Johnson Controls Unitary Products  
   
356214-XIM-A-0108  
B
E
F
C
D
A
A
C
FRONT  
FRONT  
D
B
FIGURE 11 - FOUR AND SIX POINT LOADS  
TABLE 6: FOUR AND SIX POINT LOADS  
Total  
4 Point Loads (lbs)  
Unit Size  
Shipping  
Weight  
A
B
C
D
180 Gas  
240 Gas  
300 Gas  
180 Elec  
240 Elec  
300 Elec  
2300  
2500  
3130  
2100  
2300  
2890  
539  
538  
615  
492  
295  
487  
563  
563  
671  
514  
517  
619  
612  
715  
962  
558  
658  
646  
586  
684  
882  
536  
630  
508  
Total  
6 Point Loads (lbs)  
Unit Size  
Shipping  
Weight  
A
B
C
D
E
F
180 Gas  
240 Gas  
300 Gas  
180 Elec  
240 Elec  
300 Elec  
2300  
2500  
3130  
2100  
2300  
2890  
351  
334  
418  
320  
307  
415  
367  
350  
438  
335  
322  
471  
392  
426  
533  
358  
392  
528  
416  
502  
628  
380  
462  
551  
399  
481  
603  
364  
442  
492  
375  
407  
510  
343  
375  
433  
FIGURE 12 - CENTER OF GRAVITY  
Johnson Controls Unitary Products  
19  
     
356214-XIM-A-0108  
TABLE 7: PHYSICAL DATA  
MODELS  
DM180  
DM240  
DM300  
CENTRIFUGAL BLOWER (Dia. x Wd.)  
FAN MOTOR HP  
15x15  
5.0  
18x15  
7.5  
3
18x15  
10  
EVAPORATOR  
BLOWER  
ROWS DEEP  
3
4
EVAPORATOR COIL FINS PER INCH  
13.5  
20.5  
30  
FACE AREA (Sq. Ft.)  
15.5  
25  
PROPELLER DIA. (In.) (Each)  
CONDENSER FAN  
(Two Per Unit)  
FAN MOTOR HP  
NOM. CFM TOTAL  
ROWS DEEP  
(Each)  
(Each)  
1
6,000  
2
8,000  
2
7,200  
3
CONDENSER  
COIL  
FINS PER INCH  
FACE AREA (Sq. Ft.)  
13  
36  
1
20  
15  
43.3  
~
43.3  
~
5 TON HERMETIC (RECIP.)  
10 TON TANDEM (RECIP.)  
1*  
~
~
COMPRESSOR  
(Qty. Per Unit)  
10 TON SCROLL  
~
2
~
12.5 TON  
~
~
2
QUANTITY PER UNIT (12" X 24" X 2" or 4”)  
QUANTITY PER UNIT (16" X 20" X 2" or 4”)  
QUANTITY PER UNIT (16" X 25" X 2" or 4”)  
QUANTITY PER UNIT (18" X 24" X 2" or 4”)  
TOTAL FACE AREA (Sq. Ft.)  
~
~
12  
~
4
~
FILTERS  
CHARGE  
~
4
~
5
~
~
15  
16  
7/8  
1900  
2100  
2140  
20  
24  
SYSTEM No.1  
SYSTEM No. 2  
COOLING ONLY  
19/0  
16/4  
2100  
2300  
2340  
160  
25/8  
24/8  
2709  
2909  
2971  
REFRIGERANT  
22 (Lb./Oz.)  
BASIC UNIT  
N24  
N32  
GAS / ELECTRIC  
ECONOMIZER  
ECONOMIZER WITH  
POWER EXHAUST  
245  
MOTORIZED DAMPER  
150  
25  
18 KW  
36 KW  
54 KW  
72 KW  
OPERATING  
WEIGHTS  
(LBS.)  
30  
ELECTRIC HEATER  
35  
40  
ROOF CURB  
175  
200  
185  
45  
185  
220  
BAROMETRIC DAMPER  
ECONOMIZER / MOTORIZED  
DAMPER RAIN HOOD  
55  
ECONOMIZER / POWER  
EXHAUST RAIN HOOD  
90  
WOOD SKID  
220  
* NOTE: This compressor will be energized first.  
20  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
TABLE 8: DM ELECTRICAL DATA -WITHOUT POWERED CONVENIENCE OUTLET  
COMPRESSORS  
HEATER OPTION  
MAX.  
FUSE/  
BRKR1  
SIZE  
ID  
MIN.  
OD FAN  
MOTORS  
FLA EACH  
CONV  
OUTLET  
AMPS  
MODEL  
TONNAGE  
BLOWER  
MOTOR  
FLA  
CIRCUIT  
AMPACITY  
(AMPS)  
VOLTAGE  
RLA  
LRA  
MODEL KW STAGES AMPS  
EACH EACH  
(AMPS)  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
0.0  
-
-
46.0  
46.0  
53.3  
74.6  
96.0  
46.0  
46.0  
57.2  
80.6  
85.2  
62.5  
62.5  
62.5  
80.6  
100.3  
62.5  
62.5  
62.3  
84.6  
89.2  
74.7  
76.0  
76.0  
87.9  
109.4  
74.7  
76.0  
76.0  
94.0  
98.6  
50  
50  
11.3  
22.6  
33.8  
45.1  
0.0  
1
2
2
2
-
17.1  
34.3  
51.4  
68.6  
-
380  
9.6  
9.6  
62  
62  
2.1  
2.1  
2.1  
2.1  
2.1  
2.1  
8.3  
8.3  
11.7  
11.5  
19  
0.0  
0.0  
0.0  
0.0  
0.0  
0.0  
60  
80  
100  
50  
15  
20  
25  
13.5  
26.9  
40.4  
53.8  
0.0  
1
2
2
2
-
18.7  
37.4  
56.2  
74.9  
-
50  
415  
380  
415  
380  
415  
60  
90  
100  
80  
11.3  
22.6  
33.8  
45.1  
0.0  
1
2
2
2
-
17.1  
34.3  
51.4  
68.6  
-
80  
20.7  
20.7  
22.9  
22.9  
130  
130  
145  
145  
80  
90  
110  
80  
13.5  
26.9  
40.4  
53.8  
0.0  
1
2
2
2
-
18.7  
37.4  
56.2  
74.9  
-
80  
80  
90  
100  
90  
11.3  
22.6  
33.8  
45.1  
0.0  
1
2
2
2
-
17.1  
34.3  
51.4  
68.6  
-
90  
90  
90  
110  
90  
13.5  
26.9  
40.4  
53.8  
1
2
2
2
18.7  
37.4  
56.2  
74.9  
90  
19  
90  
100  
110  
Note 1: HACR Type per NEC.  
Johnson Controls Unitary Products  
21  
 
356214-XIM-A-0108  
TABLE 9: DM ELECTRICAL DATA -WITH POWERED CONVENIENCE OUTLET  
COMPRESSORS  
HEATER OPTION  
MAX.  
FUSE/  
BRKR1  
SIZE  
ID  
MIN.  
CIRCUIT  
AMPACITY  
(AMPS)  
OD FAN  
MOTORS  
FLA EACH  
CONV  
OUTLET  
AMPS  
MODEL  
TONNAGE  
BLOWER  
MOTOR  
FLA  
VOLTAGE  
RLA  
LRA  
MODEL KW STAGES AMPS  
EACH EACH  
(AMPS)  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
None  
E18  
E36  
E54  
E72  
0.0  
-
-
52.3  
52.3  
61.2  
82.4  
103.9  
52.3  
52.3  
65.0  
88.5  
93.1  
68.8  
68.8  
68.8  
86.7  
108.2  
68.8  
68.8  
69.0  
92.5  
97.1  
82.3  
82.3  
82.3  
95.8  
117.3  
82.3  
82.3  
82.3  
101.9  
106.5  
50  
60  
11.3  
22.6  
33.8  
45.1  
0.0  
1
2
2
2
-
17.1  
34.3  
51.4  
68.6  
-
380  
9.6  
9.6  
62  
62  
2.1  
2.1  
2.1  
2.1  
2.1  
2.1  
8.3  
8.3  
11.7  
11.5  
19  
6.3  
6.3  
6.3  
6.3  
6.3  
6.3  
70  
90  
110  
50  
15  
20  
25  
13.5  
26.9  
40.4  
53.8  
0.0  
1
2
2
2
-
18.7  
37.4  
56.2  
74.9  
-
60  
415  
380  
415  
380  
415  
70  
90  
100  
80  
11.3  
22.6  
33.8  
45.1  
0.0  
1
2
2
2
-
17.1  
34.3  
51.4  
68.6  
-
80  
20.7  
20.7  
22.9  
22.9  
130  
130  
145  
145  
80  
90  
110  
80  
13.5  
26.9  
40.4  
53.8  
0.0  
1
2
2
2
-
18.7  
37.4  
56.2  
74.9  
-
80  
80  
100  
100  
100  
100  
100  
100  
125  
100  
100  
100  
110  
110  
11.3  
22.6  
33.8  
45.1  
0.0  
1
2
2
2
-
17.1  
34.3  
51.4  
68.6  
-
13.5  
26.9  
40.4  
53.8  
1
2
2
2
18.7  
37.4  
56.2  
74.9  
19  
Note 1: HACR Type per NEC.  
22  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
ECONOMIZER / MOTORIZED DAMPER,  
FIXED OUTDOOR INTAKE AIR AND  
POWER EXHAUST RAIN HOODS  
(See detail "Y")  
BLOWER  
ACCESS  
BLOWER MOTOR  
ACCESS  
FIELD-SUPPLIED  
DISCONNECT SWITCH  
LOCATION  
COMPRESSOR  
ACCESS  
BLOWER  
COMPARTMENT  
ACCESS  
COIL  
GUARD  
(Auxiliary)  
DOT PLUG  
(For pressure  
Drop Reading)  
48-5/8"(15 TON)  
52-5/8" (20, 25 TON)  
ELECTRIC/  
GAS HEAT  
ACCESS  
CONDENSER  
COILS  
VENT AIR  
OUTLET  
HOODS  
21"  
5"  
7-1/8"  
COMBUSTION  
AIR INLET  
HOOD  
6-3/8"  
9-3/4"  
5-7/8"  
92"  
)
(C)  
(A)  
GAS SUPPLY  
ENTRY  
CONTROL WIRING  
ENTRY  
46-5/8"  
CONTROL BOX  
ACCESS  
11-1/2"  
(B)  
35"  
POWER WIRING  
ENTRY  
BOTTOM SUPPLY  
AND RETURN  
AIR OPENINGS  
(See Note)  
FRONT  
VIEW  
RETURN  
AIR  
3-3/4"  
33"  
SUPPLY  
AIR  
2-3/4" 21-1/2"  
11-1/8"  
All dimensions are in inches. They are  
subject to change without notice. Certified  
dimensions will be provided upon request.  
UNIT BASE WITH RAILS  
(B)  
(D)  
Shown separately to illustrate  
Bottom Duct openings, Power  
and Gas Piping Connection  
locations  
POWER WIRING  
ENTRY  
GAS SUPPLY  
ENTRY  
(A)  
CONTROL WIRING  
ENTRY  
8-1/8"  
NOTE:  
46-5/8"  
For curb mounted units, refer to the curb hanger  
dimensions of the curb for the proper size of the  
supply and return air duct connections.  
9-1/4"  
12-1/2"  
9-3/4"  
UTILITIES ENTRY DATA  
HOLE  
A
OPENING SIZE (DIA.)  
USED FOR  
29 / 1-1/8” KO  
Side  
Control Wiring  
Power Wiring  
19 / 3/4” NPS (Fem.)  
92 / 3-5/8” KO  
Bottom  
Side  
Bottom  
1
B
76 / 3” NPS (Fem.)  
60 / 2-3/8” KO  
C
D
Gas Piping (Front)  
2
43 / 1-11/16” Hole  
Gas Piping (Bottom)  
1.  
2.  
One-inch gas piping NPT required.  
Opening in the bottom of the unit can be located by the slice in the  
insulation.  
NOTE: All entry holes should be field sealed to prevent rain  
water entry into the building.  
FIGURE 13 - FRONT VIEW DIMENSIONS (15, 20 & 25 TON)  
Johnson Controls Unitary Products  
23  
   
356214-XIM-A-0108  
EVAPORATOR  
SECTION  
DOT PLUG  
(For pressure  
drop reading)  
40-3/8"  
FILTER  
ACCESS  
SUPPLY  
AIR  
RETURN  
AIR  
COMPRESSOR  
ACCESS  
OUTDOOR  
AIR  
40-1/2"  
SUPPLY AIR  
ACCESS  
18-5/8"  
1" NPT FEMALE  
COND. DRAIN  
CONNECTION  
27-3/4"  
Dimensions listed are for side  
5-1/8"  
RETURN AIR  
ACCESS  
duct flange openings; see  
Field Accessories for Side  
Duct Flange Kit.  
OUTDOOR AIR  
COMPARTMENT  
ACCESS  
28-5/8” (15 TON)  
39-5/8" (20, 25 TON)  
REAR  
VIEW  
FIGURE 14 - REAR VIEW DIMENSIONS  
NOTE: Units are shipped with the bottom duct open-  
ings covered. An accessory flange kit is avail-  
able for connecting side ducts.  
For bottom duct applications:  
For side duct applications:  
1. Remove the side panels from the supply and return air  
compartments to gain access to the bottom supply and  
return air duct covers.  
1. Replace the side panels on the supply and return air  
compartments with the side duct flange accessory kit  
panels.  
2. Remove and discard the bottom duct covers. Duct  
openings are closed with sheet metal covers except  
when the unit includes a power exhaust option. The  
covering consists of a heavy black paper composition.  
2. Connect ductwork to the flanges on those panels.  
3. Replace the side supply and return air compartment  
panels.  
24  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
NOTE: ELEC / ELEC Models: Units and ductwork are  
approved for zero clearance to combustible material  
when equipped with electric heaters.  
CLEARANCES  
LOCATION  
Front  
CLEARANCE  
914 / 36”  
610 / 24” (Less Economizer)  
1245 / 49” (With Economizer)  
Rear  
GAS / ELEC Models: A 25mm/1” clearance must be  
provided between any combustible material and the  
supply air ductwork for a distance of .9 meter/3 feet  
from the unit.  
