Johnson Controls 100 Series User manual

LD19506

CONTROL SEQUENCES

SERIES 100

50–130 TON - MOD F

120–150 TON - MOD G

50 HZ AND 60 HZ

R-410A

PACKAGED ROOFTOP UNITS

START-UP GUIDE NEW RELEASE Form 100.50-SU8 (116)

Issue Date:

January 28, 2016

JOHNSON CONTROLS

FORM 100.50-SU8

ISSUE DATE: 1/28/2016

This equipment is a relatively complicated apparatus.

During rigging, installation, operation, maintenance,

or service, individuals may be exposed to certain com-

ponents or conditions including, but not limited to:

heavy objects, refrigerants, materials under pressure,

rotating components, and both high and low voltage.

Each of these items has the potential, if misused or

handled improperly, to cause bodily injury or death. It

is the obligation and responsibility of rigging, instal-

lation, and operating/service personnel to identify and

recognize these inherent hazards, protect themselves,

and proceed safely in completing their tasks. Failure

to comply with any of these requirements could result

in serious damage to the equipment and the property in

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

which it is situated, as well as severe personal injury or

death to themselves and people at the site.

This document is intended for use by owner-authorized

rigging, installation, and operating/service personnel. It

is expected that these individuals possess independent

training that will enable them to perform their assigned

tasks properly and safely. It is essential that, prior to

performing any task on this equipment, this individual

shall have read and understood the on-product labels,

this document and any referenced materials. This in-

dividual shall also be familiar with and comply with

all applicable industry and governmental standards and

regulations pertaining to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to specific situations:

Indicates a possible hazardous situation

which will result in death or serious injury

if proper care is not taken.

Indicates a potentially hazardous situa-

tion which will result in possible injuries

or damage to equipment if proper care is

not taken.

Identies a hazard which could lead to

damage to the machine, damage to other

equipment and/or environmental pollu-

tion if proper care is not taken or instruc-

tions and are not followed.

Highlights additional information useful

to the technician in completing the work

being performed properly.

External wiring, unless specied as an optional connection in the manufacturer’s product line, is not

to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls

and any external wiring must not be installed inside the micro panel. All wiring must be in accor-

dance with Johnson Controls’ published specications and must be performed only by a qualied

electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper

connections to the controls or application of improper control signals. Failure to follow this warn-

ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3

FORM 100.50-SU8

ISSUE DATE:1/28/2016

MANUAL DESCRIPTION FORM NUMBER

Installation, Operation, and Maintenance 50-65 Ton Unit, Mod F 100.50-NOM5

Installation, Operation, and Maintenance 70-105 Ton Unit, Mod F 100.50-NOM9

Installation, Operation, and Maintenance 120-130 Ton Unit, Mod F 100.50-NOM10

Installation, Operation, and Maintenance 120-150 Ton Unit, Mod G 100.50-NOM11

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con-

tinuous product improvement, the information con-

tained in this document is subject to change without

notice. Johnson Controls makes no commitment to

update or provide current information automatically

to the manual or product owner. Updated manuals, if

applicable, can be obtained by contacting the nearest

Johnson Controls Service office or accessing the John-

son Controls QuickLIT website at http://cgproducts.

johnsoncontrols.com.

It is the responsibility of rigging, lifting, and operating/

service personnel to verify the applicability of these

documents to the equipment. If there is any question

regarding the applicability of these documents, rig-

ging, lifting, and operating/service personnel should

verify whether the equipment has been modified and

if current literature is available from the owner of the

equipment prior to performing any work on the chiller.

CHANGE BARS

Revisions made to this document are indicated with a

line along the left or right hand column in the area the

revision was made. These revisions are to technical in-

formation and any other changes in spelling, grammar

or formatting are not included.