610 / 24” (Less Economizer)  
1372 / 54” (With Economizer)  
Left Side (Filter Access)  
Right Side (Cond. Coil)  
3
914 / 36”  
0 / 0”  
1
Below Unit  
The products of combustion must not be allowed to  
accumulate within a confined space and recirculate.  
1829 / 72” With 914 / 36”  
Maximum Horizontal Overhang  
(For Condenser Air Discharge)  
2
Above Unit  
Locate unit so that the vent air outlet hood is at  
least:  
1.  
Units may be installed on combustible floors made from wood  
or class A, B, or C roof covering material.  
2.  
Units must be installed outdoors. Overhanging structures or  
shrubs should not obstruct condenser air discharge outlet.  
3. If economizer is factory installed, the unassembled rain hood  
must be removed from its ride along position in front of evapo-  
rator coil, or in the outdoor air compartment, prior to final instal-  
lation.  
9 meters/3 feet above any force air inlet located  
within 3.0 meters/10 horizontal feet (excluding  
those integral to the unit).  
1.2 meters/4 feet below, four horizontal feet  
from, or one foot above any door or gravity air  
inlet into the building.  
1.2 meters/4 feet from electric and gas meters,  
regulators and relief equipment.  
ECONOMIZER  
MOTORIZED  
DAMPER  
POWER EXHAUST  
RAIN HOOD  
(on Return Air Compartment)  
SUPPLY AIR  
RAIN HOOD  
(on Outdoor Air Compartment)  
COMPARTMENT  
ECONOMIZER / MOTORIZED DAMPER  
AND POWER EXHAUST RAIN HOODS  
FIXED  
OUTDOOR AIR  
INTAKE HOOD  
(located on  
Return Air  
Compartment)  
930  
(36-5/8”)  
25 (1“) CONDENSATE  
DRAIN  
(Must be trapped)  
410  
(16-1/8”)  
127 (5”)  
716  
(28-3/16”)  
2337  
(92”)  
REAR VIEW  
LH VIEW  
DETAIL “Y”  
UNIT WITH RAIN HOODS  
FIGURE 15 - UNIT CLEARANCES AND RAIN HOOD DIMENSIONS (15, 20 & 25 TON)  
Johnson Controls Unitary Products  
25  
 
356214-XIM-A-0108  
order to use the indoor blower tables for high altitude applica-  
tions, certain corrections are necessary.  
CFM, STATIC PRESSURE, AND POWER -  
ALTITUDE AND TEMPERATURE CORRECTIONS  
A centrifugal fan is a "constant volume" device. This means  
that, if the rpm remains constant, the CFM delivered is the  
same regardless of the density of the air. However, since the  
air at high altitude is less dense, less static pressure will be  
generated and less power will be required than a similar  
application at sea level. Air density correction factors are  
shown in Table 10 and Figure 16.  
The information below should be used to assist in application  
of product when being applied at altitudes at or exceeding  
1000 feet above sea level.  
The air flow rates listed in the standard blower performance  
tables are based on standard air at sea level. As the altitude  
or temperature increases, the density of air decreases. In  
TABLE 10: ALTITUDE CORRECTION FACTORS  
ALTITUDE (METER)  
AIR TEMP  
°C  
0
305  
610  
914  
1219  
0.916  
0.898  
0.880  
0.864  
0.848  
0.833  
0.817  
1524  
0.882  
0.864  
0.848  
0.832  
0.817  
0.802  
0.787  
1829  
0.849  
0.832  
0.816  
0.801  
0.787  
0.772  
0.758  
2134  
0.818  
0.802  
0.787  
0.772  
0.758  
0.744  
0.730  
2438  
0.788  
0.772  
0.757  
0.743  
0.730  
0.716  
0.703  
2743  
0.758  
0.743  
0.729  
0.715  
0.702  
0.689  
0.676  
3048  
0.729  
0.715  
0.701  
0.688  
0.676  
0.663  
0.651  
4.4  
10  
1.060  
1.039  
1.019  
1.000  
0.982  
0.964  
0.946  
1.022  
1.002  
0.982  
0.964  
0.947  
0.929  
0.912  
0.986  
0.966  
0.948  
0.930  
0.913  
0.897  
0.880  
0.950  
0.931  
0.913  
0.896  
0.880  
0.864  
0.848  
15.5  
21  
26.6  
32  
38  
ALTITUDE (FEET)  
AIR TEMP  
°F  
0
1000  
1.022  
1.002  
0.982  
0.964  
0.947  
0.929  
0.912  
2000  
0.986  
0.966  
0.948  
0.930  
0.913  
0.897  
0.880  
3000  
0.950  
0.931  
0.913  
0.896  
0.880  
0.864  
0.848  
4000  
0.916  
0.898  
0.880  
0.864  
0.848  
0.833  
0.817  
5000  
0.882  
0.864  
0.848  
0.832  
0.817  
0.802  
0.787  
6000  
0.849  
0.832  
0.816  
0.801  
0.787  
0.772  
0.758  
7000  
0.818  
0.802  
0.787  
0.772  
0.758  
0.744  
0.730  
8000  
0.788  
0.772  
0.757  
0.743  
0.730  
0.716  
0.703  
9000  
0.758  
0.743  
0.729  
0.715  
0.702  
0.689  
0.676  
10000  
0.729  
0.715  
0.701  
0.688  
0.676  
0.663  
0.651  
40  
50  
1.060  
1.039  
1.019  
1.000  
0.982  
0.964  
0.946  
60  
70  
80  
90  
100  
The examples below will assist in determining the airflow per-  
formance of the product at altitude.  
blower tables to select the blower speed and the BHP  
requirement.  
Example 1: What are the corrected CFM, static pressure,  
and BHP at an elevation of 5,000 ft. if the blower performance  
data is 6,000 CFM, 1.5 IWC and 4.0 BHP?  
Solution: As in the example above, no temperature informa-  
tion is given so 70°F is assumed.  
The 1.5" static pressure given is at an elevation of 5,000 ft.  
The first step is to convert this static pressure to equivalent  
sea level conditions.  
Solution: At an elevation of 5,000 ft the indoor blower will still  
deliver 6,000 CFM if the rpm is unchanged. However, Table  
10 must be used to determine the static pressure and BHP.  
Since no temperature data is given, we will assume an air  
temperature of 70°F. Table 10 shows the correction factor to  
be 0.832.  
Sea level static pressure = 1.5 / .832 = 1.80"  
Enter the blower table at 6000 sCFM and static pressure of  
1.8". The rpm listed will be the same rpm needed at 5,000 ft.  
Corrected static pressure = 1.5 x 0.832 = 1.248 IWC  
Corrected BHP = 4.0 x 0.832 = 3.328  
Suppose that the corresponding BHP listed in the table is 3.2.  
This value must be corrected for elevation.  
Example 2: A system, located at 5,000 feet of elevation, is to  
BHP at 5,000 ft = 3.2 x .832 = 2.66  
deliver 6,000 CFM at a static pressure of 1.5". Use the unit  
26  
Johnson Controls Unitary Products  
   
356214-XIM-A-0108  
FIGURE 16 - ALTITUDE/TEMPERATURE CONVERSION FACTOR  
Johnson Controls Unitary Products  
27  
 
356214-XIM-A-0108  
TABLE 11: SUPPLY AIR BLOWER PERFORMANCE (15 TON) - COOLING ONLY  
180 MBH - BOTTOM DUCT CONNECTIONS  
AIRFLOW  
MOTOR  
BLOWER  
SPEED,  
(RPM)  
3
3
3
3
3
PULLEY  
(TURNS  
OPEN)*  
2.10 m /s  
2.45 m /s  
2.80 m /s  
3.10 m /s  
3.40 m /s  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
3
HIGH STATIC DRIVE (m /s)  
1030  
1070  
1115  
1155  
1200  
1240  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
357  
405  
461  
514  
577  
636  
2.4  
2.5  
2.7  
2.9  
3.1  
3.3  
2.8  
3.0  
3.2  
3.4  
3.7  
3.9  
316  
362  
416  
468  
529  
587  
2.8  
3.0  
3.2  
3.4  
3.6  
3.8  
3.4  
3.6  
3.8  
4.0  
4.3  
4.5  
253  
298  
351  
401  
461  
-
3.3  
3.5  
3.7  
3.9  
4.1  
-
3.9  
4.2  
4.4  
4.7  
5.0  
-
183  
3.7  
3.9  
4.2  
-
4.5  
4.7  
5.0  
-
97  
-
4.2  
5.0  
226  
-
-
-
-
-
-
-
-
-
-
278  
-
-
-
-
-
-
-
-
-
-
-
AIRFLOW  
5930 CFM  
MOTOR  
PULLEY  
(TURNS  
OPEN)*  
BLOWER  
SPEED,  
(RPM)  
4450 CFM  
5190 CFM  
6565 CFM  
7200 CFM  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
HIGH STATIC DRIVE (CFM)  
1030  
1070  
1115  
1155  
1200  
1240  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
1.4  
1.6  
1.9  
2.1  
2.3  
2.6  
3.2  
3.4  
3.6  
3.9  
4.1  
4.4  
2.8  
3.0  
3.2  
3.4  
3.7  
3.9  
1.3  
1.5  
1.7  
1.9  
2.1  
2.4  
3.8  
4.0  
4.3  
4.5  
4.8  
5.1  
3.4  
3.6  
3.8  
4.0  
4.3  
4.5  
1.0  
1.2  
1.4  
1.6  
1.8  
-
4.4  
4.7  
5.0  
5.2  
5.5  
-
3.9  
4.2  
4.4  
4.7  
5.0  
-
0.7  
0.9  
1.1  
-
5.0  
5.3  
5.6  
-
4.5  
4.7  
5.0  
-
0.4  
5.6  
5.0  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
NOTES: 1.Blower performance includes fixed outdoor air, 2” T/A filters, a dry evaporator coil and no electric heat.  
2.Refer to Table 16 for additional static resistances.  
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total  
static pressure of the blower.  
* Do NOT close the pulley below 1 turn open.  
** Factory setting.  
28  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
TABLE 12: SUPPLY AIR BLOWER PERFORMANCE (20 TON) - COOLING ONLY  
240 MBH - BOTTOM DUCT CONNECTIONS  
AIRFLOW  
MOTOR  
BLOWER  
SPEED,  
(RPM)  
3
3
3
3
3
PULLEY  
(TURNS  
OPEN)*  
2.80 m /s  
3.30 m /s  
3.80 m /s  
4.10 m /s  
4.40 m /s  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
3
HIGH STATIC DRIVE (m /s)  
895  
930  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
312  
362  
421  
473  
535  
590  
3.5  
3.7  
4.0  
4.2  
4.4  
4.6  
4.0  
4.3  
4.5  
4.8  
5.0  
5.3  
268  
318  
377  
429  
491  
546  
3.7  
4.0  
4.2  
4.5  
4.8  
5.0  
4.3  
4.5  
4.9  
5.1  
5.5  
5.8  
198  
248  
306  
359  
420  
475  
4.2  
4.5  
4.8  
5.1  
5.4  
5.7  
4.8  
5.1  
5.5  
5.8  
6.2  
6.5  
143  
193  
252  
304  
365  
420  
4.6  
4.9  
5.2  
5.6  
5.9  
6.2  
5.2  
5.6  
6.0  
6.4  
6.8  
7.1  
79  
129  
187  
240  
-
5.1  
5.4  
5.8  
6.1  
-
5.8  
6.2  
6.6  
7.0  
-
970  
1005  
1045  
1080  
-
-
-
AIRFLOW  
8050 CFM  
MOTOR  
PULLEY  
(TURNS  
OPEN)*  
BLOWER  
SPEED,  
(RPM)  
5930 CFM  
6990 CFM  
8685 CFM  
9320 CFM  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
HIGH STATIC DRIVE (CFM)  
895  
930  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
1.3  
1.5  
1.7  
1.9  
2.1  
2.4  
4.7  
5.0  
5.3  
5.6  
5.9  
6.2  
4.0  
4.3  
4.5  
4.8  
5.0  
5.3  
1.1  
1.3  
1.5  
1.7  
2.0  
2.2  
5.0  
5.3  
5.7  
6.0  
6.4  
6.8  
4.3  
4.5  
4.9  
5.1  
5.5  
5.8  
0.8  
1.0  
1.2  
1.4  
1.7  
1.9  
5.6  
6.0  
6.4  
6.8  
7.3  
7.7  
4.8  
5.1  
5.5  
5.8  
6.2  
6.5  
0.6  
0.8  
1.0  
1.2  
1.5  
1.7  
6.1  
6.6  
7.0  
7.4  
7.9  
8.4  
5.2  
5.6  
6.0  
6.4  
6.8  
7.1  
0.3  
0.5  
0.8  
1.0  
-
6.8  
7.2  
7.8  
8.2  
-
5.8  
6.2  
6.6  
7.0  
-
970  
1005  
1045  
1080  
-
-
-
NOTES: 1.Blower performance includes fixed outdoor air, 2” T/A filters, a dry evaporator coil and no electric heat.  
2.Refer to Table 16 for additional static resistances.  
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total  
static pressure of the blower.  
* Do NOT close the pulley below 1 turn open.  
** Factory setting.  
Johnson Controls Unitary Products  
29  
 
356214-XIM-A-0108  
TABLE 13: SUPPLY AIR BLOWER PERFORMANCE (15 TON) - GAS HEAT  
180 MBH - BOTTOM DUCT CONNECTIONS  
AIRFLOW  
MOTOR  
BLOWER  
SPEED,  
(RPM)  
3
3
3
3
3
PULLEY  
(TURNS  
OPEN)*  
2.10 m /s  
2.45 m /s  
2.80 m /s  
3.10 m /s  
3.40 m /s  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
3
HIGH STATIC DRIVE (m /s)  
1030  
1070  
1115  
1155  
1200  
1240  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
378  
417  
461  
502  
548  
590  
2.3  
2.4  
2.6  
2.8  
3.0  
3.2  
2.7  
2.9  
3.1  
3.3  
3.6  
3.8  
321  
361  
407  
448  
495  
538  
2.7  
2.9  
3.1  
3.3  
3.6  
3.8  
3.2  
3.4  
3.7  
4.0  
4.3  
4.6  
258  
299  
345  
387  
435  
-
3.2  
3.4  
3.7  
3.9  
4.2  
-
3.8  
4.1  
4.4  
4.7  
5.0  
-
199  
3.6  
3.9  
4.2  
-
4.4  
4.7  
5.0  
-
134  
4.2  
5.0  
240  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
286  
-
-
-
-
-
-
-
AIRFLOW  
5930 CFM  
MOTOR  
PULLEY  
(TURNS  
OPEN)*  
BLOWER  
SPEED,  
(RPM)  
4450 CFM  
5190 CFM  
6565 CFM  
7200 CFM  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
HIGH STATIC DRIVE (CFM)  
1030  
1070  
1115  
1155  
1200  
1240  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
1.5  
1.7  
1.9  
2.0  
2.2  
2.4  
3.1  
3.3  
3.5  
3.7  
4.0  
4.3  
2.7  
2.9  
3.1  
3.3  
3.6  
3.8  
1.3  
1.4  
1.6  
1.8  
2.0  
2.2  
3.6  
3.8  
4.1  
4.4  
4.8  
5.1  
3.2  
3.4  
3.7  
4.0  
4.3  
4.6  
1.0  
1.2  
1.4  
1.6  
1.7  
-
4.3  
4.5  
4.9  
5.2  
5.6  
-
3.8  
4.1  
4.4  
4.7  
5.0  
-
0.8  
1.0  
1.2  
-
4.9  
5.2  
5.6  
-
4.4  
4.7  
5.0  
-
0.5  
5.6  
5.0  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
NOTES: 1.Blower performance includes a gas-fired heat exchanger, fixed outdoor air, two-inch T/A filters and a dry evaporator coil.  
2.Refer to the additional Static Resistances table.  
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total  
static pressure of the blower.  
* Do NOT close the pulley below 1 turn open.  
** Factory setting.  
30  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
TABLE 14: SUPPLY AIR BLOWER PERFORMANCE (20 TON) - GAS HEAT  
240 MBH - BOTTOM DUCT CONNECTIONS  
AIRFLOW  
MOTOR  
BLOWER  
SPEED,  
(RPM)  
3
3
3
3
3
PULLEY  
(TURNS  
OPEN)*  
2.80 m /s  
3.30 m /s  
3.80 m /s  
4.10 m /s  
4.40 m /s  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
ESP  
(Pa)  
Output Input  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
3
HIGH STATIC DRIVE (m /s)  
895  
925  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
0.0  
361  
400  
439  
486  
527  
569  
612  
2.8  
2.9  
3.1  
3.3  
3.5  
3.7  
3.9  
3.2  
3.4  
3.6  
3.8  
4.0  
4.2  
4.4  
249  
290  
332  
381  
425  
469  
514  
3.5  
3.7  
3.9  
4.1  
4.3  
4.6  
4.8  
4.0  
4.2  
4.4  
4.7  
5.0  
5.2  
5.5  
114  
157  
201  
254  
299  
346  
393  
4.3  
4.5  
4.7  
5.0  
5.2  
5.5  
5.8  
4.9  
5.1  
5.4  
5.7  
6.0  
6.3  
6.6  
22  
4.7  
5.0  
5.2  
5.5  
5.8  
6.1  
6.4  
5.4  
5.7  
6.0  
6.3  
6.7  
7.0  
7.3  
-
-
-
-
-
-
66  
955  
112  
166  
213  
261  
310  
15  
70  
119  
-
5.8  
6.1  
6.4  
-
6.6  
7.0  
7.3  
-
990  
1020  
1050  
1080  
-
-
-
AIRFLOW  
8050 CFM  
MOTOR  
PULLEY  
(TURNS  
OPEN)*  
BLOWER  
SPEED,  
(RPM)  
5930 CFM  
6990 CFM  
8685 CFM  
9320 CFM  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
ESP  
(iwg)  
Output Input  
(bhp)  
(kW)  
(kW)  
(kW)  
(kW)  
(kW)  
HIGH STATIC DRIVE (CFM)  
895  
925  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
0.0  
1.5  
1.6  
1.8  
2.0  
2.1  
2.3  
2.5  
3.7  
3.9  
4.2  
4.4  
4.7  
4.9  
5.2  
3.2  
3.4  
3.6  
3.8  
4.0  
4.2  
4.4  
1.0  
1.2  
1.3  
1.5  
1.7  
1.9  
2.1  
4.7  
4.9  
5.2  
5.5  
5.8  
6.1  
6.4  
4.0  
4.2  
4.4  
4.7  
5.0  
5.2  
5.5  
0.5  
0.6  
0.8  
1.0  
1.2  
1.4  
1.6  
5.7  
6.0  
6.3  
6.7  
7.0  
7.4  
7.7  
4.9  
5.1  
5.4  
5.7  
6.0  
6.3  
6.6  
0.1  
0.3  
0.4  
0.7  
0.9  
1.0  
1.2  
6.3  
6.7  
7.0  
7.4  
7.8  
8.2  
8.5  
5.4  
5.7  
6.0  
6.3  
6.7  
7.0  
7.3  
-
-
-
-
-
-
955  
0.1  
0.3  
0.5  
-
7.8  
8.2  
8.6  
-
6.6  
7.0  
7.3  
-
990  
1020  
1050  
1080  
NOTES: 1.Blower performance includes a gas-fired heat exchanger, fixed outdoor air, two-inch T/A filters and a dry evaporator coil.  
2.Refer to the additional Static Resistances table.  
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total  
static pressure of the blower.  
* Do NOT close the pulley below 1 turn open.  
** Factory setting.  
Johnson Controls Unitary Products  
31  
 
356214-XIM-A-0108  
TABLE 15: SUPPLY AIR BLOWER PERFORMANCE (25 TON) - COOLING APPLICATIONS  
300 MBH - BOTTOM DUCT CONNECTIONS  
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS (CFM)  
7500 CFM  
8750 CFM  
10000 CFM  
INPUT  
BLOWER  
SPEED (rpm) TURNS OPEN  
PULLEY  
INPUT  
(kW)  
ESP (iwg) OUTPUT (bhp) INPUT (kW) ESP (iwg) OUTPUT (bhp)  
ESP (iwg) OUTPUT (bhp)  
(kW)  
6.9  
7.2  
7.6  
8.0  
8.3  
8.7  
9.0  
945  
975  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
0.0  
1.2  
1.4  
1.6  
1.8  
2.0  
2.1  
2.3  
5.6  
5.9  
6.2  
6.6  
6.9  
7.3  
7.6  
4.6  
4.9  
5.1  
5.4  
5.7  
6.0  
6.2  
0.8  
1.0  
1.2  
1.4  
1.6  
1.8  
2.0  
7.0  
7.3  
7.7  
8.1  
8.5  
8.9  
9.3  
5.7  
6.0  
6.3  
6.7  
7.0  
7.3  
7.6  
0.3  
0.5  
0.7  
0.9  
1.1  
1.3  
1.5  
8.4  
8.8  
1005  
1040  
1070  
1100  
1130  
9.2  
9.7  
10.2  
10.6  
11.0  
3
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS (m /s)  
3
3
3
3.53 m /Sec.  
4.13 m /Sec.  
4.72 m /Sec.  
BLOWER  
SPEED (rpm) TURNS OPEN  
PULLEY  
INPUT  
(kW)  
INPUT  
(kW)  
ESP (Pa) OUTPUT(bhp) INPUT (kW) ESP (Pa) OUTPUT (bhp)  
ESP (Pa) OUTPUT(bhp)  
945  
975  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
0.0  
303  
347  
391  
443  
489  
536  
583  
5.6  
5.9  
6.2  
6.6  
6.9  
7.3  
7.6  
4.6  
4.9  
5.1  
5.4  
5.7  
6.0  
6.2  
198  
244  
291  
347  
396  
445  
495  
7.0  
7.3  
7.7  
8.1  
8.5  
8.9  
9.3  
5.7  
6.0  
6.3  
6.7  
7.0  
7.3  
7.6  
71  
8.4  
8.8  
6.9  
7.2  
7.6  
8.0  
8.3  
8.7  
9.0  
120  
169  
228  
280  
332  
385  
1005  
1040  
1070  
1100  
1130  
9.2  
9.7  
10.2  
10.6  
11.0  
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS - GAS HEAT MODELS (CFM)  
7500 CFM  
8750 CFM  
10000 CFM  
BLOWER  
SPEED (rpm) TURNS OPEN  
PULLEY  
INPUT  
(kW)  
INPUT  
(kW)  
ESP (iwg) OUTPUT (bhp) INPUT (kW) ESP (iwg) OUTPUT (bhp)  
ESP (iwg) OUTPUT (bhp)  
945  
975  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
0.0  
1.0  
1.2  
1.4  
1.6  
1.8  
2.0  
2.2  
5.6  
5.9  
6.2  
6.6  
6.9  
7.3  
7.6  
4.6  
4.9  
5.1  
5.4  
5.7  
6.0  
6.2  
0.3  
0.5  
0.7  
0.9  
1.1  
1.3  
1.5  
7.0  
7.3  
7.7  
8.1  
8.5  
8.9  
9.3  
5.7  
6.0  
6.3  
6.7  
7.0  
7.3  
7.6  
-
-
-
-
-
-
1005  
1040  
1070  
1100  
1130  
-
-
-
0.2  
0.4  
0.6  
0.8  
9.7  
10.2  
10.6  
11.0  
8.0  
8.3  
8.7  
9.0  
3
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS - GAS HEAT MODELS (m /s)  
3
3
3
3.53 m /sec.  
4.13 m /sec.  
4.72 m /sec.  
BLOWER  
SPEED (rpm) TURNS OPEN  
PULLEY  
INPUT  
(kW)  
INPUT  
(kW)  
ESP (Pa) OUTPUT (bhp) INPUT (kW) ESP (Pa) OUTPUT (bhp)  
ESP (Pa) OUTPUT (bhp)  
945  
975  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
0.0  
258  
301  
345  
398  
444  
490  
537  
5.6  
5.9  
6.2  
6.6  
6.9  
7.3  
7.6  
4.6  
4.9  
5.1  
5.4  
5.7  
6.0  
6.2  
87  
7.0  
7.3  
7.7  
8.1  
8.5  
8.9  
9.3  
5.7  
6.0  
6.3  
6.7  
7.0  
7.3  
7.6  
-
-
-
-
133  
180  
236  
285  
334  
384  
-
-
1005  
1040  
1070  
1100  
1130  
-
-
-
43  
94  
146  
199  
9.7  
10.2  
10.6  
11.0  
8.0  
8.3  
8.7  
9.0  
NOTES: 1.Blower performance includes a gas-fired heat exchanger, fixed outdoor air, two-inch T/A filters and a dry evaporator coil.  
2.Refer to the additional Static Resistances table.  
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total  
static pressure of the blower.  
* Do NOT close the pulley below 1 turn open.  
** Factory setting.  
32  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
1
TABLE 16: STATIC RESISTANCES  
RESISTANCE, Pa/IWG  
3
m /s/CFM  
DESCRIPTION  
MODEL 180  
MODEL 240  
MODEL 300  
2.1/4500 2.8/6000 3.4/7200 2.8/6000 3.8/8000 4.4/9400 3.78/8000  
4.25/9000 4.72/10000  
WET COIL  
GAS HEAT  
24.8/0.1  
24.8/0.1  
24.8/0.1  
24.8/0.1  
50.0/0.2  
50.0/0.2  
24.8/0.1  
50.0/0.2  
24.8/0.1  
24.8/0.1  
24.8/0.1  
50.0/0.2  
74.4/0.3  
24.8/0.1  
24.8/0.1  
24.8/0.1  
74.4/0.3  
99.2/0.4  
24.8/0.1  
24.8/0.1  
24.8/0.1  
24.8/0.1  
50.0/0.2  
24.8/0.1  
24.8/0.1  
24.8/0.1  
50.0/0.2  
74.4/0.3  
24.8/0.1  
24.8/0.1  
24.8/0.1  
74.4/0.3  
99.2/0.4  
25/0.1  
25/0.1  
25/0.1  
25/0.1  
50/0.2  
50/0.2  
25/0.1  
50/0.2  
25/0.1  
25/0.1  
25/0.1  
50/0.2  
75/0.3  
100/0.4  
25/0.1  
75/0.3  
25/0.1  
25/0.1  
25/0.1  
75/0.3  
100/0.4  
150/0.6  
25/0.1  
125/0.5  
18 KW  
36 KW  
54 KW  
72 KW  
ELECTRIC HEAT OPTIONS  
ECONOMIZER OPTION  
99.2/0.4 149.0/0.6 50.0/0.2  
24.8/0.1 24.8/0.1 24.8/0.1  
74.4/0.3 124.0/0.5 50.0/0.2  
99.2/0.4 149.0/0.6  
24.8/0.1 24.8/0.1  
74.4/0.3 124.0/0.5  
HORIZONTAL DUCT CONNECTIONS  
1.  
Deduct these resistance values from the available external static pressures shown in the respective Blower Performance Table except for Horizontal  
Duct Connections.  
Add these values due to less airflow resistance.  
TABLE 17: POWER EXHAUST PERFORMANCE  
STATIC RESISTANCE OF RETURN DUCTWORK, IWG  
MOTOR  
SPEED  
0.2  
0.3  
0.4  
0.5  
0.6  
CFM  
5250  
4900  
4400  
KW  
0.83  
0.77  
0.72  
CFM  
4500  
3900  
3700  
KW  
0.85  
0.79  
0.74  
CFM  
4200  
3500  
3000  
KW  
0.88  
0.82  
0.78  
CFM  
3750  
2900  
-
KW  
0.93  
0.85  
-
CFM  
KW  
HIGH*  
MEDIUM  
LOW  
3000  
0.99  
-
-
-
-
* Factory Setting  
Power Exhaust motor is a 3/4 HP, PSC type with sleeve bearings, a 48 frame and inherent protection.  
TABLE 18: BLOWER MOTOR AND DRIVE DATA  
BELT  
(NOTCHED)  
2
3
FIXED BLOWER PULLEY  
PITCH  
MOTOR  
ADJUSTABLE MOTOR PULLEY  
BLOWER  
RANGE  
(RPM)  
MODEL  
SIZE  
1
DRIVE  
PITCH  
PITCH  
LENGTH QTY.  