ASSOCIATED LITERATURE

JOHNSON CONTROLS

FORM 100.50-SU8

ISSUE DATE: 1/28/2016

7 : 200/3/60

5 : 208/3/60

230/3/60

8 : 230/3/60

0 : 380/3/60

5 : 400/3/50

6 : 460/3/60

8 : 575/3/60

NOMENCLATURE

BASE MODEL NUMBER

C : Constant Volume

V : VAV, VFD

F : FlexSys

C : Cooling Only

N : Staged Natural Gas Heat

G : Staged Natural Gas Heat SS HX

M : Full Modulating Gas Heat

F : Full Modulating Gas Heat SS Staged HX

E : Electric Heat

H : Hot Water Heat

S : Steam Heat

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

BASE PRODUCT TYPE NOMINAL APPLICATION REFRIGERANT VOLTAGE SUPPLY RETURN DESIGN SPECIAL GAS HEAT

A: Std. Product, Simplicity Elite

B: Special Product, Simplicity Elite

X: Std. Product, IPU

S: Special Product, IPU

B : R-407C

C : R-22

E : R-410A

B: Bottom

R: Rear

S: Side

L : Scroll

P : Packaged Rooftop

A : Air-Cooled

Y : YORK

B: Bottom

L: Left

R: Right

F : Revision Level

G : Revision Level

N : No Gas Heat

L : Low (375 MBH)

M : Med (750 MBH)

H : High (1125 MBH)

CAPACITY OPENINGS OPENINGS CAPACITY

: 50-Ton Std.

: 50-Ton High

: 60-Ton Std.

: 60-Ton High

: 70-Ton

: 75-Ton

: 80-Ton

: 90-Ton

: 105-Ton

: 120-Ton

: 120-Ton Mod G

: 130-Ton

: 130-Ton Mod G

: 150-Ton Mod G

JOHNSON CONTROLS 5

FORM 100.50-SU8

ISSUE DATE:1/28/2016

TABLE OF CONTENTS

SECTION 1 - INTRODUCTION.................................................................................................................................7

SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH

THE IPU CONTROLLER ..........................................................................................................................................9

BACnet MS/TP .................................................................................................................................................9

BACnet IP.........................................................................................................................................................9

LON ................................................................................................................................................................ 11

N2................................................................................................................................................................... 11

Other Protocols .............................................................................................................................................. 11

End of Line Termination..................................................................................................................................12

Miscellaneous.................................................................................................................................................12

Technical Support...........................................................................................................................................12

SECTION 3 - UNIT MODE ......................................................................................................................................13

SECTION 4 - OCCUPIED/UNOCCUPIED OPERATION ........................................................................................15

SECTION 5 - COMMANDING THERMOSTAT INPUTS FROM THE BAS.............................................................17

SECTION 6 - COMMUNICATING A ZONE TEMPERATURE.................................................................................19

SECTION 7 - SINGLE ZONE VAV OPERATION....................................................................................................21

What is Single Zone VAV?..............................................................................................................................21

Modes of Operation........................................................................................................................................21

Occupied Standby .................................................................................................................................21

Occupied Cooling Low .........................................................................................................................21

Occupied Cooling High..........................................................................................................................21

Occupied Heating Low ..........................................................................................................................21

Occupied Heating High .........................................................................................................................21

Other Points ..........................................................................................................................................22

SECTION 8 - SUPPLY AIR TEMPERATURE (SAT) SP RESET ............................................................................23

Sequence of Operation ..................................................................................................................................23

Other Points That Can Be Written to for SAT SP Reset........................................................................ 24

Flexsys .................................................................................................................................................24

Constant Volume ..................................................................................................................................24

SECTION 9 - DUCT STATIC PRESSURE RESET (BAS) ......................................................................................25

SECTION 10 - MORNING WARM-UP ....................................................................................................................27

Morning Warm-Up Sequence.........................................................................................................................27

JOHNSON CONTROLS

FORM 100.50-SU8

ISSUE DATE: 1/28/2016

LIST OF TABLES

TABLE 1 - BACnet MS/TP Points ...........................................................................................................................33

TABLE 2 - Series 100 Flexsys BACnet MS/TP Points............................................................................................49

TABLE 3 - Warning Description Table.....................................................................................................................51

LIST OF FIGURES

FIGURE 1 - IPU Controller Port Locations ..............................................................................................................10

FIGURE 2 - E-Link Connections and Addressing Instructions ................................................................................ 11

TABLE OF CONTENTS (CONT'D)

SECTION 11 - SERIES 100: FLEXSYS OPERATION............................................................................................29

Flexsys: Current Operating Mode (Occupied)................................................................................................29

Flexsys: Fan Operation ..................................................................................................................................29

Flexsys: Cooling .............................................................................................................................................30

Occupied ...............................................................................................................................................30

Unoccupied ...........................................................................................................................................31

Flexsys: Compressor Control .........................................................................................................................31

Occupied Cooling w/o Bypass...............................................................................................................31

Occupied Cooling w/ Bypass.................................................................................................................31

Flexsys: Heating.............................................................................................................................................31