(mm/IN.)  
EFF.  
(%)  
DESIG-  
NATION  
BORE  
DESIG-  
BORE  
DESIG-  
kW/HP FRAME  
DIA.  
DIA.  
(mm/IN.) NATION  
(mm/IN.) NATION  
(mm/IN.)  
(mm/IN.)  
High  
Static  
109-135  
4.3-5.3  
180  
240  
300  
1030/1240 3.7/5.0  
895-1080 5.6/7.5  
950/1130 7.5/10  
184 T  
213 T  
254 T  
83  
87  
89  
1VP62  
1VP75  
29/1-1/8  
BK75  
175/6.9  
239/9.4  
25/1  
BX68  
BX81  
1773/69.8  
1
1
1
High  
Static  
140-165  
5.5-6.5  
4
35/1-3/8  
A2  
BK100  
2103/82.8  
2134/84  
30/1-3/16  
High  
Static  
1LVP58  
B70A  
157-188  
(6.2-7.4) Bushing  
B
1B5V94 241 (9.5)  
5VX840  
Bushing  
1.  
2.  
All 50 Hz DM180-300 models come standard with factory filtered High Static Drive.  
All motors have a nominal speed of 1450 RPM, a 1.15 service factor and a solid base. They can operate to the limit of their service factor because  
they are located in the moving air, upstream of any heating device.  
3.  
4.  
Do NOT close this pulley below 1 turn open.  
Requires bushing (included in kit).  
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PHASING  
YORK MODEL DM, units are properly phased at the  
factory. Check for proper compressor rotation. If the  
blower or compressors rotate in the wrong direction at  
start-up, the electrical connection to the unit is mis-  
phased. Change the incoming line connection phasing  
to obtain proper rotation. (Scroll compressors operate  
in only one direction. If the scroll is drawing low amper-  
age, has similar suction and discharge pressures, or  
producing a high noise level, the scroll is misphased).  
Scroll compressors require proper rotation to  
operate correctly. Units are properly phased at  
the factory. Do not change the internal wiring to  
make the blower, condenser fans, or compres-  
sor rotate correctly.  
CHECKING AIR SUPPLY CFM  
The RPM of the supply air blower will depend on the  
required CFM, the unit accessories or options and the  
static resistances of both the supply and the return air  
duct systems. With this information, the RPM for the  
supply air blower and the motor pulley adjustment  
(turns open) can be determined from the Blower Per-  
formance Data Tables.  
FIGURE 17 - BELT ADJUSTMENT  
Note the following:  
1. The supply air CFM must be within the limitations  
shown in the Unit Application Data Table 1.  
2. Pulleys can be adjusted in half turn increments.  
3. The tension on the belt should be adjusted as  
shown in the Belt Adjustment Figure 17.  
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Start the supply air blower motor. Adjust the resis-  
tances in both the supply and the return air duct sys-  
tems to balance the air distribution throughout the  
conditioned space. The job specifications may require  
that this balancing be done by someone other than the  
equipment installer.  
measuring the pressure drop across a wet coil  
under field conditions would be inaccurate. To  
assure a dry coil, the compressors should be deac-  
tivated while the test is being run.  
4. Knowing the pressure drop across a dry coil, the  
actual CFM through the unit can be determined  
from the curve in Pressure Drop vs. Supply Air  
CFM Figure 18.  
To check the supply air CFM after the initial balancing  
has been completed:  
1. Remove the two 5/16" dot plugs from the blower  
motor and the filter access panels shown in the  
Dimensions and Clearances Figure 13.  
Failure to properly adjust the total system air  
quantity can result in extensive blower dam-  
age.  
2. Insert at least 8" of 1/4 inch tubing into each of  
these holes for sufficient penetration into the air  
flow on both sides of the indoor coil.  
After readings have been obtained, remove the tubes  
and reinstall the two 5/16" dot plugs that were removed  
in Step 1.  
NOTE: The tubes must be inserted and held in a posi-  
tion perpendicular to the air flow so that veloc-  
ity pressure will not affect the static pressure  
readings.  
NOTE: DE-ENERGIZE  
THE  
COMPRESSORS  
BEFORE TAKING ANY TEST MEASURE-  
MENTS TO ASSURE A DRY INDOOR COIL.  
3. Using an inclined manometer, determine the pres-  
sure drop across a dry evaporator coil. Since the  
moisture on an evaporator coil may vary greatly,  
0.65  
0.6  
0.55  
0.5  
240 MBH  
300 MBH  
180 MBH  
0.45  
0.4  
0.35  
0.3  
0.25  
4
5
6
7
8
9
10  
11  
12  
13  
NOMINAL CFM (THOUSANDS) SUPPLY AIR  
FIGURE 18 - PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM FOR ALL UNIT  
TONNAGES  
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condenser fan motor #1, and condenser fan motor #2  
for 15 and 20T only (if the ambient temperature is  
above 60°F), are energized. After completing the spec-  
ified fan on delay for cooling, the UCB will energize the  
blower motor.  
OPERATION  
SEQUENCE OF OPERATIONS OVERVIEW  
For these units, the thermostat makes a circuit  
between "R" and "Y1" for the first stage of cooling.  
When the thermostat calls for the second stage of cool-  
ing, the low-voltage control circuit from "R" to "Y2" is  
completed. Compressor #2, and condenser fan motor  
#2, 25T only (if the ambient temperature is above  
60°F), is energized, provided it has not been locked-  
out.  
The call is passed to the unit control board (UCB),  
which then determines whether the requested opera-  
tion is available and, if so, which components to ener-  
gize.  
For gas heating, the UCB monitors the "W1" call but  
does not handle the operation of the gas furnace. An  
ignition control board controls the gas heater operation.  
If there is an initial call for both stages of cooling, the  
UCB will delay energizing compressor #2 by 30 sec-  
onds in order to avoid a power in rush.  
For electric heat units, the UCB passes the call to the  
electric heater.  
Once the thermostat has been satisfied, it will de-ener-  
gize Y1 and Y2. If the compressors have satisfied their  
minimum run times, the compressors and condenser  
fans are de-energized. Otherwise, the unit operates  
each cooling system until the minimum run times for  
the compressors have been completed. Upon the final  
compressor de-energizing, the blower is stopped fol-  
lowing the elapse of the fan off delay for cooling.  
In both cases, when the "W1" call is sensed, the indoor  
air blower is energized following a specified heating  
delay.  
If at any time a call for both heating and cooling are  
present, the heating operation will be performed. If  
operating, the cooling system is halted as with a com-  
pletion of a call for cooling. Heating always takes prior-  
ity.  
To be available, a compressor must not be locked-out  
due to a high or low-pressure switch or freezestat trip  
and the anti-short cycle delay (ASCD) must have  
elapsed.  
COOLING SEQUENCE OF OPERATION  
CONTINUOUS BLOWER  
ECONOMIZER WITH SINGLE ENTHALPY SENSOR -  
When the room thermostat calls for "first-stage" cool-  
ing, the low voltage control circuit from "R" to "G" and  
"Y1" is completed. The UCB energizes the blower  
motor (if the fan switch on the room thermostat is set in  
the "AUTO" position) and drives the economizer damp-  
ers from fully closed to their minimum position. If the  
enthalpy of the outdoor air is below the setpoint of the  
enthalpy controller (previously determined), "Y1" ener-  
gizes the economizer. The dampers will modulate to  
maintain a constant supply air temperature as moni-  
tored by the discharge air sensor. If the outdoor air  
enthalpy is above the setpoint, "Y1" energizes com-  
pressor #1, condenser fan motor #1, and condenser  
fan motor #2, 15 and 20T only (if the ambient tempera-  
ture is above 60°F).  
By setting the room thermostat fan switch to "ON," the  
supply air blower will operate continuously.  
INTERMITTENT BLOWER  
With the room thermostat fan switch set to "AUTO" and  
the system switch set to either the "AUTO" or "HEAT"  
settings, the blower is energized whenever a cooling or  
heating operation is requested. The blower is ener-  
gized after any specified delay associated with the  
operation.  
When energized, the indoor blower has a minimum run  
time of 30 seconds. Additionally, the indoor blower has  
a delay of 10 seconds between operations.  
When the thermostat calls for "second-stage" cooling,  
the low voltage control circuit from "R" to "Y2" is  
completed. The UCB energizes the first available  
compressor If the enthalpy of the outdoor air is below  
the setpoint of the enthalpy controller (i.e. first stage  
NO OUTDOOR AIR OPTIONS  
When the thermostat calls for the first stage of cooling,  
the low-voltage control circuit from "R" to "Y1" and "G"  
is completed. For first stage cooling, compressor #1,  
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HIGH-PRESSURE LIMIT SWITCH  
has energized the economizer), "Y2" will energize  
compressor #1. If the outdoor air is above the setpoint,  
"Y2" will energize compressor #2.  
During cooling operation, if a high-pressure limit switch  
opens, the UCB will de-energize the associated com-  
pressor, initiate the ASCD (Anti-short cycle delay), and,  
if the other compressor is idle, stop the condenser  
fans. If the call for cooling is still present at the conclu-  
sion of the ASCD, the UCB will re-energize the halted  
compressor.  
Once the thermostat has been satisfied, it will de-ener-  
gize Y1 and Y2. If the compressors have satisfied their  
minimum run times, the compressors and condenser  
fans are de-energized. Otherwise, the unit operates  
each cooling system until the minimum run times for  
the compressors have been completed. Upon the final  
compressor de-energizing, the blower is stopped fol-  
lowing the elapse of the fan off delay for cooling, and  
the economizer damper goes to the closed position. If  
the unit is in continues fan operation the economizer  
damper goes to the min. position.  
Should a high-pressure switch open three times within  
two hours of operation, the UCB will lock-out the asso-  
ciated compressor and flash a code (see Table 24). If  
the other compressor is inactive, the condenser fans  
will be de-energized.  
LOW-PRESSURE LIMIT SWITCH  
ECONOMIZER WITH DUAL ENTHALPY SENSORS -  
The low-pressure limit switch is not monitored during  
the initial 30 seconds of a cooling system's operation.  
For the following 30 seconds, the UCB will monitor the  
low-pressure switch to ensure it closes. If the low-pres-  
sure switch fails to close after the 30-second monitor-  
ing phase, the UCB will de-energize the associated  
compressor, initiate the ASCD, and, if the other com-  
pressor is idle, stop the condenser fans.  
The operation with the dual enthalpy sensors is identi-  
cal to the single sensor except that a second enthalpy  
sensor is mounted in the return air. This return air sen-  
sor allows the economizer to choose between outdoor  
air and return air, whichever has the lowest enthalpy  
value, to provide maximum operating efficiency.  
ECONOMIZER (SINGLE OR DUAL ENTHALPY) WITH  
POWER EXHAUST -  
Once the low-pressure switch has been proven (closed  
during the 30-second monitor period described above),  
the UCB will monitor the low-pressure limit switch for  
any openings. If the low-pressure switch opens for  
greater than 5 seconds, the UCB will de-energize the  
associated compressor, initiate the ASCD, and, if the  
other compressor is idle, stop the condenser fans.  
This system operates as specified above with one  
addition. The power exhaust motor is energized 45  
seconds after the actuator position exceeds the  
exhaust fan setpoint on the economizer control. When  
the power exhaust is operating, the second stage of  
mechanical cooling will not operate. As always, the "R"  
to "G" connection provides minimum position but does  
not provide power exhaust operation.  
If the call for cooling is still present at the conclusion of  
the ASCD, the UCB will re-energize the halted com-  
pressor.  
MOTORIZED OUTDOOR AIR DAMPERS -  
This system operation is the same as the units with no  
outdoor air options with one exception. When the "R" to  
"G" circuit is complete, the motorized damper drives  
open to a position set by the thumbwheel on the  
damper motor. When the "R" to "G" circuit is opened,  
the damper spring returns fully closed.  
Should a low-pressure switch open three times within  
one hour of operation, the UCB will lock-out the associ-  
ated compressor and flash a code (Table 24). If the  
other compressor is inactive, the condenser fans will  
be de-energized.  
FREEZESTAT  
COOLING OPERATION ERRORS  
During cooling operation, if a freezestat opens, the  
UCB will de-energize the associated compressor, initi-  
ate the ASCD, and, if the other compressor is idle, stop  
the condenser fans. If the call for cooling is still present  
at the conclusion of the ASCD, the UCB will re-ener-  
gize the halted compressor.  
Each cooling system is monitored for operation outside  
of the intended parameters. Errors are handled as  
described below. All system errors override minimum  
run times for compressors.  
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Should a freezestat open three times within two hours  
of operation, the UCB will lock-out the associated com-  
pressor and flash a code (Table 24). If the other com-  
pressor is inactive, the condenser fans will be de-  
energized.  
The other refrigerant system will continue in operation  
unless it is affected by the fault as well.  
The unit control board monitors the temperature limit  
switch of electric heat units and the temperature limit  
switch and the gas valve of gas furnace units.  
LOW AMBIENT COOLING  
COMPRESSOR PROTECTION  
To determine when to operate in low ambient mode,  
the UCB has a pair of terminals connected to a temper-  
ature-activated switch set at 30ºF. When the low ambi-  
ent switch is closed and the thermostat is calling for  
cooling, the UCB will operate in the low ambient mode.  
The compressors also have inherent (internal) protec-  
tion. If there is an abnormal temperature rise in a com-  
pressor, the protector will open to shut down the  
compressor. The UCB incorporates features to mini-  
mize compressor wear and damage. An anti-short  
cycle delay (ASCD) is utilized to prevent operation of a  
compressor too soon after its previous run. Addition-  
ally, a minimum run time is imposed any time a com-  
pressor is energized.  
Low ambient mode operates the compressors in this  
manner: 10 minutes on, 5 minutes off. The indoor  
blower is operated throughout the cycle. The 5-minute  
off period is necessary to defrost the indoor coil.  
Low ambient mode always begins with compressor  
operation. Compressor minimum run time may extend  
the minutes of compressor operation. The defrost cycle  
will begin immediately following the elapse of the mini-  
mum run time.  
The ASCD is initiated on unit start-up and on any com-  
pressor reset or lock-out.  
FLASH CODES  
The UCB will initiate a flash code associated with  
errors within the system. Refer to UNIT CONTROL  
BOARD FLASH CODES Table 24.  
When operating in low ambient mode, the UCB will not  
lockout the compressors due to a freezestat trip. How-  
ever, a freezestat trip will de-energize the associated  
compressor. If the call for cooling is still present at the  
end of the ASCD and the freezestat has closed, the  
unit will resume operation.  
RESET  
Remove the call for cooling, by raising thermostat set-  
ting higher than the conditioned space temperature.  
This resets any pressure or freezestat flash codes.  
SAFETY CONTROLS  
The unit control board monitors the following inputs for  
each cooling system:  
ELECTRIC HEATING SEQUENCE OF OPERATIONS  
The following sequence describes the operation of the  
electric heat section.  
1. A suction line freezestat to protect against low  
evaporator temperatures due to a low airflow or a  
low return air temperature, (opens at 26 ± 5 °F and  
resets at 38 ± 5°F).  
Single-stage heating (applies only to 18 KW heater, all  
other heaters MUST use a two-stage thermostat):  
2. A high-pressure switch to protect against exces-  
sive discharge pressures due to a blocked con-  
denser coil or a condenser motor failure, (opens at  
380 ± 10 psig and resets at 300 ± 10 psig).  
a. Upon a call for heat by the thermostat, the heater  
contactor (6M) will be energized. After completing  
the specified fan on delay for heating, the UCB will  
energize the blower motor.  
b. The thermostat will cycle the electric heat to satisfy  
the heating requirements of the conditioned space.  
3. A low-pressure switch to protect against loss of  
refrigerant charge, (opens at 22 ± 5 psig and resets  
at 45 ± 5 psig).  
Two-stage heating (applies to all heaters except 18  
KW):  
The above pressure switches are hard-soldered to the  
unit. The refrigeration systems are independently mon-  
itored and controlled. On any fault, only the associated  
system will be affected by any safety/preventive action.  
a. Upon a call for first-stage heat by the thermostat, the  
heater contactor (6M) (6M & 7M on 72 KW, 240V)  
will be energized. After completing the specified fan  
38  
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on delay for heating, the UCB will energize the  
blower motor.  
cated in the Limit Control Setting Table 19. It is a  
manual reset limit. These limit switches will de-  
energize the heaters should the primary limit fail to  
open or the contactors fail to open in a failure  
mode.  
If the second stage of heat is required, heater con-  
tactor (7M) will be energized. Note that on the 54  
KW, 240V heater, heater contactors (7M & 8M) will  
be energized and on the 72 KW, 240V heater,  
heater contactors (8M & 9M) will be energized. After  
completing the specified fan on delay for heating,  
the UCB will energize the blower motor.  
TABLE 19: LIMIT CONTROL SETTING  
TEMPERATURE LIMIT  
SWITCH 1, 2  
TEMPERATURE  
LIMIT SWITCH 3, 4, 5,  
6 OPENS, ºF  
UNIT  
(Tons)  
HEATER  
kW  
VOLTAGE  
415  
OPENS, ºF  
b. The thermostat will cycle the electric heat to satisfy  
the heating requirements of the conditioned space.  
18  
36  
54  
72  
120  
120  
120  
120  
170  
170  
170  
170  
15, 20,  
25  
NOTE: All 50 Hz heaters are provided with manual  
reset backup protection limits. These will de-  
energize the heaters should the primary limit  
fail to open or the contactors fail to open in a  
failure mode.  
FLASH CODES  
The UCB will initiate a flash code associated with  
errors within the system. Refer to UNIT CONTROL  
BOARD FLASH CODES Table 24.  
HEATING OPERATION ERRORS  
TEMPERATURE LIMIT  
RESET  
If the UCB senses zero volts from the high temperature  
limit, the indoor blower motor is immediately energized.  
Remove the call for heating by lowering the thermostat  
setting lower than the conditioned space temperature.  
This resets any flash codes.  
This limit is monitored regardless of unit operation sta-  
tus, i.e. the limit is monitored at all times.  
HEAT ANTICIPATOR SETPOINTS  
If the temperature limit opens three times within one  
hour, it will lock-on the indoor blower motor and a flash  
code is initiated (See Table 24).  
It is important that the anticipator setpoint be correct.  
Too high of a setting will result in longer heat cycles  
and a greater temperature swing in the conditioned  
space. Reducing the value below the correct setpoint  
will give shorter "ON" cycles and may result in the low-  
ering of the temperature within the conditioned space.  
Refer to Table 20 for the required heat anticipator set-  
ting.  
SAFETY CONTROLS  
The unit control board monitors the temperature limit  
switch of electric heat units.  
The control circuit includes the following safety con-  
trols:  
TABLE 20: ELECTRIC HEAT ANTICIPATOR  
SETPOINTS  
1. Temperature Limit Switch (TLS 1, 2).  
SETTING, AMPS  
HEATER  
KW  
VOLTAGE  
TH1  
TH2  
-
This control is located inside the heater compart-  
ment and is set to open at the temperature indi-  
cated in the Limit Control Setting Table 19. It resets  
automatically. The limit switch operates when a  
high temperature condition, caused by inadequate  
supply air flow occurs, thus shutting down the  
heater and energizing the blower.  
18  
36  
54  
72  
0.29  
0.29  
0.29  
0.29  
0.29  
0.29  
0.29  
380/415-3-50  
GAS HEATING SEQUENCE OF OPERATIONS  
2. Temperature Limit Switch (TLS 3, 4, 5 and 6).  
The following sequence describes the operation of the  
gas heat section.  
This control is located inside the heater compart-  
ment and is set to open at the temperature indi-  
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356214-XIM-A-0108  
When the thermostat calls for the first stage of heating,  
the low-voltage control circuit from "R" to "W1" and "G"  
is completed, thru the UCB. The heat relay "RW1" is  
energized. The "RW1-2" contacts close energizing the  
draft motor control. The draft motor control contacts  
close and start the draft motor. As the speed of the  
draft motor reaches approximately 2500 RPM, the cen-  
trifugal switch contact, located on the end of the draft  
motor shaft, closes to power the first stage ignition  
module "IC1", thru the "RW1-1 contacts.  
24V power is removed from the module either at the  
unit or by resetting the room thermostat.  
NOTE: That the second stage furnace can operate  
even if first stage has locked out.  
When the thermostat satisfies de-energizing the  
"RW2"and "RW1", thus opening all gas valves. The  
blower motor will continue to run after the furnace is  
shut down until the specified fan off delay for heating  
has been satisfied. The UCB will de-energize the  
blower motor.  
Ignition module "IC1" will immediately start the first  
stage igniter sparking and will open the redundant  
valve located inside the first stage main gas valve  
"GV1" to allow a flow of gas to only the first stage carry-  
over tube. Only after the pilot flame has been ignited  
and the presence of pilot flame detected at the "IC1" by  
a signal sent back through the flame sensor is sparking  
terminated and the first stage main gas valve opened.  
REDUNDANT  
VALVE  
MAIN VALVE  
GAS MAIN  
Gas flows into each of the main burners and is ignited  
from the carryover tube flame.  
GAS  
VALVE  
TO MAIN  
BURNER  
TO PILOT BURNER  
After completing the specified fan on delay for heating,  
the UCB will energize the blower motor.  
FIGURE 19 - GAS VALVE PIPING  
When the thermostat calls for the first stage of heating,  
the low-voltage control circuit from "R" to "W1" is com-  
pleted. A call for heat passes through the UCB to the  
ignition control board (ICB). The UCB monitors the  
"W1" call and acts upon any call for heat. Once voltage  
has been sensed at “W1”, the UCB will initiate the fan  
on delay for heating, energizing the indoor blower after  
the specified delay has elapsed.  
If "IC1" fails to detect a pilot flame, it will continue to try  
for a maximum of 85 seconds to ignite the pilot tube. If  
the pilot flame is not detected, then "IC1" will lock out  
first stage furnace operation for five minutes or until  
24V power is removed from the module either at the  
unit or by resetting the room thermostat.  
When the thermostat calls for the second stage of  
heating, the low-voltage control circuit from "R" to "W2"  
is completed, thru the UCB. Heat relay "RW2" is ener-  
gized. The "RW2-1" contact is closed energizing the  
second stage ignition module "IC2". "IC2" will immedi-  
ately start the second stage igniter sparking and will  
open the redundant valve located inside the second  
stage main gas valve "GV2" to allow a flow of gas to  
the second stage carryover tube. Only after the pilot  
flame has been ignited and the presence of pilot flame  
detected at "IC2" by a signal sent back through the  
flame sensor is sparking terminated and the main gas  
valve opened.  
When the thermostat has been satisfied, heating calls  
are ceased. The GV is immediately de-energized. The  
blower is de-energized after the fan off delay for heat-  
ing has elapsed. The draft motor performs a 25-second  
post purge.  
GAS HEATING OPERATION ERRORS  
TEMPERATURE LIMIT  
If the UCB senses zero volts from the high temperature  
limit, the indoor blower motor is immediately energized.  
When the UCB again senses 24 volts from the temper-  
ature limit, the draft motor will perform a 25-second  
post-purge and the indoor blower will be de-energized  
following the elapse of the fan off delay for heating.  
Gas flows into each of the second stage main burners  
and is ignited from the carryover tube flame.  
If "IC2" fails to detect a pilot flame, it will continue to try  
for a maximum of 85 seconds to ignite the pilot tube. If  
the pilot flame is not detected, then "IC2" will lock out  
first stage furnace operation for five minutes or until  
This limit is monitored regardless of unit operation sta-  
tus, i.e. the limit is monitored at all times.  
40  
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356214-XIM-A-0108  
If the temperature limit opens three times within one  
hour, it will lock-on the indoor blower motor and a flash  
The redundant valves are located upstream of the  
main gas valves. Should either or both of the main  
gas valves fail in the open position the redundant  
valves serve as back-ups and shut off the flow of  
gas.  
GAS VALVE  
The UCB continuously monitors the GV. Any time the  
UCB senses voltage at the GV without a call for heat  
for a continuous five-minute period, the UCB will lock-  
on the indoor blower and a flash code is initiated  
(Table 24). When voltage is no longer sensed at the  
GV, the UCB will de-energize the indoor blower follow-  
ing the elapse of the fan off delay for heating.  
4. Flame Sensor Rod / 100% Ignition Control Lock-  
Out.  
The flame rods and controls are located per Proper  
Flame Adjustment Figure 22. If an ignition control  
fails to detect a signal from the flame sensor indi-  
cating the pilot flame is properly ignited, then the  
main gas valve will not open. It will continue to try  
and ignite the pilot for a maximum of 85 seconds,  
then if the pilot flame is not detected, the ignition  
control will lock out furnace operation until 24V  
power is removed from the module either at the  
unit or by resetting the room thermostat.  
If voltage has been sensed at the GV for at least 15  
seconds during the fan on delay for heating and GV  
voltage or "W1" is lost, the indoor blower is forced on  
for the length of the fan off delay for heating.  
SAFETY CONTROLS  
5. Rollout Switch.  
The unit control board monitors the temperature limit  
switch and the gas valve of gas furnace units.  
This switch is located above the main burners in  
the control compartment, which in the event of a  
sustained main burner rollout shuts off and locks  
out both ignition controls closing both gas valves.  
The ignition controls lock out furnace operation  
until 24V power is removed from the controls either  
at the unit or by resetting the room thermostat.  
The control circuit includes the following safety con-  
trols:  
1. Limit Control (LS).  
This control is located inside the heat exchanger  
compartment and is set to open at the temperature  
indicated in the Limit Control Setting Table 21. It  
resets automatically. The limit switch operates  
when a high temperature condition, caused by  
inadequate supply air flow occurs, thus shutting  
down the ignition control and closing the main gas  
valves and energizing the blower.  
NOTE: The auto reset rollout switch must reset before  
allowing furnace operation.  
6. Auxiliary limit switch (AUX) -  
This control is located inside the heat exchanger  
compartment and is set to open at 190°F. It is a  
manual reset switch. If AUX trips, then the primary  
limit has not functioned correctly. Replace the pri-  
mary limit.  
2. Centrifugal Switch (CS).  
If the draft motor should fail, the centrifugal switch  
attached to the shaft of the motor prevents the igni-  
tion controls and gas valves from being energized.  
TABLE 21: LIMIT CONTROL SETTING  
Capacity, MBH  
Units  
Limit Control  
Opens, ºF  
(Tons)  
3. Redundant Gas Valve.  
Input  
300  
Output  
240  
15, 20 & 25  
15, 20 & 25  
195  
195  
There are two separate gas valves in the furnace.  
Each valve contains a main and a redundant valve.  
350  
280  
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START-UP (COOLING)  
PRESTART CHECK LIST  
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After installation has been completed:  
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1. Check the electrical supply voltage being supplied.  
Be sure that it is the same as listed on the unit  
nameplate.  
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2. Set the room thermostat to the off position.  
3. Turn unit electrical power on.  
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4. Set the room thermostat fan switch to on.  
5. Check indoor blower rotation.  
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• If blower rotation is in the wrong direction. Refer to  
Phasing Section in general information section.  
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FIGURE 20 - GAS VALVE AND CONTROLS  
• Check blower drive belt tension.  
FLASH CODES  
6. Check the unit supply air (CFM). See "CHECKING  
SUPPLY AIR CFM" on page 34.  
The UCB will initiate a flash code associated with  
errors within the system. Refer to UNIT CONTROL  
BOARD FLASH CODES Table 24.  
7. Measure evaporator fan motor's amp draw.  
8. Set the room thermostat fan switch to off.  
RESETS  
9. Turn unit electrical power off.  
OPERATING INSTRUCTIONS  
1. Turn unit electrical power on.  
Remove the call for heating by lowering the thermostat  
setting lower than the conditioned space temperature.  
This resets any flash codes.  
HEAT ANTICIPATOR SETPOINTS  
2. Set the room thermostat setting to lower than the  
room temperature.  
It is important that the anticipator setpoint be correct.  
Too high of a setting will result in longer heat cycles  
and a greater temperature swing in the conditioned  
space. Reducing the value below the correct setpoint  
will give shorter "ON" cycles and may result in the low-  
ering of the temperature within the conditioned space.  
3. First stage compressors will energize after the  
built-in time delay (five minutes).  
4. The second stage of the thermostat will energize  
second stage compressor if needed.  