Flexsys: Underfloor Temperature Control.......................................................................................................31

Dew Point Reset....................................................................................................................................31

Active Slab Control................................................................................................................................32

Flexsys: All Other Sequences ........................................................................................................................32

Flexsys: BACnet Points..................................................................................................................................32

SECTION 12 - BACNET MS/TP POINTS...............................................................................................................33

JOHNSON CONTROLS 7

FORM 100.50-SU8

ISSUE DATE:1/28/2016

The Series 100 unit is a large tonnage rooftop unit, with

sizes ranging from 50-150 tons. It can be configured to

run as a Constant Volume unit, a Multizone Variable

Air Volume (VAV) unit, Single Zone VAV, or as a Flex-

Sys (underfloor air) unit. There are many different op-

tions that can be added to the machine, which will add

to its complexity.

This start up guide indicates control sequences to pro-

vide proper unit operation. This guide does not include

installation information. Please refer to the proper In-

stallation, Operation, and Maintenance (IOM) manual

for this information.

• 50-65 ton units, Mod F: Form 100.50-NOM5

(1115)

• 70-105 ton units, Mod F: Form 100.50-NOM9

(1115)

• 120-130 ton units, Mod F: Form 100.50-NOM10

(1115)

• 120-150 ton units, Mod G: Form 100.50-NOM11

(1115)

In addition, any system alarms indicated by the User

Interface should be diagnosed as referenced in the ap-

propriate IOM. You can refer to the Fault Description

Table located in the Service section of the IOM.

SECTION 1 - INTRODUCTION

JOHNSON CONTROLS

FORM 100.50-SU8

ISSUE DATE: 1/28/2016

SECTION 1 - INTRODUCTION

THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 9

FORM 100.50-SU8

ISSUE DATE:1/28/2016

SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH

THE IPU CONTROLLER

A Series 100/YPAL rooftop unit with the IPU control-

ler ships from the factory ready to connect and com-

municate with a Building Automation System utilizing

BACnet MS/TP protocol.

The S100/YPAL unit can also communicate via BAC-

net IP, LON or N2 with the addition of a field provided/

installed component.

BACNET MS/TP

• Communication wires MUST be connected to

Port 1 using only terminals 3 and 4. Connecting

wires to any of the other terminals could result in

erratic or no communication. (See Figure 1)

a. Terminal 3: Receive (+)

b. Terminal 4: Transmit (-)

• MAC address can be set using dip switch SW2 or

in the Service Key. Preferred method is through

the Service Key. This prevents someone acciden-

tally hitting a dipswitch key and changing the

MAC address

• Using the Service Key to set the MAC address

a. Press the Service Key on the keyboard

b. Enter the level 2 password, 9725 and press

the checkmark

c. The screen should display “Data Log For-

mat”. If not, press the Service key again, and

“Data Log Format” should appear

d. Use the UP arrow to scroll up through the

menu until the screen displays “P1 Stop Bits

=1”

e. This is the part of the menu for Port 1

f. Press the UP arrow again to “P1 Protocol”

Should be set to BACnet

g. Use the UP arrow again until the screen dis-

plays “P1 Manual Mac Address”. If the val-

ue is set to -1, the unit address is set by the

dipswitches. Press the checkmark key and

enter the MAC address for the unit using the

numbered section of the keypad, then press

the checkmark to accept this value

h. Use the UP arrow again to find the “P1 Baud

Rate” Set this value to the required Baud

Rate.

i. Press the “X” key on the keypad to exit the

programming menu

j. Cycle main power OFF then ON for new val-

ues to be locked in.

• The S100 unit is now ready to communicate to

the BAS

BACNET IP

• Since the IPU controller does not have a function-

al IP port, a gateway must be used.

• We recommend using a JCI NCE (MS-

NCE2560-0)

• The gateway will be connected to Port 1 on the

IPU controller like above (See Figure 1 on page

10)

JOHNSON CONTROLS

FORM 100.50-SU8

ISSUE DATE: 1/28/2016

SECTION 2 - CONNECTING BAS TO A SERIES 100/YPAL UNIT WITH THE IPU CONTROLLER

IPU Board

SW2: MAC Address Switch SD Card Slot

Port 3 (J2)

Port 1 (J4) BACnet MS/TP

MUST connect here

Port 4 (J3)Port 2 (J5)5 VDC Power

Battery

SW1: Not

Used

FIGURE 1 - IPU CONTROLLER PORT LOCATIONS

LD20051

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