POST START CHECK LIST  
TABLE 22: GAS HEAT ANTICIPATOR SETPOINTS  
Anticipator Setpoint  
Gas Valve  
1. Verify proper system pressures for both circuits.  
1st Stage  
2nd Stage  
Honeywell VR8440  
2. Measure the temperature drop across the evapora-  
tor coil.  
0.30 amp  
0.11 amp  
White-Rodgers 36C68  
42  
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356214-XIM-A-0108  
3. Measure the system Amperage draw across all  
legs of 3 phase power wires.  
POST-START CHECK LIST (GAS)  
After the entire control circuit has been energized and  
the heating section is operating, make the following  
checks:  
4. Measure the condenser fan amp draw.  
SHUT DOWN  
1. Check for gas leaks in the unit piping as well as the  
supply piping.  
1. Set the thermostat to highest temperature setting.  
2. Turn off the electrical power to the unit.  
START-UP (GAS HEAT)  
FIRE OR EXPLOSION HAZARD  
PRE-START CHECK LIST  
FAILURE TO FOLLOW THE SAFETY WARN-  
ING EXACTLY COULD RESULT IN SERIOUS  
INJURY, DEATH OR PROPERTY DAMAGE.  
Complete the following checks before starting the unit.  
NEVER TEST FOR GAS LEAKS WITH AN  
OPEN FLAME. USE A COMMERICALLY  
AVAILABLE SOAP SOLUTION MADE SPE-  
CIFICALLY FOR THE DETECTION OF  
LEAKS TO CHECK ALL CONNECTIONS. A  
FIRE OR EXPLOSION MAY RESULT CAUS-  
ING PROPERTY DAMAGE, PERSONAL  
INJURY OR LOSS OF LIFE.  
1. Check the type of gas being supplied. Be sure that  
it is the same as listed on the unit nameplate.  
2. Make sure that the vent and combustion air hoods  
have been properly installed.  
OPERATING INSTRUCTIONS  
2. Check for correct manifold gas pressures. See  
“Checking Gas Input” page 44.  
This furnace is equipped with an intermittent  
pilot and automatic re-ignition system. DO  
NOT attempt to manually light the pilot.  
3. Check the supply gas pressure. It must be within  
the limits shown on rating nameplate. Supply pres-  
sure should be checked with all gas appliances in  
the building at full fire. At no time should the  
standby gas line pressure exceed 13", nor the  
operating pressure drop below 5.0" for natural gas  
units. If gas pressure is outside these limits, con-  
tact the local gas utility for corrective action.  
TO LIGHT PILOT AND MAIN BURNERS:  
1. Turn “off” electric power to unit.  
2. Turn room thermostat to lowest setting.  
3. Turn gas valve knob or switch to “on” position.  
4. Turn “on” electric power to unit.  
5. Set room thermostat to desired temperature.  
(If thermostat “set” temperature is above room tem-  
perature, pilot burner ignition will occur and, after  
an interval to prove pilot flame, main burners will  
ignite).  
TO SHUT DOWN:  
1. Turn “off” electric power to unit.  
FIGURE 21 - TYPICAL GAS VALVES  
2. Depress knob of gas valve while turning to “off”  
position or turn gas valve switch to “off” position.  
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MANIFOLD GAS PRESSURE ADJUSTMENT  
1. Remove the screws holding either end of the mani-  
fold to the burner supports.  
Small adjustments to the high-fire gas flow may be  
made by turning the pressure regulator adjusting screw  
on the automatic gas valve.  
2. Open the union fitting in the gas supply line just  
upstream of the unit gas valve and downstream  
from the main manual shut-off valve.  
Adjust as follows:  
3. Remove the gas piping closure panel.  
1. Remove the cap on the regulator. It's located next  
to the push-on electrical terminals.  
4. Disconnect wiring to the gas valves and spark ignit-  
ors. Remove the manifold-burner gas valve  
assembly by lifting up and pulling back.  
2. To decrease the gas pressure, turn the adjusting  
screw counterclockwise.  
3. To increase the gas pressure, turn the adjusting  
screw clockwise.  
NOTE: The correct manifold pressure for these fur-  
naces is 3.65 IWG ±0.3.  
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FIGURE 23 - TYPICAL FLAME APPEARANCE  
Burners are now accessible for service.  
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Reverse the above procedure to replace the assem-  
blies. Make sure that burners are level and seat at the  
rear of the heat exchanger.  
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BURNER AIR SHUTTER ADJUSTMENT  
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Adjust burner shutters so no yellow flame is observed  
in the heat exchanger tubes.  
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FIGURE 22 - PROPER FLAME ADJUSTMENT  
PILOT CHECKOUT  
CHECKING GAS INPUT  
NATURAL GAS  
The pilot flame should envelope the end of the flame  
sensor. To adjust pilot flame, (1) remove pilot adjust-  
ment cover screw, (2) increase or decrease the clear-  
ance for air to the desired level, (3) be sure to replace  
cover screw after adjustment to prevent possible gas  
leakage.  
1. Turn off all other gas appliances connected to the  
gas meter.  
2. With the furnace turned on, measure the time  
needed for one revolution of the hand on the small-  
est dial on the meter. A typical gas meter usually  
has a 1/2 or a 1 cubic foot test dial.  
Put the system into operation and observe through  
complete cycle to be sure all controls function properly.  
3. Using the number of seconds for each revolution  
and the size of the test dial increment, find the  
cubic feet of gas consumed per hour from the Gas  
Rate - Cubic Feet Per Hour Table 23.  
BURNER INSTRUCTIONS  
To check or change burners, pilot or orifices, CLOSE  
MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF  
ALL ELECTRIC POWER TO THE UNIT.  
If the actual input is not within 5% of the furnace rating  
(with allowance being made for the permissible range  
44  
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356214-XIM-A-0108  
of the regulator setting), replace the orifice spuds with  
spuds of the proper size.  
BELT DRIVE BLOWER  
All units have belt drive single-speed blower motors.  
The variable pitch pulley on the blower motor can be  
adjusted to obtain the desired supply air CFM.  
NOTE: To find the Btu input, multiply the number of  
cubic feet of gas consumed per hour by the  
Btu content of the gas in your particular locality  
(contact your gas company for this information  
- it varies widely from city to city.)  
TROUBLESHOOTING  
COOLING TROUBLESHOOTING GUIDE  
TABLE 23: GAS RATE - CUBIC FEET PER HOUR  
Seconds  
for One  
Rev.  
Size of Test Dial  
1/2 cu. ft.  
1 cu. ft.  
4
6
8
450  
300  
228  
180  
900  
600  
450  
360  
Troubleshooting of components may require  
opening the electrical control box with the  
power connected to the unit. Use extreme  
care when working with live circuits! Check  
the unit nameplate for the correct line voltage  
and set the voltmeter to the correct range  
before making any connections with line termi-  
nals.  
10  
12  
14  
16  
18  
20  
150  
129  
113  
100  
90  
300  
257  
225  
200  
180  
When not necessary, shut off all electric power  
to the unit prior to any of the following mainte-  
nance procedures so as to prevent personal  
injury.  
22  
24  
26  
28  
82  
75  
69  
64  
164  
150  
138  
129  
Example: By actual measurement, it takes 13 seconds for the hand on the 1-  
cubic foot dial to make a revolution with just a 300,000 Btuh furnace running.  
Read across to the column in the table above, headed “1 Cubic Foot”, where  
you will see that 278 cubic feet of gas per hour are consumed by the furnace at  
that rate. Multiply 278 x 1050 (the Btu rating of the gas obtained from the local  
gas company). The result is 292,425 Btuh, which is close to the 300,000 Btuh  
rating of the furnace.  
Label all wires prior to disconnection when ser-  
vicing controls. Wiring errors can cause  
improper and dangerous operation, which  
could cause injury to person and/or damage  
unit components. Verify proper operation after  
servicing.  
ADJUSTMENT OF TEMPERATURE RISE  
The temperature rise (or temperature difference  
between the return air and the heated air from the fur-  
nace) must lie within the range shown on the rating  
plate and the data in the Gas Heat Application Table 4.  
On calls for cooling, if the compressors are operating  
but the supply air blower motor does not energize after  
a short delay (the room thermostat fan switch is in the  
“AUTO” position).  
Btuh Input x 0.8  
CFM =  
1.08 x oF Temp. Rise  
1. Turn the thermostat fan switch to the ON position.  
If the supply air blower motor does not energize, go  
to Step 3.  
After the temperature rise has been determined, the  
cfm can be calculated as follows:  
After about 20 minutes of operation, determine the fur-  
nace temperature rise. Take readings of both the return  
air and the heated air in the ducts (about six feet from  
the furnace) where they will not be affected by radiant  
heat. Increase the blower cfm to decrease the temper-  
ature rise; decrease the blower cfm to increase the  
rise. Refer to the Blower Motor and Drive Data  
2. If the blower motor runs with the fan switch in the  
ON position but will not run after the first compres-  
sor has energized when the fan switch is in the  
AUTO position, check the room thermostat for con-  
tact between R and G in the AUTO position during  
calls for cooling.  
Johnson Controls Unitary Products  
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356214-XIM-A-0108  
3. If the supply air blower motor does not energize  
when the fan switch is set to ON, check that line  
voltage is being supplied to the contacts of the M3,  
contactor, and that the contactor is pulled in. Check  
for loose wiring between the contactor and the sup-  
ply air blower motor.  
providing free cooling and the compressors will not  
immediately operate. If both stages of cooling are  
requested simultaneously and the economizer pro-  
vides free cooling, following a short delay compres-  
sor #1 will be energized unless it is locked out. If  
compressor #1 is locked out, compressor #2 is  
energized. Compressor #2 is always energized in  
place of compressor #1 when compressor #1 is  
requested but locked out.  
4. If M3 is pulled in and voltage is supplied to M3,  
lightly touch the supply air blower motor housing. If  
it is hot, the motor may be off on internal protec-  
tion. Cancel any thermostat calls and set the fan  
switch to AUTO. Wait for the internal overload to  
reset. Test again when cool.  
2. If no economizer is installed or the economizer is  
not opening to provide free cooling and compres-  
sor #1 does not energize on a call for cooling,  
check for line voltage at the compressor contactor,  
M1, and that the contactor is pulled in. Check for  
loose wiring between the contactor and the com-  
pressor.  
5. If M3 is not pulled in, check for 24 volts at the M3  
coil. If 24 volts are present at M3 but M3 is not  
pulled in, replace the contactor.  
3. If M1 is pulled in and voltage is supplied at M1,  
lightly touch the compressor housing. If it is hot, the  
compressor may be off on inherent protection.  
Cancel any calls for cooling and wait for the inter-  
nal overload to reset. Test again when cool.  
6. Failing the above, if there is line voltage supplied at  
M3, M3 is pulled in, and the supply air blower  
motor still does not operate, replace the motor.  
7. If 24 volts is not present at M3, check that 24 volts  
is present at the UCB supply air blower motor ter-  
minal, “FAN”. If 24 volts is present at the FAN,  
check for loose wiring between the UCB and M3.  
4. If M1 is not pulled in, check for 24 volts at the M1  
coil. If 24 volts are present and M1 is not pulled in,  
replace the contactor.  
8. If 24 volts is not present at the “FAN” terminal,  
check for 24 volts from the room thermostat. If 24  
volts are not present from the room thermostat,  
check for the following:  
5. Failing the above, if voltage is supplied at M1, M1  
is pulled in, and the compressor still does not oper-  
ate, replace the compressor.  
6. If 24 volts is not present at M1, check for 24 volts at  
the UCB terminal, C1. If 24 volts is present, check  
for loose wiring between C1 and the compressor  
contactor.  
a. proper operation of the room thermostat (contact  
between R and G with the fan switch in the ON posi-  
tion and in the AUTO position during operation  
calls), b. proper wiring between the room thermostat  
and the UCB, and c. loose wiring from the room  
thermostat to the UCB.  
7. If 24 volts is not present at the C1 terminal, check  
for 24 volts from the room thermostat at the UCB  
Y1 terminal. If 24 volts is not present from the room  
thermostat, check for the following:  
9. If 24 volts is present at the room thermostat but not  
at the UCB, check for proper wiring between the  
thermostat and the UCB, i.e. that the thermostat G  
terminal is connected to the G terminal of the UCB,  
and for loose wiring.  
a. 24 volts at the thermostat Y1 terminal  
b. Proper wiring between the room thermostat and the  
UCB, i.e. Y1 to Y1, Y2 to Y2  
c. Loose wiring from the room thermostat to the UCB.  
10. If the thermostat and UCB are properly wired,  
replace the UCB.  
8. If 24 volts is present at the UCB Y1 terminal, the  
compressor may be out due to an open high-pres-  
sure switch, low-pressure switch, or freezestat.  
Check for 24 volts at the HPS1, LPS1, and FS1  
terminals of the UCB. If a switch has opened, there  
should be a voltage potential between the UCB ter-  
minals, e.g. if LPS1 has opened, there will be a 24-  
volt potential between the LPS1 terminals.  
On calls for cooling, the supply air blower motor is  
operating but compressor #1 is not (the room thermo-  
stat fan switch is in the “AUTO” position).  
1. If installed, check the position of the economizer  
blades. If the blades are open, the economizer is  
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356214-XIM-A-0108  
9. If 24 volts is present at the UCB Y1 terminal and  
none of the protection switches have opened, the  
UCB may have locked out the compressor for  
repeat trips. The UCB should be flashing an alarm  
code. If not, press and release the ALARMS button  
on the UCB. The UCB will flash the last five alarms  
on the LED. If the compressor is locked out, cancel  
any call for cooling. This will reset any compressor  
lock outs.  
nect the Mate-N-Locks and jumper between the  
WHITE and YELLOW wires of the UCB's Mate-  
NLock plug. If compressor #1 energizes, there is a  
fault in the economizer wiring or economizer con-  
trol.  
14. The UCB can be programmed to lock out compres-  
sor operation during free cooling and in low ambi-  
ent conditions. These options are not enabled by  
default. Local distributors can test the UCB for this  
programming.  
NOTE: While the above step will reset any lockouts,  
compressor #1 may be held off for the ASCD.  
See the next step.  
For units with factory installed economizers, the  
UCB is programmed to lock out compressor opera-  
tion when the LAS set point is reached.  
10. If 24 volts is present at the UCB Y1 terminal and  
none of the switches are open and the compressor  
is not locked out, the UCB may have the compres-  
sor in an ASCD. Check the LED for an indication of  
an ASCD cycle. The ASCD should time out within  
5 minutes. Press and release the TEST button to  
reset all ASCDs.  
For units without factory installed or with field  
installed economizers, the UCB allows compressor  
operation all the time. This programming can be  
checked or changed by the local distributor.  
15. If none of the above corrected the error, test the  
integrity of the UCB. Disconnect the C1 terminal  
wire and jumper it to the Y1 terminal. DO NOT  
jump the Y1 to C1 terminals. If the compressor  
engages, the UCB has faulted.  
11. If 24 volts is present at the UCB Y1 terminal and  
the compressor is not out due to a protective  
switch trip, repeat trip lock out, or ASCD, the econ-  
omizer terminals of the UCB may be improperly  
wired. Check for 24 volts at the Y1 “OUT” terminal  
of the UCB. If 24 volts is present, trace the wiring  
from Y1 “OUT” for incorrect wiring. If 24 volts is not  
present at the Y1 “OUT” terminal, the UCB must be  
replaced.  
16. If none of the above correct the error, replace the  
UCB.  
On calls for the second stage of cooling, the supply air  
blower motor and compressor #1 are operating but  
compressor #2 is not (the room thermostat fan switch  
is in the “AUTO” position).  
12. For units without economizers:If 24 volts is present  
at the Y1 OUT terminal, check for 24 volts at the  
Y1 “ECON” terminal. If 24 volts is not present,  
check for loose wiring from the Y1 “OUT” terminal  
to the Mate-N-Lock plug, the jumper in the Mate-N-  
Lock plug, and in the wiring from the Mate-N-Lock  
plug to the Y1 “ECON” terminal.  
1. If installed, check the position of the economizer  
blades. If the blades are open, the economizer is  
providing free cooling. If the second stage of  
cooling is requested, following a short delay,  
compressor #1 will be energized unless it is locked  
out. Typically, compressor #2 is energized only  
during free cooling if the call for the second stage  
of cooling persists for 20 minutes.  
13. For units with economizers: If 24 volts is present at  
the Y1 "OUT" terminal, check for 24 volts at the Y1  
"ECON" terminal. If 24 volts is not present, check  
for loose wiring from the Y1 "OUT" terminal to the  
Mate-N-Lock plug, a poor connection between the  
UCB and economizer dMate-N-Lock plugs, loose  
wiring from the Mate-N-Lock plug to the econo-  
mizer, back to the Mate-N-Lock plug, and from the  
Mate-N-Lock plug to the Y1 "ECON" terminal. If  
nothing is found, the economizer control may have  
faulted and is failing to return the 24-volt "call" to  
the Y1 "ECON" terminal even though the econo-  
mizer is not providing free cooling. To test, discon-  
2. Compressor #2 will not energize simultaneously  
with compressor #1 if a call for both stages of cool-  
ing is received. The UCB delays compressor #2 by  
30 seconds to prevent a power surge. If after the  
delay compressor #2 does not energize on a sec-  
ond stage call for cooling, check for line voltage at  
the compressor contactor, M2, and that the contac-  
tor is pulled in. Check for loose wiring between the  
contactor and the compressor.  
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356214-XIM-A-0108  
3. If M2 is pulled in and voltage is supplied at M2,  
lightly touch the compressor housing. If it is hot, the  
compressor may be off on inherent protection.  
Cancel any calls for cooling and wait for the inter-  
nal overload to reset. Test again when cool.  
10. If 24 volts is present at the UCB Y2 terminal and  
none of the switches are open and the compressor  
is not locked out, the UCB may have the compres-  
sor in an ASCD. Check the LED for an indication of  
an ASCD cycle. The ASCD should time out within  
5 minutes. Press and release the TEST button to  
reset all ASCDs.  
4. If M2 is not pulled in, check for 24 volts at the M2  
coil. If 24 volts is present and M2 is not pulled in,  
replace the contactor.  
11. The UCB can be programmed to lock out compres-  
sor operation during free cooling and in low ambi-  
ent conditions. These options are not enabled by  
default. Local distributors can test the UCB for this  
programming.  
5. Failing the above, if voltage is supplied at M2, M2  
is pulled in, and the compressor still does not oper-  
ate, replace the compressor.  
6. If 24 volts is not present at M2, check for 24 volts at  
the UCB terminal, C2. If 24 volts are present,  
check for loose wiring between C2 and the com-  
pressor contactor.  
For units with factory installed economizers, the  
UCB is programmed to lock out compressor opera-  
tion when the LAS set point is reached.  
For units without factory installed or with field  
installed economizers, the UCB allows compressor  
operation all the time. This programming can be  
checked or changed by the local distributor.  
7. If 24 volts is not present at the C2 terminal, check  
for 24 volts from the room thermostat at the UCB  
Y2 terminal. If 24 volts is not present from the room  
thermostat, check for the following:  
12. If none of the above corrected the error, test the  
integrity of the UGB. Disconnect the C2 terminal  
wire and jumper it to the Y2 terminal. DO NOT  
jump the Y2 to C2 terminals. If the compressor  
engages, the UCB has faulted.  
a. 24 volts at the thermostat Y2 terminal  
b. Proper wiring between the room thermostat and the  
UCB, i.e. Y1 to Y1, Y2 to Y2  
c. Loose wiring from the room thermostat to the UCB.  
13. If none of the above correct the error, replace the  
UCB.  
8. If 24 volts is present at the UCB Y2 terminal, the  
compressor may be out due to an open high-pres-  
sure switch, low-pressure switch, or freezestat.  
Check for 24 volts at the HPS2, LPS2, and FS2  
terminals of the UCB. If a switch has opened, there  
should be a voltage potential between the UCB ter-  
minals, e.g. if LPS2 has opened, there will be 24  
volts of potential between the LPS2 terminals.  
On a call for cooling, the supply air blower motor and  
compressor #2 are operating but compressor #1 is not  
(the room thermostat fan switch is in the “AUTO” posi-  
tion).  
1. Compressor #2 is energized in place of compres-  
sor #1 when compressor #1 is unavailable for cool-  
ing calls. Check the UCB for alarms indicating that  
compressor #1 is locked out. Press and release  
the ALARMS button if the LED is not flashing an  
alarm.  
9. If 24 volts is present at the UCB Y2 terminal and  
none of the protection switches have opened, the  
UCB may have locked out the compressor for  
repeat trips. The UCB should be flashing a code. If  
not, press and release the ALARMS button on the  
UCB. The UCB will flash the last five alarms on the  
LED. If the compressor is locked out, remove any  
call for cooling at the thermostat or by disconnect-  
ing the thermostat wiring at the Y2 UCB terminal.  
This will reset any compressor lock outs.  
2. Check for line voltage at the compressor contactor,  
M1, and that the contactor is pulled in. Check for  
loose wiring between the contactor and the com-  
pressor.  
3. If M1 is pulled in and voltage is supplied at M1,  
lightly touch the compressor housing. If it is hot, the  
compressor may be off on inherent protection.  
Cancel any calls for cooling and wait for the inter-  
nal overload to reset. Test again when cool.  
NOTE: While the above step will reset any lock outs,  
compressor #1 will be held off for the ASCD,  
and compressor #2 may be held off for a por-  
tion of the ASCD. See the next step.  
48  
Johnson Controls Unitary Products  
356214-XIM-A-0108  
4. If M1 is not pulled in, check for 24 volts at the M1  
coil. If 24 volts is present and M1 is not pulled in,  
replace the contactor.  
11. If 24 volts is present at the UCB Y1 terminal and  
the compressor is not out due to a protective  
switch trip, repeat trip lock out, or ASCD, the econ-  
omizer terminals of the UCB may be improperly  
wired. Check for 24 volts at the Y1 “OUT” terminal  
of the UCB. If 24 volts is present, trace the wiring  
from Y1 “OUT” for incorrect wiring. If 24 volts is not  
present at the Y1 “OUT” terminal, the UCB must be  
replaced.  
5. Failing the above, if voltage is supplied at M1, M1  
is pulled in, and the compressor still does not oper-  
ate, replace the compressor.  
6. If 24 volts is not present at M1, check for 24 volts at  
the UCB terminal, C1. If 24 volts is present, check  
for loose wiring between C1 and the compressor  
contactor.  
12. For units without economizers: If 24 volts is present  
at the Y1 “OUT” terminal, check for 24 volts at the  
Y1 “ECON” terminal. If 24 volts is not present,  
check for loose wiring from the Y1 “OUT” terminal  
to the Mate-N-Lock plug, the jumper in the Mate-N-  
Lock plug, and in the wiring from the Mate-N-Lock  
plug to the Y1 “ECON” terminal.  
7. If 24 volts is not present at the C1 terminal, check  
for 24 volts from the room thermostat at the UCB  
Y1 terminal. If 24 volts are not present at the UCB  
Y1 terminal, the UCB may have faulted. Check for  
24 volts at the Y1 ECON terminal. If 24 volts is not  
present at Y1 “ECON”, the UCB has faulted. The  
UCB should de-energize all compressors on a loss  
of call for the first stage of cooling, i.e. a loss if 24  
volts at the Y1 terminal.  
For units with economizers: If 24 volts is present at  
the Y1 "OUT" terminal, check for 24 volts at the Y1  
"ECON" terminal. If 24 volts is not present, check  
for loose wiring from the Y1 "OUT" terminal to the  
Mate-N-Lock plug, a poor connection between the  
UCB and economizer Mate-N-Lock plugs, loose  
wiring from the Mate-N-Lock plug to the  
economizer, back to the Mate-N-Lock plug, and  
from the Mate-N-Lock plug to the Y1 "ECON"  
terminal. The economizer control may have faulted  
and is not returning the 24 volts to the Y1 "ECON"  
terminal even though the economizer is not  
providing free cooling. To test the economizer  
control, disconnect the Mate-N-Locks and jumper  
between the WHITE and YELLOW wires of the  
UCB's Mate-N-Lock plug.  
8. If 24 volts are present at the UCB Y1 terminal, the  
compressor may be out due to an open high-pres-  
sure switch, low-pressure switch, or freezestat.  
Check for 24 volts at the HPS1, LPS1, and FS1  
terminals of the UCB. If a switch has opened, there  
should be a voltage potential between the UCB ter-  
minals, e.g. if LPS1 has opened, there will be a 24-  
volt potential between the LPS1 terminals.  
9. If 24 volts is present at the UCB Y1 terminal and  
none of the protection switches have opened, the  
UCB may have locked out the compressor for  
repeat trips. The UCB should be flashing a code. If  
not, press and release the ALARMS button on the  
UCB. The UCB will flash the last five alarms on the  
LED. If the compressor is locked out, remove any  
call for cooling. This will reset any compressor lock  
outs.  
13. The UCB can be programmed to lock out compres-  
sor operation during free cooling and in low ambi-  
ent conditions. These options are not enabled by  
default. They can be checked by local distributors.  
For units with factory installed economizers, the  
UCB is programmed to lock out compressor opera-  
tion when the LAS set point is reached.  
NOTE: While the above step will reset any lock outs,  
compressor #2 will be held off for the ASCD,  
and compressor #1 may be held off for a por-  
tion of the ASCD. See the next step.  
For units without factory installed or with field  
installed economizers, the UCB allows compressor  
operation all the time. This programming can be  
checked or changed by the local distributor.  
10. If 24 volts is present at the UCB Y1 terminal and  
none of the switches are open and the compressor  
is not locked out, the UCB may have the compres-  
sor in an ASCD. Check the LED for an indication of  
an ASCD cycle. The ASCD should time out within  
5 minutes. Press and release the TEST button to  
reset all ASCDs.  
14. If none of the above corrected the error, test the  
integrity of the UCB. Disconnect the C1 terminal  
wire and jumper it to the Y1 terminal. DO NOT  
jump the Y1 to C1 terminals. If the compressor  
engages, the UCB has faulted.  
Johnson Controls Unitary Products  
49  
356214-XIM-A-0108  
15. If none of the above correct the error, replace the  
UCB.  
1. Place the thermostat fan switch in the “ON” posi-  
tion. If the supply air blower motor energizes, go to  
Step 10.  
GAS HEAT TROUBLESHOOTING GUIDE  
2. If the supply air blower motor does not energize  
when the fan switch is set to “ON,” check that line  
voltage is being supplied to the contacts of the M3  
contactor, and that the contactor is pulled in. Check  
for loose wiring between the contactor and the sup-  
ply air blower motor.  
Troubleshooting of components may require  
opening the electrical control box with the  
power connected to the unit. Use extreme  
care when working with live circuits! Check  
the unit nameplate for the correct line voltage  
and set the voltmeter to the correct range  
before making any connections with line termi-  
nals.  
3. If M3 is pulled in and voltage is supplied at M3,  
lightly touch the supply air blower motor housing. If  
it is hot, the motor may be off on inherent protec-  
tion. Cancel any thermostat calls and set the fan  
switch to “AUTO”, wait for the internal overload to  
reset. Test again when cool.  
When not necessary, shut off all electric power  
to the unit prior to any of the following mainte-  
nance procedures so as to prevent personal  
injury.  
4. If M3 is not pulled in, check for 24 volts at the M3  
coil. If 24 volts is present at M3 but M3 is not pulled  
in, replace the contactor.  
5. Failing the above, if there is line voltage supplied at  
M3, M3 is pulled in, and the supply air blower  
motor still does not operate, replace the motor.  
Label all wires prior to disconnection when ser-  
vicing controls. Wiring errors can cause  
improper and dangerous operation, which  
could cause injury to person and/or damage  
unit components. Verify proper operation after  
servicing.  
6. If 24 volts is not present at M3, check that 24 volts  
is present at the supply air blower motor terminal  
on the UCB. If 24 volts is present at the UCB termi-  
nal, check for loose wiring between the UCB and  
M3.  
7. If 24 volts is not present at the UCB supply air  
blower motor terminal, check for 24 volts from the  
room thermostat. If 24 volts is not present from the  
room thermostat, check for the following:  
NOTE: To find the Btu input, multiply the number of  
cubic feet of gas consumed per hour by the  
Btu content of the gas in your particular locality  
(contact your gas company for this information  
- it varies widely from city to city.).  
a. Proper operation of the room thermostat (contact  
between R and G with the fan switch in the “ON”  
position and in the “AUTO” position during operation  
calls).  
b. Proper wiring between the room thermostat and the  
UCB.  
The furnace may shut down on a high temper-  
ature condition during the procedure. If this  
occurs, the UCB energize the supply air blower  
motor until the high temperature limit has reset.  
Caution should be used at all times as the sup-  
ply air blower may energize regardless of the  
room thermostat fan switch position.  
c. Loose wiring from the room thermostat to the UCB.  
8. If 24 volts is present at the room thermostat but not  
at the UCB, check for proper wiring between the  
thermostat and the UCB, i.e. that the thermostat G  
terminal is connected to the G terminal of the UCB,  
and for loose wiring.  
On calls for heating, the draft motor operates and the  
furnace lights but the supply air blower motor does not  
energize after a short delay (the room thermostat fan  
switch is in “AUTO” position).  
9. If the thermostat and UCB are properly wired,  
replace the UCB.  
50  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
10. If the blower motor runs with the fan switch in the  
“ON” position but does not run shortly after the fur-  
nace has ignited when the fan switch is in the  
“AUTO” position, check the room thermostat for  
contact between R and G during “W1” calls.  
4. If the furnace is cold, check for 24 volts at wire 241  
attached to the electrical time delay (ETD) located  
in the main control box. If 24 volts is not found,  
replace the ETD.  
5. 24 volts is found at wire 241, remove the wires  
attached to the (TDR) and with a VOM, check for  
continuity across contacts 1 and 2. If none is found,  
the (TDR) is open and must be replaced. If there is  
continuity, re-attach the wires.With the draft motor  
running, check for 24 volts at terminal 4 of (RW1-2)  
and (RW2-1). If 24 volts is not present, the centrifu-  
gal switch (CS) has not closed or has gone bad.  
Check the line voltage to the unit - if it is correct,  
replace the draft motor. If line voltage is low, call  
the power company.  
On calls for heating, the supply air blower operates but  
the draft motor does not (the room thermostat fan  
switch is in the “AUTO” position).  
1. The draft motor has inherent protection. If the  
motor shell is hot to the touch, wait for the internal  
overload to reset.  
2. If the motor shell is cold with the room thermostat  
calling for heat, check for line voltage at the  
motor's Mate-N-Lok connector attached to the  
evaporator partition. If line voltage is present,  
replace the draft motor.  
6. Check for 24V at terminal 2 of (RW1-2 and RW2-  
1). If 24V is not present, check for 24V at (RW1  
and RW2) relay coils. If these relays are pulled in,  
then check for a loose connection at terminal 2 and  
terminal 4 of each relay. If no problem is found,  
then replace (RW1 and/or RW2) as required.  
3. If line voltage is not present, check for line voltage  
at the heat relay (RW1) contacts in the main con-  
trol box and check to see if the (RW1) is pulled in.  
4. If the (RW1) relay is pulled in, check for a loose line  
voltage connection.  
7. If 24 volts is present at the ignitor controls, check  
all control wiring at the ignitor controls and the high  
tension wire to the ignitors. Check that the ground  
wires from the ignitor controls, the gas valves and  
pilot burners are all intact and making good electri-  
cal connection. Check to make sure that the  
ceramic insulator on the pilot ignitors or sensors is  
not broken or cracked, if all are intact, replace the  
ignition control IC1 or IC2.  
5. If the (RW1) relay is not pulled in, check for 24 volts  
at the (RW1) coil. If 24 volts is present, replace the  
(RW1) relay. If 24 volts is not present, check for a  
loose 24 volt connection back to the relay board  
and check the connections from the room thermo-  
stat to the relay board. If all connections are cor-  
rect, replace the relay board.  
The draft motor runs and the ignitor sparks at the pilot  
burner but the pilot does not ignite and a gas odor is  
not detected at the draft motor outlet.  
The draft motor runs but the furnace does not light and  
the sparker does not spark.  
1. The ignition control (IC1, IC2) may be locked out  
due to either a flame roll out or 100% shut off.  
These safety features are described above. If lock-  
out has occurred, 24V must be removed from the  
ignition controls. This is done at the unit or by  
resetting the room thermostat. After resetting 24V,  
check for proper furnace operation. If lock-out con-  
tinues to occur, locate the source of the problem  
and correct.  
1. Check to make sure gas is being supplied to the  
unit. Make sure that the gas pressure to the unit is  
within the proper limits as described in the “POST  
START CHECK LIST” page 43 and that the pilot  
adjust screw is allowing some flow of gas as  
described in “PILOT CHECKOUT” page 44.  
2. Check all wiring between the ignitor control and the  
gas valve. Check to make sure the ground connec-  
tions are intact.  
2. Check all 24 volt connections from the relay board  
to and in the gas heat section. Check low voltage  
connections to the (ETD) located in the control  
box.  
3. If the wiring is intact, check for 24 volts across ter-  
minals “PV” and “COMMON” on the ignitor control.  
If 24 volts is not present, replace the ignitor control.  
3. If the furnace is hot, it may be out on an over-tem-  
perature condition, wait for limit reset.  
Johnson Controls Unitary Products  
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356214-XIM-A-0108  
4. If 24 volts is present, remove the pilot burner and  
remove the pilot orifice from the pilot burner. The  
orifice is removed in the direction opposite the flow  
of gas. Inspect the orifice for obstruction. If it is  
clear, replace the main gas valve.  
1. Make sure that the pilot burner is aligned properly  
with the carryover as described in “PILOT CHECK-  
2. Make sure that the carryovers on adjoining burners  
are screwed fast and are level with respect to one  
another.  
The ignitor sparks at the pilot burner but the pilot does  
not ignite and a gas odor is detected at the draft motor  
outlet.  
Main burners light but exhibit erratic flame characteris-  
tics.  
1. Adjust the pilot adjust screw on the gas valve as  
described in “PILOT CHECKOUT” page 44.  
1. Adjust air shutters as described in “BURNER AIR  
SHUTTER ADJUSTMENT” page 44.  
2. Check the main burner orifices for obstruction and  
alignment. Removal procedure is described in  
BURNER INSTRUCTIONS page 44. Clean or  
replace burner orifices and burners as needed.  
2. Check the supply pressure as described in “POST  
START CHECK LIST” page 43. Make adjustments  
as necessary.  
3. Check the pilot orifice for obstruction as described  
in paragraph above. Clean as needed but the prob-  
lem should not be the gas valve.  
UNIT FLASH CODES  
Various flash codes are utilized by the unit control  
board (UCB) to aid in troubleshooting. Flash codes are  
distinguished by the short on and off cycle used  
(approximately 200ms on and 200ms off). To show  
normal operation, the control board flashes a 1 second  
on, 1 second off "heartbeat" during normal operation.  
This is to verify that the UCB is functioning correctly.  
Do not confuse this with an error flash code. To prevent  
confusion, a 1-flash, flash code is not used.  
The pilot burner ignites but the ignitor continues to  
spark and the main burners do not ignite.  
1. Make the same checks and adjustment as  
described in “PILOT CHECKOUT” page 44.  
2. Check the supply pressure as described in “POST  
START CHECK LIST” page 43. Make adjustments  
as necessary.  
Alarm condition codes are flashed on the UCB lower  
left Red LED, See Figure 24. While the alarm code is  
being flashed, it will also be shown by the other LEDs:  
lit continuously while the alarm is being flashed. The  
total of the continuously lit LEDs equates to the number  
of flashes, and is shown in the table. Pressing and  
releasing the LAST ERROR button on the UCB can  
check the alarm history. The UCB will cycle through the  
last five (5) alarms, most recent to oldest, separating  
each alarm flash code by approximately 2 seconds. In  
all cases, a flashing Green LED will be used to indicate  
non-alarm condition.  
3. Make sure that the pilot burner is not bent or dam-  
aged.  
4. Make sure that the ground connections at the pilot  
burner, gas valve and ignitor control are intact.  
Check the high tension wire for good electrical con-  
nection. If all are intact, replace the ignitor module.  
The pilot burner lights and the spark stops but the main  
burners do not light.  
1. Check electrical connections between the ignitor  
control and the gas valve. If intact, check for 24  
volts across terminals “MV” and “COMMON” termi-  
nals. If no voltage detected, replace ignitor control.  
If voltage is present, replace gas valve.  
In some cases, it may be necessary to "zero" the  
ASCD for the compressors in order to perform trouble-  
shooting. To reset all ASCDs for one cycle, press and  
release the UCB TEST/ RESET button once.  
Furnace lights with roll-out or one burner has delayed  
ignition.  
Flash codes that do and do not represent alarms are  
listed in Table 24.  
52  
Johnson Controls Unitary Products  
 
356214-XIM-A-0108  
TABLE 24: UNIT CONTROL BOARD FLASH CODES  
GREEN  
LED  
16  
RED  
LED  
8
RED  
LED  
4
RED  
LED  
2
RED  
LED  
1
FLASH CODE  
DESCRIPTION  
On Steady  
1 Flash  
This is a Control Failure  
Not Applicable  
-
-
-
-
-
-
-
-
-
-
Control waiting ASCD1  
2 Flashes  
3 Flashes  
4 Flashes  
5 Flashes  
6 Flashes  
7 Flashes  
8 Flashes  
9 Flashes  
10 Flashes  
Flashing  
Off  
Off  
Off  
Off  
Off  
Off  
Off  
On  
On  
On  
Off  
Off  
On  
On  
On  
On  
Off  
Off  
Off  
On  
On  
Off  
Off  
On  
On  
Off  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
HPS1 Compressor Lockout  
HPS2 Compressor Lockout  
Off  
LPS1 Compressor Lockout  
Off  
LPS2 Compressor Lockout  
Off  
FS1 Compressor Lockout  
Off  
FS2 Compressor Lockout  
Off  
Ignition Control Locked Out / Ignition Control Failure  
Off  
Compressors Locked Out on Low Outdoor Air Temperature1  
Compressors locked out because the Economizer is using free  
Cooling1  
Flashing  
11 Flashes  
Flashing  
On  
Off  
On  
On  
12 Flashes  
13 Flashes  
Unit Locked Out due to Fan Overload Switch Failure  
Off  
Flashing  
Off  
On  
On  
On  
Off  
On  
On  
On  
Off  
Off  
Off  
On  
Off  
Off  
On  
Off  
Off  
Compressor Held Off due to Low Voltage1  
EEPROM Storage Failure  
14 Flashes  
OFF  
No Power or Control Failure  
Off  
1.  
Non-alarm condition.  
Check  
Alarm  
History  
Reset All  
ASCDs for  
One Cycle  
Non Alarm  
Condition Green  
LED Flashing  
Current Alarm  
Flashed  
Red LED  
FIGURE 24 - UNIT CONTROL BOARD  
Johnson Controls Unitary Products  
53  
   
356214-XIM-A-0108  
• The 8, 4, 2 and 1 LEDs will then show the status of the  
Heat Delay, (See Table 25). Press the UP or Down  
button to change the LED status to correspond to the  
desired Heat Delay Value.  
UNIT CONTROL BOARD OPTION SETUP  
OPTION BYTE SETUP  
• Enter the Option Setup mode by pushing the OPTION  
SETUP / STORE button, and holding it for at least 2  
seconds.  
• To save the current displayed value, push the OPTION  
SETUP / STORE button and hold it for at least 2  
seconds. When the value is saved, the red LED will  
flash a few times and then normal display will resume.  
• The green status LED (Option Byte) will be turned on  
and the red status LED (Heat Delay) is turned off.  
NOTE: While in either Setup mode, if no buttons are  
pushed for 60 seconds, the display will revert  
to its normal display, exiting the Option Setup  
mode. When saving, the control board only  
saves the parameters for the currently dis-  
played mode (Option Byte or Heat Delay).  
• The 8, 4, 2 and 1 LEDs will then show the status of the  
4 labeled options ((8) Fan Off at Heat Start, (4) Low  
Ambient Lockout, (2) Free Cooling Lockout, and (1)  
Lead / Lag).  
• Press the UP or Down button to change the LED status  
to correspond to the desired Option Setup.  
• To save the current displayed value, push the OPTION  
SETUP / STORE button and hold it for at least 2  
seconds. When the value is saved, the green LED will  
flash a few times and then normal display will resume.  
TABLE 25: HEAT DELAY  
Heat  
Fan On  
Delay  
60  
Heat  
Fan Off  
Delay  
180  
90  
Red  
LED 8  
Red  
Red  
Red  
LED 4  
LED 2  
LED 1  
On  
On  
On  
On  
On  
On  
On  
On  
Off  
Off  
Off  
Off  
Off  
Off  
Off  
Off  
On  
On  
On  
On  
Off  
Off  
Off  
Off  
On  
On  
On  
On  
Off  
Off  
Off  
Off  
On  
On  
Off  
Off  
On  
On  
Off  
Off  
On  
On  
Off  
Off  
On  
On  
Off  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
NOTE: While in either Setup mode, if no buttons are  
pushed for 60 seconds, the display will revert  
to its normal display, exiting the Option Setup  
mode. When saving, the control board only  
saves the parameters for the currently dis-  
played mode (Option Byte or Heat Delay).  
60  
60  
60  
60  
30  
45  
180  
90  
45  
45  
60  
45  
30  
HEAT DELAY SETUP  
30  
180  
90  
30  
•Enter the Option Setup mode by pushing the OPTION  
SETUP / STORE button, and holding it for at least 2  
seconds.  
30  
60  
30  
30  
0
60  
0
30  
•The green status LED (Option Byte) will be turned on  
and the red status LED (Heat Delay) is turned off.  
0
10  
Non-std  
Non-std  
•Press the COMM SETUP / SELECT button to toggle into  
the Heat Delay Setup, the green LED will turn off and  
the red LED for Heat Delay will turn on.  
54  
Johnson Controls Unitary Products  
       
356214-XIM-A-0108  
Johnson Controls Unitary Products  
55  
Subject to change without notice. Printed in U.S.A.  
356214-XIM-A-0108  
Copyright © 2008 by Johnson Controls, Inc. All rights reserved.  
Supersedes: 175240-XIM-B-0707  
Johnson Controls Unitary Products  
5005 York Drive  
Norman, OK 73069  

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